Trace Engineering ST1000 Setup guide

Installation and Operator’s Manual
2000 Trace Engineering
Sun Tie Inverter
ST1000,ST1500,ST2000andST2500
P/N 975-0003-01-01 Rev. B 06/00

I
©2000 Trace Engineering
Sun Tie Inverter
ST1000, ST1500, ST2000 and ST2500
Table of Contents
Section Description Page
1.0 INTRODUCTION................................................................................1
Standard Features......................................................................1
2.0 INSTALLATION .................................................................................2
Pre-Installation ...........................................................................2
Tools Required .....................................................................2
Hardware/Materials Required...............................................2
AC Connections ...................................................................2
DC Connections ...................................................................3
Grounding ............................................................................3
AC Grounding ................................................................3
DC Grounding ................................................................3
PV Arrays .............................................................................3
AC Circuit Breakers..............................................................4
Wire Routing ........................................................................4
Mounting .................................................................................5
Wiring .................................................................................9
DC Wiring .............................................................................9
PV Array ...............................................................................9
AC Wiring ...........................................................................11
Lightning Protection...........................................................14
3.0 OPERATION ...............................................................................15
Startup Procedure ....................................................................15
Required Equipment...........................................................15
AC Utility Voltage Check.....................................................15
Solar Array DC Voltage Check ............................................16
Operational Test .................................................................17
4.0 TROUBLESHOOTING .....................................................................21
5.0 SPECIFICATIONS ...........................................................................22
6.0 SERVICE INFORMATION ................................................................23
7.0 WARRANTY ...............................................................................24

©2000 Trace Engineering
II
Disclaimer of Liability
Since the use of this manual and the conditions or methods of installation, operation, use and
maintenance of the unit are beyond the control of Trace Engineering, Trace Engineering does not
assume responsibility and expressly disclaims liability for loss, damage, or expense arising out of or
any way connected with such installation, operation, use, or maintenance.

©2000 Trace Engineering III
SAVE THESE INSTRUCTIONS
IMPORTANT SAFETY INSTRUCTIONS
This manual contains important safety instructions that should be followed during the installation
and maintenance of this product.
To reduce the risk of electrical shock, and to ensure the safe installation and operation of this
product,the following safety symbols have been placed throughout this manual to indicate
dangerous conditions and important safety instructions.
WARNING - A dangerous voltage or condition exists in this area.
Use extreme caution when performing these tasks.
AVERTISSEMENT - Une tension ou condition dangereuse existe dans cette one.
Faire preuve dextrême prudence lors de la réalisation de ces tâches.
CAUTION - This procedure is critical to the safe installation or operation of the unit. Follow these
instructions closely.
ATTENTION - Cette procédure est essentielle à linstallation ou lutilisation
de lunité en toute sécurité. Suivre ces instructions de près.
NOTE - This statement is important. Follow instructions closely.
NOTE - Cette déclaration est importante. Suivre les instructions de près.
 All electrical work must be done in accordance with local and national electrical codes.
 Before installing or using this device, read all instructions and cautionary markings located in
(or on) the manual, the inverter and the PV array.
 Do not expose this unit to rain, snow or liquids of any type without the rain/weather shield
hood installed (optional on some models).
 To reduce the chance of short-circuits when installing or working with the inverter or the PV
array, use insulated tools.
 Remove all jewelry such as rings, bracelets, necklaces, etc., while installing this system. This
will greatly reduce the chance of accidental exposure to live circuits.
 The ST unit contains more than one live circuit (PV array and AC line). Power may be present
at more than one source even when the circuit breakers are off.
 This product contains no user serviceable parts. Return the unit to a Trace Authori ed Service
Center for maintenance.
 Wiring to the utility should only be done after receiving prior approval from the utility company
and performed only by qualified personnel.
 Completely cover the surface of all PV arrays with an opaque (dark) material BEFORE wiring
them. PV arrays produce electrical energy when exposed to light, and could create a
ha ardous condition.

