Trace Engineering PM DR 175 Assembly Instructions Manual Download

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Table of Contents

Introducing the Power Module System . . . . . 1-1

IMPORTANT SAFETY INSTRUCTIONS . . . . . 2-1

General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Personal Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Underwriters Laboratory (U.L.) Compliance Requirements. . . . . . . . . 2-3

Power Module Installation

. . . . . . . . . . . 3-1

Powering Up the System . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Stacked Pair Inverters . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Power Module Systems . . . . . . . . . . . . . 4-1

Power Module Fastener Facts . . . . . . . . . . . . . . . . . . . . . . . 4-2

PM DR 175/250 Single Inverter Diagram . . . . . . . . . . . . . . . . . . 4-4

PM DR 175/250 Dual Diagram . . . . . . . . . . . . . . . . . . . . . . . 4-8

PM SW 175/250 S Diagram . . . . . . . . . . . . . . . . . . . . . . . . 4-10

PM SW 175/250 Dual Diagram . . . . . . . . . . . . . . . . . . . . . . 4-12

Sinewave 3 - Phase System. . . . . . . . . . . . . . . . . . . . . . . . 4-16

3-Phase Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . 4-17

Electrical Components Assembly Instructions 5-1

PMO-AC15/20/60 Front View . . . . . . . . . . . . . . . . . . . . . . . . 5-3

PMO-AC60 3-Phase Breaker . . . . . . . . . . . . . . . . . . . . . . . . 5-5

PMO-C40, C40K & VLC40 for DR Systems . . . . . . . . . . . . . . . . 5-7

PMO-C40, C40K & VLC40 for DR Systems . . . . . . . . . . . . . . . . 5-8

PMO-40, C40k & VLC40 for Sinewave Systems . . . . . . . . . . . . . . 5-9

PMO-DC20/60/110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

PMO-DC20/60/110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

PMO-DC175/250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

PMO-DC175/250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

PMO-DCBB/Kit/SW/DR . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

PMO-DCBB/Kit/(SW)(DR) . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

PMO-DCBB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

PMO-IOX60 Input/Output/Bypass Breaker . . . . . . . . . . . . . . . . 5-19

Summary of Contents for PM DR 175

Page 1: ...mbly Instructions How To Use This Manual inside cover Inverter Systems Chapter Four Electrical Components Chapter Five Cabinet Components Chapter Six 5916 195th Street NE Arlington WA USA 98223 360 43...

Page 2: ...to Chapter Five and select the assembly instructions for each electrical component listed in the system Go to Chapter Six and select the assembly instructions for each cabinet component listed on the...

Page 3: ...gram 4 4 PM DR 175 250 Dual Diagram 4 8 PM SW 175 250 S Diagram 4 10 PM SW 175 250 Dual Diagram 4 12 Sinewave 3 Phase System 4 16 3 Phase Assembly Sequence 4 17 Electrical Components Assembly Instruct...

Page 4: ...Cabinet Components 6 1 PM 6 3 PM ADD 6 5 PM EXT 6 7 PMO BLANK 6 9 PMO BRACE 6 11 PMO COVER 6 13 PM DOOR 6 15 PM FEET 6 17 PM LID 6 19 PM LATCHES LOCKS 6 21 PMO SLIDER 6 23 PMO TRAY 6 25 Limited Warra...

Page 5: ...ers controllers busses DC shunt and bonding blocks grounding blocks wiring and fasteners for field installation These components and batteries can also be shipped or acquired separately When ordering...

Page 6: ...Engineering Co Inc Telephone 360 435 8826 Part Number 3471 5916 195th Street NE Fax 360 435 2229 Released Thursday April 29 1999 Arlington WA 98223 USA www traceengineering com 1 2 This page intention...

Page 7: ...is risk the inverter by pass breaker must be used and the power module must be totally disconnected from all sources Solar photovoltaic modules produce current when exposed to light cover them with op...

Page 8: ...cautions 1 Someone should be within range of your voice to come to your aid when you work near batteries 2 Have plenty of fresh water and soap nearby in case battery acid contacts skin clothing or eye...

Page 9: ...ules and lid must have a star washer on the outside between the head of the carriage bolt and the module and on the inside between the module and the nut to insure grounding continuity between modules...

