Freedom 10, 15, 20, 25 Owner's Manual

OWNER’S MANUAL

FREEDOM COMBITM INVERTER/CHARGERS

UL

FREEDOM MODELS 10, 15, 20, 25

®

A Valley Forge Company

Part No. 90-0113-00

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Thank you for purchasing a Heart Interface Freedom CombiTM Inverter/Charger. Heart Interface takes pride in manufacturing quality products specifically designed to meet your power requirements.

Freedom Combi Inverter/Chargers provide silent, efficient and reliable AC power for a variety of applications. They feature “hands-free” operation, automatic 3-stage battery charging and automatic AC transfer switching. For your convenience, service is available world-wide by qualified service centers.

If you have any questions about your Freedom Combi, please contact Heart Interface toll free: [phone].

For technical support and additional information about Heart Interface products, visit our web site at http://www.heartinterface.com or send us e-mail:

[e-mail]

[e-mail]

For your convenience, we’ve included a record log on page 39. Regular system maintenance is important for optimum performance of your Freedom Inverter/Charger. Use this record to keep track of any changes to your electrical system.

SAFETY SUMMARY

General safety information for installation and operation is contained throughout this manual where it applies and is not included in this summary.

Definitions Warning statements identify conditions or practices which could result in personal injury, loss of life, damage to equipment or other property.

Fuse Replacement For continued protection against the possibility of fire, replace the fuse

only with a fuse of the specified voltage, current and type ratings.

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. There are no user serviceable parts inside. Refer all service to qualified personnel.

The statements, specifications and instructions in this publication are believed to be correct. No warranty is made, expressed or implied by the seller or manufacturer with respect to any results or lack thereof from the use of information in this publication and no liability is assumed for any direct or consequential damages, personal loss or injury. All statements made herein are strictly to be used or relied on at the user’s risk. © 1997, 1998 Heart Interface Corporation. All rights reserved.

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TABLE OF CONTENTS

	Introduction. . . . . . . . . . . . . . . . . . . . . . . .	. 4	Troubleshooting . . . . . . . . . . . . . . . . . . . . . . .	27
	Things You Should Know . . . . . . . . . . . . .	5	Freedom Remote Control Panel Addendum . 28
	Circuit Breaker Protection		Remote Power Switch
	Electronic Protection		System Status LEDs
	Thermostat Controlled Cooling		DC Volts Bargraph
	Inverter Idle Circuit		DC Amps Bargraph
	Low and High Battery Protection		Dip Switches
	Power Sharing		Dip Switch Status
	Remote Control Panels	6	Remote Control Wiring
			Status LEDs
	Freedom Remote Control Panel
			Dip Switch Programming
	Link Instrumentation
			Troubleshooting
	Operation . . . . . . . . . . . . . . . . . . . . . . . . . .	7	Glossary	35
	Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . .	8	Specifications	37
	Battery Types
			Notes	38
	Battery Interconnection
	Battery Bank Ratings and Sizing		System Record	39
	Battery Charging	12
			Warranty	40
	Conventional Battery Chargers
	Freedom Battery Chargers
	Charging Over-Discharged Batteries
	Battery Charger Voltage Table . . . . . . . . .	17
	Installation Precautions . . . . . . . . . . . . . .	18
	Installation . . . . . . . . . . . . . . . . . . . . . . . . .	19
	Key Installation Points
	Grounding
	Neutral Bonding
	AC Wiring
	AC Output
	Ground Fault Circuit Interrupters

Remote Control Wiring

DC Wiring

Battery Cable Fusing

Power ON Checks

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INTRODUCTION

This owner’s manual describes the Freedom CombiTM 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.

