Xantrex Technology SW User 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

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

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

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

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

 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

IMPORTANT SAFETY INSTRUCTIONS

SW Series Inverter/Charger

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

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

INTRODUCTION

SW Series Inverter/Charger

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

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 m ay 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 num ber indicate the continuous AC power output in

hundreds of VA (Volt-Amps). Power levels available s tart 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 s ame 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 118, 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/Charger

Part No. 2031-5

Rev. C: February 2001

Page

UNIT IDENTIFICATION

SW Series Inverter/Charger

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

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

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

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

Telephone: 360/435-8826

Fax: 360/435-2229

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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.

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Telephone: 360/435-8826

Fax: 360/435-2229

www.traceengineering.com

SW Series Inverter/Charger

Part No. 2031-5

Rev. C: February 2001

Page

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

 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

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 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

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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

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.

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

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

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

 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

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

 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)

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

 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

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

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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

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SW Series Inverter/Charger

Part No. 2031-5

Rev. C: February 2001

Page

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

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

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Part No. 2031-5

Rev. C: February 2001

INSTALLATION

DC DISCONNECT AND OVERCURRENT PROTECTION

For safety and to comply with regulations, battery over-current protection is required. Fuses and disconnects must be s ized to protect the wiring in the system. The fuse or disconnect is required to open before the wire reaches its maximum current carrying capability.

For residential and commercial electr ical systems, the National Electrical Code requir es both overcurrent protection and a disconnect switch. These installation parts are not supplied as part of the inverter. However, Xantrex offers a DC rated, UL listed, circuit breaker disconnect specifically designed for use with Tr ac e™ inverter s for applic ations requiring NEC c ompliance. T wo amper age ratings are available - a DC250 (250 amps) and a DC175 (175 am ps). Thes e disconnects are available in a s ingle or double pole configuration to handle either one or two inverters. The DC disconnect enclosure will acc omm odate up to four smaller break ers f or use as DC load dis connects, PV ar ray disconnects, etc. and the top is designed to allow direct connection of up to two Xantrex charge controllers. The Trace™ DC disconnect is not designed to accept doubled (paralleled) cables which may be required for long cable runs. Also, the plastic red and black covers on the end of the inverter is not designed to accommodate dual cables. If dual cables are used, the optional conduit box (SWCB) should be used.

When sizing the DC disconnect, the ex pec ted c ontinuous load on the inver ter is us ed to determine the DC current involved. You must account for the efficiency loss through the inverter (see the POWER VS. EFFICIENCY section on page 59 in this manual) which increases the DC current draw. Divide the maximum continuous current draw by the lowest efficiency to determine the DC current, a 25% safety margin should be included to comply with the code requirements. When a break er has been selected as the overcurrent device, tighter sizing may be acceptable since the breaker is more easily reset when compared to a high current, bolt-in type fuse.

Marine and RV installations typically do not require conduit or a means of disconnection, although overcurrent protection (fus e) is r equired. Xantr ex of fers a fus eblock (TFB) that pr ovides the code required inverter overcurrent protection for residential, commercial, RV and Marine applications.

TFB’s include a fast acting, current limiting class-T fuse to protect your battery, inverter and high amperage cables from damage by short circuits and overloads. This fuse provides extremely fast protection when a short circuit occurs . When properly selected, it also has a time delay that allows the inverter to surge to full power without blowing the fuse. A slide off cover prevents accidental contact with the fuse’s live terminals. For maxim um protection, install the fuseblock within 18 inches ( 45 cm) of the battery. The fuses are available in 110, 200, 300, and 400 amp sizes.

Use Table 3 below, to determine the proper size disconnect ( breaker) or f use for the battery cables you are using. These recom mendations may not meet all local code or the NEC requirem ents, consult your applicable electrical code for more information regarding acceptable fuse and cable sizes.

Table 3, Battery Cable To Maximum Breaker/Fuse Size

CABLE SIZE

REQUIRED

RATING IN

CONDUIT

MAXIMUM

BREAKER SIZE

RATING IN

“FREE AIR”

MAXIMUM

FUSE SIZE

# 2 AWG 115 amps 125 amps* 170 amps 175 amps*

00 AWG 175 amps 175 amps 265 amps 300 amps*

0000 AWG 250 amps 250 amps 360 amps 400 amps*

*The NEC allows rounding up to the next standard fuse size from the cable rating, i.e. 150-amp cable size rounds up to a standard 175-amp fuse or breaker size. The term "free air" is defined by the NEC as cabling that is not enclosed in conduit or a raceway. Cables enclosed in raceways or conduits have substantially lower continuous current carrying ability due to heating factors.

Contact your Xantrex dealer to order the inverter disconnects/fuses or see the OTHER PRODUCTS section in this manual on page 129 for more information.

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SW Series Inverter/Charger

Part No. 2031-5

Rev. C: February 2001

Page

INSTALLATION

SW Series Inverter/Charger

BATTERY CABLE CONNECTIONS

Cables must have crimped (or preferably, soldered and crimped) copper compression lugs unless aluminum mec hanical lugs are used. Soldered connections alone are not acc eptable. We suggest us ing high quality, UL-listed Xantrex battery cables. These cables are available in a spec ific ass ortm ent of sizes from 1-½ to 10 feet, and in 2/0 or 4/0 AWG. They are color-coded and have pressure-crimped, sealed-ring terminals. Contact your Xantrex dealer to order. Figure 11, illustrates proper method to connect the battery cables to the SW Series Inverter/Charger.

Do not place anything

between battery cable lug

and terminal surface.

Assemble exactly as shown.

2/0 Copper Compression Lug 2/0 Aluminum Mechanical Lug

Figure 11, Battery to Inverter Cable Connection

INSTALLATION PROCEDURE - BATTERY CABLES

CAUTION: THIS INVERTER IS NOT REVERSE POLARITY PROTECTED. If the positive

terminal of the battery is connected to the negative term inal of the inverter and vice vers a, the result will be instantaneous failure of nearly every power transistor. This type of damage is obvious and requires an extensive rebuilding of the inverter at your own cost. It is not c overed by the warranty.

Ensure that the inverter is off bef ore connecting or disconnecting th e battery cables and that all AC power is disconnected from the inverter’s inputs.

Determine the correct s ize battery cable to use for your installation from Table 2, on page 22 and the proper size disconnect/fuse from Table 3, Battery Cable To Maximum Breaker/Fuse Size on page 23. Color-code the cables with colored tape or heat shrink tubing [the standard colors ar e red for positive (+) and black for negative (-)]. Always double-check the polarity with a voltmeter before mak ing the battery connections

Install the over-current device (fuse or circuit breaker) between the inverter and battery - as close as possible to the battery - in the ungrounded conductor [typically the positive (red) cable]. Connect a cable from the battery negative terminal to the negative (black) terminal on the inverter.

Observe Battery Pola ri ty ! Place the battery cable ring terminals over the stud and directly against the inverter’s battery terminals. Red is positive (+), Black is negative (-). Use a 1/2-inch wrench or socket to tighten the 5/16 SAE nut to 10-15 foot/pounds. Do not place anything betw een the cable ring terminal and t he flat metal

part of the terminal or overh eating of the terminal may occur. DO NOT APPLY ANY TYPE OF ANTIOXIDANT PASTE until after the battery cable wiring is tightened to 10–15 foot-pounds!

Note: Connecting the battery cables to the inverter battery ter minals may c ause a br ief s park or arc

- usually accompanied by a "snapping" sound. This is normal - don’t let it scare you. It is s imply the internal capacitors of the inverter being charged.

Page

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Part No. 2031-5

Rev. C: February 2001

INSTALLATION

CONTROL WIRING

More advanced installations will require additional wiring to interface the inver ter to other components of the system. Proper installation is important to ensure the reliability of the system.

Although the circuits may carry little or even no actual power, the use of quality wire in conduit is recommended to pr ovide good results. All circuits s hould also be fused at the sourc e of the power in the circuit to provide both protection and indication of problem s with the control circ uit. Consult local c ode and the NEC for minimum wire size and type required based on the length that you want to run.

The AC circuit board provides m ale type push on connectors and you are provided crim p-on term inals in your hardwire package to connect to these Aux and Gen Control relays. These terminals allow easier connection of a variety of wire sizes and allow faster installation and troubleshooting. T his circuit board also includes two LED indicators to allow visual indication of the generator control s equence provided by relays RY7 and RY8. These relays are not intended to directly control the starter motor or operate the ignition system - rather they can be used to send a signal or operate the coil of another higher am perage device which does the actual switching of the power.

CAUTION: A fuse rated at 5 amps or less must be included t o protect each of the relays. Damage to these relays is not covered by the Warranty and requires the inverter to be returned to a service center for repair.

GEN CONTROL WIRING

The configuration of the starting relays on all SW Series inverters allows st arting of both Honda and O nan type generators. The COM terminals of relay RY7 and RY8 are separated and both the normally open and normally closed contacts are provided.

It is much easier to m ake the connections to the generator if a remote control terminal or connector is available on the generator. This som etimes requires that the generator optional remote c ontrol panel be purchased. This allows examination of how the generator remote control panel work s - which is what the inverter’s generator control system in the inverter must duplicate.

Connection of the inverter’s generator control r elays in the inverter to the generator’s r em ote control panel also eliminates the need to make modifications and thus violate the generator’s warranty.

You should also ensure that there is a switch to allow disabling of the autom atic generator control system at the generator. This will allow local control of the generator, preventing starting while servicing, etc.

AUX RELAY WIRING

The auxiliary relays are RY9, RY10, and RY11 and can be used to control external power sources or loads. The voltage settings that determine when the relays are activated are individually adjustable. The relays are connected to a terminal block located in the wiring compartment at the left end of the inverter and must be fused to prevent dam age if they are miswired or a short- circuit occurs . The m aximum fuse size must not exceed 5 amps and the f us es s hould be loc ated as c los e as pos s ible to the sour ce of power e.g. generator battery.

REMOTE CONTROL WIRING

An optional remote control panel for the SW Series Inverter/Charger is available (Trace™ part num ber SWRC or SWRC/50FT) which provides complete duplication of the control panel on the front of the inverter. It is connected to the REMOTE PORT on the left side (AC side) of the inverter (s ee page 12 for the location of the REMOTE PORT ) thr ough a pr ovided cable. Two cable lengths are available - 25 feet ( 8 meters) or 50 feet (16 meters). Distances longer than 50 feet (16 meters) are not recomm ended. The remote control cable should be k ept away from sources of r adio frequency interference such as motors and antennas. The cable must be protected from abrasion and hot surfaces.

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Telephone: 360/435-8826

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SW Series Inverter/Charger

Part No. 2031-5

Rev. C: February 2001

Page

INSTALLATION

SW Series Inverter/Charger

SYSTEM GROUNDING

GROUNDING INSTRUCTIONS - This inverter/charger should be connected to a grounded, permanent

wiring system. For most installations, the negative battery conductor should be bonded to the grounding system at one (and only one point) in the system. The subjec t is mor e easily discuss ed if it is divided into three separate subjects; Chass is Ground, Ground Rods and Bonding. The grounding requirements vary by country and application. All installations should comply with national and local codes and ordinances . Even system designers and electricians often misunders tand system grounding. Consult loc al codes and the NEC for specific requirements. Refer to Table 15, page 133 for safety ground wire sizes.

EQUIPMENT OR CHASSIS GROUNDS

This is the simplest part of grounding. The idea is to connect the metallic chassis of the various enclosures together to have them at the same voltage potential, which reduces the possibility for electric shock. It also provides a path f or fault currents to flow through to blow fus es or trip circuit breaker s. The size of the connecting conductors should be coordinated with the size of the overc urrent devices involved. Under some circumstances, the conduit and enclosures themselves will provide the current paths.

GROUNDING ELECTRODES/GROUND RODS

The purpose of the grounding electrode (often called a ground rod) is to “bleed” off any electrical charge that may accumulate in the electrical system and to provide a path for “induced electromagnetic energy” or lightning to be dissipated. The size for the conductor to the grounding electrode or gr ounding system is usually based on the size of the largest conductor in the system. Mos t s ystems use a 5/8” (16 mm) copper plated rod 6 feet (2 meters) long driven into the earth as grounding electrode. It is also com mon to use copper wire placed in the concrete foundation of the building as a grounding system. Either method m ay be acceptable, but the local code will prevail. Connection to the ground electrode should be done with special clamps located above ground where they can be periodically inspected.

Many large systems use multiple ground rods. The most com m on exam ple is providing a direct path f rom the solar array to earth near the location of the solar array. Most electrical codes want to see the multiple ground rods connected by a separate wire with its own set of clamps. If this is done, it is a good idea to make the connection with a bare wire located outside of the conduit (if us ed) in a tr enc h. T he r un of buried wire may be a better grounding electrode than the ground rods! Well casings and water pipes can also be used as grounding electrodes. Under no circ umstance should a gas pipe or line be used. Consult local codes and the NEC for more information.

BONDING THE GROUNDING SYSTEM

This is the most confusing part of grounding. The idea is to connect one of the current carrying conductors (usually the AC neutral and DC negative) to the grounding system. This connection is why we call one of the wires “neutral” in the North American type electrical systems. You can touch this wire and the grounding system and not be shocked. When the other ungrounded conductor (the hot or positive) touches the grounding system, current will flow through it to the point of connection to the grounded conductor and back to the sourc e. This will cause the overcurrent protection to stop the flow of current, protecting the system. This point of connection between the grounding system (ground rod, vehicle frame, boat hull, etc.), the cur rent carrying grounded conductor (AC neutral and DC negative), and the equipment grounding conductor (green ground wire, equipment ground) is often called a “bond”. It is usually located in the overcurrent protection device enclosures (both AC and DC) . Although it c an be done at the inverter, codes do not generally allow it since the inverter is considered a “serviceable” item that may be removed from the system. In residential systems, it is located at the service entranc e panel, after the power has gone through the kilowatt-hour meter of the utility. In mobile applications (RV and m arine) this “bond” is provided by the different AC sources on board, see NEUTRAL-TO-GROUND BOND SWITCHING (RV AND MARINE APPLICATIONS) on page 27.

Bonding must be done at only one point in an electrical system. Our systems inherently have two separate electric systems - a DC system and an AC s ystem. This means that two bonding points will occur in all inverter applications. The bonding point will also be connected to the equipment (chassis) grounding conductors. It is common to have two separate conductors connect the ground electrode and the two bonding points. Each conductor should use a separate clamp.

Page

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Telephone: 360/435-8826

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Part No. 2031-5

Rev. C: February 2001

INSTALLATION

RY1

In some countries, the neutral is not bonded to the grounding system. This means you may not know when a fault has occurred since the overc ur rent devic e will not tr ip unles s a “double” fault occurs. In some marine electrical codes, this type of system is used.

NEUTRAL-TO-GROUND BOND SWITCHING (RV AND MARINE APPLICATIONS)

As required by NEC code and UL specification 458, inverter/char ger installations in the U.S. that ar e used in RV or Marine applications employ ground-to-neutral switching. T he purpose for this requirement is to ensure that all the neutral conductors are connec ted (“bonded”) to a single ground point in a three-wire (hot, neutral and ground) AC system. This prevents a voltage difference from developing between the vehicle/boat’s AC neutral and the external AC source’s (generator or shore power) neutral, which may cause an electric shock or cause nuisanc e tripping of GFI’s. The SW Series In verter/Charger does not

include Neutral-to-Ground switching and must be provided in the AC installation.

When the unit is oper ating as an inverter, the AC output neutral should be connected or “bonded” to the frame/hull (chas sis ground). W hen an external AC source (AC shore c ord) is provided, the inverter’s AC output neutral should be disconnected from the frame/hull (chassis ground) and allow the “bond” to be provided by the external AC source. The requirement to switch the neutral c an be met by your inverter internally or can be easily met by using an external relay to connect and disconnect the external AC source’s neutral. If another AC sourc e (on-board generator) is included in the RV or boat, this AC sour ce neutral is required to be connected to ground when it is being used, and to disconnec t all other neutrals from ground. An AC transfer switch can be used if it switches both the shore cords and generators neutral.

In some marine applic ations, neutral-to-ground switching is not required or acceptable. T he potential for galvanic corrosion caused by small leak age c urrents between boats with dissim ilar m etals is pres ent. T he proper and safe ways to prevent this is by using galvanic isolators or include an isolation trans former f or the AC input. Disconnecting the common ground between the AC and DC system could contribute

to a hazardous and potentially fatal situation.

The figures below graphically describes the neutral-to-ground switching system for the two cases in question: the unit operating as an inverter feeding the AC subpanel, and the unit connected to an external AC source (generator, shore power, etc.).

No external AC

source is present

AC HOT IN

AC NEUTRAL IN

EARTH GROUND

CHASSIS GROUND

NEUTRAL-TO-GROUND

“BOND” is provided by this relay

for the entire AC system

INVERTER

(AC Terminal Block)

AC HOT OUT

AC NEUTRAL OUT

NEUTRAL-TO-GROUND SWITCHING

RELAY (provided in the AC installation): Connects the output neutral to chassis or vehicle ground when AC is not present at

inverter input. This assures all equipment in

the vehicle is referenced to the same

ground.

AC PANEL

(RV/Marine)

HOT

NEUTRAL

GROUND

The neutral conductor should

not be connected to the

equipment grounding

conductors or enclosures.

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

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Telephone: 360/435-8826

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SW Series Inverter/Charger

Rev. C: February 2001

Part No. 2031-5

Page

INSTALLATION

SW Series Inverter/Charger

AC SOURCE

AC NEUTRAL IN

EARTH GROUND

CHASSIS GROUND

NEUTRAL-TO-GROUND “BOND” is

provided by an external AC source for

the entire AC system

INVERTER

(AC Terminal Block)

AC HOT IN

RY1

NEUTRAL-TO-GROUND SWITCHING RELAY

(Provided in the AC installation): Connects the

neutral from external AC source, and neutral of

the AC panel loads together when AC is applied

to the inverter input.

AC PANEL

(RV/Marine)

HOT

The neutral conductor

should not be

NEUTRAL

connected to the

equipment grounding

conductors or

enclosures.

AC HOT OUT

AC NEUTRAL OUT

GROUND

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

Figure 14, graphically shows the current path if no ground switching was employed in a multiple AC source system. If one neutral was tied to the AC subpanel ground buss and another neutral tied to the vehicle or chassis ground, the two different ground points would now form a current car rying conductor with the frame/hull (chassis ground) acting as the “wire” between the two different ground points. This means any ground point in the vehicle or boat becomes a potential current carrying conductor, which could result in an electric shock . Any form of Ground Fault Circuit Interrupter (GFCI) such as those found in bathroom outlets, will pop if a ground loop (a s ituation where a voltage difference exist between m ultiple ground points) is created.

If, however, the ground switching system were in place, it would ensure that there is only one ground point in the system at all times. Th is would be either the vehicle/boat ground or the exter nal AC source ground, but never both at once.

GFI’s will nuisance trip with multiple

Neutral-to-

Ground bonds

AC SOURCE

GFI

AC NEUTRAL IN

EARTH GROUND

CHASSIS GROUND

NEUTRAL-TO-GROUND

“BOND” is provided by

the external AC source

INVERTER

(AC Terminal Block)

AC HOT IN

RY1

AC HOT OUT

AC NEUTRAL OUT

NEUTRAL-TO-GROUND SWITCHING RELAY (Provided in the AC installation): Connects the

neutral from external AC source, and neutral of

the inverter output (AC panel loads) together

when AC is applied to inverter input.

AC PANEL

(RV/Marine)

HOT

Another NEUTRAL-

TO-GROUND

“BOND” is

incorrectly provided

in the AC panel.

NEUTRAL

The neutral

conductor should

not be connected to

GROUND

the equipment

grounding

conductors or

enclosures.

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

Page

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Part No. 2031-5

Rev. C: February 2001

INSTALLATION

across Component Grounds

GROUNDING VS. LIGHTNING

This information is intended to provide bas ic grounding techniques that will help prevent inverter dam age due to lightning. It is not intended to be a complete course on grounding or a guarantee against protection during a lightning strike situation. The NEC is the ultimate authority as to legitimate gr ounding techniques for your electrical system.

If an electrical system has com ponents gr ounded at differ ent points in the earth, large voltage dif ferences will exist between these points during a lightning strike (See Figure 15). If this voltage appears between the AC and DC side of the inverter, it will fail. All T race™ inverters are designed to withstand a minim um of 1750 volts between AC and ground, and 500 volts between DC and ground.

ONE GROUND FOR ALL EQUIPMENT

The first step in inverter protection is to make sure that all equipment in the system is physically grounded at the same location. This ass ures that ther e is no voltage potential between grounds in the system (See Figure 15 and Figure 16). No voltage means no current flow through the system. Practically speaking, this would mean connecting the generator and batter y grounds together, as well as the case or “safety” grounds in the system, and then attaching all to the sam e earth grounding rod (See the NEC for specific information on grounding requirements, and hardware).

In severe conditions, the generator frame should physically be isolated from the earth by a wood frame or some other insulating means. This assures that the single point ground system is maintained.

KEEP EQUIPMENT CLOSE TOGETHER

All equipment involved in a system should physically be located as close as possible to one another. This reduces the potential that is developed between the ground site and the individual components of the system during a lightning strike. This single point grounding greatly reduces the potential for lightning damage to electrical equipment.

If you are unable to achieve single-point grounding due to large distances between equipm ent or other variables, other means of lightning protection must be considered. Consult a reputable lightning protection company.

Equipment acts as a

Equipment all grounded at

same point. No voltage

across system, and no

current flow through

equipment and wiring.

Lightning

Strike

conductor due to

voltage between the

grounds. Bad!

Lightning

Strike

GENERATOR INVERTER BATTERY

Generator

Ground

Difference

Inverter

Ground

Voltage

BANK

Battery

Ground

Voltage

Difference

GENERATOR INVERTER BATTERY

Generator

Ground

Inverter Ground

Zero Voltage Difference

BANK

Battery

Ground

Figure 15, Multiple Point Ground System Figure 16, Single Point Ground System

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Telephone: 360/435-8826

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SW Series Inverter/Charger

Part No. 2031-5

Rev. C: February 2001

Page

INSTALLATION

SW Series Inverter/Charger

Page

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Telephone: 360/435-8826

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Part No. 2031-5

Rev. C: February 2001

FUNCTIONAL TEST

Once the AC and DC wiring have been installed and connected, take a moment to go back over all connections and mak e sure they are secure and have been installed pr operly. Ensure that there is no AC or DC power provided to the inverter/charger and that all AC loads are disconnected from the output of the inverter.

The below steps will complete a functional test of the inverter. If any area fails, figure out why before proceeding. The TROUBLESHOOTING GUIDE section, starting on page 112, will hopefully help solve problems you may encounter.

1. After ensuring the correct polarity, apply battery (DC) power to the inverter by turning on the battery bank DC disconnect or connecting the pr oper fuse inline to the batter y to complete the battery circuit. The inverter will power up, the LCD display will be on, but the inverter will remain in the OFF mode.

2. Press the red ON/OFF MENU switch twice (SEARCH then ON) to turn the inverter on. Monitor your INVERTING LED (Yellow) to ensure what mode you are in:

• Off – The Inverter/Charger is off. This is the default position of the inverter upon power-up. No

inverter or pass-thru power will be applied to the AC loads.

