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!

5
2.0 INSTALLATION
©2000 Trace Engineering
Mounting
The ST unit must be mounted to a flat, vertical surface such as wallboard or wood siding.
Installation onto wallboard or concrete requires the use of anchors to properly hold the screws.
Outdoor installation requires the use of the optional rain shield (STRS) to prevent water from entering
the unit.
WARNING: DO NOT INSTALL THE SUN TIE UNIT OUTDOORS WITHOUT THE RAINSHIELD
HOOD. WATER ENTERING THE UNIT COULD CAUSE A DANGEROUS CONDITION AND CAUSE
THE UNIT TO FAIL. FAILURES DUE TO IMPROPER INSTALLATION WILL VOID THE WARRANTY.
Procedure
WARNING: BEFORE DRILLING HOLES TO MOUNT THE SUN TIE, ENSURE THERE ARE NO
ELECTRICAL WIRES OR PLUMBING IN THIS AREA. SINCE THIS UNIT IS INSTALLED CLOSE
TO THE UTILITY ENTRANCE OR METER, THERE MAY BE A HIGH CONCENTRATION OF
ELECTRICAL WIRES IN THE AREA.
1. Locate the area where the ST is to be installed. It should be as close to the utility service panel as
possible. The bottom of the unit must be at least 36 inches from the floor or ground when mounted.
2. Using a level, place the mounting bracket up to the wall (in a horizontal position) and mark the
area for the three screws (Figure 1A).
3. If required, remove the bracket and drill the holes using a #10 (0.193 inch diameter) drill bit. Drill
appropriately sized holes for anchors when installing on non-wood surfaces.
4. Mount the bracket to the wall using the screws and washers provided. If mounting to other than a
wood wall or surface, use appropriate screws and anchors if required.
5. Place the Sun Ties rear lip, located on the back top of the enclosure, over the bracket and
ensure it is seated properly (Figure 1B).
6. Remove the lower external cover to access the internal circuit breaker panel by removing the
screw on each side of the cover (Figure 2).
7. Remove the internal breaker panel by removing the screws in the breakers and two screws from
the underside of the unit, then lifting until the lower locking tabs are free, then gently pull the
inner cover outward (Figure 3). Save the screws for reinstallation.
8. After the unit is correctly seated on the upper bracket, locate the two screw holes on the bottom
(back) area of the enclosure and mark these locations on the wall (Figures 1B and 4). Remove
the ST (if required).
9. Drill two pilot holes (as above, if required).
10. Reinstall the ST, to the bracket and secure the bottom of the unit with the wood screws and
washers provided (or appropriate screws and anchors for non-wood surfaces) and tighten
(Figures 1B and 4).
NOTE Mounting hardware for surfaces other than wood is not supplied.

6
2.0 INSTALLATION
©2000 Trace Engineering
Figure 1A
Bracket Mounting
Mounting: (continued)
Figure 1B
Enclosure Mounting
4068-E00-002
Screw
holes
Enclosure
mounted on wall
bracket
3.20"
26 - 21/32"
19/64"
8 - 55/64"
4 - 13/16"
9 - 41/64"
Slide ST enclosure lip onto bracket
4068-E00-001
Sun Tie back view
Wall Bracket, screws
and washers
(supplied

7
2.0 INSTALLATION
©2000 Trace Engineering
Figure 2
Outer Cover Components
Figure 3
Inner Breaker Cover
Remove breaker screws
Lift up and pull forward to
remove
Remove screws
from tabs
Locking tabs
Upper cover
External breaker cover
(remove during installation
Remove screws
(one on each side

8
2.0 INSTALLATION
©2000 Trace Engineering
Figure 4
Mounting Holes and AC DC Conduit in Customer Access Area
Internal mounting
holes
DC Conduit
AC Conduit
PV Combiner Board
(included on some
models
NOTE: The internal
Combiner Board is not
available on all models.

