Trace Sun Tie ST1000, Sun Tie ST1500, Sun Tie ST2000, Sun Tie ST2500 Installation And Operator's Manual

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Sun Tie

ST1000, ST1500, ST2000 and ST2500

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Inverter

Installation and Operators Manual

2000 Xantrex/Trace Engineering

975-0003-01-02 Rev. A 11/00

Sun Tie Inverter

ST1000, ST1500, ST2000 and ST2500

Table of Contents

Section Description Page

1.0 INTRODUCTION .....................................................................................1

Standard Features ........................................................................... 1

2.0 INSTALLATION....................................................................................... 2

Pre-Installation ................................................................................2

Tools Required ..........................................................................2

Hardware/Materials Required .................................................. 2

AC Connections ........................................................................ 2

DC Connections ........................................................................ 3

ST1500 and ST2500 ............................................................ 3

ST1000 and ST2500 ............................................................ 4

Grounding ................................................................................. 5

AC Grounding .....................................................................5

DC Grounding .....................................................................5

PV Arrays ...................................................................................5

AC Circuit Breakers .................................................................. 6

Wire Routing ............................................................................. 6

Mounting .......................................................................................... 7

Wiring ........................................................................................... 11

DC Wiring ................................................................................ 11

PV Array ................................................................................... 11

ST1500 and ST2500 DC Wiring ....................................... 11

PV Array Conduit/Wire Run .............................................11

ST1000 and ST2000 DC Wiring .......................................13

PV Array Conduit/Wire Run .............................................13

AC Wiring ................................................................................ 14

Lightning Protection ...............................................................17

3.0 OPERATION ......................................................................................... 18

Start-up Procedure ........................................................................18

Required Equipment ...............................................................18

AC Utility Voltage Check ........................................................ 18

Solar Array DC Voltage Check ............................................... 19

Operational Test ...................................................................... 20

4.0 TROUBLESHOOTING ..........................................................................24

5.0 SPECIFICATIONS .................................................................................27

6.0 SERVICE INFORMATION .....................................................................28

7.0 WARRANTY.......................................................................................... 29

Disclaimer of Liability

Since the use of this manual and the conditions or methods of installation, operation, use and maintenance of the unit are beyond the control of Xantrex/Trace, the company does not assume responsibility and expressly disclaims liability for loss, damage, or expense arising out of or any way connected with such installation, operation, use, or maintenance.

IMPORTANT SAFETY INSTRUCTIONS

This manual contains important safety instructions that should be followed during the installation

and maintenance of this product.

To reduce the risk of electrical shock, and to ensure the safe installation and operation of this product, the following safety symbols have been placed throughout this manual to indicate dangerous conditions and important safety instructions.

WARNING - A dangerous voltage or condition exists in this area.

Use extreme caution when performing these tasks.

AVERTISSEMENT - Une tension ou condition dangereuse existe dans cette zone.

Faire preuve dextrême prudence lors de la réalisation de ces tâches.

CAUTION - This procedure is critical to the safe installation or operation of the unit. Follow these

instructions closely.

ATTENTION - Cette procédure est essentielle à linstallation ou lutilisation

de lunité en toute sécurité. Suivre ces instructions de près.

NOTE - This statement is important. Follow instructions closely.

NOTE - Cette déclaration est importante. Suivre les instructions de près.

 All electrical work must be done in accordance with local and national electrical codes.

 Before installing or using this device, read all instructions and cautionary markings located in

(or on) the manual, the ST and the PV array.

 Do not expose this unit to rain, snow or liquids of any type without the rain/weather shield

hood installed (optional on some models).

 To reduce the chance of short-circuits when installing or working with the inverter or the PV

array, use insulated tools.

 Remove all jewelry such as rings, bracelets, necklaces, etc., prior to installing this system.

This will greatly reduce the chance of accidental exposure to live circuits.

 The ST unit contains more than one live circuit (PV array and AC line). Power may be present

at more than one source even when the circuit breakers are off.

 This product contains no user serviceable parts. Return the unit to a Trace Authorized Service

Center for maintenance.

 Wiring to the utility should only be done after receiving prior approval from the utility company

and performed only by a qualified electrician.

 Completely cover the surface of all PV arrays with an opaque (dark) material BEFORE wiring

them. PV arrays produce electrical energy when exposed to light, and could create a hazardous condition.

SAVE THESE INSTRUCTIONS

iii

Solar PV Array

DC Input Voltage

Sun Tie Unit

AC Output

Voltage

OFF

Sun Tie

OFF

Solar Power

AC to Grid

AC Utility

Meter

Main Utility

Service Panel

975-F00-008SA

NOTE: This is a one line drawing intended as a system overview only. System grounding and other electrical details are not included.

