Xantrex Technology 2500 User Manual

OWNER'S MANUAL  
FLEET POWER  
INVERTER/BATTERY CHARGERS  
FLEET POWER 1000  
FLEET POWER 2000  
FLEET POWER 2500  
U
®
C
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.  
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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  
Electronic Protection  
Charging Over-Discharged Batteries  
Power Sharing  
Power Switch  
Remote Control Programming  
Battery Charger Voltage Table . . . . . . . . . . 21  
Installation Precautions . . . . . . . . . . . . . . . 22  
Installation . . . . . . . . . . . . . . . . . . . . . . . 23  
Key Installation Points  
Location  
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  
Remote Control Panel . . . . . . . . . . . . . . . . . . 7  
Remote Power Switch  
System Status LEDs  
DC Volts Bargraph  
Grounding  
Neutral Bonding  
AC Wiring  
DC Amps Bargraph  
Dip Switches  
Ground Fault Circuit Interrupters  
Remote Control Wiring  
DC Wiring  
Equalize or 3-Stage Charging  
Battery Type  
Battery Cable Fusing  
Auto Range  
Power Sharing  
Dip Switch Status  
Remote Control Wiring  
Link 2000 Remote Control  
Installation Options . . . . . . . . . . . . . . . . . . 29  
DC Wiring Options . . . . . . . . . . . . . . . . . . . 32  
Troubleshooting . . . . . . . . . . . . . . . . . . . . . .34  
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . 36  
Specifications . . . . . . . . . . . . . . . . . . . 38  
Warranty . . . . . . . . . . . . . . . . . . . . . . 40  
Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . 10  
Dip Switch Programming . . . . . . . . . . 11  
Batteries . . . . . . . . . . . . . . . . . . . . 12  
Battery Types  
Battery Interconnection  
Battery Bank Ratings and Sizing  
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INTRODUCTION  
This owner's manual describes the  
Fleet Power Inverter/Chargers from Heart  
Interface. These units perform three distinct  
functions:  
Fleet Power Inverter/Chargers operate  
as self-contained backup power systems,  
just add batteries.  
1. DC to AC power inverting.  
• Fleet Power battery chargers are electroni-  
cally controlled and rated:  
2. Automatic transfer switching between  
inverter power and incoming AC power.  
3. Automatic 3-Stage Battery charging plus  
manual battery equalizing.  
FP 1000-12..................50 Amps DC  
FP 2000-12................100 Amps DC  
FP 2500-12................130 Amps DC  
4. AC to DC power converter.  
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, Accep-  
tance Charge and Float Charge. In addition,  
using the remote control, a manually-en-  
gaged Equalizing Charge cycle is possible.  
• 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  
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.  
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 mo-  
tors. High efficiency insures the longest  
possible battery life between recharges.  
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 mainte-  
nance is required.  
• 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 switch-  
ing back to the inverter.  
*Adustable with optional remote  
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THINGS YOU SHOULD KNOW  
The optional Fleet Power Remote  
Control Panel provides a power switch,  
on the units protect the incoming AC circuit  
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-  
ment of the following:  
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.  
• Manual Initiation of Equalize Charging  
• Ambient Battery Temperature  
• Battery Type  
• Charger Mode (Auto or Controlled)  
• Power Sharing  
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 over-  
load, recharge batteries or allow to cool.  
Reset by cycling the power switch OFF/ON.  
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.  
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 trip-  
ping. This feature can be adjusted using  
the remote control panel. This feature is set  
at the transfer rating of each unit by default.  
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 over-  
loads over 3600 watts. The 30 Amp circuit  
breaker protects the incoming AC leg which  
feeds the battery charger.  
INPUT  
INV/CHG  
GFCI  
The 30 Amp TRANSFER circuit breaker  
5
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.  
Power Switch  
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.  
Fleet Power 1000 shown.  
Inverter overload protection, transfer  
switching, power sharing and battery  
charger regulation will all function automati-  
cally.  
If installed with the remote control  
panel, the power switch on the unit should  
be left in the OFF position. Refer to Re-  
mote Control Panel, page 7.  
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REMOTE CONTROL PANEL  
An optional remote control panel is  
available which offers several features not  
Volts bargraph will stop indicating battery  
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 also display dip switch posi-  
current in inverter mode and DC output  
tions and shut down conditions.  
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  
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  
page 34.  
a remote control is used, the power switch  
on the inverter should be left in the OFF  
position.  
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 seg-  
ment 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  
The battery LED blinks when equaliz-  
ing. See page 18 for a discussion of the  
theory and procedure for battery equalizing.  
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 unit is  
operating. Following is a discussion of  
each adjustment. Refer to the table on  
page 11 for dip switch programming.  
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  
Warm Wet Cell  
Cool Gel Cell  
Warm Gel Cell  
< 80 degrees F.  
> 80 degrees F.  
< 80 degrees F.  
> 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 opera-  
tion. 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.  
BACK VIEW  
Fleet Power Remote Control Panel  
SWITCH 1 - Manual Equalizing Cy-  
cling 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 dam-  
age.  
SWITCH #5 & #6 - Not used for adjust-  
ments.  
SWITCH #7 & #8 - Power Sharing These  
switches should be set to match the value of  
the circuit breaker which protects the incom-  
ing AC power. They may also limit the  
output current from the battery charger.  
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.  
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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 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, how-  
ever, 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  
Sta tus LED  
Purp ose  
Powe r on light. It will be illumina te d whe ne ve r the  
p owe r switc h is on (inve rte r on) or whe n the re is  
incoming AC powe r a nd the cha rger come s on.  
INV/CHRG  
(Inve rte r/Cha rg  
Illumina te s whe n inc oming AC powe r ha s be e n  
a pplie d a nd the tra nsfe r re la ys ha ve e nga ge d.  
The re is a 7-12 se c ond de la y from the time the AC  
is a p p lie d a nd this LED illumina te s.  
AC Input  
Ste a dy  
Overloa d  
Indic a te s a n ove r-te mpe ra ture c ondition, the unit is  
shut down. It will re se t a utoma tic a lly a fte r c ooling.  
