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Samlexpower Evolution EVO-1212F Owner's Manual

Evolution series inverter/charger pure sine wave
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Evolution
Series
TM
Inverter/Charger
Pure Sine Wave
Models:
EVO-1212F
EVO-1212F-HW
EVO-1224F
EVO-1224F-HW
Owner's
Please read this
manual BEFORE
Manual
operating.
Firmware:
Rev 0.74

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Summary of Contents for Samlexpower Evolution EVO-1212F

  • Page 1 Evolution Series Owner's Please read this manual BEFORE Manual Inverter/Charger operating. Pure Sine Wave Models: EVO-1212F EVO-1212F-HW EVO-1224F Firmware: EVO-1224F-HW Rev 0.74...

  • Page 2: Table Of Contents

    INVERTER/CHARGER MANUAL | Index SECTION 1 Safety Instructions & General Information ......3 SECTION 2 Components & Layout ............25 SECTION 3 Installation ................. 30 SECTION 4 General Description and Principles of Operation ....71 SECTION 5 Battery Charging in Evolution Series ........

  • Page 3: Safety Instructions & General Information

    SECTION 1 | Safety Instructions & General Information 1.1 IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS. THIS MANUAL CONTAINS IMPORTANT INSTRUCTIONS FOR MODELS: EVO-1212F, EVO-1212F-HW, EVO-1224F AND EVO-1224F-HW THAT SHALL BE FOLLOWED DURING INSTALLATION & MAINTENANCE OF THE INVERTER/CHARGER. THE FOLLOWING SYMBOLS WILL BE USED IN THIS MANUAL TO HIGHLIGHT SAFETY AND IMPORTANT INFORMATION: WARNING! Indicates possibility of physical harm to the user in case of non-compliance.
  • Page 4 SECTION 1 | Safety Instructions & General Information CAUTION! For indoors use only. WARNING! Hot Surfaces! To prevent burns, do not touch! CAUTION! The AC input / output wiring terminals are intended for field connection using Copper conductors that are to be sized based on 75°C. See Table 1.1 for sizing of conductors for AC INPUT circuits and Table 1.2 for sizing of conductors for AC OUTPUT circuits.
  • Page 5 SECTION 1 | Safety Instructions & General Information WARNING! Precautions When Working With Batteries. Lead Acid Batteries Batteries contain very corrosive diluted Sulphuric Acid as electrolyte. Precautions – should be taken to prevent contact with skin, eyes or clothing. Wear eye protection. Batteries generate Hydrogen and Oxygen during charging resulting in evolution of –...
  • Page 6 SECTION 1 | Safety Instructions & General Information Table 1.2 AC OUTPUT WIRING AND BREAKERS (Refer to Table 3.3 for more details) Model No. Rated AC Output NEC Ampacity = Wire Size based on NEC Breaker Size (Rated Power in Current in 125% of Column 2 Ampacity at Column 3...
  • Page 7 SECTION 1 | Safety Instructions & General Information MISE EN GARDE! MISE EN GARDE! Pour réduire les risques d’explosion, ne pas installer dans les locaux de machines ou dans la zone où l’équipement protégé contre les incendies doit être utilisé. ATTENTION! Cet appareil est conçu pour une installation PAS Météo-pont.
  • Page 8 SECTION 1 | Safety Instructions & General Information terminal de terre-câblage. Toutefois, ce symbole est utilisable avec le cercle omis pour identifier divers points de l’unité qui sont liés à la masse. Grounding Symbol / Défaut à la terre 15. MISE EN GARDE! Précautions lorsque vous travaillez avec des piles. Batteries au plomb Les piles contiennent très corrosif acide sulfurique dilué...
  • Page 9 SECTION 1 | Safety Instructions & General Information vector leads or lags the voltage vector in a sinusoidal voltage. In a purely inductive load, the current vector lags the voltage vector by Phase Angle (φ) = 90°. In a purely capacitive load, the current vector leads the voltage vector by Phase Angle, (φ) = 90°.
  • Page 10 SECTION 1 | Safety Instructions & General Information Maximum Continuous Running AC Power Rating: This rating may be specified as “Active Power” in Watts (W) or “Apparent Power” in Volt Amps (VA). It is normally specified in “Active Power (P)” in Watts for Resistive type of loads that have Power Factor =1. Reactive types of loads will draw higher value of “Apparent Power”...
  • Page 11 SECTION 1 | Safety Instructions & General Information Load: Electrical appliance or device to which an electrical voltage is fed. Linear Load: A load that draws sinusoidal current when a sinusoidal voltage is fed to it. Examples are, incandescent lamp, heater, electric motor, etc. Non-Linear Load: A load that does not draw a sinusoidal current when a sinusoidal voltage is fed to it.
  • Page 12 SECTION 1 | Safety Instructions & General Information The 120V output waveform of the Evolution series inverters is a Pure Sine Wave like the wave- form of Utility / Grid power. Please see Sine Waveform represented in the Fig. 1.1 that also shows equivalent Modified Waveform for comparison.
  • Page 13 SECTION 1 | Safety Instructions & General Information – Devices that use radio frequency signals carried by the AC distribution wiring. – Some new furnaces with microprocessor control / Oil burner primary controls. – High intensity discharge (HID) lamps like Metal Halide lamps. These may get damaged. Please check with the manufacturer of these types of devices for suitability.
  • Page 14 SECTION 1 | Safety Instructions & General Information TABLE 1.6 INVERTER SIZING FACTOR Inverter Sizing Factor Type of Device or Appliance (See Note 1) Air Conditioner / Refrigerator / Freezer (Compressor based) Air Compressor Sump Pump / Well Pump / Submersible Pump Dishwasher / Clothes Washer Microwave (where rated output power is the Cooking Power) Furnace Fan...
  • Page 15 SECTION 1 | Safety Instructions & General Information • Shield the DC side wires with metal sheathing / copper foil / braiding. • Use coaxial shielded cable for all antenna inputs (instead of 300 ohm twin leads). • Use high quality shielded cables to attach audio and video devices to one another. •...
  • Page 16 SECTION 1 | Safety Instructions & General Information NOTE: Voltage and Current scales are di erent Input voltage Peak Inrush Current Rated Steady State Input RMS Current Inrush current Fig 1.2 Inrush current in an SMPS Peak Current NOTE: Voltage and Non-linear Current scales Input Current...
  • Page 17 SECTION 1 | Safety Instructions & General Information 1.4.1 Deep Cycle Lead Acid Batteries Deep cycle batteries are designed with thick-plate electrodes to serve as primary power sources, to have a constant discharge rate, to have the capability to be deeply discharged to up to 80 % capacity and to repeatedly accept recharging.
  • Page 18 SECTION 1 | Safety Instructions & General Information 1.4.5 Specifying Charging / Discharging Currents: C-Rate Electrical energy is stored in a cell / battery in the form of DC power. The value of the stored energy is related to the amount of the active materials pasted on the battery plates, the surface area of the plates and the amount of electrolyte covering the plates.
  • Page 19 SECTION 1 | Safety Instructions & General Information Typical Flooded Lead-Acid Battery Chart - 80˚F / 26.7˚C 24V 12V 33.0 16.5 C/10 32.0 16.0 CHARGE C/20 31.0 15.5 C/40 30.0 15.0 29.0 14.5 28.0 14.0 27.0 13.5 26.0 13.0 C/100 C/20 25.0 12.5...
  • Page 20 SECTION 1 | Safety Instructions & General Information TABLE 1.9 BATTERY CAPACITY VERSUS RATE OF DISCHARGE – C-RATE C-Rate Discharge Current Usable Capacity (%) C/20 100% C/10 Table 1.9 shows that a 100 Ah capacity battery will deliver 100% (i.e. full 100 Ah) capacity if it is slowly discharged over 20 Hours at the rate of 5 Amperes (50W output for a 12V inverter and 100W output for a 24V inverter).
  • Page 21 SECTION 1 | Safety Instructions & General Information Check the individual cell voltages / specific gravity. If the inter-cell voltage difference is more than a 0.2V, or the specific gravity difference is 0.015 or more, the cells will require equalization. Please note that only non-sealed / vented / flooded / wet cell batteries are equalized.
  • Page 22 SECTION 1 | Safety Instructions & General Information TABLE 1.11 TERMINAL VOLTAGE AND SOC OF LOADED BATTERY Discharge Terminal Voltage at 80% State of Terminal Voltage When Completely Current: Discharge (20% SOC) Discharged (0% SOC) C-Rate C/3 A 10.45V 20.9V 09.50V 19.0V C/5 A...
  • Page 23 SECTION 1 | Safety Instructions & General Information 1.4.12 Depth of Discharge of Battery and Battery Life The more deeply a battery is discharged on each cycle, the shorter the battery life. Using more batteries than the minimum required will result in longer life for the battery bank. A typical cycle life chart is given in the Table 1.12 below: TABLE 1.12 TYPICAL CYCLE LIFE CHART Depth of Discharge...
  • Page 24 SECTION 1 | Safety Instructions & General Information Now, the capacity of the batteries is determined based on the run time and the usable capacity. From Table 1.9 “Battery Capacity versus Rate of Discharge”, the usable capacity at 3 Hour discharge rate is 60%.

