OWNER'S MANUAL FLEET POWER INVERTER/BATTERY CHARGERS FLEET POWER 1000 FLEET POWER 2000 FLEET POWER 2500 C U ®L KKK Fleet Power 1000 & 2000 models are certified by UL to comply with FED spec-KKK-A1822, SAE spec-SAE-JRR1, for emergency vehicle application. All models UL and C-UL Listed for Canadian use. 90-0115-00 10/97 Fltman.
INTRODUCTION General safety information for installation and operation is contained throughout this manual where it applies and are not included in this summary. Warnings Warning statements identify conditions or practices which could result in personal injury, loss of life, damage to equipment or other property. Power Source To avoid damage, operate the equipment only within the specified AC (line) and DC (battery) voltages. Servicing To reduce the risk of electric shock do not open this unit.
TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Things You Should Know . . . . . . . . . . . . . . . 5 Circuit Breaker Protection Electronic Protection Power Sharing Power Switch Remote Control Programming Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Remote Control Panel . . . . . . . . . . . . . . . . . .
INTRODUCTION This owner's manual describes the Fleet Power Inverter/Chargers from Heart Interface. These units perform three distinct functions: 1. DC to AC power inverting. 2. Automatic transfer switching between inverter power and incoming AC power. 3. Automatic 3-Stage Battery charging plus manual battery equalizing. 4. AC to DC power converter. • The inverters provide regulated 120 Volt AC power and crystal controlled frequency at 60Hz from a deep cycle battery bank in specified watts: FP 1000-12......
THINGS YOU SHOULD KNOW The optional Fleet Power Remote Control Panel provides a power switch, system status LEDs, DC Volts and DC Amps LED bargraphs. On the back of the remote is a set of dip switches which allow adjustment of the following: • Manual Initiation of Equalize Charging • Ambient Battery Temperature • Battery Type • Charger Mode (Auto or Controlled) • Power Sharing Circuit Breaker Protection Fleet Power Inverter/Chargers are circuit breaker protected.
OPERATION Power Switch The Power Switch is located on the front panel. This switch controls ON/OFF and RESET for the inverter. Expect a 3 second delay when the power switch is turned ON before the unit is activated. If the unit is connected to external AC power, the battery charger and transfer switch will continue to function, regardless of the position of the switch. When external AC power is removed and the power switch is in the ON position, the inverter will automatically be ON.
REMOTE CONTROL PANEL An optional remote control panel is available which offers several features not found on the unit. The remote control panel provides LED bargraphs which show system status, battery voltage, and DC Amps in both inverter and charge modes. These bargraphs can also display dip switch positions and shut down conditions. Remote Power Switch The switch on the remote is used to control the inverter and can also be used to control the battery charger function.
REMOTE CONTROL PANEL Dip Switches On the back of the Fleet Power remote control panel is a set of 8 dip switches which are used to make several adjustments. On the switch block, each switch is numbered . . .1 through 8 and the ON position is indicated. The switch settings can be changed at any time, even while the unit is operating. Following is a discussion of each adjustment. Refer to the table on page 11 for dip switch programming. The battery LED blinks when equalizing.
REMOTE CONTROL PANEL Use the 5 Amp setting for small generators, or for charging deeply discharged batteries. Dip Switch Status You can check the position of the dip switches by quickly cycling the power switch OFF/ON twice. The DC Volts bargraph will cease to display battery voltage and will indicate the settings of each dip switch. In this mode the bottom LED will illuminate if switch 1 is on; the second LED will illuminate if switch 2 is on, etc.
STATUS LEDs Status LED Purpose Power on light. It will be illuminated whenever the INV/CHRG power switch is on (inverter on) or when there is (Inverter/Charg incoming AC power and the charger comes on. AC Input Illuminates when incoming AC power has been applied and the transfer relays have engaged. There is a 7-12 second delay from the time the AC is applied and this LED illuminates. Steady Overload Indicates an over-temperature condition, the unit is shut down.
