Tripp Lite Welding System User Manual

Safety 2

Feature Identification 3

Operation 4

Application Guide 5

Mounting 6

Battery Connection 7

AC Output Connection 8 (back page)

Troubleshooting/Service/
Maintenance/Warranty 8 (back page)

Warranty Registration 8 (back page)

Owner’s Manual

PowerVerter®Plus

DC-to-AC Inverters

Input Output

12 VDC 120V, 60 Hz. AC

1111 W. 35th Street, Chicago, IL 60609 USA

Customer Support: [phone]

www.tripplite.com

Copyright © 2005. PowerVerter®is a registered trademark of Tripp Lite. All rights reserved.

* Inverters are moisture-resistant, not waterproof.

Contents

Reliable AC Power Wherever You Need It!

Congratulations! You’ve purchased the most advanced, feature-rich
Inverter designed as a mobile energy source for your vehicle.
PowerVerter Inverters efficiently convert DC (battery) power into
120V AC (household) power, allowing you to use equipment you
commonly use at home—appliances, entertainment systems, computers,
power tools and more—while cruising the open road. PowerVerter
Inverters, through a high-efficiency conversion process and a charge
conservation setting, draw the highest level of performance from your
batteries without overtaxing them, lengthening their service life. An
automatic low battery shutdown feature ensures you'll always have
plenty of power for starting purposes.

• Automatic Overload Protection

• Automatic “Battery-Saver” Low Voltage Shutdown

• High Efficiency DC-to-AC Inversion

• Multi-Function Lights & Switches

• Optional Remote Control Capability

• Frequency-Controlled Output

• Moisture-Resistant Construction*

• Battery Charge Conserver (Load Sense)

Warranty

Registration

Register online today for a

chance to win a FREE

Tripp Lite product!

www.tripplite.com/warranty

Regulatory Compliance Identification Numbers

For the purpose of regulatory compliance certifications and identification, your Tripp Lite product has been assigned a unique series number. The series number can be found on
the product nameplate label, along with all required approval markings and information. When requesting compliance information for this product, always refer to the series number.
The series number should not be confused with the marking name or model number of the product.

* Applies to models with "UL" in their model numbers.

Important Safety Instructions

SAVE THESE INSTRUCTIONS!

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

Location Warnings

• Install your Inverter in a location or compartment in your vehicle that minimizes exposure to heat, dust, direct sunlight and moisture.
Flooding the unit with water will cause it to short circuit and could cause personal injury due to electric shock.

• Leave a minimum of 2" clearance at front and back of the Inverter for proper ventilation. To avoid overheating the Inverter, any
compartment that contains the Inverter must be properly ventilated with adequate outside air flow. The heavier the load of connected
equipment, the more heat will be generated by the unit.

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

• Do not install near flammable materials, fuel or chemicals.

Battery Connection Warnings

• Multiple battery systems must be comprised of batteries of identical voltage, age, amp-hour capacity and type.

• Because explosive hydrogen gas can accumulate near batteries if they are not kept well ventilated, your batteries should not be
installed in a “dead air” compartment. Ideally, any compartment would have some ventilation to outside air.

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

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

Ground Connection Warnings

• Safe operation requires connecting the Inverter's Main Ground Lug directly to the frame of the vehicle or earth ground.

Equipment Connection Warnings

• Do not use a Tripp Lite Inverter in life support or healthcare applications where a malfunction or failure of a Tripp Lite

Inverter could cause failure of, or significantly alter the performance of, a life support device or medical equipment.

• You may experience uneven performance results if you connect a surge suppressor, line conditioner or UPS system to the output of
the Inverter.

Operation Warnings

• Your Inverter does not require routine maintenance.

• Potentially lethal voltages exist within the Inverter as long as the battery supply is connected. During any service work, the battery
supply should therefore be disconnected.

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

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Feature Identification

Identify the premium features on your specific model and quickly locate instructions on how to maximize their use.

