Airpax Dimensions ADI-24/2400N User manual

Airpax Dimensions, Inc.
U.P.S.
Unintertuptable Power Supply
(External Battery Type)
OWNERS MANUAL for Models:
ADI-24/2400N UPS
ADI-24/4800N UPS
Including Option "D"
Form 121585
121585B
OWNER'S MANUAL FEBRUARY 2007
A
irpax Dimensions, Inc.
4467 White Bear Parkway [phone]
St. Paul, MN 55110-7626 Fax [phone]

OWNERS MANUAL
FOR AIRPAX DIMENSIONS
INVERTERS
Model ADI-24/2400N UPS
Model ADI-24/4800N UPS
Including Options "D"
Table of Contents
Page
1. General . . . . . . . . . . . 2
2. Description . . . . . . . . 2
3. Installation . . . . . . . . 3
4. Start Up/Operation. . . 5
5. Troubleshooting. . . . . 5
6. Installation Figure 1 . . 7
7. Limited Warranty . . . . 8
1. GENERAL
1.01 DimensionsU.P.S.havebeendesignedand
manufactured for many user applications and long
life. Theyutilizepatentedconstructionmethodsand
hightechnologyelectronicpartsand
circuitry.
1.02
CAUTION: The U.P.S. produces hazardous
voltages,toavoid riskofharm orfirethe unitmust
beproperlyinstalled.Therearenouserserviceable
parts inside, do not remove the cover.
CAUTION: The U.P.S.should not be mounted in a
location that may be exposed to rain or spray.
CAUTION: The U.P.S. should not be installed in a
zeroclearanceenclosure.
CAUTION: DamagetotheU.P.S.willoccurifcorrect
polarityisnotobservedwheninstallingtheDCinput
cables.
CAUTION: Damage to the U.P.S. will occur if an
externalACpowersourceisappliedtotheinverter’s
AC output or its hardwire output.
CAUTION: The U.P.S. contains a circuit breaker
and capacitor that may produce a spark. Do not
mount in a confined battery or gas compartment.
CAUTION: Working in the vicinity of lead-acid
batteriesisdangerous.Batteriesgenerateexplo-
sive gases during operation. There is a risk of
acidexposure.Thereisalsoariskofhigh current
discharge from shorting the battery that can
causefireandexplosion.
CAUTION: Be sure both the U.P.S. and the
external AC input circuit breaker or fuse are
turned
"OFF"duringinstallation.
2. DESCRIPTION
2.01The U.P.S. converts24VDCto120VAC,
(120/240 VAC with "D" option) 60 HZ, having a
pure sine wave form.
2.02TheU.P.S.hasinternalprotectionagainst
output short circuit, output overload and high
temperature conditions. Also, there is a ther-
mallycontrolledcoolingfan.
2.03 The U.P.S. is designed to operate any
120 VAC,
(120/240 VAC with "D" option) 60 HZ
single phase appliance, equipment or tool within
its power ratings.
2.04 The built in battery charger has a
sophisticated, patented recharge detection cir-
cuitry to ensure complete battery charging. It is
fullyautomaticandregulated,andistemperature
compensated.
U.P.S. Rating
U.P.S. Input Output
Model (VDC) (ADC) (VAC) (Watts)
24/2400N 25.2 Up to 120 120 2400
24/4800N 25.2 Up to 240 120 4800
Page 2

