Xantrex SW Series Inverter Owner’s Manual

™

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SW Series Inverter/Chargers

With Revision 4.01 Software

Owner’s Manual

 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223

Telephone: 360/435-8826

Fax: 360/435-2229

www.traceengineering.com

SW Series Inverter/Charger

Part No. 2031-5

Rev. C: February 2001

 2001 Xantrex Technology, Inc.

SW Series Inverter/Charger

http://www.wholesalesolar.com/inverters.html

5916 - 195th Street N. E. Arlington, WA 98223

Telephone: 360/435-8826

Fax: 360/435-2229

www.traceengineering.com

Part No. 2031-5

Rev. C: February 2001

PRODUCT MATERIALS PACKAGE

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Thank you for choosing Xantrex products to meet your powering needs. W e m ake every effor t to ensure that your inverter/charger is properly packaged for shipping including the following:

q Owner’s Manual; q Battery Temperature Sensor (BTS); q Red and black battery terminal covers with attaching hardware; q Hardware package (AC access panels with screws, crimp-on terminals); q Trace™ bumper sticker;

If any of the above listed materials are m issing f rom your pack age, or if it is uns atisf actory in any manner , please contact our Service department at 360-435-8826; or, fax this page explaining the discrepancy to 360-474-0616. Please provide:

Model Number: ________________________________ Serial Number: ________________________________

Comments:

Visit our web site at www.traceengineering.com for more information and answers to frequently asked questions.

 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223

Telephone: 360/435-8826

Fax: 360/435-2229

www.traceengineering.com

SW Series Inverter/Charger

Part No. 2031-5

Rev. C: February 2001

 2001 Xantrex Technology, Inc.

SW Series Inverter/Charger

http://www.wholesalesolar.com/inverters.html

5916 - 195th Street N. E. Arlington, WA 98223

Telephone: 360/435-8826

Fax: 360/435-2229

www.traceengineering.com

Part No. 2031-5

Rev. C: February 2001

TABLE OF CONTENTS

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TABLE OF CONTENTS

IMPORTANT SAFETY INSTRUCTIONS ..................................................................................................... 1

GENERAL PRECAUTIONS....................................................................................................................................1

SPECIAL NOTICES................................................................................................................ ................................2

PERSONAL PRECAUTIONS..................................................................................................................................3

INTRODUCTION .......................................................................................................................................... 5

UNIT IDENTIFICATION................................................................................................................................ 7

MODEL NUMBER...................................................................................................................................................7

CONTROLS, INDICATORS AND COMPONENTS...................................................................................... 9

CONTROL PANEL..................................................................................................................................................9

AC SIDE ...............................................................................................................................................................12

DC SIDE...............................................................................................................................................................14

INSTALLATION.......................................................................................................................................... 15

QUICK INSTALL...................................................................................................................................................16

COMPLETE INSTALL...........................................................................................................................................17

FUNCTIONAL TEST .................................................................................................................................. 31

MENU SYSTEM.......................................................................................................................................... 33

OVERVIEW ..........................................................................................................................................................33

USER MENU MAP................................................................................................................................................34

SETUP MENU MAP..............................................................................................................................................35

USER MENU ........................................................................................................................................................36

SETUP MENU ......................................................................................................................................................44

OPERATION............................................................................................................................................... 57

THEORY OF OPERATION...................................................................................................................................57

POWER VS. EFFICIENCY...................................................................................................................................59

INVERTER CAPACITY VS TEMPERATURE .......................................................................................................60

OPERATING MODES...........................................................................................................................................61

INVERTER MODE................................................................................................................................................62

CHARGER MODE................................................................................................................................................64

INVERTER/CHARGER MODE.............................................................................................................................69

GENERATOR SUPPORT MODE.........................................................................................................................71

AUTOMATIC GENERATOR CONTROL MODE...................................................................................................73

UTILITY BACKUP MODE.....................................................................................................................................81

UTILITY INTERACTIVE MODE ............................................................................................................................83

ENERGY MANAGEMENT MODE.........................................................................................................................90

PEAK LOAD SHAVING MODE.............................................................................................................................92

IN BRIEF...............................................................................................................................................................92

LOW BATTERY TRANSFER (LBX) MODE..........................................................................................................93

USING MULTIPLE INVERTERS...........................................................................................................................95

TECHNICAL INFORMATION..................................................................................................................... 99

BATTERY TYPE...................................................................................................................................................99

BATTERY SIZING...............................................................................................................................................101

BATTERY BANK SIZING....................................................................................................................................102

BATTERY CARE AND MAINTENANCE.............................................................................................................104

BATTERY INSTALLATION.................................................................................................................................106

BATTERY HOOK-UP CONFIGURATIONS.........................................................................................................107

BATTERY CABLE INDUCTANCE......................................................................................................................110

APPLICATIONS..................................................................................................................................................111

TROUBLESHOOTING GUIDE............................................................................................................................112

INVERTER/CHARGER TERMINOLOGY............................................................................................................115

SPECIFICATIONS AND FEATURES (60 Hz Models)........................................................................................118

SPECIFICATIONS AND FEATURES (50 Hz Models)........................................................................................119

DIMENSIONS.....................................................................................................................................................121

INSTALLATION DIAGRAMS..............................................................................................................................121

USER SETTINGS WORKSHEETS.....................................................................................................................123

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Telephone: 360/435-8826

Fax: 360/435-2229

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SW Series Inverter/Charger

Part No. 2031-5

Rev. C: February 2001

TABLE OF CONTENTS

SW Series Inverter/Charger

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APPENDIX................................................................................................................................................ 128

OPTIONS........................................................................................................................................................... 128

OTHER PRODUCTS.......................................................................................................................................... 129

REFERENCE TABLES AND GRAPHS.............................................................................................................. 130

STORAGE CHECKLIST..................................................................................................................................... 133

WARRANTY/REPAIR INFORMATION .................................................................................................... 135

LIMITED WARRANTY............................................................................................................... ......................... 135

WARRANTY REGISTRATION...........................................................................................................................135

LIFE SUPPORT POLICY....................................................................................................................................135

WARRANTY OR REPAIR SERVICE REQUIRED.............................................................................................. 136

INDEX ....................................................................................................................................................... 137

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Fax: 360/435-2229

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Part No. 2031-5

Rev. C: February 2001

TABLE OF CONTENTS

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INDEX OF FIGURES

Figure 1, Identification Label .................................................................................................................. 7

Figure 2, SW Series Inverter/Charger.................................................................................................... 9

Figure 3, Control Panel........................................................................................................................... 9

Figure 4, AC Side................................................................................................................................. 12

Figure 5, Internal Components and Indicators ..................................................................................... 13

Figure 6, Aux and Gen Control Relays................................................................................................. 14

Figure 7, DC Side................................................................................................................................. 14

Figure 8, Air Flow Intake Location........................................................................................................ 18

Figure 9, AC Input/Output Power Connection......................................................................................19

Figure 10, Warning Label..................................................................................................................... 21

Figure 11, Battery to Inverter Cable Connection .................................................................................. 24

Figure 12, Neutral-To-Ground Bond Switching: No External AC Source Connected........................... 27

Figure 13, Neutral-To-Ground Bond Switching: External AC Source Connected ................................ 28

Figure 14, Neutral-To-Ground Bond Switching: Neutral Bonded To Ground....................................... 28

Figure 15, Multiple Point Ground System............................................................................................. 29

Figure 16, Single Point Ground System ............................................................................................... 29

