Xantrex Technology 2500 manual


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Table of contents for the manual

  • Page 1

    90-01 15-00 10/97 Fltman.pm65 OWNER'S MANUAL FLEET POWER INVERTER/BA TTER Y CHARGERS FLEET POWER 1000 FLEET POWER 2000 FLEET POWER 2500 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. KKK U L ® C[...]

  • Page 2

    90-01 15-00 10/97 Fltman.pm65 INTRODUCTION General safety information for installation and operation is contained throughout this manual where it applies and are not included in this summary . W arnings W arning statements identify condi- tions or practices which could result in personal injury , loss of life, damage to equipment or other property [...]

  • Page 3

    90-01 15-00 10/97 Fltman.pm65 T ABLE OF CONTENTS 3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Things Y ou Should Know . . . . . . . . . . . . . . . 5 Circuit Breaker Protection Electronic Protection Power Sharing Power Switch Remote Control Programming Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Remot[...]

  • Page 4

    90-01 15-00 10/97 Fltman.pm65 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 equa[...]

  • Page 5

    90-01 15-00 10/97 Fltman.pm65 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 adjust- ment of the following: • Manual Initiation of Equalize Charging • Ambient Battery T emperature[...]

  • Page 6

    90-01 15-00 10/97 Fltman.pm65 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[...]

  • Page 7

    90-01 15-00 10/97 Fltman.pm65 REMOTE CONTROL P ANEL V olts 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. T wo r[...]

  • Page 8

    90-01 15-00 10/97 Fltman.pm65 REMOTE CONTROL P ANEL 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 adjust- ments. On the switch block, each switch is numbered . . .1 through 8 and the ON posi- tion is indicated. The switch settings can be changed at any time, even while the[...]

  • Page 9

    90-01 15-00 10/97 Fltman.pm65 REMOTE CONTROL P ANEL Use the 5 Amp setting for small genera- tors, or for charging deeply discharged batteries. Dip Switch Status Y ou can check the position of the dip switches by quickly cycling the power switch OFF/ON twice. The DC V olts bargraph will cease to display battery voltage and will indicate the settings[...]

  • Page 10

    90-01 15-00 10/97 Fltman.pm65 Status LED Purpose INV/ CHRG (Inverter/Charg Pow er on ligh t. It will be i lluminate d whenever t he power swi tch is on (inver ter on) o r when there is incom ing AC power an d the charge r comes on. AC Input Illuminates when incoming AC power h as been appl ied and t he transfer relays have engaged. There is a 7-12 [...]

  • Page 11

    90-01 15-00 10/97 Fltman.pm65 Feature Switch Num ber Set Point Equalize or 3 Stage Charging 1 Toggle On/Off Equalize (D o not leave on.) Off 3 Sta ge Charging* Battery Type 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.)* Aut o Ch arge 4 On D[...]

  • Page 12

    90-01 15-00 10/97 Fltman.pm65 BA TTERIES BA TTER Y 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 T rue deep-cycle wet cell batteries are characterized by relatively thick plates that are alloyed with antimony . Common marine/RV deep-cycle [...]

  • Page 13

    90-01 15-00 10/97 Fltman.pm65 BA TTERIES Beware of so-called maintenance- free batteries . These batteries have cal- cium 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 Bat[...]

  • Page 14

    90-01 15-00 10/97 Fltman.pm65 BA TTERIES Always use proper terminals for your interconnecting battery cables which are appropriate to handle the current. 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, there- fore, a 100 Amp-hour battery can deliver 5 A[...]

  • Page 15

    90-01 15-00 10/97 Fltman.pm65 BA TTERIES T o achieve 50% cycling you should calculate your Amp-hour consumption between charging cycles and use a battery bank with twice that capacity . T o calculate Amp-hour consumption first look at the rating plate on your AC appli- ance or tools. Each appliance or tool will be rated in either AC Amps or AC watt[...]

  • Page 16

    90-01 15-00 10/97 Fltman.pm65 Battery Charging Completely recharging wet cell deep- cycle 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 dete- riorat[...]

  • Page 17

    90-01 15-00 10/97 Fltman.pm65 BA TTER Y CHARGING NOTE: Fleet Power battery chargers are on whenever there is AC power connected to the charger input, regardless of the condi- tion 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 [...]

  • Page 18

    90-01 15-00 10/97 Fltman.pm65 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 gradu- ally ramps down. [...]

  • Page 19

    90-01 15-00 10/97 Fltman.pm65 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 re- charged), a small amount of sulfate is left on the[...]

  • Page 20

    90-01 15-00 10/97 Fltman.pm65 BA TTER Y CHARGING 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 [...]

  • Page 21

    90-01 15-00 10/97 Fltman.pm65 BA TTER Y CHARGER VOL T AGE SETTINGS 21 d n a e p y T y r e t t a B e r u t a r e p m e T / e g a t l o V k l u B e m i T x a M t a o l F e g a t l o V e z i l a u q E e g a t l o V l l e C t e W t l o V 2 1 e r u t a r e p m e T m r a W r h 1 / 0 . 4 11 . 3 18 . 5 1 l l e C t e W t l o V 2 1 e r u t a r e p m e T l o [...]

