Trace Engineering SW Series User manual

Installation and Wiring Guide
IPP
Integrated Power Panel
Version 1.2
ã 1999 Trace Engineering P/N #2903 Rev. A 01/00

©1999 Trace Engineering

©1999 Trace Engineering i
Integrated Power Panel
Version 1.2
Table of Contents
Section Description Page
1.0 INTRODUCTION .......................................................................................................... 1
2.0 INSTA ATION ............................................................................................................ 2
Pre-Installation
Tools Required
Hardware/Materials Required
Wiring
AC Connections
DC Connections
Grounding
AC Grounding
DC Grounding
Batteries
PV Arrays
Main Service Panel
Sub-Panel
AC Circuit Breakers
Wire Routing
Plywood Backing
Mounting
DC Wiring
PV Array
Battery Temperature Sensor Wiring
SW Models
DR Models
Battery Wiring
AC WiringSW Series Dual Inverter Models
AC Input Wiring to the AC Bypass Box
AC Output Wiring To the AC Bypass Box
AC Input/Output Wiring (SW Single Inverter Models)
AC Input/Output Wiring to the AC Bypass Box
AC WiringDR Series Dual Inverter Models
AC Input Wiring to the AC Bypass Box
AC Output Wiring to the AC Bypass Box
AC Input/Output WiringDR Series Single Inverter Models
AC Input Output Wiring to the AC Bypass Box
AC Input/Output Wiring to Sub-panel
Wiring Check
3.0 OPERATION ................................................................................................................ 23
System Check
Start-up Procedure
AC Disconnect Module
Inverter In Circuit
Inverter Out of Circuit
Both AC ine and Inverter OFF
4.0 TROUB ESHOOTING ................................................................................................. 26
5.0 SYSTEM SHUTDOWN ................................................................................................. 27
Emergency Shutdown Procedure
6.0 SPECIFICATIONS ........................................................................................................ 28
7.0 SERVICE INFORMATION ............................................................................................ 30
8.0 IFE SUPPORT APP ICATIONS PO ICY .................................................................. 31
9.0 WARRANTY................................................................................................................. 32

©1999 Trace Engineering
ii
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 zone.
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, national, and/or international electrical codes.
· Before installing or using this device, read all instructions and cautionary markings located in (or on) the
manual, the inverter, the controller, the batteries, and the PV array.
· Do not expose this unit to rain, snow or liquids of any type. This product is designed only for indoor
mounting.
· To reduce the chance of short-circuits when installing or working with the inverter, the batteries, 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 inverter contains more than one live circuit (batteries and AC line). Power may be present at
more than one source.
· This product contains no user serviceable parts. Do not attempt to repair this unit unless fully qualified.

©1999 Trace Engineering iii
BATTERY SAFETY INFORMATION
· Always wear eye protection, such as safety glasses, when working with batteries.
· Remove all loose jewelry before working with batteries.
· Never work alone. Have someone assist you with the installation or be close enough to come to your
aid when working with batteries.
· Always use proper lifting techniques when handling batteries.
· Always use identical types of batteries.
· Never install old or untested batteries. Check each battery s date code or label to ensure age and type.
· Batteries are temperature sensitive. For optimum performance, they should be installed in a stable
temperature environment.
· Batteries should be installed in a well vented area to prevent the possible buildup of explosive gasses.
If the batteries are installed inside an enclosure, vent its highest point to the outdoors.
· When installing batteries, allow at least 1 inch of air space between batteries to promote cooling and
ventilation.
· NEVER smoke in the vicinity of a battery or generator.
· Always connect the batteries first, then connect the cables to the inverter or controller. This will greatly
reduce the chance of spark in the vicinity of the batteries.
· Use insulated tools when working with batteries.
· When connecting batteries, always verify proper voltage and polarity.
· Do not short-circuit battery cables. Fire or explosion can occur.
· In the event of exposure to battery electrolyte, wash the area with soap and water. If acid enters the
eyes, flood them with running cold water for at least 15 minutes and get immediate medical attention.
· Always recycle old batteries. Contact your local recycling center for proper disposal information.

