Conext™ MPPT 60 150 Solar Charge Controller (865-1030-1) Installation and Owner’s Guide 975-0400-01-01 Revision G May 2015 Owner’s Manual solar.schneider-electric.
Conext™ MPPT 60 150 Solar Charge Controller Installation and Owner’s Guide solar.schneider-electric.
Copyright and Contact Copyright © 2013-2015 Schneider Electric. All Rights Reserved. All trademarks are owned by Schneider Electric Industries SAS or its affiliated companies.
About This Guide Purpose The purpose of this Guide is to provide explanations and procedures for installing, configuring, operating, and troubleshooting the Conext MPPT Solar Charge Controller (solar charge controller). Scope This Guide provides safety guidelines, detailed planning and setup information, procedures for installing the unit, as well as information about operating and troubleshooting the unit. It does not provide details about particular brands of photovoltaic (PV) panels.
About This Guide Abbreviations and Acronyms CEC CSA DC FCC GFP IMP Canadian Electric Code Canadian Standards Association Direct Current Federal Communications Commission Ground Fault Protection Current at maximum power per STC ISC Short circuit current rating of an PV panel under STC LCD LED MPP MPPT MSDS NFPA PDP PV SCP STC UL VAC VDC VMP Liquid Crystal Display Light Emitting Diode Maximum Power Point Maximum Power Point Tracking Material Safety Data Sheet National Fire Protection Association Conext
Important Safety Instructions READ AND SAVE THESE INSTRUCTIONS - DO NOT DISCARD This guide contains important safety instructions for the Conext MPPT Solar Charge Controller that must be followed during installation procedures. Read and keep this Installation and Owner’s Guide for future reference. Read these instructions carefully and look at the equipment to become familiar with the device before trying to install, operate, service or maintain it.
Safety Safety Information 1. Before installing or using this device, read all instructions and cautionary markings located in (or on) this guide, the unit, the batteries, PV array, and any other equipment used. 2. All electrical work must be done in accordance with local, national, and/or international electrical codes. 3. This product is designed for indoor mounting only. Do not expose this unit to rain, snow or liquids of any type. 4.
Safety CAUTION BURN HAZARD Do not touch heatsink Failure to follow these instructions can result in injury. NOTICE LIGHTNING PROTECTION To protect the solar 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.
Safety • Always connect the batteries first, then connect the cables to the inverter or controller. This will greatly reduce the chance of spark in the vicinity of the batteries. • Use insulated tools when working with batteries. • When connecting batteries, always verify proper voltage and polarity. • Do not short-circuit battery cables. Fire or explosion can occur. • Do not open or damage the batteries. Exposure to electrolyte is harmful to eyes and skin. It is toxic.
Contents Important Safety Instructions- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - v Battery Safety Information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–vii 1 Introduction Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2 Maximum Power Point Tracking - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Contents Minimum Wire Gauge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Over-current Protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Long-distance Wire Runs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Maximum One-way Distance and Wire Size - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Connecting the Charge Controller - - - - - - - - - - - - - - - - - -
Contents Daily Logs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–14 Monthly Logs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–14 Battery Equalization - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–14 5 Troubleshooting PV Charge Control Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
xii
1 Introduction Chapter 1 describes features and functions of the Conext MPPT Solar Charge Controller. It includes: • Features • Maximum Power Point Tracking • Charge Controlling • Auxiliary Output Functions • Automatic PV Array Night Disconnect 975-0400-01-01 Revision G This manual is for use by qualified personnel only.
Introduction Features The Conext MPPT Solar Charge Controller (solar charge controller) is a photovoltaic (PV) charge controller that tracks the maximum power point of a PV array to deliver the maximum available current for charging batteries. The solar charge controller can be used with 12-, 24-, 36-, 48-, and 60-volt DC battery systems. The solar charge controller is designed to regulate PV source, but will also work with other DC sources.
Maximum Power Point Tracking • Over-temperature protection and power derating when output power and ambient temperature are high. • Battery Temperature Sensor (BTS) to provide automatically temperaturecompensated battery charging. If the BTS is lost or damaged, a replacement can be ordered from Schneider (part number 808-0232-02). • Xanbus communications network.
Introduction Charge Controlling The solar charge controller can regulate PV array current for charging batteries at 12, 24, 36, 48, and 60 volts. It produces 60 amps of charging current and up to 3500 W (on 60-volt batteries) of charging power. + + – + – + – – Figure 1-3 PV Charge Controller The solar charge controller controls how the batteries are charged by the DC source (the PV array). It can be configured to use a two-stage (“No Float”) or three-stage charging process.
Charge Controlling Three-Stage Battery Charging The three-stage charging process results in more efficient charging compared to on-off relay type or constant voltage solid-state regulators. The final float stage reduces battery gassing, minimizes electrolyte loss, and ensures complete battery recharging. Battery voltage and current vary during the three-stage charging process as shown in Figure 1-4.
Introduction Bulk State Bulk/Boost Voltage Voltage Absorption State Float State Absorption Voltage Float Voltage Recharge Voltage Boost Timer 1hr fixed Time Max Absorb Time - dflt 3 hrs (adjustable 1 min - 8 hrs ) Current Max Current Limit Absorption Exit Current Threshold = 2% of programmed AH capacity Time Figure 1-4 Three-stage Battery Charging Cyclea a.
