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SW Series Inverter/Chargers Owner`s Manual

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1. Conduit Box SWCB Conduit Connectors CONTRAST Control rented ener entree Control Panel CONTRAST Control i DIS Pl MP PHI baii LED Status Indicators 10 AC1 In Good AC2 In Good Bulk o Iioc Float Inverting Line Tie Overcurrent Menu Buttons GEN MENU Button Menu Access Adjustment Buttons 10 MENU HEADING Buttons 10 MENU ITEM Buttons 10 ON OFF MENU Button 10 SET POINTS Buttons 10 RESET TO FACTORY DEFAULTS Button 10 Copyright Trace Engineering Company Inc 5916 195th Street E Arlington WA 98223 Telephone 360 435 8826 Fax 360 435 2229 www traceengineering com SW Series Inverter Charger Part No 2031 5 Page Rev B Sept 1 1999 137 INDEX Control Wiring ette ege Aux Relay Fusing Gen Control Relays Remote Control Wiring eene 27 DC Disconnect And Overcurrent Protection 24 DG Ground recreo tete te erede DG Side kiere bien e DC Wiring eese Battery Cable Connections Battery Cable Sizing
2. 83 Automatic Generator Stop Cool Down 88 Generator Support 69 79 Generator Support Overload 80 Generator Sync 89 Generator Sync Error Menu 2 39 Generator Sync Error Menu 5 44 Generator Timer Menu 7 46 Generator Under Over Speed Menu 5 45 GFI Ground Fault Interrupt 22 Grid AC1 Volts AC Menu 4 42 Grid Usage Timer 61 78 94 97 102 Grid Usage Timer Menu 18 62 Ground Fault Interrupt GFI 22 Gro ndinig 2 15e sneven nene 27 Grounding Electrodes Ground Rods uua Grounding Vs Lightning nennen ennen vennen 30 H Heatsink Overtemp Menu 5 43 High Battery Voltage Menu 5 43 l Identification Label neenon Induced Voltage Irnductive LEoads nee rte Information Display Menu 1 Inverter Mode Menu 2 Generator Mode Menu 3 Trace Engineering T Menu 4
3. 52 Start Bulk Time Menu 15 sese 60 Start Charge Time Menu 18 62 Start Quiet Time Menu 7 46 DIMENSIONS cia 134 Display Battery Actual Volts DC Menu 4 Battery TempComp Volts DC Menu 4 Generator AC2 Volts AC Menu 4 Grid AC1 Volts AC Menu 4 Input Amps AC Menu 4 Inverter Volts AC Menu 4 41 Inverter Charger Amps AC Menu 4 41 Load Amps AC Menu 4 Read Frequency Hertz Menu 4 Software Revision Menu 3 End Charge Time End Charge Time Menu 18 End Quiet Time Menu 7 nennen erneer Energy Management Equalization Charging 39 52 76 77 89 90 110 118 Equalizing Batteries eee Equipment Or Chassis Grounds Error Causes AC Source Wired To Output Menu 5 44 Exercise Start Ready Menu 2 40 External Error Stacked Menu 5
4. ENU SET POINTS V MENU A GEN ON OFF HEADINGS MENU MENU Figure 3 Control Panel Eight pushbuttons are used to select the various menus menu items and operating setpoint values for 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 Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 9 CONTROLS INDICATORS AND COMPONENTS CONTRAST CONTROL The CONTRAST adjustment enables you to adjust the contrast of the LCD display screen to accommodate changing lighting conditions Less contrast is usually preferable in brighter lighting conditions RESET TO FACTORY DEFAULTS BUTTON The RESET TO FACTORY DEFAULTS button returns all of the inverter settings except for
5. 8218 ys 9 ol Ze DEFA 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 interface adapter allows for remote setup adjustment monitoring 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 complete description of the SWRC 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 also used to connect two units in a PARALLEL configuration The parallel stacking interface cable SWI PAR allows two inverters to be connected to provide twice the continuous and surge capability at the same AC voltage See the USING MULTIPLE INVERTERS section on page 95 for more information INVERTER CHARGER CIRCUIT BREAKER This circuit breaker 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 br
6. 2 Menu 7 Generator Menu 12 Gen Auto Start Setup Menu 14 Auxiliary Relays Menu 15 Bulk Charge Trigger Timer 60 Menu 16 Low Battery Transfer 61 Menu 17 Battery 62 Menu 18 Grid Usage 63 Menu 19 Information File Battery 63 Information File Battery Menu 19 63 Input Amps AC Menu 4 41 Input Lower Limit 53 Input Requirements AC GOUEFenDt i aede EIU EE 74 AC Voltage 2 74 Delay Period 2 74 oer cene e eee eet rtr erder Penne 74 Installation Diagrams 135 Internal LED Indicators 13 AC1 Relay Indicator 14 RY7 Indicator 13 RYB Indicator iere eee es 13 Inverter UripacklHg ict ierat etta Cato i denkenden 18 Inverter Breaker Tripped Menu 5 Inverter Mode eene Low Battery Protection Search Mode Theory of Operation Block Diagram Output Waveform e Inverter Mode Menu 1 eene Inverter Setup Menu 9 nanne erneer Inverter Ventilation
7. 19 AC Output Connections 19 Installation Guidelines 21 Control Wiring 26 Aux Relay Wiring eene 26 FUSING uae toties 26 27 83 101 Gen Control 26 Remote Control Wiring 27 DC Wiring 23 Battery Cable Connections 25 Battery Cable Sizing 28 Copyright Trace Engineering Company Inc 5916 195th Street E Arlington WA 98223 Telephone 360 435 8826 Fax 360 435 2229 www traceengineering com SW Series Inverter Charger Part No 2031 5 Page Rev B Sept 1 1999 141 INDEX Worksheet Battery SIZilg sr nnee rennende dalle User Settings T Setup Menu 12 VDC Setup Menu 24 VDC Setup Menu 48 VDC A User nott e etd Page Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 142 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 INSIDE Bi A Co y Sse 5916 195th Street N E Arlington WA 98223 Phone 360 435 8826 Fax 360 435 2229 ENGINEERING visit our website at www traceengineering com
8. POSITIVE Inverter is drawing power from grid NEGATIVE Inverter is selling power to grid Max Sell Amps AC Setting Set Max Sell amps AC 30 Battery charging from grid has harging fi Charging from the DC Slansd source wind hydro or solar has stopped AC amps to grid AC amps from grid 4 Max Charge Amps AC Setting Set Max Charge amps AC 30 LEGEND Display Settings on Control Panel Figure 27 Selling Power From A DC Charging Source Hypothetical Time Of Day Operational History Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 85 OPERATION 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 programmed to sell the energy in the batteries at a specific time and then to recharge the batteries at another time Both the discharge level and discharge 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 cl
9. icto REA ette De e I ee HELD es EE 34 SEIUP MENU MAP cuida iaa ic de 35 USER MENU 0 DU ee D Ue uA EE E Is 36 SETUPB MENILJ dnl ie et etie eter tt dend venen Bic pet edite ii neee eere de pe ep ede rna ia 44 OPERATION e E E 57 S des D E To LE UU E t 57 POWER VS EFFICIENCY etienne el ette 59 INVERTER CAPACITY VS TEMPERATURE cin dremelen senteerd on em eea 60 OPERATING MOBES irt oreille ve i ei ee eere i ee Ee ede Yeas ine en eid 61 INVERTER MODE 5 mede dt tiara dd 62 GHARGER MODE ROI ne DR ERRORS 64 INVERTER CHARGER MODE cinc A ree e dee ege a Dee aie ce eee env 69 GENERATOR SUPPORT MODE beant sad nt eene teln titio hubiese eene pie ber tape eere 71 AUTOMATIC GENERATOR CONTROL cnn rene 73 UTILITEY BACKUP MODE comicas lid lea 81 1 arto daa 83 ENERGY MANAGEMENT MODE aaa 90 PEAK LOAD SHAVING MODE 52 03 ter bee rl ave oec dte ea ati tada ed 92 INNS ALTE 92 LOW BATTERY TRANSFER LBX 93 USING MULTIPLE INVERTERS creron efte esc eerte c tectae Ae bc ne eee 95 TECHNICAL INFORMATION nnn aaneen ennn en nennen 99 BATTERY NA dE 99 BATTERY SIZING sica traca on it tos 101 BATTERY BANK SIZIN 3 criter
10. Inverter Volts AC Menu 4 Inverter Charger Circuit Breaker uc Inverter Charger Amps AC Menu 4 Inverter Charger Mode Transfer Time ue oreet enin Transferring Based On Battery Voltage Transferring Upon Availability Of AC Power Inverter Charger Inverting LED cosita a Islanding Protection e norte K Knockout Hole Size To Conduit 12 147 L LED Status Indicators oooonocccnnccnncnnocanocccancconanonananarccnnno 10 AC In Good noe eme tree eds 11 AG2 ln G d 4 edet 11 Bulk 2r 11 o HEC C ate Ateca 11 ize onere cte rete eevee stand 11 32 Ec E 11 Overcurrent 12 Life Support Policy Lightning erret 90 Line Tie LED 11 Load Amps AC Menu 4 41 Load Start Amps Ready Menu 2 40 Loads 240 81 107 108 A AT 18 Locked Rotor Amps cccoooccccnoccconocncnononcnonanano nana na nana ncnnnnnno 125 Low Battery Cut Out VDG 55 61 71 106 ACJUSIMENE iii 71 Low Battery 71 Low Battery Transfer Mode 49 69 Low Battery Transfer Menu 16 60 Lo
11. set Relay 11 volts DC 10 0 35 5 30 0 R11 Hysteresis volts DC 00 1 12 8 02 0 Bulk Charge Trigger Timer 15 Start Bulk Time H M 00 00 23 50 00 00 Low Battery Transfer LBX 16 Set Low Battery transfer VDC 10 0 35 5 22 6 Set Low Battery cut in VDC 10 0 35 5 26 0 Battery Selling 17 Set Battery Sell volts DC 20 0 32 0 26 8 Set Max Sell amps AC 01 35 30 cria Usage Timer 18 Set Charge time h m 00 00 23 50 21 00 End Charge time h m 00 00 23 50 21 00 Copyright Trace Engineering Company Inc 5916 195th Street N E Arlington WA 98223 Fax 360 435 2229 Telephone 360 435 8826 www traceengineering com SW Series Inverter Charger Part No 2031 5 Rev B Sept 1 1999 TECHNICAL INFORMATION SETUP MENU 48 VDC 120 VAC 60HZ MODELS To access the SETUP MENU press the RED and GREEN buttons on your CONTROL PANEL or SWRC at the same time To exit the Setup Menu press the ON OFF MENU button or use the down MENU HEADING button until you reach the USER MENU menu headings 1 8 MENU HEADING MENU ITEM SELECTION DEFAULT USER RANGE SETTINGS SETTINGS Inverter Setup 9 set Grid Usage FLT SELL SLT LBX FLT Set Low Battery cut out VDC 32 0 70 0 44 0 Set LBCO delay minutes 00 255 15 Set Low
12. gt Bulk Volts Setting Absorption Time Float Volts Setting DC Voltage Increased Voltage Constant Voltage Reduced Voltage Max Charge Amps Setting If a generator was started automatically 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 Reduced Current Reduced Current Constant Current AC Current Figure 21 Three Stage Battery Charging Pa e Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger g 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 64 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 OPERATION 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 METERS 4 menu heading shows this adjusted charge voltage If the temperature sensor is NOT installed and if the battery is subjected 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 I
13. A problem has occurred with the series interface cable or one of the inverters 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 start cycles and requires that the generator operate for a minimum of 5 minutes 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 frequency is not well adjusted This error condition will cause the red ERROR LED to illuminate but will not cause the automatic generator c
14. Relays have 2 Second delay on I Close 0 1 sec 1 1 delay on open 1 End Setup Menu 20 Telephone 360 435 8826 Copyright O Trace Engineering Company Inc 5916 195th Street E Arlington WA 98223 Fax 360 435 2229 www traceengineering com SW Series Inverter Charger Part No 2031 5 Rev B Sept 1 1999 MENU SYSTEM 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 adjust the inverter s time clock MENU HEADINGS included and controlled by the inverter 4 the inverter and other AC sources Inverter Mode Allows control of the inverter and enables the search and charger only 1 modes Generator Mode Allows control of the generator enables automatic operation or triggers an 2 equalization charge cycle This menu heading is used only if a generator is Trace Provides information for accessing Trace Engineering Also provides the Engineering 3 software revision number and allows resetting to the factory default values Meters Allows monitoring of the DC battery voltage AC voltages and AC current of Error Causes Provides an indication of the cause of an error condition Check this menu 5 heading if the red ERROR LED indicator is illuminated on the control panel Time of Day Sets the inter
15. position using the common and normally open contacts Some generators use a similar system with two push button switches one to start and one to stop GEN CONTROL RELAYS HONDA TYPE GENERATOR EMP USE rop E O Mec Rm CONTACTS BTART SWITCH T rm PA ood en CONTACTS Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 TT OPERATION 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 glowplugs 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 converter which vary from simple relays to advanced microprocessor types Onan offers a simple 3 to 2 wire converter that works well for many installations Universal 3 to 2 wire converters can be used with virtually any generator as well as control glow plugs for diesel generators T
16. ERA COMPUTER DUTLETS AC IN 1 SECURITY e Se Oo Qe O NEUTRAL Borne REFRIGERATOR NEU IN 1 PELLET STOVE NEU IN 2 NEU QUT AC OUT GROUND Se Se O SUB PANEL AUX GEN RELAYS FUSE RELAYS 5 AMPS RY10 No ELECTRIC START 240VAC GENERATOR HOOK UP MAY VARY WITH YOUR GEN gt C HOT LEG A NL Y SWRC or SWCA SAFETY GND o Due C HOT LEG B 0000 o NEUTRAL AUXILLARY RELAYS STOP CIRCUIT 120 VAC START CIRCUIT SW INVERTER No 2 COMMON GREEN LED YELLOW Le 5 AMP FUSE 240VAC REI RE SYST BATTERY DISCONNECT WITH GR D CONN ED WI OVERCURRENT PROTECTION G E N RA BACKUP SWINSTLDWG 7 99 REMOTE STACKING Pa e Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger 9 5916 195th Street E Fax 360 435 2229 Part No 2031 5 122 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 TECHNICAL INFORMATION USER SETTINGS WORKSHEETS Your SW Series Inverter Charger may have USER and or SETUP operating settings that are different or are changed from the standard factory settings The USER DEFAULT settings are the
17. LOW BATTERY TRANSFER 16 MENU HEADING Set Low Battery Set Low Battery Set Low Battery Transfer VDC 11 3 Transfer VDC 22 6 Transfer VDC 45 2 12 VDC models 24 VDC models 48 VDC models Range 05 0 to 16 5 Range 10 0 to 33 0 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 temperature compensated The transfer will occur 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 Set Low battery Set Low battery cut in VDC 13 0 cut in VDC 26 0 cut in VDC 52 0 12 VDC models 24 VDC models 48 VDC models Range 05 0 to 16 5 Range 10 0 to 33 0 Range 20 0 to 66 0 This setting controls when the inverter turns 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 resumes powering the AC loads from the inverter when LBX mode is being used In LBX mode the best performance 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 sources wind solar etc must then cause the battery voltage to rise above
18. 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 bution is pressed while in any other menu item or menu heading only the control panel display and remote control display is reset no settings will be reset This is useful for clearing any garbled display information This may be encountered when a remote 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 Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 9 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 39 MENU SYSTEM METERS 4 MENU HEADING The current meters provided measure only the real in phase component of the curren
19. 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 determined by the charge cycle FLOAT or BULK and the settings of the BULK CHARGE TRIGGER TIMER 15 and the GRID USAGE TIMER 18 settings 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 HOT 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 avail
20. sse enema 76 Figure 24 Three Wire Start Wiring Diagram HONDA Type 77 Figure 25 Three Wire Start Wiring Diagram ONAN 77 Figure 26 Relay RY7 and RY8 Sequence ssssssssssssssssee eene nnne nennen 78 Figure 27 Selling Power From 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 ssssssssssssses eene 89 Figure 31 Series Configuration 6 Volt Battery Wiring sssssseeeneeenens 107 Figure 32 Series Configuration 12 Volt Battery Wiring essesseeeeeene 107 Figure 33 Parallel Configuration 12 Volt Battery Wiring sse 108 Figure 34 Series Parallel Configuration 6 Volt Battery Wiring anneer enneerenneneenn 109 Figure 35 Series Parallel Configuration 12 Volt Battery Wiring nnen eenen eenen eneen 109 Figure 36 AC PARS da 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
21. 15 0 ET Hysteresis volts DC 00 1 12 8 01 0 Bulk Charge Trigger Timer 15 Start Bulk Time H M 00 00 23 50 00 00 Low Battery Transfer LBX 16 Set Low Battery transfer VDC 05 0 16 5 11 3 Set Low Battery cut in VDC 05 0 16 5 13 0 Battery Selling 17 set Battery Sell volts DC 10 0 16 0 13 4 Set Max Sell amps AC 01 25 30 cria Usage Timer 18 Set Start Charge time h m 00 00 23 50 21 00 End Stop Charge time h m 00 00 23 50 21 00 Arlington WA 98223 Copyright O Trace Engineering Company Inc 5916 195th Street E Telephone 360 435 8826 Fax 360 435 2229 www traceengineering com SW Series Inverter Charger Part No 2031 5 Rev B Sept 1 1999 TECHNICAL INFORMATION SETUP MENU 24 VDC 120 VAC 60HZ MODELS To access the SETUP MENU press the RED and GREEN buttons on your CONTROL PANEL or SWRC at the same time To exit the Setup Menu press the ON OFF MENU button or use the down MENU HEADING button until you reach the USER MENU menu headings 1 8 MENU HEADING MENU ITEM SELECTION DEFAULT USER RANGE SETTINGS SETTINGS Inverter Setup 9 set Grid Usage FLT SELL SLT LBX FLT Set Low Battery cut out VDC 16 0 35 5 22 0 Set LBCO Delay minutes 00 255 15 Set Low battery cut
22. 195th Street E Fax 360 435 2229 Part No 2031 5 100 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 TECHNICAL INFORMATION BATTERY SIZING Batteries are the inverter s fuel tank The larger the batteries the longer the inverter can operate before recharging is necessary An undersized battery bank results in reduced battery life and disappointing system performance Batteries should not be discharged more than 50 of their capacity on a regular basis Under extreme conditions such as a severe storm or a long utility outage cycling to a discharge level of 80 is acceptable Totally discharging a battery may result in permanent damage and reduced life For stand alone applications it is common to size a battery to provide between 3 and 5 days worth of storage before the battery requires recharging The power contribution from other charging sources is not included in this calculation to duplicate the conditions present during a cloudy or windless period This is often referred to as the number of days of autonomy If the system is a hybrid system with daily generator run periods then the battery size may be smaller During cloudy periods the generator would be expected to run longer Utility connected applications often have very small batteries If the system does not provide utility backup function the minimum battery capacity recommended is 320 amp hours 12 vdc 160 amp hours 24 vdc and 80 amp hours
23. Fax 360 435 2229 Equalization Charging 39 52 76 77 89 90 110 2 22222 cc 21s Ds ra iod ore Frequency Gen Control Wiring Maximum Run Time nnen nnn ennneneeneeennnnnnnenren 56 SPIN iederen eerden 32 Start Routines NS Start Status haiti nem He ERI nU ee Starting and Stopping Three Wire Start Two Wire Start tend eode ee eerta Warm Up tlme ee eee ntn tentent enne nene nnn Generator AC2 Volts AC Menu 4 Generator Auto Start Requirements Three Wire Start Generators Two Wire Start Generators E Generator Control Equalization Charging Generator Error Causes Generator Max Run Time Generator Stop Cool Down Period Generator Error Causes Gen Max Run Time Error Gen Under Over Speed m Generator Start Error sess Generator Sync Error Generator Exercising Generator Max Run Time Generator Mode Menu 2 Generator Start Error essen Generator Start Error Menu 2 Generator Start Error Menu 5 Generator Start Stop Configurations 84 Generator Starting Scenarios
24. Grounding Vs Lightning Neutral To Ground Bond Switching T T240 Transformer sss 144 TFB iii 24 Theory of Operation ennn nennen vens eennerenenen 65 Block Diagram re need et 65 Output Waveform nnen vennen enne 66 Three Wire Start Generators esses 87 Time of Day Metering Time of Day Menu 6 Torque Wire Connections nnn anneer eneen ronca nc ncananannnns 21 Trace Engineering Menu 3 40 Trace Meter TM500 neee eener eenen 144 Transfer Time 21 78 91 Inverter Charger Mode 78 Transferring Based On Battery Voltage Inverter Charger Mode 78 Transferring Upon Availability Of AC Power Inverter Charger Mode Transformer Overtemp Menu 5 m Two Wire Start Generators U Universal motors See Inductive Loads Unpacking ierit vaarden cene inen 18 User Menu 37 Menu 37 Menu Map nn eren fna nes 35 User Settings Worksheet 138 Setup Menu 12 VDC 139 Setup Menu 24 VDC 140 Se
25. Higher battery voltage decreases the number of steps 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 assist 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 mode circuit is available to minimize the power draw of the inverter when no loads are being operated This reduces the power consumption 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 presence 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 considerable 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 clock 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
26. gas tank requiring more frequent refueling by the back up source usually a generator This should be considered when designing the system If extremely cold temperatures are expected at the location of a system either a heated equipment room or alkaline batteries should be considered If the system is located in an unheated space an insulated enclosure is highly recommended for the batteries During the charging process the batteries release heat due to the internal resistance of the battery If the batteries are insulated the heat can be kept in the batteries to keep them warmer This will substantially increase the performance of the system Insulated battery enclosures also ensure that the temperatures of the individual battery cells are more consistent preventing unequal charging which can cause battery failure some cells will be overcharged while others are undercharged The batteries should also be protected from high temperature as well This can be caused by high ambient temperatures solar heating of the battery enclosure or heat released by a closely located generator High battery temperatures will result in short battery life and should be avoided by ventilating the enclosure and reducing the external heat sources by shading and insulation Pa e Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger 9 5916 195th Street E Fax 360 435 2229 Part No 2031 5 106 Arlington WA
27. nennen eneen 112 Care And Maintenance 118 Enclosure eee Ces 120 Hook Up 121 Parallel Connection annen nennen nennen 122 Series Connection nanne enneenenneerenneneeneen 121 Series Parallel Connection 122 Hydrogen Sulfide Gas Installation Monthly Polantys Temperature Terminals riter Battery Actual Volts DC Menu 4 41 Battery Cable Battery To Inverter 120 Cable Inductance nisn niai 124 Cable Size vs Cable Length 23 146 Connections 2 25 Installation Procedure 25 Maximum Breaker Fuse 12 146 Sizing tmd ree RN ERR diens dd 23 Battery Charging Absorption Time essen Absorption Time AC Input Requirements Bulk Charging 48 60 63 72 75 78 92 94 98 103 Bulk Voltage Charge Rate de Charger Only Operation 73 Charging Setpoints sees 75 118 Equalization Charging 39 52 76 77 89 90 110 118 Float Charging 51 73 98 11
28. 195th Street E Fax 360 435 2229 Arlington WA 98223 www traceengineering com SW Series Inverter Charger Part No 2031 5 Rev B Sept 1 1999 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 control system when the current 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 system 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 Set 24 hr start Set 24 hr start volts pc 12 3 volts DC 24 6 volts DC 49 2 12 VDC models 24 VDC models 48 VDC models Range 05 0 to 16 5 Range 10 0 to 35 5 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 setting is not temperature compensated This 24 hour start is defeated if the QUIET TIME under GENERATOR TIMER 7 is enab
29. Operating heavy loads while charging an unstable generator or even low electrolyte levels in the battery can cause this This may 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 conditions increasing the SET MAXIMUM RUN TIME menu item setting may be necessary for your application When using the automatic generator control system to complete a equalization cycle the additional time required for the EQ cycle should be considered 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 from AUTO or ON to OFF in the SET GENERATOR menu item This clears all the generator error conditions and resets the start attempts counter Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 79 OPERATION 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 fro
30. PAGS Msn HOT VOE Pa e Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger g 5916 195th Street E Fax 360 435 2229 Part No 2031 5 8 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 CONTROLS INDICATORS AND COMPONENTS CONTROLS INDICATORS AND COMPONENTS The SW Series Inverter Chargers have an integral full function Control Panel with LED status indicators The following components are also included inverter charger circuit breaker battery temperature sensor BTS port remote port and a stacking port Stacking Interface Remote Interface AC Side e e e h Control Panel DC Side BTS Sensor Input Power Conversion Center N 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 operation of the unit The control panel is operational whenever DC power is applied to the inverter DC input terminals CONTRAST ACT IN GOOD INVERTING 2 IN GOOD OVER CURRENT RESET TO FACTORY DEFAULTS
31. STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7 STEP 8 STEP 9 Copyright O Trace Engineering Company Inc 5916 195th Street E Arlington WA 98223 Determine what appliances the inverter will power and enter the Appliance Running Wattage of each appliance Determine the number of hours or fractions of hours you will use the appliance each day Multiply the number of days you will use the appliance during the week this is your Weekly Watt Hours Needed Divide your Weekly Watt Hours Needed by 7 to obtain the Average Daily Watt Hours Needed Total Average Daily Watt Hours Needed to determine your Total Daily Watt Hours Needed Multiply your Total Daily Watt Hours Needed Step 5 by the number of anticipated days of autonomy days between charging usually 1 to 5 to determine your Autonomy Battery Size example used 3 days Multiply your Autonomy Battery Size Step 6 x 2 to allow for a 50 maximum battery discharge in normal operation and an additional 50 for emergency situations to obtain your Rough Battery Size in watt hours Multiply your Rough Battery Estimate x 1 2 to allow for an efficiency of 80 This number is your Safe Battery Size in watt hours Convert your Safe Battery Size to amp hours Divide Safe Battery Size by the DC system voltage i e 12 24 or 48 VDC example used 24 volts This number is your Safe Battery Size in amp hours which is the battery bank capacity
32. amp 2 volts 1 valid only when Inverter synced to that input temen IBatt volt actual I lis used for 1 LBCO HBCO LBX LBCI sell volts land starting volt is us Batt wit Terp pa ed i for float bulk eg 1 amp aux relays over Current Current EE NO Transformer overtemp NO Heatsink overtemp High Battery voltage NO Low Battery voltage No Inverter breaker tripped NO source wired to output No External error stacked NO Generator start error Ni Generator sync error 3 Gen max run time error la 3 Gen under over speed 3 Inverter breaker tripped No Telephone 360 435 8826 Fax 360 435 2229 www traceengineering com set Clock 00 00 Clock 00 00 Clock hour 00 minute 00 second 00 Generator Timer 7 Start Quiet Time h m End Quiet Time h m for 30 seconds To defeat timers end Iset start If exercise day set to 1 then I gen will always _ L 08 00 08 00 unless batt lts is less m o Istart endquiet I End User Menu SW Series Inverter Charger Part No 2031 5 Rev B Sept 1 1999 MENU SYSTEM SETUP MENU MAP The SETUP MENU provides all the controls and settings needed when installing or adjusting the system T
33. 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 supporting 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 VAC 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 combination 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 Trace Engineering offers a balancing transformer Part Number T 240 for this purpose See OTHER PRODUCTS section on page 129 or contact your inver
34. 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 Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 0 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 57 OPERATION 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 tracked and the inverter constantly adjusts its frequency 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 created by the inverter has a higher voltage than the paralleled AC source then power flows from the batteries to the load If the waveform generated has a lower voltage than the AC source power flows from the source to the battery 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 stage charge cycle If the level of AC current exceeds the user programme
35. 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 inter active modes Adjustable sellback current level for utility inter active 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 Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 61 OPERATION INVERTER MODE BATTERY DC INVERTER AC AC LOADS IN BRIEF The inverter makes a stepped approximation to a sine wave The number of steps typically varies from 34 to 52 per cycle Lower battery voltage and or higher output power level increases the number of steps
36. 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 extremely good oversizing the inverter does not reduce system performance Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 59 OPERATION INVERTER CAPACITY VS TEMPERATURE The current protection circuit in the SW Series Inverter Charger is temperature compensated therefore the maximum sized load that the inverter can run changes with temperature As the temperature of the power devices FET s increase the allowable current is reduced When the available current is reduced the capacity of the inverter to run loads is reduced The graph below shows the effect temperature has on the inverter s capacity to run loads notice that the inverter reduces its capacity at temperature above 25 C The temperature 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 of 80 total rated 60 power ca
37. 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 71 OPERATION 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 exceeds 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
38. 48 vdc If utility back up is required larger batteries will be needed ESTIMATING BATTERY REQUIREMENTS In order to determine the proper battery bank size it is necessary to compute the number of amp hours that will be used between charging cycles When the required amp hours are known size the batteries at approximately twice this amount Doubling the expected amp hour usage ensures that the batteries will not be overly discharged and extends battery life To compute total amp hours usage the amp hour requirements of each appliance that is to be used are determined and then added together You can compute your battery requirements using the nameplate rating of your appliances The critical formula is Watts Volts X Amps Divide the wattage of your load by the battery voltage to determine the amperage the load will draw from the batteries If the AC current is known then the battery amperage will be AC current X AC voltage _ pc amps battery voltage Multiply the amperage by the number of hours the load will operate and you have reasonably enough amp hours Motors are normally marked with their running current rather than their starting current Starting current may be 3 to 6 times running current Manufacturer literature may provide more accurate information compared to the motor nameplate If large motors will be started increase the battery size to allow for the high demand start ups require Follow this procedure for each ite
39. 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 13 CONTROLS INDICATORS AND COMPONENTS 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 RY7 RUN RY8 CRANK RY9 11 AUX Auxiliary Control Generator Control Relay Connectors 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 WARNING HERGA ee x OS 2 d m D x x o o Hd DC Equipment Ground 9 3AILVO3N AH3LLV8 Battery Terminal Battery Terminal ANNANAANANNNANNNNANN VUUUUU ANANDA VUUUUU Anm VUUUUU VUUUUU Figure 7 DC Side BATTERY TERMINALS WARNING Before connecting the battery cables to the inverter verify the correct battery voltage and cable polarity using a voltmeter The inverter is not reverse polarity protected If the positive terminal of the
40. 56 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 OPERATION OPERATION The SW Series Inverter Charger 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 size or functioning as a utility interactive inverter which will allow you to send excess power back to the utility grid 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 The extensive configurations 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 inverters employ a new patented inverter design This design uses 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 Bridges are mixed by Controllers Micro Controll
41. 98223 www traceengineering com Rev B Sept 1 1999 TECHNICAL INFORMATION BATTERY HOOK UP CONFIGURATIONS Battery banks of substantial size are generally created by connecting several smaller batteries together There are three ways to do this Batteries can be connected in series to increase voltage in parallel to increase amp hour capacity or in series parallel to achieve the required voltage and capacity The cables which connect the individual batteries together to make a larger battery bank should be connected together will heavy cables The actual size of the cable depends upon whether the batteries are connected in parallel or series Generally the cables should not be smaller than the inverter cables if the main cables are 4 0 AWG the battery interconnects should be 4 0 AWG Remember for safety and to comply with UL regulations battery over current protection is required in the ungrounded battery cable SERIES CONNECTION When batteries are connected with the positive terminal of one to the negative terminal of the next they are connected in series In a series configuration the battery bank has the same amp hour rating of a single battery but an overall voltage equal to the sum of the individual batteries This is common with 24 volt or higher battery inverter systems FUSED DISCONNECT 24V INVERTER Total Battery Capacity 100 Amp Hours 12V INVERTER Total Battery Capacity 100 Amp
42. AC 30 See menu 9 to enable SELL mode Gen Auto Start 11 setup 12 gt Set Load Start Ac 20 Set Load Start delay min 5 0 Set Load Stop delay min Set 24 hr start volts DC Set 2 hr start volts 11 8 Set 15 start volts DC 11 3 Read LBCO 30 sec start voc 11 0 Set Exercise period days 30 Set Maximum run time h m 08 00 I Set Max Run time 1 Ito 0 to defeat 1 Set Exercise to 0 l See menu 9 to Ito set LBCO nnn Grid Usage Timer 18 Start Charge time 21 00 End Charge time l time FLT mode drops laci and inverts 5 9 4 starting details 13 set RY7 Function RY7 Function G1owstep Run Set Gen warmup seconds 60 set Pre Crank 10 Set Cranking seconds 10 Set Post Crank seconds 30 OE Information file battery 19 Batt temp comp changes battery voltage gt reading 7 l away from actual HBCO resets at Ov 48 3v 24 and LowBattTransfer in LEX FT il ror LBX mode set l below LBCI so Sell and float I modes use timer 1 Auxiliary Relays R9 R10 R11 14 IIM set Relay 9 volts DC R9 Hysteresis volts DC 01 0 Set Relay 10 volts 14 8 R10 Hysteresis volts DC 01 0 Set Relay 11 volts 15 0 R11 Hysteresis volts DC 01 0
43. Amps AC Menu 11 Set Grid Usage Menu 9 Set High Battery Cut Out VDC Menu 9 50 Set Input Lower Limit VAC Menu 11 53 Set Input Upper Limit VAC Menu 11 53 Set Inverter Menu 1 38 Set LBCO Delay Minutes Menu 9 49 Set Load Start Amps AC Menu 12 54 Set Load Start Delay Min Menu 12 54 Set Load Stop Delay Min Menu 12 54 Set Low Battery Cut in VDC Menu 9 49 Set Low Battery Cut In VDC Menu 1 Orientada 61 Set Low Battery Cut Out VDC Menu 9 49 Set Low Battery Transfer VDC Menu 16 60 Set Max Charge Amps AC Menu 10 52 Set Max Cranking Seconds Menu 13 57 Set Max Sell Amps AC Menu 17 62 Set Maximum Run Time Menu 12 56 Set Post Crank Seconds Menu 13 57 Set Pre Crank Seconds Menu 13 57 Set RY7 Function Menu 13 56 Set Search Spacing Menu 9 50 Set Search Watts Menu 9 50 Set Temp Comp Menu 10
