Related Manuals for Trace Engineering DR Series
Summary of Contents for Trace Engineering DR Series
- Page 1 Owner’s Manual V 3.2 DR SERIES INVERTER/CHARGERS Trace Engineering Company, Inc. 5916 195th Street N.E. Arlington, WA 98223 Tel (360) 435-8826 Fax (360) 435-2229 Effective 9/7/98 PN: 830-5 Rev 3.2...
- Page 3 Serial Number: _____________________________________ Purchase Date: _____________________________________ Comments: _____________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Thank you for choosing Trace Engineering to meet your independent power needs. Check out our web site at www.traceengineering.com for more information and answers to your FAQ’s.
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Page 5: Table Of Contents
Table of Contents IMPORTANT SAFETY INSTRUCTIONS .............. Theory of Inverter Operation ................Inverter Operation ....................Front Panel Controls and LED Indicators ................4 Power On/Off ..........................4 Inverter Mode LED........................4 Search Mode Watts ........................5 Over Discharge Protection and AC Transfer Voltage ............. 6 AC Transfer Voltage ........................ - Page 6 Tables TABLE 1, AC TRANSFER VOLTAGE ..................... 7 TABLE 2, BULK, FLOAT, AND EQUALIZE VOLTAGES FOR DR SERIES INVERTERS .... 12 TABLE 3, PEAK VOLTAGE VS. CHARGE RATE AMPS .............. 14 TABLE 4, MAXIMUM CHARGE RATE WITH SOME TYPICAL GENERATOR MODELS .... 14 TABLE 5, MINIMUM RECOMMENDED WIRE SIZES..............
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Page 7: Important Safety Instructions
This manual covers all DR series inverter/charger models. The entire DR Series of inverters is ETL listed to the UL standard 1741 (Draft), Power conditioning units for use in residential photovoltaic power systems. The DR series is also ETL listed to Canadian standard CSA - C 22.2 No. -
Page 8: Personal Precautions
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 2 Tools required to make AC wiring connections: Wire strippers, ½” (13MM) open-end wrench or socket, Phillips screw driver #2, Slotted screw driver ¼” (6MM) blade. 10. This inverter/charger is intended to be used with a battery supply of nominal voltage that matches the last two digits of the model number, e.g. -
Page 9: Theory Of Inverter Operation
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 3 Theory of Inverter Operation Waveform The output waveform of the inverter is referred to as a modified sine wave. This waveform is suitable for a wide variety of applications. Induction motors (i.e. refrigerators, drill presses), resistive loads (i.e. -
Page 10: Inverter Operation
Inverter Operation Front Panel Controls and LED Indicators Shown below are the controls and indicator lights on the front of the DR series inverter/charger. These control and provide information when in either inverter or battery charging mode of operation. All models of the DR series operate identically. -
Page 11: Search Mode Watts
The SEARCH MODE WATTS control is used for adjusting the sensitivity of the search mode circuit. The DR Series inverters feature a circuit that minimizes power drain by reducing the inverter’s output to small test pulses when there is no load connected to the inverter. These pulses are used to detect the presence of a load. -
Page 12: Over Discharge Protection And Ac Transfer Voltage
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 6 Over Discharge Protection and AC Transfer Voltage This control enables or disables the over discharge protection system (ODP) and allows adjustment of the AC transfer voltage. With the dial set to either the left or right side of the scale, transfer voltage can be adjusted from minimum to maximum. -
Page 13: Ac Transfer Voltage
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 7 AC Transfer Voltage When the AC source (either public power or a generator) fails or falls to a low level (browns out), the unit changes from battery charger mode to inverter mode. The AC voltage point at which the inverter decides to change modes is called the AC transfer voltage. -
Page 14: Protection Circuitry
Note: In alternative energy applications (solar, wind, hydro) all DC charge controllers must be set to a level below the inverter’s MAXIMUM INPUT VOLTAGE or the inverter may shut off unexpectedly. The maximum input voltage for DR series inverters is, 15.5 volts DC for 12 volt inverters, and 31.0 volts DC for 24 volt models. -
Page 15: Battery Charger
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 9 Battery Charger Theory of Operation Inverter to Charger Transition The internal battery charger and automatic transfer relay allows the unit to operate as either a battery charger or inverter (but not both at the same time). -
Page 16: Three Stage Battery Charging
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 10 Three Stage Battery Charging The battery charger in the Trace DR series inverters, charges in three stages - BULK, ABSORPTION, and FLOAT - to provide rapid and complete charge cycles without undue battery gassing. A manually operated equalize stage is provided for periodic battery maintenance. -
Page 17: Battery Charger Controls And Led Indicator
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 11 Battery Charger Controls and LED Indicator A three state LED reports on the activity of the battery charger. Controls are provided that make it simple to tailor the charger’s characteristics for various types of batteries. -
Page 18: Battery Type Selector
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 12 Battery Type Selector This control automatically sets the correct bulk and charge voltages according to the type of battery selected. The switch has ten positions. Each position provides different charge parameters. Select the correct position according to the following table. -
Page 19: Battery Charger Settings
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 13 Battery Charger Settings BATTERY TYPE AND BULK FLOAT DR BATTERY MANUFACTURER VOLTAGE VOLTAGE SELECTOR POSITION GEL CELL BATTERIES East Penn/Sonnenschein/Prevailer 14.1 13.8 5 GEL Series Interstate SG type 14.4... -
Page 20: Generator Requirements
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 14 Generator Requirements The maximum charge rate of the battery charger is dependent upon the peak AC voltage available. Since the battery charger uses only the top portion of the input sine wave, small variations in peak voltage result in large variations in the amount of energy to the charger*. -
Page 21: Batteries
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 15 Batteries Batteries come in different sizes, types, amp hours, voltages and chemistries. There are nearly as many descriptions of exactly how batteries should be charged as there are people willing to offer explanations. - Page 22 This makes the job for the inverter/charger much more difficult. One way to use NiCad/NiFe batteries with a 24 volt DR series inverter is to use nineteen NiCad/NiFe cells in the battery bank instead of the usual twenty. This will reduce the battery bank charging voltage requirements to about the same level as a lead-acid bank, so more standard charger settings can be used.
