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Manual - Samlex America Inc.

1. SECTION 2 RE A Lid SECTION 3 iSo irn SECTION 4 Parameter Setup SECTION 5 SD Can DE SECTION 6 Monitoring of Operation Using LED and Buzzer SECTION 7 Fault Messages and Troubleshooting Guide SECTION 8 SD CILICATIONS erue oim tatu eden E Le NE SECTION 9 Warnan 2 SAMLEX AMERICA INC SECTION 1 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 1 1O CO UT gt LCD Screen 2 rows of 16 characters each ON OFF Key Green LED Status Red LED Alarm Fault Navigation Key Back Navigation Key Up Navigation Key Down Navigation Key Enter SD Card Slot FAT16 32 for mat Up to 16 GB RJ 45 Jack At the back not shown RJ 45 Data Cable Straight Wired 10 meter 33 feet length Fig1 1 b samlexpower SD Card Model EVO RC Fig 1 1 a Optional Remote Control EVO RC Layout Plug Fig 1 1 b Cable For Remote Control EVO RC SAMLEX AMERICA INC 3 SECTION 2 2 1 INSTALLATION GUIDELINES The remote control is provided with 10M 33ft RJ 45 Data Cable Straight Wired Check the popri
2. PAGE No GROUP 1 GROUP 2 GROUP 3 GROUP 4 Pade 1 STANDBY INVERTING CHARGING N CC POWER SAVING 9 BATTERY 12 000V OUTPUT 120 00V GRID 120 00V BATTERY 12 000 Page 2 STANDBY INVERTING CHARGING N CC POWER SAVING 9 OUTPUT 0 00V C OUTPUT 60 00Hz GRID 60 00Hz BATEXT 0 0A STANDBY g INVERTING Y CHARGING N CC2 POWER Page 3 9 GRID 0 00V OUTPUT 10 00 GEN 0 00V ID 1 RC 007 Page 4 STANDBY INVERTING CHARGING N CC2 9 0 00V OUTPUT 1200W GEN 0 00Hz Page 5 STANDBY INVERTING CHARGING N CC 9 2014 10 16 16 00 OUTPUT 1200VA INPUT 20 00A Page 6 STANDBY INVERTING CHARGING N CC ID 1 RC XXX OUTPUT PF 1 000 INPUT 2400W Page 7 INVERTING CHARGING N CC BATTERY 12 000V INPUT 2400VA INVERTING CHARGING N CC Page 8 BATTERY 140 0A INPUT PF 1 000 C 2 INVERTING CHARGING N CC Page 9 BATEXT _ 00A OUTPUT 120 00V INVERTING CHARGING N CC Page 10 _ BATTERY 25 0C OUTPUT 10 00A 2 INVERTING CHARGING N CC Page 11 GRID 0 00V OUTPUT 1200W INVERTING CHARGING 2 Page 12 GEN 0 00V OUTPUT 1200VA INVERTING CHARGING N CC Page 13 ID 1 RC Xxx OUTPUT PF 1 000 CHARGING Page 14 BATTERY 12 000V CHARGING N CC Page 15 BATTERY 10 00A CHARGING N CC Page 16 BAT EXT 0 00A CHARGING N CC Page 17 BATTERY 25 0 CHARGING N CC Page 18 ID 1 RC XXX NOTES Please see next Page 10 Fig 3 2 Overall Operating Mode Display Screen Menu Map SAMLEX AMERICA INC 9 SECTION 3 NOTES FOR FIG 3 2 1
3. GYD 9 35 19 S t 8 614 s OA uo Buipunoin 79 ras ueis s gs LD 293 s1032npuo juawdinby 104 aeq sng EH sng Gam OA Aq pay speo OL 00800000 7T3NVd NOILNAIYLSIC SV TaNVd gt H35HVHO H31H3ANI SAMLEX AMERICA INC 53 SECTION 3 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 Battery Temperature Sensor Model EVO BCTS is installed on the Positive or Negative post of the battery and connected to the port for the Temperature Sensor Supplementary battery charging is being carried out through a solar array and a Charge Controller connected to the DC input provided for external battery charger AC input to the EVO is fed from the Grid and Generator Panel AC output from the EVO is fed to the AC Distribution Panel Automatic Generator start stop is possible as follows Start operation is initiated by closure of NO and Common contacts of the Status Relay 14 Fig 2 1 when battery voltage drops to the programmed value of the Low Voltage Ala
4. Online Mode In this mode PRIORITY is given to the Inverter Section This mode has to be programmed through the optional Remote Control EVO RC Please see details at Sec tion 4 4 of the attached Owner s Manual for EVO RC Appendix A Even if qualified AC input within the programmed voltage and frequency limits is avail able at the Grid Generator AC inputs the unit always operates in Inverting Mode and AC output is provided by the Inverter Section as long as the battery is in charged condition above the LOW VOLT ALARM threshold When the battery discharges to the programmed value of LOW VOLT ALARM threshold 12V Version 9 50V to 12 50V Default 11 0V 24V Version 19 00V to 25 00V Default 22 00V Transfer Relay en ergizes and the unit changes over to Charging Mode and qualified AC input from the Grid Generator is passed through to the AC Output and at the same time the Internal SAMLEX AMERICA INC 67 SECTION 4 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 When the battery voltage rises to the programmed value of RECONNECT VOLTAGE 12V Version 13 50V to 16 00V Default 14 0V 24V Version 27 00V to 32 00V Default 27 6V the Transfer Relay is de energized the unit changes over to
5. POWER SAVING DISCHARGE CHARGE CURVE OTHER FUNCTION 1 Enable 0 OFF DEFAULT RESET This is to reset all of the parameters to the Default Values Up Key x 4 Enter Key Up Key x 8 SELECT GROUP c SELECT GROUP c POWER SAVING c DEFAULT RESET CHARGE CURVE OTHER FUNCTION 1 Enable 0 No 28 SAMLEX AMERICA INC SECTION 4 DATALOG TIME AND DATALOG DISABLE Set the time period of the data log 0 Disable 1 1 sec 2 10sec 3 30 sec 4 60 sec 5 5 min 6 10 min Up Keyx4 Enter Key Up Key x 9 SELECT GROUP SELECT GROUP POWER SAVING DATALOG TIME CHARGE CURVE OTHER FUNCTION 1 Enable 1 1 PARAMETER SAVE Save all parameters to SD Card see Details at Section 5 Up Keyx4 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 under Group 6 at Fig 4 2 Set up details are given below The Date and Time Format is Year Month Day Hour Minute 24 hour clock Up Key x 5 Enter Key SELECT GROUP c SELECT GROUP c TIME SETTING CHARGE CURVE TIME SETTING 2000 01 01 00 00 4 10 GROUP 7 PARAMETER SETUP STOP SD CARD Please refer to Parameter STOP SD CARD under Group 7 at Fig 4 2 Set up details are given below Once SD Card is being used it should be removed ejected only after the operation
6. 3 or 4 Stage Charging Equalization 4 Stage 0 Normal 3 Stage 3 ON LINE MODE or O OFF Off Line Grid Generator Priority OFF LINE 1 ON On Line Mode Battery Invertor Priority j RECONNEET VOLT 13 50V 16 00V 27 00V 32 00V 14 00V 27 60V For On Line Mode 5 FLOATING EXIT 10 00V 13 00V 20 00V 26 00V 12 00V 24 00V BULK CURRENT This sets the maximum charging current of EVO Inverter Charger This value is the sum of charging currents from the internal AC Charger and external Charge Controller connected to the EXT Charger terminals of EVO Inverter Charger 3 4 Fig 2 1 in Owner s Manual for EVO Inverter Charger Enter Key cnr Ge ABSORP VOLTAGE This sets the charging voltage in the Constant Voltage Absorption Stage Enter Key Up Key x 1 SELECT GROUP BULK CURRENT ABSORP VOLTAGE CHARGE CURVE 40A 14 40 V EQUALIZE VOLTAGE This sets the charging voltage in the Constant Voltage Stage in the 4 stage Equalization Charging Stage Enter Key Up Key x2 SELECT GROUP BULK CURRENT EQUALIZE VOLTAGE CHARGE CURVE 40A 14 40 V FLOATING VOLTAGE This sets the charging voltage in the Constant Voltage Float Stage Enter Key Up Key x3 SELECT GROUP BULK CURRENT c FLOATING VOLTAGE CHARGE CURVE 40A 13 50V SAMLEX AMERICA INC 17 SECTION 4 COMPENSATE This parameter sets the temperature compensation for the battery The operational range of the EVO Inverter Cha
7. There will be no AC output or charging because the Transfer Relay will be de energized and PWM drive to the Inverter Section will be switched OFF The fault will be cleared automatically when the battery voltage drops to 0 5V below to the set upper threshold of BATT OVER VOLT The EVO Inverter Charger will restart in Inverting Mode synchronize with the AC input and then he Transfer Relay will be energized to transfer to AC input at zero crossing The unit will thus resume operation in Charging Mode Input over current EVO Inverter Charger is in FAULT MODE because the input current being drawn from the AC input source Input current Charging Current Pass Through Current to the load is 1A more than the set threshold of MAXIMUM CURRENT for 5 seconds e There will be no AC output because the Transfer Relay will be de energized charg ing will be stopped and PWM drive to the Inverter Section will be switched OFF The Green LED marked Status will be switched OFF and the Red LED marked Alarm will be steady ON The buzzer in EVO Inverter Charger will beep steady Inverter Charger will be latched in OFF condition and will require manual reset by powering OFF waiting for 1 minute and then powering ON again e set threshold of MAXIMUM CURRENT Section 4 5 should match the breaker capacity of the AC input source AC input Branch Circuit If AC input current capacity cannot be increased reduce the A
8. Inverting Mode and the AC Output is fed from the internal Inverter Section This mode is preferred in solar applications where Grid Generator backup power is available but the primary source of power is batteries that are charged through Solar Panels Charge Controller The Inverter Section of EVO Inverter Charger will provide AC power most of the time and AC power from the Grid Generator will be drawn to charge the batteries only when the batteries are discharged to Low Voltage Alarm Threshold due to excessive load or due to long cloudy periods This application is desir able in areas where Grid Utility Energy Rates are high and use of solar power is more cost effective 4 9 TEMPERATURE SENSOR FOR BATTERY CHARGING Battery Temperature Sensor Model EVO BCTS Fig 2 5 has been provided to ensure optimum charging by modifying the charging voltages based on temperature if the battery sees very wide temperature swings Temperature compensation can be programmed with the help of optional Remote Control EVO RC see Appendix A Range is 3 to 4 mv C cell Default is 4 mv C cell Without temperature compensation the battery life is likely to be drastically reduced be cause the battery will be undercharged during cold conditions will build up sulfation or will be overcharged during hot conditions will boil and lose excessive water Please read White Paper titled Batteries Chargers amp Alternators available online at www sam
9. 9 5V 12 5V 19 0V 25 0V 11 0V 22 0V Battery Low Voltage Alarm BATT LOW VOLTAGE gt 9 0V 12 0V gt 18 0V 24 0V 10 5V 21 0V Battery Low Voltage Shut Down LV DETECT TIME 0 600 sec 10 sec Low Voltage Detect Time LV CUT OFF TIME 0 7200 sec 1200 sec Low Voltage Cut Off Time RESET VOLTAGE 12 0V 17 0V 24 0V 35 0V 12 5V 25 0V Battery Low Voltage Reset BATT OVER VOLT 14 0V 17 0V 28 0V 35 0V 16 0V 32 0V Battery Over Voltage Shut Down CHARGE MODE Normal 3 Stage Equalization 4 Stage Normal 3 Stage 3 or 4 Stage Charging ON LINE MODE 0 OFF 12 0 OFF RECONNECT VOLT 13 50V to 16 00V 27 00V to 32 00V 14 00V 27 60V For On Line Mode FLOATING EXIT 10 00V to 13 00V 20 00V to 26 00V 12 00V 24 00V SAMLEX AMERICA INC 81 SECTION 6 TABLE 6 3 PROGRAMMABLE AND DEFAULT PARAMETERS GROUP INPUT SETTING Programming Range Default value Parameter name EVO EVO Evo EvO EVO EVO EVO EVO 2212 3012 2224 4024 2212 3012 2224 4024 MAXIMUM 5 40A 5 70A 5 40A 5 70A 30A CURRENT SETTING TABLE 6 4 PROGRAMMABLE AND DEFAULT PARAMETERS GROUP INPUT LOW LIMIT 2212 3012 2224 4024 2212 3012 2224 4024 DETECT TIME 1 0 2000 cycle 300 cycle w uwr Urorromr2 600 0007 so LOW LIMIT CUT OFF POINT 2 60 0 200 0V 85 0V DETECT TIME 2 0 2000 cycle 60 cycle CUT OFF POINT 3 60 0 200 0V 80 0V TABLE 6 5 PROGRAMMABLE AND DEFAULT PARAMETERS G
10. Evolution Series Owner s Please read this manual BEFORE Inverter Charger Manual operating Pure Sine Wave Models EVO 2212 EVO 3012 EVO 2224 EVO 4024 EVO INVERTER CHARGER MANUAL SECTION 1 Safety Instructions amp General Information 3 SECTION 2 Components amp Layout 24 SECTION 3 IristallatlOni 28 SECTION 4 General Description and Principles of 59 SECTION 5 Battery Charging in Evolution Series 70 SECTION 6 Operation Protections and Troubleshooting 78 SECTION 7 Tore ila T 85 SECTION 8 Warrafily iiec tete ect dete deg tul dere ads 88 APPENDIX A EVO RC Optional Remote Control Owner s Manual 2 SAMLEX AMERICA INC SECTION 1 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 amp MAINTENANCE OF THE INVERTER CHARGER THE FOLLOWING SYMBOLS WILL BE USED IN THIS MANUAL TO HIGHLIGHT SAFETY AND IMPORTANT INFORMATION A N WARNING Indicates possibility of physical harm to the user in case of non compliance ATTENTION Ily a une possibilit de faire du mal physique l utilisateur si les consignes de s curit s sont
11. If the unit is in Fault Mode it will be possible to power OFF the unit with the ON OFF Push Button As explained under paragraph 6 1 2 as long as AC input voltage 60VAC is present the unit CANNOT BE POWERED OFF using the ON OFF Button on the front panel of the unit or on the optional Remote Control EVO RC see Appendix A In order to power off using the Power ON Off Button switch OFF the AC input first 6 7 12V 100 CAPACITY DC SOURCE FOR SIGNALING A 12V 100mA capacity DC source has been provided 16 Fig 2 1 This voltage may be routed through the contacts of the Status Relay 14 Fig 2 1 to feed 12V ON OFF control signal to drive circuits of remote monitoring of the following 3 programmable conditions of operation of the unit Refer to Table 6 6 under Relay Function 0 Relay will be ON contacts will close when in Charging Mode 1 Relay will be ON contacts will be closed in Fault Mode 2 Relay will be ON contacts will close at Low Battery Alarm and OFF contacts will open at Low Battery Reset This option may be used for Generator Auto Start Stop with the help of optional Generator Auto Start Module Please see Section 4 7 for details 84 SAMLEX AMERICA INC SECTION 7 Models EVO 2212 EVO 3012 EVO 2224 EVO 4024 INVERTER SECTION Output Waveform Pure Sine Wave Input Battery Voltage Range gt 9 1
12. Maximum Charging Current 50A COOLING PROTECTIONS AND ALARMS Cooling 2 Fans Temperature Controlled Variable Speed Protections and Alarms Battery Low Voltage Alarm and Low Over Voltage Shut Down Shut Down under Input Over Current Output Over Current Output Over load and Output Short Transformer and Heat Sink Overheat Shut Down Immunity Against Conducted Electrical Transients in Vehicles OPTIONAL REMOTE CONTROL Model No EVO RC see Appendix A Specifications Advanced Features for programming various parameters and modes of operation 2 Rows of 16 Character Alpha Numeric LCD Display for messaging Up to 16 GB SD Card Slot for Data Logging Comes with 10M 33ft RJ 45 Data Cable 86 SAMLEX AMERICA INC SECTION 7 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 Intertek ETL listed Conforms to ANSI UL STD 458 with Marine Supplement Safety Compliance EMI EMC Compliance Certified to FCC Part 15 B Class B ENVIRONMENTAL SPECIFICATIONS Operating Temperature 20 C to 60 C 4 F to 140 F Storage Temperature 40 C to 70 C 40 F to 158 F Operating Humidity 0 to 95 RH non condensing WEIGHTS AND DIMENSIONS Dimensions W x D H 325 x 426 x 207 mm 12 79 x 16 77 x 8 15 in Weights
13. Resistance Ohm It is the property of a conductor that opposes the flow of current when a voltage is applied across it In a resistance the current is in phase with the voltage It is denoted by and its unit is Ohm also denoted as Inductive Reactance Capacitive Reactance X and Reactance X Reactance is the opposition of a circuit element to a change of electric current or voltage due to that element s inductance or capacitance Inductive Reactance X is the property of a coil of wire in resisting any change of electric current through the coil It is proportional to frequency and inductance and causes the current vector to lag the voltage vector by Phase Angle o 90 Capacitive re actance X is the property of capacitive elements to oppose changes in voltage X is inversely proportional to the frequency and capacitance and causes the current vector to lead the voltage vector by Phase Angle o 90 The unit of both X and X is Ohm also denoted as The effects of inductive reactance X to cause the current to lag the voltage by 90 and that of the capacitive reactance X to cause the current to lead the voltage by 90 are exactly oppo site and the net effect is a tendency to cancel each other Hence in a circuit containing both inductances and capacitances the net Reactance X will be equal to the difference between the values of the inductive and capacitive reactances The ne
14. TXT Fie 758 09181218 18 09 2014 12 18 PM TXT Fie 73K8 109151407 15 09 2004 2 07PM 09151404 15 09 2014204PM TXT Fie 09151158 15 09 2014 11 58 AM TXT Fie 123KB 09150123 15 09 2014 1 23AM TXT Fle peras z File name 09301051 x re Files E Fig 5 1 Screen Showing txt Files e Click Open Button Bottom right corner of Fig 5 1 e Text Import Wizard Step 1 will be shown Fig 5 2 Choose Delimited File Type Text Import Wizard Step 1 of 3 31 xl The Text Wizard has determined that your data is Delimited If this is correct choose Next or choose the data type that best describes your data data type Choose the file type that best describes your data Delimited Characters such as commas or tabs separate each field C Fixed width Fields are aligned in columns with spaces between each field Start import at row 1 File origin Ms Dos 8 Preview of file FS Users Products Library Suppliers Winstream Product Review S 109301051 TXT 3012 ate Time Gen status Gen freq Gen volt Grid status Grid freq Grid volt 014 09 30 10 51 41 33341 000 00 000 32 33343 000 00 000 21 lt 00 12 lt 0015 014 09 30 10 51 42 33341 000 00 000 32 33343 000_00 000_24 lt 00_12 lt 0015 014 09 30 10 51 43 33341 000 00 000 32 33343 000 00 000 24 00 12 0015 v Cancel sock we Fig 5 2 Screen Shot of Step 1 of Text Import Wizard in Excel e
15. 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 When the Group for the desired setting is displayed on the LCD the Enter Key is used again to select this Group The Up and Down Keys are used to move to the individual param eters within the Group Pressing the Back Key will exit the specific Parameter or Group backing to previous level There is a 30 second timeout for setting parameters after 30 seconds the Setting Mode will be cancelled and the EVO RC will revert to the mode associated with current operation It is highly recommended to set the EVO Date and Time Parameter Group 6 as this value is used to record data logging files Refer to Section 4 9 for Date and Time set up C Enter Key J Group up Up Key Back Key 4 Group down Down Key Any Operationg Mode Screen from Fig 3 2 Parameter Setup Screen eg BULK CURRENT E ERES INVERTING gt Group 1 SELECT GROUP gt BULK CURRENT OUTPUT 120 00v lt p CHARGE CURVE 40 SELECT GROUP Group 2 INPUT SETTING SELECT GROUP Group 3 INPUT Low LIMIT Select Group Menu Map SELECT GROUP Group 4 INPUT HIGH LIMIT SELECT GROUP OTHER FUNCTION SELECT GROUP Group 6 TIME SETTING SELE
16. 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 See guidelines at Tables 1 1 a 1 1 b and 1 1 c for sizing of breakers for AC INPUT circuits and Table 1 2 for sizing of breakers for AC OUTPUT circuits National and Local Electrical Codes will supersede these guidelines The battery terminals are intended for field connection using Copper conductors that are sized based on 90 C and are LARGER than AWG 1 42 4 mm See Tables 1 3 a and 1 3 b for recommended sizes for installation in free air and conduit respectively Over current protection fuse for battery and External Charger circuits has NOT been provided and has to provided by the installer user See guidelines at Tables 1 3 a and 1 3 b for recommended sizes for installation in free air and conduit respectively Na tional and Local Electrical Codes will supersede these guidelines Tightening torques to be applied to the wiring terminals are given in Table 1 4 This unit has been provided with integral protections against overloads WARNING To reduce risk of electric shock and fire Installation should be carried out by certified installer and as per Local and National Electrical Codes Do not connect to circuit operating at more than 150 Volts
17. 27 Kg 59 Ib 29 kg 64 Ib 26 Kg 57 lb 29 Kg 64 LB NOTES 1 All AC power ratings in the Inverter Section are specified at Power Factor 0 95 2 All specifications given above are at Ambient Temperature of 25 C unless specified otherwise 3 Specifications are subject to change without notice 4 Marine Supplement is valid when installed using Drip Shield Please see Figs 3 1 a 3 2 b 3 3 b and 3 4 b SAMLEX AMERICA INC 87 SECTION 8 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 Warranty outside of the United States and Canada is limited to 6 months For a warranty claim the Pur chaser should contact the place of purchase to obtain a Return Authorization Number The defective part or unit should be returned at the Purchaser s expense to the authorized location A written statement describing the nature of the defect the date of purchase the place of purchase and the Purchaser s name address and telephone number should also be included If upon the Warrantor s examination the defect proves to be the result of defective material or workman ship the equipment will be repaired or replaced at the Warrantor s option w
18. As per UL Standard 248 15 This special purpose current limit ing very fast acting fuse will blow in less than 8 ms under short circuit conditions Appropriate capacity of the above Class T fuse or equivalent should be installed within 7 of the battery Plus Terminal Please see Table 3 1 for fuse sizing Marine Rated Battery Fuses MRBF xxx Series made by Cooper Bussmann may also be used These fuses comply with ISO 8820 6 for road vehicles SAMLEX AMERICA INC 37 SECTION 3 AN WARNING It is mandatory to use appropriately sized external fuse in the battery and External Charger Cir cuits If external fuse is not used and reverse polarity connection is made by oversight the input section of the unit will be damaged burnt Warranty will be voided in such a situation AN ATTENTION Il est obligatoire d utiliser un fusible externe de taille appropri e la batterie et les circuits chargeur externe Si le fusible externe est pas utilis et les inversions de polarit est faite par la surveillance la section d entr e de l unit est endom mag e br l La garantie sera annul e dans une telle situation 3 5 5 DC Input Connection for Battery Battery is connected to terminals 1 2 shown in Fig 3 8 The terminal consists of M10 Stud amp Nut Tightening torque for the nut is 70 kgf cm 5 lbf ft Sizes of cables and fuses are shown in Table 3 1 Sizing is based on safety considerations specified in UL 1741 and NEC
19. Refer to NEC 2014 National Electri cal Code Section 215 3 regarding over current protection of Feeder Circuit Conductors b Closest Standard Ampere Rating of Breaker has been used Refer to NEC 2014 National Electrical Code Section 240 6 A regarding Standard Ampere Ratings c Where Standard Breaker Rating does not match the required NEC Ampacity at Column 3 the next higher Standard Ampere Rating of the breaker has been used Refer to NEC 2014 National Electrical Code Section 240 4 B regarding over current devices rated 800 Amps or less d Type of breaker Standard circuit breaker for 120VAC Load Center Breaker Panel SAMLEX AMERICA INC 49 SECTION 3 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 are given in Table 3 4 3 11 GROUNDING TO EARTH OR TO OTHER DESIGNATED GROUND For safety against electrical shock the metal chassis of unit is required to be grounded to the Earth Ground or to the other designated ground For example in a mobile RV the metal frame of the RV is normally designated as the Negative DC ground RV Ground Similarly Boat Ground is provided in the boats An Equipment Grounding Connector 5 in Fig 3 8 has been provided on the metal chas sis for connecting to the appropriate ground throug
20. The inverter design incorporates Soft Start feature with the following advan tages and protections When the unit powers up it starts in Inverting Mode first The output voltage ramps up gradually from around 48 VAC to 120 VAC in around 200 ms This reduces other wise very high starting inrush current drawn by AC loads like Switched Mode Power Supplies SMPS and motor driven loads like fans pumps compressors etc This will result in lower motor inrush current which typically can be up to 650 of the full load current of the motor which means lesser mechanical stresses wear and tear and increased lifetime of the motor coupling and fan Additionally the impact on the load side components is greatly reduced meaning less likelihood of causing problem atic voltage drops during starting Power Surge Up to 300 The inverter is able to deliver very high surge power current of up to 30096 for 1 ms followed by 200 for 100 ms This range of high instantaneous power is delivered at the rated voltage and hence it is able to provide very high starting torque for difficult motor driven loads like compressors and pumps that require higher Locked Rotor Cur rent during startup f the power drawn by the load exceeds the above surge ratings the inverter pro tects itself by limiting the load current to 30096 200 which results in reduction of output voltage and consequent reduction in load current The output voltage recovers auto
21. dimming speed control may not function Sewing machines with speed microprocessor control Transformer less capacitive input powered devices like i Razors flashlights night lights smoke detectors etc ii Re chargers for battery packs used in hand power tools These may get damaged Please check with the manufacturer of these types of devices for suitability SAMLEX AMERICA INC 11 SECTION 1 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 Some fluorescent lamps light fixtures that have power factor correction capacitors The inverter may shut down indicating overload Induction Cooktops 1 3 3 Power Rating Of Inverters The Continuous Output Power rating of an inverter is normally specified in Active Power in Watts for resistive types of loads like heating elements incandescent lamps etc where Power Factor PF 1 The Surge Power rating is specified as a multiple of the Continuous Power Rat ing and normally lasts for duration of 1ms to 100ms Non resistive reactive loads with Power Factor 1 like motors PF 0 4 to 0 8 non Power Factor corrected electronics PF 0 5 to 0 6 etc will draw higher Apparent Power in Volt
22. or to the Positive battery post of the first battery string Battery 1 of String 1 in Fig 3 7 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 3 6 or to the Negative Post of the first battery string Battery 1 of Battery String 1 as in Fig 3 7 the following abnormal conditions will result The resistances of the connecting cables will not be balanced The individual batteries will see different series resistances All the individual batteries will be charged discharged at different charging discharging current and thus will reach fully charged discharged state at different times The battery with lower series resistance will take shorter time to charge discharge as compared to the battery which sees higher series resistance and hence will experience over charging over discharging and its life will be reduced 32 SAMLEX AMERICA INC SECTION 3 ATTENTION Quand il y a 2 batteries fils de batterie ou plus qui sont li s en parall le et branch la fois un chargeur Voir Figs 3 6 et 3 7 il faut faire attention la mani re dont le chargeur est branch la banque de batterie Veuillez assurer que le c ble positif de sortie du chargeur de batterie C ble A est li la borne positive de la premi re batterie La batterie 1 dans la Fig 3 6 ou la borne positive de batterie qui est li e au premier fil Le
23. rentes ainsi elles atteindront un tat de rechargement compl t mais en d calage La batterie ayant le moins de r sistance dans la s rie prendrait moins de temps pour tre recharg e compar aux autres batteries Alors elle serait surcharg e et en cons quence aurait une vie plus courte SAMLEX AMERICA INC 33 SECTION 3 installation 3 5 DC SIDE CONNECTIONS Status Relay BATTERY POSITIVE MEGATIVE E FIG 3 8 DC Side Connections Protection Covers for Battery Terminals 1 Battery Positive Input Connector M10 x 1 25 Nut amp Bolt RED Protection Cover 1 a is Removed 1a RED Protection Cover For Battery Positive Input Connector 2 Battery Negative Input Connector M10 x 1 25 Nut amp Bolt Black Protection Cover 1 b is Removed 2a Black Protection Cover for Battery Negative Input Connector External Charger Input Connector M12 x 0 75 Thumb Nut and Bolt External Charger Input Connector M12 x 0 75 Thumb Nut and Bolt DC Side Ground Connector Hole Dia 6 5mm for AWG 4 to 6 Set Screw M 8 oO KR W RJ 45 Jack for Battery Temperature Sensor EVO BCTS The following DC side connections are required to be made see Fig 3 8 Deep cycle batteries are connected to the battery input terminals 1 and 2 The termi nals are provided with protective covers RED for Positive and BLACK for Negative Fit these covers once connections have been made For detai
24. tion is completed the load is transferred to the Grid Generator at zero crossing of the voltage waveform 4 8 5 Off Line On Line Modes The unit is able to operate in two modes Off Line Mode Default and On Line Mode Off Line Mode is the Default Mode Mode can be changed to On Line Mode through optional Remote Control Model EVO RC Please see Section 4 4 in the attached Owner s Manual for EVO RC Appendix A Off line Mode Default Mode In this Mode PRIORITY is given to the AC input fed from the Grid Generator Inputs This is the Default Mode If qualified AC input within the programmed voltage and frequency limits is available at the Grid Generator AC inputs Transfer Relay energizes and the unit operates 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 Value of Current fed from the External Charger When the Grid Generator AC input fails or is not within the programmed value of voltage and frequen Cy the Transfer Relay is de energized the unit changes over to Inverting Mode and the AC Output is fed from the internal Inverter Section When Grid Generator input is restored the unit reverts back to Charging Mode
25. 0 No 1 Yes 10 DATA OG DISABLE A ipium Bos 121sec DATALOG TIME 4 21min 5 2 5 min 6 10 min 11 PARAMETER SAVE 0 No 1 Yes POWER SAVING Enable or disable Power Saving Mode when in Inverting Mode Up Key x 4 Enter Key SELECT GROUP SELECT GROUP POWER SAVING CHARGE CURVE OTHER FUNCTION 1 Enable ENTER POINT If the value of power drawn by AC load falls to the ENTER POINT value for 5 sec the unit will enter Power Save Mode Up Key x 4 Enter Key Up Key x 1 SELECT GROUP SELECT GROUP POWER SAVING ENTER POINT CHARGE CURVE OTHER FUNCTION 1 Enable 6W 8W 26 SAMLEX AMERICA INC SECTION 4 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 Up Keyx4 Enter Key Up Key x2 SELECT GROUP SELECT GROUP POWER SAVING WAKE UP POINT CHARGE CURVE OTHER FUNCTION 1 Enable 7W 10W REMOTE SWITCH This selection is used when ON OFF control of EVO Inverter Charger is desired through exter nal 12 VDC signal fed to Remote ON OFF terminals on the Front Panel of EVO Inverter Char ger 15 Fig 2 1 in EVO Inverter Charger Owner s Manual On Off Logic Diagram is shown in Fig 4 8 below 12VDC signal is fed through Push Button Type of Switch 0 Button Type Momentary contact of Push Button
