Tripp Lite Welding System APSX700HF User Manual

Owner’s Manual  
PowerVerter®  
DC-to-AC  
Inverter/Charger  
1111 W. 35th Street, Chicago, IL 60609 USA  
Model: APSX700HF  
Input  
Output  
Invert:  
12 V DC  
230 V, 50 Hz AC  
Charge: 230 V, 50 Hz AC 12 V DC  
Reliable Emergency Backup Power  
Congratulations on your purchase of the PowerVerter® APSX700HF Inverter/Charger! The  
APSX700HF gives you a convenient, reliable source of AC power anywhere and anytime you need it.  
It keeps connected equipment up and productive through all utility power problems (blackouts,  
brownouts and high voltages) by inverting DC power from user-supplied batteries into AC power. When  
utility power is present, the APSX700HF automatically passes through power to your equipment while  
simultaneously recharging your connected battery bank. Built-in surge suppression provides connected  
equipment with additional protection. The APSX700HF is the clean, quiet emergency backup power  
alternative to gas generators—with no fuel, fumes, or noise to deal with!  
Better for Your Equipment  
Premium Protection Levels  
Built-In Isobar® Surge Protection  
Automatic Overload Protection  
Ideal Output for All Loads  
Frequency-Controlled Output  
Better for Your Batteries  
Better for You  
Faster Battery Recharge  
High-Amp, 3-Stage Battery Charger  
Critical Battery Protection  
High-Efficiency DC-to-AC Inversion  
Simple, Maintenance-Free Operation  
Multi-Function Lights & Switches  
Contents  
Important Safety Instructions  
Features  
2
3
4
5
6
7
Operation  
7-8  
9
Troubleshooting  
Specifications  
Battery Selection  
Mounting  
10  
11  
11  
Service and Maintenance  
Warranty  
Battery Connection  
AC Connection  
Copyright © 2007. All rights reserved. PowerVerter® and Isobar® are trademarks of Tripp Lite.  
 
Features  
1
Operating Mode Switch: controls Inverter/  
Charger operation. When this switch is set to  
“AUTO”, connected equipment receives  
constant, uninterrupted utility AC power,  
with simultaneous charging of connected  
batteries. The “CHARGE ONLY” setting  
prevents unwanted battery rundown when  
there is no need for battery backup.  
Connected batteries are recharged. When the  
Operating Mode Switch is set to “DC OFF”,  
both the inverter and the battery charger are  
shut off. However, the unit will still pass  
utility AC power to connected equipment if  
it is plugged into an AC outlet.  
5
AC Output: IEC 60320 C13 permits  
connection of equipment that would  
normally be plugged into a utility outlet.  
Note: The unit will always pass AC power  
to connected equipment if plugged into a  
live AC outlet, regardless of the position of  
the Operating Mode Switch.  
6
7
Circuit Breaker: Protects the Inverter/  
Charger against damage due to overload. See  
the Operation section for resetting  
instructions.  
Low Line Adjustment: Sets the AC input  
voltage at which the Inverter/Charger will  
switch from utility AC power to inverted  
battery power, allowing you to optimize  
operation in areas with frequent brownouts.  
If the dial is set fully counterclockwise, the  
unit will allow AC input to drop to  
approximately 160 V before switching to  
inverter mode. Note: The unit will continue  
to pass lower-voltage AC utility power to  
connected equipment until the unit  
switches to inverter mode.  
“OPERATION” Indicator Lights: These  
intuitive “traffic light” signals show whether  
the Inverter/Charger is operating from AC  
line power or from DC battery power. They  
also signal an alert if the connected  
equipment load is too high. See the  
Operation section for details.  
2
“BATTERY” Indicator Lights: These  
“traffic light” signals show the approximate  
charge level of your battery. See the  
Operation section for details.  
3
4
8
9
DC Connectors: Connect to your battery  
terminals with user-supplied cabling. See  
Battery Connection section for instructions.  
AC Input: IEC 60320 C14 connects the  
Inverter/Charger to a source of utility- or  
generator-supplied AC power. See the AC  
Connection section for instructions.  
Cooling  
Fan:  
Regulates  
internal  
temperature and prolongs equipment service  
life.  
10  
Main Ground Lug: Grounds the Inverter/  
Charger to earth ground or vehicle  
grounding system. See Battery Connection  
section for instructions.  
1
2
6
3
10  
4
7
5
10  
9
8
 
