Xantrex SW Series Owner's Manual
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Xantrex SW Series Owner's Manual

Sw series inverter/chargers
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SW Series Inverter/Chargers
With Revision 4.01 Software
Owner's Manual
2001 Xantrex Technology, Inc.
Telephone: 360/435-8826
SW Series Inverter/Charger
Fax: 360/435-2229
Part No. 2031-5
5916 - 195th Street N. E.
www.traceengineering.com
Rev. C: February 2001
Arlington, WA 98223

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  • Page 1 ™ SW Series Inverter/Chargers With Revision 4.01 Software Owner’s Manual 2001 Xantrex Technology, Inc. Telephone: 360/435-8826 SW Series Inverter/Charger Fax: 360/435-2229 Part No. 2031-5 5916 - 195th Street N. E. www.traceengineering.com Rev. C: February 2001 Arlington, WA 98223...
  • Page 2 2001 Xantrex Technology, Inc. Telephone: 360/435-8826 SW Series Inverter/Charger Fax: 360/435-2229 Part No. 2031-5 5916 - 195th Street N. E. www.traceengineering.com Rev. C: February 2001 Arlington, WA 98223...
  • Page 3 Model Number: ________________________________ Serial Number: ________________________________ Comments: Visit our web site at www.traceengineering.com for more information and answers to frequently asked questions. 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223 Telephone: 360/435-8826 Fax: 360/435-2229 www.traceengineering.com SW Series Inverter/Charger Part No.
  • Page 4 2001 Xantrex Technology, Inc. Telephone: 360/435-8826 SW Series Inverter/Charger Fax: 360/435-2229 Part No. 2031-5 5916 - 195th Street N. E. www.traceengineering.com Rev. C: February 2001 Arlington, WA 98223...

  • Page 5: Table Of Contents

    SPECIFICATIONS AND FEATURES (60 Hz Models) ...118 SPECIFICATIONS AND FEATURES (50 Hz Models) ...119 DIMENSIONS ...121 INSTALLATION DIAGRAMS ...121 USER SETTINGS WORKSHEETS...123 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223 TABLE OF CONTENTS Telephone: 360/435-8826 Fax: 360/435-2229 www.traceengineering.com...
  • Page 6 WARRANTY/REPAIR INFORMATION ... 135 LIMITED WARRANTY... 135 WARRANTY REGISTRATION ... 135 LIFE SUPPORT POLICY... 135 WARRANTY OR REPAIR SERVICE REQUIRED... 136 INDEX ... 137 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223 Telephone: 360/435-8826 Fax: 360/435-2229 www.traceengineering.com SW Series Inverter/Charger Part No.
  • Page 7 Figure 35, Series-Parallel Configuration: 12-Volt Battery Wiring... 109 Figure 36, AC Waveforms ... 116 Figure 37, SW Series Dimensions: With AC Access Covers – Showing Knockout Sizes ... 120 Figure 38, Installation Diagram, 120 VAC, 1 Phase, Grid Connected, Generator Backup ... 121 Figure 39, Installation Diagram, 240 VAC, 3 Wire, Grid Connected, Generator Backup ...

  • Page 8: Index Of Tables

    Table 13, Recommended Minimum AC Wire Sizes (75 C)... 132 Table 14, Knockout/Hole Size To Conduit Size Required ... 132 Table 15, Safety Ground Wire Sizes ... 132 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223...

  • Page 9: Important Safety Instructions

    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 and Marine Craft.

  • Page 10: Special Notices

    3. Use of battery cable or custom attachment not recommended or sold by Xantrex Technology Inc. for the SW Series Inverter/Charger may result in a risk of fire, electric shock, or injury to persons. 4. Do not disassemble the inverter/charger. Take it to a qualified service center when service or repair is required.

  • Page 11: Personal Precautions

    This helps purge excessive gas fumes from the cells. Do not overfill. For a battery without cell caps, carefully follow the manufacturer’s recharging instructions. 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223...
  • Page 12 IMPORTANT SAFETY INSTRUCTIONS Telephone: 360/435-8826 SW Series Inverter/Charger 2001 Xantrex Technology, Inc. Page Fax: 360/435-2229 Part No. 2031-5 5916 - 195th Street N. E. www.traceengineering.com Rev. C: February 2001 Arlington, WA 98223...