9
2.0 INSTALLATION
©2000 Trace Engineering
Figure 5
ST Electrical Component Location
Wiring:
DC Wiring
The combiner board (included on some models) in the ST accepts up to six individual PV array
circuits (positive and negative wires). Each circuit on the combiner board contains a fuse to protect
against over-current. Always replace this fuse with one of the same type and rating (GBB, 20 amp
max.).
The combiner board PV array input connection block is located in the lower section of the ST
unit.
PV Array
1. Install the DC conduit from the PV arrays to the bottom of the ST unit, via one of the knockout
holes (Figure 4).
2. Route the wires from the PV array(s) through conduit and into the lower section of the ST
enclosure (Figure 6).
NOTE: If more than one PV array is used, label the wire pairs (positive and negative) appropriately
(i.e., PV 1, PV 2, etc.).
3. Connect the positive (+) wire from the #1 array to the terminal strip labeled PV INPUT 1
POSITIVE terminal. Check that the wire is in the proper location and tighten the screw.
4. Connect the negative (–) wires from the PV array to the PV INPUT 1 NEGATIVE terminal.
Check that the wire is in the proper location and tighten the screw.
5. Repeat this procedure for each PV array circuit, connecting the #2 PV Positive wire to the
terminal labeled PV INPUT 2 POSITIVE, etc.
NOTE: The solar arrays do not have to connect in the order marked on the board (this is just for
reference). All solar array positives on the combiner board are joined together AFTER the fuse.
L1breaker
ACconnection
L2breaker
ACconnection
Solararray
100 amp DC breaker
PVGFP (ganged)
1 amp DC breaker
PVGFP (ganged)
100 amp DC breaker
Solar DC terminal block
Solar input 4
+
-
Solar input 3
+
-
Solar input 2
+
-
Solar input 1
+
-
Solar input 5
+
-
Solar input 6
+
-
Solar DC Fuses
Grounding
block
L1
15 amp AC breaker
(ganged)
L2
15 amp AC breaker
(ganged)
Combiner board
(included on some
models)

10
2.0 INSTALLATION
©2000 Trace Engineering
Figure 6
PV Arra DC Connection Points
Wiring: (continued)
Wire Size Torque (in-lb)
14-10 AWG 35
8 AWG 40
6 AWG 45
975-000-003
6. Repeat this procedure for each PV array circuit, connecting the #2 PV Negative wire to the
terminal labeled PV INPUT 2 NEGATIVE, etc.
NOTE The solar arrays do not have to connect in the order marked on the board (this is just for
reference). All solar array negatives on the combiner board are common.
7. Torque wires according to the following table.
Table 3
Wire Torque Values
PV array wiring
(note polarity
DC conduit wiring
(from solar arrays
NOTE: The internal
Combiner Board is not
available on all models.

11
2.0 INSTALLATION
©2000 Trace Engineering
Wiring: (continued)
AC Wiring
AC HOT wiring is connected to the ST units L1 and L2 breakers, the Ground wire connects to
the Ground block. All AC wiring is located in the lower section of the ST unit.
WARNING: AC UTILITY WIRING TO THE ST UNIT IS PERFORMED DIRECTLY AT THE MAIN
BREAKER PANEL. THIS SHOULD BE DONE ONLY BY A QUALIFIED UTILITY INSTALLER OR
ELECTRICIAN WITH PRIOR UTILITY COMPANY APPROVAL.
NOTE The ST unit can be connected to a single bidirectional meter, or to installations requiring a
separate meter indicating sold power (power supplied back to the utility). The installer and utility
must determine the proper components to install.
WARNING: BEFORE WIRING THE ST UNIT, ENSURE THE MAIN 120/240 VOLT BREAKER IN
THE MAIN UTILITY BREAKER BOX IS SWITCHED OFF. SWITCH THIS BREAKER TO ON ONLY
AFTER ALL WIRING IS COMPLETED AS INSTRUCTED IN THE PROCEDURES.
1. Run conduit from the main utility breaker panel to the lower section of the ST unit. Run the
two HOT wires (L1 and L2) and ground through the conduit and into the ST units lower
section.
2. Install a dual 15 amp, ganged circuit breaker in the main utility breaker panel.
3. Connect the L1 HOT wire (black) from the 15 amp, double-pole breaker installed in the main
breaker panel, to the breaker labeled L1 in the ST unit.
4. Connect the L2 HOT wire (red) from the remaining 15 amp, double-pole breaker installed in
the main breaker panel, to the breaker labeled L2 in the ST unit.
5. Connect the ground wire (green or bare copper) from the ground block in the main breaker
panel, to the ground block in the lower section of the ST unit.
6. Ensure all connections are correctly wired and properly torqued.
7. Torque wires according to the following table.
Wire Size Torque (in-lb)
14-10 AWG 35
8 AWG 40
6 AWG 45
975-000-003
Table 4
Wire Torque Values

