Tripp Lite Alternative Power Source User Manual

Owner’s Manual

APS PowerVerter

Alternative Power Sources (120V, 60 Hz)

• Voltage- and Frequency-Controlled • Peak Power • High Efficiency

Introduction

Important Safety Instructions

Configuration & Connection

Features

Maintenance and Service

Warranty

Troubleshooting

Specifications

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1111 W. 35th Street Chicago, IL 60609 USA

Customer Support: (773) 869-1234 • www.tripplite.com

Introduction

Congratulations! You’ve purchased the most advanced, feature-rich integrated inverter/battery charger on the market. Your APS provides your equipment with utility-supplied AC power when it is available, and during blackouts, overvoltages and brownouts, your APS automatically switches over to an external battery source to power connected equipment with voltage and frequency-controlled AC power. In addition to reliable APS performance, your model features:

High Efficiency Output

Your APS’s advanced circuitry produces a more efficient DC-to-AC conversion, minimizing energy loss. This allows you to run connected equipment longer between battery charges. The APS will maintain this highly-efficient output even as the battery charge decreases.

Automatic Overload Protection

If you overload your APS, it will automatically protect itself and your valuable batteries from damage.

Fast Load Switching

Your APS provides an uninterruptible power supply. If AC power goes down, your APS will switch over to providing battery backup power in 6 milliseconds or less so that your equipment will operate with no interruption.

Multi-Function Indicator Lights

Several sets of multifunction indicator lights keep you constantly informed of battery charge levels, fault conditions and APS operation.

Multi-Operation Switches

An array of user-configurable switches gives you convenient options when operating your APS. You can select the voltage level at which your APS’s inverter will turn on to maximize equipment protection and minimize battery drain; set your APS for maximum charging efficiency with your battery type; even set up your APS for remote control operation.

Introduction

Stage 2

Absorption

Stage 3

Float

Stage 1

Bulk

continued

3-Stage Battery Charger

Your APS recharges your battery faster than conventional chargers because its three-stage charger profile (Bulk, Absorption and Float) are optimized, regardless of the type of battery you use (Wet or Gel).* In addition, the advanced charging system protects against over-charge and over-discharge to ensure a longer service life from your battery.

* The Absorption and Float levels vary according to battery

type, which can be set to either “Wet” or “Gel”cell.

Voltage Regulation (Select models only)

“VR” APS models regulate incoming AC power by automatically “boosting” or “cutting” the voltage to keep your equipment running through brownouts and overvoltages without draining battery power.

Load Sharing (Select models only)

Select APS models can be set to limit their own charging functions so they can charge their batteries at the quickest rate possible without overloading their power input circuits.

Frequency-Controlled Inverter Output

All APS models feature Frequency-Controlled Inverter Output which allows devices dependent on AC line frequency (such as computers, VCRs, CD players, tape recorders, clocks and turntables) to operate properly.

Circuit Board Protection

A silicone conformal coating safeguards the circuit boards against moisture.

Important Safety Instruction

SAVE THESE INSTRUCTIONS

This manual contains important instructions and warnings that should be followed during the installation, operation and storage of all Tripp Lite APS Systems.

APS Location Warnings

• Install your APS indoors, away from excess moisture or heat, dust or direct sunlight.

• Your APS is NOT waterproof. Contact with water can cause the unit to short circuit and could cause personal injury due to electric shock. Never immerse your APS. Mount it in the driest location available.

• Leave adequate space around all sides of the APS for proper ventilation. The heavier the load of connected equipment, the more heat will be generated by the APS.

• When mounting unit on a vertical surface, mount it with the control panel facing to the side to reduce the risk of foreign objects entering the APS enclosure.

• Do not install the APS near magnetic storage media, as this may result in data corruption.

Battery Connection Warnings

• Your APS will not operate with or without utility power until batteries are connected.

• Multiple battery systems must be made up of batteries of the same voltage, age, amp hour capacity and type.

• Keep battery location well ventilated. Explosive hydrogen gas can accumulate near batteries if they are not kept well ventilated.

• Sparks may result during final battery connection. Always observe proper polarity as batteries are connected.

• Do not allow objects to contact the two DC input terminals. Do not short or bridge these terminals together. Serious injury to property or person could result.

Equipment Connection Warnings

• Do not use Tripp Lite APS Systems in life support applications where a malfunction or failure of a Tripp Lite APS System could cause failure or significantly alter the performance of a life support device.

