Page 1
EvolutionTM Series
Inverter/Charger
Pure Sine Wave
Models:
EVO-1212F
EVO-1212F-HW
Owner's
Manual
Please read this
manual BEFORE
operating.
EVO-1224F
EVO-1224F-HW
Firmware:
Rev 0.78
Page 2
EVO™ INVERTER/CHARGER MANUAL | Index
SECTION 1.1
Safety Instructions ................................................................ 3
SECTION 1.2
Denitions .......................................................................... 9
SECTION 1.3
General Information – Inverter Related .............................. 12
SECTION 1.4
General Information – Battery Related ............................... 16
SECTION 2
Components & Layout ....................................................... 30
SECTION 3
Installation ........................................................................ 35
SECTION 4
General Description & Principles of Operation ................... 76
SECTION 5
Battery Charging in Evolution™ Series ................................. 89
SECTION 6
Operation, Protections & Troubleshooting ....................... 117
SECTION 7
Specications ................................................................... 127
SECTION 8
Warranty ...................................................................... 130
Disclaimer of Liability
UNLESS SPECIFICALLY AGREED TO IN WRITING, SAMLEX AMERICA INC.:
1. MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR
OTHER DOCUMENTATION.
2. ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES, DAMAGES, COSTS OR EXPENSES, WHETHER SPECIAL, DIRECT, INDIRECT, CONSEQUENTIAL OR
INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USERS RISK.
Samlex America reserves the right to revise this document and to periodically make changes to the content hereof without obligation or
organization of such revisions or changes.
Copyright Notice/Notice of Copyright
Copyright © 2019 by Samlex America Inc. All rights reserved. Permission to copy, distribute and/or modify this document is prohibited without
express written permission by Samlex America Inc.
2 | SAMLEX AMERICA INC.
Page 3
SECTION 1.1 | Safety Instructions
!
i
!
!
1.1 IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS. THIS MANUAL CONTAINS IMPORTANT INSTRUCTIONS FOR MODELS: EVO1212F, EVO-1212F-HW, EVO-1224F AND EVO-1224F-HW THAT SHALL BE FOLLOWED DURING INSTALLATION
& MAINTENANCE OF THE INVERTER/CHARGER.
THE FOLLOWING SYMBOLS WILL BE USED IN THIS MANUAL TO HIGHLIGHT SAFETY AND IMPORTANT INFORMATION:
Indicates possibility of physical harm to the user in case of non-compliance.
Indicates possibility of damage to the equipment in case of non-compliance.
Indicates useful supplemental information.
Il y a une possibilité de faire du mal physique à l'utilisateur si les consignes de sécurités sont pas suivies.
Il y a une risque de faire des dégâts à l'équipement si l'utilisateur ne suit pas les instructions.
Please read these instructions BEFORE installing or operating the unit to prevent personal injury or
damage to the unit.
WARNING!
CAUTION!
INFO
MISE EN GARDE!
ATTENTION!
WARNING! /
1. WARNING! 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 CAUTION! (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.
3.1 CAUTION! EVO
Acid, Nickel Zinc (Ni-Zn) and Lithium Ion Batteries. When EVO
marked "ON" will be blinking.
3.2 WARNING! Lithium Ion Battery Hazard. Option is available to use 12V / 24V nominal Lithium Ion batteries.
The user/installer should ensure that charging voltages, currents and proles are programmed appropriately to
meet all operating and safety requirements of the battery being used. Make sure that the Lithium Ion Battery
includes Battery Management System (BMS) with built-in safety protocols. Follow the instructions specied by
the Lithium Ion Battery manufacturer. When the EVO
"ON" will be blinking.
™
Inverter/Charger with fully automatic charging circuit charges properly rated 12V / 24V Lead
CAUTION!
™
Inverter/Charger is in Charge Mode, Blue LED
™
Inverter/Charger is in Charge Mode, Blue LED marked
SAMLEX AMERICA INC. | 3
Page 4
SECTION 1.1 | Safety Instructions
4. CAUTION! For indoors use only.
5. WARNING! Hot Surfaces! To prevent burns, do not touch!
6. CAUTION! The AC input / output wiring terminals are intended for eld connection using Copper conductors
that are to be sized based on 75°C. See Table 1.1.1 for sizing of conductors for AC INPUT circuits and Table
1.1.2 for sizing of conductors for AC OUTPUT circuits.
7. WARNING! Over current protection (AC Breakers) for the AC input / output circuits has NOT been provided
for EVO-1212F-HW and EVO-1224F-HW and has to be provided by the installer / user. See guidelines at Table
1.1.1 for sizing of breakers for AC INPUT circuits and Table 1.1.2 for sizing of breakers for AC OUTPUT circuits.
National and Local Electrical Codes will supersede these guidelines.
8. CAUTION! The battery terminals are intended for eld connection of battery side cables using Copper
conductors that are sized based on 90°C. See Table 1.1.3 for recommended sizes of battery side cables for
installation in free air and conduit respectively.
9. WARNING! 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 Table 1.1.3 for recommended sizes for installation in free
air and conduit respectively. National and Local Electrical Codes will supersede these guidelines.
10. Tightening torques to be applied to the wiring terminals are given in Table 1.1.4.
11. This unit has been provided with integral protections against overloads.
12. WARNING! To reduce risk of electric shock and re:
Installation should be carried out by certied installer and as per Local and National Electrical Codes.
Do not connect to circuit operating at more than 150 Volts 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 qualied servicing personnel.
Do not mount in zero clearance compartment.
Do not cover or obstruct ventilation openings.
Fuse(s) should be replaced with the same type and rating as of the original installed fuse(s).
13. WARNING! Risk of electric shock. Use only those GFCIs that are listed at Table 1.1.5. Other types may fail to
operate properly when connected to this unit.
14. GROUNDING: The Grounding symbol shown below is used for identifying only the eld 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.
15. WARNING! Precautions When Working With Batteries.
Grounding Symbol / Défaut à la terre
Lead Acid 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.
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 recommendations.
4 | SAMLEX AMERICA INC.
Page 5
SECTION 1.1 | Safety Instructions
!
Never smoke or allow a spark or ame 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.
If you need to remove a battery, always remove the Ground terminal from the battery rst. Make sure that
all the accessories are off so that you do not cause a spark.
Lithium Ion Batteries
Ensure that the battery includes Battery Management System (BMS) with built-in safety protocol.
Ensure that voltage, current and charging prole settings of the charger are correct
Ensure that the Battery Management System (BMS) of the battery is able to provide contact closure signal
to the EVO
(ii) deep discharge (to stop inverting) [Refer to Section 5.11.2].
™
Inverter/Charger under conditions of (i) over voltage / over heating (to stop charging) and
MISE EN GARDE! /
ATTENTION!
1. MISE EN GARDE! Pour réduire les risques d’explosion, ne pas installer dans les locaux de machines ou
dans la zone où l’équipement protégé contre les incendies doit être utilisé.
2. ATTENTION! Cet appareil est conçu pour une installation PAS Météo-pont. Pour réduire les risques de
choc électrique, ne pas exposer à la pluie ou à la neige.
3.1 ATTENTION! L'onduleur / chargeur EVO
™
avec circuit de charge entièrement automatique charge
des batteries plomb-acide, nickel-zinc (Ni-Zn) et Lithium-Ion 12V / 24V correctement dimensionnées.
Lorsque l'onduleur / chargeur EVO
™
est en mode de charge, la DEL bleue marquée «ON» clignote.
3.2 ATTENTION! Danger pour la batterie lithium-ion. L'option est disponible pour utiliser des batteries
au lithium de 12V / 24V. L'utilisateur / installateur doit s'assurer que les tensions de charge, les
courants et les prols sont programmés de façon appropriée pour répondre à toutes les exigences de
fonctionnement et de sécurité de la batterie utilisée. L'onduleur / chargeur EVO
™
est alors en mode de
charge, le voyant bleue marqué "ON" clignote.
4. ATTENTION! Pour éviter les dommages dus à des vibrations excessives / choc, ne pas utiliser sur les
navires plus petits avec des longueurs de moins de 65 pi. (19,8).
5. MISE EN GARDE! Surfaces chaudes! Pour éviter les brûlures, ne touchez pas.
6. ATTENTION! Les bornes de câblage entrée / sortie CA sont prévus pour un raccordement sur le terrain
avec des conducteurs de cuivre qui doivent être dimensionnés en fonction de 75 ° C. Voir le tableau
1.1.2 et pour le dimensionnement des conducteurs pour les circuits d’entrée CA et le tableau 1.2 pour
le dimensionnement des conducteurs pour les circuits de sortie AC.
7. MISE EN GARDE! Protection contre les surintensités (AC Les disjoncteurs) pour l'AC circuits d'entrée
/ de sortie n'a pas été fournie pour EVO-1212F-HW / 1224F-HW et doit être fournie par l'installateur/
utilisateur. Voir les lignes directrices à tableau 1.1.1 pour le dimensionnement des disjoncteurs pour les
circuits d’entrée CA et le tableau 1.1.2 pour le dimensionnement des disjoncteurs pour les circuits de
sortie AC. Codes électriques nationaux et locaux remplaceront ces lignes directrices.
SAMLEX AMERICA INC. | 5
Page 6
SECTION 1.1 | Safety Instructions
8. ATTENTION! Les bornes de la batterie sont destinés pour le champ Connexion à l'aide de conducteurs
de cuivre qui sont dimensionnés en fonction de 90°C. Voir les tableau 1.1.3 pour les tailles
recommandées pour l’installation à l’air libre et conduit respectivement.
9. MISE EN GARDE! Protection contre les surintensités (fusible) pour la batterie et les circuits chargeur
externe n’a pas été fournis et a fourni à l’installateur / utilisateur. Voir les lignes directrices à tableau 1.1.3
pour les tailles recommandées pour l’installation à l’air libre et conduit respectivement. Codes électriques
nationaux et locaux remplaceront ces lignes directrices.
10. Couples de serrage pour être appliqués sur les bornes de câblage sont donnés dans le tableau 1.1.4.
11. Cet appareil a été fourni avec des protections intégrées contre les surcharges.
12. MISE EN GARDE! Pour réduire les risques de choc électrique et d’incendie:
L’installation doit être effectuée par un installateur certié et selon les codes électriques locaux et
nationaux
Ne pas se connecter au circuit fonctionnant à plus de 150 volts à la terre
Ne pas se connecter au Centre de charge AC (Circuit de panneau de disjoncteurs) ayant Direction
Multi-l circuits reliés
L es deux sources de tension AC et DC sont terminées à l’intérieur de cet équipement. Chaque
circuit doit être déconnecté individuellement avant l’entretien
Ne pas retirer le couvercle. Aucune partie réparable par l’utilisateur à l’intérieur. Faites appel à un
installateur qualié
Ne pas monter dans zéro compartiment de jeu
Ne pas couvrir ou obstruer les ouvertures de ventilation.
Fusible (s) doit être remplacé par le même type de fusible du fusible installé d’origine (s)
13. MISE EN GARDE! Risque de choc électrique. N'utilisez que les GFCIs qui sont indiqués au tableau
1.1.5. D'autres types peuvent ne pas fonctionner correctement lorsqu'il est connecté à cet appareil.
14. MISE À LA TERRE: Le symbole de mise à la terre ci-dessous est utilisé pour identier uniquement
l’équipement terminal de terre-câblage. Toutefois, ce symbole est utilisable avec le cercle omis pour
identier divers points de l’unité qui sont liés à la masse.
15. MISE EN GARDE! Précautions lorsque vous travaillez avec des piles.
Batteries au plomb
Grounding Symbol / Défaut à la terre
Les batteries contiennent de très corrosif de l'acide sulfurique dilué comme électrolyte. Des
précautions doivent être prises pour éviter tout contact avec la peau, les yeux ou les vêtements.
Porter des lunettes de protection.
Générer de l'hydrogène des batteries et de l'oxygène au cours de la charge résultant de l'évolution
du mélange de gaz explosifs. Il faut prendre soin de bien aérer la zone de la batterie et de suivre les
recommandations du fabricant.
Ne jamais fumer ou permettre qu'une étincelle ou une amme à proximité des batteries.
Procédez avec précaution pour réduire le risque de chute d'un outil métallique sur la batterie.
Il pourrait déclencher ou court-circuit de la batterie ou d'autres pièces électriques et pourraient
provoquer une explosion. Toujours utiliser des outils isolés.
6 | SAMLEX AMERICA INC.
Page 7
SECTION 1.1 | Safety Instructions
Retirer les objets métalliques tels que bagues, bracelets et montres lors de travaux avec des
batteries. Les batteries peuvent produire un courant de court-circuit sufsamment haut pour souder
un anneau ou similaires à metal et donc provoquer des brûlures sévères.
Si vous avez besoin de retirer la batterie, retirez toujours la borne de masse de la batterie en
premier. S'assurer que tous les accessoires sont off an de ne pas provoquer une étincelle.
Les batteries au lithium-ion
S'assurer que la batterie comprend Battery Management System (BMS) avec protocole de sécurité intégré.
S'assurer que la tension, le courant et les paramètres de prol de charge le chargeur sont corrects
S'assurer que le système de gestion de la batterie (BMS) de la batterie est en mesure de fournir de la fermeture
du contact signal à l'onduleur/chargeur EVO
le chargement) et (ii) une décharge profonde (pour arrêter l'inversion) [Se reporter à la Section 5.11.2].
TABLE 1.1.1 SIZING OF AC INPUT WIRING AND BREAKERS (Refer to Section 3.8.1, Table 3.2 for more details)
Model No.
(Rated Output Power
in Inverter Mode)
Current Rating of
AC Input Breaker
(15, Fig 2.1)
™
dans des conditions de (i) surtension / plus de chauffage (d'arrêter
NEC Ampacity =
125% of Column 2
Conductor Size Based
on NEC Ampacity
at Column 5
Size of Breaker
Based on Column 4
(Column 1)
EVO-1212F
(1200VA, 10A)
EVO-1212F-HW
(1200VA, 10A)
EVO-1224F
(1200VA, 10A)
EVO-1224F-HW
(1200VA, 10A)
(Column 2)
20A 25A AWG# 12 20A
20A 25A AWG# 12 20A
20A 25A AWG# 12 20A
20A 25A AWG# 12 20A
(Column 3)
(Column 4)
(Column 5)
Table 1.1.2 AC OUTPUT WIRING AND BREAKERS (Refer to Section 3.9.2, Table 3.3 for more details)
Model No.
(Rated Power in
Inverter Mode)
(Column 1)
EVO-1212F
(1200VA)
EVO-1212F-HW
(1200VA)
Rated AC Output
Current in
Inverter Mode
(Column 2)
10A 12.5A AWG# 14 15A
10A 12.5A AWG# 14 15A
NEC Ampacity =
125% of Column 2
(Column 3)
Wire Size based on
NEC Ampacity at
Column 3 and 75°C
Copper Conductor
in Conduit
(Column 4)
Breaker Size
(Based on NEC
Ampacity at Column 3)
(Column 5)
EVO-1224F
(1200VA)
EVO-1224F-HW
(1200VA)
10A 12.5A AWG# 14 15A
10A 12.5A AWG# 14 15A
SAMLEX AMERICA INC. | 7
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SECTION 1.1 | Safety Instructions
TABLE 1.1.3 SIZING OF BATTERY SIDE CABLES AND EXTERNAL BATTERY SIDE FUSES
(Refer to Section 3.5.5, Table 3.1 for more details)
Model No.
Rated
Continuous
DC Input
Current
NEC
Ampacity
= 125% of
Rated DC
Input Current
at Column 2
90°C Copper Conductor. Size Based on NEC Ampacity at
Column (3) or 2%Voltage Drop, whichever is Thicker
Cable Running Distance
between the Unit
and the Battery
(Cable Routing In Free Air)
Up to 5 ft.
Up to 10 ft.
Cable Running Distance
between the Unit
and the Battery
(Cable Routing In Raceway)
Up to 5 ft.
External
Fuse Based
on NEC
Ampacity at
Column (3)
Up to 10 ft.
(Column 1)
EVO-1212F
EVO-1212F-HW
EVO-1224F
EVO-1224F-HW
External Char-
ger
(Column 2)
152 190 AWG #2 AWG #2/0 AWG #2/0 AWG #2/0 200A
76 95 AWG #6 AWG #4 AWG #3 AWG #3 100A
50A 63A
(Column 3)
(Column 5)
AWG #6
(2% voltage
drop is thicker)
(Column 6)
AWG #2
(2% voltage
drop is thicker)
(Column 7)
AWG #6
(Column 8)
AWG #2
(2% voltage
drop is thicker)
(Column 9)
70A
TABLE 1.1.4 TIGHTENING TORQUES
Battery Input Connectors External Charger Input Connectors AC Input and Output Connectors
70 kgf.cm
(5.0 lbf.ft)
35 kgf.cm
(2.5 lbf.ft)
7 to 12 kgf.cm
(0.5 to 0.9 lbf.ft)
TABLE 1.1.5 USE OF SPECIFIED GROUND FAULT CIRCUIT INTERRUPTER (GFCI) FOR DISTRIBUTION OF AC
OUTPUT POWER IN RECREATION VEHICLES
Manufacturer of GFCI Manufacturers’ Model No. Description
Jiaxing Shouxin Electric Technology Co. Ltd TS-15, TS-20
NEMA5-20, Duplex, 20A
NEMA5-15, Duplex, 15A
8 | SAMLEX AMERICA INC.
Page 9
SECTION 1.2 | Denitions
The following denitions are used in this manual for explaining various electrical concepts, specications 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), Volts: 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 – ow in one direction only) or AC (Alternating
Current – direction of ow changes periodically). The AC value shown in the specications 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 ow 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.
Efciency, (η): This is the ratio of Power Output ÷ Power Input.
Phase Angle, (φ): It is denoted by “φ” and species 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 (φ) = 90°. In a purely capacitive load, the current vector leads the voltage vector by Phase Angle,
(φ) = 90°. In a purely resistive load, the current vector is in phase with the voltage vector and hence, the Phase
Angle, (φ) = 0°. In a load consisting of a combination of resistances, inductances and capacitances, the Phase
Angle (φ) of the net current vector will be > 0° < 90° and may lag or lead the voltage vector.
Resistance (R), Ohm, Ω: It is the property of a conductor that opposes the ow of current when a voltage is
applied across it. In a resistance, the current is in phase with the voltage. It is denoted by “R” and its unit is “Ohm”
- also denoted as “”.
Inductive Reactance (X
), Capacitive Reactance (XC) and Reactance (X): Reactance is the opposition of a
L
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
L
proportional to frequency and inductance and causes the current vector to lag the voltage vector by Phase Angle
(φ) = 90°. Capacitive reactance (X
) is the property of capacitive elements to oppose changes in voltage. XC is
C
inversely proportional to the frequency and capacitance and causes the current vector to lead the voltage vector
by Phase Angle (φ) = 90°. The unit of both X
reactance X
to cause the current to lag the voltage by 90° and that of the capacitive reactance XC to cause the
L
and XC is “Ohm” - also denoted as “”. The effects of inductive
L
current to lead the voltage by 90° are exactly opposite 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 net Reactance (X) will be inductive
if X
> XC and capacitive if XC > XL.
L
SAMLEX AMERICA INC. | 9
Page 10
SECTION 1.2 | Denitions
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 voltage (Negative value). Hence, when averaged over a span of one cycle, the net value
of this power 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 Power (S), VA: This power, denoted by “S”, is the vectorial sum of the Active Power in Watts 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 protection devices have to be sized based on the Apparent Power.
Maximum Continuous Running AC Power Rating: This rating may be specied as “Active Power” in Watts
(W) or “Apparent Power” in Volt Amps (VA). It is normally specied in “Active Power (P)” in Watts for Resistive
type of loads that have Power Factor =1. Reactive types of loads will draw higher value of “Apparent Power”
that is the sum of “Active and Reactive Powers”. Thus, AC power source should be sized based on the higher
“Apparent Power” Rating in (VA) for all Reactive Types of AC loads. If the AC power source is sized based on the
lower “Active Power” Rating in Watts (W), the AC power source may be subjected to overload conditions when
powering Reactive Type of loads.
Starting Surge Power Rating: Certain loads require considerably higher Starting Surge Power for short duration
(lasting from tens of millisecs to few seconds) as compared to their Maximum Continuous Running Power Rating.
Some examples of such loads are given below:
• Electric Motors: At the moment when an electric motor is powered ON, the rotor is stationary (equivalent
to being “Locked”), there is no “Back EMF” and the windings draw a very heavy starting current (Amperes)
called “Locked Rotor Amperes” (LRA) due to low DC resistance of the windings. For example, in motor driven
loads like Air-conditioning and Refrigeration Compressors and in Well Pumps (using Pressure Tank), LRA
may be as high as 10 times its rated Full Load Amps (FLA) / Maximum Continuous Running Power Rating.
The value and duration of LRA of the motor depends upon the winding design of the motor and the inertia
/ resistance to movement of mechanical load being driven by the motor. As the motor speed rises to its
rated RPM, “Back EMF” proportional to the RPM is generated in the windings and the current draw reduces
proportionately till it draws the running FLA / Maximum Continuous Running Power Rating at the rated RPM.
• Transformers (e.g. Isolation Transformers, Step-up / Step-down Transformers, Power Transformer in
Microwave Oven etc.): At the moment when AC power is supplied to a transformer, the transformer draws
very heavy “Magnetization Inrush Current” for a few millisecs that can reach up to 10 times the Maximum
Continuous Rating of the Transformer.
10 | SAMLEX AMERICA INC.
Page 11
SECTION 1.2 | Denitions
• Devices like Infrared Quartz Halogen Heaters (also used in Laser Printers) / Quartz Halogen
Lights / Incandescent Light Bulbs using Tungsten heating elements: Tungsten has a very high Positive
Temperature Coefcient of Resistance i.e. it has lower resistance when cold and higher resistance when hot.
As Tungsten heating element will be cold at the time of powering ON, its resistance will be low and hence,
the device will draw very heavy Starting Surge Current with consequent very heavy Starting Surge Power with
a value of up to 8 times the Maximum Continuous Running AC Power.
• AC to DC Switched Mode Power Supplies (SMPS): This type of power supply is used as stand-alone
power supply or as front end in all electronic devices powered from Utility / Grid e.g. in audio/video/
computing devices and battery chargers (Please see Section 4 for more details on SMPS). When this power
supply is switched ON, its internal input side capacitors start charging resulting in very high Inrush Current
for a few millisecs (Please see Fig 4.1). This inrush current / power may reach up to 15 times the Continuous
Maximum Running Power Rating. The inrush current / power will, however, be limited by the Starting Surge
Power Rating of the AC source.
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 0 for purely inductive or purely capacitive loads. Practically, the loads will be a
combination of resistive, inductive and capacitive elements and hence, its value will be > 0 <1. Normally it ranges
from 0.5 to 0.8.
Load: Electrical appliance or device to which an electrical voltage is fed.
Linear Load: A load that draws sinusoidal current when a sinusoidal voltage is fed to it. Examples 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 lament lamps, cook tops, toaster,
coffee maker etc.) and draws only 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 lament lamps, Quartz/Halogen lamps and Quartz / Halogen Infrared 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, computers, audio/ video etc.). The Power Factor
(PF) of this type of load is < 1 e.g. AC Motors (PF = 0.4 to 0.8), AC to DC Switch Mode Power Supplies (PF = 0.5
to 0.6), Transformers (PF = 0.8) 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 the Starting Surge Power.