©1999 Trace Engineering
iv
Figure 1
Integrated Power Panel
(layout varies depending upon type of inverter)
PV Charge Controllers 2 each)
AC Circuit Breakers
DC Circuit Breakers
Inverters 2 each)
AC Sub Panel
to loads)
AC Main Panel
from utility)
or
Generator
Ø×
×
Ú
Ú

©1999 Trace Engineering 1
1.0 INTRODUCTION
The Power Panel is a self-contained power conversion center designed around two styles of Trace
inverters: the DR Series and the SW Series. The inverter type determines the physical component layout.
Typically, a power panel contains at least one inverter, ac and dc disconnect circuit breakers, and a battery
temperature sensor. Optional PV solar controllers and disconnects can be added to the system at the time of
order, or added later. The inverters, controllers (if ordered) and protection circuitry are fully integrated into a
single enclosure to ensure safety and reliability. Each power panel is ETL listed to UL standard 1741 (Draft),
and comes pre-wired and tested at the factory to maximize system performance and ease of operation.
Installing a power panel is as simple as mounting it to the wall and connecting a dc source (PV array,
batteries, etc.), an ac source (utility power, generator, etc.), and ac loads (via a sub-panel).
Power Panels feature:
Trace DR Series or SW Series inverter/charger(s)
AC circuit protection
DC circuit protection
Trace DR Series inverters feature:
1500, 2400 or 3600 watt continuous output
Modified sinewave output with voltage and frequency regulation
High efficiency, high surge capacity and low idle current
Three-stage battery charging for optimum battery performance
Automatic low battery protection
Fast switching for standby power applications
Stackable capabilities for 120/240 V ac powering applications
Trace SW Series inverters feature:
2500, 4000 or 5500 watt continuous output
Sinewave output with superior voltage and frequency regulation
Intelligent generator control - automatic start and stop
Programmable generator quiet time for areas with noise curfews
Frequency matching and phase synchronization - parallel operation for maximum generator efficiency
Microprocessor control for maximum flexibility and reliability
Three-stage battery charging for optimum battery performance
Automatic low battery protection
Stackable capabilities for 120/240 V ac powering applications
Optional features:
PV charge controller(s) with array disconnect(s)
Battery cables with flex conduit
Trace products are built rugged and designed to provide you with years of trouble-free service.
Recognized throughout the world as a leader in the field of alternative energy, Trace Engineering ensures
your system fully meets your quality expectations and powering needs. We thank you for your purchase and
welcome you to the exciting world of environmentally friendly, alternative powering.

©1999 Trace Engineering
Pre-Installation
Before installing the power panel, read all instructions and cautionary markings located in this
manual.
NOTE: The power panel is quite heavy (weighing up to 400 pounds depending upon configuration).
Always use proper lifting techniques during installation to prevent personal injury.
Mounting: The power panel should be mounted indoors in a clean, dry environment. If the panel must be
installed in close proximity to the batteries, make sure the area is adequately ventilated to the outside.
Tools required:
#2 Phillips screw driver Level
1/4" Slotted screw driver Wire strippers
1/2" open-end wrench Torque wrench
Socket wrench and fittings Electrical Tape
Multimeter Pencil
Hole saw Utility knife
Hardware / Materials required:
4' x 8' sheet of 3/4" plywood
#12 wood screws (or 3/4" x 1-1/4" lag bolts)
#10 wood screws
1/4" x 3" lag bolts
Conduit and appropriate fittings
Wire nuts (if allowed by code)
Wiring:
All wiring and installation methods should conform to applicable electrical and building codes.
Pre-plan the wire and conduit runs. The ac terminal blocks accept up to a #6 AWG wire; the dc circuit
battery disconnects accept cable sizes up to #4/0 AWG. Use #4/0 AWG for a 250 amp dc disconnect and #2/0
AWG for a 175 amp dc disconnect.
For maximum safety, run both ac and dc wires/cables in (separate) conduits.
AC Connections:
Use #6 AWG THHN wire for all ac wiring.
DC Connections:
Battery to inverter cabling should be only as long as required. If #4/0 AWG cables are used for example,
do not exceed 5 feet (one way) in 12 V dc systems; 10 feet (one way) in 24 V dc systems; or, 15 feet (one
way) for 48 V dc systems. For optimum performance, use pre-assembled battery cables from Trace,
designed specifically for this application.
Grounding:
AC Grounding
The power panel should be connected to a grounded, permanent wiring system. Neutral and Ground
conductors should only be bonded at the main service panel.
DC Grounding
The negative battery 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.
2
2.0 INSTALLATION

