Tripp Lite APS 612 User Manual

Owner’s Manual

APS 612 PowerVerter

Inverter/Charger (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/charger on the market. Your APS powers connected equipment, switching manually or automatically from utility power to power inverted from an external battery or batteries. In addition to reliable APS performance,your model provides:

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.

Multi-Function Indicator Lights

Several sets of multi-function 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) is optimized for 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.

Frequency-Controlled Inverter Output

Your APS has 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 Instructions

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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.

• 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 alter the cord of your APS in a way that would eliminate its connection to ground. Do not use adapters that would eliminate the APS’s connection to ground. Connect the input cord of your APS to a properly grounded,3-wire, 120V 60 Hz power receptacle.Do not plug your APS into itself; this may damage the unit and will void your warranty.

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

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 cord 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*

DIP Switches

Using a small tool, set the four “Battery Type / Voltage Point” Configuration DIP Switches (located on the front panel of your APS); see Diagram 4, p. 28.

• 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 6 for more information.

(DIP Switch #1)

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• Select High AC Voltage Switch To Battery Point

VVoollttaaggee SSwwiittcchh PPoossiittiioonn 145V Up 135V Down*

(DIP Switch #2)

• Select Low AC Voltage Switch To Battery Point

VVoollttaaggee SSwwiittcchh PPoossttiioonn 105V #4 Up & #3 Up 95V #4 Up & #3 Down 85V #4 Down & #3 Up 75V #4 Down & #3 Down*

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. Your APS will switch to battery due to voltage swings the least if the High AC Voltage Switch to Battery Point is on its highest setting and the Low AC Voltage Switch to Battery Point is on its lowest setting.

(DIP Switches #4 & #3)

* Factory default settings.

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 DC voltage, 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 “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 be recharged 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.

Battery Connection

1. Make sure that your APS batteries have proper overcurrent protection.

NEC article 551 requires that you install a recognized UL component fuse block and UL listed 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 page 13.

2. Choose a battery configuration appropriate to your batteries.

• Single Battery Connection:Refer to Diagram 1,page 27.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 2, page 27. 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 3, page 27. 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. Securely fasten the APS’s DC connector to the battery connection cables.

For best results, use 1/0 gauge cable for battery connection. Battery connection cable lengths should be as short as possible,and never greater than 20 feet.Using longer cables, or cables of too small a gauge, could result in dangerous overheating or fire.*

You must tighten your battery terminals to approximately 4 Newton-meters (36 Inch Pounds) 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 DC voltage, its rated output capacity is limited by the length and gauge of the wires running from the battery to the APS.

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.

You must use 15A branch circuit protection (user-supplied) on the input circuit.

AC Input Electrical Connection

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

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

Set Operating Mode Switch

••

Switch to “AUTO/REMOTE” when you are using your connected equipment.ADVANTAGE:APS will automatically switch from providing connected equipment with utility power to providing connected equipment with power inverted from external batteries when utility power is unavailable.

Note: when the switch is in the "AUTO/REMOTE" position, you can remotely monitor and control your APS by connecting a Tripp Lite Remote Control Module (sold separately) to the APS's RJ45 Remote Module Connector.

••

Switch to “CHARGE ONLY” when you are not using your 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 Diagram 4, p. 28, to locate the following switches, indicator lights and other features.)

Switches

11.. OOppeerraattiinngg MMooddee SSwwiittcchh:: “AUTO/REMOTE”,“OFF” or “CHARGE ONLY”). See “Set Operating Mode Switch”, p. 8 to select the appropriate setting for this switch.

This switch selects the APS operating mode (either

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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”, p. 5 to select the optimum settings for these switches.

Indicator Lights

33.. ““LLIINNEE””:: receiving utility-supplied AC power and your APS is set to “AUTO/REMOTE”,meaning that it will automatically switch to battery power if AC power becomes unavailable. It will flash intermittently when connected equipment is receiving utility power and your APS’s Operating Mode Switch is set to “CHARGE ONLY” to indicate that the APS’s inverter is OFF and that the APS will not supply power from its batteries.

44.. ““IINNVV””:: receiving battery-supplied AC power. It will flash if the APS does not detect the minimum load necessary to activate the inverter.

55.. ““LLOOAADD””:: continuously ON when the APS’s load is between 80% and 110% of capacity, to alert you that the inverter might not be able to support the load.The light will flash intermittently after 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.

66.. ““BBAATTTTEERRYY HHII//MMEEDD//LLOO””:: the approximate charge level and voltage of your connected battery bank and alert you to several fault conditions:

BATTERY CHARGE INDICATION (Approximate)

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

** Approximately 1/4 second on, 1/4 second off.See Troubleshooting section.

This green light will turn continuously ON whenever connected equipment is

This yellow light will turn continuously ON whenever connected equipment is

When your UPS is receiving utility-supplied AC power, this red light will turn

These THREE lights will turn ON in several sequences to show

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((LLIINNEE OONN)) ((IINNVV OONN))

Green Float High Charge State Green & yellow Absorption (50% Done) High/Medium Charge State Yellow Absorption Medium Charge State Yellow & red Bulk (50% Done) Medium/Low Charge State Red Bulk Low Charge State All three lights off Charger Inhibited Very Low Charge State Flashing green Equalizing Charge N/A Flashing red N/A Low Battery Shutdown

All three lights flash slowly* Excessive discharge;check batteries All three lights flash quickly** Overcharge;check charger

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