Trace Engineering Integrated Power Panel 1.2 Installalion And Wiring Manual

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Page 1

IPP

Integrated Power Panel

Version 1.2

Installation and Wiring Guide

1999 Trace Engineering P/N #2903 Rev. A 01/00

Page 2

Page 3

Integrated Power Panel

Version 1.2

Table of Contents

Section Description Page

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

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

Pre-Installation

Tools Required Hardware/Materials Required

Wiring

AC Connections DC Connections Grounding

AC Grounding

DC Grounding Batteries PV Arrays Main Service Panel Sub-Panel AC Circuit Breakers Wire Routing Plywood Backing Mounting DC Wiring

PV Array Battery Temperature Sensor Wiring SW Models DR Models Battery Wiring

AC WiringSW Series Dual Inverter Models

AC Input Wiring to the AC Bypass Box AC Output Wiring To the AC Bypass Box

AC Input/Output Wiring (SW Single Inverter Models)

AC Input/Output Wiring to the AC Bypass Box

AC WiringDR Series Dual Inverter Models

AC Input Wiring to the AC Bypass Box AC Output Wiring to the AC Bypass Box

AC Input/Output WiringDR Series Single Inverter Models

AC Input Output Wiring to the AC Bypass Box AC Input/Output Wiring to Sub-panel Wiring Check

3.0 OPERATION ................................................................................................................ 23

System Check Start-up Procedure AC Disconnect Module

Inverter In Circuit Inverter Out of Circuit Both AC Line and Inverter OFF

4.0 TROUBLESHOOTING ................................................................................................. 26

5.0 SYSTEM SHUTDOWN ................................................................................................. 27

Emergency Shutdown Procedure

6.0 SPECIFICATIONS ........................................................................................................ 28

7.0 SERVICE INFORMATION ............................................................................................ 30

8.0 LIFE SUPPORT APPLICATIONS POLICY .................................................................. 31

9.0 WARRANTY................................................................................................................. 32

Page 4

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, national, and/or international electrical codes.

Before installing or using this device, read all instructions and cautionary markings located in (or on) the manual, the inverter, the controller, the batteries, and the PV array.

Do not expose this unit to rain, snow or liquids of any type. This product is designed only for indoor mounting.

To reduce the chance of short-circuits when installing or working with the inverter, the batteries, or the PV array, use insulated tools.

Remove all jewelry such as rings, bracelets, necklaces, etc., while installing this system. This will greatly reduce the chance of accidental exposure to live circuits.

The inverter contains more than one live circuit (batteries and AC line). Power may be present at more than one source.

This product contains no user serviceable parts. Do not attempt to repair this unit unless fully qualified.

SAVE THESE INSTRUCTIONS

Page 5

BATTERY SAFETY INFORMATION

Always wear eye protection, such as safety glasses, when working with batteries.

Remove all loose jewelry before working with batteries.

Never work alone. Have someone assist you with the installation or be close enough to come to your aid when working with batteries.

Always use proper lifting techniques when handling batteries.

Always use identical types of batteries.

Never install old or untested batteries. Check each batterys date code or label to ensure age and type.

Batteries are temperature sensitive. For optimum performance, they should be installed in a stable temperature environment.

Batteries should be installed in a well vented area to prevent the possible buildup of explosive gasses. If the batteries are installed inside an enclosure, vent its highest point to the outdoors.

When installing batteries, allow at least 1 inch of air space between batteries to promote cooling and ventilation.

NEVER smoke in the vicinity of a battery or generator.

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.

In the event of exposure to battery electrolyte, wash the area with soap and water. If acid enters the eyes, flood them with running cold water for at least 15 minutes and get immediate medical attention.

Always recycle old batteries. Contact your local recycling center for proper disposal information.

iii

Page 6

AC Main Panel

(from utility)

Generator

PV Charge Controllers (2 each)

AC Circuit Breakers

AC Sub Panel

(to loads)

Inverters (2 each)

Figure 1

Integrated Power Panel

(layout varies depending upon type of inverter)

DC Circuit Breakers

Page 7

1.0 INTRODUCTION

The Power Panel is a self-contained power conversion center designed around two styles of Trace inverters: the DR Series and the SW Series. The inverter type determines the physical component layout. Typically, a power panel contains at least one inverter, ac and dc disconnect circuit breakers, and a battery temperature sensor. Optional PV solar controllers and disconnects can be added to the system at the time of order, or added later. The inverters, controllers (if ordered) and protection circuitry are fully integrated into a single enclosure to ensure safety and reliability. Each power panel is ETL listed to UL standard 1741 (Draft), and comes pre-wired and tested at the factory to maximize system performance and ease of operation.

Installing a power panel is as simple as mounting it to the wall and connecting a dc source (PV array, batteries, etc.), an ac source (utility power, generator, etc.), and ac loads (via a sub-panel).

Power Panels feature:

 Trace DR Series or SW Series inverter/charger(s)  AC circuit protection  DC circuit protection

Trace DR Series inverters feature:

 1500, 2400 or 3600 watt continuous output  Modified sinewave output with voltage and frequency regulation  High efficiency, high surge capacity and low idle current  Three-stage battery charging for optimum battery performance  Automatic low battery protection  Fast switching for standby power applications  Stackable capabilities for 120/240 V ac powering applications

Trace SW Series inverters feature:

 2500, 4000 or 5500 watt continuous output  Sinewave output with superior voltage and frequency regulation  Intelligent generator control - automatic start and stop  Programmable generator quiet time for areas with noise curfews  Frequency matching and phase synchronization - parallel operation for maximum generator efficiency  Microprocessor control for maximum flexibility and reliability  Three-stage battery charging for optimum battery performance  Automatic low battery protection  Stackable capabilities for 120/240 V ac powering applications

Optional features:

 PV charge controller(s) with array disconnect(s)  Battery cables with flex conduit

Trace products are built rugged and designed to provide you with years of trouble-free service. Recognized throughout the world as a leader in the field of alternative energy, Trace Engineering ensures your system fully meets your quality expectations and powering needs. We thank you for your purchase and welcome you to the exciting world of environmentally friendly, alternative powering.

Page 8

2.0 INSTALLATION

Pre-Installation

Before installing the power panel, read all instructions and cautionary markings located in this

manual.

NOTE: The power panel is quite heavy (weighing up to 400 pounds depending upon configuration). Always use proper lifting techniques during installation to prevent personal injury.

Mounting: The power panel should be mounted indoors in a clean, dry environment. If the panel must be

installed in close proximity to the batteries, make sure the area is adequately ventilated to the outside.

Tools required:

#2 Phillips screw driver Level 1/4" Slotted screw driver Wire strippers 1/2" open-end wrench Torque wrench Socket wrench and fittings Electrical Tape Multimeter Pencil Hole saw Utility knife

Hardware / Materials required:

4' x 8' sheet of 3/4" plywood #12 wood screws (or 3/4" x 1-1/4" lag bolts) #10 wood screws 1/4" x 3" lag bolts Conduit and appropriate fittings Wire nuts (if allowed by code)

Wiring:

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

Pre-plan the wire and conduit runs. The ac terminal blocks accept up to a #6 AWG wire; the dc circuit battery disconnects accept cable sizes up to #4/0 AWG. Use #4/0 AWG for a 250 amp dc disconnect and #2/0 AWG for a 175 amp dc disconnect.

For maximum safety, run both ac and dc wires/cables in (separate) conduits.

AC Connections:

Use #6 AWG THHN wire for all ac wiring.