Page 10: ...ne 360 435 8826 Part Number 3471 5916 195th Street NE Fax 360 435 2229 Released Thursday April 29 1999 Arlington WA 98223 USA www traceengineering com 2 4 Underwriters Laboratory U L Compliance Requir...

Page 11: ...nal AC input it should be connected to AC2 it will normally have an additional AC input output bypass breaker Grounding Parameters Connect D C Ground wire 8 AWG to grounding rod Connect the A C Ground...

Page 12: ...stacked pair of inverters the physical connection of the PM is no different However since 240 volts AC is available across the two inverter s AC outputs connection of the AC loads to the system via th...

Page 13: ...umber 3471 5916 195th Street NE Fax 360 435 2229 Released Thursday April 29 1999 Arlington WA 98223 USA www traceengineering com 4 1 PM Systems Single DR Inverter Diagram 3 Dual DR Inverter Diagram 5...

Page 14: ...4 x 1 2 SS carriage bolt 14 485 1 4 SS internal star washer 14 2147 1 4 SS external star washer 14 465 10 SS flat washer 14 442 10 24 SS hex nut 14 PM LID 3191 10 24 x 1 SS carriage bolt 6 485 1 4 SS...

Page 15: ...DR System Copyright Trace Engineering Co Inc Telephone 360 435 8826 Part Number 3471 5916 195th Street NE Fax 360 435 2229 Released Thursday April 29 1999 Arlington WA 98223 USA www traceengineering c...

Page 16: ...ied Qty Part No Description 1 1 DC175 175 amp DC circuit breaker used with DR1512 1524 OR 2424 DC250 250 amp DC circuit breaker used with DR2412 or3624 2 1 DCBB DC bonding block with shunt 3 US PV wir...

Page 17: ...e 19 11 any additional AC or DC breakers 12 Slider Page 23 13 Cover Page 13 14 connect ground conductors 15 AC output cables 16 AC neutral cables 17 DC cables 18 Decals 19 Lid Page 19 20 Door Page 15...

Page 18: ...Telephone 360 435 8826 Part Number 3471 5916 195th Street NE Fax 360 435 2229 Released Thursday April 29 1999 Arlington WA 98223 USA www traceengineering com 4 6 PM DR 175 250 Single Inverter Diagram...

Page 19: ...Trace Engineering Co Inc Telephone 360 435 8826 Part Number 3471 5916 195th Street NE Fax 360 435 2229 Released Thursday April 29 1999 Arlington WA 98223 USA www traceengineering com PM DR 175 250 Sin...

Page 20: ...to secure the module to the floor or base FROM AC UTILITY OR GENERATOR GROUND BATTERY FROM AC UTILITY OR GENERATOR NEUTRAL Battery Battery BATTERY MAX OVER TEMP RED OVERLOAD GRN BATTERY HI RED BATTERY...

Page 21: ...DC175 250 9 DC20 60 110 10 IOX60 11 any additional AC or DC breakers 12 Slider 13 Cover 14 connect ground conductors 15 AC output cables 16 AC neutral cables 17 DC cables 18 Decals 19 Lid 20 Door Remo...

Page 22: ...n the reverse side of this page Qty P N Description 1 1 decal To AC Hot Loads 2 AR IOX60 AC input output bypass disconnect w lockout 3 AR 3200 decal From AC Hot Utility Generator 4 2 Slider unused bre...

Page 23: ...110 10 IOX60 11 any additional AC or DC breakers 12 Slider 13 Cover 14 ground conductors 15 AC output cables 16 AC neutral cables 17 DC cables 18 Decals 19 Lid 20 Door Invert PM to install feet rever...

Page 24: ...N 2 NEUTRAL IN 1 GENERATOR IN EXTERNAL BATTERY TEMP RY8 COM J2 RY10 RY11 RY8 NO NO RY7 NC LOWER COM COM NC RY11 NO NC COM NO TB2 NO NC COM RY10 UPPER RY9 AC CONNECTIONS BATTERY SOLAR ARRAY 1 SOLAR ARR...

Page 25: ...for SW right panel for DR 5 DC bonding block Page 5 15 left for DR right for SW 6 DC175 250 Page 5 14 7 DC20 60 110 Page 5 12 8 IOX60 Page 5 19 9 any additional AC or DC breakers 10 Slider Page 6 23...