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Page 23: Battery Sizing
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 17 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. -
Page 24: Battery Care And Maintenance
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 18 Battery Care and Maintenance If you have read the battery charger 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 25: Battery Hook-Up Configurations
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 19 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 parallel, series, or series - parallel. -
Page 26: Battery Installation
With the DR series inverter, the batteries are best located to the left end. This is where the DC connections are located. Do not locate the inverter in the same compartment with non-sealed batteries (sealed batteries are all right). - Page 27 Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 21 Battery Cabling The cables which connect the individual batteries together to make a larger battery bank should be connected together with heavy cables. The actual size of the cable depends upon whether the batteries are connected in parallel or series.
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Page 28: Installation
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 22 Installation Environment Inverters are sophisticated electronic devices and should be treated accordingly. When selecting the operating environment for the inverter, don’t think of it in the same terms as other equipment that works with it, e.g. -
Page 29: Bonding The Grounding System To The Neutral And Negative Conductors
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 23 Grounding Electrodes / Ground Rods The purpose of the grounding electrode (often called a ground rod) is to “bleed” off any electrical charge that may accumulate in the electrical system and to provide a path for “induced electromagnetic energy”... -
Page 30: Ac Wiring
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 24 AC Wiring Overview The National Electrical Code (NEC) defines the standards for AC and DC installation wiring in residential, commercial, and RV applications, but there are still many installation variables. Most are determined by the level of automatic switching desired and the amount of external AC power to be switched. -
Page 31: Minimum Recommended Wire Sizes
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 25 Minimum Recommended Wire Sizes MODEL AC INPUT AC OUTPUT 120 VAC 220-240 VAC 120 VAC 220-240 VAC DR1512 10 gauge 14 gauge 12 gauge 16 gauge... -
Page 32: Dc Wiring
175 amp (Trace #DC175) or 250 amp (Trace #DC250) size with single or dual pole breakers. See the options section at the end of this manual or the latest Trace Engineering price list for more information. -
Page 33: Battery Cable Connection
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 27 Trace offers a class “T” DC rated fuse block designed specifically for DR series inverter/chargers. These are available in 110, 200, 300, and 400 Amp sizes. See the Trace price list or contact your Trace Engineering dealer for more information. -
Page 34: System Safety Wiring Requirements
To Battery Negative (-) Note: The above UL required safety parts are not supplied by Trace Engineering. High quality Trace Engineering DC disconnects, covered class T fuses, and battery cables are available from your Trace dealer. Other items may be obtained by calling or faxing:... -
Page 35: Stacking Inverters
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 29 Stacking Inverters Note: Stacking allows twice the power output for operating 240VAC loads. “E” and “W” models of the DR series can not be stacked. Precautions Only stack like models of the DR inverter. -
Page 36: Operation
NOTE: The DR series inverters, unlike the “U series”, are series stacking, meaning the outputs are connected in series thus doubling the voltage to 240 VAC. The DR inverters cannot be paralleled to double power at 120VAC. -
Page 37: Rc4 Remote Control
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 31 RC4 Remote Control The optional RC4 remote control unit duplicates the power On/Off Switch on The DR series inverter/charger, and gives several LED indications. The on/off switch is a momentary switch. Pressing it alternately turns the unit on and off. -
Page 38: Installation Diagrams
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 32 Installation Diagrams Installation with Single AC Panel In all installations it is important to ensure that AC power from any source (generator, public power) is never fed to the inverter’s AC output. It is essential that the inverter’s AC output is not fed to its AC input. -
Page 39: Installation With Ac Sub Panel
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 33 Installation with AC Sub Panel This is the recommended configuration for installing an inverter with the built-in battery charger. It operates in the following manner: When there is power available at the main panel, the inverter’s automatic transfer relay closes, connecting the main panel to the sub-panel. -
Page 40: Installation With External Relay
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 34 C. Installation with External Relay This configuration may be desirable when the pass through current is greater than 30 amps. Safety Ground - See Table 11... -
Page 41: Troubleshooting Guide
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 35 Troubleshooting Guide BATTERY HI - RED (LED) is on Battery voltage is above the high battery Check for the correct battery voltage at and a buzzer is heard voltage input tolerance. - Page 42 Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 36 CHARGER LED: - indicates charging, but no charge is Circuit breaker on side of inverter is Engage ’AC INPUT’ circuit breaker on side of unit occurring to the batteries...
