DualLite LiteGear User manual

Installation Instructions
and User Manual
250 VA Inverter
Power System

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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
 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 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

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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