• The inverters provide regulated 120 Volt AC power and crystal controlled frequency from a deep cycle battery bank in specified watts:

Freedom 10 . . . . . . . . . 1000 watts Freedom 15 . . . . . . . . . 1500 watts Freedom 20 . . . . . . . . . 2000 watts Freedom 25 . . . . . . . . . 2500 watts

The output is a modified sine wave and is compatible with most appliances, tools and other 120 VAC equipment. An idle circuit reduces battery power consumption when the loads are removed from the inverter. There is a low battery cutout circuit and momentary surge power of more than twice the inverter rating is available for starting electric motors. High efficiency insures the longest possible battery life between recharges.

• The internal transfer switch allows the Freedom Inverter/Charger to be connected to an external AC source and transfer the source power through to the loads. When disconnected, the transfer switch allows automatic switching back to the inverter.

The Freedom Inverter/Charger operates as a self-contained backup power system, just add batteries.

• Freedom battery chargers are electronically controlled and rated:

Model	12 Volts	24 Volts
Freedom 10	50 Amps DC	25 Amps DC
Freedom 15	75 Amps DC	N/A
Freedom 20*	100 Amps DC	50 Amps DC
Freedom 25	130 Amps DC	65 Amps DC

*Also available in 32 Volt model rated at 35 Amps DC

They are designed to rapidly and optimally recharge either wet** or gel** cell deep-cycle batteries. Battery charging is accomplished in 3 automatic stages: Bulk Charge, Acceptance Charge and Float Charge. Using a Freedom Remote Control Panel or Link Instrumentation, a manuallyengaged Equalizing Charge cycle is possible.

Simple, automatic operation is made possible by the microprocessor in the Freedom Inverter/Charger. In most cases, the unit is left ON and no attention or maintenance is required.

Electronic Protection

Fast-acting electronic circuits protect the inverter from extreme overloads and short circuits. Other protection includes a low and high battery cutoff and automatic shutdown if over temperature occurs. The fault condition must be eliminated before reset will occur. Example: remove overload, recharge batteries or allow to cool. Reset by cycling the power switch on the Freedom Remote Control Panel, Link Instrument or the Freedom unit one time--OFF/ ON.

**Adustable with optional remote (Freedom Remote Panel or Link Instrumentation)

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THINGS YOU SHOULD KNOW

Circuit Breaker Protection

The Freedom Inverter/Charger is circuit breaker protected. The INV/CHG breaker on the front of the unit protects against sustained inverter/charger over current conditions.

Model	Circuit Breaker
Freedom 10	12 Amp
Freedom 15	20 Amp
Freedom 20	25 Amp
Freedom 25	30 Amp

The 30 Amp INPUT circuit breaker on the Freedom unit protects the incoming AC circuit. The incoming AC circuit provides power to the battery charger and transfers power to the loads connected to the inverter AC output. The breakers are reset by pushing the button back in.

NOTE: Freedom 25 only. There are 3 circuit breakers on the Freedom 25. The OUTPUT 30 Amp circuit breaker on the front of the unit protects against sustained inverter overloads. The TRANSFER 30 Amp circuit breaker on the unit protects the incoming AC leg which is transferred through to the loads. The CHARGER 30 Amp circuit breaker protects the incoming AC leg which feeds the battery charger.

Thermostat Controlled Cooling

Freedom Inverter/Chargers are equipped with a thermostat controlled fan that cools the unit so it can operate continually at its rating.

Inverter Idle Circuit

This automatic energy saving feature reduces battery power consumption when no load is present. Response from idle is instant. In most cases, the operation of the idle circuit is not noticeable. Use of the Freedom Remote Control Panel or Link Instrumentation allows

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the idle circuit sensitivity to be adjusted. The unit will not put out 120 Volts when in idle. To bring the unit out of the idle condition, apply a load.

Low and High Battery Protection

When the battery voltage drops to 10 Volts, the Freedom Inverter/Charger will automatically shut off. Recharge the batteries to 13.5 Volts (12 V model). For 24 Volt models, recharge batteries to 31.0 Volts. For 32 Volt models, recharge batteries to 41.38 Volts. Freedom units will automatically reset when shore power is disconnected or reset manually by cycling the power switch OFF/ON

Shut down also occurs for a high battery condition at 15.5 Volts. To restore inverter operation, battery voltage must be below 15.5 Volts. Check all DC sources on the system for excessive voltage.