DIP SWITCH PROGRAMMING Feature Switch Number Set Point 1 Equalize or 3 Stage Charging Toggle On/Off Equalize (Do not leave on.) Off Battery Type 3 Stage Charging* 2 3 On On Warm Gel Cell (>80 deg. F.) Off On Cool Gel Cell (<80 deg. F.) On Off Warm Wet Cell (>80 deg. F.) Off Off Cool Wet Cell (<80 deg. F.)* 4 Auto Charge Power Sharing On Disable: Charger responds to On/Off switch. Off Enable: Charger on when AC connected.* 5 6 Not used. 7 8 1000 On On 2.
BATTERIES BATTERY TYPES Use only deep-cycle batteries with your Fleet Power Inverter/Charger. These fall into two broad categories, wet cell and gel cell. Wet Cell Batteries True deep-cycle wet cell batteries are characterized by relatively thick plates that are alloyed with antimony. Common marine/RV deep-cycle batteries are acceptable. However, golf cart batteries have better performance and life. They are 6 Volt batteries that must be used in series pairs.
BATTERIES Beware of so-called maintenancefree batteries. These batteries have calcium alloyed with the lead and hold the liquid electrolyte in a sponge-like material. They are sealed and water cannot be added. Do no confuse them with true gel cell batteries, they will not hold up to deep discharging. Gel Cell Batteries Gel cell batteries are lead-acid batteries similar in many ways to the common wet cell battery, but differences in the chemistry and construction provide some unique features.
BATTERIES Parallel Connecting 2 batteries in parallel will double the Amp-hour rating of the battery bank, while the voltage will be the same as each individual battery. Example, two 12 Volt 105 Amp-hour batteries in parallel will produce one 12 Volt 210 Amp-hour battery bank. + + Parallel Only similar batteries should be connected together in one bank. Do not connect old and new batteries together or wet and gel cell batteries together.
BATTERIES To achieve 50% cycling you should calculate your Amp-hour consumption between charging cycles and use a battery bank with twice that capacity. To calculate Amp-hour consumption first look at the rating plate on your AC appliance or tools. Each appliance or tool will be rated in either AC Amps or AC watts or AC VA (Volts-Amps) apparent power. Use one of the following formulas to calculate the DC Amp-hour draw for a 12 Volt system: (AC Amps x 10) x 1.
BATTERY CHARGING Battery Charging Completely recharging wet cell deepcycle batteries requires the battery voltage to be raised beyond what is known as the gassing point. This is the voltage at which the battery begins to bubble and gas is given off. If charging stops short of this point, sulfate is left on the plates and deterioration of the battery begins. The gassing point will vary with battery temperature. Gel cell batteries must not be charged to their gassing point.
BATTERY CHARGING NOTE: Fleet Power battery chargers are on whenever there is AC power connected to the charger input, regardless of the condition of the On/Off switch. This feature can be disabled by setting the dip switch #4 (back of the remote) to "On" so that the charger will also be controlled by the On/Off switch. Each time the battery charger is engaged, the 3 stages proceed automatically, resulting in an efficient, complete recharge and safe battery maintenance.
BATTERY CHARGING Gel cell batteries can accept a higher rate of charge. Consult the manufacturer for specifications. Stage 2 - Acceptance Charge The acceptance stage immediately follows the bulk charge stage. During this stage the battery voltage is held constant at the bulk charge voltage limit and the current gradually ramps down. During this stage the battery is accepting its final amount of charge current and the last of the sulfate on the plates is removed.
BATTERY CHARGING charging cycle. The battery voltage will increase to 16.3 using the cool temperature wet cell setting. This will cause the battery bank to gas profusely and will accomplish the following: 1. Removal of residual sulfate. Each time a battery is cycled (discharged and recharged), a small amount of sulfate is left on the plates. Over time, this gradual build-up of sulfate will compromise the performance of the battery.
BATTERY CHARGING WARNINGS 1. Do not equalize gel cell batteries with the remote programmed for wet cells. 2. Always monitor the equalize charge. Provide proper ventilation for battery fumes. Do not allow any sparks during equalizing. If one or more cells begin to overflow, terminate the equalize charge. 3. Check and top off the battery electrolyte both before and after the equalizing charge. Do not expose the battery plates to air. Leave the battery caps on while equalizing. 4.