Page 26: ...Power Module Copyright Trace Engineering Co Inc Telephone 360 435 8826 Part Number 3471 5916 195th Street NE Fax 360 435 2229 Released Thursday April 29 1999 Arlington WA 98223 USA www traceengineeri...

Page 27: ...435 8826 Part Number 3471 5916 195th Street NE Fax 360 435 2229 Released Thursday April 29 1999 Arlington WA 98223 USA www traceengineering com Three Phase Power Module 4 15 A B C D 11 13 12 14 14 15...

Page 28: ...bly to each negative battery bank terminal 8 3 DC175or250 DC circuit breaker connect a red 2 0 or 4 0 cable from the battery bank positive terminal to the top of each breaker connect a red 4 0 cable f...

Page 29: ...to the DC breakers and C40 s where used 12 Secure the Phase A inverter to the floor of the Phase A module with the fasteners provided for this purpose 13 Plug the 3 Phase interface cable into the con...

Page 30: ...et NE Fax 360 435 2229 Released Thursday April 29 1999 Arlington WA 98223 USA www traceengineering com 4 18 3 Phase Assembly Sequence 17 Cover Detail 15 PV Array Breakers Detail 6 Three Phase Monitor...

Page 31: ...first installing the two IOX60 bypass breakers page 5 19 then add a SLIDER to the unused breaker openings page 6 23 and edgeguards to the openings in the bottom Then install a BLANK page 6 9 on the ri...

Page 32: ...o Inc Telephone 360 435 8826 Part Number 3471 5916 195th Street NE Fax 360 435 2229 Released Thursday April 29 1999 Arlington WA 98223 USA www traceengineering com 4 20 3 Phase Assembly Sequence This...

Page 33: ...s Assembly Instructions Copyright Trace Engineering Co Inc Telephone 360 435 8826 Part Number 3471 5916 195th Street NE Fax 360 435 2229 Released Thursday April 29 1999 Arlington WA 98223 USA www trac...

Page 34: ...for DR Systems 5 8 C40 C40k VLC40 for Sinewave Systems 5 9 Wiring Instructions 5 9 DC20 60 110 5 11 DC20 60 110 5 12 DC175 250 5 13 DC175 250 5 14 DCBB K SW 5 15 DCBB 5 16 DCBB 5 17 IOX60 Input Outpu...

Page 35: ...iagrams on this and the next page Strip wire approximately 425 both ends and cut to appropriate length Qty Part No Description 1 1 3371 decal AC LOADS 2 2 401 6 32 X 3 8 HH SS bolt 3 2 492 6 starwashe...

Page 36: ...ffset to the inside of the enclosure Slide a 6 SAE flat washer 466 over the bolt followed by a 6 32 nut 440 Do not tighten just catch a few threads 5 Tilt the top of the circuit breaker while sliding...

Page 37: ...Phase A bypass breaker It accepts its input from the three phase monitor when used or directly from each individual inverter bypass breaker IOX60 A decal describing the startup and shutdown procedure...

Page 38: ...from the inside so that the ears are offset to the inside of the enclosure Slide a 6 SAE flat washer 466 over the bolt followed by a 6 32 nut 440 Do not tighten just catch a few threads 5 Tilt the top...

Page 39: ...egative to the bonding block Connect the frames of the PV Modules to the bonding block through ground wiring The PV negative and battery negatives are connected at the negative bonding block Do not co...

Page 40: ...a voltage limiting controller It includes all of the items that come with the PMO C40 but uses a modified C4O for systems that use PV modules generating high open circuit voltage over 70 volts DC wit...

Page 41: ...uctor between the DCBB and a rod or pipe driven into the earth Qty Part No Description 1 AR PMO C40 K charge load or diversion controller 2 2 3220 1 375 thermoplastic knockout bushing 3 1 PMO BTS batt...

Page 42: ...PV charge control mode DC load control mode and diversion load control mode the controller can operate in only one mode at a time In addition the C40 option includes a 60 amp Heineman DC breaker 6 AW...

Page 43: ...er connect the C40 Battery terminal to the bottom of the DCXX and your PV array positive to the barrel lug at the top of the DCXX to complete the installation When a charge controller is not used conn...