  • Page 25: Components & Layout

    SECTION 2 | Components & Layout LAYOUT 2.1 LAYOUT OF EVO-1212F AND EVO1224F – FRONT VIEW 1 2 3 4 5 6 7 8 RJ-45 Jack – Layout of Pins Black Fig 2.1 Layout of Front side EVO-1212F / EVO-1224F LEGEND for Fig 2.1 1.
  • Page 26 SECTION 2 | Components & Layout 2.2 LAYOUT OF EVO-1212F / 1212F-HW AND EVO-1224F / 1224F-HW – BACK VIEW Fig 2.2 Layout of Back Side - EVO-1212F / 1212F-HW and EVO-1224F / 1224F-HW LEGEND for Fig 2.2 1. Air outlet vents for 2 variable speed, temperature controlled cooling fans (fans are not shown). 2.3 LAYOUT OF EVO-1212F-HW AND EVO-1224F-HW –...
  • Page 27 SECTION 2 | Components & Layout LEGEND for Fig 2.3 Battery Positive (+) Input Connector (marked "BATTERY POSITIVE"): Stud and Nut, M8 (Pitch 1.25mm) • 1a Red Protective Cover for Battery Positive (+) Input Connector – mounted using 2 pcs of M3 (Pitch 0.5mm) x 10mm long screws Battery Negative (-) Input Connector (marked "BATTERY NEGATIVE"): Stud and Nut, M8 (Pitch 1.25) •...
  • Page 28 SECTION 2 | Components & Layout 2.4 REMOTE CONTROL EVO-RC-PLUS Fault Fig 2.4(a) Optional Remote Control EVO-RC-PLUS LEGEND for Fig 2.3 LCD Screen: - 4 rows of 20 characters each - Blue screen with white characters ON/OFF Key Blue LED “Status” Red LED “Fault”...
  • Page 29 SECTION 2 | Components & Layout 2.5 BATTERY TEMPERATURE SENSOR EVO-BCTS [FIG 2.5 (a)] Temperature Sensor [Negative Temperature Coefficient (NTC) resistor]: Mounting hole: 10mm/0.39” suitable for 3/8” or 5/16” battery studs RJ-45 Plug: Pin 4 Ò + NTC ; Pin 5 Ò – NTC 5 meter/16.5 ft cable Note: Mount the sensor on the Positive or Negative terminal stud on the battery as shown in Fig 2.5(b)