BATTERY CHARGER VOLTAGE SETTINGS B at t er y Ty p e an d Temp er at u r e B u lk Vo lt ag e/ Max T ime Flo at Vo lt ag e Eq u alize Vo lt ag e 12 Volt Wet Cell Warm Temperature 14.0 / 1 hr 13.1 15.8 12 Volt Wet Cell Cool Temperature 14.4 / 1 hr 13.5 16.3 12 Volt Gel Cell Warm Temperature 13.8 / 3 hr 13.3 13.8 12 Volt Gel Cell Cool Temperature 14.1 / 3 hr 13.6 14.1 21 90-0115-00 10/97 Fltman.
INSTALLATION PRECAUTIONS CAUTION This equipment is not ignition protected and employs components that tend to produce arcs or sparks. To reduce the risk of fire or explosions, do not install in compartments containing batteries or flammable materials or areas in which ignition-protected equipment is required. WARNING For continued protection against risk of electric shock, use only the groundfault circuit interrupter (GFCI) type receptacles detailed in this owner's manual.
INSTALLATION Key Installation Points The Power Switch must be turned OFF before you begin. 1. Observe proper polarity when connecting batteries. Reverse DC polarity will result in damage to the unit and will void the warranty. Use care when making the DC connections. 2. Do not back-feed the AC output of the inverter with incoming AC power. A back-feed occurs when AC power from shore power or generator is connected to the output of the inverter. This will damage the inverter and void the warranty.
INSTALLATION 10. If installing in a system which includes an existing battery charger or converter, make sure these do not operate from the inverter output AC power. This sets up a power loop which, due to inefficiencies, will quickly drain the batteries. 11. Make sure all wiring conforms to local and national electrical codes. If in doubt, consult with a qualified electrician. 12. Keep the overall length of each battery cable less than 10 feet. If needed, attach short extension cables.
INSTALLATION This procedure will connect the chassis of your unit to AC ground. In addition, the AC input and AC output green wires are connected to chassis ground. It is important to connect these wires to the AC ground bus in the circuit breaker panel. Note: The battery cables are not connected to ground or the chassis of the unit. Neutral Bonding For safety purposes, the Fleet Power inverter/charger unit internally bonds the AC output neutral to the AC ground when the unit is OFF or in the inverter mode.
INSTALLATION WARNING Do not connect incoming AC from any source to the AC output of the inverter/ charger. This is known as back-feeding and will damage the unit and void the warranty. occur when power is applied to both inputs. The charger can draw up to 27 Amps on one leg of power and the transfer switch can pass up to 30 Amps from the other leg of power. Single Input: Both the battery charger and the transfer switch may be fed from the same AC input.
INSTALLATION WARNING Persons with heart problems or other conditions which make them susceptible to electric shock may still be injured by ground faults on circuits protected by the GFCI Receptacle. No safety devices yet designed will protect against all hazards or carelessly handled or misused electrical equipment or wiring. tools or appliances operating from this device.
INSTALLATION The remote control cable can be extended up to 50 feet if required. Use standard 4 or 6 conductor telephone cable. Use a single length cable with no connectors or in-line splices. If phone cable is left over, coil it up and store it in an area away from AC equipment to prevent electrical interference. Once the above steps have been completed the unit can be bolted down. DC Wiring Two battery cables are provided with the unit.
INSTALLATION OPTION 1 15, 20 or 30 Amp Shore Power Inverter Runs Entire Panel In this system, the shore power is the only external AC power source available. The entire circuit breaker panel is connected to the output of the inverter/charger. Take these things into consideration are: 1. When you unplug from shore power, be sure to turn OFF any appliances or tools that you do not want on the inverter. This will prevent overloading the inverter or a rapid discharge of the battery bank. 2.