Charge Controlling Note: This note is applicable to Figure 1-4 and Figure 1-5. 1. When the charge cycle is interrupted, the charger will restart charging at the beginning of the multi-stage algorithm. 2. Exit Current Threshold can be effectively disabled by programming the amp hour capacity to zero. In this case, Absorption will only exit once the Max Absorption timer expires. 3.
Introduction Bulk State Bulk/Boost Voltage Voltage No Float State Absorption State Absorption Voltage Float Voltage Recharge Voltage Boost Timer 1hr fixed Time Max Absorb Time - dflt 3 hrs (adjustable 1 min - 8 hrs ) Current Max Current Limit Absorption Exit Current Threshold = 2% of programmed AH capacity Time Figure 1-5 Two-stage Battery Charging Cycle 1–8 975-0400-01-01 Revision G This manual is for use by qualified personnel only.
Charge Controlling Battery Temperature Compensation The Battery Temperature Sensor (BTS) automatically adjusts the charging process of the solar charge controller. With the BTS installed, the solar charge controller increases or decreases the battery charging voltage depending on the temperature of the battery to optimize the charge to the battery and to protect it from over-charge or damage. Using the BTS can extend battery life and improve overall charging.
Introduction Important: The solar charge controller maximum output voltage is limited to 72 volts for a 60-volt battery system, which is the bulk voltage setting for 60-volt batteries. Because of this output limit, the solar charge controller does not equalize 60-volt batteries.
Automatic PV Array Night Disconnect Automatic PV Array Night Disconnect At night, or when the PV array voltage is less than the battery voltage, the solar charge controller opens an internal relay to prevent battery current from flowing back to the PV array. In this mode of operation the solar charge controller draws minimal power from the battery. This automatic night-time disconnect eliminates the need for a blocking diode between the battery and the PV array.
1–12
2 Installation Chapter 2 contains information and procedures to install the Conext MPPT Solar Charge Controller. It includes: • Materials List and Tool Requirements • PV Array Requirements • Mounting • Grounding • Wiring • Installing the Battery Temperature Sensor • Commissioning Before installing the solar charge controller, read this entire chapter. Depending on your installation, you may need to perform certain installation stages in a different order than the order presented in this chapter.
Installation Materials List and Tool Requirements The following materials are shipped with the charge controller: • One Conext MPPT 60 150 Solar Charge Controller • One Conext Solar Charge Controller Owner’s Manual • One CE Conformity Declaration • One Battery Temperature Sensor (BTS) • One network terminator The following tools are required for installation: • Phillips head screwdriver • Wire cutters and wire strippers PV Array Requirements Note: The following information provides only gener
Mounting Table 2-1 MPPT Operational Window Charge Controller Mode Voltage Effect of Array Voltage Voc < Vbatt (system battery voltage) Charge controller does operate. Low Light VMPP < Vbatt Harvest of solar energy less than optimal. Charging VMPP = Vbatt to 120 VDC Maximum harvest of solar energy. Charging (MPPT window) 120 VDC < VMPP < 140 VDC Charge controller reduces the charging current to protect the unit from voltage spikes.
Installation WARNING EXPLOSION/CORROSION HAZARD To reduce the risk of fire or explosion, do not install the solar charge controller in sealed compartments containing batteries or in locations that require ignition-protected equipment. To reduce the risk of corrosion from hydrogen-sulfide gas vented by batteries, do not install the solar charge controller in sealed compartments containing batteries.
Mounting 6 inches (150 mm) on top and side(s) Figure 2-1 Minimum Clearance Requirements 975-0400-01-01 Revision G This manual is for use by qualified personnel only.
Installation Removing the Wiring Compartment Cover Before mounting, remove the wiring compartment cover to access the mounting holes and the wiring terminals. The wiring compartment cover is secured with two Phillips #8-32 × 2 ½-inch (63.5 mm) screws on the front cover of the unit. See Figure 2-2. Remove screws to access the wiring terminals.
Mounting Keyhole slot for wall mounting 73 (2 7/8) 323 (12 3/4) 280 (11) Additional mounting holes 368 (14 1/2) Ø 6.35 (1/4) 60 (2 3/8) 53 (2 1/16) 118 (4 5/8) 14 (9/16) 26.5 (1) 146 (5 3/4) 138 (5 7/16) All measurements in mm (in.) Figure 2-3 Dimensions and Knockout Locations Single knockouts are intended for BTS and network cables DUAL KNOCKOUT 34.52 (1 3/16) & 27.78 (1 1/16) 2 PL DUAL KNOCKOUT 34.52 (1 3/16) & 27.78 (1 1/16) 2 PL KNOCKOUT 27.78 (1 1/16) KNOCKOUT 27.78 (1 1/16) 31.
Installation Mounting the Charge Controller The solar charge controller is vertically mounted using three #10 × ½-inch or #12 × ½-inch (12.5 mm) pan-head screws. To mount the solar charge controller: 1. Remove the wiring compartment cover. 2. Mark the location of the keyhole slot on the wall. 3. Secure the top mounting screw in the location marked. Leave the screw head backed out approximately ¼ inch (6 mm). 4. Place the controller onto the screw and pull it down into the keyhole slot. 5.