3
Battery Selection  
Match Battery Amp-Hour Capacity to Your Application  
Select a battery or system of batteries that will provide your Inverter/Charger with proper DC voltage  
and an adequate amp-hour capacity to power your application. Even though Tripp Lite Inverter/Chargers  
are highly efficient at DC-to-AC inversion, their rated output capacities are limited by the total amp-  
hour capacity of connected batteries plus the output of an alternator when one is used.  
Example  
• STEP 1) Determine Total Wattage Required  
Add the wattage ratings of all equipment you will  
Tools  
Cordless Tool  
Charger  
¼" Drill  
Orbital Sander  
connect to your Inverter/Charger. Wattage ratings  
are usually listed in equipment manuals or on  
nameplates. If your equipment is rated in amps,  
multiply that number times AC utility voltage to  
estimate watts. (Example: a ¼ in. drill requires  
1.3 amps. 1.3 amps × 230 volts = 300 watts.)  
300W  
+
220W  
+
20W  
= 540W  
NOTE: Your Inverter/Charger will operate at higher efficiencies  
at about 75% - 80% of nameplate rating.  
Appliances  
Blender  
Color TV  
Laptop Computer  
300W  
+
140W  
+
100W  
= 540W  
STEP 2) Determine DC Battery Amps Required  
540 watts ÷ 12V =  
45 DC Amps  
Divide the total wattage required (from step 1, above) by the battery  
voltage to determine the DC amps required.  
STEP 3) Estimate Battery Amp-Hours Required  
Multiply the DC amps required (from step 2, above) by the number of  
hours you estimate you will operate your equipment exclusively from  
battery power before you need to recharge your batteries with utility-  
or generator-supplied AC power. Compensate for inefficiency by  
multiplying this number by 1.2. This will give you a rough estimate of  
how many amp-hours of battery power (from one or several batteries)  
you should connect to your Inverter/Charger.  
45 DC Amps ×  
2 Hours Runtime ×  
1.2 Inefficiency Rating =  
108 Amp-Hours  
NOTE: Battery amp-hour ratings are usually given for a 20-hour discharge rate. Actual amp-  
hour capacities are less when batteries are discharged at faster rates. For example, batteries  
discharged in 55 minutes provide only 50% of their listed amp-hour ratings, while batteries  
discharged in 9 minutes provide as little as 30% of their amp-hour ratings.  
STEP 4) Estimate Battery Recharge Required  
You must allow your batteries to recharge long enough to replace the  
charge lost during inverter operation or else you will eventually  
deplete your batteries. To estimate the minimum amount of time you  
need to recharge your batteries given your application, divide your  
required battery amp-hours (from step 3, above) by your Inverter/  
Charger’s rated charging amps (see the Specifications section).  
NOTE: For Tripp Lite Inverter/Chargers providing 1000 watts or less of continuous AC power,  
108 Amp-Hours ÷  
6 Amps  
Inverter/Charger Rating =  
18 Hours Recharge  
a
full-size battery will normally allow sufficient power for many applications before  
recharging is necessary. For mobile applications, if a single battery is continuously fed by an  
alternator at high idle or faster, then recharging from utility or generator power may not be  
necessary. Tripp Lite Inverter/Chargers will provide adequate power for ordinary usage  
within limited times without the assistance of utility or generator power. However, when  
operating extremely heavy electrical loads at their peak in the absence of utility power, you  
may wish to “assist your batteries” by running an auxiliary generator or vehicle engine, and  
doing so at faster than normal idling.  
 