1.0 INTRODUCTION

The Trace Sun Tie (ST) solar power conversion center is designed to convert a home or business into a green power generating station. The ST unit converts solar electric (PV) power into utility grade electricity which can be used by the home, or sold to the power company. Installing an ST unit is as simple as mounting it to the wall and connecting a DC source (PV array), and the AC output to the utility.

Standard Features All-in-one Design

All necessary DC input and AC output connections, disconnects and circuit breakers are housed within the STs easily installed, compact enclosure. A built-in LCD panel provides easy-to-read system status and daily cumulative energy production information.

Uses Most Types of PV Technology

The ST is designed to take advantage of most types of solar electric technologies. The inverter allows up to 120 VDC open circuit PV modules to be used so both crystalline and thin film PV modules can be used.

Maximum Power Point Tracking

The inverter performs a power sweep every minute adjusting array voltage and current, maximizing PV power generation. Maximum Power Point Tracking (MPPT) ensures the system produces as much AC power as possible under any light condition.

High Efficiency and Long Life

The high frequency, solid-state design of the ST inverter is extremely efficient. When array output is over 500 watts, the inversion process is over 90% efficient (with a peak efficiency of 94%). The ST inverter has a design life of over twenty years.

Expandable

ST inverters may be connected in a parallel configuration for increasing net metering capacity. The modular expandability of the ST Series allows for system growth.

UL Listed

The ST has complete on-board islanding protection and meets safety operating standards and code requirements world wide. In North America, it is UL listed (UL 1741-First Edition) and cUL listed to CSA C22.2 No. 107.1-95. NEC 690 building code requirements for PV may be met with the optional ground fault protection (PVGFP).

Options

These features are included on some models:

 PV array combiner board with six 20 amp max. protected inputs

 PV array Ground Fault Protection PVGFP

2.0 INSTALLATION

Pre-Installation

Before installing the Trace ST unit, read all instructions and cautionary markings located in

this manual, on the PV array and on the main service panel.

NOTE: The Trace ST weighs approximately 35 pounds (depending upon configuration and model). Always use proper lifting techniques during installation to prevent personal injury.

Mounting:

The Trace ST unit can be mounted outdoors with the optional Rain Shield (STRS).

Tools required:

Phillips screw drivers level slotted screw drivers wire strippers open-end wrenches torque wrench socket wrench and fittings electrical tape multimeter (true rms) pencil frequency counter (optional) utility knife

Hardware/Materials required:

wood screws and washers (supplied) conduit and appropriate fittings anchors for screws (material dependent)

AC Connections:

The inverters AC output breakers accept wire sizes from #614 AWG. Refer to the table

below for minimum recommended wire size.

Inverter

Model

ST1000 ST1500 ST2000 ST2500

AC Am ps

Output per

leg

4.2 5.2 14 AWG 14 AWG 12 AWG

6.3 7.8 14 AWG 12 AWG 10 AWG

8.3 10.4 14 AWG 12 AWG 10 AWG

10.4 13 14 AWG 12 AWG 8 AWG

NEC Amp

(Amps *125%)

Recommended Minimum AC Wire Sizes

Minimum Wire Size for Specified Distance

0–50 Ft

One Way

50–100 Ft

One Way

100–200 Ft

Table 1

One Wa y

975-000-001

NOTE: These are the minimum recommended wire sizes in conduit. Installing a large number of wires in conduit or enclosed locations may require larger wire sizes. Consult your local/national electrical code for more information.

2.0 INSTALLATION

Pre-Installation (continued)

DC Connections: ST1500 and ST2500

DC connections are made on the combiner board for models ST1500 and ST2500. The combiner board accepts wire sizes from #614 AWG. Refer to the table below for minimum recommended wire sizes.

DC Amps

1.0 1.6 14 AWG 14 AWG 14 AWG

3.0 4.7 14 AWG 12 AWG 10 AW G

5.0 7.8 12 AWG 10 AWG 6 AW G

7.0 10.9 12 AWG 8 AWG 6 AWG

9.0 14.0 10 AWG 8 AWG Not Recommended

11.0 17.2 10 AWG 6 AWG Not Recommended

NEC Amp

(Amps x 156%)

Minimu m W ire S ize fo r Spe c ifie d Dista n ce

0–25 Ft

One Way

25–50 Ft

One Way

50–100 Ft

One Way

975-000-002

Table 2

Recommended Minimum DC Wire Sizes

NOTE: These are the minimum recommended wire sizes. Installing a large number of wires in conduit or enclosed locations may require larger wire sizes. Consult your local/national electrical code for more information.

