Samlexpower EVO-2212 Owner's Manual
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Samlexpower EVO-2212 Owner's Manual

Evolution series inverter charger pure sine wave
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See also: Owner's Manual
Evolution
Series
TM
Inverter Charger
Pure Sine Wave
Models:
EVO-2212
EVO-3012
EVO-2224
EVO-4024
Owner's
Please read this
manual BEFORE
Manual
operating.

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Summary of Contents for Samlexpower EVO-2212

  • Page 1 Evolution Series Owner's Please read this manual BEFORE Manual Inverter Charger operating. Pure Sine Wave Models: EVO-2212 EVO-3012 EVO-2224 EVO-4024...

  • Page 2: Table Of Contents

    EVO INVERTER CHARGER MANUAL | Index SECTION 1 Safety Instructions & General Information ......3 SECTION 2 Components & Layout ............24 SECTION 3 Installation ................. 28 SECTION 4 General Description and Principles of Operation ....59 SECTION 5 Battery Charging in Evolution Series ........70 SECTION 6 Operation, Protections and Troubleshooting ......

  • Page 3: Safety Instructions & General Information

    1.1 IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS. THIS MANUAL CONTAINS IMPORTANT INSTRUCTIONS FOR MODELS: EVO-2212, EVO-2224, EVO-3012, EVO-4024 THAT SHALL BE FOLLOWED DURING INSTALLATION & MAINTENANCE OF THE INVERTER CHARGER. THE FOLLOWING SYMBOLS WILL BE USED IN THIS MANUAL TO HIGHLIGHT SAFETY AND...
  • Page 4 SECTION 1 | Safety Instructions & General Information ). See Tables 1.1(a), 1.1 (b) and 1.1 (c) for sizing of conductors for AC INPUT circuits and Table 1.2 for sizing of conductors for AC OUTPUT circuits. Over current protection (AC Breakers) for the AC input / output circuits has NOT been provided and has to provided by the installer / user.
  • Page 5 Column 2 75°C Copper Conductor pacity at Column 3) in Conduit (Column 1) (Column 2) (Column 3) (Column 4) (Column 5) EVO-2212 EVO-2224 37.5A AWG #8 (Default) EVO-3012 EVO-4024 TABLE 1.1 (b) AC INPUT WIRING AND BREAKERS (FOR AC INPUT CURRENT LIMIT PROGRAMMED AT 45A FOR EVO-3012 AND EVO-4024)
  • Page 6 (Based on NEC Am- verter Mode and 75°C Copper Conduc- pacity at Column 3) tor in Conduit (Column 1) (Column 2) (Column 3) (Column 4) (Column 5) EVO-2212 18.33A 22.91 AWG #10 EVO-2224 18.33A 22.91 AWG #10 EVO-3012 31.25 AWG #8 EVO-4024 33.33A...
  • Page 7 SECTION 1 | Safety Instructions & General Information TABLE 1.5 USE OF SPECIFIED GROUND FAULT CIRCUIT INTERRUPTER (GFCI) FOR DISTRIBU- TION OF AC OUTPUT POWER IN RECREATION VEHICLES Manufacturer of GFCI Manufacturers’ Model No. Description Pass & Seymour 2095W NEMA5-20, Duplex, 20A Pass &...
  • Page 8 SECTION 1 | Safety Instructions & General Information ATTENTION! Risque de choc électrique. Utilisez uniquement les GFCIs suivantes. D’autres types peuvent ne pas fonctionner correctement lorsqu’il est connecté à cet appareil. MISE À LA TERRE: Le symbole de mise à la terre ci-dessous est utilisé pour identifier uniquement l’équipement terminal de terre-câblage.
  • Page 9 SECTION 1 | Safety Instructions & General Information consisting of a combination of resistances, inductances and capacitances, the Phase Angle (φ) of the net current vector will be > 0° < 90° and may lag or lead the voltage vector. Resistance (R), Ohm, Ω: It is the property of a conductor that opposes the flow of current when a voltage is applied across it.
  • Page 10 SECTION 1 | Safety Instructions & General Information capacitive elements and hence, its value will be > 0 <1. Normally it ranges from 0.5 to 0.8. 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. Ex- amples are, incandescent lamp, heater, electric motor, etc.
  • Page 11 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 the grid power. Please see sine waveform represented in the Fig. 1.1 that also shows equivalent modified waveform for comparison.
  • Page 12 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 13 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 14 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 15 SECTION 1 | Safety Instructions & General Information NOTE: Voltage and Current scales are di erent Input voltage RMS Current Inrush current Fig 1.2 Inrush current in an SMPS Peak Current NOTE: Voltage and Non-linear Current scales Input Current are di erent RMS Current Input Sine Wave Voltage...
  • Page 16 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 17 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 18: Inverter Application

    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 19 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 20 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 21 SECTION 1 | Safety Instructions & General Information Table 1.11 TERMINAL VOLTAGE AND SOC OF LOADED BATTERY Discharge Terminal Voltage at 80% State Terminal Voltage When Completely Current: of Discharge (20% SOC) Discharged (0% SOC) C-Rate C/3 A 10.45V 20.9V 09.50V 19.0V C/5 A...
  • Page 22 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 23 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 24: Components & Layout