• One blink/sec – The Inverter/Charger is in the Search mode and is looking for an AC load greater

than the SEARCH WATTS setting (default = 16 watts).

• On – Indicates the Inverter/Charger is on. The inverter will produce a low audible “buzz” is able to

provide power to the AC loads.

If the inverter does not produce an low audible “buzz” or come on, check all connections. Check the inverter’s DC voltage on the positive (+) and negative (–) terminals. If the DC voltage is low, the battery bank needs to be charged externally. Charge the battery bank and restart the functional test.

3. W ith the inverter ON, check the AC voltage on the AC output term inal of the inverter and ensure you get the correct AC voltage for your particular unit. After confirming the corr ect AC voltage, connect your AC output breaker and place a load on the inverter (plug in a light or other load to an outlet the inverter is powering), and make sure it works.

4. Check your battery charger. To charge your batteries, provide AC power - by plugging in a power cord or turning on the AC input breaker - to the AC HOT IN 1 and NEUTRAL IN 1 terminals on the inverter. The AC1 IN GOOD (Green) light will initially blink until AC power has synchronized and then turn solid to indicate the AC power is getting to the inverter. After a minimum 20 s econd delay, the Battery BULK LED (Yellow) or FLOAT LED (Green) on the inverter should be on. This indicates the charger is working properly. The Control Panel lights should indicate which charge stage (bulk or float) the inverter is currently in. Any AC loads powered by the inverter should also work at this point s inc e a portion of the AC input power (Utility or Generator) is passed through the inverter to power the loads.

5. Disconnect AC power. Take away the AC input power by turning the AC power breaker off, or unplugging the AC power cord. The inverter should transfer to inverter mode immediately. The INVERT (yellow) LED coming on will indicate this. The inverter will begin to produce an low audible “buzz” as it takes power from the batteries and uses it to power the loads. The loads s hould continue to operate uninterrupted.

6. This completes the functional test, if all areas pass, the inverter is ready for use. If any of the inverter’s internal setpoints are to be adjusted, consult the MENU SYSTEM section starting on page 33.

 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

FUNCTIONAL TEST

SW Series Inverter/Charger

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

MENU SYSTEM

OVERVIEW

The operation of the inverter is determined by the settings in the menu system. The menu system is divided into a USER MENU and a SETUP MENU. Each of the menu systems is divided into MENU HEADINGS and MENU ITEMS. The menu headings break the m enu into groups of related menu item s. At the Menu Item level a setting can be adjusted, a mode can be selected or information can be displayed. When a num ber is included with the graphic of the m enu heading or m enu item in this m anual, the values shown are the default value and are for a 12-volt domestic (120VAC/60Hz) model SW Series Inverter/Charger. For 24 volt systems multiply the DC settings shown by 2, for 48 volt systems multiply the

DC settings shown by 4.

• The USER MENU provides the contr ols and settings needed on a daily basis. It allows you to turn on the inverter and generator, read the AC and DC meters , check on an error cause and even adjus ts the inverter’s time clock.

• The SETUP MENU provides all of the settings required to configure the inverter to operate in the necessary modes for your installation. They are separated from the USER MENU to reduce tampering and simplify the daily operation of the inverter.

The SW Series Inverter/Charger MENU SYSTEM is accessed through the CONTROL PANEL on the front of the unit. To access the SETUP MENU, press both the red ON/OFF MENU and green GEN MENU buttons at the same time once. The display will show INVERTER SETUP (9). This is simply the continuation of the same m enu system of the USER MENU. If you select a menu heading less than nine, or press either the red or green buttons, you will have to re-enter the setup menu by pressing the red and green buttons at the same time again.

 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

MENU SYSTEM

SW Series Inverter/Charger

USER MENU MAP

Menu Heading

Menu Item

Information

Inverter Mode

Set Inverter OFF SRCH ON CHG

CHG avail. Only in FLT mode.

Press red or setpoint button

to move. Move cursor to

Inverter OFF to resetOverCurrent

Setpoint

The values shown are the factory default val ues for Model SW2512.

See the USER and SETUP m enu i tem descriptions for default values for other models.

MENU HEADINGS

Generator Mode

Set Generator OFF AUTO ON EQ

Gen under/over speed NO

Generator start error NO

Generator sync error NO

Gen max run time error NO

Load Amp Start Ready NO

Voltage Start Ready NO

Exercise Start Ready NO

Move cursor to GEN OFF to reset

Generator error. AC1 & AC2 volts

If no start in 5 trys then error.

If Gen starts & runs for 5 min

then stops the inverter will

not attempt restart until

gen auto start conditions are

again satisfied. for float, bulk, eq

If Gen runs for More than max

Run time then Error.

Under/Over speed Will cause a

Sync error in 10 minutes

Trace

Engineering 3

Press reset now for defaults

Revision 4.01 Input amps AC

5916 195th St NE Arlington, WA

98223 USA Battery actual

Ph 360-435-8826 Fax 360-435-2229

Meters

Inverter/charger Amps AC 00

Load amps AC 00

volts DC 12.6

Battery TempComp volts DC 12.6

Inverter volts AC 00

Grid (AC1) volts AC 00

Generator (AC2) volts AC 00

Read Frequency Hertz 60

valid only when

inverter synced to that input.

Batt volt actual is used for

LBCO,HBCO,LBX, LBCI,sell volts,

and gen starting gen will always

Batt volt temp comp is used,

& aux relays

Error Causes

Over Current

Transformer

overtemp NO

Heatsink overtemp NO

High Battery voltage NO

Low Battery voltage NO

Inverter breaker tripped NO

AC source wired to output NO

External error (stacked) NO

Generator start error NO

Generator sync error NO

Gen max run time error NO

Gen under/over speed NO

Inverter breaker tripped NO

Push buttons on

Control Panel

Time of Day

00:00:00 6

Set Clock hour

00:00:00

Set Clock minute 00:00:00

Set Clock second

Generator Timer

Start Quiet Time h:m 08:00

End Quiet Time h:m 08:00

Gen doesn’t run During quiet

time unless batt volts is less.

than LBCO volts for 30 seconds.

To defeat timers set start = end.

If exercise day set to 1 then

start @ endquiet

End User Menu 8

MENU ITEMS

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

MENU SYSTEM

SETUP MENU MAP

The SETUP MENU provides all t he controls and settings need ed when installing or adjusting the system. To access the SETUP MENU, press both the red ON/OFF MENU and green GEN MENU buttons

on the Control Panel at the same time. To exit the SETUP MENU, press the red ON/OFF MENU button or press the down MENU HEADING button until you reach the USER MENU (menu headings 1-8).

MENU HEADINGS

Inverter Setup

Set Grid Usage FLT SELL SLT LBX

Set Low battery cut out VDC 11.0

Set LBCO delay minutes 10

Set Low battery cut in VDC 13.0

Set High battery cut out VDC 16.0

Set search watts 48

Set search

MENU ITEMS

spacing 59

Bulk Charge Trigger Timer 15

Set Start Bulk time 00:00

To disable timer set to 00:00

If grid timer active set bulk

time after start charge time.

In SLT mode don’t disable this

timer. It is the daily chg time.

Battery Charging10AC Inputs

Set Bulk volts DC 14.4

Set Absorption time h:m 02:00

Set Float volts DC 13.4

Set Equalize volts DC 14.4

Set Equalize time h:m 02:00

Set Max Charge amps AC 20

Set Temp Comp LeadAcid NiCad

Low Battery Transfer (LBX) 16

Set Low Battery TransferVDC 11.3

Set Low battery cut in VDC 13.0

See menu 9 to enable LBX mode.

Make sure LBX is above LBCO volts.

Gen Auto Start

setup 12

Set Grid (AC1) amps AC 60

Set Gen (AC2) amps AC 30

Set Input lower limit VAC 108

Set Input upper limit VAC 132

Battery Selling17Grid Usage Timer18Information file

Set Battery Sell volts DC 13.4

Set Max Sell amps AC 30

See menu 9 to enable SELL mode.

Make sure LBX is above LBCO volts.

Set Load Start amp AC 20

Set Load Start delay min 5.0

Set Load Stop delay min 5.0

Set 24 hr start volts DC 12.3

Set 2 hr start volts DC 11.8

Set 15 min start volts DC 11.3

Read LBCO 30 sec start VDC 11.0

Set Exercise period days 30

Set Maximum run time h:m 08:00

Set Max Run time to 0 to defeat.

Set Exercise to 0 to defeat.

See menu 9 to to set LBCO.

Start Charge time 21:00

End Charge time 21:00

After Start Charge time:

SELL mode charges battery.

FLT mode charges battery

After End Charge time:

SELL mode sells battery to AC1.

FLT mode drops AC1 and inverts

Timer on when start < > end;

timer off when start = end

Sell and float modes use timer

SLT and LBX mode ignore timer

Gen starting details 13

Set RY7 Function GlowStop Run

Set Gen warmup seconds 60

Set Pre Crank seconds 10

Set Max Cranking seconds 10

Set Post Crank seconds 30

battery 19

Batt temp comp changes battery

voltage reading away from actual

HBCO resets at: 6v/48, 3v/24 and

1.5v/12v under HBCO.

LowBattTransfer used in LBX, FLT

Modes only. Goes back to battery

at LowBattCutIn (aka LBCI).

For LBX mode set below LBCI so

charger won’t cycle batteries

up and down and set LBCO below.

Auxiliary Relays R9 R10 R11 14

Set Relay 9 volts DC 14.5

R9 Hysteresis volts DC 01.0

Set Relay 10 volts DC 14.8

R10 Hysteresis volts DC 01.0

Set Relay 11 volts DC 15.0

R11 Hysteresis volts DC 01.0

Close on batt > setpoint.

Open on batt < setpoint - Hys

Relays have 2 second delay on

Close, 0.1 sec delay on open

End Setup Menu

 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

MENU SYSTEM

SW Series Inverter/Charger

LBCO 30 sec start

USER MENU

The USER MENU provides all the controls and settings needed on a daily basis. It allows you to turn on the inverter and generator, read the AC and DC meters, check on an error cause and even adjus t the inverter’s time clock.

MENU HEADINGS

Inverter Mode

Generator Mode

Trace Engineering 3

Meters

Error Causes

Time of Day

Allows control of the inverter and enables the search and charger only

modes.

Allows control of the generator, enables autom atic operation or triggers an

equalization charge cycle. This menu heading is used only if a gener ator is included and controlled by the inverter.

Provides information for accessing Xantrex. Also provides the software revision number and allows resetting to the factory default values.

Allows monitoring of the DC battery voltage, AC voltages and AC current of

the inverter and other AC sources.

Provides an indication of the cause of an error c ondition. Check this menu

heading if the red ERROR LED indicator is illuminated on the control panel.

Sets the internal 24-hour clock. This is used for time sensitive operating

modes and to determine the “quiet time” period for generator run lockout.

Generator Timer

End User Menu

Used to set a run lockout period called “quiet tim e”. During quiet time, the

generator starts only if the battery voltage reaches the VDC setting.

Used to display that you have reached the end of the USER MENU.

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

MENU SYSTEM

INVERTER MODE (1) MENU HEADING

Set Inverter OFF SRCH ON CHG

Allows turning the inverter ON and OFF, enabling the SEARCH mode or selecting the char ger only mode CHG. The inverter always starts in the OFF position when powered up. Pressing the red ON/OFF MENU

button on the control panel can also access this display. Use the SET POINTS button to move the s ingle space cursor under the desired s elec tion or you can continue to pus h the r ed button to move the cursor to the right.

• OFF - Disables the inverter. When the OFF position is selected, no power will be provided to the AC loads even if an AC source is available. This is the default position of the inverter upon power-up.

• SRCH - Enables the automatic load search mode control system. This system will turn on the inverter if a large enough load is connected. If not enough AC loads are detected, the INVERTING LED will blink slowly. The required AC load level is adjustable in the INVERTER SETUP (9) menu heading of the SETUP MENU.

• ON - Allows the inverter to provid e AC voltage to th e output an d energiz e the AC loads eit her from the battery or any “synchronized” AC source available on the input. This position must be

manually selected.

• CHG - Allows the inverter to op erate only as a battery ch arger. AC power will be available to the AC loads only if an AC source is available and “synchronized”. This mode is used to prevent discharge of the batteries by the AC loads when a utility outage occurs. This mode is only operational on the AC1 input and when the SET GRID USAGE menu item under the INVERTER SETUP (9) menu heading is in the FLT mode. W hen a different mode under the INVERTER SETUP (9) menu heading is selected, this position will be locked out. Selecting the ‘CHG’ mode will disable the Automatic Generator control features.

INFORMATION DISPLAY

The following information is displayed as additional Menu Items.

CHG Avail. Only in FLT mode. Press red or setpoint button to move. Move cursor to Inverter OFF to reset Overcurrent

GENERATOR MODE (2) MENU HEADING

Set Generator OFF AUTO ON EQ

Allows the generator to be turned ON and OFF or enables AUTO-matic and EQualization operation. This menu display always starts in the OFF position when the inverter is powered up. Pressing the green GEN MENU button on the control panel can access this display. Use the SET POINTS button to move the single space cursor under the desired selection. You can also push the green button again to m ove the cursor to the right.

• OFF - Disables the ‘auto start’ system or turns of f a generator that has been started by the inverter. Also resets the automatic generator control system after an ERROR condition has occurred.

• AUTO - Enables the automatic generator control feat ures. When the battery voltage or load am ps reach the auto start settings for the r equired tim e period, the gener ator will be started unles s the tim er is in the “quiet time” period. The generator will only start if the SET LOW BATTERY CUT OUT VDC setting under the INVERTER SETUP (9) menu heading is reached for over 30 seconds continuously. If the generator is started automatic ally based on battery voltage, the generator will shut off automatically once the battery has completed the BULK and ABSORPTION stages of the battery charging process. If the generator is started automatic ally based on load amps, as set in under the GEN AUTO START SETUP

(12) m enu heading, the generator will turn off once the load cur rent has decreased below the LOAD START AMPS continuously for the LOAD STOP DELAY MIN period. The AUTO-matic generator control operation is disabled if the ‘CHG’ mode under INVERTER MODE (1) menu heading is selected.

 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

MENU SYSTEM

SW Series Inverter/Charger

• ON - Starts the generator that is controlled by the inverter. If this position is selected, it will manually turn on the generator that is connected to the GEN CONTROL relays. The OFF position must be selected to manually turn the generator off.

• EQ - Triggers the battery charger to complete the equalization process. If an AC source is connected to the AC HOT IN 1 terminals, then the equalization process will begin. If no AC sourc e is connected to the AC HOT IN 1 terminals, then the generator will start the equalization process the next time the generator is automatic ally started. Once the equalization process has been completed, the cursor will return to the AUTO position. If you are battery charging - in FLOAT charge - from the Utility or a manually controlled generator, you may initiate another BULK charge by moving the cursor through EQ.

Gen under/over speed NO

If YES is displayed, it indicates that the automatic generator control system has detected that the generator frequency is with in acceptable tolerance, but is not well adjusted. This error condition will cause the red ERROR LED to blink , but will not cause the automatic gener ator control system to shut down the generator.

The ERROR LED can be used to indicate when the generator frequency is well adjusted. When the frequency is within is within 3 hertz of the nominal value (57 to 63 for 60 Hz units, 47 to 53 for 50 Hz units), the LED will be off. Once outside this window, the LED will blink slowly. A frequency meter is also provided in the METERS (4) menu heading to allow a more precise adjustment of the generator. It is able to indicate the frequency of the generator only after the inverter has been able to synchronize to the generator. The acceptable frequency range for the SW Series is 53 to 67 Hertz for 60-Hertz m odels and 44 to 56 Hertz for 50-Hertz models.

Generator start error NO

If YES is displayed, it indicates that the automatic generator control system was not able to successfully start the generator. The system com pletes five start cycles and requires that the gener ator operate for a minimum of 5 m inutes before the s tarting attem pts counter is cleared. T o m anually clear this error, select OFF and then AUTO or ON from the SET GENERATOR menu item, which can also be accessed by pressing the green GEN MENU button on the control panel.

Generator sync error NO

If YES is displayed, it indicates that the automatic generator control system was not able to successfully connect to the generator after it was running. If the gener ator runs f or 10 minutes without operating in the AC voltage and frequency tolerance windows, then the automatic control system stops the generator and indicates an error condition. To m anually clear this error, s elect OFF and then AUTO or ON from the SET GENERATOR menu item, which can also be acces sed by pressing the green GEN MENU button on the control panel.

Gen max run time error NO

If YES is displayed, it indicates that the generator ran for a period of tim e that exceeded the SET MAX RUN TIME menu item setting under the GEN AUTO START SETUP (12) menu heading. This error

indication will only light to let the user know that the generator ran longer than originally expected. This may be caused by many variables such as; excessive AC or DC loads oper ating while the generator is trying to charge the battery; the generator operating near the INPUT LOWER LIMIT VAC setting; or the batteries no longer holding a charge. This error LED is an advisory indication only and will not allow the inverter to stop the generator. To disable the MAX RUN TIME, set the time to zero. To manually clear this error, select OFF and then AUTO or ON from the SET GENERATOR menu item, which can also be accessed by pressing the green GEN MENU button on the control panel.

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

MENU SYSTEM

Load Start Amps Ready NO

If YES is displayed, it indicates that the automatic control system has started or is about to start the generator because the AC load current has reached the LOAD START AMPS setting. The automatic start is delayed by the time period set by the LOAD START DELAY MIN setting in the GEN AUTO START SETUP (12). This allows checking why the generator was automatically started.

Voltage Start Ready NO

If YES is displayed, it indicates that the automatic control system has started or is about to start the generator because the DC battery voltage reached one of the START VOLTS settings. The automatic start is delayed by the time period of the START VOLTS setting involved in the GEN AUTO START SETUP (12). This allows checking why the generator was automatically started.

Exercise Start Ready NO

If YES is displayed, it indicates that the automatic control system has started or is about to start the generator because the EXERCISE PERIOD DAYS setting has been reached. This allows c hecking of why the generator was automatically started.

INFORMATION DISPLAY

The following information is displayed as additional Menu Items.

Move cursor to GEN OFF to reset Generator error. If no start in 5 trys then error. If Gen starts & runs for 5 min then stops the inverter will not attempt restart until gen auto start conditions are again satisfied. If Gen r uns for more than max run time then error. Under/Over speed will cause a Sync error in 10 minutes.

TRACE ENGINEERING (3) MENU HEADING

Press reset now for defaults

Allows resetting of all menu item settings to the factory default values. This also occurs when the battery is disconnected from the inverter. The RESET TO FACTORY DEFAULTS button on the control panel will only reset the default values if it is pressed while this menu item is displayed. All factory default settings will be reset except for the TIME OF DAY (6) clock.

If the RESET TO FACTORY DEFAULTS button is pressed while in any other menu item or menu heading, only the control panel display (and remote c ontrol display) is reset, no settings will be reset. This is useful for clearing any garbled display inform ation. This may be encountered when a rem ote display is initially connected or when a remote is used in a high electrical noise environment such as a vehicle application.

Revision 4.01

Displays the software revision. Used to ensure compatibility with other units when stacked, etc.

INFORMATION DISPLAY

The following information is displayed as additional Menu Items.

5916 195th St NE Arlington, WA 98223 USA Ph 360-435-8826 Fax 360-435-2229

 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

MENU SYSTEM

SW Series Inverter/Charger

METERS (4) MENU HEADING

The current meters provided meas ure only the real, in phase component of the c urrent. T his is the portion of the power that actually uses power from the battery. This allows better estimation of the DC power drawn by the load or the battery charger. This may cause the reading to vary from other AC meters.

NOTE: The meters do not display a (+) symbol for positive values.

Inverter/charger Amps AC 00

All models

Range: -64 to +64 Amps

Reads AC amperage. Positive (+) am ps indicates inverter is charging the batteries. Negative (-) amps indicate the inverter is powering the AC loads and the batteries are being discharged.

Input Amps AC 00

All models

Range: -64 to +64 Amps

Reads total AC input current from the grid (AC1) or generator (AC 2). T he reading is positive (+) if the inverter is drawing power from the utility grid to charge the battery or power AC loads and negative (-) if the inverter is selling power into the utility grid (only available if SELL mode is enabled).

Load Amps AC 00

All models

Range: 00 to 64 Amps

Reads the current that is going to the AC loads. This reading is always positive (+).

Battery actual volts DC 12.6

12 VDC models

Range: 5.0 to 17.5 VDC

Battery actual volts DC 25.2

24 VDC models

Range: 10.0 to 35.5 VDC

Battery actual volts DC 50.4

48 VDC models

Range: 20.0 to 71.0 VDC

Reads the battery voltage. Similar to the voltage reading of a standard DC voltmeter. The ac tual battery voltage value is used for the LOW BATTERY CUT OUT; HIGH BATTERY CUT OUT, LOW BATTERY TRANSFER, LOW BATTERY CUT IN and BATTERY SELL VOLTS settings.

Battery TempComp volts DC 12.6

12 VDC models

Range: 5.0 to 17.5 VDC

Battery TempComp volts DC 25.2

24 VDC models

Range: 10.0 to 35.5 VDC

Battery TempComp volts DC 50.4

48 VDC models

Range: 20.0 to 71.0 VDC

Note: The BTS must be installed for temperature compensation to be operational.

Reads the battery voltage after it has been adjusted based on the battery’s temperature. This value is used by the battery charger for its regulation settings. The value will decrease from the actual battery voltage if the battery is cold and will increase if the battery is hot, which may give the appearance that the batteries are being overcharged during winter and undercharged in the summert ime. This improves the performance of the batteries in cold weather and r educes gas sing in hot weather. If you are using a NiCad or other alkaline type battery, be sure to adjust the SET TEMP C OMP menu item under the BATTERY CHARGING (10) menu heading of the SETUP MENU to NiCad.

Inverter volts AC 120

Standard models

Range: 00 to 255 VAC

Reads the RMS value of the inverter’s AC output voltage. When synchronized to an AC source, the inverter AC output voltage would match the AC inputs value.

Page

Inverter volts AC 230

“E” models

Range: 00 to 510 VAC

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

Inverter volts AC 105

“ J & K” models

Range: 00 to 255 VAC

Telephone: 360/435-8826

Fax: 360/435-2229

www.traceengineering.com

Inverter volts AC 220

“W” models

Range: 00 to 510 VAC

Part No. 2031-5

Rev. C: February 2001

MENU SYSTEM

Grid (AC1) volts AC 120

Standard models

Range: 00 to 255 VAC

Grid (AC1) volts AC 230

“E” models

Range: 00 to 510 VAC

Grid (AC1) volts AC 105

“J & K” models

Range: 00 to 255 VAC

Grid (AC1) volts 220

“W” models

Range: 00 to 510 VAC

Reads the RMS value of the AC voltage at the inverter’s AC HOT 1 input and NEUTRAL IN 1 ter minals. This is usually the connection for the utility grid. Value will drift around before inverter has synchronized.