26. 03V 2 2V 24 40V 50 2 02V 2 1V 24 20V 40 2 00V 2 0V 24 00V 30 1 97V 1 8V 23 60V 20 1 95V 1 7V 23 40V 10 1 93V 1 6V 23 20V 0 lt 1 93V lt 11 6 lt 23 20 SAMLEX AMERICA INC 19 SECTION 1 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 Do not equalize sealed VRLA type of AGM or Gel Cell Batteries 1 4 9 State of Discharge of a Loaded Battery Low Battery DC Input Voltage Alarm and Shutdown in Inverters Most inverter hardware estimate the State of Discharge of the loaded battery by measuring the voltage at the inverter s DC input terminals considering that the DC input cables are thick enough to allow a negligible voltage drop between the battery and the inverter Inverters are provided with a buzzer alarm to warn that the loaded battery has been deeply discharged to around 8096 of the rated capacity Normally the buzzer alarm is triggered when the voltage at the DC input terminals of the inverter has dropped to around 10 5V for a 12V battery or 21V for 24V battery at C Rate discharge current of C 5 Amps and electrolyte temp of 80 F The inverter is shut down if the terminal voltage at C 5 dis charge current falls further to 10V for 12V battery or 20V
27. 10 SAMLEX AMERICA INC SECTION 1 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 In a sine wave the voltage rises and falls smoothly with a smoothly changing phase angle and also changes its polarity instantly when it crosses O Volts In a modified sine wave the voltage rises and falls abruptly the phase angle also changes abruptly and it sits at OV for some time before changing its polarity Thus any device that uses a control circuitry that senses the phase for voltage speed control or instantaneous zero voltage crossing for timing control will not work properly from a voltage that has a modified sine waveform Also as the modified sine wave is a form of square wave it is comprised of multiple sine waves of odd harmonics multiples of the fundamental frequency of the modified sine wave For example a 60 Hz modified sine wave will consist of sine waves with odd harmonic frequencies of 3rd 180 Hz 5th 300 Hz 7th 420 Hz and so on The high frequency harmonic content in a modified sine wave produces enhanced radio interference higher heating effect in inductive loads like microwaves and motor driven devices like hand tools refrigeration air conditioning compressors pumps etc The higher frequency harmonics also produce overloading effect in
28. 2 sec will switch EVO Inverter Charger ON E 1 12VDC input After power ON After power ON gt 2 sec will switch ON 12VDC input 5 sec 12VDC input 5 sec EVO Inverter Charger will have no effect will switch OFF EVO Inverter Charger 1 Switch Type 12VDC input is No 12VDC input available Power On for 2 sec Off Fig 4 8 On Off Logic Diagram for Remote Switch Options A CAUTION On Off Logic shown in Fig 4 8 also controls the operation of the On Off Button on the front panel of EVO Inverter Charger 11 Fig 2 1 in EVO Inverter Charger Owner s Manual The Default Setting is Button Type If the On Off control is changed to external Remote Switch it will not be possible to switch On Off the EVO Inverter Charger from the front panel On Off Push Button because it will work with Switch Type Logic at Fig 4 8 it will be ON only as long as the Push Button is kept pressed and will switch off when released Up Keyx4 Enter Key Up Key x 3 SELECT GROUP SELECT GROUP c POWER SAVING 5 REMOTE SWITCH CHARGE CURVE OTHER FUNCTION 1 Enable 0 Button SAMLEX AMERICA INC 27 SECTION 4 RELAY FUNCTION This is to select the function of Status Relay 14 Fig 2 1 in the EVO Manual The Status Relay has 2 sets of contacts i Normally Open NO and Common and ii Normally Closed NC and Common NO and Common contacts will be open when the Status Relay is de energized and will close when the
29. 2014 See details under Notes for Table 3 1 3 5 6 DC Input Connection for External Charger External charger is connected to terminals consisting of M12 Stud with Thumb Nut 3 4 in Fig 5 3 Max current fed through these terminals should be lt 50A Use wire size given in Table 3 1 Tightening torque for the Thumb Nut is 35 kgf cm 2 5 Ibf ft Use 70A fuse in series with the Positive wire to protect against short circuit along the length of the connecting wires Fuse should be close to the Positive Input Terminal 3 38 SAMLEX AMERICA INC SECTION 3 TABLE 3 1 SIZING OF BATTERY SIDE CABLES AND EXTERNAL BATTERY SIDE FUSES Rated NEC 90 C Copper Conductor Size Based on NEC Ampacity at External Continuous Ampac Column 3 or 2 Voltage Drop whichever is Thicker See Fuse Based DC Input ity 12596 Note 3 on NEC Current of Rated Cable Running Distance Ampacity See Note DC Input Cable Running Distance betwaen the ait andithe at Column 1 Current at between the Unit and the Batte 3 See Column 2 Battery ry Note 4 See Note Cable Routing In Free Air Cable Routing In Race 2 way Up to 5 ft Up to 10 ft Up to 5 ft Up to 10 ft Column 1 Column 2 Column 3 Column 5 Column 6 Column 7 Column 8 Column 9 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 NEC based size wor avon wenn
30. 60 Hz RESET VOLTAGE 95 0 V RESET VOLTAGE 135 0V 2 1 2 ABSORP VOLTAGE 14 40 MAXIMUM CURRENT 30 00 A CUT OFF VOLT 1 90 0 V J CUT OFF VOLT 1 140 0 V ME EQUALIZE VOLTAGE 14 40 V HIGH CUT OFF 65 00 Hz DETECT TIME 1 300 cycles 4 DETECT TIME 1 60 cycles S7 FLOATING VOLTAGE 13 50 V HIGH RESET 64 00 Hz CUT OFF VOLT 2 85 0V CUT OFF VOLT 2 145 0V ay ay COMPENSATE 4 LOW CUT OFF 55 00 Hz Fr DETECT TIME 2 60 cycles r V DETECT TIME 2 15 cycles 2 V BATT OVER VOLT 16 00 V LOW RESET 56 00 Hz CUT OFF VOLT 3 80 0 V CUT OFF VOLT 3 150 0 V RESET VOLTAGE 12 50 V T a ee T LOW VOLT ALARM 11 00 V LV DETECT TIME 10 sec SS M LV CUT OFF TIME 1200 sec a o5 CHARGE MODE 0 Normal LM a FLOATING EXIT 12 00 V DETECT TIME 3 1 cycle DETECT TIME 3 1 NOTES Please refer to Page 13 Fig 4 1 Parameter Setup Menu Map Groups 1 to 4 12 SAMLEX AMERICA INC SECTION 4 J Page Up Up Key C Enter Key To Group towards th Page Down Down Key lt Back Key To Group towards the Group 5 Group 6 Group 7 SELECT GROUP SELECT GROUP SELECT GROUP OTHER FUNCTION TIME SETTING STOP SD CARD PO
31. Algorithm is used in the Equalization Mode Equalization Mode is selected using optional Remote Control EVO RC see Appendix A This mode is used only for Flooded or Wet Cell batteries The 4 stages will be Bulk Absorption Equalization and Float For details see Section 5 7 and Charging Curves at Fig 5 2 Equalization Mode is desirable for the proper health of Wet Cell Batteries Equalization voltage is programmable Equalization current and Equalization time are computed automatically Please see Table 5 1 for details 5 2 DYNAMIC INPUT POWER DIVERSION CONTROL OF BATTERY CHARGING CURRENT In Charging Mode the net AC input current from the Grid Generator is the sum of the AC 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 input current from the Grid Generator The Grid Branch Circuit Generator will also be required to provide current to the AC loads With the optional Remote Control Model EVO RC the desired 70 SAMLEX AMERICA INC SECTION 5 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
32. Amps VA This Apparent Power is the sum of Active Power in Watts plus Reactive Power in VAR and is Active Power in Watts Power Factor Thus for such reactive loads higher sized inverter is required based on the Apparent Power Further all reactive types of loads require higher inrush starting surge power that may last for gt 1 to 5 sec and subsequent lower running power If the inverter is not sized adequately based on the type of AC load it is likely to shut down or fail prematurely due to repeated overloading Gi INFO The manufacturers specification for power rating of the appliances and devices indicates 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 1 6 below lists some common loads that require high Surge Power on start up A Sizing Factor has been recommended against each which is a multiplication factor to be applied to the rated Running Watt rating of the load to arrive at the Continuous Power Rating of the inverter Multiply the running Watts of the device appliance by the Sizing Factor to arrive at the Continuous Power Rating of the inverter 12 SAMLEX AMERICA INC SECTION 1 TABLE 1 6 INVERTER SIZING FACTOR Type of Device or Appliance I
33. Bond Switching Relay K4 in Figs 4 1 a and 4 1 b to switch bonding of the Output Neutral Connector of the Inverter Charger as follows e When operating as an inverter the current carrying conductor of the Inverter Section that is connected to the Output Neutral connector of the Inverter Charger is bonded to the metal chassis of the inverter by the Output Neutral to Chassis Ground Bond Switching Relay K4 in Figs 4 1 a and 4 1 b As the metal chassis of the inverter is in turn bonded to the RV Ground chassis of the RV or to the Boat Ground DC Negative Grounding Bus Bar and the Main AC Grounding Bus Bar are tied together in a boat and this is called the Boat Ground this current carrying conductor of the Inverter Section will become the Grounded Conductor GC or the Neutral of the Inverter Section SAMLEX AMERICA INC 51 SECTION 3 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 This will ensure that the Grounded Conductor GC Neutral of the Grid power Generator is bonded to the Earth Ground at one single point at the location of the AC Power Distribution System of the Marina RV Park e Di
34. Breaker Power in In Through Current Current AC Input Column 5 on NEC Size verter Mode Current See Note 2 Columns Current Ampacity Based See Note 2 3 Limit See Note 5 at Column on NEC 1 See Note 3 6 Ampacity at See Note See Note Column 6 4 6 See Note 7 Column 1 Column 2 Column 3 Column 4 Column 5 Column 6 Column 7 Column 8 EME ES 2x ANG NOTES FOR TABLES 3 2 1 3 2 2 and 3 2 3 SIZING OF GRID AND GENERATOR INPUT WIRING AND BREAKERS 1 Column 2 indicates the Rated AC Pass Through Current when in Charger Pass Through Mode value of this current 2 Rated AC Output Current in Inverter Mode 2 Column 3 indicates the Rated AC Side Charging Current in Charger Pass Through Mode 3 Column 4 indicates the total Rated AC Input Current which is the sum of the Rated AC Pass Through Current Column 2 and the Rated AC Side Charging Current Column 3 4 Column 5 indicates the Programmed AC Input Current Limit The value of this current is programmable using the optional Remote Control Model EVO RC See Appendix A under Group 2 Parameter Setup for Input Settings Max Current Appropriate value can be programmed to match the available capacity of the Grid input AC Branch Circuit or the rated capacity of the Generator Default value for all the 4 models is 30A 5 Column 6 indicates NEC Ampacity based on which the wiring conductor size Column 7 is determined This NEC Ampacity is not le
35. Control Model No EVO RC see Appendix A for 2 types of external 12V control signal fed through Remote ON OFF Terminal 15 Fig 2 1 Details of these options are given below 6 2 1 Button Type Default This type of logic is applicable when the 12V Control Signal is fed through a series connected Push Button contact Control logic used is as follows e When the unit is in OFF condition a momentary contact of the Push Button gt 2 seconds will turn the unit ON e When the unit is in ON condition pressing of the Push Button lt 5 seconds will have no effect and the unit will continue to remain in ON condition e When the unit is in ON condition pressing the Push Button gt 5 seconds will turn the unit OFF 6 2 2 Switch Type This type of logic is applicable when the 12V Control Signal is fed through a series connected external manual Switch or through an external relay contact Logic used is as follows e When the unit is in OFF condition toggling the external manual switch to ON position or closing the external relay contact will immediately turn the unit ON e When the unit is in ON condition toggling the external manual switch to OFF position for 2 seconds or opening the relay contact for 2 sec will turn the unit OFF CAUTION When Switch Type of ON OFF control described above is selected the ON OFF Button on the front panel of the unit 12 Fig 2 1 should NOT be used to turn ON or turn OFF the unit The front panel O
36. LV CUT OFF TIME while in Battery low voltage fault condition the Inverter Section will restart and Battery low voltage fault condition will be cleared While in Battery low voltage fault condition if AC input is made available be fore the expiry of LV CUT OFF TIME the Battery low voltage fault condition will be cleared The EVO Inverter Charger will restart in Inverter Mode synchro nize with the AC input and then transfer to the AC input at zero crossing It will now operate in Charging Mode Battery ultra low voltage 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 will be displayed Red LED marked Alarm will be steady ON the Green LED marked Status will be switched OFF and the buzzer in EVO Inverter Charger will beep steady When the duration in Battery ultra low voltage fault condition is equal to the set duration of LV DETECT TIME the message will change to Battery low volt age If Battery low voltage fault condition is not reset within the IV CUT OFF TIME EVO Inverter Charger will be shut down completely after the expiry of LV CUT OFF TIME If the batteries are charged by external charger connect
37. N ATTENTION Breakers AC pour les circuits d entr e AC ont pas t fournis en interne Ceux ci doivent tre fournies l ext rieur par l installateur utilisateur sur la base des directives donn es ci dessous Se il vous pla t noter que les directives ci dessous sur dimensionnement des c bles et protection contre les surintensit s seront remplac es par les nationaux codes lectriques locaux applicables 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 programmed at 45A Table 3 2 3 For EVO 4024 when AC Input Current Limit Max Current is pro grammed at 60A AC wiring and breaker sizes depend upon the maximum continuous AC input current under various operating conditions described in the succeeding paragraphs The Maximum Load Current on the output side has to be limited to the rated output Amp SAMLEX AMERICA INC 45 SECTION 3 capacity of the specific model when operating in Inverter Mode Column 1 When Grid Generator input is available and the unit is operating in Charging Pass Through Mode the AC Input Current will be determined as follows The maximum possible AC Input Current Column 4
38. PARAMETER SET UP CHARGE CURVE Please refer to Parameters under Group 1 at Fig 4 1 Details of Parameter set up are given below TABLE 4 4 GROUP 1 PARAMETER SET UP CHARGE CURVE Page Programming Range Default No for Group Parameter EVO EVO EVO EVO EVO EVO EVO EVO 1 AP 2212 3012 2224 4024 2212 3012 2224 4024 1 BULK CURRENT Bulk Charge Current 0 100 0 130A 0 70A 0 110A 40A lo 2 ABSORP VOLTAGE 13 5V 16 0 27 0V 32 0 14 4 28 8V Absorption Voltage 3 EQUALIZE VOLTAGE Q 14 0V 16 0V 28 0V 32 0V 14 4V 28 8V Equalization Voltage 4 FLOATING VOLTAGE 13 0V 15 0V 26 0V 30 0V 13 5V 27 0V Float Voltage 5 COMPENSATE Temperature 3mV to 5mV C Cell 4mV C Cell Compensation 6 BATT OVER VOLT Shut Down 7 RESET VOLTAGE Battery Low Voltage 49 9v 17 0v 240v 350v 12 5V 25 0V Reset 8 LOW VOLT ALARM Battery Low Voltage 9 5V 12 5V 19 0V 25 0V 11 0V 22 0V Alarm 16 SAMLEX AMERICA INC SECTION 4 9 BATT LOW VOLTAGE Shut Down 10 LV DETECT TIME Detect Time to Qualify 0 600 sec 10 sec as Battery Low Voltage Shut Down Condition 11 LV CUT OFF TIME Time in Low Voltage Shut Down Condition 0 7200 sec 1200 sec before Shut Down is Activated 2 CHARGE MODE Normal 3 Stage
39. RJ 45 Jack for EVO RC Remote Air inlet vents for 2 internal cooling fans Additional air inlet vents at the bottom not shown 9A 9B RJ 45 Jacks for Communication Ports COMM 1 and COMM 2 For RS 485 networking and MODBUS Serial Communication Protocol for future use 9C 9D RJ 45 Jacks for Communication Ports COM 3 and COM 4 For CANbus Serial Communi cation Protocol for future use 10A to 10C Knock outs for AC wiring inlet exit wiring entry Diameter 27 8mm 1 3 32 For 34 conduit fittings 11 ON OFF Push Button 12 Green LED ON 13 Red LED Fault 14 Output Terminals for Status Relay Screw M 2 5 AWG 30 to 12 NO Normally Open Common NC Normally Closed N 24 SAMLEX AMERICA INC SECTION 2 Components amp Layout 15 12V Input Terminals for Remote On Off 9 to 15V 3mA Screw M 2 5 AWG 30 to 12 16 Output Terminals for 12VDC source up to 100mA available only when unit is ON Screw M 2 5 2 2 MAIN UNIT LAYOUT BACK FIG 2 2 1 Air outlet vents for 2 internal fans AWG 30 to 12 Fig 2 2 Layout Back 2 3 MAIN UNIT LAYOUT AC SIDE FIG 2 3 w Cover plate for pocket for AC Input Output terminals Pocket for AC Input Output Terminals behind cover plate 1 AC Input Output Terminal Block e Terminal hole diameter 6mm for up to AWG 6 Set Screw M4 Grid Input Line Grid Input Ground Grid Input Neutral Generator Input Line Gen
40. See Note 3 Column 1 Column 2 Column 3 Column 4 Column 5 EVO 2212 2200VA 18A EVO 2224 2200VA 18A EVO 3012 3000VA 25A EVO 4024 4000VA 33A NOTES FOR TABLE 3 3 AC OUTPUT WIRING AND BREAKERS 1 Column 2 indicates the Rated AC Output Current in Inverter Mode 2 Column 3 indicates NEC Ampacity based on which the output wiring conductor is sized This NEC Ampacity is not less than 125 of the Rated Output Current in Inverter Mode Column 2 Refer to NEC 2014 National Electrical Code Section 215 2 1 regarding Feeder Circuit Conductors PLEASE NOTE that when the unit is operating in Inverter Mode it is considered to be an AC source that is feed ing power to the Load Center Breaker Panel on the load side Hence the AC out put circuit of the unit is considered to be a Feeder Circuit for purposes of NEC 2014 3 Column 4 indicates conductor size for the output side wiring The size is based on NEC 2014 National Electrical Code Ampacity Table 310 15 B 16 for Raceway Conductor size is based on i NEC Ampacity Column 3 ii conductor temperature of 75 C and iii ambient temperature of 30 C 86 F 4 Column 5 indicates the Amp rating of EXTERNAL breaker that is required to be in stalled in the Load Center Breaker Panel that is being fed from the AC output from this unit Amp rating of the breaker is based on the following considerations a Not less than NEC Ampacity Column 3
41. Sine Wave Voltage TIME CREST FACTOR PEAK CURRENT 3 RMS CURRENT Current Current Volatge a gt Voltage Fig 1 3 High Crest Factor of current drawn by SMPS 1 4 GENERAL INFORMATION LEAD ACID BATTERIES INFO For complete background information on Lead Acid Batteries and Charging Process visit www samlexamerica com gt Support gt White Papers gt Whitepaper Batteries Chargers and Alternators Lead acid batteries can be categorized by the type of application 1 Automotive service Starting Lighting Ignition SLI a k a cranking and 2 Deep cydle service Deep Cycle Lead Acid Batteries of appropriate capacity are recommended for powering of inverters SAMLEX AMERICA INC 15 SECTION 1 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 96 capacity and to repeatedly accept recharging They are marketed for use in recreation vehicles RV boats and electric golf carts so they may be referred to as RV batteries marine batteries or golf cart batteries Use Deep Cycle batteries for powering inverters 1 4 2 Rated Capacity Specified in Ampere hour Ah Battery capacity C is specified in Ampere hours Ah An Ampere is the unit of measure ment for electrical current and is defined as a Coulomb of charge pass
42. Text Import Wizard Step 2 will appear see Fig 5 3 Choose Semicolon and click Finish button 32 SAMLEX AMERICA INC SECTION 5 SD Card Text Import Wizard Step 2 of 3 2 xl This screen lets you set the delimiters your data contains You can see how your text is affected in the preview Treat consecutive delimiters as one 014 09 30 014 09 30 014 09 30 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 oo mui Fig 5 4 Screen Shot and Data Log Work Sheet SAMLEX AMERICA INC 33 SECTION 5 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 e g 2212 or 2224 or 3012 or 4024 and the second group of 3 digits YYY is the Revision No for that Model e g 061 e For saving first insert the SD Card in the SD Card Slot e Then go to Parameter Save Screen See Section 4 8 and Table 4 8 under heading PARAMETER SAVE Steps are given below Up Keyx4 Enter Key Up Key x 10 SELECT GROUP SELECT GROUP POWER SAVING PARAMETER SAVE CHARGE CURVE OTHER FUNCTION 1 Enable 0 e select PAR
43. 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 Mode Column 4 Group 3 will indicate one of he following 6 charging states Normal N Equalization Abbreviation 3 Stage Charging E 4 Stage Charging N CC Constant Current CC Bulk Stage N CV Constant Voltage CV Absorption Stage E CC Constant Current CC Bulk Stage E CVA Constant Voltage Absorption CVA Stage E CVE Constant Voltage Equalization CVE Stage FLOAT Float Stage Float Stage 18 Screens Pages 1 to 18 for CHARGING Mode Column 4 Group 3 are shown as an ex ample for Bulk Charging Stage in Normal Charging Mode N CC Depending upon the Charg ing Mode and Stage the unit is in at any particular time 18 sets of screens will be seen for each of the 6 states of operation in Charging Mode N CC N CV E CC E CVA E CVE or Float Page Up is shown with downward pointer YW because Page Nos in this Menu Map in crease in the downward direction Page Down is shown with upward pointer because Page Nos in this Parameter Setting Menu Map decrease in the upward direction 10 SAMLEX AMERICA INC SECTION 4 4 0 GROUP AND PARAMETER SETUP MENUS Up to 46 operating parameters can be programmed to suit the desired operating conditions The oper
44. Wired CONNECTION 10 Meters 33 ft ENVIRONMENT OPERATING TEMPERATURE RANGE 20 C to 60 C DIMENSIONS W XH XD MM 144x 114 x 35 5 W X H X D INCHES 5 6x4 5 x 1 4 WEIGHT WEIGHT WITHOUT CABLE 0 2 kg 0 4 Ib WEIGHT WITH CABLES 0 5 kg 1 2 Ib SAMLEX AMERICA INC 39 SECTION 9 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 Warranty outside of the United States and Canada is limited to 6 months For a warranty claim the Pur chaser should contact the place of purchase to obtain a Return Authorization Number The defective part or unit should be returned at the Purchaser s expense to the authorized location A written statement describing the nature of the defect the date of purchase the place of purchase and the Purchaser s name address and telephone number should also be included If upon the Warrantor s examination the defect proves to be the result of defective material or workman ship the equipment will be repaired or replaced at the Warrantor s option without charge and returned to the Purchaser at the Warrantor s expense Contiguous US and Canada only using a carrier of the warran tor s choice Warranty service shall be performed only by the
45. caps covering the holes and install appropriate 34 Trade Size Fitting for routing the AC input and output wires conduits Screw down type of terminal block 3 Fig 3 9 is used for connecting the wires The hole size for wire entry is 6 mm and set screw size is M4 It can accommodate conductors with solid or multi stranded wire size range of AWG 6 to AWG 20 44 SAMLEX AMERICA INC SECTION 3 Strip adequate insulation from the end of the wire Fig 3 11 Avoid nicking the wire when stripping the insulation Wire End Terminals have been provided see Section 2 6 page 27 for firm connection under the set screw Insert the bare end of the wire into the barrel portion of the Wire End Terminal amp crimp barrel portion using suitable crimping tool Fig 3 11 Insert the terminated end of the wire fully into the terminal slot till it stops Tighten the screw firmly Tightening torque for the screws 7 to 12 Kgf cm 0 5 to 0 9 Ibf ft Crimp Barrel Portion Stripped Wire End Wire End Terminal Fig 3 11 Stripped Wire End Terminal on AC Wiring 3 8 SIZING OF WIRING AND BREAKERS AC INPUT SIDE A WARNING AC Breakers for the AC input circuits have NOT been provided internally These have to be provided externally by the installer user based on guidelines given below Please note that guidelines given below on wire sizing and over current protection will be superseded by the applicable National Local Electrical Codes A
46. commutation Dans Mode de chargement l interne Neutre ch ssis relais de commutation d connecte le neutre de la connexion de sortie AC du ch ssis de l unit Le neutre de la connexion de sortie CA de l unit va obtenir li la terre des masses travers le neutre la terre liaison au sol dans le centre de panneau de disjoncteurs AC charge alimenter Grille connexions de sortie CA du g n rateur Mise la terre du syst me tel que requis par la National codes lectriques locaux normes est de la responsabilit de l installateur utilisateur syst me 3 6 2 AC Input Considerations Voltage And Frequency The EVO unit is designed to accept 120 VAC 60 Hz 50 Hz single phase AC power from Grid or generator These 120V versions come preset for 60 Hz operation Frequency can be pro grammed at 50 Hz using optional Remote Control EVO RC see Appendix A 3 6 3 Preventing Paralleling of the AC Output WARNING The AC output of the unit cannot be synchronized with another AC source and hence it is not suitable for paralleling on the output side The AC output of the unit should never be connected directly to an electrical breaker panel load center which is also fed from another AC source Such a connection may result in parallel operation of different power sources and AC power from the other AC source will be fed back into the unit which will instantly dam 42 SAMLEX AMERICA INC SECTION 3 age th
47. elevated operating temperature of the terminals to which these are connected Ampacity of cables is based on UL 1741 and the National Electrical Code NEC 2014 Please see details given under Notes for Table 3 1 SAMLEX AMERICA INC 35 SECTION 3 The DC input circuit is required to handle very large DC currents and hence the size of the cables and connectors should be selected to ensure minimum voltage drop between the battery 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 amp the resis tance of the length of the cable should be less than 296 Use oil resistant multi stranded cop per wire cables rated at 90 C minimum Do not use aluminum cable as it has higher resistance per unit length Cables can be bought at a marine welding supply store Effects of low voltage on common electrical loads are given below e Lighting circuits incandescent and Quartz Halogen A 5 voltage drop causes an ap proximate 1096 loss in light output This is because the bulb not only receives less power but the cooler filament drops from white hot towards red hot emitting much less visible light Lighting circuits fluorescent Voltage drop causes a nearly proportional drop in light output e AC induction motors These ar
48. fil 1 et la batterie 1 Fig 3 7 et puis le c ble n gatif de sortie du chargeur de batterie Cable B est li la borne n gative de la derni re batterie La Batterie 4 dans la Fig 3 6 ou la borne n gative de batterie qui est li e au dernier fil Le fil 2 et La batterie 4 dans la Fig 3 7 Cette connexion assure la suivante Les r sistances des c bles interconnect s seront quilibr es Tous les batteries fils de batterie dans la s rie auront la m me r sistance Toutes les batteries individuelles vont recharger au m me courant ainsi elles seront recharg es l tat pareille au m me temps Aucune des batteries auront une condition de surcharge Si le c ble positif de sortie du chargeur de batterie Cable A est li la borne positive de la premi re batterie La batterie 1 dans la Fig 3 6 ou la borne positive de batterie qui est li e au premier fil Le fil 1 et La Batterie 1 Fig 3 7 et puis le c ble n gatif de sortie du chargeur de batterie Cable B est li la borne n gative de la premi re batterie La batterie 1 dans la Fig 3 6 ou la borne n gative de batterie qui est li e au premier fil Le fil 1 de La Batterie 1 dans la Fig 3 7 les conditions anormales r sulteront Les r sistances des c bles interconnect s seront pas quilibr es Tous les batteries fils de batterie dans la s rie n auront pas la m me r sistance Toutes les batteries individuelles vont recharger des courants diff
49. first line and shows the ID number found on the second line When the default ID of 1 is found the display will then show the EVO Inverter Charger a EVO 3012 VERX XX Model No and Firmware Version 3 digit number X XX as INVERTER CHARGER shown on the left Power OFF Press ON OFF Key and hold for 5 seconds to turn OFF the EVO Inverter Charger POWER OFF When EVO Inverter Charger is ON and the ON OFF key is pressed and held for minimum of 5 seconds the LCD screen will show POWER OFF and both the Status and Alarm LEDs will turn ON Now release the ON OFF key Please note that Power Off sequence will be completed and display POWER OFF will disappear only when the ON OFF key is released NOTE If the EVO Inverter Charger has AC input voltage over 60VAC the Power OFF function is disabled and the unit will remain in the ON condition if the power off sequence is attempted The AC input must be removed before the unit can be powered OFF 3 3 DATE AND TIME SETUP Set date and time as per procedure given at Section 4 9 GROUP 6 PARAMETER SETUP TIME SETTING 3 4 STANDBY MODE When in Standby Mode the EVO will stop inverting or passing through AC input to AC out put Also charging is cancelled when in Standby Mode A short press 0 1 seconds of the ON OFF Button will change the operational mode from Inverting or Charging Mode to Standby Mode A subsequent short press when in Standby Mode will return the EVO Inverter Cha