44. 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 00 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 Causes the automatic generator control system to ignore the AC load and battery voltage start settings The quiet time period is usually set for the sleeping hours End Quiet Time h m 08 00 This setting finishes the quiet time period 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 exercise system will start at this time setting and will run for 15 minutes if the generator exercise timer has reached the SET EXERCISE DAYS menu item setting For example if the SET EXERCISE DAYS menu item is set for 1 then the generator will start every day at this time To disable the generato
45. Fax 360 435 2229 Part No 2031 5 6 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 UNIT IDENTIFICATION 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 1490 MODEL Sw4024 _ SW4024K sw4024MC SW4024MC2 Sw4024W SW4024 Model Number CONTINUOUS DUTY DUTY DC INPUT DC Input Voltage 220 300 VDO TE E rating Ran DC OUTPUT Operating Range 800 AMPS PEAK 25 20V0G J 0 20 AMPS AC OUTPUT 1 amp Y AC INPUT 14 105VAC 38 1 AMPS 120VAC 33 3 AMPS 220VAC 18 2 AMPS 230VAC 17 4 AMPS 240VAC 16 6 AMPS 60 HZ AC Input Output PROVIDED WITH INTEGRAL PROTECTION AGAINST OVERLOADS Phase TRACE ENGINEERING USA PATENT No 5 373 433 f 5916 195TH ST NE ARLINGTON WA 98223 USA Waveform QUARTER YEAR Frequency and Voltage DATE OF MFR 1 Product Code and Serial IS N W Number Figure 1 Identification Label MODEL NUMBER The Model Number of your inverter determines the different features your unit may have Consider the following unit with a SW4024 model number SW 40 24 Model Power Nominal DC A
46. File 63 Menu Buttons gic tasa nda adds 10 GEN MENU BUHON tna 10 Menu Access Adjustment Buttons 10 MENU HEADING Buttons annen eenen 10 MENU ITEM Buttons nonnen iiaeiai 10 ON OFF MENU Button neee 10 SET POINTS Buttons nanne eenen eenneneenneerenn 10 MENU HEADING Buttons nanne eenen eenn 10 Menu Headings Setup Menu ett a dae ntes 46 User Menu MENU ITEM Buttons ooooccccocccccnoncnnonoccnonancncnnnncncanacaconancnnos 10 Menu Map Setup Melania eee ens 36 User Menu Meters Menu 4 41 Model Identification 7 Model Number Mounting an Multiple Inverter Stacking Port 12 Multiple Inverters nennen 107 Automatic Generator 110 Battery Charging esee 109 Charger Settings sene 109 Parallel Stacked 108 Generator Control 5 109 Series Stacked Operation 107 240 VAC Input Output Breaker 108 240 VAC Only 108 N Neutral To Ground Bond Switching External AC Source Connected RV And
47. Marine Applications esses ON OFF MENU Button nnen eeen 10 Options Mica 143 Remote Control ronte tete ente eee ensi 143 SineWave Communications Adapter 143 SWEAT A oa A te etim eet ente 143 SWRG a 143 Other Products 5 sain eei ne ee Ee EUER 144 C12 Charge Controller 144 C40 Multi Function 144 Overcurrent Protection essen 144 SW Series Power Panel 144 T240 Transformer esses 144 TM500 Trace Meter Battery Status Monitor 144 rete tore tte eden Overcurrent LED Overcurrent Protection Overcurrent Menu 5 P Parallel Stacked 108 Generator Control Settings 109 Peak Load Shaving 69 Personal Precautions cierres 3 Power Consumption Of Common Appliances 145 Power Vs Efficiency 67 Press Reset Now For Defaults Menu 3 40 Quick Install zen 21 eec a AC In Cabling AC Out Cabling DC Cabling Moun
48. NET metering where only one meter is installed and spins either direction The purchase and sell prices are equal Dual metering requires two meters and is less desirable since 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 from a DC source is available it will be used to power any AC loads connected to the AC output first Any excess power available from the system will be sold into the utility gird through the AC HOT IN 1 terminals e SLT The silent mode does not maintain 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 grid charging the battery 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 returned This is typically used only
49. NEUTRAL RV Marine TO GROUND BOND is GFI s will z incorrectly provided nuisance trip 5 in the AC panel with multiple The neutral Neutral to conductor should Ground bonds not be connected to the equipment grounding conductors or enclosures Figure 14 Neutral To Ground Bond Switching Neutral Bonded To Ground Pa e Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger g 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 28 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 INSTALLATION GROUNDING VS LIGHTNING This information is intended to provide basic grounding techniques that will help prevent inverter damage 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 15 the ultimate authority as to legitimate grounding techniques for your electrical system If an electrical system has components grounded at different points in the earth large voltage differences 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 Trace inverters are designed to withstand a minimum 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 th
50. OVERLOAD PROTECTION on page 82 Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 81 OPERATION UTILITY SUPPORT OVERLOAD PROTECTION This battery charger is very powerful and without limits could draw more current than is available from 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 current 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 amount 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 current 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 may 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
51. Press the SW Inverter Charger s green GEN MENU pushbutton to access the SET GENERATOR menu Select OFF to disable the auto generator start feature e Configure the vehicle s electrical system for the correct shore power service settings e Connect the vehicle s shore power cord to a properly rated receptacle confirm it is live e Press the SW Inverter Charger s red ON OFF MENU pushbutton to access the SET INV menu Select CHG to put the unit into the charger only mode e Switch OFF all unnecessary AC and DC loads WARNING DO NOT STORE THE VEHICLE INDOORS WITH THE AUTO GEN START FEATURE ENABLED GENERATORS EXHAUST DANGEROUS FUMES WHEN RUNNING Exterior Storage For exterior storage follow the same steps as above If shore power is not available enable the Auto Gen Start feature and ensure there is enough fuel available to run the generator for charging the batteries The generator will automatically start and stop depending on the batteries state of charge Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 133 APPENDIX PAGS TUBE MYT Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Page 5916 195th Street E Fax 360 435 2229 Part No 2031 5 134 Arlington WA 98223 www trac
52. Series Inverter Charger using the provided DB 25 communications cable may connect either the SWRC SWCA Both options cannot be connected at the same time The SWCA provides the following features e Remote set up The SWCA is capable of direct connection to a modem for use in remote sites where a computer is not desired This makes remote set up simple and easy for end users dealer distributors or anyone familiar SW Series Inverter Chargers With an on site modem and cellular communications network costly trips are no longer necessary Simply dial up your onsite modem and reset or adjust your systems via a virtual control panel simulation e Troubleshooting In the event that problems occur in the field the SWCA can be used to do simple troubleshooting by accessing meters and error conditions from your home or office This feature is great for new users and allows dealers to guide their customers through simple set up and adjustment problems that would usually require on site assistance An ideal service program for authorized Trace service centers distributors and dealers e Monitoring By simply paralleling the four cable conductor access to eight adapters is made possible Further long term monitoring can be made via an external data logging device SWCB The SWCB conduit box consists of a metal enclosure for connection to the SW Series Inverter Charger and is provided to meet applicable codes and safety standards The SWCB
53. Systems Set 15 Min Start Volts DC Menu 12 Set 2 Hr Start Volts DC Menu 12 Set 24 Hr Start Volts DC Menu 12 Set Absorption Time Menu 10 Set Aux Relay 9 Volts DC Menu 14 Set Aux Relay 10 Volts DC Menu 14 Set Aux Relay 11 Volts DC Menu 14 Set Battery Sell Volts DC Menu 17 Set Bulk Volts DC Menu 10 Set Clock Hours Menu 6 Set Clock Minute Menu 6 Set Clock Second Menu 6 Set Equalize Time Menu 10 Set Equalize Volts DC Menu 10 Set Exercise Period Days Menu 12 Set Float Volts DC Menu 10 Set Gen AC2 Amps AC Menu 11 Set Gen Warmup Seconds Menu 13 Pa e Copyright O Trace Engineering Company Inc 9 5916 195th Street E 140 Arlington WA 98223 Telephone 360 435 8826 www traceengineering com SW Series Inverter Charger Part No 2031 5 Rev B Sept 1 1999 Fax 360 435 2229 Set Generator Menu 2 seen Set Grid AC1 Amps AC Menu 11 Set Grid Usage Menu 9 Set High Battery Cut Out VDC Menu 9 Set Input Lower Limit Set Input Lower Limit VAC Menu 11
54. 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 are red for positive and black for negative Always double check the polarity with a voltmeter before making 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 Polarity 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 between the cable ring terminal and the flat metal part of the terminal or overheating of the terminal may occur DO NOT APPLY ANY TYPE OF ANTI OXIDANT PASTE until after the battery cable wiring is tightened to 10 15 foot pounds Note Connecting the battery cables to the inverter battery terminals may cause a brief spark or arc usually accompanied by a snapping sound This is normal don t let it scare you It is simply the internal capacitors of the inverter being charged Pa e Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger g 5916 195
55. Telephone 360 435 8826 SW Series Inverter Charger 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 PUE hi TzW TIU ALLf HOT Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 TABLE OF CONTENTS IMPORTANT SAFETY INSTRUCTIONS 1 GENERAL PREGAUTIONGS 5 1 22 2 ains e Peces He epe he Dade Dt des ertet ta a 1 SPECIAL NOTICES sint tie eee te e tere Se e tato e pi eed e Dee tet oett doter n Re 2 PERSONAL PREGAUTIONINS 41 iio DE 3 INTRODUCTION a tacna 5 UNIT IDENTIFICAT O N m 7 etos DID dme e 7 CONTROLS INDICATORS AND COMPONENTS annen enen enan serene eneen ensen snanenensenrenseunananenanenenseneenn 9 CONTROL PANEL ico dee oh dtu edad t ad ate 9 A A a A a ve tee ea eee ee 12 EN 14 A A 15 QUICK INSTALL con iS a E ee ie 16 COMPLETE INSTADLI s s ciet ocior E to m boe tain tt 17 FUNCTIONAL EE 31 MENU SYSTEM TO neee 33 OVERVIEW RN PE 33 USER MENU MAP
56. 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 adjusts the inverter s time clock e 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 SYSTEMis accessed through the CONTROL PANEL on the front of the unit To access the SETUP MENU press both the red ONOFF 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 menu system of the USER MENU lf 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 Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 33 MENU SYSTEM USER MENU MAP Menu Heading Menu Item The values shown are the factory default values for Model SW2512 See the USER and SETUP menu item descriptions Setpoint for default values for other models aaa A Push button
57. batteries at the float voltage level This can be used when the source of power is a utility grid or a generator When AC power is available the inverter will complete 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 for use with stand alone systems with back up generators or utility back up systems FLT mode does not sell excess power into the utility grid If a DC power source is available and the battery 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 more power is available from the DC source 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 e SELL SELL mode enables the inverter to sell the excess power to 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 must be met Be advised some utilities will be more receptive than others will The most advantageous configuration is called
58. battery cut in VDC 20 0 71 0 52 0 Set High battery cut out VDC 20 0 66 0 64 0 Set search watts 00 240 48 Set search spacing 20 255 59 Battery Charging 10 Set Bulk volts DC 40 0 64 0 57 6 Set Absorption time h m 00 00 23 50 02 00 Set Float volts DC 40 0 64 0 53 6 Set Equalize volts DC 40 0 64 0 57 6 Set Equalize time h m 00 00 23 50 02 00 Set Max Charge amps AC 01 35 30 Set Temp Comp LeadAcid Nicad LeadAcid AC Inputs 11 set Grid AC1 amps AC 00 63 i 60 Set Gen 2 amps AC 00 63 30 Set Input lower limit VAC 80 111 108 Set Input upper limit VAC 128 149 132 cen Auto Start Setup 12 Set Load Start amps AC 00 63 33 Set Load Start delay min 00 0 25 5 05 0 Set Load Stop delay min 00 0 25 5 05 0 Set 24 hr start volts DC 20 0 71 0 49 2 Set 2 hr start volts DC 20 0 71 0 47 2 Set 15 min start volts DC 20 0 71 0 45 2 Read LBCO 30 sec start VDC 20 0 71 0 44 0 Set Exercise period days 00 255 30 Set Maximum run time h m 00 00 23 50 08 00 Gen Starting Details 13 set RY7 Function GlowStop Run Run Set Gen warmup seconds 16 255 60 Set Pre Crank seconds 00 255 10 Set Max Cranking seconds 00 15 10 Set Post Crank seconds 00 255 30 auxiliary Relays R9 R10 14 Set Relay 9 volts DC 20 0 71 0 58 0 Hysteresis volts DC 00 2 25 6 04 0 set Relay 10 volts DC 20 0 71 0 59 0 R10 Hysteresis volts
59. defaulted to the same value as the SET FLOAT VOLTS DC setting the inverter will sell the power from 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 offers the individual system owner with several advantages The 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 End Day 00 00 20 00 23 59 Bulk Charge Trigger Timer is Set Start Bulk enabled not the default setting time 20 00 Battery Sell Volts Bulk Volts DC Setting DC Setting Set Bulk Volts DC 14 4 Float Volts DC Setting DC Volts 13 0 Charging from the DC source wind hydro or solar has started Set Float VoltsDC 13 4 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 Set Absorption time h m 02 00 Absorption Time
60. discharge The disadvantage is high initial cost and because water cannot be added they are less tolerant of overcharging Two methods are used to seal batteries by a process of immobilizing the electrolyte which in turn eliminates free flowing acid Both these methods can be used in inverter applications Gel Cell Silica gel is added to the electrolyte causing it to set in gelatin form Absorbed Glass Mat AGM Highly absorbent glass mat separators are used between each plate to retain the liquid electrolyte Even with all the advantages of sealed batteries there is still a place for the standard flooded deep cycle battery Sealed batteries will cost 2 to 2 5 times as much as liquid or flooded batteries In many installations where the batteries are set in an area where you don t have to worry about fumes or leakage a standard or industrial deep cycle is a better economic choice NICAD AND NICKEL IRON NIFE BATTERY Trace inverters and battery chargers are optimized for use with lead acid batteries that have a nominal voltage of 2 0 volts per cell NiCad NiFe batteries also called alkaline batteries have a nominal cell voltage of 1 2 volts per cell The nominal voltage of a NiCad NiFe battery bank can be made the same as a lead acid bank just by juggling the number of cells 10 cells for 12 volts 20 cells for 24 volts and 40 cells for 48 volt systems However the NiCad NiFe battery bank must be charged to a higher voltage to f
61. 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 difficulty 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 Water cooled units are usually more quiet but can require more maintenance Low speed 1800 1500 rpm generators are preferred by many system designers as they often provide longer life due to less mechanical wear and tear TWO WIRE START GENERATORS Generator starting requirements can be divided into two categories two wire start types and three wire start types The two wire start type generator is more simple and the easiest to automate To start simply connect the two remote control wires together and starts The generator provides its own cranking control circuit for start 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 of the inverter and connect the generator output to AC HOT IN 2 input of the inverter Two wire start generators are specifically designed for unattended operat
62. inverter as you would any fine piece of electronic equipment When selecting the location for the inverter don t think of it in the same terms as the other interfacing equipment e g batteries diesel generators motor generators washing machines etc It is a highly complex microprocessor controlled device There are nearly 500 000 silicon junctions in its output devices and integrated circuits The crystal oscillator runs at 4 megahertz The drive circuitry timing is accurate to a thousandth of a second Genetically speaking it is a cousin to stereo equipment television sets or computers The use of conformal coated circuit boards plated copper bus bars powder coated metal components and stainless steel fasteners improves tolerance to hostile environments However in a corrosive or condensing environment one in which humidity and or temperature change cause water to form on components all the ingredients for electrolysis are present water electricity and metals In a corrosive or condensing environment the life expectancy of the inverter is indeterminate and the warranty is voided Caution It is in your best interests to install the inverter in a dry protected location 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 possible in order to keep the battery cable length short Do not locate the inverter directly ab
63. is initiated Load Start amps AC setting for enabled before the next longer than the Set Load Stop auto generator start delay min period attempt RUN or ON engages to the N O position GLOW OFF ON OFF engages to the N C position ON OFF ON STOP opm _____ START SET PRE SET MAX SET Gen LOCK ON GEN RUN PERIOD COOL Generatoris START SET PRE DELAY CRANK CRANKING WARM UP GOOD DOWN off and DELAY CRANK PERIOD SECONDS SECONDS SECONDS DELAY Determined by the PERIOD waiting for PERIOD SECONDS PERIOD voltage and time next auto 8 SECS 10 SECS 10 SECS 60 SECS settings under the 40 SECS generator 8 SECS 10 SECS FIXED DEFAULT DEFAULT DEFAULT 12 SECS BATTERY FIXED start FIXED DEFAULT FIXED CHARGING heading sequence RY8 goes Starts once or by the current and Only used off with a voltage Starts when delay min settings with Set 1 sec delay exceeds AC is within under the GEN Generator to when 80 VAC 108 to 132 AUTO START AUTO AC HOT IN VAC SETUP heading gt 80 VAC and 53 67 Hz RY8 ON OFF engages to the N C pasition m Time Sec 0 8 18 28 88 100 100 140 0 8 18 GEN CONTROL RELAYS OFF relay contact closed from N C to COM relay disengaged ON relay contact closed from N O to COM relay engaged Figure 26 Relay RY7 and RY8 Sequence Pa e Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger g 591
64. 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 Pa e Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger g 5916 195th Street E Fax 360 435 2229 Part No 2031 5 92 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 OPERATION LOW BATTERY TRANSFER LBX MODE UTILITY GRID kWH METER AC LOADS SUB PANEL SOLAR ARRAY DC AC LOADS MAIN PANEL INVERTER CHARGER GROUND FAULT PROTECTION AC OVERVOLTAGE pe PROTECTION Low Battery Transfer mode is an alternative way of operating off the grid using the utility for backup power instead of a generator The system essentially operates as a stand alone power system independent of the utility grid When the system is no longer able to keep up with the power requirements of the AC load discharging the batteries to the LOW BATTERY TRANSFER VDC setting the inverter connects to the utility grid It then feeds utility power directly to the load and recharges the batteries When the battery voltage reaches the LOW BATTERY CUT IN VDC setting the inverter disconnects from the utility grid and once again operates the AC load from the batteries Since power is never sold back to the utility this configuration does not requir
65. load will bring the inverter out of the search mode while a 5 watt load will not When in the search mode the yellow INVERT LED will blink slowly and the inverter will make a ticking sound At full output voltage the yellow INVERT LED will stay on and the inverter will make a steady humming sound When the inverter is used as an uninterruptable power supply the search mode should be defeated Exceptions Murphy s Law Unfortunately things don t always work the way the manual says Pa e Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger g 5916 195th Street E Fax 360 435 2229 Part No 2031 5 62 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 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 much greater than 32 watts when its filament is cold When the light gets bright the filament heats up and the light becomes 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 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 smaller load than 32 watts until the gas in the florescent tube ionizes and begins to glow This problem is more common
66. may be fitted to the DC side of the SW Series Inverter Charger The SWCB has Y 34 and 2 knockouts for attaching conduit hardware Page Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger 5916 195th Street E Fax 360 435 2229 Part No 2031 5 128 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 APPENDIX OTHER PRODUCTS Contact your Trace Engineering dealer for details of any of the products below C40 MULTI FUNCTION CONTROLLER The C40 Multi Function Controller may be used as a PV solar charge controller DC load controller or DC diversion regulator The unit works with 12 24 or 48 volts systems and is rated at 40 amps continuous capacity Other features of the C40 Multi Function Controller are field adjustable setpoints temperature compensation and protection electronic overload protection with manual or auto reset ability optional LCD meter and an optional battery temperature compensation sensor BTS C12 CHARGE CONTROLLER The C 12 Charge Controller is a 12 amp 3 stage solar charge controller DC load and automatic lighting control center The C12 Charge Controller is fully protected against overload short circuit and reverse polarity It is ideal for controlling lighting systems as it uses a PV array as an electric eye to see when it is dark so it knows when to turn on the lights Automatic reset battery over discharge and overcharge protection
67. or furnace piping Avoid chafing sources such as steering cables engine shafts and throttle connections Hopefully this information gives a much more realistic and clear idea of why battery cables should be kept short and close together Maximum performance is the goal of any well designed power system and the details such as this will help achieve the goal Pa e Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger 9 5916 195th Street E Fax 360 435 2229 Part No 2031 5 110 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 TECHNICAL INFORMATION APPLICATIONS RESISTIVE LOADS These are the loads that the inverter finds the simplest and most efficient to drive Voltage and current are in phase or in this case in step with one another Resistive loads usually generate heat in order to accomplish their tasks Toasters coffee pots and incandescent lights are typical resistive loads Larger resistive loads such as electric stoves and water heaters are usually impractical to run off an inverter Even if the inverter could accommodate the load the size of battery bank required would be impractical INDUCTIVE LOADS Any device that has a coil of wire in it probably has an inductive load characteristic Most electronic devices have transformers TV s stereos etc and are therefore inductive Typically the most inductive loads are motors The most difficult load for the inver
68. provide power when an outage occurs In order to disconnect from the grid during a specific 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 e Connect utility AC power to the inverters AC HOT IN 1 and NEUTRAL IN 1 terminals e Connect AC loads to the inverters AC HOT OUT and NEUTRAL OUT terminals e 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 e Set the SET GRID USAGE menu item under the INVERTER SETUP 9 menu heading to FLT e 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 e 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 m
69. 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 ltems 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 lt gt 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 lt 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 LowBattCutln aka LBCI For LBX mode set below LBCI so charger won t cycle batteries up and down set LBCO below Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 55 MENU SYSTEM PUE hi TzW TIU ALLf HOT Pa e Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger g 5916 195th Street N E Fax 360 435 2229 Part No 2031 5
70. settings During the equalization process check the temperature of each battery every hour by momentarily feeling the battery case If the batteries are excessively 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 Mmenu 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 timer is an accumulating type and does not reset if the voltage momentarily 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 bution 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 avai
71. settings of the inverters are best set to the same settings Only when a system is being operated in automatic generator control mode should staggered settings be used The most significant problem with multiple inverters charging the same battery is the voltage ripple caused on the battery This causes the chargers to not reach their full output two battery chargers on the same battery may not provide twice the charging rate to fill the battery in half the time The higher the charger rate and or the smaller the battery the more pronounced this problem would be The only way to reduce the problem is to individually cable each inverter and to connect them at opposite corners of the battery bank Keeping the cable size as short as possible also helps Since the inverters will all be charging the same battery one inverter may taper off first and finish the bulk stage before the others When a single inverter has reached the float stage it is best to turn off the generator at this time It may take a longer period of time for the remaining inverters to reach the float stage Running the generator to only power an inverter that is float charging is very inefficient and should be avoided If multiple Battery Temperature Sensors are installed ensure they are all connected to the same location battery This will also help prevent one inverter from tapering off first AUTOMATIC GENERATOR CONTROL WITH MULTIPLE INVERTERS Several considerations m
72. 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 frequency of the AC source it is connected to INFORMATION DISPLAY The following information is displayed as additional Menu Items AC1 amp 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 amp aux relays Read Frequency Hertz ERROR CAUSES 5 MENU HEADING When an error has occurred the red ERROR LED on the control panel will be illuminated 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 lf an error condition has occurred the word NO will be changed to YES To reset the error turn the inverter OFF and then ON Over Current NO Too large of a load was connected or the AC output wiring was short circuited This can occur in inverter or charger mode To clear this fault disconnect the loads and restart the inverter To restart push the red 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 problem If the inverter will not restart with all loads and inputs disconnected remove all AC wiring from the t
73. the automatic generator control system is enabled When the generator has started it will continue to blink slowly until the generator has been connected If the generator does not successfully start the AC 21 GOOD LED will stop blinking and the red ERROR LED will turn on The ERROR CAUSES 5 menu heading will indicate a GENERATOR SYNC ERROR condition BULK Yellow This indicator will be on to indicate the inverter is in the Bulk or Absorption charge stage 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 selected 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 process 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 charge to the battery until another Bulk Charge Cycle is initiated or the AC source is disconnected If a generator is manually controlled and powering the battery charger the FLOAT indicator will come on to indicate that the generator should be turned off since the ba
74. the charger settings before the system resumes inverter mode operation This setting 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 Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 0 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 53 MENU SYSTEM BATTERY SELLING 17 MENU HEADING Note See the battery section of this manual for recommended settings for different battery types Set Battery Sell Set Battery Sell Set Battery Sell volts DC 13 4 volts DC 26 8 volts DC 53 6 12 VDC models 24 VDC models 48 VDC models Range 5 0 to 16 0 Range 10 0 to 32 0 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 mode is enabled and the GRID USAGE TIMER 18 is programmed This setting will not be adjusted for the battery temperature if the temperature sensor is installed Set Max Sell Set Max Sell Set Max Sell Set Max Sell amps AC 30 amps AC 15 0 amps AC 35 amps AC 16 5 Standard models E models J 8 K models W models Range 01 to 35 Range 01 to 18 Range 01 to 40 Range 01 to 18 Sets the maximum AC amps allo
75. the red ON OFF MENU button can also access the SRCH mode It is also located as the first menu item under the INVERTER MODE 1 menu heading Pressing the red ON OFF MENU button again will move the cursor one position to the right The SET POINT buttons can also be used to move the cursor right or left To disable the search mode select ON from the SET INVERTER menu item Successful operation of the system utilizing the search mode requires some initial tuning of the search mode settings to match 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 circuit only is realized if the inverter is able to enter the energy saving search mode for substantial periods of the day Occasional checking of the yellow INVERT LED operation should be done to ensure that the search mode 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 With 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
76. the system types and sizes of loads operating environment time of unit operation and temperature 3 If your unit has not been registered a copy of your proof of purchase or purchase receipt is required for Warranty repair Repaired products will be returned freight C O D unless sufficient return shipment funds are included with the unit Products sent to the factory from outside the U S must include return freight funds and sender is fully responsible for all customs documents duties tariffs and deposits Record the model and serial numbers on your product and retain for your files Pa e Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger 9 5916 195th Street E Fax 360 435 2229 Part No 2031 5 136 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 INDEX INDEX A Absorption Time dle inediti 113 AC Inputs Menu 11 52 AC Pass Through Ability 19 AG Safety Ground seriene ece eiii epa raeo 14 12 AC Source Wired To Output Menu 5 0 44 AC Terminal 2 14 AC Wiring wld AC Input Connections 19 AC Output Connections nnee eneen eenen 19 Installation Guidelines nnen nennen eneen ennen 21 ACA In Good LED AC1 Relay Indicator AC In Good LED ui ar Automatic Generator Control Mo
77. to Ground switching and must be provided in the AC installation When the unit is operating as an inverter the AC output neutral should be connected or bonded to the frame hull chassis ground When an external AC source AC shore cord 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 can 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 source on board generator is included in the RV or boat this AC source neutral is required to be connected to ground when it is being used and to disconnect 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 applications neutral to ground switching is not required or acceptable The potential for galvanic corrosion caused by small leakage currents between boats with dissimilar metals is present The proper and safe ways to prevent this is by using galvanic isolators or include an isolation transformer for 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 th
78. to be available on a single output circuit from two inverters The pass through capacity is also doubled when connected to an AC source such as a fuel powered generator or a utility grid The inverter s operate in parallel and split the loads between them The inverters must be identical models and must have software revision REV 4 01 or higher software The inverters must be connected to the same battery bank with equivalent cabling both in length and in cable size The inverter negative terminals of the inverters must be connected together either at the inverters or at a location close to the inverters within 18 inches 0 5 meters The parallel stacking interface cable SWI PAR simply plugs into the stacking port on the left end of each inverter and allows the two inverters to operate as a single inverter The interface method is based on the series stacking system offered for the SW Series inverters since their introduction for the North American market The parallel stacking system operates the inverters in phase by having one of the inverters operate as the MASTER and the other as a SLAVE When an AC source is connected the MASTER first synchronizes to the AC source then connects to it and battery charges Since the SLAVE follows the master and is set up with a longer warm up delay the SLAVE inverter is already synchronized when it transfers the loads and starts battery charging This allows very smooth transitions from inverter mode to char
79. transformer in the system When used with a well pump connect the step up transformer after the pressure switch in order to reduce the load the transformer itself puts on the inverter This requires that 120 vac instead of 240 vac be connected to the pressure switch As a last resort consider powering the well pump directly from the generator instead of the inverter Many systems do not have enough battery capacity or excess power to handle a load as heavy as a well pump Using the generator with a storage tank with several days capacity may be more economical than oversizing the inverter battery and solar array just to power the well pump Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 111 TECHNICAL INFORMATION TROUBLESHOOTING GUIDE Page 1 INVERTER If ERROR LED comes on see ERROR CAUSES section PROBLEM INDICATION SOLUTION Unit will not DC voltage on the inverters DC Check the battery voltage fuses or no LED s are on and the terminals is incorrect breakers and DC cable connections to Control Panel Display is blank or off the inverter terminals is correct DC voltage on the inverters DC Have unit serviced Unit comes on but goes off quickly Excessive load on output unit is in over temperature protection needs to c
80. two stage lightning protection and surge suppression and optional temp compensation sensor are a few of the features of the C12 Charge Controller SW SERIES POWER PANEL SYSTEMS Pre assembled complete power panels featuring the SW Series Inverter Chargers are now available Each panel is complete and complies with all codes it is ETL listed All you do is connect to the battery and hook up AC loads An AC system bypass allows AC loads to operate while the inverter is locked out for servicing TM500 TRACE METER BATTERY STATUS MONITOR The Trace TM500 battery status monitor features seven data monitoring functions and two alarms that monitor battery state of charge real time amps total charging amps total load amps days since fully charged cumulative amp hours recharge alarm and full charge indicator Mounts up to 50 feet from the batteries Easily configured for liquid lead acid or gel cell batteries Works with 12 24 or 48 volt systems with an optional 48V shunt board STEP UP STEP DOWN BALANCING TRANSFORMER The Trace T240 Transformer uses high efficiency transformer technology and is constructed with high temperature rated materials This provides an unusually high efficiency device for voltage conversion from an inverter generator or conventional AC source The T240 Transformer has two identical windings that can be connected and used for line isolation voltage step up and step down or generator balancing The 3 9 Kva continuou