Operating Mode Switch: controls Inverter operation. Set this
2-position slide switch to “ON/REMOTE” to have your Inverter
provide connected equipment with AC power by converting DC
power from an attached battery or remotely monitor and control
the Inverter with the use of an optional remote module. Set
switch to “OFF” when not using connected equipment to pre­vent battery drain.

“LOAD” Indicator Lights: intuitive “traffic light” signals show
approximate equipment load level. See page 4 for instructions
on reading indicator lights.

“BATTERY” Indicator Lights: intuitive “traffic light” signals
show approximate charge level of your battery. See page 4 for
instructions on reading indicator lights.

DC Power Terminals: connect to your battery terminals. See
page 7 for connection instructions.

Ground Fault Interrupter (GFI) AC Receptacles: allow you
to connect equipment that would normally be plugged into a
utility outlet. They feature ground fault interrupter switches that
trip if there is excessive current on the ground safety wire.

Resettable Circuit Breaker: protects your Inverter against
damage due to overload. See page 4 for resetting instructions.

Remote Control Module Connector: allows remote monitoring
and control with an optional module (Tripp Lite model
APSRM4, sold separately). See remote module owner’s manu­al for connection instructions.

Battery Charge Conserver (Load Sense) Dial: conserves battery
power by setting the low-load level at which the Inverter auto­matically shuts off. See page 4 for setting instructions.

Multi-Speed Cooling Fan(s): quiet, efficient fans prolong
equipment service life.

Main Ground Lug: properly grounds the Inverter to vehicle
grounding system or earth ground. See page 7 for connection
instructions.

Low Battery Alarm/Shutdown (internal, not shown): auto­matically detects low voltage and shuts down Inverter to preserve
vehicle battery.

Overload Alarm/Shutdown (internal, not shown): automatically
detects wattage overload on Inverter outlets and shuts down
Inverter as a protective measure.

Ignition Switch Control Jack (rear panel, not shown): use to
connect the Inverter to your vehicle’s ignition switch (with user­supplied cable) in order to automatically control the Inverter
with the vehicle's ignition switch. See Operation section.

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Front View (750 & 1250 Models)

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Operation

Switch Modes

Switch between the following operating modes as appropriate to
your situation:

“ON/REMOTE”: Switch to this setting to pro­vide connected equipment with AC power. Also,
switch to this setting to remotely monitor and
control the Inverter with the use of an optional
remote module. See remote module’s owner’s manual for operating
instructions.

“OFF”: Switch to this setting to shut down the
Inverter completely, preventing it from drawing
power from the batteries. Use this switch to auto­matically reset the unit if it shuts down due to low
battery or overload. Use an optional remote control module (Tripp Lite
model APSRM4, sold separately) to reset unit due to overload only.

Indicator Lights

Your Inverter is equipped with a simple, intuitive, user-friendly set of
indicator lights. These easily-remembered “traffic light” signals will
allow you, shortly after first use, to tell at a glance the charge condition
of your batteries, as well as ascertain approximate equipment load level.

“BATTERY” Indicator Lights: These three lights will illuminate in
several sequences to show the approximate charge level of your con­nected battery:

Approximate Battery Charge Level

†

Indicator Illuminated Battery Capacity

Green 91%–Full
Green & Yellow 81%–90%
Yellow 61%–80%
Yellow & Red 41%–60%
Red 21%–40%
Flashing Red (slowly)* 1%–20%
Flashing Red (quickly)** 0% (Inverter

has shutdown)

“LOAD” Indicator Lights: These three lights will illuminate in
several sequences to show the approximate equipment load level on
the Inverter’s AC receptacles.

Approximate Equipment Load Level

Indicator Illuminated Load Level

Green 0%-50%
Green & Yellow 51%-75%
Yellow 76%-90%
Red >

90%

Flashing Red (quickly)** OVERLOAD

(Inverter has
shutdown)

† Charge levels listed are approximate. Actual conditions vary depending on battery condition
and load. * Approximately ½ second on, ½ second off. ** Approximately ¼ second on, ¼ second
off. See “Resetting Your Inverter to Restore AC Power” to reset after Inverter shut down.