Page 44: ...he back of the circuit breaker and install the barrel lug over the stud Replace the flat washer followed by the starwasher and the nut then tighten Insert the breaker in the side panel from the inside...

Page 45: ...h table to determine the length of battery cables Fabricate cables as shown in 7 through 10 below Qty Part No Description 1 AR 3204 decal Inverter 2 AR 2079 250 amp circuit breaker DR2412 DR3624 SW251...

Page 46: ...talled Rotate cable lugs on top and bottom 180 degrees prior to installing the breaker in the enclosure see illustrations above Strip insulation from cables 0 425 inch on each end and install ring ter...

Page 47: ...ther tapped hole in the bonding block Don t forget to place an external tooth starwasher between the bonding block and the enclosure on each machine screw This assures an electrical bond between the b...

Page 48: ...e bottom of the DCBB shown in the photo above with a DC175 250 installed Connect a bare ground conductor from the bottom of the DCBB to a copper or iron rod driven into the ground to form a ground rod...

Page 49: ...e DC175 250 inverter positive breakers provides a ground bond for all of the inverter negatives The 50mV 500 amp shunt that is a part of the DCBB provides an interface for an ammeter or battery monito...

Page 50: ...eering Co Inc Telephone 360 435 8826 Part Number 3471 5916 195th Street NE Fax 360 435 2229 Released Thursday April 29 1999 Arlington WA 98223 USA www traceengineering com 5 18 PMO DCBB This page inte...

Page 51: ...ervicing the inverter In normal operation AC power passes through the inverter to the AC loads enabling the inverter to monitor the AC supply and charge the batteries In the event of an interruption o...

Page 52: ...al Normal Operation 4 1 2346 bypass interlock 5 1 2358 decal Inverter 1 6 1 2359 decal Inverter 2 7 1 3200 decal From AC Hot Utility Generator 8 1 3202 decal To AC Hot Loads 9 6 2322 6 AWG Blk THHN st...

Page 53: ...0 AWG cable If additional capacity is required a second neutral bonding block can be snapped to the first A ground bonding block is also included as part of the PMO Neutral option Drill the appropriat...

Page 54: ...ering Co Inc Telephone 360 435 8826 Part Number 3471 5916 195th Street NE Fax 360 435 2229 Released Thursday April 29 1999 Arlington WA 98223 USA www traceengineering com 5 22 PMO NEUTRAL This page in...

Page 55: ...Components Copyright Trace Engineering Co Inc Telephone 360 435 8826 Part Number 3471 5916 195th Street NE Fax 360 435 2229 Released Thursday April 29 1999 Arlington WA 98223 USA www traceengineering...

Page 56: ...Engineering Co Inc Telephone 360 435 8826 Part Number 3471 5916 195th Street NE Fax 360 435 2229 Released Thursday April 29 1999 Arlington WA 98223 USA www traceengineering com 6 2 This page intention...

Page 57: ...d or wooden platform The gaskets baffles and screens for the door and cabinet bottom prevent insects and small animals from entering the cabinets Install the neoprene perimeter gasket only after all P...

Page 58: ...ngineering Co Inc Telephone 360 435 8826 Part Number 3471 5916 195th Street NE Fax 360 435 2229 Released Thursday April 29 1999 Arlington WA 98223 USA www traceengineering com 6 4 PM This page intenti...

Page 59: ...PM ADD is used for adding equipment including batteries an inverter charge controllers or what ever you like It is fabricated from the same high quality material as the PM module Qty Part No Descripti...

Page 60: ...ineering Co Inc Telephone 360 435 8826 Part Number 3471 5916 195th Street NE Fax 360 435 2229 Released Thursday April 29 1999 Arlington WA 98223 USA www traceengineering com 6 6 PM ADD This page inten...

Page 61: ...teries or other components that require more clearance than afforded by the PM or PM ADD PM EXT is constructed of the same high quality materials and is powder coated for long life Qty Part No Descrip...

Page 62: ...ineering Co Inc Telephone 360 435 8826 Part Number 3471 5916 195th Street NE Fax 360 435 2229 Released Thursday April 29 1999 Arlington WA 98223 USA www traceengineering com 6 8 PM EXT This page inten...

Page 63: ...a 0 080 aluminum plate used to cover the circuit breaker openings in the wing panels of the PM and PM ADD Install these blanks on the outside of the wing panel using the six self tapping stainless st...

