Trace Engineering SW Series Installalion And Wiring Manual
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Trace Engineering SW Series Installalion And Wiring Manual

Integrated power panel
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IPP
Integrated Power Panel
Version 1.2
Installation and Wiring Guide
ã
1999 Trace Engineering
P/N #2903 Rev. A 01/00

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Summary of Contents for Trace Engineering SW Series

  • Page 1 Integrated Power Panel Version 1.2 Installation and Wiring Guide ã 1999 Trace Engineering P/N #2903 Rev. A 01/00...
  • Page 2 ©1999 Trace Engineering...

  • Page 3: Table Of Contents

    Battery Temperature Sensor Wiring SW Models DR Models Battery Wiring AC Wiring–SW Series Dual Inverter Models AC Input Wiring to the AC Bypass Box AC Output Wiring To the AC Bypass Box AC Input/Output Wiring (SW Single Inverter Models) AC Input/Output Wiring to the AC Bypass Box AC Wiring–DR Series Dual Inverter Models...
  • Page 4 IMPORTANT SAFETY INSTRUCTIONS WARNING - AVERTISSEMENT - CAUTION - ATTENTION - NOTE - NOTE - · · · · · · · SAVE THESE INSTRUCTIONS ©1999 Trace Engineering...
  • Page 5 BATTERY SAFETY INFORMATION · · · · · · · · · · · · · · · · ©1999 Trace Engineering...
  • Page 6 PV Charge Controllers (2 each) Generator AC Circuit Breakers Ø × × Ú DC Circuit Breakers Inverters (2 each) Ú AC Sub Panel (to loads) Figure 1 Integrated Power Panel (layout varies depending upon type of inverter) ©1999 Trace Engineering...

  • Page 7: Introduction

    1.0 INTRODUCTION Ÿ Ÿ Ÿ Ÿ Ÿ Ÿ Ÿ Ÿ Ÿ Ÿ Ÿ Ÿ Ÿ Ÿ Ÿ Ÿ Ÿ Ÿ Ÿ Ÿ Ÿ ©1999 Trace Engineering...

  • Page 8: Installation

    NOTE: The power panel is quite heavy (weighing up to 400 pounds depending upon configuration). Always use proper lifting techniques during installation to prevent personal injury. Mounting: Tools required: Hardware / Materials required: Wiring: AC Connections: DC Connections: Grounding: AC Grounding DC Grounding ©1999 Trace Engineering...

  • Page 9: Batteries

    OUTPUT CABLES OR EXPOSED TERMINALS. TO REDUCE THE RISK OF SHOCK DURING INSTALLATION, DISCONNECT THE ARRAY, OR COVER IT WITH AN OPAQUE (DARK) MATERIAL BEFORE MAKING ANY CONNECTIONS TO THE POWER PANEL. Main Service Panel: Sub-Panel: AC Circuit Breakers: Wire Routing: Plywood Backing: ©1999 Trace Engineering...

  • Page 10: Mounting

    2 x 4 support studs 2 x 4 support studs Approximately Approximately 3-1/2–4 ft 3-1/2–4 ft Floor Floor 2903-00-003 2903-00-003 Figure 2 Figure 3 Power Panel Support Structure Power Panel Support Structure (16" on-center studs) (24" on-center studs) ©1999 Trace Engineering...
  • Page 11 5" 9" 13" 21" 29" 33" 37" 32" 42 1/16" 42 15/16" Figure 4 Mounting Hole Dimensions Adjust the height of the panel so the bypass switch is within easy reach 2903-00-004 Figure 4A Mounted Power Panel ©1999 Trace Engineering...
  • Page 12 (red) Utility or Generator Solar PV Array 1 POSITIVE PV Array Chassis GROUND PV Array NEGATIVE DC Earth GROUND Battery NEGATIVE *Solar (PV) Array 2 POSITIVE *Battery POSITIVE Terminal Battery POSITIVE Terminal Figure 8 Wire Connection Locations (SW Model) ©1999 Trace Engineering...
  • Page 13 *AC INPUT from LINE 2 (red) PV Array 1 POSITIVE PV Array Chassis GROUND PV Array NEGATIVE *PV Array 2 POSITIVE DC Earth GROUND Battery NEGATIVE *Battery POSITIVE Terminal Battery POSITIVE Terminal Figure 6 Wire Connection Locations (DR Model) ©1999 Trace Engineering...

