Synchron User Manual - Dual-Lite
Contents
1. Installation Instructions and User Manual For Inverter Power Systems 400 to 2100 VA SYNCHRON 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 Do not install the Synchron system outdoors Do not install near gas or electric heaters or in other high temperature locations Usecaution when servicing batteries Battery acid can cause burns to skin and eyes If acid is spilled on skin or in the eyes flush with fresh water and contact a physician immediately Equipment should be mounted in locations where it will not be readily subjected to tampering by unauthorized personnel The use of accessory equipment not recommended by the manufacturer may cause an unsafe condition and may void the warranty Do not use this equipment for other than intended use All servicing of this equipment must be performed by qualified service personnel SAVE THESE INSTRUCTIONS VIPOR LAN i N N JN The installation and use of this product must comply with all national federal state municipal or local codes that apply For technical assistance contact Dual Lite s Systems Technical Support Center at 1 800 848 6439 Technicians are available during normal working hours EST DUALJLITE Table of Contents Section 100 System Inst2. 409 825 750 i00 i50 200 System DC votas 36 36 72 72 72 96 6 8 Battery Fuse Rating Amps 90 80 0 e 60 60 Wiring Diagram Fi f 1 1 2 2 2 3 IMPORTANT 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 Figure 1 Figure 2 36 Volt Battery Connection Diagram 72 Volt Battery Connection Diagram 400 and 525 VA Model 750 1000 and 1500 VA Model Figure 3 96 Volt Battery Connection Diagram 2100 VA Model IMPORTANT Once batteries have been wired as shown the system s DC fuse e c c mi must be installed The DC fuse is shipped separately inside the cabinet and needs to be installed in its fuse block holder located on the underside of the electronics shelf Use insulated tools to perform this task full battery voltage will be present at the fuse block DO NOT TURN ON THE DC BREAKER AT THIS TIME AS SIGNIFICANT DAMAGE TO THE SYSTEM WILL OCCUR See Section 108 for proper system start up procedure i ri 7 eo MAKE SURE THE DC BREAKER IS IN THE OFF T 1 A iif i POSITION BEFORE PROCEEDING SYNCHRON 105 4 Electronics Cabinet Voltage Check Using a digital volt ohm meter check for correct nominal battery voltage between electronics cabinet DC Input NEG and POS wires Refer to table in section 105 3 for proper system D
3. Line Inverter 70 260 92 341 131 382 175 510 263 765 368 886 Weight Ibs kg including batteries 143 65 1 173 78 8 281 128 346 157 6 400 182 2 480 218 7 DUAL LITE 102 Receiving Moving and Storing Systems and Batteries 102 1 Shipping Damage Synchron inverter systems and batteries are shipped separately Carefully inspect all cartons upon receipt for evidence of shipping damage Notify carrier immediately of leaking or damaged cartons for possible concealed damage 102 2 Moving Units and Batteries CAUTION Batteries and Synchron Electronics cabinets are very heavy Proper equipment should always be used to move batteries and units to avoid damage and personal injury WARNINGS e ALWAYS WEAR PERSONAL EYE PROTECTION WHEN WORKING WITH BATTERIES SEE PAGE 10 Batteries contain liquid caustic or acid electrolytes which CAN CAUSE SEVERE BURNS Care must be taken when moving batteries to avoid tipping and spillage of electrolyte material In case of accidental spill FIRST AID e EYES Flush immediately with flowing water for at least 15 minutes Seek medical attention e EXTERNAL Flush immediately with water Seek medical attention 102 3 Temporary Storage of Units and Batteries For temporary storage of Synchron inverter systems and batteries prior to installation select a clean cool dry location with normal ventilation for human habitation and level floors CAUTION Batteries and Synchron Electroni
4. render the battery bank useless during a power outage 3 Break down the battery bank beginning with the intercell connectors These cables tie the batteries installed on the same shelf together 4 Next remove the inter tier cables These cables connect the batteries located on different shelves together 5 Remove the batteries from the cabinet Batteries can be very heavy use proper lifting methods when removing battery 6 Install new batteries following the instructions outlined in Section 105 3 Battery Disposal WARNINGS Do not dispose of batteries in a fire the batteries could explode Do not open or mutilate batteries Released electrolyte is highly toxic and harmful to the skin and eyes CAUTION