INSTALLATION OPTION 2 30 Amp Shore Power and Generator. Inverter Runs Entire Panel. This system has 2 sources of AC power, shore power and generator. There is a transfer switch between these two AC sources. The output of this transfer switch is switched to the input of the inverter/ charger where it is passed through to the circuit breaker panel. The same considerations for Installation 1 apply to this installation. 30 90-0115-00 10/97 Fltman.
INSTALLATION OPTION 3 50 Amp Shore Power/Generator Inverter Runs 30 Amp Sub-Panel. In this system the main circuit breaker panel contains many loads that will not operate from the inverter such as air conditioning, stove, water or space heater. The AC receptacle circuits are removed from the main circuit breaker panel and a 30 Amp sub-panel is installed.
INSTALLATION OPTION 4 (Dual AC Input) Fleet Power 2500 Only • 50 Amp 120 Volt Shore Power Service • Generator The transfer switch shown, switches, either manually or automatically, between generator and shore power. This switch is unrelated to the transfer switch inside the Fleet Power 2500. This AC panel has a single 120 volt leg. The transfer AC input and the Charger AC input are fed from separate 30 Amp circuit breakers.
DC WIRING OPTIONS WARNING For Installations using Battery Switches NOTE: No other DC loads should be connected to the common on the battery switch. This will prevent their operation directly from charger power when the battery switch is OFF. DC Wiring #1 - Two Battery* System Using Manual Battery Switch This system is simple and effective, providing the user with the ability to choose between either battery for inverter use or charging.
DC WIRING OPTIONS DC Wiring #3 - Two Auxiliary Batteries* with Battery Switch and One Engine Battery This system allows the inverter to use either auxiliary battery. The engine battery can always be charged by the alternator, but cannot be discharged by the inverter. The user can select between the two auxiliary batteries with the battery switch for charging or for inverter operation.
TROUBLESHOOTING LED Number Indication LED 1 Illuminates if the unit shuts down for any reason. LED 2 Over-temperature. Allow to cool. LED 3 The unit detected a failure. Call Heart Interface Technical Support. LED 4 Inverter overload caused by too large a load or short circuit. Reset by cycling power switch or plugging in incoming AC power. LED 5 Battery overload caused by excessively discharged batteries. Refer to page 40. LED 6 Incoming AC backfeed. Potentially damaging to the unit.
TROUBLESHOOTING Problem No Inverter Output Things to Check 1. Battery voltage under load. 2. Battery connections and DC fuse. 3. Circuit breaker on front panel. 4. Thermal condition, high powered loads or inadequate ventilation may cause overheating. 5. Overloads or short circuit, check for excessive loads or bad wiring connections. 6. Reset button oin GFCI outlet. Confirm that your volt meter is a true RMS meter.
GLOSSARY Alternating Current (AC) An electric current that reverses direction at regular intervals. Sources of alternating current are shore power, generator power, inverter power or household current. Ampere (Amp, A) The unit of measure of electron flow rate of current through a circuit. Ampere-hour (Amp-Hr.
GLOSSARY Equalize Charge A controlled overcharge of the batteries which brings all cells up to the same voltage potential, extends the battery life, restores capacity and mixes the electrolyte. Gel Cell Battery A type of battery that uses a gelled electrolyte solution. These batteries are sealed and are virtually maintenance-free. Not all sealed batteries are the gel cell type.
SPECIFICATIONS MODEL FP 1000-12 FP 2000-12 FP 2500-12 Nominal Battery Voltage 12 VDC 12 VDC 12 VDC Battery Voltage Range 10.0 - 15.5 VDC 10.0 - 15.5 VDC 10.0 - 15.5 VDC Low Battery Cutout 10 VDC 10 VDC 10 VDC AC Input Voltage Range 90-130 VAC 90-130 VAC 90-130 VAC Frequency Regulation .05% @ 60 Hz .05% @ 60 Hz .
WARRANTY Your Heart Interface Fleet Power Inverter/Charger is under limited warranty for a period of 12 months from date of purchase. Terms of the warranty are detailed on the warranty registration card. Please complete this card and return it to Heart Interface to register your warranty. If the unit requires service, contact Heart Interface by telephone. The service technician will ask for the serial number of your unit. Please have this information ready.