  • Page 14: Dc Wiring

    PV Array #1 Grounding Block Disconnect PV Array *PV Array #2 Negative (–) Wires Disconnect BATTERY DISCONNECT SOLAR ARRAY SOLAR ARRAY *PV Array #2 Positive (+) Wire   DR Series SW Series Figure 9 Wire Connection Locations ©1999 Trace Engineering...
  • Page 15 These wires are already installed Mount the battery temperature sensors (BTS) to the side of the same battery (located in the middle of the battery bank). BATTERY TEMPERATURE SENSORS BATTERY Figure 10 Battery Temperature Sensor (BTS) Wiring ©1999 Trace Engineering...

  • Page 16: Battery Temperature Sensor Wiring

    PO WE R SUP P LIES CERT IFIE D TO CAN/CS A- C2 2.2 No. 1 07.1-M 1 6 7664 TRACE ENGINEERING 5916 195TH ST NE ARLING TON, WA. 98223 M ADE IN U.S.A.  BTS wires run through the grommets in the inverter housing and along the back of the inverter.

  • Page 17: Battery Wiring

    12 Volt Battery Battery and provides an equal charge/ Negative 2 discharge through all of the batteries. – – 12 Volt 12 Volt Battery Battery 2903-00-021 Figure 12 Battery Wiring (24 v dc System) ©1999 Trace Engineering...

  • Page 18: Ac Wiring–Sw Series Dual Inverter Models

    2.0 INSTALLATION AC Wiring–SW Series Dual Inverter Models WARNING: THIS SECTION DEALS WITH WIRING THE MAIN SERVICE UTILITY PANEL TO THE POWER PANEL. ENSURE THAT ALL AC POWER TO THE UTILITY PANEL IS SWITCHED OFF. Ground Block GROUND Inverter 1 (Top ac breaker)

  • Page 19: Ac Input Wiring To The Ac Bypass Box

    2.0 INSTALLATION AC Wiring–SW Series Dual Inverter Models (continued) AC Input Wiring To The AC Bypass Box Neutral from L1 from Utility Utility or or Generator Generator Ground from L2 from Utility Utility or or Generator Generator NOTE: DO NOT REMOVE FACTORY...

  • Page 20: Ac Output Wiring To The Ac Bypass Box

    2.0 INSTALLATION AC Wiring–SW Series Dual Inverter Models (continued) AC Output Wiring To AC Bypass Box GROUND BLACK INV 1 #6AWG NEUTRAL INPUT AND OUTPUT SOURCE AND LOAD WHITE #6AWG INV 2 #6AWG 2903-00-011A NOTE: DO NOT REMOVE FACTORY WIRING!

  • Page 21: Ac Input/Output Wiring (Sw Single Inverter Models)

    DO NOT REMOVE FACTORY WIRING! To Sub-panel (Loads) Figure 17 AC Input/Output Wiring (Single Inverter Models) Breaker Lug Service Crimp Added Input or Output Wire Existing Factory Wiring 2906-00-026 Figure 17A Breaker Terminal Lug Detail (side view) ©1999 Trace Engineering...

  • Page 22: Ac Wiring–Dr Series Dual Inverter Models

    *Inverter 2 (Bottom ac breaker) GROUND 2903-00-027 Ground Block Figure 18 DR Series AC Disconnect Component Identification Service Crimp Breaker Lug Added Input or Output Wire Existing Factory Wiring 2906-00-026A Figure 19 Breaker Terminal Lug Detail (side view) ©1999 Trace Engineering...

  • Page 23: Ac Input Wiring To The Ac Bypass Box

    Utility or Utility or Generator Generator NOTE: DO NOT REMOVE FACTORY WIRING! WHITE #6AWG INV 1 NEUTRAL NOT BONDED TO GROUND NEUTRAL INPUT AND OUTPUT SOURCE AND LOAD INV 2 RED#6AWG GROUND 2903-00-022A Figure 20 AC Input Wiring ©1999 Trace Engineering...

  • Page 24: Ac Output Wiring To The Ac Bypass Box

    INPUT AND OUTPUT SOURCE AND LOAD INV 2 RED#6AWG GROUND 2903-00-023 NOTE: Neutral to DO NOT REMOVE L2 to Sub-panel FACTORY WIRING! Sub-panel (Loads) (Loads) L1 to Sub- Ground to panel (Loads) Sub-panel (Loads) Figure 21 AC Output Wiring ©1999 Trace Engineering...