DC Connections:

Battery to inverter cabling should be only as long as required. If #4/0 AWG cables are used for example, do not exceed 5 feet (one way) in 12 V dc systems; 10 feet (one way) in 24 V dc systems; or, 15 feet (one way) for 48 V dc systems. For optimum performance, use pre-assembled battery cables from Trace, designed specifically for this application.

Grounding:

AC Grounding

The power panel should be connected to a grounded, permanent wiring system. Neutral and Ground conductors should only be bonded at the main service panel.

DC Grounding

The negative battery 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.

Page 9

2.0 INSTALLATION

Pre-Installation (continued)

Batteries:

The battery voltage MUST match the voltage requirements of the inverter. To determine the correct voltage for the system, check the last two digits on the inverters model number. For example, the DR1512 is a 12 volt inverter and requires a 12 V dc battery system. The SW4024 is a 24 volt inverter and requires a 24 V dc battery system.

PV Arrays:

The optional controller is designed to work with a wide variety of PV array systems. DO NOT connect the controller to an array operating at more than 110 V dc.

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, DISCONNECT THE ARRAY, OR COVER IT WITH AN OPAQUE (DARK) MATERIAL BEFORE MAKING ANY CONNECTIONS TO THE POWER PANEL.

Main Service Panel:

The main input to the Power Panel requires a minimum 60 amp breaker for each 120 V ac inverter. A 15 amp breaker is required for all 230 V ac inverters.

Sub-Panel:

Loads backed up by the Power Panel will need to be rerouted from the main service panel to a subpanel. This can be done several different ways, depending upon the installation. Always refer to electrical codes for safe wiring practices.

AC Circuit Breakers:

Always use a properly rated circuit breaker. Depending upon the application, circuit breakers used to protect the load can be removed from the main service panel and put into the sub-panel ONLY if the two panels are from the same manufacturer and are the same type of service panel.

Wire Routing:

Determine all wire routes both to and from the Power Panel. Possible routing scenarios include:

AC Input wiring from the main service panel to the Power Panel AC Input wiring from the generator to the Power Panel DC Input wiring from the PV array to the Power Panel DC Input wiring from the batteries to the Power Panel AC Output wiring from the Power Panel to the sub-panel Battery Temperature Sensor cable from the Power Panel to the batteries Remote Control cable to the Power Panel DC Ground from the batteries to an external ground rod Load circuit wiring rerouted from the main service panel to the sub-panel

Check for existing electrical or plumbing prior to making cuts in the walls. Cut holes in the walls at appropriate locations for routing wiring/cables.

Plywood Backing:

A 4' x 8' x 3/4" plywood backing may be used to provide additional wall support. It should run the entire height of the wall (floor to ceiling). For aesthetic purposes, pre-paint the plywood.

NOTE: 3/4" plywood backing is required for supporting walls where the total weight exceeds 300 lbs (136 kg).

Page 10

2.0 INSTALLATION

Mounting:

NOTE: The mounting recommendations and instructions contained in this section have been developed to meet seismic code requirements according to the 1997 Uniform Building Code for all seismic regions within the United States. This applies to light wood framed structures such as those commonly found in residential construction. If the Power Panel is to be mounted to a structure that is not a residential-type wood framed wall, and/or the mounting wall supports more than one floor and one roof simultaneously, or if the structure is classified as a commercial or industrial building, contact the local building inspector for further information before proceeding with this installation.

The Power Panel can be installed on either a load bearing or non-load bearing wall. Depending upon the

Power Panels components, it can weigh as much as 400 lbs (182 kg). A 4' x 8' x 3/4" sheet of plywood (floor to ceiling) is recommended to provide additional wall strength. The plywood backing is required for Power Panels weighing more than 300 lbs (136 kg) installed on load bearing walls.

Procedure

1. Locate the studs in the wall (either 16" or 24" on center) and mark their locations.

2. If plywood is used, apply adhesive to the back and center it on the wall. Secure it into the studs and

around the perimeter using #12 wood screws on 6" spacing. Counter sink the screws. Paint the plywood to match the surrounding wall color if desired.

3. Using 2 x 4's, build a frame for holding the Power Panel in place while it is being secured. The top of the frame should be approximately 3-1/2 to 4 feet from the floor. Use 3" x 1/4" lag bolts (on 6" centers) to mount the 2 x 4. Keep all screws at least 3/4" away from the top of the horizontal 2 x 4 to allow the bottom flange of the Power Panel to slip behind it. See Figures 2 and 3.

4. Drill pilot holes according to the dimensions in Figure 4.

5. With the help of a friend, lift the Power Panel into position. It should be centered (and level) on the

plywood. Secure the Power Panel using #10 wood screws (on 16" center) or #12 wood screws (on 24" center) through each of the holes in the backing panel. Avoid hitting the wood screws. Screws must penetrate 1-3/4" into the framing.

Ceiling

Approximately

3-1/2–4 ft

Wall studs 16 inch on

center

4 ft. x 8 ft. x 3/4 in plywood

backing

Adjust the height of the panel so the bypass switch is within easy reach

2 x 4 frame

2 x 4 support studs

Ceiling

Approximately

3-1/2–4 ft

Wall stud s 24 inch on

center

4 ft. x 8 ft. x 3 /4 in plywood

backing

2 x 4 frame

2 x 4 support st uds

Floor

2903-00-003

Figure 2

Power Panel Support Structure

(16" on-center studs)

Power Panel Support Structure

(24" on-center studs)

Figure 3

Floor

2903-00-003

Page 11

39 9/16"

2.0 INSTALLATION

16” 16”

16”

24”

38 13/16"

24"

31 1/4"

27 1/4"

19 1/4"

11 1/4"

7 1/4"

ø3/8" X 24

13"

21"

29"

33"

Figure 4

Mounting Hole Dimensions

37"

32"

42 1/16"

42 15/16"

Adjust the height of the panel so the bypass switch is within easy reach

2903-00-004

Figure 4A

Mounted Power Panel

Page 12

2.0 INSTALLATION

AC Disconnect/Bypass Box

*PV Array #2 Controller

PV Array #1 Controller

Inverter #1

*Inverter #2

AC INPUT from LINE 1 (black) Utility or Generator

Solar (PV) Array #1 Disconnect

Battery (positive) Disconnect #1

*Battery (positive) Disconnect #2

DC Negative Ground Bond

*Solar (PV) Array #2 Disconnect

Figure 7

Component Locations (SW Model)

120 V ac Output 1

*120 V ac Output 2

AC GROUND wires

All NEUTRAL wires (white)

*AC INPUT from LINE 2 (red) Utility or Generator

*Battery POSITIVE Terminal

Battery POSITIVE Terminal

Figure 8

Wire Connection Locations (SW Model)

NOTE: Items marked with an astrict (*) are only applicable to dual inverter/controller models.

Solar PV Array 1 POSITIVE

PV Array Chassis GROUND

PV Array NEGATIVE

DC Earth GROUND

Battery NEGATIVE

*Solar (PV) Array 2 POSITIVE

Page 13

2.0 INSTALLATION

PV Array #1 Controller (optional)

Solar (PV) Array #1 Disconnect

*Battery (positive) Disconnect #2

Battery (positive) Disconnect #1

DC Negative Ground Bond

*Solar (PV) Array #2 Disconnect

*PV Array #2 Controller (optional)

Component Locations (DR Model)

All NEUTRAL wires (white)

AC GROUND wires

Figure 5

120 V ac Output 1

*120 V ac Output 2

AC Disconnect/Bypass Box

Inverter #1

*Inverter #2

AC INPUT from LINE 1 (black)

PV Array Chassis GROUND

PV Array NEGATIVE

DC Earth GROUND

Battery NEGATIVE

*AC INPUT from LINE 2 (red)

PV Array 1 POSITIVE

*PV Array 2 POSITIVE

*Battery POSITIVE Terminal

Battery POSITIVE Terminal

Figure 6

Wire Connection Locations (DR Model)

NOTE: Items marked with an astrict (*) are only applicable to dual inverter/controller models.