PV array wiring

(note polarity)

DC conduit wiring

(from solar arrays)

Figure 1

Combiner Board Indicating DC PV Array Wire Connection Points

NOTE: The National Electrical Code (NEC) places restrictions on minimum DC wire bending radius. A #6 AWG wire is the largest that may be used on the ST1500 and ST2500 inverters.

2.0 INSTALLATION

Pre-Installation (continued)

DC Connections: ST1000 and ST2000

DC connections are made at the 100 amp DC circuit breaker and the DC negative terminal block for models ST1000 and ST2000. Refer to the table below for minimum recommended wire sizes.

DC Amps

(from PV array)

10 15.6 10 AWG 6 AWG 4 AWG 15 23.4 8 AWG 4 AWG *2 AWG 20 31.2 6 AWG 4 AWG *1 AWG 30 46.8 4 AWG *2 AWG Not Recommended 40 62.4 4 AWG *1 AWG Not Recommended 60 93.6 *2 AWG Not Recommended Not Recommended

NEC Amp

(Amps x 156% )

Minimum Wire Size for Specified Distance

0–25 Ft

One Way

25–50 Ft One Way

50–100 Ft

One Way

975-000-004

Table 3

Recommended Minimum DC Wire Sizes

*NOTE: The National Electrical Code (NEC) places restrictions on minimum DC wire bending radius. If the enclosures side is used for routing the wires to the DC terminals, then the wires must be bent to make the appropriate connections. A #3 AWG wire is the largest that may be used on the ST1000 and ST2000 inverters if the side panel is used. Side knockouts are NOT provided on the unit.

PV array Negative wiring

PV array Positive wiring

Figure 2

DC PV Array Wire Connection Points

(with no combiner board)

2.0 INSTALLATION

Pre-Installation (continued)

Grounding:

AC Grounding

The Trace ST unit should be connected to a grounded, permanent wiring system.

DC Grounding

The negative PV conductor should be bonded to the grounding system at only one point in the system. The size for the conductor is usually based on the size of the largest conductor in the DC system. Negative/ground bonding is accomplished by factory wired PVGFP breakers (when this option is installed) or a factory installed grounding block (when PVGFP is not installed).

PV Arrays:

The ST unit is optimized to work with 4-each, 12 volt nominal crystalline PV modules in series

(48 VDC nominal), or various combinations of amorphous, thin film PV modules. Ensure the PV array used in the system operates within the MPPT operational window.

The solar array connected to the ST Series inverter should have a minimum of 50 volts DC

open-circuit in full sunlight conditions. Crystalline solar arrays configured for 48 volts DC nominal will have a open-circuit voltage in the area of 84 volts DC in full sunlight. The maximum peak power tracking (MPPT) software controls the output of the solar modules, under loaded conditions, in the 42-85 volts DC range (full inverter output power occurs between 5285 VDC). Other array voltage will either not operate the inverter or will not allow maximum harvest of the suns energy.

WARNING: WHENEVER A PV ARRAY IS EXPOSED TO SUNLIGHT, A SHOCK HAZARD EXISTS AT THE OUTPUT CABLES OR EXPOSED TERMINALS. TO REDUCE THE RISK OF SHOCK DURING INSTALLATION, COVER THE ARRAY WITH AN OPAQUE (DARK) MATERIAL BEFORE MAKING ANY CONNECTIONS.

ST1000 and ST2000 Models

ST1500 and ST2500 Models

Ground Bar Location

(connect to solid earth ground)

Figure 3

Ground Bar Location

2.0 INSTALLATION

AC Circuit Breakers:

The main service panel must dedicate a 15 amp minimum, double pole breaker (120/240 volts

AC) to operate the ST unit.

Wire Routing:

Determine all wire routes both to and from the Sun Tie. Possible routing considerations include:

 AC input wiring from the main service panel to the ST

 DC input wiring from the PV array to the ST

 DC ground from the PV array to an external ground rod

 All wiring and installation methods should conform to applicable electrical and building codes.

 Pre-plan the wire and conduit runs. The DC terminal blocks accept up to a #6 AWG wire

(ST1500 and ST2500) and #2 AWG* wire (ST1000 and ST2000); the AC circuit disconnects accept cable sizes up to #6 AWG.

 For maximum safety, run AC and DC wires/cables in (separate) conduits.

*NOTE: #2 AWG wire can only be used if the bottom knockouts are used. If punching side walls for wire routing, the largest wire for acceptable wire bend radius is #3 AWG maximum.

WARNING: CHECK FOR EXISTING ELECTRICAL OR PLUMBING PRIOR TO DRILLING HOLES IN THE WALLS!

2.0 INSTALLATION

Mounting:

The ST unit must be mounted to a flat, vertical surface such as wallboard or wood siding. Installation onto wallboard or concrete requires the use of anchors to properly hold the screws. Outdoor installation requires the use of the optional rain shield (STRS) to prevent water from entering the unit.