4
Mounting  
WARNING! Mount your Inverter/Charger BEFORE DC  
battery and AC power connection. Failure to follow these  
instructions may lead to personal injury and/or damage  
to the Inverter/Charger and connected systems.  
Tripp Lite recommends that you permanently mount your Inverter/Charger in the configuration  
illustrated below. The APSX700HF features integrated mounting brackets at the front and rear of the  
unit. The user must supply mounting hardware and is responsible for determining if the hardware and  
mounting surface are adequate to support the weight of the unit. Read the Important Safety Instructions  
section before mounting.  
A
Using the measurements shown in the diagram, install two user-supplied fasteners , leaving the heads  
B
slightly raised. Slide the unit over the fasteners to engage the mounting bracket slots  
C
. Tighten the  
fasteners. Install two additional fasteners  
over the remaining mounting bracket.  
C
10.93 in. (27.8 cm)  
4.31 in.  
(10.95 cm)  
B
A
 
5
Battery Connection  
Connect your Inverter/Charger to your batteries using the following procedures  
• Connect DC Wiring: Though your Inverter/Charger is a high-efficiency  
converter of electricity, its rated output capacity is limited by the length and gauge  
of the cabling running from the battery to the unit. Use the shortest length and  
largest diameter cabling (maximum 2 AWG (6.544 mm)) to fit your  
Inverter/Charger’s DC connectors. Shorter and heavier gauge cabling reduces  
DC voltage drop and allows for maximum transfer of current. Your  
Inverter/Charger is capable of delivering peak wattage above its rated  
DC Connectors  
continuous wattage output for brief periods of time. See the Specifications  
section for details. Heavier gauge cabling should be used when continuously operating heavy draw  
equipment under these conditions. Tighten your Inverter/Charger and battery terminals to approximately  
3.5 Newton-meters of torque to create an efficient connection and to prevent excessive heating at this  
connection. Insufficient tightening of the terminals could void your warranty. See the Specifications  
section for battery wiring recommendations.  
• Connect Ground: Use an 8 AWG (3.264 mm) wire or larger to connect the Main Ground Lug to earth  
ground. See the Features section to locate the Main Ground Lug on your Inverter/Charger. All  
installations must comply with national and local codes and ordinances.  
• Connect Fuse: NEC (National Electrical Code) article 551 requires that you connect all of your  
Inverter/Charger’s positive DC connectors directly to a UL-listed fuse(s) and fuse block(s) within 18  
inches (45.72 cm) of the battery. The minimum rating of the DC fuse is listed in the Specifications  
section. See the following battery configuration diagrams for proper fuse placement.  
WARNING!  
• Failure to properly ground your Inverter/Charger may result in a lethal  
electrical shock hazard.  
• Never attempt to operate your Inverter/Charger by connecting it directly  
to output from an alternator rather than a battery or battery bank.  
• Observe proper polarity with all DC connections.  
Battery Configuration  
You may connect one or more batteries to your Inverter/Charger in either of the following  
configurations.  
1
Parallel Connection: The voltage of each connected battery must match the Inverter/Charger's  
Nominal DC Input Voltage (12 V).  
2
Series Connection: The total voltage of all connected batteries must match the Inverter/Charger's  
Nominal DC Input Voltage (12 V). Example: 6 V + 6 V = 12 V.  
Contact Tripp Lite technical support for assistance with battery connection configurations.  
A
A
APSX700HF  
6 Volts  
6 Volts  
APSX700HF  
12 Volts  
12 Volts  
C
C
B
B
1
Series Connection  
Parallel Connection  
2
A
Battery  
B UL-Listed Fuse & Fuse Block mounted within 18 inches (45.72 cm) of battery  
C Large-Diameter Cabling, Maximum 2 AWG (6.544 mm), to Fit Terminals  
 