Figure 17, Trace™ SW Series Inverter Simple Block Diagram ........................................................... 57

Figure 18, Trace™ SW Series Inverter Output Waveform................................................................... 58

Figure 19, Trace™ SW Series Efficiency Curves.................................................................................. 59

Figure 20, Inverter Capacity vs. Temperature...................................................................................... 60

Figure 21, Three-Stage Battery Charging ............................................................................................ 64

Figure 22, BTS (Battery Temperature Sensor) .................................................................................... 65

Figure 23, Two Wire Start Wiring Diagram .......................................................................................... 76

Figure 24, Three Wire Start Wiring Diagram (HONDA Type) .............................................................. 77

Figure 25, Three Wire Start Wiring Diagram (ONAN Type)................................................................. 77

Figure 26, Relay RY7 and RY8 Sequence...........................................................................................78

Figure 27, Selling Power From A DC Charging Source; Hypothetical Time Of Day Oper. History...... 85

Figure 28, Selling Power Stored In The Batteries; Hypothetical Time Of Day Operational History...... 86

Figure 29, Utility Interactive Line-Tie System With Battery Backup Flow Diagram.............................. 88

Figure 30, Overvoltage Protection for Battery ...................................................................................... 89

Figure 31, Series Configuration: 6-Volt Battery Wiring....................................................................... 107

Figure 32, Series Configuration: 12-Volt Battery Wiring..................................................................... 107

Figure 33, Parallel Configuration: 12-Volt Battery Wiring................................................................... 108

Figure 34, Series-Parallel Configuration: 6-Volt Battery Wiring.......................................................... 109

Figure 35, Series-Parallel Configuration: 12-Volt Battery Wiring........................................................ 109

Figure 36, AC Waveforms.................................................................................................................. 116

Figure 37, SW Series Dimensions: With AC Access Covers – Showing Knockout Sizes................. 120

Figure 38, Installation Diagram, 120 VAC, 1 Phase, Grid Connected, Generator Backup ................ 121

Figure 39, Installation Diagram, 240 VAC, 3 Wire, Grid Connected, Generator Backup................... 122

Figure 40, AWG Wire Size................................................................................................................. 131

 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223

Telephone: 360/435-8826

Fax: 360/435-2229

www.traceengineering.com

SW Series Inverter/Charger

Part No. 2031-5

Rev. C: February 2001

TABLE OF CONTENTS

SW Series Inverter/Charger

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INDEX OF TABLES

Table 1, AC Input and Output Wiring Connections .............................................................................. 19

Table 2, Minimum Recommended Battery Cable Size vs. Cable Length............................................. 22

Table 3, Battery Cable To Maximum Breaker/Fuse Size .....................................................................23

Table 4, Charging Setpoints For Common Battery Types.................................................................... 67

Table 5, Typical Wattage Of Common Appliances ............................................................................ 101

Table 6, Battery Charging: Charging Setpoints.................................................................................. 104

Table 7, Battery State of Charge Voltage........................................................................................... 105

Table 8, Battery Cable Inductance .....................................................................................................110

Table 9, Power Consumption Of Common Appliances...................................................................... 130

Table 10, AWG to Metric Wire Conversion Chart .............................................................................. 130

Table 11, Minimum Recommended Battery Cable Size vs. Cable Length......................................... 131

Table 12, Battery Cable to Maximum Breaker/Fuse Size................................................................... 131

Table 13, Recommended Minimum AC Wire Sizes (75° C)............................................................... 132

Table 14, Knockout/Hole Size To Conduit Size Required.................................................................. 132

Table 15, Safety Ground Wire Sizes.................................................................................................. 132

 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223

Telephone: 360/435-8826

Fax: 360/435-2229

www.traceengineering.com

Part No. 2031-5

Rev. C: February 2001

IMPORTANT SAFETY INSTRUCTIONS

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IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS!

This manual contains im portant safety and operating instructions as prescribed by UL Standards for the Trace™ SW Series Inverter/Chargers for use in residential and commercial applications. This manual specifically covers products with the revision 4.01 software.

The 120 VAC/60 Hertz models of the SW Series Inverter/Chargers are ETL listed to UL Standard 1741 (Draft), Static Inverters and Charge Controllers for use in Photovoltaic Systems. The 12 and 24 VDC, 120 VAC/60 Hertz models of the SW Ser ies Inverter/Char gers are ET L lis ted to UL stan dard 458, Pow er

Converters/Inverters and Power Converter/Inverter Systems for Land Vehicles and Marine Craft.

The 120 VAC/60 Hertz models of the SW Series Inverter/Chargers are also ETL listed to Canadian Standard CSA - C 22.2 No. 107.1 - M1, Commercial and Industrial Power Supplies.

The following Model Numbers of the SW Series Inverter /Chargers listed above comply with the following EU directives:

• 89/336/EEC, “Council Directive of 3 May 1989 on the approximation of the laws of Member States relating to Electromagnetic compatibility” (EMC)

• 73/23/EEC, “Council Directive of 19 February 1973 on the harmonization of the laws of Mem ber States relating to electrical equipment for use within certain voltage limits” (LVD)

SW2612E SW4548AHC SW4548EPV SW2612A SW2612EHC SW4548EHC SW2612AHC SW3048AHC SW4548E3PH

SW3024E SW3048E

SW3048A SW3024EHC SW3048E SW4548E SW4548A

SW3048EHC SW3024E SW3048EPV SW3048E3PH SW3024AHC SW3024A SW3048APV SW4548APV

SW3048E

The compliance of the above mentioned products with the Directives is confirmed through the application of the following essential requirements:

Emissions and Immunity Safety EN 50091-1

EN 50091-2 and EN 60950

NOTE: To achieve compliance to EN50091-1, Conducted RF emissions, product mus t not be connected to AC mains. Compliance is assured for off-grid applications only.

As the manufacturer we declare under our sole responsibility that the above m entioned products c omply with the above named directives.

GENERAL PRECAUTIONS

1. Before using the SW Series Inverter/Charger, read all instructions and cautionary markings on: (a) the inverter/charger; (b) the batteries and; (c) all appropriate sections of this manual.

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

2. Do not expose inverter /charger to rain, snow or liquids of any type. The inverter is designed f or indoor mounting only. Protect the inverter from splashing if used in vehicle applications.

 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223

Telephone: 360/435-8826

Fax: 360/435-2229

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SW Series Inverter/Charger

Part No. 2031-5

Rev. C: February 2001

Page

IMPORTANT SAFETY INSTRUCTIONS

SW Series Inverter/Charger

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3. Use of battery cable or custom attac hment not recom mended or sold by Xantrex Tec hnology Inc. for the SW Series Inverter/Charger may result in a risk of fire, electric shock, or injury to persons.

4. Do not disassem ble the inverter/charger. T ak e it to a qualif ied service c enter when servic e or repair is required. Incorrect re-assembly may result in a risk of electric shock or fire.

5. To reduce risk of electric shock , disconnect all wiring befor e attempting any maintenance or cleaning. Turning off the inverter will not reduce this risk. Solar m odules produce power when exposed to light. Cover them with opaque material before servicing any connected equipment.

WARNING – RISK OF EXPLOSIVE GASSES

(a) WORKING IN VICINITY OF A LEAD ACID BATTERY IS DANGEROUS. BATTERIES

GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION. FOR THIS REASON, IT IS OF UTMOST IMPORTANCE THAT EACH TIME BEFORE SERVICING EQUIPMENT IN THE VICINITY OF THE BATTERY, YOU READ THIS MANUAL AND FOLLOW THE INSTRUCTIONS EXACTLY.

