Tripp Lite APS 1024 INT User manual

Owner’s Manual
1111 W. 35th Street Chicago, IL 60609 USA
Customer Support: [phone] • www.tripplite.com
Introduction 2
Important Safety Instructions 4
Configuration & Connection 5
Features 11
Maintenance and Service 14
Copyright © 2002 Tripp Lite. PowerVerter®is a registered trademark of Tripp Lite. All rights reserved.
APS PowerVerter®
Power Inverters (120V, 60 Hz)
• Voltage- and Frequency-Controlled • Peak Power • High Efficiency
Warranty 14
Troubleshooting
Español 18
Specifications 16
15
CUS
UL
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2
Introduction
Congratulations! You’ve purchased the most advanced, feature-rich integrated inverter/battery
charger on the market. Your APS powers connected equipment, switching manually or automat-
ically from utility power to power inverted from an external battery or batteries. In addition to
reliable APS performance, your model provides:
High Efficiency Output
Your APS’s advanced circuitry produces a more efficient DC-to-AC conversion, minimizing
energy loss. This allows you to run connected equipment longer between battery charges. The
APS will maintain this highly-efficient output even as the battery charge decreases.
Automatic Overload Protection
If you overload your APS, it will automatically protect itself and your valuable batteries from
damage.
Fast Load Switching
If AC power goes down, your APS will switch over to providing battery backup power in 6
milliseconds or less so that your equipment will operate with no interruption.
Multi-Function Indicator Lights
Several sets of multifunction indicator lights keep you constantly informed of battery charge
levels, fault conditions and APS operation.
Multi-Operation Switches
An array of user-configurable switches gives you convenient options when operating your
APS. You can select the voltage level at which your APS’s inverter will turn on to maximize
equipment protection and minimize battery drain; set your APS for maximum charging
efficiency with your battery type; even set up your APS for remote control operation.
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3
3-Stage Battery Charger
Your APS recharges your battery faster than
conventional chargers because its three-stage
charger profile (Bulk, Absorption and Float) are
optimized, regardless of the type of battery you
use (Wet or Gel).* In addition, the advanced
charging system protects against over-charge
and over-discharge to ensure a longer service
life from your battery.
* The Absorption and Float levels vary according to battery
type, which can be set to either “Wet” or “Gel”cell.
Load Sharing
Your APS can be set to limit its own battery
charging current so it can charge its
batteries at the quickest rate possible without
overloading its power input circuits.
Frequency-Controlled
Inverter Output
Your APS has frequency-controlled inverter out-
put, which allows devices dependent on AC line
frequency (such as computers, VCRs, CD play-
ers, tape recorders, clocks and turntables) to
operate properly.
Circuit Board Protection
A silicone conformal coating safeguards the
circuit boards against moisture.
Introduction continued
15
14
13
12
Stage 2
Absorption
Stage 3
Float
Stage 1
Bulk
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4
Important Safety Instruction
SAVE THESE INSTRUCTIONS
This manual contains important instructions and warnings that should be followed during
the installation, operation and storage of all Tripp Lite APS Systems.
APS Location Warnings
• Install your APS indoors, away from excess moisture or heat, dust or direct sunlight.
• Your APS is NOT waterproof. Contact with water can cause the unit to short circuit and
could cause personal injury due to electric shock. Never immerse your APS. Mount it in
the driest location available.
• Leave adequate space around all sides of the APS for proper ventilation. The heavier the
load of connected equipment, the more heat will be generated by the APS.
• Do not install the APS near magnetic storage media, as this may result in data corruption.
• Install your APS in land vehicles only.
• Do not attempt to mount your APS on a vertical surface.
Battery Connection Warnings
• Your APS will not operate with or without utility power until batteries are connected.
• Multiple battery systems must be made up of batteries of the same voltage, age, amp hour
capacity and type.
• Keep battery location well ventilated. Explosive hydrogen gas can accumulate near
batteries if they are not kept well ventilated.
• Sparks may result during final battery connection. Always observe proper polarity as
batteries are connected.
• Do not allow objects to contact the two DC input terminals. Do not short or bridge these
terminals together. Serious injury to property or person could result.
Equipment Connection Warnings
• Do not use Tripp Lite APS Systems in life support applications where a malfunction or
failure of a Tripp Lite APS System could cause failure or significantly alter the perform-
ance of a life support device.
• Do not connect a surge suppressor, line conditioner or UPS to the output of the APS.
• Corded models: Do not modify the APS’s plug in a way that eliminates its ground
connection. Do not use power adapters that will eliminate the plug's ground connection.
