Trace Engineering SW II - REV 4.01 Owner's Manual
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Trace Engineering SW II - REV 4.01 Owner's Manual

Trace Engineering SW II - REV 4.01 Owner's Manual

Inverter/chargers with revision 4.01 software
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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
Fax: 360/435-2229
Part No. 2031-5
5916 - 195th Street N. E.
www.traceengineering.com
Rev. B: Sept 1, 1999
Arlington, WA 98223

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Summary of Contents for Trace Engineering SW II - REV 4.01

  • Page 1 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 Fax: 360/435-2229 Part No. 2031-5 5916 - 195th Street N. E. www.traceengineering.com Rev. B: Sept 1, 1999 Arlington, WA 98223...
  • Page 2 Copyright  Trace Engineering Company, 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. B: Sept 1, 1999 Arlington, WA 98223...
  • Page 3 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: Owner’s Manual; Battery Temperature Sensor (BTS); Red and black battery terminal covers with attaching hardware; Hardware package (AC access panels with screws, crimp-on terminals);...
  • Page 4 Copyright  Trace Engineering Company, 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. B: Sept 1, 1999 Arlington, WA 98223...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS IMPORTANT SAFETY INSTRUCTIONS ..................... 1 GENERAL PRECAUTIONS ............................1 SPECIAL NOTICES..............................2 PERSONAL PRECAUTIONS..........................3 INTRODUCTION ............................5 UNIT IDENTIFICATION..........................7 MODEL NUMBER..............................7 CONTROLS, INDICATORS AND COMPONENTS..................9 CONTROL PANEL..............................9 AC SIDE ................................12 DC SIDE ................................14 INSTALLATION............................15 QUICK INSTALL ..............................16 COMPLETE INSTALL............................17 FUNCTIONAL TEST ..........................
  • Page 6 TABLE OF CONTENTS APPENDIX ..............................128 OPTIONS ................................128 OTHER PRODUCTS ............................129 REFERENCE TABLES AND GRAPHS ......................130 STORAGE CHECKLIST ............................. 133 WARRANTY/REPAIR INFORMATION ....................135 LIMITED WARRANTY............................135 WARRANTY REGISTRATION ........................... 135 LIFE SUPPORT POLICY............................ 135 WARRANTY OR REPAIR SERVICE REQUIRED....................136 INDEX ...............................
  • Page 7 TABLE OF CONTENTS INDEX OF FIGURES Figure 1, Identification Label ........................7 Figure 2, SW Series Inverter/Charger ....................9 Figure 3, Control Panel........................... 9 Figure 4, AC Side ..........................12 Figure 5, Internal Components and Indicators ..................13 Figure 6, Aux and Gen Control Relays ....................14 Figure 7, DC Side ..........................
  • Page 8 TABLE OF CONTENTS INDEX OF TABLES Table 1, AC Input and Output Wiring Connections ................19 Table 2, Minimum Recommended Battery Cable Size vs. Cable Length..........22 Table 3, Battery Cable To Maximum Breaker/Fuse Size ..............23 Table 4, Charging Setpoints For Common Battery Types..............67 Table 5, Typical Wattage Of Common Appliances ................

  • Page 9: Important Safety Instructions

    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.

  • Page 10: Special Notices

    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. 5. Do not disassemble the inverter/charger. Take it to a qualified service center when service or repair is required.

  • Page 11: Personal Precautions

    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.
  • Page 12 IMPORTANT SAFETY INSTRUCTIONS Copyright  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 www.traceengineering.com Rev. B: Sept 1, 1999 Arlington, WA 98223...

  • Page 13: Introduction

    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 proper installation, the inverter will operate satisfactorily for many applications straight out of the box, using the factory default settings.
  • Page 14 INTRODUCTION Copyright  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 Arlington, WA 98223 www.traceengineering.com Rev. B: Sept 1, 1999...