Power Sharing

When connected to shore power or when using a generator, the battery charger and transfer functions are engaged. A unique Power Sharing feature automatically reduces the AC consumption of the battery charger allowing necessary AC power to the load. This prevents the source AC INPUT circuit breaker from tripping.

The Power Sharing set point of each unit has a factory default setting. This can be adjusted using the Freedom Remote Control Panel or a Link Instrument.

NOTE: Freedom 25 only. Since the Freedom 25 has dual AC inputs, one transfer and one charge, factory default setting for Power Sharing is OFF. If only one leg is used to supply both inputs, set Power Sharing accordingly.

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REMOTE CONTROL PANELS

Freedom Remote Control Panel

An optional remote control panel is available. When the remote is used, the power switch on the unit should be left OFF. The remote control panel provides LED bargraphs which show system status, battery voltage and DC current in both inverter and charger modes.

These bargraphs can also display dip switch positions and shutdown conditions. Dip switches allow the selection of battery type, battery temperature, idle sensitivity, Power Sharing, manual equalizing and auto/manual charge modes. Refer to the Freedom Remote Control Panel Addendum, pages 28-34, in this manual for more information.

Link Instrumentation

More advanced optional remote control panels are also available: the Link 1000, 2000 and 2000R.

Link 1000 controls the Freedom Inverter/ Charger and provides complete battery state- of-charge information including DC voltage, current, Amp-hours consumed, Time Remaining and historical data for a single battery bank.

The Link 2000 provides inverter/charger control and complete battery state-of-charge information for up to two battery banks.

The Link 2000R adds the ability to control an engine-driven alternator. This precision regulator transforms an alternator into a 3-stage battery charging system.

If Link Instrumentation is used to control the inverter/charger, refer to the Link Owner’s Manual for setup and control information.

Refer to Installation Guide for installation options.

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OPERATION

The Freedom Inverter/Charger provides household 120 Volt AC power from auxiliary DC batteries, automatic battery charging and automatic AC transfer switching.

Power Switch

The Power Switch is located on the front panel. This switch controls ON/OFF and RESET for the inverter.

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.

Freedom 25 shown.

When external AC power is removed and the power switch is in the ON position, the inverter will automatically be ON. If the switch is in the OFF position and external AC power is removed, the inverter will be OFF.

Inverter overload protection, transfer switching, default Power Sharing and 3-stage battery charger regulation will all function automatically.

If installed with the Freedom Remote Control Panel or Link Instrument, the power switch on the unit should be left in the OFF position. Refer to Freedom Remote Control Panel Addendum, pages 28-34, or the Link Owner’s Manual.

Power Switch

Freedom 10 and 20 Circuit Breakers	Freedom 25 Circuit Breakers
INPUT	CHARGER
INV/CHG	TRANSFER
	OUTPUT
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BATTERIES

BATTERY TYPES

Use only deep-cycle batteries with your Freedom Inverter/Charger. These fall into three broad categories: wet cell, gel cell and Advanced AGM (Absorbed Glass Mat) batteries.

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 perform well and may have a longer life. They are 6 Volt batteries that must be used in series pairs. High quality marine deep-cycle batteries offer good performance and are available in a wide variety of sizes. Floor sweeper, fork lift or large 2 Volt cells can also offer excellent performance, if their large size can be accommodated.

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It should be noted that high antimony deep-cycle batteries will give off gas as a natural result of charging and will experience some water loss. It is very important that the electrolyte level be checked frequently and topped off with distilled water when necessary. Never allow the tops of the plates to be exposed to air, as contamination of the cell will result. Keeping the tops of batteries clean will reduce self-discharging. Always provide ventilation for the battery storage compartment.