    SECTION 2 | Components & Layout 1 MAIN UNIT: LAYOUT-FRONT (FIG 2.1) 1a Red 1b Black Protection Covers for Battery Terminals Fig 2.1 Layout-Front 1. Battery Positive (+) Input Connector – M10 x 1.25 Nut & Bolt (RED Protection Cover 1(a) is Removed) 1a.
  • Page 25 SECTION 2 | Components & Layout 2.2 MAIN UNIT: LAYOUT-BACK (FIG 2.2) 1. Air outlet vents for 2 internal fans Fig 2.2 Layout-Back 2.3 MAIN UNIT: LAYOUT-AC SIDE (FIG 2.3) Cover plate for pocket for AC Input/Output terminals Pocket for AC Input/Output Terminals (behind cover plate 1) AC Input/Output Terminal Block •...
  • Page 26 SECTION 2 | Components & Layout 2.4 REMOTE CONTROL EVO-RC (FIG 2.4) [OPTIONAL] Fig 2.4(a) Optional Remote Control EVO-RC LCD Screen - 2 rows of 16 characters each ON/OFF Key Green LED “Status” Red LED “Alarm” (Fault) Navigation Key “Back” Navigation Key “Up”...
  • Page 27 SECTION 2 | Components & Layout 2.5 BATTERY TEMPERATURE SENSOR EVO-BCTS [FIG 2.5 (a)] Temperature Sensor: Mounting hole: 10mm/0.39” suitable for 3/8” or 5/16” battery studs RJ-45 Plug 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) Fig 2.5(a) Temperature Sensor Model EVO-BCTS Fig 2.5(b) Temperature Sensor Installation 2.6 CONTENTS OF PACKAGE...

  • Page 28: Installation

    SECTION 3 | Installation 3.1 SAFETY OF INSTALLATION WARNING! Please ensure safety instructions given under Section 1 are strictly followed. ATTENTION! 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 29 SECTION 3 | Installation CAUTION! Ensure there is OVER 200 mm clear space surrounding the inverter for ven- tilation. ATTENTION! Assurer qu’il y a PLUS QUE 200 mm d’espace DÉGAGÉ entourant l’onduleur pour faciliter la ventilation. Mounting Orientation: • Mount horizontally on a horizontal surface (e.g. table top or a shelf). Please see Fig. 3.2. Fig 3.2 Mounting Arrangement: Horizontally On Horizontal Surface •...

  • Page 30: Series Connection

    SECTION 3 | Installation • 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. (If necessary, install a suitable sloping guard at least 200mm from the top surface). Also, ensure there is no combustible material directly under the unit.

  • Page 31: Parallel Connection

    SECTION 3 | Installation 3.4.2 Parallel Connection Cable “A” Battery 1 Battery 2 Battery 3 Battery 4 12V Inverter or 12V Charger Cable “B” Fig 3.6 Parallel Connection When two or more batteries are connected in parallel, their voltage remains the same but their Ah capacities add up.
  • Page 32 SECTION 3 | Installation 3.4.4 Wiring Order in Parallel Connection of Batteries CAUTION! When 2 or more batteries / battery strings are connected in parallel and are then connected to inverter/charger (See Figs 3.6 and 3.7), attention should be paid to the manner in which the inverter/charger is connected to the battery bank.
  • Page 33 SECTION 3 | Installation Quand il y a 2 batteries/fils de batterie ou plus qui sont liés en parallèle et branché à la fois, à un chargeur (Voir Figs. 3.6 et 3.7), il faut faire attention à la manière dont le chargeur est branché à la banque de batterie. Veuillez assurer que le câble positif de sortie du chargeur de batterie (Câble A) est lié...
  • Page 34 SECTION 3 | Installation 3.5 DC SIDE CONNECTIONS 1a Red 1b Black FIG 3.8 DC Side Connections Protection Covers for Battery Terminals 1. Battery Positive (+) Input Connector – M10 x 1.25 Nut & Bolt (RED Protection Cover 1(a) is Removed) 1a.
  • Page 35 It is to be ensured that the DC input voltage of this unit does not exceed 17 VDC for the 12V battery version EVO-2212 and EVO-3012, and 35 VDC for the 24V battery versions EVO-2224 and EVO-4024 to prevent permanent damage to the unit.
  • Page 36 SECTION 3 | Installation and the inverter. Thinner cables and loose connections will result in poor inverter performance and will produce abnormal heating leading to risk of insulation melt down and fire. Normally, the thickness of the cable should be such that the voltage drop due to the current & the resis- tance of the length of the cable should be less than 2%.
  • Page 37 SECTION 3 | Installation température de l’isolation. Les matériaux isolants des câbles seront aussi affecter par la température de fonctionnement élèvée des bornes, à qui ils sont connectés. L’ampacité des câbles est basé sur UL-1741 et la Norme Nationale Électrique (NEC)-2014.
  • Page 38 SECTION 3 | Installation Il est obligatoire d’utiliser un fusible externe de taille appropriée à la batterie et les circuits chargeur externe . Si le fusible externe est pas utilisé et les inversions de polarité est faite par la surveillance , la section d’entrée de l’unité est endom- magée / brûlé...
  • Page 39 (Column 3) (Column 9) (Column 5) (Column 6) (Column 7) (Column 8) AWG #4/0 (This size, based on 2% 2 X AWG 2 X AWG EVO-2212 266A 333A AWG#3/0 voltage drop, #4/0 #4/0 350A is thicker than (MCM 350) (MCM 350)
  • Page 40 SECTION 3 | Installation Column 9 indicates the size of external fuse in the battery circuit. It is manda- tory to install this fuse within 7” of the battery Positive terminal to protect the internal DC Input Section of the unit and also to protect the battery cables against short circuit.