81. 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 specific precautions such as removing or not removing 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 Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series mercem Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 9 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 3 IMPORTANT SAFETY INSTRUCTIONS PUE hi TzW TIU ALLf HOT Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Page 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 4 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 INTRODUCTION INTRODUCTION Congratulations You are the proud owner of the finest inverter on the market today and one very complex piece of equipment The Trace Engineering SineWave SW Series Inverter Charger has many features and capabilities previously either non existent or found only in separate products With p
82. 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 Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 51 MENU SYSTEM Set Relay 9 Set Relay 9 Set Relay 9 volts DC 14 5 volts DC 29 0 volts DC 58 0 12 VDC Models 24 VDC Models 48 VDC Models Range 05 0 to 17 6 Range 10 0 to 35 5 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 This allows fast response to rapid voltage changes in the system R9 Hysteresis R9 Hysteresis R9 Hysteresis volts DC 01 0 volts DC 02 0 volts DC 04 0 12 VDC Models 24 VDC Models 48 VDC Models Range 00 1 to 12 8 Range 00 1 to 12 8 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 Set Relay 10 Set Relay 10 volts DC 14 8 volts DC 29 5 volts DC 59 0 12 VDC Models 24 VDC Models 48 VDC Models Range 05 0 to 17 6 Range 10 0 to 35 5 Range 20 0 to 71 0 Sets the voltage trip point for the auxiliary relay number
83. 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 occurs the inverter turns on and runs the loads When power returns the inverter will return to the SLT mode after it has completed the Bulk and Absorption stages of the battery charging process The advantage of SLT mode is silent operation and slightly less power consumption under most conditions and quieter operation since the battery charger is off most of the time The disadvantage of SLT mode 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 inverter is charging The transition 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 timer is defeated by setting it to 00 00 no bulk charging will tak
84. 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 Black Hot Utility Power NEUTRAL IN 1 White Neutral Utility Power AC HOT IN 2 Black Hot Generator NEUTRAL IN 2 White Neutral Generator AC HOT OUT Black or Red Hot AC Loads NEUTRAL OUT AC Loads White Neutral Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 1 9 INSTALLATION AC INSTALLATION GUIDELINES The following steps are a basic guideline for 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 side fuse or opening the DC disconnect Then remove the AC wiring compartment cover from the front of the inverter by removing the two screws on the cover 2 f conduit will be utilized consult code it may be required in your installation determine which knockout s will be utilize
85. 0 118 Float Voltage ertet re Max Charge Amps Multiple Inverters Charger Settings Ms Recommended Battery Charger Settings 75 Selecting Battery State of 7 Temperature Compensation Battery Charging Menu 10 Battery Overvoltage Protection Battery Selling Battery Selling Menu 17 Battery Sizing Example ete Worksheet nnen enn DE Battery TempComp Volts DC Menu 4 Battery Temperature Sensor BTS 110 Battery Terminals 2 15 Bonding The Grounding System 28 BUS Port Ree 14 Bulk Charge Trigger Timer 63 72 78 92 94 98 103 Bulk Charge Trigger Timer Menu 15 60 Bulk Charging 48 60 63 72 75 78 92 94 98 103 aaa 11 C C12 Charge Controller eee 144 C40 Multi Function Controller 144 Charger Mode 69 AC Input Requirements 74 Charger Only Operation 73 Recommended Battery Charger Settings 75 Circuit Breaker Inverter Charger nnen senn eene eennenenevennereneeennenen Compressors
86. 1 1999 69 OPERATION 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 amp 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 time 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 transfer from 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 internal AC input relay Once the relay has opened the inverter 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 Pa e Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger g 5916 195th Street N E Fax 360 435 2229 Pa
87. 10 This setting is compensated for the battery temperature when using the BTS There is no intentional time delay on the reaction for this setting This allows fast response to rapid voltage changes in the system R10 Hysteresis R10 Hysteresis R10 Hysteresis volts DC 01 0 volts DC 02 0 volts DC 04 0 12 VDC Models 24 VDC Models 48 VDC Models Range 00 1 to 12 8 Range 00 1 to 12 8 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 Set Relay 11 Set Relay 11 volts DC 15 0 volts DC 30 0 volts DC 60 0 12 VDC Models 24 VDC Models 48 VDC Models Range 05 0 to 17 6 Range 10 0 to 35 5 Range 20 0 to 71 0 Sets the voltage trip point for the auxiliary relay number 11 This setting is compensated for the battery temperature when using the BTS There is no intentional time delay on the reaction for this setting This allows fast response to rapid voltage changes in the system R11 Hysteresis R11 Hysteresis R11 Hysteresis volts DC 01 0 volts DC 02 0 volts DC 04 0 12 VDC Models 24 VDC Models 48 VDC Models Range 00 1 to 12 8 Range 00 1 to 12 8 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 gt setpoint Open on batt setpo
88. 360 amps Input Voltage Range 11 8 to 16 5 vdc 22to 33vdc 4410 66vdc 4410 66 vdc 22to33vde 44to66 vdc 2210 33 vac AC Output Characteristics AC Output Waveform Voltage Regulation Total Harmonic Distortion Power Factor Allowed Frequency Regulation Load Sensing Range Sinewave 34 to 52 steps per cycle i 296 3 to 5 stand alone operation 1to1 0 04 crystal regulated 16 to 240 Watts Standard Features Control Panel Low Battery Protection Battery Temperature Sensor Auto Generator Control system Auxiliary Relays Fan Cooling Built in 2 line back lit alphanumeric liquid crystal display with eight LED status indicators Adjustable low battery cut out and cut in with current compensation 15 foot plug in battery temperature sensor with phone type jack can be extended Automatic generator control system for two and three wire start generators no glow plug control Three user adjustable voltage controlled signal relays for control of loads or charging sources Variable speed brushless DC fans Options Remote Control Panel Stacking Interface for 2X power requires two inverters Conduit Box SWRC SWRC SWRC SWRC SWRC SWRC SWRC SWI swr SWI SWI No No No 120 240 vac 120 240 vac 120 240 vac 120 240 vac SwcB swcB swcB swcB swcB swcB Environmental Limitations Enclosure Type Specified Temp Range Allowed Temperature R
89. 39 Installation Diagram 240 VAC Wire Grid Connected Generator Backup 122 Figure 40 AWG Wire SIZE nn eee oneens enaar todo acu dukes nessen kad enen eed 131 Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 TABLE OF CONTENTS INDEX OF TABLES Table 1 AC Input and Output Wiring Connections unne ennen narnia 19 Table 2 Minimum Recommended Battery Cable Size vs Cable 22 Table 3 Battery Cable To Maximum Breaker Fuse Size annae onnnenronneenenenneenrnenneeernenneeenennens 23 Table 4 Charging Setpoints For Common Battery Types nnn annen en enneenenneereneeeneneennnenenneerenvenn 67 Table 5 Typical Wattage Of Common Appliances 101 Table 6 Battery Charging Charging Setpoint nnn anneer en nenenenenneenenserrenernnnenenneneneneenn 104 Table 7 Battery State of Charge Voltage nnn ennen eee nnns 105 Table 8 Battery Cable Inductance 110 Table 9 Power Consumption Of Common Appliances sse 130 Table 10 AWG to Metric Wire Conversion Chart nanne eneen eenen ve venenenenenenenevenenenenenenen 130 Table 11 Minimum Recommende
90. 44 Gen Max Run Time 5er eere ete 56 Gen Max Run Time Error Menu 2 39 Gen Under Over Speed Menu 2 39 Generator Start Error Menu 2 39 Generator Start Error Menu 5 44 Generator Sync Error Menu 2 39 Generator Sync Error Menu 5 44 Generator Under Over Speed Menu 5 45 Heatsink Overtemp Menu 5 43 High Battery Voltage Menu 5 43 Inverter Breaker Tripped Menu 5 45 Load Start Amps Ready Menu 2 40 Low Battery Voltage Menu 5 Overcurrent Menu 5 Transformer Overtemp Menu 5 Voltage Start Ready Menu 2 Error Causes Menu 5 sse Ertot LED s iios Estimating Battery Requirements Exercise Petiod ene egent Exercise Start Ready Menu 2 External Error Stacked Menu 5 External Transfer Relays Float Float LED Frequency ToleranCe cocooocccinococococccoon
91. 6 195th Street N E Fax 360 435 2229 Part No 2031 5 78 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 OPERATION GENERATOR STOP COOL DOWN PERIOD When the automatic generator stop system is used to stop 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 STOP signal is provided immediately if the generator is manually shut off from the Control Panel If the generator is shut off 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 turbocharged generators as it allows cooler oil to reach 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 manually from the Control Panel the generator is stopped immediately with no cool down GENERATOR ERROR CAUSES The red ERROR LED indicator will blink slowly if one of the following generator errors occurs e 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 ena e GENERATOR START ERROR T
92. 8223 www traceengineering com Rev B Sept 1 1999 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 time allowed for this tapering period is called the ABSORPTION TIME period This setting is very important for systems which use generators since it determines how long a generator will run and when the generator shuts off Using a generator 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 This 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 fully charged the battery would be when the charger is shut off Often 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 settings for several different 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 Batt
93. AL IN 1 terminals e Connect the critical AC loads that are required to be backed up to the inverters AC HOT OUT and NEUTRAL OUT terminals e Use the GRID USAGE TIMER 18 and the BULK CHARGE TRIGGER TIMER 15 with the battery charger parameters adjusted under the BATTERY CHARGING 10 menu heading to determine the battery voltage level you require for your batteries e Select SELL from the SET GRID USAGE menu item in the INVERTER SETUP 9 menu heading e Adjust the GRID AC1 AMPS AC menu item located in the AC INPUTS 11 menu heading See UTILITY SUPPORT OVERLOAD PROTECTION on page 82 to match the amperage of the circuit supplying AC to the inverter input e 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 Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 0 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 83 OPERATION 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 SETUP 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 batter
94. C 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 e 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 Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 0 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 73 OPERATION GEN CONTROL RELAYS WARNING All circuits connecting the auto generator control system MUST be protected with fuses rated at 5 amps or less The warranty does not cover damage to these relays Fuses should be located as close as possible to the point of connection to the larger cond
95. C Voltage Options Voltage Model The first letter s SW indicate the model in this case the SW Series Power The first and second positions in the model number indicate the continuous AC power output in hundreds of VA Volt Amps Power levels available start at 2500 up to 5500 Volt Amps with different DC voltages In the example above 40 would stand for a 4000 VA 4 kVA continuous output inverter Input Output DC Voltage The number 24 following the power rating indicates an inverter charger that is designed to convert 24 VDC input to an AC voltage output and charge 24 VDC batteries when powered by the same AC voltage Available DC voltages are 12 24 and 48 volt models Input Output AC Voltage Options The letter following the power rating indicates what AC voltage and frequency or particular option this inverter charger is specifically designed to provide No letter after the DC voltage number indicates an AC voltage of 120 VAC 60 Hz and requires the same AC voltage and frequency 120 VAC 60 Hz to charge the inverter batteries Available voltages range from 105 to 240 VAC at 50 or 60 Hz See the SPECIFICATIONS AND FEATURES section on page 118 for the different models available Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 7 UNIT IDENTIFICATION
96. CAN BE COMBINED INTO ONE TWO WAY METER IF NET BILLING IS ALLOWED kWh METER WITH DETENTS ONE WAY 120 240 kWh METER WITH DETENTS ONE WAY 120 240 VAC VAC UTILITY GRID 120 240 BUY METER SELL METER AC DISCONNECT LOCKABLE SERVICE ENTRANCE PANEL 120 240 BREAKER BREAKER 60A 120 VAC 60A 120 VAC CIRCUIT BREAKERS FOR HOUSE AC LOADS 120 240 VAC 6 AWG REQUIRED UTILITY INTERACTIVE LINE TIE SYSTEM WITH BACKUP OF CRITICAL AC LOADS DESIGNATES BI DIRECTIONAL CURRENT PATH OUTDOORS NEXT TO THE UTILITY SERVICE ENTRANCE OPTIONAL kWh METER WITH DETENTS ONE WAY 120 VAC FUSED DISCONNECT 60A 120 VAC NEMA 3R PRODUCED OUTDOOR TYPE METER FUSED DISCONNECT 60A 120 VAC NEXT TO THE INVERTER AC SUBPANEL AC LOADS PARURA FUSED TOBE LOADS SONES AC OUTPUT AC INPUT BACKED UP TERMINALS TERMINAL 60A 120 VAC 120 VAC ONLY PRODUCED TRACE SW SERIES INVERTER INVERTER CHARGER 120 VAC DC BATTERY TERMINALS WIND FUSED GENERATOR DISCONNECT CONTROLLER BATTERE BATTERY STORAGE DISCONNECT SYSTEM SOLAR FUSED PV CHARGE ARRAY DISCONNECT CONTROLLER Figure 29 Utility Interactive Line Tie System With Battery Backup Flow Diagram Copyright Trace Engineering Company Inc 5916 195th Street N E Arlington WA 98223 Telephone 360 435 Fax 360 435 2229 www traceengineerin
97. Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 0 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 75 OPERATION GENERATOR AUTO START REQUIREMENTS AND TYPES In order for the generator to be automatically started it must include electric start and an automatic choke An automatic primer system may also be required on natural gas and propane powered generators The generator should also include remote start ability with accessible remote start terminals 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 simplicity for automatic starting and because they are intended for remote automatic unattended operation Generators used can be fueled by gasoline propane or diesel fuel 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 residential applications will already have a tank and propane service Gasoline is also common but can be difficult to transport and store on site safely Most small generators do not hold much fuel in their built in tanks refitting the generator to use marine outboard motor type
98. DC 00 2 25 6 04 0 set Relay 11 volts DC 20 0 71 0 60 0 Em Hysteresis volts DC 00 2 25 6 04 0 Bulk Charge Trigger Timer 15 Start Bulk Time H M 00 00 23 50 00 00 Low Battery Transfer LBX 16 Set Low Battery transfer VDC 20 0 71 0 45 2 Set Low Battery cut in VDC 20 0 71 0 52 0 Battery Selling 17 set Battery Sell volts DC 40 0 64 0 53 6 Set Max Sell amps AC 01 35 30 cria Usage Timer 18 Set Start Charge time h m 00 00 23 50 21 00 End Stop Charge time h m 00 00 23 50 21 00 Arlington WA 98223 Copyright O Trace Engineering Company Inc 5916 195th Street N E Telephone 360 435 8826 Fax 360 435 2229 www traceengineering com SW Series Inverter Charger Part No 2031 5 Rev B Sept 1 1999 TECHNICAL INFORMATION PAJE HITY Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 127 APPENDIX APPENDIX OPTIONS Options available for the SW Series Inverter Charger include a choice of remote controls and a battery temperature control SWRC The optional SWRC Remote Control SWRC or SWRC 50FT has the ability to communicate with and adjust settings in the SW Series Inverter Charger It is operational whenever DC power is applied to the inverter DC inp
99. DC systems This setting is not temperature compensated Set search watts 48 All models Range 00 to 240 The sensitivity threshold of the search mode circuit is adjustable If set to zero it is effectively disabled The sensitivity is only adjustable in increments of 16 watts Set search spacing All Models Range 10 to 255 The length of time between each search pulse is also adjustable The setting is in cycles Therefore a setting of 60 would generate search pulses that are 1 second apart The range of settings 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 search 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 59 Copyright Trace Engineering Company Inc Telephone 360 435 8826 5916 195th Street E Fax 360 435 2229 Arlington WA 98223 www traceengineering com SW Series Inverter Charger Part No 2031 5 Rev B Sept 1 1999 MENU SYSTEM BATTERY CHARGING 10 MENU HEADING Note See the battery section of this manual for recommended setting for different battery types Set Bulk Set Bulk Set Bulk volts DC 14 4 volts DC 28 8 volts DC 57 6 12 VDC models 24 VDC model
100. Distance Between Battery Cables Taped Together 12 Separation 48 Separation Inductance an m ba in micro Henries The above table shows that with only a foot of distance between the battery cables the inductance almost doubles and at four feet between cables the inductance is almost three times the inductance of cables taped together Since the induced voltage in a conductor varies as the inductance times the rate of change of current in the inductor the induced voltage may be three times greater than it would be if cables were not taped together For more advanced readers consider flyback effects and the induced voltage spikes can get into the thousands of volts range if the battery were suddenly removed from the circuit worst case These induced voltage changes cause ripple in the battery cables and must be absorbed or filtered by the filter capacitors in the inverter This ripple will lead to eventual premature breakdown of the filter capacitors and performance loss in the inverter In addition to the problems mentioned the induced current opposes the applied current battery current which directly causes a loss of inverter performance as greatly reduced efficiency To avoid this problem route your positive and negative DC cables in parallel as close together as possible Secure the cables against movement with clamps or straps every 18 inches Avoid routing conductors near heat sources such as dry exhaust
101. EPAIR SERVICE REQUIRED If your product needs repair at the factory it must be shipped fully insured in the original packaging or equivalent shipping damage is not covered under warranty and will likely delay the repair and return of your unit The shipper will not accept any damage claims even if insured on products damaged through improper packaging i e peanuts soft foam undersized boxes etc If possible avoid sending products through the mail Warranty or repair service should be performed only at an Authorized Trace Service Center or at the Trace Engineering factory Unauthorized service performed on any Trace product will void the existing warranty You must notify Trace Engineering before returning any equipment for repair To obtain an RMA Return Merchandise Authorization number please contact our Warranty Coordinator at Phone 360 435 8826 Fax 360 474 0616 Email tracewarrantyOtraceengineering com Please provide Model Number Serial Number Purchase Date Problem Ship the item for repair to Trace Engineering Company Inc Attn Service Department RMA 5916 195 NE Arlington WA 98223 Be sure to include in the package 1 Complete return shipping address P O Box numbers are not acceptable and telephone number where you can be reached during work hours 2 A detailed description of any problems experienced including the make and model numbers of any other equipment in
102. FEATURES 60 Hz Models Note All specifications are subject to change without notice A A SSSA A SO General Specifications Nominal DC Input Voltage 12 vdc 24 vdc 48 vdc 48 vdc 24 vdc 48 vdc 24 vdc AC Output Voltage RMS 120 vac 120 vac 120 vac 120 vac 105 vac 105 vac 220 vac Nominal Frequency 60 Hz 60 Hz 60 Hz 60 Hz 60 Hz 60 Hz 60 Hz Continuous Power 20 2500 VA 4000 VA 4000 VA 5500 VA 4000 VA 4000 VA 4000 VA Continuous Output 25 C 21 amps AC 33 amps AC 33 amps AC 46 amps AC 38 amps AC 38 amps AC 18 amps AC Maximum Output RMS 60 amps AC 78 amps AC 78 amps AC 78 amps AC 78 amps AC 78 amps AC 39 amps AC Efficiency peak 90 94 95 96 94 95 94 Automatic Transfer Relay 60 amps AC 60 amps AC 60 amps AC 60 amps AC 60 amps AC 60 amps AC 30 amps AC Maximum Charging Rate 150 amps DC 120 amps DC 60 amps DC 75 amps DC 120 amps DC 60amps DC 120 amps DC Charger Regulation Method 3 stage 3 stage 3 stage 3 stage 3 stage 3 stage 3 stage DC Input Requirements Search Mode 0 08 A 1 0 04A 1 0 025 1 0 04A 1W 0 04A 1W 0 025 A 1 0 04 A 1 On Mode no load idle 1 0 A 12 W 0 66 A 16 W 0 33 A 16 W 0 40 A 20 W 0 66 A 16 W 0 33 A 16 W 0 66 A 16W At Full Rated Power 275 amps 200 amps 100 amps 137 amps 200 amps 100 amps 200 amps Short Circuited Output 700 amps 360 amps 180 amps 180 amps 360 amps 180 amps
103. H BATTERY CUT OUT VDC setting unless a charge control device limits the battery voltage Note that the LOW BATTERY CUT IN VDC setting must be set below the external charge controllers regulation setting or the system would never transfer back to the battery The best compromise involves setting the BULK VOLTS DC equal to the FLOAT VOLTS DC default value and setting the LOW BATTERY CUT IN VDC setting to the default BULK VOLTS DC setting Make sure the external charge controller is set slightly higher than the LOW BATTERY CUT IN VDC setting so that the voltage can be reached without the charging source shutting off The LOW BATTERY TRANSFER VDC setting must be always set higher than the LOW BATTERY CUT OUT VDC setting If utility back up operation is expected keep the LOW BATTERY TRANSFER VDC setting high to prevent excessive discharging of the battery It should not be set to a level that is higher than the normal at rest battery voltage level or the system will transfer whenever no alternative power source is available such as each night with solar If the utility grid is not energized the inverter will operate the AC loads until the battery voltage reaches the LOW BATTERY CUT OUT VDC setting It will then shut off and only reset if the battery voltage reaches the LOW BATTERY CUT IN VDC level or the utility power becomes available again If time of day metering is available from your utility you might consider the ENERGY MANAGEMENT MODE as it may off
104. Hours FUSED DISCONNECT 48V INVERTER Total Battery Capacity 100 Amp Hours Each individual 6 volt battery capacity 100 amp hours Figure 31 Series Configuration 6 Volt Battery Wiring FUSED DISCONNECT 48V INVERTER Total Battery Capacity 50 Amp Hours 24V INVERTER Total Battery Capacity 50 Amp Hours Each individual 12 volt battery capacity 50 amp hours Figure 32 Series Configuration 12 Volt Battery Wiring Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 107 TECHNICAL INFORMATION PARALLEL CONNECTION Batteries are connected in parallel when all the positive terminals of a group of batteries are connected and then separately all the negative terminals are connected In a parallel configuration the battery bank have the same voltage as a single battery but an amp hour rating equal to the sum of the individual batteries This is usually only done with 12 volt battery inverter systems 2 IDA ANA A gt 12V INVERTER Total Battery Capacity 200 Amp Hours Each individual 12 volt battery capacity 50 amp hours Figure 33 Parallel Configuration 12 Volt Battery Wiring SERIES PARALLEL CONNECTION As the name implies both the series and parallel techniques are used in c
105. ISPLAY NO None Low AC Output Voltage DISPLAY NO None Manual Off DISPLAY NO None AC Source Wired to Output DISPLAY NO None External Error Stacked DISPLAY NO None Generator Start Error DISPLAY NO None Generator Sync Error DISPLAY NO None Gen Maximum Run Time Error DISPLAY NO None Gen Under Over Speed DISPLAY NO None Time of Day 6 SET HR MIN SEC 00 00 Generator Timer 7 Start Quiet Time H M 00 00 23 59 08 00 End Quiet Time H M 00 00 23 59 08 00 Copyright O Trace Engineering Company Inc 5916 195th Street E Arlington WA 98223 Telephone 360 435 8826 Fax 360 435 2229 www traceengineering com SW Series Inverter Charger Part No 2031 5 Rev B Sept 1 1999 TECHNICAL INFORMATION SETUP MENU 12 VDC 120 VAC 60HZ MODELS To access the SETUP MENU press the RED and GREEN buttons on your CONTROL PANEL or SWRC at the same time To exit the Setup Menu press the ON OFF MENU button or use the down MENU HEADING button until you reach the USER MENU menu headings 1 8 MENU HEADING MENU ITEM SELECTION DEFAULT USER RANGE SETTINGS SETTINGS Inverter Setup 9 set Grid Usage FLT SELL SLT LBX FLT Set Low Battery cut out VDC 0 80 25 5 11 0 Set LBCO delay minutes 00 255 15 Set Low battery cut in VDC 00 0 16 5 13 0 Set High battery Cut
106. In order for this technique to be cost effective the off peak rate foe electricity 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 e Set the SET GRID USAGE menu item under the INVERTER SETUP 9 menu heading to FLT e Set the START CHARGE TIME menu item under the GRID USAGE TIMER 18 menu heading to 6 PM 18 00 e Set the END CHARGE TIME menu item under the GRID USAGE TIMER 18 menu heading to NOON 12 00 e 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 e 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 occurs between time periods yet will allow limited charging to prevent sulfation of the battery while sitting partially discharged Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 91 OPERATION PEAK LOAD SHAVING MODE INVERTER UTILITY GRID AC CHABGER AC AC LOADS BATTERY IN BRIEF The inverter can also be used to limit the maximum dr
107. LLATION DC DISCONNECT AND OVERCURRENT PROTECTION For safety and to comply with regulations battery over current protection is required Fuses and disconnects must be sized 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 electrical systems the National Electrical Code requires both overcurrent protection and a disconnect switch These installation parts are not supplied as part of the inverter However Trace Engineering offers a DC rated UL listed circuit breaker disconnect specifically designed for use with Trace inverters for applications requiring NEC compliance Two amperage ratings are available a DC250 250 amps and a DC175 175 amps These disconnects are available in a single or double pole configuration to handle either one or two inverters The DC disconnect enclosure will accommodate up to four smaller breakers for use as DC load disconnects PV array disconnects etc and the top is designed to allow direct connection of up to two Trace Engineering 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 exp
108. MENU button will move the cursor one position to the right selecting the next item You can also use the SET POINTS 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 first letter of the selected item will be underlined Pressing the green GEN MENU button will move the cursor one position to the right selecting the next item You can also use 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 SETUP 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 t
109. N SEALED LEAD ACID BATTERY The most common type of deep cycle battery is the non sealed liquid electrolyte battery Non sealed types have battery caps The caps should be removed periodically to check the level of electrolyte When a cell is low distilled water should be added The electrolyte level should be checked monthly and topped up if needed after recharging The most common non sealed deep cycle battery is the type used with boats and motor homes They typically are called Group 27 batteries and are similar in size to a large truck battery They are 12 volt batteries rated at 80 to 100 amp hours Often the deep cycle claim is over stated They do work better than a car battery but are not recommended for anything but the smallest systems Another popular and inexpensive battery of this type is the golf cart battery It is a 6 volt battery rated at 220 amp hours They can be cycled repeated to 80 of their capacity without being damaged This is the minimum quality of battery that should be used with SW Series inverter applications Many systems use the L16 type of battery These are 6 volt batteries rated at 350 amp hours and are available from a number of manufacturers They are 17 inches in height and weigh up to 130 pounds each which may be troublesome in some applications such as RV or marine installations Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th
110. NG RV AND MARINE APPLICATIONS section on page 27 for more information AC Tomine selon ro RE E n TB1 a p LED SIMULATES RELAY EN A a tre PRESENT R3 AC CONNECTIONS Os AC HOT IN 1 Y UBLIC POWER IN INE TIE OUT AC HOT IN 2 ide E 2DJ Yl GENERATOR IN From AC IN 2 O Utility Power From NEUTRAL IN 1 Generator Power 2 JO 4D yg NEUTRAL IN 2 Gb e ueurraL out 6 AC OUT To GREEN CRANK LITE SS gm INDIGATES RY8 NO E C HOT OUT AC Loads CONTACTS CLOSED YELLOW RUN LITE J2 INDICATES RY7 EXTERNAL CONTACTS BATTERY ue ET EE 0 RUN CRANK E a o ML ENT mm RY7 RY8 RY9 RYO avale RYS AUX ig c c c 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 side 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
111. OUND 90 92 9 SUB PANEL 120VAG SING ASE SYST ELECTRIC START 120 VAC GENERATOR GR D GON ED WI l H CHOOK UP MAY VARY WITH YOUR GEND GEN ER BACKUP SAFETY GND START CIRCUIT STOP CIRCUIT Figure 38 Installation Diagram 120 VAC 1 Phase Grid Connected Generator Backup Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 121 TECHNICAL INFORMATION ADEN RELAYS ELECTRIC TA S PS FURNACE ELECTRIC STOVE RY10 No 1 NL Y AUXILLARY RELAYS INVERTER BYPASS BREAKER ELECTRIC WATER HEATER i SWRC or SWCA O o Oo Oo 8 GROUND 9 0000 o 120 GREEN LED YELLOW LED BATTERY DISCONNECT WITH OVERCURRENT PROTECTION SW INVERTER No DEEP WELL PUMP TABLE SAW SHOP POWER INVERTER BYPASS BREAKER AC TERMINAL
112. Out VDC 00 0 16 5 16 0 Set search watts 00 240 48 Set search spacing 00 255 59 Battery Charging 10 Set Bulk volts DC 10 0 16 0 14 4 Set Absorption time h m 00 00 23 50 02 00 Set Float volts DC 10 0 16 0 13 4 Set Equalize volts DC 10 0 16 0 14 4 Set Equalize time h m 00 00 23 50 02 00 Set Max Charge amps AC 01 25 20 Set Temp Comp LeadAcid Nicad LeadAcid AC Inputs 11 set Grid AC1 amps AC 00 63 f 60 Set Gen AC2 amps AC 00 63 30 Set Input lower limit VAC 80 111 108 Set Input upper limit VAC 128 149 132 cen Auto Start Setup 12 Set Load Start amps AC 00 63 33 Set Load Start delay min 00 0 25 5 05 0 Set Load Stop delay min 00 0 25 5 05 0 Set 24 hr start volts DC 05 0 25 5 12 3 Set 2 hr start volts DC 05 0 16 5 11 8 Set 15 min start volts DC 05 0 16 5 11 3 Read LBCO 30 sec start VDC 05 0 16 5 11 0 Set Exercise period days 00 255 30 Set Maximum run time h m 00 00 23 50 08 00 Gen Starting Details 13 set RY7 Function GlowStop Run Run Set Gen warmup seconds 16 255 60 Set Pre Crank seconds 00 255 10 Set Max Cranking seconds 01 15 10 Set Post Crank seconds 00 255 30 auxiliary Relays R9 R10 14 Set Relay 9 volts DC 00 0 16 5 14 5 Hysteresis volts DC 00 1 12 8 01 0 set Relay 10 volts DC 00 0 16 5 14 8 R10 Hysteresis volts DC 00 1 12 8 01 0 set Relay 11 volts DC 00 0 16 5
113. Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 129 APPENDIX REFERENCE TABLES AND GRAPHS Table 9 Power Consumption Of Common Appliances APPLIANCE WATTS 5 15 30 60 120 240 Single PL Light 10 1 dec uc ee ee 53 B amp W TV 50 4 1 2 4 8 17 Computer 100 1 2 4 8 17 34 Color TV 200 2 4 8 17 34 67 Blender 400 3 8 17 34 67 133 Skil Saw 800 6 17 34 67 133 266 Toaster 1000 8 23 46 93 185 370 Microwave 1200 10 28 57 114 227 455 Hot Plate 1800 15 44 88 176 353 706 AMP HOURS If the current draw at 120 VAC 15 known then the battery amperage at 12VDC will be 10 times the AC amperage divided by the efficiency 90 in this table Motors are normally marked with their running rather than their starting current Starting current can be five times running current Keep this in mind when sizing a motor into a system Refrigerators and icemakers typically run about 1 3 of the time Therefore their average battery current draw is 1 3 what their amp rating would indicate Table 10 AWG to Metric Wire Conversion Chart DC RESISTANCE AWG DIAMETER MM AREA MM aac Ee 14 1 63 2 08 3 14 4 11 13 3 Ll 5 19 212 Pg EE 6 54 33 6 10 40 85 0 11 68 107 2 Note Stranded wire sizes and ampacity for 75 C Pa e Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger 9 5916 195th Street E Fax 360 435 2229 Part No 2031 5 130 Arli
114. RPM REN M tr RR RE M 130 STORAGE CHECKLIST i e ls reteset ide 133 WARRANTY REPAIR INFORMATION 135 LIMITED WARRANT Y ERAN RUD E 135 5 1 52 teiten eden bennie nadele Rae are eerie ri 135 HEE SUPRORT POLO Visitors co rer Decitre oe recte teet Dr dee iz cesarean ite 135 WARRANTY OR REPAIR SERVICE REQUIRED nonnen 136 INDEX x LEE 137 Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 TABLE OF CONTENTS INDEX OF FIGURES Figure 1 Identification Label eenen enn 7 Figure 2 SW Series Inverter CharYer oooonnicnnnnccnnnccnnccnnnocnnnnccccnnccnnnnnnn nn 9 Figure 3 Control Panel nier ei a 9 Figure 4 AC Side HR EUR M Dane Rue DU ded 12 Figure 5 Internal Components and Indicators anneer enneerennenreneenennenenneevenvernnnenenneenenvenn 13 Figure 6 Aux and Gen Control 14 Figure 7 DES caia oi erdee ren ages 14 Figure 8 Air Flow Intake Location n
115. Rev B Sept 1 1999 OPERATION UTILITY BACKUP MODE UTILITY GRID GENERATOR AC AC MAIN AC BREAKER PANEL ADDITIONAL AC BREAKER SUB PANEL INVERTER CHARGER DC CRITICAL AC LOADS NON CRITICAL AC LOADS BATTERY 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 grid and continues to support 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 may at times be noticeable This is due to the inverter s output reaching the overcurrent trip level as it tries to maintain the load before the internal relay transfers to battery power To operate the system in utility backup mode e Connect utility AC power to the inverter s AC HOT IN 1 and NEUTRAL IN 1 terminals e Connect the AC loads to the inverter s AC HOT OUT and NEUTRAL OUT terminals e 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 e Adjust the GRID AC1 AMPS AC menu item to match the amperage of the circuit breaker supplying AC to the inverter input This setting is located in the AC INPUTS 11 menu heading See UTILITY SUPPORT
116. Set Input Upper Limit VAC Set Input Upper Limit VAC Menu 11 Set Inverter Menu 1 Set LBCO Delay Minutes Menu 9 Set Load Start Amps AC Menu 12 Set Load Start Delay Min Menu 12 Set Load Stop Delay Min Menu 12 Set Low Battery Cut in VDC Menu 9 Set Low Battery Cut In VDC Menu 16 Set Low Battery Cut Out VDC Set Low Battery Cut Out VDC Menu 9 Set Low Battery Transfer VDC Menu 16 Set Max Charge Set Max Charge Amps AC Menu 10 Set Max Charge Amps Setting Set Max Cranking Seconds Menu 13 Set Max Sell Amps AC Menu 17 Set Maximum Run Time Menu 12 SET POINTS Buttons ae Set Post Crank Seconds Menu 13 Set Pre Crank Seconds Menu 13 Set Function Menu 13 di Set Search Spacing Menu 9 is Set Search Watts Menu 9 Set Temp Comp Menu 10 Setup E Menu 14 Auxiliary Relays soa Menu 15 Bulk Charge Trigger Timer Menu Headings 5 eren enitn evene Menu Map Silent SL