• Do not connect a surge suppressor, line conditioner or UPS to the output of the APS.

• Corded models: Do not modify the APS’s plug in a way that eliminates its ground connection. Do not use power adaptors that will eliminate the plug's ground connection. Connect your APS only to a properly grounded AC power outlet. Do not plug your APS into itself; this will damage the APS and void your warranty.

Operation Warnings

• Your APS does not require routine maintenance. Do not open your APS for any reason. There are no user-serviceable parts inside.

• Potentially lethal voltages exist within this unit as long as the battery supply and/or AC input are connected. During any service work, the battery supply and AC input connection (if any) should therefore be disconnected.

• Do not connect or disconnect batteries while the APS is operating from the battery supply. Dangerous arcing may result.

Configuration

4321

Gel Cell

Wet Cell*

4321

145V

135V*

4321

105V

4321

95V

4321

85V

4321

75V*

Configuration Dip Switch Settings

DIP SWITCH GROUP A

(All models)

BATTERY TYPE / VOLTAGE POINT

Using a small tool, set the 4 “Battery Type / Voltage Point” Configuration DIP Switches, Group A (located on the front panel of your APS; see Diagram 1, p. 36) to select battery type and set the voltage range outside of which your APS will switch to battery power.

• Select Battery Type

CAUTION: The Battery Type DIP Switch setting must match the type of batteries you connect or your batteries may be degraded or damaged over an extended period of time. See “Battery Selection,” page 8 for more information.

(DIP Switch #1, Group A)

Battery Type Switch Position

Gel Cell (Sealed) Battery Up

Wet Cell (Vented) Battery Down*

• Select High AC Voltage Switch To Battery Point

Voltage Switch Position

145V Up

135V Down*

(DIP Switch #2, Group A)

• Select Low AC Voltage Switch To Battery Point

Voltage Switch Postion

105V #4 Up & #3 Up

95V #4 Up & #3 Down

85V #4 Down & #3 Up

75V #4 Down & #3 Down*

(DIP Switches #4, Group A & #3, Group A)

Most loads will perform adequately when your APS’s High AC Voltage Point DIP Switch #2 is set to 135V and its Low AC Voltage Point DIP Switches #3 and #4 are set to 95V. However, if your APS frequently switches to battery power due to momentary high/low line voltage swings that would have little effect on equipment operation, you may wish to adjust these settings. By raising the High AC Voltage Switch to Battery point and/or lowering the Low AC Voltage Switch to Battery Point, you may reduce the number of times your APS switches to battery due to voltage swings.

* Factory default settings.

Configuration

4321

continued

DIP SWITCH GROUP B (Available on Select Models)

LOAD SHARING/EQUALIZE BATTERY CHARGE

The “Load Sharing” Configuration DIP Switches, #1 and #2 of Group B (located on the front panel of your APS; see Diagram 1, p. 36), should be set with a small tool according to the guidelines below. DIP Switch #3, Group B should be kept in the “UP” position when you are not equalizing your batteries' charges. DIP Switch #4, Group B has different functions, or no function, depending on your APS model.

• Load Sharing

Your APS features a high-output battery charger that can draw a significant amount of power from your line power source when charging at its maximum rate. If an APS is supplying its full AC power rating to its connected load at the same time as it is charging, it could trip its line source circuit breaker. Tripping this breaker will cut off AC power to your load and stop battery charging.

To reduce the chance of tripping this breaker, select APS models may be set to automatically limit their charger output to keep the sum of their AC load and charger power within their circuit breakers’ rating.

This charger limiting function has four settings, allowing you to choose less charger limiting for APS configurations with higher rated breakers. The figures below show how to set your DIP Switches to select how heavy a load can be placed on your APS before charger limiting begins.

(DIP Switches #1, Group B & #2, Group B)

Battery Charger Limiting Points

Most Limiting (#1 & #2 Up*): Charger limiting takes effect the moment any load is applied; charger output falls gradually from full output at no load to no output at full load.

Less Limiting (#1 Down & #2 Up): Charger limiting begins when the APS's load reaches 33% of the APS’s load rating. Charger output falls gradually from full output at 33% of the APS's load rating to about 40% of full output at full load.