Resetting Your Inverter to Restore
AC Power

Your Inverter may cease supplying AC power in order to protect
itself from overload or to protect your electrical system. To restore
normal functioning:

Low Battery Shutdown Reset: Set operating mode switch to
“OFF” and run vehicle engine to recharge battery. When battery is
adequately charged, switch operating mode switch back to
“ON/REMOTE.”

Overload Shutdown Reset: Set operating mode switch to “OFF”
and remove some of the connected electrical load (ie: turn off some
of the AC devices drawing power which may have caused the over­load of the unit). Wait one minute, then switch operating mode
switch back to “ON/REMOTE.”

Output Circuit Breaker Reset (Select Models): Alternatively,
check output circuit breaker on the unit’s front panel. If tripped,
remove some of the electrical load, then wait one minute to allow
components to cool before resetting the circuit breaker. See
Troubleshooting for other possible reasons AC output may be absent.

Set Battery Charge Conserver (Load Sense) Dial

In order to save battery power, the Inverter automatical­ly shuts off in the absence of any power demand from
connected equipment or appliances (the electrical
load). When the unit detects a load, it automatically
turns on. Users may choose the minimum load the
Inverter will detect by adjusting the Battery Charge Conserver Dial
(see diagram). Using a small tool, turn the dial clockwise to lower
the minimum load that will be detected, causing the Inverter to turn
on for smaller loads. When the dial is turned fully clockwise, the
Inverter will operate even when there is no load. Turn the dial counter­clockwise to set a higher minimum load, causing the Inverter to stay
off until the new minimum load is reached. When the dial is turned
fully counterclockwise, the Inverter will turn on when it detects any
load greater than approximately 150 Watts.

Note: The factory setting for the dial is fully clockwise. However, based on the threshold load to which
you’d like the Inverter to respond, you should adjust the dial counterclockwise to reduce its sensitivity
until the Inverter is active only when connected equipment or appliances are actually in use.

Connect Remote Control—OPTIONAL

All models feature an 8-conductor telephone style receptacle on the
front panel for use with an optional remote control module (Tripp Lite
model APSRM4, sold separately.) The remote module allows the
Inverter to be mounted in a compartment or cabinet out of sight, while
operated conveniently from your vehicle’s dashboard. See instructions
packed with the remote control module.

Connect Ignition Switch Control Jack—OPTIONAL

All models feature a jack which can be used to connect the Inverter to
your vehicle's ignition switch in order to automatically control the
Inverter. This connection is optional; the Inverter will function without
this connection.

WARNING! THE IGNITION SWITCH CONTROL
FUNCTION IS ONLY FOR USE WITH 12V NEGA­TIVE GROUND SYSTEMS.

Wiring the Ignition Switch Control Cable to your
vehicle’s ignition requires a qualified technician,
who must determine the proper wiring procedure.

When connected to the vehicle’s ignition switch, this function automat­ically disables (turns OFF) the AC power output from the Inverter when
the vehicle’s ignition switch is placed in the “Engine Run” position.
This function will satisfy local codes and requirements concerning
video monitors (or TVs) that are located within a driver’s view by auto­matically turning them off when the engine is started. Tripp Lite makes
a current-limited cable assembly (part # 73-0977) for this purpose.
Connect the current-limited cable's red wire to the ignition switch's
"Engine Run" terminal. The cable's black wire can be left unterminated.
Then, connect the current-limited cable's mini-plug to the Ignition
Switch Control Jack located on the Inverter's rear panel. After connect­ing the interface cable, set the Inverter's switch to "ON/REMOTE". The
current-limited cable's mini-plug should remain in the Inverter's
Ignition Switch Control Jack whenever the ignition is on to avoid short­ing the battery.

