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OWNER'S MANUAL
FLEET POWER
INVERTER/BATTERY CHARGERS
FLEET POWER 1000
U
FLEET POWER 2000
®
C
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.
90-0115-00
10/97 Fltman.pm65
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INTRODUCTION General safety information for installation Power Source To avoid damage, operate the and operation is contained throughout this equipment only within the specified AC (line) manual where it applies and are not included and DC (battery) voltages. in this summary. Servicing To reduce the risk of electric shock Warnings Warning statements identify condi- do not open this unit. There are no user ser- tions or practices which could result in personal viceable parts inside. Refer all ser
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TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Battery Charging . . . . . . . . . . . . . . . . . . 16 Conventional Battery Chargers Things You Should Know . . . . . . . . . . . . . . . 5 Fleet Power Battery Charger Circuit Breaker Protection Charging Over-Discharged Batteries Electronic Protection Power Sharing Battery Charger Voltage Table . . . . . . . . . . 21 Power Switch Installation Precautions . . . . . . . . . . . . . . . 22 Remote Control Programmi
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INTRODUCTION This owner's manual describes the Fleet Power Inverter/Chargers from Heart Fleet Power Inverter/Chargers operate Interface. These units perform three distinct as self-contained backup power systems, functions: just add batteries. 1. DC to AC power inverting. • Fleet Power battery chargers are electroni- 2. Automatic transfer switching between cally controlled and rated: inverter power and incoming AC power. FP 1000-12..................50 Amps DC 3. Automatic 3-Stage Battery
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THINGS YOU SHOULD KNOW The optional Fleet Power Remote on the units protect the incoming AC circuit Control Panel provides a power switch, which is transferred through to the loads system status LEDs, DC Volts and DC Amps connected by the hardwire output. LED bargraphs. On the back of the remote The 15 Amp circuit breaker protects the is a set of dip switches which allow adjust- GFCI outlet on the Fleet Power 1000 and ment of the following: 2000 models. When a circuit breaker trips, • Manual In
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OPERATION Power Switch The Power Switch is located on the Power Switch 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
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REMOTE CONTROL PANEL An optional remote control panel is Volts bargraph will stop indicating battery available which offers several features not voltage and display the dip switch settings. found on the unit. The remote control panel It will return to indicating battery voltage provides LED bargraphs which show system only after the unit has been reset. status, battery voltage, and DC Amps in DC Amps Bargraph both inverter and charge modes. These These LEDs approximate DC input bargraphs can a
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REMOTE CONTROL PANEL Dip Switches The battery LED blinks when equaliz- On the back of the Fleet Power remote ing. See page 18 for a discussion of the control panel is a set of 8 dip switches theory and procedure for battery equalizing. which are used to make several adjust- SWITCH #2 & #3 - Battery Type Gel cell ments. On the switch block, each switch is and wet cell batteries have slightly different numbered . . .1 through 8 and the ON posi- charge voltage requirements. Optimum tion is indi
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REMOTE CONTROL PANEL Use the 5 Amp setting for small genera- tors, 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 illumi- nate if switch 2 is on, etc. Dip switch set- tings are indicated for
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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. Illuminates when incoming AC power has been applied and the transfer relays have engaged. AC Input There is a 7-12 second delay from the time the AC is applied and this LED illuminates. Steady Indicates an over-temperature condition, the unit is Overload shut down. It will reset automatically af
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DIP SWITCH PROGRAMMING Switch Feature Set Point Number 1 Equalize or Toggle 3 Stage Equalize (Do not leave on.) On/Off Charging Off 3 Stage Charging* 2 3 On On Warm Gel Cell (>80 deg. F.) Battery Off On Cool Gel Cell (<80 deg. F.) Type On Off Warm Wet Cell (>80 deg. F.) Off Off Cool Wet Cell (<80 deg. F.)* 4 Disable: Charger responds to On/Off Auto On switch. Charge Enable: Charger on when AC Off connected.* 5 6 Not used. 7 8 1000 2000 2500 5 Amps On On 2.5 Amps 5 Amps Power Of