  • Page 30: Installation

    SECTION 3 | Installation 3.1 SAFETY OF INSTALLATION WARNING! Please ensure safety instructions given under Section 1 are strictly followed. MISE EN GARDE! Se il vous plaît assurer consignes de sécurité fournies à la section 1 sont strictement suivies. 3.2 OVERALL DIMENSIONS The overall dimensions and the location of the mounting holes are shown in Fig.
  • Page 31 SECTION 3 | Installation 3.3 MOUNTING OF THE UNIT In order to meet the regulatory safety requirements, the mounting has to satisfy the following requirements: • Mount on a non-combustible material • The mounting surface should be able to support a weight of at least 60 Kg / 132 lbs. Use 4 pcs of 1/4"...
  • Page 32 SECTION 3 | Installation • Mounting Arrangement No. 2: Mount horizontally on a vertical surface (like a wall). Please see Fig. 3.3. Fig 3.3 Mounting Arrangement 2: On Vertical Surface • Mounting Arrangement No. 3: Mount vertically on a vertical surface, see Fig. 3.4. Protect against possibility of small objects or water entering the ventilation openings on the top.
  • Page 33 SECTION 3 | Installation 3.4 INSTALLING BATTERIES - SERIES AND PARALLEL CONNECTION Batteries are normally available in voltages of 2V, 6V and 12V and with different Ah capacities. A number of individual batteries can be connected in series and in parallel to form a bank of batteries with the desired increased voltage and capacity.
  • Page 34 SECTION 3 | Installation 3.4.3 Series – Parallel Connection 12V String 1 12V String 2 Battery 1 Battery 2 Battery 3 Battery 4 Cable “A” 12V Inverter or 12V Charger Cable “B” Fig. 3.7 Series-Parallel Connection Figure 3.7 shows a series – parallel connection consisting of four 6V, 200 Ah batteries to form a 12V, 400 Ah battery bank.
  • Page 35 SECTION 3 | Installation of the first battery (Battery 1 as in Fig. 3.6) or to the Negative Post of the first battery string (Battery 1 of Battery String 1 as in Fig 3.7), the following abnormal conditions will result: - The resistances of the connecting cables will not be balanced.
  • Page 36 SECTION 3 | Installation 3.5 DC SIDE CONNECTIONS Black Fig 3.8 DC Side Connections LEGEND for Fig 3.8 Battery Positive (+) Input Connector (marked "BATTERY POSITIVE"): Stud and Nut, M8 (Pitch 1.25 mm) (RED Protection Cover 1(a) is removed) 1a. RED Protection Cover For Battery Positive (+) Input Connector Battery Negative (-) Input Connector (marked "BATTERY NEGATIVE"): Stud and Nut, M8 (Pitch 1.25 mm) (Black Protection Cover 2(a) is removed) 2a.
  • Page 37 SECTION 3 | Installation 3.5.1 Preventing DC Input Over Voltage It is to be ensured that the DC input voltage of this unit does not exceed 17 VDC for the 12V battery version EVO-1212F / EVO-1212F-HW, and 34 VDC for the 24V battery versions EVO-1224F and EVO-1224F-HW to prevent permanent damage to the unit.
  • Page 38 SECTION 3 | Installation temperature rating of its insulation. The insulating material of the cables will also be affected by the elevated operating temperature of the terminals to which these are connected. Ampacity of cables is based on UL-1741 and the National Electrical Code (NEC)- 2014.
  • Page 39 SECTION 3 | Installation Les conducteurs sont protègés par des matériaux isolants classés pour une température spécifique, par exemple,une température de 90˚C/194˚F. Le flux de courant produit de la chaleur et affecte l’isolation. Alors, il y a une valeur de courant maximale (aussi appellé « L’ampacité ») qui est permise pour chaque taille de conducteur et pour la classification température de l’isolation.
  • Page 40 SECTION 3 | Installation WARNING! It is mandatory to use appropriately sized external fuse in the battery and External Charger Circuits. If external fuse is not used and reverse polarity connection is made by oversight, the input section of the unit will be damaged/burnt. Warranty will be voided in such a situation.
  • Page 41 SECTION 3 | Installation NOTES FOR TABLE 3.1 - SIZING OF BATTERY SIDE CABLES AND EXTERNAL BATTERY SIDE FUSES 1) Column 2 indicates the Rated Continuous DC Input Current drawn from the battery in Inverter Mode 2) Column 3 indicates NEC Ampacity based on which cable conductor sizes (Columns 4 to 7) are determined.
  • Page 42 SECTION 3 | Installation 3.5.9 Taping Battery Wires Together To Reduce Inductance Do not keep the battery wires far apart. Keep them taped together to reduce their inductance. Reduced inductance of the battery wires helps to reduce induced voltages. This reduces ripple in the battery wires and improves performance and efficiency.
  • Page 43 SECTION 3 | Installation As soon as the Inverter is switched OFF and 120 VAC is removed from the internal Line Side of the GFCI, Red LED marked “Life End Alarm” (10c in Figs 2.1 and 3.9.1) will flash once and then will remain OFF.
  • Page 44 SECTION 3 | Installation 3.6.2 AC Input and Output Connections and Layout Arrangement for EVO-1212F-HW and EVO-1224F-HW AC input and output connections for EVO-1212F-HW and EVO-1224F-HW are shown in Figs 3.9.2(a) and 3.9.2(b) below. (Extracted from the layout at Fig 2.3). 2 holes (27.8 mm / 1 3/ "...
  • Page 45 SECTION 3 | Installation Earth Ground through the Neutral to Earth Ground bond in the AC Breaker Panel/ Load Center supplying Grid power / AC output connections of the generator. • Disabling Neutral to Ground Bond: In some applications, the Output Neutral may be required to remain isolated from chassis/Ground at all times.
  • Page 46 SECTION 3 | Installation additional AC source should first be fed to a suitable Manual/Automatic Transfer Switch and the output of the transfer switch should be connected to the electrical breaker panel / load center. To prevent possibility of paralleling and severe damage to the inverter, never use a simple jumper cable with a male plug on both ends to connect the AC output of the inverter to a handy wall receptacle in the home / RV.
  • Page 47 SECTION 3 | Installation 3.7.2 AC Input / Output Supply Connectios – EVO-1212F-HW / EVO-1224F-HW WARNING! Please ensure that when using the hard-wired version EVO-1212F/1224F- HW, the AC input is connected to the AC input terminals and not to the AC output terminals and that this connection is made only when the unit is in OFF condition.