117. Street N E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 99 TECHNICAL INFORMATION Type 8D batteries are available with either cranking or deep cycle construction The deep cycle versions are 12 volt batteries rated at 200 amp hours or so Since they are most commonly used to start truck engines you should make sure you purchase the deep cycle version SEALED LEAD ACID BATTERIES CAUTION IF USING GELLED BATTERIES THE BATTERY CHARGER MUST BE SET TO THE APPROPRIATE SETTINGS OR BATTERY DAMAGE WILL OCCUR Another type of deep cycle battery construction is the sealed valve regulated lead acid battery They are a rechargeable battery which recombines suppressed gases thus eliminating the need to add water Since they are tightly sealed these batteries will not leak and can be installed in certain applications where liquid type batteries could not be installed While there are many manufacturers of quality non sealed batteries there are only a few manufacturers of suitable sealed batteries Don t confuse sealed batteries with maintenance free batteries the later is typically a standard liquid electrolyte type battery without caps for adding water when the electrolyte gets low you replace the battery The advantages of true deep cycle sealed batteries are no maintenance does not require acid checks or periodic watering long life 800 cycles claimed and low self
118. T Mode SineWave Communications Adapter SWCA 143 SLT Silent Mode 48 92 Software Revision 1 5 108 Software Revision Menu 3 40 Special Notices 2 Specifications and Features 132 133 50 Hz Models rs eerdere eant dae 133 60 Hz ModelS coooooocconococococoncconnononcconcconcnnnnccanc cnn nannncnnnos 132 Stacking Parallel oooooonnoconnccinnccnnccnocnnonnconanonrnaracnrarcnonoos 108 Stacking Series oiii ez 107 Stacking Inverters 120 240 VAC 81 108 Stacking Polonia 12 Start Bulk Time Menu 15 sse 60 Start Charge Time 97 98 102 103 Start Charge Time Menu 18 62 Start Quiet Time Menu 7 46 Storage Seasonal sese 133 SW Series Power Panel 144 143 Remote Monitoring nanne eeen vennereneeennenen 143 Remote Setup nnen rennen vennerenveennenen 143 Remote Troubleshooting 143 SWCB Conduit 24 143 SWRC System Grounding SE Bonding The Grounding 28 Equipment Or Chassis Grounds nnen Grounding Electrodes Ground Rods
119. 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 connects 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 SETUP 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 mode for most utility connected applications or for use with a back up generator that is being manually or automatically started The SLT mode is used only with AC power supplied to the AC HOT IN 1 input The SLT mode 15 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 time 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 used 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 engag
120. TTERY CUT OUT LOW BATTERY TRANSFER LOW BATTERY CUT IN and BATTERY SELL VOLTS settings Battery TempComp Battery TempComp Battery TempComp volts DC 12 6 volts DC 25 2 volts DC 50 4 12 VDC models 24 VDC models 48 VDC models Range 5 0 to 17 5 VDC Range 10 0 to 35 5 VDC 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 summertime This improves the performance of the batteries in cold weather and reduces gassing in hot weather you are using a NiCad or other alkaline type battery be sure to adjust the SET TEMP COMP menu item under the BATTERY CHARGING 10 menu heading of the SETUP MENU to NiCad Inverter Inverter Inverter Inverter volts AC 120 volts AC 230 volts AC 105 volts AC 220 Standard models E models J amp models W models Range 00 to 255 VAC Range 00 to 510 VAC Range 00 to 255 VAC Range 00 to 510 VAC Reads the RMS value of the inverter s AC output voltage When synchronized to an AC source the inverter AC output volt
121. Time started T E Max Sell Max Charge POSITIVE Inverter is drawing power from grid Amps Setting Amps Setting NEGATIVE ter i lli to grid G Inver 1 selling power to gri Set Max Sell amps 30 Set Max Charge amps AC 30 amps to grid E m grid E LEGEND Display Settings AC amps fro on Control Panel Figure 28 Selling Power Stored In The Batteries Hypothetical Time Of Day Operational History Pa e Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger g 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 86 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 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 setti
122. Tr ENGINEERING SW Series Inverter Chargers With Revision 4 01 Software Owner s Manual Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger 5916 195th Street E Fax 360 435 2229 Part No 2031 5 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 PRODUCT MATERIALS PACKAGE Thank you for choosing Trace Engineering products to meet your powering needs We make every effort to ensure that your inverter charger is properly packaged for shipping including the following L owners Manual E Battery Temperature Sensor BTS Red and black battery terminal covers with attaching hardware E Hardware package AC access panels with screws crimp on terminals L Trace bumper sticker If any of the above listed materials are missing from your package or if it is unsatisfactory in any manner please contact our Service department at 360 435 8826 or fax this page explaining the discrepancy to 360 474 0616 Please provide Model Number Serial Number Comments Visit our web site at www traceengineering com for more information and answers to frequently asked questions Copyright Trace Engineering Company Inc
123. a raceway Cables enclosed in raceways or conduits have substantially lower continuous current carrying ability due to heating factors Table 14 Knockout Hole Size to Conduit Size Required ENOGKOSIOIHORE TRADE SIZE OF CONDUIT DIAMETER INCHES MM INCHES 7 8 875 22 2 Va 1 3 32 1 093 27 8 Y 1 23 64 1 359 34 5 1 1 23 32 1 719 43 7 1 1 31 32 1 968 50 0 1 2 15 32 2 468 62 7 2 3 76 2 2 Y Table 15 Safety Ground Wire Size Table The ground wire should be sized per NEC 250 95 The following table is derived from this portion of the NEC code Ground Wire 30 Amp or 60 Amp 10 AWG 100 8 200 6 300 Amps 2 AWG or greater Battery DC Disconnect Size Minimum Size of Copper Pa e Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger 9 5916 195th Street E Fax 360 435 2229 Part No 2031 5 132 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 APPENDIX Storage Checklist If the SW Series Inverter Charger is used in a vehicular application such as a motor coach truck or boat certain steps must be taken prior to seasonal storage These steps are especially important for maintaining batteries as well as ensuring the automatic generator function if installed is disabled Preparation for Storage Interior Storage e Check that all batteries are fully charged e
124. able and connected to the batteries to the SELL VOLTS DC setting The FLOAT LED indicator blinking indicates this 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 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 maintain the batteries to the SET FLOAT VOLTS DC setting This is indicated by the FLOAT LED indicator being on Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 0 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 87 OPERATION UTILITY INTER ACTIVE OPERATION WITH UTILITY B ACKUP The SW Series Inverter Charger is capable of operating both as a utility interactive and a stand alone inverter This allows the system to normally 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 NOTE THE BUY AND SELL METERS
125. able of detecting several types of failures e Grid shorted Normally when the utility power fails the inverter momentarily tries to power the entire 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 e 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 e Islanding This occurs when the grid has failed and the neighborhood that the inverter is powering requires a power level that the inverter can supply This condition is called islanding The islanding detection circuit checks grid condition on each cycle 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 large electric motor is connected it may provide enough generator capacity that the inverter thinks the grid is still connected This can fool this protective system Two additional protective systems are provided to then handle this condition over under frequency and over under v
126. above Trace Engineering shall in no event be liable for consequential incidental contingent or special damages even if Trace Engineering has been advised of the possibility of such damages Any and all other warranties expressed or implied arising by law course of dealing course of performance usage of trade or otherwise including but not limited to implied warranties of merchantability and fitness for a particular purpose are limited in duration for a period of two 2 years from the original date of purchase Some countries or states do not allow limitations on the term of an implied warranty or the exclusion or limitation of incidental or consequential damage which means the limitations and exclusions of this warranty may not apply to you Even though this warranty gives you specific legal rights you may also have other rights that vary from state to state WARRANTY REGISTRATION Complete the warranty card and mail it to Trace Engineering within 10 days from the date of purchase keep your bill of sale as proof of purchase should any difficulties arise concerning the registration of the warranty card Warranty Registration is tracked by model and serial numbers only not by owner s name Therefore any correspondence or inquiries made to Trace Engineering must include the model and serial number of the product in question LIFE SUPPORT POLICY As a general policy Trace Engineering Inc does not recommend the use of any of it
127. ading 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 battery 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 cycle 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
128. age would match the AC inputs value Pa e Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger g 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 40 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 MENU SYSTEM Grid ACI Grid AC1 Grid ACI Grid AC1 volts AC 120 volts AC 230 volts AC 105 volts 220 Standard models E models J 8 models W models Range 00 to 255 VAC Range 00 to 510 VAC Range 00 to 255 VAC Range 00 to 510 VAC Reads the RMS value of the AC voltage at the inverters AC HOT 1 input and NEUTRAL IN 1 terminals This is usually the connection for the utility grid Value will drift around before inverter has synchronized Generator AC2 volts AC 120 Generator AC2 volts AC 230 Generator AC2 volts AC 105 Generator AC2 volts AC 220 Standard models Range 00 to 255 VAC E models Range 00 to 510 VAC J 8 models Range 00 to 255 VAC 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 terminals This is usually the connection for a back up fuel powered generator Value will drift around before inverter has synchronized Read Frequency 60 Hertz 50 60 Hz models 50 Hz models Range 53 to 67 Hz Range 44 to 56 Hz Reads the frequency of
129. an efficiency of 85 2NEC AMPS is based on Low Battery Voltage an efficiency of 85 and a 125 NEC de rating Table 12 Battery Cable to Maximum Breaker Fuse Size CABLESIZE RATINGIN MAXIMUM RATINGIN MAXIMUM REQUIRED CONDUIT BREAKER SIZE FREE AIR FUSE SIZE 2 AWG 115 amps 125 amps 170 amps 175 amps 2 0 00 AWG 175 amps 175 amps 265 amps 300 amps 4 0 0000 AWG 230 amps 250 amps 360 amps 400 amps The NEC allows rounding up to the next standard fuse size from the cable rating e 150 amp cable size rounds up to a standard 175 amp 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 Copyright Trace Engineering Company 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 B Sept 1 1999 APPENDIX Table 13 Recommended Minimum AC Wire Sizes 75 CABLE SIZE CABLE SIZE FULL pd PASS THRU ie REQUIRED REQUIRED CAPABILITY IN CONDUIT IN FREE AIR a 60 amps 60 amps 6 AWG 8 AWG THHN au 30 amps 30 amps 10 AWG THHN 10 AWG THHN e term free air is defined by the NEC as cabling that is not enclosed in conduit or
130. and 60 for a 48 VDC system Since equalizing is basically overcharging the battery which can be harmful to battery s life and performance it is done only when required CAUTION Equalization should be done only with standard electrolyte batteries If you have sealed or gel cell batteries check first with the battery manufacturer before equalizing DC loads should be disconnected before equalization to protect them from damage by the high battery voltage involved Table 6 Battery Charging Charging Setpoints TYPICAL BULK AND FLOAT SETPOINTS FOR COMMON BATTERY TYPES Battery Type Sealed Gel Lead Acid battery Bulk Volts Float Volts Equalizing Charge Process 14 1 VDC BULK 13 6 VDC FLOAT Not Recommended Consult manufacturer A G M Lead Acid battery 14 4 VDC BULK 13 4 VDC FLOAT Charge to 15 5 VDC or as per manufacturer Maintenance Free RV Marine Lead Calcium Battery 14 4 VDC BULK 13 4 VDC FLOAT Not Recommended Consult manufacturer Lead Antimony Battery Deep Cycle Liquid Electrolyte 14 6 VDC BULK 13 4 VDC FLOAT Charge to 15 8 VDC or as per manufacturer using 10 cells in series Note NiCad or NiFe Alkaline Battery 16 0 VDC BULK 14 5 VDC FLOAT Consult manufacturer Values shown are for 12 volt systems For 24 volt systems multiply the settings shown by 2 For 48 volt systems multiply the settings shown by 4 These setti
131. ange Non operating Temperature Altitude Limit Operating Altitude Limit Non operating Dimensions Inverter Only Dimensions Shipping Mounting Indoor ventilated steel chassis with powdercoat finish 32 F to 104 F 0 C to 40 C output will meet specified tolerances 40 F to 140 F 40 C to 60 C output may not meet specified tolerances 67 F to 284 F 55 C to 75 C 15 000 feet 5000 meters 50 000 feet 16 000 meters 15 38 cm high 22 5 57 cm wide 9 23 cm deep when wall mounted 20 5 52 cm 27 69 cm 15 5 40 cm Wall or Shelf Mount Weight Inverter Only Weight Shipping 90 lbs 42 kg 105 lbs 48 kg 105 lbs 48 kg 136 Ibs 63 kg 105 lbs 48 ko 105 lbs 48 kg 105 lbs 48 kg 96 lbs 44 kg 111 Ibs 50 kg 111 lbs 50 kg 143 lbs 65 kg 111 lbs 50 ko 111 lbs 50 kg 111 Ibs 50 kg Copyright O Trace Engineering Company Inc 5916 195th Street E Arlington WA 98223 Telephone 360 435 8826 Fax 360 435 2229 www traceengineering com SW Series Inverter Charger Part No 2031 5 Rev B Sept 1 1999 TECHNICAL INFORMATION SPECIFICATIONS AND FEATURES 50 Hz Models Note All specifications are subject to change without notice General Specifications Nominal DC Input Voltage 12 vdc 24 vdc 48 vdc 48 vdc 24 vdc 48 vdc 48 vdc AC Output Voltage RMS 230 vac 230 vac 230 vac 230 vac 105 va
132. arge 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 small amount of power all of the time to power the coil of the relay Other circuits are possible but may have other drawbacks This circuit P N provides protection against overcharging the batteries 120VAC COIL AC OUTPUT NEU AC OUTPUT HOT SW SERIES INVERTER AUX RELAY 9 COM AUX RELAY 9 N C 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 They 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 i
133. aw the AC loads place on the utility grid Many utilities impose a surcharge on their customers based on the peak load used by a facility 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 surcharge All AC loads must 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 inverter to provide a utility back up function in addition This mode is also useful for applications where AC loads require 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 amps 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 eliminate 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 improve the power quality by reducing the load placed on the AC
134. battery is connected 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 Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 14 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 INSTALLATION INSTALLATION This section is very important since it tells you how to properly install your SW Series Inverter Charger It becomes very frustrating when your inverter system does not perform properly simply because care was not taken during installation Please read this entire 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 defines the standards for both the AC and DC wiring in residential commercial and RV applications It will list the requirement for wire sizes overcurrent protection and installation methods and requirements There are still many other variables not covered by the NEC Most are de
135. battery temperature is higher or lower than 25 77 and will only occur if the battery temperature sensor BTS 15 installed The setting should be changed from the default setting only if NiCad or Nickel Iron batteries are used NICAD AC INPUTS 11 MENU HEADINGS set Grid AC1 60 Set Grid AC1 30 0 amps AC 60 Standard models E amp W models J 8 K models Range 00 to 63 Range 00 to 31 5 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 circuit breaker that feeds the AC HOT IN 1 Set Gen AC2 amps AC Standard models E amp W models J 8 K models Range 00 to 63 Range 00 0 to 31 5 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 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 Grid AC1 amps AC Set Gen AC2 amps AC Set Gen AC2 30 15 0 jamps AC set Input Lower 88 limit VAC 196 Standard models E models J 8 models W models Range 80 to 111 Range 170 to 220 Ran
136. 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 battery explosion follow the instructions in this manual and those published by the battery manufacturer as well as manufacturer of any additional equipment used in the vicinity of the battery Review all cautionary markings on these products SPECIAL NOTICES 1 10 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 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 terminal lugs with a 5 16 hole should be used to connect the battery cables to the DC terminals of the inverter charger Soldered cable lugs are also acceptable Torque all AC wiring connections to 20 inch pounds Torque all DC cable connections to 10 15 foot pounds Avoid dropping metal tools onto the batteries A short circuit could resu
137. bly soldered and crimped copper compression lugs unless aluminum mechanical lugs are used Soldered connections alone are not acceptable We suggest using high quality UL listed Trace Engineering battery cables These cables are available in a specific assortment of sizes from 1 7 to 10 feet and in 2 0 or 4 0 AWG They are color coded and have pressure crimped sealed ring terminals Contact your Trace 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 WARNING THIS INVERTER IS NOT REVERSE POLARITY PROTECTED If the positive terminal of the battery is connected to the negative terminal of the inverter and vice versa 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 covered by the warranty Ensure that the inverter is off before connecting or disconnecting the battery cables and that all AC power is disconnected from the inverter s inputs Determine the correct size battery cable to use for your installation from Table 2 on page 22 and the proper size disconnect fuse from
138. c 105 vac 240 vac Nominal Frequency 50 Hz 50 Hz 50 Hz 50 Hz 50 Hz 50 Hz 50 Hz Continuous Power 20 2600 VA 3300 VA 3300 VA 4500 VA 3300 VA 4000 VA 4500 VA Continuous Output 25 11 amps AC 14 amps AC 14 AC 20amps AC 31 33 amps AC 20 amps AC Maximum Output RMS 28 amps AC 34 amps AC 34 amps AC 34 amps AC 78 amps AC 78 amps AC 34 amps AC Efficiency peak 90 94 95 96 94 95 96 Automatic Transfer Relay 30 amps AC 30 amps AC 30 amps AC 30 amps AC 60 amps AC 60 amps AC 30 amps AC Maximum Charging Rate 150 amps DC 100 amps DC 50 amps DC 60ampsDC 100 amps DC 60ampsDC 60 amps DC Charger Regulation Method 3 stage 3 stage 3 stage 3 stage 3 stage 3 stage 3 stage DC Input Requirements em Mode 0 08 A 1 W 0 04 1 0 025 1 0 04A 1W 0 04A 1 0 025 1 0 04 A 1 W On Mode no load idle 1 6 12 W 0 66 A 16W 0 33 A 16 W 0 40 A 20 W 0 40 A 20 W 0 33 A 16 W 0 40 A 20 W At Full Rated Power 300 amps 166 amps 83 amps 137 amps 137 amps 83 amps 137 amps Short Circuited Output 700 amps 320 amps 160 amps 180 amps 180 amps 160 amps 180 amps Input Voltage Range VDC 11 8 10 16 5 vdc 2210 33vdc 441066 vdc 44t066vdc 44to66vdc 44to66 vdc 44 to 66 vac AC Output Characteristics AC Output Waveform Voltage Regulation Total Harmonic Distortion Power Factor Allowed Frequency Regulation Load Sensing Ra
139. can be adjusted by the SET GEN AC2 AMPS AC menu item These adjustments 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 15 the Utility Power connection point The frequency tolerance is 53 to 67 Hz for 60 Hz models 44 to 56 for 50 Hz models The typical transfer delay is approximately 30 seconds once the AC HOT IN 1 terminals are energized When the SELL mode 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 connection 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 fuel powered generator must be stable for the inverter to synchronize and connect DELAY PERIOD The delay period approximately 30 seconds occurs after the AC source has been applied to the AC HOT 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 l
140. ccnoncannanccnonncanananicnno Fuse Block TFB Fuses and Disconnects Battery Cable Disconnect Breaker Rating 24 G Gen Auto Start Setup Menu 12 54 Gen Control Relays Gen Max Run Time Error 89 Gen Max Run Time Error Menu 2 39 GEN MENU Button nennen enen ennersnen 10 Gen Size Amps AC 81 Gen Starting Details Menu 13 56 Gen Under Over 89 Gen Under Over Speed Menu 2 39 General Precautions nnn eneen enneerenneereenvervensenennnen 1 Generator 120 240 VAC 81 Automatic ContrOl ooooonnccccnnccccinncccconaconononcccnana ca nana caracas 87 Automatic 77 80 86 89 110 With Multiple Inverters ennen 110 Automatic Start Stop nanne eneen 82 Control entente enne nnns 57 Control Relays oooooonoccioccccocccoccccocanonccancconnncnana rra 56 83 Cool Down Period sensan nire corte te 85 88 Pa e Copyright O Trace Engineering Company Inc g 5916 195th Street N E 138 Arlington WA 98223 Telephone 360 435 8826 www traceengineering com SW Series Inverter Charger Part No 2031 5 Rev B Sept 1 1999
141. conductor to the grounding electrode or grounding system is usually based on the size of the largest conductor in the system Most systems use a 5 8 16 mm copper plated rod 6 feet 2 meters long driven into the earth as grounding electrode It is also common to use copper wire placed in the concrete foundation of the building as a grounding system Either method may 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 common example is providing a direct path from 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 used in a trench The run 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 circumstance 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 wi
142. cross system and no Lightning current flow through Strike Lightning equipment and wiring Strike GENERATOR INVERTER BATTERY BANK GENERATOR INVERTER BATTERY BANK Generator Inverter Battery _ Ground Ground Ground L Generator Inverter Battery Ground Ground Ground Voltage Voltage Difference Difference Zero Voltage Difference across Component Grounds Figure 15 Multiple Point Ground System Figure 16 Single Point Ground System Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street E Fax 360 435 2229 Part No 2031 5 9 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 29 INSTALLATION PAGS Msn HOT VOE Pa e Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger g 5916 195th Street E Fax 360 435 2229 Part No 2031 5 30 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 FUNCTIONAL TEST FUNCTIONAL TEST Once the AC and DC wiring have been installed and connected take a moment to go back over all connections and make sure they are secure and has been installed properly 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 se
143. ction starting on page 112 will hopefully help solve problems you may encounter After ensuring the correct polarity apply battery DC power to the inverter by turning on the battery bank DC disconnect or connecting the proper fuse inline to the battery 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 Press the red ONOFF MENU switch twice SEARCH then to turn the inverter on Monitor your INVERTING LED Yellow to ensure what mode you are in e 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 e 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 e 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 inverters 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 With the inverter ON check the AC voltage on the AC output terminal of the inverter and ensure you get the correct AC voltage for your particular unit Aft
144. ctors or enclosures EARTH GROUND CHASSIS GROUND L NEUTRAL AC NEUTRAL OUT 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 carrying 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 situation where a voltage difference exist between multiple 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 This would be either the vehicle boat ground or the external AC source ground but never both at once NEUTRAL TO GROUND NEUTRAL TO GROUND SWITCHING RELAY BOND is provided by Provided in the AC installation Connects the the external AC source neutral from external AC source and neutral of the inverter output AC panel loads together when AC is applied to inverter input AC PANEL Another
145. d 400 amp sizes Use Table 3 below to determine the proper size disconnect breaker or fuse for the battery cables you are using These recommendations may not meet all local code or the NEC requirements 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 RATING IN MAXIMUM RATING IN MAXIMUM REQUIRED CONDUIT BREAKER SIZE FREE AIR 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 Trace dealer to order the inverter disconnects fuses or see the OTHER PRODUCTS section in this manual on page 129 for more information Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 23 INSTALLATION BATTERY CABLE CONNECTIONS Cables must have crimped or prefera
146. d Battery Cable Size vs Cable 131 Table 12 Battery Cable to Maximum Breaker Fuse 5 2 131 Table 13 Recommended Minimum AC Wire Sizes 75 C 132 Table 14 Knockout Hole Size To Conduit Size Required nanne nennen senen eneen ee ensene eneen 132 Table 15 Safety Ground Wire Sizes ooonoocccconoccccnoconnccnononnnncnnonnncnnnnnncnnanonnnnnnn nn nn naar nn nn naar rr rr nennen 132 Copyright O Trace Engineering Company Inc 5916 195th Street E Arlington WA 98223 Telephone 360 435 8826 SW Series Inverter Charger Fax 360 435 2229 Part No 2031 5 www traceengineering com Rev B Sept 1 1999 IMPORTANT SAFETY INSTRUCTIONS IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important safety and operating instructions as prescribed by UL Standards for the Trace Engineering 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 Series Inverter Chargers are ETL listed to UL standard 458 Power Converters Inverters and Power Converter Inverter Systems for Land Vehicles an
147. d Marine Craft The 120 VAC 60 Hertz models of the SW Series Inverter Chargers are also ETL listed to Canadian Standard CSA C 22 2 No 107 1 M1 Commercial and Industrial Power Supplies The following Model Numbers of the SW Series Inverter Chargers listed above comply with the following EU directives e 89 336 EEC Council Directive of May 1989 on the approximation of the laws of Member States relating to Electromagnetic compatibility EMC e 73 23 EEC Council Directive of 19 February 1973 on the harmonization of the laws of Member States relating to electrical equipment for use within certain voltage limits LVD SW2612bE SW4548AHC SW4548EPV SW2612A SW3048E SW2612EHC SW4548EHC SW2612AHC SW3048AHC SW4548E3PH SW3024E SW3048EHC SW3024E SW3048EPV SW3048E3PH SW3048E SW3024AHC SW3024A SW3048APV SW4548APV SW3048A SW3024EHC SW3048E SW4548E SW4548A The compliance of the above mentioned products with the Directives is confirmed through the application of the following essential requirements Emissions and Immunity Satety EN 50091 2 and EN 50091 1 EN 60950 NOTE To achieve compliance to EN50091 1 Conducted RF emissions product must 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 Charge
148. d and remove them from the inverter Using appropriate conduit connectors fasten the conduit to the inverter Feed all AC wiring through the conduit and into the inverter AC terminal block Be sure to leave yourself several extra inches of wire to work with Remember that you need at least two sets of three conductor wiring one for AC Hot Neutral and Ground into the inverter and another for AC Hot Neutral and Ground out of the inverter to the loads Torque all AC terminals 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 terminal 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 Inspect all wiring for proper installation and then replace the access cover using the two screws to secure it IMPORTANT PRECAUTION The AC output of the inverter must at no time be connected directly to utility power or a generator This condition can be far worse than a short circuit If the inverter survives this condition it will shut down until corrections are made Connection to a utility or generator must be only done internally by the inverters built in relays This allows the inverter to first synchronize to the other AC sources wavefor
149. d generator or grid size and then the inverter will switch to a generator support mode and create waveforms that are larger than the AC source This causes power to flow from the batteries to the AC loads to prevent overloading of the AC source In utility inter active 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 regulate the battery voltage Some external control device such as Trace C40 Load Charge controller must be provided to prevent damage to the battery Pa e Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger g 5916 195th Street E Fax 360 435 2229 Part No 2031 5 58 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 OPERATION POWER VS EFFICIENCY There are two primary losses that combine to create the efficiency curve of the SW Series inverter The first is the energy that is required to operate the inverter at fu
150. de Generator Auto Start Requirements Three Wire Start Generators Two Wire Start Generators Generator Control Equalization Charging Generator Error Causes Generator Stop Cool Down 88 Generator Exercising nennen enn eennenene vennen 84 Generator Start Stop Configurations 84 Generator Starting Scenarios 83 Automatic 88 NELE A EEE ETE 84 Aux and Gen Control Relays 14 Aux Relays 14 26 101 Auxiliary Relays Menu 14 57 AWG to Metric Wire 145 AWG Wire SiZe seriem tente 146 B Battery Amphour Usage Battery Type Deep Cycle 112 Absorbed Glass 113 alus ded b A stems uen 113 Gel Gell 44e uen pe 113 Maintenance 113 Non sealed Lead Acid 112 Sealed Lead Acid 113 NiCad NiFe 113 Starting Battery
151. des a cool down timer that causes the controlling inverter to disconnect from the generator before it turns the generator off If the MASTER controls the generator then the SLAVE may not stay in sync with the MASTER during the cool down period since it will remain in sync with the generator and not follow the MASTER There currently is no adjustment for the cool down period so restricting the generator control to the SLAVE is the only solution available at this time The SLAVE also must be set with a longer warm up period than the MASTER in order to prevent them from trying to synchronize to the generator at the same time When the MASTER synchronizes first the SLAVE will automatically sync after its warm up period passes This also makes the transfer from inverter to generator smoother and less noticeable Pa e Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger g 5916 195th Street E Fax 360 435 2229 Part No 2031 5 96 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 OPERATION BATTERY CHARGING WITH MULTIPLE INVERTERS The inverters can operate in parallel as battery chargers from the same AC source connected to the same battery The AC input terminals and DC terminals would all be in parallel The inverters will synchronize individually to the AC source and then connect When multiple inverters are connected to the same battery and operated as in battery charger mode the
152. determines the voltage level that the battery must reach for 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 Once the inverter has shut off 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 many applications by battery manufacturers It is set to allow maximum performance from 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 control on a regular basis then increasing this setting is recommended Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 63 OPERATION CHARGER MODE AC SOURCE AC CHARGER DC BATTERY IN BRIEF When AC power is available the inverter can operate as a very powerful battery charger with low current distortion Power is drawn over the full AC cycle This improves the performance 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 overlo
153. dingly Reduce your Set AC Amps setting to limit the pull on the AC source Open the Upper Lower VAC limit settings window to allow synchronization Circuit breaker on inverter is open Ambient temperature may be high the charging Cold temperature around batteries with BTS Battery Temperature Sensor installed may be causing unit to reach HIGH BATTERY CUTOUT setting See ERROR CAUSES section Loose corroded battery connections causing unit to overheat and ramp down Engage circuit breaker on side of unit press hard on breaker button to ensure it is engaged Cool the unit down or check the inverter cooling fan or check for anything preventing air flow Disconnect BTS during charging or increase HIGH BATTERY CUTOUT setting Check and clean all connections Loose AC input connections Check all AC wiring connections Batteries being charged above the Bulk Float setting Weak soft batteries Replace batteries Battery cables too small or too long NOTE To bring batteries that are cold to the correct state of charge may require Refer to cable and battery recommendations in owner s manual charging at a higher voltage Remove the BTS and determine if your voltage returns to the bulk float voltage Temperature probe is installed Temperature probe is not installed LBX mode is enabled but you do not want the unit to go into Float mode F
154. e 59 is acceptable for most applications The range is from 4 to 255 LOW BATTERY PROTECTION When the actual battery voltage reaches the LOW BATTERY CUT OUT menu item setting for 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 80 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 terminals 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 are located under the INVERTER SETUP 9 menu heading See the SETUP MENU section for instructions on accessing these settings The SET LOW BATTERY CUT OUT menu item
155. e float stage or until the AC load is reduced The generator is then shut off 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 may be programmed in the setup menu Utility Back Up Mode Phase synchronized fast AC transfer switching for utility back up power supply applications Includes adjustable AC transfer voltage and line conditioning ability Utility Inter Active Mode Excess power from charging sources or stored 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 time periods This mode can be used with time of day metering to shift energy consumption to off peak periods Peak Load Shaving Mode 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 are 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
156. e 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 example 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 array 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 greater the value of this operating mode When combined with a solar array this mode may be more economic than operating the system 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
157. e place on a daily basis except immediately after a grid failure has occurred and the power has been restored The default setting is 00 00 that defeats the BULK CHARGE TRIGGER TIMER BATTERY REQUIREMENTS Utility back up 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 products If the battery is not large enough unsatisfactory performance may result For the best performance oversizing of the battery is strongly recommended Pa e Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger g 5916 195th Street E Fax 360 435 2229 Part No 2031 5 82 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 OPERATION UTILITY INTER ACTIVE MODE MAIN AC LOADS UTILITY GRID kWh METER AC NOT PROVIDED SOLAR ARRAY WITH BACK UP AC y OUTDOOR AC DISCONNECT INVERTER CHARGER GROUND FAULT PROTECTION BACKED UP AC LOADS SUB PANEL OVERVOLTAGE BATTERY DC PROTECTION IN BRIEF In this mode SW Series Inverter Chargers can be used to move power from the DC system into the AC utility grid This is often called selling p
158. e system is physically grounded at the same location This assures that there 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 battery grounds together as well as the case or safety grounds in the system and then attaching all to the same 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 equipment or other variables other means of lightning protection must be considered Consult a reputable lightning protection company Equipment acts as a conductor due to Equipment all grounded at voltage between the same point No voltage grounds Bad a
