Xantrex Trace SW4024 User manual

Installation Guide
Grid Tie Interface (GTI)
SW Series
SW4024, SW4048, SW5548

ii © 2002 Xantrex Technology Inc.
P/N 975-0041-01-02 Rev A 03/02
About Xantrex
Xantrex Technology Inc., is a world-leading supplier of advanced power
electronics and controls with products from 50 watt mobile units to 1 MW utility-
scale systems for wind, solar, batteries, fuel cells, microturbines, and backup power
applications in both grid-connected and stand-alone systems. Xantrex products
include inverters, battery chargers, programmable power supplies, and variable
speed drives that convert, supply, control, clean, and distribute electrical power.
Trademarks
Trace and Xantrex are registered trademarks of Xantrex International.
Notice of Copyright
Grid Tie Interface (GTI) Installation Guide ©March 2002 Xantrex Technology
Inc. All rights reserved.
Disclaimer
While every precaution has been taken to ensure the accuracy of the contents
of this guide, Xantrex International assumes no responsibility for errors or
omissions. Note as well that specifications and product functionality may change
without notice.
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 Xantrex
Technology Inc., the company 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.
Due to continual improvement through product updates, photographs and/or
illustrations used in this manual may not exactly match your unit. Xantrex
Technology Inc., reserves the right to update this product without notice or releasing
an updated manual when fit, form or function are not affected.
Date and Revision
March 2002, Revision A
Part Number
975-0041-01-02
Contact Information
Web: www.xantrex.com
Email: [email protected]
Phone: [phone]
Fax: [phone]

© 2002 Xantrex Technology Inc.
P/N 975-0041-01-02 Rev A 03/02 iii
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.
WARNINGWARNING
WARNINGWARNING
WARNING - A DANGEROUS VOLTAGE OR
CONDITION EXISTS IN THIS AREA. USE EXTREME
CAUTION WHEN PERFORMING THESE TASKS.
AA
AA
AVERTISSEMENTVERTISSEMENT
VERTISSEMENTVERTISSEMENT
VERTISSEMENT - UNE TENSION OU CONDITION
DANGEREUSE EXISTE DANS CETTE ZONE. FAIRE
PREUVE D’EXTRÊME PRUDENCE LORS DE LA
RÉALISATION DE CES TÂCHES.
CAUTIONCAUTION
CAUTIONCAUTION
CAUTION - This procedure is critical to the safe
installation or operation of the unit. Follow these
instructions closely.
AA
AA
ATTENTIONTTENTION
TTENTIONTTENTION
TTENTION - Cette procédure est essentielle à
l’installation ou l’utilisation de l’unité en toute
sécurité. Suivre ces instructions de près.
NOTENOTE
NOTENOTE
NOTE - This statement is important. Follow instructions
closely.
NOTENOTE
NOTENOTE
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 the manual, and on the inverter, 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 use instulated tools when installing or
working with the inverter, the batteries, or the PV array.
• Remove all jewelry while installing this system. This will greatly reduce the
chance of accidental exposure to live circuits.

iv © 2002 Xantrex Technology Inc.
P/N 975-0041-01-02 Rev A 03/02
SAVE THESE INSTRUCTIONS
• The unit contains more than one live circuit (inverter and utility grid). Power
may be present at more than one source.
• This product contains no user-serviceable parts. Do not attempt to repair this
unit.
• To reduce risk of electric shock, disconnect all wiring before attempting any
maintenance or cleaning.
• Do not mount this device in unventilated enclosures.
• To reduce risk of electric shock, disconnect all wiring before attempting any
maintenance or cleaning.
• Additional AC disconnects may be required as part of the system installation.
Consult local and national electrical code requirements.
• This unit is designed to be horizontally wall mounted.
• The AC input and output neutral conductors are not connected (bonded) to
the chassis.
• The AC input and output HOT conductor are not isolated from each other.
• The chassis housing of the GTI must be connected to a permanent grounding
system as required by the National Electric Code, ANSI/NFPA 70-1996. This is
the responsibility of the system installer. A grounding terminal lug is provided
for connection of an equipment grounding conductor.
• CSA certified for sale in the U.S. under Photovoltaic Power Systems (UL1741).
IMPORTANT SAFETY INSTRUCTIONS (Continued)