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SENSE

GREATER

LOAD

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LESSER
LOAD
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Application Guide

540 watts ÷ 12V = 45 DC Amps

45 DC Amps × 5 Hrs. Runtime

× 1.2 = 270 Amp-Hours

Match Battery Amp-Hour Capacity to Your Application

Select a battery or system of batteries that will provide your Inverter with proper DC voltage and an adequate amp-hour capacity to power
your application. Even though Tripp Lite Inverters are highly efficient at DC-to-AC inversion, their rated output capacities are limited by
the total amp-hour capacity of connected batteries and the support of your vehicle’s alternator if the engine is kept running.

• STEP 1: Determine Total Wattage Required

Add the wattage ratings of all equipment you will connect to your Inverter.
Wattage ratings are usually listed in equipment manuals or on nameplates. If
your equipment is rated in amps, multiply that number times AC utility voltage
to determine watts. (Example: a ¼ in. drill requires 2½ amps. 2½ amps × 120
volts = 300 watts.)

Note: Your Inverter will operate at higher efficiencies at about 75% - 80% of nameplate rating.

• STEP 2: Determine DC Battery Amps Required

Divide the total wattage required (from step 1, above) by the battery voltage (12)
to determine the DC amps required.

• STEP 3: Estimate Battery Amp-Hours Required (for operation
unsupported by the alternator)
Multiply the DC amps required (from step 2, above) by the number of hours
you estimate you will operate your equipment exclusively from battery power
before you have to recharge your batteries. Compensate for inefficiency and
wiring losses by multiplying this number by 1.2. This will give you a rough
estimate of how many amp-hours of battery power (from one or several batteries)
you should connect to your Inverter.

NOTE: Battery amp-hour ratings are usually given for a 20-hour discharge rate. Actual amp-hour capacities are less when
batteries are discharged at faster rates. For example, batteries discharged in 55 minutes provide only 50% of their
listed amp-hour ratings, while batteries discharged in 9 minutes provide as little as 30% of their amp-hour ratings.

You must allow your batteries to recharge long enough to replace the charge lost during Inverter operation or else you will eventually run down your batteries.

NOTE: For Tripp Lite Inverters over 1000 watts used in mobile applications, Tripp Lite recommends you use at least two batteries, if possible, fed by a heavy-duty alternator anytime the vehicle is
running. Tripp Lite Inverters will provide adequate power for ordinary usage within limited times without the assistance of your vehicle’s alternator. However, when operating extremely heavy electrical
loads at their peak, you may wish to “assist your batteries” by running your vehicle engine faster than normal idling.

Example

Tools

300W + 220W + 20W = 540W

¼" Drill Orbital Sander Cordless Tool Charger

Appliances

300W + 140W + 100W = 540W

Blender Color TV Laptop Computer

Vehicular and Non-Vehicular Horizontal Mount

Using the measurements from the diagram, install two user-sup­plied ¼" (6 mm) fasteners into a rigid horizontal surface, leaving
the heads slightly raised. Slide the Inverter/Charger back over
the fasteners to engage the mounting slots molded on the bottom of
the Inverter/Charger cabinet. Install and tighten two user-sup­plied ¼" (6 mm) fasteners into the mounting feet molded on the
front of the Inverter/Charger cabinet.

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Mounting

optional

WARNING! If you choose to mount your Inverter, mount it and wire its DC input
BEFORE DC battery connection. Failure to follow these instructions may lead to
personal injury and/or damage to the Inverter and connected systems.

Tripp Lite Inverters are designed for horizontal mounting in a variety of vehicular or non-vehicular applications. User must supply mounting
hardware and is responsible for determining if the hardware and mounting surface are suitable to support the weight of the Inverter. Contact
Tripp Lite if you require further assistance in mounting your Inverter.

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7.87 in (20 cm)

6.75 in (17.1 cm)

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• Connect DC Wiring:

You must run positive

cable(s) through user-sup-

plied UL-listed fuse(s)

and fuse block(s) of the

proper size.

See Specifications page for Minimum Recommended Cable Sizing

Chart. An excellent source of cables is battery jumper cables. Output

performance will decrease if you use only one jumper cable.