  • Page 15: Unit Identification

    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 Copyright  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 Arlington, WA 98223 www.traceengineering.com Rev. B: Sept 1, 1999...

  • Page 17: Controls, Indicators And Components

    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 Control Panel...
  • Page 18 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 the TIME OF DAY settings) to the factory default values.
  • Page 19 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.

  • Page 20: Ac Side

    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.

  • Page 21: Figure 5, Internal Components And Indicators

    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.

  • Page 22: Dc Side

    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 Generator Control Auxiliary 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.

  • Page 23: Installation

    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

    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.

  • Page 25: Complete Install

    INSTALLATION COMPLETE INSTALL UNPACKING Before beginning, unpack the inverter/charger; record the serial number on the inside cover of this booklet and on the warranty card. Right now, please do the following: • Verify that you have everything listed on the Packaging Materials sheet.

  • Page 26: Figure 8, Air Flow Intake Location

    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.

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

    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.
  • Page 28 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.

  • Page 29: Figure 10, Warning Label

    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 & 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 system. This label should be installed at the electrical panel that is being powered by the inverter.

  • Page 30: Table 2, Minimum Recommended Battery Cable Size Vs. Cable Length

    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.

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

    INSTALLATION 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.

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

    INSTALLATION BATTERY CABLE CONNECTIONS Cables must have crimped (or preferably, 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 1-½...
  • Page 33 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.
  • Page 34 INSTALLATION SYSTEM GROUNDING GROUNDING INSTRUCTIONS - This inverter/charger should be connected to a grounded, permanent wiring system. For most installations, the negative battery conductor should be bonded to the grounding system at one (and only one point) in the system. The subject is more easily discussed if it is divided into three separate subjects;...

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

    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.

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

    INSTALLATION NEUTRAL-TO-GROUND SWITCHING RELAY NEUTRAL-TO-GROUND “BOND” is AC SOURCE (Provided in the AC installation): Connects the provided by an external AC source for neutral from external AC source, and neutral of the entire AC system the AC panel loads together when AC is applied to the inverter input.

  • Page 37: Figure 15, Multiple Point Ground System

    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 is the ultimate authority as to legitimate grounding techniques for your electrical system.
  • Page 38 INSTALLATION Copyright  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 Arlington, WA 98223 www.traceengineering.com Rev. B: Sept 1, 1999...

  • Page 39: Functional Test

    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.
  • Page 40 FUNCTIONAL TEST Copyright  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 Arlington, WA 98223 www.traceengineering.com Rev. B: Sept 1, 1999...

  • Page 41: Menu System

    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.

  • Page 42: User Menu Map

    MENU SYSTEM USER MENU MAP The values shown are the factory default values for Menu Heading Model SW2512. See the USER and SETUP menu item descriptions Menu Item Setpoint for default values for other models. Information Push buttons on Control Panel MENU HEADINGS Inverter Mode Generator Mode...

  • Page 43: Setup Menu Map

    MENU SYSTEM SETUP MENU MAP 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 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).

  • Page 44: User Menu

    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.
  • Page 45 MENU SYSTEM INVERTER MODE (1) MENU HEADING Set Inverter SRCH 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.
  • Page 46 MENU SYSTEM • ON - Starts the generator that is controlled by the inverter. If this position is selected, it will manually turn on the generator that is connected to the GEN CONTROL relays. The OFF position must be selected to manually turn the generator off. •...
  • Page 47 MENU SYSTEM Load Start Amps Ready If YES is displayed, it indicates that the automatic control system has started or is about to start the generator because the AC load current has reached the LOAD START AMPS setting. The automatic start is delayed by the time period set by the LOAD START DELAY MIN setting in the GEN AUTO START SETUP (12).
  • Page 48 MENU SYSTEM METERS (4) MENU HEADING The current meters provided measure only the real, in phase component of the current. 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.
  • Page 49 MENU SYSTEM Grid (AC1) Grid (AC1) Grid (AC1) Grid (AC1) volts AC volts AC volts AC volts Standard models “E” models “J & K” 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 inverter’s AC HOT 1 input and NEUTRAL IN 1 terminals.
  • Page 50 MENU SYSTEM High Battery voltage Battery voltage was above the HIGH BATTERY CUT OUT VDC setting. This can be caused by the solar array or other charging source not being regulated. Check the controller for proper operation. Some controllers have a “equalize” setting which over-rides the normal operation, allowing the battery voltage to be unregulated.
  • Page 51 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.