Batteries contain lead Many state and local governments have regulations about used battery disposal Please dispose of the batteries properly For help contact the Dual Lite Technical Support Center 16 DUALJLITE 301 Warranty Information WARRANTY The system is guaranteed under normal and proper use against defects in workmanship and materials for a period of two years from the date of shipment Batteries supplied as part of the system are covered under a separate pro rata warranty as described below Batteries 1 year plus pro rata period Pro Rata Periods Lead Calcium 9 years IMPORTANT Lengthy storage of batteries will cause irreversible damage to the cells Failure to connect Synchron inverte
5. 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 or with the battery cable kit When connecting cables never allow a cable to short across a battery s terminals the string of batteries or to the cabinet Align the cables on the battery terminals so that the cable lug will not contact any part of the cabinet even if the battery is moved Keep the cable away from any sharp metal edges Install the battery cables so they cannot be pinched by the Synchron inverter system cover door 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 A qualified electrician who is familiar with battery systems and required pr
6. synchronize with the input line The inverter will turn off when synchronization is achieved 12 200 STATUS INDICATORS The Synchron system is equipped with 3 LED indicators and an audible alarm rast swen manm showing the operating mode of the inverter and also to alert you of any possible SG abnormal conditions Depending on which of the LEDs are On Off or Blinking will Fees indicate a very specific condition The following table is used to illustrate as to p 4 ed what these conditions may be init Her np SYNCHRON AC INVERTER SYSTEM Audible AC Input Load Alarm Symptom Explanation A mu EX Normal Mode LINE NORMAL EE Inverter ON Load current 5 System Shutdown OFF Shutdown overload heatsink overtemp or battery failure possible Inverter On System Malfunction INV Load current 5 and either probe failure or output breaker tripped 0 o f o metron f nv NORMAL 8 Inverter On QUU EN Malfunction Probe failure X breaker tripped Line NoLoad No Load LINE Load current Lloadcwrent 5 ETT Shutdown OFF Shutdown overload heatsink overtemp or severely discharged batteries BEEN EN Ld Load current lt 5 and either charger or probe failure output breaker tripped or low battery voltage Line System Malfunction LINE Charger or probe failure output breaker tripped or low battery voltage 0 O 0j OjO0fnott j OF WDoOF Act
7. the batteries as shown on the battery wiring diagram provided in this manual or with the battery cable kit When connecting cables never allow a cable to short across a battery s terminals the string of batteries or to the cabinet Align the cables on the battery terminals so that the cable lug will not contact any part of the cabinet even if the battery is moved Keep the cable away from any sharp metal edges Install the battery cables so they cannot be pinched by the battery cabinet or the Synchron inverter system cover doors External battery cabinet chassis ground or earth must be connected to the Synchron inverter system unit s chassis ground or earth The ground conductor must be insulated If you use conduit this ground conductor must be routed in the same conduit as the battery conductors Where conductors may be exposed to physical damage protect conductors in accordance with NEC requirements If replacing batteries or repairing battery connections follow the procedure in this manual to shut down the Synchron inverter system and remove both AC and DC input power 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 contactin
8. 924 Output Output voltage 120 or 277VAC e Output regulation static 5 based on a 0 100 resistive load Minimum loading none required e Output distortion Less than 5 THD linear load Load power factor 75 lag to 8 lead Output frequency Normally synchronized to utility 05 Hz during emergency e Overload 115 momentary Time to transfer to inverter after a utility power failure No break Battery Battery charger Fully automatic and temperature compensated with internal diagnostic indicators Recharge time 60 hours Battery protection Automatic low battery voltage disconnect Automatic restart upon utility return e Battery switch Also used as battery isolator e Standard battery Sealed lead calcium 10 year life Battery voltage 36 72 or 96VDC system dependent e Runtimes 90 minutes standard Operating temperature 20 C to 30 C 68 F to 86 F Relative humidity 95 non condensing Note Battery performance rated at 25 C 77 F Table 1 Synchron Sizing Chart VA Watts 750 1000 1500 I e o N Cc Power Factor Range 5 Lag to 8 Lead Input Output Voltage 120 120 or 277 277 AC Input Circuit Breaker Rating GA 3A TAIA 10A 5A 13A 6A 20A 8A 120 27 7VAC Charger Size 2 Amps System DC Voltage 6 OD NO gt NO NO 25A 10A Cabinet Size 22 W x 23 H x 10 D 32 W x 36 5 H x 12 D 55 9cm W x 58 4cm H x 25 4cm D 81 3cm W x 92 7cm H x 30 5cm D BTU Hour