  • Page 48: Section 4

    SECTION 3 | Installation the set screw. Insert the bare end of the wire into the barrel portion of the Wire End Terminal & crimp barrel portion using suitable crimping tool (Fig 3.11). Use #12 AWG terminals for AWG #12 wiring for AC input and AWG #14 terminals for AWG #14 wiring for AC output. Insert the terminated end of the wire fully into the terminal slot till it stops.

  • Page 49: Section 4

    SECTION 3 | Installation TABLE 3.2 SIZING OF AC INPUT WIRING AND BREAKERS Model No. Maximum AC Input NEC Ampacity = 125% Conductor Size Based Size of Breaker (Rated Output Power Current Limit (Parameter of Column 2 on NEC Ampacity based on Column 4 in Inverter Mode) "GRID MAX CURRENT")
  • Page 50 SECTION 3 | Installation 3.9 SIZING OF AC OUTPUT WIRING AND BREAKERS 3.9.1 EVO-1212F and EVO-1224F 120 VAC output is supplied through NEMA5-15 Duplex GFCI Outlets (15, Fig 2.1). The outlets are protected against over current through 15A Circuit Breaker (14, Fig 2.1). Use power cord with NEMA5-15 plug and conductor size AWG #14.
  • Page 51 SECTION 3 | Installation NOTES FOR TABLE 3.3 - AC OUTPUT WIRING AND BREAKERS 1) Column 2 indicates the Rated AC Output Current in Inverter Mode 2) Column 3 indicates NEC Ampacity based on which the output-wiring conductor is sized. This NEC Ampacity is not less than 125% of the Rated Output Current in Inverter Mode (Column 2).
  • Page 52 SECTION 3 | Installation chassis in an RV / motorhome / caravan. When this energized exposed surface is touched, the voltage will drive current through the body to Earth Ground producing electric shock. When properly grounded to Earth Ground (or Frame / Chassis Ground in motorhome or caravan), the Leakage Current Protection Device (like RCD, GFCI etc.) or Over Current Protection Device (like Circuit Breaker or Fuse) will trip and interrupt the circuit feeding power from the AC source (EVO...
  • Page 53 SECTION 3 | Installation ATTENTION! Selon le « American Boat and Yacht Council » (ABYC) la norme E-11 pour le système électrique CA et CC des bateaux, la taille du fil de mise à la terre du côté CC ne doit pas être inférieure à un format sous celle requise pour les conducteurs tenant le courant pour alimenter l'appareil.
  • Page 54 SECTION 3 | Installation 3.14 AC SIDE GROUNDING 3.14.1 AC Side Grounding Requirements for Generators Small portable generators supplied with receptacles will often have the Neutral conductor bonded to the generator frame. The frame of portable generator is normally isolated from the Earth Ground. Larger generators typically do not have the Neutral grounded to the frame.
  • Page 55 SECTION 3 | Installation 3.14.2.2 EVO-1212F-HW and EVO-1224F-HW: AC Side Grounding of Typical Shore Based Installation Refer to the Installation Diagram for Typical Shore Based Installation for EVO-1212F-HW and EVO-1224F-HW at Fig 3.13 (a) AC Input Grounding: The metal chassis of EVO gets bonded to the Grounding Electrode (GE) / “Ground Rod”...
  • Page 56 SECTION 3 | Installation • The Grounding Bus Bar (G-B) in the Electrical Panel of the RV / vehicle is bonded to the RV / Vehicle Chassis Ground. When the RV / vehicle is connected to the Grid through the Grid Power Inlet and Cord, the RV / Vehicle Chassis Ground gets bonded to the Earth Ground of the premises through the Grounding Electrode (GE) / “Ground Rod”...
  • Page 57 SECTION 3 | Installation • The metal chassis of the AC load(s) is connected to the Grounding Bus Bar (G-B) of the Electrical Sub Panel for EVO Output • Grounding Bus Bar (G-B) of the Electrical Sub Panel for EVO Output is connected to metal chassis of EVO through the “OUTPUT GND”...