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SECTION 1.3 | General Information – Inverter Related
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
V
= 169.68V
peak
V
= 140 to 160V
peak
V
RMS
16.66 ms
= 120 VAC
Modied Sine
Wave sits at
ZERO for some
time and then
rises or falls
Sine Wave
• V
= 120VAC
RMS
• V
Modied Sine Wave
• V
• V
= 169.68V
peak
= 120V
RMS
= 140 to 160V
peak
VOLTS − VOLTS +
180
160
140
120
100
80
60
40
20
20
40
60
80
100
120
140
160
180
0
Pure Sine Wave
crosses zero V
instantaneously
TIME
Fig 1.3.1 Pure and Modied Sine Waveforms for 120V, 60 Hz
™
The 120V output waveform of the Evolution
series inverters is a Pure Sine Wave like the waveform of Utility / Grid
power. Please see Sine Waveform represented in the Fig. 1.3.1 that also shows equivalent Modied 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 0 Volts. In a Modied Sine Wave, the voltage rises and falls abruptly, the phase
angle also changes abruptly and it sits at 0V 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 Modied Sine Waveform.
Also, as the Modied 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 Modied Sine Wave. For example, a 60 Hz Modied
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 Modied 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
low frequency capacitors due to lowering of their capacitive reactance by the higher harmonic frequencies. These
capacitors are used in ballasts for uorescent lighting for Power Factor improvement and in single-phase induction
motors as start and run capacitors. Thus, Modied and Square Wave Inverters may shut down due to overload
when powering these devices.
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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 Grid / Utility supplied
electricity.
Inductive loads like microwaves, motors, transformers etc. run faster, quieter and cooler.
More suitable for powering uorescent lighting xtures containing Power Factor Improvement Capacitors and single
phase motors containing Start and Run Capacitors.
Reduces audible and electrical noise in fans, uorescent lights, audio ampliers, 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 Modied Sine Wave and may also get
damaged are given below:
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 (dimming /
speed control may not function).
Sewing machines with speed / microprocessor control.
Transformer-less capacitive input powered devices like (i) Razors, ashlights, night-lights, smoke detectors etc. (ii) Some
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.
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 uorescent lamps / light xtures that have Power Factor Correction Capacitors. The inverter may shut down
indicating overload.
Induction Cooktops.
1.3.3 Power Rating of Inverters
INFO
For proper understanding of explanations given below, please refer to denitions
of Active / Reactive / Apparent / Continuous / Surge Powers, Power Factor, and
Resistive / Reactive Loads at Section 1.2 under “DEFINITIONS”
The power rating of inverters is specied as follows:
• Maximum Continuous Running Power Rating
• Starting Surge Power Rating
Please read details of the above two types of power ratings in Section 1.2 under “DEFINITIONS”
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SECTION 1.3 | General Information – Inverter Related
Table 1.3.1 provides a list of some common AC appliances / devices that require high Starting Surge Power. An
“Inverter Sizing Factor” has been recommended against each which is a Multiplication Factor to be applied to the
Maximum Continuous Running Power Rating (Active Power Rating in Watts) of the AC appliance / device to arrive
at the Maximum Continuous Running Power Rating of the inverter (Multiply the Maximum Continuous Running
Power Rating (Active Power Rating in Watts) of the appliance / device by recommended Sizing Factor to arrive at the
Maximum Continuous Running Power Rating of the inverter.
TABLE 1.3.1 INVERTER SIZING FACTOR
Type of Device or Appliance
Air Conditioner / Refrigerator / Freezer (Compressor based) 5
Air Compressor 4
Sump Pump / Well Pump / Submersible Pump 3
Dishwasher / Clothes Washer 3
Microwave (where rated output power is the Cooking Power) 2
Furnace Fan 3
Industrial Motor 3
Portable Kerosene / Diesel Fuel Heater 3
Circular Saw / Bench Grinder 3
Incandescent / Halogen / Quartz Lamps 3
Ceramic / Positive Temperature Coefcient (PTC) type of heaters 5
Laser Printer / Other Devices using Infrared, Quartz Halogen Heaters 4
Switch Mode Power Supplies (SMPS): no Power Factor correction 2
Photographic Strobe / Flash Lights 4 (See Note 2)
INFO
The manufacturers’ specication for power rating of AC appliances and devices indicates only the Maximum
Continuous Running Power Rating. The Starting Surge Power required by some specic 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.
Inverter Sizing Factor
(See Note 1)
NOTES FOR TABLE 1.3.1:
1 Multiply the Maximum Continuous Power Rating (Active Power Rating in Watts) of the appliance / device by the
recommended sizing factor to arrive at the Maximum Continuous Running Power Rating of the Inverter.
2 For photographic strobe / ash unit, the Surge Power of the inverter should be > 4 times the Watt Sec rating of
photographic strobe / ash unit.
1.3.4 Electro-Magnetic Interference (EMI) and FCC Compliance
These inverters contain internal switching devices that generate conducted and radiated electromagnetic 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 A. These
limits are designed to provide reasonable protection 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
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SECTION 1.3 | General Information – Inverter Related
used in accordance with the instruction manual, may cause harmful interference 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:
• Ensure that the inverter is rmly grounded to the Ground System of the building or the vehicle.
• Locate the inverter as far away from the EMI receptors like radio, audio and video devices as possible.
• Keep the DC side wires between the battery and the inverter as short as possible.
• 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 efciency.
• 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 Characteristics of Switch Mode Power Supplies (SMPS)
Switch 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 circuits used in electronic equipment like battery
chargers, computers, audio and video devices, radios etc. These power supplies use large capacitors in their input section
for ltration. When the power supply is rst 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. 1.3.2. 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 lter capacitors, the current drawn by an SMPS (With no Power
Factor correction) is not sinusoidal but non-linear as shown in Fig 1.3.3. 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 of around 3. Crest Factor is dened 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 Coefcient) 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. Normally, inverters have short duration Surge Power Rating of 2 times their
Maximum Continuous Power Rating. Hence, it is recommended that for purposes of sizing the inverter, to
accommodate Crest Factor of 3, the Maximum Continuous Power Rating of the inverter should be > 2
times the Maximum Continuous Rated Power of the SMPS. For example, an SMPS rated at 100 Watts
should be powered from an inverter that has Maximum Continuous Power Rating of > 200 Watts.
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SECTION 1.3 | General Information – Inverter Related
NOTE: Voltage and
Current scales
are dierent
Input voltage
Peak Inrush Current
Inrush current
Fig 1.3.2 Inrush current in an SMPS
Peak Current
RMS Current
CREST FACTOR = PEAK CURRENT = 3
RMS CURRENT
Input Sine
Wave Voltage
Current − Current +
Volatge − Voltage +
TIME
Non-linear
Input Current
Rated Steady State
Input RMS Current
NOTE: Voltage and
Current scales
are dierent
Fig 1.3.3 High Crest Factor of current drawn by SMPS
SECTION 1.4 | General Information – Battery Related
1.4.1 Lead Acid Battery – Basic Description And Electro-Chemical Reactions
1.4.1.1 A Lead Acid battery consists of a number of 2 V nominal cells (actual voltage of the cell is around 2.105 V)
that are connected in series e.g. a 12 V nominal battery will have six, 2 V nominal cells in series (actual approximate
voltage of the 6 cells will be 2.105 x 6 = 12.63 V). Each 2 V nominal cell in this battery consists of an independent
16 | SAMLEX AMERICA INC.
INFO
For complete information on Lead Acid Batteries and Charging Process, please visit www.samlexamerica.com >
Support > White Papers > White Paper – Batteries, Chargers and Alternators
Page 17
SECTION 1.4 | General Information – Battery Related
enclosed compartment that has Positive and Negative Plates (also called Electrodes) dipped in electrolyte that is
composed of diluted Sulphuric Acid.
1.4.1.2 A fully charged Lead Acid Battery comprises of (i) Positive Plates: Lead Dioxide (PbO
Sponge Lead (Pb) and (iii) Electrolyte: Mixture of 65% water and 35% Sulfuric Acid (H
SO4) with Specic Gravity =
2
), (ii) Negative Plates:
2
1.265 at Standard Room Temperature of 77°F / 25°C (Fully charged condition). During discharging, electro-chemical
reactions lead to: (i) At Positive Plates: Conversion of Lead Dioxide (PbO
(ii) At Negative Plates: Conversion of Sponge Lead (Pb) to soft Lead Sulfate (PbSO
Conversion of portion of Sulfuric Acid (H
SO4) to water leading to reduction in Specic Gravity (1.120 for fully
2
) to soft Lead Sulfate (PbSO4) crystals,
2
) crystals and (iii) In Electrolyte:
4
discharged condition).
1.4.2 Types Of Lead Acid Batteries
1.4.2.1 Sealed Lead Acid (SLA) Or Valve Regulated Lead Acid (VRLA) Batteries: These can either be Gel Cell or
AGM (Absorbed Glass Mat). In a Gel Cell battery, the electrolyte is in the form of a gel. In AGM (Absorbed Glass Mat)
battery, the electrolyte is soaked in Glass Mat. In both these types, the electrolyte is immobile. There are no rell caps
and the battery is totally sealed. Hydrogen and Oxygen released during the charging process is not allowed to escape
and is recombined inside the battery through use of Recombinant Catalyst (s). Hence, there is no water loss and the
batteries are maintenance free. These batteries have safety valves on each cell to release excessive pressure that may be
built up inside the cell. The Gel Cell is the least affected by temperature extremes, storage at low state of charge and
has a low rate of self-discharge. An AGM battery will handle overcharging slightly better than the Gel Cell.
1.4.2.2 Non Sealed (Vented / Flooded / Wet Cell) Lead acid Batteries: In these batteries, each individual cell
compartment has a rell cap that is used to top up the cell with distilled water and to measure the specic gravity of
the electrolyte using a hydrometer. When fully charged, each individual cell has a voltage of approximately 2.105 V
and electrolyte specic gravity of 1.265. As the cell discharges, its voltage and specic gravity drop. Thus, a healthy,
fully charged, 12 V nominal battery with each of the 6 cells fully charged to 2.105 V will measure a standing voltage
of 12.63 V at Standard Room Temperature of 77º F / 25º C. Also, in a healthy battery, all the individual cells will have
the same voltage and same specic gravity. If there is a substantial difference in the voltages (0.2 V or higher) and
specic gravities of the individual cells (0.015 or more), the cells will have to be “equalized” (Refer to Sections 1.4.3.4
and 1.4.4 regarding further details on equalization).
1.4.2.3 SLI (Starting, Lighting, and Ignition) Batteries: Everybody is familiar with the SLI batteries that are used
for automotive starting, lighting, ignition and powering vehicular accessories. SLI batteries are designed to produce
high current in short bursts for cranking. This current is also called also called “Cranking Amps”. SLI batteries use lots
of thin plates to maximize the surface area of the plates for providing very large Cranking Amps. This allows very high
starting current but causes the plates to warp when the battery is cycled. Vehicle starting typically discharges 1%-3%
of a healthy SLI battery’s capacity. The automotive SLI battery is not designed for repeated deep discharge where up to
80 % of the battery capacity is discharged and then recharged. If an SLI battery is used for this type of deep discharge
application, its useful service life will be drastically reduced. This type of battery is not recommended for the storage
of energy for inverter backup applications.
1.4.2.4 Deep Cycle Lead Acid Batteries: These 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 up to 80 %
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.
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SECTION 1.4 | General Information – Battery Related
1.4.3 Battery Charging Stages:
General descriptions of 4 stages of battery charging are given at Sections 1.4.3.1 to 1.4.3.4 below. Depending upon
the type of battery and its application, different Charging Proles can be created using appropriate charging stages.
NOTE:
7 types of Charging Proles are available in EVO through programming parameter "CHARGING PROFILE". Refer to
Section 5.6 for details.
1.4.3.1 Stage 1 - Constant Current Bulk Charge Stage: In the rst stage, known as the Bulk Charge Stage,
the charger delivers a constant, maximum charging current that can be safely handled as specied by the battery
manufacturer. The value of the Bulk Charge Current depends upon the total Ampere Hour (Ah) capacity 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% capacity as the Gassing Voltage rises with higher charging current due to “Peukert Effect”.
Also, very high charging current produces higher temperature in the active material of the plates resulting in loss of
cohesion and shedding of the active material that settles on the bottom of the plates. Shedding of the active material
results in loss of capacity. If the quantity of the shedded active material at the bottom of the plates rises, it may short
the cells.. As a general thumb rule, the Bulk Charging Current should be limited to 10% to 13% of the Ah capacity of
the battery (20 Hour discharge rate). Higher charging current may be used if permitted by the battery manufacturer.
This current is delivered to the batteries until the battery voltage approaches its Gassing Voltage of around 2.4 V per
cell at 77º F / 25º C or 14.4 V for a 12 V battery and 28.8 volts for a 24 volt battery. The Bulk Charge Stage restores
about 75% of the battery's capacity. 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 during Equalization Stage) since this will cause the battery to lose electrolyte
and dry out over time. Once the Gassing Voltage is approached, the charger transfers to the next stage, known as the
Absorption Stage.
1.4.3.2 Stage 2 - Constant Voltage Absorption Stage During the Absorption Stage, the charger changes from
constant current to constant voltage charging. 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 Absorption Stage feeds
additional 40% of the capacity that adds up to a total charged capacity of around 115% to take care of around
15% loss of charging efciency. As the output voltage of the charger is held constant, the battery absorbs the charge
slowly and the current reduces gradually till all of the soft Lead Sulfate (PbSO
Dioxide (PbO
Absorption Stage before it transitions to the next Float Stage is determined in one or more of the following conditions:
a) By a xed timer (e.g. 4 to 8 Hours). This may result in overcharging of almost fully charged batteries.
b) When charge current drops to specied threshold: Switching over to the Float Stage when the charge
INFO
As the Bulk Charge Stage is a constant current stage, the charger does not control the voltage and the
voltage seen at the output terminals of the charger will be the actual battery voltage (this will rise slowly
towards the Gassing Voltage under the inuence of the constant charging current).
) crystals have been converted to Lead
4
) on the Positive Plates and Sponge Lead (Pb) on the Negative Plates. The time the charger is held in the
2
current drops below a certain threshold (e.g. 10% of the charger Bulk Charge Current). This may result in
overcharging and locking in the Absorption Stage if the battery is feeding an external load that has a value > the
specied threshold.
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SECTION 1.4 | General Information – Battery Related
c) Using Adaptive Charging Algorithm: This ensures that the battery is completely charged in a safe manner
for longer battery life (Suitable for battery that does not have load connected to it). In this algorithm, the time
the battery remains in Absorption and Equalization Stages is automatically made 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. EVO Series has 2 programmable options to use this Adaptive
Charging Algorithm – (i) 3-Stage Adaptive (Table 5.2, Srl. 1) & (ii) 4-Stage Adaptive for Equalization (Section
5.8).
1.4.3.3 Stage 3 - Constant Voltage Float Stage: The Float Stage is a maintenance stage in which the output
voltage is reduced to a constant lower level, typically about 13.5 V for a 12 V battery and 27 V for a 24V battery to
maintain the battery's charge without losing electrolyte through gassing and also, to compensate for self discharge.
Self discharge of Lead Acid Battery is the electrical Ampere Hour (Ah) capacity that is lost when the battery is not
being charged and there is no load connected to it. i.e. sits idle in storage. Self-discharge is caused by electro-chemical
processes within the battery and is equivalent to application of a small electrical load. For example, Lead Acid battery
stored at 30°C / 86°F would self-discharge at around 1% of remaining capacity every day. Self-discharge increases
with increase in temperature. Self-discharge of the battery under long term storage will create condition equivalent to
under charging and consequently, lead to “sulfation” as explained at Section 1.4.4.1.
1.4.3.4 Stage 4 - Constant Voltage Equalization Stage: This stage is normally initiated manually because it is
not required every time the battery is recharged [In EVO, it is carried out manually through programming parameter
"EQUALIZE-4STAGES"(See Section 4.4.2.12 in EVO-RC-PLUS Remote Control Manual)]. Normally, only vented / wet cell
/ ooded batteries are equalized. Some sealed AGM batteries may be equalized if recommended by the manufacturer
(e.g. Life Line brand of sealed, AGM batteries). Equalization Stage is normally activated after completion of the Bulk
and Absorption Stages. During the Equalization Stage, the battery is intentionally charged at a constant voltage at a
value above the Gassing Voltage which is normally in the region of 2.5 to 2.7 V per cell at 25º C / 77º F (e.g. 15 to
16 V for 12 V batteries and 30 to 32 V for 24 V batteries). The time the battery remains in this stage is determined as
follows:
• By a xed timer (e.g. 4 to 8 Hours): This may result in overcharging of almost fully charged batteries
• Using an automatic Adaptive Charging Algorithm: This ensures that the battery is equalized in a safe
manner for longer battery life. EVO Inverter Charger Series uses this Adaptive Charging Algorithm for
Equalization. [Refer to Section 1.4.3.2 (c) for details.]
Recommendations of the battery manufacturer are to be followed for equalizing the batteries as the equalization
voltage, current, time and frequency will depend upon the specic design of the battery. As a guide, a heavily used
ooded battery may need to be equalized once per month and a battery in light duty service, every two to four months.
The Equalization Charge Current should be a relatively low current of around 2% to 10% of the Ah capacity of the
battery. Such a low current prevents an overcharge condition that results in excessive gassing and excessive loss of water.
1.4.4 Why Flooded / Wet Cell Lead Acid Batteries Are Equalized?
For proper health and long life of a Lead Acid battery, it is required to undergo an Equalization Stage (described at
Section 1.4.3.4 above) during the charging process to prevent / reduce the following undesirable effects:
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SECTION 1.4 | General Information – Battery Related
1.4.4.1 Sulfation: Section 1.4.1.2 above gives details of basic electrochemical reactions during charging and
discharging. If the charging process is not complete due to the inability of the charger to provide the required voltage
levels or if the battery is left uncharged for a long duration of time, the soft Lead Sulfate (PbSO
Positive and Negative plates that are formed during discharging / self discharge are not fully converted back to Lead
Dioxide (PbO
) on the Positive plate and Sponge Lead on the Negative plate and get hardened and are difcult to
2
dislodge through normal charging. These crystals are less-conducting and hence, introduce increased internal resistance
in the battery. This increased internal resistance introduces internal voltage drop during charging and discharging.
Voltage drop during charging results in overheating and undercharging and formation of more Lead Sulfate (PbSO
crystals. Voltage drop on discharging results in overheating and excessive voltage drop in the terminal voltage of the
battery. Overall, this results in poor performance of the battery. To dislodge these hardened Lead Sulfate crystals, some
chargers are designed to detect a sulfated condition at the start of the charging process and go through an initial
De-sulfation Mode that sends high frequency, high voltage pulses at the natural oscillation frequency of the crystals to
dislodge the hardened crystals. Sulfation may also be reduced partially by the stirring / mixing action of the electrolyte
due to gassing and bubbling because of intentional overcharging during the Equalization Stage.
1.4.4.2 Electrolyte Stratication: Electrolyte stratication can occur in all types of ooded batteries. As the
battery is discharged and charged, the concentration of Sulfuric Acid becomes higher at the bottom of the cell
and lower at the top of the cell. The low acid concentration reduces capacity at the top of the plates, and the high
acid concentration accelerates corrosion at the bottom of the plates and shortens battery life. Stratication can be
minimized by the Equalization Stage by raising the charging voltage so that the increased gassing and bubbling
agitates / stirs the electrolyte and ensures that the electrolyte has uniform concentration from top to bottom. The
stirring action also helps to break up any Lead Sulfate crystals, which may remain after normal charging.
) crystals on the
4
)
4
1.4.4.3 Unequal charging of cells: During normal charging, temperature and chemical imbalances prevent
some cells from reaching full charge. As a battery is discharged, the cells with lower voltage will be drained further
than the cells at higher voltage. When recharged, the cells with the higher voltage will be fully charged before
the cells with the lower voltage. The more a battery is cycled, the more cell voltage separation takes place. In a
healthy battery, all the individual cells will have the same voltage and same specic gravity. If there is a substantial
difference in the cell voltages (0.2 V or more) and in the specic gravities (0.015 or more) of the individual cells,
the cells will require equalization. Equalizing batteries helps to bring all the cells of a battery to the same voltage.
During the Equalization Stage, fully charged cells will dissipate the charging energy by gassing while incompletely
charged cells continue to charge.
1.4.5 Temperature Compensation To Prevent Over And Under Charging
1.4.5.1.1 Electrochemical reactions during charging / discharging of Lead Acid / Nickel Zinc (Ni-Zn) Batteries are
affected by changes in the temperature of the electrolyte. These type of batteries have a Negative Temperature
Coefcient of Voltage i.e. the battery charging / discharging voltages will fall due to rise in electrolyte temperature and
will rise due to fall in electrolyte temperature. Battery manufacturers, therefore, specify battery voltages and capacity at
Standard Room Temperature of 77º F / 25º C. The Negative Temperature Coefcient is normally within a range of -3 to
-5mV/ ºC/Cell or (i) -18 to -30mV / ºC for a 6-cell, 12V battery or (ii) -36 to -60mV / ºC for 12-cell, 24V battery.
1.4.5.1.2 Lithium Ion charging voltages are not affected by temperature and hence, do not require temperature
compensation.
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SECTION 1.4 | General Information – Battery Related
1.4.5.2 Rise / fall in the temperature of the electrolyte with respect to the Standard Room Temperature of 77º
F / 25º C will require temperature compensation. Charging voltages will be required to be reduced at higher
electrolyte temperature and increased at lower electrolyte temperature with respect to the Standard Room
Temperature of 77º F / 25ºC. If charging voltages are not temperature compensated, the battery will boil / be
overcharged during higher temperatures and under charged during lower temperatures. This will result in reduced
battery life / damage to the battery. It is, therefore, desirable that a temperature compensated battery charger
is used if the Room Temperature swings more than 7º F / 5ºC. Temperature compensated battery chargers are
provided with either internal or external Temperature Sensor.
1.4.5.3 Effects of Over Charging: Over charging will lead to excessive amount of decomposition of water into
Hydrogen and Oxygen and generation of excessive heat. As the battery electrolyte temperature rises, the battery
charging voltage is required to be reduced. However, the charger voltage will not reduce in a charger that has no
temperature compensation. This condition will drive more current and ,therefore, heating up the electrolyte even
further. This is called “thermal runaway” and may damage the battery within a few hours:
• Flooded battery will lose water / shed pasted material.
• Sealed battery will see rise in internal pressure as the rate of generation of Hydrogen and Oxygen will be
more than the designed rate of recombination provided by the Recombinant Catalyst. The battery casing
will bulge excessively and the pressure release valves may open.
1.4.5.4 Effects of Under Charging – Sulfation: Refer to Section 1.4.4.1 for details.
1.4.6 Self Discharge Of Lead Acid Batteries:
1.4.6.1 Self discharge of Lead Acid Battery is the electrical Ampere Hour (Ah) capacity that is lost when the
battery is not being charged and there is no load connected to it i.e. it sits idle in storage. Self-discharge is caused
by electro-chemical processes within the battery and is equivalent to application of a small electrical load. For
example, Lead Acid battery stored at 30°C / 86°F would self-discharge at around 1% of remaining capacity every
day. Self-discharge increases with increase in temperature. Self-discharge of the battery under long term storage
will create condition equivalent to under charging and consequently, lead to sulfation as explained at Sections
1.4.4.1 above. To prevent this, the battery should be “Float Charged” as explained in Section 1.4.3.3.