(b) To reduce ris k of batter y explosion, follow the instructions in this manual and those publis hed

by the battery manufacturer as well as manufacturer of any additional equipment used in the vicinity of the battery. Review all cautionary markings on these products.

SPECIAL NOTICES

1. Tools required to make AC and DC wiring connections: Wire strippers; 1/2" (13MM) open-end or socket wrench; Phillips #2 screwdriver; flat blade 1/4" (6MM) screwdriver.

2. No terminals or lugs are required for hook-up of the AC wiring. AC wiring must be copper wire and rated for 75°C or higher. The maximum wire size for the AC terminals is #6 AWG (4.11 mm diameter). Battery cables must be rated for 75°C or higher. Crimped and sealed copper ring term inal lugs with a 5/16 hole should be used to connect the battery cables to the DC terminals of the inver ter/charger. Soldered cable lugs are also acceptable.

3. Torque all AC wiring connections to 20 inch-pounds. T orque all DC cable connections to 10-15 footpounds. Avoid dropping metal tools onto the batteries. A shor t-circuit could result in a spark , fire or possible explosion.

4. T his inverter /c harger is des igned f or us e with a battery supply with a nominal voltage that matches the last two digits of the model number (e.g., 12 Volt with an SW2512).

5. For instructions on mounting, see the MOUNTING section on page 17 of this manual.

NOTE: Do not use the keyhole mounting slots for permanent ins tallations. F or batter y installation and maintenance refer to the battery manufacturer’s instructions.

6. No AC or DC disconnects are provided as an integral part of this inverter. Both AC and DC disconnects must be pr ovided as part of the s ystem installation. Refer to the INSTALLATION section beginning on page 15 for more information.

7. No overcurrent protection for the battery supply is provided as an integral part of this inverter. Overcurrent protection of the battery cables must be provided as part of the system installation. Ref er to the INSTALLATION section beginning on page 15 and the DC DISCONNECT AND OVERCURRENT PROTECTION section on page 23 for more information.

8. No over current protection for the AC output wiring is provided as an integral part of this inverter. Overcurrent protection of the AC output wiring m ust be provided as part of the s ystem installation. Ref er to the INSTALLATION section on page 15 and the AC WIRING section on page 18 for more information.

9. The AC output neutral conductor and DC negative conductors are not connected (bonded) to the inverter chassis. Both the input and output conductors are isolated from the enclos ur e and each other . System grounding, if required by sections 690-40, and 690-42 of the National Electric Code, ANSI/NFPA 70-1996, is the responsibility of the system installer. All installations must comply with local and national electrical codes and standards.

Page

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Part No. 2031-5

Rev. C: February 2001

IMPORTANT SAFETY INSTRUCTIONS

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10. GROUNDING INSTRUCTIONS - This inverter/battery charger should be connected to a grounded, permanent wiring system. For m ost installations, the negative battery conductor should be bonded to the grounding system at one (and only one point) in the system. All installations should com ply with national and local codes and ordinances. Refer to the SYSTEM GROUNDING section on page 26 for more information.

PERSONAL PRECAUTIONS

1. Someone should be within range of your voice or close enough 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.

(a) Baking soda neutralizes lead acid battery electrolyte. (b) Vinegar neutralizes spilled NiCad and NiFe battery electrolyte. (c) Keep a supply on hand in the area of the batteries.

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

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

7. Remove personal m etal items s uch as rings, brac elets, necklaces , and watches when working with a battery. A battery can produce a short-cir cuit current high enough to weld a ring or the like to metal, causing severe burns.

8. NEVER charge a frozen battery.

9. If necessary to remove the battery, make sur e all accessories are off. Then, remove the gr ounded terminal from the battery first.

10. If a remote or automatic generator

control system is used, disable the automatic starting circuit and/or

disconnect the generator from its starting battery while perform ing maintenanc e to prevent ac cidental starting.

11. Provide ventilation to outdoors from the battery compartment. The battery enclosure should be designed to prevent accumulation and conc entration of hydrogen gas in “pockets” at the top of the compartment. Vent the batter y compartment from the highest point. A sloped lid c an also be used to direct the flow to the vent opening location.

12. Clean battery terminals. Be careful to keep corrosion from coming in contact with eyes.

13. Study all the battery manufacturer’s specif ic precautions , such as rem oving or not rem oving cell caps while charging and recommended rates of charge.

14. For flooded lead acid batteries, add distilled water in each cell until the battery acid reaches the level specified by the battery manufacturer. This helps purge excessive gas fumes from the cells. Do not overfill. For a battery without cell caps, carefully follow the manufacturer’s recharging instructions.

 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223

Telephone: 360/435-8826

Fax: 360/435-2229

www.traceengineering.com

SW Series Inverter/Charger

Part No. 2031-5

Rev. C: February 2001

Page

IMPORTANT SAFETY INSTRUCTIONS

SW Series Inverter/Charger

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Page

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Fax: 360/435-2229

www.traceengineering.com

Part No. 2031-5

Rev. C: February 2001

INTRODUCTION

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INTRODUCTION

Congratulations! You are the proud owner of the finest inverter on the market today - and one very complex piece of equipment. T he Trace™ Sine wave (SW Series) Inverter/Charger has many features and capabilities previously either non-existent, or found only in separate products.

With proper installation, the inverter will operate satisf actor ily for many applications str aight out of the box , using the factory default settings. To fully utilize the inverter's generator interactive, or utility interactive capabilities, it is necessary to understand the way the inverter operates and then tailor its operation via the Control Panel and the USER and SETUP menu systems. This manual will provide the necessary information. However, it is recom mended that you consult with your authorized dealer to ensure correct installation and maximum utilization of the numerous featur es of this pr oduct. If you do not understand any aspect of installation, contact your authorized Xantrex dealer/installer for assistance.

If you intend to operate the inverter in a utility interactive mode, in which power will be sold to the utility, you must contact the local utility office and get their approval. T he utility may require additional inf or mation that may not be included in this manual. Please contact your authorized Xantrex dealer/installer for assistance.

As a minimum , you should read the sections of the manual that relate to your type of installation. The MENU SYSTEM section, beginning on page 33, explains how to make changes to the inverter’s user/setup menus. T he OPERATION section, beginning on page 57, explains how the inverter works in each of its different operating modes. Focus on the operating modes that relate best to your type of installation and make the appropriate selections and adjustm ents. Installation diagrams are provided for many of the various applications. This m enu system provides control of the inverter, allows features to be enabled, and allows setting of operating parameters.

This is a long manual and much of it is fairly technical. Throughout this m anual terms may be used that are unfamiliar, see the INVERTER/CHARGER TERMINOLOGY glossary on page 115 for clarification. If you are an insomniac, properly used, this manual is guaranteed to provide several good nights of sleep.

Note: This manual is specific to the REVISION 4.01 software. Some features disc ussed may not be included in previous software revisions provided in inverters manufactured before March

1996.

You can verify that the inverter is using REVISION 4.01 software by checking under the TRACE ENGINEERING (3) m enu heading. The second menu item should read REVISION 4.01. If your inverter

includes a previous software version, please contact your authorized Xantrex dealer regar ding upgrade options.