charging of the internal input capacitor.
3.05.2 Use stranded copper wire between
the battery and inverter as indicated. A line fuse
must be installed between the battery and the
inverter. U.L. requires that the fuse be within 18
inches of the battery.
DC Input Wire Lengths (maximum)
and Fusing Guide
Distance (feet)
Model 1-20 Fuse
24/2400N 2 ga 250A
24/4800N 2/0 ga 400A
3.05.3 NOTE: Usingsmallerinputcableor
longer length will greatly degrade the inverter
peakperformance.
3.05.4 Install the wires at the battery, U.P.S.
and then fuse holder. Make sure that good, clean
connections are made. Use care not to touch the
positiveandnegativewirestogether. Thiswillresult
in a violent spark and could result in exploding
batteriesandfire.
3.05.5 The battery input terminals are lo-
cated in the wiring compartment. A mounting
spark may result when connecting the battery
wire,duetoaninitial chargingofthe internalinput
capacitor.
3.05.6
CAUTION: Connecting the U.P.S.
incorrectlytothe batterywillcausedamage thatis
notcoveredunderwarranty.
3.06 Remote Switch for Inverter
Operation - Fig. 1
3.06.1 All material used for the remote
switch should be U.L. listed and installed per low
voltage, Class 2, wiring code.
3.06.2 A remote switch may be connected
tothevioletwiremarked"RemoteSwitchHookup"
inthewiringcompartment.Youshouldfirstremove
this violet wire from the battery positive input
terminal; then connect the violet wire to the load
3. INSTALLATION
3.01 The following instructions should be thor-
oughly read and understood before installation.
3.02 CAUTION: The U.P.S. produces hazardous
voltages, to avoid risk of harm or fire the unit must
beproperlyinstalled.
CAUTION: DamagetotheU.P.S.willoccurifcorrect
polarityisnotobservedwheninstallingtheDCinput
cables.
CAUTION: Damage to the U.P.S. will occur if an
externalACpowersourceisappliedtotheinverter’s
AC outlet or its hardwire output.
CAUTION: BesureboththeU.P.S.andtheexternal
AC circuit breaker or fuse (if needed) are turned
"OFF"duringinstallation.
NOTE: All wiring must follow the National Electric
Code,Provincialor othercodesin effectatthe time
of installation, regardless of suggestions in this
manual. All wires should be copper conductors.
3.03 Mounting
3.03.1 Locate a suitable, secure vertical or
horizontalmountingsurfaceasclose to the battery
as possible without being in the same air tight
compartment. The maximum recommended dis-
tance between the mounting location and the
battery is 20 feet.
3.03.2The location should provide adequate
ventilation and clearance to maintain room tem-
perature during operation. At least 1/2 inch of
clearance is required on all sides.
3.03.3 Secure the unit with 1/4 inch screws
or bolts in the mounting slots on the flanges of the
chassis.
3.04 Chassis Bonding Lug - FIG. 1
3.04.1 Connect a #8 gauge or greater cop-
per wire between the bonding lug on the inverter
andtheearthgroundingsystem.
3.05 Battery Cabling - FIG. 1
3.05.1
CAUTION: Assure that hydrogen gas
doesnotaccumulatenearthebatterybykeepingthe
area well ventilated. A spark may result when con-
necting the final battery wiring due to the initial
Page 3

termainal of the switch. The input terminal of the
switch should be connected to 5 Amp. fused +24
VDC.Thecableclampstrainreliefshouldbeusedto
securethefieldwires.
3.06.3 The switch should be mounted at a
convenient location in a listed outlet box with
approvedstrainrelief.
3.06.4
NOTE: Aremoteswitch,ifinstalled,will
operateonly if the local On/Off switch on the face
of the U.P.S. is turned "On". You may use several
switches or relays in parallel in lieu of one remote
switch.
3.07 Remote Temperature Sense
3.07.1
CAUTION: Failure to connect the
remotetemperaturesenseprobecorrectlywillresult
in improperbatterycharging.
3.07.2 A 10 foot long cable with temperature
senseprobeisprovidedwiththeunit. Thisallowsthe
unit to know the exact battery temperature for
correctoperationofthetemperaturecompensated
circuitry. This changes the output voltage as re-
quired by the battery at a given temperature.
3.07.3 Installtheprobe endona NEGATIVE
batteryterminalpost.
3.08 120VACOutput(120/240VACwith
"D"option)
3.08.1
CAUTION: Do not connect another
source of AC power directly to the output of the
U.P.S.
Thiswillresultindamagetotheinverterthat
isnotcovered under warranty!
3.08.2 The 120 VAC output of the U.P.S. is
providedatthereceptacleoutlet on the inverter.
3.08.3 The output is also presented
behind the wiring compartment panel for direct
hardwire wire leads. The black wire is hot (2 black
hot wires with "D" option), the white wire is neutral
and the green wire is ground. The cable clamp strain
relief should be used to secure the field
wires.
3.08.4 The remote AC outlets should be
mounted at a convenient location in a listed outlet
box with approved strain relief.
3.09 120VACInput(120/240VACwith"D"
option)
3.09.1 120 VAC (120/240 VAC with "D"
option), 60HZ power from the electric utility or
generator can be connected to the U.P.S. with
hardwire connections at the AC Input wire leads
providedinthehardwirecompartment. The black
wire is hot (2 black hot wires with "D" option), the
whitewireis neutral,andthe greenwireis ground.
The cable clamp strain relief should be used to
securethefieldwires.
3.09.2 The input circuit should have 20
amp circuit protection from the distribution panel.
3.09.3 When external AC is supplied, the
internal transfer switch is automatically activated,
the inverter is turned “Off”, and the
U.P.S. loads will operate from external AC input.
3.09.4 The unit has a separate 120 VAC
(240 VAC with "D" option), 20 amp second input
circuit. Thefirstcircuitactivatestheinternaltransfer
switch supplying utility or generator power to the
U.P.S.outputloads,andturns“Off”theinverter.The
secondcircuitactivatesthebatterychargerandalso
turns “Off” the inverter Both the transfer switch
input and the battery charger input must be at the
samephase.
Page 4
inverter.