© 2002 Xantrex Technology Inc.
P/N 975-0041-01-02 Rev A 03/02 v
CC
CC
Contentsontents
ontentsontents
ontents
IMPORTANT SAFETY INSTRUCTIONS ............................................................. iii
1.0 INTRODUCTION1.0 INTRODUCTION
1.0 INTRODUCTION1.0 INTRODUCTION
1.0 INTRODUCTION ............................................................................................................................
............................................................................................................................
.............................................................. 11
11
1
Introduction .......................................................................................................... 1
Standard Features ................................................................................................. 4
Utility Interactive Mode .................................................................................... 4
Bypass Mode .................................................................................................... 4
2.0 INST2.0 INST
2.0 INST2.0 INST
2.0 INSTALLAALLA
ALLAALLA
ALLATIONTION
TIONTION
TION ..................................................................................................................................
..................................................................................................................................
................................................................. 55
55
5
Pre-Installation ...................................................................................................... 5
Required Tools and Materials .......................................................................... 5
Removing the Top Cover .................................................................................. 5
Mounting ............................................................................................................... 6
Procedure .......................................................................................................... 6
Wiring .................................................................................................................... 8
AC Wiring for Single-Inverter Installations ...................................................... 8
Ground Wiring ........................................................................................... 10
Utility Grid AC Wiring to the GTI .............................................................. 12
Inverter AC Input Wiring to the GTI .......................................................... 14
Inverter AC Output Wiring to the GTI ....................................................... 16
GTI Wiring to the Sub-Panel ...................................................................... 18
Communications Cable ............................................................................. 20
AC Wiring for Dual-Inverter Installations ...................................................... 22
Ground Wiring ........................................................................................... 24
Utility Grid AC Wiring to Dual GTIs .......................................................... 26
Inverter AC Input and Output Wiring to the GTIs ................................... 28
GTI Wiring to the Sub-Panel ...................................................................... 30
Connecting the Communications Cables for Dual Inverter Installations 30
AC Rewiring for Dual-Inverter Power Panel Installations ............................. 32
AC Rewiring for Power Module Installations ................................................ 34
AC Rewiring for Power Module Installations (continued) ............................ 36
Wiring Check ....................................................................................................... 37
Operating Stacked Inverters ............................................................................... 37
Start-up and Test ................................................................................................. 37
3.0 TROUBLESHOOTING3.0 TROUBLESHOOTING
3.0 TROUBLESHOOTING3.0 TROUBLESHOOTING
3.0 TROUBLESHOOTING ..........................................................................................................
..........................................................................................................
..................................................... 3939
3939
39
APPENDIX A – SPECIFICAAPPENDIX A – SPECIFICA
APPENDIX A – SPECIFICAAPPENDIX A – SPECIFICA
APPENDIX A – SPECIFICATIONSTIONS
TIONSTIONS
TIONS ..................................................................................
..................................................................................
.........................................A-1A-1
A-1A-1
A-1
Electrical Specifications1 .................................................................................. A-1
Mechanical Specifications ................................................................................ A-1
APPENDIX B – PRODUCT AND SYSTEM INFORMAAPPENDIX B – PRODUCT AND SYSTEM INFORMA
APPENDIX B – PRODUCT AND SYSTEM INFORMAAPPENDIX B – PRODUCT AND SYSTEM INFORMA
APPENDIX B – PRODUCT AND SYSTEM INFORMATIONTION
TIONTION
TION ........
........
....B-1B-1
B-1B-1
B-1
Warranty ............................................................................................................ B-1
Return Material Authorization Policy ............................................................... B-2
Return Material Procedure ........................................................................... B-2
Service Information .......................................................................................... B-3

vi © 2002 Xantrex Technology Inc.
P/N 975-0041-01-02 Rev A 03/02
List of FiguresList of Figures
List of FiguresList of Figures
List of Figures
Figure 1-1 Grid Tie Interface Flow Diangram .......................................................... 2
Figure 1-2 Grid Tie Interface Flow Diagram
with External Manual Bypass Switch ................................................. 3
Figure 1-3 Grid Tie Interface Unit ............................................................................. 4
Figure 2-1 Removing the Top Cover ......................................................................... 5
Figure 2-2 Mounting Holes ...................................................................................... 6
Figure 2-3 Dimensional Drawing (Not to scale) ..................................................... 7
Figure 2-4 GTI Circuit Board Enlargement ............................................................... 8
Figure 2-5 AC Input and Output Wiring for Single-Inverter Installations .............. 9
Figure 2-5a Ground Wiring for a Single-Inverter Installations ................................11
Figure 2-5b Utility Grid AC Wiring to the GTI .......................................................... 13
Figure 2-5c Inverter AC Input Wiring to the GTI ..................................................... 15
Figure 2-5d Inverter AC Output Wiring to the GTI .................................................. 17
Figure 2-5e GTI Wiring to the Sub-Panel ................................................................. 19
Figure 2-6 GTI Communications Cable Location .................................................. 20
Figure 2-7 Connecting the Communications Cable to the Circuit Board ............. 21
Figure 2-8 Wiring Diagram for Dual-Inverter Installations ................................... 23
Figure 2-8a Ground Wiring for Dual-Inverter Installations ..................................... 25
Figure 2-8b Utility Grid AC Wiring to Dual GTIs ..................................................... 27
Figure 2-8c Inverter AC Input and Output Wiring to Dual GTIs ............................ 29
Figure 2-8d GTI Wiring to the Sub-Panel ................................................................. 31
Figure 2-9 Re-wiring Power Panel Installations to include dual GTIs ................... 33
Figure 2-10 Original Power Module Wiring ............................................................. 35
Figure 2-10a Power Module Rewiring for dual GTI Installations .............................. 36