Least Limiting (#1 Up & #2 Down): Charger limiting begins at when the APS’s load reaches 66% of the APS’s load rating. Charger output falls gradually from full output at 66% of the APS's load rating to about 40% of full output at full load.

No Limiting (#1 & #2 Down): No charger limiting occurs at any load size.

* Factory default settings.

Configuration

4321

Partial*

Full

continued

• Equalize Battery Charge

This DIP Switch is momentarily engaged to begin the process of equalizing the internal resistance of your battery's cells. This can extend the useful life of certain types of batteries; consult with your battery's manufacturer to determine if your batteries could benefit from this process. The charge equalization process is automatic and once started can only be stopped by removing the input power.

(DIP Switch #3, Group B)

Setting Procedure:

• Move to “Equalize” (DOWN) position for three seconds.

• Move to “Reset” (UP) position and leave it there.

CAUTION: Battery charge equalization should only be performed in strict accordance with the battery manufacturer’s instructions and specifications.

CAUTION: Do not leave DIP switch #3 in the down position after beginning process.

Battery Charge Switch Position

Reset Up*

Equalize Down

* Factory default setting.

• Limit Battery Charger

To prevent overheating smaller batteries, the charger on these UPS systems is initially set to deliver only a fraction of its maximum power rating to connected batteries. If you are using either of these APS systems with a larger battery or battery system (over 100 amp-hours), you may switch your charger to full power without overheating your batteries.

Battery Charger Switch Position

Partial (1/3) Charging Power Up*

Full Charging Power Down

* Factory default setting.

(APS1012, APS1524 & APS2012 only)

(DIP Switch #4, Group B)

Battery Selection

Selecting Battery Type

Select a battery or system of batteries that will provide your APS with proper DC voltage and an adequate amp hour capacity.* Select ‘Deep-Cycle’batteries to enjoy optimum performance from your APS. Batteries of either Wet-Cell (vented) or Gel-Cell/Absorbed Glass Mat (sealed) construction are ideal. 6 Volt “golf-cart,” Marine Deep-Cycle or 8D Deep-Cycle batteries are also acceptable.**

* Even though APS models are high-efficiency converters of electricity, their rated output capacities are limited by the amp-hour size of the external batteries. ** You must set Configuration DIP Switch #1, Group A (Battery Type) to match the type of batteries you connect or your batteries may be degraded or damaged over an extended period of time. See “APS Configuration,” page 5 for more information.)

Selecting Battery Amp Hour Capacity

1. Add the Wattage Ratings of your connected equipment to determine the Total Wattage Required.*

2. Divide the Total Wattage Required (from Step 1) by the battery voltage to determine the DC Amperes Required.

3. Multiply the DC Amperes Required (from Step 2) by the number of hours you estimate will pass without AC power before your battery can recharge to determine a Battery Amp-Hours Required Rough Estimate.**

4. Compensate for inefficiency by multiplying your Battery Amp-Hour Required Rough Estimate (from Step 3) by 1.2 to determine how many amp-hours of battery backup (from one or several batteries) you should connect to your APS. Note that the Amp-Hour ratings of batteries are usually given for a 20 hour discharge rate. Actual Amp-Hour capacities are less when batteries are discharged at faster rates: batteries discharged in 55 minutes provide only about 50% of their listed Amp-Hour ratings, while batteries discharged in 9 minutes provide as little as 30% of their Amp-Hour ratings.

* The wattage rating is usually stated in the equipment’s manuals or on their nameplates. If your equipment is rated in amperes, convert to watts by multiplying the ampere rating by your nominal AC line voltage (120). ** Your charging amps multiplied by the charging hours must exceed the discharge amp-hours taken from the batteries between charges or you will eventually run down your battery bank.

Mounting

(Optional)

(See Diagram 2, p. 36)

Horizontal mounting should be used for all vehicular applications. Due to their size and weight, all APS PowerVerter systems in vehicles should be mounted on a rigid horizontal (not vertical) surface, mounting plate or bracket before battery connection. User must supply all fasteners and brackets and verify their suitability for use with the intended mounting surface. Turn your APS PowerVerter and connected equipment OFF before mounting.

• Install two 8 mm (1/4 in.) fasteners (A) into a rigid horizontal surface using the

measurements in the diagram. Leave the heads of fasteners raised slightly above the surface in order to engage the slots in the APS’s feet.