  • Page 58: Section 4

    SECTION 3 | Installation 3.15 BATTERY TEMPERATURE SENSOR FOR LEAD ACID BATTERIES Lead Acid Battery charging voltages are required to be compensated based on the temperature of the battery cells. Hence, Battery Temperature Sensor Model EVO-BCTS has been provided. Please see constructional and fitment details at [Fig 2.5(a)] and [Fig 2.5(a)] respectively. The sensor head contains a Negative Temperature Coefficient (NTC) Resistor with 2 output wires: “NTC+”...
  • Page 59 SECTION 3 | Installation • EVO in Charging Mode: The charging will stop (charging current will be reduced to 0A). The 2nd Line of the Charging Mode Screens shown in the Menu Map for Charging Mode Screens (Fig 3.7 in EVO-RC Plus Manual) will show “Charger Off by BMS” as shown in example below for Screen No.
  • Page 60 SECTION 3 | Installation 3.17 SHORE BASED INSTALLATION 3.17.1 Typical Shore Based Installation Fig. 3.12 illustrates a typical shore based installation for EVO-1212F / EVO-1224F. Fig 3.13 il- lustrates typical shore based installation for EVO-1212F-HW / EVO-1224-HW. Battery is connected to the DC input connections through DC Electrical Panel with an ap- —...
  • Page 61 SECTION 3 | Installation SAMLEX AMERICA INC. | 61...

  • Page 62: Section 4

    SECTION 3 | Installation LEGEND for Fig 3.12 NOTE: For sizing of wiring and fuses, refer to the following: (a) DC side wiring: Table 3.1 (b) AC side wiring: Table 3.2 Line Terminal L-B. Line Bus Bar Neutral Terminal N-G. Neutral to Ground Bond N-B.
  • Page 63 SECTION 3 | Installation SAMLEX AMERICA INC. | 63...

  • Page 64: Section 4

    SECTION 3 | Installation LEGEND for Fig 3.13 NOTE: For sizing of wiring and fuses, refer to the following: (a) DC side wiring: Table 3.1 (b) AC side wiring: Table 3.2 for AC input and Table 3.3 for AC output. Line Terminal L-B.
  • Page 65 SECTION 3 | Installation 3.18 MOBILE INSTALLATION - GENERAL INFORMATION 3.18.1 GFCI Protection for Vehicle Application When EVO-1212F-HW / EVO-1224F-HW is installed in vehicles, it is to be ensured that Ground Fault Circuit Interrupter(s) [GFCI] are installed in the vehicle wiring system to protect all branch circuits.
  • Page 66 SECTION 3 | Installation • For EVO-1224F / EVO-1224-HW: The maximum continuous DC current required is 76A. The capacity of the Battery Isolator should be more than 76A or more than the capacity of the alternator, whichever is higher. 3.18.3 Requirement to Keep the Neutral Conductor of Shore Power Isolated From the Chassis Ground of the RV As explained in on-line White Paper titled “Grounded Electrical Power Distribution Sys- tem”...
  • Page 67 SECTION 3 | Installation SAMLEX AMERICA INC. | 67...

  • Page 68: Section 4

    SECTION 3 | Installation LEGEND for Fig 3.14 NOTE: For sizing of wiring and fuses, refer to the following: (a) DC side wiring: Table 3.1 (b) AC side wiring: Table 3.2 Line Terminal L-B. Line Bus Bar Neutral Terminal N-G. Neutral to Ground Bond N-B.
  • Page 69 SECTION 3 | Installation SAMLEX AMERICA INC. | 69...

  • Page 70: Section 4

    SECTION 3 | Installation LEGEND for Fig 3.15 NOTE: For sizing of wiring and fuses, refer to the following: (a) DC side wiring: Table 3.1 (b) AC side wiring: Table 3.2 for AC input and Table 4.3 for AC output. Line Terminal L-B.