Although your Inverter is a high-efficiency

converter of electricity, its rated output

capacity is limited by the length and gauge

of the cabling running from the battery to

the unit. Use the shortest length and largest

diameter cabling (maximum 00 gauge) to fit

your Inverter’s DC Input terminals. Shorter

and heavier gauge cabling reduces DC volt-

age drop and allows for maximum transfer
of current. Your Inverter is capable of deliv­ering peak wattage at up to 200% of its rated
continuous wattage output instantaneously.
See Specifications page for details. Heavier
gauge cabling should be used when continu­ously operating heavy draw equipment under
these conditions. Tighten your Inverter and
battery terminals to approximately 3.5
Newton-meters (2.58 foot lbs.) of torque to
create an efficient connection and to prevent
excessive heating at this connection.
Insufficient tightening of the terminals could
void your warranty.

• Connect Ground: Using a #8 AWG wire
or larger, directly connect the Main Ground
Lug to the vehicle's chassis ground or earth
ground. See Feature Identification section to
locate Main Ground Lug. All installations
must comply with national and local codes
and ordinances.

• Connect Fuse: In addition to the
protection provided by the Inverter’s
internal fuses, NEC article 551 requires that
you connect your Inverter’s positive DC
Terminal(s) directly to a UL-listed fuse(s)
and fuse block(s) within 18 inches of the
battery. See diagrams below for proper fuse
placement.

Battery Connection

Vehicular

Your Inverter’s Nominal DC Input Voltage must match the voltage of your battery or batteries—12 Volts in most vehicular applications. It is possible

to connect your Inverter to the main battery within your vehicle’s electrical system. In many vehicular contexts, the Inverter will be connected

to one or more dedicated auxiliary (house) batteries which are isolated from the drive system to prevent possible draining of the main battery.

12 Volt Main Battery Connection—two DC terminals

12 Volt Alternator

Vehicle Battery Ground

12 Volt Main Battery

12 Volt Auxiliary (House)
Battery

UL-Listed Fuses & Fuse
Blocks (mounted within 18
inches of the battery)

Battery Isolator

Large Diameter Cabling,
Maximum 00 Gauge to Fit
Terminals

8 AWG (minimum) Ground
Wire to Vehicle Frame or
Earth Ground

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12 Volt Main and Auxiliary (House) Battery Connection (Isolated Parallel)—two DC terminals

Connect your Inverter to your batteries using the following procedures—always loosely twist each pair of cables together before

connecting them separately to the appropriate DC terminal on the Inverter (positive or negative).

WARNING! Never attempt to operate your Inverter by connecting it directly to output from an alternator rather than
a battery or battery bank.

CAUTION! Observe proper polarity with all DC connections.

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12 Volts

12 Volt Inverter

12 Volt Inverter

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Try these remedies for common Inverter problems before calling for assistance. Call Tripp Lite Customer Service at [phone] before
returning your unit for service.

Troubleshooting

SYMPTOM PROBLEMS CORRECTIONS

No AC Output Operating Mode Switch is set to “OFF.” Set Operating Mode Switch to “ON/REMOTE.”
(All Indicator Lights Are OFF)

User-supplied UL-listed external DC input fuses have blown. Replace fuses.

Red Battery Indicator Light Unit has shut down due to excessive battery discharge. Run your engine to raise battery voltage. Check external battery
Is Rapidly Flashing connections and fuse. Reset by moving Operating Mode Switch
(¼ Second Flashes) to “OFF.” Wait one minute and switch to “ON/REMOTE.”

If unit remains in shutdown mode after several attempts to reset
contact Tripp Lite Customer Service for assistance.

Red Load Indicator Light Unit has shut down due to overload. Reduce load. Reset by moving Operating Mode Switch to “OFF.”
Is Rapidly Flashing Wait one minute and switch to “ON/REMOTE.” If unit remains in
(¼ Second Flashes) shutdown mode after several attempts to reset contact Tripp Lite

Customer Service for assistance.