  • Page 13: Introduction

    Congratulations! You are the proud owner of the finest inverter on the market today - and one very complex piece of equipment. The Trace™ Sine wave (SW Series) Inverter/Charger has many features and capabilities previously either non-existent, or found only in separate products.
  • Page 14 INTRODUCTION Telephone: 360/435-8826 SW Series Inverter/Charger 2001 Xantrex Technology, Inc. Page Fax: 360/435-2229 Part No. 2031-5 5916 - 195th Street N. E. Arlington, WA 98223 www.traceengineering.com Rev. C: February 2001...

  • Page 15: 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.
  • Page 16 UNIT IDENTIFICATION Telephone: 360/435-8826 SW Series Inverter/Charger 2001 Xantrex Technology, Inc. Page Fax: 360/435-2229 Part No. 2031-5 5916 - 195th Street N. E. Arlington, WA 98223 www.traceengineering.com Rev. C: February 2001...

  • Page 17: Controls, Indicators And Components

    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.
  • Page 18 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. 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N.
  • Page 19 OVERCURRENT indicator means that the inverter has reached it maximum output AC amps and has automatically reset itself. This may occur during motor startups and is acceptable. 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E.

  • Page 20: Ac Side

    Figure 4, AC Side REMOTE PORT The SW Series Inverter/Charger can be controlled remotely from the unit by plugging in a Sine wave Remote Control (SWRC) or Sine wave Communications Adapter (SWCA). The SWRC remote control is a full function, programmable remote control with backlit LCD which duplicates the functions of the integral Control Panel.

  • Page 21: Figure 5, Internal Components And Indicators

    Allows visual indication of AC1 relay operation. The LED will be on when the AC1 relay is closed (engaged). This LED along with the test-jumper adjacent to the LED is used by utilities to perform voltage and frequency tests to qualify the SW Series Inverter/Charger for line-tie applications. BTS PORT The battery temperature sensor (BTS) can be connected (plugged in) at the RJ-11 four-conductor connector, located on the AC Circuit Board.

  • Page 22: Dc Side

    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. 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E.

  • Page 23: 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.

  • Page 24: 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.

  • Page 25: Complete Install

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

  • Page 26: Figure 8, Air Flow Intake Location

    Typically, a 60 amp circuit breaker will protect #6 AWG wiring. Consult your local code for more information and for other wire sizes. 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E.

  • Page 27: Figure 9, Ac Input/Output Power Connection

    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 SWITCHING (RV AND MARINE APPLICATIONS) section on page 27 for more information.

  • Page 28: Important Precaution

    - if both are available, the generator will be disconnected and the inverter will connect to the utility on AC HOT IN 1. 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E.

  • Page 29: Figure 10, Warning Label

    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. Figure 10, Warning Label 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223...

  • Page 30: Battery Cable Sizing

    NEC AMPS is based on Low Battery Voltage, an efficiency of 85%, and a 125% NEC de-rating. WARNING! Battery cables that are too small will melt and burn the first time the inverter is operated at high power levels. 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E.

  • Page 31: Table 3, Battery Cable To Maximum Breaker/Fuse Size

    Contact your Xantrex dealer to order the inverter disconnects/fuses or see the OTHER PRODUCTS section in this manual on page 129 for more information. 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223...

  • Page 32: Figure 11, Battery To Inverter Cable Connection

    1-½ to 10 feet, and in 2/0 or 4/0 AWG. They are color-coded and have pressure-crimped, sealed-ring terminals. Contact your Xantrex dealer to order. Figure 11, illustrates proper method to connect the battery cables to the SW Series Inverter/Charger. 2/0 Copper Compression Lug...

  • Page 33: Remote Control Wiring

    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.

  • Page 34: Equipment Or Chassis Grounds

    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. 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E.

  • Page 35: Figure 12, Neutral-To-Ground Bond Switching: No External Ac Source Connected

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

  • Page 36: Figure 13, Neutral-To-Ground Bond Switching: External Ac Source Connected

    CHASSIS GROUND Neutral-to- Ground bonds AC NEUTRAL OUT Figure 14, Neutral-To-Ground Bond Switching: Neutral Bonded To Ground 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E. Arlington, WA 98223 NEUTRAL-TO-GROUND SWITCHING RELAY (Provided in the AC installation): Connects the...

  • Page 37: Figure 15, Multiple Point Ground System

    Ground Ground Voltage Voltage Difference Difference Figure 15, Multiple Point Ground System 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223 Equipment all grounded at same point. No voltage across system, and no Lightning equipment and wiring.
  • Page 38 INSTALLATION Telephone: 360/435-8826 SW Series Inverter/Charger 2001 Xantrex Technology, Inc. Page Fax: 360/435-2229 Part No. 2031-5 5916 - 195th Street N. E. Arlington, WA 98223 www.traceengineering.com Rev. C: February 2001...

