DualLite LG125S Manual

Installation Instructions
and
User Manual
For
For 125VA/110W & 250VA/220W Mini-Inverter Power Systems
Models: LG125S Surface Mounted Version
LG125R Recessed Wall Mounted Version
LG125T Recessed Ceiling T-Grid Mounted Version
LG250S Surface Mounted Version
LG250SI Surface Mounted Version w/ Self-Test

2
READ AND FOLLOW ALL SAFETY
INSTRUCTIONS
IMPORTANT SAFEGUARDS
When using electrical equipment, you should always follow basic safety precautions,
including the following:
1. Read and follow all safety instructions.
2. Do not install the LiteGear system outdoors.
3. Do not let power supply cords touch hot surfaces.
4. Do not install near gas or electric heaters or in other high-temperature locations.
5. Use caution when servicing batteries. Battery acid can cause burns to skin and
 eyes.Ifacidisspilledonskinorintheeyes,ushwithfreshwaterandcontacta
physician immediately.
6. Equipment should be mounted in locations where it will not be readily subjected to
tampering by unauthorized personnel.
7. The use of accessory equipment not recommended by the manufacturer may
cause an unsafe condition and may void the warranty.
8. Do not use this equipment for other than intended use.
9. Allservicingofthisequipmentmustbeperformedbyqualiedservicepersonnel.
SAVE THESE INSTRUCTIONS
IMPORTANT SAFETY INSTRUCTIONS
The installation and use of this product must comply with all national, federal, state,
municipal, or local codes that apply.
Please read this manual thoroughly before operating the LiteGear Inverter System.
For technical assistance, contact Dual-Lite’s Technical Support Center at 1-800-848-
6439. Technicians are available during normal working hours (EST).

3
Table of Contents
Description Page
Section 100
System Installation Instructions
101........ Unit Specication ................................................................................................................. 4
102. ...... Receiving, Moving and Storing Systems and Batteries ....................................................... 5
102.1..... Shipping Damage ............................................................................................................... 5
102.2 .... Temporary Storage of Units and Batteries........................................................................... 5
103. ...... Installation Requirements .................................................................................................... 5
103.2 .... High Altitude Operation........................................................................................................ 5
104. ...... Cabinet Mounting................................................................................................................. 6
104.1 .... Tools Required..................................................................................................................... 6
104.2 .... Mounting Hardware ............................................................................................................. 6
104.3 .... Knockout Locations ............................................................................................................. 6
104.4 .... Cabinet Mounting - Surface (-S) Models ............................................................................. 6
104.5..... Cabinet Mounting - Surface (-R) Models ............................................................................. 7
104.6..... Cabinet Mounting - Surface (-T) Models.............................................................................. 7
105. .......AC Connectors.................................................................................................................... 8
105.1 .... AC Wiring Preparations ....................................................................................................... 8
105.2 .... AC Input and AC Output Connections ................................................................................. 8
...............Wiring Diagram 1 - 120VAC Connections ........................................................................... 9
...............Wiring Diagram 2 - 277VAC Connections ........................................................................... 9
106.........Battery Information.............................................................................................................. 10
106.1......Tools.................................................................................................................................... 10
106.2......Battery Installation and Connections................................................................................... 10
...............Wiring Diagram ................................................................................................................... 10
106.3......Battery Connection Voltage Check ..................................................................................... 10
107.........Final Installation Checklist................................................................................................... 12
108. .......System Start-Up Procedure ................................................................................................ 12
109........ Manual System Test ............................................................................................................ 12
109.1 .... For LG125 and LG250 Models ............................................................................................ 12
109.2......For LG250SI Model............................................................................................................. 12
110.........System Self-Test/Diagnostics.............................................................................................. 13
110.1..... Self-Test / Diagnostic Functions .......................................................................................... 13
110.2......Self-Test / Diagnostic Indication .......................................................................................... 13
Section 200
Maintenance
200.1......Safe Shut Down Procedure................................................................................................. 14
200.2......Routine System Maintenance ............................................................................................. 14
200.3......Manual Routine Inverter Tests ............................................................................................ 14
200.4......Replacement Fuses ............................................................................................................ 15
200.5......Routine Battery Inspection and Maintenance ..................................................................... 15
200.6......Battery Replacement Procedure ......................................................................................... 15
200.7......Battery Disposal .................................................................................................................. 15

