Samlexpower SAM-1500C-12 Owner's Manual
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Samlexpower SAM-1500C-12 Owner's Manual

Sam series inverter/charger
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SAM Series
Inverter /
Charger
SAM-1500C-12
owner's
Please read this
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Manual
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inverter

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Summary of Contents for Samlexpower SAM-1500C-12

  • 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

    MANUAL | Index Section 1: Safety ..................... 1 Section 2: Features, Applications & Principle of Operation ........3 Section 3: Layout ..................... 8 Section 4: Installation ..................10 Section 5: Operation ................... 19 Section 6: Protections, Monitoring & Troubleshooting .......... 22 Section 7 Specifications ..................

  • Page 3: Safety

    SECTION 1 | Safety 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, in- structions 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 caution! 1. Please ensure the following when using the unit as backup AC Power Source (UPS) • That the Utility AC Power input is fed from 15A/20A GFCI protected outlet to provide Ground fault Protection. • Do not ground using external Chassis Ground Connection (15, Fig 3.1). The unit gets grounded to the earth Ground of the Utility Grounding System automatically through the Grounding Wire of the AC Input Power Cord (10A, b- fig 3.1).

  • Page 5: Features, Applications & Principle Of Operation

    SECTION 2 | Features, Applications & Principle of Operation 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 or off-Line AC UPS (Un-interruptible Power Supply). The unit consists of the following 3 component integrated into a single unit: • Modified Sine Wave Inverter for AC back up when utility AC Power fails: •...

  • Page 6: Principle Of Operation

    SECTION 2 | Features, Applications & Principle of Operation applications • Backup AC Power Source or Off-Line AC UPS (Un-interruptible Power Supply) to provide AC power during power outages • 12V Lead Acid Battery charging • RVs, trucks and remote housing 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 principle of operation - inverter Conversion of 12 VDC from the battery / other DC source to 115 VAC takes place in 2 stages. In the first stage, the 12 VDC is converted to high voltage DC (around 160 VDC) using high frequency switching and Pulse Width Modulation (PWM) technique. In the 2nd stage, the 160V high voltage DC is converted to 115V, 60 Hz Modified Sine Wave AC. (note: 115V is the RMS value of the Modified Sine Wave AC voltage. The peak value of the Modified Sine Wave AC voltage will be equal to the value of the above high voltage of around 160V. See the fig 2.1 below). moDifieD Sine WaVeform - cHaracteriSticS &...
  • Page 8 SECTION 2 | Features, Applications & Principle of Operation caution! Certain devices (few examples given below) may malfunction when powered from Modi- fied Sine Wave. Check with the manufacturer of the device for suitability of powering with Modified Sine Wave: • Devices utilizing zero voltage crossing for timing control: Some clocks used in consumer electronic items (will not keep accurate time) • Devices using modulation of RF signals on AC lines during zero crossing e.g. X-10 System for Home Automation • Devices utilizing Triac based phase control for transformer less voltage step down e.g.: • Small battery chargers for hand tools, flashlights, night-lights, shavers etc. • Variable motor speed control in hand tools • Light dimmers • Temperature controllers e.g.: • Temperature Controlled Electric Blankets • Devices using high capacitance based voltage multipliers for generating high voltage (will create very high surge currents) e.g.: •...
  • Page 9 SECTION 2 | Features, Applications & Principle of Operation Bulk Charge Float Charge Stage Stage 13.8V Charger Voltage Curve Charger Current Curve Time LEGEND Charging Starts 1 to 2. Bulk Charge Stage: Constant Current = 15A Exits Bulk & Enters Float 2 to 3.

  • Page 10: Layout

    SECTION 3 | Layout AC INPUT/OUTPUT SIDE DC INPUT SIDE 15A/20A GFCI Protected Outlet - Utility AC Power – 12V Battery LEGEND 11a. BLACK plastic cover for Negative AC Outlet - NEMA5-15R Input Terminal ON/OFF Switch - Charger Positive Input Terminal (M9) for ON/OFF Switch - Inverter 12V Battery Positive Breaker for AC Input - 15A...
  • Page 11 SECTION 3 | Layout Fig 3.2 Dimensions & Mounting Arrangement SAMLEX AMERICA INC. | 9...