9. C voltage Voltage reading should be 10 of system DC voltage Caution Torque all connections in accordance with the following tables Failure to do so may create an unsafe condition or fire hazard Battery Terminal Torque Specifications Lead Calcium Batteries Manufacturer s Dual Lite Battery Fuse Block 2 5 inch lbs Part Number Part Number Torque GP12260 0120937 2 2 ft lbs Battery Fuse GP12340 0120935 6 0 ft lbs 420 inch Ibs GP12400 0120936 2 2 ft lbs Poe 93012368 2 5 ft lbs 106 AC Connections CAUTION A All Synchron inverter system units contain hazardous AC and DC voltages Because of these voltages a qualified electrician must install the Synchron 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 B Before installing maintaining or servicing the unit always remove or shut off all sources of AC and DC power and shut off the Synchron inverter system Disconnect AC line input at the service panel and turn off the Main DC Switch and the Main AC Switch to make sure the unit will not supply output voltage C Whenever AC and or DC voltage is applied there will be AC voltage inside the Synchron inverter system unit the unit can supply power from AC line or from its batteries To avoid equipment damage or personal injury always assume that there may be voltage inside th
10. allation Instructions Description Page 101 Unit SPOS IT CAL ONS usare o enden Ku bx E EET KEV E Es VVEVE VUE VEEEE EE NUM ME SUE 4 102 Receiving Moving and Storing Systems and Batteries eese eee eee eee eene 5 102 1 ASHIPPING DIMAGE iius dabei de ci ducis ated nan T uses tasse eto cd erue 5 1022 Moving Ynits and Balen CS us d Galea de laine Seer vb b eiua ge Deut ge d lan Saab chi usare xcv oai eut dida 5 102 3 Temporary Storage of Units and Batteries eessssssssessesesee eene 5 103 Installation FRO CUIC CITC IGS aise iret ccaiteseescacuite cna nics acl AE Ee Sae wate weld WEAR EU M ME NU RENE E ERE 6 103 1 Operating Environment cx inser feta ates rare eee re eh eae lee dnobus 6 103 2 High Allit de PSratlOM oie its stssoy at tats seles ndasyanmelzuctbstamionaye Gan Dux ede So deena acta aaa pauca te teu d 6 104 Cabinet Mounting Physical 2 1555525 viscevaedeccscccasi bec snccsasanevteniececanedueabecceatiaseeretdsacsnevesduactavieesveieess 7 105 Battery Installation and COMME CTION cccccceeeeeceeeeeeeeeeeeesneneeeeeneeseaneeseesneeseaaeseeeneesseneeseasaessagneesaneenens 8 9 1051 TOO er RERUM 8 105 2 Installation Considerations x i opo oc tei o E ded dado E asco ieee ieee 9 105 3 Battery Installati ri PTOCGGQUEG usc pneu take rep hae aov a v cati bu Ree ir vw cde en 9 105 4 Electronics Cabinet Voltage Check cccccccccccssscecesseeceeseeceeseecceu
11. commend these guidelines be followed to insure system readiness and to prolong battery life The Synchron system was designed with a front panel test switch to facilitate monthly testing Simply depress the button and hold to test the inverter at anytime Once released the Synchron will revert back to standby operation this may take a few seconds to allow the unit to synchronize back to the line For annual 90 minute discharge or other prolonged tests simply turn off the AC Input breaker 14 DUAL LITE 300 4 Battery Maintenance and Replacement This section provides precautions for qualified service personnel working with unit batteries Important Safety Precautions The service technician must take these precautions 10 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 Synchron inverter system or battery cabinet 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