• Slide PowerVerter forward to fully engage the fasteners in the APS’s feet. Install two

8 mm (1/4 in.) fasteners (B) into the surface, through the slots in the APS’s two unsecured feet. Tighten the screws to secure the APS in position.

Battery Connection

Standard

1. Connect your APS’s positive DC Terminal directly to a fuse.

UL recommends that you install a recognized UL component fuse block and fuse within 18 inches of the battery. The fuse’s rating must equal or exceed the Minimum DC Fuse Rating listed in your APS model’s specifications on pages 16 or 17.

2. Choose a battery configuration appropriate to your batteries.

• Single Battery Connection: Refer to Diagram 4, page 37. When using a single battery, its voltage must be equal to the voltage of your APS's Inverter Nominal Input Voltage (see specs).

• Parallel Battery Connection: Refer to Diagram 5, page 37. When using multiple batteries in parallel, each battery's voltage must be equal to the voltage of your APS’s Inverter Nominal Input Voltage (see specs).

• Series Battery Connection: Refer to Diagram 6, page 37. When using multiple batteries in series, all batteries must be equal in voltage and amp hour capacity, and the sum of their voltages must be equal to the voltage of your APS's Inverter Nominal Input Voltage (see specs).

3. Use 2/0 gauge wire ONLY to make battery connections. Tighten terminals to a torque of 4 N-m.

Battery connection cable lengths should be short as possible, and must not exceed the Maximum Cable Length listed under Specifications, page 16 or 17. Shorter and heavier gauge cabling limits DC voltage drop and allows for maximum transfer of current.* You must tighten your battery terminals to approximately 4 Newton-meters of torque to create an efficient connection and prevent excessive heating. Insufficiently tightening terminals could void your PowerVerter’s warranty.

* APS models are capable of delivering a much higher wattage output for brief periods of time. Wiring should be configured to handle this brief high-current draw. Though your APS is a high-efficiency converter of electricity, its rated output capacity is limited by the length and gauge of the wires running from the battery to the APS.

DC Vehicular

APS systems may be permanently mounted in a car, truck or boat and connected to draw power from the vehicle's battery. Note: An APS can ONLY be connected to vehicle batteries with

voltage that matches the APS’s Nominal DC Input—12V vehicle batteries to 12V Nominal DC Input APS systems, etc. (See Specifications). There are two main ways to make this sort of

vehicular battery connection. Choose the Basic Connection if you are running light hand tools or other small appliances for a brief period of time (see Diagram 7, p. 38). Choose the Advanced Connection if you are using your APS to power heavy loads for extended periods of time (see Diagram 8, p. 38). The Advanced Connection incorporates a battery isolator and separate battery system to provide battery power to your APS while preventing it from draining your vehicle’s battery. Note: Depending on your application, you may require more than one Deep Cycle Battery.

Note: The main ground stud on the rear panel must be connected to the vehicle chassis. A non-grounded unit could cause an electrical shock hazard. Caution: Never operate your APS from an alternator without a battery connected as shown in Diagrams 7 or 8, p. 38.

DC Ground Connection

APS systems must be connected to a grounded, permanent wiring system. For most installations, the negative battery conductor must be bonded to the grounding system at one (and only one) point in the system. All installations must comply with national and local codes and ordinances.

AC Connection

Before AC connection, match the power requirements of your

equipment with the power output of your APS to avoid overload.

When figuring the power requirements of your equipment, do not confuse “continuous” power ratings with “peak” power ratings. Electric motors require more power to turn on (“peak power”) than they require to run continuously. “Peak” power ratings are usually 2 to 5 times “Continuous” ratings. Most electric motors require “peak power” only when they are first turned on. The electric motors in equipment such as refrigerators and sump pumps, however, constantly turn on and off according to demand. These motors require “peak power” at multiple, unpredictable times during their operation.

Hardwired Electrical Connections (All hardwire models)

Consult a qualified electrician and follow all applicable electrical codes and requirements.

HARDWIRE PROCEDURE

1. Remove screws and cover plate from your APS’s Hardwire AC electrical box. Remove the knockout covers closest to the desired electrical source and to your equipment.