50. for a particular model will be equal to the sum of the Rated AC Side Battery Charging Current Column 3 and the Rated Pass Through current Column 2 Rated Pass Through Current Column 2 the Rated Output Current in Inverter Mode Column 1 AC Input current in Charging Pass Through Mode will be restricted by the maximum Amp rating of the Generator or the Amp rating of the breaker in the Grid Branch Circuit that is feeding the unit The AC Input Current drawn by the unit can be programmed to the desired limit Column 5 to match the output Amp rating of the Generator or the Amp rating of breaker in the Grid Branch Circuit Optional Remote 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 21 Higher Power Models will require higher Amp rating of the Generator the Grid Branch Circuit Wiring and breaker sizing for Input Current Limit at 45A for EVO 3012 4024 is given at Table 3 2 2 and for 60A for EVO 4024 is given at Table 3 2 3 TABLE 3 2 1 SIZING OF GRID AND GENERATOR INPUT WIRING AND BREAKERS FOR DEFAULT INPUT CURRENT LIMIT PROGRAMMED AT 30A FOR EVO 2212 EVO 2224 EVO 3012 EVO 4024 Model No and Rated AC Total Rated Pro NEC Ampac Conductor External Rated Output Charging AC Input grammed ity 125 of Size Based Breaker P
51. for powering the AC loads Please note that in this condition the Output Neutral OUTPUT NEUTRAL is isolated from the chassis of the unit o When Grid Generator power fails relay K4 will be de energized and contact 4 switches over to contact 3 Neutral output from the Inverter Section is fed the Neutral of the Bi directional Transformer and onwards to the output Neutral OUTPUT NEUTRAL for powering the AC loads At the same time the output Neutral OUTPUT NEUTRAL gets bonded to the chassis of the unit through the mated contacts of the Insulated Quick Disconnect QD located in the AC Wiring Compartment 13 Fig 3 9 4 5 3 Operation of Transfer and Output Neutral to Chassis Ground Bond Switching Relays EVO 3012 and EVO 4024 Refer to Schematic at Fig 4 1 b The Bi directional Transformer is used as follows o Feeds AC output from the Inverter Section when Grid Generator power is not available o Feeds Grid Generator power to the Battery Charger Section when Grid Utility are available Switching of Hot Output OUTPUT LINE o 70 rated DPDT Relays K2 and are used to switch the Hot Output Connector OUT PUT LINE to either the Inverter Section or to the Grid Generator Please note that in this relay each of the 2 poles is rated for 35A The 2 poles are used in parallel to increase the contact current carrying capacity to 70A o When Grid Generator Power is available relays K2 or K3 will be energized and contacts 7
52. of LOW VOLT ALARM threshold 12V Version 9 50V to 12 50V Default 11 0V 24V Version 19 00V to 25 00V Default 22 00V Transfer Relay energizes and the unit changes over to 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 Value of Current fed from the External Charger When the battery voltage rises to the programmed value of RECONNECT VOLTAGE 12V Version 13 50V to 16 00V Default 14 0V 24V Version 27 00V to 32 00V Default 27 6V the Transfer Relay is de energized the unit changes over to Inverting Mode and the AC Output is fed from the internal Inverter Section In the Default Mode also called Off Line Mode PRIORITY is given to the AC input fed from the Grid Generator Inputs If qualified AC input within the programmed voltage and frequency limits is available at the Grid Generator AC inputs Transfer Relay energizes and the unit oper ates in Charging Mode and qualified AC input from the Grid Generator is passed through 20 SAMLEX AMERICA INC SECTION 4 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
53. of the Card has been stopped as shown below and mesage Please remove SD Card appears If the SD card is not removed within 30 sec it will reset After the card is removed it reverts to the original operating screen Up Key x 6 Enter Key Up Key x 1 Enter Key SELECT GROUP 5 SELECT STOP 5 STOP SD CARD STOP SD CARD 5 Please remove CHARGE CURVE SD CARD 0 1 Yes the SD Card If SD Card is not removed within 30 sec the unit will reset SAMLEX AMERICA INC 29 SECTION 5 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 is detected and shows the Version and capacity xx is the capacity Not supported card AN CAUTION Do not remove SD Card when data loggin has been enabled may corrupt files Follow STOP SD CARD procedure Section 4 10 before removing the SD Card 5 2 DATA LOGGING It is highly recommended that the current date and time be set as the data log files will be re corded with this EVO s programmed date and time Please see Section 4 9 for TIME SETTING Data logging can be disabled and data logging times can be selected using Parameter Set ting Mode under Other Functions See Section 4 8 and Table 4 8 under heading DATALOG TIME and DATALOG DISABLE When the SD car
54. of the input current Crest Factor is defined by the following equation CREST FACTOR PEAK VALUE RMS VALUE Many SMPS units incorporate Inrush Current Limiting The most common method is the NTC Negative Temperature Coefficient resistor The NTC resistor has a high resistance when cold and a low resistance when hot The NTC resistor is placed in series with the input to the power supply The higher cold resistance limits the input current as the input capacitors charge up The input current heats up the NTC and the resistance drops during normal operation However if the power supply is quickly turned OFF and back ON the NTC resistor will be hot so its low resistance state will not prevent an inrush current event The inverter should therefore be sized adequately to withstand the high inrush current and the high Crest Factor of the current drawn by the SMPS Hence it is recommended that for purposes of sizing the inverter the continuous power of the inverter should be gt 2 times the continuous rated power of the SMPS For example an SMPS rated at 100 Watts should be powered from an inverter that has continuous power of gt 200 Watts 14 SAMLEX AMERICA INC SECTION 1 NOTE Voltage and Current scales are different Input voltage RMS Current Inrush current Fig 1 2 Inrush current in an SMPS Non linear Peak Current NOTE Voltage and Input Current Current scales PA are different RMS Current Input
55. or above seen at the AC Output Terminals at the time of boot up of EVO Inverter Charger will activate this protection e Green LED marked Status will be switched OFF and the Red LED marked Alarm will be steady ON The buzzer in EVO Inverter Charger will beep steady e Inverter Charger will be latched in OFF condition and will require manual reset by powering OFF waiting for 1 minute and then powering ON again Check the connection If there is 10V over at the output terminal remove the connection Transformer over heat EVO Inverter Charger is in FAULT MODE because the main Bidirectional Transformer in the EVO Inverter Charger has overheated to 150 C Green LED marked Status will be switched OFF and the Red LED marked Alarm will be steady ON The buzzer in EVO Inverter Charger will beep steady e Inverting Mode Inverter Section will be switched OFF If in Charging Mode the Transfer Relay will be de energized and the Inverter Section will be switched OFF e Check that the fans are working properly there is no blockage of air suction and discharge vents adequate cool replacement air is available and the ambient tem perature is within the limits Reduce the load BULK CURRENT Section 4 4 e fault will be cleared when the transformer has cooled down to 80 C Heat sink over heat EVO Inverter Charger is in FAULT MODE because the internal heat sink in the EVO Inverter Charger has overhe
56. prendre soin de ventiler la zone de la batterie et de suivre les recommandations du fabricant de la batterie Ne jamais fumer ou permettre une tincelle ou une flamme pr s des batteries Faites preuve de prudence afin de r duire le risque de chute d un outil m tallique sur la batterie Il pourrait provoquer un court circuit ou la batterie ou d autres pi ces lectriques et pourrait causer une explosion Toujours utiliser des outils isol s Retirez les articles m talliques tels que des bagues des bracelets et des montres lorsque vous travaillez avec des batteries Les batteries peuvent produire un court circuit suffisamment lev pour souder une bague ou autre m tal et ainsi causer de graves br lures Si vous devez retirer la batterie retirez toujours la borne de terre de la batterie Assurez vous que tous les accessoires sont hors de sorte que vous ne causent pas une tincelle 1 2 DEFINITIONS The following definitions are used in this manual for explaining various electrical concepts specifications and operations Peak Value It is the maximum value of electrical parameter like voltage current RMS Root Mean Square Value It is a statistical average value of a quantity that varies in value with respect to time For example a pure sine wave that alternates between peak values of Positive 169 68V and Negative 169 68V has an RMS value of 120 VAC Also for a pure sine wave the RMS value Peak value 1 414 Voltage V V
57. relay energizes NC and Common will be closed when the Status Relay is de energized and will open when the reay energizes 0 2 Charger Other When the EVO Inverter Charger is in Charging Mode the Status Relay turns OFF in Other Mode other than Charging Mode the Relay is ON 1 2 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 When the battery voltage is higher than the RESET VOLTAGE the Status Relay turns OFF This function may be used for Generator Auto Start Stop in conjunction with optional external Generator Auto Stop Start Module See Section 4 7 of EVO Manual Up Keyx4 Enter Key Up Key x4 c SELECT GROUP c POWER SAVING c RELAY FUNCTION CHARGE CURVE OTHER FUNCTION 1 Enable 2 Generator COMM Communication ID This sets the ID number for the COMM Port and EVO RC Remote Control Up Keyx4 Enter Key Up Key x5 SELECT GROUP SELECT GROUP POWER SAVING COMM ID CHARGE CURVE gt OTHER FUNCTION gt 1 Enable gt 1 BUZZER Set the buzzer ON OFF Up Key x 4 Enter Key Up Key x 6 SELECT GROUP SELECT GROUP POWER SAVING BUZZER CHARGE CURVE OTHER FUNCTION 1 Enable 1 0N DISCHARGE BEEP To select the buzzer ON OFF while in Inverting Mode Up Key x 4 Enter Key Up Key x 7 SELECT GROUP SELECT GROUP
58. sur le dernier contact du boucle d entr e m me si l interrupteur ON OFF du l onduleur est dans la position OFF Assurez que le fusible est ins rer seulement apr s que toutes les connexions sont faites dans le boucle pour que des tincelles se produisent seulement l endroit du fusible Le flux du courant dans un conducteur est oppos par la r sistance du conducteur La r sistance du conducteur est corr lative la longueur du conducteur et inversement corr latif son diam tre l paisseur La r sistance dans un conducteur produit des effects ind sirables comme une perte de tension et une surchaffe La taille l paisseur des conducteurs est class e par le AWG American Wire Guage Les conducteurs qui sont plus pais que la taille AWG 4 0 sont class par MCM kcmil 36 SAMLEX AMERICA INC SECTION 3 Les conducteurs sont prot g s par des mat riaux isolants class s pour une temp rature sp cifique par exemple une temp rature de 90 C 194 F Le flux de courant produit de la chaleur et affecte l isolation Alors il y a une valeur de courant maximale aussi appell l ampacit qui est permise pour chaque taille de conducteur et pour la classification temp rature de l isolation Les mat riaux isolants des c bles seront aussi affecter par la temp rature de fonctionnement l v e des bornes qui ils sont connect s L ampacit des c bles est bas sur UL 1741 et la Norme Nationale lectrique NEC 201
59. the 24V battery bank 30 SAMLEX AMERICA INC SECTION 3 3 4 2 Parallel Connection Cable M 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 Fig 3 6 above shows 4 pieces of 12V 100 Ah batteries connected in parallel to form a battery bank of 12V with a capacity of 400 Ah The four Positive terminals of batteries 1 to 4 are paralleled connected together and this common Positive connection be comes the Positive terminal of the 12V bank Similarly the four Negative terminals of batteries 1 to 4 are paralleled connected together and this common Negative connection becomes the Negative terminal of the 12V battery bank 3 4 3 Series Parallel Connection 12V String 1 12V String 2 O Battery 1 Battery 2 Battery 3 Battery 4 Cable A 12V Inverter or 12V Charger Fig 3 7 Series Parallel Connection Figure 3 7 shows a series parallel connection consisting of four 6V 200 Ah batteries to form a 12V 400 Ah battery bank Two 6V 200 Ah batteries Batteries 1 and 2 are connected in series to form a 12V 200 Ah battery String 1 Similarly two 6V 200 Ah batteries Batteries 3 and 4 are connected in series to form a 12V 200 Ah battery String 2 These two 12V 200 Ah Strings 1 and 2 are connected in parallel to form a 12V 400 Ah b
60. the instant the battery voltage reaches 0 3V below the programmed Absorption Voltage then registers this time as Bulk Charge Time To and computes the Absorption Time T1 as 10 times the Bulk Charge Time To in the internal T1 Timer i e T1 To x 10 The T1 Timer is used to determine the time the charging will take place in the next Absorption Stage 5 6 1 1 Automatic Adjustments of Internal AC Charger Current When External Charger is Also Charging in Parallel Please note that if an external charging source is also used to charge the batteries at the same time in parallel with the internal AC charger of the unit the charging current of the internal AC charger will be controlled so that the total charging current of the external charger and the internal charger is the programmed Bulk Charging Current lo For example if the programmed charging current is say 40A and the charging current of the external charger is 30A the internal AC charger will output only 10A Programmed setting of 40A external charging current of 30A 10 Similarly if the programmed setting is say 30A and the external charger is 50A the internal AC charger will not provide any charging 5 6 2 Absorption Stage During the Absorption Stage the charging voltage is held constant near the Gassing Voltage to ensure that the battery is further charged to the full capacity without overcharging The Absorp tion Stage restores the remaining 2596 of the battery s ch
61. the other end of remote cable and plug it into the RJ 45 Jack at the back of the EVO RC Fig 2 3 5 Check the remote display to ensure the Power up self test initiates 6 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 3mm self tapping screws flat head Fig 2 2 EVO RC Flush Mounting Bottom view WALL PANEL BOARD RJ 45 Jack The thickness of the wall panel board at the place of mounting should not be more than 13mm to ensure that the RJ 45 jack opening is not obstructed Fig 2 3 Wall Panel Thickness SAMLEX AMERICA INC 5 SECTION 3 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 3 1 NAVIGATING THE REMOTE The EVO RC provides menu items and adjustable settings to configure your EVO Inverter Charger to your specific parameters Please refer to the layout at Fig 1 1 a LCD Display 1 The 2 line 16 characters each LCD display shows status and informa tion for the EVO Inverter Charger All Setup Menus and faults also appear on the LCD display ON OFF Key 2 The ON OF
62. to Ground Do not connect to AC Load Center Circuit Breaker Panel having Multi wire Branch Circuits connected Both AC and DC voltage sources are terminated inside this equipment Each circuit must be individually disconnected before servicing Do not remove cover No user serviceable part inside Refer servicing to qualified servicing personnel Do not mount in zero clearance compartment not cover or obstruct ventilation openings Fuse s should be replaced with the same type and rating as of the original installed fuse s WARNING Risk of electric shock Use only those GFCIS that are listed at Table 1 5 Other types may fail to operate properly when connected to this unit GROUNDING The Grounding symbol shown below is used for identifying only the field wiring equipment grounding terminal However this symbol is usable with the circle omitted for identifying various points within the unit that are bonded to Ground Grounding Symbol D faut a la terre 15 Precautions When Working With Batteries Batteries contain very corrosive diluted Sulphuric Acid as electrolyte Precautions should be taken to prevent contact with skin eyes or clothing Wear eye protection 4 SAMLEX AMERICA INC SECTION 1 Batteries generate Hydrogen and Oxygen during charging resulting in evolution of explosive gas mixture Care should be taken to ventilate the battery area and follow the battery manufacturer s rec
63. to support the AC loads on priority and use whatever is extra for charging This will prevent overloading of the Grid Branch Circuit Generator 5 3 ADAPTIVE CHARGING CONTROL FOR COMPLETE CHARGING AND PREVENTION OF OVER CHARGING BOILING OF BATTERIES An automatic Adaptive Charging Algorithm is used to ensure that the battery is completely charged in a safe manner for longer battery life In this algorithm the time the battery remains in Absorption and Equalization Stages is proportional to the time the battery remains in the Bulk Charge Stage A battery that is deeply discharged will remain in Bulk Stage for a longer duration and will require longer time in the Absorption and Equalization Stages for complete charging On the other hand a battery that is almost completely charged will remain in the Bulk Stage for a shorter duration and consequently will remain in Absorption and Equalization stages for a shorter duration This will prevent overcharging boiling of the battery Note In other inverter chargers that execute Absorption and Equalization Stages for a fixed time of 4 to 8 Hours a nearly fully charged battery may overcharge boil and hence will reduce battery life 5 4 PARALLEL CHARGING OF BATTERIES THROUGH EXTERNAL CHARGER The Battery Charger Section is able to operate in parallel with another external charging source like Solar Charge Controller AC Charger of up to 50A capacity The output of the external charging source is rout
64. wenn 2 X AWG EVO 3012 373A 466A 3 0 QUEM 1 o 500A MCM 300 o zxawa 2 X AWG EVO 4024 266A 333A AWG 3 0 dion 4 0 34 0 350A thicker MCM 350 MCM 350 AWG 6 AWG 2 AWG 2 0 0 External 50A 63A 296 voltage 2 voltage 296 voltage 70A Charger drop is drop is thicker drop is thicker p thicker NOTES FOR TABLE 3 1 SIZING OF BATTERY SIDE CABLES AND EXTERNAL BATTERY SIDE FUSES 1 Column 2 indicates the Rated Continuous DC Input Current drawn from the battery in Inverter Mode 2 Column 3 indicates NEC Ampacity based on which cable conductor sizes Columns 5 to 8 are determined NEC Ampacity is not less than 12596 of the Rated Continuous DC Input Current Column 2 Refer to NEC 2014 National Electrical Code Section 215 2 A 1 a for Feeder Circuits 3 Columns 5 to 8 indicate cable conductor size that is based on the following 2 considerations Thicker conductor out of the following 2 considerations has been chosen a As per guidelines in NEC 2014 National Electrical Code Ampacity Table 310 15 B 16 for Raceway and Ampacity Table 310 15 B 17 for Free Air Conductor size is based on i NEC Ampacity specified at Column 3 ii Copper conductor with temperature rating of 90 C and iii Ambient temperature of 30 C 86 F b Voltage drop across the length of cables has been limited to 2 of 12V 24V Voltage drop has been calculated by multiplying the Rated DC Input Current Column 2 and the resistanc
65. when the battery is deeply discharged and for a shorter duration if the battery has a shallow discharge LEGEND l BULK gt ABSORPTION EQUALIZATION 5x FLOAT 5 Displayed as E CC Displayed Displayed Displayed as Float Voltage Curve 16 pe P CVA ECVE D ond POET Current Curve V Set value of 0 3V i lt Equalization D E E Voltage Boost Note 1 The voltage curve shows the voltage output of charger The intrinsic battery voltage may be different and will be proportional to the state of charge Note 2 The graph is for 12V version For 24V version double the voltages VDC 4100 50 0 3u2un Ang 19S 40 96 1 4 To gt 4 T T2 gt 10 Days TIME Fig 5 2 Charging Curve for 4 Stage Charging in Equalization Mode N CAUTION For effective equalization to take place it is desirable that the batteries undergo a longer Bulk Stage applicable to the deeply discharged condition of the battery Please ensure that before the batteries are equalized they should be deeply discharged to 20 of its capacity The Standing Voltage Terminal Voltage after disconnecting charging source s and load s for at least 3 hours at 20 capacity will be o 12V Battery Around 11 7V o 24V Battery Around 23 4V Do not equalize partially or fully charged batteries N ATTENTION Pour
66. your load to run and then specific calculation can be done to determine the proper battery bank size There are a few basic formulae and estimation rules that are used 1 Active Power in Watts W Voltage in Volts V x Current in Amperes A x Power Factor 2 Foran inverter running from a 12V battery system the DC current required from the 12V batteries is the AC power delivered by the inverter to the load in Watts W divided by 10 amp for an inverter running from a 24V battery system the DC current required from the 24V batteries is the AC power delivered by the inverter to the load in Watts W divided by 20 3 Energy required from the battery DC current to be delivered A x Time in Hours H The first step is to estimate the total AC watts W of load s and for how long the load s will operate in hours H The AC watts are normally indicated in the electrical nameplate for each appliance or equipment In case AC watts W are not indicated Formula 1 given above may be used to calculate the AC watts The next step is to estimate the DC current in Amperes A from the AC watts as per Formula 2 above An example of this calculation for a 12V inverter is given below Let us say that the total AC Watts delivered by the inverter 1000W Then using Formula 2 above the DC current to be delivered by the 12V batteries 1000W 10 100 Amperes or by 24V batteries 1000W 20 50A Next the energy required by the load in Amp
67. 120 240 VAC Split syst me phase et multi fils Circuits de d rivation www samlexamerica com Accueil Support Livres blancs 3 7 ACINPUT amp OUTPUT WIRING A WARNING Please ensure that the AC input voltage from the Grid Generator is connected to the AC input terminals and not to the AC output terminals and that this connection is made only when the unit is in OFF condition Please note that when the unit is powered on a Self Test is carried out which includes a check if the AC input voltage from the Grid Generator connection has been erroneously connected to the AC output terminals instead of AC input terminals If this wrong connection is detected voltage gt 10 VAC is seen on terminals OUTPUT LINE amp OUTPUT NEUTRAL at the time of switching on of the unit the unit will not be powered on and a message Output Fault will be displayed This protection against error in connection of the AC input wiring is active only when this wrong connection is made when the unit is in OFF condition and is switched ON subsequently If the AC input voltage from the Grid Generator is erroneously connected fed to the AC output connections when the unit is ON condition the above protection will not work and the Inverter Section will be burnt instantaneously and may become a fire hazard N ATTENTION Se il vous plait faire en sorte que la tension d entr e d alimentation de la grille g n rateur est reli e aux bornes d e
68. 3 12 is normally provided to connect the batteries and distribute DC power to the inverter and to the other DC loads The Negative of the battery is connected to the Neg Bus which is connected to the Bus bar for Equipment Grounding Conductors G3 which in turn is bonded to the Grounding Electrode GE also called Ground Rod Hence the Battery Negative and the chassis of the DC Panel and the chassis of the EVO will all be bonded to the Earth Ground Connect the combined DC and AC Grounding Terminal G2 5 in the DC side layout in Fig 3 8 to the Equipment Grounding Bus Bar G3 in the DC Panel using AWG 6 insulated stranded copper wire For application of EVO on a boat the size of this wire should be of the same size as the battery Negative wire 50 SAMLEX AMERICA INC SECTION 3 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 A WARNING For application of EVO on a boat the size of the Equipment Grounding Conductor EGC from the Grounding Terminal on the EVO G2 to the boat s system Ground should be the same size as the battery cable A N ATTENTION Si vous utilisez le EVO sur un bateau la taille du conducteur de terre de l quipement EGC pour le c t de terre CC devrait tre de la m me tai
69. 4 Notes for table 3 1 Le circuit d entr e CC doit subir des courants CC forts et ainsi il faut que la taille des c bles et des connecteurs est s lectionn e pour r duire la perte de tension entre la batterie et l onduleur Avec des c bles moins pais et des connexions l ches la performance de l onduleur est diminu e et en plus ca pourrait produire une r chauffement anormale qui risque de fondre l isolation ou commencer un incendie Normalement il faut que le c ble soit assez pais pour r duire la perte de tension d au courant la r sistance du c ble moins que 2 Utilisez des c ble multifiliares fils en cuivre et r sistant l huile qui sont class s au moins 90 C N utilisez pas des c bles en aluminium car ils ont une r sistance plus haute par la longueur de l unit On peut ach ter des c bles aux magasins de fournitures pour marin soudage Les effets d une faible tension pour des charges lectriques communes Circuits d allumage incandescent et Halog ne Quartz Une perte de tension 596 causera une perte de 1096 de la lumi re mise Cet effet est gr ce deux choses non seulement l ampoule recoive moins de puissance mais aussi le filament refroidi change de la chaleur blanc la chaleur rouge qui met moins de lumi re visible Circuits d allumage fluorescent la perte de tension est presque proportionelle la perte de la lumi re mise Moteurs Induction CA Souvent Ils fo
70. 7 VDC gt 18 34 VDC Nominal AC Output Voltage 120 VAC x 596 Output Frequency 60 Hz x 0 1 Hz Total Harmonic Distortion of Pure lt 5 Sine Wave Form THD d Continuous Output Power 2200 VA 3000 VA 2200 VA 4000 VA Continuous AC Output Current 18A 25A 18A 33A 30096 30096 30096 30096 Surge POWEE TOUT mseg re 9000VA 75A 6600VA 54A 12 000 VA 99 20096 20096 20096 20096 Surge Power dor 100 imsec er 6000 50 4400VA 36A 8000VA 66A Power Boost for 5 sec PO 156 ee 150 3300W 3900W 3300W 6000W Power Boost for 30 sec 202 bod TO 3080W 3800W 3080W 5600W Power Boost for 5 min 206 jode 120 e 2640W 3400W 2640W 4800W Power Boost for 30 min 3180 110 10 110 2420W 3200W 2420W 4400W Maximum Continuous DC Input 266 A 373A 133A 266 A Current Inverter Efficiency Peak 9096 9096 9396 9496 No Load Power Consumption in lt 8W Power Saving Mode No Load Power Consumption in Normal Mode 120 VAC Output 30 watts 25 watts Typical AC INPUT FROM GRID GENERATOR AC Input Voltage 120VAC 60 140VAC 5 AC Input Frequency 60Hz 50Hz Maximum Programmable Default 5 40A 5 70A 5 40A 5 70A AC Input Current Default 30A Default 30A Default 30A Default 30A TRANSFER CHARACTERISTICS DPDT 70A DPDT 70A Transfer Relay Type and Capacity SPDT 40A 2X35A contacts SPDT 40A 2X35A contacts in parallel in parallel Transfer Time Inverter to Grid Generator 1 ms Synchronized Tra
71. A INC 41 SECTION 3 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 Relay K4 in Figs 4 1 a and 4 1 b n Charging Mode the internal Output Neutral to Chassis Switching Relay discon nects the Neutral of the AC output connection from the chassis of the unit The Neutral of the AC output connection of the unit will get bonded to the Earth Ground through the Neutral to Earth Ground bond in the AC Breaker Panel Load Center supplying Grid power AC output connections of the generator e Disabling Neutral to Ground Bond In some applications the Output Neutral may be required to remain isolated from chassis Ground at all times For this automatic Output Neutral to chassis Ground bond can be disabled by disconnecting the Male Female Dis connect 13 Fig 3 9 located in the AC Wiring Compartment System grounding as required by National Local Electrical Codes Standards is the responsibility of the user system installer For further details please refer to Sections 4 5 1 to 4 5 3 N ATTENTION En tat de d faut le neutre de la sortie CA de l unit dans le Mode de l onduleur d charge obtient li au chassis m tallique de l unit travers la interne Neutre chassis relais de
72. AVEVRSAVE The parameters will be saved and message saved file end will be seen and then the screen will revert to 5 4 2 Uploading Saved Parameters If there is a xxxx_yyy cfg file in the SD card with stored programmed parameters then on inserting the card the Remote Control will ask to upload the Config File Press Enter Button to confirm or Back Button to cancel Upload conf Yes Enter Key Upload conf No Back Key Asks to cancel upload Asks to confirm upload upload conf Configuration uploading 34 SAMLEX AMERICA INC SECTION 6 TABLE 6 1 LED amp BUZZER INDICATIONS FOR OPERATION MONITORING Red LED Alarm Status Green LED Status Fault Buzzer Power ON Flash 3 times OFF OFF Power OFF ON ON OFF Normal charging Flash 1 time per second OFF OFF Equalization charging Flash 2 times per second OFF OFF Inverting ON OFF QUA Low battery alarm ON Flash 1 time per second Beep per second Power saving Flash 1 time per 3 second OFF OFF Standby OFF OFF OFF Fault OFF O ON NOTE Buzzer is available only in EVO Inverter Charger There is no buzzer in Remote Control EVO RC SAMLEX AMERICA INC 35 SECTION 7 TABLE 7 1 FAULT MESSAGES AND TROUBLESHOOTING GUIDE NOTES 1 Please see Table 6 1 for LED indications in EVO RC and buzzer indications in EVO Inverter Charger 2 Buzzer is available only in EVO Inverter Charger There is no buzzer in Remote C
73. Active Power Watts from the inverter The inverter can be sized based on the Active Power rating Watts of the Resistive Load without creating overload except for resistive loads with Tungsten based heating element like filament lamps Quartz Halogen lamps and Quartz heaters These require higher starting surge power due to lower resistance value when the heating elements are cold Reactive Load A device or appliance that consists of a combination of resistive inductive and capacitive elements like motor driven tools refrigeration compressors microwaves comput ers audio video etc These devices require Apparent Power VA from the inverter to operate The Apparent Power is a vectorial sum of Active Power Watts and Reactive Power VAR The inverter has to be sized based on the higher Apparent Power VA and also based on starting surge power 1 3 GENERAL INFORMATION INVERTER RELATED General information related to operation and sizing of inverters is given in succeeding sub sections 1 3 1 AC Voltage Waveforms 180 160 140 L Sine Wave Modified Sine VRMS 120VAC Wave sits at Vpeak 169 68V ZERO for some time and then e Modified Sine Wave rises or falls VRMS 120V Vpeak 140 to 160V Pure Sine Wave crosses zero V instantaneously VOLTS lt gt VOUS CPABNiNERAD Fig 1 1 and Modified Sine Waveforms for 120 60 Hz