12. cs cabinets are very heavy Check to assure that the floor in the temporary storage area is capable of safely bearing the load IMPORTANT Lengthy storage of batteries will cause irreversible damage to the cells Failure to connect Synchron inverter system batteries to an energized charging circuit within 90 days from the date of shipment will void the battery warranty Storage Temperature Store all batteries at 10 to 30 C 50 to 86 F Batteries will have a longer shelf life if stored at 10 to 30 C 50 to 86 F The Synchron electronics and battery cabinets may be stored at 20 to 60 C 4 to 140 F Ventilation The air around the unit must be clean dust free and free of corrosive chemicals or other contaminants Do not place the Synchron inverter system or batteries in a sealed room or container DANGER EXPLOSIVE CAN CAUSE BLINDNESS OR OTHER SEVERE INJURIES Every type of battery can produce hydrogen gas even sealed maintenance free batteries The gas is vented through the vent caps and into the air Do not allow smoking sparks or flames in battery storage location because hydrogen is concentrated under the vent cap of each cell of the battery Hydrogen is highly explosive and is hard to detect because it is colorless odorless and lighter than air SYNCHRON 103 Installation Requirements 103 1 Operating Environment Install the Synchron inverter system in a clean cool dry place with no
13. d into the air mainly when the unit is charging the batteries The batteries produce the most hydrogen when maximum voltage is present in fully charged batteries The amount of current that the charger supplies to the batteries not the battery ampere hour determines how much hydrogen is produced Do not allow smoking sparks or flames in battery storage location because hydrogen is concentrated under the vent cap of each cell of the battery Hydrogen is highly explosive and is hard to detect because it is A CAUTION colorless odorless and lighter than air NEVER INSTALL BATTERIES INA SEALED ROOM OR ENCLOSURE IMPORTANT Lengthy storage of batteries will cause irreversible damage to the cells Failure to connect Synchron inverter system batteries to an energized charging circuit within 90 days from the date of shipment will void the battery warranty 103 2 High Altitude Operation The maximum operating temperature drops 1 Celsius per 300 meters 2 F per 1000 feet above sea level Maximum elevation is 3000 meters 10 000 feet UUAL LITE 104 Cabinet Mounting The Synchron 400 and 525 VA models are supplied with two full length brackets for wall mounting while the 750 VA and up models are designed for floor mounting These are also supplied with side mount stabilizing brackets to secure the cabinet to the wall Dual Lite supplies the hardware to attach the brackets to the cabinet Necessary hardware to fasten the cabinet
14. e 4 Turn on all output circuit breakers located within the Synchron system and or in the external Load Distribution Panel if any 5 Hold the Pre charge Switch in the ON position for 30 seconds 6 Release the Pre charge Switch and immediately turn ON the Main DC Switch 7 Turn on the Main AC switch 8 After approximately five seconds the system should turn on the lighting loads should be energized the front panel green AC ON and LOAD LEDs should illuminate 109 System Verification At this point the connected load should be energized the Load and AC On LEDs should be lit Depending on the state of charge of the batteries the inverter may or may not come on when the test switch is depressed Allow a 24 hour charge period before testing the inverter system If you need assistance call Dual Lite s Technical Support Center at 800 848 6439 To simulate a power failure simply press the test switch for a momentary test or by opening the AC input circuit breaker for a prolonged test The inverter and the cooling fans if any will begin operating the AC On LED will go off and the Load LED will remain lit All connected loads should be energized and operational HID fixtures should not wink out Allow the inverter to run for several minutes or until satisfied with its operation Close the AC input breaker to end the test and return the unit to standby mode Note It will take a few seconds for the unit to re
15. e Synchron inverter system D 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 servicing an energized unit with the inside panel open electric shock is possible follow all local safety codes TEST BEFORE TOUCHING E To reduce the risk of fire or electric shock install the Synchron inverter system and the batteries in a temperature controlled and humidity controlled indoor area free of conductive contaminants See Section 103 for operating environment specifications 106 1 AC Wiring Preparations 1 Open or remove the system s front cover door Make sure all breakers are in the off position 2 Make sure the Synchron inverter system input and output voltages are correct for the particular application Remember that the Synchron system provides single phase power only 3 The input circuit breaker in the input service panel provides the means for disconnecting AC to the Synchron inverter system Only authorized persons shall be able to disconnect AC to the unit See NEC 700 20 and 700 21 10 UUAL LITE CAUTION To prevent electrical shock or equipment damage for all units the Main AC Switch the Main DC Switch all output circuit breakers and the AC input at the service panel are all off before making AC connections to the Synchron inverter system 4 If not previously done remove knockout
