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Power Module System

Assembly 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) 435-8826

Part Number 3471

Содержание PM DR 175

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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