Do not use car batteries or engine starting batteries of any kind with your inverter/charger. Beware of any battery that is rated in Cold Cranking Amps (CCA). This is a rating which applies only to engine starting batteries. In general, most wet cell batteries that are described as hybrid batteries, suitable for either engine starting or deep-cycle applications, are a compromise and will have limited life if deeply discharged.

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BATTERIES

Beware of so-called maintenance-free batteries. These batteries have calcium alloyed with the lead and hold the liquid electrolyte in a sponge-like material. They are sealed and water can not be added. Do not confuse them with true gel cell or Advanced AGM batteries, they will not hold up to deep discharging and repeated cycling.

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.

•No Maintenance

•Low Self-Discharging

•Low Internal Resistance

Even though gel cells are sealed batteries, the battery compartment should be ventilated.

Advanced AGM (Absorbed Glass Mat) Batteries

This battery is lead acid but maintenance-free. The performance is similar to gel cell batteries. The charge perameters are similar to wet cell batteries.

Battery Selection The most important feature to consider in making your battery selection is to select true deep cycle batteries rated in Amp-hours (AH).

BATTERY INTERCONNECTION

In most cases, you will be using a bank of two or more batteries with your inverter/ charger. You may connect batteries together

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in two configurations, series and parallel.

Series

Connecting two batteries in series will double the voltage of the battery bank. For instance, two 6 Volt batteries connected in series will produce 12 Volts. The Amp-hour capacity of the battery bank will be the same as each individual battery. Example, two 6 Volt 220 Amp-hour batteries in series will produce one 12 Volt 220 Amp-hour battery bank.

+

+

+

Series

Series Increase Voltage

	+	+	+
	6V	6V	12V INVERTER
	_	_
			_
	EACH BATTERY		TOTAL BATTERY
	CAPACITY:		BANK CAPACITY:
	220		220
	AMP-HOURS		AMP-HOURS
	@ 6 VDC		@ 12 VDC

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BATTERIES

Parallel

Connecting two 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

Parallel Increase Amp-hour Capacity

	+	+	+
	12V	12V	12V INVERTER
	_	_
			_
	EACH BATTERY		TOTAL BATTERY
	CAPACITY:		BANK CAPACITY:
	105		210
	AMP-HOURS		AMP-HOURS
	@ 12 VDC		@ 12 VDC

Note: It is not advisable to connect batteries of different case sizes or Amp-hour ratings in the same battery bank.

Always use wire and terminals for your interconnecting battery cables which are appropriate to handle the current. They must be the same size or larger AWG as the cables supplied with the inverter/ charger.

BATTERY BANK RATINGS AND SIZING

Deep-cycle batteries are usually rated in Amp-hours. The Amp-hour rating is based on a 20 hour discharge cycle, therefore, a 100 Amp-hour battery can deliver 5 Amps for 20 hours. If the discharge rate is greater than 5 Amps, the available Amp-hours are decreased. For example, if the load is increased to 100 Amps, only about 45 Amp-hours will be available at this rate of discharge.

Deep-cycle batteries can be discharged about 80% before permanent damage occurs, though shallower cycling will result in much longer battery life. 50% cycling is generally considered to be a good compromise between long battery life and a reasonably sized battery bank.

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. In the above drawing, the load is connected to the positive terminal of the first battery and the negative terminal of the last battery. This practice helps to balance the battery bank and is called cross-connecting the battery bank.

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BATTERIES

To achieve 50% cycling you should calculate your Amp-hour consumption between charging cycles and use a battery bank with twice that capacity**. Each AC appliance or tool has a rating plate on it and will be rated in either AC Amps or Watts or AC VA (Volt-Amps) apparent power. To calculate Amp-hour consumption, use one of the formulas to the right to calculate the DC Amp-hour draw for a 12 Volt system.

Calculate the Amp-hours for every AC appliance or tool that will be operated on the inverter. This will provide the total number of Amp-hours used between recharges. Size the battery bank using this number as a guideline. A good rule to follow is to size the battery bank a minimum of 2 times larger than the total Amp-hour load requirement. Plan on recharging when 50% discharged.