WARNING: DO NOT INSTALL THE SUN TIE UNIT OUTDOORS WITHOUT THE RAIN SHIELD HOOD. WATER ENTERING THE UNIT COULD CAUSE A DANGEROUS CONDITION AND CAUSE THE UNIT TO FAIL. FAILURE DUE TO IMPROPER INSTALLATION WILL VOID THE WARRANTY.

Procedure

WARNING: BEFORE DRILLING HOLES TO MOUNT THE SUN TIE, ENSURE THERE ARE NO ELECTRICAL WIRES OR PLUMBING IN THIS AREA. SINCE THIS UNIT IS INSTALLED CLOSE TO THE UTILITY ENTRANCE OR METER, THERE MAY BE A HIGH CONCENTRATION OF ELECTRICAL WIRES IN THE AREA.

1. Locate the area where the ST is to be installed. It should be as close to the utility service panel as

possible. The mounted.

bottom of the unit must be at least 36 inches from the floor or ground when

2. Using a level, place the mounting bracket up to the wall (in a horizontal position) and mark the

area for the three screws (Figure 4A). To achieve the 36 inch height from the bottom of the ST unit to the ground, mount the bracket 70 inches from the ground.

3. If required, remove the bracket and drill the holes using a #10 (0.193 inch diameter) drill bit. Drill

appropriately sized holes for anchors when installing on non-wood surfaces.

4. Mount the bracket to the wall using the screws and washers provided. If mounting to other than a

wood wall or surface, use appropriate screws and anchors if required.

5. Place the Sun Ties rear lip, located on the back top of the enclosure, over the bracket and

ensure it is seated properly (Figure 4B).

6. Remove the lower external cover to access the internal circuit breaker panel by removing the

screw on each side of the cover (Figure 5).

7. Remove the internal breaker panel by removing the screws in the breakers and two screws from

the underside of the unit, then lifting until the lower locking tabs are free, then gently pull the inner cover outward (Figure 6). Save the screws for reinstallation.

8. After the unit is correctly seated on the upper bracket, locate the two screw holes in the bottom

(back) area of the enclosure and mark these locations on the wall (Figures 4B and 7A). Remove the ST (if required).

9. Drill two pilot holes (as above, if required).

10. Reinstall the ST, to the bracket and secure the bottom of the unit with the wood screws and

washers provided (or appropriate screws and anchors for non-wood surfaces) and tighten (Figures 4B and 7A).

NOTE: Mounting hardware for surfaces other than wood is not supplied.

2.0 INSTALLATION

Mounting: (continued)

Sun Tie back view

Wall Bracket, screws

and washers

(supplied)

Mount 70 inches from ground

Screw

holes

4068-E00-001

9 - 41/64"

4 - 13/16"

Enclosure

mounted on wall

bracket

8 - 55/64"

Figure 4A

Bracket Mounting

Slide ST enclosure lip onto bracket

19/64"

26 - 21/32"

3.20"

4068-E00-002

Figure 4B

Enclosure Mounting

Upper cover

Remove screws

(one on each side)

External breaker cover

(remove during installation)

2.0 INSTALLATION

Remove screws

from tabs

Locking tabs

Figure 5

Outer Cover Components

Remove breaker screws

Lift up and pull forward to

remove

Figure 6

Inner Breaker Cover

2.0 INSTALLATION

PV Combiner Board

(included on some

models)

NOTE: The internal Combiner Board is not available on all models.

Internal mounting

holes

3-11/32"

2-1/16"

DC Conduit

AC Conduit

Figure 7A

Mounting Holes and AC DC Conduit in Customer Access Area

11-13/64"

9-15/32"

5-1/64"

Lightning Arrestor

27/32"

61/64"

2-13/32"

3-23/32"

61/64"

2-13/32"

3-5/32"3-5/32"

3-23/32"

975-0003-D-001

Figure 7B

Conduit Hole Locations

2.0 INSTALLATION

Wiring:

DC Wiring

The combiner board (included on some models) in the ST accepts up to six individual PV array circuits (positive and negative wires). Each circuit on the combiner board contains a fuse to protect against over-current. Always replace this fuse with one of the same type and rating (GBB, 20 amp maximum, ceramic type, 0.25" x 1.25").

The combiner board PV array input connection block is located in the lower section of the ST

unit.

ST1500 and ST2500 DC Wiring (Refer to Figures 8 and 9) PV Array Conduit/Wire Run

1. Install the DC conduit from the PV arrays to the bottom of the ST unit, via one of the knockout

holes (Figures 7A and 7B).