Connect your APS only to a properly grounded AC power outlet. Do not plug your APS
into itself; this will damage the APS and void your warranty.
Operation Warnings
• Your APS does not require routine maintenance. Do not open your APS for any reason.
There are no user-serviceable parts inside.
• Potentially lethal voltages exist within this unit as long as the battery supply and/or AC
input are connected. During any service work, the battery supply and AC input connection
(if any) should therefore be disconnected.
• Do not connect or disconnect batteries while the APS is operating from the battery supply.
Dangerous arcing may result.
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Configuration
DIP SWITCH GROUP A
BATTERY TYPE / VOLTAGE POINT
Using a small tool, set the 4 “Battery Type / Voltage Point” Configuration DIP Switches, Group
A (located on the front panel of your APS; see Diagram 1, p. 35) to select battery type and set
the voltage range outside of which your APS will switch to battery power.
• Select Battery Type (DIP Switch #1, Group A)
CAUTION: The Battery Type DIP Switch setting must match the type of batteries you connect or your batteries may be
degraded or damaged over an extended period of time. See “Battery Selection,” page 8 for more information.
Configuration Dip Switch Settings
4321
Gel Cell
Wet Cell*
Battery Type Switch Position
Gel Cell (Sealed) Battery Up
Wet Cell (Vented) Battery Down*
• Select High AC Voltage Switch To
Battery Point (DIP Switch #2, Group A)
Voltage Switch Position
145V Up
135V Down*
• Select Low AC Voltage Switch To
Battery Point (DIP Switches #4, Group A & #3, Group A)
Voltage Switch Position
105V #4 Up & #3 Up
95V #4 Up & #3 Down
85V #4 Down & #3 Up
75V #4 Down & #3 Down*
Most loads will perform adequately when your APS’s High AC Voltage
Point DIP Switch #2 is set to 135V and its Low AC Voltage Point DIP
Switches #3 and #4 are set to 95V. However, if your APS frequently
switches to battery power due to momentary high/low line voltage
swings that would have little effect on equipment operation, you may
wish to adjust these settings. By raising the High AC Voltage Switch to
Battery point and/or lowering the Low AC Voltage Switch to Battery
Point, you may reduce the number of times your APS switches to
battery due to voltage swings.
* Factory default settings.
4321
145V
135V*
4321
105V
4321
95V
4321
85V
4321
75V*
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DIP SWITCH GROUP B
LOAD SHARING/EQUALIZE BATTERY CHARGE
The “Load Sharing” Configuration DIP Switches, #1 and #2 of Group B (located on the front
panel of your APS; see Diagram 1, p. 35), should be set with a small tool according to the guide-
lines below. DIP Switch #3, Group B should be kept in the “UP” position when you are not equal-
izing your batteries' charges. DIP Switch #4, Group B can be set to allow your APS to charge
large battery systems faster.
• Load Sharing (DIP Switches #1, Group B & #2, Group B)
Your APS features a high-output battery charger that can draw a significant amount of power
from your line power source when charging at its maximum rate. If an APS is supplying its
full AC power rating to its connected load at the same time as it is charging, it could trip its
line source circuit breaker. Tripping this breaker will cut off AC power to your load and stop
battery charging.
To reduce the chance of tripping this breaker, select APS models may be set to automatically
limit their charger output to keep the sum of their AC load and charger power within their
circuit breakers’ rating.
This charger limiting function has four settings, allowing you to choose less charger limiting
for APS configurations with higher rated breakers. The figures below show how to set your DIP
Switches to select how heavy a load can be placed on your APS before charger limiting begins.
Configuration
continued
4321
Battery Charger Limiting Points
Most Limiting (#1 & #2 Up*): Charger limiting takes effect the
moment any load is applied; charger output falls gradually from full
output at no load to no output at full load.
Less Limiting (#1 Down & #2 Up): Charger limiting begins when the
APS's load reaches 33% of the APS’s load rating. Charger output falls
gradually from full output at 33% of the APS's load rating to about 33%
of full output at full load.
Least Limiting (#1 Up & #2 Down): Charger limiting begins at when
the APS’s load reaches 66% of the APS’s load rating. Charger output
falls gradually from full output at 66% of the APS's load rating to about
66% of full output at full load.
No Limiting (#1 & #2 Down): No charger limiting occurs at any load size.
* Factory default settings.
4321
4321
4321
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• Equalize Battery Charge (DIP Switch #3, Group B)
This DIP Switch is momentarily engaged to begin the process of equalizing the internal resistance
of your battery's cells. This can extend the useful life of certain types of batteries; consult with
your battery's manufacturer to determine if your batteries could benefit from this process. The
charge equalization process is automatic and once started can only be stopped by removing the
input power.