Inve rte r mode - Shutdown, dia gnose proble m using  
DC Amps ba r gra ph. Cha rge r mode - The rma l  
shutdown, a fte r c ooling re se t by c yc ling powe r  
switc h.  
Blinking  
Overloa d  
This is a Hig h/Low Ba tte ry wa rning c ond ition.  
Ste a dy Ba tte ry Inve rte r mod e : Ba tte ry > 15.25 or < 10.50 volts  
Cha rge r mode : Ba tte ry > 15.25 or < 10.00 volts  
Indic a te s e ithe r a shutd own or e qua lizing.  
Ba tte ry > 15.50 volts, will a uto-re se t a t 15.25.  
Inve rte r mod e : Ba tte ry < 10.00 volts, will a uto re se t  
a t c ha rge r floa t volta ge or upon AC input.  
Cha rge r mod e : Ba tte ry < 8.00 volts for 1 minute ,  
Blinking  
Ba tte ry  
re move a ll DC loa ds a nd ma nua lly re se t by c
disconnecting and reapplying shorepower.  
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DIP SWITCH PROGRAMMING  
Switc h  
Fe a ture  
Se t Point  
Numbe r  
1
Eq ua lize o r  
3 Sta ge  
Cha rging  
Toggle  
On/Off  
Equa lize (Do not le a ve on.)  
3 Sta ge Cha rging*  
Off  
2
3
On  
Off  
On  
Off  
4
On  
On  
Off  
Off  
Wa rm Ge l Ce ll (>80 d e g . F.)  
Ba tte ry  
Typ e  
Cool Ge l Ce ll  
(<80 d e g . F.)  
Wa rm We t Ce ll (>80 d e g . F.)  
Cool We t Ce ll (<80 d e g . F.)*  
Disa ble : Cha rge r re spond s to On/Off  
switc h.  
Auto  
Charge  
On  
Off  
Ena ble : Cha rge r on whe n AC  
connected.*  
5
6
Not use d.  
7
8
1 0 0 0  
2 0 0 0  
2 5 0 0  
5 Am ps  
On  
Off  
On  
Off  
On  
On  
Off  
Off  
2.5 Amp s  
5 Am ps  
Powe r  
Sha ring  
5 Amp s  
10 Amp s  
15 Amp s*  
15 Am ps  
20 Am ps  
30 Am ps*  
20 Am ps  
30 Am ps  
Disabled*  
*in dicates factory defau lt settin g.  
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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 storage compartment.  
Do not use car batteries or engine  
BATTERY TYPES  
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 bat-  
teries, suitable for either engine starting or  
deep-cycle applications, are a compromise  
and will give limited life if deeply dis-  
charged.  
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 perfor-  
mance and are available in a wide variety  
of sizes. Floor sweeper, fork lift or large 2  
Volt cells can also offer excellent perfor-  
mance, if their large size can be accommo-  
dated.  
Beware of 8-D starting batteries that  
are commonly used for starting diesel en-  
gines. These batteries are not deep-cycle.  
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BATTERIES  
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.  
The features of the gel cell batteries  
solve many common problems. Cycle life is  
high, even under constant deep discharg-  
ing.  
BATTERY INTERCONNECTION  
In most cases you will be using a bank  
of two or more batteries with your inverter/  
charger. You may connect batteries to-  
gether in two configurations, series and  
parallel.  
Gel Cell Batteries  
Gel cell batteries are lead-acid batter-  
ies similar in many ways to the common wet  
cell battery, but differences in the chemistry  
and construction provide some unique  
features.  
Series  
Connecting 2 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  
No Maintenance - There is no need to  
add water and the tops of the batteries stay capacity of the battery bank will be the  
clean. Also, the batteries can be used in  
any position and may be used without a  
battery box.  
same as each individual battery. Example,  
two 6 Volt 220 Amp-hour batteries in series  
will produce on 12 Volt 220 Amp-hour bat-  
tery bank.  
Low Self-Discharging - Unlike wet cell  
batteries, the gel cell will hold its charge for  
months if left sitting with no load and no  
float charge. They can be stored without a  
constant float charge and without fear of  
freezing.  
-
-
+
Low Internal Resistance - The result  
of low internal resistance is a higher battery  
voltage under load, which will result in  
better inverter performance on demanding  
high power loads. In addition, this allows  
the gel cell to accept a high rate of charge,  
a plus for rapid recharging.  
+
Series  
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BATTERIES  
Parallel  
Always use proper terminals for your  
interconnecting battery cables which are  
appropriate to handle the current.  
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.  
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  
Amps for 20 hours. If the discharge rate is  
greater than 5 Amps, the available Amp-  
hours are decreased. If the load is in-  
creased to 100 Amps, only about 45 Amp-  
hours will be available at this rate of dis-  
charge.  
+
+
-
-
Another common rating is reserve  
capacity expressed in minutes. This is  
derived by placing a 25 Amp load on the  
battery and measuring the time until the  
battery voltage reaches 10.5 Volts.  
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. 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.  
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 compro-  
mise between long battery life and a rea-  
sonably sized 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.  
To 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 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:  
Typical PowerCon su m pt ion  
Loads  
Wat t s  
On -Board Com pu ters  
Qu artz Halogen Flood  
0.2 HP Ben ch Grin der  
Ham m er Drill  
2 0 0  
3 0 0  
3 0 0  
5 0 0  
3/ 8" Electric Drill Motor  
Sawzall  
5 0 0  
5 0 0  
0.5 HP Ben ch Grin der  
1.0 HP Tile Saw  
7 5 0  
8 0 0  
0.5 HP Skil® Saw  
2.0 HP Radial Arm Saw  
2.5 HP Ch ain Saw  
Han d Blower/ Vacu u m  
Qu artz Halogen Flood  
11 gal. Air Com pressor  
Ch ain Saw  
20 gal. Air Com pressor  
10" Table Saw  
10" Miter Saw  
1200  
1200  
1200  
1450  
1500  
1600  
1700  
1800  
1800  
1800  
1800  
2000  
(AC Amps x 10) x 1.1 x hours of  
operation = DC Amp-hours  
(AC watts/12) x 1.1 x hours of operation  
= DC Amp-hours  
(AC VA/12) x 1.1 x hours of operation =  
DC Amp-hours  
Plan er  
Corin g System  
In all formulas, 1.1 is the factor for  
inverter efficiency.  