Generator (AC2) volts AC 120

Standard models

Range: 00 to 255 VAC

Generator (AC2) volts AC 230

“E” models

Range: 00 to 510 VAC

Generator (AC2) volts AC 105

“J & K” models

Range: 00 to 255 VAC

Generator (AC2) volts AC 220

“W” models

Range: 00 to 510 VAC

Reads the RMS value of the AC voltage at the inverter’s AC HOT 2 input and NEUTRAL IN 2 ter minals. This is usually the connection for a back-up, fuel- powered generator . Value will drif t ar ound bef or e inverter has synchronized.

Read Frequency Hertz 60

60 Hz models

Range: 53 to 67 Hz

Read Frequency Hertz 50

50 Hz models

Range: 44 to 56 Hz

Reads the frequency of the AC source that the inverter is synchronized to. This value may drift around until the inverter has synchronized to the source. Once synchronized, the inverter follows the f requency of the AC source it is connected to.

INFORMATION DISPLAY

The following information is displayed as additional Menu Items.

AC1 & AC2 volts valid only when inverter synced to that input. Batt volt actual is used for LBCO, HBCO, LBX, LBCI, sell volts and gen starting. Batt volt temp comp is used for float, bulk, eq & aux relays

ERROR CAUSES (5) MENU HEADING

When an err or has occurred, the red ERROR LED on the control panel will be illum inated. If a generator error has occurred, the ERROR LED will blink slowly. This menu is provided to assist with the investigation into the error cause. If an error c ondition has occ urred, the word NO will be changed to YES. T o reset the error, turn the in verter OFF and then ON.

Over Current

Too large of a load was connected or the AC output wiring was short-circ uited. This can occur in inverter or charger mode. T o clear this f ault, disc onnect the loads and r estart the invert er. T o restar t, push the r ed ON/OFF MENU button on the control panel and then select OFF and then ON or SRCH. Reconnect the loads one at a time to find the load or combination of loads that cause the pr oblem. If the inverter will not restart with all loads and inputs disconnected remove all AC wiring from the terminal block and try to restart again. If it restarts, the problem is with the wiring. If it does not restart, refer to the TROUBLESHOOTING GUIDE on page 112.

Transformer overtemp NO

The transformer or power transistors have exceeded their s af e operating temperature and the inverter has turned off. When operating as a battery charger, the inverter will reduce its charging rate to prevent overheating. As an inverter, overheating can be caused by attempting to operate too large of a load for too long, a failure of the inverter cooling fans, or that the air flow into or out of the inverter is being bloc ked. The inverter will automatically reset once it has cooled. W hile the inverter has shut down, AC power from any AC source will not pass through the inverter to power AC loads. Any power management provided by the inverter will not be able to occur while the inverter is off.

Heatsink overtemp NO

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

Telephone: 360/435-8826

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SW Series Inverter/Charger

Part No. 2031-5

Rev. C: February 2001

Page

MENU SYSTEM

SW Series Inverter/Charger

High Battery voltage NO

Battery voltage was above the HIGH BATTERY CUT OUT VDC setting. This can be caused by the solar array or other charging source not being regulated. Check the controller for proper operation. Some controllers have a “equalize” setting which over-rides the normal operation, allowing the battery voltage to be unregulated. Return the controller to the “normal” setting and c heck for proper operation. If you are using NiCad type batteries, you will need to increase the HIGH BATTERY CUT OUT VDC setting. The inverter will automatically reset once the battery voltage has dropped 1.5 volts below the HBCO s etting for a 12 VDC system, 3 volts for a 24 VDC system and 6 volts for a 48 VDC system.

Low Battery voltage NO

Battery voltage is below the LOW BATTERY CUT OUT VDC setting. The inverter has shut off to prevent over-discharge of the battery. Allow the battery to recharge or connect to an AC source su ch as a bac k-up generator. The inverter will reset when the battery exceeds the LOW BATTERY CUT IN VDC setting.

AC source wired to output NO

Reports that an AC voltage source was connected directly to the AC output. This can be caused by improper wiring or incorrect installation of the inverter. Check the AC input and output wiring. This condition is much worse than a short circuit and m ay cause damage to the inverter. Find the cause and correct the problem before restarting the inverter. A defective utility or generator AC input relay could cause this condition. To test, disc onnect all input wiring from AC inputs 1 and 2 and res tart the inver ter. If the AC IN GOOD LED indicator on the control panel glows, then the inverter’s internal relay is defective.

External error (stacked) NO

A problem has occurr ed with the series interface c able or one of the inverter s operated in series . Check the cable for damage and replace it to see if the problem is corrected. Also, check the connecting AC wiring.

Generator start error NO

Indicates that the automatic generator control system was not able to successfully start the generator. The system completes five s tart cycles and requires that the generator operate for a m inimum of 5 m inutes before the starting attempts counter is cleared. To manually clear this error, select OFF and then AUTO or ON from the SET GENERATOR menu item , which pressing the green GEN MENU button on the control panel can access.

Generator sync error NO

Indicates that the automatic generator control system was not able to successfully connect to the generator after it was running. If the generator runs for 10 minutes without operating in the AC voltage and frequency tolerance windows, then the automatic control system stops the generator and indicates an error condition. To manually clear this error, select OFF and then AUTO or ON from the SET GENERATOR menu item, or press the green GEN MENU button on the control panel can access.

Gen under/over speed NO

Indicates that the automatic generator control system has detected that the generator f r equenc y is not well adjusted. This error condition will cause the red ERROR LED to illuminate, but will not cause the automatic generator control system to shut down the generator. If the inverter can not synchronize to the generator after a 10-minute period, then the GENERATOR SYNC ERROR condition will be reached.

Page

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Telephone: 360/435-8826

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Part No. 2031-5

Rev. C: February 2001

MENU SYSTEM

The ERROR LED can be used to indicate when the generator frequency is well adjusted. When the frequency is within ± 5% of the nominal value, the LED will be off. Once outs ide this window, the LED will be on. A frequency meter is also provided in the METERS ( 4) menu heading to allow a more precise adjustment of the generator. It is able to indicate the f requency of the generator only after the inver ter has been able to synchronize to the generator. The acceptable frequency range for the SW Series is 53 to 67 Hertz for 60-Hertz models and 44 to 56 Hertz for 50-Hertz models.

Inverter breaker tripped NO

The inverter’s output AC circuit break er on the left end of the chas sis has tripped or is “open”. Operating too large of an AC load may cause this. Reduce the loads connected and reset the circuit break er by pressing it in or moving the handle depending upon the type of breaker included.

TIME OF DAY (6) MENU HEADING

Provides the reference for any time func tions enabled. Does not res et when the “PRESS FOR FACTORY DEFAULTS” button is pressed. Will reset only if DC power to the inverter is lost.

Set Clock hour 00:00:00

Indicates and allows setting of the hours for the internal clock. This setting is based on a 24-hour clock and adjusts in 10-minute increments.

Set Clock minute 00:00:00

Indicates and allows setting of the minutes for the internal clock.

Set Clock second

Indicates and allows setting of the seconds for the internal clock.

GENERATOR TIMER (7) MENU HEADING

Start Quiet Time h:m 08:00

Generator will not be started during this period unless the actual battery voltage reaches the LOW BATTERY CUT OUT VDC setting for a continuous period of 30 seconds. Caus es the automatic generator

control system to ignore the AC load and battery voltage start settings. The quiet time period is us ually set for the sleeping hours.

End Quiet Time h:m 08:00

This setting finishes the quiet tim e per iod, allowing the generator to start as required by the settings of the GEN AUTO START SETUP (12) menu heading in the SETUP MENU. To disable the quiet time, set the start and end times equal. The generator exerc ise system will start at this tim e setting and will run for 15 minutes if the generator exer cise timer has reached the SET EXERCISE DAYS m enu item setting. For example, if the SET EXERCI SE DAYS menu item is s et for 1, then the generator will start every day at this time. To disable the generator exercise system, set the SET EXERCISE DAYS menu item to zero.

INFORMATION DISPLAY

The following information is displayed as additional Menu Items.

Gen doesn’t run during quiet time unless batt volts is less than LBCO volts for 30 seconds, or load > load start amps. To defeat timers set start = end. If exercise day set to 1 then gen will always start @ end quiet.

 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

MENU SYSTEM

SW Series Inverter/Charger

SETUP MENU

The SETUP MENU provides all the controls and s ettings needed when inst alling or adjus ting the system. To access the SETUP MENU, press both the red ON/OFF MENU and green GEN MENU buttons at the same time on the control panel of the inverter or remo te control. To exit, simply go to one of the USER MENU headings numbers 1 through 8, or press the red ON/OFF MENU or green GEN MENU button once.

MENU HEADINGS

Inverter Setup

Battery Charging

AC Inputs

Gen Auto Start setup 12

Gen starting details 13

Auxiliary Relays R9 R10 R11 14

Bulk Charge Trigger Timer 15

Use to program and adjust the operation of the inverter. Also allows

adjustment of how the inverter/ charger mode uses the utility grid.

Use to adjust the operation of the battery charger.

Use to adjust the operating characteristic s of the utility grid (AC1) and the generator (AC2) inputs.

Use to setup the when the automatic generator control system and the maximum run time allowed

Use to adjust the starting sequence of the automatic generator control system.

Use to adjust the operation of the auxiliary signal relays for controlling external power sources or system loads.

Use to set a time when the battery will be given a bulk charge cycle from the utility grid (AC1) input. Usually only used when SLT mode is enabled.

Low Battery Transfer (LBX) 16

Battery Selling

Grid Usage Timer

Information File battery 19

End Setup Menu

Page

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

Use to set up the transfer voltage setting for the LBX mode.

Use to control the SELL mode when it is us ed to dis char ge a batter y into the utility grid. Also allows setting of the maximum sell amps.

Use to control when the inverter/charger mode uses the utility grid for the FLT and SELL modes.

Provides information about the operation of some settings and meters.

Used to display that you have reached the end of the SETUP MENU.

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Part No. 2031-5

Rev. C: February 2001

MENU SYSTEM

INVERTER SETUP (9) MENU HEADING

Set Grid Usage FLT SELL SLT LBX

• FLT - Float will try to maintain the batteries at the float voltage level. This can be used when the source of power is a utility grid or a generator. W hen AC power is available, the inver ter will com plete a full three stage charge cycle and then hold the battery at the float level until the source of utility power is no longer available. This is the default setting and is appropriate f or use with stand-alone systems with back-up generators or utility back-up systems. F LT mode d oes not sell excess pow er into the utility grid. If a DC power source is available and the batter y is full, its power will be used to directly power the AC loads connected to the inverter output even though the AC power is also connected to the loads. If mor e power is available from the DC sourc e than is required to power the AC loads, the battery voltage will increase above the float level. An external charge control device – such as the Trace™ C40 Load/Charge controller - is therefore required to prevent over charging of the battery.

• SELL – SELL mo de enables the inverter to “sell” the excess power t o the grid (AC HOT IN 1 only). This mode must have the approval of the local power utility prior to its use. In the US,

utility companies are required by law to purchase any excess power generated by their customers; however, they decide what can be connected and what safety requirements m us t be m et. Be advised: some utilities will be mor e receptive than others will. The most advantageous c onfiguration is called “NET” metering where only one meter is installed and spins either direction. T he purchase and sell prices are equal. “Dual” metering requires two meters and is less desirable s ince the power you sell is usually worth only a fraction of the price for the power you purchase. Power from any DC source, such as a solar array, and a battery can be sold. When power f rom a DC s ource is available, it will be used to power any AC loads connected to the AC output first. Any excess power available from the s ystem will be sold “into” the utility gird through the AC HOT IN 1 terminals.

• SLT - The silent mode does not main tain the battery at float voltage all the time. The battery charger only operates for part of each day. AC power from the utility grid is passed through the inverter to the loads 24 hours a day. Once a day, at the time prescribed by the BULK CHARGE TRIGGER TIMER, the batteries are given a bulk and absorption charge cycle. The inverter will perform a bulk charge once per day from the gr id, c harging the batter y to near the SET BULK VOLTS DC setting until the battery charger has held the battery near the SET BULK VOLTS DC setting for the ABSORPTION TIME period setting. The inverter will then go totally silent and will wait for the utility power to fail, or until the next day when it performs another bulk charge. After each power outage, the inverter will perform another bulk charge cycle once the AC source has retur ned. T his is typically used only in utility back-up applications.

• LBX - The low battery transfer mode allows a system to automatically switch between utility connected and stand alone battery operation. In this mode, the inverter will power the loads from the battery and solar array (or other energy source) until the battery voltage drops to the LOW BATTERY TRANSFER VDC setting. It will then connect to the utility grid and charge the battery. The

loads will be powered by the utility until the battery voltage reaches the LOW BATTERY CUT IN VDC setting. The inverter will then disconnect the utility and power the loads from the battery and any other source of DC power connected. This mode is often used instead of the SELL mode because approval from the utility is not required - no power will be sent into the utility distribution s ystem when LBX is selected. To use the LBX mode, the AC s ource (utility power) must be connected to AC1 input only, transfer to the inverter will not occur if the AC source is connected to the AC2 input. If AC is present on the AC1 input in the LBX mode, the AUTO GENERATOR CONTROL MODE will be disabled.

CAUTION: If the system is not properly sized, the LBX mode can result in frequent transfers from the battery to the utility and result in poor performanc e of the system and excessive energy consumption from the utility. The daily output of the alternative power source (solar, wind etc.) should be able to meet the daily power requirements of the loads being operated under typical conditions. See the low battery transfer mode section for more 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

MENU SYSTEM

SW Series Inverter/Charger

Set Low Battery cut out VDC 11.0

12 VDC models

Range: 08.0 to 16.0

Set Low Battery cut out VDC 22.0

24 VDC models

Range: 16.0 to 32.0

Set Low Battery cut out VDC 44.0

48 VDC models

Range: 32.0 to 64.0

This setting controls when the inverter turns off due to a low battery voltage condition. The inverter will turn off only after this level has been reached for the period of time set by the following item. When the automatic generator control system is used, the generator will be started when the battery voltage has dropped below this value for 30 seconds continuous ly. This will occur even during the quiet tim e period. This setting is not temperature compensated.

Set LBCO delay minutes 15

All models

Range: 00 to 255

This setting controls how long the inverter delays before tur ning off due to a low battery voltage condition. The inverter will turn off only after the LOW BATTERY CUT OUT VDC level has been reached for this period of time continuously. If you are using the automatic generator control system, don’t set this delay period shorter than the amount of tim e it takes the generator to start and connect or the power will go off and then back on when the generator auto starts due to a LBCO condition.

Set Low battery cut in VDC 13.0

12 VDC models

Range: 05.0 to 17.5

Set Low battery cut in VDC 26.0

24 VDC models

Range: 10.0 to 35.0

Set Low battery cut in VDC 52.0

48 VDC models

Range: 20.0 to 70.0

This setting controls when the inverter turns bac k on once it has shut off after the battery reached the LOW BATTERY CUT OUT VDC setting. It is also used to control when the system resum es powering the AC loads from the inverter when LBX mode is being used. In LBX mode, the best perfor mance will often be achieved if this setting is higher than the BULK and FLOAT VOLTS DC setting in order to reduce cycling of the system. The DC charging sourc es (wind, solar etc.) mus t then cause the battery voltage to rise above the charger settings before the system r esumes inverter mode operation. This s etting is not temperature compensated.

Set High battery cut out VDC 16.0

12 VDC models

Range: 00.0 to 16.5

Set High battery cut out VDC 32.0

24 VDC models

Range: 00.0 to 33.0

Set High battery cut out VDC 64.0

48 VDC models

Range: 00.0 to 66.0

This is the battery voltage at which the inverter turns off . The inverter will automatically restart once the battery voltage has dropped 1.5 VDC below the HBCO setting for 12 VDC systems, 3 VDC for 24 VDC systems, and 6 VDC for 48 VDC systems. This setting is not temperature compensated.

Set search watts 48

All models

Range: 00 to 240

The sensitivity threshold of the search m ode circuit is adjustable. If set to zero, it is ef fectively disabled. The sensitivity is only adjustable in increments of 16 watts.

Set search spacing 59

All Models

Range: 10 to 255*

The length of time between each search pulse is also adjustable. The s etting is in cycles. Therefore, a setting of 60 would generate search pulses that are 1 s econd apart. The range of s ettings is from 10 to 255 cycles, which equals a search pulse from 6 times a second to once every 4.25 seconds. This adjustment can be used to speed up the response of the sear ch circuit, which will reduce the delay when starting a load. Reducing the spacing increases the power consumption of the inverter when it is in the search mode, reducing the benefit of it. Typically, the default value is acceptable.

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

MENU SYSTEM

BATTERY CHARGING (10) MENU HEADING

Note: See the battery section of this manual for recommended setting for different battery types.

Set Bulk volts DC 14.4

12 VDC models

Range: 10.0 to 16.0

Set Bulk volts DC 28.8

24 VDC models

Range: 20.0 to 32.0

Set Bulk volts DC 57.6

48 VDC models

Range: 40.0 to 64.0

Sets the voltage level that will be maintained during the first and sec ond stage of the charging process. This will be the maximum voltage at which the batteries will be charged. This setting will be

compensated for the battery temperature if the BTS sensor is installed.

Set Absorption time h:m 02:00

All models

Range: 00:00 to 23:50

Sets the time period that the batteries will be held near the SET BULK VOLTS DC level for the second stage of the battery charging process, this ensures that the battery is well charged. If the automatic generator control system is used, the generator will turn off when the batter ies have been held near the SET BULK VOLTS DC setting until the ABSORPTION TIME period has elapsed. This time is an accumulating or up/down type timer - it counts up while the voltage is near the BULK setting and c ounts back down if the voltage drops. This makes the process more reliable and predictable. If the system designer wants to minimize generator operation, a shorter time may be used. If the system designer wants to ensure that the batteries are fully charged before stopping the charging pr ocess, then a longer setting may be used. If the ABSORPTION TIME is set to zero (00:00) the unit will not provide any absorption charge time and go straight to the float charge stage after reaching near the BULK voltage setting.

Set Float volts DC 13.4

12 VDC models

Range: 10.0 to 16.0

Set Float volts DC 26.8

24 VDC models

Range: 20.0 to 32.0

Set Float volts DC 53.6

48 VDC models

Range: 40.0 to 64.0

Sets the voltage level that will be maintained at the final stage of the charging process. T his is impor tant for systems which are connected to utility power since the battery charger will often be in this stage mos t of the time. This setting will be compensated for the battery temperature if the BTS sensor is installed.

Set Equalize volts DC 14.4

12 VDC models

Range: 10.0 to 16.0

Set Equalize volts DC 28.8

24 VDC models

Range: 20.0 to 32.0

Set Equalize volts DC 57.6

48 VDC models

Range: 40.0 to 64.0

Sets the voltage level that the batteries will be limited to during the equalization process. T his will be the maximum voltage at which the batteries will be charged. This setting will be compensated for the

battery temperature if the BTS sensor is installed.

Set Equalize time h:m 02:00

All models

Range: 00:00 to 23:50

Sets the amount of time battery voltage must exceed the BULK VOLTS DC setting before the equalization process is considered to be completed. If the automatic generator control system is used; it will turn off the generator when this timer has reached its setting, and return the cursor from the EQ to the AUTO position. This time is an ac cumulating or up/down type timer - it counts up while the voltage is above the BULK setting and counts back down if the voltage drops below the BULK setting for a period of time.

 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

MENU SYSTEM

SW Series Inverter/Charger

Set Max Charge amps AC 20

12 VDC models Range: 01 to 25

Set Max Charge amps AC 30

24 VDC & 48 VDC models

Range: 01 to 35

Set Max Charge amps AC 15

“E & W” models

Range: 01 to 18

Set Max Charge amps AC 35

“J & K” models Range: 02 to 40

Sets the maximum am ount of AC input cur rent that the battery charger will use to charge the batter y. This can be used to limit the charger output as well. The charger will “back-off” if the com bination of AC loads and the charger reaches the AM PS AC setting of the AC IN PUT connected to prevent overloading the source or tripping breakers. This process occurs automatically.

Set Temp Comp LEADACID NICAD

All models

Allows selection of the battery type for the battery temperature compensation system. This effectively reduces the battery charging set points when the battery is hot and increases them when the battery is cold. The battery charging set points change ±0.005 volts per degree Celsius for the LEADACID setting and ±0.003 volts per degree Celsius per battery cell for the NICAD setting. These battery setpoint changes occur if the battery temperatur e is higher or lower than 25° C (77°F), and will only occur if the battery temperature sensor (BTS) is installed. The s etting should be changed f rom the def ault setting only if NiCad or Nickel Iron batteries are used.

AC INPUTS (11) MENU HEADINGS

Set Grid (AC1) amps AC 60

Standard models

Range: 00 to 63

This setting determines the level in AC amps at which the inverter begins to back -off the battery charger or operates in parallel to reduce the load on the utility grid. Typically, this is set to the size of the AC cir cuit breaker that feeds the AC HOT IN 1.

Set Grid (AC1) amps AC 30.0

“E & W” models

Range: 00 to 31.5

Set Grid (AC1) amps AC 60

“J & K” models Range: 00 to 63

Set Gen (AC2) amps AC 30

Standard models

Range: 00 to 63

Set Gen (AC2) amps AC 15.0

“E & W” models

Range: 00.0 to 31.5

Set Gen (AC2) amps AC 30

“J & K” models Range: 00 to 63

This setting determines the level in AC am ps at which the inverter begins to back -off the battery charger or operates in parallel to reduce the load on the generator. Typically, this is set to the size of the generator’s circuit breaker feeding the inverter (AC HOT IN 2) or the maximum output amperage ability of the generator.

Set Input Lower limit VAC 108

Standard models

Range: 80 to 111

Set Input Lower limit VAC 206

“E” models

Range: 170 to 220

Set Input Lower limit VAC 88

“J & K” models

Range: 70 to 90

Set Input Lower limit VAC 196

“W” models

Range: 160 to 210

Sets the lowest voltage at which the inverter is allowed to be connected to the utility grid (AC INPUT 1) or the generator (AC INPUT 2). W hen the AC input voltage reaches this level, the inverter will stop battery charging and begin to invert in parallel with the AC source to reduce the load. If the voltage continues to drop, the inverter will disconnect and will power the loads from the battery. NOTE: Typically the INPUT LOWER LIMIT VAC setting will be based upon the minimum AC voltage tolerable by the AC loads.

Set Input Upper limit VAC 132

Standard models

Range: 128 to 149

Set Input Upper limit VAC 254

“E” models

Range: 250 to 298

Set Input Upper limit VAC 112

“J & K” models

Range: 105 to 129

Set Input Upper limit VAC 244

“W” models

Range: 240 to 288

Sets the highest voltage at which the inverter is allowed to be connected to the utility grid (AC INPUT 1) or generator (AC INPUT 2). This is also the maximum voltage at which the inver ter will sell power into the line if SELL is enabled. When this voltage is r eached the inverter will disconnect and power the AC loads from the battery. If this voltage drops below this setting, the inverter will reconnect the loads to the AC source.

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

MENU SYSTEM

GEN AUTO START SETUP (12) MENU HEADING

Set Load Start amps AC 33

All models

Range: 00 to 63

Sets the AC load current that will initiate the automatic generator c ontr ol s ystem when the cur r ent remains above this setting continuously for the LOAD START DELAY MIN period.

Set Load Start delay min 05.0

All models

Range: 00.0 to 25.5

Sets the time delay period that will initiate automatic generator control s ystem when the current remains above the LOAD START AMPS AC setting continuously for this time period.