Page 5
4. START UP / OPERATION
4.01
The battery charger will operate anytime
that there is external AC power and the battery is
not 100% charged. The status lights will indicate
that there is external power and the battery’s
condition.
4.02 There are two switches on the right side
that should be set.
4.03 Theswitchlabeled"BatteryType"should
besettothecorrectsettingbasedonthecompo-
sition of the batteries attached to the inverter.
Use the following table to determine the correct
setting.
BATTERYTYPESELECTION
SETTING BATTERY TYPE
A Vented Nickel-Cadium 10 cells
B Vented Lead-Acid (Antimony)
FloodedElectrolyte
C Sealed Lead-Acid Absorbed or
Vented Nickel-Cadium 9 cell
D SealedLead-AcidGelled
NOTE: Used batteries should be put through 5
charge cycles with the switch set one position
lower(totheright)thandesired. Example:Start
a used vented-lead acid battery on the "C"
setting.
4.04 The switch labeled "Battery Size"
shouldbesetto the correctsettingbased on the
totalamphourcapacityofthebatteriesattached
to the inverter. Use the following table to
determinecorrectsetting.
BATTERY CAPACITY SELECTOR
SETTING AMP HOUR CAPACITY
A Over 600
B 600 - 400
C 400 - 200
D Less than 200
4.05 To operate the U.P.S., turn the On/
Off switch to “ON”. Assure that the output breakers
are reset. If a remote switch is used, the inverter is
turned “On” or “Off” by the remote switch.
BATTERY CHARGER RATING
U.P.S. Input Current Output Current
Model @ 120VAC, 60Hz @ 24VDC
24/2400N Up to 20 Amp AC 40 Amp DC
24/4800N Up to 40 Amp AC 105 Amp DC
5. CUSTOMERSERVICE
TROUBLESHOOTING
5.01 Dimensions offers free phone consulta-
tionconcerninginstallationortroubleshooting. Call
theCustomerServiceDepartmentat:
1-800-553-6418 or 651-653-7000
fax: [phone]
e-mail:[email protected]
5.02 If the U.P.S. fails to operate, use the
followingtroubleshootingprocedure.
5.02.1 Connect a 100 watt light bulb to the
inverteroutput.
5.02.2 Make sure that the U.P.S. is turned
“On”,andthecircuitbreakersarereset.
5.02.3 Check the connection to the remote
switch, if used. +24VDC must be present at the
violet wire for the unit to operate. If not, check any
fuses in the remote switch circuit.
5.02.4 Observe the fault indicating lights on
the front of the inverter.

a) The Low input voltage light indicates a
low battery condition. Switch the U.P.S. “Off” for
5 seconds, then “On” again. The light coming on
againindicatesafaultinthebatterywiring,battery
capacity and voltage or the line fuse.
b) The Overload light indicates an output
wiringshortcircuitoraloadthatistoolargeforthe
power rating of the U.P.S.. Switch the inverter
“Off”, remove the short circuit or excessive load
fromtheoutput,thenswitchtheinverterback“On”.
c) TheHightemperaturelightindicates the
U.P.S.hasoverheated. Theunitwillautomatically
turnbackonwhenithascooledto400C. Verifythat
theU.P.S.isnotinaclosedcompartmentandthat
the fan is not blocked.
5.03 When the battery charger fails to operate
correctlychecktheU.P.S.trouble shootingproce-
dure in 5.02, assure that the remote trmperature
probeis installedcorrectly,thenobservethefront
panellights:
a) The external power light should be lit, if
not,verifythattheexternalpowercircuitisprovid-
ingcorrectACpowertotheunit. Checkallexternal
powerwiringandexternalcircuitbreakersorfuses.
b) ThegreenTimerCompletelightindicates
theunit’sbatterychargerwasunabletocompletely
charge the batteries during the 12 hour charge
cycle. Oneormoreofthefollowingconditionscan
causethiscondition.
1)Verifythatthetwoswitchsettings("BAT-
TERY TYPE" and "BATTERY BANK SIZE") are
correctlyset.
2)Thechargerwasunabletodetectthe80%
charge level point during the 12 hour cycle due to
adefectivebattery.
3)Thebattery’svoltagedroppedbelow25.2
voltswhilethechargerwasattemptingtodetectthe
80%chargelevel. Abatterywith a shorted cell or
incorrectaciddensitycancause this condition.
Page 6
4)Morethan20AmpsofDCloadcurrentwas
drawndirectlyfromthebatteriesduringthecharge
cycle. 5)ACpowerloss(brownout)intheexternal
AC input that limited the amount of AC power
availabletothebatterycharger.
5.04 A new charge cycle may correct the
TimerCompleteconditionifthecauseseemstobe
conditions1,4,or5. Thenewchargecyclecan be
started by disconnecting both external AC inputs
for 5 seconds then reconnecting them.
5.05Call Airpax Dimensions, Inc. for technical
assistanceand/oraReturnAuthorizationNumber
if the above steps are completed and the U.P.S.
orbattery chargerwill notoperate satisfactorily.