1.4.6.2 Float Charging of Batteries under Long Term Storage: In order to prevent sulfation due to under
charging as a result of self-discharge, Lead Acid Battery under long term storage should be rst fully charged and
then left under continuous charge using a suitable “Float Charger” that will Float Charge the battery and provide
low value of “Float Charge Current” of around 0.1% of the Ah capacity of the battery to compensate for self
discharge. Samlex Model SC-05 and SC-10 SunCharger Solar Panels may be used. These are designed to provide
this “Float Charge Current" and thus, prevent sulfation.
1.4.7 Rated Capacity Specied in Ampere-hour (Ah)
Battery capacity “C” is specied in Ampere-hours (Ah). An Ampere is the unit of measurement for electrical current
and is dened as a Coulomb of charge passing through an electrical conductor in one second. The Capacity “C”
in Ah relates to the ability of the battery to provide a constant specied value of discharge current (also called
“C-rate” - see Section 1.4.10) over a specied time in hours before the battery reaches a specied discharged
terminal voltage (Also called “End Point Voltage”) at a specied 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
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SECTION 1.4 | General Information – Battery Related
battery can deliver for 20 Hours at 80ºF (26.7ºC) till the voltage 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.
1.4.8 Rated Capacity Specied in Reserve Capacity (RC)
Battery capacity may also be expressed as Reserve Capacity (RC) in minutes typically for automotive 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 battery can deliver 25 Amperes at 80ºF (26.7ºC) 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
1.4.9 Typical Battery Sizes
Table 1.4.1 shows details of some popular battery sizes:
TABLE 1.4.1 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
1.4.10 C-rate of Charge / Discharge
1.4.10.1 The rate of charge / discharge of a battery is normally expressed in “C-rate” which is a multiple of the
numerical value of the battery’s Ampere Hour (Ah) Capacity (C) (See Section 1.4.7 for information on Ampere Hour
Capacity). Few examples of C-rates (2C, 1C, 0.2C etc.) for 100Ah capacity battery (C=100 Ah) are given below:
• 2C = (2x100) A = 200A (As the battery capacity is 100 Ah, the battery will be completely discharged in 0.5 Hrs.)
• 1C = (1x 100) A = 100A (As the battery capacity is 100 Ah, the battery will be completely discharged in 1 Hr.)
• 0.2C (or C/5) = (0.2 x 100) A = 20A (As the battery capacity is 100 Ah, the battery will be completely discharged
in 5 Hrs.)
1.4.10.2 Example for Determining C-rate of Charge for Particular Value of Charge Current:
• Determine the Ah capacity (C) of the battery – say 100 Ah (C=100 Ah)
• Determine the value of charge current – say 10 Amperes
• C-rate of charge at 10A = Multiple of numerical value Ampere Hour Capacity (C) = (10 ÷ 100) C = 1/10 C or 0.1C
1.4.10.3 Example for Determining C-rate of Discharge for Particular Value of Discharge Current:
• Determine the Ah capacity (C) of the battery – say 100 Ah (C=100)
• Determine the value of discharge current – say 20 Amperes
• C-rate of discharge at 20A = Multiple of numerical value of Ah Capacity (C) = (20 ÷ 100) C = 1/5 C
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SECTION 1.4 | General Information – Battery Related
1.4.10.4 Table 1.4.2 gives some examples of typical C-rates of Discharge and applications:
TABLE 1.4.2 TYPICAL “C-rates” OF DISCHARGE
C-rate of Discharge
(Column 1)
2C 200A
1C 100A
C/5 or 0.2C (Inverter application) 20A
C/8 or 0.125C (UPS application) 12.5A
C/10 or 0.1C (Telecom application) 10A
C/20 or 0.05C (Automotive application) 5A
C/100 or 0.01C 1A
1.4.11 Charge / Discharge Curves to Determine State of Charge of Lead Acid Battery Based on its
Terminal Voltage and C-rates of Charge / Discharge
1.4.11.1 Fig 1.4.1 shows examples of State of Charge / Discharge Curves for different C-rates for typical 12V / 24V
Lead Acid Battery at 80°F / 26.7°C. These curves are used to determine the State of Charge / Discharge of the battery
based on its terminal voltage.
Examples of C-rate of Discharge
for 100 Ah capacity battery
(Column 2)
The Y-Axis shows the terminal voltage of the battery. The X-Axis shows % State of Charge. % State of Discharge can
be converted to % State of Charge using formula:
• % State of Charge = (100% - % State of Discharge) e.g. 80% State of Discharge = 100%-80% = 20% State of Charge
1.4.11.2 Example of Determining State of Charge (using Fig 1.4.1) when Charging 12V, 100Ah Battery at
C-rate of 0.1C or C/10 or 10A: Refer to Charge Curve marked C\10 of the upper 4 curves marked “CHARGE”. States
of Charge at different battery terminal voltages will be: (a) At 5.3V = 100% charged; (b) At 14.3V = 90% charged; (c)
At 13.5V = 70% charged; (d) At 12.5V = 15% charged
1.4.11.3 Example of Determining State of Discharge (using Fig 1.4.1) when Discharging 12V, 100Ah
Battery at C-rate of 0.33C or C/3 or 33.3A: Refer to Charge Curve marked C\3 of the lower 4 curves marked
“DISCHARGE”. States of Discharge at different battery terminal voltages will be: [a] At 9.5V = 100% discharged (0%
charged); [b] At 10.4V = 80% discharged (20% charged): [c] At 11.5V = 28% discharged (72% charged) and [d]
11.75V = 0% discharged (100% charged)
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SECTION 1.4 | General Information – Battery Related
Typical 12V/24V Flooded Lead-Acid Battery Chart - 80˚F / 26.7˚C
24V 12V
16.5
33.0
16.0
32.0
15.5
31.0
15.0
30.0
14.5
29.0
14.0
28.0
13.5
27.0
13.0
26.0
12.5
25.0
Battery Voltage in VDC
12.0
24.0
11.5
23.0
11.0
22.0
10.5
21.0
10.0
20.0
9.5
19.0
9.0
18.0
0 10 20 30 40 50 60 70 80 90 100 110 120 130
CHARGE
C/100
C/20
C/10
C/5
C/3
Battery State of Charge in Percent (%)
C/5
C/10
C/20
C/40
DISCHARGE
Fig 1.4.1 Charging / Discharging Curves for Typical 12V/24V Flooded Lead Acid Battery
1.4.12 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 C-rate of C/20 (or, 0.05C). 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 1.4.3.
TABLE 1.4.3 BATTERY CAPACITY VERSUS RATE OF DISCHARGE – C-rate
C-rate Discharge Current Usable Capacity (%)
C/20 or, 0.05C 100%
C/10 or, 0.10C 87%
C/8 or, 0.125C 83%
C/6 or, 0.17C 75%
C/5 or, 0.20C 70%
C/3 or, 0.34C 60%
C/2 or, 0.50C 50%
1C 40%
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SECTION 1.4 | General Information – Battery Related
Table 1.4.3 shows that a 100 Ah capacity battery will deliver 100% (i.e. full 100 Ah) capacity if it is slowly discharged
over 20 Hours at the rate of 5 Amperes (50W output for a 12V inverter and 100W output for a 24V inverter). However,
if it is discharged at a rate of 50 Amperes (500W output for a 12V inverter and 1000W output for a 24V inverter) then
theoretically, it should provide 100 Ah ÷ 50 = 2 Hours. However, Table 1.4.3 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.
1.4.13 State of Charge (SOC) of a Battery – Based on “Standing Voltage”
The “Standing Voltage” of a battery under open circuit conditions (no charger or 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 letting the battery “stand” idle for 3 to 8 hours
before the voltage measurement is taken. Table 1.4.4 shows the State of Charge versus Standing Voltage for a typical
12V/24V battery system at 80°F (26.7ºC).
TABLE 1.4.4 SOC VERSUS STANDING VOLTAGE (TYPICAL FLOODED BATTERY)
Percentage of
Full Charge
100% 2.105V 12.63V 25.26V
90% 2.10V 12.6V 25.20V
80% 2.08V 12.5V 25.00V
70% 2.05V 12.3V 24.60V
60% 2.03V 12.2V 24.40V
50% 2.02V 12.1V 24.20V
40% 2.00V 12.0V 24.00V
30% 1.97V 11.8V 23.60V
20% 1.95V 11.7V 23.40V
10% 1.93V 11.6V 23.20V
0% = / < 1.93V = / < 11.6V = / < 23.20V
Standing Voltage
of Individual Cells
Standing Voltage of
12V Battery
Standing Voltage
of 24V Battery
Check the individual cell voltages / specic gravity. If the inter-cell voltage difference is more than a 0.2V, or the
specic gravity difference is 0.015 or more, the cells will require equalization. Refer to Section 1.4.3.4 and 1.4.4
regarding details on equalization). Please note that only non-sealed / vented / ooded / wet cell batteries are
equalized. Do not equalize sealed / VRLA type of AGM or Gel Cell Batteries.
1.4.14 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].
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SECTION 1.4 | General Information – Battery Related
Inverters are provided with a buzzer alarm to warn that the loaded battery has been deeply discharged to around
80% 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 discharge current falls
further to 10V for 12V battery or 20V 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 electrochemical reactions
inside the battery and produces a Negative Voltage Coefcient – 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 resistance and hence, as the
discharge current increases, the battery terminal voltage decreases non-linearly.
The discharge curves in Fig. 1.4.1 show the % State of Charge versus the terminal voltage of typical Flooded Lead
Acid Battery under different charge /discharge currents, i.e. “C-rates” and xed 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).
1.4.14.1 Low DC Input Voltage Alarm in Inverters
As stated earlier at Section 1.4.14, 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 State of Discharge decreases with the rise in the
value of the discharge current. For example, terminal voltages for a State of Discharge of 80% (State of Charge of
20%) for various discharge currents will be as given at Table 1.4.5 (Refer to Fig. 1.4.1 for parameters and values
shown in Table 1.4.5):
TABLE 1.4.5 TERMINAL VOLTAGE AND SOC OF LOADED BATTERY
Terminal Voltage at 80% State of Discharge
Discharge Current:
C-rate
C/3 A 10.45V 20.9V 09.50V 19.0V
C/5 A 10.90V 21.8V 10.30V 20.6V
C/10 A 11.50V 23.0V 11.00V 22.0V
C/20 A 11.85V 23.7V 11.50V 23.0V
C/100 A 12.15V 24.3V 11.75V 23.5V
12V 24V 12V 24V
(20% SOC)
Terminal Voltage When Completely
Discharged (0% SOC)
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.
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SECTION 1.4 | General Information – Battery Related
In view of the above, it may be seen that a xed 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 function of age and charging history.
Older batteries have lower capacity 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 function is designed to protect the inverter from excessive current drawn at
the lower voltage.
1.4.14.2 Low DC Input Voltage Shutdown in Inverters
As explained above at Section 1.4.14, 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 or, at around 21V
for 24V battery to warn the user to disconnect the battery to prevent further draining of the battery. If the load is not
disconnected at this stage, the batteries 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 or, 20V for 24V battery.
Referring to the Discharge Curves given in Fig 1.4.1, 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 % of State of Charge.
The % of State of Discharge will be 100% - % 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 % 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 xed Low DC Input Voltage Shutdown 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 function of age and charging history. Older
batteries have lower capacity 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 shut-down function is designed to protect the inverter from excessive current
drawn at the lower voltage.
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SECTION 1.4 | General Information – Battery Related
1.4.15 Depth of Discharge of Battery and Battery Life
The more deeply a battery is discharged on each cycle, the shorter the battery life. Using more batteries than the
minimum required will result in longer life for the battery bank. A typical cycle life chart is given in the Table 1.4.6 below:
TABLE 1.4.6 TYPICAL CYCLE LIFE CHART
Depth of Discharge
% of Ah Capacity Cycle Life of Group 27 /31 Cycle Life of Group 8D Cycle Life of 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 50%.
1.4.16 Series and Parallel Connection of Batteries
Refer to details at Section 3.4.
1.4.17 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 inverter. Usually this question is turned around to
ask “How long do you want your load to run?”, and then specic 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. For an inverter running from a 12V battery system, the approximate DC current required from the 12V batteries
is the AC power delivered by the inverter to the load in Watts (W) divided by 10 & for an inverter running from a
24V battery system, the approximate 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 rst 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 approximate 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 Ampere Hours (Ah) is determined.
For example, if the load is to operate for 3 hours then as per Formula 3 above, the energy to be delivered by the 12V
batteries = 100 Amperes × 3 Hours = 300 Ampere Hours (Ah), or by the 24V batteries = 50A x 3 Hrs = 150 Ah.
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SECTION 1.4 | General Information – Battery Related
Now, the capacity of the batteries is determined based on the run time and the usable capacity.
From Table 1.4.3 “Battery Capacity versus Rate of Discharge”, the usable capacity at 3 Hour discharge rate (C/3) is
60%. 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 nally, the actual desired rated capacity of the batteries is determined based on the fact that normally
only 80% 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 nal 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 nal 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 batteries should be twice the energy required by the
load in Ah.
1.14.18 Charging Batteries
Batteries can be charged by using good quality AC powered battery charger or from alternative 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 10% to 20% of their Ah capacity (Ah capacity based on 20 Hr Discharge Rate).
Based on the application, batteries may be charged using 2-Stage / 3-Stage / 4-Stage Charging Proles as follows:
Float Application Charging (2-Stage)
Stage 1 (Bulk Stage at constant current) " Stage 2 (Absorption Stage at constant voltage. May also be called Float
Stage in some applications).
Normal Charging (3-Stages)
Stage 1 (Bulk Stage at constant current) " Stage 2 (Absorption Stage at constant voltage) " Stage 3 (Float Stage
at constant voltage)
Equalization Charging (4-Stages)
Stage 1 (Bulk Stage at constant current) " Stage 2 (Absorption Stage at constant voltage) " Stage 3 (Equalization
Stage at constant voltage) " Stage 4 (Float Stage at constant voltage)
Please refer to Section 5 for details of charging algorithm used in the Battery Charger Section of EVO
Inverter/Charger.
™
Series
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SECTION 2 | Components & Layout
2. LAYOUT
2.1 LAYOUT OF EVO-1212F AND EVO1224F – FRONT VIEW
10
14 15
5
10a 10b10c
10d
N L
G
9
16
1213
11
7
8
6
17
3 4
1
18
Batt Temp
1K
19
Red
to DSP
5.1K
1a
2a
Black
+5V
1 2 3 4 5 6 7 8
2
RJ-45 Jack (for Battery Temp. Sensor - Pinout)
Fig 2.1 Layout of Front side EVO-1212F / EVO-1224F
Legend for Fig 2.1
1. Battery Positive (+) Input Connector (marked "BATTERY POSITIVE"): Stud and Nut, M8 (Pitch 1.25 mm)
• 1a Red Protective Cover for Battery Positive (+) Input Connector – mounted using 2 pcs of M3 (Pitch 0.5 mm) x 10 mm long screws
2. Battery Negative (-) Input Connector (marked "BATTERY NEGATIVE"): Stud and Nut, M8 (Pitch 1.25)
• 2a Black Protective Cover for Battery Negative (-) Input Connector - mounted using 2 pcs of M3 (Pitch 0.5 mm) x 10 mm long screws
3. External Charge Controller Positive (+) Input Connector (marked "+ EXT. charger"): Stud and Thumb Nut, M6 (Pitch 1 mm)
4. External Charge Controller Negative (-) Input Connector (marked "– EXT. charger"): Stud and Thumb Nut, M6 (Pitch 1 mm)
5. DC Side Ground Connector (marked "
6. RJ-45 Jack marked "Battery Temp. Sensor"(Pinout at 19) is used for 2 functions as follows:
a) Connecting Battery Temperature Sensor “EVO-BCTS”[Fig 2.5(a)] for temperature compensation when Parameter "BATTERY TYPE"is
set for option "0=Lead Acid", or
b) Connecting potential free contact switching signal from Lithium Ion Battery Management System (BMS) to stop charging/ stop
inverting [See Sections 3.16 & 5.11.2]
7. RJ-45 Jack (marked "Remote Control") for “EVO-RC Plus” Remote Control
8. RJ-45 Jack (marked "COMM") - for future use.
9. Male AC Power Inlet Plug – Rating 20A (IEC60320 C-20). Will require 20A rated Female Socket
Connector (IEC 60320 C-19). For convenience, the connector has been supplied with the unit
(See Section 2.6 – “Contents of Package”)
10. NEMA5-15R Duplex GFCI Outlets for 120 VAC output [See Section 3.6.1.2 for details].
• 10a. Test Button • 10c. Red LED: GFCI Life End Alarm
• 10b. GFCI Reset Button • 10d. Green LED: GFCI ON
11. ON/Off Push Button
12. Blue LED “ON”
13. Red LED “Fault”
14. AC output Breaker, 15A
15. AC Input Breaker, 20A
16. Connector (marked "Remote On/Off") for On/Off Control through external +12V signal (9 – 15V, < 10mA):
Screw M2.5; Wire size AWG#30 to AWG#12. Refer to Section 6.2 for details.
• CAUTION! Observe correct polarity - Upper terminal is Negative and Lower terminal is Positive
17. Air inlet vents for 2 variable speed, temperature controlled cooling fans.
18. Removable top cover: Fixed with 8 screws – M4 (Pitch 0.7mm) x 4 mm
19. Pinout for RJ-45 Jack marked "Battery Temp. Sensor"(6, Fig 2.1)
") – Hole Diameter 6.5 mm for AWG #4 to #6; Set screw M6 (Pitch 0.75 mm)
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SECTION 2 | Components & Layout
2.2 LAYOUT OF EVO-1212F / 1212F-HW AND EVO-1224F /1224F-HW – BACK VIEW
1
1
Fig 2.2 Layout of Back Side - EVO-1212F / 1212F-HW and EVO-1224F / 1224F-HW
Legend for Fig 2.2
1. Air outlet vents for 2 variable speed, temperature controlled cooling fans (fans are not shown).
2.3 LAYOUT OF EVO-1212F-HW AND EVO-1224F-HW – FRONT VIEW
19a
18
3 4
2
1
28
20
2223242526 27
21
1213
11
16
7
8
6
19b
1a
Red
2a
Black
5
17
Fig 2.3 Hardwired AC Input and output connections: EVO-1212F-HW and EVO-1224F-HW
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SECTION 2 | Components & Layout
LEGEND for Fig 2.3
1. Battery Positive (+) Input Connector (marked "BATTERY POSITIVE"): Stud and Nut, M8 (Pitch 1.25mm)
• 1a Red Protective Cover for Battery Positive (+) Input Connector – mounted using 2 pcs of M3
2. Battery Negative (-) Input Connector (marked "BATTERY NEGATIVE"): Stud and Nut, M8 (Pitch 1.25)
• 2a Black Protective Cover for Battery Negative (-) Input Connector - mounted using 2 pcs of M3 (Pitch 0.5mm) x 10mm long screws
3. External Charge Controller Positive (+) Input Connector (marked "+ EXT. charger"): Stud and Thumb Nut, M6 (Pitch 1mm)
4. External Charge Controller Negative (-) Input Connector (marked "– EXT. charger"): Stud and Thumb Nut, M6 (Pitch 1 mm)
5. DC Side Ground Connector (marked "
6. RJ-45 Jack marked "Battery Temp. Sensor"(Pinout at 19) is used for 2 functions as follows:
a) Connecting Battery Temperature Sensor “EVO-BCTS”[Fig 2.5(a)] for temperature compensation when Parameter "BATTERY TYPE"is
b) Connecting potential free contact switching signal from Lithium Ion Battery Management System (BMS) to stop charging/ stop
7. RJ-45 Jack (marked "Remote Control") for “EVO-RC Plus” Remote Control
8. RJ-45 Jack (marked "COMM") - for future use
9. Blank
10. Blank
11. ON/Off Push Button
12. Blue LED “ON”
13. Red LED “Fault”
14. Blank
15. Blank
16. Connector (marked "Remote On/Off") for On/Off Control through external +12V signal (9 – 15V, < 10mA): Screw M2.5; Wire size
• CAUTION! Observe correct polarity - Upper terminal is Negative and Lower terminal is Positive
17. Air inlet vents for 2 variable speed, temperature controlled cooling fans.
18. Removable top cover: Fixed with 8 screws – M4 (Pitch 0.7mm) x 4mm
19(a). Pocket with Terminal Block for hard wiring
19(b). Plate to cover Pocket 19(a). Uses 4 mounting screws M3 (Pitch 0.5mm) x 6mm long (not shown).
20. Terminal Block for AC Input and AC output Connections: Terminal Hole: 3.5 mm x 3.0 mm for up to AWG#10; Set Screw M3 (0.5mm
21. INPUT L
22. INPUT N
23. INPUT GND
24. OUTPUT L
25. OUTPUT N
26. OUTPUT GND
27. Insulated Male / Female Quick Disconnect for disconnecting Output Neutral to Chassis Ground bond in Inverter Mode (Please see
28. AC Input and Output Ground connection to metal chassis: Stud and Nut; M4 (Pitch 0.7mm)
(Pitch 0.5mm) x 10mm long screws
") – Hole Diameter 6.5mm for AWG #4 to #6; Set screw M6 (Pitch 0.75mm)
set for option "0=Lead Acid", or
inverting [See Sections 3.16 & 5.11.2]
AWG#30 to AWG#12
The plate has 2 holes (27.8 mm /13/32” dia.) for ¾” Trade Size Fitting for conduit / cable entry
Pitch) x 6 mm long
Sections 4.5.1 to 4.5.3 and Fig 3.12(a) and 3.12(b)
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SECTION 2 | Components & Layout
2.4 REMOTE CONTROL EVO-RC-PLUS
1
9
3
2
Fault
4
Fig 2.4(a) Optional Remote Control EVO-RC-PLUS
LEGEND for Fig 2.3
1. LCD Screen:
- 4 rows of 20 characters each
- Blue screen with white characters
2. ON/OFF Key
3. Blue LED “Status”
4. Red LED “Fault”
5. Navigation Key “Back”
6. Navigation Key “Up”
7. Navigation Key “Down”
8. Navigation Key “Enter”
9. SD Card Slot – FAT16/32 format, up to 16 GB
10. RJ-45 Jack
11. RJ-12 Jack
12. RJ-45 Data Cable (Straight Wired), 10 m / 33 ft [Fig 2.4(b)]
INFO
Refer to more details under Section 1 of
EVO-RC-PLUS Remote Control Manual.
5
6
10 11
7
8
12
RJ-45
Plug
Fig 2.4(b) Cable for Remote Control
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3
1
2
SECTION 2 | Components & Layout
2.5 BATTERY TEMPERATURE SENSOR EVO-BCTS [FIG 2.5(a)]
Temperature Sensor [Negative Temperature Coefcient (NTC) resistor]: Mounting hole: 10mm/0.39” suitable for 3/8”
or 5/16” battery studs
1. RJ-45 Plug: Pins 1 to 4 Ò + NTC ; Pins 5 to 8 Ò – NTC (See pinout of mating RJ-45 Jack at 19, Fig 2.1)
2. 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
LEGEND for Fig. 2.5(a)
1. Temperature Sensor with Ring Terminal: Mounting hole: 10mm/0.39” suitable for 3/8” or 5/16” battery studs
2. RJ-45 Plug: Plug this into the RJ-45 Jack marked "Battery Temp. Sensor" (6, Fig 2.1). See pinout of mating
RJ-45 at Fig 3.13.