Many electric motors have momentary  
starting requirements well above their op-  
erational rating. Start up watts are listed  
where appropriate. Individual styles and  
brands of appliances may vary.  
Calculate the above for every AC  
appliance or tool you intend to use on your  
inverter. This will give you the total number  
of Amp-hours used between recharges.  
Size your battery bank using this number as  
a guideline. A good rule to follow is to size  
the battery bank about 2 times larger than  
your total Amp-hour load requirement. Plan  
on recharging when 50% discharged.  
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BATTERY CHARGING  
Battery Charging  
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  
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-  
rioration of the battery begins. The gassing suffer from another inherent characteristic of  
point will vary with battery temperature.  
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  
design, which is a tapering output. While  
they will deliver their rated current into a  
deeply discharged battery, as the battery  
becomes charged and the voltage rises, the  
output current of the charger tapers down.  
lower bulk charge voltage and a higher float This taper continues as the battery is  
voltage. Consult the battery manufacturer  
for specifications.  
charged, taking a very long time to reach an  
acceptable recharge.  
Conventional Battery Chargers  
Fleet Power Battery Chargers  
Most conventional battery chargers are  
single-stage constant voltage chargers.  
Fleet Power battery chargers are de-  
signed to overcome the limitations of con-  
They must stop short of the gassing point or ventional chargers by utilizing 3 distinct  
they will overcharge the battery bank.  
Therefore, most 12 volt battery chargers  
bring the battery voltage up to about 13.8  
Volts.  
stages, each designed for optimal recharg-  
ing of both wet cell and gel cell deep-cycle  
batteries.  
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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  
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  
Stage 1 - Bulk Charge During the bulk  
charge stage most of the charge current is  
delivered to the battery bank. This phase is  
engaged as soon as the battery charger is  
activated. Full rated charger current is  
charger will also be controlled by the On/Off delivered to the battery bank until the bulk  
switch.  
Each time the battery charger is en-  
charge voltage limit is reached. This results  
in a relatively rapid recharge.  
gaged, the 3 stages proceed automatically,  
resulting in an efficient, complete recharge  
and safe battery maintenance. Use of the  
remote control provides the ability to peri-  
odically apply an 8-hour timed equalizing  
charge.  
Generally, a wet cell battery bank  
should not be charged up to the gassing  
point at a rate which exceeds 25% of its  
capacity. In other words, a 12 volt battery  
bank of 520 Amp-hours should not be  
charged at over 130 Amps.  
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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  
the battery charger is available to operate  
any DC appliances that may be on the  
system, while constantly maintaining the  
float charge voltage.  
The battery charger remains in the float  
charge stage indefinitely until the charger is  
disconnected from incoming AC power.  
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. During this stage the  
battery is accepting its final amount of  
charge current and the last of the sulfate on  
the plates is removed.  
Stage 4 - Equalizing Charge This is  
the only battery charger stage which is not  
engaged automatically. It must be manually  
initiated each time it is necessary to equal-  
The acceptance stage lasts until the  
charge current reaches about 6-7 Amps. A  
timer will terminate the acceptance stage if  
this current level is not reached. This timer ize using a dip switch on the back of the  
is set automatically when the dip switches  
for battery type are set. Maximum accep-  
tance time is 1 hour for wet cells and 3  
hours for gel cells. Gel cell acceptance time  
remote control. Applying an equalizing  
charge is not possible without the use of a  
remote.  
Periodic equalizing is recommended by  
can be increased because the battery is not most wet cell deep-cycle battery manufac-  
gassing. Expect wet cell batteries to gas  
somewhat during acceptance, this is a  
necessary part of the charging process.  
turers. There are no firm rules for how often  
an equalizing charge should be applied, but  
once a month is a good rule of thumb for  
batteries which are regularly cycled, less  
often for systems in only occasional use.  
The equalizing charge is a timed, 8-  
hour cycle. If desired, it can be ended by  
interrupting the AC power to the charger at  
any time during the cycle. Equalizing  
should be engaged after the batteries have  
been fully charged by a normal battery  
Stage 3 - Float Charge When the  
acceptance stage is terminated, either  
because the charge current ramped down to  
6-7 Amps or the timer engaged, battery  
charger current will shut off. The unit moni-  
tors the battery voltage while it drifts down  
from the bulk charge voltage limit. When it  
reaches the float voltage set point, the float  
charge stage is engaged.  
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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  
bank to gas profusely and will accomplish  
the following:  
switches are set in one of the two gel cell  
positions, the equalizing charge voltage is  
the same as the bulk charge voltage, there-  
fore, equalizing is equivalent to an 8-hour  
acceptance stage and is not harmful.  
To limit the DC current during equaliz-  
ing to less than 15 Amps, turn on dip  
switches 7 and 8 before starting the equal-  
ize charge. Do not operate AC loads that  
are on the output of the inverter/charger  
when equalizing.  
1. Removal of residual sulfate. Each time  
a battery is cycled (discharged and re-  
charged), 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. By applying an equalizing  
charge, the sulfate is returned back to the  
electrolyte, raising the specific gravity and  
fully exposing the active material of the  
plates.  
Charging Over-Discharged Batteries  
Charging into a battery bank with a  
terminal voltage of less than 8 Volts pre-  
sents a special problem for the unit. If this  
situation arises, the unit will attempt to  
charge for 1 minute. If the inverter senses  
excessive ripple voltage, it will shut down to  
protect itself.  
2. Bring all cells to the same potential.  
All lead-acid batteries are made up of indi-  
vidual 2 Volt cells. As the battery bank is  
cycled, slight differences in the cells result  
in different cell voltages, affecting the over-  
all charge effectiveness. Equalizing brings  
all cells up to the same voltage and the  
electrolyte in each cell to the same specific  
gravity.  