• Move to “Equalize” (DOWN) position for three seconds.
• Move to “Reset” (UP) position and leave it there.
Battery Charge Switch Position
Reset Up*
Equalize Down
* Factory default setting.
• Limit Battery Charger (DIP Switch #4, Group B)
Your APS has a high powered charger. To prevent it from overheating smaller batteries, its charg-
er is initially set to deliver only a fraction of its maximum power rating to connected batteries. If
you are using it with a larger battery or battery system (over 100 amp-hours), you may switch
your charger to full power without overheating your batteries.
Battery Charger Switch Position
Partial (1/3) Charging Power Up*
Full Charging Power Down
* Factory default setting.
Configuration
continued
Setting Procedure:
CAUTION: Battery charge equalization should only be performed in
strict accordance with the battery manufacturer’s instructions and
specifications.
CAUTION: Do not leave DIP switch #3 in the down position after
beginning process.
4321
Partial*
Full
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Battery Selection
Select a battery or system of batteries that will provide your APS with proper DC voltage and an
adequate amp hour capacity.* Select ‘Deep-Cycle’ batteries to enjoy optimum performance from
your APS. Batteries of either Wet-Cell (vented) or Gel-Cell/Absorbed Glass Mat (sealed)
construction are ideal. 6 Volt “golf-cart,” Marine Deep-Cycle or 8D Deep-Cycle batteries are also
acceptable.**
* Even though APS models are high-efficiency converters of DC voltage, their rated output capacities are limited by the
amp-hour size of the external batteries. ** You must set Configuration DIP Switch #1, Group A (Battery Type) to match the
type of batteries you connect or your batteries may be degraded or damaged over an extended period of time. See “APS
Configuration,” page 5 for more information.)
1. Add the Wattage Ratings of your connected equipment to determine the Total Wattage Required.*
2. Divide the Total Wattage Required (from Step 1) by the battery voltage to determine the DC
Amperes Required.
3. Multiply the DC Amperes Required (from Step 2) by the number of hours you estimate will
pass without AC power before your battery can recharge to determine a Battery Amp-Hours
Required Rough Estimate.**
4. Compensate for inefficiency by multiplying your Battery Amp-Hour Required Rough Estimate
(from Step 3) by 1.2 to determine how many amp-hours of battery backup (from one or several
batteries) you should connect to your APS. Note that the Amp-Hour ratings of
batteries are usually given for a 20 hour discharge rate. Actual Amp-Hour capacities are less
when batteries are discharged at faster rates: batteries discharged in 55 minutes provide only
about 50% of their listed Amp-Hour ratings, while batteries discharged in 9 minutes provide
as little as 30% of their Amp-Hour ratings.
* The wattage rating is usually stated in the equipment’s manuals or on their nameplates. If your equipment is rated in
amperes, convert to watts by multiplying the ampere rating by your nominal AC line voltage (120). ** Your charging amps
multiplied by the charging hours must exceed the discharge amp-hours taken from the batteries between charges or you will
eventually run down your battery bank.
Due to their size and weight, all APS PowerVerter systems should be mounted on a rigid hori-
zontal (not vertical) surface, mounting plate or bracket before battery connection. The user must
supply all fasteners and brackets and verify their suitability for use with the intended mounting
surface. Turn your APS PowerVerter and connected equipment OFF before mounting.
• Install two 8 mm (1/4 in.) fasteners (A) into a rigid horizontal surface using the
measurements in the diagram. Leave the heads of fasteners raised slightly above
the surface in order to engage the slots in the APS’s feet.
• Slide PowerVerter forward to fully engage the fasteners in the APS’s feet. Install two
8 mm (1/4 in.) fasteners (B) into the surface, through the slots in the APS’s two
unsecured feet. Tighten the screws to secure the APS in position.
Selecting Battery Type
Selecting Battery Amp Hour Capacity
Mounting
(See Diagram 2, p. 35)
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For ease and safety, Tripp Lite recommends using Tripp Lite battery packs with your APS.
1. Make sure that your APS batteries have proper overcurrent protection.
NEC article 551 requires that you install a recognized UL component fuse block and UL listed
fuse within 18 inches of the battery. The fuse’s rating must equal or exceed the Minimum DC
Fuse Rating listed in your APS model’s specifications on pages 16 or 17. Use Littelfuse Type
#KLNR 150 (for the APS 1012) or Type # KLNR 300 (for the APS 2012) to provide overcur-
rent protection.