  • Page 25: Ac Input Output Wiring To The Ac Bypass Box

    FROM UTILITY OR GENERATOR From Utility or Generator (HOT) Figure 22 AC Input/Output Wiring (Single Inverter Models) Service Crimp Breaker Lug Added Input or Output Wire Existing Factory Wiring 2906-00-026A Figure 22A Breaker Terminal Lug Detail (side view) ©1999 Trace Engineering...
  • Page 26 GROUND EARTH GROUND NOTE: FOR ILLUSTRATIVE PURPOSES ONLY. BREAKER BOXES VARY DEPENDING ON APPLICATION. MAIN PANEL WIRING TO NON-CRITICAL LOADS IS NOT ILLUSTRATED. LINE OUT NEUTRAL GROUND 2903-00-028 Figure 23 AC Input/Output Utility–Sub-panel Wiring (Single Inverter Models) ©1999 Trace Engineering...
  • Page 27 LINE OUT 120 V AC (L1) 240 V AC GREEN GROUND (to receptacle box or ground terminal) WHITE NEUTRAL RED (L2) BLACK (L1) 240 V AC (L1-L2) 2903-00-019 Figure 24B AC Input/Output Utility–Sub-panel Wiring for 120–240 V ac Circuits (Dual Inverter Models) ©1999 Trace Engineering...

  • Page 28: Wiring Check

    2.0 INSTALLATION Wiring Check CAUTION: PERMANENT SYSTEM DAMAGE CAUSED BY IMPROPER WIRING IS NOT COVERED UNDER WARRANTY. DO NOT SKIP THE ABOVE STEPS! ©1999 Trace Engineering...

  • Page 29: Operation

    Bypass breaker(s) Switch the Battery Disconnect(s) ON Switch the ac power ON at the main utility breaker box Switch the inverters ON. Verify proper operation  Switch the Solar PV Array Disconnect(s) Figure 25 Power Panel Operating Controls ©1999 Trace Engineering...

  • Page 30: Ac Disconnect Module

    3.0 OPERATION AC Disconnect Module AC Disconnect/Bypass INV 1 for Inverter 1 AC Disconnect/Bypass INV 2 for Inverter 2 Figure 26 AC Disconnect Breakers (Dual Inverter Model) ©1999 Trace Engineering...

  • Page 31: Inverter In Circuit

    Both AC Line and Inverter OFF BREAKER OFF INVERTER BYPASS Bypass circuit is de-energized. INV 1 BREAKER OFF INVERTER OUTPUT Inverter circuit is de-energized. 2903-00-018 Figure 29 Both AC Line and Inverter OFF ©1999 Trace Engineering Figure G Both AC Line and Inverter OFF...

  • Page 32: Troubleshooting

    4.0 TROUBLESHOOTING WARNING: THESE STEPS INVOLVE REMOVING THE COVER ON THE DC SIDE OF THE INVERTER, EXPOSING DANGEROUS VOLTAGES AND SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONS. ©1999 Trace Engineering...

  • Page 33: System Shutdown

    5.0 SYSTEM SHUTDOWN Emergency Shutdown Procedure Switch the Battery Switch the AC Disconnect(s) OFF Disconnect(s) OFF  Switch the Solar PV Array Disconnect(s) Figure 30 Emergency Shutdown ©1999 Trace Engineering...

  • Page 34: Specifications

    6.0 SPECIFICATIONS SW Series Power Panel General Specifications: PART NUMBER INVERTER(S) OUTPUT DC INPUT MINIMUM DC AC OUTPUT CHARGER AMPS WEIGHT POWER VOLTAGE CABLE SIZE VOLTAGE PP-SW2512/S SW2512 2.5 kW 12 V dc 4/0 AWG 120 V ac/60 Hz 150 amps 196 lbs (88.9 kg)
  • Page 35 95 lbs (43.0 kg) General Specifications SW and DR Series Mechanical Overall size (H x W x D) DR Model 39-9/16" x 43" x 8" SW Model 39-9/16" x 43" x 9-3/4" Material Indoor rated, power coated steel Color White ©1999 Trace Engineering...

  • Page 36: Service Information

    7.0 SERVICE INFORMATION visit our website at: www.traceengineering.com ©1999 Trace Engineering...

  • Page 37: Life Support Applications Policy

    8.0 LIFE SUPPORT APPLICATIONS-POLICY ©1999 Trace Engineering...

  • Page 38: Warranty

    9.0 WARRANTY Limited Warranty 5916 - 195th Street N.E., Arlington, WA 98223 Phone: (360) 435-8826 Fax: (360) 435-2229 ©1999 Trace Engineering...
  • Page 39 ©1999 Trace Engineering...
  • Page 40 5916 - 195th Street N.E., Arlington, WA 98223 Phone: (360) 435-8826 Fax: (360) 435-2229 visit our website at: www.traceengineering.com...

This manual is also suitable for:

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