Set Load Stop delays min 05.0

All models

Range: 00.0 to 25.5

Sets the amount of time that the automatic generator will continue to run after the load current (determined by the LOAD AMPS AC meter) decreases below the LOAD START AMPS AC setting.

Set 24 hr start volts DC 12.3

12 VDC models

Range: 05.0 to 16.5

Set 24 hr start volts DC 24.6

24 VDC models

Range: 10.0 to 35.5

Set 24 hr start volts DC 49.2

48 VDC models

Range: 20.0 to 71.0

Sets the battery voltage that will initiate the automatic generator control system if the voltage remains below this setting continuously for 24 hours. This s etting is not temperature compensated. This 24- hour start is defeated if the QUIET TIME under GENERATOR TIMER (7) is enabled.

Set 2 hr start volts DC 11.8

12 VDC models

Range: 05.0 to 16.5

Set 2 hr start volts DC 23.6

24 VDC models

Range: 10.0 to 35.5

Set 2 hr start volts DC 47.2

48 VDC models

Range: 20.0 to 71.0

Sets the battery voltage that will initiate the automatic generator control system if the voltage remains below this setting continuously for 2 hours. This setting is not temperature com pens ated. T his 2-hour start is defeated if the QUIET TIME under GENERATOR TIMER (7) is enabled.

Set 15 min start volts DC 11.3

12 VDC models

Range: 05.0 to 16.5

Set 15 min start volts DC 22.6

24 VDC models

Range: 10.0 to 35.5

Set 15 min start volts DC 45.2

48 VDC models

Range: 20.0 to 71.0

Sets the battery voltage that will initiate the automatic generator control system if the voltage remains below this setting continuously for 15 minutes. This setting is not temperature compensated. This 15minute start is defeated if the QUIET TIME under GENERATOR TIMER (7) is enabled.

Read 30 sec LBCO start VDC 11.0

12 VDC models

Range: 05.0 to 16.5

Read 30 sec LBCO start VDC 22.0

24 VDC models

Range: 10.0 to 35.5

Read 30 sec LBCO start VDC 44.0

48 VDC models

Range: 20.0 to 71.0

Displays the battery voltage setting that will initiate the automatic generator control system if the voltage remains below the setting continuously for 30 seconds . This setting is not temperature com pens ated. This display is linked and is adjusted by the SET LOW BATTERY CUT OUT VDC menu item setting under the INVERTER SETUP (9) menu heading. T his 30-second start will attempt to s tart the auto start gener ator even if the QUIET TIME under GENERATOR TIMER (7) is enabled.

 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

MENU SYSTEM

SW Series Inverter/Charger

Set Exercise period days 30

All models

Range: 00 to 255

Sets a maximum number of days allowed between operation of the generator. W hen an internal counter reaches the number of days set, the generator will be star ted at the END QUIET TIME menu item setting. The run time is fixed at 10 minutes. If the generator is m anually or automatically operated for 5 m inutes at any time during this period, then this counter will reset and the period will start again. If this m enu item is set for 1 day, then the generator will start everyday at this time. If the period is set to zero, then the exercise system will be disabled. If power is present at the AC1 input, the generator will not be connected to during the exercising operating period.

Set Maximum run time h:m 08:00

All Models

Range: 00:00 to 23:50

This setting provides an indication that the generator operated excessively after it was automatically or manually started. Once this time per iod is reached, the error LED will flash and a GEN MAX RUN TIME ERROR condition will be indicated in the GENERATOR MODE (2) menu heading. This error is an advisory only error and does not stop the generator and the inverter/charger will continue to operate normally. While the error condition exists, the generator can be s tar ted manually or automatically. To reset the error condition, press the green GEN MENU button to selec t OFF, then the AUTO or ON. Setting the time to 00:00 defeats this function.

INFORMATION DISPLAY

The following information is displayed as additional Menu Items.

Set Max Run Time to 0 to defeat. Set exercise to 0 to defeat. See menu 9 to set LBCO.

GEN STARTING DETAILS (13) MENU HEADING

Set RY7 Function GlowStop Run

All Models

Allows Relay 7 (RY7) to provide two different generator start routines. T he relay labeled RY7 is used to either provide a STOP signal or a RUN signal. It can also be us ed to provide a GLOW signal on diesel generators with glowplugs. Note that the right side choice, RUN, is the default.

When RUN is s elected as the function of the RY7 relay, the RY7 COM and RY7 N.O. contacts remain closed while the generator is running. The RY7 N.C. (normally closed) contac t is open (not connected to the c omm on terminal) while the generator is running. W hen the generator is off, the RY7 N.C. term inal is connected to the RY7 COM terminal. This configuration is useful for starting a two wire (auto crank) type generator.

When GLOWSTOP is selected as the function of the RY7 relay, the RY7 COM and RY7 N.O. contacts remain open while the generator is running. T he contac ts clos e only when it is time for the gener ator to be stopped, then re-open. This is useful for generators that require a stop signal to shut down the generator.

The GLOWSTOP setting can also be used for diesel generators . This relay can be used to provide both the GLOW and STOP signals. W hen this is done the generator will be given both GLOW and STOP signals before cranking and when stopping.

Set Gen warmup seconds 60

All Models

Range: 16 to 255

Sets the number of sec onds the generator is allowed to warm up before the load is connected and the battery charger started. If the generator is located in a cold location (below freezing), a longer setting may be required.

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Part No. 2031-5

Rev. C: February 2001

MENU SYSTEM

Set Pre Crank seconds 10

All Models

Range: 00 to 255

Sets the number of sec onds the system delays closing of relay RY8 - the star signal r elay - once relay RY7 is closed. See the AUTOMATIC GENERATOR CONTROL MODE for more information. This period

may also be the amount of time that the glow plugs will be on if they are connected to the automatic control sy st em.

Set Max Cranking seconds 10

All Models

Range: 00 to 15

Sets the maximum num ber of s econds the starter will be cranked dur ing the starting sequence by closing relay RY8. See the AUTOMATIC GENERATOR CONTROL MODE for more information.

Set Post Crank seconds 30

All Models

Range: 00 to 255

Sets the number of sec onds the system will delay after c om pleting the start sequenc e. If the generator has not started, this sequence will be repeated up to 5 tim es . See the AUTOMATIC GENERATOR CONTROL MODE for more inform ation. This period is provided to allow the starter motor to c ool off. It can also allow generators with built in warm-up delay contactors to provide AC output before the inverter attempts a re-crank cycle.

AUXILIARY RELAYS (14) MENU HEADING

Three voltage-controlled relays are provided to simplify installations that have battery voltage related tasks to perform. T hey are single pole double throw, five amp relays. Both the normally closed and normally open contacts are available for each relay. The operation of the relays is individually controlled and adjustable. The three auxiliary relays operate independently of the inverter/charger status (being on or off). Both the normally open (N.O.) and normally closed (N.C.) contacts are available for each of thes e aux iliary relays. Use the crimp-on terminals provided in the hardware package to connect to these contacts.

CAUTION: These relays are not intended to directly control a load or charging s ource - rather they can be used to send a signal or operate the coil of another higher amperage device which does the actual switching of the power. A fuse rated at 5 amps or less should be included to protect each of the relays. Damage to thes e relays from overloading is not covered by warranty and requires the inverter to be returned to a repair c enter. This also applies to the relays that are provided to start a generator.

The SET RELAY VOLTS DC setting sets the voltage trip point for each of the auxiliary relays (9, 10, and

11). When the battery voltage exceeds this setting, the relay energizes and closes the N.O. and COM

terminals on the relay. This setting is compensated for the battery temperature when the BTS is used. There is no intentional time delay (0.1 sec) on the r eaction for this setting; this allows fas t response to rapid voltage changes in the system

The HYSTERESIS VOLTS DC setting determines the voltage difference between when the relay becomes energized and when it is de-energized. This is an “active high” type of control. The N.O. and

COM terminals of the relay close (relay is energized) when the battery voltage exceeds the AUX RELAY 9 VOLTS DC setting and opens (relay is de-energized) at this setting minus the R9 HYSTERESIS VO LTS DC setting. The N.O. and COM terminals of the relay remain open (de-energized) until it again reac hes

the AUX RELAY 9 VOLTS DC setting. (For example, the default setting energizes the relay when the voltage exceeds 14.5 VDC and de-energizes when it drops below 13.5 VDC for 12-volt systems). There is

an intentional 2-second time delay to reduce cycling.

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Telephone: 360/435-8826

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SW Series Inverter/Charger

Part No. 2031-5

Rev. C: February 2001

Page

MENU SYSTEM

SW Series Inverter/Charger

Set Relay 9 volts DC 14.5

12 VDC Models

Range: 05.0 to 17.6

Set Relay 9 volts DC 29.0

24 VDC Models

Range: 10.0 to 35.5

Set Relay 9 volts DC 58.0

48 VDC Models

Range: 20.0 to 71.0

Sets the voltage trip point for the auxiliary relay number 9. This setting is compensated for the battery temperature when using the BTS. There is no intentional time delay on the reaction for this setting. T his allows fast response to rapid voltage changes in the system.

R9 Hysteresis volts DC 01.0

12 VDC Models

Range: 00.1 to 12.8

R9 Hysteresis volts DC 02.0

24 VDC Models

Range: 00.1 to 12.8

R9 Hysteresis volts DC 04.0

48 VDC Models

Range: 00.2 to 25.6

The hysteresis setting for relay number 9. There is an intentional 2-second time delay to reduce cycling.

Set Relay 10 volts DC 14.8

12 VDC Models

Range: 05.0 to 17.6

Set Relay 10 volts DC 29.5

24 VDC Models

Range: 10.0 to 35.5

Set Relay 10 volts DC 59.0

48 VDC Models

Range: 20.0 to 71.0

Sets the voltage trip point for the auxiliary relay number 10. This se tting is compensated for the battery temperature when using the BTS. There is no intentional time delay on the reaction for this setting. T his allows fast response to rapid voltage changes in the system.

R10 Hysteresis volts DC 01.0

12 VDC Models

Range: 00.1 to 12.8

R10 Hysteresis volts DC 02.0

24 VDC Models

Range: 00.1 to 12.8

R10 Hysteresis volts DC 04.0

48 VDC Models

Range: 00.2 to 25.6

The hysteresis setting for relay number 10. There is an intentional 2-second time delay to reduce cycling.

Set Relay 11 volts DC 15.0

12 VDC Models

Range: 05.0 to 17.6

Set Relay 11 volts DC 30.0

24 VDC Models

Range: 10.0 to 35.5

Set Relay 11 volts DC 60.0

48 VDC Models

Range: 20.0 to 71.0

Sets the voltage trip point for the auxiliary relay number 11. This se tting is compensated for the battery temperature when using the BTS. There is no intentional time delay on the reaction for this setting. T his allows fast response to rapid voltage changes in the system.

R11 Hysteresis volts DC 01.0

12 VDC Models

Range: 00.1 to 12.8

R11 Hysteresis volts DC 02.0

24 VDC Models

Range: 00.1 to 12.8

R11 Hysteresis volts DC 04.0

48 VDC Models

Range: 00.2 to 25.6

The hysteresis setting for relay number 11. There is an intentional 2-second time delay to reduce cycling.

INFORMATION DISPLAY

The following information is displayed as additional Menu Items.

Close on batt > setpoint. Open on batt < setpoint – hys. Relays have 2 seconds delay on close, 0.1 sec delay on open.

Page

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Telephone: 360/435-8826

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Part No. 2031-5

Rev. C: February 2001

MENU SYSTEM

BULK CHARGE TRIGGER TIMER (15) MENU HEADING

Set Start Bulk time 00:00

All Models

Range: 00:00 to 23:50

Starts the bulk charge process at the time shown. Setting to 00:00 defeats this function. This setting should be enabled when using the SLT mode so that the batteries are c harged once each day. With the GRID USAGE TIMER enabled, the START BULK TIME setting should be set near the beginning of the charging time window for best operation. Since the battery will usually be fully charged when this timer setting is reached, the battery charger will usually reach the ABSORPTION stage of the char ging process quickly and will then hold the battery near the SET BULK VOLTS DC setting for the ABSORPTION TIME setting (default time period is 2 hours ). This setting does not need to be adjusted if you are using FLT mode with a generator. This setting works with the AC1 HOT IN 1 input only.

INFORMATION DISPLAY

The following information is displayed as additional Menu Items.

To disable timer set to 00:00. If grid timer active set bulk time after start charge time. In SLT mode don’t disable this timer. It is daily chg time.

LOW BATTERY TRANSFER (16) MENU HEADING

Set Low Battery Transfer VDC 11.3

12 VDC models

Range: 05.0 to 16.5

Set Low Battery Transfer VDC 22.6

24 VDC models

Range: 10.0 to 33.0

Set Low Battery Transfer VDC 45.2

48 VDC models

Range: 20.0 to 66.0

This is the voltage at which the inverter transfers the loads from the battery to the utility grid. It is used only with the LBX and FLT modes. This setting is not tem perature c om pensated. T he transf er will occ ur only if the battery voltage remains below this setting for 20 seconds. The system returns to powering the AC loads from the battery once the battery voltage has reached the LOW BATTERY CUT IN setting. This setting works with the AC1 HOT IN 1 input only.

Set Low battery cut in VDC 13.0

12 VDC models

Range: 05.0 to 16.5

Set Low battery cut in VDC 26.0

24 VDC models

Range: 10.0 to 33.0

Set Low battery cut in VDC 52.0

48 VDC models

Range: 20.0 to 66.0

This setting controls when the inverter tur ns back on once it has shut off when the battery reached the LOW BATTERY CUT OUT VDC setting. It is also used to control when the system resum es powering the AC loads from the inverter when LBX mode is being used. In LBX mode, the best perfor mance will often be achieved if this setting is higher than the BULK and FLOAT VOLTS DC setting in order to reduce cycling of the system. The DC charging sourc es (wind, solar etc.) mus t then cause the battery voltage to rise above the charger settings before the system re sumes inverter mode operation. This s etting is not temperature compensated

INFORMATION DISPLAY

The following information is displayed as additional Menu Items.

See menu 9 to enable LBX mode. Make sure LBX is above LBCO volts.

 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

MENU SYSTEM

SW Series Inverter/Charger

BATTERY SELLING (17) MENU HEADING

Note: See the battery section of this manual for recommended settings for different battery types.

Set Battery Sell volts DC 13.4

12 VDC models

Range: 5.0 to 16.0

Set Battery Sell volts DC 26.8

24 VDC models

Range: 10.0 to 32.0

Set Battery Sell volts DC 53.6

48 VDC models

Range: 20.0 to 64.0

Sets the level to which the batteries will be discharged when power is being sold from the batteries to the grid. This is only used if the SELL m ode is enabled and the GRID USAGE TIMER (18) is programm ed. This setting will not be adjusted for the battery temperature if the temperature sensor is installed.

Set Max Sell amps AC 30

Standard models

Range: 01 to 35

Set Max Sell amps AC 15.0

“E” models

Range: 01 to 18

Set Max Sell amps AC 35

“J & K” models Range: 01 to 40

Set Max Sell amps AC 16.5

“W” models

Range: 01 to 18

Sets the maximum AC amps allowed to be delivered to the utility grid from a solar array and/or the batteries during utility interactive operation. This is only used if the SELL mode is enabled. If batteries are being “sold” into the utility grid, this setting together with the SET BATTERY SELL VOLTS DC setting determines the depth of discharge the batteries will experience. Note: The default setting will vary

between models with different continuous output power ratings.

INFORMATION DISPLAY

The following information is displayed as additional Menu Items.

See menu 9 to enable SELL mode. Make sure LBX is above LBCO volts.

GRID USAGE TIMER (18) MENU HEADING

The Grid Usage Timer selects when power may be drawn from the utility grid for battery charging. It is used only when either the FLT or SELL modes are selected in the SET GRID USAGE menu item under the INVERTER SETUP (9) m enu heading. Utility Power must be connec ted to the AC1 for this timer to be operational.

Start Charge time 21:00

All Models

Range: 00:00 to 23:50

End Charge time 21:00

All Models

Range: 00:00 to 23:50

FLT mode: After the START CHARGE TIME, the inverter turns on the battery charger, connects the

utility grid and powers the AC loads from the utility grid and charges the battery to the FLOAT VOLTS DC setting. At the END CHARGE TIME, the inverter disconnects from the utility grid and powers the loads from the battery.

SELL mode:

• With the GRID USAGE TIMER enabled (the START CHARGE TIME is different from the END CHARGE TIME), the inverter will charge the battery to the FLOAT VOLTS DC setting at the START CHARGE TIME. After the END CHARGE TIME, the inverter turns off the battery charger and begins

to “sell” power into the utility grid from the battery (or any other DC sources available and connected to the batteries) to the SELL VOLTS DC setting. The current will be limited to a maximum level controlled by the MAX SELL AMPS AC menu item setting under the BATTERY SELLING (17) menu heading.

• With the GRID USAGE TIMER disabled (the START CHARGE TIME beginning time is equal to the END CHARGE TIME), the inverter will use the utility grid (or any other DC sources available and

connected to the batteries) to maintain the batteries to the FLOAT VOLTS DC setting.

In the SELL mode, battery voltage will be held near the SET BULK VOLTS DC setting for the adjustable

ABSORPTION TIME period setting after an AC failure or upon encountering a BULK CHARGE TRIGGER TIMER event.

Page

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Telephone: 360/435-8826

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Part No. 2031-5

Rev. C: February 2001

MENU SYSTEM

In either mode, the SET START BULK TIME menu item setting under the BULK CHARGE TRIGGER TIMER (15) menu heading can be used to increase the battery charging regulation voltage to the BULK VOLTS DC setting.

Note: By setting the beginning time equal to the ending time, the grid usage timer feature is defeated. INFORMATION DISPLAY

The following information is displayed as additional Menu Items.

After Start Charge time: SELL mode charges battery. FLT mode charges battery. After End Charge time: SELL mode sells battery to AC1. FLT mode drops AC1 and inverts. Timer on when start <> end. Timer off when start = end; Sell and float modes use timer. SLT and LBX mode ignore timer.

INFORMATION FILE BATTERY (19) MENU HEADING

This Menu Heading provides additional information about the battery charging system. It has no user adjustable settings.

INFORMATION DISPLAY

The following information is displayed as Menu Items.

Batt temp comp changes battery voltage reading away from actual. HBCO resets at: 6v/48, 3v/24 and 1.5v12 under HBCO. LowBatt Transfer used in LBX, FLT modes only. Goes back to battery at LowBattCutIn (aka LBCI). For LBX mode set below LBCI so charger won’t cycle batteries up and down set LBCO below.

 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

MENU SYSTEM

SW Series Inverter/Charger

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

OPERATION

The SW Series Inverter/Char ger can be configured as a simple stand- alone unit, working in conjunction with your generator to handle loads too large for the generator alone, allowing two-wire or three-wire generators to be turned on and off based on battery voltage or loads amp s ize, or functioning as a utility interactive inverter which will allow you to send excess power back to the utility grid. Often, the inver ter will be set-up to operate in several modes at the same or different times - such as operating as an inverter/charger in utility back-up mode with automatic generator control mode and generator support mode during extended utility outage periods. The extensive c onfigurations available are described in this section will allow you to enhance and customize your inverter’s particular operation.

Before operating the SW Series Inverter/Charger, ensure that the unit is installed in accordance with the instructions in the INSTALLATION section beginning on page 15.

THEORY OF OPERATION

The SW Series inver ters employ a new patented inverter design. This design us es a combination of three transformers, each with its own low frequency switcher, coupled in series and driven by separate interconnected micro-controllers. In essence, it is three inverters linked together by their transformers.

Micro-

Controllers

Bridges are “mixed” by

Micro-Controllers

Controlling the H-Bridges.

Low

Frequency

Transformer

H-Bridge

Battery

Low

Frequency

Transformer

Loads

H-Bridge

Low

Frequency

Transformer

H-Bridge

Figure 17, Trace™ SW Series Inverter Simple Block Diagram

By mixing the outputs from the diff er ent tr ansformers, a sine wave is produc ed. Shown in F igure 18, is the output waveform from a Trace™ SW Series Inverter/Charger. Notice the “steps” f orm a staircase that is shaped like a sine wave. The total harm onic distortion in this sine wave approach is typically 3-5%. The multi-stepped output is formed by modulation of the voltage through mixing of the transformers in a specific order. Anywhere from 34- 52 “steps” per AC cycle are present in the waveform . The heavier the load or lower DC input voltage the more steps there are in the waveform.

This type of inverter solves many of the problem s associated with high frequency or ferroresonant sine wave inverters. The low frequency method desc ribed has excellent surge ability, high ef ficiency (typically 85 to 90%), good voltage and frequency regulation, and low total harmonic distortion.

The inverter runs in two basic f ormats: as a stand-alone inverter ( converting DC to AC), or as a parallel inverter (with its output synchronized to another AC source). In inverter mode, only 60 Hz (50 Hz for export units) waveforms are created. As the battery voltage rises, wavefor ms with progressively fewer steps are generated. More steps are used when battery voltage decreases. Since the battery voltage tends to drop with increased load, the waveform has increased number of steps with heavier AC loads.

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Telephone: 360/435-8826

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SW Series Inverter/Charger

Part No. 2031-5

Rev. C: February 2001

Page

OPERATION

SW Series Inverter/Charger

Figure 18, Trace™ SW Series Inverter Output Waveform The inverter is able to synchronize with other AC sources before connecting it to the AC load. The

frequency of the AC source is track ed and the inverter cons tantly adjusts its frequenc y to maintain a lock. A normally open contactor is used to parallel the inverter’s output and the AC source.

The inverter’s power topology is bi-directional. If the waveform c reated by the inverter has a higher voltage than the paralleled AC source, then power flows from the batteries to the load. If the wavef orm gener ated has a lower voltage than the AC source, power flows from the s ourc e to the batter y. The various modes of operation use different algorithms for determining the size of the waveform to be created by the inverter. In battery charger mode, for example, waveforms smaller than the AC source are created to cause current to flow into the batteries. This process is fully regulated to provide a three-st age charge c ycle. If the level of AC current exceeds the user progr ammed generator or grid size, and then the inverter will switch to a generator support mode and create wavef orms that are lar ger than the AC source. This c auses power to flow from the batteries to the AC loads to prevent overloading of the AC source.

In utility-interactive mode, the inverter can operate as a battery charger or paralleled AC source to the utility grid. If an external source such as solar panels attempts to raise the batteries above the float voltage setting, the inverter will try to hold the battery voltage at the float voltage level by “selling” the excess power into the utility grid. This is done by increasing the inverter’s output voltage level. This moves the excess DC power from the solar array to the AC utility grid, preventing the battery from being overcharged. If the utility grid connected to the inverter is de-energized, the inverter can not r egulate the battery voltage. Some external control device, s uch as Tr ace™ C40 Load/Charge controller, mus t be provided to prevent damage to the battery.