©2000 Trace Engineering
IV
NOTE: This is a one line drawing intended as a system overview only. System grounding and other
electrical details are not incluced.
DC Input Voltage AC Output
Voltage
Main Utility
Service Panel
AC Utility
Meter
Solar Power
AC to Grid
Solar PV Array
975-F00-008S
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON OFF
ON
OFF
ON OFF
ON
OFF
ON
OFF
ON
OFF
Sun Tie
Trace Engineering
Sun Tie Unit

1
1.0 INTRODUCTION
©2000 Trace Engineering
The Trace Engineering Sun Tie (ST) solar power conversion center is designed to convert a
home or business into a green power generating station. The ST unit converts solar electric (PV)
power into utility grade electricity which can be used by the home or sold to the power company.
Installing an ST unit is as simple as mounting it to the wall and connecting a DC source (PV array)
and the AC output to the utility.
Standard Features
All-in-one Design
All necessary DC input and AC output connections disconnects and circuit breakers are housed
within the STs easily installed compact enclosure. A built-in LCD panel provides easy-to-read
system status and daily cumulative energy production information.
Uses Most Types of PV Technology
The ST is designed to take advantage of all types of solar electric technologies. The inverter
allows up to 120 VDC open circuit PV modules to be used so both conventional crystalline and
newer thin film PV modules can be used.
Maximum Po er Point Tracking
The inverter performs a power sweep every minute adjusting array voltage and current
maximizing PV power generation. Maximum Power Point Tracking (MPPT) ensures the system
produces as much AC power as possible under any light condition. MPPT operates between 52-85
volts DC for full rated output power.
High Efficiency and Long Life
The high frequency solid-state design of the ST inverter is extremely efficient. When array
output is over 500 watts the inversion process is over 90% efficient (peak efficiencies of 94% can
be reached). The ST inverter has a design life of over twenty years (the life of a PV array).
Expandable
ST inverters may be connected in a parallel configuration for increasing net metering
capacity. The modular expendability of the ST Series allows for system growth.
UL Listed
The ST has complete on-board islanding protection and meets safety operating standards
and code requirements world wide. In the North Americia it is UL listed (UL 1741-1999) and cUL
listed to CSA C22.2 No. 107.1-95. NEC 690 building code requirements for PV may be met with the
optional ground fault protection (GFP).
Options
These features are included on some models:
 PV array combiner board with six PV 20 amp max. protected inputs
 PV array Ground Fault Protection PV-GFP
 SOV type surge/lightning arrestor for AC/DC surge protection

2
2.0 INSTALLATION
©2000 Trace Engineering
Pre-Installation
Before installing the Trace ST unit, read all instructions and cautionary markings located in
this manual, on the PV array and on the main service panel.
NOTE The Trace ST weighs approximately 35 pounds (depending upon configuration and model).
Always use proper lifting techniques during installation to prevent personal injury.
Mounting:
The Trace ST unit can be mounted outdoors with the optional rainshield (STRS).
Tools required:
Phillips screw drivers Level
Slotted screw drivers Wire strippers
open-end wrenches Torque wrench
Socket wrench and fittings Electrical tape
Multimeter (true rms) Pencil
Frequency counter (optional) Utility knife
Hardware/Materials required:
Wood screws and washers (supplied)
Conduit and appropriate fittings
Anchors for screws (material dependent)
AC Connections:
The inverters AC output breakers accept wire sizes from #1-14 AWG. Refer to the table
below for minimum recommended wire size.
Inverter
Model
AC Amps
Output per
leg
NEC Amps
per Leg
(Amps *125%)
Minimum Wire Size for Specified Distance
0–50 Ft
One Way 50–100 Ft One Way 100–200 Ft One Way
ST1000 4.2 5.3 14 AWG 12 AWG 10 AWG
ST1500 6.3 7.9 14 AWG 10 AWG 8 AWG
ST2000 8.3 10.4 14 AWG 10 AWG 6 AWG
ST2500 10.4 13.0 12 AWG 8 AWG 6 AWG
975-000-001
Table 1
Recommended Minimum AC Wire Sizes
NOTE These are the minimum recommended wire sizes in conduit. Installing a large number of wires
in conduit or enclosed locations may require larger wire sizes. Consult your local/national electrical
code for the proper wire size in enclosed locations.