Connected Equipment Experiences Audio/Video interference. Reposition equipment antennas and Inverter.
Buzzing Sound Or Picture Distortion

Inverter Output Seems Intermittent Loose cable connections. Check and secure all connections.

Operating Mode Switch

Battery Indicator Lights

Load Indicator Lights

200501058 93-2425

Limited Warranty

Tripp Lite warrants its Inverters to be free from defects in materials and workman­ship for a period of one year (domestic) or 120 days (export) from the date of retail
purchase by end user.

Tripp Lite’s obligation under this warranty is limited to repairing or replacing (at its
sole option) any such defective products.To obtain service under this warranty you
must obtain a Returned Material Authorization (RMA) number from Tripp Lite or an
authorized Tripp Lite ser vice center. Products must be returned to Tripp Lite or an
authorized Tripp Lite ser vice center with transportation charges prepaid and must
be accompanied by a brief description of the problem encountered and proof of
date and place of purchase. This warranty does not apply to equipment which has
been damaged by accident, negligence or misapplication or has been altered or
modified in any way, including opening of the unit’s casing for any reason. This
warranty applies only to the original purchaser who must have properly regis­tered the product within 10 days of retail purchase.

EXCEPT AS PROVIDED HEREIN, TRIPP LITE MAKES NO WARRANTIES,
EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE. Some states do not permit lim­itation or exclusion of implied warranties; therefore, the aforesaid limitation(s) or
exclusion(s) may not apply to the purchaser.

EXCEPT AS PROVIDED ABOVE, IN NO EVENT WILL TRIPP LITE BE LIABLE
FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAM­AGES ARISING OUT OF THE USE OF THIS PRODUCT, EVEN IF ADVISED OF
THE POSSIBILITY OF SUCH DAMAGE. Specifically, Tr ipp Lite is not liable for
any costs, such as lost profits or revenue, loss of equipment, loss of use of equip­ment, loss of software, loss of data, costs of substitutes, claims by third parties,
or otherwise.

Tripp Lite has a policy of continuous improvement. Specifications are subject to
change without notice.

Service

If you are returning your Inverter to Tripp Lite, please pack it carefully, using the ORIGINAL PACKING MATERIAL that came with the
unit. Enclose a letter describing the symptoms of the problem. If the Inverter is within the warranty period, enclose a copy of your sales
receipt. To obtain service you must obtain a Returned Material Authorization (RMA) number from Tripp Lite or an authorized Tripp Lite
service center.

Your Inverter requires no maintenance and contains no user-serviceable or replaceable parts, but should be kept dry at all times. Periodically
check, clean and tighten all cable connections, as necessary, both at the unit and at the battery.

Maintenance

Warranty Registration

Visit www.tripplite.com/warranty to register the
warranty of your new Tripp Lite product.You'll be
automatically entered into a drawing for a chance
to win a FREE Tripp Lite product!*

* No purchase necessary. Void where prohibited. Some restrictions
apply. See website for details.

This product designed and engineered in the USA.

AC Output Connection

To avoid overloading your Inverter, be sure to match the power requirements of the equipment you plan to run at any one time (add their total
watts) with the output wattage capacity of your Inverter model (see Specifications). When figuring the power requirements of your equip­ment, do not confuse “continuous” wattage with “peak” wattage ratings. Most electric motors require extra power at start-up (“peak”
wattage) than required to run continuously after start-up, sometimes over 100% more. Some motors, such as in refrigerators and pumps,
start and stop intermittently according to demand, requiring “peak” wattage at multiple, unpredictable times during operation.

• DoubleBoost™Feature

Tripp Lite Inverters deliver up to twice their nameplate rated
wattage for up to 10 seconds,* providing the extra power
needed to cold start heavy-duty tools and equipment.

• OverPower™Feature

Tripp Lite Inverters deliver up to 150% of their name
plate rated wattage for up to 1 hour,* providing plenty of reserve
power to reliably support tools and equipment longer.

* Actual duration depends on battery age, battery charge level and ambient temperature.