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Part No. 2031-5

Rev. C: February 2001

OPERATION

Power (VA)

POWER VS. EFFICIENCY

There are two primary losses that combine to create the eff iciency curve of the SW Series inver ter. The first is the energy that is required to operate the inverter at full output voltage while deliver ing no current. This is the no load or idle power. At low power levels, the idle power is the largest contributor to ef ficienc y losses. At high power, the largest source of loss is a r esult of the res istance in the trans former and power transistors. The power lost here is pr oportional to the s quar e of the output power. For ex ample, losses at 2000 watts will be four times higher than losses at 1000 watts. This graph represents a typical inverter’s efficiency while operating resistive loads. Inductive loads such as motors ar e run less eff iciently due to the impact of power factor losses.

100%

90%

80%

S W

2 6

1 2 E

2500

2750

SW3024E / SW304 8E

3000

3250

SW4024 / SW4048

3500

3750

4000

SW4548E

4250

4500

4750

SW5548

5000

5250

5500

70%

60%

50%

Efficiency

40%

30%

20%

10%

SW2512

250

500

750

1000

1250

1500

1750

2000

2250

Figure 19, Trace™ SW Series Efficiency Curves

The SW Series of f ers an ex trem ely good efficiency curve. The inver ter reac hes high ef f iciency at very low AC load levels, which is important because the inver ter often spends the m ajority of the tim e at the lower power range. The high efficiency is maintained over a wide power range. Only when operating at high power levels at or above the continuous power levels does the efficiency begin to drop off. Since this usually only occurs for short periods of time, the impact may be negligible.

If your application involves the inverter powering heavy loads for significant periods of time, selecting a model with a higher continuous power rating and a higher DC input voltage would improve the operation of the system. Since the low power efficiency of all the SW Series is extrem ely good, oversizing the inverter does not reduce system performance.

 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

OPERATION

SW Series Inverter/Charger

INVERTER CAPACITY VS TEMPERATURE

The current protection circuit in the SW Series Inverter/Charger is tem perature compensated, therefore the maximum s ized load that the inverter can run changes with temperature. As the temperature of the power devices (FET’s) inc rease, the allowable current is reduc ed. W hen the available current is reduced, the capacity of the inverter to run loads is reduced.

The graph below shows the effect tem perature has on the inverter’s c apacity to run loads, notice that the inverter reduces its capacity at temperatur e above 25 °C. The temper ature derating graph assumes that the inverter is at sea level and the airflow to the inverter is unrestricted.

Temperature Derating for SW Series Inverters

120

100

Percent

total

rated

power

capacity

25 32.5 40 47.5 55 62.5 70 77.5 85 92.5 100

Figure 20, Inverter Capacity vs. Temperature

Temperature °C

Page

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Part No. 2031-5

Rev. C: February 2001

OPERATION

OPERATING MODES

The SW Series Inverter/Charger can be used in a wide variety and combination of operating modes:

• Inverter Mode - DC to AC inverter with sine wave output, high starting sur ge, power saving search mode, low idle current, and very high efficiency DC to AC conversion.

• Charger Mode - Low AC current distortion, three stage, temper ature compensated, high amperage battery charger.

• Inverter/Charger Mode - Automatic transfer f rom inverter to battery charging upon presence of utility or generator AC power source.

• Generator Support Mode - Automatic “no glitch” switching from charger mode to inverter mode allowing the inverter to assist the generator in starting and powering lar ge loads . Adjus table gener ator support current and voltage thresholds.

• Automatic Generator Control Mode - Automatic generator starting, based on the battery voltage reaching an adjustable voltage setting or the AC loads exceeding an amperage setting. Both start conditions include adjustable time delays. Once started, the inverter operates in battery charger mode until battery is charged to the float stage or until the AC load is reduced. The generator is then s hut of f and the loads are powered from the battery through the inverter. Automatic generator exercising of the generator and adjustable quiet time period to reduce generator operation m ay be programmed in the setup menu.

• Utility Backup Mode - Phase synchronized fast AC transfer s witching for utility backup power supply applications. Includes adjustable AC transfer voltage and line conditioning ability.

• Utility Interactive Mode - Excess power from charging sour ces or stor ed power from the battery can be “sold” back into a utility grid. Also allows selling of the stored energy in the battery during a specific time period.

• Energy Management Mode - Onboard clock to set inverter and charger operating tim e periods . This mode can be used with “time of day” metering to shift energy consumption to off-peak periods.

• Peak Load Shaving M ode - Used to limit the draw of AC loads from a utility grid by powering it from the batteries. The batteries are recharged when the AC loads ar e reduced. This can “level” the load on a utility.

• Low Battery Transfer Mode - Automatic transfer of the AC loads from the batteries to the utility when the system reaches an adjustable low battery voltage setting. Independent settings allow control of when the AC loads return to battery once it is recharged.

Often, the inverter will be set-up to operate in several modes at the same or different times - such as operating as an inverter/charger in utility back-up mode with automatic generator control mode and generator support mode during extended utility outage periods.

ADDITIONAL FEATURES

Numerous additional features are provided to enhance and customize the inverter's operation for the various operational modes:

• Automatic generator control system with adjustable quiet time period to reduce generator operation.

• Three-stage battery charging with fully adjustable charge settings and battery temperature sensing.

• AC and DC voltmeters and AC ammeters to allow monitoring of inverter, generator, and utility grid.

• On-board 24-hour clock for programming of generator quiet time and utility interactive modes.

• Adjustable sellback current level for utility interactive mode.

• Two separate AC inputs for utility and generator sources with utility priority.

• Three independently adjustable auxiliary signal relays for controlling charging sources, loads etc.

 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

OPERATION

SW Series Inverter/Charger

INVERTER MODE

BATTERY INVERTER AC LOADS

DC AC

IN BRIEF

The inverter makes a stepped approxim ation to a sine wave. T he num ber of s teps typically varies from 34 to 52 per cycle. Lower battery voltage and/or higher output power level increases the number of steps. Higher battery voltage decreases the number of st eps. Distortion varies from 3% to 5%. The inverter is able to control the AC output voltage, allowing the inverter to also sell power into a utility grid or ass ist during the operation of heavy loads by operating in parallel with another AC power source such as a engine powered generator.

SEARCH MODE CONTROL

An automatic search m ode circuit is available to minim ize the power draw of the inverter when no loads are being operated. This reduces the power consum ption from 16 watts with no load to less than 1 watt (when using the default settings). To do this , the output is reduced to pulses of a single AC cycle with an adjustable delay between pulses. These pulses are used to detect the pr esence of a load. When a load is detected, the inverter’s output goes to full 120 VAC output. The sensitivity of the detection circuit and the spacing of the pulses are user adjustable using the Control Panel.

This feature can save a c onsiderable amount of power, particularly in smaller systems that do not have loads operating all of the time. In larger systems, this feature may not result in as much savings. If continuous operation of an AC load is required (such as when powering a microwave cloc k, VCR timer, computer, or fax machine), then using the search mode is not recommended.

To enable the search mode: Select SRCH mode from the SET INVERTER menu item, accessible by pushing the red ON/OFF MENU button. Pressing the red ON/OFF MENU button can also access the SRCH mode. It is also located as the fir st menu item under the INVERTER MOD E (1) menu heading. Pressing the red ON/OFF MENU button again will move the cursor one position to the right. T he SET POINT buttons can also be used to move the cursor right or lef t. To disable the search m ode, select ON from the SET INVERTER menu item.

Successful operation of the system utilizing the search mode requir es some initial tuning of the search mode settings to matc h the loads connected in the system. If the loads change significantly, re-tuning of the settings may be required. The benefit of the search mode c ircuit only is realized if the inverter is able to enter the energy saving search mode for s ubstantial periods of the day. Occasional checking of the yellow INVERT LED operation should be done to ensure that the search m ode is being used when all of the loads are turned off (it should blink slowly if it is searching for a load).

SETTING SEARCH MODE WATTS

The search mode is user adjustable to allow fine-tuning of its operation. The settings are located under the INVERTER SETUP (9) menu heading in the SETUP MENU. The following example explains the operation:

Example: W ith the SEARCH WATTS setting at 32, a 50-watt load will bring the inverter to full output voltage. However, a 30-watt load will leave the inverter in its energy saving search mode. If the sensitivity is increased by lowering the setting to 16, a 20-watt load will bring the inverter out of the sear ch mode, while a 5-watt load will not.

When in the sear ch mode, the yellow INVERT LED will blink slowly and the inverter will make a tick ing sound. At full output voltage, the yellow INVERT LED will stay on and the inverter will make a steady humming sound. W hen the inverter is used as an uninterruptible power supply, the search m ode should be defeated.

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Part No. 2031-5

Rev. C: February 2001

OPERATION

Example A: If the SEARCH WATTS is set at 32 and a 30-watt incandescent light is turned on, the inverter

will detect the light. The initial load of the bulb is muc h greater than 32 watts when its filament is cold. When the light gets bright, the f ilam ent heats up and the light bec om es a 30-watt load. Since this is below the setting of 32, the inverter will not detect it and the light will turn off. This can cause cycling of the inverter between on and off.

Example B: If the SEARCH WATTS setting is 32 and a 40-watt florescent light is turned on, the inverter will not detect the light. The light presents a sm aller load than 32 watts until the gas in the f lorescent tube ionizes and begins to glow. This problem is more common with the non-electronic type fluorescent bulbs.

Example C: There are some appliances that draw power even though they are turned off. TVs with instant on circuits, microwave ovens with digital displays and VCRs with clock s are examples. These loads can present a dilemma. If the SEARCH WATTS is set higher than the combination of these loads, then an additional load must be used to bring the inverter out of the search mode before the applianc es can be turned on. If the SEARCH WATTS is set lower than this combination of loads , then the inverter and the loads will be left on. This will put an additional drain on the batteries (three such 15-watt loads would amount to an additional 45 amp/hours per 24 hours in a 24 VDC system). One solution is to turn these items off by using an extension cor d with a rocker switch, a switched outlet, or a circuit breaker for the circuit. Unfortunately, this solution does not allow a clock to r etain its setting and may cause it to blink constantly while operating.

SETTING SEARCH MODE SPACING

The SET SEARCH SPACING menu item is calibrated in cycles. To test for loads once each second, adjust this setting to 59 (for 60 Hz models ) ; to test for loads about twice a second, adjus t the s etting to 30. NOTE: The lower the search spacing value – the less time it tak es f or the inverter to bring up a load. T he lower the setting), the greater the power consumption while in the sear ch mode, thus reducing power. The factory default value (59) is acceptable for most applications. The range is from 4 to 255.

LOW BATTERY PROTECTION

When the actual batter y voltage reaches the LOW BATTERY CUT OUT menu item setting f or the LBCO DELAY period, the inverter shuts off to prevent the battery from being over-discharged. If the inverter is

setup to automatically start a backup generator (Gen Auto Start Menu), then it will start once the battery reaches the LBCO setting for the selected time (30 seconds, etc).

Any of the following three conditions will return the inverter to normal operation, after a LBCO condition:

1. Power is applied to the AC HOT IN 1 or AC HOT IN 2 input term inals, allowing the inverter to operate as a battery charger.

2. The inverter is manually restarted by pushing the red ON/OFF button and selecting OFF and then SRCH or ON.

3. Battery voltage rises above the SET LOW BATTERY CUT IN menu item setting.

While the inverter is shut off due to the battery reaching the LOW BATTERY CUT OUT settings, the red ERROR LED will be illuminated. When the battery voltage increases to the LOW BATTERY CUT IN setting, the inverter will automatically turn back on and the ERROR LED will turn off.

ADJUSTING THE LOW BATTERY PROTECTION

There are three settings used to prevent over -discharge of the battery. These settings ar e located under the INVERTER SET UP (9) menu heading. See the SETUP MENU section for instructions on accessing these settings.

The SET LOW BATTERY CUT OUT menu item deter m ines the voltage level that the battery must r each f or it to be considered low. The inverter will continue to operate until the voltage has continuously remained below this setting for the time period from the SET LBCO DELAY menu item. Onc e the inverter has shut of f, the battery voltage must rise above the value from the SET LOW BATTERY CUT IN menu item.

The default LOW BATTERY CUT OUT setting may be lower than what is often recommended for m any applications by battery manufacturers. It is set to allow max imum performance f rom the inverter, not to maximize the life of the battery. If the system is properly designed, the inverter should not reach the LBCO setting very often. If the system is expected to utilize the LBCO c ontrol on a regular basis, then inc reasing this setting is recommended.

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SW Series Inverter/Charger

Part No. 2031-5

Rev. C: February 2001

Page

OPERATION

SW Series Inverter/Charger

CHARGER MODE

AC SOURCE CHARGER BATTERY

AC DC

IN BRIEF

When AC power is available, the inver ter can operate as a very powerful battery charger with low current distortion. Power is drawn over the full AC cycle. This improves the per f or mance with low AC input voltage or with small generators.

The SW Series Inverter/Charger includes the ability to automatically “back-off” the battery charger to prevent overloading a generator or tripping a circuit breaker when other AC loads are being operated through the inverter. This improves system reliability and allows greater use of the power available. The charger will also be turned off if the AC voltage drops to an adjustable lower limit VAC setting.

THREE STAGE CHARGING PROCESS

The charging cycle uses three stages. During the initial "Bulk Charge" stage, the inverter charges at maximum rate allowed by the SET MAX CHARGE AMPS AC setting. This causes the battery voltage to rise over time. After the batter y voltage nears the SET BULK VOLTS DC setting, the charger starts the second or “Absorption” stage. During this phase, the charge rate is gradually reduced while the battery voltage is held near the bulk voltage setting. This ensures that the battery is fully charged. The final "Float" stage is initiated when the battery has been held near the SET BULK VOLTS DC setting for the adjustable ABSORPTION TIME period setting. At this point, the battery voltage is allowed to fall to the FLOAT VOLTS DC voltage setting, where it is maintained until another bulk charge c ycle is initiated. This reduces gassing of the battery and keeps it fully charged. A new three-stage charge cycle is initiated after an AC source is reapplied to the AC HOT input terminals, or daily if the BULK CHARGER TRIGGER TIMER (15) is enabled and if AC power is available continuously.

Bulk Stage Absorption Stage Float Stage

Charging

Started

DC Voltage

AC Current

Increased Voltage Constant Voltage Reduced Voltage

Max Charge Amps

Setting

Constant Current Reduced Current Reduced Current

Time

Figure 21, Three-Stage Battery Charging

Bulk Volts Setting

Absorption Time

Float Volts Setting

If a generator was started autom atically by the

inverter to charge the battery, it will be shut off when

the charger reaches the float stage after the

bulk/absorption period. (GENERATOR must be in

AUTO mode)

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Part No. 2031-5

Rev. C: February 2001

BATTERY TEMPERATURE SENSOR (BTS)

A plug-in external Battery Temperature Sensor (BTS), which is provided, automatically fine-tunes the charging process of the battery charger in relation to temperature. When the temperature sensor is installed, the charge voltage is adjusted either higher or lower than the BULK and

FLOAT setpoints based on temperature. The BATTERY TEMP COMP VOLTS DC menu item under the METER S (4) menu heading shows this

adjusted charge voltage. If the temperature s ensor is NOT installed and if the battery is subjec ted to

large temperature variations, a shorter battery life cycle may be expected. Install the BTS on the side of the battery below the electrolyte level. It is best

if the sensor is placed between batteries and if the batteries are placed in an insulated box to reduce the influence of the ambient temperature outs ide the battery enclosure. Ventilate the battery box at the highest point to prevent hydrogen accumulation.

OPERATION

Figure 22, BTS (Battery

Temperature Sensor)

The BTS provided may be extended beyond the standard 15 feet by an additional 20 feet using standard telephone cables with RJ-11 plugs.

CHARGER ONLY OPERATION

When the CHG mode is selected, the inverter will operate only as a charger. Th is is usef ul f or unattended operation where a power failure might allow the inverter to drain the batteries by powering an AC load unnecessarily. To allow the Charger Only mode, FLT m us t be s elec ted f r om the SET GRID USAGE menu item under the INVERTER SETUP (9) menu heading in the SETUP MENU (FLT is the factory default setting).

This feature is comm only used in marine applications where the inverter operates a ref rigeration system from the batteries. Norm ally, the engine’s alternators keep the batteries charged. W hen docked, a shore cord is connected to the inverter to power the battery charger and run the refrigerator.

AC INPUT REQUIREMENTS

When an AC sour ce is applied to the AC input, the AC1 IN GOOD or AC2 IN GOOD LED indicator will blink slowly once the AC voltage has been detected. If the AC source is acceptable, the inverter will synchronize to it after a delay period has passed. Once synchronized, the inverter will close an internal relay, connecting the AC source to the AC loads, indicated by the green AC IN GOOD LED (ON solid), and begin charging the batteries, indicated by the orange BULK LED (ON solid).

The AC source, connected to the inverter ’s AC HOT IN 1 and AC HOT IN 2 term inals, is used to power both the battery charger and the AC loads while the inverter is in the battery charger mode. T here are several settings, listed below, that involve the AC INPUT. See the USER SETTING S WORKSHEET on page 123 for factory default settings.

INPUT AC VOLTAGE

The AC HOT IN 1 and AC HOT IN 2 inputs share the same upper and lower limits for restricting connection to an acceptable AC voltage operating window.

The AC input voltage window is typically set to the minimum / maximum range that the AC loads can tolerate - the inverter itself can operate over an extremely wide voltage range. The upper and lower settings are adjustable with the Control Panel and are located under the AC INPUTS (11) m enu heading in the SETUP MENU.

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SW Series Inverter/Charger

Part No. 2031-5

Rev. C: February 2001

Page

OPERATION

SW Series Inverter/Charger

AC CURRENT LEVEL

The maximum current draw into the AC HOT IN 1 terminal can be adjusted by the SET GRID (AC1) AMPS AC menu item. The maxim um current draw into the AC H O T I N 2 term inal can be adjusted by the SET GEN (AC2) AMPS AC menu item. These adj ustments are used to “back off ” the battery charger’s

AC current draw while other AC loads are being powered through the inverter. This prevents the overloading of the AC source and prevents nuisance tripping of the AC source circuit breakers.

FREQUENCY AC HOT IN 1 is the Utility Power connection point. The frequency tolerance is 53 to 67 Hz for 60 Hz

models (44 to 56 for 50 Hz m odels). The typical transfer delay is approximately 30 s econds once the AC HOT IN 1 terminals are energized. W hen the SELL m ode is enabled from the SET GRID USAGE menu

item, the transfer delay period is typically 90 seconds and the frequency tolerance is restricted to 58 to 62 Hz for 60 Hz models (48 to 52 Hz for 50 Hz models).

AC HOT IN 2 is used as a fuel-powered generator c onnection point. There is a default 60-second delay before transfer occurs. This gives the generator time to stabilize before being loaded. Frequency tolerance is 53 to 67 Hz for 60 Hz models (44 to 56 for 50 Hz models). The f uel-powered generator mus t be stable for the inverter to synchronize and connect.

DELAY PERIOD The delay period, approximately 30 seconds, occurs af ter the AC sour c e has been applied to the AC H OT

IN 1 terminal. If SELL mode is enabled (from the SET GRID USAGE menu item under the INVERTER

SETUP (9) menu heading) and a power outage occurs, reconnection back to the utility power will be delayed for a period of at least 90 seconds. This delay allows the utility distribution system to stabilize before the inverter resumes selling power back to the utility. It is not adjustable.

The delay period for the AC H OT IN 2 ter minal is adj ustable through the SET GEN WARMUP SECONDS menu item under the GEN STARTING DETAILS (13) menu heading. This allows the generator to reac h a stable operating condition before being loaded. The default generator warm-up period is 60 seconds. Once warmed up, the inverter synchronizes to the generator. If the AC source is not stable, the inverter may not be able to synchronize and will not connect. If the generator runs for 5 minutes without the inverter being able to connect, then the generator will be shut off and the ERROR LED indicator will be illuminated. A GENERATOR SYNC, YES error condition will be displayed in the ERROR CAUSES (5) menu heading on the Control Panel.

RECOMMENDED BATTERY CHARGER SETTINGS

The settings for the battery charger primarily depend upon the battery chemistry and construction. Other factors such as usage, age and battery bank size need to be considered as well. T he battery charger settings will automatically adjust if the temperature c ompensation sensor is installed. If it is not installed, the settings should be adjusted manually to allow for the typical battery temperature. This may require seasonal readjustment for optimum performance.

The default settings are typical values for liquid, lead acid battery applications. They will work satisfac torily for many systems.

CAUTION: To prevent battery damage and achieve maximum performance, adjust the battery charger settings to the manufacturer’s recommendations. NiCad (or alkaline) battery users must also adjust the SET TEMP CO MP menu item setting. The battery charger settings are located under the BATTERY CHARGER (10) menu heading in the SETUP MENU.

The SET MAX CHARGE AMPS AC menu item will need to be reduced if you are using a small battery bank. High charge rates can caus e a small battery to overheat. This may cause dam age and is not an efficient way to recharge the battery. With the Control Panel, adjust the charger for a maximum rate that is less than 1/5 of the battery capacity for efficient recharging. For ex ample, if the battery is rated at 500 amp-hours, set the m aximum charge rate for 100 amps DC. Since the setting is adjus ted in amps AC drawn by the battery charger, divide the DC charge rate by 8 for 12 volt systems, 4 for 24 volt systems and 2 for 48 volt systems (these f actors are for 120 VAC systems and include the power lost in the battery charger). If the exam ple battery bank of 500 amp hours was a 24 volt system, the m aximum AC amps setting should be around 25 amps AC (500 x 1/5 = 100 amps DC, 100 / 4 = 25 amps AC

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Part No. 2031-5

Rev. C: February 2001

OPERATION

Once the battery voltage nears the BULK VOLTS DC setting, the voltage will be held at this level while the current into the battery tapers off. The tim e allowed for this tapering period is called the ABSORPTION TIME period. This setting is very important for systems which us e generator s sinc e it deter mines how long a generator will run and when the generator shuts off. Using a gener ator to “trickle” charge a battery is not efficient and should be avoided. Some users may want to decrease the ABSORPTION TIME to keep generator-running time to a minimum. T his may result in the batteries not being fully charged. The higher the BULK VOLTS DC setting and the longer the ABSORPTION TIME period, the more f ully charged the battery would be when the charger is shut off. Of ten, the generator is used only to “BULK CHARGE” the battery and the solar array is allowed to trickle charge the battery to a full charge condition.

The following chart provides a guideline in setting the battery charger s ettings for several differ ent types of batteries. The battery manufacturer is the best source of information and should be consulted if your battery type is not shown. Since the settings also depend on the system design, other factors may apply.

Table 4, Charging Setpoints For Common Battery Types

TYPICAL BULK AND FLOAT SETPOINTS FOR COMMON BATTERY TYPES

Battery Type Bulk Volts Float Volts Equalizing Charge Process

Sealed Gel Lead Acid battery

A.G.M. Lead Acid battery

Maintenance-Free RV/Marine Lead Calcium Battery

Deep-Cycle, Liquid Electrol yte Lead Antimony Battery

NiCad or NiFe Alkaline Batte ry* (using 10 cells in series )

14.1 VDC BULK 13.6 VDC FLOAT Not Recommended - Consult manufacturer

14.4 VDC BULK 13.4 VDC FLOAT Charge to 15.5 VDC or as per manufacturer

14.4 VDC BULK 13.4 VDC FLOAT Not Recommended - Consult manufacturer

14.6 VDC BULK 13.4 VDC FLOAT Charge to 15.5 VDC or as per manufacturer

16.0 VDC BULK 14.5 VDC FLOAT Consult manufacturer

Note: Values shown are f o r 12 vol t syste ms. For 2 4 vo l t syst em s mul ti p l y the sett i ng s shown by 2. For 48 volt systems multiply the settings shown by 4. These settings are guidelines, refer to your battery manufacturer for specific settings.