Grounding Grounding The charge controller can be configured to be compatible with negativegrounded and ungrounded PV systems. For information about routing the ground connection, see Figure 2-10. The maximum size of the ground conductor is #6 AWG (16 mm2). This wire gauge is determined by electrical code requirements regarding conduit knockout sizes, wire bending radius, and space available within the solar charge controller wiring compartment.
Installation CAUTION The factory default configuration of the solar charge controller will ground the PV array negative to the chassis ground through the internal PV-GFP fuse. The PV-GFP circuit must be disabled for ungrounded PV arrays. This symbol identifies the protective conductor (grounding) connection.
Grounding Enabled Disabled Figure 2-7 PV Negative Ground Jumper Location Installing a Positive-Grounded Battery System The solar charge controller’s internal design has a built-in fuse—rated at 1 A, 600 V—which grounds both the PV negative and battery negative conductors and provides PV ground-fault protection (PVGFP) to the system. To avoid a short circuit, ground fault protection must be disabled before grounding the positive battery terminal for negative voltage reference.
Installation These voltage levels on both battery and auxiliary outputs are considered safe, extra-low voltages and do not present a hazard as long as the PV terminals are kept floated or ungrounded. Follow the instructions in Chapter 2, “Installation” for connecting the PV array and battery to the unit. Next, follow these steps for a safe, negative voltage reference connection: 1. Disable the solar charge controller’s internal PVGFP circuit.
Grounding Enabled Disabled Figure 2-8 Jumper Location (CE Marked Model) PV Connection and Auxiliary Lines WARNING haz HAZARD OF FIRE Do not ground the negative conductor of the auxiliary circuit. Failure to follow these instructions could result in death or serious injury. The PV array must not be grounded in either its positive or negative terminal. Do not attempt to ground the PV+ terminal to have a common ground with the battery.
Installation Wiring Important: Installations must meet all local electrical codes.This equipment should only be installed by a qualified electrician or a Certified Renewable Energy System Installer. WARNING SHOCK HAZARD Disconnect PV and battery circuits before wiring. DC Terminal Connector Locations Terminal connectors for DC wiring are located inside the wiring compartment. The labels above the DC wiring terminals and inside the wiring compartment identify all the connection points. See Figure 2-9.
Wiring Current Rating The solar charge controller PV input is rated for 60 A maximum Isc. Since PV outputs can vary due to the array size or sunlight angle, the safe minimum wire size must be chosen for maximum array short-circuit current. Consult PV array manufacturer specifications. Minimum Wire Gauge For installations where the PV array output is the maximum allowable 60 A Isc, the minimum allowable wire gauge is #6 AWG (16 mm2) copper wire with a 90°C (194°F) insulation rating.
Installation WARNING EQUIPMENT DAMAGE Do not connect an array capable of delivering over 60 A Isc to the solar charge controller. Wire sizes larger than #6 AWG (16 mm2) may be used to reduce resistive losses but should not be installed directly into the solar charge controller. Use a splicer block or similar to connect wires of different gauges together. Follow manufacturer’s recommendations for torque and mounting.
Wiring Table 2-3 One-Way Wire Distance and Wire Size Maximum one-way wire distance for a < 3% voltage drop assuming 60 A charging current 12 Vdc application shown For 24 Vdc systems, multiply distance by 2 For 36 Vdc systems, multiply distance by 3 For 48 Vdc systems, multiply distance by 4 For 60 Vdc systems, multiply distance by 5 Distance in feet (meters)a Distance in feet (meters) Amp s 60 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG 3 AWG 2 AWG 1 AWG 1/0 AWG 6.3 (1.92) 9.3 (2.83) 11.8 (3.60) 14.9 (4.
Installation Connecting the Charge Controller The following procedure is illustrated in Figure 2-10. WARNING 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. WARNING SHOCK HAZARD Do not connect the battery negative to ground. Bonding the battery negative to ground disables the unit’s internal PV ground-fault protection. For more information, see “Grounding” on page 2–9.
Wiring CAUTION REVERSE POLARITY DAMAGE Before making the final DC connection or closing the DC breaker or disconnect, check cable polarity at both the battery and the solar charge controller. Positive (+) must be connected to positive (+). Negative (–) must be connected to negative (–). 8. Connect a second positive (+) cable to the other side of the battery disconnect and connect to the positive (+) battery terminal. 9.
Installation + – BAT BAT PV PV + - + BTS Port PV array disconnect Battery disconnect/ overcurrent protector Do not connect the battery negative to ground. Grounding electrode conductor Ground the metal - + - + LEGEND Ground DC Positive DC Negative + - + - Figure 2-10 Charge Controller Power Wiring 2–20 975-0400-01-01 Revision G This manual is for use by qualified personnel only.
Connecting Multiple Units Connecting Multiple Units In a multiple-unit installation, each solar charge controller must be connected to a separate PV array. For other multiple-unit installation considerations, see “Network Installation” on page 2–25. Important: Only one solar charge controller is to have the PV-GFP fuse installed in installations with multiple parallel solar charge controllers. Before mounting and connecting the solar charge controllers, remove the PV-GFP fuse from each unit except one.
Installation PV Array #1 + PV Array #2 – + BAT BAT PV PV + - + BTS Port PV Array #1 – – + BAT BAT PV PV + - + PV Array #2 BTS Port + BAT BAT PV PV + - + Correct wiring— no wires crossed Grounding not shown.