159. e than the voltage at which they are charged Adjust the FLOAT VOLTS DC setting to control the battery voltage Temperature Compensation Temperature affects the optimum voltage values for the bulk and float charging stages The Battery Temperature Sensor BTS automatically fine tunes these voltages for you Equalization Non Sealed Batteries Only Many experts recommend that batteries be equalized A fancy term for over charged every month or two However a leading battery manufacturer recommends equalizing only when low or wide ranging specific gravity 015 are detected after fully charging a battery Since the individual battery cells are not exactly identical some may still have sulfate on their plates after a complete charge cycle On the other hand if the batteries never received a full charge all plates will have sulfate left on them If the sulfate remains on the plates for an extended period of time it will harden and seal off a percentage of the plate area reducing the capacity of the battery By equalizing the batteries the entire sulfate is removed from the plates Additionally the gassing that result stirs up the electrolyte which tends to stratify Stratification concentrates the sulfuric acid in the bottom of the cell while the top becomes watery This corrodes the plates Equalization is accomplished by charging batteries above a voltage of 2 6 VDC per cell This is over 15 VDC for a 12 VDC system 30 for a 24 VDC system
160. e unit operating as an inverter feeding the AC subpanel and the unit connected to an external AC source generator shore power etc NEUTRAL TO GROUND NEUTRAL TO GROUND SWITCHING BOND is provided by this relay RELAY provided in the AC installation for the entire AC system 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 Mas AC NEUTRAL OUT The neutral conductor should v not be connected to the equipment grounding conductors or enclosures No external AC source is present V a pes ca CHASSIS GROUND NEUTRAL Figure 12 Neutral To Ground Bond Switching No External AC Source Connected Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 27 INSTALLATION NEUTRAL TO GROUND BOND is NEUTRAL TO GROUND SWITCHING RELAY provided by an external AC source for Provided in the AC installation Connects the the entire AC system neutral from external AC source and neutral of the AC panel loads together when AC is applied to the inverter input AC SOURCE AC PANEL RV Marine The neutral conductor should not be connected to the equipment grounding condu
161. e 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 models 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 completes five start cycles and requires that the generator operate for a minimum of 5 minutes 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 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 generator runs for 10 minutes without operating in the AC voltage and frequency tolerance windows then the automatic control system stops the
162. e utility approval Simple in concept this configuration may not provide the desired results Incompatible settings and poor system designs i e having excessive loads connected and or low output of the charging source caused by undersizing the system or poor weather conditions affecting PV array output often cause frequent cycling to and from the grid thus reducing efficiency Such cycling can actually increase power consumption from the utility grid The most common problem occurs when the LOW BATTERY CUT IN setting is lower than the BULK VOLTS DC setting causing the batteries to only partially recharge before transferring off utility power Since the batteries are not fully recharged they can only support the load for a limited amount of time This results in rapid cycling every day or even multiple times per day between the battery system and the utility grid One way to reduce the amount of cycling is to set the MAX CHARGE AMPS AC value to its minimum setting of 2 amps AC however this increases the system s dependency on the utility grid If the system is also used for utility backup performance could be drastically affected if the batteries are not fully charged when the utility outage occurs The best performance can be achieved by recharging the battery from the utility grid and then waiting until the alternative power source usually solar panels or a wind generator has excess power available beyond what it takes to power the AC l
163. eakers are required Press the breaker to reset to reset on 48 volt units move the breaker handle to the ON position Page Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger 5916 195th Street E Fax 360 435 2229 Part No 2031 5 12 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 CONTROLS INDICATORS AND COMPONENTS INTERNAL COMPONENTS AND INDICATORS Additional components and indicators are 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 RY8 Green AC1 Relay Red LED UTILI A REMOVE TO DI LED SIMULATES RELA ITY JE TEST ACT IN RELAY em j S Er er PRESENT R3 gt JO SN NAL fo co NEUTRAL IN 1 NEUTRAL IN 2 INC nya RY7 RUN RYS ti AUX y a a Aux and Gen Control AC p Relay Connectors Safety Ground Figure 5 Internal Components and Indicators LED INDICATORS Three LED indicators allow visual indication of operation of the RY7 RY8 and ACT relays RY7 Yellow LED Allows visual indication of relay RY7 operation During the automatic g
164. east 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 HOT IN 2 terminal is adjustable through the SET GEN WARMUP SECONDS menu item under the GEN STARTING DETAILS 13 menu heading This allows the generator to reach 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 The battery charger settings will automatically adjust if the temperature compensation 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 app
165. ected continuous load on the inverter is used 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 breaker 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 fuse is required Trace Engineering offers a fuseblock TFB that provides 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 maximum protection install the fuseblock within 18 inches 45 cm of the battery The fuses are available in 110 200 300 an
166. ed 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 BASED ON BATTERY VOLTAGE The LBX mode is used only with AC power supplied to the AC HOT IN 1 input The LBX mode is selected from the GRID USAGE menu item under the INVERTER SETUP 9 menu heading In this mode the decision to transfer to and from charger mode will be based upon the battery voltage With LBX enabled the SET LOW BATTERY CUT IN VDC setting and the SET LOW BATTERY TRANSFER VDC setting determine the DC transfer voltages When 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 Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept
167. ed 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 inverters AC HOT IN 1 and AC HOT IN 2 terminals is used to power both the battery charger and the AC loads while the inverter is in the battery charger mode There are several settings listed below that involve the AC INPUT See the USER SETTINGS 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 menu heading in the SETUP MENU Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 65 OPERATION 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 maximum current draw into the AC HOT IN 2 terminal
168. ed 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 The contacts close only when it is time for the generator 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 seiting 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 generator 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 cranking 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 generator cranking 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 terminal
169. eee Default Setting End Charge Time Menu 18 62 End Quiet Time Menu 7 nnee nennen 46 R 9 Hysteresis Volts DC Menu 14 58 R10 Hysteresis Volts DC Menu 14 59 R11 Hysteresis Volts DC Menu 14 59 Read 30 Sec LBCO Start VDC Menu 12 55 Set 15 Min Start Volts DC Menu 12 55 Set 2 Hr Start Volts DC Menu 12 sse 55 Set 24 Hr Start Volts DC Menu 12 54 Set Absorption Time Menu 10 51 Set Aux Relay 9 Volts DC Menu 14 58 Set Aux Relay 10 Volts DC Menu 14 59 Set Aux Relay 11 Volts DC Menu 14 59 Set Battery Sell Volts DC Menu 17 Set Bulk Volts DC Menu 10 Set Clock Hours Menu 6 Set Clock Minute Menu 6 Set Clock Second Menu 6 Set Equalize Time Menu 10 Set Equalize Volts DC Menu 10 51 Set Exercise Period Days Menu 12 55 Set Float Volts DC Menu 10 Set Gen AC2 Amps AC Menu 11 Set Gen Warmup Seconds Menu 13 57 Set Generator Menu 2 Set Grid AC1
170. eengineering com Rev B Sept 1 1999 WARRANTY REPAIR INFORMATION WARRANTY REPAIR INFORMATION LIMITED WARRANTY Trace Engineering warrants its power products against defects in materials and workmanship for a period of two 2 years from the date of purchase and extends this warranty to all purchasers or owners of the product during the warranty period This warranty is void under the following circumstances 1 improper and or unauthorized repair not provided by Trace Engineering or its Authorized Service Centers 2 when the product is installed or exposed or exposed to an unsuitable environment as evidenced by generalized corrosion or biological infestation 3 abnormal use of the product or use in violation of the instructions 4 when used as a component parts of a product expressly warranted by another manufacturer Trace Engineering agrees to supply all parts and labor or repair or replace defects covered by this warranty with parts or products of original or improved design at the company s option Trace Engineering also reserves the right to improve the design of its products without obligation to modify or upgrade those previously manufactured Defective products must be returned to Trace Engineering or its Authorized Service Center in the original packaging The cost of transportation and insurance on items returned for service is the responsibility of the customer All remedies and the measure of damages are limited to the
171. enerator 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 During the automatic generator control sequence 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 ACT 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 The BTS provides information that enables the three stage standby battery charger to fine tune the battery charge voltages for better charging performance greater efficiency and longer battery life AC TERMINAL BLOCK A six position terminal block is provided to make the AC connections The terminal block is located on the AC Circuit Board The terminal block is used to hardwire all AC input and output connections Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031
172. ennen nennen nennen nn nn cnn nn nn rana nr nene nennen 18 Figure 9 AC Input Output Power Connection sssssssessseseeene eene 19 Figure 10 Warning Label aiii at 21 Figure 11 Battery to Inverter Cable Connection ooonnncinnccnnccnnnncnnnccnnanoccnonn ronca cnn rr nennen 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 28 Figure 15 Multiple Point Ground 29 Figure 16 Single Point Ground System 29 Figure 17 Trace SW Series Inverter Simple Block Diagram sse 57 Figure 18 Trace SW Series Inverter Output Waveform sse 58 Figure 19 Trace SW Series Efficiency Curves ssssssssssssssssseseee eene nennen nnne nennen 59 Figure 20 Inverter Capacity vs Temperature nnnunnnenennenrenneenenenenenenenr enen ennemis 60 Figure 21 Three Stage Battery Charging sse ener enne 64 Figure 22 BTS Battery Temperature Sensor ssssssssssssseseeeeeee enne nennen 65 Figure 23 Two Wire Start Wiring Diagram
173. enu 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 e 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 setting This 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 period Adjusting the SET FLOAT VOLTS DC menu item to just above the normal at rest 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 Pa e Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger g 5916 195th Street E Fax 360 435 2229 Part No 2031 5 90 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 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 rat
174. er a more economical way to operate the system Pa e Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger g 5916 195th Street E Fax 360 435 2229 Part No 2031 5 94 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 OPERATION USING MULTIPLE INVERTERS Multiple SW Series Inverter Chargers can be used in the same system There are some limitations to the design of the system for successful and reliable operation For North American applications the inverters can be used in a series configuration to operate 240 VAC loads and to connect to 120 240 VAC power systems Series stacking of E versions 230 VAC 50 Hz would result in 230 460 VAC power Two inverters can also be connected together and operated in parallel to provide twice the power at the same output AC voltage The inverters can operate in parallel as battery chargers from the same AC source connected to the same battery The AC input terminals and DC terminals would then be all in parallel The inverters will synchronize individually to the AC source and then connect SERIES STACKED OPERATION As mentioned in North America two inverters can be connected in a series stacked configuration to provide 120 and 240 VAC output When series stacked you get twice the power of a single inverter available for operating 240 VAC loads but only one inverter s power is available for operating a single la
175. er confirming the correct 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 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 second 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 since a portion of the AC input power Utility or Generator is passed through the inverter to power the loads 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 should continue to operate uninterrupted This completes the functional test if all areas pass the in
176. er typical conditions See the low battery transfer mode section for more information Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 45 MENU SYSTEM Set Low Battery cut out VDC Set Low Battery cut out VDC 12 VDC models 24 VDC models 48 VDC models Range 08 0 to 16 0 Range 16 0 to 32 0 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 continuously This will occur even during the quiet time period This setting is not temperature compensated Set Low Battery 11 0 22 0 cut out VDC 44 0 Set LBCO delay minutes 15 models Range 00 to 255 This setting controls how long the inverter delays before turning 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 time it takes
177. eration allowing the battery voltage to be unregulated Return the controller to the normal setting and check 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 setting 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 such as a back 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 may 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 disconnect all input wiring from AC inputs 1 and 2 and restart the inverter If the AC IN GOOD LED indicator on the control panel glows then the inverter s internal relay is defective External error stacked NO
178. erent delay times for each A quiet time 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 e Connect the generator AC output to the inverter s AC HOT IN 2 and NEUTRAL IN 2terminals e Connect the AC loads to the inverters AC HOT OUT and NEUTRAL OUT terminals e Select AUTO from the SET GENERATOR menu item accessed by pressing the green GEN MENU button The AUTO mode is disabled if the CHG mode under INVERTER MODE 1 menu heading is selected e Adjust the battery charger parameters to match the requirements of the batteries connected if the factory defaults listed in the technical section are not satisfactory e 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 support feature to function correctly preventing the generator from being overloaded The generators 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 e Adjust the SET INPUT LOWER LIMIT VAC menu item located in the A
179. ering com SW Series Inverter Charger Part No 2031 5 Rev B Sept 1 1999 TECHNICAL INFORMATION INVERTER CHARGER TERMINOLOGY The following is a glossary of terms with which you may not be familiar while reading this manual They appear in the description of inverter and battery charger operation Absorption Stage In this second stage of three stage charging the batteries are held at a constant voltage the bulk voltage setting and the battery is charged to its maximum capacity AC Alternating Current Electrical current that varies with time The rate at which the voltage changes polarity is the frequency in Hertz Hz Ampacity The ampacity of a wire is its current carrying capacity with reference to the cross sectional area of the conductors the temperature rating of the insulation and the ambient temperature Automatic Transfer Relay inside the inverter An automatic switch that switches between inverter and charger mode depending on availability of AC input power If AC is present the unit will be a battery charger when AC goes away the unit becomes an inverter Bulk Charge Stage This is the first of the three stages in three stage charging In this stage a constant current is fed to the batteries and as they accept the current the battery voltage will rise Current Amps The volume of electricity flowing through a conductor Equivalent to a volume of water flowing through a hose DC Direct Current Elect
180. erminal 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 Heatsink NO jovertemp NO Trans former jovertemp The transformer or power transistors have exceeded their safe 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 blocked The inverter will automatically reset once it has cooled While 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 Telephone 360 435 8826 SW Series Inverter Charger Fax 360 435 2229 Part No 2031 5 www traceengineering com Rev B Sept 1 1999 Copyright Trace Engineering Company Inc 5916 195th Street E Arlington WA 98223 MENU SYSTEM 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 op
181. ers Controlling the H Bridges Low Frequency Transformer H Bridge Low Frequency Transformer H Bridge Low Frequency H Bridge Transformer Figure 17 Trace SW Series Inverter Simple Block Diagram By mixing the outputs from the different transformers a sine wave is produced Shown in Figure 18 is the output waveform from a Trace Engineering SW Series Inverter Charger Notice the steps form a staircase that is shaped like a sine wave The total harmonic 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 problems associated with high frequency or ferroresonant sine wave inverters The low frequency method described has excellent surge ability high efficiency typically 85 to 90 good voltage and frequency regulation and low total harmonic distortion The inverter runs in two basic formats 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 waveforms with progressively fewer steps are
182. erter terminal Torque all terminals to 10 15 foot pounds NOTE 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 knockout from the inverter chassis 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 marked AC HOT OUT to the hot bus of your AC load center or AC sub panel 2 Connect the white wire from the terminal 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 fas
183. ery Type Bulk Volts Float Volts Equalizing Charge Process 14 1 VDC BULK 13 6 VDC FLOAT Not Recommended Consult manufacturer eer battery 14 4 VDC BULK 13 4 VDC FLOAT Charge to 15 5 VDC or as per manufacturer cine R 14 4 VDC BULK 13 4 VDC FLOAT Not Recommended Consult manufacturer 14 6 VDC BULK 13 4 FLOAT Charge to 15 5 VDC or as per manufacturer iens 10 cell nee 16 0 VDC BULK 14 5 VDC FLOAT Consult manufacturer Note Values shown are for 12 volt systems For 24 volt systems multiply the settings 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 extended periods at partial charge levels can result 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 many manufacturers recommend a periodic equalization charge to mix up the electrolyte re activate unused battery plate material and bring up all of the indiv
184. es a voltage in the original conductor The voltage induced into the original conductor is called self inductance and tends to oppose the current that produced it The magnitude of the self induced voltage is proportional to the size of the loop formed by a wire The larger the loop the larger the self induced voltage The positive and negative battery cables in a system are in reality only a single circuit wire and so the inductance of the battery circuit depends on how the cables are physically positioned or arranged with respect to one another If battery cables are separated by a distance they have much more inductance than if they are close together If the two battery cables were coaxial there would be virtually no induced current flow since the magnetic fields would cancel one another However we don t have coaxial battery cables but we can approximate them by taping the cables together every four to six inches When the cables are taped together the magnetic fields around each battery cable tend to cancel each other When cables are separated the magnetic fields add together and increase the inductance of the battery cables If you aren t convinced that taping battery cables together helps reduce inductance consider the following table of information collected by Trace Engineering We tested two sixteen foot long 4 0 AWG battery cables connected together at one end and parallel to one another Table 8 Battery Cable Inductance
185. et Float volts DC 13 4 volts DC 26 8 volts DC 53 6 12 VDC models 24 VDC models 48 VDC models Range 10 0 to 16 0 Range 20 0 to 32 0 Range 40 0 to 64 0 Sets the voltage level that will be maintained at the final stage of the charging process This is important for systems which are connected to utility power since the battery charger will often be in this stage most of the time This setting will be compensated for the battery temperature if the BTS sensor is installed Set Equalize Set Equalize Set Equalize volts DC 14 4 volts DC 28 8 volts DC 57 6 12 VDC models 24 VDC models 48 VDC models Range 10 0 to 16 0 Range 20 0 to 32 0 Range 40 0 to 64 0 Sets the voltage level that the batteries will be limited to during the equalization 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 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 accumulating or up down type timer it counts up while the voltage is above the BULK setting and counts back do
186. et Max Cranking seconds 10 All Models Range 00 to 15 Sets the maximum number of seconds the starter will be cranked during 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 seconds the system will delay after completing the start sequence If the generator has not started this sequence will be repeated up to 5 times See the AUTOMATIC GENERATOR CONTROL MODE for more information This period is provided to allow the starter motor to cool 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 They 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 these auxiliary 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 l
187. exhaust port on the right side will allow cool outside air to flow through the inverter and back out of the enclosure Top Left Os S20 ARO Right AC Side DC Side AIR ANNM FLOW A E ME Power Conversion Center e f f f e e O co Oo O Once 0 Bottom Figure 8 Air Flow Intake Location AC WIRING This section describes AC wiring requirements and recommendations including AC connections wire sizing overcurrent devices GFCls external relays hookup procedure and neutral to ground switching Your local electrical code and the National Electrical Code NEC define the standards for AC installation 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 qualified personnel such as a licensed electrician AC INPUT AND OUTPUT CONNECTIONS A six position terminal block is provided to make the AC connections The terminal 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 terminal block can accept up to 6 AWG stranded wire and is used to hardwire al
188. fication Over time a battery s electrolyte liquid tends to separate The electrolyte at the top of the battery becomes watery while at the bottom it becomes more acidic This effect is corrosive to the plates Sulfating As a battery discharges its plates become covered with lead sulfate During recharging the lead sulfate leaves the plates and recombines with the electrolyte If the lead sulfate remains on the plates for an extended period of time over two months it hardens and recharging will not remove it This reduces the effective plate area and the battery s capacity Temperature Compensation Peak available battery voltage is temperature dependent As ambient temperatures fall the proper voltage for each charge stage needs to be increased An optional temperature probe BTS automatically re scales charge voltage settings to compensate for ambient temperatures The compensation slope based on cell voltage is 2 17 mv per degree Fahrenheit 30 mv per degree Celsius per cell for lead acid batteries Voltage The pressure of electrical flow Equivalent to water pressure in a hose Watts Measure of power output or utilization Watts Volts x Amps Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 0 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 117 TECHNICAL INFORMATION SPECIFICATIONS AND
189. g com 8826 SW Series Inverter Charger Part No 2031 5 Rev B Sept 1 1999 OPERATION OVERVOLTAGE PROTECTION FOR THE BATTERY IN SELL MODE Normally the inverter will regulate the charging process of the battery by selling excess power into the utility grid The battery will receive a three stage charge routine as previously described If the utility grid is not available due to an outage or tripped AC input circuit breaker etc or if the inverter shuts 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 control is required to provide overvoltage protection for the battery when an outage has occurred The Aux Relays in the SW Series Inverter Charger are designed to control an externally connected power relay that would disconnect the solar array and stop the charging process The voltage and hysteresis difference between opening and closing voltage are both adjustable The external relay can be either a standard mechanical type or a mercury displacement type depending on the voltage and current required The mercury 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 the solar array is divided into several source circuits do not parallel relays for higher current Another option is to use a ch
190. ge 70 to 90 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 When 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 Lower set Input Lower 206 limit VAC 108 limit VAC Set Input Lower limit VAC Set Input Upper limit VAC Set Input Upper limit VAC Set Input Upper limit VAC Standard models E models J 8 K models W models Range 128 to 149 Range 250 to 298 Range 105 to 129 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 inverter will sell power into the line if SELL is enabled When this voltage is reached 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 Set Input Upper 132 254 112 limit VAC 244 Copyright O Trace Engineering Company Inc Telephone 360 435 8826 5916
191. generator and indicates an error condition 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 Gen max run time error NO If YES is displayed it indicates that the generator ran for a period of time 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 operating 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 Pa e Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger g 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 38 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 MENU SYSTEM Load Start Amps Ready NO If YES is displayed it indicates that the au
192. ger mode The parallel stacking interface system allows doubling of the AC pass through capacity This is useful when large generators are used Both inverters will battery charge as allowed by the settings in each of the inverters The hook up depends upon the other components included in the system and whether it was ordered as only inverters a power panel system or a power module system With the power module system the paralleling enclosure is eliminated and all of the wiring is completed for you With the individual inverters and the power panel system the paralleling enclosure and parallel stacking interface cable must be installed on site The paralleling enclosure is connected to each of the inverters outputs and is also connected to the AC loads being powered At this time the paralleled inverters are intended to operate as a single unit In case of an inverter fault or error condition both inverters turn off as one When the error has been corrected the inverter will automatically or manually reset depending upon the type of error condition If an inverter failure occurs the parallel stacking interface can be manually bypassed and the special parallel stacking interface cable can be removed to allow temporary operation on one unit GENERATOR CONTROL SETTINGS When using two units in parallel it is recommended that only the SLAVE inverter be used to control the generator This is required because the generator control system inclu
193. has automatically reset itself This may occur during motor startups and is acceptable Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 11 CONTROLS INDICATORS AND COMPONENTS AC SIDE Figure 4 shows the components located on the AC side of the inverter The removable AC Access 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 Charger Circuit Breaker Identification Label Remote Port Stacking Port Figure 4 AC Side REMOTE PORT The SW Series Inverter Charger can be controlled remotely from the unit by plugging in a SineWave Remote Control SWRC or SineWave Communications Adapter SWCA coru E leri AS N w Knockouts Also On Side VUUVUUUU Three Removable Access Panel One Panel on Side VUUVUUUUUUUUUUU OANANNANNANNNN VUUVUVUUVUVUUVUUUVU AANANNANNANNNN VUVUUUUUUUUUUU UUUUUUUUUUUUUU nnnnnnnnnnnnan VUVUUUU
194. he 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 terminal 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 counter 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 required time delay period e 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 e 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 excessive generator operation if the system has not been able to fully charge the battery
195. hese also feature additional system components to signal the generator control system to start GENERATOR CONTROL SEQUENCE The relays close in a specific sequence to start the generator Some of the timing periods are adjustable through the GEN STARTING DETAILS 13 menu heading GLOWSTOP has been added to the sequence for diesel generator applications RY7 can be configured for 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 below 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 start 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 initiated if generator is manually turned on via Set Generator to ON First auto The auto generator stop sequence The generator will stop Next auto Second generator is initiated if 1 The battery immediately with an generator auto start voltage has been held at the Set inverter fault or if Set Start generator attempt Bulk volts DC setting for the Set Generator is set to sequence start Absorption time h m period or 2 OFF Also a Kill Before has been attempt The load amps drops below the Cranking signal
196. i A erheen bendes dine 102 BATTERY CARE AND MAINTENANGE 3 rre ete x toe eia beoe 104 BATTERY INSTALLATION co IER Ep CRUDUM p 106 BATTERY HOOK UP CONFIGURATION S esses nennen nennen neret nnne tenni nnns etre nnne nennen entere 107 BATTERY GABLE INDUGTANGE x xe ptite th aos tse af eile ir e ga ea IAS 110 ABPEIGATIONS 5 is aid 111 TROUBLESHOOTING GUIDE 2 2 Itin nein tnc rere HERE DRM eii 112 INVERTER CHARGER 115 SPECIFICATIONS AND FEATURES 60 Hz Models ann eeneeeennerenenennenennerennerenenennereneeeneerenn 118 SPECIFICATIONS AND FEATURES 50 Hz Models nnn eeneeeennernnerenneeeenenenerenenenereneeeneerenn 119 DIMENSIONS 3 5 niet eee mE PRADESH 121 INSTALLATION DIAGRAMS 5 Gee e Drehen uie oid eter eiae P CE dp ee er 121 USER SETTINGS WORKSHEET Skiroi d petra redde cte cab 123 Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 TABLE OF CONTENTS APPENDIX ico ae 128 OPTION Scotia AAA ES 128 OTHER PRODUGTS a tetti ie tbe ento aa LU Ee ghe ecd e iuo e ed ate eee 129 REFERENCE TABLES AND ORA PHS area RR RE aro aA Aaea Ra
197. iately 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 metal items such as rings bracelets necklaces and watches when working with a battery A battery can produce a short circuit current high enough to weld a ring or the like to metal causing severe burns 8 NEVER charge a frozen battery 9 If necessary to remove the battery make sure all accessories are off Then remove the grounded terminal from the battery first 10 If a remote or automatic generator contro system is used disable the automatic starting circuit and or disconnect the generator from its starting battery while performing maintenance to prevent accidental starting 11 Provide ventilation to outdoors from the battery compartment The battery enclosure should be designed to prevent accumulation and concentration of hydrogen gas in pockets at the top of the compartment Vent the battery compartment from the highest point A sloped lid can also be
198. idual cells to a full state of charge This requires that the battery 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 more 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 The process will cause the electrolyte to gas and will release hydrogen and oxygen in the process The chance of explosion due to the accumulation of these gasses is therefore a realistic hazard The batteries must be provided with good ventilation with no ignition sources present Some users have found that the battery 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 Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 0 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 67 OPERATION The battery manufacturer or supplier should be consulted before equalizing to provide the recommended process and
199. 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 e ON Allows the inverter to provide AC voltage to the output and energize the AC loads either from the battery or any synchronized AC source available on the input This position must be manually selected e CHG Allows the inverter to operate only as a battery charger 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 When 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 i
200. in VDC 10 0 35 5 26 0 Set High battery cut out VDC 10 0 33 0 32 0 Set search watts 00 240 48 Set search spacing 00 255 59 Battery Charging 10 set Bulk volts DC 20 0 32 0 28 8 Set Absorption time h m 00 00 23 50 02 00 Set Float volts DC 20 0 32 0 26 8 Set Equalize volts DC 20 0 32 0 28 8 Set Equalize time h m 00 00 23 50 02 00 Set Max Charge amps AC 01 35 30 Set Temp Comp LeadAcid Nicad LeadAcid AC Inputs 11 set Grid AC1 amps AC 00 63 60 Set Gen 2 amps AC 00 63 30 Set Input lower limit VAC 80 111 108 Set Input upper limit VAC 128 149 132 cen Auto Start Setup 12 Set Load Start amps AC 00 63 33 Set Load Start delay min 00 0 25 5 05 0 Set Load Stop delay min 00 0 25 5 05 0 Set 24 hr start volts DC 10 0 35 5 24 6 Set 2 hr start volts DC 10 0 35 5 23 6 Set 15 min start volts DC 10 0 35 5 22 6 Read LBCO 30 sec start VDC 10 0 35 5 22 0 Set Exercise period days 00 255 30 Set Maximum run time h m 00 00 23 50 08 00 Gen Starting Details 13 set RY7 Function GlowStop Run Run Set Gen warmup seconds 16 255 60 Set Pre Crank seconds 00 255 10 Set Max Cranking seconds 01 15 10 Set Post Crank seconds 00 255 30 auxiliary Relays R9 R10 14 Set Relay 9 volts DC 10 0 35 5 29 0 Hysteresis volts DC 00 1 12 8 02 0 set Relay 10 volts DC 10 0 35 5 29 5 R10 Hysteresis volts DC 00 1 12 8 02 0