Page 14

2.0 INSTALLATION

Wiring: DC Wiring

The dc wiring enters the DC Disconnect Box through the conduit located on the bottom of the disconnect

box. Use #6 AWG wire for the PV array connections.

PV Array

If a PV array is used in the system, connect the wiring as follows:

NOTE: For dual controller models, split the PV arrays output evenly between the two PV Array Disconnects.

1. Route the wires from the PV array through the conduit located at the bottom of the DC Disconnect Box.

2. Connect the positive (+) wire from the #1 array to the lower terminal of the PV Array #1 Disconnect

breaker.

3. Connect the positive (+) wire for the #2 array to the lower terminal of the PV Array #2 Disconnect.

4. Connect the negative () wires from the array(s) to the Grounding Block.

5. Connect the ground wire(s) from the frame of the PV array to the Grounding Block.

6. Ensure all connections are snug.

DC Disconnect Box

PV Array Ground Wire

PV Array Negative () Wires

Grounding Block

PV Array #1 Positive (+) Wire

SOLAR ARRAY

OFFONOFF

BATTERY DISCONNECT

SOLAR ARRAY

PV Array #1 Disconnect

*PV Array #2 Disconnect

*PV Array #2 Positive (+) Wire



DR Series

Figure 9

Wire Connection Locations

DC Disconnect Box

PV Array Ground Wire

Grounding Block

PV Array Negative () Wires



SW Series

NOTE: Items marked with an astrict (*) are only applicable to dual controller models. For clarity, wiring not used in this step may not be shown.

Page 15

2.0 INSTALLATION

Battery Temperature Sensor (BTS) Wiring (SW Models)

Battery Temperature Sensors (BTS) should be placed on the side of the battery. They transmit temperature information to the charger and adjust the charging rate according to the battery temperature. Up to four sensors can be connected in a dual inverter system with two charge controllers.

1. Locate the battery temperature sensors and route them down through the conduit in the DC Disconnect

Box to the batteries.

2. Place all sensors onto the side of same battery (located in the middle of the battery bank) to prevent

different charging rates based on temperature variances.

NOTE: Temperature sensor cables are already connected to the inverters and PV controllers (if ordered). The cables only need be run through the conduit to the batteries.

Inverters

PV Charge Controllers

BTS Connectors (internal)

BTS Connector (internal) See Note

Battery Temperature Sensor wires.

BTS wires run through the grommets in the inverter housing and along the back of the inverter. These wires are already installed

Mount the battery temperature sensors (BTS)

BATTERY TEMPERATURE SENSORS

BATTERY

to the side of the same battery (located in the middle of the battery bank).

Figure 10

Battery Temperature Sensor (BTS) Wiring

DC Disconnect Box

NOTE: For clarity, wiring not used in this step may not be shown.

Page 16



2.0 INSTALLATION

Battery Temperature Sensor Wiring (DR Models)

Battery Temperature Sensors (BTS) should be placed on the side of the battery. They transmit

temperature information to the charger and adjust the charging rate according to the battery temperature. Up to four sensors can be connected in a dual inverter system with two charge controllers.

1. Locate the battery temperature sensors and route them down through the conduit in the DC Disconnect Box to the batteries.

2. Place all sensors onto the side of same battery (located in the middle of the battery bank) to prevent different charging rates based on temperature variances.

NOTE: Temperature sensor cables are already connected to the inverters and PV controllers (if ordered). The cables only need be run through the conduit to the batteries.

6060

OFF

RED#6AWG

INV 1

0N0N

OFF OFF

INV 2

OFF

BTS Connector (front panel)

INV 1 OUTPUT

NEU OUT

NEU IN

INV 1 INPUT

GND

HOT OUT

NEU OUT

NEU IN

HOT IN

GND

DC Disconnect Box

Battery Temperature Sensor wires.

BAT+ PV+ BAT-PV- PV+BAT+ BAT-PV-

ONON

OFF

BATTERY DISCONNECT

#2385 #2355

NEUTRAL NOT BONDED TO GROUND

SOLAR ARRAY

#2360

SOLAR ARRAY

POSITIVE

NEGATIVE

POSITIVE

NEGATIVE

INVERTER 1

CHARGER: GRN=FLO AT/ORN BLI NK= ABS ORP /ORN= BUL K BATTERY HI RED/ BATTERY LOW GRN OVER TEMP RED/OVERLOAD GRN SEARCH MODE WATTS INVERTER MODE POWER ON/OFF COM PORT

INVERTER 2

CHARGER: GRN=FLO AT/ORN BLI NK= ABS ORP /ORN= BUL K BATTERY HI RED/ BATTERY LOW GRN OVER TEMP RED/OVERLOAD GRN SEARCH MODE WATTS INVERTER MODE POWER ON/OFF COM PORT

NEUTRAL

INPUT AND OUTPUT SOURCE AND LOAD

GROUND

Battery Type S electo r

LEAD ACID 7

DEEP CYCLE

PbCa-MAINTENANCE FREE

GEL CELL

EQUALIZE 1

EQUALIZE 2

BATTERY CHARGER RATE OVER-DISCHARGE PROTECTION

AC TRANSFER THRESHOLD

BATTERY CAPACITY

BATTERY SENSE

250

.37K

125

MIN .5K

OFF

MAX

>100

Amp/Hrs

Battery Type S electo r

DEEP CYCLE LEAD ACID

PbCa-MAINTENANCE FREE

GEL CELL

EQUALIZE 1

EQUALIZE 2

BATTERY CHARGER RATE OVER-DISCHARGE PROTECTION

AC TRANSFER THRESHOLD

BATTERY CAPACITY

BATTERY SENSE

250

125

.37K

MIN

.5K

OFF

MAX

>100

Amp/Hrs

DANGER:

HAZARD OF ELECTRICAL SHOCK OR BURN. TURN OFF THE AC AND DC POWER SUPPLYING THIS EQUIPMENT BEFORE WORKING INSIDE. THIS SYSTEM MAY RECEIVE POWER FROM MORE THAN ONE SOURCE. REPLACE COVER BEFORE TURNING POWER ON.

AVERTISSEMENT:

RISQUE DE CHOCS ELECTRIQUES. NE PAS TOUCHER LES PARTIES NON ISOLEES DU CONNECTEUR DE SORTIE OU LE S BORNES NON ISOLEES DE L’ACCUMULATEUR. COUPER TOUTLES LES SOURCES D’ALIMENTATIO N AVANT DE FAIRE L’ENTRETIEN ETLES REPARATIONS.

67664

TRACE ENGINEERING 5916 195TH ST NE ARLINGTON, WA. 98223 MADE IN U.S.A.