 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223

Telephone: 360/435-8826

Fax: 360/435-2229

www.traceengineering.com

SW Series Inverter/Charger

Part No. 2031-5

Rev. C: February 2001

Page

INTRODUCTION

SW Series Inverter/Charger

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Page

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Part No. 2031-5

Rev. C: February 2001

UNIT IDENTIFICATION

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UNIT IDENTIFICATION

This section describes the marking and location of the model and serial numbers for SW Series Inverter/Chargers. Use this section to determine the type and model of your inverter/charger. The unit identification label on the left side panel of the inverter/charger will show the serial number, model number, listings, ratings, and date of manufacture.

Model Number

DC Input Voltage Operating Range

AC Input/Output

Phase,

Quarter and Year of

Manufacture

Waveform,

Frequency and

Voltage

Product Code and Serial

Number

Figure 1, Identification Label

MODEL NUMBER

The Model Number of your inverter determines the different features your unit may have. Consider the following unit with a SW4024 model number:

SW 40 24 *

Model Power Nominal DC

Voltage

Model: The first letter(s) (SW) indicate the model, in this case the SW Series.

Power: The first and second positions in the model number indicate the continuous AC power output in

hundreds of VA (Volt-Amps). Power levels available start at 2500 up to 5500 Volt-Amps with different DC voltages. In the example above, 40 would stand for a 4000 VA (4 kVA), continuous-output inverter.

Input/Output DC Voltage: The number (24) following the power rating indicates an inverter/charger that is designed to convert 24 VDC input to an AC voltage

output, and charge 24 VDC batteries when

AC Voltage/Options

Input/Output AC Voltage/Options: The letter following the power rating indicates what AC voltage and frequency or particular option this inverter/charger is specifically designed to provide. No letter after the DC voltage number indicates an AC voltage of 120 VAC/60 Hz and requires the same AC voltage and frequency (120 VAC/60 Hz) to charge the inverter batteries. Available voltages range from 105 to 240 VAC at 50 or 60 Hz.

See the SPECIFICATIONS AND FEATURES section, on page 121, for the different models available.

 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223

Telephone: 360/435-8826

Fax: 360/435-2229

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SW Series Inverter/Charge

Part No. 2031-5

Rev. C: February 2001

Page

UNIT IDENTIFICATION

SW Series Inverter/Charger

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Page

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Part No. 2031-5

Rev. C: February 2001

CONTROLS, INDICATORS AND COMPONENTS

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CONTROLS, INDICATORS AND COMPONENTS

The SW Series Inver ter/Chargers have an integral, full f unction Control Panel with LED status indicators. The following components are als o included: inverter/charger circ uit breaker; battery tem perature sensor (BTS) port, remote port, and a stacking port.

Stacking Interface Remote Interface

Control Panel

AC Side

DC Side

BTS Sensor Input Circuit Breaker

Figure 2, SW Series Inverter/Charger

CONTROL PANEL

The Control Panel, on the front of the SW Series Inverter/Charger, provides the controls and displays needed to adjust, control and monitor the oper ation of the unit. T he control panel is operational whenever DC power is applied to the inverter DC input terminals.

Figure 3, Control Panel

Eight pushbuttons are used to select the various menus, menu items and operating s etpoint values f or the unit, including the ability to turn the inverter on and off. A Liquid Crystal Display (LCD) presents the various system settings and data as selected by the operation of the MENU BUTTONS on the control panel. Eight LED indicators are provided to show the operating condition of the inverter, battery charger, AC inputs and self-protection systems.

DISPLAY

The Liquid Crystal Display (LCD) displays data as selected by the menu buttons. Refer to the USER MENU, beginning on page 36, and the SETUP MENU, beginning on page 44, for specific information on

the Menu Items, functions and display information.

 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223

Telephone: 360/435-8826

Fax: 360/435-2229

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SW Series Inverter/Charger

Part No. 2031-5

Rev. C: February 2001

Page

CONTROLS, INDICATORS AND COMPONENTS

SW Series Inverter/Charger

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CONTRAST CONTROL

The CONTRAST adjustm ent enables you to adjust the contrast of the LCD display screen to accom modate changing lighting conditions. Less contrast is usually preferable in brighter lighting conditions.

RESET TO FACTORY DEFAULTS BUTTON

The RESET TO FACTORY DEFAULTS button returns all of the inverter settings ( except f or the TIME OF DAY settings) to the factory default values. The def ault values will be re-entered only when this button is pushed from a spec ific m enu item in the USER MENU. You must first select the TRACE ENGINEERING (3) menu heading and then go to the first menu item, which will display “PRESS RESET NOW FOR

DEFAULTS”. Once this reset button is pressed from this menu item, you must reprogram all settings required by your installation into the inverter.

Removing DC power from the inverter will also return the inverter to the factory default values (including the TIME OF DAY settings). You must then reprogram the inverter with the required s ettings

for proper operation of your system. Recording your settings on the USER SETT INGS W ORKSHEET, in the TECHNICAL INFORMATION section of this manual, will make the reprogramming of the inverter much easier.

The reset button is also used to re-synchronize the remote control (SW RC) display if the character s becom e jumbled. Pressing the reset button anywhere in the menu s ystem (ex cept the PRESS RESET NOW FOR DEFAULTS menu item) will re-synchronize the display, but the default values will not be reset.

MENU BUTTONS

ON/OFF MENU BUTTON (Red)

Pressing the red ON/OFF MENU button at any time will take you directly to the SET INVERTER menu item of the INVERTER MODE (1) menu heading. There are four options available from this m enu item. The first letter of the selec ted item will be underlined. Pressing the red ON/OFF MENU button will move the cursor one position to the right, selecting the next item. You can also use the SET POINT S buttons to move either right or left.

GEN MENU BUTTON (Green)

Pressing the green GEN MENU button at any time will display the SET GENERATOR menu item of the GENERATOR MODE (2) menu heading. There are four options available from this menu. The f irst letter

of the selected item will be underlined. Pres sing the green GEN MENU button will move the cursor one position to the right, selecting the next item. You can also us e the SET POINTS buttons to move either right or left.

MENU ACCESS/ADJUSTMENT BUTTONS (Black)

The MENU HEADING buttons are used to move either up or down through the selection of menu headings. Once a menu heading is selected, the MENU ITEM buttons are used to move up or down through the list of related menu items. The SET POINTS buttons change the value of a parameter or select a mode, for the selected menu item.

LED STATUS INDICATORS

The Control Panel features eight colored LED indicators that identify the various operating conditions of the inverter. Unless otherwise indicated, the LED’s will be "solid" in appearance, when illuminated.

LINE TIE (Yellow)

Selecting SELL from the GRID USAGE menu item under the INVERTER SETU P (9) menu heading will enable sell mode. This should only be done with utility connected systems and after you have received the approval of the local utility. This mode allows excess power to be sent into the utility grid.

INVERTING (Yellow)

The inverter is operational and AC output is available. If this LED is blinking, the inverter is in the search mode and is looking for an AC load greater than the SET SEARCH WATTS setting.

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CONTROLS, INDICATORS AND COMPONENTS

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AC1 IN GOOD (Green)

Indicates that AC power is present at the AC HOT IN 1 and NEUTRAL IN 1 input terminals. T his input is intended for utility power. When an AC sourc e is connected to the input term inals, it will s tart to blink slowly (once a second) to show the AC voltage has been detected. After the inverter has connected to the AC source, the LED will be solid. If the LED starts to blink during operation, utility power has been dropped.

