LiteGear Inverter Power System Manual

Installation Instructions
and
User Manual
For
100 Watt
Inverter
Power
System

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Installation Instructions and User Manual For
LiteGear®100 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........................................................................................................................................................ 6
101.3 AC Input Voltage Selection .................................................................................................................................................. 6
101.4 AC Output Voltage Selection ............................................................................................................................................... 6
101.5 AC Output Wattage 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 ........................................................................................................................................................ 7
102.4 Externally Switched Loads .................................................................................................................................................. 7
103. Installing the Batteries and DC Wiring ........................................................................................................................ 7-8
103.1 General Precautionary Measures ........................................................................................................................................ 7
103.2 Installation Considerations................................................................................................................................................... 8
103.3 Battery Installation Procedure.............................................................................................................................................. 8
103.4 Electronics Cabinet Voltage Check...................................................................................................................................... 8
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 .............................................................................................................................................................. 9
200.1 Indicators Provided .............................................................................................................................................................. 9
200.2 Unusual Circumstances ..................................................................................................................................................... 10
300. Maintenance............................................................................................................................................................... 10-12
300.1 General Precautionary Measures ...................................................................................................................................... 10
300.2 Final Shut Down Procedure ............................................................................................................................................... 10
300.3 Routine System Maintenance ............................................................................................................................................ 10
300.4 Manual Routine Inverter Tests ........................................................................................................................................... 10
300.5 Battery Maintenance and Replacement ............................................................................................................................ 10
300.6 Important Safety Precautions .............................................................................................................................................11
300.7 Routine Battery Inspection and Maintenance .....................................................................................................................11
300.8 Battery Replacement Procedure.........................................................................................................................................11
300.9 Battery Disposal ................................................................................................................................................................ 12
301. Technical Service and Support ..................................................................................................................................... 12
301.1 Toll-Free Number ............................................................................................................................................................... 12
302. Warranty Information ..................................................................................................................................................... 12
302.1 Warranty ............................................................................................................................................................................ 12

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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
Surface/Recessed 14"W x 18.125"H x 4.25"D (35.6cm W x 46cm H x 10.8cm D)
Ceiling 23.85"W x 10.55H x 7.0"D (60.58cm W x 26.80cm H x 17.78cm D)
Weight (including batteries)
• SurfaceWallMountUnits 43lbs
• RecessedWallMountUnits 45lbs
• RecessedCeilingMountUnits 41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.
For surface and recessed cabinets remove the electronics plate by removing the four nuts holding it in place. All units
should be mounted with the batteries removed.
The LiteGear surface models are supplied with four keyholes for wall mounting (Fig 100-1); recessed models are
supplied with trim plates and mounted using ¼” knockouts (three on each side) for mounting to studs (Fig. 100-2);
while the ceiling mount units are supplied with two locations for chain support (Fig’s. 100-3, 100-4).
Necessary hardware to fasten the cabinet to the wall is to be supplied by the installing contractor.
Please refer to the following illustrations.
Fig. 100-1
Surface Wall Mount
(Cabinet should be empty
before mounting)
Use 1/4" lag screws to
mount cabinet to studs
(choose most convenient
pair of vertical knockouts)
Fig. 100-2
Recessed Wall Mount
(Cabinet should be empty
before mounting)
Add shims
to one side if
both sides are
to be secured
Add brace
to support
cabinet
Secure cabinet to
studs with screws
through knockouts
See Fig. 100-4 for
chain/cable note
S hooks
Fig. 100-3
Recessed Ceiling Mount

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Fig. 100-4 – Chain/Cable Options for Ceiling Mount
A chain with a 50 lb. minimum working load or a cable with a 250 lb. minimum break strength is required to hang the ceiling unit in a T-Grid.
For example, the following can be used.
# 5 Double Loop Chain
# 10 Register Chain
# 8 Sash Chain
# 8 Single Jack Chain
3/64" 7x7 Stainless Steel
Aircraft Cable
Fig. 100-4
Recessed Ceiling Mount
Wall Mount Models: Once the cabinet is securely fastened to the wall, install and attach conduit using the knockouts
provided.
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).
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.

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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
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. 102-1.
For 120VAC input:
• Black–ConnecttoFT22
• Orange–Remove“pushon”connectorandcapoffusingappropriatemechanical
connector
OR
For 277VAC input:
• Orange–ConnecttoFT23
• Black-Remove“pushon”connectorandcapoffusingappropriatemechanical
connector
101.4 AC Output Voltage Selection
Refer to Fig. 102-2
For 120VAC output:
• Install120VACfuseintoholderandinstallfuseholderinbracket
• Discard277VACfuseandinstallfuseholderinbracket
OR
For 277VAC output:
• Install277VACfuseintoholderandinstallfuseholderinbracket
• Discard120VACfuseandinstallfuseholderinbracket
101.5 AC Output Wattage Selection
Refer to Fig. 102-3
For loads less than 36 Watts:
• RemovejumperconnectedbetweenJ1andJ2onthestandoff
electronics board
• Ifloadwattageisincreasedlater,thenjumpershouldbereapplied.
Otherwise, unit will fail to provide output voltage.
OR
For loads greater than or equal to 36 Watts:
• ProceedtoSection102
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"Normaly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. 102-1 and ensure the input, output, and chassis are
grounded.
Fig. 102-2
Fig. 102-1
COM OUT
COM IN
120V IN
277V IN
120V OUT
277V OUT
277V
IN
120V
IN
COM
IN
COM
OUT
120V
OUT
277V
OUT
FT16 FT14
FT17
FT15
FT23 FT22 FT20 FT21 FT19 FT18
J2
J1
JUMPER
Fig. 102-3
JUMPER