BTS wires run through the grommets in the inverter housing and along the back of the inverter. These wires are already installed

BATTERY TEMPERATURE SENSORS

Battery Temperature Sensor (BTS) Wiring

PN 2355

POWER CONDITIONING UNITS FOR USE IN PHOTOVOLTAIC POWER SYSTEMS STANDARD UL1741

COMMERCIAL AND INDUSTRIAL POWER SUPP L IES CERTIFIED TO CAN/CSA-C22.2 No. 107.1-M1

BATTERY

Figure 11



Mount the battery temperature sensors (BTS) to the side of the same battery (located in the middle of the battery bank).

Page 17

2.0 INSTALLATION

Battery Wiring

Route the battery cables through the conduit to the DC Disconnect Box. Use a minimum of #4/0 AWG wire for a 250 amp battery disconnect breaker (or #2/0 AWG for a 175 amp battery disconnect breaker). Smaller diameter wire results in poor inverter performance and the risk of fire due to the wires overheating.

 Connect the Negative wires to the negative grounding bond block and tighten connections.

 Connect a Positive wire to one of the lower terminals on the Battery Disconnect breaker.

 Connect the other Positive wire to the lower terminal on the second Battery Disconnect breaker.

 Torque Battery breaker connections to 275 in-lb (23 ft-lb), (31 N-m). Refer to battery manufacturers

specifications for battery terminal torque specifications.

 After torquing, coat the battery connections with petroleum jelly or other anticorrosion grease designed

for battery terminals. Do not put any anticorrosion grease between the terminals and the battery cable.

NOTE: Use only

one battery bank for both inverters. Refer to Figure 12 for an example of a battery hookup.

NOTE: Refer to the inverters Operators manual for more detailed examples of battery hookups (i.e., 12 V, 24 V and 48 V).

DC Disconnect Box

Negative Grounding Bond Block (On opposite side on SW installations)

Torque to 275 in-lb (23 ft-lb)

Negative 1

CONDUIT FOR

INVERTER 1

OFFONOFF

BATTERY

DISCONNECT

Positive 1

CONDUIT FOR

INVERTER 2

SOLAR ARRAY



Battery Disconnect 1 Breaker (DR system shown) (Disconnect 2 on SW Systems)

Battery Disconnect 2 Breaker (DR system shown) (Disconnect 1 on SW Systems)

Positive 1

Positive 2

Negative 2

Positive 2

NOTE: Connect each inverter at opposite ends of the battery bank. This balances the current flowing through the entire bank and provides an equal charge/ discharge through all of the batteries.

– + – +

12 Volt Battery

–

12 Volt

Battery

12 Volt Battery

12 Volt

Battery

+–

2903-00-021

Figure 12

Battery Wiring (24 v dc System)

Negative 2

Page 18

2.0 INSTALLATION

AC WiringSW Series Dual Inverter Models

WARNING: THIS SECTION DEALS WITH WIRING THE MAIN SERVICE UTILITY PANEL TO THE POWER PANEL. ENSURE THAT ALL AC POWER TO THE UTILITY PANEL IS SWITCHED OFF.

Ground Block

GROUN

OFF

INV 1

INV 2

OFF

NEUTRAL

INPUT AND OUTPUT SOURCE AND LOAD

Inverter 1 (Top ac breaker)

Inverter 1

HOT IN L1

HOT OUT L1

*Inverter 2 (Top ac breaker)

*Inverter 2

WHITE

*Inverter 2

HOT IN L2

#6AWG

HOT OUT L2

(Center ac breaker)

(Bottom ac breaker)

(Center ac breaker)

(Bottom ac breaker)

Neutral Block

2903-00-011b

Service Crimps are provided to allow utility and load connections. DO NOT REMOVE FACTORY INSTALLED WIRING!

Figure 13

SW Series AC Disconnect Component Identification

NOTE: Service Crimps, provided on the breaker terminals, are for external input (utility) and output (load) wiring. Do NOT remove existing factory wiring or screws.

Breaker Lug

Existing Factory W iring

Service Crimp

Added Input or

Output Wire

2906-00-026

Figure 14

Breaker Terminal Lug Detail (side view)

Page 19

2.0 INSTALLATION

AC WiringSW Series Dual Inverter Models (continued)

AC Input Wiring To The AC Bypass Box

 Select a convenient knockout on the AC Disconnect/Bypass Box for installing conduit which will carry the

wires from the main utility panel or generator.

 Install a 60 amp circuit breaker in the main utility service panel for each ac input to the inverters.

 Use #6 AWG THHN wire (minimum) and route it through the conduit to the AC Disconnect/Bypass Box.

 Connect the Ground from the main utility box to the ground terminal in the AC Disconnect/Bypass Box as

indicated in Figure 15.

 Connect the L1 (Hot-black) wire to the INVERTER 1 HOT IN L1 (center ac breaker) as indicated in

Figures 13 and 15.

 *Connect the L2 (Hot-red) wire to the INVERTER 2 HOT IN L2 (center ac breaker) as indicated in

Figures 13 and 15.

 Connect the Neutral wire from the main utility box to the Neutral block in the AC Disconnect/Bypass box

as indicated in Figure 15.

 Torque service crimps to 45 in-lb (3.75 ft-lb), (5 N-m).

NOTE: The Ground and Neutral are bonded only at the main utility service panel.

L1 from Utility

or Generator

HOT

L2 from Utility

or Generator

#6AWG

HOT

NOTE: DO NOT REMOVE FACTORY WIRING!

BLACK

#6AWG

RED

#6AWG

INV 1

INV 2

Ground from

Utility or

Generator

GROUN

OFF

NEUTRAL

INPUT AND OUTPUT SOURCE AND LOAD

WHITE

Neutral from

Utility or

Generator

Figure 15

AC Input Wiring

NOTE: Items marked with an astrict (*) are applicable to dual inverter models only.

2903-00-011

Page 20

2.0 INSTALLATION

AC WiringSW Series Dual Inverter Models (continued)

AC Output Wiring To AC Bypass Box

 Select a convenient knockout on the AC Disconnect/Bypass Box for installing conduit which will carry the

wires from the inverters output to the sub-panel.

 Use #6 AWG THHN wire (minimum) and route it through the conduit between the AC Disconnect/Bypass

Box and the sub-panel.

 Connect the Ground wire to the Ground block in the AC Disconnect/Bypass Box. Connect the other end

to the sub-panels Ground Bar.

 Connect the L1 (Hot-black) wire to the INVERTER 1 HOT OUT L1 as indicated in Figures 13 and 16.

 *Connect the L2 (Hot-red) wire to the INVERTER 2 HOT OUT L2) as indicated in Figures 13 and 16.

 Connect the Neutral wire to the Neutral block in the AC Disconnect/Bypass Box. Connect the other end to

the sub-panels Neutral Bar.

 Torque service crimps to 45 in-lb (3.75 ft-lb), (5 N-m).

NOTE: The Ground and Neutral are bonded only at the main utility service panel.

OFF

BLACK

#6AWG

RED

#6AWG

INV 1

INV 2

OFF

NOTE: DO NOT REMOVE FACTORY WIRING!

GROUND

NEUTRAL

INPUT AND OUTPUT SOURCE AND LOAD

WHITE

Neutral to

Sub-panel

(Loads)

L2 to Sub-panel

(Loads)

HOT

Figure 16

AC Output Wiring

#6AWG

2903-00-011A

Ground to Sub-panel

(Loads)

L1 to Sub-panel

(Loads)

HOT

NOTE: Items marked with an astrict (*) are applicable to dual inverter models only.

Page 21

2.0 INSTALLATION

AC WiringSW Single Inverter Models

AC Input/Output Wiring To AC Bypass Box

 Connect the Ground wire to the Ground block in the AC Disconnect/Bypass Box. Connect the other end

to the sub-panels Ground Bar.