201. in the motor specifications This is usually the best guide to the maximum load the pump will place on the inverter lt must be less than the AC amps noted under the Maximum Output RMS given in the Specifications And Features section starting on page 118 Pump suppliers and well drillers often oversize the pump considerably in order to reduce complaints of poor pressure low flow etc Get several quotations and explain that you are very concerned about the inverter being able to power the pump It makes sense to operate a smaller pump longer instead of a larger pump for a shorter period of time when you are powering it from batteries or a solar electric system When buying a pump select a three wire type This refers to the electrical configuration of the power and starting windings in the pump motor A three wire pump requires a separate box at the top of the well for the starting circuit a two wire pump has the start electronics built inside The separate starting box is preferred If possible select a relay type starting box instead of an all electronic type the relay types have been found to work better with inverters and generators The relay types also allow use of a larger or additional starting capacitor it may help if the inverter has a hard time starting the pump Consult your pump supplier for more information If a 220 240 vac motor is required you must either use two 120 vac inverters in a stacked configuration or include a step up
202. in utility back up applications e 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 system when LBX is selected To use the LBX mode the AC source 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 performance 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 und
203. ineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 0 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 37 MENU SYSTEM e Starts the generator that is controlled by the inverter f 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 e EQ Triggers the battery charger to complete the equalization process l an AC source is connected to the AC HOT IN 1 terminals then the equalization process will begin If no AC source is connected to the AC HOT IN 1 terminals then the generator will start the equalization process the next time the generator is automatically 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 generator control system to shut down the generator The ERROR LED can b
204. int hys Relays have 2 seconds delay on close 0 1 sec delay on open Pa e Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger g 5916 195th Street E Fax 360 435 2229 Part No 2031 5 52 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 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 charged 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 charging 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
205. inverters are connected to a 120 240 VAC distribution system without using the stacking interface cable the AC neutral wiring must be capable of handling twice the inverter output This is due to the lack of synchronization between the inverters If both inverters are operating in exact synchronization as opposed to operating 180 degrees out of synch then the AC neutral will carry the current of both inverters which was split among the two AC hot conductors This often is not a problem since the AC distribution system may be oversized to handle the higher output level of a generator When an AC source is connected to the inverters the inverters will synchronize independently and transfer at different times This is not a problem if no 240 VAC loads are connected to the output of the system Caution You must connect the two chassis of the inverters together and to the grounding system by their grounding lugs or a hazardous voltage may be present on the chassis of the inverters INPUT OUTPUT BYPASS BREAKER SWITCH 240 VAC LOADS An inverter bypass breaker switch diverts power around an inverter and is meant to be used only during times of maintenance or to remove the inverter out of the installation There is a possibility with a multiple inverter installation stacked in series 120 240 VAC with two bypass switches installed that one inverter bypass breaker switch could be in the Bypass Operation position power diverted around the in
206. ion 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 2 WIRE TYPE GENERATOR GEN CONTROL RELAYS COM 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 storage tank When the water level drops the float switch closes a set of contacts which signals the generator to run When the tank is full the float switch opens its contacts and the generator stops The float switch can be used in parallel with the automatic control system of the inverter Either switch can start the generator This allows easy automation of the entire system 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 Pa e Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger g 5916 195th Street E Fax 360 435 2229 Part No 2031 5 76 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 OPERATION THREE WIRE START GENERATORS Three wire start generators do not include automatic engine cranking control system Separate control of the starter motor requires additional interaction between the inverter s aut
207. 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 e 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 Pa e Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger g 5916 195th Street E Fax 360 435 2229 Part No 2031 5 54 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 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
208. is selected as the function of the RY7 relay the RY7 COM and RY7 N O contacts remain open while the generator is running The contacts close only when it is time for the generator 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 When 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 seconds 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 Pa e Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger g 5916 195th Street E Fax 360 435 2229 Part No 2031 5 50 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 MENU SYSTEM Set Pre Crank seconds 10 All Models Range 00 to 255 Sets the number of seconds the system delays closing of relay RY8 the star signal relay 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 system S
209. l AC connections For 120 VAC inverters we recommend 6 AWG THHN wire for full utilization of the inverters 60 amp AC pass through capability The code requires that disconnect switches be provided in the AC input and output wiring circuits AC circuit breakers in an AC load center can be used to meet this requirement The wiring both in and out of the inverter must also be protected from short circuits and overloads by a fuse or circuit breaker Typically a 60 amp circuit breaker will protect 6 AWG wiring Consult your local code for more information and for other wire sizes Page Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 18 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 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 ground 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 SWITCHI
210. lable the generator must 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 Pa e Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger g 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 68 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 OPERATION INVERTER CHARGER MODE UTILITY GRID AC INVERTER CHARGER AC AC LOADS AC GENERATOR BATTERY IN BRIEF The SW Series Inverter Charger is capable of automatically transferring AC loads from the inverter 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 specific time each day using the GRID USAGE
211. le lugs the connection should be metal to metal Apply the protective material after the bolts have been tightened BATTERY STATE OF CHARGE A good estimate of a battery s state of charge can be made by measuring the voltage across the battery terminals with the battery at rest No energy input no energy output for at least three hours These readings are best taken in the early morning at or before sunrise or in late evening Take the reading while almost all loads are off and no charging sources are producing power Connect a voltmeter across the positive and negative outputs of the battery or battery bank Voltages are for a 12 volt battery system For 24 volt systems multiply by 2 for 48 volt system multiply by 4 Monitor your cell voltage if you measure more than a 2 volt difference between each cell you may need to equalize Do not equalize Gel Cell Batteries The following table will allow conversion of the readings obtained to an estimate of state of charge The table is good for batteries at 77 F that have been at rest for 3 hours or more If the batteries are at a lower temperature you can expect lower voltage readings Table 7 Battery State of Charge Voltage zk a 12 VOLT DC SYSTEM CELL VOLTAGE EA 2 12 O 2 10 8026 12 5 2 08 HI 2 05 60 12 2 2 03 HA 2 02 aoe 12 0 2 00 HH 1 97 20 11 7 1 95 HO 1 93 0 lt 11 6 lt 1 93 i innit Copyright Trace Engineering Compan
212. le used 3 days Multiply your Autonomy Battery Size Step 6 x 2 to allow for a 50 maximum battery discharge in normal operation and an additional 50 for emergency situations to obtain your Rough Battery Size in watt hours Multiply your Rough Battery Estimate x 1 2 to allow for an efficiency of 80 This number is your Safe Battery Size in watt hours Convert your Safe Battery Size to amp hours Divide Safe Battery Size by the DC system voltage i e 12 24 or 48 VDC example used 24 volts This number is your Safe Battery Size in amp hours which is the battery bank capacity needed before recharging Telephone 360 435 8826 Fax 360 435 2229 www traceengineering com Copyright Trace Engineering Company Inc 5916 195th Street N E Arlington WA 98223 Total Daily Watt Hours Needed 5 139 Autonomy Battery Size Watt Hours 15 417 Rough Battery Size Watt Hours 30 834 Safe Battery Size Watt Hours 37 001 Safe Battery Size Amp Hours 1 542 SW Series Inverter Charger Part No 2031 5 Rev B Sept 1 1999 TECHNICAL INFORMATION WORKSHEET Complete the steps that follow to calculate your inverter s battery bank capacity STEP 1 4 AC APPLIANCE Determine your Average Daily Watt Hours Needed APPLIANCE RUNNING WATTS HOURS USED EACH DAY X DAYS USED EACH WEEK STEP 4 7 AVERAGE DAILY WATT HOURS NEEDED
213. led Set 2 hr start Set 2 hr start Set 2 hr start volts DC 11 8 volts DC 23 6 volts DC 47 2 12 VDC models 24 VDC models 48 VDC models Range 05 0 to 16 5 Range 10 0 to 35 5 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 compensated This 2 hour start is defeated if the QUIET TIME under GENERATOR TIMER 7 is enabled Set 15 min start Set 15 min start Set 15 min start volts pc 11 3 volts DC 22 6 volts pc 45 2 12 VDC models 24 VDC models 48 VDC models Range 05 0 to 16 5 Range 10 0 to 35 5 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 15 minute start is defeated if the QUIET TIME under GENERATOR TIMER 7 is enabled Read 30 sec LBCO Read 30 sec LBCO Read 30 sec LBCO start VDC 11 0 start VDC 22 0 start VDC 44 0 12 VDC models 24 VDC models 48 VDC models Range 05 0 to 16 5 Range 10 0 to 35 5 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 compensated This display is linked a
214. lephone 360 435 8826 SW Series Inverter Charger 9 5916 195th Street E Fax 360 435 2229 Part No 2031 5 108 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 TECHNICAL INFORMATION FUSED DISCONNECT 12V INVERTER Total Battery Capacity 200 Amp Hours 24V INVERTER Total Battery Capacity 200 Amp Hours 48V INVERTER Total Battery Capacity 200 Amp Hours Each individual 6 volt battery capacity 100 amp hours NOTE If cross tying is not required the dash connections are not needed Figure 34 Series Parallel Configuration 6 Volt Battery Wiring FUSED DISCONNECT 24V INVERTER Total Battery Capacity 100 Amp Hours 48V INVERTER Total Battery Capacity 100 Amp Hours Each individual 12 volt battery capacity 50 amp hours NOTE If cross tying is not required the dash connections are not needed Figure 35 Series Parallel Configuration 12 Volt Battery Wiring Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 109 TECHNICAL INFORMATION BATTERY CABLE INDUCTANCE When current passes through a conductor a magnetic field is set up around the conductor As this magnetic field builds it induces voltage in any conductor that is close by and it induc
215. lications They will work satisfactorily for many systems WARNING 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 COMP 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 cause a small battery to overheat This may cause damage 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 example if the battery is rated at 500 amp hours set the maximum charge rate for 100 amps DC Since the setting is adjusted 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 factors are for 120 VAC systems and include the power lost in the battery charger If the example battery bank of 500 amp hours was a 24 volt system the maximum AC amps setting should be around 25 amps AC 500 x 1 5 100 amps DC 100 4 25 amps Pa e Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger g 5916 195th Street E Fax 360 435 2229 Part No 2031 5 66 Arlington WA 9
216. ll 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 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 overcurrent device will not trip unless a double fault occurs In some marine electrical codes this type of system is used Pa e Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger g 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 26 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 INSTALLATION NEUTRAL TO GROUND BOND SWITCHING RV AND MARINE APPLICATIONS As required by NEC code and UL specification 458 inverter charger installations in the U S that are used in RV or Marine applications employ ground to neutral switching The purpose for this requirement is to ensure that all the neutral conductors are connected 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 boats AC neutral and the external AC source s generator or shore power neutral which may cause an electric shock or cause nuisance tripping of GFI s The SW Series Inverter Charger does not include Neutral
217. ll output voltage while delivering no current This is the no load or idle power At low power levels the idle power is the largest contributor to efficiency losses At high power the largest source of loss is a result of the resistance in the transformer and power transistors The power lost here is proportional to the square of the output power For Example 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 are run less efficiently due to the impact of power factor losses Power vs Efficiency 100 90 80 70 60 50 Efficiency 8v SGMS 40 38v Sv MS 30 20 4 A8v0EMS AvVcOEMS 8707MS vVCOUMS 10 0 082 009 094 N Q al 000 0921 0091 0941 000 0922 0926 00S 09 6 000v oszt 00Sv OSZv 0005 0929 00985 Figure 19 Trace SW Series Efficiency Curves The SW Series offers an extremely good efficiency curve The inverter reaches high efficiency at very low AC load levels which is important because the inverter often spends the majority of the time 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
218. loat LED is ON Refer to the Battery TempComp volts DC reading while charging Refer to the Battery actual volts DC reading while charging Ensure your Set Low Battery Cut In VDC setting is lower than the Set Bulk volts DC setting a Ensure that the temperature probe is not in a cold area or has not fallen off the batteries b Ensure that there is no other DC charging source on the batteries Ensure that there is no other DC charging source on the batteries Low Battery Cut In voltage is set to high to prevent the charger from going into the float charge Copyright Trace Engineering Company 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 B Sept 1 1999 TECHNICAL INFORMATION TROUBLESHOOTING GUIDE ERROR CAUSES ERROR LED is On or Flashing look under the ERROR CAUSES display INDICATION Page 3 SOLUTION OVER CURRENT Excessive load on the AC output TRANSFORMER OVERTEMP or HEATSINK OVERTEMP Unit is warm hot to the touch Let inverter cool down and try restarting HIGH BATTERY VOLTAGE or LOW BATTERY VOLTAGE Battery voltage is not within the High or Low battery cut out settings LOW AC OUTPUT VOLTAGE The AC output voltage has fallen below SET INPUT LOWER LIMIT VAC setting AC SOURCE WIRED TO OUTPUT Indicates that an AC source was wired directl
219. lowing diagrams and information is provided to assist you or your system installer with the design and installation of the Trace SW Series Inverter Charger Due to the variety of applications models available and differences in local and national electrical codes these diagrams and information should be used as general guidelines only You must consider your application and local and national electrical codes when designing and installing your system PUBLIC POWER AC TERMINAL BLOCK AC IN 1 AC IN 2 PHASE A NEU IN 1 NEU IN 2 NEU DUT AC QUT AUX GEN RELAYS FUSE RELAYS AT 5 AMPS gt RY10 No ELECTRIC FURNACE ELECTRIC STOVE NON CRITICAL NON CRITICAL O e Se So Oo S NEUTRAL INVERTER BYPASS BREAKER HOT TUB ELECTRIC HOT WATER HEATER AUXILLARY RELAYS N GROUND Ge Se S C lt gt Od Et BATTERY DISCONNECT WITH UVERCURRENT PROTECTION COMPUTER DUTLETS SECURITY REFRIGERATOR PELLET STOVE SWRC or SWCA oooo GR
220. lt in a spark fire or possible explosion This inverter charger 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 For instructions on mounting see the MOUNTING section on page 17 of this manual NOTE Do not use the keyhole mounting slots for permanent installations For battery installation and maintenance refer to the battery manufacturer s instructions No AC or DC disconnects are provided as an integral part of this inverter Both AC and DC disconnects must be provided as part of the system installation Refer to the INSTALLATION section beginning on page 15 for more information No overcurrent protection for the battery supply is provided as an integral part of this inverter Overcurrent protection of the battery cables must be provided as part of the system installation Refer to the INSTALLATION section beginning on page 15 and the DC DISCONNECT AND OVERCURRENT PROTECTION section on page 23 for more information 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 must 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 The AC output neutral conductor and DC negative conductors are not connected bonded to the inverter chassis Both the input a
221. m Most transfer 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 can 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 disconnected and the inverter will connect to the utility on AC HOT IN 1 Pa e Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger g 5916 195th Street E Fax 360 435 2229 Part No 2031 5 20 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 INSTALLATION 120 VAC GROUND FAULT INTERRUPT OUTLETS GFI S Trace Engineering has tested the following 120 VAC GFI s and found them to work satisfactorily with our inverters LEVITON 6599 PASS amp SEYMOR 1591 4A957 ACE Hardware ACE 33238 WARNING LABEL A warning label is provided to inform all personnel that an inverter is installed in your electrical syste
222. m This label should be installed at the electrical panel that is being powered by the inverter Be cautious until the inverter is disconnected from your electrical system WARNING ELECTRICAL SHOCK HAZARD THIS ELECTRICAL SYSTEM IS EQUIPPED WITH A DC TO AC POWER INVERTER DISCONNECT THE DC AND AC SOURCES BEFORE SERVICING Figure 10 Warning Label Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 21 INSTALLATION 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 stress 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 are required either oversize them substantially or switch to a higher voltage system such as 24 vdc
223. m preventing damage Connect the utility or generator to the provided input terminals AC HOT IN 1 or AC HOT IN 2 respectively When the inverter output is connected directly to an external source the inverter will shut down and indicate an error on the control panel Checking the ERROR CAUSES menu heading will show a YES for the AC SOURCE WIRED TO OUTPUT menu item Either determine the source of the AC or call a qualified electrician to correct the situation EXTERNAL TRANSFER RELAYS It is not acceptable to switch the AC input from one AC source to another while the inverter is connected This applies whether the inverter is in battery charging mode or inverter 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 relays If a transfer relay is used it must provide a center OFF position break before make that causes a loss of input power to the inverter for 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 source about a thirty second period at the minimu
224. m 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 automatically 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 before the equalization process is considered to be completed This timer is an accumulating type timer that does not reset if the voltage drops momentarily 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 process has finished the FLOAT LED will be on if the generator or utility power is still available Pa e Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger g 5916 195th Street E Fax 360 435 2229 Part No 2031 5 80 Arlington WA 98223 www traceengineering com
225. m you want to use with the inverter Add the resulting amp hour requirements for each load to arrive at a total requirement The minimum properly sized battery bank will be approximately double this amount This will allow the battery to be cycled only 50 on a regular basis Table 5 Typical Wattage Of Common Appliances TYPICAL APPLIANCE WATTS Po OO Watts Watts One FL Light 10 Microwave compact 600 800 B amp W TV 12 100 500 Microwave full size 1500 Color TV 19 150 1000 200 350 Hot Plate 1800 Stereo or VCR 50 Washer Dryer 375 1000 Hair or Iron 1000 Blender 400 Vacuum or coffee maker 1200 Refrigerator 3 cu ft 180 3 8 Drill 500 Refrigerator 12 cu ft 480 Refrigerators icemakers typically only run about 1 3 of the time therefore the running wattage is 1 3 of the total wattage of the appliance Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 101 TECHNICAL INFORMATION BATTERY BANK SIZING EXAMPLE Complete the steps that follow to calculate your inverter s battery bank capacity No two installations will require exactly the same battery bank capacity The following example provides a guide for determining y
226. n Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 0 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 1 5 INSTALLATION QUICK INSTALL This section provides installers licensed electrical contractors and knowledgeable 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 section and read the entire INSTALLATION section before installing the inverter charger MOUNTING Mount the unit securely in a clean dry properly ventilated enclosure Do not mount the unit in the same enclosure as vented or maintenance free type vented batteries Bolt the unit securely Allow adequate clearance to allow access to the indicators or controls DC CABLING 1 Connect an appropriate sized cable from the positive batter terminal or battery bank to the inverter s positive red terminal See Table 12 in the Appendix to determine the proper size cable and lengih 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 inv
227. nal 24 hour clock This is used for time sensitive operating 6 modes and to determine the quiet time period for generator run lockout Generator Timer Used to set a run lockout period called quiet time During quiet time the 7 generator starts only if the battery voltage reaches the LBCO 30 sec start VDC setting End User Menu Used to display that you have reached the end of the USER MENU 8 Pa e Copyridhi Trace Engineering Company Inc l Telephone 360 435 8826 SW Series Inverter Charger 9 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 36 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 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 charger 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 single space cursor under the desired selection or you can continue to push the red button to move the cursor to the right e 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 e SRCH Enables the automatic load search mode control system This system will turn on the inverter
228. nd is adjusted by the SET LOW BATTERY CUT OUT VDC menu item setting under the INVERTER SETUP 9 menu heading This 30 second start will attempt to start the auto start generator even if the QUIET TIME under GENERATOR TIMER 7 is enabled Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 49 MENU SYSTEM Set Exercise period days 30 All models Range 00 to 255 Sets a maximum number of days allowed between operation of the generator When an internal counter reaches the number of days set the generator will be started at the END QUIET TIME menu item setting The run time is fixed at 10 minutes If the generator is manually or automatically operated for 5 minutes at any time during this period then this counter will reset and the period will start again If this menu 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 period is reached
229. nd output conductors are isolated from the enclosure and each other System grounding if required by sections 690 40 and 690 42 of the National Electric Code ANSI NFPA 70 1996 is the responsibility of the system installer All installations must comply with local and national electrical codes and standards Pa e Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger 9 5916 195th Street E Fax 360 435 2229 Part No 2031 5 2 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 IMPORTANT SAFETY INSTRUCTIONS 11 GROUNDING INSTRUCTIONS This inverter battery 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 All installations should comply 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 Have plenty of fresh water and soap nearby in case battery acid contacts skin clothing or eyes Wear complete eye protection and clothing protection Avoid touching eyes while working near batteries Wash your hands when done 4 f battery acid contacts skin or clothing wash immediately with soap and water If acid enters eye immed
230. needed before recharging Total Daily Watt Hours Needed Autonomy Battery Size Watt Hours Rough Battery Size Watt Hours Safe Battery Size Watt Hours Safe Battery Size Amp Hours Telephone 360 435 8826 Fax 360 435 2229 www traceengineering com SW Series Inverter Charger Part No 2031 5 Rev B Sept 1 1999 TECHNICAL INFORMATION BATTERY CARE AND MAINTENANCE If you have read the battery charger mode section of this manual you already have a good idea of the stages of battery charging that combine to promote fast charging and ensure long battery life Basically there are five charger related considerations to properly care for your batteries Charge Rate The maximum safe charge rate is related to the size and type of your batteries Standard vented lead acid batteries with battery caps can be charged at a high rate equal to their capacity Small batteries may require a lower charge rate Check with the battery manufacturer Adjust the MAX CHARGE AMPS AC setting to control the charging rate Bulk Voltage This is the maximum voltage the batteries reach during the normal charging process Gel cell batteries are usually set to a lower value while non sealed batteries are set to the higher Adjust the SET BULK VOLTS DC setting to control the battery voltage during the BULK and ABSORPTION stages Float Voltage The batteries experience less gassing if they are maintained at a lower voltag
231. ng 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 charge at the rate allowed by the SET MAX CHARGE AMPS AC 2 amps AC is the lowest setting allowed The battery 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 system from 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 time 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 many 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 inverter The batteries can however be small if the system does not provide back up power in case of utility failure Two thousand watt hours is sufficient 100 amp hours at 24 volts is 2400 watt hours This can be achieved by using two Group 27
232. nge Sinewave 34 to 52 steps per cycle t 296 3 to 5 stand alone operation 1to1 0 04 crystal regulated 16 to 240 Watts Standard Features Control Panel Low Battery Protection Battery Temperature Sensor Auto Generator Control system Auxiliary Relays Fan Cooling Built in 2 line back lit alphanumeric liquid crystal display with eight LED status indicators Adjustable low battery cut out and cut in with current compensation 15 foot plug in battery temperature sensor with phone type jack can be extended Automatic generator control system for two and three wire start generators no glow plug control Three user adjustable voltage controlled signal relays for control of loads or charging sources Variable speed brushless DC fans Options Remote Control Panel Stacking Interface for 2X power requires two inverters Conduit Box SWRC SWRC SWRC SWRC No No No No SWCB SWCB SWCB SWCB SWRC SWRC SWRC No No No SWCB SWCB SWCB Environmental Limitations Enclosure Type Specified Temp Range Allowed Temperature Range Non operating Temperature Altitude Limit Operating Altitude Limit Non operating Dimensions Inverter Only Dimensions Shipping Mounting Indoor ventilated steel chassis with powdercoat finish S2 F to 104 F 0 C to 40 C output will meet specified tolerances 40 F to 140 F 40 C to 60 C output may no
233. ngs are guidelines refer to your battery manufacturer for specific settings 5916 195th Street Copyright Trace Engineering Company Inc Arlington WA 98223 Telephone 360 435 8826 Fax 360 435 2229 www traceengineering com SW Series Inverter Charger Part No 2031 5 Rev B Sept 1 1999 TECHNICAL INFORMATION MONTHLY MAINTENANCE At the minimum check the level of the electrolyte in each battery cell once a month lt should be above the top of the plates but not completely full Most batteries have a plastic cup that the electrolyte should just touch when full Don t overfill the batteries or the electrolyte will spill out of the batteries when they are being charged Only refill the batteries with distilled water spring water and regular tap water may have high levels of minerals that can poison the battery chemistry and reduce battery performance and life It is also good to check the battery interconnections for tightness and corrosion If any corrosion is found disconnect the cables and carefully clean with a mild solution of baking soda and water DO NOT ALLOW THE SOLUTION TO ENTER THE BATTERY Rinse the top of the battery with clean water when finished To reduce the amount of corrosion on the battery terminals coat them with a thin layer of petroleum jelly or anti corrosion grease available from automotive parts stores or battery suppliers Do not apply any material between the terminal and the cab
234. ngton WA 98223 www traceengineering com Rev B Sept 1 1999 APPENDIX ee 6 O Oe CO O O 10 8 115 146 6 4 184 235 281 3 2 295 1 0 1 335 380 20000000 SIZE 14 12 DIAMETER 073 072 SIZE 2 0 3 0 DIAMETER 420 475 4 0 530 250 MCM 300 MCM 580 635 350 MCM 690 400 MCM 730 500 MCM 820 Note Sizes shown are for the conductor do not include any insulation when determining your wire size Figure 40 AWG Wire Size Table 11 Minimum Recommended Battery Cable Size vs Cable Length INVERTER bise e NEC 1 TO 3 FEET 3 TO 5 FT 5 TO 10 FT MODEL amp AMPS ONE WAY ONE WAY ONE WAY SW2512 267 Amps 334 Amps 4 0 AWG 107 mm 4 0 AWG 107 mm Not Recommended SW2612E 278 Amps 348 Amps 4 0 AWG 107 mm 4 0 AWG 107 mm Not Recommended SW3024E or J 160 Amps 201 Amps 4 0 AWG 107 mm 4 0 AWG 107 mm 44 0 AWG 107 mm SW4024 or W 214 Amps 267 Amps 4 0 AWG 107 mm 4 0 AWG 107 mm 4 0 AWG 107 mm SW3048E 80 Amps 100 Amps 2 0 AWG 67 4 mm 2 0 AWG 67 4 mm 4 0 AWG 107 mm SW4048 orK 107 Amps 134 Amps 2 0 AWG 67 4 mm 2 0 AWG 67 4 mm 4 0 AWG 107 mm SW4548E or A 120 Amps 150 Amps 2 0 AWG 67 4 mm 2 0 AWG 67 4 mm 4 0 AWG 107 mm SW5548 147 Amps 184 Amps 4 0 AWG 107 mm 4 0 AWG 107 mm 4 0 AWG 107 mm TYPICAL DC AMPS is based on Low Battery Voltage with
235. nted STARTING BATTERY These are designed for high cranking power but not deep cycling Don t use them It does not hurt the inverter they simply will not last long in a deep cycle application The way they are rated should give a good indication of their intended use Cold Cranking Amps a measure of the amperage output that can be sustained for 30 seconds Starting batteries use lots of thin plates to maximize the surface area of the battery This allows very high starting current but lets the plates warp when the battery is cycled TELEPHONE COMPANY BATTERY Second hand telephone company batteries are often available at far below original cost They are often used to power the telephone system for short power outages They are sometimes used successfully in remote home systems Typically they are a lead calcium type battery similar in construction to a starting battery Therefore they should not be repeatedly discharged more than 20 of their amp hr rating Keep this in mind when evaluating their amp hr to cost ratio DEEP CYCLE BATTERY This is the type of battery best suited for use with inverters The physical dimension of the plates are thicker and the active material that holds the charge is more dense to increase cycle life The deep cycle type of battery is designed to have the majority of their capacity used before being recharged They are available in many sizes and in either non sealed or sealed types NO
236. ntended to directly 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 covered by warranty and requires the inverter to be returned to a repair center This also applies to the generator control relays Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 89 OPERATION ENERGY MANAGEMENT MODE INVERTER CHARGER UTILITY GRID AC LOADS BATTERY IN BRIEF The purpose of this mode is to manage how utility power is used One method is to charge 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 discharging of the battery 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 inter active 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
237. nverter Charger g 5916 195th Street E Fax 360 435 2229 Part No 2031 5 98 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 TECHNICAL INFORMATION TECHNICAL INFORMATION BATTERY TYPE This section of the manual is included to help you better understand the factors involved with battery charging care and maintenance by discussing the physical make up and characteristics of chemical storage batteries This is not intended to be an exhaustive discussion of battery types but simply a guideline The manufacturer of each specific battery is the best authority as to its use and care Batteries come in different sizes types amp hours voltages and chemistries There are nearly as many descriptions of exactly how batteries should be charged as there are people willing to offer explanations It is not possible here to discuss all aspects in detail However there are basic guidelines you can follow that will help in battery selection and ensure that the batteries are better maintained than the majority See the INVERTER CHARGER TERMINOLOGY on page 115 for a brief description of terms that appear in this section with which you may not be familiar SELECTION OF BATTERY TYPE There are two principal types of batteries starting and deep cycle There are several different types of battery chemistries including liquid lead acid nickel iron NiFe nickel cadmium NiCad alkaline and gel cell Batteries are either sealed or ve
238. nverter 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 move the cursor to the right e OFF Disables the auto start system or turns off a generator that has been started by the inverter Also resets the automatic generator control system after an ERROR condition has occurred e AUTO Enables the automatic generator control features When the battery voltage or load amps reach the auto start settings for the required time period the generator will be started unless the timer 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 automatically 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 automatically based on load amps as set in under the GEN AUTO START SETUP 12 menu heading the generator will turn off once the load current 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 Copyright Trace Eng