AC2 IN GOOD (Green)

Indicates that AC power is present at the AC HOT IN 2 and NEUTRAL IN 2 input terminals. T his input is intended for generator power. When an AC source is connected to the input term inals, it will start to blink slowly (once a second) to show the AC voltage has been detected. After the inverter has connected to the AC source, the LED will be solid. If the LED starts to blink dur ing oper ation, generator power may have been dropped.

This LED will also blink slowly (once a second) when the automatic gener ator control system is enabled. When the generator has star ted, it will continue to blink s lowly until the generator has been c onnected. If the generator does not successfully start, the AC 2 IN GOOD LED will stop blinking and the red ERROR LED will turn on. The ERROR CAUSES (5) menu heading will indicate a GENERATOR SYNC ERROR condition.

BULK (Yellow)

This indicator will be on to indicate the inverter is in the Bulk or Absor ption c harge s tage. This indicator will go off and the FLOAT indicator will illuminate when the battery voltage has been held near the SET BULK

VOLTS DC setting for the time period determined by the SET ABSORPTION TIME setting from the BATTERY CHARGING (10) menu heading.

If the EQ mode is selec ted from the SET GENERATOR menu item under the GENERATOR MODE (2) menu heading, the BULK LED will slowly blink while the charger completes the equalization process.

FLOAT (Green)

This indicator will be on when the battery voltage has reached the Float Stage of the charging proc ess. It will now regulate the charging process to the SET FLOAT VOLTS DC setting from the BATTERY CHARGING (10) menu heading. The SET FLOAT VOLTS DC setting provides a maintenance char ge to the battery until another Bulk Charge Cycle is initiated or the AC sourc e is disconnected. If a generator is manually controlled and powering the battery charger, the FLOAT indicator will com e on to indicate that the generator should be turned off, since the battery is now fully charged.

This indicator is also used to indicate the r egulation setpoint when the inverter is operating as an Utility Interactive Inverter (SELL mode). The indicator will blink slowly to indicate the battery is regulated to the SET BATTERY SELL VOLTS DC setting from the BATTERY SELLING (17) menu heading, and the indicator will be “solid” to indicate the battery is regulated to the SET FLOAT VOLTS DC setting from the BATTERY CHARGING (10) menu heading.

ERROR (Red)

Indicates that an operating error has occur red (refer to the ERRO R CAUSES (5) menu heading f or a list of possible causes). T o reset the inverter, pres s the red ON/OFF MENU button and then select OFF and then ON with the SET POINTS buttons or by pressing the red button several times.

This indicator will blink slowly to indicate that the AC source f requency is not well-adjusted (3 to 7 hertz from nominal). You can use the LED blink to help adjust the AC source frequency. Once the f requency is within 3 hertz of your nominal frequency, the LED will turn off.

OVERCURRENT (Red)

The load requirement has ex ceeded the inverter’s maximum output AC amps . A sustained overcurrent condition will require a manual reset by pressing the red ON/OFF MENU button and then selecting OFF and then ON with the SET POINTS buttons or by pressing the red button several times. Momentary flashing of the red OVERCURRENT indicator means that the inverter has reac hed it max imum output AC amps and has automatically reset itself. This may occur during motor startups and is acceptable.

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SW Series Inverter/Charger

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Rev. C: February 2001

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CONTROLS, INDICATORS AND COMPONENTS

SW Series Inverter/Charger

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AC SIDE

Figure 4 shows the components located on the AC side of the inverter. The r em ovable AC Acces s Panels cover and protect the Internal Components and Indicators, such as the AC Terminal Block, BTS Connection, LED status indicators (for the AC1 and Gen Control relays) and the Aux and Gen Control relay terminals. Refer to the INSTALLATION section beginning on page 15, for all wiring connections.

Inverter/

Identification

Label

Remote

Port

Charger

Circuit Breaker

Knockouts

(Also On Side}

Stacking

Port

Three

Removable

Access Panel

(One Panel on

Side)

Figure 4, AC Side

REMOTE PORT

The SW Series Inverter/Charger can be controlled remotely from the unit by plugging in a Sine wave Remote Control (SWRC) or Sine wave Communications Adapter (SWCA).

The SWRC remote control is a full function, programmable remote control with backlit LCD which duplicates the functions of the integral Control Panel.

The SWCA serial communications interf ace adapter allows for rem ote setup, adjustment, m onitoring and troubleshooting of SW Series Inverter/Chargers from a personal computer and allows modem access monitoring over long distances.

See the APPENDIX, OPTIONS section, starting on page 128, for a com plete description of the SW RC Remote Control and SWCA Serial Communications Adapter.

STACKING PORT

The stacking port allows multiple SW Series Inverter/Chargers to be used in the same system. The inverters can be used in a “SERIES” configuration to operate 240 Vac loads and to connect to 120/240 Vac power systems. A series stacking interface cable (SWI) is required to connect the series stacking ports of the inverters. This port is als o used to connec t two units in a “PARALLEL” configur ation. The parallel stacking interf ace cable (SWI/PAR) allows two inverters to be connected to provide twice the continuous and surge capability at the same AC voltage. See the U SING MULTIPLE INVER TERS section on page 95 for more information.

INVERTER/CHARGER CIRCUIT BREAKER

This circuit break er protects the unit’s internal wiring while the unit is inverting or charging. It is not used for the pass-through current. This is not a branch-circuit rated breaker, separate output breakers are required. Press the breaker to reset (to reset on 48-volt units, move the breaker handle to the ON position).

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CONTROLS, INDICATORS AND COMPONENTS

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INTERNAL COMPONENTS AND INDICATORS

Additional components and indicators ar e located behind three removable AC Access Panels located on the AC Side of the unit. They include the AC Terminal Block , BTS Connector, three LED indicators and the Aux and Gen Control Relay Connectors.

RY7 (Yellow)

LED

RY8 (Green)

LED

AC1 Relay (Red) LED

Figure 5, Internal Components and Indicators

LED INDICATORS

Terminal Block

BTS

Connector

Aux and Gen Control

Relay Connectors

Safety Ground

Three LED indicators allow visual indication of operation of the RY7, RY8 and AC1 relays.

RY7 (Yellow) LED

Allows visual indication of relay RY7 operation. During the automatic generator control sequence, the LED will be on to show that RY7 is closed (engaged) from the N.O. to the COM contacts, and will be off when RY7 is opened (disengaged).

RY8 (Green) LED

Allows visual indication of relay RY8 operation. Dur ing the automatic generator control sequenc e, the LED will be on to show that RY8 is closed (engaged) from the N.O. to the COM contacts, and will be off when RY8 is opened (disengaged).

AC1 RELAY (Red) LED

Allows visual indication of AC1 relay operation. The LED will be on when the AC1 relay is closed (engaged). This LED along with the test-jumper adjacent to the LED is used by utilities to perform voltage and frequency tests to qualify the SW Series Inverter/Charger for line-tie applications.

BTS PORT

The battery temperature sensor (BTS) can be connected (plugged in) at the RJ-11 four-conductor connector, located on the AC Circuit Board. T he BTS provides information that enables the three-stage standby battery charger to “fine tune” the battery charge voltages for better charging perf orm anc e, greater efficiency and longer battery life.

AC TERMINAL BLOCK

A six position terminal block is pr ovided to m ak e the AC connections . T he term inal block is located on the AC Circuit Board. The terminal block is used to hardwire all AC input and output connections.

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CONTROLS, INDICATORS AND COMPONENTS

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AC SAFETY GROUND

The AC Safety Ground is used to connect the inverter chassis to the AC Grounding System.