Aux Output Connections CAUTION The auxiliary output is intended only to energize a low-current circuit such as a relay coil. Connection to a high-amperage device will open the fuse in the common line and possibly damage the unit. The auxiliary output connectors can accept #22 to #14 AWG (0.5 to 1.5 mm2) copper solid or stranded wire. The auxiliary output is short-circuit protected and is disabled when a ground fault occurs.
Installation Disconnecting the Charge Controller WARNING SHOCK HAZARD Ensure both the PV array and the batteries are disconnected from the solar charge controller before servicing the solar charge controller or the batteries. After disconnecting the batteries, the solar charge controller can appear deenergized when the PV array is still connected.
Network Installation Network Installation The Conext Solar Charge Controller is a Xanbus-enabled device. Xanbus is a network communications protocol developed by Schneider Electric. The solar charge controller is able to communicate its settings and activity to other Xanbus-enabled devices, such as the Conext XW+ inverter/charger, Conext System Control Panel (SCP), Conext Automatic Generator Start (AGS), and other charger controllers.
Installation CAUTION EQUIPMENT DAMAGE Do not use crossover cable. • Network terminators (Figure 2-13)—the Xanbus network must be properly terminated at each end to ensure the communication signal quality on the network. Network terminators plug into network ports on Xanbus-enabled devices. The solar charge controller and other Xanbus-enabled devices ship with one terminator. Depending on your network layout, this terminator may need to be inserted into another device elsewhere in the network.
Network Installation Connecting Network Cable Between Multiple Units WARNING SHOCK HAZARD Do not route the network cables in the same conduit or panel as the DC input/ output cables. WARNING SHOCK HAZARD Before opening the solar charge controller wiring compartment, ensure the PV array and batteries are disconnected. To reduce the risk of shock, cover the array with an opaque (dark) material.
Installation 6. Connect another network cable to solar charge controller #2 and route the cable to the next device in the network. 7. Ensure the factory-supplied network terminators are inserted into the empty Xanbus ports in the devices at the beginning and end of the network. There should be no empty Xanbus ports in any of the solar charge controllers.
Installing the Battery Temperature Sensor Figure 2-15 Attaching the BTS to a Battery Terminal 4. Pass the end of the BTS cable through a conduit hole on the solar charge controller and insert the BTS plug into the BTS port. See Figure 2-16. Important: The BTS cable must not pass through the same conduit used for PV wiring and battery cables. 5. Replace the solar charge controller wiring compartment cover. BAT BAT PV PV + - + BTS Port Insert the BTS plug into the solar charge controller BTS port.
Installation Commissioning During commissioning, the solar charge controller prompts you to enter important system information such as the nominal battery voltage, battery type, and battery bank capacity. Ensure you have this system information prior to commissioning. In systems where a SCP is present, the SCP is intended to be the configuration interface, so the prompt screens on the charge controller are suppressed. See “Commissioning Units Using a System Control Panel” on page 2–34.
Configuration Screens Figure 2-17 Configuration Screens Commissioning a Single Unit Without a System Control Panel To commission the solar charge controller: 1. Apply battery power to the unit. The LCD displays the two startup screens in sequence, as shown in Table 24, followed by the first of four configuration prompt screens.
Installation Or, if the unit has not automatically detected the voltage, select the correct voltage using the arrow buttons. When the correct battery voltage appears, press Enter. 8. At the Battery Capacity screen, select the battery capacity of your system. 9. Press Enter to confirm the battery capacity. 10. Uncover the PV array and/or apply power with the disconnect or selector switch.
Configuration Screens To commission multiple solar charge controllers: 1. Close the DC disconnect or use a selector switch to apply battery power to all of the solar charge controllers at the same time. The LCD on each unit displays the two startup screens in sequence, as shown in Table 2-4, followed by a prompt screen for you to set the device number. 2. On all the charge controllers, set the device number to a value other than its default value of 00.
Installation 7. Uncover the PV array and/or apply power with the disconnect or selector switch. The solar charge controller starts up in sleep mode and waits for a short period to determine that the input voltage is greater than the output voltage. The LCD indicates the solar charge controller mode or any error conditions that may be present (see “Viewing Operating Status” on page 4–2). After the input voltage exceeds the output voltage by the required margin for 10 seconds, the unit begins operating.
Configuration Screens 8. Repeat steps 3 through 7 for the next solar charge controller. When you have set the device number for all solar charge controllers, you can configure Connections and Charger Settings for the first solar charge controller. To configure Connections and Charger Settings for the first solar charge controller: 1. On the Select Device Menu, select “MPPT60 01.” 2. Navigate to the Multi Unit Config menu and select Connections.
Installation The solar charge controller starts up in sleep mode and waits for a short period to determine that the input voltage is greater than the output voltage. After the input voltage exceeds the output voltage by the required margin for 10 seconds, the unit begins operating. 2–36 975-0400-01-01 Revision G This manual is for use by qualified personnel only.
3 Configuration Chapter 3 contains information and procedures to configure the Conext MPPT Solar Charge Controller. It includes: • Configuration Menus • Configuring Battery Characteristics and Battery Charging • Configuring Charge Controller Input • Configuring the LCD • Resetting to Factory Defaults 975-0400-01-01 Revision G This manual is for use by qualified personnel only.