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Section 100 System Installation Instructions
101. Specications
Input
• Input voltage: Universal 120 or 277VAC
• Input frequency: 60HZ ±2%
• Operating Temperature: 20°C to 30°C (68°F to 86°F)
• Input Surge Protection: Meets UL 924
Output
• Output voltage: Universal 120 or 277VAC, 60HZ. Other voltages available upon request
• Output regulation: (static) ±5% based on a 0% - 100% resistive load
• Minimum loading: none required
• Output distortion: Less than 3% THD linear load
• Load power factor: .88 lead to .88 lag
• Output frequency: ±0.3 Hz during emergency
• Time to transfer to inverter after a utility power failure: <1 second
Battery
• Battery type: Maintenance free sealed lead calcium
• Battery charger: Fully automatic dual-mode with temperature compensation
• Recharge time: Meets UL requirements (96 Hours)
• Battery protection: Automatic low-battery voltage disconnect and reverse polarity protection.
• Battery switch: Also used as battery isolator
• Standard battery: Sealed lead-calcium: 10-year life
• Battery voltage: 24 or 48 (system dependent - See Table 1 below)
• Runtimes: 90 minutes standard.
• Operating temperature: 20°C to 30°C (68°F to 86°F)
• Relative humidity: 95% non-condensing
Note: Battery performance rated at 25°C (77°F)
Table 1
System Model
Number Type Input/ Output Volts
Capacity For
11/2Hours Battery Volt-
age (VDC)
Cabinet Dimensions System Weight*
In Watts Length Height Depth (Lbs.) (Kg.)
LG125S Surface 120/277 110 24 165/8”
(42.2cm)
115/8”
(29.5cm)
4 3/8”
(11.1cm) 42 19
LG125R Recessed 120/277 110 24 181/8”
(46.0cm)
131/8”
(33.3cm)
4 3/8”
(11.1cm) 42 19
LG125T Ceiling
T-Grid 120/277 110 24 237/8” (60.6cm)
61/4”
(15.9cm)
8.0”
(20.3cm) 43 20
LG250S /
LG250SI Surface 120/277 220 48 165/8” (42.2cm)
115/8”
(29.5cm)
6 3/8”
(16.2cm) 60 27
System Weights shown include installed batteries
Table 2
System Model
Number
On-Line
System Ef-
ciency (Full
Load)
Number Of
Batteries
Battery Volt-
age (VDC)
Battery Cur-
rent (Amps)
AC Input Current Thermal Output In BTUs
120VAC
(Max.)
277VAC
(Max.) On-Line Emergency
LG125S,R,T 98% 2 24 5.7 1.2 0.52 9 95
LG250S / LG-
250SI 98% 4 48 5.6 2.4 1.1 18 167

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102. Receiving, Moving and Storing Systems and Batteries
102.1 Shipping Damage
LG125S,R and T inverter system batteries are shipped installed within the unit housing. The LG250S and LG250SI
inverter system batteries are shipped separately from the inverter cabinet.
Carefully inspect all cartons upon receipt for evidence of shipping damage.
Notify carrier immediately of leaking or damaged cartons for possible concealed damage.
102.2 Temporary Storage of Units and Batteries
For temporary storage of LG inverter systems and batteries prior to installation, select a clean, cool, dry location with
normal ventilation for human habitation and level oors.
Storage Temperature:
Store all batteries at 0° to +40° C (32° to +104° F). Batteries will have a longer shelf life if stored at 15° C (60° F). The
LG electronics and battery cabinets may be stored at -20° to +60° C (-4° to +140° F).
IMPORTANT:
Lengthy storage of batteries will cause irreversible damage to the cells.
Failure to connect LG inverter system batteries to an energized charging circuit within 90 days from the date of ship-
ment will void the battery warranty.
DANGER: Explosive - Can Cause Blindness Or Other Severe Injuries
Every type of battery can produce hydrogen gas, even sealed, maintenance-free batteries. The gas is vented through
the vent caps and into the air. Do not allow smoking, sparks, or ames in battery storage location because hydrogen is
concentrated under the vent cap of each cell of the battery. Hydrogen is highly explosive, and is hard to detect because
it is colorless, odorless, and lighter than air.
103. Installation Requirements
103.1 Operating Environment
Install the LG inverter system in a clean, cool, dry place with normal ventilation for human habitation and in such a loca-
tion to hamper vandalism but allow easy access for testing and maintenance.
Operating Temperature:
LG inverter Systems are UL Listed for 20° to 30° C (+ 68° to +86° F) operation.
Battery performance and service life is maximized if the operating temperature is maintained at 25° C (77° F).
Temperature Effect On Battery Performance:
Batteries will be less efcient at temperatures below 20° C (68° F), and high temperatures will reduce battery life. Typi-
cally, at 35° C (95° F), battery life will be half of what it would be at normal temperature of 25° C (77° F). At 45° C (113°
F), battery life will be one-fourth of normal.
Ventilation:
The air around the unit must be clean, dust-free, and free of corrosive chemicals or other contaminants. Do not place
the LG inverter system or batteries in a sealed room or container.
CAUTION: Never Install Batteries in A Sealed Room Or Enclosure
103.2 High Altitude Operation:
The maximum operating temperature drops 1° Celsius per 300 meters (2° F per 1000 feet) above sea level. Maximum
elevation is 3000 meters (10,000 feet).

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104. Cabinet Mounting
104.1 Tools Required
The following tools are required to install the system:
Socket Set, Phillips Screwdriver, Diagonal Wire Cutters, Long Nose Pliers, Electrical Tape, Digital Volt-Ohm Meter,
Safety Glasses with Side Shields, Small Punch (knockout removal), Hammer, Electric Drill, Wood or Masonry Bits,
Level.
104.2 Mounting Hardware
Mounting hardware is not provided. Care should be taken when selecting mounting hardware to assure that it is the
proper type for the application and sized to safely support the systems full weight when installed assuring safe and
secure attachment of system to wall surface. For ease of installation, the factory recommends that the head size of
mounting screws or bolts be small enough to pass through the keyhole knockouts provided for mounting. This will allow
the unit to be hung on partially installed mounting hardware and facilitate easy cabinet removal if ever necessary.
104.3 Knockout Locations
All models provide knockouts on the top and left-hand side of the unit.
Additional entry points, if required can be added using a metal punch. Do not drill into the cabinet as metal lings can
cause short circuits and damage the equipment.
NOTE: Consider unit knockout locations prior to mounting unit. Allow room for easy routing of conduit to entry point.
104.4 Surface Mount Models (LG125S, LG250S, and LG250SI):
1) Remove cover and any packing material inside unit
housing that may have been used for shipping purposes.
2) For ease of installation, and to prevent possible damage
to the equipment, the inverter/charger assembly may
be temporarily removed prior to knockout removal and
attachment to mounting surface. This is accomplished
by removing (4) 8-32 hex nuts on the inverter/charger
mounting plate. If shipped factory installed, batteries
may also be temporarily removed to facilitate ease of
installation.
3) Remove the appropriate knockouts, 7/8”diameter, on the
top and/or left side of the unit housing to facilitate conduit
attachment. Also remove keyhole knockouts in the upper
corners on the back of the housing on LG125S model.
Due to the additional battery weight, the LG250S and
LG250SI models are supplied with mounting keyhole
knockouts located at all four corners on the back of the
unit housing. Remove all four keyhole knockouts on this model.
4) Secure housing to mounting surface through all keyhole knockouts provided using mounting hardware (not supplied)
sized appropriately to support the unit weight.
5) Re-install inverter/charger assembly if removed in step 2.

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104.5 Recessed Wall Mount Model (LG125R):
1) Remove cover and any packing material inside unit
housing that may have been used for shipping purposes.
2) For ease of installation, and to prevent possible damage
to the equipment, the inverter/charger assembly may
be temporarily removed prior to knockout removal and
attachment to mounting surface. This is accomplished
by removing (4) 8-32 hex nuts on the inverter/charger
mounting plate. If shipped factory installed, batteries
may also be temporarily removed to facilitate ease of
installation.
3) Remove the appropriate knockouts, 7/8” diameter, on
the top and/or left side of the unit housing to facilitate
conduit attachment. Also remove the appropriate round
knockouts, 5/16” diameter, which are located on all
sides of unit housing. Specic knockout requirements
are dictated by mounting orientation of unit (vertical or
horizontal) and location of wall studs and /or other support members.
4) Secure housing to support members through round knockouts using mounting hardware (not supplied) sized
appropriately to support the unit weight.
IMPORTANT:Unitshouldbesopositionedthatthecabinetextendsbetween3/8”and3/4”beyondthenished
wall surface after installation.
5) Prior to nal attachment of unit cover, the LED indicator panel assembly position must be adjusted to sit ush against
inside surface of cover after attachment. This is accomplished using the (2) 8-32 hex nuts on the indicator assembly.
6) Re-install inverter/charger assembly if removed in step 2.
104.6 Recessed Ceiling T-Grid Mount Model (LG125T):
1) Remove cover and any packing material inside unit hous-
ing that may have been used for shipping purposes.
2) For ease of installation, and to prevent possible damage
to the equipment, the inverter/charger assembly may
be temporarily removed prior to knockout removal and
attachment to mounting surface. This is accomplished by
removing (4) 8-32 hex nuts on the inverter/charger mount-
ing plate. If shipped factory installed, batteries may also
be temporarily removed to facilitate ease of installation.
3) Remove the appropriate knockout(s), 7/8” diameter, located on either side of unit housing to facilitate conduit
attachment.
IMPORTANT: Take care to remove only the knockouts required for utility connection. Removal of knockouts
if unused and left open will void the plenum rating of the unit.
4) Mount the unit securely in place between T-Grid members.
NOTICE: Safety chain or cable, rated 50lb minimum working load, 250lb minimum breaking strength is
required to hang the unit in a T-Grid system. Failure to correctly install unit will cause an unsafe condition!
5) Re-install inverter/charger assembly if removed in step 2.

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105. AC Connections
CAUTION:
A) All LG inverter system units contain hazardous AC and DC voltages. Because of these voltages, a qualied electrician
must install the LG inverter system, AC line service, and batteries. The electrician must install the AC line service
according to local, state and NEC codes and must be familiar with batteries and battery installation.
B) Before installing, maintaining, or servicing the unit, always remove or shut off all sources of AC and DC power to the
LG inverter system. Turn off the AC line input circuit breaker at the service panel and place the LG Battery Switch S2
in the OFF position to make sure the unit will not supply output voltage.
C) Whenever AC and/or DC voltage is applied, there will be AC voltage inside the LG inverter system unit; the unit can
supply power from AC line or from its batteries. To avoid equipment damage or personal injury, always assume that
there may be voltage inside the LG inverter system.
D) Remove rings, watches, and other jewelry before installing the AC wiring. Always wear protective clothing and eye
protection and use insulated tools when working near batteries. Whenever servicing an energized unit with the inside
panel open, electric shock is possible; follow all local safety codes. TEST BEFORE TOUCHING!
E) To reduce the risk of re or electric shock, install the LG inverter system and the batteries in a temperature-controlled
and humidity-controlled indoor area free of conductive contaminants. See Section 103 for operating environment
specications.
105.1 AC Wiring Preparations
1) Remove the system’s front cover. Make sure the LG Battery Switch S2 is in the OFF position.
2) Make sure the LG inverter system input and output voltages are correct for the particular application. Remember that
the LG system provides single-phase power only.
3) The input circuit breaker in the input service panel provides the means for disconnecting AC to the LG inverter sys-
tem. Only authorized persons shall be able to disconnect AC to the unit. (See NEC 700-20 and 700-21.)
CAUTION: To prevent electrical shock or equipment damage, for all units, the LG Battery Switch S2 and the
AC input circuit breaker at the service panel are all OFF before making AC connections to the LG inverter
system.
4) If not previously done, remove cabinet knockouts for AC Input and AC Output as described in Sections 104-4, 104.5
or 104.6 depending on mounting method
CAUTION:Donotdrillthecabinet;drilllingsmaydamagetheunitandpreventitfromoperating.Iflarger
knockouts are needed, use a chassis punch to enlarge the appropriate knockout. Do not add additional or
unnecessary knockouts.
5) Install the input and output conduits.
6) Run the AC Input service conductors and AC Output conductors through separate conduits. LG inverter system emer-
gency output circuits shall be installed in dedicated conduit systems and not shared with other electrical circuits as
described in NEC 700-9(b).
105.2 AC Input and AC Output Connections
CAUTION: Prior to making any wiring connections to unit make sure branch AC input circuit breaker feeding
the LG unit is turned off at the service panel!
The LG models can be congured for various modes of operation and are described in this section. Refer to the
appropriate wiring diagrams to properly connect the utility AC power, xtures and external switching device (where
applicable). Perform all wiring procedures in accordance with applicable codes.

9
Normally-On Operation - Fixtures remain illuminated in AC and emergency operating modes.
See “A” in Wiring Diagram 1for 120V wiring or “E” in Wiring Diagram 2 for 277V wiring.
Normally-Off Operation - Fixtures illuminate only upon loss of utility AC power.
See “B” in Wiring Diagram 1 for 120V wiring or “F” in Wiring Diagram 2 for 277V wiring.
Normally-On and Normally-Off Operation - A combination of the operating modes described above.
See “C” in Wiring Diagram 1 for 120V wiring or “G” in Wiring Diagram 2 for 277V wiring.
Switched Load Operation - Single Circuit - Fixtures can be externally switched and will illuminate upon loss of utility
AC power regardless of external switch position.
See “D” in Wiring Diagram 1 for 120V wiring or “H” in Wiring Diagram 2 for 277V wiring.
A) B)
C) D)
Wiring Diagram 1 - 120VAC Connections
Wiring Diagram 2 - 277VAC Connections
E) F)
G) H)

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106. Battery Information
Important Safety Precautions
The installer must take these precautions:
1) Wear protective clothing, eye-wear, rubber gloves and boots. Batteries contain corrosive acids or caustic alkalis and
toxic materials and can rupture or leak if mistreated. Remove rings and metal wristwatches or other metal objects
and jewelry. Don’t carry metal objects in pockets where the objects can fall onto the batteries or into the LG inverter
system.
2) Tools must have insulated handles so that they will not short battery terminals. Do not allow a tool to short a battery
terminal to another battery terminal or to the cabinet at any time. Do not lay tools or metal parts on top of the batteries,
and do not lay any objects where they could fall onto the batteries or into the cabinet.
3) Install the batteries as shown on the battery wiring diagram provided in this manual. When connecting cables, never
allow a cable to short across a battery’s terminals, the string of batteries, or to the cabinet.
4) Keep the cable away from any sharp metal edges.
5) Install the battery cables so they cannot be pinched by the LG inverter system cover/door.
6) Where conductors may be exposed to physical damage, protect conductors in accordance with NEC requirements.
7) Full voltage and current are always present at the battery terminals. The batteries used in this system can produce
dangerous voltages, extremely high currents, and possible risk of electric shock. Batteries may cause severe injury if
the terminals are shorted together or to ground (earth).
Be extremely careful to avoid electric shock and burns caused by contacting battery terminals or shorting terminals
during battery installation. Do not touch uninsulated battery terminals.
8) A qualied electrician who is familiar with battery systems and required precautions must install and service the
batteries. Any battery used with this unit shall comply with the applicable requirements for batteries in the standard
for emergency lighting and power equipment, UL 924. Cabinets are designed to be used with, and batteries must be
replaced by identical cells or a Manufacturer approved equivalent. If using substitute batteries not supplied by the
Manufacturer, the unit’s UL listing will be void, and the equipment may fail to perform properly. The installation must
conform to national and local codes as well. Keep unauthorized personnel away from batteries.
106.1 Tools
The following tools are required to install the system batteries: Socket Set, Tape, Digital Volt-Ohm Meter, Safety
Glasses
CAUTION: Always use insulated tools for battery installation.
106.2 Battery Installation and Connection
CAUTION: Prior to connection of battery string to the inverter/charger assembly make sure the
LG Battery Switch S2 is in the OFF (down) position.
* LG125S,R and T models are supplied with two (2) batteries installed (24VDC string voltage) with the positive
(+) battery lead disconnected. This connection will need to be completed prior to system startup. See Battery Wiring
Diagrams 1 and 2 for verication of proper battery connections.
* LG250S and LG250SI models are supplied with four (4) batteries shipped separately (48VDC string voltage). See
Battery Wiring Diagram 3 for battery connections. Install batteries with terminals facing outwards. Connect batteries
using wiring conductors supplied with the system.