Trace Engineering PM DR 250 S, PM DR 175, PM DR 175 Dual, PM DR 250 Dual, PM SW 175 S Assembly Instructions Manual

Power Module System

Assembly Instructions

How To Use This Manual (inside cover)

Inverter Systems ...Chapter Four

Electrical Components … Chapter Five

Cabinet Components … Chapter Six

5916 195th Street NE, Arlington WA USA 98223 [phone]

Part Number 3471

How to Use this Manual

Go to Chapter Four and select the assembly instructions for the
desired system.

Single DR system .... Page 4-4

Dual DR system … Page 4-8

Single SW system .... Page 4-10

Dual SW system .... Page 4-12

Three-phase SW system .... Page 4-14

Go to Chapter Five and select the assembly instructions for each
electrical component listed in the system.

Go to Chapter Six and select the assembly instructions for each
cabinet component listed on the system assembly instructions.

Gather all cabinet and electrical components and tools listed on
the system assembly instructions.

Arrange all instruction sheets in the order suggested on the
system assembly instructions.

Assembly your system.

Table of Contents

Introducing the Power Module System .....1-1

IMPORTANT SAFETY INSTRUCTIONS .....2-1

General Precautions ............................2-1

Personal Precautions ............................2-2

Underwriters Laboratory (U.L.) Compliance Requirements.........2-3

Power Module Installation ...........3-1

Powering Up the System ..........................3-1

Stacked Pair Inverters ...........................3-2

Power Module Systems .............4-1

Power Module Fastener Facts .......................4-2

PM DR 175/250 Single Inverter Diagram ..................4-4

PM DR 175/250 Dual Diagram .......................4-8

PM SW 175/250 S Diagram ........................4-10

PM SW 175/250 Dual Diagram ......................4-12

Sinewave 3 - Phase System........................4-16

3-Phase Assembly Sequence .......................4-17

Electrical Components Assembly Instructions 5-1

PMO-AC15/20/60 Front View ........................5-3

PMO-AC60 3-Phase Breaker ........................5-5

PMO-C40, C40K & VLC40 for DR Systems ................5-7

PMO-C40, C40K & VLC40 for DR Systems ................5-8

PMO-40, C40k & VLC40 for Sinewave Systems ..............5-9

PMO-DC20/60/110 ............................5-11

PMO-DC20/60/110 ............................5-12

PMO-DC175/250 .............................5-13

PMO-DC175/250 .............................5-14

PMO-DCBB/Kit/SW/DR ..........................5-15

PMO-DCBB/Kit/(SW)(DR) .........................5-16

PMO-DCBB ................................5-17

PMO-IOX60 Input/Output/Bypass Breaker ................5-19

PMO-IOX60 ................................5-20

PMO-NEUTRAL ..............................5-21

Cabinet Components ...............6-1

PM .....................................6-3

PMADD...................................6-5

PM-EXT ...................................6-7

PMO-BLANK ................................6-9

PMO-BRACE ...............................6-11

PMO-COVER ...............................6-13

PM-DOOR .................................6-15

PM-FEET .................................6-17

PM-LID ..................................6-19

PM-LATCHES & LOCKS .........................6-21

PMO-SLIDER ...............................6-23

PMO-TRAY ................................6-25

Limited Warranty .................7-1

Life Support Policy ................7-2

1-1

Introducing the Power Module System

The Trace Modular Power System incorporates all the components of an alternative energy installation (except
external AC and DC power sources) in a package designed to permit seamless integration of the components.
The modular approach enables you to order individual components or complete systems fully assembled, tested,
and inspected.

The Power Module System allows isolation of components, wiring, and safety circuitry in a secure cabinet that
can be weatherproofed for exterior installations. Cabinets can be stacked up to four high for integration of
batteries, inverters, controllers, circuit breakers, and associated devices. Each module can house individual or
multiple components.

The base configuration is supplied as individual components or in complete assemblies (inverters are shipped
separately) from the factory. Assembled systems can include as many or as few components as desired. For
example: use one standalone module to house vented liquid lead-acid batteries, and another to house electronic
components; or stack multiple modules to house sealed batteries and all other components in one
installation.System components provided with the modules can include AC and DC breakers, disconnects,
inverters, controllers, busses, DC shunt and bonding blocks, grounding blocks, wiring, and fasteners for field
installation. These components (and batteries) can also be shipped or acquired separately.

When ordering parts, always use the PMO- prefix.