© 2002 Xantrex Technology Inc.
P/N 975-0041-01-02 Rev A 03/02 1
1.0 INTRODUCTION
INTRODUCTION
The Grid Tie Interface (GTI) is an integrated assembly used with the Trace™
SW Series II inverter/charger with Revision 4.2 (or higher) software. This new device
provides active anti-islanding protection and reduces current Total Harmonic
Distortion (THD) as required in UL-1741-2000.
The Grid Tie Interface is an accessory, which is connected between the grid, the
AC loads, and the SW Series II inverter to optimize the “SELL” feature. While there
is a small inductor in the GTI, this device is not a “filter”; rather it contains an
additional control microprocessor, which connects to the SW Series II with a
communications cable.
When the GTI is connected and the Inverter “SELL” mode is selected, the
microprocessor of the GTI takes control of the SW Series II and operates the inverter
“SELL” feature. The GTI affords a dedicated microprocessor and new, sophisticated
control algorithms that are able to optimize the sell function.
The SW Series II with the GTI meets all power quality requirements of UL1741,
including harmonic distortion, power factor, and anti-islanding requirements. In
addition, it has increased the SW Series II’s efficiency in SELL mode to within 1% of
the impressive off-grid efficiency of the SW.
The GTI also contains an automatic transfer/shorting relay, which the SW
Series II uses to disconnect the GTI from the circuit when it is not needed, for
example when the SW Series II is charging batteries from the grid. This is also used
to disconnect the GTI so that it does
NOTNOT
NOTNOT
NOT represent a phantom load or parasitic
loss to the system.
All new SW Series II units (manufactured since December of 2001) are
equipped to allow the GTI to be installed in the field. The SW Series II inverter is
Certified to UL1741 for off grid and backup power applications. The SW can be
connected to the grid as a battery charger; however, it is
NOTNOT
NOTNOT
NOT approved to use the
SELL feature (net meter) without the GTI accessory. The GTI carries all necessary
approvals and markings to allow a safety inspector to approve the installation for net
metering.

1.0 INTRODUCTION
2© 2002 Xantrex Technology Inc.
P/N 975-0041-01-02 Rev A 03/02
Figure 1-1
Grid Tie Interface Flow Diagram

1.0 INTRODUCTION
© 2002 Xantrex Technology Inc.
P/N 975-0041-01-02 Rev A 03/02 3
Figure 1-2
Grid Tie Interface Flow Diagram with External Manual Bypass Switch

1.0 INTRODUCTION
4© 2002 Xantrex Technology Inc.
P/N 975-0041-01-02 Rev A 03/02
STANDARD FEATURES
The Grid Tie Interface (GTI) is an external unit that is required for use with the
Xantrex SW Series Inverters, models SW4024, SW4048, and SW5548 with Rev. 4.2
firmware or higher, being used in Utility Interactive “Sell” mode. This device ensures
compliance with regulatory standards for utility interface applications.
The GTI utilizes a highly-efficient inductor constructed of high temperature
materials and M-6 grade steel laminations, meeting UL Class-H standards.
The unit is housed in a powder-coated, steel enclosure, suitable for indoor
installations and contains dual knockouts for ¾" - 1" and ½" - ¾" conduit
connections. The unit includes a control board with one 10-pin, polarized, connector
that connects to the SW inverter.
The GTI has two functions: 1) Utility Interactive Mode, and 2) Bypass Mode.
Utility Interactive Mode
Utility Interactive Mode is only engaged when the SW inverter begins selling
power in the “Sell” mode. When in this mode, the GTI engages an inductor
through an internal relay that filters out current harmonics and ensures that the
power transferred to the grid has Total Harmonic Distortion (THD) levels that are
within acceptable ranges and ensures the power factor is high. The GTI also
provides anti-islanding protection in the event of a utility grid failure.
Bypass Mode
The GTI includes a bypass relay that is controlled by the current direction and
levels in the GTI and allows the critical loads to be connected to the grid or to the
output of the SW inverter. When a low level “sell” current begins, the GTI will
engage the bypass relay to allow the loads to be connected to the grid. In this
operation (grid-connected), the inverter’s AC1 relay and the bypass relay work
together to ensure fast transfer of the critical loads in a backup situation.
The critical loads are effectively connected directly to the grid – through the GTI
– rather than passing through the inverter, resulting in the “LOAD AMPS AC” menu
item displayed on the SW inverter to read zero. This zero reading will continue until
the inverter batteries require a “buy” current of 10-15 amps AC or if a loss of grid
power is detected. If either one of these conditions is detected, the bypass relay will
engage to allow the critical loads to be directly powered by the inverter (inverter-
connected). The inverter will continue to power the critical loads until another “sell”
current begins, which again switches to the grid-connected operation.
Figure 1-3
Grid Tie Interface Unit

