Xantrex Technology 2500, 2000 User Manual
OWNER'S MANUAL
FLEET POWER
INVERTER/BATTER Y CHARGERS
FLEET POWER 1000
FLEET POWER 2000
C
U
®
L
FLEET POWER 2500
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.
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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 condi-
tions 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 rating.
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 servicing 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 Heart Interface Corporation. All rights reserved.
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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 . . . . . . . . . . . . . . . . . . 7
Remote Power Switch
System Status LEDs
DC Volts Bargraph
DC Amps Bargraph
Dip Switches
Equalize or 3-Stage Charging
Battery Type
Auto Range
Power Sharing
Dip Switch Status
Remote Control Wiring
Link 2000 Remote Control
Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . 10
Dip Switch Programming . . . . . . . . . . 11
Batteries . . . . . . . . . . . . . . . . . . . . 12
Battery Types
Battery Interconnection
Battery Bank Ratings and Sizing
Battery Charging . . . . . . . . . . . . . . . . . . 16
Conventional Battery Chargers
Fleet Power Battery Charger
Charging Over-Discharged Batteries
Battery Charger Voltage Table . . . . . . . . . . 21
Installation Precautions . . . . . . . . . . . . . . . 22
Installation . . . . . . . . . . . . . . . . . . . . . . . 23
Key Installation Points
Location
Grounding
Neutral Bonding
AC Wiring
Ground Fault Circuit Interrupters
Remote Control Wiring
DC Wiring
Battery Cable Fusing
Installation Options . . . . . . . . . . . . . . . . . . 29
DC Wiring Options . . . . . . . . . . . . . . . . . . . 32
Troubleshooting . . . . . . . . . . . . . . . . . . . . . .34
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . 36
Specifications . . . . . . . . . . . . . . . . . . . 38
Warranty . . . . . . . . . . . . . . . . . . . . . . 40
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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................1000 watts
FP 2000-12................2000 watts
FP 2500-12................2500 watts
The output is a modified sinewave and
is compatible with appliances, tools and
other 120 VAC equipment. Momentary
surge power of three times the inverter
rating is available for starting electric motors. High efficiency insures the longest
possible battery life between recharges.
• The transfer switch allows the Fleet Power
Inverter/Chargers to be connected to an
external AC source and transfer the source
through to the loads. When disconnected,
the transfer switch allows automatic switching back to the inverter.
Fleet Power Inverter/Chargers operate
as self-contained backup power systems,
just add batteries.
• Fleet Power battery chargers are electronically controlled and rated:
FP 1000-12..................50 Amps DC
FP 2000-12................100 Amps DC
FP 2500-12................130 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. In addition,
using the remote control, a manually-engaged Equalizing Charge cycle is possible.
With an external AC source connected,
the Fleet Power charger also serves the
functions of a AC to DC converter to supply
all of the DC loads which are connected to
the battery.
Simple, automatic operation is made
possible by the microprocessor in the Fleet
Power Inverter/Chargers. In most cases, the
unit is left on and no attention or maintenance is required.
*Adustable with optional remote
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THINGS YOU SHOULD KNOW
The optional Fleet Power Remote
Control Panel provides a power switch,
system status LEDs, DC V olts 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.
The Fleet Power 1000 has a 12 Amp
INV/CHG circuit breaker on the front of the
unit that protects against sustained inverter
overloads over 1440 watts and the AC input
to the battery charger. The 15 Amp INPUT
circuit breaker on the unit protects the
incoming AC circuit which is transferred
through to the loads via the GFCI.
The Fleet Power 2000 has a 25 Amp
INV/CHG circuit breaker that protects
against sustained inverter overloads over
3000 watts and the AC input to the battery
charger. .
The Fleet Power 2500 has a 30 Amp
OUTPUT circuit breaker on the unit that
protects against sustained inverter overloads over 3600 watts. The 30 Amp circuit
breaker protects the incoming AC leg which
feeds the battery charger.
The 30 Amp TRANSFER circuit breaker
on the units protect the incoming AC circuit
which is transferred through to the loads
connected by the hardwire output.
The 15 Amp circuit breaker protects the
GFCI outlet on the Fleet Power 1000 and
2000 models. When a circuit breaker trips,
the circuit breaker is reset by pushing the
button back in.
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 OFF/ON.
Power Sharing
When connected to shorepower or
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 circuit breaker from tripping. This feature can be adjusted using
the remote control panel. This feature is set
at the transfer rating of each unit by default.
INPUT
INV/CHG
GFCI
Fleet Power 2000 shown.
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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. If the
switch is in the OFF position and external
AC power is removed, the inverter will be
OFF.
Inverter overload protection, transfer
switching, power sharing and battery
charger regulation will all function automatically.
Power Switch
Fleet Power 1000 shown.
If installed with the remote control
panel, the power switch on the unit should
be left in the OFF position. Refer to Remote Control Panel, page 7.
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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. When
a remote control is used, the power switch
on the inverter should be left in the OFF
position.
Volts bargraph will stop indicating battery
voltage and display the dip switch settings.
It will return to indicating battery voltage
only after the unit has been reset.