 Connect the Hot (input) wire from the utility service panel to the AC Disconnect breaker as shown in

Figure 17.

 Connect the Hot wire (output) to the AC Disconnect breaker as shown in Figure 17. Connect the other

end of this wire to the input breaker in the sub-panel.

 Connect the Neutral wire to the Neutral block in the AC Disconnect/Bypass Box. Connect the other end to

the sub-panels Neutral Bar.

 Torque service crimps to 45 in-lb (3.75 ft-lb), (5 N-m).

NOTE: The Ground and Neutral are bonded only at the main utility service panel.

From Utility or

Generator

HOT

INV

OUT

OFF

NOTE: DO NOT REMOVE FACTORY WIRING!

To Sub-panel

(Loads)

HOT

Figure 17

AC Input/Output Wiring (Single Inverter Models)

Breaker Lug

Existing Factory Wiring

Service Crimp

Added Input or

Output Wire

2906-00-026

Figure 17A

Breaker Terminal Lug Detail (side view)

Page 22

2.0 INSTALLATION

AC WiringDR Series Dual Inverter Models

WARNING: THIS SECTION DEALS WITH WIRING THE MAIN SERVICE UTILITY PANEL TO THE POWER PANEL. ENSURE THAT ALL AC POWER TO THE UTILITY PANEL IS SWITCHED OFF.

Service Crimps are provided to allow utility and load connections. DO NOT REMOVE FACTORY INSTALLED WIRING!

Neutral Block

Inverter 1

Inverter 1 (Bottom ac breaker)

*Inverter 2

HOT OUT L1

HOT IN L1

NEUTRAL NOT BONDED TO GROUND

HOT OUT L2

HOT IN L2

(Top ac breaker)

(Center ac breaker)

(Top ac breaker)

(Center ac breaker)

*Inverter 2 (Bottom ac breaker)

WHITE #6AWG

NEUTRAL

INPUT AND OUTPUT SOURCE AND LOAD

RED#6AWG

GROUND

6060

OFF

INV 1

0N0N

OFF OF F

INV 2

OFF

2903-00-027

Ground Block

Figure 18

DR Series AC Disconnect Component Identification

NOTE: Service Crimps, provided on the breaker terminals, are for external input (utility) and output (load) wiring. Do NOT remove existing factory wiring or screws.

Service Crimp

Added Input or

Output Wire

Existing Factory Wiring

2906-00-026A

Figure 19

Breaker Terminal Lug Detail (side view)

Breaker Lug

Page 23

2.0 INSTALLATION

AC WiringDR Series Dual Inverter Models (continued)

AC Input Wiring To The AC Bypass Box

 Select a convenient knockout on the AC Disconnect/Bypass Box for installing conduit which will carry the

wires from the main utility panel or generator.

 Install a 60 amp circuit breaker in the main utility service panel for each ac input to the inverter(s).

 Use #6 AWG THHN wire (minimum) and route it through the conduit to the AC Disconnect/Bypass Box.

 Connect the Ground from the main utility box to the ground terminal in the AC Disconnect/Bypass Box as

indicated in Figure 20.

 Connect the L1 (Hot-black) wire to the INVERTER 1 HOT IN L1 (center ac breaker) as indicated in

Figures 18 and 20.

 *Connect the L2 (Hot-red) wire to the INVERTER 2 HOT IN L2 (center ac breaker) as indicated in

Figures 18 and 20.

 Connect the Neutral wire from the main utility box to the Neutral block in the AC Disconnect/Bypass Box

as indicated in Figure 20.

 Torque service crimps to 45 in-lb (3.75 ft-lb), (5 N-m).

NOTE: The Ground and Neutral are bonded only at the main utility service panel.

L2 from Utilit

or Generator

HOT

Ground from

Utility or

Generator

NEUTRAL NOT BONDED TO GROUND

Neutral from

Utility or

Generator

L1 from Utility

or Generator

WHITE #6AWG

NEUTRAL

INPUT AND OUTPUT SOURCE AND LOAD

RED#6AWG

GROUND

HOT

NOTE: DO NOT REMOVE FACTORY WIRING!

6060

OFF

INV 1

0N0N

OFF OFF

INV 2

OFF

2903-00-02 2A

Figure 20

AC Input Wiring

Page 24

2.0 INSTALLATION

AC WiringDR Series Dual Inverter Models (continued)

AC Output Wiring To The AC Bypass Box

 Select a convenient knockout on the AC Disconnect/Bypass Box for installing conduit which will carry the

wires from the inverters output to the sub-panel.

 Use #6 AWG THHN wire (minimum) and route it through the conduit to the between the AC Disconnect/

Bypass Box and the sup-panel.

 Connect the Ground wire to the Ground block in the AC Disconnect/Bypass Box. Connect the other end

to the sub-panel's Ground Bar.

 Connect the L1 (Hot-black) wire to the INVERTER 1 HOT OUT L1 (top ac breaker) as indicated in

Figure 21.

 Connect the L2 (Hot-red) wire to the INVERTER 2 HOT OUT L2 (top ac breaker) as indicated in Figure

21.

 Connect the Neutral wire to the Neutral block in the AC Disconnect/Bypass Box. Connect the other end to

the sub-panel's Neutral Bar.

 Torque service crimps to 45 in-lb (3.75 ft-lb), (5 N-m).

NOTE: The Ground and Neutral are bonded at the main utility service panel only.

NEUTRAL NOT BONDED TO GROUND

Neutral to Sub-panel

(Loads)

L1 to Sub-

panel (Loads)

HOT

WHITE #6AWG

GROUND

Ground to

Sub-panel

(Loads)

NEUTRAL

INPUT AND OUTPUT SOURCE AND LOAD

RED#6AWG

L2 to Sub-panel

(Loads)

HOT

6060

OFF

INV 1

0N0N

OFF OFF

INV 2

OFF

NOTE: DO NOT REMOVE FACTORY WIRING!

2903-00-023

Figure 21

AC Output Wiring

Page 25

2.0 INSTALLATION

AC WiringDR Series Single Inverter Models

AC Input/Output Wiring To AC Bypass Box

 Connect the Ground wire to the Ground block in the AC Disconnect/Bypass Box. Connect the other end

to the sub-panel's Ground Bar.

 Connect the Hot (input) wire from the utility service panel as indicated in Figure 22.

 Connect the Hot wire (output) as indicated in Figure 22. Connect the other end of this wire to the input

breaker in the sub-panel.

 Connect the Neutral wire to the Neutral block in the AC Disconnect/Bypass Box. Connect the other end to

the sub-panel's Neutral Bar.

 Torque service crimps to 45 in-lb (3.75 ft-lb), (5 N-m).

NOTE: The Ground and Neutral are bonded only at the main utility service panel.

To Sub-panel

Loads (HOT)

TO SUB-PANEL

(LOADS)

HOT

FROM UTILITY OR

From Utility or

Generator

(HOT)

GENERATOR

HOT

OFF

Figure 22

AC Input/Output Wiring (Single Inverter Models)

Service Crimp

Added Input or

Output Wire

Existing Factory Wiring

Breaker Lug

INV

OUT

INV

NOTE: DO NOT REMOVE FACTORY WIRING!

2906-00-026A

Figure 22A

Breaker Terminal Lug Detail (side view)

Page 26

2.0 INSTALLATION

AC Input/Output Wiring to the Utility and Sub-panel

The following diagrams illustrate wiring the Power Panels to the utility service box and to the sub-panel.