  • Page 41: Section 4

    SECTION 3 | Installation 3.6 AC INPUT AND OUTPUT - LAYOUT AND CONNECTION ARRANGEMENT AC side layout and connection arrangement are shown in Fig 3.9. 1. Cover plate for pocket for AC Input/Output terminals 2. Pocket for AC Input/Output Terminals (behind cover plate 1) 3.
  • Page 42 SECTION 3 | Installation 3.6.1 System Grounding and Output Neutral to Chassis Ground Bond Switching WARNING! • In "Inverting Mode" (default condition), the Neutral of the AC output of the unit gets bonded to the metal chassis of the unit through the internal “Neutral to Chassis Switch- ing Relay”...
  • Page 43 SECTION 3 | Installation age the output section of the unit and may also pose a fire and safety hazard. If an electrical breaker panel / load center is fed from this unit and this panel is also required to be powered from additional alternate AC source, the AC power from the 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.
  • Page 44 SECTION 3 | Installation primaire de ce transformateur et les deux sorties chaud (120 VAC divisé phases) et le neutre du secondaire de ce transformateur doit être relié au panneau de disjoncteur électrique / Centre de gravité. Se il vous plaît voir les détails en ligne sous Livre blanc intitulé “120/240 VAC Split système phase et multi-fils Circuits de dérivation”...
  • Page 45 3.8.1 Tables for Wire and Breaker Sizing - AC Input Side Tables 3.2.1 to 3.2.3 provide details of wire and breaker sizing for the AC input side. • Table 3.2.1: For EVO-2212, 2224, 3012 and 4024 with AC Input Current Limit (Max Current) set at 30A (Default Setting) • Table 3.2.2: For EVO-3012 and 4024 when AC Input Current Limit (Max Current) is...
  • Page 46 Control EVO-RC is required to change this limit (See Appendix A under Group 2 Pa- rameter Select for Input Settings-"Max Current"). All the 4 models EVO-2212, 2224, 3012 and 4024 come with Input Current Limit set at 30A (Default Setting). See Table 3.2.1.
  • Page 47 SECTION 3 | Installation TABLE 3.2.2 SIZING OF GRID AND GENERATOR INPUT WIRING AND BREAKERS (FOR INPUT CURRENT LIMIT PROGRAMMED AT 45A FOR EVO-3012 AND EVO-4024) Model No. and Rated Rated AC Total Rated Pro- NEC Ampac- Conductor External Rated Output AC Pass Charging AC Input...
  • Page 48 SECTION 3 | Installation Electrical Code) - Section 210.19(A)(1)(a) regarding minimum Ampacity and size of Branch Circuit Conductors. 6) Column 7 indicates the wiring conductor size that has been determined based on NEC-2014 (National Electrical Code) - Ampacity Table 310.15(B)(16) for Raceway. This conductor size is based on (i) NEC Ampacity (Column 6) (ii) conductor temper- ature of 75°C and (iii) ambient temperature of 30°C / 86°F.
  • Page 49 (See Note 2) Column 3 Column 3 Mode (See Note 3) (See Note 3) (Column 1) (Column 2) (Column 3) (Column 4) (Column 5) EVO-2212 18.33A 22.91 AWG #10 (2200VA, 18A) EVO-2224 18.33A 22.91 AWG #10 (2200VA, 18A) EVO-3012 31.25...
  • Page 50 SECTION 3 | Installation 3.10 GFCI PROTECTION FOR VEHICLE APPLICATION When this unit is installed in vehicles, ensure that Ground Fault Circuit Interrupter(s) are installed in the vehicle wiring system to protect all branch circuits. Details of tested and approved GFCI’s are given in Table 3.4.
  • Page 51 SECTION 3 | Installation The connections must be tight against bare metal. Use star washers to penetrate paint and corrosion. As the Equipment Grounding Bus Bar (G3) in the DC Panel is bonded to the Grounding Electrode (GE), the chassis of the EVO / DC side will be bonded to Earth Ground.
  • Page 52 SECTION 3 | Installation • When in Charging Mode, the Neutral conductor of the Grid power/Generator will be connected to the Output Neutral connector of the Inverter Charger. At the same time, the “Output Neutral to Chassis Ground Bond Switching Relay” [K4 in Figs 4.1(a) and 4.1(b)] will unbond (disconnect) the Output Neutral connector of the Inverter Charger from the chassis of the Inverter Charger.
  • Page 53 SECTION 3 | Installation SAMLEX AMERICA INC. | 53...
  • Page 54 SECTION 3 | Installation 3.15 SHORE BASED INSTALLATION 3.15.1 Typical Shore Based Installation Fig. 3.13 illustrates a typical shore based installation • Battery is connected to the DC input connections through an appropriate fuse to protect the DC input cables against short circuit •...
  • Page 55 SECTION 3 | Installation To Remote Start/Stop Battery Terminals on the Temperature Generator Sensor - Model EVO-BCTS Optional Generator Auto Start/Stop Module Deep Cycle Fuse Battery Bank (Within 7” of battery terminal) Optional Fuse Remote Control AC DISTRIBUTION LINE EVO-RC PANEL Loads Ground...
  • Page 56 SECTION 3 | Installation 3.16 MOBILE INSTALLATION - GENERAL INFORMATION 3.16.1 GFCI Protection For Vehicle Application When this unit 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. WARNING! Please ensure that Ground Fault Circuit Interrupter(s) [GFCI] are installed in the vehicle wiring system to protect all branch circuits.
  • Page 57 SECTION 3 | Installation • For EVO-3012: The maximum continuous DC current required is 373A. The capacity of the Battery Isolator should be more than 373A or more than the capacity of the alternator, whichever is higher • For EVO-4024: The maximum continuous DC current required is 266A. The capacity of the Battery Isolator should be more than 266A or more than the capacity of the alternator, whichever is higher 3.16.3 Requirement To Keep The Neutral Conductor Of Shore Power Isolated...
  • Page 58 SECTION 3 | Installation Battery Temperature To Remote Start/Stop Sensor - Model EVO-BCTS Terminals on the Generator Optional Generator Auto Deep Cycle Fuse Start/Stop Battery Bank Module (Within 7” Battery Isolator of battery Engine Starting terminal) Battery Fuse Optional Remote Control EVO-RC Grounding Terminal...