To successfully charge an over-  
discharged battery, you must remove as  
much DC load as possible. Set dip  
switches 7 and 8 to the ON position to limit  
the amount of charge current and the result-  
ing ripple voltage. After the battery voltage  
has reached 10 Volts, these switches can  
be set to their previous positions.  
3. Mixing up of the electrolyte. Electro-  
lyte in battery cells tend to separate into  
layers of acid and water. The vigorous  
boiling action of the battery during equaliz-  
ing serves to physically mix the electrolyte.  
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BATTERY CHARGING  
Note: If a continuous DC load in ex-  
cess of the charge rate is placed on the  
battery bank, eventually the battery voltage  
will drop below 8 Volts and the battery  
charger will shut off. This load must be  
significantly reduced and the power to the  
charger cycled to resume charging.  
Blinking of the battery LED on the  
remote control while charging is a warning  
that an over-discharge is imminent and that  
the DC load should be reduced.  
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.  
NOTE: Equalize only after a regular  
charge cycle.  
3. Check and top off the battery elec-  
trolyte both before and after the  
equalizing charge. Do not expose the  
battery plates to air. Leave the battery  
caps on while equalizing.  
4. Remove all loads from the DC sys-  
tem before equalizing. Some DC loads  
may not tolerate the high charge voltage.  
5. Do not leave the equalize dip  
switch in the ON position. It must be  
cycled OFF and left in the OFF position.  
If left ON, the unit will engage the equal-  
izing cycle every time the battery charger  
is engaged.  
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BATTERY CHARGER VOLTAGE SETTINGS  
Battery Type and  
Temperature  
Bulk Voltage/  
Max Time  
Float  
Voltage  
Equalize  
Voltage  
12 Volt Wet Cell  
Warm Temperature  
14.0 / 1 hr  
14.4 / 1 hr  
13.8 / 3 hr  
14.1 / 3 hr  
13.1  
13.5  
13.3  
13.6  
15.8  
16.3  
13.8  
14.1  
12 Volt Wet Cell  
Cool Temperature  
12 Volt Gel Cell  
Warm Temperature  
12 Volt Gel Cell  
Cool Temperature  
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INSTALLATION PRECAUTIONS  
CAUTION Th is equ ipm en t is n ot ign i-  
t ion prot ect ed an d em ploys com po-  
n en ts th at ten d to produ ce arcs or  
sparks. To redu ce th e risk of fire or  
explosion s, do n ot in st all in com part -  
m en t s con t ain in g bat t eries or flam -  
m able m at erials or areas in wh ich  
ign ition -protected equ ipm en t is re-  
qu ired.  
CAUTION Risk of electrical shock. Both  
AC & DC voltage sources are terminated  
inside this equipment. Each circuit must  
be individually opened before servicing.  
CAUTION Risk of electrical shock. Do  
not remove cover, no user serviceable  
parts inside. Refer servicing to qualified  
service personnel.  
APPLICATION INFORMATION Provided  
with integral electronic protection  
against AC & DC overloads.  
WARNING  
For continued protection against risk of  
electric shock, use only the ground-  
fault circuit interrupter (GFCI) type  
receptacles detailed in this owner's  
manual. Other types may fail to operate  
properly when connected to this inverter,  
resulting in a potential shock hazard.  
AC In pu ts  
AC Ou tpu t  
Rem ote  
J ack  
CAUTION To reduce the risk of electric  
shock and prevent premature failure due to  
corrosion, do not mount where exposed  
to rain or spray.  
Ch assis  
Grou nd  
Lu g  
CAUTION To prevent fire, do not obstruct  
ventilation openings. Do not mount in a  
zero clearance compartment, overheating  
may result.  
Fleet Power 2500 shown.  
NOTICE The output of this device is not  
sinusoidal. It has a maximum total har-  
monic distortion of 47% and a maximum  
single harmonic of 34%.  
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INSTALLATION  
Key Installation Points  
DC cable is required. The AC wire size is  
dependant on potential current in the circuit.  
Consult the NEC (National Electric Code)  
for proper wire gauge.  
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.  
5. Keep the inverter/charger out of  
the elements and out of direct contact  
with water or spray. Remember that the  
unit is a piece of electronic equipment and  
treat it accordingly.  
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. Remem-  
ber that incoming AC must be fed only to  
the AC input and never to the AC output.  
Always check for AC voltage before con-  
necting wires to the AC output. Do NOT  
6. Mount the unit as close to the  
batteries as possible but not in the pres-  
ence of flammable fumes or in an enclosed  
battery compartment.  
7. The connectors for the remote  
control and the chassis ground bonding  
lug, as well as for the AC wires, are lo-  
cated on the bottom of the unit. Be sure  
to make these connections before bolting  
turn the inverter ON until all AC connections the unit down.  
have been made. Back-feeding the inverter  
8. You may mount the unit horizon-  
tally (on a shelf) or vertically (on a wall or  
voids the warranty.  
3. Do not connect the AC input to the bulkhead). If mounted vertically, you must  
AC output. In effect, this would be plug-  
ging the battery charger into the inverter.  
This could occur if the unit is connected to  
the entire leg of a circuit breaker panel, then  
a circuit breaker on that leg is used to feed  
the battery charger. This will cause the unit  
to oscillate ON and OFF when the unit is in  
inverter mode.  
orient the unit so the switch and the circuit  
breakers are facing up and the fan and  
battery cables are facing down.  
9. Allow several inches of clearance  
around the unit and allow for a supply of  
fresh air to the cooling fan. Do not block  
any of the vents or louvers. The fan pulls  
air from outside the unit. It blows air across  
the internal components, particularly the  
transformer and heat sinks, then out the  
side vents.  
4. Always use proper wire and con-  
nectors. The proper battery cable size is  
critical because considerable amperage  
flows in the DC circuit. Fusing the positive  
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INSTALLATION  
10. If installing in a system which in-  
cludes an existing battery charger or con-  
verter, make sure these do not operate  
from the inverter output AC power. This  
sets up a power loop which, due to ineffi-  
ciencies, will quickly drain the batteries.  
