SamplexPower SAM Series Owner's Manual

Inverter / charger

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SAM Series

Inverter /

Charger

SAM-1500C-12

owner's

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manual before

Manual

installing your

inverter

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Page 1 SAM Series owner's Please read this manual before Manual Inverter / installing your Charger inverter SAM-1500C-12...
Page 2: Table Of Contents
Owner'S MAnuAl | Index Section 1 Safety Instructions ....................3 Section 2 Features, Applications & Principle of Operation ..........5 Section 3 Layout .......................12 Section 4 Installation ...................... 14 Section 5 Operation .......................23 Section 6 Protections, Monitoring & Troubleshooting ............30 Section 7 Specifications ....................37 Section 8 Warranty...
Page 3: Safety Instructions
SeCTIOn 1 | Safety Instructions 1.1 important Safety inStructionS This manual contains important information regarding safety, operation, maintenance and storage of this product. before use, read and understand all cautions, warnings, instructions and product labels, plus your vehicle’s battery manufacturer’s guidelines. failure to do so could result in injury and / or property damage.
Page 4 SeCTIOn 1 | Safety Instructions • I f you need to remove a battery, always remove the Ground (Nega- tive) terminal from the battery first. Make sure that all the accesso- ries are off so that you do not cause a spark. Do not make any electrical connections or disconnections in areas desig- nated as iGnition protecteD.
Page 5: Features, Applications & Principle Of Operation
SeCTIOn 2 | Features, Applications & Principle of Operation 2.1 GeneraL info for additional technical and operational information on Inverters, battery Chargers and related topics, please refer to www.samlexamerica.com/ Support/application notes/White papers. This unit is a Modified Sine Inverter / Charger with a Transfer relay with primary function of backup AC Power Source.
Page 6 SeCTIOn 2 | Features, Applications & Principle of Operation • Low Interference Technology for controlled RF noise • Ideal for RV’s, Trucks and remote housing 2.3.1 Soft Start technology This feature offers the following advantages: • When the Inverter is switched ON, the voltage ramps up to 115 VAC in around 2 sec. If the load was already oN at the time of switching oN of the Inverter, starting surge current demanded by certain reactive devices like motors etc.
Page 7 SeCTIOn 2 | Features, Applications & Principle of Operation 2.4.1. modified Sine Waveform - characteristics & comparison with pure Sine Waveform Please refer to fig 2.1 below which shows one cycle of Modified Sine Wave and Pure Sine Wave for comparison. (Both with RMS voltage of 115 VAC) = 162.61V peak = 160V ±...
Page 8 SeCTIOn 2 | Features, Applications & Principle of Operation • Temperature controllers e.g.: • Temperature Controlled Electric Blankets • D evices using high capacitance based voltage multipliers for generating high voltage (will create very high surge currents) e.g.: • Photographic Strobe Lights • Laser Printers 2.4.2 measuring modified Sine Wave voltage with a "true rmS" voltmeter As mentioned above, Modified Sine Wave voltage is a type of square wave that has an RMS (Root Mean Square) value of 115 VAC in this Inverter. A general-purpose AC volt- meter is calibrated to accurately measure the rMS value of a Pure Sine Wave and NoT of a Modified Sine Wave.
Page 9 SeCTIOn 2 | Features, Applications & Principle of Operation 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 Standing Voltage 26.0 13.0 C/100...
Page 10 SeCTIOn 2 | Features, Applications & Principle of Operation 2.5.2 2 Stage charging - Bulk charge and float charge Stages The built-in battery Charger is a "2 stage charger". Working of a 2 Stage Charger is explained below. Please refer to Fig 2.3. Bulk Charge Float Charge Stage Stage 13.8V Charger Voltage Curve Charger Current Curve Time LEGEND...
Page 11 SeCTIOn 2 | Features, Applications & Principle of Operation iii. The “Standing Voltage” of a battery is the terminal voltage of the battery after it has “rested” for at least 4 hours (no charging or discharging during resting period of 4 hours). The Standing Voltages of 12V Lead Acid battery are as follows (See Fig 2.2): fully Charged: Around 12.8V fully discharged: Around 11.8V iv. B efore the charger is switched ON (before Point 1 in Fig 2.3), the battery is almost completely discharged to “Standing Voltage” of around 11.8V (Fig 2.2) and its inter- nal resistance is, say 16 milli ohm.
Page 12: Layout