EQUALIZING BATTERIES (UNSEALED OR VENTED BATTERIES ONLY)

In many of the inverter/charger applications, batteries are subjected to less than ideal operating conditions. This can result in significant differences in the state-of-charge level between the individual battery cells. Furthermore, the low charge rates and ex tended periods at par tial char ge levels c an res ult in both stratified battery electrolyte and inactive areas of battery plate material. If the condition is allowed to remain for extended periods of time, the battery can “sulfate” and become unusable.

To correct this condition, m any manufacturers recomm end a periodic “equalization” charge to mix up the electrolyte, re-activate unused battery plate material, and bring up all of the individual cells to a f ull s tate of charge. This requires that the batter y be given a controlled “overcharge” by increasing the charge voltage for a limited period of time. The voltage and time required are both dependent upon the amount of correction required. The mor e frequently the batteries are equalized, the lower the equalize voltage and shorter the time period.

Equalizing a battery is only recommended on unsealed or vented batteries. T he process will cause the electrolyte to gas and will release hydrogen and oxygen in the process. The chance of explos ion due to the accumulation of these gasses is therefor e a r ealistic hazard. T he batteries must be provided with good ventilation with no ignition sources present. Some us ers have f ound that the batter y cell caps are subject to clogging during an equalization charge and therefore remove them during this process. Since the batteries may rapidly bubble while being charged, it is advised that the battery be refilled only after the equalization process is finished (if the battery electrolyte level is low, add enough to cover the plates before charging).

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SW Series Inverter/Charger

Part No. 2031-5

Rev. C: February 2001

Page

OPERATION

SW Series Inverter/Charger

The battery manufacturer or supplier s hould be consulted before equalizing to provide the recom mended process and settings. During the equalization process, check the temperature of eac h battery every hour by momentarily feeling the battery case. If the batteries are excess ively warm (too hot to keep your hand on), terminate the charging immediately. Let the batteries cool before checking the need for further equalization charging.

A manual or automatically controlled equalization charge process is available in the SW Series Inverter/Charger. This equalization process can be powered by any AC source. The SET EQUALIZE TIME H: M menu item under the BATTERY CHARGING (10) menu heading sets the amount of time that the battery voltage must exceed the SET BULK VOLTS DC setting before the equalization process is completed. This tim er is an acc umulating type and does not reset if the voltage m omentarily drops below the bulk voltage setting. During the equalization process, the voltage is limited to the level of the SET EQUALIZE VOLTS DC menu item under the BATTERY CHARGING (10) menu heading.

To start the equalization process (either manually or automatically):

Select EQ from the SET GENERATOR menu item, by pressing the green GEN MENU button on the Control Panel. During the equalization process, the BULK LED will flash slowly to indicate that the EQ position has been selected from the SET GENERATOR menu item.

To manually equalize the batteries, AC power must be available at the AC HOT IN 1 (utility power) or AC HOT IN 2 (generator) terminals. If utility power is not available, the generator m ust be manually started. The inverter uses this power to start the battery charger and begin the equalization process. Equalization will continue to run for the amount of time programmed. When the equalization process finishes, the FLOAT LED will come on (as long as utility or generator power is still available).

NOTE: If the generator was manually started to equalize the batteries, it must be manually shut off once equalization has completed. Return the cursor to the OFF position in the SET GENERATOR

menu item (accessible by pressing the green GEN MENU button on the Control Panel). If the automatic generator control system is selected, the inverter will complete an equalization charge

process during the next - automatically started - generator run period.

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Part No. 2031-5

Rev. C: February 2001

INVERTER/CHARGER MODE

UTILITY GRID

INVERTER/

CHARGER

OPERATION

AC LOADS

GENERATOR

BATTERY

IN BRIEF

The SW Series Inverter/Charger is capable of autom atically transferring AC loads from the inver ter to a utility grid or generator. Once transferred, the inverter can recharge the battery. The inverter/charger can transfer upon the availability of AC power (FLT mode), either at a spec ific tim e each day (using the GRID USAGE TIMER (18) menu heading), or upon a low battery condition (LBX mode).

TRANSFERRING UPON AVAILABILITY OF AC POWER

When AC power is supplied to the AC HOT IN 1 or AC HOT IN 2 input, the inverter automatically transfers from inverter mode to battery charger mode. Before transferring, the inverter verifies that both the AC input voltage and frequency are within tolerance. It then synchronizes waveforms and c onnects to the inverter’s AC output without interruption of power.

The FLT mode is the default mode ( see the GRID USAGE menu item under the INVERTER SET UP (9) menu heading) and may be used with AC power supplied to either the AC HOT IN 1 or AC HOT IN 2 input. This is the proper m ode for most utility connected applications or for use with a back-up generator that is being manually or automatically started.

The SLT m ode is used only with AC power supplied to the AC HOT I N 1 input. The SLT m ode is selected from the GRID USAGE menu item under the INVERTER SETUP (9) menu heading. In this mode, the only operational difference is that the battery charger will only be engaged for a single period of tim e each day, set by the BULK CHARGE TRIGGER TIMER (15) menu heading setting. This reduces the power consumption of the inverter over the period of a day. It is also us ed in applications where the slight noise of the inverter might be undesirable, such as at night. AC power continues to be passed through the inverter’s transfer relay while the charger is not engaged. If the AC source fails, the inverter will turn on automatically and power the connected AC loads. When utility power returns, the AC loads will be reconnected to the utility and the battery charger will complete a bulk charge cycle. Once this has been completed the battery charger will turn off, but the loads will remain connected to the utility.

TRANSFERRING BA SED ON BATTERY VOLTAGE

The LBX mode is used only with AC power supplied to the AC HOT IN 1 input. The LBX mode is selec ted from the GRID USAGE menu item under the INVERTER SETUP (9) menu heading. In this mode, the decision to transfer to and from charger m ode will be based upon the battery voltage. W ith LBX enabled, the SET LOW BATTERY CUT IN VDC setting and the SET LOW BATTERY TRANSFER VDC setting determine the DC transfer voltages. W hen the battery voltage reaches the LOW BATTERY TRANSFER VDC setting for more then 20 seconds, the AC loads are transferred from the inverter to the utility. If the battery voltage reaches the LOW BATTERY CUT IN VDC setting, the AC loads are transferred from the utility to the inverter. The low battery transfer system includes a 20 second delay so that large loads are less likely to cause a transfer to the utility grid during motor startup, etc.

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SW Series Inverter/Charger

Part No. 2031-5

Rev. C: February 2001

Page

OPERATION

SW Series Inverter/Charger

While connected to the utility, the battery charger will be engaged. Some applications may want to allow the alternate power source (solar, wind or hydro) to recharge the battery instead of allowing the utility to provide the power. The only option is to program the SET MAX CHARGE AMPS AC menu item under the BATTERY CHARGING (10) menu heading to the minimum value, 1 am p AC, and set the BULK VOLTS and FLOAT VOLTS settings, also under the BATTERY CHARGING (10) menu heading, to a low value.

TRANSFER TIME

Normally there is no transfer tim e from the inverter to utility power or generator. The inverter operates in parallel with the AC source at all times - even when battery charging. This allows the trans f er f r om inverter to the utility grid or generator to be interruption-free and virtually unnoticeable.

However, in SELL mode, when the utility grid fails, the inverter will reach the overcurrent protection system setting (since it is will try to power everything that is connected to the grid). The inverter will momentarily shut off while it opens the inter nal AC input r elay. Once the relay has opened, the invert er will begin to operate within a single cycle. This results in a 20 millisecond transfer period. Most AC loads, including computers, will not be affected during the transfer.

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Part No. 2031-5

Rev. C: February 2001

GENERATOR SUPPORT MODE

OPERATION

GENERATOR AC LOADS

AC AC

INVERTER/

CHARGER

BATTERY

IN BRIEF

The factory default settings are intended to operate the inverter as an inverter/charger connected to a generator. When the generator is off, the inverter will power the AC loads from the battery. Once the generator is started, the AC loads will be transferred to the generator and the inverter will become a battery charger and store the unused power in the batteries f or later use. The inver ter will automatically limit the draw of the battery charger to prevent overloading the generator. When the generator is turned off it will be disconnected and the inverter will instantly take over and power the AC loads from the batteries. Generator support does not require that the automatic generator control system be used.

To operate in this mode the system must be set-up as follows:

• Connect the generator AC output to the inverter’s AC HOT IN 2 and NEUTRAL IN 2 terminals.

• Connect the AC loads to the inverter’s AC HOT OUT and NEUTRAL OUT terminals.

• Adjust the battery charger parameters to m atch the requirements of the batteries connected (if the

factory defaults listed in the technical section are not satisfactory).

• Adjust the SET GEN (AC2) AMPS AC menu item located in the AC INPUTS (11) menu heading, to the continuous output ability of the generator. This allows the generator s upport feature to function correctly, preventing the generator from being overloaded. The gener ator’s output should be de-rated for altitude and if propane or natural gas is the power source. It is best to err or on the low side for this setting, or to experiment with higher settings after the system has been operational.

• Adjust the SET INPUT LOWER LIMIT VAC located in the AC INPUTS (11) menu heading, to the lowest AC voltage that the AC loads can tolerate. If the gener ator is pulled down to this level while powering a load, the inverter will back-off its battery charging or even oper ate in parallel to reduc e the load on the generator. Keep in mind that when the inverter supports the generator it uses energy from the batteries to power the AC loads. Therefore, when generator support occurs, the batteries can be discharging instead of recharging even though the generator is running.

• Adjust the SET INPUT UPPER LIMIT VAC located in the AC INPUT (11) menu heading, to the highest voltage that the generator will be allowed to operate without being considered out of tolerance. At this voltage the inverter will disconnect to protect the AC loads. W hen the voltage returns to the operating window, the inverter will require a minimum of 20 seconds to re-synchronize and connect the generator to the loads.

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Telephone: 360/435-8826

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SW Series Inverter/Charger

Part No. 2031-5

Rev. C: February 2001

Page

OPERATION

SW Series Inverter/Charger

GENERATOR SUPPORT/OVERLOAD PROTECTION

This battery charger is quite powerful and, without limits, could overload a generator. When the generator is running, it has to power both the battery charger and any connected AC loads. If the AC load current, combined with the charge current, exc eeds the SET GEN (AC2) AMPS AC setting, the charge rate will automatically be reduced to avoid overloading the generator or tripping its circuit breaker.

If the amount of current demanded by the AC load is greater than the GEN (AC2) AMPS AC setting, the inverter is capable of supplementing the generator’s power. The inverter attempts to hold the current drawn from the generator at the setting of the GEN (AC2) AMPS AC. This allows the generator to start larger loads than it could normally and reduces the load on the generator during motor start-ups.

Generator support is also available if AC voltage falls to the SET INPUT LOWER LIMIT VAC. In this case, the inverter will assist the generator as long as there is power flowing from the generator to the load. This is typically used when a large AC load is being operated and the generator’s AC output voltage drops.

For example, if you have a 20 amp generator and the GEN SIZE AMPS AC setting is at 15 amps, the inverter will start providing additional power from the batteries whenever the load reaches 15 amps or higher (even though it may not be required). When setting the GEN SIZE AMPS AC value, allow for headroom but do not set the value too low.

While the inverter is suppor ting the generator, the BULK or FLOAT LED Indicator will remain on even though the inverter may not be battery charging. The INVERTER/CHARGER AMPS AC meter will indicate the support process by displaying “negative” current flowing from the inverter to the loads. The INPUT AMPS AC will also drop during this process while the LOAD AMPS AC remains the same.

120 VAC VS. 120/240 VA C GENERATORS

In the US, generators are available with either 120/240 VAC “split phase” or 120 VAC only output. Some generators can be rewired in the field, or have a switch, for changing from one output to the other. If a system uses only one inverter, having the generator put out all of its power at 120 VAC is advantageous. If two inverters are used, having the generator wired for 120/240 VAC output is better.

If you are using one inverter and can not rewire your generator for 120 VAC, or have a com bination of 120 and 240 VAC loads which need to be operated, you may need to include a balancing transformer to allow full use of the generator output at 120 VAC. This allows the battery charger to use power from both “halves” of the generator, instead of only half of it. Xantrex of f er s a balancing tr ans f ormer (Part Number T-

240) for this purpose. See OTHER PRODUCTS section on page 129 or contact your inverter supplier for more information.

If your generator can be wired for 120 VAC output and you are using only one inverter, 240 VAC loads can be operated from the system by using a transform er in a step-up conf iguration. This is c omm on for deep well submersible well pumps. If the step-up is done on the pump side of the pressur e switch or manual switch for the pump (run 120 VAC through the switch then step it up to 240 VAC), the transf orm er will not interfere with using the search mode or increase idle current draw by the inverter when the pump is off.

When two inverters are operating in a “series stacked” configuration (120/240 VAC); each inverter operates as a separate inverter. One inverter can be battery charging with the excess power fr om one half of the generator, while the other inverter is supporting the generator by operating in parallel to support a heavy 120 VAC load on that half of the system. This allows greater utilization of limited system capacity and is very useful when starting large 120 VAC loads such as water pumps or compressors.

Two 120 VAC/60 HZ inverters can be used to provide 240 VAC. T his provides both 120 and 240 VAC since a center “neutral” is provided between the two inverters. If a 240 VAC only AC source is c onnected to the AC input terminals of the inverter without this center neutral, unacceptable operation will r esult. To allow connection of a 240 VAC only source, a small (500 VA) autotransform er m ust be connected acros s the 240 VAC input and to the AC neutral terminals of the inverters. This will allow the inverter to oper ate properly. No transformer is requir ed on the AC output side - the 240 VAC can be taken directly from the two AC hot output terminals (one from each inverter).

Page

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

Telephone: 360/435-8826

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Part No. 2031-5

Rev. C: February 2001

AUTOMATIC GENERATOR CONTROL MODE

OPERATION

GENERATOR AC LOADS

CONTROL

INVERTER/

CHARGER

BATTERY

IN BRIEF

Automatic start/stop contr ol of a back -up generator can be us ed with any of the other oper ating m odes. If used with an application that includes utility power, the generator will be started only if the utility power is not available. It is not possible to use both generator and utility power at the same time. If the generator is manually started while the inverter is connected to utility power, the inverter will ignore the generator and not connect to it. W ith utility power connected to the AC HOT IN 1 terminals, the autom atic gener ator start and stop control is disabled.

Extensive control of automatic generator operation is available through the items under the menu headings GEN AUTO START SETUP (12), GEN STARTING DETAILS (13) and GENERATOR TIMER (7). The generator can be set to start based on four diff erent low battery voltage levels with diff erent delay times for each. A quiet tim e period can be set that restricts the generator from starting during defined hours of the day. The generator will be started during the quiet time period only if the battery voltage reaches the setting of the SET LOW BATTERY CUT OUT VDC MENU ITEM for a continuous 30- second period of time.

To operate in this mode the system must be set-up as follows:

• Connect the generator AC output to the inverter’s AC HOT IN 2 and NEUTRAL IN 2 terminals.

• Connect the AC loads to the inverter’s AC HOT OUT and NEUTRAL OUT terminals.

• Select AUTO f rom the SET GENERATOR menu item, accessed by pressing the green GEN MENU

button. The AUTO mode is dis abled if the CHG mode under INVERTER MODE (1) menu heading is selected.

• Adjust the battery charger parameters to m atch the requirements of the batteries connected (if the factory defaults listed in the technical section are not satisfactory).

• Adjust the SET GEN (AC2) AMPS AC menu item, located in the AC INPUTS (11) menu heading, to the continuous output ability of the generator. This allows the generator s upport feature to function correctly, preventing the generator from being over loaded. The generator’s output should be derated for altitude and if propane or natural gas is powering it. It is best to error on the low side for this setting, or to experiment with higher settings after the system has been operational.

• Adjust the SET INPUT LOWER LIMIT VAC menu item, located in the AC INPUTS (11) menu heading, to the lowest AC voltage that the AC loads can tolerate. If the generator is pulled down to this level while powering a load, the inverter will back-off its battery charging or even operate in parallel to reduce the load on the generator. Keep in mind that when the inverter supports the generator it uses energy from the batteries to power the AC loads. Therefore, when generator support occurs, the batteries can be discharging instead of recharging even though the generator is running.

• Adjust the SET INPUT UPPER LIMIT VAC menu item , located in the AC INPUT (11) menu heading, to the highest voltage that the generator will be allowed to operate without being considered out of tolerance. At this voltage the inverter will disconnect to protect the AC loads. When the voltage returns to the operating window, the inverter will require a minimum of 20 seconds to re-synchronize and connect the generator to the 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

OPERATION

SW Series Inverter/Charger

GEN CONTROL RELAYS

CAUTION: All circuits connecting the auto generator control system M UST be protected with fuses rated at 5 amps o r less. T he warranty does not cov er damage to these relays.

Fuses should be located as close as possible to the point of connection to the lar ger conductors providing power from the battery. A fuse mus t be used, even if the c ircuit is providing only a “dry contact” or “ground” connection - it will prevent dam age if the connection is miswired or if the cable connecting the inverter to the generator is damaged.

The generator control relays are not intended to directly control the starter motor or operate the ignition system - rather they are used to send a signal to operate the coil of another higher amperage device which does the actual switching of power. For location and wiring inform ation on the GEN CONTROL RELAYS, see AUXILIARY AND GENERATOR CONTROL RELAY on page 14.

The SW Series Inverter/Charger provides two relays, labeled RY7 and RY8, to allow starting of many types of generators. Two LED indicators provide status indications whether RY7 or RY8 have been energized.

The relay labeled RY7 is used to provide either a STOP signal or a RUN signal. It can also be used to provide a GLOW signal on diesel generators with glow-plugs. The relay labeled RY8 is used to provide a crank signal for the starter of the generator engine. It is not used on two-wire type (auto cranking) generators. The COM (comm on) term inals of the relays are separated and both the N.O. (nor mally open) and N.C. (normally closed) contacts of the relays are provided.

It is much easier to m ake the connections to the generator if a remote control terminal or connector is available on the generator. This sometimes requires that the generator optional remote control be purchased. This also allows exam ination of how the generator rem ote control works - which is what the inverter’s generator control system in the inverter must duplicate.

Connection of the GEN CONTROL RELAYS to the generator remote control also eliminates the need to modify the generator and violate the warranty of the generator.

You should also add a switch to allow disabling of the automatic generator contr ol s ystem at the gener ator to allow local control of the generator, preventing starting while servicing, etc. Many generators include this switch with the optional remote control.

GENERATOR STARTING SCENARIOS

The generator can be set to start based on the four following scenarios:

AUTOMATICALLY

(1) AC Current: The generator starts whenever the current travelling through the inverter to the AC

loads remains above the LOAD START AMPS AC setting for the selected LOAD START DELAY MIN period. T he current can be m onitored by the LOAD AMPS AC menu item under the METERS menu. The generator will start, unles s the tim er is in the “quiet tim e” period, at which time it will only start if the READ LBCO 30 SEC START VDC setting is reached. W henever the generator starts automatically, based on load amps, it will shut off once the load current drops below the LOAD START AMPS value for the selected LOAD STOP DELAY MIN period.

(2) Battery Voltage: The generator starts whenever the battery voltage reaches one of the four

adjustable low battery voltage levels for the selected delay periods (24 hours, 2 hours, 15 minutes, or 30 seconds). The low battery voltage levels are set under the GEN AUTO START SETUP. Actual battery voltage can be monitored from the BATTERY ACTUAL VOLTS DC menu item under the METERS menu. The generator will start, unless the timer is in the “quiet time” period, at which tim e it will only start if the SET LOW BATTERY CUTOUT VDC or READ LBCO 30 SEC START VDC setting is reached. Whenever the generator starts automatically, based on low battery voltage it will shut off once the BULK and ABSORPTION stages of the battery charging have completed, thus fully recharging the batteries.

Page

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

Telephone: 360/435-8826

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Part No. 2031-5

Rev. C: February 2001

OPERATION

(3) Time (Exercise Period Days): The generator is automatically started at a pre-selected time

whenever it exceeds a set number of days without running. Once the start comm and is initiated, the generator starts and runs for 15 minutes to ensure that it remains f ully operational and that the generator’s starting battery is maintained at an optimal state of charge. To set generator start time, go to END QUIET TIME under the GENERATOR TIMER menu. To set the number of days between exercise periods, go to SET EXERCISE PERIOD DAYS under the GEN AUTO START SETUP menu. If the value is s et to 10, the generator will start every tenth day of c ontinuous nonoperation. To disable this feature, set the value to zero.

MANUALLY

(4) M anual Start – T he generator can be m anually started by selecting ON from SET GENERATOR

directory under the GENERATOR MODE menu. In manual mode, the generator MUST be manually switched OFF by selecting OFF from the SET GENERATOR menu item.

GENERATOR STARTING AND STOPPING CONFIGURATIONS

Two different generator start routines are available to allow use with a wider variety of generator types. The sequence of closing and opening of the RY7 relay changes depending upon what position the underlining cursor is in fr om the SET RY7 FUNCTION menu item under the GEN STARTING DETAILS (13) menu item. The choices are GLOWSTOP or RUN.

When RUN is selected as the func tion of the RY7 relay, the RY7 COM and RY7 N.O. contacts remain closed while the generator is running. This is usually wired to the ignition system of the generator engine and/or a fuel solenoid valve. The norm ally closed contacts of this relay are also available on the term inal block, mark ed RY7 N.C. The normally closed contact is open ( not connected to the common terminal) while the generator is running. W hen the generator is off , the RY7 N.C. terminal is c onnected to the RY7 COM terminal. This configuration is us eful for starting many HONDA brand gener ators as well as som e others. This should also be used to select when the RY7 COM and RY7 N.O. contacts are used to control a two wire (auto crank) type generator.

When GLOWSTOP is selected as the function of the RY7 relay, the RY7 COM and RY7 N.O. contacts remain open while the generator is running. T he contac ts clos e only when it is time for the gener ator to be stopped. This is useful for generators that require a stop signal to shut down the generator. The GLOWSTOP configuration is useful for starting ONAN brand generators.

The GLOWSTOP setting can also be used for diesel generators. The RY7 COM and RY7 N.O. contacts will be closed during the PRE CRANK SECONDS period. This relay can be used to provide both the GLOW and STOP signals. When this is done the gener ator will be given both GLOW and STOP signals before cranking and when stopping. This is done on many diesel generators by their own starting systems. You should also check that the control system also powers the glow plugs during the cr anking signal - the generator manufacturer or dealer can provide more information.

The terminals RY8 COM and RY8 N.O. provide contacts that remain closed only during the gener atorcranking period. This is usually wired to the starter solenoid (relay) of the generator engine. This relay closes after an initial PRE CRANK delay period (the default MAX CRANKING SECONDS period is 10 seconds). Relay RY8 will open after a half-second delay, once the inverter senses an AC voltage above 80 VAC on the AC HOT IN 2 terminals. If the voltage r emains for the POST CRANK period, relay RY8 will remain open. If the generator doesn’t start, it will close again after a POST CRANK delay period. The inverter will attempt to start the generator up to 5 times (the number of times the inverter tries to start the generator is fixed at 5 attempts). If the required voltage level is not reached, relay RY7 opens (in RUN mode) to “kill” the gener ator before a restar t is attempted. T his reduces the chanc e that the starter m otor will be engaged on a spinning generator engine. This protection is inherent in the GLOWSTOP mode.