16. ecautions 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 by 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 105 1 Tools The following tools are required to install the system batteries Other tools may be necessary if optional batteries have been ordered CAUTION Always use insulated tools for battery installation Always torque to the manufacturer s recommendations e Socket Set e Safety Equipment Required by Local Codes e Slotted Screwdriver Torque Wrench Calibrated in Inch pounds or Newton meters Electrical Tape Digital Volt Ohm Meter e Safety Glasses with Side Shields UUAL LITE 105 2 Installation Considerations This section explains how to install the Synchron system s batteries fuses and cables A qualified electrician who is familiar with battery installations and applicable building and electrical codes should install the batteries 105 3 Battery Installation Procedure Battery Voltage Select which wiring diagram to use from this table vaw O
17. g battery terminals or shorting terminals during battery installation Do not touch uninsulated battery terminals A qualified 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 by 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 15 SYNCHRON CAUTION A battery can present a risk of electrical shock and high short circuit current Battery replacement should only be performed by qualified service personnel familiar with battery systems All safety precautions outlined at the beginning of this section must be observed when servicing maintaining or replacing batteries Routine Battery Inspection and Maintenance Sealed Lead Calcium Batteries Lead Calcium cells are the most common type of battery used today in standby equipment By design it is as maintenance free as a battery can be Coupled with the diagnostic and self testing capabilities of the Synchron system these batteries provide one of the mos
18. he input circuit breaker in the building service panel serving as the AC disconnect to the Synchron system is in the OFF position 3 Check for proper ground connections in the Synchron Inverter cabinet the building service panel and the external load distribution panel 4 Check for any loose wiring connections in the Synchron Inverter cabinet the building service panel and the external load distribution panel 5 Check that correct nominal battery voltage 36 72 or 96VDC is present in the Synchron Inverter cabinet between the DC Input NEG and POS Refer to Section 105 2 for proper system DC voltage 6 On the Synchron Inverter insure that the Pre charge Switch the Main DC Switch and the Main AC Switch are all in the OFF position 11 SYNCHRON 108 System Start Up Procedure IMPORTANT The Synchron 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 will result in erroneous alarm messages and possible equipment failure CAUTION Familiarize yourself with the shut down procedure in section 300 1 before proceeding with the Start Up 1 Make sure the front cover door is installed and secured shut 2 Turn on the input circuit breaker in the building service panel serving as the AC disconnect to the Synchron system 3 Open the front access panel so that the input output circuit breakers within the Synchron unit are accessibl
19. ive X Flashing O Off Once an abnormal condition has been detected please contact your local Factory Authorized service center or call 800 848 6439 for assistance Do not attempt to make any repairs yourself the system is fed from more than one power source and extreme care must be taken before servicing 13 SYNCHRON 300 Maintenance 300 1 Safe Shut Down Procedure CAUTION To avoid possible equipment damage or personal injury assume that there is AC voltage present inside the Synchron inverter system unit any time AC input power or DC battery voltage is applied The inverter is capable of providing 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 AC AND DC VOLTAGES WILL BE PRESENT INSIDE THE UNIT UNTIL LINE AC IS DISCONNECTED AND ALL INTERNAL SWITCHES ARE TURNED OFF Do not touch components inside the unit DC voltage is always present at the batteries and battery cables B Final Shut Down Procedure 1 Open the unit s front access panel 2 Turn off the Main DC Switch the Main AC Switch and any Output Circuit Breakers CAUTION HAZARDOUS ENERGY IS STORED IN CAPACITORS INSIDE THE SYNCHRON UNIT AFTER TURNING OFF SWITCHES ALLOW 5 MINUTES FOR CAPACITORS TO DISCHARGE BEFORE ATTEMPTING ANY SERVICE PROCEDURES 3 If the service technician does not need to access the inside of the uni