Existing wiring can be used by routing the output of the sub-panel back into the main utility service box and wire-nut splicing these wires to the existing house wiring. Refer to Figures 23 (single inverter 120 V ac), 24A and 24B (dual inverter (120/240 V ac) for general wiring diagrams.

WARNING: ENSURE ALL POWER IS DISCONNECTED IN THE MAIN UTILITY BREAKER BOX BEFORE PROCEEDING.

 Select the circuits that require backup power and disconnect them from the main utility breaker.

 Mark the breaker as "not used" in the main utility panel.

 Wire splice these connections to the output from the sub-panel.

 Mark the sub-panel with an appropriate name for this circuit.

NOTE: Check local codes. Wire-nut splices may not be allowed in the main utility panel in some areas. In these cases, use a separate junction box for these connections and cover with a blank plate.

WARNING: REPLACE CIRCUIT BREAKERS (IN THE SUB-PANEL) WITH EQUALLY RATED BREAKERS. NEVER INCREASE THE CIRCUIT BREAKER AMPERAGE RATING.

UTILITY FEED FROM METER

LINE

NEUTRAL

MAIN PANEL

120 V AC

240 V AC

NEUTRAL BONDED TO GRO UND

EARTH GROUND

NOTE: FOR ILLUSTRATIVE PURPOSES ONLY.

BREAKER BOXES VARY DEPENDING ON APPLICATION.

MAIN PANEL WIRING TO NON-CRITICAL LOADS

IS NOT ILLUSTRATED.

MAIN

BREAKER

CAUTION:

IN MAIN PANEL ONL Y!

EXISTING 120 V ac HOUSE

WIRING (Each circuit)

FROM

UTILITY

120 V AC FROM

INVERTER

LINE OUT

NEUTRAL

GROUND

LINE OUT

120 V AC BACKUP POWER

NEUTRAL

GROUND

POWER PANEL

Single Inverter

GROUND

120 V AC LINE IN

NEUTRAL

LINE OU T

AC BYPASS BOX

DISCONNECT

TO LOAD

NEUTRAL

GROUND

SUB PANEL

120 V AC BACKUP POWER

TO LOAD

(NEW WIRING)

120 V AC LINE OUT

NEUTRAL

GROUND

2903-00-028

Figure 23

AC Input/Output UtilitySub-panel Wiring (Single Inverter Models)

Page 27

)

AC Input/Output Wiring to Utility and Sub-panel (continued)

UTILITY FEED FROM METER

LINE

NEUTRAL

MAIN UTILITY PANEL

120 V AC

NOTE: FOR ILLUSTRATIVE PURPOSES ONLY.

BREAKER BOXES VARY DEPENDING ON APPLICATION.

MAIN PANEL WIRING TO NON-CRITICAL LOADS

IS NOT ILLUSTRATED.

MAIN

BREAKER

240 V AC

CAUTION:

NEUTRAL BONDED TO GROUND

IN MAIN PANEL ONL Y!

EARTH GROUND

AC Input/Output UtilitySub-panel Wiring (Dual Inverter Models)

EXISTING HOUSE WIRING

FROM UTILITY

LINE 2 IN (Invert er 2)

LINE 1 IN (Inverter 1)

LINE 1 OUT (Inverter 1) LINE 2 OUT (Inverter 2)

FROM INVERTER

LINE OUT

120 V AC BACKUP POWER

NEUTRAL

GROUND

POWER PANEL

DUAL INVERTERS

GROUND

NEUTRAL

AC BYPASS BOX

TO LOAD

SUB PANEL

DISCONNECT

LINE 2 OUT

NEUTRAL OUT

GROUND

DISCONNE CT

240 V AC

Figure 24A

Wire-nut Connections in Main Utility Box

2.0 INSTALLATION

120/240 V AC BACKUP

POWER

TO LOAD

(NEW WIRING)

LINE OUT 120 V AC (L2)

NEUTRAL OUT

GROUND

LINE OUT 120 V AC (L1)

2903-00-029

240 V AC (L1-L2

UTILITY FEED FROM METER

LINE

NEUTRAL

120 V AC

MAIN UTILITY PANEL

EARTH GROUND

MAIN

BREAKER

240 V AC

NEUTRAL BONDED TO GROUND IN MAIN PANEL

CAUTION:

NEUTRAL/GROUND BOND MAY BE MADE VIA

ONLY!

THE METAL UTILITY HOUSING AND NOT

CONTAIN A SEPARATE BUS BAR.

FOR ILLUSTRATIVE PURPOSES ONLY.

FROM

UTILITY

LINE 2 IN (Inverter 2) LINE 1 IN (Inverter 1)

LINE 1 OUT (Inverter 1) LINE 2 OUT (Inverter 2)

FROM INVERTER

GROUND

POWER PANEL

DUAL INVERTERS

GROUND

NEUTRAL

AC BYPASS BO X

DISCONNECT

240 V AC

SUB PANEL

DISCONNECT

BLACK

WHITE

GREEN

WHITE

BLACK

GREEN

WHITE

RED (L2)

BLACK (L1)

120 V AC

LINE OUT 120 V AC (L2)

NEUTRAL

GROUND

120 V AC

GROUND

NEUTRAL

LINE OUT 120 V AC (L1)

240 V AC

GROUND (to receptacle

box or ground terminal)

NEUTRAL

240 V AC (L1-L2)

120/240 V AC BACKUP

POWER TO LOAD

2903-00-019

Figure 24B

AC Input/Output UtilitySub-panel Wiring for 120240 V ac Circuits (Dual Inverter Models)

Page 28

2.0 INSTALLATION

Wiring Check

Before placing the system into operation for the first time (or after repairs or rewiring is performed),

recheck all system wiring before placing the system into operation.

 Check the ac loads (to the sub-panel) and source (from the utility main panel or generator) are connected

properly in the AC Disconnect/Bypass box.

 Ensure there are no neutral/ground bonds (except in the main utility panel).

 Use a dc voltmeter to confirm the batteries are wired correctly and the polarities are correct.

 Check the PV array wiring is properly connected (positive wire to the lower terminals on the PV array

disconnects).

CAUTION: PERMANENT SYSTEM DAMAGE CAUSED BY IMPROPER WIRING IS NOT COVERED UNDER WARRANTY. DO NOT SKIP THE ABOVE STEPS!

 After the checks are completed, install the covers on the Power Panel components, main utility and sub-

panels.

Page 29

3.0 OPERATION

System Check

NOTE: Do not proceed with this section until the wiring checks mentioned in the previous section have been performed.

NOTE: Refer to the appropriate Operators manual (SW or DR) for detailed inverter/charger operation.

Start-up Procedure:

1. Switch the Battery Disconnect(s) to the ON (upper) position. Check for correct inverter and controller (if

installed) power-up sequence (refer to the Operators manual).

2. Turn ON the inverter(s) and check for normal operation. Refer to the individual inverter/charger

Operators manual for operating instructions. The inverters should be operating in the inverter mode from

the batteries. Refer to the troubleshooting section if the inverters are not operational. Do NOT proceed

until the inverters are operating normally.

3. Switch ON the ac power from the main ac utility panel or generator.

4. Switch ON the AC Disconnect/Bypass breaker by switching the breaker(s) to the normal operating

position.

5. Switch the Solar Array Disconnect(s) to the ON (upper) position.

The Power Panel is now fully operational. If you have questions not covered in this or the inverters

Operators manual, contact Trace Engineering or your local dealer.