6
AC Connection  
To avoid overloading your Inverter/Charger, be sure to match the power requirements of the equipment  
you plan to run at any one time (add the total watts) with the continuous output capacity of your  
Inverter/Charger (see the Specifications section). When figuring the power requirements of your  
equipment, do not confuse continuous wattage with peak wattage ratings. Most electric motors require  
more power at start-up (peak wattage) than required to run continuously after start-up, sometimes over  
100% more. Some motors, such as in refrigerators and pumps, start and stop intermittently according to  
demand, requiring peak wattage at multiple, unpredictable times during operation.  
Your Inverter/Charger has an IEC 60320 C14 input connector and an IEC 60320 C13 output connector  
(see the Features section for more information). Attach the input connector to a user-supplied cable with  
a plug appropriate for the local site, and plug the Inverter/Charger to a utility wall outlet that provides  
230 V, 50 Hz AC power. Use the output connector to power equipment that would normally be plugged  
into a utility outlet. Any equipment you plug into the output connector automatically benefits from your  
Inverter/Charger's Isobar® surge protection.  
Operation  
Switch Modes  
After mounting and connecting your Inverter/Charger, you are able to operate it by switching between  
operating modes as appropriate to your situation.  
“AUTO”: Switch to this mode when you need constant, uninterrupted AC power for  
connected equipment. The Inverter/Charger will supply AC power to connected equipment  
and charge your connected batteries while utility or generator-supplied AC power is  
present. The Inverter/Charger will automatically switch to battery to supply AC power to  
connected equipment when utility/generator power is unavailable or unsafe for connected  
equipment.  
“CHARGE ONLY”: Switch to this mode when you are not using connected equipment in  
order to conserve battery power by disabling the inverter. The Inverter/Charger will supply  
AC power to connected equipment and charge connected batteries while utility- or  
generator-supplied AC power is present. However, it WILL NOT supply AC power to  
connected equipment when utility/generator power is unavailable or unsafe for connected  
equipment.  
“DC OFF”: Switch to this mode to prevent the inverter from drawing power from the  
batteries. Use this mode to automatically reset the unit if it shuts down due to overload or  
overheating. First remove the excessive load or allow the unit to sufficiently cool, as  
applicable. Switch to “DC OFF”, then back to “AUTO” or “CHARGE ONLY” as desired.  
If the unit fails to reset, remove more load or allow the unit to cool further and try again.  
Caution: The unit will always pass AC power to connected equipment if plugged into a live AC  
outlet, regardless of the position of the Operating Mode Switch.  
 
7
(continued)  
Operation  
“OPERATION” Indicator Lights  
LINE” Green Indicator: If the operating mode switch is set to “AUTO”, this light will  
illuminate continuously while connected equipment is receiving continuous AC power  
from a utility/generator source. If the operating mode switch is set to “CHARGE ONLY”,  
this light will flash to alert you that the unit's inverter is disabled and will not supply AC  
power when utility/generator power is unavailable or unsafe for connected equipment.  
“INV” (Inverting) Yellow Indicator: This light will illuminate continuously while  
connected equipment is receiving battery-supplied, inverted AC power when  
utility/generator power is unavailable or unsafe for connected equipment.  
“LOAD” Red Indicator: This red light will flash if the power demanded by connected  
appliances and equipment exceeds load capacity while the Inverter/Charger is operating  
from battery power. It will also flash due to inverter overheating. If this happens, turn the  
operating mode switch to “DC OFF”, remove the overload and allow the inverter to cool.  
After the unit has adequately cooled, you may turn the operating mode switch to either  
“AUTO” or “CHARGE ONLY”.  
“BATTERY” Indicator Lights  
These three lights will illuminate in several sequences to show the approximate charge level of your  
connected battery bank and alert you to fault conditions:  
Battery Charge Level*  
Indicator Illuminated  
Battery Capacity  
(Charging/Discharging)  
~ 91%–Full  
1
2
3
4
5
6
7
Green  
Green & Yellow  
Yellow  
~ 81%–90%  
3
6
2
5
1
~ 61%–80%  
Yellow & Red  
Red  
~ 41%–60%  
~ 21%–40%  
All three lights off  
Flashing red  
~ 1%–20%  
~ 0% (Inverter shutdown)  
4
7
* Charge levels are approximate.  
Actual levels vary depending on battery condition and load.  
Fault Condition  
Indicator Illuminated  
Fault Condition  
Overcharge (Charger shutdown)  
1
All three lights flash quickly*  
* Approximately ¼ second on, ¼ second off. May also indicate a battery  
charger fault exists. See the Troubleshooting section.  
1
Resetting Your Inverter/Charger to Restore AC Power  
Your Inverter/Charger may cease to supply AC power or DC charging power in order to protect itself  
from overload or to protect your electrical system. To restore normal functioning:  
Overload Reset: Switch the operating mode switch to “DC OFF” and remove some of the connected  
electrical load (i.e. turn off some of the AC devices drawing power which may have caused the overload  
of the unit). Wait one minute, then switch the operating mode switch to either “AUTO” or “CHARGE  
ONLY”.  
Output Circuit Breaker Reset: Alternatively, check the unit's output circuit breaker. If it has tripped,  
remove some of the electrical load, wait one minute to allow components to cool, and reset the circuit  
breaker. See the Troubleshooting section for other reasons why AC output may be absent.  
 