2. Route the wires from the PV array(s) through conduit and into the lower section of the ST enclosure (Figure 9).

NOTE: If more than one PV array is used, label the wire pairs (positive and negative) appropriately (i.e., PV 1, PV 2, etc.).

3. Connect the positive (+) wire from the #1 array to the terminal strip labeled PV INPUT 1 POSITIVE terminal. Check that the wire is in the proper location and tighten the screw.

4. Connect the negative () wires from the PV array to the PV INPUT 1 NEGATIVE terminal. Check that the wire is in the proper location and tighten the screw.

5. Repeat this procedure for each PV array circuit, connecting the #2 PV Positive wire to the terminal labeled PV INPUT 2 POSITIVE, etc.

NOTE: The solar arrays do not have to connect in the order marked on the board (this is just for reference). All solar array positives on the combiner board are joined together AFTER the fuse.

Solar DC terminal block

Solar input 1

Solar input 2

Solar input 3

Solar input 4

Solar input 5

Solar input 6

Solar DC Fuses

PVGFP (ganged)

100 amp DC breaker

PVGFP (ganged)

1 amp DC breaker

Solar array

100 amp DC breaker

15 amp AC breaker

(ganged)

15 amp AC breaker

(ganged)

L2 breaker

AC connection

L1 breaker

AC connection

Grounding

block

Combiner board

ST1500 and ST2500 Electrical Component Location

Figure 8

2.0 INSTALLATION

Wiring: (continued)

PV array wiring

(note polarity)

DC conduit wiring

(from solar arrays)

Figure 9

PV Array DC Connection Points (ST1500 and ST2500)

6. Repeat this procedure for each PV array circuit, connecting the #2 PV Negative wire to the

terminal labeled PV INPUT 2 NEGATIVE, etc.

NOTE: The solar arrays do not have to connect in the order marked on the board (this is just for reference). All solar array negatives on the combiner board are electrically tied together.

7. Torque wires according to the following table.

Wire Siz e Torque (in-lb)

14 -10 AWG 35

8 AWG 40

4 - 6 AWG 45

2 - 1/0 AWG 50

975-000-003

Table 4

Wire Torque Values

2.0 INSTALLATION

Wiring: (continued)

ST1000 and ST2000 DC Wiring (Refer to Figure 10) PV Array Conduit/Wire Run

1. Install the DC conduit from the PV arrays to the bottom of the ST unit, via one of the knockout

holes.

2. Route the wires from the PV array through conduit and into the lower section of the ST enclosure.

3. Connect the positive (+) wire from the array to the 100 amp DC CIRCUIT BREAKERs lower terminal. Check that the wire is in the proper location and tighten the screw (Figure 10).

4. Connect the negative () wire from the PV array to the DC NEGATIVE TERMINALs lower connection. Check that the wire is in the proper location and tighten the screw (Figure 10).

5. Torque all wires according to Table 4 (previous page).

Use knockouts in lower

section of ST for installing

conduit and routing wires

PV Array DC Connection Points (ST1000 and ST2000)

PV Array DC Negative

(-) Wire

Figure 10

PV Array DC Positive

(+) Wire

2.0 INSTALLATION

Wiring: (continued)

AC Wiring

AC HOT wiring is connected to the ST units L1 and L2 breakers, the ground wire connects to

the GROUND bar. All AC wiring is located in the lower section of the ST unit.

WARNING: AC UTILITY WIRING TO THE ST UNIT IS PERFORMED DIRECTLY AT THE MAIN BREAKER PANEL. THIS SHOULD BE DONE ONLY BY A QUALIFIED UTILITY INSTALLER OR ELECTRICIAN WITH PRIOR UTILITY COMPANY APPROVAL.

NOTE: The ST unit can be connected to a single bidirectional meter, or to dual meters, where one meter indicates power used the second meter indicates power sold (power supplied back to the utility). The installer and utility must determine the proper components to install.

WARNING: BEFORE WIRING THE ST UNIT, ENSURE THE MAIN 120/240 VOLT BREAKER IN THE MAIN UTILITY BREAKER BOX IS SWITCHED OFF. SWITCH THIS BREAKER TO ON ONLY AFTER ALL WIRING IS COMPLETED AS INSTRUCTED IN THE PROCEDURES.

1. Run conduit from the main utility breaker panel to the lower section of the ST unit. Run the

two HOT wires (L1 and L2) and ground through the conduit and into the ST units lower section.

2. Install a dual 15 amp, ganged circuit breaker in the main utility breaker panel.

3. Connect the L1 HOT wire (black) from the 15 amp, double-pole breaker installed in the main

breaker panel, to the breaker labeled L1 in the ST unit. Refer to Figure 11A for ST1500 and ST2500, or Figure 11B for ST1000 and ST2000 models.