  • Page 12: Installation

    SECTION 4 | Installation Safety of installation Warning! Please read safety instructions in Section 1 before commencing installation. When using the unit as a backup AC Power Source, Utility AC Power Input should be fed from 15A/20A, GfCI Protected outlet. installation environment For best operating results, the inverter should be placed on flat surface, such as the ground, car floor, or other solid surface. The power cord allows easy positioning of the inverter. The...
  • Page 13 SECTION 4 | Installation Fig 4.1 Mounting Orientation on Wall Grounding arrangement caution! 1. For grounding requirements, the METAL CHASSIS of the unit is connected as follows: • To the Grounding Nut and Bolt (15, Fig, 3.1) for external Earth Ground connection, when required. • To the Grounding Pin of NEMA5-15P plug of the AC Input Power Cord (10A, B- Fig 3.1). When the AC Input Power Cord is plugged into 15A/20A GfCI protected outlet being fed with Utility AC Power, the metal chassis of the inverter automatically gets bonded to the earth Ground of the Utility Distribution System.

  • Page 14: General Information

    SECTION 4 | Installation the Grounding terminal of the nema5-15r ac outlet will be connected to the input section of the electronic Ground fault protection circuit on the power circuit Board. • Due to the above implementation, the voltage on the Neutral and Line Terminals of the nema5-15r ac outlet with respect to the chassis of the inverter / chassis of the ac loads will be a pulsing Dc voltage with average Dc value of up to 50V (will falsely read 75 Vac on ac scale of the Voltmeter because of pulsing nature of Dc voltage).
  • Page 15 SECTION 4 | Installation important Wiring/cabling information Although wires and cables are good conductors of electric current, they do have some resistance, which is directly proportional to the length and inversely proportional to the thickness (diameter) i.e. resistance increases in thinner and longer wires. Current flowing through resistance produces heat. Cables and wires are covered with insulating material that can withstand a specified temperature of the conductor under specified conditions.
  • Page 16 SECTION 4 | Installation table 4.1 recommended cable and fuse Sizes for Battery connection Distance between inverter, Battery and % Voltage rated Dc 1.25 times rated Samlex cable Drop input current for cable Size max fuse Samlex fuse + fuse Kit current Sizing (ampacity)
  • Page 17 SECTION 4 | Installation caution! 1. Do not connect the ac output of the unit to ac distribution wiring where the neutral is bonded to Ground. the inverter will see this as abnormal condition of Ground fault and will shut down. 2.

  • Page 18: Series Connection

    SECTION 4 | Installation connecting Batteries Series connection Battery 2 Battery 4 Battery 3 Battery 1 Cable “A” 6V Battery 6V Battery 6V Battery 6V Battery Inverter/ Charger Cable “B” Battery 1 Battery 2 Battery 3 Battery 4 Fig. 4.2 Series Connection Cable “A”...
  • Page 19 Cable “A” 12V Battery 12V Battery 12V Battery 12V Battery Inverter/ SECTION 4 | Installation Charger Cable “B” Series – parallel connection 12V String 1 12V String 2 Battery 1 Battery 2 Battery 3 Battery 4 Cable “A” 6V Battery 6V Battery 6V Battery 6V Battery...
  • Page 20 SECTION 4 | Installation Negative Post of the first battery string (Battery 1 of Battery String 1 as in Fig. 4.4), the following abnormal conditions will result: • The resistances of the connecting cables will not be balanced. • The individual batteries will see different series resistances. • All the individual batteries will be charged at different charging current and thus, will reach fully charged state at different times. • The battery with lower series resistance will take shorter time to charge as compared to the battery which sees higher series resistance and hence, will experience over charging and its life will be reduced. Sizing inverter Battery Bank The following basic rules are used to determine the size of the battery bank: • Active Power in Watts (W) = Voltage in Volts (V) x Current in Amperes (A) x Power Factor ......

  • Page 21: Operation

    SECTION 5 | Operation Sizing chart for typical Loads that require High Starting Surge The manufacturers’ specifications for power rating of appliances and devices indicate only the Running Power required. The Surge Power required by some specific types of devices as explained above has to be determined by actual testing or by checking with the manufacturer. This may not be possible in all cases and hence, can be guessed at best, based on some general rules of Thumb. Table 5.1 lists some common loads that require high surge power on start up. A “Siz- ing factor”...
  • Page 22 SECTION 5 | Operation When the Charger is switched oN, Green LeD “Charger” (7, fig 3.1) is lighted. Please note that the Charger is powered from the Utility AC Power. Hence, the charger will switch off when Utility AC Power fails even if the charger oN/off Switch is in oN Condition.
  • Page 23 SECTION 5 | Operation 7. Under normal operation, the load(s) will be powered from the inverter. refer to Troubleshooting Guide in case abnormal operation is observed. operation as Stand-alone inverter - Switching off 1. Switch off the load(s) 2. Switch off the Inverter operation as Stand-alone charger - Switching on 1. Switch OFF the Inverter ON/OFF Switch (3, Fig 3.1). As only battery charging is required, the inverter should be off.

  • Page 24: Protections Monitoring & Troubleshooting

    SECTION 6 | Protections Monitoring & Troubleshooting protections & monitoring when inverter is Supplying power & is operating as Backup ac power Source note: please refer to table 6.1 for status of monitoring LeDs and Buzzer for various protections / operational conditions explained below. over temperature protection The unit is cooled by load-controlled fan.

  • Page 25: Troubleshooting

    SECTION 6 | Protections Monitoring & Troubleshooting info it is normal for the alarm to sound while the unit is being connected to or disconnected from the power source. this is not indicative of a problem. Ground fault protection - General Due to loss of insulation as a result of aging of insulating materials, accident or malfunc- tion, voltage source inside an electrical device can get connected to its metal chassis.
  • Page 26 SECTION 6 | Protections Monitoring & Troubleshooting failure to Start Some Devices on Load Some high capacitance loads like Compact fluorescent Lamp (CfL) or Switched Mode Power Supply (SMPS) will shut down the inverter under overload condition if the inverter is switched oN with these loads in oN condition.
  • Page 27 SECTION 6 | Protections Monitoring & Troubleshooting yeLLoW operating Green LeD (6, condition/ threshold/ LeD (8, input LeD (9, protection reason inverter) fault) fault) Buzzer remedy/reset No output due Output power Check starting surge rating to Over Load is > Continu- of load.
  • Page 28 SECTION 6 | Protections Monitoring & Troubleshooting protections and monitoring When utility ac power is available, is Being passed through to the Load(s) and Battery charger is charging the Batteries: 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 Utility AC Power Pass Through Mode.

  • Page 29: Specifications

    SECTION 7 | Specifications parameter moDeL no.Sam-1500c -12 continuouS actiVe output poWer 1500W (Power Factor = 1) maximum SurGe poWer 3000W (<1 sec; Power Factor = 1) output - nominaL output VoLtaGe 115 VAC, +10% / -5% inVerter output freQuency 60 Hz ± 5% moDe peaK efficiency 90% (@ 50% load) inVerter on/off controL by front panel Switch output - GriD nominaL VoLtaGe, freQuency of GriD 120 VAC, 60 Hz paSS tHrouGH...

  • Page 30: Warranty

    SECTION 8 | Warranty 2 year LimiteD Warranty SAM-1500C-12 manufactured by Samlex America, Inc. (the “Warrantor“) is 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 31 Notes SAMLEX AMERICA INC. | 29...
  • Page 32 Information Toll Free Numbers Ph: 800 561 5885 Fax: 888 814 5210 Local Numbers Ph: 604 525 3836 Fax: 604 525 5221 Website www.samlexamerica.com USA Shipping Warehouse Kent WA Canadian Shipping Warehouse Delta BC Email purchase orders to orders@samlexamerica.com 11002-SAM-1500C-12-1113...

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