A.C A.C. INPUT
OUTPUT
NEG
A.C. A.C. Input Battery REMOTE
Output Transfer Charger POS
A.C. INPUT EARTH GROUND
EARTH GROUND
WARNING: CONNECTING THE BATTERY WITH THE WRONG POLARITY TO
THE U.P.S WILL CAUSE DAMAGE THAT IS NOT COVERED UNDER THE WAR-
RANTY.
FIG. 1 INSTALLATION WIRING
FUSE
FUSE
+24 FROM BATTERY
REMOTE SWITCH
CUSTOMER INSTALLED OPTION
Page 7
REMOTE TEMPERATURE SENSE
24 VDC

Limited Warranty Terms & Conditions
SHIPPING TERMS
F.O.B. St. Paul Minnesota - USA
LOSS OR DAMAGE
Lossordamageintransit is the responsibilityof thecarrier. Any claim shouldbe filedwith thedelivering transport company. Invoice,Bill
of Lading and Delivery receipt with damage noted therein must accompany any claims for freight damage. Claims for shortage and lost
shipmentsmustbemadeinwritingtoAirpaxDimensions, St.Paul,MNwithin10daysofdateofshipment. Claimsnotreportedwithinthis
time frame will not be honored.
RETURN GOODS POLICY
•No returnedmaterialswill beacceptedwithout anaccompanyingReturned MaterialsAuthorizationNumber (RMA)fromthe factory.
•Creditwillbeissuedforreturnedgoodstotheoriginalpurchaserwithin60daysofpurchase,providedtheinverterisreturnedtoDimensions
unused and not mounted. The amount of credit will be issued at Dimensions discretion based on the condition of the product.
• Customer must be in good standing with Dimensions.
• Inverters that are discontinued, high-voltage (over 24vdc), special-order or used are excluded and will not be eligible for credit. Non-
inverter items such as cable assemblies, fuses and fuse holders, will not be eligible for credit
•Support components suppliedbyDimensions vendors willbecovered underthatmanufacturer’s credit returnpolicy.
• Customer pays return freight.
PLEASE SHIP AUTHORIZED RETURNS TO: Airpax Dimensions, Inc. / 4467 White Bear Parkway / St. Paul, MN 55110
ReturnFreightPrepaid
LIMITED WARRANTY
AirpaxDimensions, Inc. extendsthefollowingwarranty to theoriginalpurchaserof those goodssubjecttothe qualificationsindicated.
Dimensionswarrantstotheoriginalpurchaserforuse that the goods orany component thereof manufacturedby Dimensions willbefree
fromdefectsin workmanship foraperiodof 1 year fromthedateof purchase, providedsuch goodsareinstalled,maintained and used in
accordancewithDimensionsandtheoriginalmanufacturer’swritteninstructions.
Componentsnotmanufacturedby Dimensions, but usedwithintheassemblyprovidedbyDimensions,aresubjecttothewarranty period
asspecifiedbytheindividualmanufacturerofsaidcomponent,providedsuchgoodsareinstalled,maintainedandusedinaccordancewith
Dimensionsandthemanufacturer’swritteninstructions.
DimensionssoleliabilityandthePurchaser’ssoleremedyforafailureofgoodsunderthislimitedwarrantyandforanyandallclaimsarising
outof thepurchase and useof thegoods, shall belimited tothe repair orreplacement ofthe goods thatdo notconform to thiswarranty.
Toobtainrepairorreplacementserviceunderthelimitedwarranty,thepurchasermustcontactthefactoryforaReturnMaterialAuthorization
(RMA). Onceobtained,sendtheReturnMaterialAuthorizationNumberalongwiththedefectivepartorgoodsto:AirpaxDimensions,Inc.,
4467 White Bear Parkway, St. Paul, MN 55110, freight prepaid.
THEREARENOEXPRESSWARRANTIESCOVERINGTHESEGOODSOTHERTHANASSETFORTHABOVE. THEIMPLIEDWARRANTIESOF
MERCHANTABILITYANDFITNESSFORAPARTICULARPURPOSEARELIMITEDINDURATIONTOONEYEARFROMDATEOFPURCHASE.
DIMENSIONSASSUMESNOLIABILITYINCONNECTIONWITHTHEINSTALLATIONORUSEOFTHEPRODUCT,EXCEPTASSTATEDINTHIS
LIMITEDWARRANTY. DIMENSIONSWILLINNOEVENTBELIABLEFORINCIDENTALORCONSEQUENTIALDAMAGES.
WARNING: LIMITATIONS ON USE
DimensionsproductsarenotintendedforuseinconnectionwithLifeSupportSystemsandforAvionicuse. Dimensionsmakesnowarranty
or representation in connection with their products for such uses.
Page 8