  • Page 52: Setup Menu

    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.
  • Page 53 MENU SYSTEM INVERTER SETUP (9) MENU HEADING Set Grid Usage SELL • FLT - Float will try to maintain the batteries at the float voltage level. This can be used when the source of power is a utility grid or a generator. 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.
  • Page 54 MENU SYSTEM Set Low Battery Set Low Battery Set Low Battery cut out VDC 11.0 cut out VDC 22.0 cut out VDC 44.0 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.
  • Page 55 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 models 48 VDC models Range: 10.0 to 16.0...
  • Page 56 MENU SYSTEM Set Max Charge Set Max Charge Set Max Charge Set Max Charge amps AC amps AC amps AC amps AC 12 VDC models 24 VDC & 48 VDC models “E & W” models “J & K” models Range: 01 to 25 Range: 01 to 35 Range: 01 to 18 Range: 02 to 40...
  • Page 57 MENU SYSTEM GEN AUTO START SETUP (12) MENU HEADING Set Load Start amps AC 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...
  • Page 58 MENU SYSTEM Set Exercise period days 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.
  • Page 59 MENU SYSTEM Set Pre Crank seconds 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.
  • Page 60 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.
  • Page 61 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.
  • Page 62 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...
  • Page 63 MENU SYSTEM In either mode, the SET START BULK TIME menu item setting under the BULK CHARGE TRIGGER TIMER (15) menu heading can be used to increase the battery charging regulation voltage to the BULK VOLTS DC setting. Note: By setting the beginning time equal to the ending time, the grid usage timer feature is defeated. INFORMATION DISPLAY The following information is displayed as additional Menu Items.
  • Page 64 MENU SYSTEM Copyright  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 Arlington, WA 98223 www.traceengineering.com Rev. B: Sept 1, 1999...

  • Page 65: Operation

    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.

  • 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. A normally open contactor is used to parallel the inverter’s output and the AC source.

  • Page 67: Power Vs. Efficiency

    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 full output voltage while delivering no current. This is the no load or idle power.

  • 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

    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. •...

  • Page 70: Inverter Mode

    OPERATION INVERTER MODE BATTERY INVERTER 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. Higher battery voltage decreases the number of steps.
  • Page 71 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.

  • Page 72: Charger Mode

    OPERATION CHARGER MODE AC SOURCE CHARGER 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.

  • Page 73: Figure 22, Bts (Battery Temperature Sensor)

    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.
  • Page 74 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 can be adjusted by the SET GEN (AC2) AMPS AC menu item.

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

    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.
  • Page 76 OPERATION The battery manufacturer or supplier should be consulted before equalizing to provide the recommended process and 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.

  • Page 77: Inverter/Charger Mode

    OPERATION INVERTER/CHARGER MODE UTILITY GRID INVERTER/ AC LOADS CHARGER 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 TIMER (18) menu heading), or upon a low battery condition (LBX mode).
  • Page 78 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.

  • Page 79: Generator Support Mode

    OPERATION GENERATOR SUPPORT MODE INVERTER/ GENERATOR AC LOADS CHARGER BATTERY IN BRIEF The factory default settings are intended to operate the inverter as an inverter/charger connected to a generator. When the generator is off, the inverter will power the AC loads from the battery. Once the generator is started, the AC loads will be transferred to the generator and the inverter will become a battery charger and store the unused power in the batteries for later use.
  • Page 80 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.