  • Page 59: General Description And Principles Of Operation

    SECTION 4 | General Description & Principles of Operations GENERAL DESCRIPTION This unit 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 60 Inverter and <1ms from Inverter to Grid/Generator. Heavy duty 70A (2x35A in parallel), Transfer Relay is used for reliable transfer of up to 300% surge power and for Neutral to Ground Bond Switching (40A rated for EVO-2212 and EVO-2224). 60 | SAMLEX AMERICA INC.
  • Page 61 “Grounding System and Lightning / Ground Fault Protection” “Neutral to Ground Switching in RV and Marine Applications” 4.5.2 Operation of Transfer and Output Neutral and Chassis Ground Bond Switching Relays – EVO-2212 and EVO-2224 Refer to Schematic at Fig 4.1(a) The Bi-directional Transformer is used as follows: Feeds AC output from the Inverter Section when Grid / Generator power is not available.
  • Page 62 SECTION 4 | General Description & Principles of Operations simultaneously). The Bidirectional Transformer works as a battery Charger. The Hot AC input from the Grid (GRID LINE) or from the Generator (GEN LINE) is fed to the Hot input of the Bi-directional Transformer for battery charging and at the same time, it is passed through to the Hot Out (OUTPUT LINE) for powering the AC loads When Grid / Generator power fails, relays K2 / K3 will be de-energized and contact 4 switches over to contact 3.
  • Page 63 Quick Disconnect (13, Fig 3.9) for disconnecting Output Neutral to Chassis Ground bond in Inverting Mode (Default - connected) NOTE: Relays are de-energized in Invertering Mode and are energized in Charging Mode Fig 4.1(a) Operation of Transfer Relay and Neutral to Ground Bond Switching in EVO-2212 and EVO-2224 SAMLEX AMERICA INC. | 63...
  • Page 64 SECTION 4 | General Description & Principles of Operations NEUTRAL METAL CHASSIS GROUND OF THE UNIT INVERTING CHARGING BI-DIRECTIONAL TRANSFORMER LINE AC OUTPUT GRID OUTPUT GRID OUTPUT GRID LINE LINE LINE NEUTRAL NEUTRAL NEUTRAL DPDT Transfer Relay (70A) for Grid, Line •...

  • Page 65: Section 5

    SECTION 4 | General Description & Principles of Operations Mode” with the AC power from the Grid / Generator charging the batteries as well as provid- ing power to the AC loads. 4.5.6 Transfer From Grid / Generator to Inverter When the unit is operating in “Charging Mode”...

  • Page 66: Modes Of Operation

    SECTION 4 | General Description & Principles of Operations Inverter is synchronized with the Generator and once synchronization is completed, the load is transferred instantly (within 1 ms) to the Generator at Zero Crossing of the voltage wave- form for seamless transfer and for better protection of Transfer Relay contacts. The unit now operates in “Charging Mode”...
  • Page 67 SECTION 4 | General Description & Principles of Operations 4.8.4 Power Saving Mode - Transfer Characteristics in Grid / Generator Mode • Transfer from Grid / Generator to Inverter: If qualified Grid or Generator AC input power is available (its voltage and frequency are within the programmed range), the Transfer Relay remains energized and the AC input power is passed through to the load and at the same time, the unit operates as a battery charger.

  • Page 68: Section 5

    SECTION 4 | General Description & Principles of Operations AC Charger starts charging the battery. If an external charger is also connected to the External Charging Terminals, the internal AC Charger will limit the charging current to a value = (Programmed Value of Charging Current - Value of Current fed from the External Charger).
  • Page 69 SECTION 4 | General Description & Principles of Operations 4.12 OPTIONAL REMOTE CONTROL EVO-RC FOR PROGRAMMING OF MODES OF OPERATION AND PARAMETERS Optional Remote Control Model EVO-RC (Fig 2.4) will be required for more advanced control and monitoring. Please see separate Owner’s Manual for EVO-RC at Appendix A. The Remote Control comes with 10M / 33 ft., RJ-45 Data Cable.

  • Page 70: Battery Charging In Evolution Series

    SECTION 5 | Battery Charging in Evolution Series INFO For background information on batteries and charging process, please read Section 1.4, “General Information - Lead Acid Batteries”. All battery charging voltages are specified at battery temperature of 25˚C / 77˚F. 5.1 PRINCIPLE OF OPERATION OF BATTERY CHARGING SECTION EVO Series is a Bi-directional Inverter / Charger with a Transfer Relay that operates either as an inverter OR as a battery charger.