The generator will be stopped when the battery charger has kept the tem perature compensated battery voltage near the BULK VOLTS DC setting for the ABSORPTION TIME period.

When it is tim e to stop the generator, r elay RY7 will open or close (depending on which RY7 FUNCTION is selected), stopping the generator. This will occur af ter a 40 second cool down period. If the generator does not stop, the inverter will continue to charge the battery at the FLOAT VOLTS DC.

The transfer f rom generator to inverter will be less notic eable if you manually turn off the generator f rom the inverter’s Control Panel instead of from the generator’s off switch. This allows the inverter to first disconnect the generator before it is turned off, reducing problems with voltage sags during the transition.

 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

OPERATION

SW Series Inverter/Charger

GENERATOR AUTO START REQUIREMENTS AND TYPES

In order for the generator to be automatically started, it must include electric star t and an automatic choke. An automatic primer system m ay also be required on natural gas and propane powered generators. The generator should also include remote s tart ability with accessible remote start term inals or a connector. Protective systems for low oil pressure, over temperature, starter lockout and over crank control are valuable features that will prevent generator damage and increase system reliability. “Two wire” start generator are recommended highly because of the greater simp licity for automatic starting and because they are intended for remote/automatic/unattended operation.

Generators used can be fueled by gasoline, propane or diesel f uel. Propane is often the best choice for residential applications due to the ease of fuel storage and delivery, cost, safety, and ease of starting. Since propane is required for the cooking stove, water heater and space heating as well, most r esidential applications will already have a tank and propane service. Gasoline is als o com m on, but c an be diff icult to transport and store on site safely. Most sm all generators do not hold much fuel in their built-in tanks refitting the generator to use mar ine outboard motor type fuel tanks is often a good solution for limited fuel capacity. This eliminates the need to pour fuel into the tank of a hot generator - which can be very dangerous. Diesel is a much safer fuel to use and store. Diesel generators can operate with very little maintenance and have very long lives. The only problems with diesel are the higher initial cost, dif ficulty with starting in cold weather and possible need for the additional control of the glow plugs before starting.

Generators can be either air or water-cooled. W ater-cooled units are usually more quiet but can r equire more maintenance. Low speed (~1800 / 1500 rpm) generators are pref erred by many system designers as they often provide longer life due to less mechanical wear and tear.

TWO WIRE START GENERATORS Generator starting requirem ents c an be divided into two categories – t w o - w ire st art types and three-wire

start types. The two-wire start type generator is more simple and the eas ies t to automate. To star t, simply

connect the two “remote control” wires together and it starts. The generator provides its own cranking control circuit for star t-up. To stop, simply disconnect the two wires. The wires can be connected by a switch or relay. To enable automatic start, connect the two wires from the generator to Relay RY7 COM and RY7 N.O. of the inverter and c onnect the generator output to AC HOT IN 2 input of the inverter. Two wire start generators are specifically designed for unattended operation and usually include all of the safety and protection devices from the factory. They are highly recommended due to the ease of hook -up and troubleshooting that they allow.

GEN CONTROL RELAYS 2 WIRE TYPE GENERATOR

RY7

COM

N.O.

5 AMP

FUSE

REMOTE

START/STOP

TERMINALS

Figure 23, Two Wire Start Wiring Diagram

When a two-wire start type generator is used, multiple loads can signal the generator to run. A good example is a float switch in a water stor age tank. When the water level dr ops, the float switch clos es a set of contacts, which signals the generator to r un. When the tank is full, the float switch opens its contac ts and the generator stops. The float switch can be used in parallel with the autom atic control system of the inverter. Either “switch” can start the generator. This allows easy automation of the entire s ystem. F or this type of generator, select RUN from the SET RY7 FUNCTION menu item under the GEN STARTING DETAILS (13) menu heading. This is the default setting of this menu item.

Page

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

Telephone: 360/435-8826

Fax: 360/435-2229

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Part No. 2031-5

Rev. C: February 2001

OPERATION

THREE-WIRE START GENERATORS Three-wire start generators do not include automatic engine cranking control system. Separate

control of the starter m otor requires additional interaction between the inverter’s auto- control system and the generator. This also adds complexity to the installation since more wires must be connected and more programming of the inverter is required. Troubleshooting can also be more difficult.

The automatic control s ystem contr ols the starter much like a person does when star ting a car engine. The starter is turned on for short periods of time and then turned off. If the engine starts up while cranking, the starter is turned off af ter a 1/2-s ec ond delay. If the engine does not s tar t, the st arter is tur ned on again after a delay period. This is repeated until either the generator starts or the m aximum number of start attempts is reached.

The comm on term “three-wire start” m ay be misleading - the actual number of wires us ed may be four or more. It simply means that c ontrol of the star ter motor is done separately from the generator. Mos t threewire start generators are not designed for automatic, unattended operation. T he generator supplier s hould be consulted regarding additional safety components r equired for your installation. The automatic c ontrol system only provides the starting and stopping signals based on what the batteries need. It will not shut off the generator if a problem such as low oil pressure occurs.

Three-wire start type generators can be divided into two basic types - “Honda” types and “Onan” types. The Honda type uses an automotive type starting circuit as previously discussed. O perating a switch that is first turned to “RUN” and then m omentarily held to a “START” position starts it. Onc e the engine has started, the switch is released and it retur ns to the “RUN” pos ition. To s hut down the generator, the switch is placed in the “OFF” position. For this type of generator, relay RY7 duplicates the “RUN” position and relay RY8 duplicates the “START” position, cranking the starter m otor. For this type of generator, select RUN from the SET RY7 FUNCTION menu item under the GEN STARTING DETAILS (13) menu heading. This is the default setting of this menu item.

GEN CONTROL RELAYS

COM

RY7

RY8

N.O. COM N.O.

5 AMP FUSE

HONDA TYPE GENERATOR

STOP SWITCH

CONTACTS

START SWITCH

CONTACTS

Figure 24, Three Wire Start Wiring Diagram (HONDA Type) Onan type generators use a different starting sequenc e. Most Onan type generators use a three-pos ition

momentary type switch that controls their operation. To start the generator, the switch is held to the “START” position. T his energizes the ignition system and cranks the starter motor. Onc e the engine has started, the switch is released and it returns to a center off position. T he starter m otor then stops crank ing but the ignition system remains energized. To shut down the generator, the switch is held to the “STOP” position until the engine dies. Once the handle is released, it retur ns to the center pos ition. For this type of generator, relay RY8 duplicates the “START” position and relay RY7 is used to duplicate the “STOP” position (using the common and normally open contacts). Some gener ators use a sim ilar s ystem with two push button switches - one to start and one to stop.

GEN CONTROL RELAYS

COM

RY7

RY8

N.O. COM N.O.

5 AMP FUSE

HONDA TYPE GENERATOR

STOP SWITCH

CONTACTS

START SWITCH

CONTACTS

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

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

Telephone: 360/435-8826

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SW Series Inverter/Charger

Part No. 2031-5

Rev. C: February 2001

Page

OPERATION

SW Series Inverter/Charger

Most diesel generators are controlled like the Onan type, except that they also require that glow plugs be operated before the generator start is attempted. The SW Series Inverter/Charger automatic generator control system can also provide glow plug control. The addition of an external relay may be required to operate the glow plugs due to the amperage required by the glow-plugs and to separate the stop signal circuit. For this type of generator, select GLOWSTOP from the SET RY7 FUNCTION menu item under the GEN STARTING DETAILS (13) menu heading.

3-TO-2 WIRE CONVERTERS

Another option for three-wire start-type generators is a 3- to-2- wire conver ter which vary from simple relays to advanced microprocessor types. Onan offers a simple 3-to- 2-wire converter that works well for m any installations. Universal 3-to-2 wire converters can be us ed with virtually any generator as well as control glow plugs for diesel generators. These also feature additional system components to signal the generator control system to start.

GENERATOR CONTROL SEQUENCE

The relays close in a specific sequenc e to start the generator. Some of the timing periods are adj ustable through the GEN STARTING DETAILS (13) menu heading. GLOWSTOP has been added to the sequence for diesel generator applications . RY7 can be configured f or either “RUN” or “GLOWSTOP” operation. The two control relays complete the following sequence:

The ’auto generator control sequence’ is initiated if the battery voltage remains bel ow the ’Set start volts DC’ setting (unless

’Start/End Quiet time h:m’ is enabled) for the required period of time or the ’Read LBCO 30 sec s tart VDC’ setting for 30 seconds;

or if the load amps reaches the ’Load Start amp AC’ setting longer than the ’Set Load Start delay min’ period. The manual

generator control sequence is in i t i ated if generator is manually turned on vi a ’Set Generator’ to ON.

RY7

RUN (or)

GLOW-

STOP

RY8

First ’auto

generator

start

attempt’

The auto generator stop sequence

is initiated if: (1) The battery

voltage has been held at the ’Set

Bulk volts DC’ setting for the ’Set

Absorption time h:m’ period or (2)

The load amps drops below the

’Load Start amps AC’ setting for

longer than the ’Set Load Stop

delay min’ period.

OFF OFF ON

OFF ON

START

SET PRE

CRANK

10 SECS.

DEFAULT

SET MAX

CRANKING

SECONDS

10 SECS

DEFAULT (RY8 goes

off with a

1 sec delay

when

AC HOT IN

>80 VAC)

DELAY

PERIOD

8 SECS

FIXED

SECONDS

ON (engages to the N.O. position)

OFF (engages to the N.C. position)

VAC

and

GEN-RUN PERIOD (Determined by the

CHARGING’ heading or by the current and

SET GEN WARM-UP SECONDS

60 SECS

DEFAULT

(Starts once

voltage

exceeds

80 VAC)

OFF (engages to the N.C. position)

LOCK ON

GOOD DELAY

PERIOD

12 SECS

FIXED

(Starts when

AC is within

108 to 132

53-67 Hz)

voltage and ti me

settings under the

delay min settings

under the ’GEN

AUTO START

SETUP’ heading)

The generator will stop

immediately with an

inverter fault or if ’Set

Generator’ is set to

OFF. Also a "Kill Before

Cranking" signal is

enabled before the next

'auto generator start

DOWN

PERIOD

’BATTERY

40 SECS

FIXED

(Only used

with ’Set

Generator’ to

AUTO)

attempt'

COOL

ON ONOFF

Generator is

off and waiting for next ’auto

generator

start

sequence

START DELAY

PERIOD

8 SECS

FIXED

Next ’auto

generator

Start

sequence

has been

initiated

SET PRE

SECONDS

10 SECS.

DEFAULT

Second

‘auto

generator

start

attempt’

CRANK

Time (Sec) 0 8 18 28 88 100 +100 +140 0 8 18

Figure 26, Relay RY7 and RY8 Sequence

Page

OFF = relay contact closed f rom N.C. to COM (relay disengaged) ON = relay contact closed f rom N.O. to COM (relay engaged)

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

GEN CONTROL RELAYS

Telephone: 360/435-8826

Fax: 360/435-2229

www.traceengineering.com

Part No. 2031-5

Rev. C: February 2001

OPERATION

GENERATOR STOP COOL DOWN PERIOD

When the autom atic generator stop system is used to st op the generator, the generator is disconnected from the inverter first by opening the AC relay inside the inverter. This allows a very clean transition from the generator to the inverter. The STO P signal is provided immediately if the generator is manually shut off from the Control Panel. If the generator is shut of f automatically the generator will be allowed to run for an additional 40 seconds before the STOP signal is provided. This allows the generator to cool down before it is turned off. This is very important for turboc har ged generator s as it allows c ooler oil to r eac h the turbo. If the generator does not stop after the 40 second cool down period when the stop signal is sent, then the inverter will reconnect to the AC source and remain connected as long as it is available.

If the generator is stopped m anually from the Contr ol Panel, the generator is st opped im m ediately with no cool down.

GENERATOR ERROR CAUSES

The red ERROR LED indicator will blink slowly if one of the following generator errors occurs:

• GEN UNDER/OVER SPEED: Indicates that the generator has synchronized with the inverter/charger but the frequency is not well adjusted (63 - 67 on the high-end or 53 - 57 on the low end).

• GENERATOR START ERROR: The automatic control system will attempt to start the generator 5 times by closing the starting relay RY8 for up to the MAX CRANKING SECONDS setting, or the inverter senses an AC voltage above 80-volts AC on the AC HOT IN 2 term inal. Once the inverter senses 80 volts AC on the AC HOT IN 2 terminal, after a half-second delay, RY8 opens. After successfully running for 5 minutes, the start attempts counter resets to zero. If the generator dies within the 5-minute period of being started, the inverter will attempt to restart the generator. An unsuccessful run is considered a failed start attempt. After 5 start attempts, the ERROR LED illuminates and the generator control system shuts down. If the generator dies after successfully running for 5 minutes, the start attempt c ounter will be reset to zero and the inverter will only restart the generator if the auto start voltage setting or load amps AC setting is reached for the requir ed time delay period.

• GENERATOR SYNC ERROR: Indicates that the generator was running but was not operating within the voltage and frequency tolerances and not able to connect (out of sync), or the unit can not maintain synchronization (AC voltage or frequency is out of tolerance).

• GEN MAX RUN TIME ERROR: Indicates that the generator ran for a period of time that exceeded the SET MAXIMUM RUN TIME setting. This setting is intended to indicate exces sive generator operation if the system has not been able to fully charge the battery. Operating heavy loads while charging, an unstable generator or even low electrolyte levels in the battery can cause this. This m ay also occur with systems that have very large batteries, requiring long charge periods, or systems with small generators with limited battery-charging ability. If the default value results in repeated error c onditions, increasing the SET MAXIMUM RUN TIME menu item setting m ay be necessary for your application. When using the autom atic generator control system to complete a equalization cycle, the additional time required for the EQ cycle should be consider ed in order to prevent reaching the SET MAXIMUM RUN TIME menu item setting and causing a GEN MAX RUN TIME ERROR. This is an advisory error only and does not stop the generator.

To clear a generator start error , access the SET GENERATOR menu item by pressing the green GEN MENU button and move the cursor fr om AUTO or ON to OFF in the SET GENERATOR menu item. T his clears all the generator error conditions and resets the start attempts counter.

 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

OPERATION

SW Series Inverter/Charger

EQUALIZATION CHARGING, AUTOMATIC GENERATOR CONTROL SYSTEM

An automatic equalization charge process is available in the SW Series Inverter/Charger. To start the equalization process, select EQ from the SET GENERATOR menu item, accessible by pressing the green GEN MENU button on the Control Panel.

During the next automatic generator run period, the inverter can be set to complete an equalization charge process. You must first select EQ from the SET GENERATOR menu item. The generator will start the equalization process the next time the generator is automatic ally started and will automatically stop and return the cursor to the AUTO position in the SET GENERATOR menu item once the equalization period has been completed.

The SET EQUALIZE TIME menu item under the BATTERY CHARGING (10) menu heading sets the amount of time that the battery voltage must exceed the BULK VOLTS DC setting befor e the equalization process is considered to be c ompleted. T his tim er is an acc umulating type timer that does not reset if the voltage drops momentar ily below the bulk voltage setting. During the equalization process, the voltage will be limited to the level of the SET EQUALIZATION VOLTS DC menu item.

During the equalization process, the BULK LED will flash slowly to indicate that the EQ position has been selected from the SET GENERATOR menu item. When the proces s has f inished, the FLOAT LED will be on if the generator or utility power is still available.

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

UTILITY BACKUP MODE

OPERATION

GENERATORUTILITY GRID

MAIN

AC BREAKER

PANEL

NON-CRITICAL

AC LOADS

AC AC

INVERTER/

CHARGER

BATTERY

ADDITIONAL

AC BREAKER

SUB-PANEL

CRITICAL

AC LOADS

IN BRIEF

SW Series Inverter/Chargers provide an excellent utility system backup under the majority of powering applications. Whenever a shorted grid condition affects voltage or frequency, the inverter disconnects itself from the gr id and continues to suppor t the AC load using battery power. Typical transfer time under a shorted grid condition is instantaneous.

Depending upon the type and amount of load, the transfer m ay, at times, be notic eable. T his is due to the inverter’s output reaching the overcurrent trip level as it tr ies to maintain the load bef ore the internal relay transfers to battery power.

To operate the system in utility backup mode:

• Connect utility AC power to the inverter's AC HOT IN 1 and NEUTRAL IN 1 terminals.

• Connect the AC loads to the inverter's AC HOT OUT and NEUTRAL OUT terminals.

• Adjust the battery charger parameters if the factory default values are not satisfactory. For UPS

applications with small battery banks, lower the battery-charging rate.

• Adjust the GRID (AC1) AMPS AC menu item to match the am perage of the cir cuit breaker s upplying AC to the inverter input. This setting is loc ated in the AC INPUTS (11) menu heading - (See UTILITY SUPPORT/OVERLOAD PROTECTION, on page 82).

 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

OPERATION

SW Series Inverter/Charger

UTILITY SUPPORT/OVERLOAD PROTECTION

This battery charger is very powerful and without limits could draw more current than is available fr om the AC input source. When the utility grid is available, the grid has to power both the battery charger and any AC loads connected. If AC charge curr ent combined with any AC load current exceeds the GRID (AC1) AMPS AC menu item setting, the charge rate will be automatically reduced to keep from tripping the utility grid breaker.

In addition, the inverter will support utility grid in the event that excessive loads threaten to trip the AC breaker. If the am ount of power demanded by the AC loads is greater than the GRID (AC1) AMPS AC menu item setting, the inverter will contribute power to operate the AC loads. This will limit the AC curr ent drawn from the utility system.

This ability allows the utility line to be sized closer to the typical draw of the system, instead of being sized to the maximum load. This m ay save considerable cost if a utility extension or upgrade is being installed. The savings can even offset part or all of the inverter / battery system in some situations.

While the inverter is supporting the AC loads, the battery will be discharging. Typically, utility line support is required for only short period of time during heavy power usage that will not cause the battery to be significantly drained.

USING SLT MODE (SILENT MODE)

In SLT mode the batteries are charged only once a day, at a time prescribed in the BULK CHARGE TRIGGER TIMER (15) menu heading. Selecting SLT in the SET GRID USAGE menu item, located under

the INVERTER SETUP (9) menu heading enables it. During the rest of the day the battery charger is turned off and the utility grid powers the AC loads. If a utility outage occur s, the inverter turns on and r uns the loads. When power r eturns, the inverter will return to the SLT mode after it has com pleted the Bulk and Absorption stages of the battery charging process . The advantage of SLT m ode is silent operation and slightly less power consumption under most conditions and quieter operation since the battery charger is off most of the tim e. The disadvantage of SLT m ode is the loss of the natural power conditioning ability of the inverter and the ability to “back off” the AC input which prevents overloading or circuit breaker tripping (except during the time that the inver ter is c harging). T he trans ition from utility to inverter when an outage occurs may also be more noticeable.

When using this mode, a START BULK TIME must be entered from the BULK CHARGE TRIGGER TIMER (15) menu heading. If the tim er is defeated by setting it to 00:00, no bulk charging will take place on a daily basis except immediately after a grid failure has occurred and the power has been restor ed. The default setting is 00:00 that defeats the BULK CHARGE TRIGGER TIMER.

BATTERY REQUIREMENTS

Utility backup applications usually are designed to discharge the battery at a higher rate for a shorter duration than alternative energy applications. Typically, batteries capacity ratings are for discharge periods of 20 hours. This means that a 100-amp hour battery can deliver 5 amp hours for 20 hours. It cannot deliver 100 amp hours for 1 hour . Battery manufactures can provide de-rating curves for their produc ts. If the battery is not large enough, unsatisfactory performance may result. For the best performance, oversizing of the battery is strongly recommended.

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

UTILITY INTERACTIVE MODE

OPERATION

UTILITY GRID

kWh METER

OUTDOOR AC

DISCONNECT

BACKED UP

AC LOADS

SUB-PANEL

MAIN AC LOADS

NOT PROVIDED

WITH BACK-UP

INVERTER/

CHARGER

BATTERY

SOLAR ARRAY

GROUND FAULT

PROTECTION

OVERVOLTAGE

PROTECTION

IN BRIEF

In this mode, SW Series Inverter/Charger s can be used to move power from the DC system into the AC utility grid. This is often called “selling” power since the utility pays for the power you produce. It is relatively simple to set the inverter up to accom plish this. However, this type of installation is so new that many utility companies have not formalized their regulations regarding acceptable installations. Regulations will vary from one utility to another. The utility companies have a right and a need to be careful about how power is fed into their system. Utility interactive should be done with the assistance of your dealer and must be done with the approval of the local utility company.

As a minimum, an outdoor mounted AC disconnect s hould be installed at the service entrance or nex t to the utility meter. It should be clearly labeled “SOLAR ELECTRIC SYST EM AC DISCONNECT”. T his will allow utility and emergency personnel to easily and safely isolate the system from the utility grid if required. This disconnect should be lockable (by the utility) and installed between the AC HOT 1 INPUT of the inverter and the circuit breaker in the AC load center connected to the utility grid. This allows the utility to shut off the system if a problem occurs.

Since a utility interactive installation requires an understanding of your local utility code, lim ited diagrams and details are included in this manual. Consult your utility or your local Xantrex dealer.

To operate the system in utility interactive mode, set-up the system as follows:

• Connect utility AC power to the inverter's AC HOT IN 1 and NEUTRAL IN 1 terminals.

• Connect the cr itical AC loads that are required to be backed-up, to the inverter ’s AC HOT OUT and

NEUTRAL OUT terminals.

• Use the GRID USAGE TIMER (18) and the BULK CHARGE TRIGGER TIMER (15) with the battery charger parameters adj usted under the BATTERY CHARGING (10) menu heading to determine the battery voltage level you require for your batteries.

• Select SELL from the SET GRID USAGE menu item in the INVERTER SETUP (9) menu heading.

• Adjust the GRID (AC1) AMPS AC menu item located in the AC INPUTS (11) menu heading (See

UTILITY SUPPORT/OVERL OAD PROTECTION, on page 82) to match the amperage of the circuit supplying AC to the inverter input.

• Adjust the AC input voltage parameters using the SET INPUT LOWER LIMIT VAC and the SET INPUT UPPER LIMIT VAC menu items, both located in the AC INPUTS (11) menu heading to match

the AC voltage requirements of your connected utility.

 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

OPERATION

SW Series Inverter/Charger

THEORY OF OPERATION

When SELL mode is selected from the SET GRID USAGE menu item located under the INVERTER SETUP (9) menu heading in the SETU P MENU, the inverter will move any excess power not required to

charge the batteries into the utility grid. In SELL mode, the inverter can be thought of as a battery charger that is able to operate in either direction

- it can send excess power fr om the battery back into the utility grid instead of drawing power fr om the utility to charge the battery. To regulate the battery charging process, the inverter tak es DC power from the solar array and converts it to AC power that supplies other AC loads through the utility grid. The inverter is more accurately described as a utility interactive battery charger. This means that the inverter will control battery voltage whenever utility power is connected and available. If a utility outage occurs, the inverter can not control the battery voltage. Some external control must be provided by the system to prevent damaging the battery as the solar array tries to overcharge the battery.