Configuration Configuring the Charge Controller The following sections describe how to configure the Conext MPPT Solar Charge Controller (charge controller) for the desired application and function. The solar charge controller is configured using the four buttons on the front of the unit. Table 3-1 Charge controller buttons Button Function Enter • Displays the next screen level. For example, pressing Enter from the Battery Menu selection screen displays the first configurable item on the Battery menu.
Configuration Menus Configuration Menus The menus for setup and monitoring solar charge controller performance are shown in Figure 3-1 and Figure 3-2. Not a configuration menu. See page 4–9. View and reset data logs and monitor solar charge controller performance. See page 4–13. Configure battery and battery charger parameters. See page 3–5 and page 4–14.
3–4 Exit Enter Exit Exit Enter Exit This manual is for use by qualified personnel only.
Configuring Battery Characteristics and Battery Charging Configuring Battery Characteristics and Battery Charging On the Battery Menu you can: • Start battery equalization • Configure your battery type, voltage and amp-hour capacity • Configure a custom battery type by adjusting settings for each battery charge stage and fine-tuning temperature-compensated charging • Monitor battery temperature.
Configuration Table 3-2 Battery Menu Values Setting Values Default Activate/Stop Activate Enables or disables Battery Equalization. If the Battery Type is set to GEL or AGM, this setting is disabled. 0–365 d(ays) 0d Sets a reminder that notifies you when the battery needs equalizing. If set to 0, the reminder is disabled. 1–12 1 Selects the battery bank connected to the solar charge controller.
Configuring Battery Characteristics and Battery Charging Table 3-2 Battery Menu Values Setting Values Default Description 12V: 10.0– 13.5V 12.5V 24V: 20.0– 27.0V 25.0V Sets the voltage at which the charger transitions from Float or No Float back to Bulk, or from Absorption back to Bulk. 36V: 30.0– 40.5V 37.5V 48V: 40.0– 54.0V 50.0V 60V: 50.0– 67.5V 62.5V 120–360 min 180 min Sets the maximum time spent at a constant voltage (the setting for Absorption voltage) during the absorption stage.
Configuration Setting a Custom Battery Type WARNING HAZARD OF FIRE OR EXPLOSION Incorrect settings for speciality batteries, such as lithium ion, can cause dangerous battery over-charging. Always connect the Battery Temperature Sensor (BTS). Custom battery settings should be configured by qualified personnel only. Failure to follow these instructions can result in death or serious injury.
Configuring Battery Characteristics and Battery Charging Table 3-3 Custom Battery Menu Values Setting Values Default Description 12V: 13.5–16.0V 16.0V 24V: 27.0–32.0V 32.0V 36V: 40.5–48.0V 48.0V 48V: 54.0–64.0V 64.0V 60V: 67.5–72.0V 72.0V 12V: 10.0–16.0V 14.4V 24V: 20.0–32.0V 28.8V 36V: 30.0–48.0V 43.2V 48V: 40.0–64.0V 57.6V 60V: 50.0–72.0V 72.0V 12V: 10.0–16.0V 14.4V 24V: 20.0–32.0V 28.8V 36V: 30.0–48.0V 43.2V 48V: 40.0–64.0V 57.6V 60V: 50.0–72.0V 72.
Configuration CAUTION EQUIPMENT DAMAGE The solar charge controller is incapable of determining battery type and cannot warn against or disallow incorrect settings. The settings for bulk, absorption, float and equalization charge must be checked carefully against the battery specifications. Incorrect settings may damage the battery or shorten battery life.
Configuring Charge Controller Input Configuring Charge Controller Input On the Input Menu you can disable automatic maximum power point tracking and configure the reference voltage level at which the solar charge controller will operate the array. Configuring the reference voltage is not required for normal operation, but can be useful for non-PV applications or for testing purposes. The Input Menu is an advanced menu item.
Configuration Configuring the Auxiliary Output The Aux Menu allows you to enable and configure the auxiliary output. The auxiliary output provides between 5 and 13 volts DC (configurable) and up to 200 milliamps to power a relay, indicator light, vent fan, or alarm. The Aux Menu is an Advanced Menu item. To display the Aux Menu, go to the Display Menu, view the Display Mode screen and select Advanced. See “Configuring the LCD” on page 3–16.
Configuring the Auxiliary Output Table 3-5 Aux Menu Values Setting Values Low Batt Voltage, Default Description Low Batt Selects the desired condition Voltage to activate the Aux Output. Hi Batt Voltage, Hi Array Voltage, Low Batt Temp, Hi Batt Temp, Hi Heat Sink Temp, Fault Depends on Trigger Source (see Table 3-6) Line 1: Selects the battery or array voltage to activate Aux Output.
Configuration Table 3-5 Aux Menu Values Setting Values Default Description Active Hi, Active Hi Sets the mode (polarity) of the aux output. When Active Hi is selected, the aux output turns on when the trigger source is present. When Active Lo is selected, the aux output turns off when the trigger source is present.
Configuring the Auxiliary Output Low Batt Temp Activates the auxiliary output when the battery temperature falls below the trigger setting for the trigger delay time. Deactivates the auxiliary output when the battery temperature rises above the clear setting for the clear delay time. Battery temperature is measured with a battery temperature sensor. Do not use this setting if a battery temperature sensor is not installed.