  • Page 71: Battery Temperature Sensor

    SECTION 5 | Battery Charging in Evolution Series value of input current from Grid/Generator can be programmed (See Appendix A under Group 2 Parameter Select for Input Setting-"Max Current". Default is 30A). The EVO will automati- cally reduce charging current to support the AC loads on priority and use whatever is extra for charging.
  • Page 72 SECTION 5 | Battery Charging in Evolution Series Table 5.1 shows the programmable range. Default settings for the temperature coefficient is -4mV/°C/Cell. 5.6 3 STAGE CHARGING MODE: BULK, ABSORPTION & FLOAT FOR NORMAL CHARGING Normal day to day charging is performed in a 3 Stage Cycle—BULK, ABSORPTION and FLOAT— to provide rapid and complete charge cycles without undue battery gassing.
  • Page 73 SECTION 5 | Battery Charging in Evolution Series The value of the Bulk Charge Current “Io” depends upon the total Ampere Hour (Ah) capac- ity of the battery or bank of batteries. A battery should never be charged at very high charging current as very high rate of charging will not return the full 100 percent capacity as the Gassing Voltage rises with higher charging current.
  • Page 74 SECTION 5 | Battery Charging in Evolution Series 5.6.3 Float Stage Float Stage is a maintenance stage in which the output voltage is reduced to a lower level, typi- cally 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 75 SECTION 5 | Battery Charging in Evolution Series When Equalization is selected (requires optional Remote Control Model EVO-RC (see Appendix A), the charger will first execute Bulk Stage followed by Absorption Stage. On completion of Absorption Stage, the charger will execute Equalization Stage. After completion of Equalization Stage, the charger will enter Float Stage.
  • Page 76 SECTION 5 | Battery Charging in Evolution Series 5.8 DETAILS OF EQUALIZTION MODE CHARGING CYCLE (Fig 5.2) • During the Bulk Stage, the charger will charge at the programmed Bulk Charge Current “ Io “ (see programmable range at Table 5.1. Default value is 40A). Bulk Charge Current “Io”...
  • Page 77 SECTION 5 | Battery Charging in Evolution Series 5.9 SWITCHING ON AND SWITCHING OFF OF EQUALIZATION MODE (4 STAGE CHARGING) The unit comes preset for charging in Normal Charging Profile (3 Stage Charging Profile). Equalization Profile (4 Stage Charging Profile) is required to be selected manually as follows: Using ON/OFF Push Button on the Front Panel: When the unit is in Charging Mode (qualified Grid / Generator Input is available), the Green LED “Status”...

  • Page 78: 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 79 SECTION 6 | Operation, Protections and Troubleshooting 6.2 POWERING ON / OFF BY FEEDING EXTERNAL +12V CONTROL SIGNAL TO TERMINALS MARKED “REMOTE ON/OFF” ON THE FRONT PANEL (15, FIG 2.1) Programming option is available through the Parameter Setting Menu of the optional Remote Control Model No.
  • Page 80 SECTION 6 | Operation, Protections and Troubleshooting TABLE 6.1 LED AND BUZZER INDICATIONS Red LED Green LED marked Status marked “ON” Buzzer “Fault” (13, Fig (12, Fig 2.1) 2.1) When powered ON Flash 3 times When powered OFF Normal charging Flash 1 time per sec Equalization charging Flash 2 times per...
  • Page 81 SECTION 6 | Operation, Protections and Troubleshooting TABLE 6.2 PROGRAMMABLE AND DEFAULT PARAMETERS: GROUP CHARGING CURVE Programming Range (Programming requires optional Re- Default mote Control Model EVO-RC) Parameter EVO- EVO- EVO- EVO- EVO- EVO- EVO- EVO- 2212 3012 2224 4024 2212 3012 2224...
  • Page 82 SECTION 6 | Operation, Protections and Troubleshooting TABLE 6.3 PROGRAMMABLE AND DEFAULT PARAMETERS - GROUP "INPUT SETTING" Programming Range Default value Parameter Group EVO- EVO- EVO- EVO- EVO- EVO- EVO- EVO- name 2212 3012 2224 4024 2212 3012 2224 4024 DEFAULT FREQ 50 / 60Hz 60Hz...
  • Page 83 SECTION 6 | Operation, Protections and Troubleshooting TABLE 6.6 PROGRAMMABLE AND DEFAULT PARAMETERS - GROUP "OTHER FUNCTIONS" Setting range Default Value Parameter name 2212 3012 2224 4024 2212 3012 2224 4024 “POWER SAVING” 1 = Enable 0 = Disable Enable • “ENTER POINT”...
  • Page 84 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 Manual at Appendix A.

  • Page 85: Specifications

    SECTION 7 | Specifications Models EVO-2212 EVO-3012 EVO-2224 EVO-4024 INVERTER SECTION Output Waveform Pure Sine Wave Input Battery Voltage Range >9 - 17 VDC >18 - 34 VDC Nominal AC Output Voltage 120 VAC ± 5% Output Frequency 60 Hz ± 0.1 Hz Total Harmonic Distortion of Pure <...
  • Page 86 SECTION 7 | Specifications Transfer Time – Grid / Generator Up to 16ms (Synchronized Transfer) to Inverter Models EVO-2212 EVO-3012 EVO-2224 EVO-4024 OPERATING MODES Grid/Generator Priority (Default) OFF-LINE Mode • Grid/Generator supplies AC loads and charges batteries • Inverter is standby Inverter Priority (Programmable) •...
  • Page 87 SECTION 7 | Specifications SAFETY AND COMPLIANCE • Intertek-ETL listed: Conforms to ANSI / UL STD. 1741 • Intertek-ETL listed: Certified to CAN / CSA STD. C22.2 No. 107.1-01 Safety Compliance • Intertek-ETL listed: Conforms to ANSI / UL STD. 458 • Certified to FCC Part 15(B), Class B EMI / EMC Compliance ENVIRONMENTAL SPECIFICATIONS...