  • Page 81: Automatic Generator Control Mode

    OPERATION AUTOMATIC GENERATOR CONTROL MODE INVERTER/ GENERATOR AC LOADS CHARGER 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.
  • Page 82 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 conductors providing power from the battery.
  • Page 83 OPERATION 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.

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

    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.

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

    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 auto-control system and the generator. This also adds complexity to the installation since more wires must be connected and more programming of the inverter is required.

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

    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.
  • Page 87 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.
  • 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. During the next automatic generator run period, the inverter can be set to complete an equalization charge process.

  • Page 89: Utility Backup Mode

    OPERATION UTILITY BACKUP MODE UTILITY GRID GENERATOR MAIN ADDITIONAL INVERTER/ AC BREAKER AC BREAKER CHARGER PANEL SUB-PANEL NON-CRITICAL CRITICAL BATTERY AC LOADS AC LOADS IN BRIEF SW Series Inverter/Chargers provide an excellent utility system backup under the majority of powering applications.
  • Page 90 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.

  • Page 91: Utility Inter-Active Mode

    OPERATION UTILITY INTER-ACTIVE MODE MAIN AC LOADS UTILITY GRID SOLAR ARRAY NOT PROVIDED kWh METER WITH BACK-UP OUTDOOR AC INVERTER/ GROUND FAULT DISCONNECT CHARGER PROTECTION BACKED UP OVERVOLTAGE BATTERY AC LOADS PROTECTION SUB-PANEL IN BRIEF In this mode, SW Series Inverter/Chargers can be used to move power from the DC system into the AC utility grid.
  • Page 92 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 battery 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.

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

    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.

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

    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.
  • Page 95 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.

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

    OPERATION UTILITY INTER-ACTIVE 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

    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.

  • Page 98: Energy Management Mode

    OPERATION ENERGY MANAGEMENT MODE INVERTER/ UTILITY GRID AC LOADS CHARGER 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.
  • Page 99 OPERATION The system should be designed so that the battery is able to operate the loads for the entire peak rate period without reaching the low battery transfer voltage. This may require that heavy loads be operated only during the non-peak rate period. This mode may be advantageous when the utility offers time-of-day metering that allows you to buy power at a variable rate during different time periods.

  • Page 100: Peak Load Shaving Mode

    OPERATION PEAK LOAD SHAVING MODE INVERTER/ UTILITY GRID AC LOADS CHARGER BATTERY IN BRIEF 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

    OPERATION LOW BATTERY TRANSFER (LBX) MODE UTILITY GRID AC LOADS SOLAR ARRAY kWH METER SUB-PANEL AC LOADS INVERTER GROUND FAULT MAIN PANEL CHARGER PROTECTION OVERVOLTAGE BATTERY PROTECTION Low Battery Transfer mode is an alternative way of operating “off the grid” using the utility for backup power instead of a generator.
  • Page 102 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 HIGH 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.

  • Page 103: Using Multiple Inverters

    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.
  • Page 104 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.
  • Page 105 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.
  • Page 106 OPERATION Copyright  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 Arlington, WA 98223 www.traceengineering.com Rev. B: Sept 1, 1999...

  • Page 107: Technical Information

    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.
  • Page 108 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.

  • Page 109: Battery Sizing

    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.

  • Page 110: Battery Bank Sizing

    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 your needs. Read through the example and then complete the worksheet on the following page. STEP 1-4: Determine your Average Daily Watt-Hours Needed.
  • Page 111 TECHNICAL INFORMATION WORKSHEET Complete the steps that follow to calculate your inverter’s battery bank capacity. 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 (÷...

  • Page 112: Battery Care And Maintenance

    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.

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

    TECHNICAL INFORMATION MONTHLY MAINTENANCE At the minimum, check the level of the electrolyte in each battery cell once a month. It 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.

  • Page 114: Battery Installation

    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.

  • Page 115: Battery Hook-Up Configurations

    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”...

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

    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.