Configuration Table 3-6 Trigger Source Configuration Ranges Trigger Source Range Default Trigger Default Clear 12V: 12–16V 14V 13V 24V: 24–32V 28V 26V 36V: 36–48V 42V 39V 48V: 48–64V 56V 52V 60V: 60–80V 70V 65V 10–145V 140V 130V 30.0–60.0 C 45.0 C 35.0 C -30.0–10.0 C 0.0 C 5.
Configuring the LCD Table 3-7 Display Menu Values Setting Values Default Description 1–9 5 Line 1: Adjusts screen contrast. 1–9 8 Line 2: Adjusts backlight brightness. 0, 5sec, 10sec, 30sec, 1min, Always On 5 sec Adjusts how long the backlight stays on after the last key press. When 0 is selected, the backlight never turns on.a 10sec, 30sec, 1min, 5min, 10min 30sec Adjusts how long the LCD displays the current screen before returning to the default home screen.
Configuration Device Menu On the Device Menu you can change the operating mode of the solar charge controller and view the solar charge controller’s device number. Both these activities may be necessary for service or diagnostics, or when adding another Xanbus-enabled device to the system. The Device Menu is an advanced menu item. To display the Device Menu, go to the Display Menu, view the Display Mode screen and select Advanced.
Device Menu Table 3-8 Device Menu Values Setting Values Default Description Operating, Operating Operating is the normal mode Standby, for the unit. Hibernate Standby disables the output by disconnecting the main power circuit from the battery. The unit cannot charge. The unit still draws some power from the battery to operate. The LCD stays on. Hibernate performs the same actions as Standby, but it also disables all Xanbus network communications.
Configuration Resetting to Factory Defaults On the Reset Menu you can restore factory default settings. The Reset Menu is an advanced menu item. To display the Reset Menu, go to the Display Menu, view the Display Mode screen and select Advanced.
4 Operation Chapter 4 contains information about the operation of the Conext MPPT Solar Charge Controller. It includes: • Viewing Operating Status • Monitoring Charge Controller Operation • Battery Equalization 975-0400-01-01 Revision G This manual is for use by qualified personnel only.
Operation Viewing Operating Status The Conext MPPT Solar Charge Controller (solar charge controller) has four buttons and a 2-line, 16 character liquid crystal display (LCD) for configuration and displaying system information and operating status. • When in Charge Control mode the LCD shows the output power, voltage and current (and additional information as shown in Figure 4-1). • When a fault condition exists, the LCD shows “Fault Active.
Viewing Operating Status Enter Press to view configuration and history menus Screen will appear if unit is in float , or is not charging and the charge algorithm is set for 3-stage Screen will appear if unit is in float , or is not charging and the charge algorithm is set for 3-stage Screen wil
Operation If there is sufficient energy from the PV array, the default operation screen is displayed while the solar charge controller is charging or not charging (in the “no float” stage when configured for two-stage charging). When more than one solar charge controller is installed and connected to the Xanbus network, the default operation screen appears as shown in Table 4-2.
Viewing Operating Status Table 4-3 Other Operation Screens Display Description Accumulated amp-hours and kilowatt-hours produced by multiple solar charge controllers today. This screen appears only when multiple solar charge controllers are installed in a network. Measured input power, voltage, and current. Accumulated amp-hours and kilowatt-hours produced today by the individual unit.
Operation Table 4-3 Other Operation Screens Display Description User-defined custom screen text (configured on the Display Menu). This screen only appears if it has been configured. Charge Stages The charge stages displayed on the LCD are described in Table 4-4. Table 4-4 Charge Stages Text Description Bulk Batteries are charging at the maximum current output of the DC source. If the solar charge controllerr shuts down because of low input voltage, the unit restarts in bulk mode.
Viewing Operating Status Dynamic Text The text that appears on the second line of the charge mode screen is described in Table 4-5. Table 4-5 Dynamic Text Text Appears When... Charging The charge stage is Bulk, Absorb, or Float. Not Charging Two-stage charging is selected and the solar charge controlleris in the No Float stage. Warning Active A warning condition is present (see Active Faults and Warnings screen).
Operation Monitoring Charge Controller Operation During operation, you may want to view Active Fault and Warning messages and logged power production data. This information is available on the configuration and history menus. To view configuration and history menus, press Enter from any Operating screen. See page 4–9. See page 4–13. See page 4–15.
Monitoring Charge Controller Operation Viewing Active Faults and Warnings You can view active faults and warnings from the Faults and Warnings Menu. Note: The Faults and Warnings menu is visible only when the solar charge controller has one or more active faults or warnings. Warning messages indicate a problem that could affect normal operation. “Warning Active” appears on the LCD to notify you of the warning condition.
Operation 4. Press Enter again to clear the “Batt Under Volt” fault. Or Press the down arrow to select the “Aux Output Ovld” fault, then Enter to clear it. Enter Exit Enter Exit Figure 4-3 Faults and Warnings Menu Table 4-6 Fault and Warning Messages Display Description During operation, the solar charge controller continuously monitors the input voltage.
Monitoring Charge Controller Operation Table 4-6 Fault and Warning Messages Display Description The Batt Under Volt (Battery Under Voltage) Fault appears when the battery voltage falls to the nominal battery voltage, minus 4 V per 12 V (for example, below 32 V in a 48 V system) for 1 second. The fault clears when battery voltage rises to the nominal battery voltage, minus 3 V per 12 V for 2 seconds.