3. 5 meter/16.5 ft cable
2.6 CONTENTS OF PACKAGE
• Inverter/Charger
• Temperature Sensor EVO-BCTS [Fig 2.5(a)]
• DC Terminal Covers (1a, 1b: Fig 2.1) (Fitted on the unit with 2 screws each)
• Mating Connector for Remote On/Off Control* (16: Fig 2.1)
• IEC 60320 C-19, Socket Connector**[Mating connector for male AC Power
Inlet Plug (9, Fig 2.1)
• Wire End Terminals for AC Wiring (Fig 3.11) for EVO-1212F-HW/ EVO-1224-HW
Model AWG#12
EVO-1212F-HW and EVO-2224-HW 4 4
• Owner's Manual
• Quick Start Guide
(for input wiring)
AWG #14
(for output wiring)
*
Mating Connector for On/ Off
Control (16 Fig 2.1)
**
IEC 60320, C-19 Socket
Connector (14 Fig 2.1)
G
N
L
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SECTION 3 | Installation
3.1 SAFETY OF INSTALLATION
WARNING!
3.2 OVERALL DIMENSIONS
The overall dimensions and the location of the mounting holes are shown in Fig. 3.1.
Please ensure safety instructions given under Section 1 are strictly followed.
MISE EN GARDE
Se il vous plaît assurer consignes de sécurité fournies à la section 1 sont strictement suivies.
415
35
380
324
303.5
Mounting Holes: 7.4 mm / 0.29”
Mounting Bolts: M6 or /”
7.40
dia
40.7 123.90 50.80
298.6
Height: 148 mm
NOTE: All dimensions are in mm
1200
Inverter Charger
Pur e Sine Wave
123.90
1200 Watts
12 VDC Input
120 VAC Output
Model
EVO -1212F
20.90
Hole dia
148
7.40
dia
13.40
Fig. 3.1 Mounting Dimensions
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!
!
SECTION 3 | Installation
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
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.
Assurer qu’il y a PLUS QUE 200 mm d’espace DÉGAGÉ entourant l’onduleur pour faciliter
Mounting Orientation:
CAUTION!
Ensure there is OVER 200 mm clear space surrounding the inverter for ventilation.
ATTENTION!
la ventilation.
• Mounting Arrangement 1:
Mount horizontally on a horizontal surface (e.g. table top or a shelf). Please see Fig. 3.2.
Fig 3.2 Mounting Arrangement No.1: Horizontally On Horizontal Surface
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SECTION 3 | Installation
• Mounting Arrangement No. 2:
Mount horizontally on a vertical surface (like a wall). Please see Fig. 3.3.
Fig 3.3 Mounting Arrangement 2: On Vertical Surface
• Mounting Arrangement No. 3:
Mount vertically on a vertical surface, see Fig. 3.4. Protect against possibility of small objects or water entering
the ventilation openings on the top. (If necessary, install a suitable sloping guard at least 200mm from the top
surface). Also, ensure there is no combustible material directly under the unit.
Fig 3.4 Mounting Arrangement 3: On Vertical Surface
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SECTION 3 | Installation
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.
3.4.1 Series Connection
Cable “A”
Battery 4 Battery 3
Battery 2
Battery 1
24V Inverter
or 24V Charger
Cable “B”
6V 6V
6V
6V
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 the 24V battery bank.
3.4.2 Parallel Connection
Cable “A”
12V Inverter
or 12V Charger
Battery 1 Battery 3Battery 2 Battery 4
12V 12V 12V 12V
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 becomes 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.
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SECTION 3 | Installation
3.4.3 Series – Parallel Connection
12V String 1 12V String 2
Cable “A”
12V Inverter
or 12V Charger
Cable “B”
Battery 1 Battery 3Battery 2 Battery 4
6V 6V 6V 6V
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 bank.
3.4.4 Wiring Order in Parallel Connection of Batteries
CAUTION!
When 2 or more batteries / battery strings are connected in parallel and are then connected to inverter/
charger (See Figs 3.6 and 3.7), attention should be paid to the manner in which the inverter/charger is
connected to the battery bank. Please ensure that if the Positive output cable of the inverter/charger
(Cable “A”) is connected to the Positive battery post of the rst battery (Battery 1 in Fig 3.6) or to the
Positive battery post of the rst 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.
- All the individual batteries / battery strings will see the same series resistance.
- All the individual batteries will charge/discharge at the same charging/discharging current 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 rst battery (Battery 1 in Fig. 3.6) or to the Positive battery post of the rst 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 rst battery (Battery 1 as in Fig. 3.6) or to the Negative Post of the rst battery
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SECTION 3 | Installation
!
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.
ATTENTION!
Quand il y a 2 batteries/ls de batterie ou plus qui sont liés en parallèle et branché à la fois, à un
chargeur (Voir Figs. 3.6 et 3.7), il faut faire attention à la manière dont le chargeur est branché à la
banque de batterie. Veuillez assurer que le câble positif de sortie du chargeur de batterie (Câble A) est
lié à la borne positive de la première batterie (La batterie 1 dans la Fig. 3.6) ou à la borne positive de
batterie qui est liée au premier l (Le l 1 et la batterie 1, Fig 3.7), et puis le câble négatif de sortie du
chargeur de batterie (Câble B) est lié à la borne négative de la dernière batterie (La Batterie 4 dans la
Fig. 3.6) ou à la borne négative de batterie qui est liée au dernier l (Le l 2 et La batterie 4 dans la Fig.
3.7). Cette connexion assure la suivante:
- Les résistances des câbles interconnectés seront équilibrées
- Tous les batteries/ ls de batterie dans la série auront la même résistance
- Toutes les batteries individuelles vont recharger au même courant, ainsi elles seront rechargées à
l’état pareille, au même temps
- Aucune des batteries auront une condition de surcharge.
Si le câble positif de sortie du chargeur de batterie (Câble A) est lié à la borne positive de la première
batterie (La batterie 1 dans la Fig. 3.6) ou à la borne positive de batterie qui est liée au premier l (Le l
1 et La Batterie 1, Fig 3.7), et puis le câble négatif de sortie du chargeur de batterie (Câble B) est lié à la
borne négative de la première batterie (La batterie 1 dans la Fig. 3.6) ou à la borne négative de batterie
qui est liée au premier l (Le l 1 de La Batterie 1 dans la Fig. 3.7), les conditions anormales résulteront:
- Les résistances des câbles interconnectés seront pas équilibrées
- Tous les batteries/ ls de batterie dans la série n’auront pas la même résistance
- Toutes les batteries individuelles vont recharger à des courants différentes, ainsi elles atteindront
un état de rechargement complèt mais en décalage.
- La batterie ayant le moins de résistance dans la série prendrait moins de temps pour être
rechargée comparé aux autres batteries. Alors elle serait surchargée et, en conséquence aurait une
vie plus courte.
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SECTION 3 | Installation
3.5 DC SIDE CONNECTIONS
3 4
2
1
6
5
Fig 3.8 D.C Side Connections
LEGEND for Fig 3.8
1. Battery Positive (+) Input Connector (marked "BATTERY POSITIVE"): Stud and Nut, M8 (Pitch 1.25 mm) (RED Protection Cover 1(a) is
removed)
1a. RED Protection Cover For Battery Positive (+) Input Connector
2. Battery Negative (-) Input Connector (marked "BATTERY NEGATIVE"): Stud and Nut, M8 (Pitch 1.25 mm) (Black Protection Cover 2(a)
is removed)
2a. Black Protection Cover for Battery Negative (-) Input Connector
3. External Charger (+) Input Connector (marked "+ EXT. charger"): Stud and Nut, M6 (Pitch 1 mm)
4. External Charger (-) Input Connector (marked "– EXT. charger"): Stud and Nut, M6 (Pitch 1 mm)
5. DC Side Grounding Connector (marked "
connected to the metal chassis of the unit
6. RJ-45 Jack (marked "Battery Temp. Sensor") is used for 2 functions as follows:
a. For input from Temperature Sensor "EVO-BCTS" for temperature compensation when Battery Type 0 = Lead Acid is selected or,
b. For input for contact closure / opening signal from the Battery Management System (BMS) to Pins 4 and 5 of the Jack when Battery
Type 1 = Lithium is selected. When pins 4 and 5 are shorted due to contact closure, charging will stop in "Charging" Mode and
inverting will stop in "Inverting" Mode
") Hole Dia 6.5 mm for up to 25 mm2 (AWG #4). Set Screw M-8. This is internally
1a
Red
2a
Black
3.5.0 Making DC Side Connections
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 terminals are provided with
protective covers – RED for Positive and BLACK for Negative. Fit these covers once connections have been made.
For general details 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.
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.
DC Side Grounding Connector (5) is connected to the Earth ground / vehicle chassis ground as follows using
minimum AWG #6 wire size:
(i) to the Bus Bar "G-B" of the DC Electrical Panel (Fig 3.12)
(ii) to the Bus Bar "G-B" of the Grid Electrical Panel (Fig 3.13)
(iii) to the RV chassis ground in RV (Figs 3.14A and 3.14B)
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SECTION 3 | Installation
!
!
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 EVO1212F / EVO-1212F-HW, and 34 VDC for the 24V battery versions EVO-1224F and EVO-1224F-HW to prevent
permanent damage to the unit.
3.5.2 Preventing Reverse Polarity On The Input Side
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.
ATTENTION!
Au moment de faire les connexions de la batterie sur le côté entrée, assurez-vous que la polarité des
connexions de la batterie est correcte (Connecter la borne positive de la batterie à la borne positive
de l'unité et la valeur négative de la batterie à la borne négative de l'appareil). Si l'entrée est reliée à
l'inversion de polarité, DC externe fusible dans le côté d'entrée fera fondre et peut également causer
des dommages permanents à l'onduleur.
Dommages causés par l'inversion de polarité n'est pas couvert par la garantie.
3.5.3 Connection From Batteries / External Charge Controller To The DC Input Side – Sizing of
Cables And Fuses
WARNING!
The input 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 (–) terminal) 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.
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SECTION 3 | Installation
MISE EN GARDE!
La section d'entrée de l'onduleur possède une grande valeur condensateurs connectés à travers
les bornes d'entrée. Dès que la connexion d'entrée CC (boucle de la batterie (+) → le fusible
→ la borne d'entrée positive d'EVO → borne d'entrée négative de l'EVO → la batterie (–) est
terminée, ces condensateurs va démarrer la charge et l'appareil se tirer momentanément
actuelle très lourd qui va produire des étincelles sur le dernier contact de la boucle d'entrée
même lorsque l'appareil est en état hors tension.
Assurez que le fusible est insèrer seulement après que toutes les connexions sont faites dans le
boucle pour que des étincelles se produisent seulement à l’endroit du fusible.
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 undesirable 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 specic temperature e.g. 90˚C/194˚F. As current ow
produces heat that affects insulation, there is a maximum permissible value of current (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 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”.
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 re. Normally, the thickness of the cable should be such that the voltage drop due to the current
& the resistance of the length of the cable should be less than 2%. Use oil resistant, multi-stranded copper wire
cables rated at 90º 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:
• Lighting circuits - incandescent and Quartz Halogen: A 5% voltage drop causes an approximate 10% loss in
light output. This is because the bulb not only receives less power, but the cooler lament drops from white-hot
towards red-hot, emitting much less visible light.
• Lighting circuits - uorescent: Voltage drop causes a nearly proportional drop in light output.
• AC induction motors - These are commonly found in power tools, appliances, well pumps etc. They exhibit very
high surge demands when starting. Signicant 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 disproportionate loss of charge
current to charge a battery. A voltage drop greater than 5% can reduce charge current to the battery by a much
greater percentage.
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SECTION 3 | Installation
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 ow 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 re, damage
nearby objects and cause injury. To prevent occurrence of hazardous conditions 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 (As per UL Standard 248-15). This special purpose current limiting, 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.
WARNING!
It is mandatory to use appropriately sized external fuse in the battery and External Charger Circuits. 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.
MISE EN GARDE!
Il est obligatoire d’utiliser un fusible externe de taille appropriée à la batterie et les circuits chargeur externe .
Si le fusible externe est pas utilisé et les inversions de polarité est faite par la surveillance , la section d’entrée
de l’unité est endommagée / brûlé . La garantie sera annulée 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 & 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 specied in UL-1741 and NEC-2014. See details under “Notes for Table 3.1”.
3.5.6 DC Input Connection for External Solar Charge Controller
External charger is connected to terminals consisting of M12 Stud with Thumb Nut (3, 4 in Fig. 5.8).
External charger is connected to terminals consisting of M6 Stud (Pitch 1 mm) with Thumb Nut (3, 4 in Fig. 3.8).
- Max current fed through these terminals should be < 50A
- Use wire size given in Table 3.1.
- Tightening torque for the Thumb Nut is 35 kgf.cm (2.5 lbf.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.
- Please refer to Section 5.4 for details of charging using external solar charge controller.
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SECTION 3 | Installation
TABLE 3.1 SIZING OF BATTERY SIDE CABLES AND EXTERNAL BATTERY SIDE FUSES
Model No.
Rated
Continuous
DC Input
Current
(See Note 1)
NEC Ampac-
ity = 125%
of Rated DC
Input Current
at Column 2
(See Note 2)
90°C Copper Conductor. Size Based on NEC Ampacity
at Column (3) or 2%Voltage Drop, whichever is Thicker
(See Note 3)
Cable Running Distance
between the Unit and
the Battery
(Cable Routing In Free Air)
Up to 5 ft.
Up to 10 ft.
Cable Running Distance
between the Unit
and the Battery
(Cable Routing In Raceway)
Up to 5 ft.
External Fuse
Based on NEC
Ampacity at
Column (3)
(See Note 4)
Up to 10 ft.
(Column 1)
EVO-1212F
EVO-1212F-HW
EVO-1224F
EVO-1224F-HW
External Charger 50A 63A
(Column 2)
152 190 AWG #2 AWG #2/0 AWG #2/0 AWG #2/0 200A
76 95 AWG#6 AWG#4 AWG#3 AWG#3 100A
(Column 3)
(Column 4)
AWG #6
(2% voltage
drop is thicker)
(Column 5)
AWG #2
(2% voltage
drop is thicker)
(Column 6)
AWG #6
(Column 7)
AWG #2
(2% voltage
drop is thicker)
(Column 8)
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 4 to 7) are determined.
NEC Ampacity is not less than 125% of the Rated Continuous DC Input Current (Column 2) - Refer to NEC2014 (National Electrical Code) - Section 215.2(A)(1)(a) for Feeder Circuits.
3) Columns 4 to 7 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 specied 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 resistance 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).
4) Column 8 indicates the size of external fuse in the battery circuit. It is mandatory 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. Ampere rating of the fuse is based on the following considerations:
a) The Ampere rating of the fuse is not less than NEC Ampacity of 125% of the Rated Continuous DC Input
Current (Column 3) - Refer to NEC-2014 (National Electrical Code) - Section 215.3
b) Standard Ampere Rating of Fuse equal to the above NEC Ampacity of 125% of the Rated DC Input
Current 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 125% 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
70A
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SECTION 3 | Installation
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 rm and tight
connection. Choose lugs to t the wire size and the stud sizes on the inverter and battery ends.
Tightening torques to be applied to the wiring terminals are given in Table below:
TIGHTENING TORQUES
Battery Input Connectors External Charger Input Connectors AC Input and Output Connectors
70 kgf.cm
(5.0 lbf.ft)
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
efciency. For details, refer to Limiting Electro-Magnetic Interference" at Section 1.3.4.
35 kgf.cm
(2.5 lbf.ft)
7 to 12 kgf.cm
(0.5 to 0.9 lbf.ft)
3.6 AC INPUT AND OUTPUT - LAYOUT AND CONNECTION ARRANGEMENT
3.6.1 AC Input and Output Connections for EVO-1212F and EVO-1224F
3.6.1.1 AC Input Connection: Grid AC input is fed through 20A AC Inlet Plug Connector – IEC60320 C-20 (9, Fig
3.9.1). Use NEMA 20A-125 VAC detachable Power Cord [NEMA5-20 Plug for connecting to the 120VAC Outlet and
IEC60320 C-19 Socket Connector on the other end for connection to the Inlet Plug Connector (9, Fig 3.9.1)]. For
convenience, IEC60320 C-19 socket connector has been provided. (See Section 2.6 - Contents of Package).
10c
10b
10a
10d
14
15
10
9
Fig 3.9.1 AC Input and Output Connections – EVO-1212F and EVO-1224F
LEGEND for Fig 3.9.1
9. 20A AC Inlet Connector – IEC60320 C-20 for connecting
detachable AC power cord for 120 VAC input from Grid
10. NEMA5-15 Duplex GFCI Outlets for 120 VAC output
10a. GFCI Test Button
10b. GFCI Reset Button
10c. Red LED: GFCI Life and End Alarm
10d. Green LED: GFCI ON
14. AC output Breaker, 15A
15. AC Input Breaker, 20A
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SECTION 3 | Installation
3.6.1.2 AC Output Connection Through Ground Fault Circuit Interrupter (GFCI)
An un-intentional electric path between a source of current and a grounded surface is referred to as a “Ground Fault”.
Ground faults occur when current is leaking somewhere. In effect, electricity is escaping to the ground. How it leaks is
very important. If your body provides a path to the ground for this leakage (dry human body has a low resistance of only
around 1 K Ohm), you could be injured, burned, severely shocked or electrocuted. A Ground Fault Circuit Interrupter
(GFCI) protects people from electric shock by detecting leakage and cutting off the AC source. The leakage detection
circuit compares the current sent to the load and returned back from the load. If the returned current is less by 5 to 6
mA due to leakage, the GFCI trips. The GFCI also trips if it sees Neutral to Ground bond on the load side of the GFCI.
The AC output of EVO-1212F and EVO-1224F is available through a NEMA5-15R GFCI Duplex Receptacle (10 in Figs
2.1 and 3.9.1). The Neutral slot of this receptacle (longer rectangular slot) is internally bonded to the metal chassis of
the inverter.
Self Monitoring GFCI: The GFCI is “Self Monitoring Type” as per UL Standard Ul-943. As soon as the Inverter is switched
ON and 120 VAC is available on the internal Line Side of the GFCI, Red LED marked “Life End Alarm” (10c in Figs 2.1
and 3.9.1) will ash once and then will remain OFF. The Green LED (10d in Figs 2.1 and 3.9.1) will switch ON indicating
that AC power is available at the Load Side outlets.
As soon as the Inverter is switched OFF and 120 VAC is removed from the internal Line Side of the GFCI, Red LED
marked “Life End Alarm” (10c in Figs 2.1 and 3.9.1) will ash once and then will remain OFF. The Green LED (10d in
Figs 2.1 and 3.9.1) will switch OFF indicating that AC power is NOT available at the Load Side outlets.
The Self Monitoring Function inside the GFCI will monitor proper operation of ground fault protection circuitry every 1
to 10 minutes. If defect in the ground fault protection circuit is detected, the Red LED marked “Life End Alarm” (10c in
Figs 2.1 and 3.9.1) will remain ON and the GFCI will have to be replaced.
Monthly Testing of GFCI: Test the operation of the GFCI monthly as follows:
• Switch ON the inverter. As soon as 120 VAC output from the inverter is available on the internal Line Side of
the GFCI, Red LED marked “Life End Alarm” (10c in Figs 2.1 and 3.9.1) will ash once within 5 sec and then will
remain OFF. The Green LED (10d in Figs 2.1 and 3.9.1) will switch ON indicating that AC power is available at the
Load Side outlets.
• Plug a test lamp into the outlet and switch ON the test lamp.
• Press the “Test Button” (10a in Figs 2.1 and 3.9.1). The “Reset Button” (10b in Figs 2.1 and 3.9.1) will pop out.
The GFCI will be forced to trip and cut off AC power to the load side outlets. Green LED (10d in Figs 2.1 and
3.9.1) will switch OFF. The test lamp will also switch OFF.
• Press the “Reset Button” (10b in Figs 2.1 and 3.9.1). The GFCI will reset and AC power to the load side outlets
will be restored. Green LED (10d in Figs 2.1 and 3.9.1) will switch ON. The test lamp will also switch ON.
• If the above Test / Reset operation cannot be carried out, replace the GFCI.
GFCI Tripping and Reset: If there is a leakage of 5 to 6mA due to ground fault on the load side or , there is a Neutral
to Ground bond on the load side, the GFCI will trip and the “Reset Button” (10b in Figs 2.1 and 3.9.1) will pop out. AC
power to the load side outlets will be cut off. Green LED (10d in Figs 2.1 and 3.9.1) will switch OFF. Remove the ground
fault in the load circuit. Press the “Reset Button” (10b in Figs 2.1 and 3.9.1). The GFCI will reset and AC power to the
load side outlets will be restored. Green LED (10d in Figs 2.1 and 3.9.1) will switch ON.
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SECTION 3 | Installation
i
!
!
INFO
For the Reset Button (10b in Figs 2.1 and 3.9.1) to operate, the Inverter has to be in ON condition so that
AC power is available to the internal Line Side of the GFCI.
CAUTION!
1. Do not feed the output from the GFCI receptacle to a Panel Board / Load Center where the Neutral is
bonded to the Earth Ground. This will trip the GFCI.
2. If an extension cord is used, please ensure that the cord is 2-Pole Grounding Type (3 pin).
ATTENTION!
N'alimentent pas la sortie de la prise GFCI à un Panel de sélection / Charger Centre où la
1.
position neutre est lié à la terre. Ce qui déclenche le disjoncteur.
2. Si une rallonge est utilisée, veuillez vous assurer que le cordon est mise à la terre à 2 pôles (3 broches)
3.6.2 AC Input and Output Connections and Layout Arrangement for EVO-1212F-HW and
EVO-1224F-HW
AC input and output connections for EVO-1212F-HW and EVO-1224F-HW are shown in Figs 3.9.2(a) and 3.9.2(b)
below. (Extracted from the layout at Fig 2.3).
20
26 25 24 23 22 21
28
19a
Fig 3.9.2(a) Pocket for AC Input and
Output Connections for EVO-1212F-HW
and EVO1224F-HW
27
2 holes (27.8 mm / 1 /32" diameter) for 3/4"
Trade Size Fitting for cable or conduit entry.
27.8 mm
"
1 /
32
Fig 3.9.2(b) Cover Plate for Pocket for
AC input and Output Connections
19b
50 mm 30 mm
Hole for
M3 screws
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SECTION 3 | Installation
LEGEND for Figs 3.9.1(a) and 3.9.1(b)
19(a). Pocket for AC Input/Output Terminals
19(b). Plate to cover pocket 19(a) - The plate is held with 4 mounting screws - M3 (Pitch 0.5 mm) x 6 mm. The plate has 2 holes (27.8 mm/ 1
3/32" diameter) for 3/4" Trade Size Fitting for cable or conduit entry.
20. AC Input/Output Terminal Block
- Terminal hole: 3.5 mm x 3.0 mm for up to AWG #10
- Set Screw: M3 (Pitch 0.5 mm)
21. "INPUT L" - For connecting Line Conductor of AC input wiring
22. "INPUT N" - For connecting Neutral Conductor of AC input wiring
23. "INPUT GND" - For connecting Earth Ground Conductor of AC input wiring
24. "OUTPUT L" - For connecting Line Conductor of output wiring to Electrical Panelboard
25. "OUTPUT N" - For connecting Neutral Conductor of output wiring to Electrical Panelboard
26. "OUTPUT GND" - For connecting Earth Ground Conductor of output wiring to Electrical Panelboard
27. Male/Female Insulated Quick Disconnect for disabling Output Neutral to chassis Ground bond in Inverter Mode (Please see Sections 4.4.1
/ 4.4.2 and Fig 4.1)
28. AC input and output Ground connection to metal chassis - Stud and Nut, M4 (Pitch 0.7 mm)
3.6.3 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 Switching Relay” [Relay RY2 in
Fig 4.1].
• In “Charging Mode”, the internal “Output Neutral to Chassis Switching Relay - RY2” disconnects
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.