AUXILIARY AND GENERATOR CONTROL RELAY CONNECTORS

Auxiliary Control

Relay Connectors

Generator Control Relay Connectors

Figure 6, Auxiliary and Generator Control Relay Connectors

DC SIDE

Figure 5 shows the components located on the DC side of the inverter. Refer to the INSTALLATION section for the battery wiring connections to the Battery Terminals and the DC Ground.

(Equipment)

Ground

Battery

Terminal

(-)

Battery

Terminal

(+)

Figure 7, DC Side

BATTERY TERMINALS

Caution: Before connecting the battery cables to the inverter, ver ify the correct battery voltage and cable polarity using a voltmeter. The inverter is not reverse polarity protected. If the

positive terminal of the battery is co nnected to the negative terminal of the inverter and vice versa, severe damage will result. If necessary, color- code the cables with colored tape or

heat shrink tubing: RED for positive (+); BLACK for negative (-) to avoid polarity problems.

DC (EQUIPMENT) GROUND

This connection is used to connect the exposed chassis of the inverter to the DC grounding system. The terminal accepts wires from #14 AWG to #2 AWG.

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Part No. 2031-5

Rev. C: February 2001

INSTALLATION

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INSTALLATION

This section is very important, since it tells you how to properly install your SW Series Inverter/Charger.

It becomes very frustrating when your inverter system does not perform properly, simply because care was not taken during installation. Please read this entir e section carefully. You will save time and avoid common mistakes.

This section also describes the requirements and recommendations for installing the SW Series Inverter/Charger. In the U.S., the National Electrical Code (NEC) def ines the standards for both the AC and DC wiring in residential, commerc ial and RV applications. It will list the requirement for wire sizes, overcurrent protection and installation m ethods and r equirem ents. T here ar e still m any other variables not covered by the NEC. Most are determined by the level of automatic operation, the amount of ex ternal AC and DC power to be controlled and the loads to be operated.

The NEC standards and regulations are described here in general for your convenience, and are not represented as comprehensive or complete. For comprehensive and complete official standards and regulations, write the address listed below:

NFPA - National Fire Protection Association

National Electrical Code Handbook

1 Batterymarch Park, PO Box 9101 Quincy, MA 02269-9101 617-770-3000.

Before beginning the installation of the SW Series Inverter/Charger , read all instructions. Disconnect all sources of AC and DC power to prevent accidental s hock. Disable and sec ure all AC and DC disconnec t devices and automatic generator starting devices.

All installations should meet all local codes and standards and be performed by qualified personnel such as a licensed electrician. Although the DC electrical system may be “low voltage”,

significant hazards may be present, particularly from s hort circuits of the battery system. Inver ter systems by their nature involve power from multiple sour ces (inverter, gener ator, utility, batteries, solar arrays etc.) that add hazards and complexity that can be very challenging.

After you have finished installing your unit, continue with the FUNCTIONAL TEST section on page 31. This Functional Tes t should be completed prior to configuring your unit’s Menu System for your specific operation.

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Telephone: 360/435-8826

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Part No. 2031-5

Rev. C: February 2001

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INSTALLATION

SW Series Inverter/Charger

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QUICK INSTALL

This section provides ins tallers, licensed electrical contractors, and k nowledgeable laymen the essential steps to quickly install the Trace™ SW Series Inverter/Charger. If you haven’t had experience with the SW Series Inverter/Charger, you are urged to skip this sec tion and read the entire INSTALLATION section before installing the inverter/charger.

MOUNTING

Mount the unit securely in a clean, dry, properly ventilated enclosure. Do not mount the unit in the same enclosure as vented or maintenance-free type vented batteries. Bolt the unit securely. Allow adequate clearance to allow access to the indicators or controls.

DC CABLING

1. Connect an appropriate sized cable from the positive batter term inal (or batter y bank) to the inverter’s positive (red) terminal. See T able 12 in the Appendix to determ ine the proper size cable and length of run needed to use with your inverter model and for your specific application. The National Electric Code (NEC) requires the use of a DC fuse or disconnect with this cable. See Table 12 in the Appendix to determine the correct fuse or breaker to use.

2. Connect an appropriate sized cable from the negative battery terminal to the negative (black ) inverter terminal. Torque all term inals to 10-15 foot-pounds. NOTE: A 's nap' caused by charging the internal capacitors may occur when first connecting the cable. This c an be avoided by first removing the DC fuse or opening the disconnect in the positive battery cable.

3. Connect a cable from the inverter’s DC Chassis Ground to the system ground.

AC IN CABLING

1. See Table 13 in the Appendix to determine the appropriate AC wire size.

2. Remove the knock out from the inverter chas sis and install a strain relief or conduit in which to route the AC cabling in and out.

3. Connect the black wire from the hot side of the AC power to the terminal labeled AC HOT IN 1 (AC HOT IN 2 if a generator is the AC source) on the inverter.

4. Connect the white wire from the neutral side of the AC power source to the terminal labeled NEUTRAL IN 1 (NEUTRAL IN 2 if a generator is the AC source) on the inverter.

5. Connect the green wire from the ground of the AC power source to the AC Ground Terminal of the inverter/charger.

AC OUT CABLING

1. Connect the black wire between the terminal m arked AC HOT OUT to the hot bus of your AC load center or AC sub-panel.

2. Connect the white wire from the term inal marked NEUTRAL OUT to the neutral bus of your AC load center or sub-panel.

3. Connect the AC Ground Terminal of the inverter to the safety ground bus of the AC load center or sub-panel.

WRAP UP

1. Secure all wiring with wire ties or other non-conductive fasteners to prevent c hafing or damage. Use strain-reliefs, grommets, or conduits to prevent damage to the wiring where it passes through any apertures. Tighten all connections to the correct torque (AC Connections at 20 inch-pounds; DC Connections at 10-15 foot-pounds).

2. Make a final check of all wiring, then reconnect to the AC power source.

3. Turn the inverter ON and check inverter operation (See the FUNCTIONAL TEST section on page 31).

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Part No. 2031-5

Rev. C: February 2001

INSTALLATION

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COMPLETE INSTALL

UNPACKING

Before beginning, unpack the inverter/charger; record the serial number on the inside cover of this booklet and on the warranty card. Right now, please do the following:

• Verify that you have everything listed on the Packaging Materials sheet. If any items are missing, please call Customer Service at (360) 435-8826.

• Save your “proof-of-purchase”, You will need the “proof-of- purchase” to obtain warranty service.

• Keep the original carton and packing materials. If you need to return your inverter for service, you should ship it in the original carton. It is also the best way to keep the inverter safe if it needs to be moved.

LOCATION

Inverters are sophisticated electronic devices and should be treated ac cordingly. Treat the inverter as you would any fine piece of electronic equipment. W hen selec ting the location for the inverter, don't think of it in the same terms as the other interf acing equipm ent, e.g. batter ies, diesel generators, motor generators, washing machines etc. It is a highly com plex micropr ocessor contr olled device. There are near ly 500,000 silicon junctions in its output devices and integr ated circuits. The crystal oscillator runs at 4 megahertz. The drive circuitry timing is acc urate to a thousandth of a second. Genetically speaking, it is a cous in to stereo equipment, television sets or computer s. The use of conformal-coated circuit boards, plated copper bus bars, powder coated metal components , and stainless steel fasteners impr oves tolerance to hostile environments. However, in a corrosive or condensing environment (one in which humidity and/or temperature change cause water to f orm on com ponents) all the ingredients for elec trolysis are present water, electricity and metals. In a corrosive or condensing environment, the life expectancy of the

inverter is indeterminate and the warranty is voided.