Other Power Module System features include:

• Powder-coated aluminum enclosures

• Stainless steel mounting hardware

• Removable front-panel for easy access

• Louvered front-panel for maximum ventilation

• Single or multiple Sinewave or DR Series inverters w/hardware

• Accessories include:

ü

cabinet weather proofing kit (PMO-ODTEK)

ü

bolt-down bottom mounting brackets (PMO-FEET)

ü

access panel locks w/keys (PMO-LOCKS)

ü

module extender for extra-high batteries (PMO-EXT)

ü

durable battery tray for isolating batteries from base (PMO-TRAY)

ü

C40 multipurpose controller (PMO-C40)

ü

voltage-limiting C40 multipurpose controller (PMO-VLC40)

ü

C40 installation kit (PMO-C40K)

ü

ground-fault disconnect (PMO-GFP)

ü

add-on module for additional battery capacity (PMO-ADD)

ü

20 to 60 amp Heineman™ DC breakers

ü

15 to 60 amp Square D™ AC breakers

ü

DC negative bonding block with shunt (PMO–DCBB)

ü

modular power distribution block (PMO-PDBB)

ü

utility/generator neutral bonding block (PMO-NEUTRAL)

ü

lockable acrylic breaker covers (PMO-COVER)

ü

sliding breaker fill-plates (PMO-SLIDER)

Copyright Trace Engineering Co., Inc. Telephone [phone] Part Number 3471
5916 195th Street, NE Fax [phone] Released: Thursday, April 29, 1999
Arlington, WA 98223 USA www.traceengineering.com

1-2

This page intentionally left blank.

Copyright Trace Engineering Co., Inc. Telephone [phone] Part Number 3471
5916 195th Street, NE Fax [phone] Released: Thursday, April 29, 1999
Arlington, WA 98223 USA www.traceengineering.com

General Precautions 2-1

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS !

This manual contains important safety and operating instructions. This manual also covers assembly of the
Trace Engineering line of Power Modules with both Sinewave and DR series inverters, C40 charge controllers,
AC and DC disconnects, PVGFP, and other devices. Specific operating and hookup instructions for each
separate component are provided in the individual component manuals packaged with these assembly
instructions. Before installation, review the applicable sections of this manual, and always follow the safety
practices described below:

General Precautions

1. Before using the inverter/charger, read all instructions and cautionary markings on (1) the
inverter/charger, (2) the batteries and (3) charge controllers, and (4) in this manual as well as the individual
manuals provided for each component of the system.

2. CAUTION - To reduce risk of injury, charge only deep-cycle lead acid, lead antimony, lead calcium, gel
cell, absorbed mat, or NiCad/NiFe type rechargeable batteries. Other types of batteries may burst, causing
personal injury and damage.

3. Do not expose the Power Module to rain, snow, or liquids of any type without proper installation of the
sealing kit, which is included with each Power Module

4. Qualified personnel (with electrical experience) should make all electrical connections. Incorrect
installation may result in a risk of electric shock or fire.

5. To reduce risk of electric shock, disconnect all wiring before attempting any maintenance or cleaning.
Turning off the inverter will not reduce this risk; the inverter by-pass breaker must be used and the power
module must be totally disconnected from all sources. Solar photovoltaic modules produce current when
exposed to light - cover them with opaque material before servicing any connected equipment.

6. If using a power module as a battery enclosure, support the additional weight the module must carry as
described in the PMO-FEET section. The mounting feet are required as well as a concrete pad or timbers
to support the bottom tray of each cabinet stack as shown in the section on PMO-FEET (page 6-17).

7. WARNING - WORKING IN THE VICINITY OF A LEAD ACID BATTERY IS DANGEROUS. BATTERIES
GENERATE EXPLOSIVE GASES DURING NORMAL OPERATION. Provide ventilation to the outdoors
from the battery compartment. The battery enclosure should be designed to prevent accumulation and
concentration of hydrogen gas in “pockets” at the top of the compartment. Vent the battery compartment
from the highest point.

8. NEVER charge a frozen battery.

9. No terminals or lugs are required for hook-up of the AC wiring. AC wiring must be no less than 10 AWG
(2.6mm) gauge copper wire and rated for 75C or higher. Battery cables must be rated for 75C or higher and
should be no less than #4/0 AWG (11.7 mm) for PM-XX250/X systems and #2/0 AWG (9.3 mm) gauge for
PM-XX175/X systems. Crimped and sealed copper ring terminal lugs with a 5/16 hole should be used to
connect the battery cables to the negative DC shunt terminals of the Power Module (lug not needed for the
positive terminal). Soldered cable lugs are also acceptable.

Copyright Trace Engineering Co., Inc. Telephone [phone] Part Number 3471
5916 195th Street, NE Fax [phone] Released: Thursday, April 29, 1999
Arlington, WA 98223 USA www.traceengineering.com

2-2 Personal Precautions

10. Torque all AC wiring connections to 20 inch-pounds. Torque all DC cable connections 10-12 foot­pounds. Be extra cautious to reduce the risk of dropping a metal tool onto batteries. It could short- circuit
the batteries or other electrical parts resulting in sparks that could cause an explosion.

11. Tools required to make AC wiring connections: Wire strippers, ½" (13MM) open-end wrench or socket,
Phillips screw driver #2, 3/16” ( 5mm) & 1/4" (6MM) slotted-screw driver, and a torque wrench.

12. The Power Module is intended to be used with a battery supply with a nominal voltage equal to the last
two digits in the inverter/charger’s model number. For example: a SW4024 is a 24 volt inverter, a DR1512 is
a 12 volt inverter. (The first two digits are Power output in hundreds of watts)

13. Instructions for mounting: See mounting instruction section of this manual. For battery
installation and maintenance: read the battery manufacturer’s installation and maintenance
instructions prior to operating.