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BATTERIES It should be noted that high antimony deep-cycle batteries will give off gas as a natural result of charging and will experi- ence 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. Keep- ing the tops of batteries clean will reduce self-discharging. Always provide ventilation for the battery storag
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BATTERIES Beware of so-called maintenance- The features of the gel cell batteries free batteries. These batteries have cal- solve many common problems. Cycle life is cium alloyed with the lead and hold the high, even under constant deep discharg- liquid electrolyte in a sponge-like material. ing. They are sealed and water cannot be BATTERY INTERCONNECTION added. Do no confuse them with true gel In most cases you will be using a bank cell batteries, they will not hold up to deep of two or more
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BATTERIES Parallel Always use proper terminals for your Connecting 2 batteries in parallel will interconnecting battery cables which are double the Amp-hour rating of the battery appropriate to handle the current. bank, while the voltage will be the same as Battery Bank Ratings and Sizing each individual battery. Example, two 12 Deep-cycle batteries are usually rated Volt 105 Amp-hour batteries in parallel will in Amp-hours. The Amp-hour rating is produce one 12 Volt 210 Amp-hour battery based
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BATTERIES To achieve 50% cycling you should Typical PowerConsumption calculate your Amp-hour consumption Loads Watts between charging cycles and use a battery On-Board Computers 200 bank with twice that capacity. Quartz Halogen Flood 300 To calculate Amp-hour consumption first 0.2 HP Bench Grinder 300 Hammer Drill 500 look at the rating plate on your AC appli- 3/8" Electric Drill Motor 500 ance or tools. Each appliance or tool will be Sawzall 500 rated in either AC Amps or AC watts or AC 0.5 HP
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BATTERY CHARGING Battery Charging This presents two problems. First, Completely recharging wet cell deep- since the battery voltage does not reach the cycle batteries requires the battery voltage gassing point, sulfate is left on the plates. to be raised beyond what is known as the Second, 13.8 volts is close enough to the gassing point. This is the voltage at which gassing point that some gas will escape, the battery begins to bubble and gas is and the wet cell battery will need to be given o
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BATTERY CHARGING NOTE: Fleet Power battery chargers are on The battery charger stages are: whenever there is AC power connected to Stage 1 - Bulk Charge During the bulk the charger input, regardless of the condi- charge stage most of the charge current is tion of the On/Off switch. This feature can delivered to the battery bank. This phase is be disabled by setting the dip switch #4 engaged as soon as the battery charger is (back of the remote) to "On" so that the activated. Full rated charg
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BATTERY CHARGING Gel cell batteries can accept a higher The float charge stage holds the battery rate of charge. Consult the manufacturer for voltage at a lower level, where it is safe for specifications. long term battery maintenance. During the float charge stage, the full output current of Stage 2 - Acceptance Charge The the battery charger is available to operate acceptance stage immediately follows the any DC appliances that may be on the bulk charge stage. During this stage the system,
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BATTERY CHARGING charging cycle. The battery voltage will Equalizing is not required on gel cell increase to 16.3 using the cool temperature batteries. You will note that if the dip wet cell setting. This will cause the battery switches are set in one of the two gel cell bank to gas profusely and will accomplish positions, the equalizing charge voltage is the following: the same as the bulk charge voltage, there- fore, equalizing is equivalent to an 8-hour 1. Removal of residual sulfate. Each
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BATTERY CHARGING Note: If a continuous DC load in ex- cess of the charge rate is placed on the WARNINGS battery bank, eventually the battery voltage will drop below 8 Volts and the battery 1. Do not equalize gel cell batteries charger will shut off. This load must be with the remote programmed for wet significantly reduced and the power to the cells. charger cycled to resume charging. 2. Always monitor the equalize Blinking of the battery LED on the charge. Provide proper ventilation for remo