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.  
11. Make sure all wiring conforms to  
local and national electrical codes. If in  
doubt, consult with a qualified electrician.  
WARNING  
Do not mount the unit in an enclosed  
battery compartment. Take precautions  
to keep road dirt and spray off the unit.  
12. Keep the overall length of each  
battery cable less than 10 feet. If needed,  
attach short extension cables. Do not use  
frame ground or a ground bonding system  
as a current carrying conductor. Run the  
negative cable directly to the battery bank.  
If the positive and negative cables run  
parallel to each other, twist the cables  
together. This will minimize the adverse  
effects of inductance.  
Grounding  
For safety purposes, the chassis of  
the inverter/charger must be connected  
to your AC ground system. The chassis  
ground bonding lug is located on the bottom  
of the unit. This connector can accept two  
wires, the first is used to connect the unit to  
AC ground, the second can be used to  
connect other AC equipment to ground.  
Use bare copper insulated wire, solid or  
stranded. Strip one end and use a screw-  
driver to secure it to the chassis ground  
bonding lug. This wire will connect to the  
ground in your AC electrical system, typi-  
cally the vehicle chassis. Make sure the  
connection is clean and tight.  
13. To meet electrical codes, a fuse  
must be installed in the positive battery  
cable within 18 inches of the battery post.  
This fuse is intended to protect the battery  
and cables against a dead short circuit.  
The inverter is protected internally and will  
not blow a properly sized fuse.  
14. DC wiring is generally very simple,  
the positive and negative cables from the  
inverter/charger are connected to the house  
or auxiliary battery. In the case of multiple  
batteries the interconnecting jumper cables  
must be of the same AWG as those sup-  
plied with the inverter/charger.  
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INSTALLATION  
Output. Each side contains 3 pigtails:  
black, white and green. Six wire nut con-  
nectors are also provided.  
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.  
Black  
White  
Green  
Hot or Line  
Neutral  
Ground  
Note: The battery cables are not con-  
nected to ground or the chassis of the unit.  
Conventional metal strain reliefs are  
provided. These can be replaced by plastic  
strain reliefs for additional corrosion resis-  
tance or 3/4 inch conduit fittings if the wiring  
will be routed through the conduit.  
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. When  
incoming AC power is applied and the  
transfer switch is engaged, the internal  
neutral-to- ground bond is automatically  
lifted.  
This means that when the vehicle is  
connected to shore power, the grounding  
system is connected to the shore power  
ground, where neutral and earth ground are  
bonded together. This technique insures  
safety in all conditions and conforms to the  
requirements of the NEC.  
Use proper wire sizes according to the  
NEC.  
AC Input (Fleet Power 1000 and Fleet  
Power 2000): Feed the 3 conductor AC  
input wire through the strain relief and into  
the AC input compartment. You should  
have 6 inches of individually insulated  
black, white and green wire. Strip 1/2 inch  
of insulation off each conductor and connect  
to the pigtails: black to black, white to white  
and green to green.  
AC Input (Fleet Power 2500): There  
are 2 options for configuring the AC input to  
the Fleet Power 2500.  
AC Wiring  
Dual Inputs: The internal battery  
The AC wires route through the holes in  
the bottom of the unit. Use a screwdriver to  
remove the screws which secure the AC  
wiring compartment cover plate. Inside, the  
compartment is divided into 2 sections, one  
labeled AC Input, the other labeled AC  
charger may be fed separately from the  
transfer input which feeds the AC loads. In  
this case, connect one 30 Amp feed to the  
charger pigtails and another 30 Amp feed to  
the transfer switch input.  
Connecting the feeds in this way bal-  
ances the AC loads when 2 legs of incoming  
AC power are available. These two feeds  
can be in or out of phase. Transfer will only  
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INSTALLATION  
connect in the same fashion as the AC input  
wires.  
WARNING  
If you are not connecting the hardwire  
output wires (Fleet Power 2000 only), make  
certain they can not cause a short circuit to  
the wiring compartment. Tug firmly on each  
connection to make sure they are secure.  
Check these connections first if the unit is  
not operating properly.  
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.  
Carefully tuck the wires into the AC  
wiring compartment. Replace cover plate.  
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. In this case, connect both  
pigtails together, black to black, white to  
white and green to green.  
This allows up to 60 Amps of AC power  
to be brought in on a single cable. Up to 30  
Amps is available to the loads, with the  
balance available to power the battery  
charger. A single cable should be protected  
by a 60 Amp breaker or smaller, and 6  
gauge wire should be used.  
Ground Fault Circuit Interrupters  
In order to conform to the NEC, certain  
branch circuits must be equipped with a  
Ground Fault Circuit Interrupter (GFCI).  
Please consult the code or a qualified  
electrician for details. Any such branch  
circuit must be protected by a circuit  
breaker consistent with the GFCI rating.  
Underwriters Laboratories has tested the  
following GFCI, and its use is recom-  
mended. Receptacle Type:  
Pass & Seymour  
Catalog Number 1591-RW  
Rated: 15 Amps at 120 Volts AC  
Fleet Power 1000 and 2000 inverter/  
chargers provide an integral GFCI outlet  
which is protected by a circuit breaker. This  
GFCI outlet does not protect the hardwire  
AC output. The hardwire AC output is  
protected by a non-GFCI circuit breaker on  
the Fleet Power 2000 only. The first outlet  
from the hardwire output should be GFCI  
protected to comply with applicable codes  
and standards.  
AC Output: On the Fleet Power 1000,  
AC output is available at the GFCI outlet  
mounted on the unit. On the Fleet Power  
2000, AC output is available at both the  
GFCI outlet and at the AC output compart-  
ment. The AC output for the Fleet Power  
2500 is available at the AC output compart-  
ment only. When installing the Fleet Power  
2000 and 2500, feed the 3 conductor AC  
output wire through the strain relief and  
The GFCI Receptacle is designed to  
protect from line-to-ground shock hazards  
which could occur from defective power  
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INSTALLATION  
that power is off at the GFCI protected  
outlets. Push the RESET back in and  
reconnect the appliances one at a time. A  
defective appliance which trips the GFCI  
should be repaired at once.  