8
Troubleshooting  
Try these remedies for common Inverter/Charger problems before calling for assistance. Call Tripp Lite  
Customer Service at +1 773 869 1234 before returning your unit for service.  
“BATTERY” Indicator Lights  
Operating Mode Switch  
“OPERATION” Indicator Lights  
SYMPTOM  
PROBLEMS  
CORRECTIONS  
No AC Output  
(All Indicator Lights Are Off)  
Unit is not properly connected  
to utility power.  
Connect unit to utility power.  
Circuit breaker is tripped.  
Connected batteries are dead.  
Battery fuse* is blown.  
Reset circuit breaker.  
Battery Not Recharging  
(AC Input Present)  
Check and replace old batteries.  
Check and replace fuse.*  
Battery cabling* is loose.  
Check and tighten or replace cabling.*  
Unit has shut down due to battery Disconnect any auxiliary chargers.  
overcharge (preventing battery  
damage). The problem may be  
Reset by moving Operating Mode  
Switch to “DC OFF.” Wait 1 minute  
with connected auxiliary chargers, and switch to “AUTO” or “CHARGE  
if any, or with the unit’s charger. ONLY.” If unit remains in shutdown  
mode after several attempts to reset,  
contact Tripp Lite Customer Service  
for assistance.  
All Three Battery Indicator  
Lights Are Flashing  
(¼ Second Flashes)  
Battery is overcharged. Unit will Disconnect any auxiliary chargers.  
shut down to prevent battery  
damage. The problem may be  
Reset by moving Operating Mode  
Switch to “DC OFF.” Wait 1 minute  
with connected auxiliary chargers, and switch to “AUTO” or “CHARGE  
if any, or with the unit’s charger. ONLY.” If unit remains in shutdown  
mode after several attempts to reset,  
contact Tripp Lite Customer Service  
for assistance.  
Red “LOW” Battery  
Indicator Light is Flashing  
Battery voltage is low. Unit will  
automatically shut down after 10 in order to recharge batteries.  
Make sure that AC power is present  
seconds to protect battery from  
damage.  
Operating Mode Switch must be set  
to “AUTO” or “CHARGE ONLY.”  
False reading due to undersized Use sufficient size DC cable  
or insufficiently connected  
DC cabling.  
sufficiently connected to the  
Inverter/Charger.  
Red “LOAD” Operation  
Indicator Light Flashing  
Inverter is overloaded. Unit will  
automatically shut down after  
5 seconds.  
Reduce load. Operating Mode  
Switch must be set to "AUTO"  
or "CHARGE ONLY."  
* User-supplied.  
 