20. r system batteries to an energized charging circuit within 90 days from the date of shipment will void the battery warranty 302 Technical Service and Support During or after installation Dual Lite s Systems Technical Support Center is available to provide expert assistance Our service representatives are available to answer customers questions or solve their problems Toll Free Number A toll free phone has been set up for Synchron technical assistance The number is 1 800 848 6439 Service representatives are available during normal working hours EST 17 SYNCHRON Notes Notes DUAL LITE SYNCHRON DUALILITE A Hubbell Lighting Inc brand with representatives offices in principal cities throughout North America Copyright Dual Lite All Rights Reserved Content subject to change without notice Printed in U S A 0602139 Rev D 4 10
21. rmal ventilation for human habitation and level floors CAUTION Batteries and Synchron Electronics cabinets are very heavy Check to assure that the floor is capable of safely bearing the load Operating Temperature Synchron inverter Systems are UL Listed for 20 to 30 C 68 to 86 F operation The Synchron Inverter System has a designed operating range of 0 to 40 C 32 to 104 F at up to 95 relative humidity Installation in environments at the temperature extremes of the designed operating range may effect unit performance or reduce service life Battery performance and service life is maximized if the operating temperature is maintained at 25 C 77 F Ventilation The air around the unit must be clean dust free and free of corrosive chemicals or other contaminants Do not place the Synchron inverter system or batteries in a sealed room or container Batteries The temperature should be near 25 C 77 F for optimum battery performance Temperature Effect On Performance Batteries will be less efficient at temperatures below 18 C 65 F and high temperatures will reduce battery life Typically at 35 C 95 F battery life will be half of what it would be at normal temperature of 25 C 77 F At 45 C 113 F battery life will be one fourth of normal WARNING Every type of battery can produce hydrogen gas even sealed maintenance free batteries The gas is vented through the vent caps an
22. s for AC Input and AC Output in the top of the Synchron inverter system See Figure 1 in Section 104 1 CAUTION Do not drill the cabinet drill filings may damage the unit and prevent it from operating If larger knockouts are needed use a chassis punch to enlarge the appropriate knockout Do not add additional or unnecessary knockouts 5 Install the input and output conduits 6 Run the AC Input service conductors and AC Output conductors through separate conduits Synchron inverter system emergency output circuits shall be installed in dedicated conduit systems and not shared with other electrical circuits as described in NEC 700 9 b 106 2 AC Input and AC Output Connections Make all AC input and output connections to the Synchron inverter system as indicated on the labels within the cabinet If system was supplied with internal output circuit breaker distribution option make output wiring connections directly to the circuit breakers Caution Torque all connections in accordance with the following tables Failure to do so may create an unsafe condition or fire hazard Terminals C Breakers Terminal Width Rating Torque 31 64 10 30 19 32 25 32 107 Final Installation Checklist Important Before proceeding to the System Start Up Procedure Section 108 complete the Final Installation Checklist below 1 Insure the Synchron Inverter cabinet is securely fastened to a wall or other structure 2 Insure that t