Operation Table 4-6 Fault and Warning Messages Display Description Auxiliary Output Overload Fault. This fault appears when too much current is being drawn from the auxiliary output. The fault triggers when the auxiliary output voltage falls more than 1 V below the auxiliary output voltage for three seconds. 4–12 Ground Fault appears when a ground fault causes the ground fault protection (GFP) fuse to blow.
Monitoring Charge Controller Operation Viewing Logged System Data The solar charge controller stores accumulated operating data for viewing on the History menu. You can also reset some of the logged data on the History menu. On the History Menu you can view logs for daily, monthly, or lifetime power production.
Operation Daily Logs To view the daily logs stored in memory, press Enter from the Daily Logs screen, then press the down arrow button to view each log, starting with the most recent. On the log screen, the current day is “Today–00,” yesterday is “Today–01,” and so on. See Figure 4-4. The solar charge controller stores up to 30 daily logs. After 30 days, the oldest daily log is overwritten with the newest log.
Battery Equalization WARNING EXPLOSIVE GASES Equalization generates explosive gases. Ensure adequate ventilation. CAUTION BATTERIES MAY BE DAMAGED Never equalize a battery more than necessary. Equalization can damage your batteries if performed too frequently or done improperly. Always check electrolyte level before and after equalization. Fill with distilled water according to the battery manufacturer’s recommendation.
Operation If the battery is in the float or no float stage, the solar charge controller goes back to the bulk stage and goes through a full charge cycle before entering the Equalization stage. The LCD displays “Equalization Pending” while the solar charge controller performs this full charge cycle. The full charge cycle ensures that the batteries are fully charged before an equalization is attempted.
5 Troubleshooting Chapter 5 contains information about identifying and resolving possible problems with systems using a Conext MPPT Solar Charge Controller. It includes: • PV Charge Control Troubleshooting • Replacing the Ground Fault Protection Fuse 975-0400-01-01 Revision G This manual is for use by qualified personnel only.
Troubleshooting PV Charge Control Troubleshooting Table 5-1 lists possible problems that may arise when using the Conext MPPT Solar Charge Controller (solar charge controller). Table 5-1 PV Charge Control Problems Problem Possible Cause Solution The LCD shows “Low Light” under all conditions. PV wires are connected in reverse polarity. Verify PV polarity relative to battery negative. Low panel output. Input and output voltages read about the same.
Replacing the Ground Fault Protection Fuse Table 5-1 PV Charge Control Problems Problem Possible Cause Solution Battery voltage is exceeding Bulk and Float settings in cold weather and not reaching settings in hot weather. BTS is compensating charging voltages based on battery temperature. No problem. This is the intended operation. The LCD shows “Ground Fault” and the unit has stopped operating. A ground fault has caused the ground fault protection (GFP) fuse to blow.
Troubleshooting WARNING SHOCK HAZARD • Dangerous voltages can exist inside the solar charge controller. If there is leakage current from the ungrounded conductor to ground at the array, touching the grounded lead could cause a life-threatening shock. • Cover PV arrays with an opaque material during this procedure. When the fuse has blown due to a fault, incorrect handling can be lifethreatening. Use insulated tools.
A Specifications Appendix A provides the specifications for the Conext MPPT Solar Charge Controller. It includes: • Electrical Specifications • Default Battery Charging • Mechanical Specifications • Output Power Versus Ambient Temperature • Optional Accessories • Regulatory Approvals All specifications are subject to change without notice. 975-0400-01-01 Revision G This manual is for use by qualified personnel only.
Specifications Electrical Specifications Maximum PV Array Voltage (Operating) 140 VDC Maximum PV Array Open Circuit Voltage 150 VDC Array Short Circuit Current 60 ADC maximum Nominal Battery Voltage 12, 24, 36, 48, 60 VDC Battery Voltage Range (Operating) 10 VDC to 80 VDC Maximum Output Current 60 A (for all battery voltages except 60 V) Maximum Output Power 3500 W Auxiliary Output 5–13 V, up to 200 mA Tare Loss/Night-time Power Consumption 2.
Mechanical Specifications Mechanical Specifications 7 Enclosure Type Indoor, ventilated, sheet metal chassis with --- " and 1" 8 (22.22 mm and 27.76 mm) knockouts and aluminum heat sink Maximum and Minimum Wire Size in Conduit #6 AWG to #14 AWG (16 to 2.5 mm2) Maximum and Minimum Wire Size Rating of Terminal Block #3 AWG to #14 AWG (25 to 2.
Specifications Optional Accessories Conext System Control Panel 865-1050 Conext Automatic Generator Start 865-1060 Network cables 3 ft (0.9 m): 809-0935 25 ft (7.6 m): 809-0940 50 ft (15.2 m): 809-0941 75 ft (22.9 m): 809-0942 Network terminators Male (2 per pack): 8090901 Regulatory Approvals Certified to UL 1741:2005 and to CSA 107.1-01 and carries the c(CSA)us mark.
B Conext System Control Panel Menus Appendix B is a guide to the Conext System Control Panel monitoring and configuration menus for the Conext Solar Charge Controller. It includes: • Using the SCP • SCP Menu Map • Changing Settings Using the SCP • Charge Controller Setup Menu • Configuration Settings • Monitoring the Charge Controller The Conext System Control Panel may be installed if the solar charge controller is part of a system that includes an Conext XW+ inverter/charger.