• 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 Insulated Male/Female Quick Disconnect [27, Fig 3.9.2(a)]
located in the AC Wiring Compartment in EVO-1212F-HW/1224F-HW. In EVO-1212F/1224F, this
Insulated Male/Female Quick Disconnect is accessible after opening the top cover of the unit.
• 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 4.4.1/ 4.4.2 and Fig 4.1.
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MISE EN GARDE!
• En état de défaut, le neutre de la sortie CA de l’unité dans le “Mode de l’onduleur / décharge” obtient
lié au châssis métallique de l’unité à travers la interne “Neutre à châssis relais de commutation” (RY2 Relais
de la gure 4.1)
• Dans “Mode de chargement”, l’interne “Neutre à châssis relais de commutation - RY2” déconnecte le
neutre de la connexion de sortie AC du châssis de l’unité. Le neutre de la connexion de sortie CA de l’unité
va obtenir lié à la terre des masses à travers le neutre à la terre liaison au sol dans le centre de panneau de
disjoncteurs AC / charge alimenter Grille / connexions de sortie CA du générateur.
• Désactivation du lien neutre à mise a terre: Dans certaines applications, il est nécessaire que la
sortie neutre soit isolé du châssis/mise a terre à tout moment. Pour cela, la production automatique de
la position neutre à la masse du châssis bon peut être désactivé en déconnectant le mâle/femelle isolée
[Déconnexion rapide, 27 Fig 3.9.2(a)] situé dans le compartiment de câblage AC dans EVO-1212F-
HW/1224F-HW. Dans EVO-1212F/1224F, ce mâle/femelle isolée est accessible à déconnexion
rapide après l'ouverture du capot de l'unité.
• Mise à la terre du système, tel que requis par la National / codes électriques locaux / normes, est de la
responsabilité de l’installateur utilisateur / système.
3.6.4 AC Input Considerations – Voltage And Frequency
The EVO™ unit is designed to accept 120 VAC, 60 Hz single phase AC power from Grid or from good quality Generator
with stable 120 VAC / 60 Hz output. These 120V versions come preset for 60 Hz operation.
3.6.5 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 damage the output section of the unit and may also pose a re 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
rst 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.
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SECTION 3 | Installation
MISE EN GARDE!
La sortie de courant alternatif de l’unité ne peut pas être synchronisée avec une autre source de courant
alternatif et, par conséquent, il ne convient pas pour mise en parallèle du côté de la sortie. La sortie AC de
l’unité ne doit jamais être connecté directement à un panneau central / de charge disjoncteur électrique
qui est également alimenté par une autre source de courant alternatif. Une telle connexion peut entraîner
un fonctionnement parallèle de différentes sources d’énergie et la puissance AC de l’autre source de
courant alternatif est réinjecté dans l’unité qui va instantanément endommager la section de sortie de
l’unité et peuvent aussi poser un risque d’incendie et de sécurité. Si un centre panneau de disjoncteur
électrique / charge est alimentée à partir de cette unité et ce panneau est également nécessaire pour être
alimenté à partir de suppléant supplémentaire source de courant alternatif, l’alimentation de la source de
courant alternatif supplémentaire doit d’abord être introduit dans un manuel approprié / commutateur
de transfert automatique et le sortie du commutateur de transfert doit être relié au centre panneau / de
la charge électrique du disjoncteur. Pour éviter possibilité de mise en parallèle et de graves dommages à
l’onduleur, ne jamais utiliser un câble de raccordement simple avec une che mâle sur les deux extrémités
pour raccorder la sortie AC de l’onduleur à une prise murale à portée de main à la maison / RV.
3.6.6 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 re.
A split phase transformer (Isolated or Auto-transformer) of suitable VA rating (25 % 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 output of the inverter should be fed to the Primary of this transformer
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 Multiwire Branch Circuits” at: www.samlexamerica.com (Home > Support > White Papers).
3.7 AC INPUT & OUTPUT WIRING SUPPLY CONNECTIONS
3.7.1 AC Input/Output Supply Connections for EVO-1212F and EVO-1224F
120 VAC input is fed through Male AC Power Inlet Plug - Rating 20A (IEC 60320 C-20) (9, Fig 2.1). Mating Female
Socket Connector rated for 20A (IEC 60320 C-19) will be required. For convenience, this Connector has been supplied
with the unit (See Section 2.6 - "Contents of Package"). The AC input connector is protected against over-current by
20A Circuit Breaker (15, Fig 2.1).
120 VAC output is supplied through NEMA5-15 Duplex GFCI Outlets (10, Fig 2.1). The outlets are protected against
over current by 15A Circuit Breaker (14, Fig 2.1).
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3.7.2 AC Input / Output Supply Connectios – EVO-1212F-HW / EVO-1224F-HW
WARNING!
Please ensure that when using the hard-wired version EVO-1212F/1224F-HW, the AC input 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
conductors have been erroneously connected to the AC output terminals instead of AC input terminals. If
this wrong connection is detected, (voltage > 10 VAC is seen on terminals OUTPUT L & OUTPUT N 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 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 re hazard.
MISE EN GARDE!
Veuillez vous assurer que lors de l'utilisation de la version laire EVO-1212F/1224F-HW, l'entrée
CA est connecté à l'entrée aux bornes et non pas à l'AC bornes de sortie et que cette connexion
est effectuée uniquement lorsque l'appareil est en position d'arrêt.
Lorsque l'unité est sous tension, un test automatique est effectué qui inclut une vérication si l'entrée CA
par erreur ont été conducteurs connectés à l'AC les terminaux de sortie au lieu d'AC les bornes d'entrée.
Si cette erreur est détectée, (tension > ; 10 VAC est perçu sur les bornes OUTPUT L & ; SORTIE N au
moment de la mise en marche de l'unité), l'appareil ne sera pas mis sous tension et un message "Défaut
de sortie" s'afche. Cette protection contre l'erreur lors de la connexion de l'entrée CA câblage est actif
seulement quand cette mauvaise connexion est établie lorsque l'appareil est en position d'arrêt et est
activée par la suite.
Si l'entrée CA est connecté par erreur / nourri à l'AC de sortie lorsque l'appareil est en état, la
protection ci-dessus ne fonctionnera pas et la Section de l'onduleur sera brûlé instantanément
et peut devenir un risque d'incendie.
The AC input and output supply connections are located in a pocket protected by a cover with a removable front
plate [19(a), Fig 3.9.2(a) and 19(b), Fig 3.9.2(b)]. Two 27.8 mm / 13/32” diameter holes [19(b), Fig 3.9.2(b)] have been
provided for cable / conduit entry. Remove the caps covering the holes and install appropriate ¾” Trade Size Fitting for
routing the AC input and output wires/conduits.
Screw down type of terminal block [20, Fig 3.9.2(a)] is used for connecting the wires. The hole size for wire entry is
3.5 x 3 mm and set screw size is M3. It can accommodate conductors with solid or multi-stranded wire size range of
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SECTION 3 | Installation
up to AWG #10. 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, "Contents of Package") for rm connection
under the set screw. Insert the bare end of the wire into the barrel portion of the Wire End Terminal & crimp barrel
portion using suitable crimping tool (Fig 3.11). Use #12 AWG terminals for AWG #12 wiring for AC input and AWG
#14 terminals for AWG #14 wiring for AC output. Insert the terminated end of the wire fully into the terminal slot till it
stops. Tighten the screw rmly. Tightening torque for the screws – 7 to 12 Kgf*cm / 0.5 to 0.9 lbf*ft.
Crimp Barrel Portion
↓
→
Stripped Wire End
Fig 3.11 Stripped Wire End Terminal on AC Wiring
3.8 SIZING OF WIRING AND BREAKERS - AC INPUT SIDE
WARNING!
For EVO-1212F-HW/ 1224F-HW, AC Breaker for the AC input circuits has NOT been provided internally.
This has 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.
MISE EN GARDE!
Pour EVO-1212F-HW/ 1224F-HW, Breaker AC pour les circuits d’entrée AC ont pas été fournis en
interne. Cela doit être fournie en externe par l’installateur / utilisateur en fonction des directives
données ci-dessous. Se il vous plaît noter que les directives ci-dessous sur dimensionnement des câbles
et protection contre les surintensités seront remplacées par les nationaux / codes électriques locaux
applicables.
Wire End Terminal
3.8.1 Table for Wire and Breaker Sizing - AC Input Side
Table 3.2 provides details of wire and breaker sizing for the AC input side.
AC input side wiring and breaker sizes depend upon the maximum continuous AC input current under various
operating conditions described in the succeeding paragraphs.
When Grid input is available and the unit is operating in Charging / Pass Through Mode, the AC Input Current
will be determined as follows:
AC Input Current will be equal to the sum of the AC Side Battery Charging Current and the Pass Through
current.
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The AC Input current in Charging / Pass Through Mode will be restricted by the breaker in the AC Input
Branch Circuit that is feeding the unit. The AC Input Current drawn by the unit can be programmed to the
desired "GRID MAX CURRENT" to match the Amp rating of breaker in the AC Input Branch Circuit. Optional
Remote Control EVO-RC-PLUS is required to change this limit [See EVO-RC-PLUS Manual: (i) Fig 4.3, Screen 2
(ii) Table 4.4 Screen 2 and (ii) Section 4.5.2.2]. The "GRID MAX CURRENT" set at 20A (Default Setting).
TABLE 3.2 SIZING OF AC INPUT WIRING AND BREAKERS
Model No.
(Rated Output Power
in Inverter Mode)
(Column 1)
Current Rating of AC In-
put Breaker (15, Fig 2.1)
(See Note 2)
(Column 2)
NEC Ampacity = 125%
of Column 2
(See Note 3)
(Column 3)
Conductor Size Based
on NEC Ampacity
at Column 3
(See Note 4)
(Column 4)
Size of Breaker
based on Column 4
(See Note 5)
(Column 5)
EVO-1212F
(1200VA, 10A)
EVO-1212F-HW
(1200VA, 10A)
EVO-1224F
(1200VA, 10A)
EVO-1224F-HW
(1200VA, 10A)
20A 25A AWG #12 20A
20A 25A AWG #12 20A
20A 25A AWG #12 20A
20A 25A AWG #12 20A
NOTES FOR TABLE 3.2 - SIZING OF GRID AND BREAKERS
1. Column 1 indicates the Model No. & output power (VA) & current (A) in Inverter Mode.
2. Column 2 indicates the Maximum AC Input Current of 20A which is equal to 20A rating of AC input
breaker (15, FIg 2.1)
3. Column 3 indicates NEC Ampacity based on which the wiring conductor size (Column 4) is determined.
This NEC Ampacity is not less than 125% of the maximum input current
(Column 2) - Refer to NEC-2014 (National Electrical Code) - Section 210.19(A)(1)(a)
regarding minimum Ampacity and size of Branch Circuit Conductors.
4. a. For EVO-1212F-HW and EVO-1224F-HW: Column 4 indicates the wiring conductor size that has
been determined based on NEC-2014 (National Electrical Code) - Ampacity Table 310.15(B)(16) for
Raceway for EVO-1212F and EVO-1224F-HW. This conductor size is based on (i) NEC Ampacity
(Column 3) (ii) conductor temperature of 75°C / 167°F and (iii) ambient temperature of 30°C / 86°F.
b. For EVO-1212F and EVO-1224F: Power may also be supplied through NEMA rated 20A-125V
detachable Power Cord (3 conductors, AWG #12) for free air - Ampacity Table 310.15(B)(17)
5. Column 5 indicates the Amp rating of AC input breaker. EVO-1212F/EVO-1224F have built-in 20A breaker
(15, Fig 2.1). External 20A AC input breaker is required to be installed for EVO-1212F-HW/1224F-HW.
The Amp rating of this breaker is based on the following considerations:
a. The Amp rating of the fuse has to be ≤ the Ampacity of wire size at Column 4. 20A rating has been
selected based on Column 2.
b. Closest Standard Ampere Rating of Breaker (20A) has been used - Refer to NEC-2014 (National
Electrical Code) - Section 240.6(A) regarding over current protection
c. Type of external AC input breaker (for EVO-1212F-HW / 1224F-HW) : Standard circuit breaker for 120
VAC Load Center/Breaker Panel/Panel Board
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3.9 SIZING OF AC OUTPUT WIRING AND BREAKERS
3.9.1 EVO-1212F and EVO-1224F
120 VAC output is supplied through NEMA5-15 Duplex GFCI Outlets (15, Fig 2.1). The outlets are protected against
over current through 15A Circuit Breaker (14, Fig 2.1).
Use power cord with NEMA5-15 plug and conductor size AWG #14.
3.9.2 EVO-1212F-HW and EVO-1224F-HW
WARNING!
For EVO-1212F-HW and EVO-1224F-HW, 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.
MISE EN GARDE!
Pour EVO-1212F-HW and EVO-1224F-HW breakers AC pour les circuits d’entrée AC ont pas été fournis
en interne. Ceux-ci doivent être fournies à l’extérieur par l’installateur / utilisateur sur la base des
directives données ci-dessous. Se il vous plaît noter que les directives ci-dessous sur dimensionnement
des câbles et protection contre les surintensités seront remplacées par les nationaux / codes électriques
locaux applicables.
Table 3.3 provides details of wire and breaker sizing for the AC output side for EVO-1212F-HW and EVO-1224F-HW.
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).
TABLE 3.3 SIZING OF AC OUTPUT WIRING AND BREAKERS
Model No. and Rated
Output Power in
Inverter Mode
(Column 1)
EVO-1212F-HW
(1200VA)
EVO-1224F-HW
(1200VA)
Rated AC Output
Current in Inverter
Mode
(See Note 2)
(Column 2)
10A 12.5A AWG #14 15A
10A 12.5A AWG #14 15A
NEC Ampacity =
125% of Column 2
(See Note 3)
(Column 3)
Conductor Size based
on NEC Ampacity at
Column 3
(See Note 4)
(Column 4)
Size of Breaker
(Column 5)
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NOTES FOR TABLE 3.3 - AC OUTPUT WIRING AND BREAKERS
1) Column 1 indicates Model No and Output Power (VA)
2) Column 2 indicates the Rated AC Output Current in Inverter Mode
3) 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(A)(1)(a) 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 feeding power to the Load Center / Breaker Panel on the
load side. Hence, the AC output circuit of the unit is considered to be a Feeder Circuit for purposes of NEC-2014.
4) 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.
5) Column 5 indicates the Amp rating of breaker. Following should be considered:
a) Ampere rating should not be less than NEC Ampacity (Column 3) - Refer to NEC-2014 (National Electrical Code)
- Section 215.3 regarding over-current protection of Feeder Circuit Conductors
b) Closest Standard Breaker Ampere Rating of 15A has been used - Refer to NEC-2014 (National Electrical Code) -
Section 240.6(A) regarding Standard Ampere Ratings
c) As Standard Breaker Rating does not match the required NEC Ampacity at Column 3 (12.5A), the next higher
Standard Ampere Rating of the breaker (15A) 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 120 VAC Load Center /Breaker Panel
e) EVO-1212F and EVO-1224F use built-in Breaker (14, Fig 2.1). External 15A Breaker is required to be used for
EVO-1212F-HW / 1224F-HW.
3.10 GFCI PROTECTION FOR VEHICLE APPLICATION
When EVO-1212F-HW and EVO-1224-HW are installed in vehicles, ensure that Ground Fault Circuit Interrupter(s)
are installed in the vehicle wiring system to protect all branch circuits. Details of tested and approved GFCI’s are
given in Table 1.5.
EVO-1212F and EVO-1224F have built-in GFCI outlet.
3.11 GROUNDING TO EARTH OR TO OTHER DESIGNATED GROUND
INFO
Please read following on-line White Papers for complete understanding of Grounding at www.
samlexamerica.com (Home > Support > White Papers):
• “Grounded Electrical Power Distribution"
• “Grounding System and Lightning / Ground Fault Protection”
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Grounding means connecting (bonding) to Earth Ground or to the other designated Ground. For example, in a
motorhome / caravan, the metal frame of the motorhome / caravan is normally designated as the Negative DC Ground
/ RV Ground. Similarly, all metal portions of boats and marine craft are bonded together and called Boat Ground.
Grounding is required for (i) protection against damage due to lightning strike and (ii) protection against electric shock
due to “Ground Fault”. In case of EVO™, “Ground Fault” may occur due to inadvertent contact between an energized
ungrounded current carrying conductor and exposed metal surface resulting in voltage getting fed to (i) the metal
chassis of the EVO™ or (ii) to the metal chassis of the devices connected to EVO™ or (iii) to the metal frame/ chassis
in an RV / motorhome / caravan. When this energized exposed surface is touched, the voltage will drive current
through the body to Earth Ground producing electric shock. When properly grounded to Earth Ground (or Frame /
Chassis Ground in motorhome or caravan), the Leakage Current Protection Device (like RCD, GFCI etc.) or Over Current
Protection Device (like Circuit Breaker or Fuse) will trip and interrupt the circuit feeding power from the AC source
(EVO™ / AC Input) or the DC source (12V / 24V battery). Proper grounding will ensure that all exposed metal surfaces
will have equal potential and will be bonded to (i) a single common Earth Ground point i.e. the Ground Rod / buried
metallic water / gas pipe at the premises or (ii) the Frame / Chassis Ground in a motorhome / caravan.
3.12 GROUNDING ARRANGEMENT
Internally, EVO™ consists of DC and AC Section that are isolated through a transformer (See these sections in Figs 3.12
and 3.13). Both these sections are required to be grounded appropriately.
For wiring details for appropriate grounding, refer to Figs 3.12 and 3.13, and associated explanation under Section 3.13
and 3.14.
When using a generator instead of Grid, please ensure that the Neutral of the generator is bonded to the metal frame
of the generator and the metal frame of the generator is bonded to Earth Ground through the Grounding Electrode
(GE) i.e. the Ground Rod. Refer to Section 3.14.1 for additional details.
3.13 DC SIDE GROUNDING
Please refer to Figs 3.12 and 3.13.
DC side grounding involves bonding of the metal frame/chassis of EVO™, the metal chassis of the DC Electrical Panel
and the Battery Negative Terminal to Earth Ground in shore based installation (Fig 3.12) or to the metal frame / “Chassis
” of the motorhome / caravan (Fig 3.13). This ensures that in case of a ground fault in the +12V / +24V circuit, the
fuse in the +Battery line blows to clear the fault. This fuse in the +Battery line has Ampere capacity matching the rated
DC input current of the EVO™ in Inverter Mode. The wire size used for DC side grounding should be minimum AWG
#6 or of the same size as the battery cable, whichever is thicker (Battery cable size should have minimum Ampacity ≥
the Ampere rating of this battery fuse depending upon the model of the EVO™ being used). This recommendation
on sizing of the DC Side Grounding Wire will be superseded by the National / Local Electrical Codes.
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CAUTION!
As per American Boat and Yacht Council (ABYC) Standard E-11 for AC and DC Electrical Systems on Boats,
the size of DC side grounding wire shall not be smaller than one size under that required for current carrying
conductors supplying the device. Hence, for application on EVO™ on boat / yacht, the size of the DC side
grounding conductor should be of the same or one size smaller than the size of battery cable specied in Table 3.1.
ATTENTION!
Selon le « American Boat and Yacht Council » (ABYC) la norme E-11 pour le système électrique CA et
CC des bateaux, la taille du l de mise à la terre du côté CC ne doit pas être inférieure à un format sous
celle requise pour les conducteurs tenant le courant pour alimenter l'appareil. Par conséquent, pour
l’application EVO™ sur le bateau / yacht, la taille du conducteur de mise a terre côté CC devrait être de la
même ou strictement une taille plus petite que la taille du câble de batterie indiqué dans le tableau 3.1.
INFO
As described at Section 3.14, the metal frame / chassis of the EVO™ [Figs 3.12 and 3.13] is bonded to the
Earth Ground "GE" (Ground Rod) for AC side grounding. It may be argued that if the metal frame / chassis of
EVO™ is already bonded to Main Earth Ground "GE" for AC side grounding, why is it necessary to provide
additional DC side grounding wiring? [Wiring that bonds DC Grounding Terminals "5", "G-B" and GE in Figs
3.12 and 3.13]. If separate thicker grounding wire of the same size as the battery cable was not provided for
the DC side grounding and there was a ground fault in the battery circuit, very large DC fault current from
Battery+ would ow through the smaller size AC grounding wires to the Battery Negative through Earth
Ground. These smaller size AC side grounding wires would be damaged due to very high DC side fault current
(100A to 200A depending on the Model of the EVO™ being used).
A DC Side Grounding Connector (5) (5 in Figs 2.1 and 3.8) is provided for connecting to the System Ground. The
connector can accept wire sizes AWG # 4–6. The set screw size is M6.
A DC Distribution Panel, as shown in Figs 3.12 and 3.13, 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 of the DC Electrical Panel which, in turn, is connected to
its Grounding Bus Bar (G-B). Grounding Bus Bar G-B of the DC Electrical Panel is further bonded to the Grounding Bus
Bar "G-B" of the Grid Electrical Panel and then to the Grounding Electrode (GE), also called Ground Rod. Hence, the
Battery Negative, the chassis of the DC Electrical Panel and the metal chassis of the EVO™ will all be bonded to the
Earth Ground.
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Connect the DC Grounding Terminal (5) [5 in Figs 2.1 and 3.8], to the Grounding Bus Bar (G-B) in the DC Electrical Panel
using AWG #6 insulated stranded copper wire. Similarly, use AWG #6 wire to connect the Grounding Bus Bar "G-B"
in the DC Electrical Panel to the Grounding Bus Bar "G-B" in the Grid Electrical Panel. For application of EVO™ on a
boat, the size of this wire should be of the same size or one size smaller than the battery Negative wire (See CAUTION!
above).
The connections must be tight against bare metal. Use star washers to penetrate paint and corrosion. As the Equipment
Grounding Bus Bar ("G-B") in the DC Electrical Panel is bonded to the Grounding Electrode (GE) through
Grounding Bus Bar "G-B" in the Grid Electrical Panel, the metal chassis of the EVO™ will be bonded to Earth
Ground for protection against Ground fault on the DC side of EVO™.
3.14 AC SIDE GROUNDING
3.14.1 AC Side Grounding Requirements for Generators
Small portable generators supplied with receptacles will often have the Neutral conductor bonded to the generator
frame. The frame of portable generator is normally isolated from the Earth Ground.
Larger generators typically do not have the Neutral grounded to the frame. It is to be ensured that in these generators,
the Neutral should be connected to the metal frame of the generator.
WARNING!
If a Generator is used to feed AC input, it is to be ensured that the Neutral of the Generator output is
bonded to the metal frame of the Generator.
MISE EN GARDE!
Si un générateur est utilisé pour envoyer de l'entrée CA, c'est de s'assurer que la position neutre de la
sortie du générateur est lié à la structure métallique du générateur.
3.14.2 AC Side Grounding of Typical Shore Based Installation
3.14.2.1 EVO-1212F and EVO-1224F: AC Side Grounding of Typical Shore Based Installation
Refer to the Installation Diagram for Typical Shore Based Installation for EVO-1212F and EVO-1224F at Fig 3.12.
a) AC Input Grounding: The metal chassis of EVO™ gets bonded to the Grounding Electrode (GE) / Ground Rod of
the premises as follows:
• The metal chassis of EVO™ is connected to the Grounding Pin (G) of the AC Power Inlet Plug (9)
• The Grounding Pin (G) of the AC Power Inlet Plug (9) gets connected to the Grounding Bus Bar (G-B) in the
Grid Electrical Panel through the grounding wire of AC input connection
• The Grounding Bus Bar (G-B) in the Grid Electrical Panel is bonded to Earth Ground through the Grounding
Electrode (GE) / “Ground Rod” of the premises.