AMP-HOUR CONSUMPTION FORMULAS

(AC Amps x 10) x 1.1 x hours of operation = DC Amp-hours

(Watts/ DC Voltage) x 1.1 x hours of operation = DC Amp-hours

(AC VA/ DC Voltage) x 1.1 x hours of operation = DC Amp-hours

DC Voltage is 12, 24 or 32 depending on your system.

In all formulas, 1.1 is the factor for inverter efficiency.

Typical Power Consumptlon

The chart below identifies typical power consumption for common AC loads. Use it as a guide when identifying your power requirements.

**Batteries are typically charged to 85% of full charge when charging with alternators without 3-stage regulators.

Many electric motors have momentary starting requirements well above their opera-

tional rating. Start up watts are

Typical Power Consumption

	Typical			Appliance Run Times / Amp Hours
Appliance
	Wattage
		5 Min.	15 Min.	30 Min.	1 Hr.	2 Hr.	3 Hr.	8 Hr.	24 Hr.
13" Color TV	50	.33	1	2	4	8	12	32	96
19" Color TV	100	.66	2	4	8	16	24	64	192
VCR	50	.33	1	2	4	8	12	32	96
Lamp	100	.66	2	4	8	16	24	64	192
Blender	300	2	6	12
Laptop Computer	50	.33	1	2	4	8
Curling Iron	50	.33	1	2
3/8 Power Drill	500	3.3	10	20
Icemaker*	200			2.6	5.2	10.4	15.6	41.6	83.2
Coffee Maker	1000	6.6	20	40	80	160
3 cu' Refrigerator*	150			2	4	8	12	32	96
20 cu' Refrigerator*	750			21	42	84	126	336	672
Compact Microwave	750	5	15	30	60	120	180
Full Size Microwave	1500	10	30	60	120	240	360
Vacuum	1100	7.3	22	44	88	176	264

Number in each box represents the total Amp hours used (@ 12 volt DC) based on various continuous run times. *Note refrigeration is typically calculated using a 1/3-duty cyle.

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listed where appropriate. Individual styles and brands of appliances may vary.

If using the same battery bank for the inverter and the DC loads, be sure to consider the power consumption of the DC loads when sizing the battery bank.

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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.

At 77 degrees F, the gassing point of a 12 Volt battery is about 14.0 Volts. Battery charging without excessive gassing of the batteries is accomplished with three-stage chargers. The Freedom Inverter/Charger utilizes this technique.

Gel cell batteries must not be charged to their gassing point. In fact, high voltage charging which gasses these batteries is harmful to them. They typically require a lower bulk charge voltage and a higher float voltage than wet cell batteries. Consult the battery manufacturer for specifications.

Conventional Battery Chargers

Most conventional battery chargers are single-stage constant voltage chargers. They must stop short of the gassing point or they will overcharge the battery bank. Most 12 Volt battery chargers bring the battery voltage up to about 13.8 Volts.

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This presents two problems. First, since the battery voltage does not reach the gassing point, sulfate is left on the plates. Second, 13.8 Volts is close enough to the gassing point that some gas will escape, and the wet cell battery will need to be frequently topped off with distilled water.

Conventional battery chargers also suffer from another inherent characteristic of design, which is a tapering effect. While they will deliver their rated current into a deeply discharged battery, as the battery voltage rises, the output current of the charger tapers down. This taper continues as the battery is charged, taking a very long time to reach an acceptable recharge level.

Freedom Battery Chargers

Freedom battery chargers are designed to overcome the limitations of conventional chargers by utilizing 3 distinct stages, each designed for optimal recharging of both wet cell and gel cell deep-cycle batteries. Battery type selection is only available through the Freedom Remote Control Panel or a Link Instrument. Refer to the Freedom Remote Control Panel Addendum, pages 28-34, or a Link Owner’s Manual.

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