  • Page 39: Functional Test

    6. This completes the functional test, if all areas pass, the inverter is ready for use. If any of the inverter’s internal setpoints are to be adjusted, consult the MENU SYSTEM section starting on page 33. 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E.
  • Page 40 FUNCTIONAL TEST Telephone: 360/435-8826 SW Series Inverter/Charger 2001 Xantrex Technology, Inc. Page Fax: 360/435-2229 Part No. 2031-5 5916 - 195th Street N. E. Arlington, WA 98223 www.traceengineering.com Rev. C: February 2001...

  • Page 41: Menu System

    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.

  • Page 42: User Menu Map

    If Gen runs for More than max Run time then Error. Under/Over speed Will cause a Sync error in 10 minutes 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E. Arlington, WA 98223 MENU HEADINGS Meters Error Causes Inverter/charger...

  • Page 43: Setup Menu Map

    Make sure LBX is charge time. above LBCO volts. In SLT mode don’t disable this timer. It is the daily chg time. 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223 MENU HEADINGS AC Inputs Gen Auto Start setup...

  • Page 44: User Menu

    LBCO 30 sec start VDC setting. Used to display that you have reached the end of the USER MENU. End User Menu 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E. Arlington, WA 98223...

  • Page 45: Information Display

    START AMPS continuously for the LOAD STOP DELAY MIN period. The AUTO-matic generator control operation is disabled if the ‘CHG’ mode under INVERTER MODE (1) menu heading is selected. 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223...
  • Page 46 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.
  • Page 47 INFORMATION DISPLAY The following information is displayed as additional Menu Items. 5916 195th St NE Arlington, WA 98223 USA Ph 360-435-8826 Fax 360-435-2229 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223 Telephone: 360/435-8826 SW Series Inverter/Charger Fax: 360/435-2229 www.traceengineering.com...
  • Page 48 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 voltage would match the AC inputs value. 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E.
  • Page 49 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. 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E.
  • Page 50 If the inverter can not synchronize to the generator after a 10-minute period, then the GENERATOR SYNC ERROR condition will be reached. 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E.
  • Page 51 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.

  • Page 52: Setup Menu

    Provides information about the operation of some settings and meters. Information File battery Used to display that you have reached the end of the SETUP MENU. End Setup Menu 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E. Arlington, WA 98223 Telephone: 360/435-8826...
  • Page 53 See the low battery transfer mode section for more information. 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223...
  • Page 54 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. 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E.
  • Page 55 This time is an accumulating or up/down type timer - it counts up while the voltage is above the BULK setting and counts back down if the voltage drops below the BULK setting for a period of time. 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E.
  • Page 56 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. 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N.
  • Page 57 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. 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223 Set 24 hr start 24.6...
  • Page 58 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. 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E.
  • Page 59 AUX RELAY 9 VOLTS DC setting. (For example, the default setting energizes the relay when the voltage exceeds 14.5 VDC and de-energizes when it drops below 13.5 VDC for 12-volt systems). There is an intentional 2-second time delay to reduce cycling. 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223...
  • Page 60 The following information is displayed as additional Menu Items. Close on batt > setpoint. Open on batt < setpoint – hys. Relays have 2 seconds delay on close, 0.1 sec delay on open. 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E.
  • Page 61 INFORMATION DISPLAY The following information is displayed as additional Menu Items. See menu 9 to enable LBX mode. Make sure LBX is above LBCO volts. 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223 Set Low Battery 22.6...
  • Page 62 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. 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E.
  • Page 63 LowBatt Transfer used in LBX, FLT modes only. Goes back to battery at LowBattCutIn (aka LBCI). For LBX mode set below LBCI so charger won’t cycle batteries up and down set LBCO below. 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223...
  • Page 64 MENU SYSTEM Telephone: 360/435-8826 SW Series Inverter/Charger 2001 Xantrex Technology, Inc. Page Fax: 360/435-2229 Part No. 2031-5 5916 - 195th Street N. E. Arlington, WA 98223 www.traceengineering.com Rev. C: February 2001...

  • Page 65: Operation

    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.

  • Page 66: Figure 18, Trace™ Sw Series Inverter Output Waveform

    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.

  • Page 67: Power Vs. Efficiency

    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 full output voltage while delivering no current.

  • Page 68: Inverter Capacity Vs Temperature

    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.