4. Connect the L2 HOT wire (red) from the remaining 15 amp, double-pole breaker installed in the main breaker panel, to the breaker labeled L2 in the ST unit.

5. Connect the ground wire (green or bare copper) from the GROUND bar in the main breaker panel, to the GROUND bar in the lower section of the ST unit.

6. Ensure all connections are correctly wired and properly torqued.

7. Torque wires according to the following table.

Wire Size Torque (in-lb)

14 -10 AWG 35

8 AWG 40 6 AWG 45

975-0003-D-003

Table 5

Wire Torque Values

2.0 INSTALLATION

240 VAC

GROUND bar

AC conduit and wiring

Figure 11A

240 V AC Connection Points (ST1500 and ST2500)

240 VAC

GROUND bar

240 V AC Connection Points (ST1000 and ST2000)

Figure 11B

SOV

LIGHTNING

15 A

ARRESTOR

(OPTION)

INVERTER

Main

Breakers

Sun-Tie

Breakers

MAIN SERVICE PANEL

NOTES: INSTALLER CONNECTIONS REQUIRED AT POINTS THE INVERTER ENCLOSURE.

THE UTILITY METER MUST BE A BI-DIRECTIONAL METER. OBTAIN UTILITY COMPAN Y APPROVAL BEFORE INSTALLING. PVGFP AND COMBINER BOARD MAY NOT BE PRESENT ON SOME

MODELS.

(A)

AND

(B)

NEUTRAL

GROUND

–

ST UNIT

BREAKERS (OPTION)

PV GROUND FAULT

100 A

–

1 A

UTILITY METER

100 A

2.0 INSTALLATION

PV ARRAY

PV COMBINER BOARD

20 A

–

20 A

–

20 A

–

20 A

–

20 A

–

20 A

–

+ +

–

UTILITY

GRID

Extra Ground Rod

Only Required on Long Runs > 100

feet (30 m).

975-S00-003A

Figure 12

Simplified Electrical Wiring Diagram (Typical for ST1500 and ST2500)

2.0 INSTALLATION

Lightning Protection

To protect the equipment from lightning damage, a single point grounding system should be used. In this system, all ground lines terminate at the same point. This point normally is the main utility ground installed by the utility company to provide a ground for the house wiring. This ground usually consists of a copper rod driven 6 to 8 feet into the earth. Ground roof mounted solar array frames directly to the external utility ground rod (Figure 13A).

If the solar array is located a considerable distance from the ST unit, then an additional ground rod must be installed close to the solar array for the most reliable lightning protection (Figure 13B). The grounded frame of the solar array provides a direct route to dissipate lightning strikes via the close ground rod. Tie this ground rod to the main utility ground rod via a heavy gauge (#86 AWG) bare copper wire which can be buried underground. Tieing these grounds together constitutes a single point ground and provides the best protection from lightning damage. Refer also to the NEC for specific grounding requirements.

Solar

Array

Solar Array

Ground

Frame to

Pole

DC Wiring

Array Ground Wire

ST Unit

Ground

Bar

> 100 feet (3 0 m)

DC Wiring

AC Wiring

Array Ground Wire

Main Utility

Breaker Panel

Ground

Bar

Bonded Neutral Wire

Utility Ground

Wire

Wiring

Utility Meter

Utility

Ground

Rod

Wiring to

Utility

Figure 13A

Typical Roof Mount Installation Grounding

Main Utility

ST Unit

Ground

Bar

AC Wiring

Breaker Panel

Ground

Bar

Bonded Neutra l Wire

Utility Ground

Wire

Wiring

Utility Meter

Wiring to

Utility

957-F00-007

Array Ground Rod

Buried Copper Wire

Utility G round Rod

975-F00-006

Figure 13B

Long Distance Grounding

3.0 OPERATION

Start-up Procedure

Required Equipment

 True rms reading AC voltmeter (or true rms multimeter)  DC voltmeter (or multimeter)  Frequency counter (optional)

NOTE: Before applying power to the ST unit, ensure all AC and DC wiring is correct.

AC Utility Voltage Check (Figure 14)

1. Switch ON the MAIN 240 V breakers in the main breaker service panel.

2. Ensure all circuit breakers located in the ST unit are in the OFF (down) position.

3. Switch ON the ganged 15 amp ST circuit breakers located in the main breaker service

panel. This applies the utility supplied 240 volts AC to the ST unit.

4. Using a true rms AC voltmeter, measure the AC open circuit utility voltage between L1 and L2. Ensure this voltage is approximately 240 volts AC. The inverter operates with a line-to-line voltage (L1 to L2) ranging from 211264 volts AC.