Conext System Control Panel Menus Using the SCP The Conext Solar Charge Controller (charge controller) can be configured using the Conext System Control Panel (SCP). If you do not have a SCP installed, all configuration items described in this appendix are also available from the charge controller LCD front panel. See the Chapter 3, “Configuration”” for more information. The SCP has four buttons for navigating between screens and menus and configuring the solar charge controller.
Using the SCP SCP Menu Map Figure B-2 shows how the SCP screens and menus are organized. The screens and menus are described in Table B-2.
Conext System Control Panel Menus Table B-2 Screen and menu descriptions Screen or menu Description Startup screen Appears for a few seconds after the system starts up or when the system has been reset. System Home screen Displays status information for the power system, consisting of all Xanbusconnected devices on a single network. The System Home screen appearance varies with the status of the inverter/charger and other Xanbus-enabled devices in the power system.
Using the SCP Changing Settings Using the SCP If you need to change a solar charge controller setting, use the buttons on the SCP to perform three basic steps: 1. View the Select Device menu. 2. Select the solar charge controller from the Select Device menu. 3. Select and adjust a changeable setting on the solar charge controller Setup menu. See page B–8. Each of these three steps is described in detail in the following sections.
Conext System Control Panel Menus To select the solar charge controller from the Select Device menu: 1. On the Select Device menu, use the down arrow button to highlight MPPT60 150. 2. Press Enter. The Setup menu appears. Charge Controller Setup Menu The Setup menu allows access to the Meters screen and several other commands that control solar charge controller operation.
Configuration Settings Configuration Settings Basic menu The configuration settings can be viewed in Basic and Advanced formats (see Figure 3-5, “Basic and Advanced Settings” on page 3–8). The Basic settings include configuration items you may have to adjust routinely, or as part of initial setup. Advanced menu The Advanced settings option gives you access to the full range of settings, including everything displayed on the Basic menu.
Conext System Control Panel Menus For a map of all solar charge controller configuration menus, see Figure B-7 on page B–9. Configurable settings are identified by the square brackets [ ] around the values along the right side of the screen. To select and change a configurable setting: 1. On the desired configuration menu, press the up arrow or down arrow button to highlight the setting you want to change. 2. Press Enter to highlight the current value of the setting. 3.
[Bulk] [Disabled] [Operating] MPPT60 01: Setup Advanced Settings 975-0400-01-01 Revision G This manual is for use by qualified personnel only. 215W 2.1A 100.5V 210W 3.7A 57.4V 3.5Ah 0.20kWh 0.1kAh 5kWh 20C Float AuxOff Device Info Meters [MPPT 02] Advanced Settings Multi Aux Input Chgr [Off] [64.0V] [57.6V] [57.6V] [54.0V] [108mV/K] “MPPT Ref Volts” can be Custom Battery [MPPT] [01] [Off] [ActiveHigh] [12V] [LowBattV] [42.0V] [1 sec] [48.
Conext System Control Panel Menus Monitoring the Charge Controller You can monitor solar charge controller operation on the SCP by viewing the: • solar charge controller Home screen • solar charge controller Meters screen Charge Controller Home Screen The solar charge controller Home screen displays real-time operational data specific to the solar charge controller.
Monitoring the Charge Controller Meters You can monitor solar charge controller operation on the Meters screen. The Meters screen displays input and output power, battery temperature, charge stage, and total power production for that day and power production over the unit’s lifetime. You can select the Meters screen from the solar charge controller Setup menu. MPPT60 01: Setup Meters Meters [Bulk] [Disabled] [Operating] 215W 2.1A 100.5V 210W 3.7A 57.4V 3.5Ah 0.20kWh 0.
B–12
C Boost Charging Appendix C provides information on boost charging for flooded lead-acid batteries in offgrid applications. 975-0400-01-01 Revision G This manual is for use by qualified personnel only.
Boost Charging Using Boost Charging Boost charging allows for better utilization of flooded lead acid batteries under moderate cycling in off grid applications. Boost charging encourages a short duration charging voltage—above the gassing voltage—at the beginning of the absorption charge state. Testing has shown that boost charging improves battery performance by providing a regular mixing of the liquid electrolyte.
Index A abbreviations iv absorption charging stage 1–5 acronyms iv advanced menus 3–3 alarms using auxiliary output 1–10 auxiliary output functions 1–10 auxiliary output menu 3–12 recommended frequency 4–15 exit button 3–2 Conext System Control Panel B–2 F faults and warnings menu 4–9 float charging stage 1–5 G B basic menus 3–3 battery equalization 4–14 battery menu 3–5 battery safety information vii battery temperature compensation 1–9, 3–10 bulk charging stage 1–5 C CAUTION, definition v charge stage
Index P parallel configuration communication between inverters 2–25 proof of purchase 1–ii purchase date 1–ii R reset menu 3–20 restore default settings B–8 S serial number 1–ii silent float charging stage 1–7 system control panel buttons described B–2 changing settings B–5 charge controller home screen B–10 meters screen B–11 select device menu B–4, B–5 startup screen B–4 system home screen B–4 T three-stage charging 1–5 Troubleshooting 5–2 two-stage charging 1–7 U up arrow button 3–2 up arrow button,
Schneider Electric solar.schneider-electric.com As standards, specifications, and designs change from time to time, please ask for confirmation of the information given in this publication. © 2015 Schneider Electric. All rights reserved.