SeCTIOn 3 | layout 3.1 Layout AC INPUT/OUTPUT SIDE DC INPUT SIDE Grid AC Power Outlet – 12V Battery LEGEND 11a. BLACK plastic cover for Negative AC Outlet - NEMA5-15R Input Terminal ON/OFF Switch - marked “CHARGER” Positive Input Terminal (M9) for ON/OFF Switch - marked “INVERTER”...
Page 13 SeCTIOn 3 | layout 3.2 DimenSionS anD mountinG arranGement Fig 3.2 Dimensions & Mounting Arrangement SAMLEX AMERICA INC. | 13...
Page 14: Installation
SeCTIOn 4 | Installation 4.1 Safety of inStaLLation WarninG! Please read safety instructions in Section 1 before commencing installation. When using the unit as a backup AC Power Source, Grid AC Power Input should be fed from 15A/20A, GfCI Protected outlet. 4.2 inStaLLation environment For best operating results, the unit should be placed on flat surface, such as the ground, car floor, or other solid surface. The power cord allows easy positioning of the unit. The unit...
Page 15 SeCTIOn 4 | Installation Fig 4.1 Mounting Orientation on Wall 4.4 GrounDinG anD GrounD fauLt / LeaKaGe protectionS 4.4.1 Dc Side Grounding and Ground fault protection For DC side grounding and protection against Ground Fault, an M5 Bolt and Nut (15, Fig 3.1) has been provided. Connect this to the earth Ground in shore based installations / Vehicle Chassis Ground using minimum AWG #8 wire.
Page 16 SeCTIOn 4 | Installation (ii) condition 2: ac input cord is plugged into Gfci protected ac outlet and Grid voltage is not available at this outlet (either Grid voltage has shut down or the breaker / switch feeding this outlet has been switched off): The Grounding conductor of the AC input cord (Green wire) is internally connected to the metal chassis of the unit. Hence, the metal chassis of the unit will also get connected to the earth Ground in the Grid AC Supply Panel through the above mentioned grounding conductor of the AC input cord.
Page 17 SeCTIOn 4 | Installation caution! Do not connect AC output from the NeMA5-15r outlets to AC distribution wiring where the Neutral is bonded to earth Ground. The Inverter will see this as abnor- mal condition of Ground fault / leakage and will shut down! 4.6 Dc SiDe connectionS 4.6.1 General information 1.
Page 18 SeCTIOn 4 | Installation specified by NEC Table 31.15 (B) (17). Further, NEC also specifies that wire size should be based on Ampacity - 1.25 times the rated current flow. resistance of wires and cables produces another undesirable effect of voltage drop. Voltage drop is directly proportional to the resistance and the value of current flow. Voltage drop produces loss of power in the form of heat. In addition, excessive voltage drop from the battery to the Inverter may prematurely shut down the Inverter due to activation of the Low Input Voltage Protection Circuitry of the inverter (10.5 ± 0.5V). DC cables should be sized to ensure maximum voltage drop is limited to less than 5%. 4.6.5 effects of Low voltage on common electrical Loads: Lighting circuits –...
Page 19 SeCTIOn 4 | Installation noteS: 1. cable Size • As per NEC, size is based on Ampacity ≥ 1.25 times the rated DC Input Current • Conductor / Insulation rating : 105 °C 2. fuse Size • Type: Class-T or Marine Rated Battery Fuse (MRBF) • The rating of the fuse should not exceed the Ampacity of the Cable 3. Distance between inverter and Battery and % voltage Drop • Voltage drop is calculated based on length of cable = 2 x Distance to consider total length of Positive and Negative cables • % drop is calculated with respect to rated battery voltage of 12.5V caution! • P lease ensure that the recommended external fuse specified in Table 4.1 above (fuse is not supplied) is installed in series with the positive cable and...
Page 20 SeCTIOn 4 | Installation parallel connection Battery 1 Battery 2 Battery 3 Battery 4 Cable “A” 12V Battery 12V Battery 12V Battery 12V Battery Inverter/ Charger Cable “B” Fig. 4.3 Parallel Connection When two or more batteries are connected in parallel, their voltage remains the same but their Ah capacities add up.
Page 21 SeCTIOn 4 | Installation nected to the battery bank. Please ensure that if the Positive output cable of the Inverter Charger (Cable “A”) is connected to the Positive battery post of the first battery (Battery 1 in Fig. 4.3) or to the Positive battery post of the first bat- tery string (Battery 1 of String 1 in Fig. 4.4), then the Negative output cable of the Inverter Charger (Cable “B”) should be connected to the Negative battery post of the last battery (Battery 4 as in Fig. 4.3) or to the Negative Post of the last battery string (Battery 4 of Battery String 2 as in Fig. 4.4). This connection ensures the following: • The resistances of the interconnecting cables will be balanced. • All the individual batteries / battery strings will see the same series resistance. • All the individual batteries will charge at the same charging current and thus, will be charged to the same state at the same time. • None of the batteries will see an overcharge condition.