Caution: Install the inverter in a dry, protected loc ation away from sources of high temperature and moisture. Exposure to saltwater is particularly destructive and potentially hazardous.

Locate the inverter as close to the batteries as pos sible in order to keep the battery cable length short. Do not locate the inverter direc tly above the batteries or in the same compartment as vented batteries. Batteries generate hydrogen sulfide gas, which is very corrosive to electronic equipm ent and everything else. They also generate hydrogen and oxygen. If these gases accumulate, an arc caused by the connecting of battery cables or the switching of a relay could ignite the mixt ure. Mounting the inverter in a ventilated enclosure with sealed batteries is acceptable.

Ensure the inverter is located in an area that prevents ins ects and rodents from entering the inverter, as the inverter can provide a warm habitat in a cold environment. This may involve installing the inverter in an enclosure and include mesh screens or nets over any openings to ensure the unit is kept well ventilated.

This inverter can create RFI (Radio Frequency Interference). Keep this in mind when determining the placement of the inverter. You should locate the inverter as far away as possible from any electronic devices that may be susceptible to RFI.

MOUNTING

UL Standard 1741 (draft) requires that the inverter be m ounted on a vertical surface ( on a wall) and that the keyhole slots not be used as the only method of mounting. The purpose of the wall mounting requirement is to orient the inverter so that its bottom c over, which has no holes, will not allow burning material to be ejected in case of an internal fire.

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Telephone: 360/435-8826

Fax: 360/435-2229

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SW Series Inverter/Charger

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INSTALLATION

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Use 1/4" minimum diameter bolts for mounting. The m ounting must be capable of supporting twice the weight of the inverter in order to com ply with UL 1741. If this unit is used in a mobile applic ation (i.e. RV, Boat) secure the inverter to a shelf or deck to prevent m ovem ent. Place flexible washers on the mounting screws or bolts between the shelf or deck and the inverter chassis to reduce vibration.

VENTILATION

Installation of the inverter in a properly ventilated enclosure is neces sary for eff icient operation of the unit. The inverter’s thermal shutdown point will be reached sooner than normal in a poorly ventilated environment and will result in a lower peak power output, reduced surge capability, and potentially shorter inverter life.

Note: Do not operate the inverter in a closed-in area or restrict ventilation in any way.

Testing has shown that the volume of the enclosure is not as important as the overall ventilation. A minimum airspace clearance of 1½ inches around the top and bottom and 3 inches of c learanc e at the lef t and right sides of the inverter will provide adequate ventilation. Because the top and bottom of the SW Series chassis is not vented, clearanc e between the enclosure and the top of the inverter is not critical. A fresh air intake port s hould be provided directly to the left side and an exhaust port on the right side will allow cool outside air to flow through the inverter and back out of the enclosure.

Top

Left

(AC Side)

Right

(DC Side)

AIR

FLOW

Bottom

Figure 8, Air Flow Intake Location

AC WIRING

This section describes AC wiring requirements and recommendations; including AC connections; wire sizing; overcurrent devices; GFCIs; external r elays; hookup procedure; and neutral-to-ground switching. Your local electrical code and the National Electrical Code (NEC) def ine the standards for AC ins tallation wiring, but there are still many installation variables to be considered. Cons ult the local code and the NEC for the proper wire sizes, connectors and conduit. All installations should meet all local codes and

standards and be performed by qualified personnel such as a licensed electrician. AC INPUT AND OUTPUT CONNECTIONS

A six position terminal block is pr ovided to m ak e the AC connections . T he term inal block is located on the left-hand side of the inverter, enclosed under a cover plate (See INTERNAL COMPONENTS AND INDICATORS on page 13 for location.). The term inal block can accept up to # 6 AWG stranded wire and is used to hardwire all AC connections. For 120 VAC inverters, we recom mend 6 AWG (THHN) wire for full utilization of the inverter’s 60 amp AC pass through capability. The code requires that disconnect switches be provided in the AC input and output wiring circuits. AC circuit breakers in an AC load center can be used to meet this requirem ent. The wiring both in and out of the inverter must also be protected from short circuits and overloads by a fuse or circuit breaker. Typically, a 60 amp circuit breaker will protect #6 AWG wiring. Consult your local code for more information and for other wire sizes.

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Rev. C: February 2001

INSTALLATION

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Note: The three neutral terminals are common to each other and can be used in any combination or order. In a residential application, it is often easier to only connect one AC neutral wire to the inverter and make the other neutral connections at a central point such as in the AC load center, etc. In mobile installations, the AC system must have the neutr al physically isolated from the ground thr oughout the load distribution powered by the inverter. The SW Series Inverter/Charger does not inc lude neutral to ground switching for the AC electrical system. This must be done externally from the inverter. See the NEUTRAL- TO-GROUND BOND SWITCHING (RV AND MARINE APPLICATIONS) section on page 27 for more information.

AC Terminal Block

(TB1)

AC IN 1

AC IN 2

From

Generator Power

From

Utility Power

AC OUT

AC Loads

Figure 9, AC Input/Output Power Connection

Before making any AC connections, make sure that the inverter is disconnected from the battery (or battery bank). Feed the wires through conduit fittings located on the left s ide or left bottom side of the inverter. (Note: Conduit fittings must be purchased separately and are required by code to comply with residential and commercial installations).

The AC wiring both in and out of the inverter must also be protected from short circuits and overloads by a fuse or circuit breaker. Consult the NEC or your local code for more information and for other wire sizes. Table 13 on page 132 gives suggestions for wire sizing. Follow the wiring guide on the circuit board inside the cover plate (see Figure 9, above). Connect the AC wiring as follows (from front to back when wall mounted):

Table 1, AC Input and Output Wiring Connections

AC CONNECTIONS AC TERMINAL BLOCK # WIRE COLOR PURPOSE

AC HOT IN 1 1b Black (Hot) Utility Power

NEUTRAL IN 1 3b White (Neutral) Utility Power

AC HOT IN 2 2b Black (Hot) Generator

NEUTRAL IN 2 4b White (Neutral) Generator

AC HOT OUT 6b Black or Red (Hot) AC Loads

NEUTRAL OUT 5b White (Neutral) AC Loads

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INSTALLATION

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AC INSTALLATION GUIDELINES

The following steps are a basic guideline f or installation and connection of the AC wiring into and out of the inverter.

1. Disconnect the inverter from the battery bank (if already connected), by either removing the DC s ide fuse, or opening the DC disconnect. T hen remove the AC wiring com partm ent cover from the front of the inverter by removing the two screws on the cover.

2. If conduit will be utilized (consult code, it may be required in your installation), determine which knockout(s) will be utilized and remove them f rom the inver ter. Using appropriate c onduit connector s, fasten the conduit to the inverter. Feed all AC wiring through the conduit and into the inverter AC terminal block. Be s ure to leave yourself s ever al extr a inc hes of wire to work with. Remember that you need at least two sets of three conductor wiring, one for AC Hot, Neutral, and Ground into the inverter, and another for AC Hot, Neutral and Ground out of the inverter to the loads. Torque all AC term inals to 10 to 15 inch-pounds.