239. o 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 A V MENU HEADINGS gt z 9 5 Setup Grid Usage SELL SLT LBX Set ELT Low battery out VDC 11 0 Set LBCO delay 10 minutes Low battery in VDC 13 0 High battery out VDC 16 0 search watts 48 Set search spacing 59 Trigger Timer Set Start Bulk Start Bulk nl ER Charge 00 00 time 00 00 l To disable timer Iset to 00 00 IF grid timer active set bulk J al Inputs set Bulk Bulk volts 14 4 Set Absorption time h m 02 00 Set Float volts 13 4 Set Equalize volts DC Set Equalize time h m 02 00 Set Max Charge amps AC 20 Set Temp Comp Leadacid NiCad Low Battery Transfer LBX 16 O9 set Low Battery TransfervDc 11 3 Set Low battery cut in VDC 13 0 See menu 9 to enable LBX mode Set Grid 1 set Grid aci amps AC 60 Set Gen AC2 amps AC 30 Set Input lower limit vac 108 Set Input upper limit VAC me Battery Selling 17 set Battery Sell volts DC 13 4 Set Max Sell amps
240. o 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 Pa e Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger g 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 10 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 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 This input is intended for utility power When an AC source is connected to the input terminals 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 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 This input is intended for generator power When an AC source is connected to the input terminals 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
241. o 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 system controls the starter much like a person does when starting 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 after a 1 2 second delay If the engine does not start the starter is turned on again after a delay period This is repeated until either the generator starts or the maximum number of start attempts is reached The common term three wire start may be misleading the actual number of wires used may be four or more lt simply means that control of the starter motor is done separately from the generator Most three wire start generators are not designed for automatic unattended operation The generator supplier should be consulted regarding additional safety components required for your installation The automatic control 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 Operating a switch that is fi
242. oad The system will continue to hold the batteries at the float voltage level until the alternative power source raises the battery voltage to a level that exceeds the battery charger settings before transferring This is done by setting the LOW BATTERY CUT IN VDC setting higher than the BULK VOLTS DC and the FLOAT VOLTS DC settings Once the battery is full the charger will maintain the battery at the float voltage setting If the alternative power source is able to contribute power it will be used to offset the amount of power that the AC load draws from the utility grid If the alternative power source is able to produce more power than the load requires the battery voltage will then increase above the float level until it reaches the LOW BATTERY CUT IN VDC setting At this time the system will then transfer to the battery and operate off the grid This reduces the amount of cycling by waiting until improved charging conditions good sun or good wind exist before transferring back to the battery Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 93 OPERATION Once the system has transferred back to the battery the battery voltage will continue to increase if the power from the alternative source exceeds the loads This can result in the battery voltage reaching the HIG
243. oad 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 covered by warranty and requires the inverter to be returned to a repair center 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 reaction for this setting this allows fast 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 VOLTS DC setting The N O and COM terminals of the relay remain open de energized until it again reaches the AUX RELAY 9 VOLTS DC setting For example the default setting energizes the relay
244. ocess the BULK LED will flash slowly on each inverter to indicate that the EQ position has been selected from the SET GENERATOR menu item If you manually equalized your batteries by using a manually started generator or utility power the FLOAT LED will come on to indicate that the equalization process has finished You must return the cursor to the OFF position in the SET GENERATOR menu item on both inverter chargers once the equalization period has been completed If the automatic generator control system is used to equalize your batteries the equalization process will begin during the next automatically started generator run period When the equalization period has been completed the generator will automatically stop and the cursor under the SET GENERATOR menu item will return to the AUTO position on the generator controlling inverter At this time you must manually return the cursor in the SET GENERATOR menu item on the non generator controlling inverter from EQ back to OFF or you will allow this inverter to charge up to the EQ voltage the next time the generator comes on Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 0 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 97 OPERATION PAGS Msn HOT VOE Pa e Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series I
245. of the inverter in order to comply with UL 1741 If this unit is used in a mobile application i e RV Boat secure the inverter to a shelf or deck to prevent movement Place flexible washers on the mounting screws or bolts between the shelf or deck and the inverter chassis to reduce vibration Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 0 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 17 INSTALLATION VENTILATION Installation of the inverter in a properly ventilated enclosure is necessary for efficient 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 1 12 inches around the top and bottom and 3 inches of clearance at the left and right sides of the inverter will provide adequate ventilation Because the top and bottom of the SW Series chassis is not vented clearance between the enclosure and the top of the inverter is not critical A fresh air intake port should be provided directly to the left side and an
246. oltage detection e 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 The settings are 58 and 62 Hertz for 60 Hertz models 48 and 52 Hertz for 50 Hertz models and are not adjustable e 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 system may require a couple of seconds to respond The default settings are 108 VAC as the lower limit and 132 VAC as the upper limit These settings are adjustable Pa e Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger g 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 84 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 OPERATION SELLING POWER FROM A DC CHARGING SOURCE The simplest and default operation of the SW Series Inverter Charger in the SELL mode is to sell the excess power from the charging source 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
247. ombination The result is an increase in both the voltage and the capacity of the total battery bank This is done very often to make a larger higher voltage battery bank out of several smaller lower voltage batteries This is common with all battery inverter system voltages The smaller lower voltage batteries are first connected in series to obtain the needed voltage then these batteries connected in series sets are connected in parallel to increase the battery bank capacity The best arrangement when using a series parallel configuration is to connect all the smaller lower voltage batteries in parallel then connect all these batteries in parallel into series sets to obtain the needed voltage This configuration is often called cross tying This is less convenient and requires additional cables but reduces imbalances in the battery can improve the overall performance and in a shorted cell scenario would cause only the battery s that are actually in parallel with the shorted battery to discharge This would allow you to re configure your battery bank with the other batteries that are in parallel with the shorted discharged battery s and still be operational only at a lower capacity The more efficient cross tying method is shown in Figure 34 and Figure 35 as dash lines If cross tying is not desired the dash lines shown may be ignored Pa e Copyright Trace Engineering Company Inc Te
248. ontrol 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 Pa e Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger g 5916 195th Street E Fax 360 435 2229 Part No 2031 5 42 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 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 outside 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 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 models and 44 to 56 Hertz for 50 Hertz models Inverter breaker tripped No The inverter s output AC circuit breaker on the left end of the chassis has tripped or is open Operating too large of an AC load may cause this Reduce the loads connected and reset the circuit breaker 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 functions enabled Does not reset when the PRESS FOR FACTORY
249. ool several attempts made down incorrect battery voltage See ERROR CAUSES section No AC power output Correct AC voltage on Control Panel display but no AC voltage on inverter AC INVERTING LED is on with no ERROR terminal block LED Check for open circuit breaker on the inverter If circuit breaker on the inverter is not open popped have the inverter serviced Look at Control Panel display under Correct AC voltage on Control Panel display and on inverter AC terminal block Inverter volts and check AC voltage on inverter AC terminal block Check for open AC output breakers or fuses and bad output wire connections AC voltage on Control Panel display or inverter AC terminal block is incorrect have unit serviced AC1 AC2 IN GOOD LED is flashing Have unit serviced with no AC connected to the input No AC power output AC load too small for Search mode Reduce search watts setting increase INVERT LED is flashing circuit to detect load above search watts setting or defeat search mode by selecting ON Low AC power output or Insufficient DC current being provided Check the battery voltage fuses or Low surge power to the inverter to operate the AC loads breakers and cable connections INVERT LED i bd Ensure the battery bank is sufficient AC inductive loads are not running at check for low DC voltage while running full speed the load Ensure the cable length and size is correct see owner s manual fo
250. or 48 vdc On 12 vdc system cables may 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 resulting 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 time 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 enormous 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 recommended 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 req
251. oss the 240 VAC input and to the AC neutral terminals of the inverters This will allow the inverter to operate properly No transformer is required on the AC output side the 240 VAC can be taken directly from the two AC hot output terminals one from each inverter Pa e Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger g 5916 195th Street E Fax 360 435 2229 Part No 2031 5 72 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 OPERATION AUTOMATIC GENERATOR CONTROL MODE AC GENERATOR CULTE AC AC LOADS CONTROL BATTERY IN BRIEF Automatic start stop control of a back up generator can be used with any of the other operating modes 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 With utility power connected to the AC HOT IN 1 terminals the automatic generator 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 different low battery voltage levels with diff
252. ost loads that will run from a sinewave will run from a modified sinewave However things such as clocks and furnace controllers may have trouble See graph below 180 160 140 120 100 80 60 94 A A lt 20 1 0 ar On MODIFIED gt 40 SNE WAVE do SINE WAVE 10 SQUARE WAVE INT 160 180 IME Figure 36 AC Waveforms NEC Code National Electric Code The guidelines and acceptable practices for electrical installations It is a book published every three years Off Grid Not connected to public power in any way Output Waveform Shape of the wave that alternating current makes as its voltage rises and falls with time Pass Through Current The amount of current the inverter can safely pass directly from the AC input to the AC output Plates Originally made of lead now fabricated from lead oxide Plates connect to the battery terminals and provide a structure for the chemicals that create current There are several plates in each cell each insulated from the other by separators PV Photovoltaic Solar powered Resistance The opposition to flow of direct current DC RMS Root Mean Square a measure of AC voltage that would provide the equivalent heating value across a resistor as a DC source of the same voltage Sellback o
253. oud 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 maximize the output of the system during a specific period of time An example of these setting follows Begin Day 00 00 End Day 23 59 Battery charging from grid has stopped Battery charging from grid has started 08 00 10 00 i End charge Start charge Bulk charging i time 08 00 18 00 E has started Battery Sell Volts Set Start Bulk Float Volts DC Setting Set Float Volts DC 13 4 Charging from the DC source wind hydro or solar has Bulk Volts Set Float DC Setting DC Setting time 20 00 VoltsDC 13 4 Set Bulk Volts DC 14 4 Set Battery Sell Volts DC 12 4 Set Absorption time h m 2 00 Absorption
254. our needs Read through the example and then complete the worksheet on the following page STEP 1 4 Determine your Average Daily Watt Hours Needed STEP 1 STEP 2 STEP 3 STEP 4 AC APPLIANCE APPLIANCE RUNNING X HOURS USED X DAYS USED 7 AVERAGE DAILY WATTS EACH DAY EACH WEEK WATT HOURS NEEDED Microwave 600 0 5 7 300 Lights x4 40 6 7 240 Hair Dryer 750 0 25 3 81 Television 100 4 7 400 Washer 375 1 2 107 Refrigerator 480 3 160 24 7 3840 Vacuum cleaner 1200 1 1 171 STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7 STEP 8 STEP 9 Determine what appliances the inverter will power and enter the Appliance Running Wattage of each appliance Refrigerators and icemakers typically only run about 1 3 of the time therefore the running wattage is 1 3 of the total wattage of the appliance Determine the number of hours or fractions of hours you will use the appliance each day Multiply the number of days you will use the appliance during the week this is your Weekly Watt Hours Needed Divide your Weekly Watt Hours Needed by 7 to obtain the Average Daily Watt Hours Needed Total Average Daily Watt Hours Needed to determine your Total Daily Watt Hours Needed Multiply your Total Daily Watt Hours Needed Step 5 by the number of anticipated days of autonomy days between charging usually 1 to 5 to determine your Autonomy Battery Size examp
255. ove the batteries or in the same compartment as vented batteries Batteries generate hydrogen sulfide gas which is very corrosive to electronic equipment 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 mixture 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 may involve installing the inverter in an enclosure and include mesh screens or nets over any openings to ensure the unit is kept well ventilated This inverter can create RFI Radio Frequency Interference Keep this in mind when determining the placement of the inverter You should locate the inverter as far away as possible from any electronic devices that may be susceptible to RFI MOUNTING UL Standard 1741 draft requires that the inverter be mounted on a vertical surface on a wall and that the keyhole slots not be used as the only method of mounting The purpose of the wall mounting requirement is to orient the inverter so that its bottom cover which has no holes will not allow burning material to be ejected in case of an internal fire Use 1 4 minimum diameter bolts for mounting The mounting must be capable of supporting twice the weight
256. ower since the utility pays for the power you produce It is relatively simple to set the inverter up to accomplish 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 inter active 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 should be installed at the service entrance or next to the utility meter It should be clearly labeled SOLAR ELECTRIC SYSTEM AC DISCONNECT This 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 inter active installation requires an understanding of your local utility code limited diagrams and details are included in this manual Consult your utility or your local Trace dealer To operate the system in utility inter active mode set up the system as follows e Connect utility AC power to the inverter s AC HOT IN 1 and NEUTR
257. ows the generator support feature to function correctly preventing the generator from being overloaded The generator s output should be de rated for altitude and if propane or natural gas is the power source It is best to error on the low side for this setting or to experiment with higher settings after the system has been operational e 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 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 e 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 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 Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435
258. pacity 20 0 25 325 40 475 55 625 70 775 85 92 5 100 Temperature C Figure 20 Inverter Capacity vs Temperature Pa e Copyright Trace Engineering Company Inc Telephone 360 435 8826 9 5916 195th Street E Fax 360 435 2229 60 Arlington WA 98223 www traceengineering com SW Series Inverter Charger Part No 2031 5 Rev B Sept 1 1999 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 surge power saving search mode low idle current and very high efficiency DC to AC conversion Charger Mode Low AC current distortion three stage temperature compensated high amperage battery charger Inverter Charger Mode Automatic transfer from 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 large loads Adjustable generator 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 th
259. r read all instructions and cautionary markings on a the inverter charger b the batteries and c all appropriate sections of this manual 2 CAUTION 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 3 Do not expose inverter charger to rain snow or liquids of any type The inverter is designed for indoor mounting only Protect the inverter from splashing if used in vehicle applications Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 1 IMPORTANT SAFETY INSTRUCTIONS 4 Use of battery cable or custom attachment not recommended or sold by Trace Engineering for the SW Series Inverter Charger may result in a risk of fire electric shock or injury to persons Do not disassemble the inverter charger Take it to a qualified service center when service or repair is required Incorrect re assembly may result in a risk of electric shock or fire To reduce risk of electric shock disconnect all wiring before attempting any maintenance or cleaning Turning off the inverter will not reduce this risk Solar modules produce power when exposed to light Cover them with opaque material
260. r Selling Back To The Grid Some inverters have the capability to take energy stored in batteries or from solar panels and put it back into the utility grid The Public Utility Company will then pay you for using your energy Check with the Public Utility Company before attempting this Sine Wave An AC waveform that looks like rolling waves on water It rises and falls smoothly with time The grid puts out a sine waveform Any plug in AC equipment will operate from a sinewave output This is shown in Figure 36 AC Waveforms Square Wave The simplest AC waveform this is shown in Figure 36 AC Waveforms Some types of equipment behave strangely when run from a square wave Pa e Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger 9 5916 195th Street E Fax 360 435 2229 Part No 2031 5 116 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 TECHNICAL INFORMATION Stacking Series Two inverters operating together to produce twice the power and voltage of a single inverter Required when operating 240 VAC loads and separate 120 VAC loads from either inverter Parallel Two inverters operating together to provide twice the continuous and surge capacity on a single output circuit Required when a single load is too large for one inverter The units must be stackable and an interface cable must be utilized See the manual for details on stacking if it is an option Strati
261. r correct cable Tie the battery cables together to reduce inductance Pa e Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger 9 5916 195th Street E Fax 360 435 2229 Part No 2031 5 112 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 TECHNICAL INFORMATION TROUBLESHOOTING GUIDE BATTERY CHARGER If ERROR LED comes on see ERROR CAUSES section PROBLEM AC IN GOOD LED is flashing but will not start charging allow 40 seconds to synchronize Check for the correct AC voltage or frequency at the AC input terminal INDICATION AC frequency at the AC input terminal is out of tolerance too high or low or AC voltage outside Upper Lower VAG limit settings Page 2 SOLUTION If AC source is a generator adjust AC voltage or frequency accordingly Charger drops off before full charging has finished No ERROR comes on Check for the correct AC voltage or frequency using the Control Panel Charger drops off before full charging or equalization has finished ERROR LED flashes and AC output drops momentarily Charger drops off before full charging has finished ERROR comes on Charger output is low AC frequency at the AC input terminal drops out of tolerance too high or low or AC voltage falls outside Upper Lower VAC limit settings If AC source is generator adjust AC voltage frequency accor
262. r 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 gt load start amps To defeat timers set start end If exercise day set to 1 then gen will always start end quiet Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 0 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 43 MENU SYSTEM SETUP MENU The SETUP MENU provides all the controls and settings needed when installing or adjusting 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 remote 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 Use to program and adjust the operation of the inverter Also allows 9 adjustment of how the inverter charger mode uses the utility grid Battery Charging Use to adjust the operation of the battery charger 10 AC Inputs Use to adjust the operating characteristics of the utility grid AC1 and the 11 generator AC2 input
263. res 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 source 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 current 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 can 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 entrance panel after the power has gone through the kilowatt hour meter of the utility In mobile applications RV and marine 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 system This means that two bonding points will occur in a
264. rge 120 VAC load Separate 120 VAC loads can be operated from either inverter Do not connect the AC output terminals of the inverters in parallel this will not work A special stacking interface cable SWI is required to connect the series stacking ports of the inverter to ensure the output voltage waveforms of the two inverters are phase synchronized and locked 180 degrees from each other This allows connection to 120 240 generators and utility grids The 120 VAC loads are split and connected to either inverter Both of the inverters operate completely independently except their frequency is locked They do not operate as a master slave device as previous inverters have One inverter can be in battery charger mode while the other is inverting to power an AC load This independent operation allows many new possible applications and abilities that were previously not possible When inverters are series stacked they do coordinate all operations that affect 240 VAC loads This requires that the inverters turn on together and switch to another AC source at the same time If either inverter shuts down both inverters are inoperable If no 240 VAC loads are required to be operated then the need and benefits of stacking are reduced Stacking adds complexity and will cause both of the inverters to shut down if either inverter goes into an error condition With separate un stacked inverters only one will shut down if over loaded etc When two
265. rical current that does not vary with time Deep Cycle A deep cycle occurs when a battery is discharged to less than 20 of its capacity 80 depth of discharge Deep Cycle Battery A battery designed to be routinely discharged to 20 of its maximum capacity without damage This is the type of battery most commonly used with an inverter system Digital VoltMeter DVM True RMS A voltmeter that incorporates a RMS converter to read true RMS for any waveform shape Averaging Type A voltmeter that requires a sinewave waveform shape to provide an accurate reading Efficiency Usually given as a percentage efficiency is the ratio of the output to the input The efficiency changes with power output levels of any inverter Electrolyte Typically a mixture of water and sulfuric acid it is commonly referred to as battery acid Equalization Controlled overcharging of the battery causing it to bubble and mix This reduces stratification Float stage During the third stage of three stage charging the voltage and current are reduced to a level that will trickle charge or maintenance charge the battery This assures the battery remains fully charged even while sitting Fuse or Disconnect An electrical pressure relief valve When current exceeds a preset limit the fuse or disconnect will fail before the wiring or equipment it is protecting Disconnects are also called circuit breakers These are usually resettable and can act a
266. rminals High battery Ensure your DC source is regulated below your High battery cut out or adjust your HIGH BATTERY CUT OUT to a higher setting Low battery Check for an external DC load on the batteries Check condition of batteries and recharge if possible or adjust your LOW BATTERY CUT OUT to a lower setting The cause for this error could be high battery voltage or an excessively large load Check for proper AC input and output wiring output of inverter is wired to an AC source Reset the auto generator control system by selecting OFF and then AUTO or ON from the SET GENERATOR menu Check the generators output voltage and frequency ensure that the Set Input lower or upper limit VAC is set correctly This is an advisory ERROR only and will not cause any other effect If you continue to have repeated error conditions then increasing the SET MAXIMUM RUN TIME menu item setting under the GEN AUTO SETUP 12 menu heading may be necessary for your application a Voltage has not reached 80 VAC during the MAX CRANK PERIOD or b Voltage did not maintain gt 80 VAC for the majority of time while the inverter was charging No problem with AC source or inverter The error LED is a visual indicator to fine tune your AC frequency this error does not affect operation 5916 195th Street N E Arlington WA 98223 Copyright Trace Engineering Company Inc Telephone 360 435 8826 Fax 360 435 2229 www traceengine
267. roper installation the inverter will operate satisfactorily for many applications straight out of the box using the factory default settings To fully utilize the inverter s generator inter active or utility inter active 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 recommended that you consult with your authorized dealer to ensure correct installation and maximum utilization of the numerous features of this product If you do not understand any aspect of installation contact your authorized Trace Engineering dealer installer for assistance If you intend to operate the inverter in a utility inter active mode in which power will be sold to the utility you must contact the local utility office and get their approval The utility may require additional information that may not be included in this manual Please contact your authorized Trace Engineering 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 The 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 ins
268. rsonnel The enclosure should be ventilated to the outdoors from the highest point to prevent accumulation of hydrogen gasses released in the battery charging process An air intake should also be provided at a low point in the enclosure to allow air to enter the enclosure to promote good ventilation For most systems a 1 inch diameter vent pipe from the top of the enclosure is adequate to prevent accumulation of hydrogen A sloped top can help direct the hydrogen to the vent location and prevent pockets of hydrogen from occurring The enclosure should also be capable of holding at least one battery cell s worth of electrolyte in case a spill or leak occurs It should be made of acid resistant material or have an acid resistant finish applied to resist the corrosion from spilled electrolyte and fumes released If the batteries are located outside the enclosure should be rainproof and include mesh screens over any openings to prevent insects and rodents from entering Before putting the batteries in cover the bottom of the enclosure with a layer of baking soda to neutralize any acid that might be spilled in the future BATTERY TEMPERATURE The effective capacity of a battery is reduced when cold This phenomenon is more significant with lead acid type batteries compared to alkaline types When the internal temperature of a lead acid battery is 32 F 0 C the capacity can be reduced by as much as 50 This effectively reduces the size of the system s
269. rst turned to RUN and then momentarily held to a START position starts it Once the engine has started the switch is released and it returns to the RUN position To shut 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 motor 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 HONDA TYPE GENERATOR STOP SWITCH START SWITCH A Figure 24 Three Wire Start Wiring Diagram HONDA Type Onan type generators use a different starting sequence Most Onan type generators use a three position momentary type switch that controls their operation To start the generator the switch is held to the START position This energizes the ignition system and cranks the starter motor Once the engine has started the switch is released and it returns to a center off position The starter motor then stops cranking 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 returns to the center position For this type of generator relay RY8 duplicates the START position and relay RY7 is used to duplicate the STOP
270. rt No 2031 5 70 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 OPERATION GENERATOR SUPPORT MODE INVERTER CHARGER GENERATOR AC AC AC LOADS 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 for later use The inverter 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 e Connect the generator AC output to the inverters AC HOT IN 2 and NEUTRAL IN 2terminals e Connect the AC loads to the inverters AC HOT OUT and NEUTRAL OUT terminals e Adjust the battery charger parameters to match the requirements of the batteries connected if the factory defaults listed in the technical section are not satisfactory e 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 all
271. s Gen Auto Start Use to setup the when the automatic generator control system and the setup 12 maximum run time allowed Gen starting Use to adjust the starting sequence of the automatic generator control details 13 system Auxiliary Relays Use to adjust the operation of the auxiliary signal relays for controlling R9 R10 R11 14 external power sources or system loads Bulk Charge Use to set a time when the battery will be given a bulk charge cycle from the Trigger Timer 15 utility grid AC1 input Usually only used when SLT mode is enabled Low Battery Use to set up the transfer voltage setting for the LBX mode Transfer LBX 16 Battery Selling Use to control the SELL mode when it is used to discharge a battery into the 17 utility grid Also allows setting of the maximum sell amps Grid Usage Timer Use to control when the inverter charger mode uses the utility grid for the 18 FLT and SELL modes Information File Provides information about the operation of some settings and meters battery 19 End Setup Menu Used to display that you have reached the end of the SETUP MENU 20 Copyright Trace Engineering Company Inc Telephone 360 435 8826 5916 195th Street N E Fax 360 435 2229 44 Arlington WA 98223 www traceengineering com SW Series Inverter Charger Part No 2031 5 Rev B Sept 1 1999 MENU SYSTEM INVERTER SETUP 9 MENU HEADING Set Grid Usage ELT SELL SLT LBX e FLT Float will try to maintain the
272. s If the voltage remains 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 generator before a restart is attempted This reduces the chance that the starter motor 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 temperature compensated battery voltage near the BULK VOLTS DC setting for the ABSORPTION TIME period When it is time to stop the generator relay RY7 will open or close depending on which RY7 FUNCTION is selected stopping the generator This will occur after 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 from generator to inverter will be less noticeable if you manually turn off the generator from the inverters 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 Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter
273. s 48 VDC models Range 10 0 to 16 0 Range 20 0 to 32 0 Range 40 0 to 64 0 Sets the voltage level that will be maintained during the first and second 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 batteries 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 counts 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 process 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 Set Float S
274. s a switch to turn off power to equipment for servicing Grid The grid Also called the utility grid this refers to the public power distribution system Impedance Opposition to flow of alternating current AC Islanding The condition present when the utility power grid fails and the inverter attempts to power the grid An inverter which is islanding protected senses the loss of AC power from the grid and does not back feed into the grid system LED Light Emitting Diode A light made up of semi conducting material Line Tie Term used when the inverter is connected to the public power or grid system Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 0 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 115 TECHNICAL INFORMATION Load s Any electrical item which draws power i e lights radio washer dryer refrigerator etc Locked Rotor Amps The current drawn by an electric motor with the shaft or rotor stopped and locked in position This can be used to determine if an inverter has enough surge current to start a motor If the inverter is capable of producing more amperage than the locked rotor amps rating of a motor it will most likely start the motor easily Modified Sinewave Also called a quasi sine wave or a modified square wave This output looks like a one step staircase M
275. s on Control Panel Inverter Mode Generator Mode Trace Meters Error Causes Time of Day A J 00 00 00 6 Set Inverter Inverter Set Generator Generator Press reset now reset now orF sRcH ON CHG ES AUTO ON EQ ES defaults 1 move 1 Move cursor to l inverter OFF to resetOverCurrent Page 34 Gen under over Generator start o error Generator sync error NO zZ Gen max run time error Ready Voltage Start Ready Exercise Start Ready ee cursor to len to reset zZ Load Amp Start VEF Gen starts amp runs for 5 min then stops the inverter will Vrot attempt Irestart until gen auto start Conditions are again satisfied If Gen runs fo ns mn l Error Under over speed Will cause a Sync error in 10 minutes AA ee o Revision 4 01 5916 195th St NE Arlington WA 98223 USA Ph 360 435 8826 Fax 360 435 2229 Copyright Trace Engineering Company Inc 5916 195th Street N Arlington WA 98223 E Inverter charger Amps 00 Input amps AC 00 Load amps AC 00 Battery actual volts DC 12 6 Battery TempComp volts 12 6 Inverter volts AC 00 eria aci volts AC 00 Generator 2 volts 00 Read Frequenc quency Hertz IACI