  • Page 69: Operating Modes

    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.

  • Page 70: Inverter Mode

    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 uninterruptible power supply, the search mode should be defeated. 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E.

  • Page 71: Low Battery Protection

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

  • Page 72: Charger Mode

    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 overloading a generator or tripping a circuit breaker when other AC loads are being operated through the inverter.

  • Page 73: Battery Temperature Sensor (Bts)

    - 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. 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223...
  • Page 74 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 AC 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N.

  • Page 75: Table 4, Charging Setpoints For Common Battery Types

    (if the battery electrolyte level is low, add enough to cover the plates before charging). 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223...
  • Page 76 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...

  • Page 77: Inverter/Charger Mode

    GENERATOR 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 TIMER (18) menu heading), or upon a low battery condition (LBX mode).

  • Page 78: Transfer Time

    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. 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E.

  • Page 79: Generator Support Mode

    At this voltage the inverter will disconnect to protect the AC loads. When the voltage returns to the operating window, the inverter will require a minimum of 20 seconds to re-synchronize and connect the generator to the loads. 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223...
  • Page 80 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). 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E.

  • Page 81: Automatic Generator Control Mode

    At this voltage the inverter will disconnect to protect the AC loads. When the voltage returns to the operating window, the inverter will require a minimum of 20 seconds to re-synchronize and connect the generator to the loads. 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223...

  • Page 82: Generator Starting Scenarios

    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.
  • Page 83 Control Panel instead of from the generator’s off switch. This allows the inverter to first disconnect the generator before it is turned off, reducing problems with voltage sags during the transition. 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E.

  • Page 84: Figure 23, Two Wire Start Wiring Diagram

    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. 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E.

  • Page 85: Figure 24, Three Wire Start Wiring Diagram (Honda Type)

    (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 Figure 25, Three-Wire Start Wiring Diagram (ONAN Type) 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223 HONDA TYPE GENERATOR...

  • Page 86: Figure 26, Relay Ry7 And Ry8 Sequence

    Most diesel generators are controlled like the Onan type, except that they also require that glow plugs be operated before the generator start is attempted. The SW Series Inverter/Charger automatic generator control system can also provide glow plug control. The addition of an external relay may be required to operate the glow plugs due to the amperage required by the glow-plugs and to separate the stop signal circuit.
  • Page 87 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. 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E.
  • Page 88 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 from the SET GENERATOR menu item, accessible by pressing the green GEN MENU button on the Control Panel.

  • Page 89: Utility Backup Mode

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

  • Page 90: Battery Requirements

    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. 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E.

  • Page 91: Utility Interactive Mode

    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” power since the utility pays for the power you produce. It is relatively simple to set the inverter up to accomplish this.
  • Page 92 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. 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E.

  • Page 93: Figure 27, Selling Power From A Dc Charging Source; Hypothetical Time Of Day Oper. History

    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.

  • Page 94: Figure 28, Selling Power Stored In The Batteries; Hypothetical Time Of Day Operational History

    AC amps from grid (+) LEGEND Display/Settings on Control Panel Information Figure 28, Selling Power Stored In The Batteries; Hypothetical Time Of Day Operational History 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E. Arlington, WA 98223 Battery charging 08:00...
  • Page 95 (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. 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E.

  • Page 96: Figure 29, Utility Interactive Line-Tie System With Battery Backup Flow Diagram

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

  • Page 97: Figure 30, Overvoltage Protection For 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.

  • Page 98: Energy Management Mode

    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. 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E.
  • Page 99 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223...

  • Page 100: Peak Load Shaving Mode

    The inverter can also be used to limit the maximum draw 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.

  • Page 101: Low Battery Transfer (Lbx) Mode

    “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. 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223...
  • Page 102 If time of day metering is available from your utility, you might consider the ENERGY MANAGEMENT MODE as it may offer a more economical way to operate the system. 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E.

  • Page 103: Using Multiple Inverters

    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.
  • Page 104 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.
  • Page 105 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. 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223...
  • Page 106 OPERATION Telephone: 360/435-8826 SW Series Inverter/Charger 2001 Xantrex Technology, Inc. Page Fax: 360/435-2229 Part No. 2031-5 5916 - 195th Street N. E. Arlington, WA 98223 www.traceengineering.com Rev. C: February 2001...

  • Page 107: Technical Information

    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.

  • Page 108: Sealed Lead Acid Batteries

    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. 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E.

  • Page 109: Battery Sizing

    3/8” Drill * 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. 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223...