NOTE: Refer to the troubleshooting section for instructions if the system does not appear to be functioning correctly.

Switch the AC Bypass breaker(s) ON

Switch the ac power ON at the main utility breaker box

Switch the inverters ON. Verify proper operation

Switch the Battery

Disconnect(s) ON

Figure 25

Power Panel Operating Controls



Switch the Solar PV Array Disconnect(s) ON

Page 30

3.0 OPERATION

AC Disconnect Module

The AC Disconnect is a manual bypass switch that allows the inverter to be removed from the circuit

without de-energizing the connected load. The Power Panel comes with either a single breaker pair for single inverter applications, or two breaker pairs (L1 and L2) to accommodate two inverters.

The AC Disconnect Module is wired between the primary ac source (utility power or generator) and the

inverters ac input and output. A lockout rocker allows only one breaker to be ON at any given time.

During normal operation, ac power passes from the power utility through the inverter to the ac loads. The

inverter monitors the incoming power and keeps the batteries charged. If utility power fails, the inverter switches to battery power and continues to power the load. In dual inverter Power Panel installations, a set of breakers control the bypass function for each inverter independently. If one inverter is bypassed for servicing, the second inverter will continue to power the loads connected to it.

In the event of an inverter failure, the breakers can be switched to the Inverter Bypass position which

allows the ac loads to be powered directly from utility power. The inverter can then be removed for servicing without affecting the connected loads.

To de-energize both circuits, switch both breaker pairs to the OFF position.

OFF

INV 1

OFF

INV 2

OFF

Figure 26

AC Disconnect Breakers (Dual Inverter Model)

AC Disconnect/Bypass for Inverter 1

AC Disconnect/Bypass for Inverter 2

Page 31

3.0 OPERATION

AC Disconnect Module (continued)

Under normal operation, the INVERTER OUTPUT breakers are ON.

NOTE: Only one AC Disconnect/Bypass breaker is illustrated below. For dual inverter models, the second breaker set controls inverter 2 in exactly the same way.

Inverter In Circuit

In this configuration, power passes through the inverter to the connected load. If an ac line failure occurs, dc from the batteries is routed through the inverter to maintain the load.

INVERTER BYPASS

OFF

BREAKER OFF Bypass circuit is de-energized.

INV 1

OFF

INVERTER OUTPUT

2903-00-016

BREAKER ON Inverter circuit is energized.

Figure 27

Inverter In Circuit (Normal Operation)

Inverter Out of Circuit

In this configuration, power passes directly to the connected load, bypassing the inverter. This allows the inverter to be removed from service without affecting the connected load. If an ac line failure occurs while the inverter is switched off, the load will be dropped.

OFF

INVERTER BYPASS

BREAKER ON Bypass circuit is energized.

INV 1

OFF

INVERTER OUTPUT

BREAKER OFF Inverter circuit is de-energized.

2903-00-017

Figure 28

Inverter Out of Circuit

Both AC Line and Inverter OFF

In this configuration, power from both the ac utility and inverter is removed from the circuit. This allows the inverter, the connected loads, or any other installed equipment beyond the AC Disconnect/Bypass switch to be serviced.

OFF

INVERTER BYPASS

BREAKER OFF Bypass circuit is de-energized.

INV 1

OFF

INVERTER OUTPUT

2903-00-018

Figure 29

Both AC Line and Inverter OFF

BREAKER OFF Inverter circuit is de-energized.

Figure G

Both AC Line and Inverter OFF

Page 32

4.0 TROUBLESHOOTING

In the event the inverters do not power up when the dc disconnects are switched on, follow the

procedure below to isolate the problem.

WARNING: THESE STEPS INVOLVE REMOVING THE COVER ON THE DC SIDE OF THE INVERTER, EXPOSING DANGEROUS VOLTAGES AND SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONS.

 Remove the side cover from the dc side of the inverter (right-hand side extension cover for the SW

series inverter and left-hand side extension cover for the DR series inverter).

 Use a dc voltmeter to check the battery voltage on the inverters dc battery input terminals.

 Check the connections from the PV array are properly wired. Verify the polarity is correct.

 If the measured voltage is appropriate for the battery configuration (12, 24 or 48 V dc), check the polarity

of the voltage. Correct if necessary.

 Ensure the batteries are not completely discharged. If the batteries are discharged, they will need to be

externally recharged until the inverters power-up on the dc battery voltage. Once the inverters power-up, switch on the ac disconnect and ac utility (or generator) power. Allow the inverters to completely recharge the batteries. Retest for proper dc operation.

 Check the battery cables and connections. All connections should be properly torqued.

If the above checks pass and the inverter still does not operate on dc battery voltage, contact the dealer or Trace Engineering for assistance.

Page 33

5.0 SYSTEM SHUTDOWN

Emergency Shutdown Procedure

To completely shutdown the system in an emergency, follow these steps:

1. Switch the BATTERY DISCONNECT(s) to the OFF position.

2. Switch the SOLAR PV ARRAY DISCONNECT breaker(s) to the OFF position.

3. Switch the AC DISCONNECT/BYPASS breaker(s) to the OFF position.

The system is completely shutdown with all sources of input dc and ac being removed from the inverter.

Switch the AC Disconnect(s) OFF

Switch the Battery Disconnect(s) OFF



Switch the Solar PV

Array Disconnect(s) OFF

Figure 30

Emergency Shutdown

Page 34

6.0 SPECIFICATIONS

For complete electrical, mechanical and environmental specifications, please refer to the appropriate system

unit Operators manual.

SW Series Power Panel General Specifications:

PART NUMBER INVERTER(S) OUTPUT DC INPUT MINIMUM DC AC OUTPUT CHARGER AMPS WEIGHT

PP-SW2512/S SW2512 2.5 kW 12 V dc 4/0 AWG 120 V ac/60 Hz 150 amps 196 lbs (88.9 kg)

PP-SW2512/D SW2512 (x 2) 5.0 kW 12 V dc 4/0 AWG (x 2) 120/240 V ac/60 Hz 150 amps (x 2) 292 lbs (132.5 kg)

PP-SW2612E/S SW2612E 2.6 kW 12 V dc 4/0 AWG 230 V ac/50 Hz 145 amps 217 lbs (98.4 kg)

PP-SW4024/S SW4024 4.0 kW 24 V dc 4/0 AWG 120 V ac/60 Hz 120 amps 217 lbs (98.4 kg)

PP-SW4024/D SW4024 (x 2) 8.0 kW 24 V dc 4/0 AWG (x 2) 120/240 V ac/60 Hz 120 amps (x 2) 334 lbs (151.5 kg)

PP-SW3024E/S SW3024E 3.3 kW 24 V dc 4/0 AWG 230 V ac/50 Hz 100 amps 217 lbs (98.4 kg)

PPSW-3048E/S SW3048E 3.3 kW 48 V dc 2/0 AWG 230 V ac/50 Hz 50 amps 217 lbs (98.4 kg)

PP-SW4048/S SW4048 4.0 kW 48 V dc 2/0 AWG 120 V ac/60 Hz 60 amps 217 lbs (98.4 kg)

PP-SW4048/D SW4048 (x 2) 8.0 kW 48 V dc 2/0 AWG (x 2) 120/240 V ac/60 Hz 60 amps (x2) 334 lbs (151.5 kg)

PP-SW4548E/S SW4548E 4.5 kW 48 V dc 2/0 AWG 230 V ac/50 Hz 57 amps 245 lbs (111.1 kg)