© 2002 Xantrex Technology Inc.
P/N 975-0041-01-02 Rev A 03/02 5
2.0 INSTALLATION
PRE-INSTALLATION
The GTI is only designed to work with the SW4024, SW4048 and SW5548
models that have revision 4.2 (or higher) software. Prior to installing the GTI,
ensure that you have the appropriate model, the proper level of software and the
inverter has the communication cable located within.
See Figure 2-6 for the location of this cable.
WARNING: THE CRITICAL LOADS ARE NOW
POWERED THROUGH THE GTI; THESE LOADS
WILL NOT BE POWERED IF THE SW INVERTER OR
THE GTI ARE OFF OR DISCONNECTED. IT IS
RECOMMENDED THAT AN EXTERNAL BYPASS
SWITCH/BREAKER BE INSTALLED BETWEEN THE
GRID AND THE CRITICAL LOAD-PANEL. THIS
SWITCH, WHEN ENGAGED, WILL ALLOW THE
GRID TO DIRECTLY POWER THE LOADS WHILE
THE GTI OR SW INVERTER IS OFF OR
DISCONNECTED. SEE FIGURE 2-9 FOR AN
EXAMPLE OF THIS RELAY IN A XANTREX POWER
PANEL.
Required Tools and Materials
• Wire strippers
• Phillips screw driver
• Slotted screw driver
• Torque wrench
• 3/16" Hex-Head wrench
• #6 AWG Wire
Removing the Top Cover
1. Remove the four Phillips screws and starwashers and set aside. Be sure to
put these screws and washers somewhere where they can’t get lost.
Figure 2-1
Removing the Top Cover
Remove
these
phillips
screws to
remove
top cover
Remove
these
phillips
screws to
remove
top cover

2.0 INSTALLATION
6© 2002 Xantrex Technology Inc.
P/N 975-0041-01-02 Rev A 03/02
Figure 2-2
Mounting Holes
Mounting
Hole
Mounting
Hole
Mounting
Hole
Mounting
Hole
MOUNTING
Place the GTI in a convenient location, close to the inverter. The GTI must
be mounted horizontally on a flat surface (such as a wall) in a clean, dry
environment. Do not mount the GTI where it will be exposed to the weather or in
a damp location.
NOTE: The GTI weighs approximately 25 pounds. Use
appropriate wall anchors or backing material (plywood,
2 x 4’s, etc.) that will support its weight.
CAUTION: Do not mount vertically as water may
enter the enclosure and damage the internal
circuitry. Damage caused by mounting the unit
vertically is NOT covered under the limited
warranty.
Procedure
1. Use a level and mark the location for mounting the unit on the wall.
2. Measure out the four mounting screw holes according to Figure 2-3.
3. Use a #10 x 3/8 (or 1/2) inch long screw and washer (and appropriate
anchors if necessary) and mount the GTI securely to the wall or backing
material (plywood, 2 x 4’s, etc.).
4. Remove the appropriate knockouts for the conduit. Install the conduit
between the GTI and the inverter. Use separate conduit for the AC wiring
and the communications cable.