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

    TECHNICAL INFORMATION FUSED FUSED DISCONNECT DISCONNECT 12V INVERTER 24V INVERTER (Total Battery Capacity (Total Battery Capacity = 200 Amp Hours) = 200 Amp Hours) FUSED DISCONNECT 48V INVERTER (Total Battery Capacity = 200 Amp Hours) Each individual 6-volt battery capacity = 100 amp hours NOTE: If “cross-tying”...

  • Page 118: Battery Cable Inductance

    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 induces a voltage in the original conductor.

  • Page 119: Applications

    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.

  • Page 120: Troubleshooting Guide

    TECHNICAL INFORMATION Page 1 TROUBLESHOOTING GUIDE INVERTER - If ERROR LED comes on, see ERROR CAUSES section PROBLEM INDICATION SOLUTION Unit will not come on DC voltage on the inverter’s DC Check the battery voltage, fuses or (no LED’s are on) and the terminals is incorrect.
  • Page 121 TECHNICAL INFORMATION TROUBLESHOOTING GUIDE Page 2 BATTERY CHARGER - If ERROR LED comes on, see ERROR CAUSES section. PROBLEM INDICATION SOLUTION AC IN GOOD LED is flashing, but will AC frequency at the AC input terminal If AC source is a generator, adjust AC is out-of- tolerance (too high or low) or voltage or frequency accordingly.
  • Page 122 TECHNICAL INFORMATION TROUBLESHOOTING GUIDE Page 3 ERROR CAUSES - ERROR LED is On or Flashing (look under the ERROR CAUSES display) INDICATION SOLUTION OVER CURRENT Disconnect all wires on the AC input and output. Excessive load on the AC output Reset the inverter by pressing the On/Off switch to OFF, then to SRCH or ON.

  • Page 123: Inverter/Charger Terminology

    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.

  • Page 124: Figure 36, Ac Waveforms

    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.
  • Page 125 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.

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

    TECHNICAL INFORMATION SPECIFICATIONS AND FEATURES (60 Hz Models) Note: All specifications are subject to change without notice. MODEL SW2512 SW4024 SW4048 SW5548 SW4024K SW4048K SW4024W General Specifications Nominal DC Input Voltage 12 vdc 24 vdc 48 vdc 48 vdc 24 vdc 48 vdc 24 vdc AC Output Voltage (RMS)

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

    TECHNICAL INFORMATION SPECIFICATIONS AND FEATURES (50 Hz Models) Note: All specifications are subject to change without notice. MODEL SW2612E SW3024E SW3048E SW4548E SW3024J SW4048J SW4548A General Specifications Nominal DC Input Voltage 12 vdc 24 vdc 48 vdc 48 vdc 24 vdc 48 vdc 48 vdc AC Output Voltage (RMS)

  • Page 128: Dimensions

    TECHNICAL INFORMATION DIMENSIONS Figure 37, SW Series Dimensions: With AC Access Covers – Showing Knockout Sizes Copyright  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 Arlington, WA 98223 www.traceengineering.com Rev.

  • Page 129: Installation Diagrams

    TECHNICAL INFORMATION 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 Copyright  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 www.traceengineering.com Rev. B: Sept 1, 1999 Arlington, WA 98223...

  • Page 131: User Settings Worksheets

    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 same for all models. The SETUP DEFAULT settings are dependent on the specific model of the SW Series Inverter/Charger.
  • Page 132 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 –...
  • Page 133 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 –...
  • Page 134 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 –...
  • Page 135 TECHNICAL INFORMATION Copyright  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 www.traceengineering.com Rev. B: Sept 1, 1999 Arlington, WA 98223...

  • Page 136: Appendix

    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 input terminals.

  • Page 137: Other Products

    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.