PP-SW5548/S SW5548 5.5 kW 48 V dc 4/0 AWG 120 V ac/60 Hz 70 amps 248 lbs (112.5 kg)

PP-SW5548/D SW5548 (x 2) 11.0 kW 48 V dc 4/0 AWG (x 2) 120/240 V ac/60 Hz 70 amps (x 2) 396 lbs (179.6 kg)

POWER VOLTAGE CABLE SIZE VOLTAGE

DR Series Power Panel General Specifications:

PART NUMBER INVERTER(S) OUTPUT DC INPUT MINIMUM DC AC OUTPUT CHARGER WEIGHT

PP-DR1512/S DR1512 1.5 kW 12 V dc 2/0 AWG 120 V ac/60 Hz 70 amps 139 lbs (63.0 kg)

PP-DR1512/D DR1512 (x 2) 3.0 kW 12 V dc 2/0 AWG (x 2) 120/240 V ac/60 Hz 70 amps (x 2) 178 lbs (80.7 kg)

PP-DR1512E/S DR1512E 1.5 kW 12 V dc 2/0 AWG 230 V ac/50 Hz 70 amps 139 lbs (98.4 kg)

PP-DR1524/S DR1524 1.5 kW 24 V dc 2/0 AWG 120 V ac/60 Hz 35 amps 139 lbs (98.4 kg)

PP-DR1524/D DR1524 (x 2) 3.0 kW 24 V dc 2/0 AWG (x 2) 120/240 V ac/60 Hz 35 amps (x 2) 178 lbs (80.7 kg)

PP-DR1524E/S DR1524E 1.5 kW 24 V dc 2/0 AWG 230 V ac/50 Hz 35 amps 139 lbs (98.4 kg)

PP-DR2412/S DR2412 2.4 kW 12 V dc 4/0 AWG 120 V ac/60 Hz 120 amps 153 lbs (69.4 kg)

PP-DR2412/D DR2412 (x 2) 4.8 kW 12 V dc 4/0 AWG (x 2) 120/240 V ac/60 Hz 120 amps (x 2) 206 lbs (93.4 kg)

PP-DR2424/S DR2424 2.4 kW 24 V dc 2/0 AWG 120 V ac/60 Hz 70 amps 148 lbs (67.1 kg)

PP-DR2424/D DR2424 (x 2) 4.8 kW 24 V dc 2/0 AWG (x 2) 120/240 V ac/60 Hz 70 amps (x 2) 196 lbs (89.0 kg)

PP-DR2424E/S DR2424E 2.4 kW 24 V dc 2/0 AWG 230 V ac/50 Hz 70 amps 148 lbs (67.1 kg)

PP-DR3624/S DR3624 3.6 kW 24 V dc 4/0 AWG 120 V ac/60 Hz 70 amps 153 lbs (69.4 kg)

PP-3624/D DR3624 (x 2) 7.2 kW 24 V dc 4/0 AWG (x 2) 120/240 V ac/60 Hz 70 amps (x 2) 206 lbs (93.44 kg)

POWER VOLTAGE CABLE SIZE VOLTAGE AMPS

Specifications subject to change without notice.

Page 35

6.0 SPECIFICATIONS

Options and weights:

Power Panel Options

PART NUMBER DESCRIPTION WEIGHT

PPO-C40 C40 dc charge or load controller installed. Includes pre-wired 60 amp breaker 4 lbs (1.81 kg)

PPO-DVM/C40 Digital meter with LCD display installed on the front of the controller 1 lbs (0.454 kg)

PPO-CD15 15 amp dc load breaker pre-wired and installed in the dc disconnect 1 lbs (0.454 kg)

PPO-CD20 20 amp dc load breaker pre-wired and installed in the dc disconnect 1 lbs (0.454 kg)

PPO-CD60 60 amp dc load breaker pre-wired and installed in the dc disconnect 1 lbs (0.454 kg)

PPO-BC5-2/0 5 foot 2/0 AWG battery cable pair with ring terminals (battery side only) and flexible conduit 6 lbs (2.72 kg)

PPO-BC10-2/0 10 foot 2/0 AWG battery cable pair with ring terminals (battery side only) and flexible conduit 12 lbs (5.44 kg)

PPO-BC5-4/0 5 foot 4/0 AWG battery cable pair with ring terminals (battery side only) and flexible conduit 10 lbs (4.54 kg)

PPO-BC10-4/0 10 foot 4/0 AWG battery cable pair with ring terminals (battery side only) and flexible conduit 19 lbs (8.62 kg)

PPO-BC15-4/0 15 foot 4/0 AWG battery cable pair with ring terminals (battery side only) and flexible conduit 29 lbs (13.2 kg)

PPO-SB Heavy duty plastic shipping container. Can be used for making a battery box. (24" H x 42" W x 46" D) 95 lbs (43.0 kg)

General Specifications SW and DR Series

Mechanical

Overall size (H x W x D)

DR Model 39-9/16" x 43" x 8"

SW Model 39-9/16" x 43" x 9-3/4"

Material Indoor rated, power coated steel

Color White

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7.0 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:

Inverter #1 Model: ________________________________________

Serial Number: ___________________________________________

Inverter #2 Model: ________________________________________

Serial Number: ___________________________________________

Charge Controller #1 Model: ________________________________

Serial Number: ___________________________________________

Charge Controller #2 Model: ________________________________

Serial Number: ___________________________________________

Purchase Date: __________________________________________

Dealer: _________________________________________________

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: ________________________________________________

visit our website at: www.traceengineering.com

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8.0 LIFE SUPPORT APPLICATIONS-POLICY

Trace Engineering, Inc., does not recommend the use of any of its products in life support applications or direct patient care. This especially applies to situations where the products failure or malfunction can be reasonably expected to cause the failure or malfunction of the life support device, or to significantly affect its safety or effectiveness.

Examples of life support devices include: neonatal oxygen analyzers, nerve stimulators (whether used for anesthesia, pain relief, or other purposes), autotransfusion devices, blood pumps, defibrillators, arrhythmia detectors and alarms, pacemakers, hemodialysis systems, peritoneal dialysis systems, neonatal ventilator incubators, ventilators for both adults and infants, anesthesia ventilators, and infusion pumps as well as any other devices designated as critical by the U.S. FDA.

Trace Engineering, Inc., will not knowingly sell its products for use in such applications unless it receives, in writing, assurances satisfactory to Trace Engineering, Inc., that (a) the risks of injury or damage have been minimized, (b) the customer assumes all such risks, and (c) the liability of Trace Engineering, Inc., is adequately protected under the circumstances.

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9.0 WARRANTY

Limited Warranty

Trace Engineering warrants its power products against defects in materials and workmanship for a

period of two (2) years from the date of purchase 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:

(1) arising out of material or workmanship not provided by Trace Engineering; (2) resulting from abnormal use of the product or use in violation of the instructions; (3) in products repaired or serviced by other than Trace Engineering repair facilities; (4) in components, parts, or products expressly warranted by another manufacturer.

Trace Engineering agrees to supply all parts and labor, or repair or replace defects covered by this

warranty with parts or products of original or improved design, at its option, if the defective product is returned to any Trace Engineering authorized warranty repair facility or to the Trace Engineering factory in the original packaging, with all transportation costs and full insurance paid by the purchaser or owner.

All remedies and the measure of damages are limited to the above. Trace Engineering shall in no event

be liable for consequential, incidental, contingent, or special damages, even if 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.

Some countries or states 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

Page 39

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

visit our website at: www.traceengineering.com