©1999 Trace Engineering
2.0 INSTALLATION
3
Pre-Installation (continued)
Batteries:
The battery voltage MUST match the voltage requirements of the inverter. To determine the correct
voltage for the system, check the last two digits on the inverter s model number. For example, the DR1512 is
a 12 volt inverter and requires a 12 V dc battery system. The SW4024 is a 24 volt inverter and requires a 24
V dc battery system.
PV Arrays:
The optional controller is designed to work with a wide variety of PV array systems. DO NOT connect
the controller to an array operating at more than 110 V dc.
WARNING: WHENEVER A PV ARRAY IS EXPOSED TO SUN IGHT, A SHOCK HAZARD EXISTS AT THE
OUTPUT CAB ES OR EXPOSED TERMINA S. TO REDUCE THE RISK OF SHOCK DURING
INSTA ATION, DISCONNECT THE ARRAY, OR COVER IT WITH AN OPAQUE (DARK) MATERIA
BEFORE MAKING ANY CONNECTIONS TO THE POWER PANE .
Main Service Panel:
The main input to the Power Panel requires a minimum 60 amp breaker for each 120 V ac inverter. A
15 amp breaker is required for all 230 V ac inverters.
Sub-Panel:
Loads backed up by the Power Panel will need to be rerouted from the main service panel to a sub-
panel. This can be done several different ways, depending upon the installation. Always refer to electrical
codes for safe wiring practices.
AC Circuit Breakers:
Always use a properly rated circuit breaker. Depending upon the application, circuit breakers used to
protect the load can be removed from the main service panel and put into the sub-panel ONLY if the two
panels are from the same manufacturer and are the same type of service panel.
Wire Routing:
Determine all wire routes both to and from the Power Panel. Possible routing scenarios include:
AC Input wiring from the main service panel to the Power Panel
AC Input wiring from the generator to the Power Panel
DC Input wiring from the PV array to the Power Panel
DC Input wiring from the batteries to the Power Panel
AC Output wiring from the Power Panel to the sub-panel
Battery Temperature Sensor cable from the Power Panel to the batteries
Remote Control cable to the Power Panel
DC Ground from the batteries to an external ground rod
Load circuit wiring rerouted from the main service panel to the sub-panel
Check for existing electrical or plumbing prior to making cuts in the walls. Cut holes in the walls at
appropriate locations for routing wiring/cables.
Plywood Backing:
A 4' x 8' x 3/4" plywood backing may be used to provide additional wall support. It should run the entire
height of the wall (floor to ceiling). For aesthetic purposes, pre-paint the plywood.
NOTE: 3/4" plywood backing is required for supporting walls where the total weight exceeds 300 lbs (136 kg).