23. seessegeesseneesseueeesseseessageessegs 10 106 PC COMME CHONS NE E E a ee quevennstausnesats 10 11 106 EE LORI Ieelmi ie irzuen mevt es side ae 10 106 2 AC Input and AC Output Connections esseesssessssessseseeeeee nennen nnne nnns nsns rsen nnns 11 107 NE leri 11 108 System Start Up adieiv o U ue 12 109 System Vernia ON mm 12 Section 200 User Manual DGSCKIDUOM ecc a E e A Page 200 Stats glo Te5 l i9 ao AE E ESA ck E AE EEE EES ec E AA A EA hs ad E E 13 Section 300 Maintenance Warranty and Technical Support 300 MalNtenaNne Ecris E OO 14 16 300 1 Safe Shut Down Procedure idus a a pda add xe Ql ei a cea osi PE p Gd V d 14 300 2 Routine System Malhltelial i68 coe uode pneu eique so Er ewe ie gu Konto eoe a eee eee gala 14 300 3 Manual Routine Inverter Tests ccccccccccecceseceeeeeeeseeceeececeseeceeeseesseceeeeaeesaeceeesaeesaeeeeteesaaes 14 300 4 Battery Maintenance and Replacement esesssssssssssessssesesee nennen nennen 15 16 301 Warranty arto ur dto messe 17 302 Techpical Service and SUDDOEL s t dex a ecu Rag ois ek Una en us ae peu n edu pian de uo AR SRae Un PE aus NOSE Pd ICE CS RE RU santos 17 SYNCHRON Section 100 System Installation Instructions 101 Specifications Input Input voltage 120 or 277VAC e Synchronizing slew rate 1 Hz per second nominal nput surge protection Meets ANSI 62 41 and UL
24. t keep the unit s front cover door closed 4 Ifthe 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 not routinely recharged NOTE To turn power back on follow the System Start up Procedure outlined in Section 109 Be sure to complete all of the steps to assure the unit will operate properly 300 2 Routine System Maintenance The Synchron inverter system unit is designed to provide years of trouble free operation Its self monitoring features and manually initiated diagnostic 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 qualified service technician at least every six months The technician must observe important safety precautions while performing the following recommended tasks e Inspect and clean the unit interiors e Inspect all batteries for leaks case swelling or terminal corrosion Check the AC and DC meter functions and recalibrate if necessary Perform an emergency operation test to check operation of all critical connected loads 300 3 Manual Routine Inverter Tests NFPA101 requires that Emergency Lighting Equipment be tested on a monthly basis for a period of at least 5 seconds and a minimum of 90 minutes once a year We strongly re
25. t reliable and carefree inverter systems available today It is recommended however that some simple steps be taken to increase system life and maximize reliability e If system is installed in a remote area where the system s alarms may not be heard it is recommended that the system be checked weekly for alarm conditions e A quarterly visual check of the batteries should be conducted to look for deformities in the cases and terminal corrosion Any defective batteries should be replaced All corroded terminals regardless how slight are to be cleaned and retightened at once to prevent failure of the entire battery bank e Once a year all battery connections should be checked for tightness and re torqued if necessary Torque specifications can be found on the battery label or in this manual Battery Replacement Procedure WARNING Always use the same quantity and type of battery as replacements Substituting batteries not supplied by Dual Lite will void the UL listing of the system and may cause equipment failure To ensure the superior performance of your Synchron inverter system and to maintain proper charger operation replace spent batteries only with Dual Lite cells having the same part number voltage and ampere hour rating as the original batteries 1 Follow the proper shut down procedure as described in Section 300 1 2 Remove battery cabinet fuses and test them for continuity Faulty fuses will prevent batteries from charging and
26. to the wall is to be supplied by the installing contractor Please refer to the following illustrations Fig 1 400 and 525 VA units Small cabinet Install Wall Mount ing Brackets To Both 6 875 Sides Of Cabinet Knockout Typ 2 21 125 Knockout NU we i i i e e INVERTER TOP Fig 2 750 to 2100 VA units Large cabinet p o0 ez s m oe I s Install Wall Mounting us c l Brackets To Both SIS Sides Of Cabinet m d INVERTER TOP Once the cabinet is securely fastened to the wall run and attach conduit using the provided knock outs on the top of the unit If you need additional entry points please use a metal punch Do not drill into the cabinet as metal filings can cause short circuits and damage the equipment Be sure to follow all federal state and local codes as it pertains to emergency circuit raceways 105 Battery Installation and Connection Installing the Batteries and DC Wiring Important Safety Precautions The installer must take these precautions 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 Synchron inverter system Tools must have insulated handles so that they will
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