If the RESET button will not stay in  
after all appliances have been disconnected  
from the circuit, the GFCI outlet has failed.  
If the RESET button does not pop out  
when the TEST button is pressed, protec-  
tion is lost. Do not use.  
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.  
Test Reminder: For maximum protec-  
tion against electrical shock hazard, test  
your ground fault circuit interrupter at least  
once a month. Test procedure:  
1. Push TEST button. The RESET  
button will pop out. Power is now ON or  
shore power is ON indicating that the device  
is functioning properly.  
2. If RESET does not pop out when  
testing, do not use this circuit. Protection is  
lost.  
3. To restore power, push the RESET  
button.  
tools or appliances operating from this  
device. It does not prevent line-to-ground  
electric shock, but does limit the time of  
exposure to a period considered safe for a  
normally healthy person. It does not protect  
persons against line-to-line, or line-to-  
neutral faults.  
The GFCI Receptacle does not protect  
against short circuits or overloads. This is  
the function of the circuit breaker.  
Any line-to-ground fault condition  
indicated by a tripped GFCI must be cor-  
rected. Grounded fault conditions are  
dangerous to personnel and property.  
Should you identify conditions not described  
in these instructions, contact a qualified  
electrician.  
In the event of power failure which has  
not affected the breaker, unplug all cord-  
connected appliances and tools from the  
GFCI receptacle, and restore power by  
pressing in the RESET button on the GFCI  
receptacle. To test, press the TEST button.  
The RESET button will pop out indicating  
Remote Control Wiring  
The remote control is supplied with a  
25 or 50 foot section of telephone cable for  
connection to the unit. Simply plug one end  
of the cable into the remote connector on  
the bottom of the unit labeled remote and  
the other end into the connector on the back  
of the remote control panel.  
Routing the remote cable away from AC  
and DC wires will minimize the potential for  
interference which may affect the LED  
bargraphs.  
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INSTALLATION  
The remote control cable can be ex-  
tended up to 50 feet if required. Use stan-  
dard 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 interfer-  
ence.  
The negative cable should be con-  
nected directly to the negative post of the  
battery bank or the ground side of a current  
shunt. Do not use the vehicle frame as the  
negative conductor. Tighten securely.  
The positive battery cable must be  
fused and connected to the positive post of  
the battery bank, or through a selector  
switch to one or more battery banks.  
A spark may be generated when the  
final battery connection is made. This is  
normal and do not be alarmed, however, do  
not make the final connection in the pres-  
ence of flammable fumes.  
Once the above steps have been com-  
pleted the unit can be bolted down.  
DC Wiring  
Two battery cables are provided with  
the unit. Both are black, the positive cable  
has a piece of red heat shrink insulation on  
the end. High current will pass through the  
DC wiring. All wires must be properly sized  
and all connections clean and tight.  
It is recommended that the battery  
cables not be lengthened, however, it is  
possible to extend the cables if necessary.  
Extension cables must be 00 AWG or the  
same type of wire supplied with the unit, and  
the total length for each battery cable must  
not exceed 10 feet.  
Battery Cable Fusing  
A fuse is required by the NEC to pro-  
tect the battery and cables. The fuse must  
be installed in the positive battery cable,  
within 18 inches of the battery.  
Recommended Fuse: Littlefuse Class T JLLN  
This fuse with fuse holder is available from your  
dealer or Heart Interface.  
For Fleet Power 1000  
200 Amp Fuse & Holder  
200 Amp Fuse Only  
PN# 84-4158-00  
PN# 84-4157-00  
Make sure the connections to the ex-  
tension cables are tight and properly insu-  
lated. Do not attempt to open the case and  
replace battery cables.  
For Fleet Power 2000, 2500  
300 Amp Fuse & Holder  
300 Amp Fuse Only  
PN#84-4154-00  
PN#84-4151-00  
WARNING  
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.  
+ (red)  
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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 appli-  
ances 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. Power Sharing should be set for  
the same value as the input shore power  
breaker.  
3. If a converter or battery charger  
was originally wired into the system, it  
should be disconnected. Do not allow a  
converter/charger to operate on the in-  
verter power. This type of power loop will  
only discharge the batteries.  
4. Fleet Power 1000 has 15 Amp  
transfer only.  
5. Use the hardwire output for 30 Amp  
transfer on the Fleet Power 2000, and  
2500.  
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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 Installa-  
tion 1 apply to this installation.  
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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.  
A 30 Amp branch circuit breaker on the  
main panel feeds the AC input of the  
inverter/charger, and feeds the sub-panel  
through the inverter's internal transfer  
switch.  
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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 automati-  
cally, 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. Make sure the wiring between the AC  
panel and the inverter will safely carry two 30  
Amp circuits. Typically, a minimum of 10 AWG  
wires would be used. 6 each (2 hot, 2 neutral  
and 2 ground).  
Please note that the inverter AC output  
breakers are isolated from the main panel.  
Keeping the inverter loads isolated is  
important. Do not back feed the unit by supply-  
ing AC from shore or generator to the inverter  
AC output. Three inverter breakers are shown  
in the particular diagram. You are not limited to  
three breakers.  
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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.  
When charging, the battery switch is  
typically left in the "All" or "Both" position so  
that both batteries are charged. When  
using the inverter, the inverter battery  
should be selected with the battery switch.  
The inverter/charger's negative battery  
cable should be connected directly to the  
battery that will normally supply the inverter.  
A fuse should be installed in the positive  
cable within 18 inches of the battery. If the  
cables to the switch exceed 18 inches, each  
cable will require a fuse.  
DC Wiring #2 - Two Battery* System  
Using an Isolator for Charging both  
Batteries  
This allows charging of both batteries  
from an alternator, but the inverter can only  
draw power from the auxiliary battery. This  
prevents accidental discharge of the engine  
battery by the inverter. A paralleling sole-  
noid can be used in place of the isolator.  