©1999 Trace Engineering
Mo nting:
NOTE: The mounting recommendations and instructions contained in this section have been developed to
meet seismic code requirements according to the 1997 Uniform Building Code for all seismic regions within
the United States. This applies to light wood framed structures such as those commonly found in residential
construction. If the Power Panel is to be mounted to a structure that is not a residential-type wood framed
wall, and/or the mounting wall supports more than one floor and one roof simultaneously, or if the structure is
classified as a commercial or industrial building, contact the local building inspector for further information
before proceeding with this installation.
The Power Panel can be installed on either a load bearing or non-load bearing wall. Depending upon the
Power Panel s components, it can weigh as much as 400 lbs (182 kg). A 4' x 8' x 3/4" sheet of plywood (floor
to ceiling) is recommended to provide additional wall strength. The plywood backing is required for Power
Panels weighing more than 300 lbs (136 kg) installed on load bearing walls.
Procedure
1. Locate the studs in the wall (either 16" or 24" on center) and mark their locations.
2. If plywood is used, apply adhesive to the back and center it on the wall. Secure it into the studs and
around the perimeter using #12 wood screws on 6" spacing. Counter sink the screws. Paint the plywood
to match the surrounding wall color if desired.
3. Using 2 x 4's, build a frame for holding the Power Panel in place while it is being secured. The top of the
frame should be approximately 3-1/2 to 4 feet from the floor. Use 3" x 1/4" lag bolts (on 6" centers) to
mount the 2 x 4. Keep all screws at least 3/4" away from the top of the horizontal 2 x 4 to allow the bottom
flange of the Power Panel to slip behind it. See Figures 2 and 3.
4. Drill pilot holes according to the dimensions in Figure 4.
5. With the help of a friend, lift the Power Panel into position. It should be centered (and level) on the
plywood. Secure the Power Panel using #10 wood screws (on 16" center) or #12 wood screws (on 24"
center) through each of the holes in the backing panel. Avoid hitting the wood screws. Screws must
penetrate 1-3/4" into the framing.
Wall studs 24 inch on
center
2 x 4 frame
4 ft. x 8 ft. x 3/4 in plywood
backing
Floor
2 x 4 support studs
Ceiling
2903-00- 003
Approximately
3-1/2–4 ft
Wall studs 16 inch on
center
2 x 4 frame
4 ft. x 8 ft. x 3/4 in plywood
backing
Floor
2 x 4 support studs
Ceiling
2903-00-003
Approximately
3-1/2–4 ft
Figure 2
Power Panel Support Structure
(16" on-center studs)
Figure 3
Power Panel Support Structure
(24" on-center studs)
2.0 INSTALLATION
4
Adjust the height of the panel so the
bypass switch is within easy reach

©1999 Trace Engineering
Figure 4
Mounting Hole Dimensions
7 1/4"
11 1/4"
19 1/4"
27 1/4"
31 1/4"
5"
9"
13"
21"
29"
33"
37"
ø3/8" X 24
32"
42 1/16"
42 15/16"
38 13/16"
39 9/16"
24"
16”16”
24”
16”
2.0 INSTALLATION
5
2903-00-004
Figure 4A
Mounted Power Panel
Adjust the height of the panel so the
bypass switch is within easy reach

©1999 Trace Engineering
2.0 INSTALLATION
6
NOTE: Items marked with an astrict (*) are only applicable to dual inverter/controller models.
Figure 7
Component ocations (SW Model)
Figure 8
Wire Connection ocations (SW Model)
PV Array #1 Controller
*PV Array #2 Controller
AC Disconnect/Bypass Box
Inverter #1
*Inverter #2
Solar PV) Array #1
Disconnect
*Solar PV) Array #2
Disconnect
Battery positive)
Disconnect #1
*Battery positive)
Disconnect #2
DC Negative
Ground Bond
120 V ac Output 1
AC INPUT from LINE 1
black) Utility or Generator
All NEUTRAL wires white)
AC GROUND wires
*Battery POSITIVE Terminal
Battery POSITIVE Terminal
PV Array
Chassis GROUND
PV Array NEGATIVE
DC Earth GROUND
Battery
NEGATIVE
*Solar PV) Array 2
POSITIVE
Solar PV Array 1
POSITIVE
*AC INPUT from LINE 2
red) Utility or Generator
*120 V ac Output 2