In a solar array configuration, a charge controller is not needed when the inverter is operational in SELL mode and utility is connected. If the inverter was turned off, or utility power was to fail, the batteries could quickly be over-charged. One of the inverter’s voltage controlled relays can be used to protect the batteries in case of utility failure. It would be programmed to open an additional external relay that contr ols the solar panels at a battery voltage above the battery charger’s BULK VOLTS DC setting. Please see the OVERVOLTAGE PROTECTION FOR THE BATTERY section on page 89 for more information.

UTILITY INTERACTIVE ISLANDING PROTECTION

In utility interactive mode, the inverter is capable of detecting several types of failures.

• Grid shorted - Normally, when the utility power fails, the inverter momentarily tries to power the entir e neighborhood. This condition looks like a short circuit to the inverter and causes it to reach the overcurrent protection setting and shuts off. It then opens its internal relay and disconnects from the utility grid. This protective system operates instantly.

• Grid open - The inverter can tell when there is no current being delivered to the grid and it will disconnect. This is used when a disconnect switch is opened or the power line which feeds the installation is cut. This protective system operates instantly.

• Islanding - This occurs when the grid has failed and the "neighbor hood" that the inverter is powering requires a power level that the inverter can supply. This condition is called “islanding”. The islanding detection circuit checks gr id condition on each c ycle. The inverter watches the utility grid and waits for it to rise a couple of volts before it begins to invert again. This is done on each cycle when SELL mode is activated. Typically, disconnect is achieved in a few cycles after the utility has failed. If a lar ge electric motor is c onnected, it may provide enough generator capacity that the inverter think s the grid is still connected. This c an fool this protective s ystem. T wo additional protec tive s ystems are provided to then handle this condition, over/under frequency and over/under voltage detection.

• Over/Under Frequency - Since the inverter is locked onto the frequency of the utility grid, the frequency of the islanding system will drift out of regulation in a short amount of time during an islanding condition. This protective system may require a couple of seconds to respond. T he settings are 58 and 62 Hertz for 60 Hertz models (48 and 52 Hertz for 50-Hertz models) and are not adjustable.

• Over/Under Voltage - Since the inverter does not try to regulate the voltage of the utility grid while selling power into it, the AC voltage will drift out of regulation in a short amount of time during an islanding condition. This protective s ystem may require a couple of seconds to respond. T he default settings are 108 VAC as the lower limit and 132 VAC as the upper limit. These settings are adjustable.

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

OPERATION

SELLING POWER - FROM A DC CHARGING SOURCE

The simplest and default operation of the SW Series Inverter/Charger in the SELL m ode is to “sell” the excess power from the charging sourc e to the utility when the batteries are full. In this mode, the battery voltage is held to the regulation level determined by the SET BATTERY SELL VOLTS DC setting. Since the SET BATTERY SELL VOLTS DC setting is defaulted to the same value as the SET FLOAT VOLTS DC setting, the inverter will sell the power f rom the charging source (wind, hydro or solar, etc.), but will hold the battery at a charged level.

The regulation process can also be accomplished and allow the three stage charging (float, bulk and absorption) of the batteries to occur each day by enabling the BULK CHARGE TRIGGER TIMER (15). The batteries will be maintained at the SET FLOAT VOLTS DC setting until the SET START BULK TIME, which will charge the batteries near the SET BULK VOLTS DC setting until the end of the ABSORPTION TIME.

This operating mode offer s the individual system owner with several advantages. T he batteries would not be cycled thereby increasing their life and the batteries would be fully charged in case of a power failure, resulting in greater system efficiency.

Begin Day

00:00

Time

Float Volts

DC Volts

13.0

Charging from the DC

source (wind, hydro or

solar) has started

POSITIVE (+) = Inverter is drawing power from grid. NEGATIVE (-) = Inverter is selling power to grid.

Input amps AC 00

AC amps to grid (-)

AC amps from grid ( +)

AC amps

{ {

DC Setting

Set Float Volts DC 13.4

Max Sell Amps

Set Max Sell amps AC 30

LEGEND

Display/Settings on Control Panel

Information

AC Setting

Bulk Charge Trigger Timer is

enabled (not the default setti ng)

Battery Sell Volts

DC Setting

Set Battery Sell Volts DC 13.4

Sell to grid period

when the current from the DC source is greater than needed to maintain

the Float/Sell Volts DC

setting.

Charging from the DC

source (wind, hydro or

solar) has stopped

Max Charge

Amps AC Setting

Set Max Charge amps AC 30

Set Start Bulk time 20:00

Bulk Volts

DC Setting

Set Bulk Volts DC 14.4

20:00

Set Absorption time h:m 02:00

Absorption Time

Battery

charging from

grid has

started

End Day

23:59

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

 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

OPERATION

SW Series Inverter/Charger

started

SELLING POWER - STORED IN THE BATTERIES

Power stored in the batteries can also be sold into the utility grid. This can be used together with the solar array or alone without a solar array. The inverter can be programm ed to sell the energy in the batteries at a specific time and then to r echarge the batteries at another time. Both the discharge level and disc harge rate can be adjusted to control the battery selling process.

Selling the power stored in the batteries can be used to level the output of the combined solar array and battery system. This is beneficial during conditions of cloudy weather when the solar array output will vary with each cloud that passes over. To set-up this ability, adjust the SET BATTERY SELL VOLTS DC menu item under the BATTERY SELLING (17) menu heading for the maximum discharge voltage level acceptable. The SET MAX SELL AMPS AC menu item should be set for the expected maximum output of the solar array. Next, access the GRID USAGE TIMER (18) menu heading to allow setting of the time period that the battery will be allowed to recharge during by adjusting the SET START CHARGE TIME and SET END CHARGE TIME menu items. Outside of this time period, the inverter will sell the power stored in the battery to the utility grid until the voltage reaches the BATTERY SELL VOLTS DC setting.

This mode can use the battery to maxim ize the output of the system during a specific period of time. An example of these setting follows:

Begin Day

00:00

Time

Float Volts

DC Setting

Set Float Volts DC 13.4

Charging from the

DC source (wind,

hydro or solar) has

started.

POSITIVE (+) = Inverter is drawing power from grid. NEGATIVE (-) = Inverter is selling power to grid.

Input amps AC 00

AC amps to grid (-)

AC amps from grid ( +)

{ {

Battery charging

from grid has

stopped

End charge time 08:00

Set Float Volts DC 13.4

DC Volts

AC amps

08:00

10:00

Battery Sell Volts

DC Setting

Set Battery Sell Volts DC 12.4

Battery charging

from grid has

Start charge time 18:00

Bulk Volts

DC Setting

Set Bulk Volts DC 14.4

Max Sell

Amps Setting

Set Max Sell amps 30

20:0018:00

Bulk charging

has started

Set Start Bulk time 20:00

Set Absorption time h: m 2:00

Absorption Time

Max Charge

Amps Setting

Set Max Charge amps AC 30

End Day

23:59

LEGEND

Display/Settings on Control Panel

Information

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

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

OPERATION

A system that includes 2400 watts of solar array is able to produce approximately 18 amps of AC power at 120 VAC. The output is most needed from 12:00 noon to 18:00 by the utility. If the GRID USAGE TIMER is set to a START CHARGE TIME of 18:00 and a END CHARGE TIME of 12:00 noon, the inverter will sell the battery from 12:00 noon to 18:00. The energy in the batteries will be used only if the solar array is not able to provide enough power to reach the 18 amps AC ( determined by the MAX SELL AMPS AC setting under the BATTERY SELLING MENU (17) menu heading. The battery will assist the solar array to meet the 18 amps AC MAX SELL AMPS AC setting during the battery sell period. If the battery reaches the SELL VOLTS DC setting during the sell period, the AC output current will slowly taper down to the solar array’s output level and the battery will not be further discharged. At 18:00, the battery will c harge at the rate allowed by the SET MAX CHARGE AMPS AC (2 amps AC is the lowest setting allowed). The batter y will be recharged only to the FLOAT VOLTS DC setting unless the BULK CHARGE TRIGGER TIMER (15) menu heading is used to trigger a bulk charge cycle.

This system offers the utility several advantages. The system can be relied on for a specific amount of output at a set time. The AC output of the s ystem f rom 12 noon to 4 PM will not vary with the level of sunlight (after all, the AC loads on the grid do not suddenly drop when a cloud passes over ). Only if it is extremely cloudy will the system not produce its rated output for the full tim e period - which would not be as important since the ambient temperature would not be as high.

This operating mode does not provide an individual system owner with m any added values. The wear and tear on the batteries would be avoided and greater efficiency achieved if the standard sell mode was used.

BATTERY REQUIREMENTS

Batteries are required for utility inter-tie operation of this inver ter. The batteries can, however, be sm all if the system does not provide back-up power in c ase of utility failure. T wo thousand watt/hours is suff icient (100 amp/hours at 24 volts is 2400 watt hours). This can be achieved by using two “Group 27” sized batteries for a 24-volt system. This is a very common size for RV and boat applications. Since the batteries are not cycled excessively, sealed batteries may be used with good success.

CAUTION: If using gelled batteries, the battery charger must be set to the appropriate settings or battery damage will occur.

BATTERY REGULATION LEVEL - SELL MODE

In the SELL mode, the regulation level of the battery is determ ined by the charge cycle (FLOAT or BULK) and the settings of the BULK CHARGE TRIGGER TIMER (15) and the GRID USAGE TIME R (18).

The SET START CHARGE TIME menu item setting under the BULK CHARGE TRIGGER TIMER (15) menu heading can be used to increase the battery charging regulation voltage to the SET BULK VOLTS

DC setting. The battery voltage will be held near the SET BULK VOLTS DC menu item setting under the BATTERY CHARGING (10) menu heading for the adjustable ABSORPTION TIME period setting upon

encountering this BULK CHARGE TRIGGER TIMER event or after a loss of AC power to the AC HO T IN 1 input terminal.

The inverter will charge the battery to the FLOAT VOLTS DC setting at the START CHARGE TIME with the GRID USAGE TIMER enabled (the START CHARGE TIME beginning time is not equal to the END CHARGE TIME). This is indicated by the FLOAT LED indicator being on. After the END CHARGE TIME, the inverter turns off the battery charger and begins to “sell” power into the utility grid from the battery (or any other DC sources available and connected to the batteries) to the SELL VOLTS DC setting. The FLOAT LED indicator blinking indicates this. The cu rrent will be limited to a max imum level c ontrolled by the MAX SELL AMPS AC menu item setting under the BATTERY SELLING (17) menu heading.

With the GRID USAGE TIMER disabled (the SET START CHARGE TIME beginning time is equal to the SET END CHARGE TIME) and the inverter in the FLOAT charge cycle, the inverter will use the utility grid (or any other DC sources available and connected to the batteries) to m aintain the batteries to the SET FLOAT VOLTS DC setting. This is indicated by the FLOAT LED indicator being on.

 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

OPERATION

SW Series Inverter/Charger

UTILITY INTERACTIVE OPERATION WITH UTILITY BACKUP

The SW Series Inverter/Charger is capable of operating both as a utility interactive and a stand-alone inverter. This allows the system to norm ally sell the excess power to the utility and, once an outage has occurred, provide power to the AC loads from the battery.

The loads that will be provided with utility backup during outages must be isolated from the non-utility backed-up loads. This usually requires the addition of an AC load center sub panel for the output of the inverter.

UTILITY GRID

120/240 VAC

NOTE: THE BUY AND SELL METERS

kWh METER WITH

DETENTS (ONE-

WAY) 120/240

“BUY” METER

AC LOADS

120/240 VAC

CAN BE COMBINED

INTO ONE TWO-WAY METER

IF NET BILLING IS ALLOWED.

kWh METER WITH

DETENTS (ONE-

WAY) 120/240

VAC

“SELL” METER

AC DISCONNECT

(LOCKABLE)

120/240 VAC

BREAKER

60A/120 VAC

(FOR HOUSE)

#6 AWG

REQUIRED

VAC

SERVICE

ENTRANCE

PANEL

BREAKER

60A/120 VAC

CIRCUIT

BREAKERS

UTILITY INTERACTIVE

LINE-TIE SYSTEM WITH

BACKUP OF CRITICAL AC

(OPTIONAL)

kWh METER WITH

DETENTS (ONE-

WAY)

120 VAC

“PRODUCED”

METER

NEXT TO THE

INVERTER

LOADS

DESIGNATES BI-DIRECTIONAL CURRENT PATH

OUTDOORS NEXT

TO THE UTILITY

SERVICE

ENTRANCE

FUSED

DISCONNECT

60A/120 VAC

NEMA 3R

OUTDOOR TYPE

FUSED

DISCONNECT

60A/120 VAC

AC SUBPANEL

FOR UTILITY BACK-UP AC

LOADS

“PRODUCED”

METER

CONTROLLER

PV CHARGE

CONTROLLER

FUSED

DISCONNECT

60A/120 VAC

NEXT TO THE

INVERTER

BATTERY

STORAGE

SYSTEM

AC OUTPUT TERMINALS

WIND

GENERATOR

SOLAR

ARRAY

AC LOADS

TO BE

BACKED UP

120 VAC ONLY

FUSED

DISCONNECT

FUSED

DISCONNECT

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

Page

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

Telephone: 360/435-8826

Fax: 360/435-2229

www.traceengineering.com

AC INPUT

TERMINAL

TRACE SW-SERIES

INVERTER/CHARGER

120 VAC

DC BATTERY

TERMINALS

BATTERY

DISCONNECT

Part No. 2031-5

Rev. C: February 2001

OPERATION

OVERVOLTAGE PROTECTION FOR THE BATTERY IN SELL MODE

Normally, the inverter will regulate the charging process of the battery by selling ex cess power into the utility grid. The battery will receive a three-stage charge r outine as previous ly described. If the utility grid is not available (due to an outage or tripped AC input circuit breaker, etc.) or if the inverter s huts off, then the inverter is not able to sell the excess power and the battery voltage will not be regulated, resulting in possible overcharging of the battery.

Therefore, a separate contr ol is required to provide over voltage protection f or the battery when an outage has occurred. The AUX Relays in the SW Series Inverter/Charger are designed to control an exter nally connected power relay that would disconnect the solar arr ay and stop the charging process. The voltage and hysteresis (difference between opening and closing voltage) are both adjus table. The external relay can be either a standard mechanic al type or a mercury displacem ent type, depending on the voltage and current required. The m ercury displacement type relay is usually required when the system voltage is 48 VDC or if the current of the solar array exceeds about 20 amps. Multiple relays can be used if the solar array is divided into several source circuits (do not parallel relays for higher cur rent). Another option is to use a charge controller such as the Trace™ C40. For more on the C40 MULTI-FUNCTION CONTROLLER, see page 129.

A typically wiring configuration for this overvoltage protection is as follows:

SOLAR ARRAY

This circuit does draw a sm all am ount of power all of the tim e to power the coil of the relay. Other circuits are possible but m ay have other drawbacks. This circuit

+P -N

provides protection against overcharging the batteries.

NORM.

OPEN

5 AMP

FUSE

AC OUTPUT - NEU AC OUTPUT - HOT

SW - SERIES

INVERTER

AUX RELAY 9 COM. AUX RELAY 9 N.C.

120VAC

COIL

-N

+P -N

BATTERY BANK

Figure 30, Overvoltage Protection for Battery

AUX RELAYS

Three voltage-controlled relays are provided to simplify installations that have battery voltage related tasks to perform. T hey are single pole double throw, five amp relays. Both the normally closed and normally open contacts are available for each relay. The operation of the relays are individually controlled and adjustable via the user menu. The battery voltage at which each of these relays are activated (SET RELAY 9, 10 or 11 VOLTS DC) and the number of volts by which the battery voltage must drop before the relay is de-activated (R9, R10 or R11 HYSTERESIS VOLTS DC) are both individually adjusted for each relay. The three AUX Relays operate independently of the inverter or charger. For location and wiring information on the AUX Relays, see the AUXILIARY AND GENERATOR CONTROL RELAY section on page 14.

CAUTION: These relays are not intended to direc tly control a load or charging source - rather they can be used to send a signal or operate the coil of another higher amperage device which does the actual switching of the power. A fuse rated at 5 amps or less should be included to protect each of the relays. Damage to these relays from overloading is not cov ered by warranty and requires the inverter to be returned to a repair center. This also applies to the generator control relays.

 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

OPERATION

SW Series Inverter/Charger

ENERGY MANAGEMENT MODE

UTILITY GRID

INVERTER/

CHARGER

AC LOADS

BATTERY

IN BRIEF

The purpose of this mode is to manage how utility power is used. One method is to char ge the batteries at a favorable time and then use the power later. This is often desirable when time of day metering is available. A solar array is not required, but can be used to reduce the dis c har ging of the batter y. Since the most expensive power is often during the afternoon, the solar array may be a valuable addition. This mode is an alternative to utility interactive systems. This mode does not involve “selling” power into the utility grid and therefore does not usually require the approval of the utility. The same system is also able to operate as a utility back-up system to provide power when an outage occurs.

In order to disconnect from the grid during a specif ic period of the day and operate only as an inverter, a window of time is created during which battery charging is allowed. Outside this window, the inverter will power the load from the battery. If the battery gets low, the system will transfer back to the utility and recharge the battery.

To operate the system in Energy Management Mode, set up the system as follows:

• Connect utility AC power to the inverter’s AC HOT IN 1 and NEUTRAL IN 1 terminals.

• Connect AC loads to the inverter’s AC HOT OUT and NEUTRAL OUT terminals.

• Set the GRID (AC1) AMPS AC menu item, in the AC INPUTS (11) menu heading, to match the

amperage of the circuit supplying AC to the inverter input (See UTILITY SUPPORT/OVERLOAD PROTECTION on page 82).

• Set the SET GRID USAGE menu item, under the INVERTER SETUP (9) menu heading, to FLT.

• Set the SET START CHARGE TIME menu item, under the GRID USAGE TIMER (18) menu heading,

to the time the inverter connects to the utility. This is the beginning of the time the battery charger is allowed to operate and the end of the inverter operating period.

• Set the SET END CHARGE TIME menu item, under the GRID USAGE TIMER (18) menu heading, to the time that the inverter disconnects from grid and begins to run the loads from the battery. At this time, the battery charger will stop charging. If the battery voltage falls to the LOW BATTERY TRANSFER VDC menu item setting during the inverter operating time period, the AC loads will be reconnected to the utility grid and the battery will be charged to the FLOAT VOLTS DC or LOW BATTERY CUT IN VDC setting, whichever is lower. This prevents over-discharging the battery. The battery will be charged until the next END CHARGE TIME is reached.

• Set the START BULK TIME menu item under the BULK CHARGE TRIGGER TIMER (15) menu heading to a time after the START CHARGE TIME menu item s etting. T his allows delaying of the bulk charge cycle to a later time. Before the bulk charge is started, the battery will be charged only to the float voltage level. The START BULK TIME is usually set to occur during the lowest cost rate per iod. Adjusting the SET FLOAT VOLTS DC menu item to just above the normal at res t voltage ( 12.6 VDC) will reduce the amount of charging that occurs in the between time periods, yet will allow limited charging to prevent sulfation of the battery while being partially discharged.

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

OPERATION

The system should be designed so that the battery is able to operate the loads for the entire peak rate period without reaching the low battery transfer voltage. This may require that heavy loads be operated only during the non-peak rate period.

This mode may be advantageous when the utility offers time-of-day metering that allows you to buy power at a variable rate during different time periods. For exam ple, the rate may be only $0.04 per kilowatt-hour from midnight to 6 AM, but $0.16 during the peak period from noon to 6 PM. The in-between periods might cost $0.08 per kilowatt-hour. The idea is to not use utility power during the peak period and to charge the battery at night, during the off-peak period. A solar arr ay is not required but, since it produces the most power during the peak period, it will reduce the amount of power required from the battery.

The greater the difference between the peak and off-peak rates, the gr eater the value of this operating mode. W hen com bined with a solar array, this mode m ay be more ec onom ic than operating the s ystem in low battery transfer mode.

If the battery is full and power is available from the solar array, it will be used to directly power the AC loads connected to the inverter output, even though the utility grid is also connected to the loads. If the amount of power exceeds the AC loads connected, the battery voltage will increase. An external solar array controller is required to limit the battery voltage to a safe level and to prevent overcharging and possible damage to the battery when only light loads are being powered.

Note: The round-trip net energy efficiency of charging and discharging a Deep Cycle battery rarely exceeds 50%. In order for this tec hnique to be cost ef f ective, the off -peak r ate f oe elec tricity should be no more than half of the on-peak rate. The cost of battery replacement should also be calculated and included when evaluating this technique.

To program the inverter for the example above:

• Set the SET GRID USAGE menu item, under the INVERTER SETUP (9) menu heading, to FLT.

• Set the START CHARGE TIME menu item, under the GRID USAGE TIMER (18) menu heading, to 6

PM (18:00).

• Set the END CHARGE TIME menu item, under the GRID USAGE TIMER (18) menu heading, to NOON (12:00).

• Set the SET START BULK TIME menu item, under the BULK CHARGE TRIGGER TIMER (15) menu heading, to a time after MIDNIGHT (00:30) to delay most of the recharging for the cheapest period.

• Setting the SET FLOAT VOLTS DC menu item, under the BATTERY CHARGING (10) menu heading, to the nominal full battery voltage level will reduce the amount of battery charging that occur s between time periods, yet will allow limited charging to prevent sulfation of the battery while sitting partially discharged.

 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

OPERATION

SW Series Inverter/Charger

PEAK LOAD SHAVING MODE

UTILITY GRID

INVERTER/

CHARGER

AC LOADS

BATTERY

IN BRIEF

The inverter can also be used to lim it the maximum draw the AC loads place on the utility grid. Many utilities impose a surchar ge on their custom ers bas ed on the peak load used by a fac ility. The SW Series Inverter/Charger can be configured to provide all of the power above a specified level, eliminating the surcharges. With the Control Panel, simply adjust the SET GRID (AC1) AMPS AC menu item to the maximum value allowed by the utility without the peak load surchar ge. All AC loads mus t be connected to the output of the inverter through the 60-amp AC transfer relay located internally. Multiple inverters may be required for larger applications with individual groups of loads connected to each inverter. This can be used in addition to time of day metering and still allows the invert er to provide a utility back-up f unction in addition.

This mode is als o useful for applications where AC loads r equire more power than a utility connection is able to supply. This often occurs in mobile applications where only a 15-amp outlet may be available. The inverter can provide the excess power above the 15 am ps when the load is operating. If this condition occurs intermittently, then the inverter will be able to recharge the batteries between the heavy load periods. This can elim inate the need to increase the size of a utility supply circuit, providing substantial savings that can offset the cost of the inverter.

This mode is used in some vehicle applications to im prove the power quality by reducing the load placed on the AC line cord. The inverter provides the “start-up” power to eliminate brown out problems experienced when starting air conditioners, etc. This also prevents tripping AC source circuit breakers when heavy loads are operating.

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

Xantrex Technology SW User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual