DualLite LiteGear User manual

Installation Instructions
and User Manual
250 VA Inverter
Power System

2
Installation Instructions and User Manual For
LiteGear®250 Watt Inverter Power System
Warning:
THIS PRODUCT CONTAINS CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO
CAUSE CANCER, BIRTH DEFECTS, AND/OR OTHER REPRODUCTIVE HARM.
THOROUGHLY WASH HANDS AFTER INSTALLING, HANDLING, CLEANING OR
OTHERWISE TOUCHING THIS PRODUCT.
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
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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 Systems Technical Support Center at
1-800-848-6439. Technicians are available during normal working hours (EST).

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Table of Contents
Description Page
100. Installation ..................................................................................................................................................................... 4-5
100.1 General Installation Requirements ....................................................................................................................... 4
100.2 Cabinet Installation............................................................................................................................................................... 4
101. AC Connections ............................................................................................................................................................ 5-6
101.1 General Precautionary Measures ........................................................................................................................................ 5
101.2 AC Wiring Preparations........................................................................................................................................................ 5
101.3 AC Input Voltage Selection .............................................................................................................................................................. 6
102. LoadCongurationWiringOptions............................................................................................................................ 6-7
102.1 AC Input and AC Output Connections ................................................................................................................................. 6
102.2 "Normally ON" Loads .......................................................................................................................................................... 6
102.3 "Normally OFF" Loads ........................................................................................................................................................ 6
102.4 Externally Switched Loads .................................................................................................................................................. 6
103. Installing the Batteries and DC Wiring ........................................................................................................................ 7-8
103.1 General Precautionary Measures ........................................................................................................................................ 7
103.2 Installation Considerations................................................................................................................................................... 7
103.3 Battery Installation Procedure.............................................................................................................................................. 8
103.4 Electronics Cabinet Voltage Check ...................................................................................................................................... 9
104. Final Installation Checklist .............................................................................................................................................. 9
104.1 Pre-Start-Up Systems Check............................................................................................................................................... 9
105. System Start-Up Procedure ............................................................................................................................................ 9
105.1 Sequence of Steps .............................................................................................................................................................. 9
105.2 Start-Up Procedure Steps.................................................................................................................................................... 9
106. SystemVerication .......................................................................................................................................................... 9
106.1 Initial System Status ............................................................................................................................................................ 9
106.2 System Transfer Test ........................................................................................................................................................... 9
200. Status Indicators ............................................................................................................................................................ 10
200.1 Indicators Provided ............................................................................................................................................................ 10
200.2 Unusual Circumstances ..................................................................................................................................................... 10
201. Spectron® Self-Testing/Self-Diagnostic Option ..................................................................................................... 10-11
201.1 Description and Operation ................................................................................................................................................. 10
201.2 Trouble Shooting Service Alert Code Faults .......................................................................................................................11
202. Remote Test Switch Accessory................................................................................................................................ 11-12
202.1 Installation...........................................................................................................................................................................11
300. Maintenance............................................................................................................................................................... 12-14
300.1 General Precautionary Measures ...................................................................................................................................... 12
300.2 Final Shut Down Procedure ............................................................................................................................................... 12
300.3 Routine System Maintenance ............................................................................................................................................ 12
300.4 Manual Routine Inverter Tests ........................................................................................................................................... 13
300.5 Battery Maintenance and Replacement ............................................................................................................................ 13
300.6 Important Safety Precautions ............................................................................................................................................ 13
300.7 Routine Battery Inspection and Maintenance .................................................................................................................... 13
300.8 Battery Replacement Procedure........................................................................................................................................ 14
300.9 Battery Disposal ................................................................................................................................................................ 14
301. Technical Service and Support ..................................................................................................................................... 14
301.1 Toll-Free Number ............................................................................................................................................................... 14
302. Warranty Information ..................................................................................................................................................... 14
302.1 Warranty ............................................................................................................................................................................ 14

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100. Installation
100.1 General Installation Requirements
CAUTION:
LiteGear cabinets are very heavy. Check to assure that the chosen location is capable of safely bearing the load.
Cabinet Size: 18.375” W x 10.2” H x 8.25” D (46.6cm W x 25.9cm H x 21cm D)
Weight (including batteries): 70 lbs.
Install the LiteGear inverter system in a clean, cool, dry place with normal ventilation for human habitation.
LiteGear inverter systems are UL Listed for 20°C to 30°C (+68°F to +86°F) operation.
Battery performance and service life is maximized if the operating temperature is maintained at 25°C (77°F).
The air around the unit must be clean, dust-free, and free of corrosive chemicals or other contaminants. Do not place
the LiteGear inverter system or batteries in a sealed room or container.
100.2 Cabinet Installation
CAUTION:
Do not drill into the cabinet; drill lings may damage the unit and prevent it from operating. If additional or larger entry
points are needed, use a chassis punch to enlarge the appropriate knockout. Do not add unnecessary knockouts.
Remove the electronics module by removing the four screws on the right side of the cabinet. (The inverter cabinet
should be installed without the batteries inside.)
The LiteGear® units are supplied with two keyhole knockouts for wall mounting. See Figure 100-1. Necessary
hardware to fasten the cabinet to the wall is to be supplied by the installing contractor.
Please refer to the following illustrations.
Install the input and output conduits.
AC Input service conductors and AC Output conductors must be run in separate conduits. LiteGear inverter system
emergency output circuits must be installed in dedicated conduit systems and not shared with other electrical circuits
as described in NEC 700-9(b).
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Cabinet should be empty before
mounting. Use 1/4" lag screws
through keyhole knockouts to mount
cabinet to studs as shown

5
Be sure to follow all federal, state, and local codes as it pertains to emergency circuit raceways.
For surface and recessed models reinstall the electronics plate and securely tighten the four mounting nuts.
For recessed mount models, adjust the trim plate to t ush to the nished wall or ceiling surface. Adjust the LED/Test
Switch bracket to be ush with the cover when installed.
Connect the LEDs to the printed circuit board ensuring the connectors are properly aligned.
Connect the test switch to the printed circuit board ensuring both pin connectors are fully engaged.
101. AC Connections
101.1 General Precautionary Measures
All LiteGear inverter system units contain hazardous AC and DC voltages. Because of these voltages, a qualied
electrician must install the LiteGear 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.
Before installing, maintaining, or servicing the unit, always remove or shut off all sources of AC and DC power and
shut off the LiteGear inverter system. Disconnect AC line input at the service panel and disconnect the batteries to
make sure the unit will not supply output voltage.
Whenever AC and/or DC voltage is applied, there will be AC voltage inside the LiteGear inverter system unit; the
unit can supply power from the AC line or from its batteries. To avoid equipment damage or personal injury, always
assume that there is voltage inside the LiteGear inverter system.
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 an energized unit is serviced with the cover
removed, electric shock is possible; follow all local safety codes. TEST BEFORE TOUCHING!
To reduce the risk of re or electric shock, install the LiteGear inverter system and the batteries in a temperature-
controlled and humidity-controlled indoor area free of conductive contaminants.
To prevent electrical shock or equipment damage, for all units, insure the AC input breakers at the service panel are
all off before making AC connections to the LiteGear inverter system.
The LiteGear inverter system is only designed to supply 120 VAC in/120 VAC out or 277 VAC in/277 VAC out. Only
authorized persons should disconnect AC to the unit. (See NEC 700-20 and 700- 21.)
Use of this equipment for simultaneous operation of 120VAC and 277VAC loads will damage the unit and void the
warranty.
101.2 AC Wiring Preparations
If not previously done, remove knockouts for AC Input and AC Output in the LiteGear inverter system and install input
and output conduits per section 100.2
Place electronics module in cabinet, turned 90˚ from original orientation as shown in Fig. 101-1 for easy access to
wire connections.
Fig. 101-1

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101.3 AC Input Voltage Selection
The battery charger transformer has two input leads:
black = 120VAC orange = 277VAC
Select proper AC input lead for the application.
Refer to Fig. 101-2.
For 120VAC input:
• Black – Connect to FT2
• Orange – Remove “push on” connector and cap off using
appropriate mechanical connector
OR
For 277VAC input:
• Orange – Connect to FT1
• Black - Remove “push on” connector and cap off using
appropriate mechanical connector
102. LoadCongurationWiring
Options
102.1 AC Input and AC Output Connections
CAUTION: Torque all terminal block connections to 4.4 to 5.3 in-lb. (0.5 to 0.6 Nm.) Failure to do so may create an
unsafe condition or re hazard. Only "Normally ON" or "Normally OFF" or "Externally Switched" loads can be selected.
102.2 “Normally ON” loads
Connect utility and load to appropriate terminal blocks per Fig. 101-2 and ensure the input, output, and chassis are
grounded.
102.3 “Normally OFF” Loads
CAUTION: To use this product with normally off lighting loads requires rewiring the circuit board to bypass an internal
relay. This process should only be performed by qualied personnel. Refer to Fig. 101-2.
For 120VAC Operation:
• Remove the black wire lead from FT8, remove the “push on” connector, and strip the end.
• Remove the red wire lead from FT10, remove the “push on” connector, and strip the end.
• Join them using an approved mechanical connector.
OR
For 277VAC operation:
• Remove the orange wire lead from FT4, remove the “push on” connector, and strip the end.
• Remove the orange wire lead from FT3, remove the “push on” connector, and strip the end.
• Join them using an approved mechanical connector.
Connect utility and load to appropriate terminal blocks and ensure the input, output, and chassis are grounded.
102.4 Externally Switched Loads
For 120VAC Operation:
• Disconnect the black wire from FT2.
• Remove the terminal and strip the wire.
• Connect to unswitched 120VAC power supply.
• Connect switched 120VAC power to the 120V input connection of the input terminal block (pins not numbered).
OR
For 277VAC operation:
• Disconnect the orange wire from FT1.
Fig. 101-2

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• Remove the terminal and strip the wire.
• Connect to unswitched 277VAC power supply.
• Connect switched 277VAC power to the 277V input connection of the input terminal block (pins not numbered).
Connect utility and load wires to appropriate terminal blocks and ensure the input, output, and chassis are grounded.
Once all the electrical and conduit connections have been made and are secure, turn the electronics module back to
its original orientation and reinstall the four screws through the side wall into the module. Be careful not to pinch any
wires between the module and the cabinet.
103. Installing The Batteries and DC Wiring
103.1 General Precautionary Measures
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 with identical cells or a Dual-Lite approved equivalent. If using substitute batteries not supplied by Dual-
Lite, 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.
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 LiteGear inverter
system.
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.
Install the batteries as shown on the battery wiring diagram provided in this manual with the cables provided. When
connecting cables, never allow a cable to short across a battery’s terminals, the string of batteries, or to the cabinet.
Keep the cables away from any sharp metal edges.
Install the battery cables so they cannot be pinched by the LiteGear inverter system’s cover.
Where conductors may be exposed to physical damage, protect conductors in accordance with NEC requirements.
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.
103.2 Installation Considerations
This section explains how to install the LiteGear system’s batteries and cables. A qualied electrician who is familiar
with battery installations and applicable building and electrical codes must install the batteries.

8
103.3 Battery Installation Procedure
Place the batteries into the cabinet as shown in Figure 103-1. Connect one end of the provided gray wire to the
Negative Terminal (-) of battery 1 to the Positive Terminal (+) of battery 2. Connect the red wire from the electronic
module to the Positive Terminal (+) of battery 1, and connect the blue wire to the Negative Terminal (-) of battery 2.
CAUTION: Be careful to follow the bolt orientation shown in Figure 103-2. Failure to do so may create an unsafe
condition or re hazard.
The head of the bolt should be toward the outside of the battery terminal as shown.
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103.4 Electronics Cabinet Voltage Check
Using a voltmeter, check for correct nominal battery voltage between battery NEG and POS wires. Voltage reading
should be 24 VDC ±10% of system DC voltage.
CAUTION: Ensure all connections are fully engaged. Failure to do so may create an unsafe condition or re hazard.
104. Final Installation Checklist
104.1 Pre-Start-Up Systems Check
Complete the following:
• Ensure the LiteGear Inverter cabinet is securely fastened to a wall or other structure.
• Ensure that the input circuit breaker in the building service panel serving as the AC supply to the LiteGear
system is in the OFF position.
• Check for proper ground connections in the LiteGear cabinet, the building service panel, and the external load
distribution panel.
• Check for any loose wiring connections in the LiteGear cabinet, the building service panel, and the external load
distribution panel.
• Check that correct nominal battery voltage (24 VDC) is present in the LiteGear cabinet between the battery NEG
and POS wires.
• Securely fasten cover and ensure no wires are pinched.
105. System Start-Up Procedure
105.1 Sequence of Steps
The LiteGear inverter system is a sophisticated electronic backup power supply. Care must be taken to follow the
steps below in their exact sequence. Failure to do so can result in possible equipment damage or failure.
105.2 Start-Up Procedure Steps
CAUTION: Familiarize yourself with the shut down procedure (section 300.1) before proceeding.
• Make sure the cover is installed and secured.
• At the building service panel, energize the circuit breaker serving as the AC supply disconnect to the LiteGear
system.
• The system should turn “ON”; the green “AC-ON” LED will illuminate.
106. SystemVerication
106.1 Initial System Status
The connected load should be energized and the “AC ON” LED should be illuminated (green). Allow a minimum
24-hour charge period before testing the inverter system. If you need assistance, call Dual-Lite’s Technical Support
Center at 1-800-848-6439.
106.2 System Transfer Test
Press the momentary “TEST” switch or, for a prolonged discharge test, de-energize the service panel circuit breaker
serving as AC input circuit breaker. The unit will transfer to inverter mode, the "AC On" LED will extinguish and the
"Inverter ON" LED will illuminate (amber). All connected loads should be energized.
Allow the inverter to run for several minutes or until satised with its operation. Energize the service panel breaker to
end the prolonged discharge test and return the unit to standby mode.

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200. Status Indicators
200.1 Indicators Provided
The LiteGear system is equipped with two LED indicators:
200.2 Unusual Circumstances
If an abnormal condition is detected, please contact the local Hubbell Lighting, Inc. Factory Authorized Service Center,
or call 1-800-848-6439 for assistance. Do not attempt to make repairs; the system is fed from more than one power
source and extreme care must be taken before servicing.
201. Spectron® Self-Testing/Self-Diagnostic Option
201.1 Description and Operation
Models equipped with the Spectron® self-testing/self-diagnostic circuitry provide:
• Visual indication of AC power status
• Visual indication of self-diagnostic test cycle
• Visual indication of any unit malfunction including -
• Battery fault
• Charger fault
• Transfer fault
• Lamp/no load fault
Spectron® equipped units also include:
• Time Delay Retransfer - upon return of normal AC power, unit will remain in emergency operation for an additional
15 minutes to allow AC power to normalize.
Note - Once normal AC power has returned Time Delay Retransfer can be overridden by pressing the test switch.
LED Status Indicator - bi-color green/red LED:
• Green Status Indicator - During normal operation, the green status LED will be constantly illuminated, indicating the
presence of AC power. During all automatic or manual self-test cycles, the green status LED will blink indicating test in
progress.
• Red Status Indicator - If a fault condition is detected during any automatic or manual self-test cycle, the test in
progress will be terminated and the red status indicator will provide the proper “service alert code”. When multiple
failures are detected during a test (example - battery fault and lamp failure), the service alert code displayed at the
end of the test cycle will be the rst one detected in the order listed below for ‘Service Alert Code’.
Manual Tests:
• Press the test switch once to initiate a 1-minute duration test
• Press the test button a second time to initiate a 90-minute duration test
• Press the test button a third time to end test routine
LED Display System Mode Reason
None Off • No AC power
• Low Voltage Battery Disconnect circuit activated following extended power outage
• Batteries disconnected
Amber Inverter-ON • Test
• Loss of utility
Green(solid or
blinking)
AC-ON and
Charging
• Utility applied, branch feeder circuit breaker energized