2. Choose a battery configuration appropriate to your batteries.
• Single Battery Connection: Refer to Diagram 5, page 36. When using a single battery, its
voltage must be equal to the voltage of your APS's Inverter Nominal Input Voltage (see
specs).
• Parallel Battery Connection: Refer to Diagram 6, page 36. When using multiple batteries
in parallel, each battery's voltage must be equal to the voltage of your APS’s Inverter
Nominal Input Voltage (see specs).
• Series Battery Connection: Refer to Diagram 7, page 37. When using multiple batteries
in series, all batteries must be equal in voltage and amp hour capacity, and the sum of their
voltages must be equal to the voltage of your APS's Inverter Nominal Input Voltage (see specs).
3. Securely fasten the APS’s DC power terminals to the battery terminals.
Use 2/0 gauge cable for battery connection. Battery connection cable lengths should be short
as possible, and never greater than 20 feet. Using longer cables, or cables of a smaller gauge,
could result in dangerous overheating or fire.*
* APS models are capable of delivering a much higher wattage output for brief periods of time. Wiring should be
configured to handle this brief high-current draw. Though your APS is a high-efficiency converter of electricity, its
rated output capacity is limited by the length and gauge of the wires running from the battery to the APS.
Instead of connecting the APS to its own battery array, you may connect it to a vehicle’s battery.
Note: An APS can ONLY be connected to vehicle batteries if their voltage matches the APS’s
Nominal DC Input—12V vehicle batteries to 12V Nominal DC Input APS systems, etc. (See
Specifications). There are two main ways to make this sort of vehicular battery connection.
Choose the Basic Connection if you are running light hand tools or other small appliances for a
brief period of time (see Diagram 8, p. 37). Choose the Advanced Connection if you are using
your APS to power heavy loads for extended periods of time (see Diagram 9, p. 37). The
Advanced Connection incorporates a battery isolator and separate battery system to provide
battery power to your APS while preventing it from draining your vehicle’s battery. Note: Depending
on your application, you may require more than one Deep Cycle Battery.
Note: When installing your APS, the main ground lug must be connected to the vehicle chassis. A non-grounded unit
could cause an electrical shock hazard.
Caution: Never operate your APS from an alternator without a battery connected as shown in Diagrams 7 or 8, p. 37.
Battery Connection
Connection to External Batteries
Connection to Vehicle Battery
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APS systems must be connected to a grounded, permanent wiring system. For most installations,
the negative battery conductor must be bonded to the grounding system at one (and only one)
point in the system. All installations must comply with national and local codes and ordinances.
When figuring the power requirements of your equipment, do not confuse “continuous” power
ratings with “peak” power ratings. Electric motors require more power to turn on (“peak power”)
than they require to run continuously. “Peak” power ratings are usually 2 to 5 times “Continuous”
ratings. Most electric motors require “peak power” only when they are first turned on. The electric
motors in equipment such as refrigerators and sump pumps, however, constantly turn on and off
according to demand. These motors require “peak power” at multiple, unpredictable times during
their operation.
You must use GFCI protection (user-supplied) on output circuits; use the Leviton Type 6599.
You must use branch circuit protection (user-supplied) on input circuits: 15 amp protection on the
APS1012UL and 40 amp protection on the APS2012UL.
Consult a qualified electrician and follow all applicable electrical codes and requirements.
HARDWIRE PROCEDURE
1. Remove screws and cover plate from your APS’s Hardwire AC electrical box. Remove the
knockout covers closest to the desired electrical source and to your equipment.
2. Attach .5 in. dia. conduits (user-supplied) to the knockouts and thread your wires through.
3. Connect the conduits with the ground bond connection supplied. (See Diagram 4, p. 35)
4. Connect the incoming ground wire to the GROUND IN (green & yellow) terminal.
5. Connect the outgoing ground wire to the GROUND OUT (green & yellow) terminal.
6. Connect the incoming hot wire to the HOT IN (brown) terminal.
7. Connect the incoming neutral wire to the NEUTRAL IN (blue) terminal.
8. Connect the outgoing hot wire to the HOT OUT (black) terminal.
9. Connect the outgoing neutral wire to the NEUTRAL OUT (white) terminal.
10. Tighten and affix strain reliefs. Replace cover plate and tighten screws.
AC Connection
Before AC connection, match the power requirements of your
equipment with the power output of your APS to avoid overload.
Hardwired Electrical Connections (All hardwire models) (See Diagram 3, p. 36)
DC Ground Connection
Battery Connection
continued
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