Figure 14

Utility 240 Volts AC Test

CONNECT

TO L2

TERMINAL

240 VAC

VOLTS

CONNECT TERMINAL

VOLTS

TO L1

975-U00-001a

3.0 OPERATION

Start-up Procedure (continued)

Solar Array DC Voltage Check (Figure 15A for ST1500 and ST2500, Figure 15B for ST1000 and ST2000 models)

1. Uncover the solar arrays and expose them to full sunlight. This test can not be done during dark or stormy weather where the available sunlight may not be intense enough to produce the required output voltage.

2. Measure the solar array open circuit DC voltage across the DC positive (+) and negative (-) terminals. This voltage must be greater than 50 volts DC for 5 minutes minimum to start the inverter.

NOTE: Some thin film modules (amorphous) may produce an open circuit voltages 100-120 volts. Crystalline solar modules will produce open circuit voltages at 75-85 volts (four modules wired in series). An open circuit voltage 50 volts or greater is required for 5 minutes to start the inverter. The 5-minute time delay is required by safety standards.

> 50 VDC

VOLTS

> 50 VDC

VOLTS

CONNECT

POSITIVE (+)

TERMINAL

VOLTS

–

CONNECT

NEGATIVE (-)

TERMINAL

975-U00-002a

Figure 15A

Solar Array DC Voltage Test (ST1500 and ST2500)

CONNECT

NEGATIVE (-)

TERMINAL

VOLTS

CONNECT

POSITIVE (+)

TERMINAL

Solar Array DC Voltage Test (ST1000 and ST2000)

–

975-U00-002B

Figure 15B

3.0 OPERATION

Start-up Procedure (continued)

Operational Test

1. Switch ON the double pole 15 amp AC circuit breakers located in the ST unit. These

breakers provide the ST produced power to the utility and provides the necessary utility voltage and frequency to the inverter (the inverter will not produce an AC output if utility voltage is not present on its output). Refer to Figure 16, item 1.

2. Switch ON the 100 amp DC circuit breaker located in the ST unit. This breaker supplies the DC power from the PV array to the ST unit. Refer to Figure 16, item 2.

3. Switch the 1 and 100 amp (ganged) PVGFP breakers to ON (if installed). These breakers open when 1 amp or greater is detected in the DC negative to ground line; indicating a ground fault condition. Refer to Figure 16, item 3.

4. The inverter's Liquid Crystal Display (LCD) displays the product name, software revision, Trace Engineering name, and finally the operational values during this sequence. During the 5-minute timer, AC voltage, frequency, and DC voltage appear on the display (Figure

17).

Figure 16

Turn-On Sequence

Start-up Procedure (continued)

AC Voltage Frequency Solar Array Voltage

3.0 OPERATION

240 VAC 60 Hz

2500 W 5000 Wh

Current Power

Produced

76 VDC

975-A00-001

Total Daily Power

Produced

Figure 17

LCD Location and Indications

5. View the LCD status meter and monitor the DC voltage: (Figure 17)

 The inverter quickly scales up the DC solar array voltage and attempts to locate the

array's maximum power point. The DC voltage continues to increase until the CPU detects that the maximum power point was passed.

 DC voltage will be scaled down and begin increasing again to find the maximum

power point. This routine may continue several times until the maximum power point is found. At this point the inverter will lock on to the array voltage and begin to sell the maximum amount of power possible under the conditions. This algorithm, known as maximum power point tracking (MPPT), operates an efficient "power sweep" once each minute throughout the day.

 Ensure the inverter begins searching for an operational DC voltage upon start-up.

After completion of the 5 minute wait protection timer, the ST begins selling power indicated in the Watt (W) and advancing Watt-hour (Wh) meters located on the LCD display.

3.0 OPERATION

Start-up Procedure (continued)

6. Replace the circuit breaker panel (Figure 18).

 Install the circuit breaker (inner) panel by sliding it in-place under the top cover and fitting

its two locking tabs into the slots on the bottom of the ST unit.

 Reinstall the two screws located on the bottom of the unit.

 Reinstall the screws on the front of the panel that secure it to the circuit breaker.

Replace screws in the

circuit breakers

Replace screws into the tabs

Figure 18

Replace Circuit Breaker Cover and Screws

7. Replace the external cover. (Figure 19).

 Position the external cover in place and install a screw in each side.

NOTE: A hole at the bottom front of this cover and the main chassis allow for installing a lock to prevent tampering or unauthorized access to the unit.

Replace screw

(one on each side)

Lock Hole

Figure 19

Replace Outer Cover and Screws

Start-up Procedure (continued)

8. Install rain shield hood if located outdoors (Figure 20).

 Install the rain shield onto the ST enclosure.

 Secure it with the four screws provided (two each side).