14. DC GROUNDING INSTRUCTIONS - This Power Module should be connected to a grounded,
permanent wiring system. For most installations, the negative battery conductor should be bonded to the
grounding system at one (and only one point) in the system. All installations should comply with all national
and local codes and ordinances.

15. Fully assemble each module from the bottom up before adding the next module, up to a maximum stack
height of four modules. This includes attaching and tightening all mounting hardware. The strength and
stability of the modular system is dependent on all fasteners being connected and tightened properly.

Personal Precautions

1. Someone should be within range of your voice to come to your aid when you work near batteries.

2. Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.

3. Wear complete eye protection and clothing protection. Avoid touching eyes while working near batteries.
Wash your hands when done.

4. If battery acid contacts skin or clothing, wash immediately with soap and water. If acid
enters eye, immediately flood eye with running cool water for at least 15 minutes and get
medical attention immediately.

5. Baking soda neutralizes lead acid battery electrolyte. Keep a supply on hand in the area of the batteries.

6. NEVER smoke or allow a spark or flame in vicinity of a battery or generator.

7. Be extra cautious to reduce the risk of dropping a metal tool onto batteries. It could short-circuit the
batteries or other electrical parts which may result in a spark which could cause an explosion.

8. Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a
battery. A battery can produce a short-circuit current high enough to weld a ring or the like to metal, causing
severe burns.

9. This is a negative grounded system. Always connect the positive or hot wires before connecting the
negative or neutral wires when installing all equipment. This will reduce the chance of shorting the wires to
the cabinet or equipment when routing wires. This is particularly important when routing the battery cables.

10. As an additional precaution, the ends of the battery cables should be taped when routing
through cabinet openings and conduit.

Copyright Trace Engineering Co., Inc. Telephone [phone] Part Number 3471
5916 195th Street, NE Fax [phone] Released: Thursday, April 29, 1999
Arlington, WA 98223 USA www.traceengineering.com

Underwriters Laboratory (U.L.) Compliance Requirements 2-3

11. If a remote or automatic generator start system is used, disable the automatic starting circuit and/or
disconnect the generator from its starting battery while servicing to prevent accidental starting.

Underwriters Laboratory (U.L.) Compliance Requirements

The Power Module cabinet is listed (UL file#39FL under “Rainproof Modular Enclosure for use as a
photovoltaic Power System Accessory,” UL1741. The modules are shipped with a listing sticker approved

for use by UL. The sticker is valid if and only if the following compliance requirements are met in the final
installation.

1. Stability Requirements The optional mounting feet (PMO-FEET) must be included for each
assembled cabinet. The bottom module of each cabinet must be secured with at least six 1/2" anchor
bolts through the mounting feet to a concrete pad or platform of sufficient mass and footprint to keep the
completed cabinet and the intended contents from being pushed over. It is the user’s responsibility to:

insure that the concrete pad or platform meet these requirements;

ü

maintain the anchor bolts over time;

ü

replace components as needed.

ü

Additional mounting of the upper module(s) to a wall may be needed to meet local earthquake code
requirements.

2. Grounding Continuity Requirements Individual modules, doors, and lids must be assembled as per
the details outlined in this manual with the fastening hardware supplied by Trace Engineering. The PM
modules and lid must have a star washer on the outside between the head of the carriage bolt and the
module, and on the inside between the module and the nut, to insure grounding continuity between
modules. The door latch assemblies are factory installed with earth nuts and the powder-coat is removed
on the module where the door latch contacts to insure grounding continuity of the doors. As an added
insurance, the neoprene gasket is attached to the module between the door to insure that the latch
remains in contact with the bare metal spot. It is the user’s responsibility to insure that the gasket remains
maintained over time and replace as needed.

3. Baffle Requirements The water baffle and screening is required on each door on a module containing
electronic components for all installations. The kit (PMO-ODTEK) is factory installed as per the
instructions outlined in this manual. After assembly, use the silicone rubber sealant included with the kit to
treat all seams to insure lone-term weather-proofing perfoamance. It is the user’s responsibility to
maintain the weatherproofing accessories over time, and to replace components as needed.

4. The installer/user is responsible to insure that the power module cabinets are properly installed and that
all electrical connections are made to meet local National Electric Code (NEC) and inspector’s
requirements.

Copyright Trace Engineering Co., Inc. Telephone [phone] Part Number 3471
5916 195th Street, NE Fax [phone] Released: Thursday, April 29, 1999
Arlington, WA 98223 USA www.traceengineering.com

2-4 Underwriters Laboratory (U.L.) Compliance Requirements

This page intentionally left blank.

Copyright Trace Engineering Co., Inc. Telephone [phone] Part Number 3471
5916 195th Street, NE Fax [phone] Released: Thursday, April 29, 1999
Arlington, WA 98223 USA www.traceengineering.com

Powering Up the System 3-1

Power Module Installation

Read all precautions at the beginning of this manual and the individual component manuals before
attempting to install the system. Because of tool clearances needed to make connections, It is easiest to
make all external connections to the PM (charge controllers, PV array, and AC inputs/outputs, before
installing the inverter. As a general rule, connections should be made along the back panel, than the side
panels, and lastly to equipment mounted on the tray.