2.0 INSTALLATION
© 2002 Xantrex Technology Inc.
P/N 975-0041-01-02 Rev A 03/02 7
Figure 2-3
Dimensional Drawing (Not to scale)
Front Internal view of unit
Side of unit
Ends of unit (both ends)
2 3/8"
4 3/8"
1 1/8"
19 7/8"
4 3/4"
3/4"
6 1/8"
1 3/4"
3 1/8"
1 3/8"
21"
1 7/8" 1 7/8" 1 7/8"
3 1/5"
1 3/8"
6 1/4"
6 3/4"
18 3/4"

2.0 INSTALLATION
8© 2002 Xantrex Technology Inc.
P/N 975-0041-01-02 Rev A 03/02
Figure 2-4
GTI Circuit Board Enlargement
WIRING
AC Wiring for Single-Inverter Installations
NOTE: All wiring should be performed by a qualified
person or a licensed electrician.
NOTE: Ensure that wire size and conduit sizes are
appropriate for this installation. AC wiring should be
routed in separate conduits from the communications
cable.
CAUTION: AC pass-through ability through the GTI
is 60 amps. It is recommended to use minimum
#6 AWG (THHN) wiring.
See Figure 2-7 for an enlargement of this circuit board showing the
location of the communications cable port.
NEUTRAL
Bar
AC IN
from the
inverter output
AC OUT
to the
subpanel
AC OUT
to the
inverter’s
AC HOT IN1
Communications
Cable Port
(behind this cable)
AC IN
from the grid
GROUND
LUG

2.0 INSTALLATION
© 2002 Xantrex Technology Inc.
P/N 975-0041-01-02 Rev A 03/02 9
Figure 2-5
AC Input and Output Wiring for Single-Inverter Installations
AC Wiring for Single-Inverter Installations (continued)
See pages 10 through 21 for detailed instructions for AC Input and AC
output wiring for single-inverter/GTI installations.

2.0 INSTALLATION
10 © 2002 Xantrex Technology Inc.
P/N 975-0041-01-02 Rev A 03/02
Wiring (continued)
AC Wiring for Single-Inverter Installations (continued)
Ground Wiring
Note: Ground wiring must be established at each unit.
Ground wiring can also be accomplished in a variety of
ways. The following instructions describe only one
method. Please consult your local electrician for specific
wiring details pertaining to your installation.
1. Connect a wire from the ground bus in the main service panel to the
ground lug in the GTI.
2. Connect a wire from the ground bus in the main service panel to the
ground terminal in the inverter.
3. Connect a wire from the ground bus in the main service panel to the
ground terminal in the sub-panel.
See Figure 2-5a for an illustration of ground wiring for a single-inverter
installation with the GTI.

2.0 INSTALLATION
© 2002 Xantrex Technology Inc.
P/N 975-0041-01-02 Rev A 03/02 11
Figure 2-5a
Ground Wiring for a Single-Inverter Installations
AC Wiring for Single-Inverter Installations (continued)

2.0 INSTALLATION
12 © 2002 Xantrex Technology Inc.
P/N 975-0041-01-02 Rev A 03/02
Wiring (continued)
AC Wiring for Single-Inverter Installations (continued)
Utility Grid AC Wiring to the GTI
WARNING: DISCONNECT THE BATTERIES FROM
THE INVERTER IF THEY ARE ALREADY CONNECTED.
1. Ensure the breaker that feeds the GTI is OFF (i.e., no power out). Feed the
HOT and NEUTRAL input wires from the GTI to the main utility panel.
Leave a sufficient amount of extra wire at each end.
2. Confirm a GROUND (green) wire exists from the main utility panel to the
GTI’s AC GROUND lug.
3. Connect the NEUTRAL (white) wire from the main utility panel to the GTI’s
NEUTRAL bar.
4. Connect the HOT (BLACK) wire from a single-pole breaker (60 amps) in
the main utility panel to the GTI’s AC1 HOT IN terminal.
5. Torque all connections to 10 to 15 inch-pounds.
See Figure 2-5b for an illustration of Utility Grid AC Wiring to the GTI.

2.0 INSTALLATION
© 2002 Xantrex Technology Inc.
P/N 975-0041-01-02 Rev A 03/02 13
Figure 2-5b
Utility Grid AC Wiring to the GTI
AC Wiring for Single-Inverter Installations (continued)

2.0 INSTALLATION
14 © 2002 Xantrex Technology Inc.
P/N 975-0041-01-02 Rev A 03/02
Inverter AC Input Wiring to the GTI
1. Feed the HOT and NEUTRAL input wires from the inverter to the GTI.
Leave three to six inches of extra wire at each end.
2. Connect the NEUTRAL (white) wire from the GTI’s NEU OUT terminal to
the inverter’s NEUTRAL IN 1 terminal.
3. Connect the AC1 HOT OUT (BLACK) wire from the GTI to the inverter’s
AC1 HOT IN terminal.
4. Torque all connections to 10 to 15 inch-pounds.
See Figure 2-5c for an illustration of the inverter AC input wiring to the
GTI.
Wiring (continued)
AC Wiring for Single-Inverter Installations (continued)