©1999 Trace Engineering
2.0 INSTALLATION
7
Figure 5
Component ocations (DR Model)
Figure 6
Wire Connection ocations (DR Model)
PV Array #1 Controller optional)
*PV Array #2 Controller optional) AC Disconnect/Bypass Box
Inverter #1
*Inverter #2
Solar PV) Array #1
Disconnect
*Solar PV) Array #2
Disconnect
*Battery positive)
Disconnect #2
Battery positive)
Disconnect #1
DC Negative
Ground Bond
NOTE: Items marked with an astrict (*) are only applicable to dual inverter/controller models.
120 V ac
Output 1
AC INPUT from LINE 1
black)
*AC INPUT from LINE 2
red)
All NEUTRAL wires white)
AC GROUND wires
*Battery POSITIVE Terminal
Battery POSITIVE Terminal
PV Array
Chassis GROUND
PV Array NEGATIVE
DC Earth GROUND
Battery
NEGATIVE
PV Array 1
POSITIVE
*PV Array 2
POSITIVE
*120 V ac
Output 2

©1999 Trace Engineering
Wiring:
DC Wiring
The dc wiring enters the DC Disconnect Box through the conduit located on the bottom of the disconnect
box. Use #6 AWG wire for the PV array connections.
PV Array
If a PV array is used in the system, connect the wiring as follows:
NOTE: For dual controller models, split the PV array s output evenly between the two PV Array Disconnects.
1. Route the wires from the PV array through the conduit located at the bottom of the DC Disconnect Box.
2. Connect the positive (+) wire from the #1 array to the lower terminal of the PV Array #1 Disconnect
breaker.
3. Connect the positive (+) wire for the #2 array to the lower terminal of the PV Array #2 Disconnect.
4. Connect the negative () wires from the array(s) to the Grounding Block.
5. Connect the ground wire(s) from the frame of the PV array to the Grounding Block.
6. Ensure all connections are snug.
Figure 9
Wire Connection ocations
NOTE: Items marked with an astrict (*) are only applicable to dual controller models. For clarity, wiring not
used in this step may not be shown.
2.0 INSTALLATION
8
DISCONNECT
BATTERY
OFF
ON
OFF
ON
ARRAY
SOLAR
SOLAR
ARR AY
ARRAY
SOLAR

Grounding Block
PV Array #1
Disconnect
*PV Array #2
Disconnect
DR Series
PV Array Ground Wire
PV Array
Negative ) Wires
PV Array #1
Positive +) Wire
*PV Array #2
Positive +) Wire
DC Disconnect Box

DC Disconnect Box
Grounding Block
PV Array
Negative ) Wires
SW Series
PV Array Ground Wire

©1999 Trace Engineering
Battery Temperat re Sensor (BTS) Wiring (SW Models)
Battery Temperature Sensors (BTS) should be placed on the side of the battery. They transmit
temperature information to the charger and adjust the charging rate according to the battery temperature. Up
to four sensors can be connected in a dual inverter system with two charge controllers.
1. Locate the battery temperature sensors and route them down through the conduit in the DC Disconnect
Box to the batteries.
2. Place all sensors onto the side of same battery (located in the middle of the battery bank) to prevent
different charging rates based on temperature variances.
NOTE: Temperature sensor cables are already connected to the inverters and PV controllers (if ordered). The
cables only need be run through the conduit to the batteries.
NOTE: For clarity, wiring not used in this step may not be shown.
Figure 10
Battery Temperature Sensor (BTS) Wiring
2.0 INSTALLATION
9
BATTERY
BATTERY TEMPERATURE SENSORS
Mount the battery temperature sensors BTS)
to the side of the same battery located in the
middle of the battery bank).
Battery Temperature Sensor
wires.
PV Charge Controllers
BTS Connectors internal)
BTS Connector
internal)
See Note
BTS wires run through the grommets in the
inverter housing and along the back of the
inverter. These wires are already installed
Inverters
DC Disconnect Box

