Xantrex Technology 120 VAC-60 User Manual
™
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
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
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 m anner,
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
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
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
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
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
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
TABLE OF CONTENTS
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
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
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 ar e ETL 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 Invert er/Chargers listed above comp ly 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 mentioned products comply
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 invert er/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
www.traceengineering.com
SW Series Inverter/Charger
Part No. 2031-5
Rev. C: February 2001
Page
1
IMPORTANT SAFETY INSTRUCTIONS
SW Series Inverter/Charger
3. Use of battery cable or custom attachm ent 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 bef ore attempting any maintenanc e or cleaning.
Turning off the inverter will not reduce this risk. Solar m odules produce power when expos ed 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 risk of batter y explosion, follow the instructions in this manual and those publis hed
by the battery manufacturer as well as manufactur er of any additional equipment us ed 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 ter minal 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 s hort-circuit could result in a spar k, fire or
possible explosion.
4. T his inverter /c harger is designed for use 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 battery 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 ins tallation. Refer
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 system installation. Refer 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 enc losur e and eac h 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 m ust comply with
local and national electrical codes and standards.
Page
2
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
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 such as rings, brac elets, necklaces , and watches when working with a
battery. A battery can produce a short-c ircuit 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 s ure all accessories are off. Then, rem ove the grounded
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 accidental
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, s uch 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
3
IMPORTANT SAFETY INSTRUCTIONS
SW Series Inverter/Charger
Page
4
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
INTRODUCTION
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 produc t. 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 contro l 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 featur es 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 r egarding 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
5
INTRODUCTION
SW Series Inverter/Charger
Page
6
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
UNIT IDENTIFICATION
r
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
powered by the same AC voltage. Available DC voltages are 12, 24 and 48 volt models.
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
www.traceengineering.com
SW Series Inverter/Charge
Part No. 2031-5
Rev. C: February 2001
Page
7
UNIT IDENTIFICATION
SW Series Inverter/Charger
Page
8
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
CONTROLS, INDICATORS AND COMPONENTS
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 contr ol 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 oper ating setpoint 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
www.traceengineering.com
SW Series Inverter/Charger
Part No. 2031-5
Rev. C: February 2001
Page
9
CONTROLS, INDICATORS AND COMPONENTS
SW Series Inverter/Charger
CONTRAST CONTROL
The CONTRAST adjustm ent enables you to adjust the contrast of the LCD display screen to accomm odate
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 inver ter settings (exc ept for 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 settings
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 charac ters bec om e
jumbled. Pressing the reset button anywhere in the menu s ystem ( except 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 SET UP (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.
Page
10
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
CONTROLS, INDICATORS AND COMPONENTS
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 ter minals, 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 during operation, generator power may have been
dropped.
This LED will also blink slowly (once a second) when the automatic generator control system is enabled.
When the generator has star ted, it will continue to blink slowly until the generator has been connected. If the
generator does not successfully start, the AC 2 IN GOOD LED w ill 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 char ge 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 c harge 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 s lowly 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 frequenc y. Once the frequency 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 am ps. 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.
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
11
CONTROLS, INDICATORS AND COMPONENTS
SW Series Inverter/Charger
AC SIDE
Figure 4 shows the components located on the AC side of the inverter. T he rem ovable AC Acc ess 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 c onnect two units in a “PARALLEL” configur ation.
The parallel stacking inter face 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).
Page
12
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
CONTROLS, INDICATORS AND COMPONENTS
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
AC
Terminal Block
BTS
Connector
Aux and Gen Control
Relay Connectors
AC
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 per form anc e, greater
efficiency and longer battery life.
AC TERMINAL BLOCK
A six position terminal block is provided to m ak e the AC connec tions. 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.
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
13
CONTROLS, INDICATORS AND COMPONENTS
SW Series Inverter/Charger
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.
DC
(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.
Page
14
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
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 car e
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 am ount of external 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 shoc k. 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 arr ays 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.
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
15
INSTALLATION
SW Series Inverter/Charger
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 s ection 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 sam e
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 c able 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. NOT E: A 'snap' caused by charging the internal
capacitors may occur when first connecting the cable. This can 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 pr event chafing or damage. Use
strain-reliefs, grommets, or conduits to prevent dam age 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).
Page
16
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
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 c ontrolled device. There ar e nearly 500,000
silicon junctions in its output devices and integrated 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. T he us e of c onf ormal-coated circuit boards, plated c opper
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 electrolysis are pres ent 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 mix ture. Mounting the inverter in a
ventilated enclosure with sealed batteries is acceptable.
Ensure the inverter is located in an area that prevents insects and rodents from entering the inverter , as
the inverter can provide a warm habitat in a cold environment. This m a y 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 surfac e (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.
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
17
INSTALLATION
SW Series Inverter/Charger
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 washer s on the m ounting
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. Consult 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 qualifie d personnel such as a licensed electrician.
AC INPUT AND OUTPUT CONNECTIONS
A six position terminal block is provided to m ak e the AC connec tions. 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 str anded 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 breaker s in an AC load center
can be used to meet this requirem ent. The wiring both in and out of the inverter mus t 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.
Page
18
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
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 neutral physically isolated from the gr ound throughout the load
distribution powered by the inverter. The SW Series Inverter/Charger does not include 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)
1b
1a
AC IN 1
2b
AC IN 2
From
Generator Power
2a
3a
4a
3b
4b
From
Utility Power
5b
5a
AC OUT
To
6a
6b
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
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
19
INSTALLATION
SW Series Inverter/Charger
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. Then r emove 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 sever al ex tra inc hes of wire to work with. Rem ember 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 c over 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 c ondition, it will s hut 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 HO T 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 TRAN SFER 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 mode. 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 r elays. If a transfer relay is used, it must provide
a center “OFF” position (“break before make”) that causes a los s of input power to the inverter f or a period
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
20
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
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 LA BEL
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 inverter. Be cautious 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
21
INSTALLATION
SW Series Inverter/Charger
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 s tres s on the inverter , 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 r equired, either overs ize them subs tantially, or switch to a
higher voltage system, such as 24 Vdc or 48 Vdc . On 12-Vdc system , cables 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
1
TYPICAL DC AMPS is based on Low Battery Voltage with an efficiency of 85%.
2
NEC AMPS is based on Low Battery Voltage, an efficiency of 85%, and a 125% NEC de-rating.
TYPICAL
DC
1
AMPS
NEC
AMPS
2
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
22
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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