  • Page 71: General Description And Principles Of Operation

    SECTION 4 | General Description & Principles of Operations 4.1 GENERAL DESCRIPTION is a Pure Sine Wave, Bi-directional, Single-Phase Inverter / Charger with a Transfer Relay that operates either as an inverter OR as a smart battery charger. It uses a common Converter Section that can work in two directions –...
  • Page 72 SECTION 4 | General Description & Principles of Operations When the unit powers up, it starts in Inverting Mode first. The output voltage ramps up gradually from around 48 VAC to 120 VAC in around 200 ms. This reduces otherwise very high starting inrush current drawn by AC loads like Switched Mode Power Supplies (SMPS) and motor driven loads like fans, pumps, compressors etc.
  • Page 73 SECTION 4 | General Description & Principles of Operations carrying conductor of the Inverter Section (connected to the output terminal) will become the Grounded Conductor (GC) or the Neutral of the Inverter Section. • When in Charging Mode, the Neutral conductor of the Grid power/Generator will be con- nected to the Output Neutral terminal of EVO .
  • Page 74 SECTION 4 | General Description & Principles of Operations When Grid / Generator input power fails, Relay RY2 (Fig 4.1) will be de-energized and contact 4 switches back to contact 3. Neutral output from the Inverter Section is fed the Neutral of the Bi-directional Transformer and onwards to the output Neutral (OUTPUT N) for powering the AC loads.

  • Page 75: Section 5

    SECTION 4 | General Description & Principles of Operations synchronized with the AC input source. This synchronization process takes few seconds. Once synchronization is completed, the load is transferred instantly (within 1 ms) to the AC input source at Zero Crossing of the voltage waveform for seamless transfer and for better protection of Transfer Relay contacts.
  • Page 76 SECTION 4 | General Description & Principles of Operations Normal Mode is around 20W. The EVO has a provision to minimize this “No Load Power Draw”, if required (Applicable only when the unit is in “Inverter Mode”). This is achieved by enabling the “Power Saving Mode”.
  • Page 77 SECTION 4 | General Description & Principles of Operations The EVO is able to operate in 3 modes – Normal (Off-line), On-line and Charger Only Modes. Normal (Off-line) Mode is the Default Mode. Mode can be changed to Online Mode or Charger Only Mode through optional Remote Control Model EVO-RC-PLUS (Please see Section 4.4.2.13 in the Owner’s Manual for EVO-RC-PLUS).

  • Page 78: Section 5

    SECTION 4 | General Description & Principles of Operations Online Mode is suitable for installations where both Grid and Photovoltaic (PV) Solar Battery Charging System are available. It is also desirable in areas where Grid / Utility Energy Rates are very high and use of supplementary battery based photovoltaic power system is more cost effective.
  • Page 79 SECTION 4 | General Description & Principles of Operations 4.9 COOLING AND OVER TEMPERATURE PROTECTION 4.9.1 Cooling Fans The unit is cooled by convection and by forced air cooling using 2 variable speed cooling fans. Temperature is sensed at the Power Transformer and H-Bridge Power Mosfets / Heat Sink. The fans will be switched ON at specified temperatures measured at the above sense points.

  • Page 80: Battery Charging In Evolution

    SECTION 5 | Battery Charging in Evolution Series 5.1 PRINCIPLE OF OPERATION OF BATTERY CHARGING SECTION Series is a Bi-directional Inverter / Charger with a Transfer Relay that operates either as an inverter OR as a battery charger. It uses a common Converter Section that can work in two directions –...
  • Page 81 SECTION 5 | Battery Charging in Evolution Series “GRID MAX CURRENT” (Default = 20A) should be set equal to the Ampere rating of the exter- nal Grid / Generator supply breakers. During Battery Charging Mode, if the AC pass through load current is increased resulting in the net AC input current increasing to a value more than the programmed “GRID MAX CURRENT”, the EVO will automatically reduce the charging...
  • Page 82 SECTION 5 | Battery Charging in Evolution Series 5.3 ADAPTIVE CHARGING CONTROL FOR LEAD ACID BATTERIES WITH NO EXTERNAL DC LOAD ON THE BATTERIES 6 programmable "CHARGING PROFILES" are available (See Section 5.6 and Table 5.2). For charging Lead Acid Batteries that do not have external DC loads connected to them, op- tion is available for an automatic Adaptive Charging Algorithm to ensure that the battery is completely charged in a safe manner for longer battery life.