  • Page 110: Battery Bank Sizing

    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. 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E.
  • Page 111 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. 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223...

  • Page 112: Battery Care And Maintenance

    Values shown are for 12-volt systems. For 24-volt systems, multiply the settings shown by two. For 48-volt systems, multiply the settings shown by four. These settings are guidelines, refer to your battery manufacturer for specific settings. 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E.

  • Page 113: Table 7, Battery State Of Charge Voltage

    Table 7, Battery State of Charge Voltage PERCENT OF FULL CHARGE 100% 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223 TECHNICAL INFORMATION 12 VOLT DC SYSTEM CELL VOLTAGE 12.7...

  • Page 114: Battery Installation

    DC disconnect. With the SW Series inverter, the batteries are best located to the right side. This is where the DC connections are located.

  • Page 115: Battery Hook-Up Configurations

    (Total Battery Capacity = 50 Amp Hours) Each individual 12-volt battery capacity = 50 amp hours Figure 32, Series Configuration: 12-Volt Battery Wiring 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223 TECHNICAL INFORMATION 24V INVERTER...

  • Page 116: Figure 33, Parallel Configuration: 12-Volt Battery Wiring

    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. 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E.

  • Page 117: Figure 34, Series-Parallel Configuration: 6-Volt Battery Wiring

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

  • Page 118: Battery Cable Inductance

    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. 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E.

  • Page 119: Applications

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

  • Page 120: Troubleshooting Guide

    Low AC power output or Low surge power INVERT LED is on (AC inductive loads are not running at full speed). 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E. Arlington, WA 98223 INDICATION DC voltage on the inverter’s DC Check the battery voltage, fuses or terminals is incorrect.
  • Page 121 Temperature probe is not installed LBX mode is enabled, but you do not want the unit to go into Float mode (Float LED is ON) 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223 TECHNICAL INFORMATION...
  • Page 122 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) 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E. Arlington, WA 98223 SOLUTION Disconnect all wires on the AC input and output.

  • Page 123: Inverter/Charger Terminology

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

  • Page 124: Figure 36, Ac Waveforms

    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. 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E.
  • Page 125 Voltage - The pressure of electrical flow. Equivalent to water pressure in a hose. Watts - Measure of power output or utilization. Watts = Volts x Amps. 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223...

  • Page 126: Specifications And Features (60 Hz Models)

    Dimensions - Shipping Mounting Weight - Inverter Only 90 lb (42 kg ) Weight - Shipping 96 lb (44 kg) 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E. Arlington, WA 98223 SW4024 SW4048 SW5548 SW4024K SW4048K SW4024W...

  • Page 127: Specifications And Features (50 Hz Models)

    Dimensions - Shipping Mounting Weight - Inverter Only 95 lb (43 kg ) Weight - Shipping 110 lb (50 kg) 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223 TECHNICAL INFORMATION 24 Vdc 48 Vdc 48 Vdc...

  • Page 128: Dimensions

    TECHNICAL INFORMATION DIMENSIONS Figure 37, SW Series Dimensions: With AC Access Covers – Showing Knockout Sizes 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E. Arlington, WA 98223 Telephone: 360/435-8826 SW Series Inverter/Charger Fax: 360/435-2229 www.traceengineering.com Part No. 2031-5...

  • Page 129: Installation Diagrams

    The following 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.

  • Page 130: Figure 39, Installation Diagram, 240 Vac, 3 Wire, Grid Connected, Generator Backup

    TECHNICAL INFORMATION Figure 39, Installation Diagram, 240 VAC, 3 Wire, Grid Connected, Generator Backup 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E. Arlington, WA 98223 Telephone: 360/435-8826 SW Series Inverter/Charger Fax: 360/435-2229 www.traceengineering.com Part No. 2031-5 Rev. C: February 2001...

  • Page 131: User Settings Worksheets

    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 same for all models. The SETUP DEFAULT settings are dependent on the specific model of the SW Series Inverter/Charger.
  • Page 132 17 Set Battery Sell volts DC Set Max Sell amps AC Grid Usage Timer 18 Set Start Charge time h:m End Stop Charge time h:m 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E. Arlington, WA 98223 SELECTION...
  • Page 133 17 Set Battery Sell volts DC Set Max Sell amps AC Grid Usage Timer 18 Set Charge time h:m End Charge time h:m 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223 TECHNICAL INFORMATION SELECTION RANGE FLT SELL SLT LBX 16.0 –...
  • Page 134 17 Set Battery Sell volts DC Set Max Sell amps AC Grid Usage Timer 18 Set Start Charge time h:m End Stop Charge time h:m 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E. Arlington, WA 98223 SELECTION...
  • Page 135 TECHNICAL INFORMATION Telephone: 360/435-8826 SW Series Inverter/Charger 2001 Xantrex Technology, Inc. Page Fax: 360/435-2229 Part No. 2031-5 5916 - 195th Street N. E. www.traceengineering.com Rev. C: February 2001 Arlington, WA 98223...