3
2.0 INSTALLATION
©2000 Trace Engineering
Grounding
AC Grounding
The Trace ST unit should be connected to a grounded, permanent wiring system.
DC Grounding
The negative PV conductor should be bonded to the grounding system at only one point in the
system. The size for the conductor is usually based on the size of the largest conductor in the DC
system. Negative/ground bonding is accomplished by factory wired PVGFP breakers (when this
option is installed) or a factory installed grounding block (when PVGFP is not installed).
PV Arra s:
The ST unit is optimized to work with 4-each, 12 volt nominal crystalline PV modules in series, or
a various combinations of amorphous, thin film PV modules. Ensure the PV array used in the system
operates within the MPPT operational window.
The solar array connected to the ST Series inverter should have a minimum of 70 volts DC
open-circuit in full sunlight conditions. Polycrystalline solar arrays configured for 48 volts DC nominal
will have a open-circuit voltage in the area of 84 volts DC in full sunlight. The maximum peak power
tracking (MPPT) software controls the output of the solar modules, under loaded conditions, in the 52-
85 volts DC range. Other array voltage will either not operate the inverter or will not allow maximum
harvest of the suns energy.
WARNING: WHENEVER A PV ARRAY IS EXPOSED TO SUNLIGHT, A SHOCK HAZARD EXISTS
AT THE OUTPUT CABLES OR EXPOSED TERMINALS. TO REDUCE THE RISK OF SHOCK
DURING INSTALLATION, COVER THE ARRAY WITH AN OPAQUE (DARK) MATERIAL BEFORE
MAKING ANY CONNECTIONS.
DC Connections:
DC connections are made on the terminal block on the combiner board or at the DC terminal block
on models without the combiner board. The terminal block accepts wire sizes from #614 AWG. Refer
to the table below for minimum recommended wire sizes.
DC Amps
(from PV array) NEC Amp (Amps x 156%)
Minimum Wire Size for Specified Distance
0–25 Ft
One Way 25–50 Ft One Way 50–100 Ft One Way
1.0 1.6 14 AWG 14 AWG 14 AWG
3.0 4.7 14 AWG 12 AWG 10 AWG
5.0 7.8 12 AWG 10 AWG 6 AWG
7.0 10.9 12 AWG 8 AWG 6 AWG
9.0 14.0 10 AWG 8 AWG Not Recommended
11.0 17.2 10 AWG 6 AWG Not Recommended
975-000-002
Table 2
Recommended Minimum DC Wire Sizes
NOTE These are the minimum recommended wire sizes. Installing a large number of wires in
conduit or enclosed locations may require larger wire sizes. Consult your local/national electrical
code for the proper wire size in enclosed locations.

4
2.0 INSTALLATION
©2000 Trace Engineering
AC Circuit Breakers:
The main service panel must dedicate a 15 amp minimum, double pole breaker (120/240 volts
AC) to operate the ST unit.
Wire Routing:
Determine all wire routes both to and from the Sun Tie. Possible routing considerations include
 AC input wiring from the main service panel to the ST
 DC input wiring from the PV array to the ST
 DC ground from the PV array to an external ground rod
 All wiring and installation methods should conform to applicable electrical and building codes.
 Pre-plan the wire and conduit runs. The DC terminal blocks accept up to a #6 AWG wire; the
AC circuit disconnects accept cable sizes up to #1 AWG.
 For maximum safety, run both AC and DC wires/cables in (separate) conduits.
WARNING: CHECK FOR EXISTING ELECTRICAL OR PLUMBING PRIOR TO DRILLING HOLES
IN THE WALLS!