  • Page 83: Section 6

    SECTION 5 | Battery Charging in Evolution Series For example, if the “BULK CURRENT” in the EVO is programmed at say 40A and the external So- lar Charge Controller is generating 15A, the internal Battery Charging Section will reduce its current from 40A to 25A so that the net charging current is equal to the programmed value of 40A.
  • Page 84 SECTION 5 | Battery Charging in Evolution Series Details of the 6 programmable charging profiles are given in TABLE 5.2 below. CAUTION! The Battery Management System (BMS) that comes with the type of Lithium Battery being used may need to have control over charging and discharging of the battery. For this, Pins 4 and 5 of the temperature Sensor Jack (6, Fig 4.1) may be used to feed potential free contact closing signal from the BMS to “Stop Charging”...
  • Page 85 SECTION 5 | Battery Charging in Evolution Series TABLE 5.2 BATTERY CHARGER SECTION – CHARGING PROFILE OPTIONS AND CHARGING STAGES (CONTINUED) Options under Battery Type and battery Parameter Charging Stages loading condition "CHARGING PROFILE" 1 = 3 Stage Type 1 1.
  • Page 86 SECTION 5 | Battery Charging in Evolution Series TABLE 5.2 BATTERY CHARGER SECTION – CHARGING PROFILE OPTIONS AND CHARGING STAGES (CONTINUED) Options under Battery Type and battery Parameter Charging Stages loading condition "CHARGING PROFILE" 3 = 2 Stage Type 1 1.
  • Page 87 SECTION 5 | Battery Charging in Evolution Series TABLE 5.2 BATTERY CHARGER SECTION – CHARGING PROFILE OPTIONS AND CHARGING STAGES (CONTINUED) Options under Battery Type and battery Parameter Charging Stages loading condition "CHARGING PROFILE" Equalize -4 Stages 1. Bulk Stage: Charge at constant current - Lead Acid: Flooded ONLY.
  • Page 88 SECTION 5 | Battery Charging in Evolution Series 5.7.1.1 Bulk Charge Stage In the first stage, known as the "BULK" Charge Stage, the charger delivers the maximum "BULK CURRENT" (“Io”) that has been programmed using optional Remote Control EVO-RC-PLUS (Refer to Section 4.4.2.1 of EVO-RC-PLUS manual).
  • Page 89 SECTION 5 | Battery Charging in Evolution Series When the unit enters Charging Mode, it starts working as a battery charger and the charger will run at full programmed "BULK CURRENT" until the charger reaches the programmed threshold of "ABSORP VOLTAGE". For Adaptive Charging Profile Options (i) 0=3 Stage Adaptive and (ii) Equalize - 4 Stages (1=Yes) [See Table 5.2], a software timer will measure the time taken from the instant the unit enters the Bulk Charging Stage until the instant the battery voltage reaches 0.3V below the...
  • Page 90 SECTION 5 | Battery Charging in Evolution Series 5.7.3 Float Stage Float Stage is a maintenance stage in which the output voltage is reduced to a lower level, typically about 13.5 volts, (27 volts for 24V models) to maintain the battery’s charge without losing electrolyte through gassing and also prevent corrosion of Positive plate by maintaining proper Positive Plate Polarization Voltage.
  • Page 91 SECTION 5 | Battery Charging in Evolution Series Please read about the necessity and details of equalizing batteries under White Paper titled “Batteries, Chargers and Alternators,” available online at www.samlexamerica. com (Home > Support > White Papers). The 4 stages will be - Bulk, Absorption, Equalization, and Float. Equalization is desirable for the proper health of Wet Cell Batteries.
  • Page 92 SECTION 5 | Battery Charging in Evolution Series CAUTION! For effective equalization to take place, it is desirable that the batteries undergo a longer Bulk Stage applicable to the deeply discharged condition of the battery. Ÿ Please ensure that before the batteries are equalized, they should be deeply discharged to 20% of its capacity.
  • Page 93 SECTION 5 | Battery Charging in Evolution Series Ÿ At the end of Absorption Stage, it transitions to the programmed "EQUALIZE VOLT- AGE" (see programmable range and defaults at Table 6.2). It remains in this stage for the computed time T2. This stage is displayed as"E-Equalization Stage" in the 2 line of Charging Mode screens in Remote Control EVO-RC-PLUS (Please refer to Table 3.2 at Section 3.6.4.2 of Owner's Manual for EVO-RC-PLUS).
  • Page 94 SECTION 5 | Battery Charging in Evolution Series If the unit was in Inverting Mode [Blue LED “ON” (12, Fig 2.1) steady] and the Mode is set to Equalization as above by pressing the ON/OFF Push Button for 1 second, the unit will undergo Equalization Mode whenever qualified AC input is available from Grid / Generator and the unit enters Charging Mode.
  • Page 95 SECTION 5 | Battery Charging in Evolution Series 5.12.1 Charging Profiles for Lithium Batteries There are 3 Charging Profiles available for charging Lithium Batteries: (i) 3 Stage Type 1, (ii) 2 Stage Type 1 and (iii) 2 Stage Type 2. Please refer to Table 5.2 for details Charging voltages of Lithium Battery are not affected by temperature and hence, Battery Temperature Sensor [Fig 2.5(a)] is not required to be used.
  • Page 96 SECTION 5 | Battery Charging in Evolution Series When the contacts in the BMS close, Pins 4 and 5 of the RJ-45 Jack (6, Fig 2.1) will be shorted. The following actions will be activated: • EVO in Charging Mode: Charging will stop (charging current will be reduced to 0A). The 2 line of the Charging Mode Screens shown in the Menu Map for Charging Mode Screens (Fig 3.7 in EVO-RC-PLUS Manual) will show "Charger Off by BMS"...