74. C load BULK CURRENT Section 4 4 accordingly Output over current EVO Inverter Charger is in FAULT MODE because the instantaneous output current being drawn by the AC load in Inverting Mode is 330 of the rated value of the EVO Inverter Charger sampling time is 33 micro seconds e There will be no AC output because the Inverter Section will be switched OFF The Green LED marked Status will be switched OFF and the Red LED marked Alarm will be steady ON The buzzer in EVO Inverter Charger will beep steady Inverter Charger will be latched in OFF condition and will require manual reset by powering OFF waiting for 1 minute and then powering ON again e Ensure that the maximum instantaneous surge current of the load is not more than 30096 of the rated current of the EVO Inverter Charger for 1 millisecond Output over load Output over load 1 Output over load 2 Output over load 3 Output over load 4 EVO Inverter Charger is in FAULT MODE because of overload conditions in Inverting Mode e There will be no AC output because the Inverter Section will be switched OFF The Green LED marked Status will be switched OFF and the Red LED marked Alarm will be steady ON The buzzer in EVO Inverter Charger will beep steady EVO Inverter Charger will be latched in OFF condition and will require manual reset by powering OFF waiting for 1 minute and then powering ON again e Ensure that overloading is limited
75. CT GROUP STOP SD CARD Group 5 Group 7 Fig 4 3 Select Group Menu Map and Example for Setting Bulk Current NOTES Group Up is shown with downward pointer W because Group Nos in this Menu Map increase in the downward direction Group Down is shown with upward pointer because Group Nos in this Menu Map decrease in the upward direction Group 7 screen will be shown only when SD card is inserted 14 SAMLEX AMERICA INC SECTION 4 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 The Password is 8052 Once you Enter the Password correctly you don t need to enter the Password again until until any key is not pressed for over 60 seconds An example of Parameter setting is shown at Section 4 3 1 below 4 3 1 Example of Changing Bulk Current Setting From Default 40A to 50A SELECT GROUP Starting from any Operating Mode Screen Fig 3 2 press Enter key and CHARGE CURVE Up Down Keys to select Group 1 Charge Curve screen from the Select Group Menu Map Fig 4 3 Press Enter Key to go to Parameter Screens under Charge Curve BULK CURRENT Press Up Down Key to select Bulk Current parameter Default current setting of 40A will be displayed Press Enter key to change Bulk Current p
76. 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 When the Grid Generator AC input fails or is not within the programmed value of voltage and frequency the Transfer Relay is de energized the unit changes over to Inverting Mode and the AC Output is fed from the internal Inverter Section When Grid Generator input is restored the unit reverts back to Charging Mode On line Mode is programmed through the Remote Control EVO RC by setting ONLINE MODE 1 ON as shown in the steps given below The Default Setting is Off Line Mode O OFF Enter Key Up Key x 12 SELECT GROUP c CHARGE CURVE c CHARGE CURVE BULK CURRENT 0 Off RECONNECT VOLT As explained under ON LINE MODE above RECONNECT VOLT setting is the battery voltage at which the unit transfers from Charging Mode to Inverting Mode Enter Key Up Key x 13 SELECT GROUP CHARGE CURVE RECONNECT CHARGE CURVE BULK CURRENT 14 00V FLOATING EXIT Please refer to Sections 5 6 4 and 5 8 of the EVO Owner s Manual regarding automatic resetting of 3 and 4 Stage Charging Cycles respectively When charging is in Float Stage and the battery discharges to the programmed discharged voltage level the Charging Cycle is reset to the Bulk Stage of the 3 Stage Charging Profile The programmable range of this voltage level is 10 to 13V for 12V battery an
77. F Key is used for switching ON switching OFF the EVO Inverter Charger Navigation Keys 5 6 7 8 These four Keys allow simple access to menu items that assists configuring monitoring and troubleshooting the EVO Inverter Charger o Navigation Key Functions Back Return to previous selection Up Move to upper Group Number or upper Page Number Screen in various Menu Maps Down Move to lower Group No or lower Page No Screen in various Menu Maps Enter Enter the selected option Status Green LED indicator for indicating operating status see details at Section 6 Table 6 1 Alarm Fault Red LED indicatorfor indicating fault conditions see details at Section 6 Table 6 1 SD Card socket This slot supports SD memory card up to 16GB FAT 16 32 The SD Card is used for i data logging of EVO Inverter Charger s operational statistics and events and ii saving and uploading of programmed parameters See Section 5 SD Card 6 SAMLEX AMERICA INC SECTION 3 3 2 POWER ON POWER OFF Power ON Press ON OFF Key and hold for 2 seconds to turn the EVO Inverter Charger ON POWER ON When the EVO Inverter Charger is OFF and the ON OFF key is pressed and held the LCD screen shows POWER ON and the Status LED flashes 3 times After 2 seconds EVO RC starts to search for the communication ID of the EVO SEARCHING ID Inverter Charger it is attached to The LCD screen shows ID 1 SEARCHING ID on the
78. ING ON OFF BUTTON ON THE FRONT PANEL 11 Fig 2 1 6 1 1 Powering ON To power ON the unit press and hold the ON OFF Button for 2 seconds Green LED marked ON 12 Fig 2 1 will flash times will go off momentarily and will then be steady Green Subsequently the lighting pattern of this LED will be controlled by various operating conditions given in Table 6 1 6 1 2 Powering OFF To power OFF the unit press and hold the ON OFF Button for 5 seconds Wait for the Green LED marked ON 12 Fig 2 1 and Red LED marked FAULT 13 Fig 2 1 to light steady and then release the ON OFF Button The unit will power OFF after the ON OFF Button is released NOTE Power OFF will not take place unless the Power ON OFF Button is released NOTE As explained under paragraph a of Info above as long as AC input voltage 60VAC is present the unit CANNOT BE POWERED OFF us ing the ON OFF Button on the front panel of the unit or on the optional Remote Control EVO RC see Appendix A In order to power off using the Power ON Off Button switch OFF the AC input first Further if the unit is in Fault Mode it will be possible to power OFF the unit with the ON OFF Push Button 78 SAMLEX AMERICA INC SECTION 6 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
79. N OFF Push Button will now follow the above Switch Type control logic wherein the unit will remain ON only as long as the Button is kept pressed and will turn OFF in 2 seconds after it is released 6 3 OPERATIONAL INFORMATION THROUGH LEDS AND BUZZER Table 6 1 below shows the operational states of the unit indicated by the following LEDs on the front panel of the unit and Buzzer o Green LED marked ON 12 Fig 2 1 o Red LED marked Fault 13 Fig 2 1 Optional Remote Control Model EVO RC see Appendix A will be required for more detailed messaging that is available through its LCD display and LEDs This remote will also be required for programming of various parameters to suit specific requirements SAMLEX AMERICA INC 79 SECTION 6 TABLE 6 1 LED AND BUZZER INDICATIONS Green LED Red LED marked Status marked ON a B Buzzer 12 Fig 2 1 Fault 13 Fig 2 1 When powered ON Flash 3 times When powered OFF Normal charging Flash 1 time per sec Off Off Off Off Beep per 3 second Of On Of Of Inverting Discharging On Of Default Off Off Off On Equalization charging Flash 2 times per p sec Low battery alarm Flash 1 persec Beep per 1 second On Power saving Flash 1 time per Off 3 sec 6 4 OPTIONAL REMOTE CONTROL EVO RC see Appendix A FOR PRO GRAMMING OF MODES OF OPERATION AND PARAMETERS Optional Remote Control Model EVO RC Fig 2 4 will be required for more advanced control a
80. NC SECTION 1 TABLE 1 5 USE OF SPECIFIED GROUND FAULT CIRCUIT INTERRUPTER GFCI FOR DISTRIBU TION OF AC OUTPUT POWER IN RECREATION VEHICLES A ATTENTION 1 DANGER Pour r duire les risques d explosion ne pas installer dans les locaux de machines ou dans la zone quipement prot g contre les incendies doit tre utilis 2 ATTENTION Cet appareil est concu pour une installation PAS M t o pont Pour r duire les risques de choc lectrique ne pas exposer la pluie ou la neige Pour une utilisation en int rieur uniquement Pour viter les dommages dus des vibrations excessives choc ne pas utiliser sur les navires plus petits avec des ongueurs de moins de 65 pi 19 8 Surfaces chaudes Pour viter les br lures ne touchez pas Les bornes de cablage entr e sortie CA sont pr vus pour un raccordement sur le terrain avec des conducteurs de cuivre qui doivent tre dimensionn s en fonction de 75 C et ne d passe pas AWG n 1 42 4 mm2 Voir les ableaux 1 1 a 1 1 b et 1 1 c pour le dimensionnement des conducteurs pour les circuits d entr e CA et le ableau 1 2 pour le dimensionnement des conducteurs pour les circuits de sortie AC Protection contre les surintensit s AC Breakers pour les circuits d entr e sortie AC n a pas t fournis et doit ourni par l installateur utilisateur Voir les lignes directrices tableaux 1 1 a 1 1 b et 1 1 c pour le dimensi onnement des disjoncte
81. ND BREAKERS AC OUTPUT SIDE WARNING AC Breakers for the AC output circuits have NOT been provided internally These have to be provided externally by the installer user based on guidelines given below Please note that guidelines given below on wire sizing and over current protection will be superseded by the applicable National Local Electrical Codes A N ATTENTION Breakers AC pour les circuits d entr e AC ont pas t fournis en interne Ceux ci doivent tre fournies l ext rieur par l installateur utilisateur sur la base des directives donn es ci dessous Se il vous pla t noter que les directives ci dessous sur dimensionnement des c bles et protection contre les surintensit s seront remplac es par les nationaux codes lectriques locaux applicables 3 9 1 Tables for Wire and Breaker Sizing AC Output Side Table 3 3 provides details of wire and breaker sizing for the AC output side AC wiring and breaker sizes on the AC output side are required to be determined by the Rated Load Current when operating in Inverter Mode Column 1 48 SAMLEX AMERICA INC SECTION 3 Table 3 3 SIZING OF AC OUTPUT WIRING AND BREAKERS Item Model No Rated AC Out NEC Ampac Conductor Size External Breaker and put Current in ity 125 based on NEC Size based on Rated Output Inverter Mode of Column 2 Ampacity at NEC Ampacity at Power in Inverter See Note 1 See Note 2 Column 3 Column 3 Mode See Note 3
82. Neutral to Ground Bond Switching in EVO 2212 and EVO 2224 SAMLEX AMERICA INC 63 SECTION 4 NEUTRAL METAL CHASSIS GROUND OF THE UNIT INVERTING 4 CHARGING BI DIRECTIONAL TRANSFORMER LINE O GEN AC OUTPUT GRID GEN OUTPUT GRID GEN OUTPUT GRID LINE LINE LINE GND GND GND NEUTRAL NEUTRAL NEUTRAL DPDT Transfer Relay 70A for Grid Line Two 35A each poles are paralleled for 70A capacity K3 DPDT Transfer Relay 70A for Generator Line Two 35A each poles are paralleled for 70A capacity DPDT Transfer Relay 70A for Neutral to Ground Bond Switching Two 35A each poles are paralleled for 70A capacity 7 1 and 9 3 Normally Closed Contacts 7 4 and 9 6 Normally Open Contacts 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 b Operation of Transfer Relay and Neutral to Ground Bond Switching in EVO 3015 and EVO 4024 4 5 4 Synchronized Transfer of Power Direct AC input from Grid and Generator can be fed simultaneously to separate AC Input Circuits Only one AC source is selected at one time When both Grid and Generator are available simultaneously Grid has priority To facilitate synchronization transfer of power from Grid to Generator or from Generator to Grid is always routed through the inve
83. O INVERTER CHARGER External Charge Controller GRID PANEL 120V 240V SPLIT PHASE GENERATOR GE Ground Rod embedded in earth Solar Panel s DCSIDE ACSIDE GRID PANEL AC DISTRIBUTION PANEL 1 Battery Positive 4 GRID LINE 68 Breaker 2 Battery Negative 5 GRID GND 120VACLegA 3 External Charger Positive 6 NEUTRAL 9 B 120VACLegB 4 External Charger Negative 7 GENLINE Legs A amp B are split phases 5 Grounding Terminal 8 GENGND N Neutral Bus Bar 6 RF 45 Jack for Temperature Sensor 9 GEN NEUTRAL NG Neutralto Ground Bond 7 RJ 45 Jack for Optional Remote Control EVO RC 10 OUTPUTLINE G Ground Bus Bar 14 Status Relay Terminals for initiating automatic generator start stop 11 OUTPUT GND GE Grounding Electrode Ground Rod status Relay 12 OUTPUT NEUTRAL To optional Generator Auto Common gt Start Stop NC Module Fig 3 13 Typical Shore Based Installation SAMLEX AMERICA INC 55 SECTION 3 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 N WARNING Please ensure that Ground Fault Circuit Interrupter s GFCI are installed in the vehicle wiring system to protect all branch cir
84. OFF when released RELAY FUNCTION 0 Relay will be ON contacts will 2 Generator close when in Charging Mode 1 Relay will be ON contacts will be closed in Fault Mode 2 Used for Generator Auto Start Stop with the help of optional Generator Auto Start Stop Module Relay will be ON contacts will close at Low Battery Alarm Relay will be OFF contacts will open at Low Battery Reset COMM ID Communication ID for optional Remote Control EVO RC DISCHARGE BEEP Beeping in Discharg OFF 1 0N 0 Off ing Inverter Mode DATA LOG TIME 0 Disable 3 30sec 6 10 For Optional Remote 1 1 sec 4 60 sec Control EVO RC 2 10sec 5 5 PARAMETER SAVE 0 No For Optional Remote Control EVO RC SAMLEX AMERICA INC 83 SECTION 6 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 Table 7 1 of EVO RC Manual at Appendix A shows details of protections and associated Fault Error Messages that will be displayed on the LCD screen of the optional Remote Control EVO RC NOTE If the optional Remote Control EVO RC see Appendix A is not used it may be dif ficult to narrow down the probable cause of the fault 6 6 POWERING OFF THE UNIT IN FAULT MODE
85. RE READ AND UNDERSTOOD BEFORE OPERATING THE UNIT Gi INFO a Minimum battery voltage required for initiating operation is as follows e 12V units Higher than 9V 24V units Higher than 18V b Please note that this unit is designed to POWER ON AUTOMATICALLY if i minimum battery voltage of 9V 18V as at a above is available at the DC input terminals and ii AC voltage 60VAC is available at the Grid Generator Input Terminals If the AC input voltage and frequency are within the programmed limits the unit will automatically operate in Charging Mode If the AC input voltage and frequency are not within the programmed limits the unit will operate in Discharging Inverter Mode Further as long as AC input voltage 60VAC is present the unit CANNOT BE POWERED OFF using the ON OFF Button on the front panel of the unit or on the optional Remote Control EVO RC see Appendix A Switch OFF the AC input first if the unit is required to be powered off However if the unit is in Fault Mode it will be possible to power OFF the unit with the help of the ON OFF Push Button c Before proceeding confirm that the unit is NOT in Standby Mode by pressing ON OFF Button briefly Standby Mode is used for Firmware upload through the optional Remote Control EVO RC see Appendix A o If LED marked ON 12 Fig 2 1 stays OFF then unit is OFF o If this LED is ON or is flashing the unit was in Standby Mode and is now ON 6 1 POWERING ON US
86. ROUP INPUT HIGH LIMIT Setting range Default value a Ea ae 2212 3012 2224 4024 2212 3012 2224 4024 RESET VOLTAGE 135 0V CUT OFF POINT 1 140 0V DETECT TIME 1 300 cycle CUT OFEPDINES 14507 DETECT TIME 2 60 cycle CUT OFF POINT 3 150 0V DETECT TIME 3 1 cycle 82 SAMLEX AMERICA INC SECTION 6 TABLE 6 6 PROGRAMMABLE AND DEFAULT PARAMETERS GROUP OTHER FUNCTIONS Parameter name 2212 3012 2224 4024 2212 3012 2224 4024 REMOTE SWITCH 0 Button Type 12V signal is fed 0 Button Type CAUTION ON OFF Logic also controls the operation of the ON OFF Button on the front panel 11 Fig 2 1 The Default setting For ON OFF control through Push Button Type of Switch through external 12V Pressing of Push Button gt 2 sec signal fed to Remote will switch the unit ON ON OFF terminals on When ON pressing Push Button ic Button Type the Front Panel 15 gt 5 sec will turn the unit OFF If the ON OFF Control is changed to external Fig 2 1 1 Switch Type 12V signal is fed Remote Switch it will not be possible to through contacts of Toggle Type of switch ON OFF the EVO Inverter Charger Switch or relay contact from the front panel ON OFF Push Button ON condition contacts closed because it will work with Switch Type will turn the unit ON Logic It will be ON only as long as the Push OFF condition contacts open Buttom is kept pressed and will switch OFF for 2 sec will switch the unit
87. WER SAVING TIME SETTING STOP SD CARD Page 1 1 Enable 2000 01 01 00 00 0 No REL ING ENTER POINT Page 2 AW WA a WAKE UP POINT Page 3 SW A REMOTE SWITCH Page 4 0 Button 47 Hn RELAY FUNCTION Page5 6 Charger Other LOW BO COMM ID Page 6 1 LE BUZZER Page 7 1 On H EPA S D NN DISCHARGE BEEP Page 8 on CO n A PAD __ DEFAULT RESET Page 9 0 No SO _ DATA LOG TIME Page 10 1 1 sec M PARAMETER SAVE Page 11 No Fig 4 2 Parameter Setup Menu Map Groups 5 to 7 NOTES FOR FIG 4 1 AND 4 2 Values or parameters shown are the default values Voltage values under Group 1 are for 12V versions EVO 2212 3012 Double these values for 24V versions EVO 2224 4024 For details of programmable ranges and default values of each of the parameters please refer to Tables and Sections given below Group No of Parameter Select Table No Section No Group 1 4 4 4 4 Group 2 4 5 4 5 Group 3 4 6 4 6 Group 4 4 7 4 7 Group 5 4 8 4 8 Group 6 4 9 Group 7 4 10 Up is shown with downward pointer because Page Nos in this Parameter Setting Menu Map increase in the downward direction Page Down is shown with upward pointer because Page Nos in this Parameter Setting Menu Map decrease in the upward direction SAMLEX AMERICA INC 13 SECTION 4 4 2 PARAMETER SETUP PROCEDURE GENERAL Please refer to Fig 4 3 below
88. Warrantor Any attempt to remedy the defect by anyone other than the Warrantor shall render this warranty void The warranty does not apply to units with a serial number that has been altered removed or modified in any way There is no warranty for defects or damages to equipment or parts caused by Installation alternation inspection or removal e Normal wear and tear e Abuse or misuse of the equipment including exposure to excessive heat salt or fresh water spray or water immersion e Corrosion fire lightening biological infestations or Acts of God e Repairs attempted by anyone other than the Warrantor e mproper use contrary to operational instructions provided in product manual e Shipping or transport No other express warranty is hereby given and there are no warranties which extend beyond those de scribed herein This warranty is expressly in lieu of any other expressed or implied warranties including any implied warranty of merchantability fitness for the ordinary purposes for which such goods are used or fitness for a particular purpose or any other obligations on the part of the Warrantor or its employees and representatives There shall be no responsibility or liability whatsoever on the part of the Warrantor or its employees and representatives for injury to any persons or damage to person or persons or damage to property or loss of income or profit or any other consequential or resulting damage which may be claimed to hav
89. an 5W on entering Sleep Mode when switched off or when no activity is seen for a specified time 66 SAMLEX AMERICA INC SECTION 4 4 8 4 Power Saving Mode Transfer Characteristics in Grid Generator Mode e 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 If AC input power from Grid Generator fails or is not qualified its voltage and frequency are not within the programmed range the Transfer Relay is de energized and the load is transferred to the inverter When this transfer takes place the inverter initially operates in Normal Mode If the AC load was greater than the programmed value of Wake up Point the inverter continues in Normal Mode However if it sees a load less than the pro grammed value of Enter Point for around 5 sec it enters Power Saving Mode e Transfer from Inverter to Grid Generator As soon as qualified AC input power from Grid Generator is available the inverter will exit Power Saving Mode and will switch over to Normal Mode This switch over is necessary for synchronizing the AC output of the inverter with the AC input before transfer Synchronization can not be carried out with pulsing wave form during Power Saving Mode After synchroniza
90. and 9 will switch over to contacts 4 and 6 respectively Grid has PRIORITY over Genera tor if both are present 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 o When Grid Generator power fails relays K2 K3 will be de energized and contacts 7 and 9 will switch over to contacts 1 and 3 respectively Output from the Inverter Sec tion is fed the Bi directional Transformer and onwards to the Hot Out OUTPUT LINE for powering the AC loads 62 SAMLEX AMERICA INC SECTION 4 Switching of Output Neutral to Chassis Ground Bonding o 70A rated DPDT Relay K4 is used to switch the bonding of the Output Neutral Connector OUTPUT NEUTRAL to the chassis of the unit Please note that in this relay each of the 2 poles is rated for 35A The 2 poles are used in parallel to increase the contact current carrying capacity to 70A o When Grid Generator Power is available relay K4 will be energized and contacts 7 and 9 will switch over to contacts 4 and 6 respectively Neutral input from the Grid GRID NEUTRAL or from the Generator GEN NEUTRAL is fed to the Neutral input of the Bi directional Transformer for battery charging and at the same time it is passed through to t
91. and the Reactive Power in VAR In magnitude it is equal to the RMS value of voltage V X the RMS value of current A The Unit is VA Please note that Apparent Power VA is more than the Active Power in Watts Hence the inverter AC wiring and over current protec tion devices have to be sized based on the Apparent Power Power Factor PF It is denoted by PF and is equal to the ratio of the Active Power P in Watts to the Apparent Power S in VA The maximum value is 1 for resistive types of loads where the Active Power P in Watts the Apparent Power S in VA It is O for purely inductive or purely capacitive loads Practically the loads will be a combination of resistive inductive and SAMLEX AMERICA INC 9 SECTION 1 capacitive elements and hence its value will be gt 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 Non Linear Load A load that does not draw a sinusoidal current when a sinusoidal voltage is fed to it For example non power factor corrected Switched Mode Power Supplies SMPS used in computers audio video equipment battery chargers etc Resistive Load A device or appliance that consists of pure resistance like filament lamps cook tops toaster coffee maker etc and draws only
92. ank SAMLEX AMERICA INC 31 SECTION 3 3 4 4 Wiring Order in Parallel Connection of Batteries AN 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 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 3 6 or to the Positive battery post of the first battery string Battery 1 of String 1 in Fig 3 7 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 3 6 or to the Negative Post of the last battery string Battery 4 of Battery String 2 as in Fig 3 7 This connection ensures the following The resistances of the interconnecting cables will be balanced Allthe individual batteries battery strings will see the same series resistance All the individual batteries will charge discharge at the same charging discharging cur rent and thus will be charged discharged to the same state at the same time None of the batteries will see an overcharge overdischarge condition 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 3 6
93. arameter setting A Password will be requested KEY IN PASSWORD Press Up Down key to change each number When displayed value 0000 is correct a short press of the Enter Key will confirm this value and move to the next digit to the right A long press of the Enter Key is used to write the parameter selection the Password in this case PASSWORD CORRECT Flashes twice when Password is correct 8052 PASSWORD ERROR Flashes twice when Password is not correct BULK CURRENT Press Up Down Key to change number to 50 40 A ig di Short press Enter Key to shift right long press Enter key to set BULK CURRENT An exclamation sign is shown when the parameter is out of the 90 A specified programming range For example if 90A was entered for EVO 2224 EVO 2224 range is 0 704 it will be out of range and an exclamation sign will be displayed WRITING Writing to the inverter 50A WRITE SUCCESS Flashes twice when writing is successful 50A SAMLEX AMERICA INC 15 SECTION 4 WRITE FAILURE 50A OUT OF RANGE 90A BULK CURRENT 50A Flashes twice when there is a write failure Flashes twice when the set value is out of range 90 A is out of range for EVO 2224 End setting Press Back Key to go back to Group select or Up Down key to the next parameter All programmable parameters Groups 1 to 7 in Parameter Menu Maps at Figs 4 1 and 4 2 and their Default Values are described below 4 4 GROUP 1
94. arge The time the charger remains in the Absorption Stage is proportional to the depth of discharge of the battery When the battery is more discharged it will take longer time in the Bulk Charge Stage to reach the Gassing Volt age As a part of the Adaptive Charging Algorithm the T1 Timer explained above computes the time the charging takes place in this stage The T1 Timer has minimum time of 1 hour and a maximum time of 12 hours When the T1 Timer runs out the charger will enter the next Float Stage Programmable range and Default values of Absorption Voltage are shown in Table 5 1 This stage is displayed as N CV in the Charging Mode screens in the Remote Control EVO RC Appendix A SAMLEX AMERICA INC 73 SECTION 5 5 6 3 Float Stage Float Stage is a maintenance stage in which the output voltage is reduced to a lower level typically about 13 5 volts 27 volts for 24V models to maintain the battery s charge without losing electro lyte through gassing and also prevent corrosion of Positive plate by maintaining proper Positive plate Polarization Voltage Programmable range value of Float Voltage are shown in Table 6 2 This stage is displayed as Float in the Charging Mode screens in the Remote Control EVO RC Appendix A 5 6 4 Automatic Resetting of Charging Cycle in 3 Stage Charging Profile The charging cycle will be reset to the Bulk Stage as follows If the AC input from the Grid Generator is d
95. arged If an SLI battery is used for this type of deep discharge application its useful service life will be drastically reduced Hence this type of battery is not recommended for the storage of energy for inverter applications A second deep cycle auxiliary battery must be installed in the RV for powering the EVO A deep cydle auxiliary battery is shown in Fig 3 14 When the second auxiliary deep cycle battery is used a Battery Isolator is required that will allow parallel connection of the two batteries for charging when the alternator is ON and disconnecting the parallel connection when the alternator is stopped Isolator is shown in Fig 3 14 The capacity of the Battery Isolator should be as follows e For EVO 2012 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 e For EVO 2224 The maximum continuous DC current required is 133A The capacity of the Battery Isolator should be more than 133A or more than the capacity of the alternator whichever is higher 56 SAMLEX AMERICA INC SECTION 3 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 m
96. ated to 60 C e Green LED marked Status will be switched OFF and the Red LED marked Alarm will be steady ON The buzzer in EVO Inverter Charger will beep steady e Inverting Mode Inverter Section will be switched OFF If in Charging Mode the Transfer Relay will be de energized and the Inverter Section will be switched OFF e Check that the fans are working properly there is no blockage of air suction and discharge vents adequate cool replacement air is available and the ambient tem perature is within the limits Reduce the load and BULK CURRENT Section 4 4 e fault will be cleared when the heat sink has cooled down to 40 C SD card unusable Data logging will not start Check that the format is FAT16 FAT32 Check that the capacity is less than 16 GB Re format the card SD card read error Data logging stops Remove and re insert the card SD card write error SD card full e Data logging stops e Remove and re insert the card e Data logging stops e Move or delete files or re format the card 38 SAMLEX AMERICA INC SECTION 8 MODEL NO EVO RC COMPATIBLE INVERTER CHARGERS MODEL NUMBERS EVO 2212 EVO 3012 EVO 2224 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
97. ating 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 For convenience each Parameter Setup Screen in Figs 4 1 and 4 2 can be referenced by 2 co ordinates Group No Column and Page No Row The desired Parameter Setup Screen can be reached by navigating through the Select Group Menus as shown in the Select Group Menu Map at Fig 4 3 Gi INFO In this section parameter set up procedures have been explained using LCD screen displays with information as seen on the actual LDC screens All parameters shown on the second row of the screen displays are the default parameters All voltage values related to battery voltages are the default values for 12V versions EVO 2212 3012 Double these values for the 24V versions EVO 2224 4024 SAMLEX AMERICA INC 11 SECTION 4 4 1 PARAMETER SETUP MENU MAPS J Page Up Up Key 4 Page Down Down Key Page 1 Page 2 Page 3 Page 4 Page 5 Page 6 Page 7 Page 8 Page 9 Page 10 Page 11 Page 12 Page 13 Page 14 Page 15 Group 1 SELECT GROUP CHARGE GROUP BULK CURRENT 40A ME C Enter Key To Group towards the right Back Key To Group towards the left Group 2 SELECT GROUP INPUT SETTING Group 3 SELECT GROUP INPUT LOW LIMIT Group 4 SELECT GROUP INPUT HIGH LIMIT DEFAULT FREQ 0
98. attery can deliver 25 Amperes at 80 F 26 7 C till the voltage drops to 1 75V Cell i e 10 5V for 12V battery or 21V for 24V battery Approximate relationship between the two units is Capacity C in Ah Reserve Capacity in RC minutes x 0 6 1 4 4 Typical Battery Sizes Table 1 7 below shows details of some popular battery sizes TABLE 1 7 POPULAR BATTERY SIZES BCI Group Battery Voltage V Battery Capacity Ah 27 31 12 105 4D 12 160 8D 12 225 GC2 6 220 Battery Council International Golf Cart 16 SAMLEX AMERICA INC SECTION 1 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 As explained above the amount of stored electrical energy is also called the Capacity of the battery and is designated by the symbol C The time in Hours over which the battery is discharged to the End Point Voltage for purposes of specifying Ah capacity depends upon the type of application Let us denote this discharge time in hours by T Let us denote the rate of discharge current of the battery as a multiple of Ah capacity C and call it as the C Rate If the battery delivers a very high discharge current the battery will be discharged t
99. ault condition will be cleared While in Battery low voltage fault condition if AC input is made available before the expiry of LV CUT OFF TIME the Battery low voltage fault condition will be cleared The EVO Inverter Charger will restart in Inverter Mode synchronize with the AC input and then transfer to the AC input at zero crossing It will now operate in Charging Mode Enter Key Up Key x 8 SELECT GROUP BULK CURRENT LOW VOLTAGE CHARGE CURVE 40A 10 50 V LV DETECT TIME To prevent low battery shut down of the inverter due to momentary dips in battery volt age as a result of high power short duration AC loading e g motor starting inrush current etc a timer is used to qualify battery low condition only if the battery voltage drops to or below the set BATTERY LOW VOLTAGE threshold for the set IV DETECT TIME The timer starts as soon as the battery voltage drops to the set threshold of BATTERY LOW VOLTAGE described above SAMLEX AMERICA INC 19 SECTION 4 Enter Key Up Key x 9 SELECT GROUP BULK CURRENT DETECT TIME CHARGE CURVE 40A 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 th
100. ch Mode Power Supplies SMPS are extensively used to convert the incoming AC power into various voltages like 3 3V 5V 12V 24V etc that are used to power various devices and cir cuits used in electronic equipment like battery chargers computers audio and video devices ra dios etc These power supplies use large capacitors in their input section for filtration When the power supply is first turned on there is a very large inrush current drawn by the power supply as the input capacitors are charged The capacitors act almost like a short circuit at the instant the power is turned on The inrush current at turn on is several to tens of times larger than the rated RMS input current and lasts for a few milliseconds An example of the input voltage versus input current waveforms is given in Fig 1 2 It will be seen that the initial input current pulse just after turn on is 15 times larger than the steady state RMS current The inrush dissipates in around 2 or 3 cycles i e in around 33 to 50 milliseconds for 60 Hz sine wave Further due to the presence of high value of input filter capacitors the current drawn by an SMPS With no Power Factor correction is not sinusoidal but non linear as shown in Fig 1 3 The steady state input current of SMPS is a train of non linear pulses instead of a sinusoidal wave These pulses are two to four milliseconds duration each with a very high Crest Factor corresponding to peak values around 3 times the RMS value
101. cuits GFCls listed in Table 1 5 have been tested to operate satisfactorily and are acceptable A N ATTENTION Veuillez assurer que le s disjoncteur s de terre GFCI est sont install dans le syst me de c blage du v hicule pour prot ger tous les circuits de d rivation Des disjoncteurs de terre ci dessous ont t test Leur fonctionnement est acceptable Table 1 5 3 16 2 Requirement Of Deep Cycle Auxiliary Battery And Battery Isolator For Powering Inverters In Mobile Installations Basic information on Lead Acid Batteries is given in Section 1 4 under General Infom ration Lead Acid batteries For details read on line White Paper titled Batteries Chargers amp Alternator at www samlexamerica com Home Support White Papers An RV vehicle has Starter Lighting and Ignition SLI battery As explained in White Paper titled Batteries Chargers and Alternators SLI batteries are designed to produce high power in short bursts for cranking SLI batteries use lots of thin plates to maximize the surface area of the plates for providing very large bursts of current also specified as Cranking Amps This allows very high starting current but causes the plates to warp when the battery is cycled Vehicle starting typically discharges 196 396 of a healthy SLI battery s capacity The automotive SLI battery is not designed for repeated deep discharge where up to 8096 of the battery capacity is discharged and then rech
102. d 20 to 26V for 24V battery and the Default Setting is 12V for 12V battery and 24V for 24V battery Enter Key Up Key x 14 SELECT GROUP CHARGE CURVE FLOATING EXIT CHARGE CURVE BULK CURRENT 12 00V 4 5 GROUP 2 PARAMETER SET UP INPUT SETTING Please refer to Parameters under Group 2 at Fig 4 1 Details of Parameter set up are given below TABLE 4 5 GROUP 2 PARAMETER SET UP INPUT SETTING Page Setting range Default value No for Group Parameter 2 Fig 2212 3012 2224 4024 2212 3012 2224 4024 4 1 1 DEFAULT FREQ 50 60Hz 60Hz 2 MAXIMUM CURRENT 5 40A 5 70A 5 40A 5 70A 30A 3 HIGH CUT OFF 50 70Hz 65Hz 4 HIGH RESET 50 70Hz 64Hz 5 LOW CUT OFF 40 60Hz 55Hz 6 LOW RESET 40 60Hz 56Hz SAMLEX AMERICA INC 21 SECTION 4 DEFAULT FREQ Default frequency sets the Inverter frequency which is also the standard frequency for AC input Up Key Enter Key SELECT GROUP SELECT GROUP DEFAUT FREQ CHARGE CURVE INPUT SETTING 0 60Hz MAXIMUM CURRENT In Charging Mode the net AC input current from the Grid Generator is the sum of the AC 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 propo
103. d is inserted and Data Logging Function is enabled Default the EVO In verter Charger will start recording statistics and events on the card File creating Data log function has been initiated and new file is being created Do not remove the SD card when file creating is displayed eec Read error the data log function update upload will stop SD card Write error Write error The Data logging function will stop 1 Card full Data logging funtion has stopped 2 There is not enough space to create Data Log File Folder or to save file with saved programmed parameters NOTE Once there is enough space to create a Data Log File Folder and subsequently it runs out of capacity due to recording newer data it will start to overwrite on older files 30 SAMLEX AMERICA INC SECTION 5 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 The File Name Format is month day hour minute txt MMDDhhmm txt TABLE 5 1 Example of Data Log Folder 10141103 TXT 10141228 TXT 10141353 TXT 10141518 TXT 10141643 TXT 10141808 TXT 10141933 TXT 10142058 TXT 10142223 TXT 10142348 TXT 10150113 TXT 10150238 TXT 1 10150403 TXT 10150528 TXT 10150653 TXT 10150818 TXT Table 5 2 shows an example of one of the Fi
104. e Battery over voltage will be displayed on the LCD screen The Green LED marked Status will switch OFF and the Red LED marked Alarm will remain ON steady The Buzzer on EVO Inverter Charger will beep steady The fault will be cleared automatically when the battery voltage drops to 0 5V below to the set upper threshold of BATT OVER VOLT The unit will start in Inverting Mode synchronize with the AC input and then the Transfer Relay will be energized to transfer to AC input at zero crossing The unit will thus resume operation in Charging Mode Enter Key Up Key x 5 SELECT GROUP c BULK CURRENT CHARGE CURVE 40A 16 00 V RESET VOLTAGE The inverter will restart when the battery voltage rises above this set value after Battery Low Voltage shutdown occurs If Relay Function is set for Generator the relay will turn OFF Enter Key Up Key x 6 SELECT GROUP BULK CURRENT c RESET VOLTAGE CHARGE CURVE C 40A 12 50 V 18 SAMLEX AMERICA INC SECTION 4 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 If in On Line Mode it will transfer from Inverting Mode to Charging Mode Enter Key Up Key x 7 SELECT GROUP BULK CURRENT LOW VOLT ALARM CHARGE CURVE 40A 11 00 V BATT LOW VOTLAGE This parameter s
105. e inverter and battery ends 3 5 8 Reducing RF Interference To reduce the effect of radiated interference shield the wires with sheathing copper foil braiding For details refer to Limiting Electro Magnetic Interference at Section 1 3 4 3 5 9 Taping Battery Wires Together To Reduce Inductance Do not keep the battery wires far apart Keep them taped together to reduce their inductance Reduced inductance of the battery wires helps to reduce induced voltages This reduces ripple in the battery wires and improves performance and efficiency For details refer to Limiting Electro Magnetic Interference at Section 1 3 4 40 SAMLEX AMERICA INC 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 AC Input Output Terminal Block Terminal hole diameter 6mm for up to AWG 6 Set Screw M4 4 Grid Input Line 5 Grid Input Ground 6 Grid Input Neutral 7 Generator Input Line 8 Generator Input Ground 9 Generator Input Neutral 10 AC Output Line 11 AC Output Ground 12 AC Output Neutral 13 Male Female Insulated Quick Disconnect for disabling Ouptut Neutral to chassis Ground bond in Inverter Mode Please see Section 4 5 1 to 4 5 3 and Fig 3 1 2 Behind Cover Plate 1 Fig 3 9 AC Input and Output SAMLEX AMERIC
106. e Normal Mode is around 25W to 30W The EVO has a provision to minimize this No Load Power Draw if required Applicable only when the unit is in Inverter Mode This is achieved by enabling the Power Saving Mode The unit is shipped in default Enabled condition i e Power Saving Mode will be active Optional Remote Control EVO RC see Appendix A is required to disable this mode When this mode is enabled the unit does not provide continuous output power A pulsing output power consisting of only 3 cydes of reduced 48 VAC output voltage that are made available every 0 5 seconds is used to sense if a minimum load is present or not As continuous power is not being supplied the No Load Power Draw is reduced to less than 8W If a load greater than the programmed value of Wake up Point is sensed the unit exits Power Save Mode and starts providing normal continuous output power If the load drops to the programmed value of Enter Point the unit once again reverts to Power Saving Mode Programmable and Default Values of Enter Point and Wake up Point are shown in Table 6 6 Further details are available in the Owners Manual for the Remote Control EVO RC See Appendix A Power Saving Mode should be disabled for the following loads e Low power loads that draw lt 5W e g digital clocks satellite receivers phones answering machines etc Audio video computing devices that consume normal operating power gt 50 W but draw less th
107. e battery has been recharged to the RESET VOLT AGE or when AC input voltage is available However if the fault is not cleared over a long period of time the battery may get completely discharged Hence a timer is used to record the duration of Battery low voltage condition The EVO Inverter Charger will be complete ly shut down when the duration of the Battery low voltage fault condition as described above is equal to the LV CUT OFF TIME Enter Key Up Key x 10 SELECT GROUP 5 BULK CURRENT c LV CUT OFF TIME CHARGE CURVE 40A 1200 sec CHARGE MODE Default setting is 3 Stage Normal Mode Parameter Screen setting shows O Normal The mode can be changed at any time to 4 stage Equalization Mode Change Screen setting to 1 Equalize After Equalization Mode is completed the charger enters Float Stage after completing Equalization Stage the screen automatically resets to Normal 0 Normal Enter Key Up Key x 11 SELECT GROUP BULK CURRENT CHARGE MODE CHARGE CURVE 40A OzNormal ON LINE MODE In this mode PRIORITY is given to the Inverter Section Even if qualified AC input within the programmed voltage and frequency limits is available at the Grid Generator AC inputs the unit always operates in Inverting Mode and AC output is provided by the Inverter Section as long as the battery is in charged condition above the LOW VOLT ALARM threshold When the battery discharges to the programmed value
108. e been incurred through the use or sale of the equipment including any possible failure of malfunction of the equipment or part thereof The Warrantor assumes no liability for incidental or consequential damages of any kind Samlex America Inc the Warrantor www samlexamerica com 40 SAMLEX AMERICA INC APPENDIX A Notes SAMLEX AMERICA INC 41 APPENDIX A Notes 42 SAMLEX AMERICA INC APPENDIX A Notes SAMLEX AMERICA INC 43 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 samlexamerica
109. e commonly found in power tools appliances well pumps etc They exhibit very high surge demands when starting Significant voltage drop in these circuits may cause failure to start and possible motor damage PV battery charging circuits These are critical because voltage drop can cause a dispro portionate loss of charge current to charge a battery A voltage drop greater than 596 can reduce charge current to the battery by a much greater percentage N ATTENTION Des d gats caus s par un renversement des polarit s n est pas couverts par la garantie Quand vous faites des connexions la batterie du c t d entr e veuillez assurer que les polarit s sont mise du bon c t Li le positif de la batterie la borne positive de l appareil et le n gatif de la batterie la borne n gative de l appareil Si les polarit de l entr e sont mise l envers le fusible CC externe du c t d entr e va s exploser et peut causer des d g ts permanent l onduleur N ATTENTION La section d entr e de l onduleur a des condensateurs de grande valeur qui sont connect aux bornes d entr es Tant que le boucle de connexion d entr e CC la borne de la batterie le fusible la borne d entr e positive du EVO la borne d entr e n gative du EVO la borne de la batterie est compl t les condesateurs commenceront recharger L appareil prendra un courant fort bri vement pour s alimenter qui va produire une tincelle
110. e of the total length of Copper conductor the total length of conductor has been taken as 2 times the running distance between the unit and the battery to cover 2 lengths of Positive and Negative cable conductors SAMLEX AMERICA INC 39 SECTION 3 4 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 Amp rating of the fuse is based on the following considerations a Notless than NEC Ampacity of 12596 of the Rated Continuous DC Input Current Column 3 Refer to NEC 2014 National Electrical Code Sec tion 215 3 b Closest Standard Ampere Rating of Fuse has been used Refer to NEC 2014 National Electrical Code Section 240 6 A c Where Standard Fuse Rating does not match the required Ampacity of 12596 of the Rated Continuous DC Input Current Column 3 the next higher Standard Rating of the fuse has been used Refer to NEC 2014 National Electrical Code Section 240 4 B d Type of fuse Fast acting Current Limiting UL Class T UL Standard 248 15 or equivalent 3 5 7 Using Proper DC Cable Termination The battery end and the inverter end of the wires should have proper terminal lugs that will ensure a firm and tight connection Choose lugs to fit the wire size and the stud sizes on th
111. e 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 To prevent possibility of paralleling and severe damage to the inverter never use a simple jumper cable with a male plug on both ends to connect the AC output of the inverter to a handy wall receptacle in the home RV N ATTENTION Pr vention en parall le de la sortie AC La sortie de courant alternatif de l unit ne peut pas tre synchronis e avec une autre source de courant alternatif et par cons quent il ne convient pas pour mise en parall le du c t de la sortie La sortie AC de l unit ne doit jamais tre connect directement un panneau central de charge disjoncteur lectrique qui est galement aliment par une autre source de courant alternatif Une telle connexion peut entra ner un fonctionnement parall le de diff rentes sources d nergie et la puissance AC de l autre source de courant alternatif est r inject dans l unit qui va instan tan ment endommager la section de sortie de l unit et peuvent aussi poser un risque d incendie et de s curit Si un centre panneau de disjoncte
112. e 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 Route the wire to ensure there are no kinks Use appropriate grommets when the wire is passed through holes in studs partitions to prevent damage to insulation 2 1 2 Tools Required Following tools are recommended Phillips Head Screwdriver Level e Hand Drill Knife Saw e Pencil e Drill Bit 2 5mm 39 Panel Cutout o 102mm H 122mm 132mm Fig 2 1 EVO RC Remote Cutout Dimensions 2 2 FLUSH MOUNT INSTALLATION To flush mount the wall opening must have at least a 2 5 cm depth to make room for the remote and cable Also the thickness of wall panel board at the place of mounting should not be more than 13 mm to ensure that the RJ 45 jack opening is not obstructed see Fig 2 3 1 2 Cut an opening in the wall using the supplied paper template based on Fig 2 1 Drill four pilot holes use 2 5mm diameter 39 drill bit for the 4 screws 3mm diameter 16mm long that will attach the remote to wall refer to Figure 2 1 for hole locations and dimensions Route one end of the cable through wall opening to the EVO Inverter Charger and then plug it into the RJ45 Remote Control Jack port on the EVO Inverter Charger 4 SAMLEX AMERICA INC SECTION 2 4
113. ed directly to the batteries or through the External Charger Input 3 4 in Fig 2 1 in EVO Inverter Charger Manual and the battery voltage recovers to the set RESET VOLTAGE before the expiry of LV CUT OFF TIME while in Battery low voltage fault condition the Inverter Section will restart and Battery low voltage fault condition will be cleared While in Battery low voltage fault condition if AC input is made available be fore the expiry of LV CUT OFF TIME the Battery low voltage fault condition will be cleared The EVO Inverter Charger will restart in Inverter Mode synchro nize with the AC input and then transfer to the AC input at zero crossing It will now operate in Charging Mode 36 SAMLEX AMERICA INC SECTION 7 Battery over voltage 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 There will be no AC output because the Inverter Section will be switched OFF The Green LED marked Status will be switched OFF and the Red LED marked Alarm will be steady ON The buzzer in EVO Inverter Charger will beep steady The fault will be cleared automatically when the battery voltage drops to 0 5V below the set upper threshold of BATT OVER VOLT b AC input is available and EVO Inverter Charger is operating in Charging Mode
114. ed through the unit Connectors 3 4 in Fig 2 1 Maximum charging cur rent from the external charging source is limited to 50A This limit should not be exceeded Please note that Lead Acid batteries should not be charged at very high charging currents to prevent adverse effects like reduction in returned capacity excessive surface charge overheat ing excessive pressure build up in sealed batteries generation of Oxygen and Hydrogen will be recombination etc Normally the maximum charging current is limited to 2096 of the Ah capacity of the battery unless the battery manufacturer allows higher charging current When a battery is charged simultaneously by multiple charging sources all the charging currents will add up and may result in very high charging current with respect to the Ah capacity of the bat tery The charging current fed from the external source is measured and the charging cur rent generated by the internal charger is automatically controlled to ensure that the net charging current fed to the battery does not exceed the net programmed Bulk Charge Current Io 5 5 Battery Temperature Sensor A Battery Temperature Sensor Model EVO BCTS has been provided Fig 2 5 a It comes with 5 m 16 5 ft cable Connect the ring terminal end houses the sensor on the battery Positive or Negative post Connect the RJ 45 plug to the Temperature Sensor Jack 6 Fig 2 1 The Temperature Sensor is used to ensure optimum charging by modify
115. equalizing batteries under White Paper titled Batteries Chargers and Alternators available online at www samlexamerica com Home Support White Papers The 4 stages of the cycle will be Bulk Absorption Equalization and Float Equalization Mode is desirable for the proper health of Wet Cell Batteries Equalization voltage is programmable through the optional Remote Control Model EVO RC see Appendix A Programmable voltage range and default values are shown in Table 6 2 Equalization current and Equalization time are computed automatically See Section 5 8 Fig 5 2 shows the voltage and current curves during the 4 stages of charging in this mode 74 SAMLEX AMERICA INC SECTION 5 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 The stage transitions will thus be Bulk Stage Con stant Current gt Absorption stage Constant Voltage gt Equalization Stage Constant Voltage 2 Float Stage Constant Voltage As part of the Adaptive Charging Algorithm the charging profile in the Equalization Stage is based on the time To which is the time the charger remains in the initial Bulk Stage The charger will remain in the initial Bulk Stage for a longer duration
116. erator Input Ground Generator Input Neutral AC Output Line AC Output Ground AC Output Neutral Male Female Insulated Quick Disconnect for disabling Output Neutral to Chassis Ground bond in Inverter Mode Please see Sections 4 5 1 to 4 5 3 and Fig 3 12 2 Behind Cover Plate D D Fig 2 3 Layout AC Side SAMLEX AMERICA INC 25 SECTION 2 2 4 REMOTE CONTROL EVO RC FIG 2 4 OPTIONAL amp samlexpower 0000 SD Card Model EVO RC 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 Navigation Key Down Navigation Key Enter SD Card Slot FAT16 32 format Up to 16GB RJ 45 Jack At the back not shown RJ 45 Data Cable Straight Wired 10 meter 33 feet length Fig 2 4 b SS 19 00 OY UI WN RJ 45 Ke Fig 2 4 b Cable for Remote Control 26 SAMLEX AMERICA INC SECTION 2 Components amp Layout 2 5 BATTERY TEMPERATURE SENSOR EVO BCTS FIG 2 5 a 1 Temperature Sensor Mounting hole 10mm 0 39 suitable for 3 8 or 5 16 battery studs 2 R45 Plug 3 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 Inverter Charger Temperat
117. ere 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 100 Amperes x 3 Hours 300 Ampere Hours Ah or by the 24V batteries 50A x 3 Hrs 150 Ah 22 SAMLEX AMERICA INC SECTION 1 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 6096 Hence the actual capacity of the 12V batteries to deliver 300 Ah will be equal to 300 Ah 0 6 500 Ah and the actual capacity of the 24V battery to deliver 150 Ah will be equal to 150 Ah 0 6 250 Ah And finally the actual desired rated capacity of the batteries is determined based on the fact that normally only 8096 of the capacity will be available with respect to the rated capacity due to non availability of ideal and optimum operating and charging conditions So the final requirements will be equal to FOR 12V BATTERY 500 Ah 0 8 625 Ah note that the actual energy required by the load was 300 Ah FOR 24V BATTERY 250 Ah 0 8 312 5 Ah Note that the actual energy required was 150 Ah It will be seen from the above that the final rated capacity of the batteries is almost 2 times the energy required by the load in Ah Thus as a Rule of Thumb the Ah capacity of the bat teries should be twice the energy required by the load
118. ets the battery low voltage threshold at which the Inverter Section the com plete EVO Inverter Charger will be shut down to protect the battery from deep discharge e When the battery voltage drops to the set threshold of BATTERY LOW VOLTAGE the Red LED marked Alarm will flash once per second The buzzer in EVO Inverter Charger will beep once per second The Inverter Section will continue to operate normally and the Green LED marked Status will continue to be ON steady e f the battery voltage stays at or below the above threshold for duration equal to the LV DETECT TIME described below only the Inverter Section will be switched OFF and mes sage Battery low voltage will be displayed The Green LED marked Status will be switched OFF and the Red LED marked Alarm will remain ON steady The buzzer in EVO nverter Charger will beep steady e f the Battery low voltage fault condition is not reset within the LV CUTOFF TIME the EVO Inverter Charger will be shut down completely after LV CUTOFF TIME has elapsed e f the batteries are charged by external charger connected directly to the batteries or through the External Charger Input 3 4 in Fig 2 1 in EVO Inverter Charger Manual and the battery voltage recovers to the set RESTART VOLTAGE before the expiry of IV CUT OFF TIME while in Battery low voltage fault condition the Inverter Section will restart and the Battery low voltage f
119. for 24V battery The State of Discharge of a battery is estimated based on the measured terminal voltage of the battery The terminal voltage of the battery is dependent upon the following Temperature of the battery electrolyte Temperature of the electrolyte affects the electro chemical reactions inside the battery and produces a Negative Voltage Coefficient during charging discharging the terminal voltage drops with rise in temperature and rises with drop in temperature The amount of discharging current or C Rate A battery has non linear internal resis tance and hence as the discharge current increases the battery terminal voltage decreases non linearly The discharge curves in Fig 1 4 show the 96 State of Charge versus the terminal voltage of typical Flooded Lead Acid Battery under different charge discharge currents i e C Rates and fixed temperature of 80 F Please note that the X Axis of the curves shows the of State of Charge The of State of Discharge will be 100 State of Charge 1 4 10 Low DC Input Voltage Alarm in Inverters As stated earlier the buzzer alarm is triggered when the voltage at the DC input terminals of the inverter has dropped to around 10 5V for a 12V battery or 21V for 24V battery at C Rate discharge current of C 5 Amps Please note that the terminal voltage relative to a particular of State Discharge decreases with the rise in the value of the discharge current For example ter mi
120. g 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 The Remote plugs into RJ 45 Jack on the front panel of the unit 7 Fig 2 1 It has provision for Data Logging using SD Card of up to 16 GB FAT16 FAT32 It also has its own Real Time Clock and Super Capacitor Type of Inter nal Battery The Remote Control will be required for Firmware upgrade through the SD Card Detailed messaging is available through its LCD display and LEDs This remote will also be required for programming of various parameters to suit specific requirements Each pro grammable parameter has a Default Value This unit has been shipped with the various parameters set at the Default Values Programmable and Default values are shown in Tables 6 2 to 6 6 SAMLEX AMERICA INC 69 SECTION 5 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 It uses a common Converter Section that can work in two directions in one direction it converts external AC power to DC power to c
121. h the Equipment Grounding Conductor EGC This Equipment Grounding Conductor EGC when appropriately bonded to Earth Ground helps to prevent electric shock and allows over current devices to operate properly when ground faults occur The size of this conductor should be coordinated with the size of the over current devices involved Marine installations require the size of this conductor to be of the same size as the Battery Negative wire Please read following on line White Papers for complete understanding of Grounding at www samlexamerica com Home Support White Papers e Grounded Electrical AC Power Distribution System e Grounding System and Lightning Ground Fault Protection 3 12 GROUNDING ARRANGEMENT IN EVO SERIES Schematic at Fig 3 12 illustrates the grounding arrangement of EVO Series Internally EVO consists of a DC Section and an AC Section that are isolated through a trans former Both these sections are required to be grounded appropriately When using a generator please ensure that the Neutral of the generator is bonded to Ground Rod 3 13 DC SIDE GROUNDING SEE FIG 3 12 DC side grounding involves proper grounding of the Negative of the battery the DC Panel and the DC side of the EVO A Grounding Connector G2 5 in the DC side layout in Fig 2 1 is provided for connecting to the System Ground The connector can accept wire sizes AWG 4 6 The set screw size is M8 A DC Panel as shown in Fig
122. harge the batter ies Charging Mode and in the other direction it converts the DC power from the battery to AC power Inverting Mode PWM design is used for both the charging and inverting sections Please note that it cannot work in both the directions at the same time i e it cannot work as an inverter and as a charger at the same time When AC input power from Grid Generator is available within the programmed limits of volt age and frequency the internal Transfer Relay passes through the AC input to the AC loads and at the same time the AC input is fed to the Battery Charger Section First the AC input voltage is stepped down by the Low Frequency Isolation Transformer and is then rectified by 4 sets of H Bridge Mosfets and fed to the batteries for charging When charg ing starts the current does not rise sharply but ramps up slowly to the full programmed Bulk Charge curent The Battery Charger Section of the EVO is a powerful 100 MHz DSP micro controller based 3 Stage or a 4 Stage Charger Battery charging parameters are detailed at Table 5 1 3 Stage Charging Algorithm Default is used for normal day to day charging The 3 stages are Bulk Absorption and Float The charging voltages and currents are programmable within the ranges given in the Table 5 1 to take care of a wide range of battery types like flooded AGM Gel Cell Lead Calcium etc For details see Section 5 6 and Charging Curves at Fig 5 1 4 Stage Charging
123. he charger delivers the maximum Bulk Charge Current lo that has been programmed through the Parameter Setting Menu of the optional Remote Control Model EVO RC Range and Default value are shown at Table 5 1 This current is delivered to the batteries until the battery voltage approaches its Gassing Voltage Absorption Voltage typically around 14 4 volts for 12 volt batteries and 28 8 volts for 24 volt batteries again this voltage can vary based upon the desired values programmed through the Parameter Setting Menu of the optional Remote Control Model EVO RC see Appendix A The Bulk Charge Stage restores about 7596 of the battery s charge The Gassing Voltage is the voltage at which the electrolyte in the battery begins to break down into Hydrogen and Oxygen gases Under normal circumstances a battery should not be charged at a voltage above its Gassing Voltage except in the manually selected Equalization Stage since this will cause the battery to lose electrolyte and dry out over time This stage is displayed as N CC in the Charging Mode screens in the Remote Control EVO RC Fig 3 2 Appendix A LEGEND Voltage Curve lt BULK ABSORPTION FLOAT Displayed as N CC Displayed as N CV Displayed as Float a 0 3V RETTET Current Curve Note 1 The voltage curve shows the voltage output of charger The intrinsic battery voltage may be different and will be p
124. he output Neutral OUTPUT NEUTRAL for powering the AC loads Please note that in this condition the Output Neutral OUTPUT NEUTRAL is isolated from the chassis of the unit o When Grid Generator power fails relay KA will be de energized and contacts 7 and 9 will switch over to contacts 1 and 3 respectively Neutral output from the Inverter Section is fed the Neutral of the Bi directional Transformer and onwards to the output Neutral OUTPUT NEUTRAL for powering the AC loads At the same time the output Neutral OUTPUT NEUTRAL gets bonded to the chassis of the unit through the mated contacts of the Insulated Quick Disconnect QD located in the AC Wiring Compartment 13 Fig QD NEUTRAL 4 5 METAL CHASSIS GROUND OF THE UNIT M e M INVERTING 4 CHARGING BI DIRECTIONAL TRANSFORMER K2 3 LINE OUTPUT GRID GEN OUTPUT GRID GEN OUTPUT GRID LINE LINE LINE GND GND GND NEUTRAL NEUTRAL NEUTRAL Transfer Relay 40A for Grid Line Transfer Relay 40A for Generator Line Relay 40A for Neutral to Ground bond Switching I LEN a com Normally Closed Contacts Normally Open Contacts 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
125. id Generator above the EVO prioritizes the Grid over the Generator input If the EVO is operating with the Generator input active and the Grid input is restored the EVO will transfer the load to its Inverter Section and then transfer back to the Grid input Both operations are synchronized and the transfer is at the zero crossing for a seamless transfer 4 6 BATTERY CHARGER SECTION The Battery Charger Section of these units is a powerful 3 4 Stage fully automatic battery charging circuit The same Isolation Transformer and the H Bridge configuration are used to work in the reverse direction ie rectify the AC voltage from the Primary AC Power Source to PWM controlled low voltage DC to charge the DC Battery Source That is why it is called a Bi directional device Normal 3 Stage Charging Mode consists of Bulk Absorption and Float stages Default 4 Stage Equalization Mode consists of Bulk Absorption Equalization and Float The Equalization Mode is selectable Equalization Mode is desirable for the proper health of Wet Cell Batteries Further the charging voltages and currents are programmable to take care of a wide range of battery types like flooded AGM Gel Cell Lead Calcium etc Important battery charging features are as follows e Adaptive Charging Control e Dynamic Input Power Diversion Control Parallel charging through External Charge Controller Temperature compensated charging Please see details under Section 5 titled Ba
126. imes per sec to show that Equalization Mode is active The unit will complete Equalization Cycle and terminate in Float Stage At the same time the Charge Mode Set ting will again reset to Normal Mode and the Green LED Status will return to 1 flash per second To terminate Equalization Mode prematurely before its completion press the ON OFF Push Button for 1 second If the unit was in Inverting Mode Green LED Status steady and the Mode is set to Equal ization as above by pressing the ON OFF Push Button for 1 second the unit will undergo Equalization Mode whenever qualified AC input is available from Grid Generator and the unit enters Charging Mode To terminate Equalization Mode prematurely before its comple tion press the ON OFF Push Button for 1 second NOTE Procedure described above is to be used when the optional Remote Con trol EVO RC has NOT been plugged into the RJ 45 Remote Control Jack Please note if the Remote Control has been plugged into the RJ 45 Jack the above procedure cannot be activated and the ON OFF of Equalization Mode will be controlled by the Remote Control EVO RC Using Optional Remote Control EVO RC Please refer to the attached manual for EVO RC at Appendix A SAMLEX AMERICA INC 77 SECTION 6 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 A
127. in Ah 1 14 15 Charging Batteries Batteries can be charged by using good quality AC powered battery charger or from alterna tive energy sources like solar panels wind or hydro systems Make sure an appropriate Battery Charge Controller is used It is recommended that batteries may be charged at 1096 to 2096 of their Ah capacity Ah capacity based on 20 Hr Discharge Rate Also for complete charging return of 10096 capacity it is recommended that a 3 Stage Charger may be used Constant Current Bulk Charging followed by Constant Voltage Boost Absorption Charging followed by Constant Voltage Float Charging SAMLEX AMERICA INC 23 SECTION 2 Components amp Layout 2 1 MAIN UNIT LAYOUT FRONT FIG 2 1 Status Relay BATTERY POSITIVE Wil Fig 2 1 Layout Front Protection Covers for Battery Terminals 1 Battery Positive Input Connector M10 x 1 25 Nut amp Bolt RED Protection Cover 1 a is Removed 1a RED Protection Cover For Battery Positive Input Connector Battery Negative Input Connector M10 x 1 25 Nut amp Bolt Black Protection Cover 1 b is Removed 2a Black Protection Cover for Battery Negative Input Connector External Charger Input Connector M12 x 0 75 Thumb Nut and Bolt External Charger Input Connector M12 x 0 75 Thumb Nut and Bolt DC Side Ground Connector Hole Dia 6 5mm for AWG 4 to 6 Set Screw M 8 RJ 45 Jack for Temperature Sensor EVO BCTS Fig 2 5
128. ing of the battery If the load is not disconnected at this stage the batter ies will be drained further to a lower voltage and to a completely discharged condition that is harmful for the battery and for the inverter Inverters are normally provided with a protection to shut down the output of the inverter if the DC voltage at the input terminals of the inverter drops below a threshold of around 10V for a 12V battery 20V for 24V battery Referring to the Discharge Curves given in Fig 1 4 the State of Discharge for various C Rate discharge currents for battery voltage of 10V 20V is as follows Please note that the X Axis of the curves shows the 96 of State of Charge The 96 of State of Discharge will be 10096 96 State of Charge 85 State of Discharge 15 State of Charge at very high C rate discharge current of C 3 Amps 100 State of Discharge 0 96 State of Charge at high C Rate discharge current of C 5 Amps 100 discharged 0 State of charge at lower C rate Discharge current of C 10 Amps It is seen that at DC input voltage of 10V 20V the battery is completely discharged for C rate discharge current of C 5 and lower In view of the above it may be seen that a fixed Low DC Input Voltage Alarm is not useful Temperature of the battery further complicates the situation All the above analysis is based on battery electrolyte temperature of 80 F The battery capacity varies with temperature Battery capacity is also a functio
129. ing the charging voltages based on temperature if the battery sees very wide temperature swings In addition to compen sating the charging voltages the thresholds of LOW VOLT ALARM BATT LOW VOLTAGE shut down RESET VOLTAGE and BATTERY OVER VOLT are also temperature compensated Temperature compensation will be carried out over a temperature range of 20 C to 60 C SAMLEX AMERICA INC 71 SECTION 5 Table 5 1 shows the programmable range Default settings for the temperature coefficient is AmV C Cell 5 6 3 STAGE CHARGING MODE BULK ABSORPTION amp 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 Please see Table 6 2 for details of programmable settings and Default Values This 3 Stage Charging is the Default Charging Mode Fig 5 1 shows the voltage and current charging curves with respect to time and different charg ing stages NOTE With the optional Remote Control Model EVO RC see Appendix A it is possible to program and activate 4 Stage Charging Mode including the 4th Equalization Stage 4 Stage charging is required to be carried out only on flooded wet cell batteries This 4 Stage Charg ing Mode is discussed separately under 4 Stage Charging Mode in Equalization Mode at Section 5 7 5 6 1 Bulk Charge Stage In the first stage known as the Bulk Charge Stage t
130. ing through an electrical conductor in one second The Capacity C in Ah relates to the ability of the battery to provide a constant specified value of discharge current also called C Rate see page 17 over a specified time in hours before the battery reaches a specified discharged terminal voltage Also called End Point Voltage at a specified temperature of the electrolyte As a benchmark the automotive battery industry rates batteries at a discharge current or C Rate of C 20 Amperes corresponding to 20 Hour discharge period The rated capacity C in Ah in this case will be the number of Amperes of current the battery can deliver for 20 Hours at 80 F 26 7 C till the volt age drops to 1 75V Cell i e 10 5V for 12V battery or 21V for 24V battery For example a 100 Ah battery will deliver 5A for 20 Hours 1 4 3 Rated Capacity Specified in Reserve Capacity RC Battery capacity may also be expressed as Reserve Capacity RC in minutes typically for automo tive SLI Starting Lighting and Ignition batteries It is the time in minutes a vehicle can be driven after the charging system fails This is roughly equivalent to the conditions after the alternator fails while the vehicle is being driven at night with the headlights on The battery alone must supply current to the headlights and the computer ignition system The assumed battery load is a constant discharge current of 25A Reserve capacity is the time in minutes for which the b
131. input vo DETECT TIME 3 the EVO Inverter Charger Up Key x 3 SELECT GROUP SELECT GROUP CHARGE CURVE INPUT HIGH LIMIT DETECT TIME 3 Enter Key Up Keyx4 E RESET VOLTAGE 135 0 V DETECT TIME 2 15 cycle tage rises above CUT OFF VOLT 3 for period gt will transfer to Inverting Mode Up Key x5 RESET VOLTAGE 135 0V CUT OFF VOLT 3 150 0V This is the time limit in cycles up to which high AC input voltage CUT OFF VOLT 3 is allowed Up Key x3 Enter Key SELECT GROUP SELECT GROUP CHARGE CURVE INPUT HIGH LIMIT SAMLEX AMERICA INC 25 DETECT TIME 3 1 cycle RESET VOLTAGE 135 0V SECTION 4 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 Parameter roup 2212 3012 2224 4024 2212 3012 2224 4024 Fig 4 2 1 POWER SAVING 1 Enable 0 Disable 1 Enable ENTER POINT 4 50W 6W 8W 6W 8w WAKE UP POINT 5 50W 7W 10W 7W 10W 0 Button 4 REMOTE SWITCH Button t 1 Switch Type 0 Charge Other 5 RELAY FUNCTION 1 Normal Fault 2 Generator 2 Generator 6 COMM ID 1 255 1 1 ON 7 BUZZER 0 OFF 1 ON 1 ON 8 DISCHARGE BEEP 0 OFF 0 OFF 9 DEFAULT RESET qoo
132. isconnected and is reconnected or the battery voltage drops below 12 VDC 24 VDC Default Programmable range for this voltage is 10 to 13V for 12V battery and 20 to 26V for 24V battery If the charger remains in the Float Mode for 10 days 5 7 4 STAGE CHARGING IN EQUALIZATION MODE N CAUTION Equalization Mode should be performed only on vented flooded non sealed or wet batteries and not on the sealed AGM Gel Cell batteries and only as often as recommended by the battery manufacturer N ATTENTION La mode d galisation devrait tre faite sur des batteries ventill es inond es batteries non scell es ou mouill es et pas sur des batteries scell es AGM ou cellulles gel es et aussi souvent que les recommandations du fabricant 4 Stage Battery Charging Cycle is used in the Equalization Mode Equalization Mode is selected using optional Remote Control EVO RC see Appendix A Equalization of the batteries is car ried out periodically normally once per month for battery under heavy duty service and every two to four months for battery under light duty service As equalization is a deliberate over charge of the battery for a specified time period equalizing your flooded wet cell batteries will reduce sulfation stir up the electrolyte to remove stratification equalize voltages of individual cells and thus help reach and maintain the peak capacity of the battery Please read about the necessity and details of
133. ithout charge and returned to the Purchaser at the Warrantor s expense Contiguous US and Canada only using a carrier of the warran tor s choice 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 The warranty does not apply to units with a serial number that has been altered removed or modified in any way There is no warranty for defects or damages to equipment or parts caused by Installation alternation inspection or removal e Normal wear and tear e Abuse or misuse of the equipment including exposure to excessive heat salt or fresh water spray or water immersion e Corrosion fire lightening biological infestations or Acts of God e Repairs attempted by anyone other than the Warrantor e Improper use contrary to operational instructions provided in product manual e Shipping or transport No other express warranty is hereby given and there are no warranties which extend beyond those de scribed herein This warranty is expressly in lieu of any other expressed or implied warranties including any implied warranty of merchantability fitness for the ordinary purposes for which such goods are used or fitness for a particular purpose or any other obligations on the part of the Warrantor or its employees and representatives There shall be no responsibility or liability whatsoever on the part of the Warrantor or its employees and
134. le s contents opened with a general purpose Text Reader The First Row is Inverter Model the Second Row is the title of columns separate by TABLE 5 2 Contents of Data Log File Follow procedure given below to open Data Log Files in Excel e Start Excel e Click File Menu Button Microsoft Office Button on the left hand corner e Click Open from the Drop Down Menu e Navigate to the Directory where the Log Files downloaded from the SD Card are located e Click on File Types selection button at the bottom right corner shows All Excel Files as default and select Text files from the Drop Down Menu e All Text Files txt will be displayed The screen will look like Fig 5 1 SAMLEX AMERICA INC 31 SECTION 5 SD Card 208 w 2 NY i Suppers Winstream Product Review Sep 2014 Samples Reviews log fles 8 2 Organge folder rne Office Exce ne 09301100 30 09 2014 11 00AM TXT File 129 5 a WT Favontes Jj Recently Changed 03030745 30 09 2014 10 59 AM TXT Fie 128 KB Roses OSA me Dowetoads 09181327 18 09 2014 1 27PM TXT File 22 Recent Places _ 09181319 18 09 2014 1 19 M TXT Pie 7208 Desktop Shortout 09181305 18 09 2014 105M TXT Fie 2 a can 09181241 18 09 2014 12 41 TXT Fie EI Google Drive 09181236 18 09 2014 13 36PM TXT Fie 75KB BE Desktop 09181227 18 09 2014 12 27
135. lexamerica com Home gt Support gt White Papers and Section 5 titled Battery Charging in EVO Series for more details 4 10 PARALLEL OPERATION WITH EXTERNAL CHARGER The Battery Charger Section is able to operate in parallel with another external charging source like Solar Charge Controller AC charger with a charging capacity of up to 50 A The output of the external charging source is routed through this unit and operates in parallel with the internal charger The internal charging current is controlled to ensure that the combined current fed to the battery does not exceed the programmed Bulk Charging Current This improves the life of the battery 4 11 COOLING FANS AND OVER TEMPERATURE PROTECTION The unit is cooled by convection and by forced air cooling using 2 variable speed cooling fans Temperature is sensed at 5 points Power Transformer 2 points for H Bridge Power Mosfets Heat Sink and Low Voltage Bus Bar The fans will be switched ON at specified temperatures measured at the above sense points The speed of the fans is increased as the temperature rises The unit will shut down due to over temperature if the sensed temperature rises above the specified overheat thresholds It will reset automatically after the unit has cooled down to the Reset Threshold 68 SAMLEX AMERICA INC SECTION 4 4 12 OPTIONAL REMOTE CONTROL EVO RC FOR PROGRAMMING OF MODES OF OPERATION AND PARAMETERS Optional Remote Control Model EVO RC Fi
136. lle que le c ble n gatif de la batterie 3 14 AC SIDE GROUNDING PLEASE SEE FIG 3 12 e The AC Input Grounds GEN GND 8 GRID GND 5 and AC Ouput Ground OUTPUT GND 11 are internally bonded to the chassis of the inverter G1 The Equipment Grounding Conductors part of the Grid Generator input wiring from Bus Bars G3 for the Equipment Grounding Conductors in the Grid and Generator Input Panels are connected to the AC input Ground terminals in GRID GND 5 GEN GND 8 e The AC output Ground terminal of the EVO OUTPUT GND 11 is connected to the Equip ment Grounding Conductor of the AC output wire which then connects to the Bus Bar G3 for the Equipment Grounding Conductors of the AC Distribution Panel The Bus Bar G3 for Equipment Grounding Conductors of the AC Distribution Panel is con nected to the Bus Bar for the Equipment Grounding Conductors G3 of the Grid Generator Input Panel which in turn is connected to the Ground Rod or the Grounding Electrode GE Thus in keeping with the NEC requirements the AC Grounds of EVO and the AC Distribution Panel will be bonded to the Earth Ground only at one single point at the Grid Generator Panel feeding the EVO 3 14 1 OUTPUT NEUTRAL TO CHASSIS GROUND BOND SWITCHING As required by NEC and UL specification 458 AUTOMATIC Output Neutral to Chassis Ground bond switching arrangement has been provided in these units through Output Neutral to Chassis Ground
137. lling to CUT OFF VOLT 1 CUT OFF VOLT 2 CUT OFF Up Key x2 Enter Key SELECT GROUP SELECT GROUP RESET VOLTAGE CHARGE CURVE INPUT LOW LIMIT 95 0V CUT OFF VOLT 1 If during Charging Mode the AC input voltage falls below CUT OFF VOLT 1 for period gt DETECT TIME 1 the EVO Inverter Charger will transfer to Inverting Mode from Charging Mode Up Key x2 Enter Key Up Key x 1 SELECT GROUP SELECT GROUP RESET VOLTAGE CUT OFF VOLT 1 CHARGE CURVE INPUT LOW LIMIT 95 0V 90 0V DETECT TIME 1 This is the time limit in cycles up to which low AC input voltage CUT OFF VOLT 1 is al lowed Up Key x2 Enter Key Up Key x2 SELECT GROUP SELECT GROUP RESET VOLTAGE DETECT TIME 1 CHARGE CURVE INPUT LOW LIMIT 95 0V 300 cycles SAMLEX AMERICA INC 23 SECTION 4 CUT OFF VOLT 2 If during Charging Mode the AC input voltage falls below CUT OFF VOLT 2 for period DETECT TIME 2 the EVO Inverter Charger will transfer to Inverting Mode Up Key x2 Enter Key Up Key x3 SELECT GROUP SELECT GROUP RESET VOLTAGE CUT OFF VOLT 2 CHARGE CURVE INPUT LOW LIMIT 95 0V 85 0V DETECT TIME 2 This is the time limit in cycles up to which low AC input voltage CUT OFF 2 is allowed Up Key x2 Enter Key Up Key x4 SELECT GROUP SELECT GROUP RESET VOLTAGE DETECT TIME 2 CHARGE CURVE INPUT LOW LIMIT 95 0V 60 cycles CUT OFF VOLT 3 If duri
138. low frequency capacitors due to lowering of their capacitive reactance by the higher harmonic frequencies These capacitors are used in ballasts for fluorescent lighting for Power Factor improvement and in single phase induction motors as start and run capacitors Thus modified and square wave inverters may shut down due to overload when powering these devices 1 3 2 Advantages of Pure Sine Wave Inverters The output waveform is a sine wave with very low harmonic distortion and cleaner power like utility supplied electricity Inductive loads like microwaves motors transformers etc run faster quieter and cooler More suitable for powering fluorescent lighting fixtures containing power factor improvement capacitors and single phase motors containing start and run capacitors Reduces audible and electrical noise in fans fluorescent lights audio amplifiers TV fax and answering machines Does not contribute to the possibility of crashes in computers weird print outs and glitches in monitors Some examples of devices that may not work properly with modified sine wave and may also get damaged are given below e Laser printers photocopiers and magneto optical hard drives Built in clocks in devices such as clock radios alarm clocks coffee makers bread makers VCR microwave ovens etc may not keep time correctly Output voltage control devices like dimmers ceiling fan motor speed control may not work properly
139. ls on sizing and charging of batteries please refer to Section 1 4 under General Information Lead Acid Batteries Use appropriate external fuse Refer to Table 3 1 within 7 of battery Positive terminal 34 SAMLEX AMERICA INC SECTION 3 External charging source if any is connected to the connectors 3 and 4 as shown above The maximum capacity of the external charging source is 50A Battery Temperature Sensor EVO BCTS is connected to the RJ 45 Jack 6 See Fig 2 5 a and 2 5 b for details 3 5 1 Preventing DC Input Over Voltage It is to be ensured that the DC input voltage of this unit does not exceed 17 VDC for the 12V battery version EVO 2212 and EVO 3012 and 35 VDC for the 24V battery versions EVO 2224 and EVO 4024 to prevent permanent damage to the unit 3 5 2 Preventing Reverse Polarity On The Input Side N CAUTION When making battery connections on the input side make sure that the polarity of battery connections is correct Connect the Positive of the battery to the Positive terminal of the unit and the Negative of the battery to the Negative terminal of the unit If the input is connected in reverse polarity external DC fuse in the input side will blow and may also cause permanent damage to the inverter Damage caused by reverse polarity is not covered by warranty 3 5 3 Connection From Batteries External Charge Controller To The DC Input Side Sizing of Cables And Fuses N WARNING The in
140. ly discharged over 20 Hours at the rate of 5 Amperes SOW output for a 12V inverter and 100W output for a 24V inverter However if it is discharged at a rate of 50 Amperes SOOW output for a 12V inverter and 1000W output for a 24V inverter then theoretically it should provide 100 Ah 50 2 Hours However Table 1 9 above shows that for 2 Hours discharge rate the capacity is reduced to 50 i e 50 Ah Therefore at 50 Ampere discharge rate 500W output for a 12V inverter and 1000W output for a 24V inverter the battery will actually last for 50 Ah 50 Amperes 1 Hour 1 4 8 State of Charge SOC of a Battery Based on Standing Voltage The Standing Voltage of a battery under open circuit conditions no load connected to it can approximately indicate the State of Charge SOC of the battery The Standing Voltage is measured after disconnecting any charging device s and the battery load s and let ting the battery stand idle for 3 to 8 hours before the voltage measurement is taken Table 1 10 below shows the State of Charge versus Standing Voltage for a typical 12V 24V battery system at 80 F 26 7 C TABLE 1 10 SOC VERSUS STANDING VOLTAGE TYPICAL FLOODED BATTERY Percentage of Standing Voltage Standing Voltage of Standing Voltage Full Charge of Individual Calls 12V Battery of 24V Battery 100 2 105V 12 63V 25 26V 90 2 10V 2 6V 25 20V 8096 2 08V 2 5V 25 00V 7096 2 05V 2 3V 24 60V 6096 2
141. matically when power drawn by the load drops below the above surge limits Power Boost up to 15096 Higher percentage of rated power can be provided for limited time periods as follows 15096 for 5 sec 14096 for 30 sec 12096 for 5 min 11096 for 30 min 4 4 DIRECT DUAL AC INPUT ARCHITECTURE For higher reliability and redundancy direct AC input from Grid and Generator can be fed simultaneously to separate AC Input Circuits Only one AC source is selected at one time When both Grid and Generator are available simultaneously Grid is given priority Transfer from Grid to Generator or from Generator to Grid is always routed through the inverter Please see details under Synchronized Transfer of Power 4 5 TRANSFER RELAY SECTION Transfer Relay Section is used to either feed AC power to the Battery Charger Section and at the same time pass through the AC power from the external AC input power source to the load As long as the external AC input power from Grid Generator is available and is within the programmed limits of voltage and frequency or to transfer the load to the Inverter Section In case of loss of the external AC input power source or if this source is not within the programmed limits of voltage and frequency Typical transfer time is 16 milliseconds from Gird Generator to Inverter and 1ms from Inverter to Grid Generator Heavy duty 70A 2x35A in parallel Transfer Relay is used for reliable transfer of up to 30096 surge power a
142. mperature Sensor Model EVO BCTS Deep Cycle Battery Bank AC SIDE li Battery Isolator Engine Starting Battery Alternator RV AC DISTRIBUTION PANEL BOARD 120V Board Do Not use 120 240V Panel Board 00000608 120V SHORE INPUT PANEL BOARD 30A Service Inlet for 30A RV Power Supply Cord DCSIDE ACSIDE 1 Battery Positive 4 GRID LINE 2 Battery Negative 5 GRID GND 3 External Charger Positive 6 GRID NEUTRAL 4 External Charger Negative 7 GENLINE 5 Grounding Terminal 8 GENGND 6 RJ 45 Jack for Temperature Sensor 9 NEUTRAL 7 0 45 Jack for Optional Remote Control EVO RC 10 OUTPUT LINE 14 Status Relay Terminals for initiating automatic generator start stop 11 OUTPUT GND Status Relay 12 OUTPUT NEUTRAL NO To optional Generator Auto Common gt Start Stop NC Module Fozs AC PANEL BOX Breaker Neutral Bus Bar Ground Bus Bar RV Chassis Ground Fig 3 14 Typical Mobile Installation Using 30A RV Service Inlet 58 SAMLEX AMERICA INC SECTION 4 4 1 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 in one di
143. n Conduit Column 1 Column 2 Column 3 Column 4 Column 5 ESTO 3012 MIU EVO 4024 56 25A TABLE 1 1 c AC INPUT WIRING AND BREAKERS FOR AC INPUT CURRENT LIMIT PROGRAMMED AT 60A FOR EVO 4024 Pro NEC Ampac Wire Size based on Breaker Size grammed ity 125 of NEC Ampacity at Based on NEC Am Input Cur Column 2 Column 3 and 75 C pacity at Column 3 rent Limit Copper Conductor in Conduit Column 1 Column 2 Column 3 Column 4 Column 5 AWG 4 or SAMLEX AMERICA INC SECTION 1 Table 1 2 AC OUTPUT WIRING AND BREAKERS Rated AC Output NEC Ampacity Wire Size based on NEC Breaker Size Current in In 125 of Column Ampacity at Column 3 Based on NEC Am verter Mode 2 75 C Copper Conduc pacity at Column 3 tor in Conduit Column 1 Column 2 Column 3 Column 4 Column 5 TABLE 1 3 a BATTERY CABLES IN FREE AIR AND EXTERNAL BATTERY SIDE FUSES Item Copper 90 C Up to 5 ft Up to 10 ft EVO 2212 AWG 13 0 AWG 1 0 350A EVO 2224 AWG 2 AWG 2 175A EVO 3012 2 X AWG 3 0 MCM 300 2 X AWG 3 0 MCM 300 500A EVO 4024 AWG 3 0 AWG 4 0 350A External Charger AWG 6 AWG 2 TABLE 1 3 B BATTERY CABLES IN RACEWAY AND EXTERNAL BATTERY SIDE FUSES Copper 90 C TABLE 1 4 TIGHTENING TORQUES Battery Input External Charger Input AC Input and Output Connectors Connectors Connectors 70 kgf cm 35 kgf cm 7 to 12 kgf cm 5 0 Ibf ft 2 5 Ibf ft 0 5 to 0 9 Ibf ft 6 SAMLEX AMERICA I
144. n Time T1 2 To x 0 5 Equalization Time T2 is then computed based on thefollowing logic T22Tl 1hr20 5 To 1 hr if TI 2 hrs T22T1 2hrsz0 5 2 hrs if 2 Tl A hrs T22Tl A4hrsz 0 5 4 hrs if 11 3 4 hrs When the battery reaches the programmed Absorption Voltage see programmable range and defaults at Table 5 1 it transitions to the Absorption Stage and remains in this stage for the computed time T1 This stage is displayed as E CVA in the Charging Mode screens in Remote Control EVO RC Appendix A At the end of Absorption Stage it transitions to the programmed Equalization Voltage see programmable range and defaults at Table 5 1 It remains in this stage for the computed time T2 This stage is displayed as E CVE in the Charging Mode screens in Remote Control EVO RC Appendix A The equalization current I is normally 5 to 10 of the Ah capacity of the battery This current is indirectly computed from the programmed Bulk Charge Current As recom mended under the Setting Mode for the Bulk Charge Current the Bulk Charge Current Io is expected to be set at 10 to 20 of the Ah capacity of the battery Hence the Equalization current l will be automatically computed at 50 of the set Bulk Charge Current Io which will effectively amount to 596 to 1096 of the Ah capacity of the battery For example the Equalization Current L for a 200 Ah capacity battery will be 10 A 20A The Bulk Charge cu
145. n of age and charging history Older batteries have lower capac ity because of shedding of active materials sulfation corrosion increasing number of charge discharge cycles etc Hence the State of Discharge of a battery under load cannot be estimated accurately However the low DC input voltage alarm and shut down function are designed to protect the inverter from excessive current drawn at the lower voltage SAMLEX AMERICA INC 21 SECTION 1 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 ife chart is given in the Table 1 12 below TABLE 1 12 TYPICAL CYCLE LIFE CHART Depth of Discharge Cycle Life of Cycle Life of Cycle Life of of Ah Capacity Group 27 31 Group 8D Group GC2 10 1000 1500 3800 50 320 480 1100 80 200 300 675 100 150 225 550 NOTE It is recommended that the depth of discharge should be limited to 5096 1 4 13 Series and Parallel Connection of Batteries Refer to details at Section 3 4 1 4 14 Sizing the Inverter Battery Bank One of the most frequently asked questions is how long will the batteries last This question cannot be answered without knowing the size of the battery system and the load on the in verter Usually this question is turned around to ask How long do you want
146. nal voltages for a State of Discharge of 8096 State of Charge of 2096 for various discharge currents will be as given at Table 1 11 Refer to Fig 1 4 for parameters and values shown in Table 1 11 20 SAMLEX AMERICA INC SECTION 1 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 cise 12V 24V 12V 24V C 3A 10 45V 20 9V 09 50V 19 0V C 5 A 10 90V 21 8V 10 30V 20 6V C 10 A 11 95V 23 9V 11 00V 22 0V C 20A 11 85V 23 7V 11 50V 23 0V C 100 A 12 15V 24 3V 11 75V 23 5V In the example given above the 10 5V 21 0V Low Battery DC Input Alarm would trigger at around 80 discharged state 20 SOC when the C Rate discharge current is C 5 Amps However for lower C Rate discharge current of C 10 Amps and lower the battery will be almost completely discharged when the alarm is sounded Hence if the C Rate discharge current is lower than C 5 Amps the battery may have completely discharged by the time the Low DC Input Alarm is sounded 1 4 11 Low DC Input Voltage Shut down In Inverters As explained above at around 80 State of Discharge of the battery at C Rate discharge current of around C 5 Amps the Low DC Input Voltage Alarm is sounded at around 10 5V for a 12V battery at around 21V for 24V battery to warn the user to disconnect the battery to prevent further drain
147. nd for Neutral to Ground Bond Switching 40A rated for EVO 2212 and EVO 2224 60 SAMLEX AMERICA INC SECTION 4 4 5 1 AC Transfer and Output Neutral To Chassis Ground Bond Switching As required by NEC and UL specification 458 AUTOMATIC Ouput Neutral to Chassis Ground bond switching arrangement has been provided in these units through Output Neutral to Chassis Ground Bond Switching Relay K4 in Figs 4 1 a and 4 1 b to switch bonding of the Neutral Output Connector of the Inverter Charger as follows e When operating as an inverter the current carrying conductor of the Inverter Section that is connected to the Output Neutral connector of the Inverter Charger is bonded to the metal chassis of the inverter by the Output Neutral to Chassis Ground Bond Switching Relay K4 in Figs 4 1 a and 4 1 b As the metal chassis of the inverter is in turn bonded to the RV Ground chassis of the RV or to the Boat Ground DC Negative Grounding Bus Bar and the Main AC Grounding Bus Bar are tied together in a boat and this is called the Boat Ground this current carrying conductor of the Inverter Section will become the Grounded Conductor GC or the Neutral of the Inverter Section When in Charging Mode the Neutral conductor of the Grid power Generator will be 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
148. nd 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 The Remote plugs into RJ 45 Jack on the front panel of the unit 7 Fig 2 1 It has provision for Data Logging using SD Card of up to 16 GB FAT16 FAT32 It also has its own Real Time Clock and Super Capacitor Type of Bat tery Detailed messaging is available through its LCD display and LEDs This remote will also be required for programming of various parameters to suit specific requirements Each program mable parameter has a Default Value This unit has been shipped with the various parameters set at the Default Values Programmable and Default values are shown in Tables 6 2 to 6 6 below 80 SAMLEX AMERICA INC SECTION 6 TABLE 6 2 PROGRAMMABLE AND DEFAULT PARAMETERS GROUP CHARGING CURVE Programming Range Programming requires optional Re Default Parameter mote Control Model EVO RC EVO EVO EVO EVO EVO EVO EVO EVO 2212 3012 2224 4024 2212 3012 2224 4024 BULK CURRENT 0 100A 0 130A 0 70A 0 110A 40A Bulk Charge Current lo ABSORP VOLTAGE 13 5V 16 0V 27 0V 32 0V 14 4V 28 8V Absorption Voltage EQUALIZE VOLTAGE 14 0V 16 0V 28 0V 32 0V 14 4V 28 8V Equalization Voltage FLOATING VOLTAGE 13 0V 15 0V 26 0V 30 0V 13 5V 27 0V Float Voltage COMPENSATE 3mV to 5mV C Cell AmV PC Cell Temperature Compensation LOW VOLT ALARM
149. ng Charging Mode the AC input voltage falls below CUT OFF VOLT 3 for period gt DETECT TIME 3 the EVO Inverter Charger will transfer to Inverting Mode Up Key x2 Enter Key Up Key x5 SELECT GROUP 5 SELECT GROUP RESET VOLTAGE c CUT OFF VOLT 3 CHARGE CURVE INPUT LOW LIMIT 95 0V 80 0V DETECT TIME 3 This is the time limit in cycles up to which the low AC input voltage CUT OFF 3 is allowed Up Key x2 Enter Key Up Key x 6 SELECT GROUP SELECT GROUP RESET VOLTAGE DETECT TIME 3 CHARGE CURVE INPUT LOW LIMIT 95 0V 1 cycle 4 7 GROUP 4 PARAMETER SET UP INPUT HIGH LIMIT Please refer to Parameters under Group 4 at Fig 4 1 Details of Parameter set up are given below TABLE 4 7 GROUP 4 PARAMETER SET UP INPUT HIGH LIMIT Setting range Default value Group 4 2212 3012 2224 4024 2212 3012 2224 4024 Fig 4 1 1 RESET VOLTAGE 120 0 350 0V 135 0V 2 CUT OFF VOLT 1 120 0 350 0V 140 0V 3 DETECT TIME 1 0 2000 cycles 60 cycles 4 CUT OFF VOLT 2 120 0 350 0V 145 0V 5 DETECT TIME 2 0 2000 cycles 15 cydles 6 CUT OFF VOLT 3 120 0 350 0V 150 0V 7 DETECT TIME 3 0 2000 cycles 1 cyde 24 SAMLEX AMERICA INC SECTION 4 RESET VOLTAGE This is the reset voltage at which the unit will revert to Charging Mode after it has Switched over to Inverting Mode due to input AC voltage risi
150. ng to CUT OFF VOLT 1 CUT OFF VOLT 2 CUT OFF VOLT 3 Up Key x 3 Enter Key SELECT GROUP SELECT GROUP CHARGE CURVE INPUT HIGH LIMIT CUT OFF VOLT 1 If during Charging Mode the AC input vo DETECT TIME 1 the EVO Inverter Charger Up Key x 3 Enter Key SELECT GROUP SELECT GROUP CHARGE CURVE INPUT HIGH LIMIT DETECT TIME 1 RESET VOLTAGE 135 0 V tage rises above CUT OFF VOLT 1 for period gt will transfer to Inverting Mode Up Key x 1 gt RESET VOLTAGE 135 0V CUT OFF VOLT 1 140 0V This is the time limit in cycles up to which high AC input voltage CUT OFF VOLT 1 is allowed Up Key x3 SELECT GROUP SELECT GROUP c CHARGE CURVE INPUT HIGH LIMIT CUT OFF VOLT 2 If during Charging Mode the AC input vo DETECT TIME 2 the EVO Inverter Charger Enter Key Up Key x 3 Enter Key SELECT GROUP SELECT GROUP CHARGE CURVE INPUT HIGH LIMIT DETECT TIME 2 Up Key x2 gt RESET VOLTAGE 135 0 V DETECT TIME 1 60 cycle tage rises above CUT OFF VOLT 2 for period gt will transfer to Inverting Mode Up Key x 3 RESET VOLTAGE CUT OFF VOLT 2 135 0V 145 0V This is the time limit in cycles up to which high AC input voltage CUT OFF VOLT 2 is allowed Up Key x 3 gt Enter Key SELECT GROUP CHARGE CURVE SELECT GROUP INPUT HIGH LIMIT CUT OFF VOLT 3 If during Charging Mode the AC
151. nsfer at Zero Crossing SAMLEX AMERICA INC 85 SECTION 7 Transfer Time Grid Generator to Inverter Up to 16ms Synchronized Transfer Models EVO 2212 EVO 3012 EVO 2224 EVO 4024 OPERATING MODES OFF LINE Mode Grid Generator Priority Default e Grid Generator supplies AC loads and charges batteries Inverter is standby ON LINE Mode Inverter Priority Programmable e Inverter supplies AC loads even if Grid Generator is available e Grid Generator takes over when batteries are discharged to Battery Low Alarm to charge batteries and to power AC loads AC loads are transferred back to Inverter at Reconnect Voltage INTERNAL BATTERY CHARGER SECTION AC Input Voltage Range 120 VAC 60 to 140 VAC 5 Max Continuous AC Input Current 15A AC 20A AC 19A AC 30A AC AC Input Power Factor gt 0 95 Programmable DC Output Charg 0100A DC 130A DC 70A DC 110A DC ing Current Charger Efficiency 75 86 85 Charging Stages Battery Temperature Compensa tion Normal Mode 3 Stages Bulk Absorption and Float Equalization Mode 4 Stages Bulk Absorption Equalization and Float Adaptive Charging Control Battery Temperature Sensor included Compensation Range from 20 C to 60 C EXTERNAL BATTERY CHARGER SECTION Solar Charge Controller Charging Voltage Range 13 15VDC 13 15VDC 26 30VDC 26 30VDC
152. nt partie des outils lectriques des dispositifs pompe puits etc Au d marrage ils exigent une surcharge de puissance Si la tension baisse trop ils pourraient pas marcher et m me seront endommager Circuit de rechargement de batterie PV La perte de tension pourrais causer une perte de puissance disproportion e Par exemple une perte de tension 596 peut r duire le courant de charge par une pourcentage beaucoup plus grande que 596 3 5 4 Fuse Protection In The Battery Circuit A battery is an unlimited source of current Under short circuit conditions a battery can supply thousands of Amperes of current If there is a short circuit along the length of the cables that connects the battery to the inverter thousands of Amperes of current can flow from the battery to the point of shorting and that section of the cable will become red hot the insulation will melt and the cable will ultimately break This interruption of very high current will generate a hazardous high temperature high energy arc with accompanying high pressure wave that may cause fire damage nearby objects and cause injury To prevent occurrence of hazardous condi tions under short circuit conditions the fuse used in the battery circuit should limit the current should be Current Limiting Type blow in a very short time should be Fast Blow Type and at the same time quench the arc in a safe manner For this purpose UL Class T fuse or equivalent should be used
153. ntr e de courant alternatif et non aux bornes de sortie courant alternatif et que cette connexion est tablie uniquement lorsque l appareil est dans un tat hors tension Se il vous plait noter que lorsque l appareil est sous tension un auto test est effectu qui inclut un contr le si la tension d entr e CA de la connexion r seau g n rateur a t tort connect aux bornes de sortie CA la place de bornes d entr e AC Si cette mauvaise connexion est d tect e tension 10 V ca se voit sur les bornes de sortie LINE et neutre de sortie au moment de la mise sous tension de l appareil l unit ne sera pas allum et un message Sortie d faut sera affich Cette protection contre les erreurs dans le cadre du c blage d alimentation est active uniquement lorsque cette mauvaise connexion est tablie lorsque l appareil est en tat hors et est allum par la suite Si la tension d entr e CA de la Grille g n rateur est erron e connect nourri aux connexions de sortie CA lorsque l appareil est en tat la protection ci dessus ne fonctionnera pas et la Section de l onduleur sera br l instantan ment et peut devenir un risque d incendie 3 7 1 AC Input Output Supply Connections The AC input and output supply connections are located in a pocket protected by a cover with a removable front plate 1 2 Fig 3 9 Three 27 8mm 1 32 diameter holes 10A to 10C Fig 2 1 have been provided for cable conduit entry Remove the
154. nverter Sizing Factor See Note 1 Air Conditioner Refrigerator Freezer Compressor based 5 Air Compressor Sump Pump Well Pump Submersible Pump Dishwasher Clothes Washer Microwave where rated output power is the Cooking Power Furnace Fan Industrial Motor Portable Kerosene Diesel Fuel Heater Circular Saw Bench Grinder Incandescent Halogen Quartz Lamps Laser Printer Other Devices using Quartz Lamps for heating Switch Mode Power Supplies SMPS no Power Factor correction amp amp amp amp amp D WIR 2 Photographic Strobe Flash Lights 4 See Note 2 NOTES FOR TABLE 1 6 1 Multiply the Running Active Power Rating Watts of the appliance by this Factor to arrive at the Continuous Power Rating of the inverter for powering this appliance 2 For photographic strobe flash unit the Surge Power of the inverter should be gt 4 times the Watt Sec rating of photographic strobe flash unit 1 3 4 Limiting Electro Magnetic Interference These inverters contain internal switching devices that generate conducted and radiated elec tromagnetic interference EMI The EMI is unintentional and cannot be entirely eliminated The magnitude of EMI is however limited by circuit design to acceptable levels as per limits laid down in North American FCC Standard FCC Part 15 B Class B These limits are designed to provide reasonable p
155. o the End Point Voltage in a shorter period of time On the other hand if the battery delivers a lower discharge current the battery will be discharged to the End Point Voltage after a longer period of time Mathematically C Rate is defined as C RATE CAPACITY C in Ah DISCHARGE TIME T Table 1 8 below gives some examples of C Rate specifications and applications TABLE 1 8 DISCHARGE CURRENT RATES C RATES ma C Rate Discharge Current Example of C Rate Voc d Par Voltage Ampas Capac A Discharge Curent 0 5 Hrs 2C 200A 1 Hrs 1C 100A 5 Hrs Inverter application C 5 or 0 2C 20A 8 Hrs UPS application C 8 or 0 125C 12 5A 10 Hrs Telecom application C 10 or 0 1C 10A 20 Hrs Automotive application C 20 or 0 05C 5A 100 Hrs C 100 or 0 01C 1A NOTE When a battery is discharged over a shorter time its specified C Rate will be higher For ex ample the C Rate at 5 Hour discharge period i e C 5 Amps will be 4 times higher than the C Rate at 20 Hour discharge period i e C 20 Amps 1 4 6 Charging Discharging Curves Fig 1 4 shows the charging and discharging characteristics of a typical 12V 24V Flooded Lead Acid battery at electrolyte temperature of 80 F 26 7 C The curves show the State of Charge X axis versus terminal voltage Y axis during charging and discharging at different C Rates Please note that X axis shows State of Charge State of Di
156. 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 Top surface of Drip Shield 10 mm Gap a Non Marine Installation b Marine Installation Fig 3 4 Mounting Arrangement 2 On Vertical Surface 3 4 INSTALLING BATTERIES SERIES AND PARALLEL CONNECTION Batteries are normally available in voltages of 2V 6V and 12V and with different Ah capacities A number of individual batteries can be connected in series and in parallel to form a bank of batteries with the desired increased voltage and capacity Cable A Battery 4 Battery 3 Battery 2 Battery 1 24V Inverter or 24V Charger Cable B Fig 3 5 Series Connection When two or more batteries are connected in series their voltages add up but their Ah capacity remains the same Fig 3 5 shows 4 pieces of 6V 200 Ah batteries connected in series to form a battery bank of 24V with a capacity of 200 Ah The Positive terminal of battery 4 becomes the Positive terminal of the 24V bank The Negative terminal of battery 4 is connected to the Positive terminal of battery 3 The Negative terminal of battery 3 is connected to the Positive terminal of battery 2 The Negative terminal of battery 2 is connected to the Positive terminal of battery 1 The Negative terminal of battery 1 becomes the Negative terminal of
157. oller connected to the DC input provided for external battery charger AC input to the EVO is fed from typical 30A RV Power Inet through suitable breaker and from the generator through suitable breaker AC output from the EVO is fed to the RV Distribution Panel Board Use 120V version and NOT 120 240 Split Phase version Automatic Generator start stop is possible as follows o Start operation is initiated by closure of No and Common contacts of the Status Relay 14 Fig 2 1 when battery voltage drops to the programmed value of the Low Voltage Alarm Stop sequence is initiated by opening of above contacts when the battery voltage rises to the programmed Restart Value Please refer to programming of Relay Function under Section 4 8 of EVO RC Manual at Appendix A o Contact closure opening signal is fed to the optional Generator Auto Start Stop Module which in turn feeds required start stop signals to the generator the gen erator should be capable of remote start stop function SAMLEX AMERICA INC 57 SECTION 3 Insi A NO Normally Open Contact B Common To Remote Start Stop Terminals on the Generator Optional Generator Auto Start Stop Module Optional Remote Control EVO RC Grounding Terminal 5 External Charge Controller C NC Normally Closed Contact i See Fig 2 1 EVO INVERTER CHARGER Solar Panel s Fuse Within 7 of batter terminal Battery Te
158. olts It is denoted by V and the unit is Volts It is the electrical force that drives electrical current I when connected to a load It can be DC Direct Current flow in one direction only or AC Alternating Current direction of flow changes periodically The AC value shown in the specifications is the RMS Root Mean Square value Current I Amps A It is denoted by I and the unit is Amperes shown as A It is the flow of electrons through a conductor when a voltage V is applied across it Frequency F Hz It is a measure of the number of occurrences of a repeating event per unit time For example cycles per second or Hertz in a sinusoidal voltage Efficiency n This is the ratio of Power Output Power Input Phase Angle 0 It is denoted by o and specifies the angle in degrees by which the current vector leads or lags the voltage vector in a sinusoidal voltage In a purely inductive load the current vector lags the voltage vector by Phase Angle p 90 In a purely capacitive load the current vector leads the voltage vector by Phase Angle o 90 In a purely resistive load the current vector is in phase with the voltage vector and hence the Phase Angle o 0 In a load 8 SAMLEX AMERICA INC SECTION 1 consisting of a combination of resistances inductances and capacitances the Phase Angle o of the net current vector will be gt 0 90 and may lag or lead the voltage vector
159. ommendations Never smoke or allow a spark or flame near the batteries Use caution to reduce the risk of dropping a metal tool on the battery It could spark or short circuit the battery or other electrical parts and could cause an explosion Always use insulated tools Remove metal items like rings bracelets and watches when working with batteries Batteries can produce a short circuit current high enough to weld a ring or the like to metal and thus cause a severe burn f you need to remove a battery always remove the Ground terminal from the battery first Make sure that all the accessories are off so that you do not cause a spark TABLE 1 1 a SIZING OF AC INPUT WIRING AND BREAKERS FOR DEFAULT AC INPUT CURRENT LIMIT PROGRAMMED AT 30A FOR EVO 2212 EVO 2224 EVO 3012 EVO 4024 Programmed NEC Ampac Size based on NEC Am Breaker Size Input Cur ity 125 of pacity at Column 3 and Based on NEC Am rent Limit Column 2 75 C Copper Conductor pacity at Column 3 in Conduit 1 Column 2 Column 3 Column 4 Column 5 EVO 2212 2212 eur 2224 BUR ES 3012 Default 37 5A AWG 8 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 Programmed NEC Ampac Wire Size based on Breaker Size Input Cur ity 125 of NEC Ampacity at Based on NEC Am rent Limit Column 2 Column 3 and 75 C pacity at Column 3 Copper Conductor i
160. on Multi fil circuits reli s Les deux sources de tension AC et DC sont termin es l int rieur de cet quipement Chaque circuit doit tre d connect individuellement avant l entretien Ne pas retirer le couvercle Aucune partie r parable par l utilisateur l int rieur Faites appel un installateur qualifi Ne pas monter dans z ro compartiment de jeu Ne pas couvrir ou obstruer les ouvertures de ventilation Fusible s doit tre remplac par le m me type de fusible du fusible install d origine s SAMLEX AMERICA INC 7 SECTION 1 ATTENTION Risque de choc lectrique Utilisez uniquement les GFCIs suivantes D autres types peuvent ne pas fonctionner correctement lorsqu il est connect cet appareil MISE LA TERRE Le symbole de mise la terre ci dessous est utilis pour identifier uniquement l quipement terminal de terre cablage Toutefois ce symbole est utilisable avec le cercle omis pour identifier divers points de l unit qui sont li s la masse Grounding Symbol D faut la terre 15 Pr cautions lorsque vous travaillez avec des piles Les piles contiennent tr s corrosif acide sulfurique dilu comme lectrolyte Des pr cautions doivent tre prises pour emp cher tout contact avec la peau les yeux ou les v tements Porter des lunettes de protection Les batteries produisent de l hydrog ne et de l oxyg ne lors de la charge r sultant de l volution du m lange de gaz explosif Il faut
161. ontrol EVO RC Fault Message Symptoms and Trouble Shooting Battery low voltage EVO Inverter Charger is in FAULT MODE because the battery voltage has dropped to the set lower threshold of BATT LOW VOLTAGE When the battery voltage drops to the set lower threshold of BATT LOW VOLTAGE activation of this fault protection is initiated The Red LED marked Alarm will flash once per second and the buzzer in EVO Inverter Charger will beep once per second The Inverter Section will continue to operate normally and the Green LED marked Status will continue to be ON steady NOTE Battery low voltage will not be displayed during this time If the battery voltage stays at or below the above threshold for duration equal to the set IV DETECT TIME only the Inverter Section will be switched OFF and message Battery low voltage will be displayed The Red LED marked Alarm will now change to steady ON the Green LED marked Status will switch OFF and the buzzer in EVO Inverter Charger will now beep steady If the Battery low voltage fault condition is not reset within the IV CUT OFF TIME EVO Inverter Charger will be shut down completely after the expiry of IV CUT OFF TIME If the batteries are charged by external charger connected directly to the batteries or through the External Charger Input 3 4 in Fig 2 1 in EVO Inverter Charger Man ual and the battery voltage recovers to the set RESET VOLTAGE before the expiry of
162. ore 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 From The Chassis Ground Of The RV As explained in on line White Paper titled Grounded Electrical Power Distribution System at www samlexamerica com Home Support White Papers in the RV the Neutral Bus Bar is NOT bonded to the Chassis of the RV In the RV the Neutral is floating with respect to the chassis of the RV This is necessary for safety because if the Neutral was bonded to the chassis of the RV and if the Neutral and the Hot got reversed by mistake the chassis of the RV will be at 120 VAC with respect to the Earth Ground If a person standing on the Earth Ground touches the chassis of the RV he will be fed with 120 VAC and will receive electrical shock 3 16 4 Typical Mobile Installation Fig 3 14 illustrates a typical RV installation using 30A Service Inlet for 30A RV Power Supply Cord A Auxiliary Battery is connected to the DC input connections through an appropriate fuse to protect the DC input cables against short circuit e Auxiliary battery will be charged by the alternator through the Battery Isolator Battery Temperature Sensor Model BTS EVO is installed on the Positive or Negative post of the auxiliary battery and connected to the port for the Temperature Sensor Supplementary battery charging is being carried out through a solar array and a Charge Contr
163. ormer and the 2 Hot outputs 120 VAC split phases and the Neutral from the Secondary of this transformer should be connected to the Electrical Breaker Panel Load Center Please see details on line under White Paper titled 120 240 VAC Single Split Phase System and Multi wire Branch Circuits at www samlexamerica com Home gt Support White Papers Connexion multi fils Circuits de d rivation NE PAS connecter directement le c t chaud de 120 VAC de l unit pour les deux Hot Legs de la Centre de charge 120 240 VAC panneau de disjoncteurs o Multi fil neutre commun du circuit de d rivation m thode de c blage est utilis pour la distribution de l alimentation secteur Cela peut conduire une surcharge surchauffe du conducteur neutre et un risque d incendie Un transformateur d calage de phase isol ou d auto transformateur de la notation appropri VA 2596 de plus que la puissance en VA de l unit avec primaire de 120 VAC et secondaire de 120 240 VAC deux 120 VAC diviser phases 180 degr s devrait tre utilis s Le fil neutre de la sortie 120 VAC de l onduleur doivent tre nourris la SAMLEX AMERICA INC 43 SECTION 3 primaire de ce transformateur et les deux sorties chaud 120 VAC divis phases et le neutre du secondaire de ce transformateur doit tre reli au panneau de disjoncteur lectrique Centre de gravit Se il vous plait voir les d tails en ligne sous Livre blanc intitul
164. ower in In Current Current AC Input Column 5 on NEC Size verter Mode See Note Columns Current Ampacity at Based 2 2 3 Limit See Note 5 Column 6 on NEC See Note 3 See Note 6 Ampacity at See Note Column 6 4 See Note 7 Column 7 Column 1 Column 2 Column 3 Column 4 Column 5 Column 6 Column 8 EVO 2212 2200VA 18A EVO 2224 jo 18A 30A 37 5A AWG 8 EVO 3012 Sex SUA m Default 3000VA 25A EVO 4024 46 SAMLEX AMERICA INC SECTION 3 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 grammed ity 125 of Size Based Breaker Size Power in In Through Current Current AC Input Column 5 on NEC Based verter Mode Current See Note Columns Current Ampacity on NEC See Note 2 2 3 Limit See Note 5 at Column Ampacity at 1 See Note 3 6 Column 6 See Note See Note See Note 7 4 6 Column 1 Column 2 Column 3 Column 4 Column 5 Column 6 Column 7 Column 8 EVO 3012 3000VA 25A 56 254 AWG 6 EVO 4024 tee TABLE 3 2 3 SIZING OF GRID AND GENERATOR INPUT WIRING AND BREAKERS FOR INPUT CURRENT LIMIT PROGRAMMED AT 60A FOR EVO 4024 Model No and Rated Rated AC Total Rated Pro NEC Ampac Conductor External Rated Output AC Pass Charging AC Input grammed ity 125 of Size Based
165. pas suivies N CAUTION Indicates possibility of damage to the equipment in case of non compliance ATTENTION ll y a une risque de faire des d g ts l quipement si l utilisateur ne suit pas les instruc tions Gi INFO Indicates useful supplemental information Please read these instructions BEFORE installing or operating the unit to prevent per sonal injury or damage to the unit AN WARNING DANGER To reduce risk of explosion do not install in machinery space or in area in which ignition protected equipment is required to be used 2 CAUTIONS a To prevent damage due to excessive vibration shock use on marine vessels with lengths more than 65 ft 19 8M b This unit is NOT designed for weather deck installation To reduce risk of electrical shock do not expose to rain or spray 3 CAUTIONS a EVO Inverter Charger with fully automatic charging circuit charges only properly rated 12V 6 Cell 24V 12 Cell Lead Acid Batteries Gel Cell AGM Flooded Lead Antimony Lead Calcium and b When EVO Inverter Charger is in Charge Mode Green LED marked ON would be flashing 4 For indoors use only 5 Hot Surfaces To prevent burns do not touch SAMLEX AMERICA INC 3 SECTION 1 10 11 12 13 14 The AC input output wiring terminals are intended for field connection using Cop per conductors that are to be sized based on 75 C and NOT larger than AWG 1 42 4 mm See Tables 1 1 a
166. put section of the inverter has large value capacitors connected across the input terminals As soon as the DC input connection loop Battery terminal Fuse Positive input terminal of EVO Negative input terminal of the EVO Battery ter minal is completed these capacitors will start charging and the unit will momentarily draw very heavy current that will produce sparking on the last contact in the input loop even when the unit is in powered down condition Ensure that the fuse is inserted only after all the connections in the loop have been completed so that sparking is limited to the fuse area Flow of electric current in a conductor is opposed by the resistance of the conductor The resistance of the conductor is directly proportional to the length of the conductor and inversely proportional to its cross section thickness The resistance in the conductor produces undesir able effects of voltage drop and heating The size thickness cross section of the conductors is designated by AWG American Wire Gauge Conductors thicker than AWG 4 0 are sized in MCM kcmil Conductors are protected with insulating material rated for specific temperature e g 90 C 194 F As current flow produces heat that affects insulation there is a maximum permissible value of cur rent called Ampacity for each size of conductor based on temperature rating of its insulation The insulating material of the cables will also be affected by the
167. rection it converts external AC power to DC power to charge the batteries using Grid or Generator Charging Mode and in the other direc tion it converts DC power from the battery to AC power Inverting Mode This allows the same power components to be used in both directions resulting in high energy transfer efficiency with fewer components Please note that it can NOT work in both the directions at the same time i e it cannot work as an inverter and as a charger at the same time High performance 100 MHz DSP Digital Signal Processing micro controller and Pulse Width Modulated PWM conversion circuits are used for the above implementation 4 2 COMPONENTS OF THE SYSTEM It consists of 3 Sections Inverter Section Battery Charger Section and AC Input Transfer Relay Section The unit is fed with the following inputs Up to 2 external AC input power sources Grid or Generator or both with PRIORITY for Grid if both Grid and Generator inputs are available at the same time DC Battery Source consisting of 12V 24V battery bank 4 versions of Inverter Charger are available 2 versions for 12 VDC battery input EVO 2012 and EVO 3012 amp 2 for 24 VDC battery input EVO 2224 and EVO 4024 Additional external charging source like Solar Charge Controller AC charger of up to 50A capacity The output of the external charging source is routed through this unit and operates in parallel with the internal charger The internal charging cu
168. representatives for injury to any persons or damage to person or persons or damage to property or loss of income or profit or any other consequential or resulting damage which may be claimed to have been incurred through the use or sale of the equipment including any possible failure of malfunction of the equipment or part thereof The Warrantor assumes no liability for incidental or consequential damages of any kind Samlex America Inc the Warrantor www samlexamerica com 88 SAMLEX AMERICA INC Notes SAMLEX AMERICA INC 89 Notes 90 SAMLEX AMERICA INC Notes SAMLEX AMERICA INC 91 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 samlexamerica APPENDIX A A samlexpower Remote Control Owner s P ease ae E manua for Evolution Manual operating Series Inverter Charger Model EVO RC NOTE REMOTE CONTROL MODEL NO EVO RC IS OPTIONAL AND IS REQUIRED TO BE ORDERED SEPARATELY EVO RC OWNER S MANUAL SECTION 1 Safety Instructions Introduction and
169. require use of Drip Shield on top of the unit to protect against ingress of water dripping from top Drawing of Drip Shield is given at Fig 3 1 a Configurations using the Drip Shield are shown under Mounting Orientation Cooling The unit has openings on the front bottom and back for cooling and ventilation Ensure that these openings are not blocked or restricted Install in cool dry and well ventilated area 28 SAMLEX AMERICA INC SECTION 3 installati 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 D GAG entourant l onduleur pour faciliter la ventilation Mounting Orientation e Mount horizontally on a horizontal surface e g table top or a shelf Please see Fig 3 2 lt Wall Top surface of Drip Shield 10 mm Gap 5 gt 55mm a Non Marine Installation b Marine Installation Fig 3 2 Mounting Arrangement Horizontally On Horizontal Surface Mount horizontally on a vertical surface like a wall with the fan axis horizontal and the DC input terminals facing left Please see Fig 3 3 Wall 105 1 Top surface of Drip Shield a Non Marine Installation b Marine Installation Fig 3 3 Mounting Arrangement 1 On Vertical Surface SAMLEX AMERICA INC 29 SECTION 3 Mount vertically on a vertical surface see Fig 3 4 Protect against possibility
170. rger 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 Enter Key Up Key x4 SELECT GROUP c BULK CURRENT COMPENSATE CHARGE CURVE 40A 4 mV OC BATT OVER VOLT This parameter sets the upper battery voltage threshold at which inverting charging opera tions are switched OFF to protect the unit against damage due to battery overvoltage ACinputis not available and EVO Inverter Charger is operating in Inverting Mode When the battery voltage rises to the set upper threshold of BATT OVER VOLT the In verter Section will be shut down and message Battery over voltage will be displayed on the LCD screen The Green LED marked Status will switch OFF and the Red LED marked Alarm will remain ON steady The buzzer on EVO Inverter Charger will beep steady The fault will be cleared automatically when the battery voltage drops to 0 5V below the set upper threshold of BATT OVER VOLT ACinputis available and EVO Inverter Charger is operating in Charging Mode When the battery voltage rises to the set upper threshold of BATT OVER VOLT the Trans fer Relay will be de energized charging and pass through will be stopped and PWM drive to the Inverter Section will be switched OFF Messag
171. rger to Inverting or Charging Mode This mode is used for uploading firmware for EVO Inverter Charger through the SD Card This mode may also be used to temporarily halt inverting charging and AC pass through SAMLEX AMERICA INC 7 SECTION 3 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 Refer to section 7 on Fault Messages 3 6 OPERATING MODES AND DISPLAY SCREENS There are 4 Operating Modes for the EVO Inverter Charger that will be displayed on the Remote Screen at any given time see Fig 3 1 i Standby ii Inverting iii Charging and iv Power Saving Each mode has several screens of status information such as Voltage Cur rent Power etc The majority of Mode screens shown in Fig 3 1 are self explanatory but the Charging Mode Status screens require additional details which are shown at Section 3 6 1 INVERTING POWER SAVING OUTPUT 120 00V BATTERY 12 000V ae f oe BATTERY 12 000V 7 4 bom CHARGING INPUT 1 120 00V Fig 3 1 EVO RC Mode Screens 3 6 1 Charging Mode Screens Explanations Please refer to 18 Screens shown against Pages 1 to 18
172. rm Stop sequence is initiated by contact opening when the battery volt age rises to the programmed Reset Value Please refer to programming of Relay Function under Section 4 8 of EVO RC Manual at Appendix A Contact closure opening signal is fed to the optional Generator Auto Start Stop Module which in turn feeds required start stop signals to the generator the generator should be capable of remote start stop function When using generator please ensure the following Neutral of the generator is bonded to the chassis of the generator and the chassis is bonded to the Earth Ground Ground Rod GE If the generator is a 120VAC 240VAC Split Single Phase with 120 VAC phase fed to the EVO then both 120VAC Split Phases of the generator should be equally loaded balanced to prevent the deterioration of regulation of generator s output voltage Poor regulation of generator output voltage may lead to interruption of charging in the EVO 54 SAMLEX AMERICA INC SECTION 3 A NO Normally Open Contact Battery B Common Temperature To Remote Start Stop NC Normally Closed Contact Sensor Model EVO BCTS Terminals on the Generator Optional Generator Auto Deep Cycle Battery Bank Within 7 of batte termina Optional Remote Control AC DISTRIBUTION PANEL Terminal 5 FRONT See Fig 2 1 o o AC SIDE See Fig 2 3 EV
173. roportional to the state of charge d 0 Note 2 The graph is for 12V p To yx Ti AF 10 Days y version For 24V version double the voltages Io 13 fe et 10096 01 Juan ing 195 jo 96 LNIHHND tl 60 Charger Voltage VDC Fig 5 1 Charging Curve for Normal 3 Stage Charging 72 SAMLEX AMERICA INC SECTION 5 The value of the Bulk Charge Current lo 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 As a general Rule of Thumb the Bulk Charging Current Io should be limited to 10 to 20 of the Ah capacity of the battery 20 Hr Rate Higher charging current may be used if permitted by the battery manufacturer Programmable range and Default values of Bulk Charge Current lo are shown in Table 6 2 The units are shipped with the Bulk Charge Current set at the Default Value of 40A When the unit enters Charging Mode it starts working as a battery charger and the charger will run at full programmed Bulk Charge Current until the charger reaches the programmed Absorption Voltage As part of the Adaptive Charging Algorithm a software timer will measure the time taken from the instant the unit enters the Charging Mode untill
174. rotection against harmful interference when the equipment is operated in a residential environment These inverters can conduct and radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause harmful interfer ence to radio communications The effects of EMI will also depend upon a number of factors external to the inverter like proximity of the inverter to the EMI receptors types and quality of connecting wires and cables etc EMI due to factors external to the inverter may be reduced as follows e Ensure that the inverter is firmly grounded to the Ground System of the building or the vehicle e Locate the inverter as far away from the EMI receptors like radio audio and video de vices as possible e Keep the DC side wires between the battery and the inverter as short as possible e 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 SAMLEX AMERICA INC 13 SECTION 1 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 Limit operation of other high power loads when operating audio video equipment 1 3 5 Powering Switch Mode Power Supplies Swit
175. rrent Io for a 200 Ah capacity at 1096 2096 will be set at 20 A 40A The firmware will compute the Equalization Current L at 5096 of 20 A i e 10A or at 50 of 40A i e 20 At the end of Equalization Stage the charger transitions to the programmed Float Voltage see programmable range and defaults at Table 5 1 This stage is displayed as Float in the Charging Mode screens in Remote Control EVO RC Appendix A Automatic Resetting of Charging Cycle The charging cycle will be reset to the Bulk Stage of 3 Stage Charging Profile as follows If the AC is reconnected or the battery voltage drops below 12 VDC 24 VDC Default Programmable range for this voltage is 10 to 13V for 12V battery and 20 to 26V for 24V battery If the charger remains in the Float Mode for 10 days 76 SAMLEX AMERICA INC SECTION 5 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 will be flashing once per second Press the ON OFF Button for 1 second The ongoing Normal Charging Mode will be terminated and Equalization Mode will be initiated The Green Status LED will start flashing 2 t
176. rrent is controlled to ensure that the combined current fed to the battery does not exceed the programmed Bulk Charging Current This improves the life of the battery 4 3 INVERTER SECTION The Inverter Section is a heavy duty continuous rated DSP micro controller based inverter gen erating a Pure Sine Wave output of 120 VAC 60 Hz 50 Hz 60 Hz default from the DC Battery Source It is able to supply AC power to various types of AC loads such as resistive loads heaters incandescent lamps etc or reactive loads motors air conditioners refrigerators vacuum clean ers fans pumps Switched Mode Power Supplies SMPS used in audio video equipment and computers etc 4 3 1 Principle of working of Inverter Section The low DC voltage from the DC Battery Source is inverted to the AC voltage in two steps The low DC voltage from the DC Battery Source is first converted to low frequency 60 Hz or 50 Hz low voltage synthesized sine wave AC using an H bridge configuration and high frequency PWM Pulse Width Modulation technique The low frequency low voltage synthesized sine wave is then stepped up to 120 VAC pure sine wave voltage using a low frequency Isolation Transformer and filtration circuit This type of DC to AC inversion is called Hybrid Type a combination of low frequency and high frequency implementation Other distinctive features of the Inverter Section are given below SAMLEX AMERICA INC 59 SECTION 4 Soft Start
177. rter 4 5 5 Transfer From Inverter to Grid Generator When Grid Generator becomes available its voltage and frequency are checked if these are within the programmed limits If yes the output voltage of the Inverter Section is synchro nized with Grid Generator through Phase Locked Loop PLL This synchronization process takes few seconds Once synchronization is completed the load is transferred instantly with in 1 ms to Grid Generator at Zero Crossing of the voltage waveform for seamless transfer and for better protection of Transfer Relay contacts The unit now operates in Charging 64 SAMLEX AMERICA INC SECTION 4 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 with the AC power from the Grid Gen erator charging the batteries as well as providing power to the AC loads the phase and frequency of Grid Generator is tracked continuously In case Grid Generator fails or is disconnected the inverter will be forced into transfer at voltage which is at the same phase and frequency at which Grid Generator had been disconnected Load will be transferred to the inverter within 16ms The unit will now work in Inverting Mode and the batteries will start discharging 4 5 7 Transfer Between Grid and Generator As discussed in Transfer from Inverter to Gr
178. rtionate higher AC in put current from the Grid Generator The Grid Branch Circuit Generator will also be required to provide current to the AC loads The desired maximum value of input current from Grid Generator can be programmed Default is 30A The EVO will automatically reduce charging current to support the AC loads on priority and use whatever is extra for charging This will prevent overloading of the Grid Branch Circuit Generator If the AC input current is over the setting value by 1A for 5 seconds the EVO Inverter Charger will stop outputting and display an error message Input over current on LCD screen Up Key Enter Key Up Key x 1 SELECT GROUP SELECT GROUP DEFAUT FREQ MAXIMUM CURRENT CHARGE CURVE INPUT SETTING 0 60Hz 30 00A HIGH CUT OFF If the AC input frequency is over the value of HIGH CUT OFF when in Charging Mode the EVO Inverter Charger will transfer to Inverting Mode Up Key Enter Key Up Key x2 SELECT GROUP c SELECT GROUP c DEFAUT FREQ c HIGH CUT OFF CHARGE CURVE INPUT SETTING 0 60 Hz 65 00 Hz HIGH RESET This is the reset frequency at which the unit will revert to Charging Mode after it has switched over to Inverter Mode due to input frequency rising above HIGH CUT OFF Up Key Enter Key Up Key x 3 SELECT GROUP SELECT GROUP DEFAUT FREQ HIGH RESET CHARGE CURVE gt INPUT SETTING gt 0 60 Hz gt 64 00 Hz LOW CUT OFF If the AC inpu
179. s K2 and K3 are used to switch the Hot Output Connector OUT PUT LINE to either the Inverter Section or to the Grid Generator o When Grid Generator Power is available relays K2 or K3 will be energized and con tact 4 switches over to contact 5 Grid has PRIORITY over Generator if both are present SAMLEX AMERICA INC 61 SECTION 4 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 o When Grid Generator power fails relays K2 K3 will be de energized and contact 4 switches over to contact 3 Output from the Inverter Section is fed to the Bi directional Transformer and onwards to the Hot Out OUTPUT LINE for powering the AC loads Switching of Output Neutral to Chassis Ground Bonding o 40A rated SPDT Relay K4 is used to switch the bonding of the Output Neutral Connector OUTPUT NEUTRAL to the chassis of the unit o When Grid Generator Power is available relay K4 will be energized and contact 4 Switches over to contact 5 Neutral input from the Grid GRID NEUTRAL or from the Generator GEN NEUTRAL is fed to the Neutral input of the Bi directional Transformer for battery charging and at the same time it is passed through to the Output Neutral OUTPUT NEUTRAL
180. sabling Neutral to Ground Bond In some applications the Output Neutral may be required to remain isolated from the chassis Ground at all times For this automatic Ouput Neutral to Chassis Ground bond can be disabled by disconnecting the Male Female Quick Disconnect located in the AC wiring compartment Please see i 13 Fig 3 9 and ii QD in Figs 4 1 a and 4 1 b Please read the following on line White Papers for more details at www samlexameri ca com Home Support White Papers Neutral to Ground Switching in RV and Marine Applications 52 SAMLEX AMERICA INC SECTION 3 v uiu eseud jo 081 salas QAJ 3ueuiebueuy zie 614 0 o 8 v 621 OZIL o V 35 POY punoi punoi uye3 papuoq 5 10 21 2U29 Jy JO EJjn9N Je eunsue esea d Z m 09 au ui WYLNAN NAD 6 pe1 euuoo jou si N39 8 3NITN35 4 panan 35 sjeuiu83 Buimo jo ubno4ui ajqejieae si peuuosiq pino EL uo smoys uon2es Dy 10 WeIBeIp LNdLNO 1 SILON GNNOYD LNdLNO LL ANITLAdLNO OL aes ur psppsquie HOLVYINIO 6 35 1ndinoandu HOlVH3N3D 8 L DV INT HOLVYINTO 4
181. scharge will be 100 State of Charge These curves will be referred to in the subsequent explanations SAMLEX AMERICA INC 17 SECTION 1 Typical Flooded Lead Acid Battery Chart 80 F 26 7 C 24V 12V 33 0 16 5 32 0 16 0 31 0 15 5 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 C 10 DISCHARGE C 5 24 0 12 0 23 0 11 5 22 0 11 0 U a 2 E Q gt gt ca 21 0 10 5 20 0 10 0 19 0 9 5 18 0 9 0 80 90 100 110 120 130 Battery State of Charge in Percent Fig 1 4 Charging Discharging Curves for Typical Flooded Lead Acid Battery 1 4 7 Reduction in Usable Capacity at Higher Discharge Rates Typical in Inverter Application As stated earlier the Ah capacity of automotive battery is normally applicable at a discharge rate of 20 Hours As the discharge rate is increased as in cases where the inverters are driving higher capacity loads the usable Ah capacity reduces due to Peukert Effect This relationship is not linear but is more or less according to the Table 1 9 18 SAMLEX AMERICA INC SECTION 1 TABLE 1 9 BATTERY CAPACITY VERSUS RATE OF DISCHARGE C RATE C Rate Discharge Current Usable Capacity C 20 10096 C 10 87 C 8 8396 C 6 7596 C 5 7096 C 3 6096 C 2 50 1C 40 Table 1 9 shows that a 100 Ah capacity battery will deliver 100 i e full 100 Ah capacity if it is slow
182. ss than 12596 of the Programmed AC Input Current Limit Column 5 Refer to NEC 2014 National SAMLEX AMERICA INC 47 SECTION 3 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 7 Column 8 indicates the Amp rating of EXTERNAL breaker that is required to be installed in the Load Center Breaker Panel feeding the unit The Amp rating of this breaker is based on the following considerations a less than the NEC Ampacity Column 6 Refer to NEC 2014 National Electrical Code Section 210 20 A regarding overcurrent protection of Branch Circuit Conductors b Closest Standard Ampere Rating of Breaker has been used Refer to NEC 2014 National Electrical Code Section 240 6 A regarding overcurrent protection c Where Standard Breaker Rating does not match the required NEC Ampacity Column 6 the next higher Standard Rating of the breaker has been used Refer to NEC 2014 National Electrical Code Section 240 4 B regarding over current devices d of breaker Standard circuit breaker for 120VAC Load Center Breaker Panel 3 9 SIZING OF WIRING A
183. t Reactance X will be inductive if X gt X and capacitive if X gt X Impedance Z It is the vectorial sum of Resistance and Reactance vectors in a circuit Active Power P Watts It is denoted as P and the unit is Watt It is the power that is consumed in the resistive elements of the load A load will require additional Reactive Power for powering the inductive and capacitive elements The effective power required would be the Apparent Power that is a vectorial sum of the Active and Reactive Powers Reactive Power Q VAR Is denoted as Q and the unit is VAR Over a cycle this power is alternatively stored and returned by the inductive and capacitive elements of the load It is not consumed by the inductive and capacitive elements in the load but a certain value travels from the AC source to these elements in the half cycle of the sinusoidal voltage Positive value and the same value is returned back to the AC source in the half cycle of the sinusoidal volt age Negative value Hence when averaged over a span of one cycle the net value of this pow er is 0 However on an instantaneous basis this power has to be provided by the AC source Hence the inverter AC wiring and over current protection devices have to be sized based on the combined effect of the Active and Reactive Powers that is called the Apparent Power Apparent S Power VA This power denoted by S is the vectorial sum of the Active Power in Watts
184. t frequency is below LOW CUT OFF value when in Charging Mode the EVO Inverter Charger will transfer to Inverting Mode Up Key Enter Key Up Keyx4 SELECT GROUP SELECT GROUP DEFAUT FREQ LOW CUT OFF CHARGE CURVE INPUT SETTING 0 60 Hz 55 00 Hz 22 SAMLEX AMERICA INC SECTION 4 LOW RESET This is the reset frequency at which the unit will revert to Charging Mode after it has switched over to Inverting Mode due to input frequency falling below LOW CUT OFF Up Key Enter Key Up Key x5 SELECT GROUP SELECT GROUP DEFAUT FREQ LOW RESET CHARGE CURVE INPUT SETTING 0 60 Hz 56 00 Hz 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 No for Group Parameter 3 Fig 2212 3012 2224 4024 2212 3012 2224 4024 4 1 1 RESET VOLTAGE 60 0 200 0V 95 0V 2 CUT OFF VOLT 1 60 0 200 0V 90 0V 3 DETECT TIME 1 0 2000 cycles 300 cycles 4 CUT OFF VOLT 2 60 0 200 0V 85 0V 5 DETECT TIME 2 0 2000 cycles 60 cycles 6 CUT OFF VOLT 3 60 0 200 0V 80 0V 7 DETECT TIME 3 0 2000 cycles 1 cycle RESET VOLTAGE This is the reset voltage at which the unit will revert to Charging Mode after it has switched over to Inverting Mode due to input voltage fa
185. the programmed Reset Voltage Default 12 5 25V the Status Relay will open and the Optional Generator Start Stop Module will shut down the Generator automatically The unit will then transfer back to Inverting Mode For installation details please refer to Section 3 15 Fig 3 13 and Section 3 16 Fig 3 14 4 8 MODES OF OPERATION 4 8 1 Charging Mode As long as the external AC input power from the Grid Generator is available and is within the programmed limits of voltage and frequency it is passed through to the AC load through the Transfer Relay Section At the same time the Battery Charger Section converts the external AC input power from the Grid Generator to DC power to charge the DC Battery Source 4 8 2 Inverting Mode If at any instant the external AC input power from the Grid Generator is interrupted or is not within the programmed limits of voltage and frequency the Transfer Relay is de energized and the load is transferred to the Inverter Section and internal battery charging is terminated This is called the Inverting Mode 4 8 3 Power Save Mode When the unit is operating without any load connected to it it requires some minimum input power from the battery to keep all the sections inside the unit alive and ready to deliver power to the AC load as soon as the load is switched on This power is called the No Load Power Draw or the Idle Power or Self Power Consumption The No Load Power Draw of these units in th
186. to the specified limit Output voltage is less than 96Vrms for 300 cycles 5 seconds at 60Hz Output power is over 11096 for 30 min Output power is over 12096 for 5 minutes Output power is over 14096 for 30 seconds Output power is over 15096 for 5 seconds SAMLEX AMERICA INC 37 SECTION 7 Output short circuit 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 e There is no AC output because the Inverter Section has been switched OFF The Green LED marked Status will be switched OFF and the Red LED marked Alarm will be steady ON The buzzer in EVO Inverter Charger will beep steady Inverter Charger will be latched in OFF condition and will require manual reset by powering OFF waiting for 1 minute and then powering ON again NOTE If there is short circuit condition in Charging Mode i e when AC input is avail able short circuit condition on the output side will trip the AC input breaker The load will be transferred to the Inverter Section and the Inverter Section will then see short circuit condition and will shut down as described above Output failure EVO Inverter Charger is in FAULT MODE because AC input from Grid Generator has been connected to the AC Output terminals by mistake 10VAC
187. ttery Charging in Evolution Series 4 7 AUTO GENERATOR START Auto Generator Start facility is available for automatic starting of the Generator with the use of Normally Open NO contacts of Status Relay 14 Fig 2 1 in the EVO Manual that close when the battery voltage drops to the programmed value of Low Volt Alarm Default 11V 22V and reset open when the battery is recharged and its voltage rises to the programmed value of Reset Voltage Default 12 5V 25V Please refer to programming of Relay Func tion under Section 4 8 of EVO RC Manual at Appendix A Relay closing and opening signal is fed to optional Generator Auto Start Stop Control Module which in turn is wired to the Remote Start Stop connections on the Generator SAMLEX AMERICA INC 65 SECTION 4 When the batteries discharge to the Low Voltage Alarm threshold Default 11V 22V relay contact in the Status Relay will close and the Generator will be started automatically The 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 with the AC power from the Generator charging the batteries as well as providing power to the AC loads As the batteries are now being charged by the Generator their voltage will rise and at
188. unbond disconnect the Output Neutral connector of the Inverter Charger from the chassis of the Inverter Charger This will ensure that the Grounded Conductor GC Neutral of the Grid power Generator is bonded to the Earth Ground at one single point at the location of the AC Power Distribution System of the Marina RV Park e Disabling Neutral to Ground Bond In some applications the Output Neutral may be required to remain isolated from the chassis Ground at all times For this automatic Output Neutral to Ground bond can be disabled by disconnecting the Male Female Quick Discon nect located in the AC wiring compartment Please see i 13 Fig 3 9 and ii QD in Figs 4 1 a and 4 1 b Please read the following on line White Papers for more details at www samlexameri ca com Home gt Support gt White Papers Grounded Electrical AC Power Distribution 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 o Feeds AC output from the Inverter Section when Grid Generator power is not available o Feeds Grid Generator power to the Battery Charger Section when Grid Utility are available Switching of Hot Output OUTPUT LINE o 40A rated SPDT Relay
189. under Group CHARGING at Fig 3 2 The 1 line of the Display Screen for Charging Mode shows CHARGING on the left and abbreviated information format Charging Mode Charging Stage on the right corner The following abbreviations have been used Abbreviation Normal N 3 Stage Charging Equalization E 4 Stage Charging Group 3 Screens Bulk Absorption Float Bulk Absorption Equalization Float N CC Constant Current CC Bulk Stage N CV Constant Voltage CV Absorption Stage E CC Constant Current CC Bulk Stage E CVA Constant Voltage Absorption CVA Stage E CVE Constant Voltage Equalization CVE Stage FLOAT Float Stage Float Stage For example in Fig 3 2 the 1 line of information under Column 4 Group 3 Charging shows N CC in the right corner This means that the unit is in Normal N 3 Stage Charg ing Mode and is in Constant Current CC Bulk Stage 3 6 2 Overall Operating Mode Display Screen Menu Map Overall Operating Mode Display Screen Menu Map is shown at Fig 3 2 Any screen within the Menu Map can be identified by 2 co ordinates Group No Column and Page No Row 8 SAMLEX AMERICA INC SECTION 3 J Page Up Up key Page Down Down key Fault Message Fault Fault RENE RER TERRE TT D
190. une galisation efficace il faut que les batteries subissent une tape majeure plus long en fonction de la condition d charg e de la batterie Veuillez assurer que les batteries sont profond ment d charg es 20 de sa capacit avant de les galiser La tension constante la tension de la borne apr s avoir d connecter toutes sources de charge pour un minimum de 3 heures quand elles sont d charg es 20 de sa capacit serait o Une batterie de 12V Environ 11 7V o Une batterie de 24V Environ 23 4V N galisez pas des batteries qui sont partiellement ou compl tement charg es SAMLEX AMERICA INC 75 SECTION 5 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 To see programmable range at Table 5 1 Default value is 40A Bulk Charge Current Io is normally limited to 1096 2096 of the Ah capacity of the battery 20Hr Rate Higher current may be used if permitted by the battery manufacturer in Equalization Mode The Bulk Stage is displayed as E CC in the Charging Mode screens of the optional Remote Control EVO RC Appendix A A Software Timer is used to measure the time taken from the time the unit transfers to the Utility Generator Mode until the battery charger reaches 0 3V below the Absorption Voltage then registered this time as time To The following times are computed based on the time To Absorptio
191. ur lectrique charge est aliment e partir de cette unit et ce panneau est galement n cessaire pour tre aliment partir de suppl ant suppl mentaire source de courant alternatif l alimentation de la source de courant alternatif suppl mentaire doit d abord tre introduit dans un manuel appropri commutateur de transfert automatique et le sortie du commutateur de transfert doit tre reli au centre panneau de la charge lectrique du disjoncteur Pour viter possibilit de mise en parall le et de graves dommages l onduleur ne jamais utiliser un cable de raccordement simple avec une fiche m le sur les deux extr mit s pour raccorder la sortie AC de l onduleur une prise murale port e de main la maison RV 3 6 4 Connecting to Multi wire Branch Circuits DO NOT directly connect the Hot side of the 120 VAC of the unit to the two Hot Legs of the 120 240 VAC Breaker Panel Load Center where Multi wire common Neutral Branch Circuit wiring method is used for distribution of AC power This may lead to overloading overheating of the Neutral conductor and is a risk of fire A split phase transformer Isolated or Auto transformer of suitable VA rating 25 96 more than the VA rating of the unit with Primary of 120 VAC and Secondary of 120 240 VAC Two 120 VAC split phases 180 degrees apart should be used The Hot and Neutral of the 120 VAC out put of the inverter should be fed to the Primary of this transf
192. ure Sensor EVO BCTS Fig 2 5 a DC Terminal Covers 1a 1b Fig 2 1 Fitted on the unit with 2 screws each Mating Connectors 14 15 16 Fig 2 1 Wire End Terminals for AC Wiring Fig 3 11 Model AWG 10 AW 8 AWG 6 EVO 2212 and EVO 2224 3 6 EVO 3012 and EVO 4024 9 6 Owner s Manual Quick Start Guide SAMLEX AMERICA INC 27 SECTION 3 3 1 SAFETY OF INSTALLATION A WARNING Please ensure safety instructions given under Section 1 are strictly followed Se il vous plait assurer consignes de s curit fournies la section 1 sont strictement suivies 3 2 OVERALL DIMENSIONS The overall dimensions and the location of the mounting holes are shown in Fig 3 1 426 je 380 Slope of top surface should be minimum 115 115 Mounting Holes 7mm 0 28 Mounting Bolts 1 4 or M6 3000 209 Height 207 2 Dimensions mm 9 o CES 9 9 gt 123 9 50 8 298 6 Fig 3 1 Mounting Dimensions Fig 3 1 a Dimensions of Drip Shield 3 3 MOUNTING OF THE UNIT In order to meet the regulatory safety requirements the mounting has to satisfy the following requirements Mount on a non combustible material The mounting surface should be able to support a weight of at least 60 Kg 132 lbs Use 4 pcs of 1 4 or M6 mounting bolts and lock washers e Installation on marine craft and vessels will
193. urs pour les circuits d entr e CA et le tableau 1 2 pour le dimensionnement des disjonc eurs pour les circuits de sortie AC Codes lectriques nationaux et locaux remplaceront ces lignes directrices Les bornes de la batterie sont concus pour se connecter sur le terrain avec des conducteurs en cuivre qui sont dimensionn s en fonction de 90 C et sont plus grandes que AWG n 1 42 4 mm2 Voir les tableaux 1 3 a et 1 3 b pour les tailles recommand es pour l installation l air libre et conduit respectivement Protection contre les surintensit s fusible pour la batterie et les circuits chargeur externe n a pas t fournis et a ourni l installateur utilisateur Voir les lignes directrices tableaux 1 3 a et 1 3 b pour les tailles recomman d es pour l installation l air libre et conduit respectivement Codes lectriques nationaux et locaux remplaceront ces lignes directrices Couples de serrage pour tre appliqu s sur les bornes de c blage sont donn s dans le tableau 1 4 Cet appareil a t fourni avec des protections int gr es contre les surcharges ATTENTION Pour r duire les risques de choc lectrique et d incendie L installation doit tre effectu e par un installateur certifi et selon les codes lectriques locaux et nationaux Ne pas se connecter au circuit fonctionnant plus de 150 volts la terre Ne pas se connecter au Centre de charge AC Circuit de panneau de disjoncteurs ayant Directi

Manual - Samlex America Inc.

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