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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.102-1.
For 120VAC Operation:
• RemovetheblackwireleadfromFT16,removethe“pushon”connector,andstriptheend.
• RemovetheredwireleadfromFT14,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FT17,removethe“pushon”connector,andstriptheend.
• RemovetheorangewireleadfromFT15,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FT22.
• 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FT23.
• 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.
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.

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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.
103.3 Battery Installation Procedure
RefertoFigures103-1and103-2dependingonmountingconguration.Forsurfaceandrecessedmodelsinstall
andconnectthelowtierofbatteriesrst.Next,installtheshelfandtheupperbatterytierandmakethenalbattery
connections.
Fig. 103-1
Surface and Recessed Wall Mount Models
Blue Leads to
PCT1 B- on PCB
Red Leads to
PCT3 B+ on PCB
Blue Leads to
PCT1 B- on PCB
Red Leads to
PCT3 B+ on PCB
Fig. 103-2
T-Grid Recessed Ceiling Model
CAUTION: Be careful to observe correct polarity on the battery terminals. Illustrations are given as a guide only;
polarity markings may vary from battery to battery.
103.4 Electronics Cabinet Voltage Check
Using a digital volt-ohm meter, check for correct nominal battery voltage between battery NEG and POS wires.
Voltage reading should be 12 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.

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LED Display System Mode Reason
No Color Off •NoACpower
•LowVoltageBatteryDisconnectcircuitactivatedfollowingextendedpoweroutage
•Batteriesdisconnected
Amber Inverter-ON •Test
•Lossofutility
Green AC-ON/Charging •Utilityapplied,branchfeedercircuitbreakerenergized
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disconnect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(12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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.
200. Status Indicators
200.1 Indicators Provided
The LiteGear system is equipped with two LED indicators:

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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.
300. Maintenance
300.1 General Precautionary Guidelines
CAUTION: To avoid possible equipment damage or personal injury, assume that there is AC voltage present inside
the LiteGear inverter cabinet when AC input power or DC battery voltage is present. The inverter is capable of provid-
ing output voltage from the batteries even when there is no AC input line voltage. When AC input voltage is present,
the unit can provide output voltage even when the batteries are disconnected.
CAUTION: AC and DC voltage will be present inside the unit until both the line AC and the batteries are disconnected.
CAUTION: Do not touch components inside the unit. DC voltage is always present at the batteries and the battery
cables.
300.2 Final Shut Down Procedure
• TurnofftheservicepanelbreakerprovidingtheACinputtotheLiteGearunit.
• Removetheunit’scover.
• Disconnectthebatteries.
CAUTION: Energy is stored in capacitors inside the unit. After disconnecting the unit from the AC supply, allow at
least 5 minutes for capacitors to discharge before attempting service procedures.
If the service technician does not need to access the inside of the unit, keep the unit's cover securely installed.
If the unit will be shut off for an extended period of time, recharge the batteries every 60 to 90 days.
CAUTION: The batteries will be damaged and the warranty voided if the batteries are not routinely recharged.
NOTE:Toturnpowerbackon,followthe“SystemStart-upProcedure”outlinedinSection105.Besuretocompleteall
of the steps to assure the unit will operate properly.
300.3 Routine System Maintenance
The LiteGear inverter unit is designed to provide years of trouble-free operation. The manually-initiated cycles are
designed to ensure proper operation of the unit's batteries and inverter. The unit does require some routine attention
toassurepeakperformance.Dual-LiterecommendsaPreventativeMaintenancecheckbeperformedbyaqualied
service technician at least every six months. The technician must observe important safety precautions while perform-
ing the following recommended tasks:
• Inspectandcleantheunitinterior
• Inspectallbatteriesforleaks,caseswellingorterminalcorrosion
• Performanemergencyoperationtesttocheckproperfunctionofallcriticalconnectedloads
300.4 Manual Routine Inverter Tests
NFPA101 requires that Emergency Lighting Equipment be tested on a monthly basis for a period of not less than 30
seconds, and a minimum of 90 minutes once a year. We strongly recommend these guidelines be followed to insure
system readiness, and to prolong battery life. The LiteGear system incorporates a test switch to facilitate monthly
testing. Simply depress the button and hold to test the inverter at anytime. Once released, the LiteGear will revert
back to standby operation. For annual 90-minute discharge or other prolonged tests, de-energize the AC breaker at
the service panel.
300.5 Battery Maintenance and Replacement
Thissectionprovidesprecautionsforqualiedservicepersonnelworkingwithunitbatteries.