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Page 43: Applications
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 37 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 step with one another. Resistive loads usually generate heat in order to accomplish their tasks. -
Page 44: Problem Loads
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 38 If a 220/240 vac motor is required, you must either use two 120 vac inverters in a stacked configuration or include a step-up transformer in the system. When used with a well pump, connect the step-up transformer after the pressure switch in order to reduce the load the transformer itself puts on the inverter. - Page 45 Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 39 Laser Printers- While many laser products are presently operating from TRACE ENGINEERING inverters, and we have personally run a Texas Instruments Microlaser and HP IIP , we have had...
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Page 46: Technical Information
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 40 Technical Information DR Series Specifications MODEL DR1512 DR2412 DR1524 DR2424 DR3624 Continuous Power @ 20°C 1500 VA 2400 VA 1500 VA 2400 VA 3600 VA Efficiency... -
Page 47: Performance Graphs
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 41 Performance Graphs Load Capacity vs. Time Loads presented to the inverter are seldom constant. Typically, large loads are operated for only short periods of time. In order to provide the maximum utility, Trace inverters are allowed to operate at power levels that exceed their continuous power ratings. -
Page 48: Figure 10, Power Output Vs. Efficiency
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 42 Power vs. Efficiency There are two primary types of losses that combine to create the efficiency curve. The first is the energy that is required to operate the inverter at full output voltage while delivering no current. This is the idle power. -
Page 49: Figure 11, Maximum Regulated Power Output Vs. Battery Voltage
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 43 Max Regulated Power vs. Battery Voltage As the battery voltage is reduced, the maximum regulated power the inverter can produce decreases. The inverter regulates RMS voltage by changing the width of its output waveform. The graph below defines the points at which the combination of power and battery voltage results in square wave output. -
Page 50: Typical Battery Draw Of Common Appliances
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 44 Typical Battery Draw of Common Appliances Table 8, Typical Battery Draw of Common Appliances (For 12 Volt Inverters) TIME IN MINUTES APPLIANCE WATTS Single PL Light B &... -
Page 51: Table 9, Typical Battery Draw Of Common Appliances (24V)
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 45 Table 9, Typical Battery Draw of Common Appliances (For 24 Volt Inverters) TIME IN MINUTES APPLIANCE WATTS Single PL Light B & W TV Computer Color TV... -
Page 52: Table 10, English To Metric Wire Conversion Table
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 46 Table 10, English to Metric Wire Conversion Table DIAMETER/ AREA/mm² Resistance / 1000ft 1.628 2.082 3.14 2.052 3.308 1.98 2.588 5.261 1.24 3.264 8.367 0.778 4.115 13.299... -
Page 53: Figure 12, Dimensioned Dr Series Installation Drawing
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 47 Figure 12, Dimensioned DR Series Installation Drawing... -
Page 54: Other Products Available From Trace Engineering
Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 48 Other Products available from Trace Engineering DC250/DC175 DC Disconnect/Overcurrent Module 250 amp or 175 amp DC-rated circuit breaker with enclosure. Can accept up to 4/0 AWG wire and is certified as a “means of disconnect”... -
Page 55: Limited Warranty
RIGHTS. YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE. Life Support Policy As a general policy, Trace Engineering, 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 56 Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 50 Warranty Procedure Complete the warranty card and mail it to Trace Engineering within 10 days from the date of purchase. KEEP YOUR BILL OF SALE as proof of purchase, should any difficulties arise concerning the registration of the warranty card.
- Page 57 Trace Engineering DR Series Owner’s Manual - Version 3.2 - 9/7/98 - Page 51 Index AC and DC installation wiring, 24 lead acid batteries, 1, 2, 9, 11, 12, 16, 18, 20 AC terminal block, 35, 36 Life Support Policy, 6, 49...