  • Page 97: Operation, Protections And Troubleshooting

    SECTION 6 | Operation, Protections and Troubleshooting BEFORE OPERATING THE UNIT, PLEASE ENSURE THAT THE UNIT HAS BEEN INSTALLED PROPERLY AS PER INSTRUCTIONS AT SECTION 3 OF THIS MANUAL. PLEASE ENSURE THAT ALL SAFETY INSTRUCTIONS AT SECTION 1 OF THIS MANUAL ARE READ AND UNDERSTOOD BEFORE OPERATING THE UNIT.
  • Page 98 SECTION 6 | Operation, Protections and Troubleshooting 6.2 POWERING ON / OFF BY FEEDING EXTERNAL +12V SIGNAL TO TERMINALS MARKED “REMOTE ON/OFF” ON THE FRONT PANEL The unit can be switched ON /OFF remotely by feeding 2 specified formats of +12VDC (+9 to15VDC, <...
  • Page 99 SECTION 6 | Operation, Protections and Troubleshooting ATTENTION! Lorsque « Switch Type » de ON/OFF contrôle décrit ci-dessus est sélectionnée, le bouton ON/OFF sur le panneau avant de l’unité (12, Fig 2.1) ne devraient pas servir à allumer ou éteindre l’appareil. La façade, bouton poussoir ON/OFF suivra désormais la logique de contrôle ci-dessus «...
  • Page 100 SECTION 6 | Operation, Protections and Troubleshooting 6.4 OPTIONAL REMOTE CONTROL EVO-RC-PLUS FOR PROGRAMMING OF MODES OF OPERATION AND PARAMETERS Optional Remote Control Model EVO-RC-PLUS [Fig 2.4(a)] will be required for more advanced control and monitoring. Please see separate Owner’s Manual for EVO-RC-PLUS. The Remote Control comes with 10M / 33 ft., RJ-45 Data Cable.
  • Page 101 SECTION 6 | Operation, Protections and Troubleshooting TABLE 6.2 PROGRAMMABLE AND DEFAULT PARAMETERS: GROUP "CHARGE CURVE" (Continued) Programming Range (Programming requires optional Remote Control Model EVO-RC-PLUS) Default EVO-1212F EVO-1224F EVO-1212F EVO-1224F Parameter EVO-1212F-HW EVO-1224F-HW EVO-1212F-HW EVO-1224F-HW "RESET TO BULK" 10.0V to 13.0V 20.0V to 26.0V 12.0V 24.0V...
  • Page 102 SECTION 6 | Operation, Protections and Troubleshooting TABLE 6.5 PROGRAMMABLE AND DEFAULT PARAMETERS - GROUP "INPUT HIGH LIMIT" Setting range Default value EVO-1212F EVO-1224F EVO-1212F EVO-1224F Group Parameter name EVO-1212F-HW EVO-1224F-HW EVO-1212F-HW EVO-1224F-HW RESET VOLTAGE 120.0 – 150.0V 125.0V CUT OFF VOLT 1 120.0 –...
  • Page 103 SECTION 6 | Operation, Protections and Troubleshooting 6.5 PROTECTIONS, FAULT MESSAGES AND TROUBLESHOOTING GUIDE The front panel of the unit has a Red LED marked “FAULT” (13, Fig 2.1). This LED will light up (steady) when the unit registers any of the FAULT MODE situations shown in Table 7.1 of EVO-RC-PLUS Manual.
  • Page 104 SECTION 6 | Operation, Protections and Troubleshooting On the Remote Control EVO-RC-PLUS: — No LED display. Blue LED marked “Status” (3, Fig 2.4a) and Red LED marked “FAULT” (4, Fig 2.4a) will both be off The LCD will display information on 9 scrollable screens as shown at Fig 3.1 - "Menu Map for Standby Mode Screens"...

  • Page 105: Specifications

    SECTION 7 | Specifications EVO-1212F EVO-1224F Models EVO-1212F-HW EVO-1224F-HW INVERTER SECTION Output Waveform Pure Sine Wave Input Battery Voltage Range 9.1 - 17 VDC 18.1 - 34 VDC Nominal AC Output Voltage 120 VAC ± 5% Output Frequency 60 Hz ± 0.1 Hz Total Harmonic Distortion of Pure <...
  • Page 106 SECTION 7 | Specifications EVO-1212F EVO-1224F Models EVO-1212F-HW EVO-1224F-HW TRANSFER CHARACTERISTICS Transfer Relay Type and Capacity SPDT, 30A Transfer Time – Inverter to Grid / < 1 ms (Synchronized transfer at zero crossing) Generator Transfer Time – Grid / Generator Up to 18ms (Synchronized transfer at zero crossing) to Inverter INTERNAL BATTERY CHARGER SECTION...
  • Page 107 SECTION 7 | Specifications Ÿ For EVO-1212F and EVO-1224F only. Input: 20A Built-in Over Current Breakers Ÿ To be installed externally for EVO-1212F-HW Output: 15A and EVO-1224F-HW EVO-1212F EVO-1224F Models EVO-1212F-HW EVO-1224F-HW INPUT AND OUTPUT CONNECTIONS Battery Connection – Stud and Nut: M8 (Pitch1.25mm) External Charge Controller –...

  • Page 108: Warranty

    SECTION 8 | Warranty 2 YEAR LIMITED WARRANTY Series Inverter/Chargers manufactured by Samlex America Inc. (the “Warrantor“) are warranted to be free from defects in workmanship and materials under normal use and service. The warranty period is 2 years for the United States and Canada, and is in effect from the date of purchase by the user (the “Purchaser“).
  • Page 109 Notes SAMLEX AMERICA INC. | 109...
  • Page 110 Notes 110 | SAMLEX AMERICA INC.
  • Page 111 Notes SAMLEX AMERICA INC. | 111...
  • Page 112 Contact Information Toll Free Numbers Ph: 1 800 561 5885 Fax: 1 888 814 5210 Local Numbers Ph: 604 525 3836 Fax: 604 525 5221 Website www.samlexamerica.com USA Shipping Warehouses Kent, WA Plymouth, MI Canadian Shipping Warehouse Delta, BC Email purchase orders to orders@samlexamerica.com 11027-EVO-1212F-1224F-1217...

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