Page 22 SeCTIOn 4 | Installation An example of this calculation for a 12V Inverter is given below: Let us say that the total continuous ac Watts delivered by the 12v inverter = 1500W. Then, using Formula 2 above, the DC current to be delivered by the 12V batteries = 1500W ÷10 = 150 Amperes. next, the energy required by the load in ampere Hours (ah) is determined: For example, if the load is to operate for 3 Hours, then as per Formula 3 above, the energy to be delivered by the 12V batteries = 150 Amperes × 3 Hours = 450 Ampere Hours. finally, as per rule of thumb at formula 4, the ah capacity of the batteries should be twice the energy required by the load in ah = 450 Ah x 2 = 900 Ah.
Page 23: Operation
SeCTIOn 4 | Installation Do not keep the battery wires far apart. Keep them taped together to reduce their inductance and induced voltages. This reduces ripple in the battery wires and improves performance and efficiency. Shield the DC side wires with metal sheathing / copper foil /braiding: - Use co- axial 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 24 SeCTIOn 5 | Operation • T ransfer Relay K1 will be in de-energized condition, and through its normally closed (NC) contacts, the Line Sockets of the AC outlets will be connected to the Line conductor of Grid input for Grid pass-through. • G round Switching Relay K2 will also be in de-energized condition and through its Normally Closed (NC) contacts, the Grounding Sockets of the two AC outlets will be connected to the metal chassis of the unit (ii) inverter mode: If the incoming Grid input fails or if the breaker / switch supplying the Grid AC outlet is switched off, the unit transfers to Inverter Mode.
Page 25 SeCTIOn 5 | Operation 5.1.3 Stand-alone inverter mode In this mode, the unit is used just as a stand-alone inverter. The unit is fed with 12V bat- tery power on the DC input side. The AC input cord is NoT connected to Grid AC outlet. The position of the Charger ON/OFF switch “CHARGER” (2, Fig 3.1) does not matter The unit operates as follows: • A s there is no AC input from the Grid, the Charger Section will be in OFF condi-...
Page 26 SeCTIOn 5 | Operation type of Device or appliance inverter Sizing factor Portable Kerosene / Diesel Fuel Heater Circular Saw / Bench Grinder Incandescent / Halogen / Quartz Lamps Laser Printer / Other Devices using Quartz Lamps for heating Photographic Strobe / Flash Lights2 noteS for taBLe 5.1 1.
Page 27 SeCTIOn 5 | Operation • T he unit will start operating in Inverter Mode. The Inverter will switch ON and will provide 115VAC to the AC outlets. • The Green LED “Inverter” (8, Fig 3.1) will be switched ON • T he 2 cooling fans will switch ON momentarily for around 6 seconds and then switch off if the load connected to the AC outlets is less than 85W. The fans are load controlled and will be switched oN automatically when the AC load in the Inverter Mode is more than 85W 8. Wait for a few minutes and then Switch ON the AC side load(s). If more than one load is used, switch oN one by one so that starting surges are staggered to prevent...
Page 28 SeCTIOn 5 | Operation • G round Switching Relay K2 will also be energised, its Normally Opened (NO) contacts will close and the Grounding Sockets of the two AC outlets will get disconnected from the metal chassis of the unit and get connected to the internal GfCI circuitry • T he Battery Charger will switch OFF. Green LED “CHARGER” (7, Fig 3.1) will also be switched off • T he battery will start discharging at current = Power of AC load(s) in Watts ÷ 10 5.3.2 Switching off procedure:...
Page 29 SeCTIOn 5 | Operation • G round Switching Relay K2 will also be energised, its Normally Opened (NO) contacts will close and the Grounding Sockets of the two NeMA5-15r AC outlets (10, Fig 3.1) will get disconnected from the metal chassis of the unit and get con- nected to the internal GfCI circuitry • The Inverter will switch ON and will provide 115VAC to the AC outlets. • The Green LED “INVERTER” (8, Fig 3.1) will be switched ON • T he 2 cooling fans will switch ON for a short duration for around 6 seconds and then switch off if the load connected to the AC outlets is less than 85W. The fans are load controlled and will be switched oN automatically when the AC load in the Inverter Mode is more than 85W 9. W ait for a few minutes and then Switch ON the AC side load(s). If more than one...
Page 30: Protections, Monitoring & Troubleshooting
SeCTIOn 5 | Operation 6. Plug the AC input cord to the 120 VAC, 15A GfCI protected Grid AC outlet. 7. S witching on the Battery charger: Switch the battery Charger oN/off Switch “CHARGER” (2, Fig 3.1) to ON position. 8. The battery Charger will switch oN and start charging the batteries. 9. The Green LED “CHARGER” (7, Fig 3.1) will be switched ON 10.
Page 31 SeCTIOn 6 | Protections, Monitoring & Troubleshooting 6.1.3 Low Battery voltage protection This condition is not harmful to the Inverter but could damage the 12V battery. The Inverter automatically shuts down when input voltage drops to 10.5 ± 0.3V. The Yellow LED "INPUT fAULT" (6, Fig 3.1) will be lighted an the Green LED "INVerTer" (8, Fig 3.1) will switch OFF. The unit will reset automatically when the battery voltage rises to 11.7 ± 0.3V. 6.1.4 over voltage protection The Inverter will automatically shut down when the input voltage exceeds 15.5 V± 0.2V. The Yellow LED "INPUT fAULT" (6, Fig 3.1) will be lighted and the Green LED "INVerTer" (8, Fig 3.1) will be switched OFF. The unit will reset automatically when voltage drops to 15.0V. Input voltage exceeding 16 volts could damage the inverter. 6.1.5 overload / Short circuit protection The Inverter will automatically shut down under (i) short circuit and (ii) continuous over- load of 110% (1650W). Red LED "fAULT" (9, Fig 3.1) will be lighted and Green LED "IN-...
Page 32 SeCTIOn 6 | Protections, Monitoring & Troubleshooting ered to be at 0V), the person will get a shock due to current leaked through the body to Earth Ground (called Leakage Current). Such condition is called “Ground Fault” / "Leak- age". As this Leakage Current is diverted to earth Ground, it does not return to the electri- cal power source supplying the AC device.
Page 33 SeCTIOn 6 | Protections, Monitoring & Troubleshooting 6.1.9 monitoring of operational Status & protections - inverter mode Normal / abnormal behavior can be monitored by observing Green LeD "INVerTer" (8, Fig 3.1), Yellow LED "INPUT fAULT" (6, Fig 3.1), Red LED "fAULT" (9, Fig 3.1) and Buzzer. Details are given in Table 6.1 below: table 6.1 protections and monitoring: inverter is Supplying power yellow operating Green LeD...
Page 34 SeCTIOn 6 | Protections, Monitoring & Troubleshooting table 6.1 protections and monitoring: inverter is Supplying power (continued) yellow operating Green LeD LeD "input red LeD condition/ threshold/ "inverter" fauLt" "fauLt" protection reason (8, fig 3.1) (6, fig 3.1) (9, fig 3.1) Buzzer remedy/reset No output due...
Page 35 SeCTIOn 6 | Protections, Monitoring & Troubleshooting 6.2 protectionS anD monitorinG in cHarGer / GriD paSS tHouGH moDe note: please refer to table 6.2 for status of monitoring LeDs for various protections / operational conditions explained below: In this mode, Grid AC Power is available, is being passed through to the Load(s) and Bat- tery Charger is charging the batteries: 6.2.1 overload / Short circuit protection in ac Load(s) 15A Breaker (4, Fig 3.1) in the AC Input Circuit of the unit provides protection against overload and short circuit in the AC loads when the unit is in Grid AC Power Pass...
Page 36 SeCTIOn 6 | Protections, Monitoring & Troubleshooting table 6.2 protections & monitoring: Battery charger / Grid ac power pass through mode (continued) LeD Display other Symptoms possible cause(s) remedy • G reen LED • Charger has stopped 5A fuse (5, Fig 3.1) feed- Replace 5A fuse (5, • G rid voltage is avail- “CHArGer” ing the Charger Section fig 3.1).
Page 37: Specifications
SeCTIOn 7 | Specifications moDeL no. Sam-1500c-12 output: inverter moDe 1500W (Power Factor = 1) CoNTINUoUS ACTIVe oUTPUT PoWer 3000W (<4 millisec; Power Factor = 1) MAXIMUM SUrGe PoWer 115 VAC, +10% / -5% NoMINAL oUTPUT VoLTAGe OUTPUT FREQUENCY 60 Hz ± 5% EFFICIENCY 87% (@ 100% load) INVerTer oN/off CoNTroL by front panel Switch output: GriD paSS tHrouGH NOMINAL VOLTAGE, FREQUENCY OF GRID 120 VAC, 60 Hz 1500W (Power Factor = 1; Battery fully charged) MAXIMUM PoWer input: Battery...
Page 38: Warranty
SeCTIOn 8 | warranty 2 year LimiteD Warranty SAM-1500C-12 manufactured by Samlex America, Inc. (the “Warrantor“) is war- ranted 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“). Warranty outside of the United States and Canada is limited to 6 months. for a warranty claim, the Purchaser should contact the place of purchase to obtain a Return Authorization Number.
Page 39 nOTeS: SAMLEX AMERICA INC. | 39...
Page 40 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 11002-SAM-1500C-12-0517...

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Sam-1500c-12