Rain Shield

3.0 OPERATION

Install screws (2 each side)

Figure 20

Replace Outer Cover and Screws

4.0 TROUBLESHOOTING

Troubleshooting

To aid in troubleshooting the ST units, there are two LEDs located on the CPU board accessible after removing the upper cover panel. The LEDs light to indicate the inverters status as per the Troubleshooting table on page 26. The upper cover should be removed only for viewing the inverter status LEDs as dangerous voltages exist in this area. Wait five minutes after disconnecting the inverter before removing the panel to allow the components to discharge. DO NOT REMOVE THIS COVER FOR ANY OTHER PURPOSE.

 Remove the Rain Shield (if installed) by removing the two screws (from each side) securing it

to the housing (Figure 21). Set the screws aside in a safe place.

 Remove the upper external panel by removing the four screws located on the front of the

panel (Figure 21). Set the screws aside in a safe place.

 Locate the red and green LEDs on the CPU board (see Figure 22).

 Refer to the Troubleshooting table (on page 26) for the LED status indications.

Remove screws

(2 each side)

(4 total)

Figure 21

Rain Shield and Upper Panel Removal

CPU Board

4.0 TROUBLESHOOTING

Close-up of LED area

Figure 22

CPU Board and LED Location

Green LED

Red LED

4.0 TROUBLESHOOTING

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100-O-3000-579

5.0 SPECIFICATIONS

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200-D-3000-579

6.0 SERVICE INFORMATION

Trace Engineering makes every effort to ensure your unit fully meets your independent powering

needs.

If your product needs repair, contact our Service department at: (360) 435-8826 to obtain an

RMA# and shipping information; or fax this page with the following information to: (360) 474-0616.

Please provide:

ST Model: _______________________________________________

Serial Number: ___________________________________________

Purchase Date: __________________________________________

Dealer/Installer: __________________________________________

Phone: ( ) ___________________________________________

Country: ________________________________________________

Problem: ________________________________________________

_______________________________________________________

Include a telephone number where you can be reached during business hours and a complete

return shipping address (P.O. Box numbers are not acceptable).

Name: __________________________________________________

Address: ________________________________________________

City: ___________________________________________________

State / Province: __________________________________________

Zip / Postal Code: _________________________________________

Phone: ( ) ___________________________________________

Country: ________________________________________________

7.0 WARRANTY

Limited Warranty

Xantrex/Trace Engineering warrants its power products against defects in materials and workmanship for a period of two (2) years from the date of purchase, established by proof of purchase or formal warranty registration, and extends this warranty to all purchasers or owners of the product during the warranty period. Trace does not warrant its products from any and all defects:

 arising out of material or workmanship not provided by Xantrex/Trace Engineering or its

Authorized Service Centers;

 when the product is installed or exposed to an unsuitable environment as evidenced by

generalized corrosion or biological infestation;  resulting from abnormal use of the product, alteration, or use in violation of the instructions;  in components, parts, or products expressly warranted by another manufacturer.

Xantrex/Trace Engineering agrees to supply all parts and labor to repair or replace defects

covered by this warranty with parts or products of original or improved design at the company's option. Xantrex/Trace Engineering also reserves the right to improve the design of its products without obligation to modify or upgrade those previously manufactured. Defective products must be returned to Xantrex/Trace Engineering or its Authorized Service Center in the original packaging or equivalent. The cost of transportation and insurance on items returned for service is the responsibility of the customer. Return transportation (UPS Ground or equivalent) as well as insurance on all repaired items is paid by Xantrex/Trace Engineering.

All remedies and the measure of damages are limited to the above. Xantrex/Trace Engineering

shall in no event be liable for consequential, incidental, contingent, or special damages, even if Xantrex/Trace Engineering has been advised of the possibility of such damages. Any and all other warranties, expressed or implied, arising by law, course of dealing, course of performance, usage of trade or otherwise, including, but not limited to, implied warranties of merchantability and fitness for a particular purpose, are limited in duration for a period of two (2) years from the original date of purchase.

ome states or counties do not allow limitations on the term of an implied warranty, or the

exclusion or limitation of incidental or consequential damage, which means the limitations and exclusions of this warranty may not apply to you. Even though this warranty gives you specific legal rights, you may also have other rights which vary from state to state.

5916 - 195th Street N.E., Arlington, WA 98223 Phone: (360) 435-8826 Fax: (360) 435-2229

visit our website at: www.traceengineering.com

5916 - 195th Street N.E., Arlington, WA 98223 Phone: (360) 435-8826 Fax: (360) 435-2229

visit our website at: www.traceengineering.com

Trace Sun Tie ST1000, Sun Tie ST1500, Sun Tie ST2000, Sun Tie ST2500 Installation And Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual