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SAMLEX AMERICA INC. | 9

SeCTIOn 2 |

Features, Applications &
Principle of Operation

Typical Flooded Lead-Acid Battery Chart - 80˚F / 26.7˚C

Battery V

oltage in VDC

Battery State of Charge in Percent (%)

0 10 20 30 40 50 60 70 80 90 100 110 120 130

16.5

16.0

15.5

15.0

14.5

14.0

13.5

13.0

12.5

12.0

11.5

11.0

10.5

10.0

9.5

9.0

C/5

C/40

C/20

C/10

DISCHARGE

CHARGE

C/20

C/3

C/5

C/10

C/100

33.0

32.0

31.0

30.0

29.0

28.0

27.0

26.0

25.0

24.0

23.0

22.0

21.0

20.0

19.0

18.0

24V 12V

Standing
Voltage

Fig 2.2 Charging / Discharging Curves for Typical Flooded Lead Acid Battery

Summary of Contents for SAM Series

Page 1: ...SAM Series Inverter Charger SAM 1500C 12 Please read this manual before installing your inverter owner s Manual ...

Page 2: ...ED IN ITS MANUALS OR OTHER DOCUMENTATION 2 ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES DAMAGES COSTS OR EXPENSES WHETHER SPECIAL DIRECT INDIRECT CONSEQUENTIAL OR INCIDENTAL WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USERS RISK Samlex America reserves the right to revise this document and to periodically make changes to the con...

Page 3: ...rking with Multiple outlet Power Strips disconnect appliance plug from outlet strip or turn off the inverter before working on the ap pliance Multiple outlet Power Strips with switches and circuit breakers interrupt power only to the Hot receptacle terminals 3 Precautions when working with batteries Batteries contain very corrosive diluted Sulphuric Acid as electrolyte Precautions should be taken ...

Page 4: ...ad 75 VAC on AC scale of the Voltmeter because of pulsing nature of DC voltage Do not toucH tHe neutraL SocKet neutraL conDuctorS of tHe ac outLetS 4 Do not connect AC output from NeMA5 15r outlets to AC distribution wir ing where the Neutral is bonded to earth Ground The inverter will see this as abnormal condition of Ground fault and will shut down 5 Do not use with Positive Grounded Electrical ...

Page 5: ...C Power is available Input 120 VAC 60Hz 15A Transfer Relay Rating 30A 2 2 appLicationS Backup AC Power Source or Off Line AC UPS to provide AC power during power outages 12V Lead Acid Battery charging RVs trucks and remote housing 2 3 featureS Integrated 1500W Modified Sine Wave Inverter 30A rated Transfer switch and 2 Stage 12 VDC 15A battery Charger High Inverter peak efficiency of 87 lightweigh...

Page 6: ...sis surface may rise to unsafe touch temperature In this unit heat dissipating components are not mounted directly on the chassis of the unit but on PCB Printed Circuit Board mounted heat sink and there is air gap between the heat sink and the chassis surface The heat sink is cooled by load controlled fan As there is no direct contact between the heat sink and the chassis the chassis surface remai...

Page 7: ...gular pulses that approximate sine wave pulses of a Pure Sine Wave The voltage rises and falls abruptly at a particular phase angle and sits at 0 volts for some time before changing its polarity In a Pure Sine Wave the voltage rises and falls smoothly with respect to phase angle and the voltage changes its polarity instantly when it crosses 0 volts caution Certain devices few examples given below ...

Page 8: ...rom the AC Input is rectified to high voltage DC of around 170 VDC which is then converted to high frequency pulses using MoSfeT Switch and then stepped down through switching transformer The transformed voltage is rectified and filtered A sample of the output voltage is used as feedback signal for the drive circuit for the switching Mosfet to achieve desired voltage regulation of 13 8 VDC using P...

Page 9: ...e in Percent 0 10 20 30 40 50 60 70 80 90 100 110 120 130 16 5 16 0 15 5 15 0 14 5 14 0 13 5 13 0 12 5 12 0 11 5 11 0 10 5 10 0 9 5 9 0 C 5 C 40 C 20 C 10 DISCHARGE CHARGE C 20 C 3 C 5 C 10 C 100 33 0 32 0 31 0 30 0 29 0 28 0 27 0 26 0 25 0 24 0 23 0 22 0 21 0 20 0 19 0 18 0 24V 12V Standing Voltage Fig 2 2 Charging Discharging Curves for Typical Flooded Lead Acid Battery ...

Page 10: ... is used in backup UPS applications where the battery remains charged is floating most of the times and will discharge at lesser frequency only during power out ages Charging details are given below i The charger outputs a constant regulated voltage of 13 8V Float Charge Stage Voltage and can deliver up to 15A of maximum charging current Bulk Charge Stage Current If the battery tries to draw curre...

Page 11: ...i above and its voltage will be clamped to the actual bat tery voltage i e 11 8V This is the start of the bulk Charge Stage v Continuous15A constant current charging in the Bulk Charge Stage Points 1 to 2 of fig 2 3 will slowly raise the battery voltage As the battery voltage rises the volt age difference between the charger s float Stage Voltage setting of 13 8V and the battery s actual voltage r...

Page 12: ... marked INVERTER 9 RED LED marked FAULT 10A AC input power cord 3x AWG 14 105ºC 10B NEMA5 15P Plug for the power cord 11 Negative Input Terminal M9 for 12V Battery Negative 11a BLACK plastic cover for Negative Input Terminal 12 Positive Input Terminal M9 for 12V Battery Positive 12A RED plastic cover for Positive Input Terminal 13 Opening for cooling fan discharge 14 Ventilation slots for air inle...

Page 13: ...A INC 13 SeCTIOn 3 layout 12 6 SAM 1500C 12 Dimensions 345 mm x 202 x 84 mm 13 54 x 7 87 x 3 35 inch Weight 4 kg 8 8 lb 302 345 120 202 Fig 3 2 Dimensions Mounting Arrangement 3 2 DimenSionS anD mountinG arranGement ...

Page 14: ...fans The fans will switch oN automati cally at load 85W when the Inverter is supplying power and at 3A 1A charging current when in battery Charging AC Pass Through Mode The fans draw cool air from the air intake ventilation slots on the AC outlet side 14 Fig 3 1 and discharge hot air out of the fan openings 13 Fig 3 1 on the DC Input Terminal side Keep the areas surrounding the inverter clear by a...

Page 15: ...nd the grounding sockets of the two NEMA5 15R AC outlets 1 Fig 3 1 will be connected to the metal chassis of the unit Hence the metal chassis of the unit and the metal chassis of the AC loads will be bonded to the earth Ground in the Grid AC Supply Panel Leakage protection will be provided by the GfCI in the AC outlet providing AC input power to the unit On detecting leakage the external GFCI supp...

Page 16: ...ected from the metal chassis of the unit and get connected to the internal GfCI circuitry Hence the metal chassis of the AC loads powered from the Inverter will be protected from leakage through the internal GfCI circuitry in the Inverter The internal GfCI circuitry will shut down the AC output of the Inverter if it detects leakage of 5 8mA Under this condition Green LeD CHARGER 7 Fig 3 1 will be ...

Page 17: ...rom a 12V battery System or from a 12 5 VDC to 15 VDC regulated DC Power Supply If a DC Power Supply is used its output current capacity should be more than 2 times the maximum DC input current drawn by the inverter further explanation of operation is based on Dc input power from a 12v bat tery It is recommended that Deep Cycle Type batteries are used for detailed technical information on types co...

Page 18: ...If there is a short circuit along the length of the cables that connect the battery to the unit thousands of Amperes of current can flow from the battery to the point of shorting and that section of the cable will overheat the insulation will melt and is likely to cause fire To prevent occurrence of hazardous conditions under short circuit fuse with Ampere rating 1 25 times the maximum continuous ...

Page 19: ...ive cable and is as close to the Battery terminal as possible preferably within 7 Please ensure that all the connections are tight Loose connections may cause overheated wires and melted insulation 4 6 8 connecting Batteries Series connection 6V Battery 6V Battery Battery 2 Battery 1 Cable A Cable B 12V Inverter Charger Fig 4 2 Series Connection When two or more batteries are connected in series t...

Page 20: ...s the Negative terminal of the 12V battery bank Series parallel connection 6V Battery 6V Battery 6V Battery 6V Battery 12V String 1 12V String 2 Battery 1 Battery 3 Battery 2 Battery 4 12V Inverter Charger Cable A Cable B Fig 4 4 Series Parallel Connection figure 4 4 above shows a series parallel connection consisting of four 6V 200 Ah batteries to form a 12V 400 Ah battery bank Two 6V 200 Ah batt...

Page 21: ...1 of String 1 in Fig 4 4 and the Negative output cable of the Inverter Charger Cable B is connected to the Negative battery post of the first battery Battery 1 as in Fig 4 3 or to the 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 batteri...

Page 22: ...bonded to Ground the inverter will see this as abnormal condition of Ground fault and will shut down 2 the ac output of this unit can not be used in parallel with another ac power Source Severe DamaGe WiLL occur 4 8 LimitinG eLectro maGnetic interference emi This unit contains internal switching devices that generate conducted and radiated electromagnetic interference EMI The EMI is unintentional ...

Page 23: ...tes higher quality of interference suppression in its power supply SeCTIOn 5 Operation 5 1 operatinG moDeS i info Please note that Transfer Relay K1 is a Single Pole Double Throw SPDT type of a relay Hence during switching from the Grid to the Inverter and vice versa the Transfer relay K1 switches only the Line connection of the AC outlets The Neutral conductor of the Grid AC input and the Inverte...

Page 24: ...acts 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 connected to the internal GfCI circuitry 5 1 2 Stand alone Battery charger mode Grid ac pass through mode In this mode the unit is used just as a stand alone battery charger with additional abil ity to pass through Grid AC to the AC loads if desired ...

Page 25: ...eQuire HiGH StartinG SurGe Certain types of AC loads described in Table 5 1 below will require higher starting surge power as compared to their running power 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 ch...

Page 26: ... using the battery Charger oN off Switch CHArG ER 2 Fig 3 1 5 Connect 12V batteries to the Battery Terminals 11 12 in Fig 3 1 6 As the Inverter ON OFF Switch INVERTER 3 Fig 3 1 is in OFF position the follow ing will be seen The Inverter will be in OFF condition The Green LED INVERTER 8 Fig 3 1 will be OFF Transfer Relay K1 will be in de energized condition and through its normally closed NC contac...

Page 27: ...e initiated Transfer Relay K1 will be de energized and through its normally closed NC contacts the connection of the Line Sockets of the AC outlets will be transferred from the Line conductor of the Inverter to the Line Conductor of the Grid input for Grid pass through Transfer Relay K2 will also be de energized and through its Normally Closed NC contacts the Grounding Sockets of the two AC outlet...

Page 28: ... 5 1 for guidance 3 Disconnect all AC side loads 4 Switch OFF the Inverter using the Inverter ON OFF Switch INVERTER 3 Fig 3 1 5 Switch off the battery Charger using the battery Charger oN off Switch CHArG ER 2 Fig 3 1 6 Connect 12V batteries to the Battery Terminals 11 12 in Fig 3 1 7 As the Inverter ON OFF Switch INVERTER 3 Fig 3 1 is in the OFF position the fol lowing will be seen The Inverter ...

Page 29: ...TER 3 Fig 3 1 to off position 115VAC output will be switched OFF The Green LED INVERTER 8 Fig 3 1 will NOT be switched OFF immediately but will dim slowly and extinguish fully in around 1 minute 5 5 connection anD operation aS StanD aLone Battery cHarGer WitH paSS tHrouGH Please refer to Section 5 1 2 for description of this mode 1 Disconnect all AC side loads 2 Switch OFF the Inverter using the I...

Page 30: ...ing LeDs and Buzzer for various protections operational conditions explained below 6 1 1 Load controlled cooling fan Cooling is carried out by convection and by forced air circulation by 2 load controlled fans The fans will normally be off and will be switched oN automatically as follows Inverter supplying AC load s When load s 85W Battery Charging AC Pass Through Mode When charging current 3A 1A ...

Page 31: ...y high inrush current due to very fast voltage rise of the square wave nature of the modified Sine Wave and shut down the inverter try using a small resistive load in parallel to reduce high inrush current to prevent overloading 6 1 6 Low input voltage alarm An alarm will sound when the voltage at the input terminals of the Inverter drops to 10 8V 0 3V This is an indication that either the battery...

Page 32: ...meter because of pulsing nature of Dc voltage Do not touch the Line neutral Sockets If there is a short circuit between the Line Neutral to metal chassis in the Inverter load up to 75V AC will be fed to the Electronic Ground Fault Protection Circuit and the AC output of the Inverter will shut down Ground fault protection will also operate if the neutral and Ground of the nema5 15r ac outlets of th...

Page 33: ... 1 red LeD fauLt 9 fig 3 1 Buzzer remedy reset Normal ON OFF OFF OFF Low DC input alarm 10 8V 0 3V ON OFF OFF ON Check battery voltage and input voltage drop Auto reset when volt age 10 5 V 0 3V No output due to Low DC input voltage shutdown 10 5V 0 3V OFF ON OFF ON Check battery voltage and input voltage drop Auto reset when volt age rises to 11 5V No output due to high DC input voltage shut down...

Page 34: ...tch OFF the INVERT ER ON OFF Switch 3 Fig 3 1 wait for 3 minutes and switch ON again No output due to Ground fault shut down i 5 8 mA leakage from Line Neutral in the load to metal chassis of the load ii Neutral and Ground are bonded on the load size ON OFF ON OFF i Check if there is Neutral to Ground bond or Ground Fault ii Check there is no leakage short from Line Neutral in the load to chassis ...

Page 35: ...e of Ground fault in the AC load s the GFCI in the 15A GFCI protected AC outlet of Grid AC Power will trip table 6 2 protections monitoring Battery charger Grid ac power pass through mode LeD Display other Symptoms possible cause s remedy Green LeD CHArGer 7 Fig 3 1 is ON Charging is normal AC output voltage is not available Unit is in Grid Pass Through Mode but the 15A AC Input breaker on the uni...

Page 36: ...onfirm if Grid has failed If not check if the breaker switch supplying the GfCI pro tected Grid AC outlet has tripped or has been switched off Green LED CHArGer 7 Fig 3 1 is OFF Red LED FAULT 9 Fig 3 1 is ON Charger has stopped Grid voltage is NOT available at the power cord AC output is NOT available There is leakage or Neutral to Ground bond on AC load side First the GFCI protected AC outlet sup...

Page 37: ...rLoAD SHorT CIrCUIT SHUTDoWN Load 15A Input Circuit breaker on the unit will trip paSS tHrouGH moDe cHarGer Section HIGH AC INPUT VoLTAGe SHUTDoWN 143 VAC Auto reset at 138 VAC No transfer to Inverter LoW AC INPUT VoLTAGe SHUTDoWN 10 VAC Auto reset at 75 VAC No transfer to Inverter protectionS inverter moDe oVerLoAD SHUTDoWN 1650 10 for up to 7 sec LOW BATTERY INPUT VOLTAGE ALARM 10 8 0 3V LOW BAT...

Page 38: ... of oppor tunities to do so Warranty service shall be performed only by the Warrantor Any attempt to remedy the defect by anyone other than the Warrantor shall render this warranty void There shall be no warranty for defects or damages caused by faulty installation or hook up abuse or misuse of the equipment including expo sure to excessive heat salt or fresh water spray or water immersion No othe...

Page 39: ...SAMLEX AMERICA INC 39 nOTeS ...

Page 40: ...e 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 ...

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SamplexPower SAM Series, Owner'S Manual

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