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b) AC Output Grounding: The metal chassis of the AC load(s) get connected to the Grounding Electrode (GE) /
Ground Rod of the premises as follows:
• The metal chassis of the AC load(s) is connected to the Grounding socket (G) of the GFCI outlet (10) in EVO™
through the Grounding Conductor of the load connection
• Grounding socket (G) of GFCI outlet “10” in EVO™ is connected to the metal chassis of EVO™.
• The metal chassis of EVO™ is connected to the Grounding Pin (G) of the AC Power Inlet Plug (9)
• The grounding Pin (G) of the AC Power Inlet (9) gets connected to the Grounding Bus Bar (G-B) in the Grid
Electrical Panel through the grounding wire of AC input connection
• The Grounding Bus Bar (G-B) in the Grid Electrical Panel is bonded to Earth Ground through the Grounding
Electrode (GE) / “Ground Rod” of the premises
3.14.2.2 EVO-1212F-HW and EVO-1224F-HW: AC Side Grounding of Typical Shore Based Installation
Refer to the Installation Diagram for Typical Shore Based Installation for EVO-1212F-HW and EVO-1224F-HW at Fig 3.13
a) AC Input Grounding: The metal chassis of EVO™ gets bonded to the Grounding Electrode (GE) / “Ground Rod”
of the premises as follows:
• The metal chassis of EVO™ is connected to the “INPUT GND” Terminal (23) of the AC Input / Output Terminal
Block (20) in EVO™
• The “INPUT GND” Terminal (23) of the AC Input / Output Terminal Block (20) in EVO™ gets connected to the
Grounding Bus Bar (G-B) in the Grid Electrical Panel through the grounding wire of AC input connection
• The Grounding Bus Bar (G-B) in the Grid Electrical Panel is bonded to Earth Ground through the Grounding
Electrode (GE) / “Ground Rod” of the premises
b) AC Output Grounding: The metal chassis of the AC load(s) gets connected to the Grounding Electrode (GE) /
“Ground Rod” of the premises as follows:
• The metal chassis of the AC load(s) is connected to the Grounding Bus Bar (G-B) of the Electrical Sub Panel for
EVO™ Output
• Grounding Bus Bar (G-B) of the Electrical Sub Panel for EVO™ Output is connected to metal chassis of EVO™
through the “OUTPUT GND” Terminal (26) of the AC Input / Output Terminal Block (20) in EVO™.
• The metal chassis of EVO™ is connected to the “INPUT GND” Terminal (23) of the AC Input / Output Terminal
Block (20) in EVO™
• The “INPUT GND” Terminal (23) of the AC Input / Output Terminal Block (20) in EVO™ gets connected to the
Grounding Bus Bar (G-B) in the Grid Electrical Panel through the grounding wire of AC input connection
• The Grounding Bus Bar (G-B) in the Grid Electrical Panel is bonded to Earth Ground through the Grounding
Electrode (GE) / “Ground Rod” of the premises
3.14.3 AC Side Grounding of Typical RV / Mobile Installation
3.14.3.1 EVO-1212F and EVO-1224F: AC Side Grounding of Typical RV / Mobile Installation
Refer to the Installation Diagram for Typical RV / Mobile Installation for EVO-1212F and EVO-1224F at Fig 3.14.
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a) AC Input Grounding: The metal chassis of EVO™ gets bonded to (i) the RV / Vehicle Chassis Ground when not
connected to Grid Power and (ii) to the Grounding Electrode (GE) / Ground Rod of the Grid Power System of the
premises when connected to Grid Power through the Grid Power Supply Cord as follows:
• The metal chassis of EVO™ is connected to the Grounding Pin (G) of the AC Power Inlet Plug (9)
• The Grounding Pin (G) of the AC Power Inlet Plug (9) gets connected to the Grounding Bus Bar (G-B) in the
Electrical Panel of the RV / vehicle through the grounding wire of AC input connection.
• The Grounding Bus Bar (G-B) in the Electrical Panel of the RV / vehicle is bonded to the RV / Vehicle Chassis
Ground. When the RV / vehicle is connected to the Grid through the Grid Power Inlet and Cord, the RV /
Vehicle Chassis Ground gets bonded to the Earth Ground of the premises through the Grounding Electrode
(GE) / “Ground Rod” of the premises of the Grid Power System supplying the RV / Vehicle .
b) AC Output Grounding: The metal chassis of AC load(s) gets bonded to (i) the RV / Vehicle Chassis Ground
when not connected to Grid Power and (ii) to the Grounding Electrode (GE) / Ground Rod of the Grid Power
System of the premises when connected to Grid Power through the Grid Power Supply Cord as follows:
• The metal chassis of the AC load(s) is connected to the Grounding socket (G) of the GFCI outlet (10) in EVO™
through the Grounding Conductor of the load connection
• Grounding socket (G) of GFCI outlet “10” in EVO™ is connected to the metal chassis of EVO™.
• The metal chassis of EVO™ is connected to the Grounding Pin (G) of the AC Power Inlet Plug (9)
• The grounding Pin (G) of the AC Power Inlet (9) gets connected to the Grounding Bus Bar (G-B) in the
Electrical Panel of the RV / vehicle through the grounding wire of AC input connection.
• The Grounding Bus Bar (G-B) in the Electrical Panel of the RV / vehicle is bonded to the RV / Vehicle Chassis
Ground. When the RV / vehicle is connected to the Grid through the Grid Power Inlet and Cord, the RV /
Vehicle Chassis Ground gets bonded to the Earth Ground of the premises through the Grounding Electrode
(GE) / “Ground Rod” of the premises of the Grid Power System supplying the RV / Vehicle
3.14.3.2 EVO-1212F-HW and EVO-1224F-HW:
Refer to the Installation Diagram for Typical RV / Mobile Installation for EVO-1212F-HW and EVO-1224F-HW at Fig 3.15.
a) AC Input Grounding: The metal chassis of EVO™ gets bonded to (i) the RV / Vehicle Chassis Ground when not
connected to Grid Power and (ii) to the Grounding Electrode (GE) / Ground Rod of the Grid Power System of the
premises when connected to Grid Power through the Grid Power Supply Cord as follows:
• The metal chassis of EVO™ is connected to the “INPUT GND” Terminal (23) of the AC Input / Output Terminal
Block (20) in EVO™
• The “INPUT GND” Terminal (23) of the AC Input / Output Terminal Block (20) in EVO™ gets connected to the
Grounding Bus Bar (G-B) in the Electrical Panel of the RV through the grounding wire of AC input connection
• The Grounding Bus Bar (G-B) in the Electrical Panel of the RV / vehicle is bonded to the RV / Vehicle Chassis
Ground. When the RV / vehicle is connected to the Grid through the Grid Power Inlet and Cord, the RV /
Vehicle Chassis Ground gets bonded to the Earth Ground of the premises through the Grounding Electrode
(GE) / “Ground Rod” of the premises of the Grid Power System supplying the RV / Vehicle
b) AC Output Grounding: The metal chassis of the AC load(s) gets bonded to (i) the RV / Vehicle Chassis Ground
when not connected to Grid Power and (ii) to the Grounding Electrode (GE) / Ground Rod of the Grid Power
System of the premises when connected to Grid Power through the Grid Power Supply Cord as follows:
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• The metal chassis of the AC load(s) is connected to the Grounding Bus Bar (G-B) of the Electrical Sub Panel for
EVO™ Output
• Grounding Bus Bar (G-B) of the Electrical Sub Panel for EVO™ Output is connected to metal chassis of EVO™
through the “OUTPUT GND” Terminal (25) of the AC Input / Output Terminal Block (20) in EVO™.
• The metal chassis of EVO™ is connected to the “GRID GND” Terminal (22) of the AC Input / Output Terminal
Block (20) in EVO™
• The “INPUT GND” Terminal (23) of the AC Input / Output Terminal Block (20) in EVO™ gets connected to the
Grounding Bus Bar (G-B) in the Electrical Panel of the RV / vehicle through the grounding wire of AC input
connection
• The Grounding Bus Bar (G-B) in the Electrical Panel of the RV / vehicle is bonded to the RV / Vehicle Chassis
Ground. When the RV / vehicle is connected to the Grid through the Grid Power Inlet and Cord, the RV /
Vehicle Chassis Ground gets bonded to the Earth Ground of the premises through the Grounding Electrode
(GE) / “Ground Rod” of the premises of the Grid Power System supplying the RV / Vehicle
• Thus, in keeping with the NEC requirements, the AC Grounds of EVO™ and the Grid Electrical Panel
will be bonded to the Earth Ground only at one single point at the Grid Electrical Panel feeding the
EVO™.
3.14.4 Switching Of Bonding Of Output Neutral To Chassis Ground
As required by NEC and UL Standard 458, automatic switching of bonding between the Output Neutral and Chassis
Ground has been provided in EVO™ through “Output Neutral and Chassis Ground Bond Switching Relay” (RY2 in Fig
4.1). Switching is carried as follows:
• When operating as an inverter, the current carrying conductor of the Inverter Section that is connected to the
Output Neutral terminal of the EVO™ is bonded to the metal chassis of EVO™ by the “Output Neutral to Chassis
Ground Bond Switching Relay” (RY2 in Fig 4.1). As the metal chassis of EVO™ is in turn bonded to the Earth
Ground (in shore installations) or 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 (connected to the Output Neutral Terminal) will become the
Grounded Conductor (GC) or the Neutral of the Inverter Section.
• When in Charging Mode, the Neutral conductor of the Grid power will be connected to the Output Neutral
terminal of EVO™. At the same time, the “Output Neutral to Chassis Ground Bond Switching Relay” (RY2 in Fig
4.1) will unbond (disconnect) the Output Neutral connector of EVO™ from the metal chassis of EVO™. This will
ensure that the Grounded Conductor (GC) i.e. the Neutral of the Grid power is bonded to the Earth Ground at
one single point at the location of the AC Power Distribution System of the Marina / RV Park / Shore Power.
• Disabling Neutral to Ground Bond: In some applications, the Output Neutral of EVO™ 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 Insulated Male/Female Quick Disconnect located in the AC wiring
compartment. [Please see (i) 27, Fig 3.9.2(a) and (ii) "27" in Figs 4.1].
Please read the following on-line White Papers for more details at www.samlexamerica.com
(Home > Support > White Papers):
- “Neutral to Ground Switching in RV and Marine Applications
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3.15 BATTERY TEMPERATURE SENSOR FOR LEAD ACID BATTERIES
Lead Acid Battery charging voltages are required to be compensated based on the temperature of the battery cells.
Hence, Battery Temperature Sensor Model EVO-BCTS has been provided. Please see constructional and tment details
at [Fig 2.5(a)] and [Fig 2.5(b)] respectively.
The sensor head contains a Negative Temperature Coefcient (NTC) Resistor with 2 output wires: “NTC+” is connected
to Pin 4 of the RJ-45 Plug and “NTC -” is connected to Pin 5 of the RJ-45 Plug. The RJ-45 Plug is required to be connected
to the RJ-45 Jack (6, Fig 2.1). The Temperature Sensor is used to ensure optimum charging of Lead Acid Batteries by
modifying the charging voltages based on the battery temperature. In addition to compensating Absorption, Float and
Equalization voltages, the voltage thresholds of parameters “LOW VOLTAGE ALARM”, “BATTERY LOW VOLTAGE”,
“RESET VOLTAGE”, “BATTERY OVER VOLTAGE” and “RESET TO BULK” are also temperature compensated. Temperature
compensation will be carried out over temperature range of -20°C to +60°C. Table 6.2 shows the programmable range.
Default setting for the Temperature Coefcient of Voltage is -4mV/°C/Cell.
3.16 INSTALLING CONTROL INPUT WIRING FROM LITHIUM BATTERY MANAGEMENT SYSTEM
(BMS) TO ENABLE/ DISABLE CHARGING OR INVERTING
The Battery Charger Section is designed to charge Lead Acid, Nickel-Zinc (Ni-Zn) or Lithium Ion Batteries.
Lead Acid Battery charging voltages are required to be compensated based on the temperature of the battery cells.
Hence, Battery Temperature Sensor is required to be connected to the RJ-45 Jack (6, Fig 2.1) as explained at Section
3.15.
Charging voltages of Lithium Battery are not affected by temperature and hence, Battery Temperature Sensor is not
required to be used.
For charging Lithium Ion Battery, programming parameter “BATTERY TYPE” has to be changed from Setting 0=Lead
Acid (Default setting) to Setting 1=Lithium. This programming change is carried out using optional Remote Control
EVO-RC-Plus. Please refer to the following Sections of EVO-RC-PLUS Manual:
• Screen 22 in Fig 4.2 and Table 4.3
• Section 4.4.2.22.1
Pins 4 and 5 of the RJ-45 Jack marked “Battery Temp. Sensor” (6 and 19, Fig 2.1) are required to be connected to the
Normally Open Contacts of relay in the Battery Management System (BMS) of the Lithium Battery for “Stop Charging
or “Stop Inverting” signals. [See details at Section 4.4.2.22.2 of EVO-RC-PLUS Remote Control Manual]. The BMS will
close the Relay contacts as follows:
• To “Stop Charging”: Due to (i) overvoltage of individual cell / overall battery pack, or (ii) over temperature of
individual cell or overall battery pack
• To “Stop Inverting”: Due to deep discharge to the level of Low Battery Cut Off Voltage
When the Relay contacts in the BMS close, Pins 4 and 5 of RJ-45 Jack will be shorted. The following actions will be
activated:
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E V O - 1 2 1 2 F C h a r g i n g
C h a r g e r O f f b y B M S
B a t t e r y 1 2 . 0 0 V 0 . 0 A
E x t e r n a l 0 . 0 A
E V O - 1 2 1 2 F b y B M S
A C O u t p u t : 0 . 0 0 V
< 0 . 1 0 A
0 0 . 0 0 H z
E V O - 1 2 1 2 F I n v s t o p
A C O u t p u t : 0 . 0 0 V
< 0 . 1 0 A
0 0 . 0 0 H z
SECTION 3 | Installation
• EVO in Charging Mode: The charging will stop (charging current will be reduced to 0A). The 2nd Line of the
Charging Mode Screens shown in the Menu Map for Charging Mode Screens (Fig 3.7 in EVO-RC Plus Manual)
will show “Charger Off by BMS” as shown in example below for Screen No. 1
Screen No.1
• EVO in Inverting Mode: Inverting will stop. EVO™ will go to Standby Mode. The right half of the 1st Line of
the Standby Mode Screens shown in the Menu Map for Standby Mode Screens (Fig 3.8 in EVO-RC Plus Manual)
will show “Inv stop by BMS” in 2 consecutive displays - rst “Inv stop” and then “by BMS” as shown in example
below:
Screen No.1 For 2 sec Screen No.1 For 2 sec
64 | SAMLEX AMERICA INC.
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SECTION 3 | Installation
3.17 SHORE BASED INSTALLATION
3.17.1 Typical Shore Based Installation
Fig. 3.12 illustrates a typical shore based installation for EVO-1212F / EVO-1224F. Fig 3.13 illustrates typical shore based
installation for EVO-1212F-HW / EVO-1224-HW.
• Battery is connected to the DC input connections through DC Electrical Panel with an appropriate fuse to
protect the DC input cables against short circuit
• Battery Charger Temperature Sensor Model EVO-BCTS is installed on the Positive or Negative post of the
battery and connected to the RJ-45 Jack 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 charge controller.
• AC input to the EVO™ is fed from the Grid. Alternatively, AC input may be fed from a generator.
• AC output from the EVO™ is fed to the AC Electrical Sub-Panel for EVO™
WARNING!
In case generator is used to feed AC input to the EVO, the following should be ensured:
• Ensure that the Neutral of the generator is bonded to the chassis of the generator. Please see Section
3.14.1 for details.
• If the Generator is a 120VAC / 240VAC Split Single Phase with 120 VAC phase fed to the EVO™, then
both 120 VAC Split Phases of the generator should be equally loaded (balanced) to prevent deterioration
of regulation of generator's output voltage / frequency. Poor regulation of generator output voltage /
frequency may lead to interruption of charging / AC pass through in the EVO™ (EVO will transfer to
Inverting Mode).
MISE EN GARDE!
En cas générateur est utilisé pour l'alimentation d'entrée AC à l'EVO, les dispositions suivantes
devraient être prises :
• S'assurer que le neutre du générateur est xé sur le châssis du générateur. Veuillez voir la section
3.14.1 pour
plus de détails.
• Si le générateur est un 120 VAC / 240 VAC monophasé avec Split 120VCA alimenté phase à l'EVO,
puis les deux phases de 120 V C.A. Split le générateur devrait être tout aussi chargé (équilibré) an
de prévenir la détérioration du règlement de générateur&# 039;s fréquence/tension de sortie. Une
mauvaise régulation de tension / fréquence de sortie du générateur peut conduire à l'interruption
de la charge / AC passer à travers dans l'EVO™ (EVO va transférer à l'inversion de mode).
SAMLEX AMERICA INC. | 65
Page 66
+
-
+
-
+
-
+
-
Grounding Electrode (GE) i.e. the Ground Rod embedded in earth.
See LEGEND on the next page
GRID ELECTRICAL PANEL
(SPLIT PHASE: 120/240 VAC)
N-B
G-B
G-B
A B
A.C. Section
D.C. Section
Neg. (-)
Bus
Battery
Bank
Pos. (+)
Bus
EVO INVERTER CHARGER: EVO-1212F / EVO-1224F
SBJ
GE
AWG #6
AWG #6
DC ELECTRICAL
PANEL
External
Charge
Controller
RJ-45
6
4
3
2
1
5
J6
RY2
J7
J1
J2
J9
J4
14
15
9
Metal Chassis
G
G
G
NL
27
10
BCTS
SECTION 3 | Installation
Fig 3.12 Installation Diagram for Typical Shore Based Installation for
EVO-1212F and EVO-1224F
66 | SAMLEX AMERICA INC.
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SECTION 3 | Installation
LEGEND FOR FIG 3.12
NOTE:
For sizing of wiring and fuses, refer to the following:
a) DC side wiring: Table 3.1
b) AC side wiring: Table 3.2 for AC input adn Table 3.3 for AC output
L. Line Terminal
L-B. Line Bus Bar
N. Neutral Terminal
N-G. Neutral to Ground Bond
N-B. Neutral Bus Bar
G-B. Grounding Bus Bar
SBJ. System Bounding Jumper
J1, 2, 4, 7, 9 Male Tab Terminals on internal Circuit Board
RY2. Relay for Neutral to Ground Bond Switching (Section 4.4.2)
BCTS. Battery Charger Temperature Sensor EVO-BCTS [Fig 2.5(a)]
1. Battery Positive Input Connector (1, Figs 2.1 / 3.8)
2. Battery Negative Input Connector (2, Figs 2.1 / 3.8)
3. Positive Input Connector for External Charge Controller (3, Figs 2.1 / 3.8)
4. Negative Input Connector for External Charge Controller (4, Figs 2.1 / 3.8)
5. DC Side Grounding Terminal on EVO™ (5, Fig 2.1)
6. RJ-45 Jack for Temperature Sensor (6, Fig 2.1)
GE. Grounding Electrode. Also called "Ground Rod"
9. 20A Inlet Plug Connector IEC 60320 C20 ((9, Fig 2.1)
10. NEMA5-15 Duplex GFCI Outlets (10, Fig 2.1)
14. 15A Built-in Breaker for AC output (14, Fig 2.1)
15. 20A Built-in Breaker for AC input (15, Fig 2.1)
27. Quick Disconnect to disconnect Neutral to Ground bond (27, Fig 3.9.2)
Circuit breaker
Fuse
A
120 VAC Leg, Phase A
120 VAC Leg, Phase B (180° out of phase with Phase A Leg)
B
WARNING!
In case a Generator is used to feed AC input, please ensure that the Neutral conductor of the Generator is
bonded to the chassis / frame of the Generator. Please refer to Section 3.14.1 for details.
MISE EN GARDE!
En cas d'un générateur est utilisé pour envoyer de l'entrée CA, veuillez vous assurer que le conducteur
neutre de la génératrice est collé sur le châssis / cadre de la génératrice. Veuillez vous reporter à la
section 3.14.1 pour plus de détails.
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SECTION 3 | Installation
ELECTRICAL
SUB-PANEL FOR
EVO (SINGLE
PHASE: 120 VAC)
N-B
G-B
To loads
backed up
by EVO
LINE
+
-
+
-
+
-
+
-
GRID ELECTRICAL PANEL
(SPLIT PHASE: 120/240 VAC)
N-B
G-B
G-B
A B
A.C. Section
D.C. Section
Neg. (-)
Bus
Battery
Bank
Pos. (+)
Bus
EVO INVERTER CHARGER: EVO-1212F-HW / EVO-1224F-HW
SBJ
GE
AWG #6
AWG #6
DC ELECTRICAL
PANEL
External
Charge
Controller
RJ-45
6
4
3
2
1
5
J6
RY2
J7
J1
J2
J9
J4
Metal Chassis
20
21
22
23
24
25
26
Grounding Electrode (GE) i.e. the Ground Rod embedded in earth.
BCTS
See LEGEND on the next page
27
Fig 3.13 Installation Diagram for Typical Shore Based Installation for
68 | SAMLEX AMERICA INC.
EVO-1212F-HW and EVO-1224F-HW
Page 69
SECTION 3 | Installation
LEGEND FOR FIG 3.13
NOTE:
For sizing of wiring and fuses, refer to the following:
a) DC side wiring: Table 3.1
b) AC side wiring: Table 3.2 for AC input and Table 3.3 for AC output
L. Line Terminal
L-B. Line Bus Bar
N. Neutral Terminal
N-G. Neutral to Ground Bond
N-B. Neutral Bus Bar
G-B. Grounding Bus Bar
SBJ. System Bounding Jumper
J1, 2, 4, 7, 9 Male Tab Terminals on internal Circuit Board
RY2. Relay for Neutral to Ground Bond Switching (Section 4.4.2)
BCTS. Battery Charger Temperature Sensor EVO-BCTS [Fig 2.5(a)]
1. Battery Positive Input Connector (1, Figs 2.1 / 3.8)
2. Battery Negative Input Connector (2, Figs 2.1 / 3.8)
3. Positive Input Connector for External Charge Controller (3, Figs 2.1 / 3.8)
4. Negative Input Connector for External Charge Controller (4, Figs 2.1 / 3.8)
5. DC Side Grounding Terminal on EVO™ (5, Fig 2.1)
6. RJ-45 Jack for Temperature Sensor (6, Fig 2.1)
GE. Grounding Electrode. Also called "Ground Rod"
20. AC Input / Output Terminal Block
21. INPUT L
22. INPUT N
23. INPUT GND
24. OUTPUT L
25. OUTPUT N
26. OUTPUT GND
27. Quick Disconnect to disconnect Neutral to Ground bond
Circuit breaker
Fuse
120 VAC Leg, Phase A
A
120 VAC Leg, Phase B (180° out of phase with Phase A Leg)
B
Refer to AC Input / Output
Connections for EVO-1212F-HW
/ 1224F-HW at Fig 3.9.2(a)
WARNING!
In case a Generator is used to feed AC input, please ensure that the Neutral conductor of the Generator is
bonded to the chassis / frame of the Generator. Please refer to Section 3.14.2 for details.
MISE EN GARDE!
En cas d'un générateur est utilisé pour envoyer de l'entrée CA, veuillez vous assurer que le conducteur
neutre de la génératrice est collé sur le châssis / cadre de la génératrice. Veuillez vous reporter à la
section 3.14.2 pour plus de détails.