©1999 Trace Engineering
Battery Temperat re Sensor Wiring (DR Models)
Battery Temperature Sensors (BTS) should be placed on the side of the battery. They transmit
temperature information to the charger and adjust the charging rate according to the battery temperature. Up
to four sensors can be connected in a dual inverter system with two charge controllers.
1. Locate the battery temperature sensors and route them down through the conduit in the DC Disconnect
Box to the batteries.
2. Place all sensors onto the side of same battery (located in the middle of the battery bank) to prevent
different charging rates based on temperature variances.
NOTE: Temperature sensor cables are already connected to the inverters and PV controllers (if ordered). The
cables only need be run through the conduit to the batteries.
Figure 11
Battery Temperature Sensor (BTS) Wiring
10
OFF
ONON
OFF
87
DEEPCYC LE LEADACID
POWER ON/OFF
INVERTERMODE
SEARCHMO DE W ATTS
OVERTEMP RED /OVERLOAD GRN
BATTERYHI RED/ BATTERY LOW GRN
CHARGE R: GR N= F LOAT/O RN BLI NK = AB SO RP /O RN= BUL K
COM PO RT
0
10
>100
25
60
PbCa-MAINTENANCE FREE
GEL CE LL
3
4
5
6
ACTRANSFER THR ESHO LD
BATTERYSENSE
BATTERY CHARG ER RATE
BATTERYCAPACITY
OVER-DISCHARGEPRO TECTION
OFF
MAX
MIN
Amp/Hrs
125
50
ON
.37K
.5K
1K
250
EQUALIZE1
EQUALIZE2
2
9
0
1
Batt ery Type Sel ector
MAX
OVERTEMP RED /OVERLOAD GRN
BATTERYHI RED/ BATTERY LOW GRN
CHARGE R: GR N= F LOAT/O RN BLI NK = AB SO RP /O RN= BUL K
POWER ON/OFF
INVERTERMODE
SEARCHMO DE W ATTS
COM PO RT
>100
0
10 25
60 MIN .5K
BATTERYSENSE
ACTRANSFER THR ESHO LD
BATTERYCAPACITY
OVER-DISCHARGEPRO TECTION
.37K
ON
OFF
125
50
1K
250
Amp/Hrs
BATTERY CHARG ER RATE
Batt ery Type Sel ector
EQUALIZE2
EQUALIZE1
GEL CE LL
PbCa-MAINTENANCE FREE
DEEPCYCLE
6
5
4
3
LEADACID 7
1
0
9
2
8
GND
NEUIN
NEUOUT
POSITIVE
NEGATIVE
POSITIVE
NEGATIVE
BAT+ PV+ BAT-PV- PV+BAT+ BAT-PV-
HOT IN
NEU IN
HOTOUT
NEUOUT
GND
NEUTRAL NOT BONDED TO GROUND
INV 1 OUT PUT
INV 1 INP UT
RED#6AWG
INVERTER 2
INVERTER 1
DISCONNECT
BATTERY
ARRAY
SOLAR
#2355 #2360
ARRAY
SOLAR
#2385
INV 1
INV 2
D
OFF
60
D
OFF OFF
D
60
D
OFF
6060
0N0N
SOURCEAND L OAD
INPUTAND OUTPUT
NEUTRAL
GROUND
PN2355
HAZARDOFELECTRICALSHOCKORBURN.
TURNOFFTHE ACAND DC P OWERSUPPLYING
THISEQUIPMENTBEFOREWORKINGINSIDE.
THISSYSTEMMAYRECEIVEPOWERFROM
MORETHANONESOURCE.REPLACECOVER
BEFORETURNINGPOWERON.
RISQUEDECHOCSE LECTRIQUES.NEPAS
TOUCHERLESPARTIESNONISOLEESDU
CONNECTEUR DE SORTIEOULE S BORNES
NONISOLEESDEL’ACCUMULATEUR.COUPER
TOUTLESLESSOURCESD’ALIMENTAT IO N
AVANT D E FAI RE L ’ENTRETIENETLES
REPAR AT IO N S .
DANGER:
AVERTISSEMENT:
POWE R SU P PL I ES
CAN/CSA-C22.2 No. 1 07.1-M 1
COMMERCIALANDINDUSTRIAL
SYSTEMS STANDARDUL1741
USEIN PHOTOVOLTAIC P OW ER
POWERCONDITIONINGUNITSFOR
L
I
S T E
D C
67664
CERTIFIEDTO
R
TRACEENGINEERING 5916 195TH STN E
ARLINGTON,WA.98223 M ADEIN U.S.A.
L
S T
I
E D R
SOLAR
ARRAY