  • Page 88: Warranty

    SECTION 8 | Warranty 2 YEAR LIMITED WARRANTY EVO 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 89 Notes SAMLEX AMERICA INC. | 89...
  • Page 90 Notes 90 | SAMLEX AMERICA INC.
  • Page 91 Notes SAMLEX AMERICA INC. | 91...
  • Page 92 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 11025-EVO-2212-3012-2224-4024-0215...
  • Page 93 APPENDIX A Remote Control Owner's Please read this manual BEFORE Manual for Evolution operating. Series Inverter Charger Model: EVO-RC NOTE: REMOTE CONTROL MODEL NO. EVO-RC IS OPTIONAL AND IS REQUIRED TO BE ORDERED SEPARATELY.
  • Page 94 EVO-RC OWNER'S MANUAL | Index APPENDIX A SECTION 1 Safety Instructions, Introduction and Layout ......3 SECTION 2 Installation ................4 SECTION 3 Operation ................6 SECTION 4 Parameter Setup ..............11 SECTION 5 SD Card ................. 30 SECTION 6 Monitoring of Operation Using LED and Buzzer ....

  • Page 95: Safety Instructions, Introduction And Layout

    1.0 INTRODUCTION AND LAYOUT The EVO-RC Remote Control allows you to monitor and customize the operating parameters of Samlex EVO Inverter Charger Models EVO-2212, 2224, 3012 and 4024. Layout is shown in Fig. 1.1(a) and (b) below. LCD Screen – 2 rows of...

  • Page 96: Installation

    SECTION 2 | Installation APPENDIX A 2.1 INSTALLATION GUIDELINES The remote control is provided with 10M/33ft, RJ-45 Data Cable (Straight Wired). Check the proposed routing distance of the wire and use longer wire, if necessary. • Flush mounting of the Remote requires appropriate cut-out in the wall/panel. Take neces- sary precautions to ensure any wiring/plumbing running behind the wall/panel is not damaged.
  • Page 97 SECTION 2 | Installation APPENDIX A Take the other end of remote cable and plug it into the RJ-45 Jack at the back of the EVO-RC (Fig. 2.3). Check the remote display to ensure the Power-up self test initiates. If the self test is successful, secure the EVO-RC to the wall using the four screws. (Fig 2.2) Flush mounting the EVO-RC on the wall with 4pcs, Φ3mm self-tapping screws (flat head).

  • Page 98: Operation

    SECTION 3 | Operation APPENDIX A 3.0 GENERAL INFORMATION EVO-RC Remote Control provides the user with the ability to modify EVO Inverter Charger’s operating parameters. The default settings in EVO Inverter Charger are adequate for some installations but may have to be modified for others. This Section provides details on the re- mote functions, status and menu maps and displays, fault messages and parameter settings.
  • Page 99 SECTION 3 | Operation APPENDIX A 3.2 POWER ON / POWER OFF Power ON Press ON/OFF Key and hold for 2 seconds to turn the EVO Inverter Charger ON. When the EVO Inverter Charger is OFF and the ON/OFF key POWER ON...
  • Page 100 SECTION 3 | Operation APPENDIX A 3.5. FAULT CLEARING If any fault occurs, the LCD screen will display the Fault Message, Red LED Alarm (Fault) will be lighted. Remove cause of the fault and the unit will remain in Fault Mode. A short press (0.1 sec- onds) of the ON/OFF button will clear the Fault Message and the EVO Inverter Charger will return to operational status (if the fault condition no longer exists).
  • Page 101 SECTION 3 | Operation APPENDIX A ò Page Up (Up key) * Fault Message Page Down (Down key) ** Fault Fault GROUP 1 GROUP 2 GROUP 3 GROUP 4 PAGE No. STANDBY INVERTING CHARGING N-CC POWER SAVING Page 1 BATTERY 12.000V OUTPUT 120.00V...
  • Page 102 SECTION 3 | Operation APPENDIX A NOTES FOR FIG 3.2: 1. The 3-digit numbers XXX in “RC-XXX” indicate the Revision No. of the firmware for the Remote Control EVO-RC 2. The 3 or 4-digit abbreviations on the top right corner of the 18 Screens (Pages 1 to 18) for “CHARGING”...

  • Page 103: Parameter Setup

    SECTION 4 | Parameter Setup APPENDIX A 4.1 GROUP AND PARAMETER SETUP MENUS Up to 46 operating parameters can be programmed to suit the desired operating conditions. The operating parameters have been organized in 7 “Select Group” Menus (Groups 1 to 7) as shown in Parameter Setup Menu Maps at Fig 4.1 for Groups 1 to 4 and Fig 4.2 for Groups 5 to 7.
  • Page 104 SECTION 4 | Parameter Setup APPENDIX A 4.1 PARAMETER SETUP MENU MAPS ò Page Up (Up Key)* Enter Key (To Group towards the right) Page Down (Down Key)** Back Key (To Group towards the left) Group 1 Group 2 Group 3 Group 4 SELECT GROUP SELECT GROUP...
  • Page 105 SECTION 4 | Parameter Setup APPENDIX A ò Page Up (Up Key)* Enter Key (To Group towards the right) Page Down (Down Key)** Back Key (To Group towards the left) Group 5 Group 6 Group 7 SELECT GROUP SELECT GROUP SELECT GROUP “OTHER FUNCTION”...
  • Page 106 SECTION 4 | Parameter Setup APPENDIX A 4.2 PARAMETER SETUP PROCEDURE – GENERAL Please refer to Fig 4.3 below. The Enter key is used to enter Parameter Setup Mode from any Operating Mode Screen in Fig 3.2. Example in Fig 4.3 below starts with Inverting Mode Screen (Group 2, Page 1 in Fig 3.2). After the Enter key is pressed, the Up/Down keys are used to navigate to the different Parameter Groups (Groups 1 to 7).
  • Page 107 SECTION 4 | Parameter Setup APPENDIX A 4.3 PASSWORD PROTECTION FOR PARAMETER CHANGE All parameters except Time and Date are protected with a Password. When the required pa- rameter screen is reached and is displayed and Enter Key is pressed to modify the parameter value, the system will request a 4-digit Password.
  • Page 108 40 A BULK CURRENT 90 A WRITING... BULK CURRENT 50 A 90 A SECTION 4 | Parameter Setup WRITING... APPENDIX A 50 A WRITE SUCCESS! WRITING... 50 A 50 A WRITE SUCCESS! Flashes twice when there is a write failure. 50 A WRITE FAILURE! WRITE SUCCESS!
  • Page 109 SECTION 4 | Parameter Setup APPENDIX A “BATT LOW VOLTAGE” >9.0V – 12.0V >18.0V – 24.0V 10.5V 21.0V (Battery Low Voltage Shut Down) “LV DETECT TIME” (Detect Time to Qualify 0-600 sec 10 sec as Battery Low Voltage Shut Down Condition) “LV CUT OFF TIME”...
  • Page 110 SECTION 4 | Parameter Setup APPENDIX A COMPENSATE: This parameter sets the temperature compensation for the battery. The operational range of the EVO Inverter Charger is -20°C to 60°C. This compensation voltage will affect the Absorbtion Voltage/Equalize Voltage/Floating Voltage/ Batt Over Volt/Restart Voltage/Low Volt Alarm/Batt Low Voltage when the Temperature Sensor is installed on the battery (see Fig 2.5 in the Owner's Manual for EVO Inverter Charger).
  • Page 111 SECTION 4 | Parameter Setup APPENDIX A LOW VOLT ALARM: When inverting, if battery voltage is under the set value, the Red LED marked "Alarm" flashes once per second. The buzzer in EVO Inverter Charger will beep once per second. If Relay Function is set for Generator, the relay will turn ON.

  • Page 112: Charge Mode

    SECTION 4 | Parameter Setup APPENDIX A Enter Key Up Key x 9 SELECT GROUP BULK CURRENT LV DETECT TIME CHARGE CURVE 40 A 10 sec LV CUT OFF TIME: Even when the Inverter Section is shut down due to “Battery low voltage!” fault condition as described above, there will still be some power drawn from the battery to keep the other circuitry in the EVO Inverter Charger alive so that the inverter can be switched on when the fault gets cleared automatically after the battery has been recharged to the “RESET VOLT-...
  • Page 113 SECTION 4 | Parameter Setup APPENDIX A ates in “Charging Mode” and qualified AC input from the Grid / Generator is passed through to the AC Output and at the same time, the Internal AC Charger starts charging the battery. If an external charger is also connected to the External Charging Terminals, the internal AC Charger will limit the charging current to a value = (Programmed Value of Charging Current –...
  • Page 114 SECTION 4 | Parameter Setup APPENDIX A side charging current and the pass through load current. Based on the rated capacity of the Grid Branch Circuit/Generator, the net AC input current will be required to be limited to pre- vent overloading of the Grid Branch Circuit/Generator. EVO Series has a very powerful battery charger that will require a proportionate higher AC in- put current from the Grid/Generator.
  • Page 115 SECTION 4 | Parameter Setup APPENDIX A 4.6 GROUP 3 PARAMETER SET UP: INPUT LOW LIMIT Please refer to Parameters under Group 3 at Fig 4.1. Details of Parameter set up are given below: TABLE 4.6. GROUP 3 PARAMETER SET UP: INPUT LOW LIMIT Page Setting range Default value...
  • Page 116 SECTION 4 | Parameter Setup APPENDIX A DETECT TIME 2: This is the time limit in cycles up to which low AC input voltage "CUT-OFF 2" is allowed. Up Key x 2 Enter Key Up Key x 4 SELECT GROUP SELECT GROUP RESET VOLTAGE DETECT TIME 2...
  • Page 117 SECTION 4 | Parameter Setup APPENDIX A CUT OFF VOLT 1: If during "Charging Mode", the AC input voltage rises above "CUT-OFF VOLT 1" for period > "DETECT TIME 1", the EVO Inverter Charger will transfer to "Inverting Mode". Up Key x 3 Enter Key Up Key x 1 SELECT GROUP...
  • Page 118 SECTION 4 | Parameter Setup APPENDIX A 4.8 GROUP 5 PARAMETER SET UP: OTHER FUNCTIONS Please refer to Parameters under Group 5 at Fig 4.2. Details of Parameter set up are given below: TABLE 4.8. GROUP 5 PARAMETER SET UP: OTHER FUNCTIONS Page Setting range Default value...

  • Page 119: Remote Switch

    SECTION 4 | Parameter Setup APPENDIX A WAKE UP POINT: If the unit is in "Power Save Mode" and the value of the AC power of the load rises to "WAKE UP POINT", the unit will quit "Power Save Mode" and will start operating in full volt- age "Inverting Mode".
  • Page 120 SECTION 4 | Parameter Setup APPENDIX A 1 = Normal/Fault. When the EVO Inverter Charger is in Fault Mode, the status Relay turns ON. The Relay is OFF when not in Fault Mode. 2 = Generator. When the battery voltage is lower than “LOW VOLT ALARM”, the Status Relay turns ON.
  • Page 121 SECTION 4 | Parameter Setup APPENDIX A Up Key x 4 Enter Key Up Key x 10 SELECT GROUP SELECT GROUP POWER SAVING PARAMETER SAVE CHARGE CURVE OTHER FUNCTION 1 = Enable 0 = No 4.9 GROUP 6 PARAMETER SETUP: TIME SETTING Please refer to Parameter "TIME SETTING"...

  • Page 122: Sd Card

    SECTION 5 | SD Card APPENDIX A 5.1 SD CARD GENERAL INFORMATION SD Card slot has been provided for data logging and for saving the programmed parameters. SD card supports FAT16/FAT32 format up to 16GB in size. When the SD card is inserted, the LCD screen will display the following. SD card detected SD card is detected and shows the Version and capacity.
  • Page 123 SECTION 5 | SD Card APPENDIX A 5.3 DATA LOG FILES AND VIEWING DATA LOG FILES USING MICROSOFT EXCEL The Data Log Files are writen as Text Files (.txt) in the DATALOG Folder on the SD Card’s Root Directory. Table 5.1 is an image of the DATALOG Folder showing example of the Data Log Files.
  • Page 124 SECTION 5 | SD Card APPENDIX A Fig 5.1 Screen Showing .txt Files • Click "Open" Button (Bottom right corner of Fig 5.1). • Text Import Wizard – Step 1 will be shown (Fig 5.2). Choose "Delimited"File Type". Fig 5.2 Screen Shot of Step 1 of "Text Import Wizard" in Excel •...
  • Page 125 SECTION 5 | SD Card APPENDIX A Fig 5.3 Screen Shot of Step 2 of "Text Import Wizard" in Excel • Data as in Fig 5.4 will be displayed on your Worksheet, with the Log Data stored in Columns and Rows. Fig 5.4 Screen Shot and Data Log Work Sheet SAMLEX AMERICA INC.
  • Page 126 SECTION 5 | SD Card APPENDIX A 5.4 SAVING / UPLOADING PROGRAMMED PARAMETERS 5.4.1 Saving Programmed Parameters All the programmed parameters can be saved on an SD Card (FAT 16 / FAT 32 Format, up to 16 GB capacity). The parameters will be saved in File named “xxxx_yyy.cfg”, where the first group of 4 digits xxxx is the Model No.

  • Page 127: Monitoring Of Operation Using Led And Buzzer

    SECTION 6 | Monitoring of Operation APPENDIX A Using LED and Buzzer TABLE 6.1 LED & BUZZER INDICATIONS FOR OPERATION MONITORING Red LED "Alarm" Status Green LED "Status" Buzzer (Fault) Power ON Flash 3 times Power OFF Normal charging Flash 1 time per second Equalization charging Flash 2 times per second Beep per 3 second...

  • Page 128: Fault Messages And Troubleshooting Guide

    • EVO Inverter Charger is in FAULT MODE because the battery voltage has dropped to 9V for EVO-2212 / 3012 or to 18 V for EVO-2224 / 4024 • When the battery voltage drops to 9V for the 12V version of EVO Inverter Char- ger or 18V for the 24V version, only the Inverter Section will be switched OFF and message “Battery ultra low voltage!”...
  • Page 129 SECTION 7 | Fault Messages and APPENDIX A Troubleshooting Guide EVO Inverter Charger is in FAULT MODE because the battery voltage has risen to the set upper threshold of “BATT OVER VOLTAGE” (a) AC input is not available and EVO Inverter Charger is operating in Invert- ing Mode: •...
  • Page 130 SECTION 7 | Fault Messages and APPENDIX A Troubleshooting Guide EVO Inverter Charger is in FAULT MODE because there is a short circuit on the output side in Inverter Mode. Short circuit protection is activated when the output current is over 18.33Arms and output voltage is less than 15 Vrms for 6 cycles (0.1 second for 60 Hz) •...

  • Page 131: Specifications

    SECTION 8 | Specifications APPENDIX A MODEL NO. EVO-RC COMPATIBLE MODEL NUMBERS EVO-2212, EVO-3012, EVO-2224, INVERTER CHARGERS EVO-4024 DISPLAY LCD DISPLAY 2 Rows, 16 Character each, Alpha-Numeric LCD Display LED INDICATORS Green (Status); Red (Fault / Alarm) INPUT / OUTPUT CABLE SET RJ-45 Data Cable (Straight Wired);...

  • Page 132: Warranty

    SECTION 9 | Warranty APPENDIX A 2 YEAR LIMITED WARRANTY EVO-RC 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 133 APPENDIX A Notes SAMLEX AMERICA INC. | 41...
  • Page 134 APPENDIX A Notes 42 | SAMLEX AMERICA INC.
  • Page 135 APPENDIX A Notes SAMLEX AMERICA INC. | 43...
  • Page 136 Contact 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 11025-EVO-RC-0215...

This manual is also suitable for:

Evo-3012Evo-2224Evo-4024

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