  • Page 136: Appendix

    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 input 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.

  • Page 137: Other Products

    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.

  • Page 138: Reference Tables And Graphs

    Table 10, AWG to Metric Wire Conversion Chart DIAMETER/MM 0 (1/0) 00 (2/0) 000 (3/0) 0000 (4/0) Note: Stranded wire sizes and ampacity for 75 C. 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E. Arlington, WA 98223 TIME IN MINUTES AMP-HOURS AREA/MM²...

  • Page 139: Figure 40, Awg Wire 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. 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223 .146...

  • Page 140: Table 13, Recommended Minimum Ac Wire Sizes (75 C)

    The ground wire should be sized per NEC 250-95. The following table is derived from this portion of the NEC code. Battery DC Disconnect Size 30 Amp or 60 Amp 100 Amp 200 Amp 300+ Amps 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E. Arlington, WA 98223 CABLE SIZE FUSE/BREAKER REQUIRED...

  • Page 141: Storage Checklist

    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.
  • Page 142 APPENDIX Telephone: 360/435-8826 SW Series Inverter/Charger 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E. Fax: 360/435-2229 Part No. 2031-5 www.traceengineering.com Rev. C: February 2001 Arlington, WA 98223...

  • Page 143: Warranty/Repair Information

    LIFE SUPPORT POLICY As a general policy, Xantrex Technology Inc., does not recommend the use of any of its 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.

  • Page 144: Warranty Or Repair Service Required

    Xantrex Technologies factory. Unauthorized service performed on any Trace™ product will void the existing warranty. You must notify Xantrex Technology Inc., before returning any equipment for repair. To obtain an RMA (Return Merchandise Authorization number, please contact our Warranty Coordinator at:...

  • Page 145: Index

    Battery To Inverter Cabling ...106 Cable Inductance...110 Cable Size vs. Cable Length... 22, 131 Connections ...24 Installation Procedure ...24 Maximum Breaker/Fuse Size...131 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223 Sizing ... 22 Battery Charging Absorption Time... 54 Absorption Time...
  • Page 146 Battery TempComp Volts DC, Menu ( 4) ... 40 Generator (AC2) Volts AC, Menu ( 4)... 41 Grid (AC1) Volts AC, Menu ( 4) ... 41 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E. Arlington, WA 98223 Input Amps AC, Menu ( 4) ...40...
  • Page 147 Menu (12) Gen Auto Start Setup ...50 Menu (14) Auxiliary Relays ...52 Menu (15) Bulk Charge Trigger Timer...53 Menu (16) Low Battery Transfer ...53 2001 Xantrex Technology, Inc. 5916 - 195th Street N. E. Arlington, WA 98223 Menu (17) Battery Selling... 54 Menu (18) Grid Usage Timer...
  • Page 148 Other Products... 129 C12 Charge Controller ... 129 C40 Multi-Function Controller... 129 Overcurrent Protection ... 129 SW Series Power Panel Systems ... 129 T240 Transformer ... 129 TM500 Trace Meter (Battery Status Monitor)... 129 Over-Current Device ... 24 Overcurrent LED ... 11 Overcurrent Protection ...
  • Page 149 Start Bulk Time, Menu (15)...53 Start Charge Time ... 86, 87, 90 Start Charge Time, Menu (18) ...54 Start Quiet Time, Menu ( 7) ...43 SW Series Power Panel Systems...129 SWCA ...128 Remote Monitoring ...128 Remote Setup ...128 Remote Troubleshooting ...128 SWCB (Conduit Box)...
  • Page 150 Setup Menu – 12 VDC ... 124 Setup Menu – 24 VDC ... 125 Setup Menu – 48 VDC ... 126 User Menu ... 123 2001 Xantrex Technology, Inc. Page 5916 - 195th Street N. E. Arlington, WA 98223 Telephone: 360/435-8826...
  • Page 152 5916 - 195th Street N.E., Arlington, WA 98223 Phone: (360) 435-8826 Fax: (360) 435-2229 visit our website at: www.traceengineering.com...

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