276. s power of the T240 Transformer is sized to take advantage of the Trace Engineering inverter line OVERCURRENT PROTECTION FUSES AND DISCONNECTS The Trace Engineering fuseblock TFB protects your battery inverter and high amperage cables from damage by short circuits and overloads Simply select the proper size fuseblock and install between the inverter and battery in the ungrounded conductor typically the positive cable TFB s include a fast acting current limiting class T fuse 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 TFB s provide the code required inverter overcurrent protection for RV and Marine applications A slide off cover prevents accidental contact with the fuse s live terminals For maximum protection install the fuseblock within 18 inches 45 cm of the battery For residential and commercial electrical systems the National Electrical Code requires both overcurrent protection and a disconnect switch Trace offers the DC250 and DC175 circuit breaker disconnects with enclosure for applications requiring NEC compliance The DC250 and DC175 are also designed to accept 2 inch conduit to protect the inverter and battery cables Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229
277. s products in life support applications where failure or malfunction of the Trace Engineering product can be reasonably expected to cause failure of the life support device or to significantly affect its safety or effectiveness Trace Engineering Inc does not recommend the use of any of its products in direct patient care Trace Engineering Inc will not knowingly sell its products for use in such applications unless it receives in writing assurances satisfactory to Trace Engineering Inc that a the risks of injury or damage have been minimized b the customer assumes all such risks and the liability of Trace Engineering Inc is adequately protected under the circumstances Examples of devices considered to be life support devices are neonatal oxygen analyzers nerve stimulators whether used for anesthesia pain relief or other purposes autotransfusion devices blood pumps defibrillators arrhythmia detectors and alarms pacemakers hemodialysis systems peritoneal dialysis systems neonatal ventilator incubators ventilators for both adults and infants anesthesia ventilators and infusion pumps as well as any other devices designated as critical by the U S FDA Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 135 WARRANTY REPAIR INFORMATION WARRANTY OR R
278. same for all models The SETUP DEFAULT settings are dependent on the specific model of the SW Series Inverter Charger Worksheets are provided for domestic US models Use the following Worksheets to record your specific USER and SETUP operating settings for SW Series Inverter Charger Model SW S N USER MENU MENU HEADING MENU ITEM SELECTION DEFAULT USER RANGE SETTINGS SETTINGS inverter Mode 1 Set Inverter OFF SRCH ON CHG OFF Generator Mode 2 set Generator OFF AUTO ON EQ OFF None Gen Under Over Speed DISPLAY NO None Generator Start Error DISPLAY NO None Generator Sync Error DISPLAY NO None Gen Max Run Time Error DISPLAY NO None Load Amp Start Ready DISPLAY NO None Voltage Start Ready DISPLAY NO None Exercise Start Ready DISPLAY NO None Trace Engineering 3 Revision 4 01 DISPLAY None Meters 4 Inverter Charger Amps AC DISPLAY 00 None Input Amps AC DISPLAY 00 None Load Amps AC DISPLAY 00 None Battery Actual Volts DC DISPLAY Battery Volts None Battery TempComp Volts DC DISPLAY Battery Volts None Inverter Volts AC DISPLAY 00 None Grid AC1 Volts AC DISPLAY 00 None Generator AC2 Volts AC DISPLAY 00 None Read Frequency Hertz DISPLAY 60 None Error Causes 5 Over Current DISPLAY NO None Transformer Overtemp DISPLAY NO None Heatsink Overtemp DISPLAY NO None High Battery Voltage DISPLAY NO None Low Battery Voltage D
279. st be included to 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 It is much easier to replace a fuse then to repair the inverter as Tobin says You fuse or you lose GEN CONTROL WIRING The configuration of the starting relays on all SW Series inverters allows starting of both Honda and Onan 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 make 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 panel be purchased This allows examination of how the generator remote control panel works which is what the inverter s generator control system in the inverter must duplicate Connection of the inverter s generator control relays in the inverter to the generator s remote 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 automatic 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
280. t This 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 nat display a symbol for positive values Inverter charger Amps AC 00 All models Range 64 to 64 Amps Reads AC amperage Positive amps 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 The 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 models Range 00 to 64 Amps Reads the current that is going to the AC loads This reading is always positive Battery actual Battery actual Battery actual volts DC 12 6 volts DC 25 2 volts DC 50 4 12 VDC models 24 VDC models 48 VDC models Range 5 0 to 17 5 VDC Range 10 0 to 35 5 VDC Range 20 0 to 71 0 VDC Reads the battery voltage Similar to the voltage reading of a standard DC voltmeter The actual battery voltage value is used for the LOW BATTERY CUT OUT HIGH BA
281. t is best if the sensor is placed between batteries and if the batteries are placed in X an insulated box to reduce the influence of the ambient temperature outside the battery enclosure Ventilate the battery box at the highest point to prevent hydrogen accumulation Figure 22 BTS Battery The BTS provided may be extended beyond the standard 15 feet by an Temperature Sensor 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 This is useful for 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 must be selected from 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 commonly used in marine applications where the inverter operates a refrigeration system from the batteries Normally the engine s alternators keep the batteries charged When docked a shore cord is connected to the inverter to power the battery charger and run the refrigerator AC INPUT REQUIREMENTS When an AC source 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 synchroniz
282. t meet specified tolerances 67 F to 284 F 55 C to 75 C 15 000 feet 5000 meters 50 000 feet 16 000 meters 15 38 cm high 22 5 57 cm wide 9 23 cm deep when wall mounted 20 5 52 cm 27 69 cm 15 5 40 cm Wall or Shelf Mount Weight Inverter Only Weight Shipping 95 lbs 43 kg 105 lbs 48 kg 105 Ibs 48 kg 136 lbs 63 kg 105 Ibs 48 kg 105 lbs 48 kg 136 Ibs 63 kg 110 lbs 50 kg 111 Ibs 50 kg 111 Ibs 50 kg 143 Ibs 65 kg 111 lbs 50 kg 111 Ibs 50 kg 143 lbs 65 kg SW Series Inverter Charger Copyright O Trace Engineering Company Inc 5916 195th Street E Arlington WA 98223 Telephone 360 435 8826 Fax 360 435 2229 www traceengineering com Part No 2031 5 Rev B Sept 1 1999 TECHNICAL INFORMATION DIMENSIONS SINE WAVE INVERTER 9 007 229mm 384mm Figure 37 SW Series Dimensions With AC Access Covers Showing Knockout Sizes OPTIONAL CONDUIT eee t 3 DUAL KNOC 1 093 amp 61 399 O DUAL KNOCK DUT 01 0093 6 875 Pa e Copyright O Trace Engineering Company Inc 9 5916 195th Street E 120 Arlington WA 98223 Telephone 360 435 8826 Fax 360 435 2229 www traceengineering com SW Series Inverter Charger Part No 2031 5 Rev B Sept 1 1999 TECHNICAL INFORMATION INSTALLATION DIAGRAMS The fol
283. tallation and make the appropriate selections and adjustments Installation diagrams are provided for many of the various applications This menu system provides control of the inverter allows features to be enabled and allows setting of operating parameters This is a long manual and much of it is fairly technical Throughout this manual terms may be used that are unfamiliar see the INVERTER CHARGER TERMINOLOGY glossary on page 115 for clarification If you are an insomniac properly used this manual is guaranteed to provide several good nights of sleep Note This manual is specific to the REVISION 4 01 software Some features discussed 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 menu heading The second menu item should read REVISION 4 01 If your inverter includes a previous software version please contact your authorized Trace Engineering dealer regarding upgrade options Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street E Fax 360 435 2229 Part No 2031 5 0 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 5 INTRODUCTION rs INTENTIONALLY WOT sy Pa e Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger 9 5916 195th Street E
284. teners to prevent chafing or damage Use strain reliefs grommets or conduit to prevent damage to the wiring where it passes through any apertures Tighten all connections to the correct torque AC Connections at 20 inch pounds DC Connections at 10 15 foot pounds Make a final check of all wiring then reconnect to the AC power source Turn the inverter ON and check inverter operation See the FUNCTIONAL TEST section on page 31 Page Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger 5916 195th Street E Fax 360 435 2229 Part No 2031 5 1 6 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 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 e Verify that you have everything listed on the Packaging Materials sheet lf any items are missing please call Customer Service at 360 435 8826 e Save your proof of purchase You will need the proof of purchase to obtain warranty service e 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 accordingly Treat the
285. ter 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 transformer in a step up configuration This is common for deep well submersible well pumps If the step up is done on the pump side of the pressure switch or manual switch for the pump run 120 VAC through the switch then step it up to 240 VAC the transformer 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 from 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 This provides both 120 and 240 VAC since a center neutral is provided between the two inverters If a 240 VAC only AC source is connected to the AC input terminals of the inverter without this center neutral unacceptable operation will result To allow connection of a 240 VAC only source a small 500 VA autotransformer must be connected acr
286. ter to drive will be the largest motor you manage to start With inductive loads the rise in voltage applied to the load is not accompanied by a simultaneous rise in current The current is delayed The length of the delay is a measure of inductance The current makes up for its slow start by continuing to flow after the inverter changes AC voltage polarity Inductive loads by their nature require more current to operate than a resistive load of the same wattage rating regardless of whether power is being supplied by an inverter a generator or grid Induction motors motors without brushes require 2 to 6 times their running current on start up The most demanding are those that start under load e g compressors and some pumps The largest motor of this type that the inverter will run varies from 1 2 to 3 4 hp Of the capacitor start motors typical in drill presses band saws etc the largest you may expect to run is 1 to 1 5 hp Universal motors are generally easier to start The inverter may start up to 2 5 hp universal motors Since motor characteristics vary only testing will determine if a specific load can be started and how long it can be run SUBMERSIBLE WELL PUMPS The well pump is often the hardest load to start for inverter system Submersible pump motors are particularly hard because the motor is very narrow in order to fit down the well and draws extremely high starting current When selecting a pump check the LOCKED ROTOR AMPS
287. termined by the level of automatic operation the amount 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 shock Disable and secure all AC and DC disconnect 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 short circuits of the battery system Inverter systems by their nature involve power from multiple sources inverter generator utility batteries solar arrays etc that add hazards and complexity that can be very challenging After you have finished installing your unit continue with the FUNCTIONAL TEST section on page 31 This Functional Test should be completed prior to configuring your unit s Menu System for your specific operatio
288. th Street N E Fax 360 435 2229 Part No 2031 5 24 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 INSTALLATION CONTROL WIRING More advanced installations will require additional wiring to interface the inverter 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 provide good results All circuits should also be fused at the source of the power in the circuit to provide both protection and indication of problems with the control circuit Consult local code and the NEC for minimum wire size and type required based on the length that you want to run The AC circuit board provides male type push on connectors and you are provided crimp on terminals 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 This circuit board also includes two LED indicators to allow visual indication of the generator control sequence 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 amperage device which does the actual switching of the power CAUTION A fuse rated at 5 amps or less mu
289. that the generator optional remote control be purchased This also allows examination of how the generator remote 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 control system at the generator 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 The current can be monitored by the LOAD AMPS AC menu item under the METERS menu The generator will start unless the timer is in the quiet time period at which time it will only start if the READ LBCO 30 SEC START VDC setting is reached Whenever 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
290. the TIME OF DAY settings to the factory default values The default values will be re entered only when this button is pushed from a specific menu 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 SETTINGS WORKSHEET 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 SWRC display if the characters become jumbled Pressing the reset button anywhere in the menu system 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 menu item The first letter of the selected item will be underlined Pressing the red ON OFF
291. 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 started manually or automatically To reset the error condition press the green GEN MENU button to select 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 The relay labeled RY7 is used to either provide a STOP signal or a RUN signal It can also be used to provide a GLOW signal on diesel generators with glowplugs Note that the right side choice RUN is the default When RUN is selected 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 contact is open not connected to the common terminal while the generator is running When the generator is off the RY7 N C terminal is connected to the RY7 COMterminal This configuration is useful for starting a two wire auto crank type generator When GLOWSTOP
292. 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 time 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 Pa e Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger 9 5916 195th Street E Fax 360 435 2229 Part No 2031 5 74 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 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 command is initiated the generator starts and runs for 15 minutes to ensure that it remains fully 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
293. 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 Set Low battery cut in VDC 26 0 Set Low battery cut in VDC 52 0 12 VDC models Range 05 0 to 17 5 24 VDC models Range 10 0 to 35 0 48 VDC models Range 20 0 to 70 0 This setting controls when the inverter turns back 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 resumes powering the AC loads from the inverter when LBX mode is being used In LBX mode the best performance 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 sources wind solar etc must then cause the battery voltage to rise above the charger settings before the system resumes inverter mode operation This setting is not temperature compensated Set High battery Set High battery Set High battery cut out VDC 16 0 cut out VDC 32 0 cut out VDC 64 0 12 VDC models 24 VDC models 48 VDC models Range 00 0 to 16 5 Range 00 0 to 33 0 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 V
294. ting Wrap UP nn esc tnter ten nter deden dee R R 9 Hysteresis Volts DC Menu 14 58 R10 Hysteresis Volts DC Menu 14 59 R11 Hysteresis Volts DC Menu 14 59 Radio Frequency Interference 18 Read 30 Sec LBCO Start VDC Menu 12 55 Read Frequency Hertz Menu 4 42 Recommended Minimum AC Wire Sizes 147 Remote Control SWRO 143 Remote POM rin reda 12 Repair Required eene 149 RESET TO FACTORY DEFAULTS Button 10 Resistive Loads neee 125 Reverse 15 25 RFI Radio Frequency Interference 18 RY7 IndiGator ida 13 ANYS dicta 13 S Safety Instructions net nete tees 1 General Precautions Personal Precautions zn Special Notices eee idos Search AS aioe Search Mode Sell Mode Input Amps AG SELL MOGe adas Selling Power From A DC Charging Source Stored In The Batteries Serial Number Series Stacked Operation 240 VAC Input Output Breaker 240 VAC Only
295. tomatic 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 checking 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 amp runs for 5 min then stops the inverter will not attempt restart until gen auto start conditions are again satisfied 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 MENU HEADING
296. ttery is now fully charged This indicator is also used to indicate the regulation setpoint when the inverter is operating as an Utility Inter Active Inverter SELL mode The indicator will blink slowly to indicate the battery is regulated to the SET BATTERY SELL VOLTS DC setting from the BATTERY SELLING 17 menu heading and the indicator will be solid to indicate the battery is regulated to the SET FLOAT VOLTS DC setting from the BATTERY CHARGING 10 menu heading ERROR Red Indicates that an operating error has occurred refer to the ERROR CAUSES 5 menu heading for a list of possible causes To reset the inverter press the red ON OFF MENU bution 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 frequency is not well adjusted 3 to 7 hertz from nominal You can use the LED blink to help adjust the AC source frequency Once the frequency is within 3 hertz of your nominal frequency the LED will turn off OVERCURRENT Red The load requirement has exceeded the inverters maximum output AC amps A sustained overcurrent condition will require a manual reset by pressing the red ON OFF MENU button and then selecting OFF and then ON with the SET POINTS buttons or by pressing the red button several times Momentary flashing of the red OVERCURRENT indicator means that the inverter has reached it maximum output AC amps and
297. tup Menu 48 VDC 141 User Menu 138 Using Multiple Inverters nnen ennen eenn 107 Utility Back Up 99 104 106 Utility Back Up Mode 48 69 102 106 114 Battery Requirement neee eenen 92 Silent SLT Mode 92 SLT Silent Mode 92 Utility Support Overload Protection 92 Utility Inter Active Mode Battery Overvoltage Protection E Islanding Protection nennen eenen erneer eenn Selling POWBr nn tarieven aan na From A DC Charging Source 95 Stored In The Batteries 96 Utility Back Up 2 oerte 99 Utility Support Overload Protection 92 V Gi in ante 19 Voltage Start Ready Menu 2 40 Warning Label tette 22 Warranty Corrosion i opcre eerte etat re ee iben see co nae E ure eae cane ee cg 18 Generator nnen nen veneeeenenenneenvenenenenveeneen 26 Not Covered 25 26 58 Shipping Address cc ws 150 Warranty Registration And 149 Well pumps eene See Inductive Loads Inverter Surge See Locked Rotor Amps Wiring AG WING cite cn eee es 19 AC Input Connections
298. uctors providing power from the battery A fuse must be used even if the circuit is providing only a dry contact or ground connection it will prevent damage 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 information 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 glowplugs 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 common terminals of the relays are separated and both the N O normally open and N C normally closed contacts of the relays are provided It is much easier to make the connections to the generator if a remote control terminal or connector is available on the generator This sometimes requires
299. uirements Table 2 Minimum Recommended Battery Cable Size vs Cable Length INVERTER TYPICAL NEC 1 TO 3 FEET 3TO5FT 5 TO 10 FT MODEL PS AMPS ONE WAY ONE WAY ONE WAY SW2512 267 Amps 334 Amps 4 0 AWG 107 mm 4 0 AWG 107 mm Not Recommended Sw2612E 278 Amps 348 Amps 4 0 AWG 107 mm 4 0 AWG 107 mm Not Recommended SW3024E or J 160 Amps 201 Amps 4 0 AWG 107 mm 4 0 AWG 107 mm 4 0 AWG 107 mm SW4024 or W 214 Amps 267 Amps 4 0 AWG 107 mm 4 0 AWG 107 mm 4 0 AWG 107 mm SW3048E or J 80 Amps 100 Amps 2 0 AWG 67 4 mm 2 0 AWG 67 4 mm 4 0 AWG 107 mm SW4048 orK 107 Amps 134 Amps 2 0 AWG 67 4 mm 2 0 AWG 67 4 mm 4 0 AWG 107 mm SW4548E or A 120 Amps 150 Amps 2 0 AWG 67 4 mm 42 0 AWG 67 4 mm 4 0 AWG 107 mm sw5548 147 Amps 184 Amps 4 0 AWG 107 mm 4 0 AWG 107 mm 4 0 AWG 107 mm TYPICAL DC AMPS is based on Low Battery Voltage with an efficiency of 85 2NEC AMPS is based on Low Battery Voltage an efficiency of 85 and a 125 NEC de rating WARNING Battery cables that are very small will melt and burn the first time the inverter is operated at high power levels Copyright O Trace Engineering Company Inc 5916 195th Street E Arlington WA 98223 Telephone 360 435 8826 Fax 360 435 2229 www traceengineering com SW Series Inverter Charger Part No 2031 5 Rev B Sept 1 1999 INSTA
300. ully recharge and will drop to a lower voltage during discharging compared to a similarly sized lead acid type battery This makes the job for the inverter charger much more difficult The easiest way to use NiCad NiFe batteries with a 24 volt inverter is to use nineteen NiCad NiFe cells in the battery bank instead of the usual twenty This will reduce the battery bank charging voltage requirements to about the same level as a lead acid bank so more standard charger settings can be used The problem with this approach is that the battery voltage will drop as low as 18 volts to fully discharge the battery A second option on 12 24 and 48 volt systems is to adjust the SET BULK VOLTS DC to its maximum setting This will provide a complete charge although it may require a longer charging period to completely recharge the battery compared to using a higher charge voltage or lesser number of cells were used The ABSORPTION TIME setting may be set shorter than with lead acid batteries since NiCad NiFe batteries do not require an absorption stage If the battery storage requirements are large industrial grade 2 volt batteries are often more suitable Note In alternative energy applications solar wind hydro all DC charge controllers must be set to a level below the inverter HIGH BATTERY CUT OUT setting or the inverter may shut off unexpectedly Pa e Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger 9 5916
301. unded 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 subject is more easily discussed if it is divided into three separate subjects Chassis 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 misunderstand system grounding Consult local 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 for fault currents to flow through to blow fuses or trip circuit breakers The size of the connecting conductors should be coordinated with the size of the overcurrent 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
302. under the GEN AUTO START SETUP menu If the value is set to 10 the generator will start every tenth day of continuous non operation To disable this feature set the value to zero MANUALLY 4 Manual Start The generator can be manually 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 from 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 function 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 normally closed contacts of this relay are also available on the terminal block marked RY7 N C The normally closed contact is open not connected to the common terminal while the generator is running When the generator is off the RY7 N C terminal is connected to the RY7 COM terminal This configuration is useful for starting many HONDA brand generators as well as some others This should also be us
303. ust be taken into account when using the automatic generator controlling system with multiple inverters The inverter that controls the generator referred to as the generator controlling inverter along with the other inverter which does not control the generator referred as the non generator controlling inverter must be programmed differently to achieve the best results The two inverters should be programmed with the same BULK VOLTS DC and FLOAT VOLTS DC settings but with the ABSORPTION TIME on the non generator controlling inverter to a longer setting This will ensure that the charge current is shared between the two inverters more equally during the absorption stage by preventing one of the inverters from switching to float before the other When the inverter that controls the generator reaches float it will shut down the generator The same consideration should be made if you are trying to equalize the batteries The two inverter chargers should be programmed with the same EQUALIZE VOLTS DC settings but with the EQUALIZE TIME on the non generator controlling inverter to a longer setting When you are ready to start the equalization process either manually or automatically you must select EQ from the SET GENERATOR menu item on both inverters accessible by pressing the green GEN MENU button on the Control Panel This will allow both units to help bring the voltage to the EQ voltage level During the equalization pr
304. ut terminals The SWRC is connected to the remote control port labeled REMOTE on the left side AC side of the SW Series Inverter Charger using the provided DB 25 communications cable Two cable lengths are available 25 feet 8 meters or 50 feet 16 meters Distances longer than 50 feet 16 meters are not recommended The SWRC displays its information on a LCD screen which duplicates the functions of the integral Control Panel on the SW Series Inverter Charger but it allows these functions to be performed and or observed from a remote location up to 50 feet from the inverter Once the desired changes have been made the SWRC may be unplugged and these changes will be retained except if the inverter is completely powered down When the SWRC is connected to the inverter the inverter s status LED s still operate normally Installation and operating instructions are included with the SWRC You may connect either the SWRC SWCA Both options cannot be connected at the same time SWCA The SineWave Communications Adapter SWCA serial communications interface adapter allows for remote set up adjustment troubleshooting and monitoring of SW Series inverters from a personal computer and allows modem access monitoring over long distances The SWCA allows direct access of up to eight SW Series inverters via standard telephone type wire The SWCA is connected to the remote control port labeled REMOTE on the left side AC side of the SW
305. verter s and the other inverter bypass breaker switch could be in the Normal Operation position power passing thru the inverter The resulting output of the two bypass switches may be less than 240 VAC which could cause problems with any 240 VAC loads that are not protected against an AC phase shift Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 0 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 95 OPERATION 240 VAC 60 HZ ONLY ELECTRICAL SYSTEMS Two 120 VAC 60 HZ inverters series stacked can be used to provide 240 VAC This provides both 120 and 240 VAC since a center neutral is provided between the two inverters If a 240 VAC only AC source is connected to the AC input terminals of the inverter without this center neutral unacceptable operation will result To allow connection of a 240 VAC only source to 120 VAC inverter s a small 2000 VA auto transformer must be connected across the 240 VAC source with the center of the transformer connected to the AC neutral terminals of the inverters This will allow the inverter to operate properly No transformer is required on the AC output side the 240 VAC can be taken directly from the two AC hot output terminals one from each inverter PARALLEL STACKED OPERATION The parallel stacking interface allows twice the continuous and surge capacity
306. verter 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 Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 31 FUNCTIONAL TEST PAGS WITS TO Sed WOT 0320 Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Page 5916 195th Street E Fax 360 435 2229 Part No 2031 5 32 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 MENU SYSTEM 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 menu into groups of related menu items At the Menu Item level a setting can be adjusted a mode can be selected or information can be displayed When a number is included with the graphic of the menu heading or menu item in this manual 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 e The USER MENU provides the controls and settings needed on
307. 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 damage if they are miswired or a short circuit occurs The maximum fuse size must not exceed 5 amps and the fuses should be located as close as possible to the source of power e g generator battery REMOTE CONTROL WIRING An optional remote control panel for the SW Series Inverter Charger is available Trace part number 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 see page 12 for the location of the REMOTE PORT through a provided cable Two cable lengths are available 25 feet 8 meters or 50 feet 16 meters Distances longer than 50 feet 16 meters are not recommended The remote control cable should be kept away from sources of radio frequency interference such as motors and antennas The cable must be protected from abrasion and hot surfaces Copyright O Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street E Fax 360 435 2229 Part No 2031 5 0 Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 25 INSTALLATION SYSTEM GROUNDING GROUNDING INSTRUCTIONS This inverter charger should be connected to a gro
308. w Battery Voltage Menu 5 43 M Max Charge Amps 98 106 Max Sell AMPS gt p tette tns 97 Copyright O Trace Engineering Company 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 Page Rev B Sept 1 1999 139 INDEX Menu 1 Inverter Mode Menu 2 Generator Menu 3 Trace Engineering Menu 4 Meters Menu 5 Error Menu 6 Time of Day essen Menu 7 Generator Timer Menu 9 Inverter Setup Menu 10 Battery Charging Menu 11 AC Inputs Menu 12 Gen Auto Start 54 Menu 13 Gen Starting 56 Menu 14 Auxiliary Relays eene 57 Menu 15 Bulk Charge Trigger 60 Menu 16 Low Battery 60 Menu 17 Battery Selling ees 61 Menu 18 Grid Usage 62 Menu 19 Information
309. wed to be delivered to the utility grid from a solar array and or the batteries during utility inter active 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 menu heading Utility Power must be connected to the for this timer to be operational Start Charge End Charge time 21 00 time 21 00 All Models All Models Range 00 00 to 23 50 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 e With the GRID USAGE TIMER enabled the START CHARGE TIME
310. 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 clocks 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 appliances 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 cord with a rocker switch a switched outlet or a circuit breaker for the circuit Unfortunately this solution does not allow a clock to retain 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 adjust the setting to 30 NOTE The lower the search spacing value the less time it takes for the inverter to bring up a load The lower the setting the greater the power consumption while in the search mode thus reducing power The factory default valu
311. wn if the voltage drops below the BULK setting for a period of time Copyright Trace Engineering Company Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 47 MENU SYSTEM Set Max Charge amps AC Set Max Charge amps AC 30 Set Max Charge amps AC Set Max Charge amps AC 35 12 VDC models Range 01 to 25 24 VDC amp 48 VDC models Range 01 to 35 E amp W models Range 01 to 18 J 8 models Range 02 to 40 Sets the maximum amount of AC input current that the battery charger will use to charge the battery This can be used to limit the charger output as well The charger will back off if the combination of AC loads and the charger reaches the AMPS AC setting of the AC INPUT connected to prevent overloading the source or tripping breakers This process occurs automatically Set Temp Comp LEADACID 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
312. y Inc Telephone 360 435 8826 SW Series Inverter Charger Pa e 5916 195th Street N E Fax 360 435 2229 Part No 2031 5 g Arlington WA 98223 www traceengineering com Rev B Sept 1 1999 105 TECHNICAL INFORMATION BATTERY INSTALLATION CAUTION Batteries can produce extremely high currents if they are short circuited Be very careful when working around them Read the important safety instructions at the start of this manual and the battery supplier s precautions before installing the inverter and batteries LOCATION Batteries should be located in an accessible location with nothing restricting the access to the battery caps and terminals on the tops At least 2 feet of clearance above is recommended They must be located as close as possible to the inverter but can not limit the access to the inverter and the inverter s DC disconnect With the SW Series inverter the batteries are best located to the right side This is where the DC connections are located Battery to inverter cabling should be only as long as required For 12 VDC systems do not exceed 5 feet one way if 4 0 AWG cables are used For 24 VDC systems do not exceed 10 feet one way if 4 0 AWG cables are used For 48 VDC cables do not exceed 10 feet one way if 2 0 AWG cables are used or 20 feet one way if 4 0 AWG cables are used BATTERY ENCLOSURES The batteries must be protected inside of a ventilated lockable enclosure or room to prevent access by untrained pe
313. y charger that is able to operate in either direction it can send excess power from the battery back into the utility grid instead of drawing power from the utility to charge the battery To regulate the battery charging process the inverter takes 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 inter active 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 controls the solar panels at a battery voltage above the battery chargers BULK VOLTS DC setting Please see the OVERVOLTAGE PROTECTION FOR THE BATTERY section on page 89 for more information UTILITY INTER ACTIVE ISLANDING PROTECTION In utility inter active mode the inverter is cap
314. y to the AC output GENERATOR START ERROR Five attempts were made to start the generator without obtaining the correct input AC voltage or frequency GENERATOR SYNC ERROR Indicates that the generator was running but was not operating within the voltage or frequency tolerances and was not able to connect GEN MAX RUN TIME ERROR Indicates that the generator ran for a period of time that exceeded the SET MAX RUN TIME GEN UNDER OVER SPEED Indicates that five Auto generator start attempts have occurred without successfully starting the generator Error LED is flashing no error under ERROR CAUSES display AC source frequency is just out of tolerance 53 57 Hz or 63 67 Hz Disconnect all wires on the AC input and output Reset the inverter by pressing the On Off switch to OFF then to SRCH or ON If unit comes on then check AC wire system shorts or miswired Charging AC input voltage may be too high check for high input ac voltage Inverting operating too large of a load for too long remove excessive loads Ambient temperature may be high Inverter cooling fan may have failed hold a piece of paper to inverter vents to check fan fan is hard to hear Inverter airflow intake may be blocked small clearance or clogged MAX CHARGE AMPS setting needs to be lowered charging setting is too high based on ambient temperature around inverter Check for the correct battery voltage at the inverter s DC input te

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