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SECTION 3 | Installation
3.18 MOBILE INSTALLATION - GENERAL INFORMATION
3.18.1 GFCI Protection for Vehicle Application
When EVO-1212F-HW / EVO-1224F-HW 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. EVO-1212F and EVO-1224F come with
Duplex GFCI, NEMA5-15 outlet.
WARNING!
Please ensure that when using hard-wired versions EVO-1212F-HW, Ground Fault Circuit Interrupter(s) [GFCI]
are installed in the vehicle wiring system to protect all branch circuits. GFCIs listed in Table 1.5 have been
tested to operate satisfactorily and are acceptable.
MISE EN GARDE!
Veuillez vous assurer que lors de l'utilisation de versions câblées EVO-1212F-HW, Disjoncteur(s) [FUITE]
sont installés dans le système de câblage du véhicule pour protéger tous les circuits de dérivation.
Des disjoncteurs de terre ci-dessous ont été testé. Leur fonctionnement est acceptable, Table 1.5.
3.18.2 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 Information - Lead Acid
batteries". For details, read on-line White Paper titled “Batteries, Chargers & 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 specied as Cranking Amps). This allows very high starting current but causes the plates to warp when the battery
is cycled. Vehicle starting typically discharges 1%–3% of a healthy SLI battery’s capacity. The automotive SLI battery is
not designed for repeated deep discharge where up to 80% of the battery capacity is discharged and then recharged.
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™ (Deep cycle, auxiliary battery is shown in Figs 3.14
and 3.15).
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 Figs 3.14 and 3.15). The capacity of the Battery Isolator should be as follows:
70 | SAMLEX AMERICA INC.
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SECTION 3 | Installation
• For EVO-1212F / EVO-1212F-HW: The maximum continuous DC current required is 152A. The capacity of the
Battery Isolator should be more than 152A or more than the capacity of the alternator, whichever is higher.
• For EVO-1224F / EVO-1224-HW: The maximum continuous DC current required is 76A. The capacity of the
Battery Isolator should be more than 76A or more than the capacity of the alternator, whichever is higher.
3.18.3 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 oating 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!
3.18.4 Typical Mobile Installation
Fig 3.14 illustrates typical RV installation for EVO-1212F / EVO-1224F using 30A, 120VAC, Single Phase Service Inlet. Fig
3.15 illustrates typical RV installation for hard-wired versions EVO-1212F / EVO-1224-HW using 30A, 120VAC Single
Phase Service Inlet:
• Auxiliary Battery is connected to the DC input connections through an appropriate fuse to protect the DC input
cables against short circuit
• When AC input from the Grid is not available, the Auxiliary battery will be charged by the alternator through the
Battery Isolator
• Battery Charger Temperature Sensor Model BCTS-EVO is installed on the Positive or Negative post of the auxiliary
battery and connected to the RJ-45 Jack 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 Electrical Panel of the RV (through suitable breaker).
• If the RV has a 50A Service, 120VAC Single Phase input to the EVO™ can be fed from either of the 2 Split Phase
Legs of the 50A RV Panel (through suitable breaker).
• AC output from the EVO™ is fed to the Electrical Sub-Panel for EVO™ (Use 120V version and NOT 120/240 Split
Phase version of the Electrical Sub-panel)
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SECTION 3 | Installation
EVO INVERTER CHARGER: EVO-1212F AND EVO-1224F
10
A.C. Section
G
G
J7
15
G
NL
J1
9
J6
RY2
D.C. Section
4
3
1
2
External
Charge
Controller
+
-
6
RJ-45
-
+
+
-
+
Battery
Bank
BCTS
-
+ + +
Battery Isolator
- +
Engine Starter
Battery
L-B L
120V, SINGLE
PHASE ELECTRICAL
PANEL OF RV
G-B
N-B
N
NL
30A Service Inlet for 30A
G
RV Power Supply Cord
J2
J9
NEMA TT-30P
27
J4
Metal Chassis
5
Alternator
See LEGEND on the next page
Fig 3.14 Installation Diagram for Typical RV / Mobile Installation for
72 | SAMLEX AMERICA INC.
EVO-1212F and EVO-1224F
Page 73
SECTION 3 | Installation
LEGEND FOR FIG 3.14
NOTE:
For sizing of wiring and fuses, refer to the following:
a) DC side wiring: Table 3.1
b) AC side wiring: Table 3.2
L. Line Terminal
L-B. Line Bus Bar
N. Neutral Terminal
N-G. Neutral to Ground Bond
N-B. Neutral Bus Bar
G-B. Grounding Bus Bar
SBJ. System Bounding Jumper
J1, 2, 4, 7, 9 Male Tab Terminals on internal Circuit Board
RY2. Relay for Neutral to Ground Bond Switching (Section 4.4.2)
BCTS. Battery Charger Temperature Sensor EVO-BCTS [Fig 2.5(a)]
1. Battery Positive Input Connector (1, Figs 2.1 / 3.8)
2. Battery Negative Input Connector (2, Figs 2.1 / 3.8)
3. Positive Input Connector for External Charge Controller (3, Figs 2.1 / 3.8)
4. Negative Input Connector for External Charge Controller (4, Figs 2.1 / 3.8)
5. DC Side Grounding Terminal on EVO™ (5, Figs 2.1/ 3.8)
6. RJ-45 Jack for Temperature Sensor (6, Fig 2.1)
GE. Grounding Electrode. Also called "Ground Rod"
9. 20A Inlet Plug Connector IEC 60320 C20 (9, Fig 2.1)
10. NEMA5-15 Duplex GFCI Outlets (10, Fig 2.1)
14. 15A Built-in Breaker for AC output (14, Fig 2.1)
15. 20A Built-in Breaker for AC input (15, Fig 2.1)
27. "Quick Disconnect" to disconnect Neutral to Ground bond (27, Fig 3.9.2)
Circuit breaker
Fuse
A
120 VAC Leg, Phase A
120 VAC Leg, Phase B (180° out of phase with Phase A Leg)
B
WARNING!
In case a Generator is used to feed AC input, please ensure that the Neutral conductor of the Generator is
bonded to the chassis / frame of the Generator. Please refer to Section 3.14.1 for details.
MISE EN GARDE!
En cas d'un générateur est utilisé pour envoyer de l'entrée CA, veuillez vous assurer que le conducteur
neutre de la génératrice est collé sur le châssis / cadre de la génératrice. Veuillez vous reporter à la
section 3.14.1 pour plus de détails.
SAMLEX AMERICA INC. | 73
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ELECTRICAL
SUB-PANEL FOR
EVO (SINGLE
PHASE: 120 VAC)
N-B
G-B
LINE
+
-
+
-
A.C. Section
D.C. Section
EVO INVERTER CHARGER: EVO-1212F-HW / EVO-1224F-HW
RJ-45
6
4
3
1
2
5
J6
RY2
J7
J1
J2
J9
J4
27
Metal Chassis
20
21
22
23
24
25
26
G-B
L-B L
120V, SINGLE
PHASE ELECTRICAL
PANEL OF RV
30A Service Inlet for 30A
RV Power Supply Cord
NEMA TT-30P
G
NL
N-B
N
+
-
+
-
Battery
Bank
External
Charge
Controller
+ + +
-
+
Battery Isolator
Engine Starter
Battery
Alternator
See LEGEND on the next page
BCTS
SECTION 3 | Installation
Fig 3.15 Installation Diagram for Typical RV / Mobile Installation for EVO-1212F-
74 | SAMLEX AMERICA INC.
HW and EVO-1224F-HW
Page 75
SECTION 3 | Installation
LEGEND FOR FIG 3.15
NOTE:
For sizing of wiring and fuses, refer to the following:
a) DC side wiring: Table 3.1
b) AC side wiring: Table 3.2 for AC input and Table 4.3 for AC output
L. Line Terminal
L-B. Line Bus Bar
N. Neutral Terminal
N-G. Neutral to Ground Bond
N-B. Neutral Bus Bar
G-B. Grounding Bus Bar
SBJ. System Bounding Jumper
J1, 2, 4, 7, 9 Male Tab Terminals on internal Circuit Board
RY2. Relay for Neutral to Ground Bond Switching (Section 4.4.2)
BCTS. Battery Charger Temperature Sensor EVO-BCTS [Fig 2.5(a)]
1. Battery Positive Input Connector (1, Figs 2.1 / 3.8)
2. Battery Negative Input Connector (2, Figs 2.1 / 3.8)
3. Positive Input Connector for External Charge Controller (3, Figs 2.1 / 3.8)
4. Negative Input Connector for External Charge Controller (4, Figs 2.1 / 3.8)
5. DC Side Grounding Terminal on EVO™ (5, Figs 2.1/ 3.8)
6. RJ-45 Jack for Temperature Sensor (6, Fig 2.1)
GE. Grounding Electrode. Also called "Ground Rod"
20. AC Input / Output Terminal Block
21. INPUT L
22. INPUT N
23. INPUT GND
24. OUTPUT L
25. OUTPUT N
26. OUTPUT GND
27. Quick Disconnect to disconnect Neutral to Ground bond
Circuit breaker
Fuse
A
120 VAC Leg, Phase A
B
120 VAC Leg, Phase B (180° out of phase with Phase A Leg)
Refer to AC Input / Output
Connections for EVO-1212F-HW
/ 1224F-HW at Fig 3.9.2(a)
WARNING!
In case a Generator is used to feed AC input, please ensure that the Neutral conductor of the Generator is
bonded to the chassis / frame of the Generator. Please refer to Section 3.14.2 for details.
MISE EN GARDE!
En cas d'un générateur est utilisé pour envoyer de l'entrée CA, veuillez vous assurer que le conducteur
neutre de la génératrice est collé sur le châssis / cadre de la génératrice. Veuillez vous reporter à la
section 3.14.2 pour plus de détails.
SAMLEX AMERICA INC. | 75
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i
SECTION 4 | General Description & Principles of Operation
4.1 GENERAL DESCRIPTION
EVO Series is a Low Frequency Type, Pure Sine Wave, Single Phase Inverter-Charger with a built-in Transfer Relay. It
uses high performance, 100MHz SP (Digital Signal Processing) type of micro-controller and Pulse Width Modulation
(PWM) control. It is Bi-Directional i.e. it uses a common Converter Section consisting of Low Frequency Isolation
Transformer and Mosfet based H-Bridge that can work in two directions as follows:
1) AC to DC Charging Mode: The common Converter Section is used to convert external AC input power to
DC output power to charge the batteries and at the same time, pass through the AC input power to the AC
loads
2) DC to AC Inverting Mode: The common Converter Section is used to convert DC input power from the
batteries to AC output power to feed the AC loads
The above Bi-Directional implementation allows the same power components to be used in both directions
resulting in high- energy transfer efciency with fewer components and higher reliability
INFO
Please note that as the unit is Bi-Directional with a common Converter Section as explained above, it
cannot work as inverter and charger at the same time
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:
120 VAC, 60 Hz, Single Phase AC input
DC Battery Source consisting of 12V/24V battery bank. - 4 versions of EVO are available. 2 versions for 12 VDC
battery input (EVO-2212F and EVO-1212F-HW) & 2 for 24 VDC battery input (EVO-1224F and EVO-1224F-HW)
Additional external charging source: Solar Charge Controller of up to 50A capacity. The output of the external
Solar Charge Controller is routed through this unit and operates in parallel with the internal charger. The current
delivered by the external charge controller is measured in real time. The internal charging current is controlled to
ensure that the combined current fed to the battery does not exceed the programmed value of parameter "BULK
CURRENT". This improves the life of the battery. Please see Section 5.4 for more details.
4.3 INVERTER SECTION
The Inverter Section is a heavy-duty, continuous rated, DSP micro-controller based inverter generating a Pure Sine Wave
output of 120 VAC, 60 Hz 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
cleaners, fans, pumps, Switched Mode Power Supplies (SMPS) used in audio / video equipment and computers, etc.).
4.3.1 Principle of working of Inverter Section
Low DC voltage from the DC Battery Source is inverted to AC voltage in two steps. Low DC voltage from the DC
Battery Source is rst converted to low frequency (60 Hz), low voltage synthesized sine wave AC using Mosfet
76 | SAMLEX AMERICA INC.
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SECTION 4 | General Description & Principles of Operation
based H-bridge conguration and high frequency (30 KHz) 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 ltration circuit to remove 30 KHz PWM frequency component. This type of
DC to AC inversion is called Hybrid Type – a combination of low and high frequency implementation. Distinctive
features of the Inverter Section are given below:
Soft Start: The inverter design incorporates “Soft Start” feature with the following advantages and protections:
- When the unit powers up, it starts in Inverting Mode rst. The output voltage ramps up gradually from
around 48 VAC to 120 VAC in around 200 ms. This reduces otherwise 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 problematic voltage drops during starting.
Power Surge – Up to 300%:
- The inverter is able to deliver very high surge power / current of up to 300% 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 difcult motor driven loads like compressors and pumps that require
higher Locked Rotor Current during startup.
- If the power drawn by the load exceeds the above surge ratings, the inverter protects itself by limiting the
load current to 300% / 200% which results in reduction of output voltage and consequent reduction in load
current. The output voltage recovers automatically when power drawn by the load drops below the above
surge limits
Power Boost up to 150%: Higher percentage of rated power can be provided for limited time periods as follows:
• 150% for 30 sec
• 140% for 1 min
• 120% for 10 min
• 110% for 30 min
4.4 TRANSFER RELAY SECTION
Transfer Relay Section is used to either feed AC input power from external AC input source (e.g. Grid/Generator)
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 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 the AC input source to Inverter and <1ms from Inverter to the AC input source. Heavy duty
40A, Transfer Relay [RY1, Fig 4.1] is used for reliable transfer of power.
4.4.1 AC Transfer and Output Neutral To Chassis Ground Bond Switching
As required by NEC and UL Standard 458, automatic switching of bonding between the Ouput Neutral and Chassis
Ground has been provided in EVO through “Output Neutral to Chassis Ground Bond Switching Relay” [RY.2 in Fig
4.1]. Switching of bonding is carried out as follows:
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(a) When operating as an inverter, the current carrying conductor of the Inverter Section that is connected to
the Output Neutral terminal of EVO is bonded to the metal chassis of EVO by the “Output Neutral to Chassis
Ground Bond Switching Relay” [RY.2 in Fig 4.1]. As the metal chassis of EVO is in turn bonded to the Earth
Ground (in shore installations) or 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 (connected to the output terminal)
will become the Grounded Conductor (GC) or the Neutral of the Inverter Section.
(b) When in Charging Mode, the Neutral conductor of the AC input source will be connected to the Output
Neutral terminal of EVO. At the same time, the “Output Neutral to Chassis Ground Bond Switching Relay”
[RY.2 in Fig 4.1] will unbond (disconnect) the Output Neutral connector of EVO from the metal chassis of
EVO. This will ensure that the Grounded Conductor (GC) i.e. the Neutral of the AC input power source is
bonded to the Earth Ground at one single point at the location of the AC Power Distribution System of the
Marina/RV Park/Shore Power.
(c) Disabling Neutral to Ground Bond: In some applications, the Output Neutral of EVO 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 Disconnect located in the AC wiring compartment.
[Please see (i) 27, Fig 3.9.2(a) and (ii) 27 in Figs 4.1]
Please read the following on-line White Papers for more details at www.samlexamerica.com (Home > Support >
White Papers):
- “Neutral to Ground Switching in RV and Marine Applications”
4.4.2 Operation of Transfer Relay and Output Neutral to Chassis Ground Bond Switching Relay
Refer to Schematic at Fig 4.1.
The Bi-directional Transformer is used as follows:
o Feeds AC output from the Inverter Section when Grid power is not available.
o Feeds Grid / Generator power to the Battery Charger Section when Grid / Generator input is available.
Switching of Hot Output (OUTPUT LINE)
o 40A* rated SPDT Relay RY1 (Fig 4.1) is used to switch the Hot Output Connector (OUTPUT L) to either the
Inverter Section or to Grid / Generator. (*Refer to Note 2 under Legend for Fig 4.1)
o When Grid / Generator input Power is available, Relay RY1 (Fig 4.1) will be energized and contact 4 switches
over to contact 5. The Bidirectional Transformer works as a battery Charger. The Hot AC input from Grid /
Generator (INPUT L) 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 L) for powering the AC loads.
o When Grid / Generator power fails, Relay RY1 (Fig 4.1) will be de-energized and contact 4 switches back to
contact 3. Output from the Inverter Section is fed to the Bi-directional Transformer and onwards to the Hot
Out (OUTPUT L) for powering the AC loads.
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SECTION 4 | General Description & Principles of Operation
Switching of Bonding of Output Neutral to Chassis Ground
o 40A* rated SPDT Relay RY2 (Fig 4.1) is used to switch the bonding of the Output Neutral Connector (OUTPUT
N) to the chassis of the unit. (*Refer to Note 2 under Legend for Fig 4.1)
o When Grid / Generator input power is available, Relay RY2 (Fig 4.1) will be energized and contact 4 switches
over to contact 5. Neutral input from Grid (GRID N) 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 N) for
powering the AC loads. Please note that in this condition, the Output Neutral (OUTPUT N) is isolated from the
chassis of the unit
o When Grid / Generator input power fails, Relay RY2 (Fig 4.1) will be de-energized and contact 4 switches back
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 N) for powering the AC loads. At the same time, the output Neutral
(OUTPUT N) gets bonded to the metal chassis of the unit through the mated contacts of the Insulated Male /
Female Quick Disconnect (27, Fig 4.1) located in the AC Wiring Compartment [27, Fig 3.9.2(a)] in EVO-1212FHW / 1224F-HW. In EVO-1212F / 1224F, the Insulated Male / Female Quick Disconnect is accessible after
opening the top cover of the unit.
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GND
GND
RY2
3
27
METAL CHASSIS
GROUND OF THE EVO
TM
INVERTING
CHARGING
BI-DIRECTIONAL
TRANSFORMER
NEUTRAL
LINE
4
RY1
5
3
4
5
LEGEND for Fig 4.1
RY1 Transfer Relay (40A - See Note 2 below) (Shown in de-energized state). Transfers the
RY2 Relay (40A - See Note 2 below) for Neutral to Ground bond Switching
4, 3 Normally Closed Contacts (Shown in de-energized state)
4, 5 Normally Open Contacts (Shown in de-energized state)
27
NOTES: 1. Relays are de-energized in Inverting Mode and are energized in Charging Mode.
OUTPUT L
INPUT L
OUTPUT
INPUT
OUTPUT N
Fig 4.1 Operation of Transfer Relay and Switching of Bond Between
Output Neutral and Metal Chassis Ground
Line Conductor of the AC load to either the Line Conductor of the input from Grid /
Generator or to the Line Conductor of the Inverter Section.
Insulated Male / Female Quick Disconnect [27, Fig 3.9.2(a)] for disconnecting
Output Neutral to Chassis Ground bond in Inverting Mode (Default - connected)
2. Although relays RY1, RY2 are rated for 40A, AC input current and output pass
through current in charging mode are limited to 20A & 15A respectively by the
20A input breaker and 15A output breaker.
INPUT N
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4.2.2.1 Synchronized Transfer of Power
4.4.2.1.1 General information
When the frequency and phase of output voltages of two AC power sources are the same (in sync), the two AC
sources are considered to be “synchronized”.
Critical AC loads require un-interruptible AC input power. It is, therefore, necessary that when the primary AC
input power is interrupted / fails, the load should be transferred to the backup AC source “very quickly” within the
“holdup time” of the load(s) .
When AC power feeding motors or inductive loads like transformers etc. is interrupted / fails, residual voltage
is induced in the load due to “generator effect” created by a rotating motor or by the stored energy released
from the inductive loads like transformer’s windings or core. The induced residual voltage in the load has the
same frequency and phase as the voltage of AC input power when it failed and, this voltage does not dissipate
immediately but within a few seconds. This induced residual voltage in the load can cause extremely high inrush
currents to occur when such loads are “very quickly” transferred to a “non-synchronized” source of backup AC
power ( the loads are transferred to the “non-synchronized” backup source before the residual voltage in the
load(s) has dissipated). The resulting effect, frequently described as “bumping” can initiate nuisance tripping of
circuit protective devices or in extreme cases, cause mechanical damage to motor shaft and couplings. To prevent
this abnormal operating condition when the load is transferred between the primary and backup AC sources “very
quickly (normally within around 16 ms)”, it is to be ensured that the voltage of the backup AC power source is
always kept “synchronized” with the voltage of the primary AC power source.
Synchronization control logic used in a backup AC source is required to be based on the frequency stability
characteristics of the primary AC source which can be Grid or Generator. The frequency of Grid voltage is very
stable. On the other hand, the frequency of Generator voltage (except Inverter Generators) may vary considerably
depending upon the performance of its Speed Governor that compensates for the drop in RPM / frequency when
electrical load is switched on / increased or, rise in RPM / frequency when electrical load is decreased / switched off.
4.4.2.1.2 Synchronization Algorithm Options
When operating as an Inverter Charger, the EVO is designed to accept external AC input power through AC Power
Inlet (9, Fig 2.1) in EVO-1212F/ 1224F and through AC Input Terminals (21,22,23 in Fig 2.3) in EVO-1212F-HW/
1224F-HW.
The frequency and phase of the internal backup Inverter Section are always kept synchronized with the AC input
source. This facilitates “extremely fast” transfer time of up to 16 ms. Also, transfer from the Inverter Section to the
AC input source and vice versa takes place at zero crossing of the voltage waveform – this ensures (i) negligible arcing
/ erosion of Transfer Relay contacts and (ii) negligible Electromagnetic Interference (EMI) associated with arcing.
Programming parameters “SYNCHRONIZATION” has been provided with two synchronization algorithm options
each: (i) 0= Fine, or (ii) 1= Coarse as shown in TABLE 4.1. Option “0 =Fine” is recommended for AC input power
source that has more stable output frequency like Grid / Inverter Generator. Option “1= Coarse” is recommended
for AC input power source with less stable output frequency like Generator.
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TABLE 4.1 SYNCHRONIZATION ALGORITHM OPTIONS ON AC INPUT CONNECTIONS
Synchronization Algorithm Options
AC Input Source is Grid or
AC Input Connection
EVO-1212F/ 1224F
AC Inlet (9, Fig 2.1)
EVO-1212F-HW/
1224F-HW
AC Input Terminals
(21,22,23 in Fig 2.3)
Programming
Parameter
SYNCHRONIZATION
(See NOTE 1)
Inverter Generator
Option
0=Fine
(Default)
NOTES:
1. For programming details for parameter "SYNCHRONIZATION", please refer to Section 4.5.2.8 in EVO-RC-PLUS
Remote Control Manual
AC Input Source is Generator
Programming
Parameter
SYNCHRONIZATION
(See NOTE 1)
Recommended
Option
Change to Option
"1=Coarse"
4.4.2.1.3
Transfer From Inverter Section to AC Input Source
When power from AC input source is made available, its voltage and frequency are monitored for 2 sec to check if
these are within the programmed limits. If yes, the output voltage of the Inverter Section is synchronized with the
AC input source. This synchronization process takes few seconds. Once synchronization is completed, the load is
transferred instantly (within 1 ms) to the AC input source at Zero Crossing of the voltage waveform for safer transfer
and for better protection of Transfer Relay contacts. The unit now operates in “Charging Mode” with the AC power
from the AC input source charging the batteries as well as providing power to the AC loads.
4.4.2.1.4
Transfer From AC Input Source to Inverter Section
When the unit is operating in “Charging Mode” with the AC input source charging the batteries as well as providing
power to the AC loads, the phase and frequency of the AC input source are tracked continuously. In case AC input
source fails or is disconnected, the inverter will be forced to transfer at voltage which is at the same phase and
frequency at which the AC input source had been disconnected. Load will be transferred to the inverter within 16ms
at zero crossing. The unit will now work in “Inverting Mode” and the batteries will start discharging.