Battery Temperature
Sensor wires.
BTS Connector
front panel)
BTS wires run through the grommets in the inverter housing
and along the back of the inverter. These wires are already
installed
DC Disconnect Box
BATTERY
BATTERY TEMPERATURE SENSORS
Mount the battery temperature sensors BTS)
to the side of the same battery located in the
middle of the battery bank).
2.0 INSTALLATION

©1999 Trace Engineering
Battery Wiring
Route the battery cables through the conduit to the DC Disconnect Box. Use a minimum of #4/0 AWG
wire for a 250 amp battery disconnect breaker (or #2/0 AWG for a 175 amp battery disconnect breaker).
Smaller diameter wire results in poor inverter performance and the risk of fire due to the wires overheating.
 Connect the Negative wires to the negative grounding bond block and tighten connections.
 Connect a Positive wire to one of the lower terminals on the Battery Disconnect breaker.
 Connect the other Positive wire to the lower terminal on the second Battery Disconnect breaker.
 Torque Battery breaker connections to 275 in-lb (23 ft-lb), (31 N-m). Refer to battery manufacturer s
specifications for battery terminal torque specifications.
 After torquing, coat the battery connections with petroleum jelly or other anticorrosion grease designed
for battery terminals. Do not put any anticorrosion grease between the terminals and the battery cable.
NOTE: Use only one battery bank for both inverters. Refer to Figure 12 for an example of a battery hookup.
NOTE: Refer to the inverter s Operator s manual for more detailed examples of battery hookups (i.e., 12 V,
24 V and 48 V).
Figure 12
Battery Wiring (24 v dc System)
2.0 INSTALLATION
11
DISCONNECT
BATTERY
OFF
ON
OFF
ON
ARRAY
SOLAR
SOLAR
ARRAY
ARRAY
SOLAR

DC Disconnect Box
Battery Disconnect 1 Breaker
DR system shown)
Disconnect 2 on SW Systems)
Battery Disconnect 2 Breaker
DR system shown)
Disconnect 1 on SW Systems)
Negative 1
Negative Grounding Bond Block
On opposite side on SW
installations)
Positive 1
Positive 2
Negative 2
–
–+–+
+–
+
CONDUIT FOR
INVERTER 2
CONDUIT FOR
INVERTER 1
2903-00-021
12 Volt
Battery
12 Volt
Battery
12 Volt
Battery
12 Volt
Battery
Positive 1
Positive 2
Negative 1
Negative 2
NOTE: Connect each inverter at
opposite ends of the battery
bank. This balances the current
flowing through the entire bank
and provides an equal charge/
discharge through all of the
batteries.
Torque to 275 in-lb 23 ft-lb)

©1999 Trace Engineering
WHITE #6AWG
0N
OFF
D
60
60
D
OFF
0N
OFF
D
60
60
OFF
D
INV 2
INV 1
GROUND
INPUT AND OUTP UT
SOURCE AND LOAD
NEUTRAL
2903-00-011b
Inverter 1 (Top ac breaker)
Inverter 1 HOT IN L1 (Center ac breaker)
Inverter 1 HOT OUT L1 (Bottom ac breaker)
*Inverter 2 (Top ac breaker)
*Inverter 2
HOT IN L2 (Center ac breaker)
*Inverter 2
HOT OUT L2 (Bottom ac breaker)
Ground Block
Neutral Block
Service Crimps are provided to allow utility
and load connections. DO NOT REMOVE
FACTORY INSTALLED WIRING!
Figure 13
SW Series AC Disconnect Component Identification
AC WiringSW Series D al Inverter Models
WARNING: THIS SECTION DEA S WITH WIRING THE MAIN SERVICE UTI ITY PANE TO THE POWER
PANE . ENSURE THAT A AC POWER TO THE UTI ITY PANE IS SWITCHED OFF.
Breaker Lug Service Crimp
Existing Factory Wiring
Added Input or
Output Wire
2906-00-026
Figure 14
Breaker Terminal ug Detail (side view)
NOTE: Service Crimps, provided on the breaker terminals, are for external input (utility) and output (load)
wiring. Do NOT remove existing factory wiring or screws.
12
2.0 INSTALLATION