Install the inverter to the module tray using all six stainless steel bolts, washers and nuts supplied. Insure
that the DC and AC sides of the inverter correspond with the DC and AC breaker locations in the Power
Module. When all six fasteners are secured there is no need for additional bracing of the module tray, since
the inverter chassis will add stiffness. Torque to 79 inch-pounds.

Connect the battery positive cable from the battery disconnect and the battery positive cables from all
charge controllers to the inverter DC positive lug. Torque nut to 12 ft-lbs and place a protective cover over
the terminal.

Connect the battery negative cable from the inverter, and the battery negative cables from all charge
controllers to the inverter DC negative bonding block (DCBB page ). Torque nut to 12 ft-lbs and place
protective cover over the terminal.

Make AC connections from the AC input/output/bypass inverter breaker to the inverter. All wires are marked
identical to the labels at the connectors inside the inverter. AC Utility In should be connected into AC1 and,
if a generator is used as an additional AC input it should be connected to AC2, (it will normally have an
additional AC input/output/bypass breaker).

Grounding Parameters: Connect D.C. Ground wire (8 AWG) to grounding rod. Connect the A.C. Ground at
the main AC panel ground connection if used in a residential or commercial application. NEC and local
codes determine the complete grounding requirements.

Powering Up the System

Before applying power to the Power Module for the first time, take time to check and confirm the following
key items:

1. Check to see that the AC loads and AC source are connected properly into the inverter bypass box.

2. Confirm that the battery cable polarities are proper. Connection with improper polarity is an expensive
mistake, very obvious and not covered under warranty.

3. Check the PV array connections at the array and at the Power Module. Be sure the PV array positive is
connected to the bottom of the PV array disconnect as illustrated.

4. Confirm that all connections are tight and wire size is appropriate as described above and shown on the
installation diagram. Once these checks have been completed, it is time to apply power to the system. Do so
as follows:

A. Turn the battery DC disconnect(s) to the on (up) position.

B. Turn the solar array disconnect(s) to the on (up) position.

C. Turn the inverter(s) on as outlined in the individual component manual, and check for proper
operation. If the inverter does not power up, go to step F.

D. Unlock the main AC breaker that will feed the inverter and activate the AC source used to provide
power to the system (generator or main breaker).

Copyright Trace Engineering Co., Inc. Telephone [phone] Part Number 3471
5916 195th Street, NE Fax [phone] Released: Thursday, April 29, 1999
Arlington, WA 98223 USA www.traceengineering.com

3-2 Stacked Pair Inverters

E. Turn the inverter bypass breaker to the position noted in the residence wiring diagram on the
bypass box that will turn the inverter system on. The Power Module system is now fully connected
and operable. Should any problems arise that are not covered in this installation manual, contact
Trace Engineering or your dealer. Note: Perform the next step only if the inverter fails to Power up
when turned on.

F. Using a multi meter, check for appropriate battery voltage at the inverter DC terminals. (This will
require removing the end cover from the inverter.) If the battery voltage is appropriate confirm proper
battery cable polarity and connection, and make sure the batteries are not completely discharged. If
the inverter still doesn’t work contact your dealer or Trace Engineering.

Stacked Pair Inverters

If your P M includes a stacked pair of inverters the physical connection of the PM is no different. However,
since 240 volts AC is available across the two inverter’s AC outputs, connection of the AC loads to the
system via the bypass breaker is a little different. Refer to the section on stacking inverters in the individual
inverters owner’s manual included with the system.

Connect the AC loads that will run from 120 volts AC, to the AC output of the individual inverters at the
bypass breaker box. It is best to try and balance the AC loads between the two inverters if possible. The
load(s) that is to run from 240 volt AC output should be connected across the two inverters outputs by
connecting the neutral wire (white) to the neutral block in the bypass box, and one hot wire to each of the
inverter bypass box AC load points

Copyright Trace Engineering Co., Inc. Telephone [phone] Part Number 3471
5916 195th Street, NE Fax [phone] Released: Thursday, April 29, 1999
Arlington, WA 98223 USA www.traceengineering.com

4-1

Power Module Systems

PM Systems

Single DR Inverter Diagram ............3

Dual DR Inverter Diagram .............5

PM SW 175/250 S Diagram.............7

Dual Sinewave Inverter Diagram .........9

Sinewave 3 - Phase System ...........11

Copyright Trace Engineering Co., Inc. Telephone [phone] Part Number 3471
5916 195th Street, NE Fax [phone] Released: Thursday, April 29, 1999
Arlington, WA 98223 USA www.traceengineering.com

4-2 Power Module Fastener Facts

Power Module Fastener Facts

Table 1, Fastener Description and Application

Where Used Trace PN Description Quantity

Inverter to PM 425 1/4-20 x 3/4" SS bolt 6

468 1/4" SS flat washer 12

2147 1/4" SS external star washer 12

444 1/4-20 SS hex nut 6

PM-FEET 3191 #10-24 x 1" SS carriage bolt 14

485 1/4" SS internal star washer 14
442 #10-24 SS hex nut 14
465 #10 SS flat washer 14