  • Page 22

    90-01 15-00 10/97 Fltman.pm65 INST ALLA TION PRECAUTIONS AC Output Remote Jack AC Inputs Chassis Ground Lug CAUTION T o reduce the risk of electric shock and prevent premature failure due to corrosion, do not mount where exposed to rain or spray . CAUTION T o prevent fire, do not obstruct ventilation openings. Do not mount in a zero clearance compa[...]

  • Page 23

    90-01 15-00 10/97 Fltman.pm65 INST ALLA TION 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[...]

  • Page 24

    90-01 15-00 10/97 Fltman.pm65 INST ALLA TION 15. If multiple battery banks are to be charged, a battery selector switch can be installed, allowing the banks to be charged either individually or simultaneously . A solenoid can also be used. 10. If installing in a system which in- cludes an existing battery charger or con- verter , make sure these do[...]

  • Page 25

    90-01 15-00 10/97 Fltman.pm65 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 con- nected to ground or the chassis of the u[...]

  • Page 26

    90-01 15-00 10/97 Fltman.pm65 INST ALLA TION 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 . connect in the same fashion as the AC input wires. If you are not connecting the hardwire output wires (Fleet Power 2000 only), make certai[...]

  • Page 27

    90-01 15-00 10/97 Fltman.pm65 INST ALLA TION 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[...]

  • Page 28

    90-01 15-00 10/97 Fltman.pm65 INST ALLA TION Fleet Power inverter/chargers are not protected against DC reverse polarity . Be very careful to connect the negative and positive cable correctly or damage will result and the warranty will be void. WARNING Recommended Fuse: Littlefuse Class T JLLN This fuse with fuse holder is available from your deale[...]

  • Page 29

    90-01 15-00 10/97 Fltman.pm65 INST ALLA TION OPTION 1 29 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 . T ake these things into consideration are: 1. When you unplug from shor[...]

  • Page 30

    90-01 15-00 10/97 Fltman.pm65 INST ALLA TION 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 thro[...]

  • Page 31

    90-01 15-00 10/97 Fltman.pm65 INST ALLA TION 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 pan[...]

  • Page 32

    90-01 15-00 10/97 Fltman.pm65 32 INST ALLA TION OPTION 4 (Dual AC Input) Fleet Power 2500 Only • 50 Amp 120 V olt Shore Power Service • Generator The transfer switch shown, switches, either manually or automati- cally , between generator and shore power . This switch is unrelated to the transfer switch inside the Fleet Power 2500. This AC panel[...]

  • Page 33

    90-01 15-00 10/97 Fltman.pm65 DC WIRING OPTIONS DC Wiring #1 - T wo 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. When charging, the battery switch is typically left in the "All" or "Both" positio[...]

  • Page 34

    90-01 15-00 10/97 Fltman.pm65 DC WIRING OPTIONS DC Wiring #3 - T wo 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 ba[...]

  • Page 35

    90-01 15-00 10/97 Fltman.pm65 TROUBLESHOOTING LED Number In di cat ion LED 1 Illumi nates if the unit sh uts do wn for any r eason. LED 2 Over-temperature. Allow to cool. LED 3 The u nit detec ted a fa ilure. Ca ll He art Inte rfac e Technica l Supp ort. LED 4 Inverter overload caused by too large a load or shor t circuit . Reset b y cycli ng pow e[...]

  • Page 36

    90-01 15-00 10/97 Fltman.pm65 TROUBLESHOOTING 1. Digital clocks either employ an internal time base or derive their time base from the incoming AC waveform. The frequency is usually well regulated at 60 Hz. The clock either counts the number of peaks in the waveform or the number of times the waveform crosses zero volts. The circuitry to count the [...]

  • Page 37

    90-01 15-00 10/97 Fltman.pm65 GLOSSAR Y 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 ., AH) [...]

  • Page 38

    90-01 15-00 10/97 Fltman.pm65 Power Sharing The ability of the charger to reduce its output when the AC power being consumed by the charger and external AC loads connected to the output of the inverter are in excess of the input breaker rating. V olt The unit of measure for electric potential. W att The unit for measuring electrical power , i.e., t[...]

  • Page 39

    90-01 15-00 10/97 Fltman.pm65 SPECIFICA TIONS 39 MODEL Nominal Battery V oltage Battery V oltage Range Low Battery Cutout AC Input V oltage Range Frequency Regulation Inverter Output Power (Continuous) Inverter V oltage Regulation Wave Shape Surge Power (15 seconds) Output AC Amps at rated load Input DC Amps Power Factors Allowed Full Load Efficien[...]

  • Page 40

    90-01 15-00 10/97 Fltman.pm65 W ARRANTY Y our Heart Interface Fleet Power Inverter/Charger is under limited warranty for a period of 12 months from date of purchase. T erms 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 servi[...]