Page 64: ...eering Co Inc Telephone 360 435 8826 Part Number 3471 5916 195th Street NE Fax 360 435 2229 Released Thursday April 29 1999 Arlington WA 98223 USA www traceengineering com 6 10 PMO BLANK This page int...

Page 65: ...PMO BRACE Brace is an aluminum channel used to reinforce the bottom of the PM and PM ADD to support extra heavy loads such as a battery bank Install the brace using the fasteners provided and tighten...

Page 66: ...eering Co Inc Telephone 360 435 8826 Part Number 3471 5916 195th Street NE Fax 360 435 2229 Released Thursday April 29 1999 Arlington WA 98223 USA www traceengineering com 6 12 PMO BRACE This page int...

Page 67: ...inged cover that prevents unauthorized tampering with the breakers These covers are provided with a foam gasket to provide protection from the insects and the elements and a lock hasp to prevent unaut...

Page 68: ...eering Co Inc Telephone 360 435 8826 Part Number 3471 5916 195th Street NE Fax 360 435 2229 Released Thursday April 29 1999 Arlington WA 98223 USA www traceengineering com 6 14 PMO COVER This page int...

Page 69: ...The door is fabricated from powder coated 0 090 aluminum for long life See reverse for door assembly instructions See Latch for latch assembly instructions The Trace Power Systems decal is usually aff...

Page 70: ...lly left blank Copyright Trace Engineering Co Inc Telephone 360 435 8826 Part Number 3471 5916 195th Street NE Fax 360 435 2229 Released Thursday April 29 1999 Arlington WA 98223 USA www traceengineer...

Page 71: ...to be the only or the bottom unit of the stack Secure the feet to the PM with 14 10 24 x 1 5 carriage bolts provided Place an internal tooth starwasher on the bolt insert through the PM and then the b...

Page 72: ...n field Be sure that the slab or flooring is strong enough to support the total weight of the modules and prevent the modules from being overturned Special consideration should be given to flooding an...

Page 73: ...mesh for the bottom plus the door label At least six fasteners are required to hold the lid to the PM Slide the lid forward from the rear then install fasteners Door slides under the leading edge of...

Page 74: ...neering Co Inc Telephone 360 435 8826 Part Number 3471 5916 195th Street NE Fax 360 435 2229 Released Thursday April 29 1999 Arlington WA 98223 USA www traceengineering com 6 20 PM LID This page inten...

Page 75: ...cam latches to locking latches In the above illustration the locking cam is shown in the open position Orient keys locking cams in the vertical position upon installation Locked position is turn to le...

Page 76: ...ng Co Inc Telephone 360 435 8826 Part Number 3471 5916 195th Street NE Fax 360 435 2229 Released Thursday April 29 1999 Arlington WA 98223 USA www traceengineering com 6 22 PM LATCHES LOCKS This page...

Page 77: ...ted aluminum plates that cover unused circuit breaker spaces in the cabinets Each cover is held in place by four dome headed stainless steel carriage bolts that cannot be removed from the exterior of...

Page 78: ...ering Co Inc Telephone 360 435 8826 Part Number 3471 5916 195th Street NE Fax 360 435 2229 Released Thursday April 29 1999 Arlington WA 98223 USA www traceengineering com 6 24 PMO SLIDER This page int...

Page 79: ...Arlington WA 98223 USA www traceengineering com PMO TRAY 6 25 PMO TRAY PMO TRAY is a glass fiber reinforced battery tray intended to be placed between the batteries and the bottom of the PM to preven...

Page 80: ...eering Co Inc Telephone 360 435 8826 Part Number 3471 5916 195th Street NE Fax 360 435 2229 Released Thursday April 29 1999 Arlington WA 98223 USA www traceengineering com 6 26 PMO TRAY This page inte...

Page 81: ...ng factory in the original packaging with all transportation costs and full insurance paid by the purchaser or owner ALL REMEDIES AND THE MEASURE OF DAMAGES ARE LIMITED TO THE ABOVE TRACE ENGINEERING...

Page 82: ...ve been minimized b the customer assumes all such risks and the liability of Trace Engineering Inc is adequately protected under the circumstances Examples of devices considered to be life support dev...

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