PMO-ADD 3190 #10-24 x 1/2" SS carriage bolt 14

485 1/4" SS internal star washer 14

2147 1/4" SS external star washer 14

465 #10 SS flat washer 14
442 #10-24 SS hex nut 14

PM-LID 3191 #10-24 x 1" SS carriage bolt 6

485 1/4" SS internal star washer 6

2147 1/4" SS external star washer 6

465 #10 SS flat washer 6

3329 #10-24 SS wingnut 6

Table 2, Fastener Torque Values

Trace PN Description Torque value

3190 #10-24 x 1/2" SS carriage bolt 25 in-lbs
3191 #10-24 x 1" SS carriage bolt 25 in-lbs

465 #10 SS flat washer N/A
442 #10-24 SS hex nut 25 in-lbs

3329 #10-24 SS wingnut Finger tight

425 1/4-20 x 3/4" SS cap screw 80 in-lbs
468 1/4" SS flat washer N/A
485 1/4" SS internal star washer N/A

2147 1/4" SS external star washer N/A

444 1/4-20 SS hex nut 80 in-lbs

Copyright Trace Engineering Co., Inc. Telephone [phone] Part Number 3471
5916 195th Street, NE Fax [phone] Released: Thursday, April 29, 1999
Arlington, WA 98223 USA www.traceengineering.com

4-3

Single DR System

Copyright Trace Engineering Co., Inc. Telephone [phone] Part Number 3471
5916 195th Street, NE Fax [phone] Released: Thursday, April 29, 1999
Arlington, WA 98223 USA www.traceengineering.com

4-4 PM DR 175/250 Single Inverter Diagram

Hot In

Hot Out

Neutral Out

Neutral In

Ground

13

14

3 US PV wiring (not included)3

#Qty Part No. Description

4 AR US DC ground cabling; one to PV array ground, other to earth ground rod

5 AR optional C40’s (not included) up to three.

6 1 LID enclosure top

7 1 US DR Inverter not included

8 1 AC Neutral AC neutral bonding block, with AC ground bonding block

9 AR US AC wiring (not included)

10 1 IOX60 AC input/output/bypass lockout disconnect

11 2 COVER, PMO- weather-tight, locking switch cover

12 2 SLIDER, PMO- unused breaker opening cover

13 1 FEET, PMO- brackets to secure the power module to the base or pad

14 4 Edge guard Cut to length and install around cable passages in the base to prevent

chaffing.

These fasteners are used for attaching the inverter to the floor of the cabinet:

A 6 425 ¼ - 20 X ¾” HH SS bolt

B 12 2147 ¼” external tooth starwasher

C 12 468 ¼” flat washer

PM DR 175/250 Single

D

B

C

A

All configurations use 6 AWG THHN wire for AC and PV wiring. Inverter cables are 4/0

for DR2412 and 3624. DR1512, 1524, and 2424 inverters use 2/0 cable. User red heat

shrink for positive and black heat shrink for negative. Refer to the DR Owner’s Manual for

cable sizing. Each assembly also includes the door (not shown). Refer to the individual

components assembly descriptions. Follow the assembly sequence as shown on the

reverse side of this page. When ordering parts for your system, always prefix the desired

part number with the letters PMO-. AR means As Required; US means User Supplied.

Qty Part No. Description
#

I nverter Diagram

Copyright Trace Engineering Co., Inc. Telephone [phone] Part Number 3471
5916 195th Street, NE Fax [phone] Released: Thursday, April 29, 1999
Arlington, WA 98223 USA www.traceengineering.com

1 1 DC175 175 amp DC circuit breaker used with DR1512, 1524, OR 2424

DC250 250 amp DC circuit breaker used with DR2412 or3624

2 1 DCBB DC bonding block with shunt

PM DR 175/250 Single Inverter Diagram 4-5

PM DR 175/250 S Assembly Sequence

1. Feet (Page 6-17)

2. Edge guards

3. C40 if equipped (Page 5-7)

4. Neutral and ground bonding block (left panel for SW, right panel for DR, Page 5-21)

5. DC bonding block (left for DR, right for SW, Page 5-15)

6. DC shunt

7. DC bus bars

8. DC175/250 (Page 13)

9. DC20/60/110 (Page 12)

10. IOX60 (Page 19)

11. any additional AC or DC breakers

12. Slider (Page 23)

13. Cover (Page 13)

14. connect ground conductors

15. AC output cables

16. AC neutral cables

17. DC cables

18. Decals

19. Lid (Page 19)

20. Door (Page 15)

Assembly Instructions: Invert PM and install feet; turn PM upright to continue. Remove appropriate
component instruction sheets and arrange in order of installation. Gather all tools and components
listed in the instructions and place them nearby. Prepare components as instructed on the
component assembly pages and set aside. When all cables, components, fasteners, etc. are
prepared and handy, assemble each component in the sequence as shown, referring to the
component assembly instructions as required.

When ordering parts, always use the PMO- prefix.

Copyright Trace Engineering Co., Inc. Telephone [phone] Part Number 3471
5916 195th Street, NE Fax [phone] Released: Thursday, April 29, 1999
Arlington, WA 98223 USA www.traceengineering.com

4-6 PM DR 175/250 Single Inverter Diagram

This page intentionally left blank.