* Each battery shown can represent  
a battery bank.  
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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.  
DC Wiring #4 - Three Batteries*  
Connected with Battery Switches  
This allows any combination of  
three battery banks to be charged  
by or selected to run the inverter.  
If both switches are on "all",  
then all batteries are in parallel.  
Batteries can be independently  
added to or removed from the  
system by selecting the  
appropriate switch position.  
* Each battery shown can  
represent a battery bank.  
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TROUBLESHOOTING  
LED  
Numbe r  
Indic a tion  
LED 1  
LED 2  
Illumina te s if the unit shuts d own for a ny re a son.  
Ove r-te mpe ra ture . Allow to c ool.  
The unit d e te c te d a fa ilure . Ca ll He a rt Inte rfa c e  
Te c hnic a l Sup port.  
LED 3  
LED 4  
LED 5  
LED 6  
LED 7  
Inve rte r ove rloa d c a use d by too la rge a loa d or  
short c irc uit. Re se t by c yc ling p owe r switc h or  
plugging in inc oming AC power.  
Ba tte ry ove rloa d c a use d by e xc e ssive ly disc ha rge d  
ba tte rie s. Re fe r to p a ge 40.  
Inc oming AC ba c kfe e d. Potentia lly da ma ging to the  
unit. Disconne c t incoming AC powe r a nd c orre ct  
the situa tion.  
Tria c the rma l run a wa y. Turn OFF a nd a llow to c ool  
down.  
High ba ttery volta ge shutdown during cha rge mode .  
Che c k a ll c ha rging sourc e s for prope r volta ge .  
Re se t by c yc ling the powe r switc h.  
LED 8  
LED 9-10  
Not use d for trouble shooting.  
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TROUBLESHOOTING  
Prob le m  
Thing s to Che c k  
1. Ba tte ry volta ge unde r loa d.  
2. Ba tte ry c onne c tions a nd DC fuse .  
3. Circ uit bre a ke r on front pa ne l.  
No Inve rte r  
Output  
4. The rma l c ondition, high powe re d loa d s or  
ina de qua te ve ntila tion ma y ca use ove rhe a ting.  
5. Ove rloa d s or short c irc uit, c he c k for e xc e ssive  
loa ds or ba d wiring c onne c tions.  
6. Re se t b utton oin GFCI outle t.  
Confirm tha t your volt me te r is a true RMS me te r.  
Sta nda rd volt me te rs will not a c c ura te ly re a d the  
wa ve form of the inve rte r a nd ma y re a d a nywhe re  
from 90 to 120 volts. If a true RMS me te r is not  
a va ila ble , c he c k the brightne ss of a n inc a nde sc e nt  
light bulb - if it a ppe a rs norma l, the output volta ge is  
prope rly re gula te d.  
Low Inve rte r  
Output Volta ge  
1. Wiring c onne c tions - c he c k both the AC a nd DC  
c onne c tions.  
Little or No  
Output from  
Ba tte ry  
2. AC input volta ge - low volta ge input will re sult in  
low DC output c urre nt. Expe c t re duc e d c ha rge r  
output from ge ne ra tors unde r 3,500 wa tts.  
3. AC re ve rse pola rity - c he c k for volta ge be twe e n  
the inc oming white a nd gre e n wire s. If 120 volts is  
me a sure d , this is re ve rse p ola rity.  
Cha rge r  
1. Mic rowa ve ove ns will norma lly c ook slow on  
inve rte rs due to a slightly low pe a k AC volta ge . 2.  
Cooking spe e d will be de te rmine d by ba tte ry  
volta ge . Low volta ge re sults in inc re a se d c ooking  
time . Support the ba tte ry ba nk with a n a lte rna tor or  
othe r c ha rging sourc e for quic ke r c ooking.  
Microwa ve  
Ove n Cooking  
Slow  
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 zero crossing events is more  
popular. The longer zero cross time of the  
inverter's modified sinewave may cause double  
clocking, resulting in a faster clock.  
Slow  
Digital  
Clock  
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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.  
first to the positive of the second, negative of  
the second to the positive of the third, etc. If  
two 6 volt batteries of 50 ampere-hours capac-  
ity are connected in series, the circuit voltage is  
equal to the sum of the two battery voltages, or  
12 volts, and the ampere-hour capacity of the  
combination is 50 ampere-hours.  
Ampere (Amp, A) The unit of measure of  
electron flow rate of current through a circuit.  
Circuit (Parallel) A circuit which provides more  
than one path for current flow. A parallel ar-  
rangement of batteries (of like voltage and  
capacity) would have all positive terminals  
connected to a conductor and all negative  
terminals connected to another conductor. If  
two 12 volt batteries of 50 ampere-hour capac-  
ity each are connected in parallel, the circuit  
voltage is 12 volts, and the ampere-hour capac-  
ity of the combination is 100 ampere-hours.  
Ampere-hour (Amp-Hr., AH) A unit of measure  
for a battery's electrical storage capacity, ob-  
tained by multiplying the current in amperes by  
the time in hours of discharge (Example: a  
battery which delivers 5 amperes for 20 hours  
delivers 5 amperes times 20 hours, or 100  
Amp-Hr. of capacity.)  
AH Capacity The ability of a fully charged  
battery to deliver a specified quantity of electric-  
ity (Amp-Hr., AH) at a given rate (Amp, A) over  
a definite period of time (Hr.). The capacity of a  
battery depends upon a number of factors such  
as: active material, weight, density, adhesion to  
grid, number, design and dimensions of plates,  
plate spacing design of separators, specific  
gravity and quantity of available electrolyte, grid  
alloys, final limiting voltage, discharge rate,  
temperature, internal and external resistance,  
age and life of the battery (bank).  
Current The rate of flow of electricity or the  
movement rate of electrons along a conductor.  
It is comparable to the flow of a stream of water.  
The unit of measure for current is ampere.  
Cycle In a battery, one discharge plus one  
recharge equals one cycle.  