2. Thread your wires through the knockouts, adding strain reliefs if desired.

3. Connect both input and output ground wires to the ground (green) terminal.

4. Connect the incoming hot wire to the input hot (brown) terminal.

5. Connect the incoming neutral wire to the input neutral (blue) terminal.

6. Connect the outgoing hot wire to the output hot (black) terminal.

7. Connect the outgoing neutral wire to the output neutral (white) terminal.

8. Tighten and affix strain reliefs. Replace cover plate and tighten screws.

(See Diagram 3, p. 36)

AC Input Electrical Connection (All corded models)

Plug the line cord into an outlet providing 120V AC, 60 Hz. power. Make sure that the circuit you connect your APS to has adequate overload protection, such as a circuit breaker or a fuse.

AC Output Electrical Connection (All corded models)

Simply plug your equipment into the unit’s AC receptacles.

AC Connection

continued

Set Operating Mode Switch

• Switch to “AUTO/REMOTE” when you are using connected equipment. ADVANTAGE:

Uninterruptible power supply. Provides battery backup power during blackouts or brownouts.

Note: When the switch is in the “AUTO/REMOTE” position, you can operate a user-supplied switch to transfer between battery-backup and charge-only modes. (See Remote Connector manual for more information.)

• Switch to “CHARGE ONLY” when you are not using connected equipment. (WARNING!

APS will not provide battery backup!) ADVANTAGES: A) Continues to charge battery when power is present, and B) Turns OFF the APS’s inverter, preventing battery drain during blackouts or brownouts.

• Switch to “OFF” to completely turn off the APS and connected equipment or to reset the APS after it has shut down due to overload or overheating.

Switches, Indicator Lights & Other Features

(See Diagrams 9a and 9b, p. 39-40, to locate the following switches, indicator lights and other features.)

Switches

1. Operating Mode Switch (All models): This switch selects the APS operating mode (either

“AUTO/REMOTE”, “OFF” or “CHARGE ONLY”). See “Set Operating Mode Switch”, pg. 11 to select the optimum setting for this switch.

2. “CONFIGURATION SWITCHES”—DIP Switch Group A (All models): These four

switches must be set for the type of battery your APS will be connected to and the voltage points at which your APS will switch to battery power. See “Configuration”, pg. 5 to select the optimum settings for these switches.

3. “CONFIGURATION SWITCHES”—DIP Switch Group B (Select models only): These

DIP Switches allow you to equalize the internal resistance of your battery’s cells and set the percentage of your model's maximum load at which the APS will limit battery charging. See “Configuration”, pg. 6 to select the optimum settings for these switches.

Switches, Indicator Lights & Other Features

continued

Indicator Lights

4. “LINE” (All models): This green light will turn continuously ON whenever connected equipment

is receiving utility-supplied AC power and your APS is set to “AUTO/REMOTE”, meaning that it will provide battery backup if utility power fails. It will flash intermittently when connected equipment is receiving utility power and your APS’s Operating Mode Switch is set to “CHARGE ONLY” to warn you that the APS’s inverter is OFF and that the APS WILL NOT provide battery backup during blackouts, brownouts or overvoltages.

5. “INV” (Inverting—all models): This yellow light will turn continuously ON whenever

connected equipment is receiving battery-supplied AC power (during a blackout, brownout or overvoltage while connected to utility power or when connected to batteries during vehicular operation).

6. “LOAD” (All models): This red light will turn continuously ON when the APS’s load is

between 80% and 110% of capacity. The light will flash intermittently when the APS’s inverter shuts down due to a severe overload or overheating. If this happens, turn Operating Mode Switch OFF. Remove the overload and let the unit cool. You may then turn the APS ON after it cools.

7. “CUT/BOOST” (VR models only): These lights will turn ON whenever your APS is

automatically correcting high (CUT) or low (BOOST) AC line voltage. This is a normal, automatic operation of your APS that does not drain battery power, and no action is required on your part.

8. “BATTERY HI/MED/LO” (All models): These three lights will turn ON in several

sequences to show the approximate charge level and voltage of your connected battery bank and alert you to several fault conditions:

BATTERY CHARGE INDICATION (Approximate)

Indicator Capacity

Green 91% - Full Green & yellow 81% - 90% Yellow 61% - 80% Yellow & red 41% - 60% Red 21% - 40% All three lights off 1% - 20% Flashing red 0% (Inverter shutdown)

All three lights flash slowly* Excessive discharge All three lights flash quickly** Overcharge

* Approximately 1/2 second on, 1/2 second off. See Troubleshooting section.

** Approximately 1/4 second on, 1/4 second off. May also indicate a battery charger fault exists. See Troubleshooting section.

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