9
Specifications  
Model:  
APSX700HF  
IEC 60320 C14  
IEC 60320 C13  
Hardwire  
AC Input Connection:  
AC Output Connection:  
Battery Connection:  
Inverter  
Continuous Output Capacity (@ 20° C)  
Peak Output Capacity (Instantaneous)  
DC Input Volts (Nominal)  
DC Input Voltage Range  
Minimum DC Fuse Rating  
DC Input Current @ Nominal V DC Full Load:  
Battery Charger  
700W/700VA  
1400W  
12 V DC  
10-15 V DC  
125 A  
72 A  
Input:  
230 V, 50 Hz AC  
6 A  
Charging Capacity DC:  
Line VAC Operation  
Total Input AC Current (Continuous, Charger at Maximum): 4.5 A  
Maximum Output Current (Continuous):  
3 A  
Battery Wiring  
For maximum efficiency, keep battery wires as short as possible. For very short runs, 6 AWG  
(4.115 mm) wiring may be adequate; for longer runs, 4 AWG (5.189 mm) or 2 AWG (6.544 mm)  
wiring is recommended.  
Note: Acceptable power is directly dependent on wire length, i.e. the shorter the wiring, the better the  
performance. Total wiring length is the sum of the positive and negative wiring lengths.  
Note on Labeling  
Two symbols are used on the APS labels.  
V~: AC Voltage  
: DC Voltage  
 
10  
Service  
If you are returning your Inverter/Charger to Tripp Lite, please pack it carefully, using the ORIGINAL  
PACKING MATERIAL that came with the unit. Enclose a letter describing the symptoms of the  
problem. If the Inverter/Charger is within the warranty period, enclose a copy of your sales receipt. To  
obtain service you must obtain a Returned Material Authorization (RMA) number from Tripp Lite or an  
authorized Tripp Lite service center.  
Maintenance  
Your Inverter/Charger requires no maintenance and contains no user-serviceable or user-replaceable  
parts, but should be kept dry at all times. Periodically check, clean and tighten all cable connections as  
necessary, both at the unit and at the battery.  
Limited Warranty  
Tripp Lite warrants its Inverter/Chargers to be free from defects in materials and workmanship for a period of one year (except  
for outside of U.S.A., Canada and Mexico—120 days) from the date of retail purchase by end user  
Tripp Lite’s obligation under this warranty is limited to repairing or replacing (at its sole option) any such defective products. To  
obtain service under this warranty you must obtain a Returned Material Authorization (RMA) number from Tripp Lite or an  
authorized Tripp Lite service center. Products must be returned to Tripp Lite or an authorized Tripp Lite service center with  
transportation charges prepaid and must be accompanied by a brief description of the problem encountered and proof of date  
and place of purchase. This warranty does not apply to equipment which has been damaged by accident, negligence or  
misapplication or has been altered or modified in any way, including opening of the unit’s casing for any reason. This warranty  
applies only to the original purchaser who must have properly registered the product within 10 days of retail purchase.  
EXCEPT AS PROVIDED HEREIN, TRIPP LITE MAKES NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING  
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Some states do not permit  
limitation or exclusion of implied warranties; therefore, the aforesaid limitation(s) or exclusion(s) may not apply to the  
purchaser.  
EXCEPT AS PROVIDED ABOVE, IN NO EVENT WILL TRIPP LITE BE LIABLE FOR DIRECT, INDIRECT, SPECIAL,  
INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE USE OF THIS PRODUCT, EVEN IF ADVISED OF  
THE POSSIBILITY OF SUCH DAMAGE. Specifically, Tripp Lite is not liable for any costs, such as lost profits or revenue, loss  
of equipment, loss of use of equipment, loss of software, loss of data, costs of substitutes, claims by third parties, or otherwise.  
Regulatory Compliance Identification Numbers  
For the purpose of regulatory compliance certifications and identification, your Tripp Lite product has been assigned a unique  
series number. The series number can be found on the product nameplate label, along with all required approval markings  
and information. When requesting compliance information for this product, always refer to the series number. The series  
number should not be confused with the marking name or model number of the product.  
Tripp Lite follows a policy of continuous improvement. Product specifications are subject to change without notice.  
 
11  
1111 W. 35th Street, Chicago, IL 60609 USA  
200705102 93-2678  
 
12  

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