©1999 Trace Engineering
AC WiringSW Series D al Inverter Models (continued)
AC Input Wiring To The AC Bypass Box
 Select a convenient knockout on the AC Disconnect/Bypass Box for installing conduit which will carry the
wires from the main utility panel or generator.
 Install a 60 amp circuit breaker in the main utility service panel for each ac input to the inverters.
 Use #6 AWG THHN wire (minimum) and route it through the conduit to the AC Disconnect/Bypass Box.
 Connect the Ground from the main utility box to the ground terminal in the AC Disconnect/Bypass Box as
indicated in Figure 15.
 Connect the L1 (Hot-black) wire to the INVERTER 1 HOT IN L1 (center ac breaker) as indicated in
Figures 13 and 15.
 *Connect the L2 (Hot-red) wire to the INVERTER 2 HOT IN L2 (center ac breaker) as indicated in
Figures 13 and 15.
 Connect the Neutral wire from the main utility box to the Neutral block in the AC Disconnect/Bypass box
as indicated in Figure 15.
 Torque service crimps to 45 in-lb (3.75 ft-lb), (5 N-m).
NOTE: The Ground and Neutral are bonded only at the main utility service panel.
Figure 15
AC Input Wiring
NOTE: Items marked with an astrict (*) are applicable to dual inverter models only.
2.0 INSTALLATION
13
WHITE #6AWG
BLACK
#6AWG
RED
#6AWG
0N
OFF
D
60
60
D
OFF
0N
OFF
D
60
60
OFF
D
INV 2
INV 1
GROUND
INPUT AND OUTPUT
SOURCE AND LOAD
NEUTRAL
Ground from
Utility or
Generator
L1 from Utility
or Generator
HOT
L2 from Utility
or Generator
HOT
Neutral from
Utility or
Generator
2903-00-011
NOTE:
DO NOT REMOVE FACTORY
WIRING!
*

©1999 Trace Engineering
14
Figure 16
AC Output Wiring
AC WiringSW Series D al Inverter Models (continued)
AC Output Wiring To AC Bypass Box
 Select a convenient knockout on the AC Disconnect/Bypass Box for installing conduit which will carry the
wires from the inverter s output to the sub-panel.
 Use #6 AWG THHN wire (minimum) and route it through the conduit between the AC Disconnect/Bypass
Box and the sub-panel.
 Connect the Ground wire to the Ground block in the AC Disconnect/Bypass Box. Connect the other end
to the sub-panel s Ground Bar.
 Connect the L1 (Hot-black) wire to the INVERTER 1 HOT OUT L1 as indicated in Figures 13 and 16.
 *Connect the L2 (Hot-red) wire to the INVERTER 2 HOT OUT L2) as indicated in Figures 13 and 16.
 Connect the Neutral wire to the Neutral block in the AC Disconnect/Bypass Box. Connect the other end to
the sub-panel s Neutral Bar.
 Torque service crimps to 45 in-lb (3.75 ft-lb), (5 N-m).
NOTE: The Ground and Neutral are bonded only at the main utility service panel.
NOTE: Items marked with an astrict (*) are applicable to dual inverter models only.
2.0 INSTALLATION
NOTE:
DO NOT REMOVE FACTORY
WIRING!
*
WHITE #6AWG
BLACK
#6AWG
RED
#6AWG
0N
OFF
D
60
60
D
OFF
0N
OFF
D
60
60
OFF
D
INV 2
INV 1
GROUND
INPUT AND OUT PUT
SOURCE AND LOAD
NEUTRAL
Ground to
Sub-panel
(Loads)
L1 to Sub-panel
(Loads)
HOT
L2 to Sub-panel
(Loads)
HOT
Neutral to
Sub-panel
(Loads)
2903-00-011A