3. Connect the Hot (black) and Neutral (white) wires from the AC source(s) to the appropriately labeled terminals in the AC term inal block. The Safety Ground (green) should be connected to the terminal stud labeled “AC Ground” bolted to the chassis. Repeat the procedure for the AC wiring going to the AC sub-panel which will power the loads, except connect these wires to the terminals labeled AC HOT OUT.

4. Ins pect all wiring for proper installation and then replace the access cover using the two screws to secure it.

IMPORTANT PRECAUTION The AC output of the inverter must at no time be connected directly to utility power or a generator.

This condition can be far wors e than a short circ uit. If the inverter survives this condition, it will shut down until corrections are made. Connection to a utility or generator must be only done internally by the inverters built-in relays. This allows the inverter to f irst synchronize to the other AC sourc es waveform, preventing damage. Connect the utility or generator to the provided input terminals AC HOT IN 1 or AC HOT IN 2 respectively.

When the inverter output is connected directly to an external source, the inverter will shut down and indicate an error on the control panel. Checking the ERROR CAUSES menu heading will show a YES for the AC SOURCE WIRED TO OUTPUT menu item. Either determine the source of the AC or call a qualified electrician to correct the situation.

EXTERNAL TRANSFER RELAYS It is not acceptable to switch the AC input from one AC source to another while the inverter is

connected. This applies whether the inverter is in battery charging mode or inverter m ode. Switching the

AC input from one source to another can result in a loss of synchronization that can cause a severe overcurrent condition that is far worse than short circuiting the inverter. Two separate AC inputs are provided to eliminate the need for use of external transfer relays. If a trans f er relay is used, it m us t pr ovide a center “OFF” position (“break before make”) that causes a los s of input power to the inverter f or a per iod of at least 100 milliseconds. This will allow the inverter to disconnect from the original AC input and then re-synchronize to the new AC source although the same AC input terminal is being used. During the transition period, the inverter will have to operate the load while it re-synchronizes to the new AC sour ce (about a thirty-second period at the minimum). Most tr ansfer relays will switch too fast for the inverter to detect - and will cause the inverter to lose synchronization with the AC source. This is indicated by the inverter shutting down upon transfer and the red overcurrent LED indicator flashing or turning on.

Manually, hand operated transfer switches may be acceptable since the transfer time c an be slow enough for the inverter to detect. The switch must go through a center “off” position. They are often used to switch from one generator to another. Since the inverter has a separate AC input for a utility grid, a transfer switch is not required to switch from the utility grid to a back-up generator. The inverter will not allow the generator to be connected to the utility - if both are available, the generator will be disc onnected and the inverter will connect to the utility on AC HOT IN 1.

Page

 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223

Telephone: 360/435-8826

Fax: 360/435-2229

www.traceengineering.com

Part No. 2031-5

Rev. C: February 2001

INSTALLATION

http://www.wholesalesolar.com/inverters.html

120 VAC GROUND FAULT INTERRUPT OUTLETS (GFI’S)

Xantrex has tested the following 120 VAC GFI’s and found them to work satisfactorily with our inverters:

LEVITON 6599 PASS & SEYMOR 1591 4A957 ACE Hardware ACE 33238

WARNING LABEL

A warning label is provided to inform all per sonnel that an inverter is installed in your electrical system. This label should be installed at the electric al panel that is being powered by the inver ter. Be c autious until the inverter is disconnected from your electrical system.

Figure 10, Warning Label

 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223

Telephone: 360/435-8826

Fax: 360/435-2229

www.traceengineering.com

SW Series Inverter/Charger

Part No. 2031-5

Rev. C: February 2001

Page

INSTALLATION

SW Series Inverter/Charger

http://www.wholesalesolar.com/inverters.html

DC WIRING

CAUTION: The inverter’s maximum peak current requirements are high. If battery cables are too small and/or connections are loose, efficiency and maximum output power are degraded. Small cables or loose connections may cause dangerous overheating and a fire.

BATTERY CABLE SIZING

The larger the battery cables the better. Undersized cables result in additional str es s on the inver ter, lower efficiency, reduced surge power and lower peak output voltage. Don’t use cables that are too small and degrade the efficiency that we have worked so hard to achieve and you have paid so much to own.

Also, don’t use cables that are too long - the shorter the better. The lower the DC system voltage, the shorter the cables need to be. If long cables ar e requir ed, either over s ize them s ubs tantially, or switch to a higher voltage system, such as 24 Vdc or 48 Vdc. O n 12-Vdc system, c ables m ay need to be doubled up (paralleled) to get maximum performance from the inverter.

NOTE: Do not separate the positive and negative cables - taping them together in parallel is best. This reduces the inductance of the wire r esulting in a better waveform and reduces the current in the inverter’s filter capacitors. Make the battery cables as short as possible.

Although large cables may seem expensive, spending an additional $100 or more to ensure the performance of your inverter is a wise investment. Using cables that are too small is like putting cheap tires on a high performance sports car - the results will be disappointing.

If the system is expected to operate at the inverter ’s continuous power level rating for long periods of tim e (over an hour), larger disconnects and cables may be required. Most systems do not operate at full capacity for periods exceeding an hour and can operate satisfactorily with the following cable and disconnects shown. If your system includes enorm ous batteries or has a very large DC source able to continuously power the inverter (such as a hydroelectric plant, etc.) then increasing the disconnect and cable sizes may be required to prevent nuisance tripping of a breaker or blowing of fuses.

The following table gives recom mended minimum cable sizes for various cable run lengths and inverter voltages. Use only all copper cables. These recommendations may not meet all local code or NEC requirements.

Table 2, Minimum Recommended Battery Cable Size vs. Cable Length

INVERTER

MODEL

SW2512 267 Amps 334 Amps #4/0 AWG/107 mm2#4/0 AWG/107 mm2Not Recommended

SW2612E 278 Amps 348 Amps #4/0 AWG/107 mm2#4/0 AWG/107 mm2Not Recommended

SW3024E or J 160 Amps 201 Amps #4/0 AWG/107 mm2#4/0 AWG/107 mm2#4/0 AWG/107 mm

SW4024 or W, K 214 Amps 267 Amps #4/0 AWG/107 mm2#4/0 AWG/107 mm2#4/0 AWG/107 mm

SW3048E or J 80 Amps 100 Amps #2/0 AWG/67.4 mm2#2/0 AWG/67.4 mm2#4/0 AWG/107 mm

SW4048 or K 107 Amps 134 Amps #2/0 AWG/67.4 mm2#2/0 AWG/67.4 mm2#4/0 AWG/107 mm

SW4548E or A 120 Amps 150 Amps #2/0 AWG/67.4 mm2#2/0 AWG/67.4 mm2#4/0 AWG/107 mm

SW5548 147 Amps 184 Amps #4/0 AWG/107 mm2#4/0 AWG/107 mm2#4/0 AWG/107 mm

TYPICAL DC AMPS is based on Low Battery Voltage with an efficiency of 85%.

NEC AMPS is based on Low Battery Voltage, an efficiency of 85%, and a 125% NEC de-rating.

TYPICAL

AMPS

NEC

AMPS

1 TO 3 FEET

ONE WAY

3 TO 5 FT

ONE WAY

5 TO 10 FT

ONE WAY

2 2 2 2 2 2

WARNING! Battery cables that are too small will melt and burn the first time the inverter is operated at high power levels.

Page

 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223

Telephone: 360/435-8826

Fax: 360/435-2229

www.traceengineering.com

Part No. 2031-5

Rev. C: February 2001

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