Copyright Trace Engineering Co., Inc. Telephone [phone] Part Number 3471
5916 195th Street, NE Fax [phone] Released: Thursday, April 29, 1999
Arlington, WA 98223 USA www.traceengineering.com

PM DR 175/250 Single Inverter Diagram 4-7

Dual DR System

Copyright Trace Engineering Co., Inc. Telephone [phone] Part Number 3471
5916 195th Street, NE Fax [phone] Released: Thursday, April 29, 1999
Arlington, WA 98223 USA www.traceengineering.com

4-8 PM DR 175/250 Dual Diagram

11

HOT
RGENERAT
OMAC UTIL

ACLOADS

HOT
RGENERAT
OMAC UTIL

ACLOADS

12

Hot Out

Neutral In

Hot In

Ground

to the floor or base

disconnect circuit breaker

Neutral Out

8 AR US AC 6 AWG THHN

9 AR US AC wiring 6AWG THHN

NEUTRAL
ORGENERATOR

GROUND
ORGENERATOR
FROMAC UTILITY

FROMAC UTILITY

10 1 PMO-SLIDER covers unused breaker slots

#Qty Part No. Description

11 2 PMO-COVER flip-up cover for breakers

12 2 PMO-IOX60 input, output, bypass,

13 1 PMO-FEET brackets to secure the module

13

PV(-) Battery(-)

Battery(+) PV(+)

PV(-) Battery(-)

Battery(+) PV(+)

DR Series Inverter #1

GND

HOTIN

NEUIN

HOTOUT

NEUOUT

PowerInverter/Charger

DRSeries

BATTERYSENSE

.5K

BATTERYCAPACITY

.37K

1K

250

Amp/Hrs

ACTRANSFERTHRESHOLD

50

125

OVER-DISCHARGEPROTECTION

BATTERYCHARGER RATE

ON

OFF

EQUALIZE1

EQUALIZE2

0

MAX

1

9

8

2

MIN

3

7

4

6

5

BatteryType Selector

LEADACID

GELCELL

60

25

>100

10

PbCa-MAINTENANCEFREE

DEEPCYCLE

0

CHARGER:GRN=FLOAT/ORNBLINK=ABSORP/ORN=BULK

COMPORT

POWERON/OFF

INVERTERMODE

SEARCHMODEWATTS

OVERTEMPRED/OVERLOADGRN

BATTERYHIRED/BATTERYLOW GRN

DR Series Inverter #2

GND

NEUIN

INVINPUT

NEUOUT

INVOUTPUT

PowerInverter/Charger

DRSeries

BATTERYSENSE

.5K

BATTERYCAPACITY

.37K

1K

250

Amp/Hrs

ACTRANSFERTHRESHOLD

50

125

OVER-DISCHARGEPROTECTION

BATTERYCHARGER RATE

ON

OFF

EQUALIZE1

EQUALIZE2

0

MAX

1

9

8

2

MIN

3

7

4

6

5

BatteryType Selector

LEADACID

GELCELL

60

25

>100

10

PbCa-MAINTENANCEFREE

DEEPCYCLE

0

CHARGER:GRN=FLOAT/ORNBLINK=ABSORP/ORN=BULK

COMPORT

OVERTEMPRED/OVERLOADGRN

BATTERYHIRED/BATTERYLOW GRN

POWERON/OFF

INVERTERMODE

SEARCHMODEWATTS

Follow the assembly sequence as shown on the reverse

side of this page.

PMO-DC250 used with DR2412 or 3624

Qty Part No. Description
#

1 2 PMO-DC175 used with DR1512, 1524, or 2424

2 AR DC20, 60, 110 amp DC breakers

3 1 PMO-DCBB D C bonding block

4 1 PMO-LID

5 AR PMO-C40, VLC40, C40K

(optional - includes one DC60 each)

6 2 DR Inverter not included

7 1 PMO-NEUTRAL neutral bonding block

PM DR

Battery (-)

BATTERY (-)

(-)

SOLARARRAY 1

Solar Array (-)

(+)
SOLARARRAY 1

(+)
SOLARARRAY 1

Solar Array (+)

BATTERY (+)

BATTERY (+)

B

Battery (+)

Copyright Trace Engineering Co., Inc. Telephone [phone] Part Number 3471
5916 195th Street, NE Fax [phone] Released: Thursday, April 29, 1999
Arlington, WA 98223 USA www.traceengineering.com

D

C

All configurations use 6 AWG THHN wire for AC and PV

wiring. Inverter cables are 4/0 for DR2412 and 3624.

DR1512, 1524, and 2424 inverters use 2/0 cable. User

red heat shrink for positive and black heat shrink for

negative. Refer to the DR Owner’s Manual for cable

sizing. Each assembly also includes the door (not shown).

A

175/250 Dual Diagram

Refer to the individual components assembly descriptions.