DC Amps Bargraph
These LEDs approximate DC input
current in inverter mode and DC output
current in battery charger mode. Two
ranges are used -- below 50 Amps each
segment represents a 10 Amp increment,
above 50 Amps each segment represents a
20 Amp increment. Above 130 Amps, a
flashing LED segment indicates the value
displayed plus 100 Amps (flashing 50 LED
is equal to 50 + 100 or 150 Amps DC).
If a shutdown occurs, the DC Amps
bargraph will stop indicating DC Amps and
will indicate the type of problem . Each LED
segment indicates a different problem as
described in the troubleshooting section on
page 34.
System Status LEDs
These 4 LEDs monitor the system as
described in the table on page 10.
DC Volts Bargraph
These LEDs indicate battery voltage as
measured inside the unit. Each LED segment indicates .5 Volts. If an overload
occurs and the unit shuts down, the DC
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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.
Fleet Power Remote Control Panel
SWITCH 1 -
BACK VIEW
Manual Equalizing
Cycling this switch ON for 1 second, then OFF,
will initiate an equalizing charge cycle. The
battery charger must be engaged before
cycling the switch. The dip switch must
always be returned to the OFF position.
If it is left ON, an equalizing charge cycle
will initiate every time the charger is
engaged - this could cause battery damage.
The equalizing cycle is timed to last 8
hours from the time the switch is cycled, at
which point the charger resumes normal
charging in the float stage.
The battery LED blinks when equalizing. See page 18 for a discussion of the
theory and procedure for battery equalizing.
SWITCH #2 & #3 -
Battery Type
Gel cell
and wet cell batteries have slightly different
charge voltage requirements. Optimum
battery charging is temperature dependent.
For these reasons, the dip switches allow
four different battery charger voltage set
points, depending on battery type and
ambient temperature:
Cool Wet Cell < 80 degrees F.
Warm Wet Cell > 80 degrees F.
Cool Gel Cell < 80 degrees F.
Warm Gel Cell > 80 degrees F.
Refer to the table on page 21 for the
specific voltages for each setting.
SWITCH #4 -
Auto Charge
With the switch
in the OFF position, the remote panel ON/
OFF switch only controls the inverter operation. With the switch turned ON, it allows
the power ON/OFF switch on the front of the
remote to control the battery charger as well
as the inverter.
SWITCH #5 & #6 - Not used for adjustments.
SWITCH #7 & #8 -
Power Sharing
These
switches should be set to match the value of
the circuit breaker which protects the incoming AC power. They may also limit the
output current from the battery charger.
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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. Dip switch settings are indicated for 10 seconds after
which time the display returns to indicating
battery voltage.
Factory default settings for all dip
switches are in the Off position.
Remote Control Wiring
The remote control panel is supplied
with 25 or 50 ft. of telephone cable. The
cable supplied may be 6 conductor, however, only 4 conductor is required. You may
buy standard 4 conductor telephone cable
and run up to 50 ft., if desired. Use only a
single length of telephone wire, do not
splice.
Refer to page 11 for the Dip Switch
Programming chart.
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STATUS LEDs
Status LED Purpose
INV/CHRG
(Inverter/Charg
AC Input
Steady
Overload
Blinking
Overload
Steady Battery
Blinking
Battery
Power on light. It will be illuminated whenever the
power switch is on (inverter on) or when there is
incoming AC power an d the ch arger comes on.
Illuminates when incoming AC power h as been
applied and the transfer relays have engaged.
There is a 7-12 second d elay from the time the AC
is applied and this LED illuminates.
Indicates an over-temperature condition, the unit is
shut down. It will reset automatically after cooling.
Inverter mode- Shutdown, diagnose problem using
DC Amps bar graph. Cha rger mode- Thermal
shutdown, after cooling re set by cycling power
switch.
This is a High /L ow Bat tery wa rnin g con dit ion.
Inverter mode: Battery > 15.25 or < 10.50 volts
Charger mode: B atter y > 15 .25 or < 10. 00 volts
Indicates eith er a shutdown or equa lizing.
Battery > 15 .5 0 vo lts, will a u to-r eset at 15.2 5.
Inverter mode: Battery < 10.00 vol ts, will auto res et
at charger float voltage or upon AC in put.
Charger mode: Battery < 8.00 volts for 1 minute,
remove all DC loads and manually reset by cycling
disconnecting and reapplying shorepower.
the power switch.
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DIP SWITCH PROGRAMMING
Feature
Equalize or
3 Stage
Charging
Battery
Type
Auto
Charge
Switch
Set Point
Number
1
Toggle
On/Off
Off 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
On
Off
Equalize (Do not leave on. )
Disable: Charger responds to On/Off
switch.
Enable: Charger on when AC
connected.*
Power
Sharing
5 6
7 8
On On 2.5 Amps
Off On 5 Amps
On Off 10 Amps
Off Off 15 Amps*
Not used.
1000 2500
2000
5 Amps
15 Amps
20 Amps
30 Amps*
*indicates factory default setting.
5 Amps
20 Amps
30 Amps
Disabled*
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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. 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.
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 give limited life if deeply discharged.
Beware of 8-D starting batteries that
are commonly used for starting diesel engines. These batteries are not deep-cycle.
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