12
2.0 INSTALLATION
©2000 Trace Engineering
Figure 7
240 V AC Connection Points
L1
L2
Ground block
AC conduit and wiring
NOTE: The
internal
Combiner Board
is not available
on all models.
240 VAC

13
2.0 INSTALLATION
©2000 Trace Engineering
Figure 9
Simplified Electrical Wiring Diagram
INVERTER
+ –
PV ARRAY
PV COMBINER BOARD
+–
+ –
L1
L2
G
PV GROUND FAULT
BREAKERS (OPTION)
100 A
1 A
UTILITY
GRID
A
SOV
NOTES: INSTALLER CONNECTIONS REQUIRED AT POINTS
(A)
AND
(B)
TO
THE INVERTER ENCLOSURE. THE UTILITY METER MUST BEA BI-DIRECTIONAL METER. OBTAIN UTILITY COMPANY APPROVAL BEFORE INSTALLING. PVGFP AND COMBINER BOARD MAY NOT BE PRESENT ON SOME MODELS.
975-S00-003A
15 A 15 A
LIGHTNING
ARRESTOR
(OPTION) 100 A
20 A
+
20 A
+
20 A
+
20 A
+
20 A
+
20 A
+
–
–
–
–
–
–
B
ST UNIT
L2
MAIN SERVICE PANEL
L1
GROUND
G
L1
L2
N
UTILITY METER
L2
L1
Main
Breakers
Sun-Tie
Breakers
Extra Ground Rod
Only Required on
Long Runs > 100
feet (30 m).
NEUTRAL
N
L2
L1
G

14
2.0 INSTALLATION
©2000 Trace Engineering
Lightning Protection
To protect the equipment from lightning damage, a single point grounding system should be
used. In this system, all ground lines terminate at the same point. This point normally is the main
utility ground installed by the utility company to provide a ground for the house wiring. This ground
usually consists of a copper rod driven 6 to 8 feet into the earth. Ground roof mounted solar array
frames directly to the external utility ground rod (Figure 10).
If the solar array is located a considerable distance from the ST unit, then an additional ground
rod must be installed close to the solar array for the most reliable lightning protection (Figure 11).
The grounded frame of the solar array provides a direct route to dissipate lightning strikes via the
close ground rod. Tie this ground rod to the main utility ground rod via a heavy gauge (#86 AWG)
bare copper wire which can be buried underground. Tieing these grounds together constitutes a
single point ground and provides the best protection from lightning damage. Refer also to the NEC
for specific grounding requirements.
ST Unit Main Utility
Breaker Panel Utility
Meter
Solar
Array
DC Wiring
AC Wiring
Buried Copper Wire
Array Ground Rod Utility Ground Rod
Utility Ground
Wire
Ground
Block
Ground
Block
> 100 feet (30 m)
Array Ground Wire
Ground
Frame to
Pole
AC
Wiring
AC
Wiring to
Utility
975-F00-006
Bonded Neutral Wire
Figure 11
Long Distance Grounding
ST Unit Main Utility
Breaker Panel Utility
Meter
DC Wiring
AC Wiring
Utility
Ground
Rod
Utility Ground
Wire
Ground
Block
Ground
Block
Array Ground Wire
AC
Wiring
AC
Wiring to
Utility
Solar
Array
957-F00-007
Bonded Neutral Wire
Figure 10
T pical Roof Mount Installation Grounding