PM DR 175/250 Dual Diagram 4-9

PM DR 175/250 Dual Assembly Sequence

1. Feet

2. edge guards

3. C40 (if equipped)

4. neutral and ground bonding block (left panel for SW, right panel for DR)

5. DC bonding block (left for DR, right for SW)

6. DC shunt

7. DC bus bars

8. DC175/250

9. DC20/60/110

10. IOX60

11. any additional AC or DC breakers

12. Slider

13. Cover

14. connect ground conductors

15. AC output cables

16. AC neutral cables

17. DC cables

18. Decals

19. Lid

20. Door

Remove appropriate component instruction sheets and arrange in order of
installation. Gather all tools and components listed in the instructions and place then
nearby. Prepare components as instructed on the component assembly pages and
set aside. When all cables, components, fasteners, etc. are prepared and handy,
assemble each component in the sequence shown above, referring to the component
assembly instructions as required. Invert PM to install feet.

Copyright Trace Engineering Co., Inc. Telephone [phone] Part Number 3471
5916 195th Street, NE Fax [phone] Released: Thursday, April 29, 1999
Arlington, WA 98223 USA www.traceengineering.com

4-10 PM SW 175/250 S Diagram

2298-60 DC 60-amp circuit breaker

2249-110 DC 110-amp circuit breaker

9 AR C40 optional charge, load, diversion controller

10 1 DCBB DC ground bonding block and shunt

11 1 3238 decal “Solar Array (-)”

12 1 3232 decal “ Battery (-)”

13AR 2957-20 DC 20-amp circuit breaker

14AR 2079-175/250 DC 175 or 250 amp circuit breaker

15AR decal “Solar Array (+)”

16AR 3231 decal “Battery (+)”

A 6 425 ¼ - 20 X ¾” HH SS bolt

B 12 468 ¼” flat washer

C 12 2147 ¼” external tooth flat washer

D 6 444 ¼-SSHHnut

Qty P/N Description
#

1 1 decal “To AC Hot Loads”

2 AR IOX60 AC input/output/bypass disconnect

w/lockout

3 AR 3200 decal “From AC Hot Utility/Generator”

4 2 Slider unused breaker opening cover

5 1 3194 decal “From AC Utility/Generator

Neutral”

6 1 Neutral AC neutral bonding block

7 1 decal “From AC Utility/Generator

Ground”

8 1 N/A ground bonding block (part of Neutral)

PM

D

B

Copyright Trace Engineering Co., Inc. Telephone [phone] Part Number 3471
5916 195th Street, NE Fax [phone] Released: Thursday, April 29, 1999
Arlington, WA 98223 USA www.traceengineering.com

C

A

All configurations use 6 AWG THHN wire for AC and PV

SW 175/250 S Diagram

wiring. Inverter cables are 4/0 for DR2412 and 3624.

DR1512, 1524, and 2424 inverters use 2/0 cable. User

red heat shrink for positive and black heat shrink for

negative. Refer to the DR Owner’s Manual for cable

sizing. Each assembly also includes the door (not

shown). Refer to the individual components assembly

descriptions. Follow the assembly sequence as shown

on the reverse side of this page.

PM SW 175/250 S Diagram 4-11

SW System Assembly Sequence

1. Feet

2. edge guards

3. C40 (if equipped)

4. neutral and ground bonding block (left panel for SW, right panel for DR)

5. DCBB bonding block (left for DR, right for SW)

8. DC175/250

9. DC20/60/110

10. IOX60

11. any additional AC or DC breakers

12. Slider

13. Cover

14. ground conductors

15. AC output cables

16. AC neutral cables

17. DC cables

18. Decals

19. Lid

20. Door

Invert PM to install feet; revert to continue. Remove appropriate component instruction
sheets and arrange in order of installation. Gather all tools and components listed in
the instructions and place then nearby. Prepare components as instructed on the
component assembly pages and set aside. When all cables, components, falters, etc.
Are prepared and handy, assemble each component in the sequence shown, referring
to the component assembly instructions as required.

Copyright Trace Engineering Co., Inc. Telephone [phone] Part Number 3471
5916 195th Street, NE Fax [phone] Released: Thursday, April 29, 1999
Arlington, WA 98223 USA www.traceengineering.com

4-12 PM SW 175/250 Dual Diagram

Battery (+)

BATTERY(+)

BATTERY(+)

(+)

(+)

SOLARARRAY1

SOLARARRAY1

TOAC LOADS

ORGENERAT

ORGENERAT

HOT

HOT

FROMAC UTIL

FROMAC UTIL

ACLOADS

FROMAC UTILITY

ORGENERATOR

GROUND

FROMAC UTILITY

ORGENERATOR

NEUTRAL

11

MASTER SW INVERTER #1

TEMP

EXTERNAL
BATTERY

J2

RY10RY11

RY8COM

RY8NO

ACHOTIN1

ACHOTIN2

(GENERATORIN)

NEUTRALIN2

NEUTRALIN1

ACCONNECTIONS

TB2

COM

COM

NC

NO

NO

NC
UPPER

RY11

RY10

RY9

COM

RY7

COM

LOWER

NC

NO

NC

NO

C40FRONT VIEWC40FRONT VIEW

controlpanel

AC1INGOOD BULK

ERROR

LINETIE

CONTRAST

VDC24.1
AMPS70
BATTERYTEMP35C

OVERCURRENTAC2INGOOD FLOAT

INVERTING

RESETTO
FACTORY
DEFAULTS

MENU

MENU SETPOINTS

ON/OFF

GEN
MENU

MENU

ITEM

HEADINGS

HAL9000

Battery (-)