Dip Switch A series of small switches used for  
special programming of the Fleet Power in-  
verter/charger. These switches are located on  
the back of the Fleet Power remote panel.  
AWG (American Wire Gauge) A standard  
used to measure the size of wire.  
Direct Current (DC) Current that flows continu-  
ously in one direction such as that from batter-  
ies, photovoltaics, alternators, chargers and DC  
generators.  
Circuit An electric circuit is the path of an  
electric current. A closed circuit has a complete  
path. An open circuit has a broken or discon-  
nected path.  
Circuit (Series) A circuit which has only one  
path for the current to flow. Batteries arranged  
in series are connected with the negative of the  
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GLOSSARY  
Equalize Charge A controlled overcharge of  
Power Sharing The ability of the charger to  
the batteries which brings all cells up to the  
reduce its output when the AC power being  
same voltage potential, extends the battery life, consumed by the charger and external AC  
restores capacity and mixes the electrolyte.  
loads connected to the output of the inverter  
are in excess of the input breaker rating.  
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.  
Volt The unit of measure for electric potential.  
Watt The unit for measuring electrical power,  
i.e., the rate of doing work, in moving electrons  
by or against an electric potential.  
GFCI (Ground Fault Circuit Interrupter) A  
protective device that rapidly de-energizes a  
circuit when current to ground exceeds a prede-  
termined value.  
Watt-Hour (Watt-HR, WH) The unit for measur-  
ing electrical energy which equals Watts x  
Hours.  
Ground The reference potential of a circuit. In  
automotive use, the result of attaching one  
battery cable to the body or frame which is used  
as a path for completing a circuit in lieu of a  
direct wire from a component. This method is  
not suitable for connecting the negative cable  
of the inverter to ground. Instead, route the  
cable directly to the negative terminal of the  
battery.  
Wet Cell Battery A type of battery that uses  
liquid as an electrolyte. The wet cell battery  
requires periodic maintenance; cleaning the  
connections, checking the electrolyte level and  
performing an equalization cycle.  
LED (Light Emitting Diode) Indicator light.  
Negative Designating or pertaining to electrical  
potential. The negative terminal is the point  
from which electrons flow during discharge.  
Ohm A unit for measuring electrical resistance.  
Ohm's Law Expresses the relationship be-  
tween Voltage (V), Current (I) in an electrical  
circuit with resistance (R). It can be expressed  
as follows: V=IR. If any two of the three  
values are known, the third value can be calcu-  
lated by using the above formula.  
Positive Designating or pertaining to electrical  
potential; opposite of negative. The positive  
battery terminal is the point where electrons  
return to the battery during discharge.  
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SPECIFICATIONS  
FP 1000-12  
12 VDC  
MODEL  
FP 2000-12  
FP 2500-12  
12 VDC  
Nominal Battery Voltage  
Battery Voltage Range  
Low Battery Cutout  
AC Input Voltage Range  
Frequency Regulation  
Inverter Output Power (Continuous)  
Inverter Voltage Regulation  
Wave Shape  
12 VDC  
10.0 - 15.5 VDC  
10 VDC  
10.0 - 15.5 VDC  
10 VDC  
10.0 - 15.5 VDC  
10 VDC  
90-130 VAC  
.05% @ 60 Hz  
1000 VA  
90-130 VAC  
.05% @ 60 Hz  
2000 VA  
90-130 VAC  
.05% @ 60 Hz  
2500 VA  
120V 5% True RMS  
+
+
+
120V 5% True RMS  
120V 5% True RMS  
-
-
-
Modified Sine Wave  
Modified Sine Wave  
Modified Sine Wave  
3000 VA  
8.33  
100  
Surge Power (15 seconds)  
Output AC Amps at rated load  
Input DC Amps  
4500 VA  
16.67  
200  
5200 VA  
20.83  
250  
All  
Power Factors Allowed  
Full Load Efficiency  
Peak Efficiency  
All  
All  
85%  
92%  
84%  
93%  
86%  
94%  
Circuit Breaker,  
Electronic, Thermal,  
High Battery, Low  
Battery, GFCI  
Protection  
Circuit Breaker,  
Electronic, Thermal,  
High Battery, Low  
Battery, GFCI  
Circuit Breaker,  
Electronic, Thermal,  
High Battery, Low  
Battery  
Yes  
Transfer Switch  
GFCI  
Yes  
Yes  
Yes  
Yes  
No  
50 Amps  
14.4 VDC*  
13.5 VDC*  
16.3 VDC*  
Yes 3'  
Charging Rate  
Bulk Charge Voltage  
Float Charge Voltage  
Equalizing Charge Voltage  
Battery Cables  
Hardwire  
100 Amps  
14.4 VDC*  
13.5 VDC*  
16.3 VDC*  
Yes 3'  
130 Amps  
14.4 VDC*  
13.5 VDC*  
16.3 VDC*  
Yes 3'  
No  
Yes  
Yes  
Optional Remote  
31 lbs.  
Status Panel  
Optional Remote  
52 lbs.  
Optional Remote  
56 lbs.  
Weight  
12" x 9.75" x 7"  
Dimensions  
12" x 11.5" x 8.75"  
12" x 11.5" x 8.75"  
FP1000-12 and FP2000-12 models are certified by UL to comply with FED spec-KKK-A1822, SAE spec-SAE-JRR1, for emergency vehicle  
application. All models are UL and C-UL Listed for Canadian use.  
*Indicates adjustable setting with the optional remote control.  
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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.  
Phone numbers:  
(253) 872-7225  
(800) 446-6180  
A return authorization number will be  
required on all returns. This number is  
issued by the service technician and should  
be written on the shipping box.  
You must ship the unit to Heart  
Interface or a field service center freight  
prepaid.  
Heart Interface Corporation  
21440 68th Ave. S.  
Kent WA 98032-2416  
(253) 872-7225  
®
Fleet Power  
by Heart Interface  
Fax (253) 872-3412  
Toll Free (800) 446-6180  
©1997 Heart Interface Corporation. All rights reserved.  
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