  • Page 138: Reference Tables And Graphs

    APPENDIX REFERENCE TABLES AND GRAPHS Table 9, Power Consumption Of Common Appliances TIME IN MINUTES APPLIANCE WATTS Single PL Light B & W TV Computer Color TV Blender Skil Saw Toaster 1000 Microwave 1200 Hot Plate 1800 AMP-HOURS If the current draw at 120 VAC is known, then the battery amperage at 12VDC will be 10 times the AC amperage divided by the efficiency (90% in this table).

  • Page 139: Figure 40, Awg Wire Size

    APPENDIX SIZE DIAMETER .073 .072 .115 .146 .184 .235 .281 .295 .335 .380 SIZE 250 MCM 300 MCM 350 MCM 400 MCM 500 MCM DIAMETER .420 .475 .530 .580 .635 .690 .730 .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.

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

    APPENDIX Table 13, Recommended Minimum AC Wire Sizes (75 ° C) FULL CABLE SIZE CABLE SIZE INVERTER FUSE/BREAKER PASS-THRU REQUIRED REQUIRED MODEL REQUIRED CAPABILITY IN CONDUIT IN “FREE AIR”* 105-120 VAC 60 amps 60 amps # 6 AWG (THHN) # 8 AWG (THHN) UNITS 220-240 VAC 30 amps...

  • Page 141: Storage Checklist

    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 •...
  • Page 142 APPENDIX Copyright  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 www.traceengineering.com Rev. B: Sept 1, 1999 Arlington, WA 98223...

  • Page 143: Warranty/Repair Information

    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.

  • Page 144: Warranty Or Repair Service Required

    WARRANTY/REPAIR INFORMATION WARRANTY OR REPAIR 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).

  • Page 145: Index

    INDEX INDEX Battery Charging Absorption Time............62 Absorption Time..........72, 75, 98 Absorption Time ..............113 AC Input Requirements..........74 AC Inputs, Menu (11) ............52 Bulk Charging ..48, 60, 63, 72, 75, 78, 92, 94, 98, 103 AC Pass Through Ability............19 Bulk Voltage..............
  • Page 146 INDEX Control Wiring ..............26 Inverter Volts AC, Menu ( 4) ..........41 Aux Relay Wiring............26 Inverter/Charger Amps AC, Menu ( 4)......41 Fusing ............26, 27, 83, 101 Load Amps AC, Menu ( 4) ..........41 Gen Control Relays ............26 Read Frequency Hertz, Menu ( 4)........42 Remote Control Wiring..........
  • Page 147 INDEX Equalization Charging....39, 52, 76, 77, 89, 90, 110 Menu (17) Battery Selling..........62 Exercise Period .............56 Menu (18) Grid Usage Timer......... 63 Frequency ...............39, 44 Menu (19) Information File Battery ........ 63 Gen Control Wiring ............26 Information File Battery, Menu (19) ........63 Maximum Run Time ............56 Input Amps AC, Menu ( 4)..........
  • Page 148 INDEX Menu ( 1) Inverter Mode ............ 38 Menu ( 2) Generator Mode ..........38 Menu ( 3) Trace Engineering..........40 Parallel Stacked Operation ..........108 Menu ( 4) Meters............... 41 Generator Control Settings ..........109 Menu ( 5) Error Causes............. 42 Peak Load Shaving Mode..........69 Menu ( 6) Time of Day ............
  • Page 149 INDEX Set Generator, Menu ( 2)...........38 Output Waveform............66 Set Grid (AC1) Amps AC, Menu (11).........53 Three Wire Start Generators..........87 Set Grid Usage, Menu ( 9)..........48 Time of Day Metering........102, 104, 106 Set High Battery Cut Out VDC, Menu ( 9)......50 Time of Day, Menu ( 6) .............
  • Page 150 INDEX Worksheet Battery Sizing.............. 117 User Settings .............. 138 Setup Menu – 12 VDC ..........139 Setup Menu – 24 VDC ..........140 Setup Menu – 48 VDC ..........141 User Menu .............. 138 Copyright  Trace Engineering Company, Inc. Telephone: 360/435-8826 SW Series Inverter/Charger Page...
  • 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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