Solar Array (+)

BATTERY(-)

Solar Array (-)

(-)

SOLARARRAY1

PMO-ELEC-MOD

(+)

(+)

(+)

(+)

(+)

SOLARARRAY1

SOLARARRAY1

SOLARARRAY1

SOLARARRAY1

C40FRONT VIEWC40FRONT VIEWC40FRONT VIEWC40FRONT VIEW

Battery(+) PV(+)Battery(+) PV(+)Battery(+) PV(+)

C40FRONT VIEW

1234

5

SOLARARRAY1

TEMP

EXTERNAL

BATTERY

J2

RY10 RY11

RY8COM

RY8NO

AC HOT OUT

NEUTRAL OUT

NEUTRALIN 2

TB2

COM

COM

NO

NO

NC

NC

UPPER

RY11

RY10

RY9

COM

RY7

LOWER

COM

NC

NO

NC

NO

AC HOT IN 1

AC HOT IN 2

(GENERATORIN)

NEUTRALIN 1

ACCONNECTIONS

11

SLAVE SW INVERTER #2

TEMP

EXTERNAL
BATTERY

J2

RY10RY11

RY8COM

RY8NO

ACHOTIN1

ACHOTIN2

(GENERATORIN)

NEUTRALIN2

NEUTRALIN1

ACCONNECTIONS

TB2

COM

COM

NC

NO

NO

NC
UPPER

RY11

RY10

RY9

COM

RY7

COM

LOWER

NC

NO

NC

NO

PM SW 175/250 Dual Diagram

All configurations use 6 AWG THHN wire for AC and PV wiring. Inverter
cables are 4/0 for SW2512, 4024 and 5548. Use 2/0 for SW4048. Use
red heat shrink for positive and black heat shrink for negative. Each
assembly also includes the door (not shown). Refer to the individual
components for assembly descriptions. Follow the assembly sequence as
shown on the reverse side of this page. All AC & DC breakers are located
in the top cabinet. Lower cabinet contains PV Solar Array DC breakers if
equipped with C40 Controllers. Install inverters last, beginning with the
bottom cabinet, after securing the modules in place. Use the fasteners
listed in A, B, C, D. Starwashers are used to lock fasteners and assure
ground continuity.

Copyright Trace Engineering Co., Inc. Telephone [phone] Part Number 3471
5916 195th Street, NE Fax [phone] Released: Thursday, April 29, 1999
Arlington, WA 98223 USA www.traceengineering.com

controlpanel

AC1INGOOD BULK

ERROR

LINETIE

CONTRAST

VDC24.1
AMPS70
BATTERYTEMP35C

OVERCURRENTAC2INGOOD FLOAT

INVERTING

RESETTO
FACTORY
DEFAULTS

MENU

MENU SETPOINTS

ON/OFF

GEN
MENU

MENU

ITEM

HEADINGS

HAL9000

A

#

Qty Part No. Description

1 2 IOX60 AC input/output/bypass disconnect
2 2 SLIDER
3 1 NEUTRAL AC neutral and ground bonding block
4 AR C40 optional
5 1 DCBB DC ground bonding block
6 2 COVER
7 2 2079-250 250-amp DC breaker or

8 AR 2298 PV Solar DC disconnects
9 AR C40’s
10 AC connections detail
11 2 Sinewave inverters
A 6 425 ¼ - 20 X ¾” HH SS bolt
B 12 2147 ¼” external tooth starwasher
C 12 468 ¼” flat washer
D 6 444 ¼-SSHHnut

2116-175 175-amp DC breaker

B

C

D

PM SW 175/250 Dual Diagram 4-13

PM SW 175/250 Dual System Assembly
Sequence

1. Feet (Page 6-14)

2. Edge guards

3. C40 (Page 5-7 if equipped)

4. Neutral and ground bonding block (Page 5-21, left

panel for SW, right panel for DR)

5. DC bonding block (Page 5-15, left for DR, right for

SW)

6. DC175/250 (Page 5-14)

7. DC20/60/110 (Page 5-12)

8. IOX60 (Page 5-19)

9. any additional AC or DC breakers

10. Slider (Page 6-23)

11. Cover (Page 6-18)

12. connect ground conductors

13. AC output cables

14. AC neutral cables

15. DC cables

16. Decals

17. Lid (Page 19)

19. Door (Page 15)

PM 175/250 D Front View

Invert PM to install feet; revert to continue. Remove
appropriate component instruction sheets and arrange in
order of installation. Gather all tools and components listed
in the instructions and place then nearby. Prepare
components as instructed on the component assembly
pages and set aside. When all components are prepared
and handy, assemble each component in the sequence
shown above, referring to the component assembly
instructions as required.

Front view of PM SW 175/250 D showing standard

components plus PVGFP and three C40’s w/BTS’s

PM 175/250 D Left Panel

PM SW 175/250 D right side panel including

DCBB, DC175/250, and PV

Copyright Trace Engineering Co., Inc. Telephone [phone] Part Number 3471
5916 195th Street, NE Fax [phone] Released: Thursday, April 29, 1999
Arlington, WA 98223 USA www.traceengineering.com