Tripp Lite APS PowerVerter User Manual

1111 W. 35th Street

Chicago, IL 60609 USA

Customer Support: (773) 869-1234

www.tripplite.com

Configuration & Connection: p. 5-10

Features: p. 10 - 11

Warranty: p. 12

Troubleshooting: p. 13

Safety: p. 4

Introduction: p. 2 - 3

Maintenance & Service: p. 12

Specifications: p. 14 - 15

Owner’s Manual

APS PowerVerter

Alternative Power Sources

(120V, 60 Hz)

• Voltage- and Frequency-Controlled

• Peak Power, High Efficiency

Español: pg. 16

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 frequencycontrolled 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.

Advanced, 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.

Stage 1

Bulk

Stage 2

Absorption

Stage 3

Float

BATTERY VOLTAGE

TIME

CHARGING PROFILE

• 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.

Safety

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.

• 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 adapters 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.

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Configuration

CONFIGURATION DIP SWITCH SETTINGS

DIP SWITCH GR

OUP 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. 32) to select battery type and set the voltage range outside of which your APS will switch to battery power.

• Select Battery Type

(DIP Switch #1, Group A)

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 7 for more information.

Battery Type Switch Position

Gel Cell (Sealed) Battery ............................Up

Wet Cell (Vented) Battery ............................Down*

• Select High AC Voltage Switch To Battery Point

(DIP Switch #2, Group A) Voltage Switch Position

145V ............................................................Up

135V ............................................................Down*

• Select Low AC Voltage Switch To Battery Point

(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.

DIP SWITCH GR

OUP B (Available on Select Models)

LOAD SHARING/EQUALIZE BATTERY CHARGE

Using a small tool, set the “Load Sharing” Configuration DIP Switches, #1 and #2 of Group B (located on the front panel of your APS; see Diagram 1, p. 32). 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.

75V*

#4 Down

& #3 Down

85V

#4 Down & #3 Up

95V

#4 Up & #3 Down

105V

#4 Up & #3 Up

Gel Cell

Wet

Cell*

145V

135V*

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• Load Sharing

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

• Equalize Battery Charge

(DIP Switch #3, Group B) 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.

SETTING PROCEDURE:

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

2) 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.

• Disable Battery Charger (APS 2448 only)

(DIP Switch #4, Group B) If you are connecting the APS 2448 to batteries with a separate charger, you may disable the APS 2448’s built-in charger with this switch to prevent overcharging.

Batter

y Charger Switch Position

Disable..........................................................Up*

Enable ..........................................................Down

* Factory default setting.

Reset*

Equalize

Disable*

Enable

Battery Charger Limiting Points

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.

* Factory default settings.

Most Limiting

#1 & #2 Up*

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.

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.

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• Limit Battery Charger (APS 1012 and APS 2012 only)

(DIP Switch #4, Group B) 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 at 12 volts for the APS 1012, over 200 amp-hours at 12 volts for the APS 2012), 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.

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

Step 1:

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

Step 2:

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

Step 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.**

Step 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.

1/3 Power*

Full

Power

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Mounting (Optional*)

(See Diagram 2, p. 32).

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.

* 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.

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 14 or 15.

2. Choose a battery configuration appropriate to your batteries.

• Single Battery Connection: Refer to Diagram 4, page 33. 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 33. 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 33. 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 external battery connections. Tighten battery terminals to a torque of 4 N-m.

WARNING! Failure to follow these instructions can lead to product failure due to excessive heating!

Battery connection cable lengths should be short as possible, and must not exceed the Maximum Cable Length listed under Specifications, page 14. 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.

Battery Connection (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. 34). Choose the Advanced Connection if you are using your APS to power heavy loads for extended periods of time (see Diagram 8, p. 34). 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.

Caution: Never operate your APS from an alternator without a battery connected as shown in Diagrams 7 or 8, p. 34.

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)

(See Diagram 3, p. 32).

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

WIRE 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 strain reliefs and through the knockouts.

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.

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

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.)

Set Operating Mode Switch

continued

• 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 Diagram 9, p. 35 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. 10 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. 7 to select the optimum settings for these switches.

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.

“INV” (Inverting—all models)

This yellow light will turn continuously ON whenever connected equipment is receiving batterysupplied AC power (during a blackout, brownout or overvoltage while connected to utility power or when connected to batteries during vehicular operation).

“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.

Other Features

9. DC Input Terminals (All models)

The terminals’ lug screws secure the wires leading from your external battery or battery system. Your battery or battery system must provide your APS with proper DC voltage and your equipment with an adequate amp hour capacity. See Battery Selection section, pg. 7 for more information.

10.

AC Receptacles: NEMA 5-15R (Corded models only)

These receptacles allow you to connect equipment that would normally be plugged into a utility outlet. They feature ground fault indicator switches that trip when the receptacles are in danger of short circuiting. If the switches trip, press to reset them when the short circuit situation is remedied.

11.

AC Input Line Cord: NEMA 5-15P fixed (Corded models only)

This cord should be plugged into a 120V, 60 Hz, dedicated 15 Amp AC utility outlet. DO NOT plug the cord into the APS’s AC receptacles.

12.

Hardwire A

C Input/Output Terminal Strip (Hardwire models only)

Use the lug screws on these terminals to secure hardwire connections for AC input and output. See pages 9 & 32 for wiring instructions.

13.

Resettable Circuit Breakers (All models)

These circuit breakers protect your APS against damage due to input or output overload. If a breaker trips, remove some of the load on the APS to prevent overload, then wait 1 minute to allow components to cool before resetting the circuit breaker.

14.

Remote Module Connector (All models)

The front panel of all models has an RJ 45 receptacle for use with the optional remote module. (Module is included with all VR models.) See the installation instructions packed with the remote module.

15.

Load Sense Potentiometer (All models)

In order to save battery power, the APS’s inverter automatically shuts off when no load is connected. When the unit detects a load, it automatically turns the inverter on. Users may choose the minimum load the APS will detect by adjusting the Load Sense Potentiometer. Using a small tool, turn the potentiometer clockwise to lower the minimum load that will be detected, causing the inverter to turn on for smaller loads. When the potentiometer is turned fully clockwise, the inverter will operate even when there is no load.Turn the potentiometer counterclockwise to increase the minimum load that will be detected, causing the inverter to stay off until the new minimum load is reached. The factory setting for the potentiometer is fully clockwise, but in areas with frequent power interruptions, the potentiometer should be adjusted counterclockwise until the inverter is only in operation when the APS’s load is in use.

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