4.5 BATTERY CHARGER SECTION
The Battery Charger Section of these units provide 2/3/4 stage charging with 7 programmable charging proles as
detailed at Section 5.6. The same Isolation Transformer and the H-Bridge conguration of the Inverter Section are
used to work in the reverse direction, i.e. the AC input is stepped down and rectied to the programmed DC battery
charging voltage using Pulse Width Modulation (PWM) Control. That is why it is called a Bi-directional device. Further,
the charging voltages and currents are programmable to take care of a wide range of battery types like Lead Acid,
Nickel-Zinc (Ni-Zn) & Lithium Ion.
Important battery charging features are as follows:
• Adaptive Charging Control for 2 Charging Proles out of the 7 proles
• Dynamic Input Power Diversion Control
• Parallel charging through External Charge Controller
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SECTION 4 | General Description & Principles of Operation
• Temperature compensated charging
• Programmable Charging Proles for Lead Acid, Nickel-Zinc (Ni-Zn) and Lithium Batteries
TM
Please see details under Section 5 titled “Battery Charging in Evolution
4.6 MODES OF OPERATION
4.6.1 Charging Mode
As long as the external AC input power 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.
4.6.2 Inverting Mode
If at any instant, the external AC input power 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.
Series”.
4.6.3 Power Saving Mode
Power Saving Mode related to inverters is a function designed to conserve battery power when the inverter is in ON
condition and no AC loads are connected to it or, AC loads are connected to it but have been switched OFF. This
condition is also called “No Load Condition”.
When an inverter is operating under “No Load Condition”, it will consume a small amount of input power from the
battery to keep all internal circuits alive and be ready to deliver the full rated output voltage and power to the load
once the load is switched ON. This input power drawn from the battery when no load is being supplied by the inverter
is called the “No Load Power Draw” (also called “Idle Power” or “Self Power Consumption). This “No Load Power
Draw” is proportional to the size of the inverter e.g. a 150 Watt inverter may have “No Load Power Draw” of around
6W and a 3000W may have “No Load Power Draw” of around 30W. This power is wasted and drains the battery
unnecessarily. It is, therefore, desirable to reduce the “No Load Power Draw” to the minimum.
The “No Load Power Draw” of EVO-1212F/1212F-HW/1224F/1224F-HW in the Normal Operating Mode is around 20W.
The EVO has an optional programmable operating mode called “Power Saving Mode” that is designed to reduce this
“No Load Power Draw” to less than 8W during conditions where the Inverter Section is ON but is not supplying any
load [Applicable only when the unit is operating in “Inverting Mode”].
Enabling / disabling of “Power Saving Mode” is carried out using optional Remote Control Model EVO-RC-PLUS. The
EVO is shipped with the “Power Saving Mode” option in “Disabled” condition [Programming Parameter “POWER
SAVING” is set at “0=Disabled” in the Default condition – See Section 4.8.2.1 of the EVO-RC-PLUS Remote Control
Manual].
When “Power Saving Mode” is enabled, the Inverter Section will NOT provide full rated output voltage of 120 VAC
of Normal Operating Mode but pulsing output voltage consisting of 3, 60 Hz cycles of “reduced 48Vrms load search
voltage” every 0.5 sec. This output voltage is used to “search” if a load is being powered and also to measure the
power drawn by this load [The power drawn by the load will be initially measured based on pulsing output voltage
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SECTION 4 | General Description & Principles of Operation
consisting of 3, 60 Hz cycles of “reduced 48VAC load search voltage” every 0.5 sec and from there, the power will be
calculated based on the rated output voltage of 120VAC for the Normal Operating Mode]. Operation of the “Power
Saving Mode” is controlled through the following programming parameters:
• 4.6.3.1 Parameter “ENTER POINT” [See Section 4.8.2.2 in the EVO-RC-PLUS Remote Control Manual]
This parameter determines the threshold of power drawn by the load at which the EVO will exit the Normal
Operating Mode (full 120VAC output voltage; No Load Power Draw from the battery will be 25-30W) and “enter”
Power Saving Mode (output voltage consisting of 3, 60 Hz cycles of “reduced 48VAC load search voltage” every 0.5
sec; No Load Power Draw from the battery will be < 8W).
The programmable range of this parameter is 4-50Watts; Default value is 6W.
Whenever the Inverter Section is switched ON with “Power Saving Mode” in enabled condition, it will initially start in
Normal Operating Mode [Full 120VAC output voltage; No Load Power Draw from the battery will be 20W]. It then
measures the power drawn by the load, if any, based on Normal Operating Voltage of 120VAC. If the power drawn
by the load is ≤ the programmed power value of “Enter Point”, the Inverter Section will enter “Power Saving Mode”
(pulsing output voltage consisting of 3, 60 Hz cycles of “reduced 48Vrms load search voltage” every 0.5 sec). It is,
therefore, important to rst determine the running power consumption of your load in Watts and then, ensure that
the programmed value of parameter “ENTER POINT” is > the running power of the load. If the running power of the
load is < the programmed value of parameter “ENTER POINT”, the load may turn ON initially due to higher initial
startup surge power but will turn OFF when it starts drawing lower running power that is < the programmed value
of parameter “ENTER POINT”. (NOTE: The initial startup surge power of AC loads may be up to 10 times higher than
their “running power” depending upon the type of AC load).
• 4.6.3.2 Parameter “WAKE UP POINT” [See Section 4.8.2.3 in the EVO-RC-PLUS Remote Control Manual]:
Once the inverter enters “Power Saving Mode” as described at Section 4.8.3.1 above [Output voltage consisting of
3, 60 Hz cycles of “reduced 48VAC load search voltage” every 0.5 sec; Power draw from the battery will be < 8W],
it will continue to remain in this mode till the time the power drawn by the load is ≥ than the programmed threshold
of Parameter “WAKE UP POINT” [Programmable range is 4-50Watts; Default is 7W]. When the power drawn by the
load ≥ the programmed threshold of Parameter “WAKE UP POINT”, the EVO will wake up and change to the Normal
Operating Mode (full 120VAC output voltage; No Load Power Draw from the battery will be 20W).
84 | SAMLEX AMERICA INC.
INFO
Power Saving Mode should be disabled for the following loads:
• Low power loads that draw less than 5W e.g. digital clocks, satellite receivers, phones / answering
machines etc.
• Audio / video / computing devices that consume normal operating power > 50 W but draw less than
5W on entering Sleep Mode when switched off or , when no activity is seen for a specied time.
• Some devices like small uorescent lights, refrigerators, microwaves, computers and other sophisticated
electronics may not be detected when scanned by the output voltage characteristics of the Power
Saving Mode [Output voltage consisting of 3, 60 Hz cycles of “reduced 48VAC load search voltage”
every 0.5 sec]. These devices have power supplies in their front end that do not present a load until
the full 120VAC line voltage is available.
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SECTION 4 | General Description & Principles of Operation
4.6.4 Power Saving Mode - Transfer Characteristics
• Transfer from AC Input Source to Inverter: If qualied 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
fails or is not qualied (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 programmed value of “Enter
Point” for around 5 sec, it enters Power Saving Mode.
• Transfer from Inverter to AC Input Source: As soon as qualied AC input power 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 synchronization is completed, the load
is transferred to the AC Input Source at zero crossing of the voltage waveform.
4.6.5 Normal (Off-Line), On-Line and Charger Only Modes
EVO has 3 modes of operation as follows that can be programmed through programming parameter “MODE” [For
details, see Section 4.4.2.13 in the EVO-RC-PLUS Remote Control Manual]
i. Option “0=Normal” (Default). Also called Off-Line Mode. See details at Section 4.6.5.1 below
ii. Option “1=On-Line”. See details at Section 4.6.5.2 below
iii. Option “2=Charger Only”. See Section 4.6.5.3 below
4.6.5.1 Option “0=Normal” (Default). This option is also called “Off-Line UPS Mode” (UPS stands for Uninterruptible Power Supply). In this mode, AC input source is the PRIMARY source of AC power and the batteries
/ Inverter Section of EVO is the BACK-UP source of DC-AC power. If qualied AC input (within the programmed
voltage and frequency limits) is available, the EVO will operate in “Charging Mode” and qualied AC input will be
passed through to the AC output and at the same time, the Internal AC Charger will start charging the batteries.
If an external Solar Charge Controller is also connected to the External Charging Terminals (3, 4 in Fig 2.1), the
internal AC Charger of EVO will limit the charging current as follows:
Value of charging current produced by EVO
Charging Section
=
(Programmed value of charging current set by
parameter “BULK CURRENT” [See Section 4.4.2.1
of EVO-RC-PLUS Remote Control Manual] minus
(Value of current fed from the external solar charge
controller)
When AC input fails or, is not within the programmed values of voltage and frequency, the unit will change over to
“Inverting Mode” and the AC Output will be fed from the internal Inverter Section of EVO. When the AC input is
restored, the EVO will revert back to “Charging Mode” to charge the batteries and at the same time, pass through
the AC input to the AC output.
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4.6.5.2 Option “1= On-Line”: This option is also called “On-Line UPS Mode” (UPS stands for Un-interruptible
Power Supply). In this mode, the Inverter Section of the EVO is the PRIMARY DC-AC source of power. The AC
input source is the BACK-UP source of AC power. In this mode, even if qualied AC input is available (within the
programmed voltage and frequency limits), the EVO will still operate in “Inverting Mode” and AC output will be
provided by the Inverter Section as long as the batteries are in charged condition above the specied programmed
value of low battery voltage that is set through programmable parameter “LOW VOLT ALARM” [See Section
4.4.2.8 of EVO-RC-PLUS Remote Control Manual] . When the battery discharges to the programmed voltage
threshold of “LOW VOLT ALARM”, or lower and remains at this threshold, or below for a sustained programmed
time period set by programmable parameter “GS DETECT TIME” [See Section 4.4.2.16 of EVO-RC-PLUS Remote
Control Manual], the EVO will change over to “Charging Mode”. On changing over to “Charging Mode”,
qualied AC input will be passed through to the AC Output and at the same time, the Internal AC Charger
will start charging the battery. If an external Solar Charge Controller is also connected to the External Charging
Terminals (3, 4 in Fig 2.1), the internal AC Charger will limit the charging current as follows:
Value of charging current produced by EVO
Charging Section
=
Programmed value of charging current set by
parameter “BULK CURRENT” [See Section 4.4.2.1
of EVO-RC-PLUS Remote Control Manual] minus
(Value of current fed from the external solar charge
controller)
Under the following 2 conditions, “Charging Mode” will be terminated, and the EVO will switch back to “Inverting
Mode”. Switching from “Charging Mode” back to “Inverting Mode” has 2 options under programming parameter
“ONLINE OPTION” [See Section 4.4.2.14 of EVO-RC-PLUS Remote Control Manual]:
i. When Parameter “ONLINE OPTION” is set at option “0= Option 1” [See Section 4.4.2.14 of EVO-RC-PLUS
Remote Control Manual]:
TM
EVO
will switch back from "Charging Mode" to "Inverting Mode" after completion of 3-Stage/ 2-Stage
charging prole programmed through parameter "CHARGING PROFILE" [See Section 4.4.2.21 in the EVO-
RC-PLUS Remote Control Manual]
ii. When Parameter “ONLINE OPTION” is set at option “1= Option 2” [See Section 4.4.2.4 in the EVO-RC-PLUS
Remote Control Manual]:
TM
EVO
will switch back from "Charging Mode" to "Inverting Mode" when the batteries have charged to
the voltage threshold set by parameter "RESET VOLTAGE"[See Section 4.4.2.7 in the EVO-RC-PLUS Remote
Control Manual] and have remained at this threshold or higher for time period set by parameter "GEN OFF
DELAY" [See Section 4.4.2.18 in the EVO-RC-PLUS Remote Control Manual].
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i
!
4.6.5.3 Option “2=Charger Only”.
In Off-grid DC powered homes, for efciency consideration, all lighting and other loads / appliances are normally
powered from batteries that are primarily charged through solar / wind power. Generator backup is used for
powering AC to DC battery charger for charging the batteries during extended periods of cloudy / no wind
conditions. To meet this requirement, the EVO
when AC input power is available within the programmed limits of voltage and frequency, charging will take place
and AC input will be passed through to the load(s). The unit will NOT transfer to Inverting Mode if AC input fails
or is outside the programmed limits of voltage and frequency [For details, see Section 4.4.2.13.3 of EVO-RC-PLUS
Remote Control Manual].
INFO
Online Mode is suitable for installations where both Grid and Photovoltaic (PV) Solar Battery
Charging System are available. It is also desirable in areas where Grid / Utility Energy Rates
are very high and use of supplementary battery based photovoltaic power system is more cost
effective.
TM
can be programmed to operate as a battery charger ONLY i.e.
4.7 TEMPERATURE SENSOR FOR BATTERY CHARGING
Battery Temperature Sensor Model EVO-BCTS [Fig 2.5(a)] has been provided to ensure optimum charging of Lead
Acid/ Nickel-Zinc (Ni-Zn) batteries by modifying the charging voltages based on temperature if the battery sees very
wide temperature swings. See Section 5.5 for details. Temperature compensation can be programmed with the
help of optional Remote Control EVO-RC [See Section 4.4.2.5 of EVO-RC-PLUS Remote Control Manual]. 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 because 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). See Section 1.4.5 for more details on
temperature compensation.
CAUTION!
1. Lithium Ion Battery charging does not require temperature compensation. Hence, do not use EVO-BCTS
Temperature Sensor when charging Lithium Ion Batteries.
2. Automatic temperature compensation using EVO-BCTS Temperature Sensor is designed for Lead Acid Batteries
based on programming parameter "COMPENSATE" [See Section 4.4.2.5 in EVO-RC-PLUS Remote Control
Manual]. When charging Nickel-Zinc (Ni-Zn) batteries, ensure that the value of programming parameter
"COMPENSATE" is set based on approximate linear compensation for the particular Ni-Zn battery.
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!
ATTENTION!
1. Le chargement au lithium-ion ne nécessite pas de compensation de température. Par conséquent,
n'utilisez pas le capteur de température EVO-BCTS lors du chargement de batteries au lithium-ion.
2. La compensation automatique de température à l'aide du capteur de température EVO-BCTS est conçue
pour les batteries au plomb selon le paramètre de programmation "COMPENSATE" [voir la section
4.4.2.5 du manuel de la télécommande EVO-RC-PLUS]. Lors de la charge en nickel-zinc (Ni-Zn) batteries,
assurez-vous que la valeur du paramètre de programmation "COMPENSATE" est dénie sur la base d'une
compensation linéaire approximative pour la batterie Ni-Zn concernée.
4.8 PARALLEL OPERATION WITH EXTERNAL SOLAR CHARGE CONTROLLER
The Battery Charger Section is able to operate in parallel with external Solar Charge Controller 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 value of parameter "BULK CURRENT" [See Section 4.4.2.1 in the EVO-RC-
PLUS Remote Control Manual]. This improves the life of the battery. Please see Section 5.4 for more details.
4.9 COOLING AND OVER TEMPERATURE PROTECTION
4.9.1 Cooling Fans
The unit is cooled by convection and by forced air cooling using 2 variable speed cooling fans. Temperature is
sensed at the Power Transformer and H-Bridge Power Mosfets / Heat Sink. The fans will be switched ON at specied
temperatures measured at the above sense points. The speed of the fans is increased as the temperature rises.
4.9.2 Over Temperature Protection
[Refer to Fault Messages and Troubleshooting Guide at Table 7.1 of EVO-RC-PLUS Remote Control Manual]. The unit
goes to Fault Mode and shuts down due to over temperature sensed at the Main Power Transformer and the Heat Sink for
the Power Mosfets: Fault messages and temperature thresholds for shut down and auto-reset are as follows:
• “Transformer over heat!” : Shut down at 150C and auto-reset at 80C
• “Heat sink over heat!” : Shut down at 100C and auto-reset at 60C
4.9.3 Automatic Reduction Of Charging Current In Higher Ambient Temperatures
In order to protect against over temperature shut down when operating in higher ambient temperatures of 50C to 60C,
the BULK CURRENT setting [See Section 4.4.2.1 in the EVO-RC-PLUS Remote Control Manual] is automatically reduced as
follows based on temperature sensed at the Power Transformer and at the Heat Sink for the Power Mosfets:
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• Power Transformer: In case the temperature is >130C, the BULK CURRENT setting is automatically reduced by
0.2% every 20 sec
• Heat Sink: In case the temperature is >90C, the BULK CURRENT is automatically reduced by 0.2% every 20 sec
4.10 OPTIONAL REMOTE CONTROL EVO-RC FOR PROGRAMMING OF MODES OF OPERATION
AND PARAMETERS
Optional Remote Control Model EVO-RC-PLUS [Fig 2.4(a)] will be required for more advanced control and monitoring.
Please see separate Owner’s Manual for EVO-RC-PLUS. 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 Internal 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 specic requirements. Each programmable 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.
SECTION 5 | Battery Charging in Evolution™ Series
5.1 PRINCIPLES OF OPERATION OF BATTERY CHARGING SECTION
5.1.1 General Information
EVO Series is a Low Frequency Type, Pure Sine Wave, Single Phase Inverter-Charger with a built-in Transfer Relay. It
uses high performance, 100MHz SP (Digital Signal Processing) type of micro-controller and Pulse Width Modulation
(PWM) control. It is Bi-Directional i.e. it uses a common Converter Section consisting of Low Frequency Isolation
Transformer and Mosfet based H-Bridge that can work in two directions as follows:
INFO
For background information on batteries and charging process, please read Section 1.4, “General
Information - Battery Related”. All battery charging voltages are specied at battery temperature
of 25˚C / 77˚F.
1) AC to DC Charging Mode: The common Converter Section is used to convert external AC input power to
DC output power to charge the batteries and at the same time, pass through the AC input power to the AC
loads
2) DC to AC Inverting Mode: The common Converter Section is used to convert DC input power from the
batteries to AC output power to feed the AC loads
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i
During “Charging Mode”, the internal Transfer Relay is energized when AC input power from Grid / Generator is
within the programmed limits of voltage and frequency and the following actions are initiated:
5.1.2 Basics of PWM (Pulse Width Modulation) Based Charging Process
5.1.2.1 AC input power is fed to the Primary Winding of the Isolation Transformer. The voltage on the Secondary of
the isolation Transformer is stepped down and fed to input of H-Bridge Converter that uses four N-Channel Mosfet
Switches. The output of the H-Bridge is fed to the battery / battery bank. PWM (Pulse Width Modulation) technique is
used for the charging process. PWM frequency is 30 kHz
5.1.2.2 The two High-Side Mosfet Switches of the H-Bridge are kept OFF and their Body Diodes are used for full-wave
rectication of the stepped down AC input voltage. The average / mean value of battery charging current will vary
between 0A and a Positive peak value in the form of DC Wave resembling sine wave. The charging current displayed
by the EVO-RC Remote Control will be the average / mean value of the above DC Wave
INFO
Please note that as the unit is Bi-Directional with a common Converter Section as explained
above, it cannot work as inverter and charger at the same time
• AC input power is fed to the Common Converter Section for conversion to DC voltage to charge the batteries
• AC input power is simultaneously passed through to the AC loads
5.1.2.3 The two Low-Side Mosfet Switches of the H-Bridge are switched ON / OFF together at PWM frequency of
30 kHz with variable “Duty Cycle” proportional to the desired value of charging current. When the two Low-Side
Mosfets are ON for period determined by the “Duty Cycle” set by the micro-controller, the Secondary Winding will be
short circuited and magnetic eld proportional to the short circuit current will be created by the winding. When the
two Low-Side Mosfet Switches are switched OFF, short circuit of the winding is removed resulting in collapse of the
magnetic eld and generation of induced voltage pulses at PWM frequency of 30 kHz with a value = - L di/dt where
“L” is the Inductance of the winding and “di/dt” is the rate of decay of Short Circuit Current. Thus, higher Duty Cycle
will produce induced pulses with higher voltage. When the voltage of the induced pulses is > the battery voltage,
charging current pulses will be produced. The value of charging current pulses will be proportional to the difference
of voltage between the voltage of the induced pulses and the battery voltage
5.1.2.4 During the Bulk Stage of charging (Section 5.7.1.1), the average / mean charging current set by programming
parameter “BULK CURRENT” [See section 4.4.2.1 of EVO-RC-PLUS Remote Control Manual] is held constant by
controlling the “Duty Cycle” of the 30 kHz induced pulses.
5.1.2.5 During Absorption Stage (Section 5.7.2), Float Stage (5.7.3) and Equalization Stage (5.8.2.3), the battery
voltage is held constant indirectly by controlling the “Duty Cycle” of the 30 kHz induced pulses. For example, if the
INFO
When charging starts, the charging current is NOT increased to the programmed value of
parameter BULK CURRENT immediately but is gradually ramped up to this value
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SECTION 5 | Battery Charging in Evolution™ Series
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battery voltage increases above the value set by parameters ABSORP VOLTAGE / FLOATING VOLTAGE / EQUALIZE
VOLTAGE, the PWM “Duty Cycle” is reduced that leads to lower short circuit current of the Secondary Winding.
This will reduce the voltage of the induced pulses and consequently, reduce the value of the charging current pulses.
Reduced value of charging current pulses will reduce the battery voltage back to the value set by ABSORP VOLTAGE /
FLOATING VOLTAGE / EQUALIZE VOLTAGE
5.1.2.6 Battery Charging Proles
7 programmable types of 2/3/4 Stage Charging Proles are available. Please see details under Section 5.6
5.2 DYNAMIC AC INPUT CURRENT DIVERSION CONTROL BETWEEN AC PASS THROUGH
CURRENT AND BATTERY CHARGING CURRENT
EVO Models have very powerful Battery Charger Section that will require very high AC input current from the AC
input source (See Table 5.1).
TABLE 5.1 CHARGING CURRENTS AND PASS THROUGH LOAD CURRENTS
Rated Charging
Current
EVO-1212F &
EVO-1212F-HW
EVO-1224F &
EVO-1224F-HW
Max. DC Side
Charging Current
60A 11.2A 1200 VA 10A
40A 11.2A 1200 VA 10A
Equivalent AC Side
Charging Current
Maximum Pass Through
Load Power and Current
Pass Through
Power
Pass Through
Amps
When batteries are being charged at or near the maximum value of charging current (See TABLE 5.1) and the pass through
load current increases, the AC input supply circuit breaker may trip if the combined value of the AC side charging current
(equivalent to the DC side charging current) and the pass through load current exceeds the AC input supply circuit breaker
capacity. This situation is prevented by “Dynamic AC Input Current Diversion Control between AC Pass through Current
and Battery Charging Current”. This is accomplished through appropriate setting of programmable parameters “GRID
MAX CURRENT”. Optional Remote Control Model EVO-RC-PLUS will be required for the above setting [Please refer to
Section 4.5.2.2 of the EVO-RC-PLUS Remote Control Manual].
“GRID MAX CURRENT” (Default = 20A) should be set equal to the Ampere rating of the external AC input supply
breakers. During Battery Charging Mode, if the AC pass through load current is increased resulting in the net AC input
current increasing by 1A more than the programmed “GRID MAX CURRENT” for 1 sec, the EVO will automatically
reduce the charging current to ensure that the equivalent AC Side Charging Current + Pass Through Load
Current is not more than the set value of “GRID MAX".
INFO
As explained above, if the net AC input current is 1A more than the value of GRID MAX CURRENT for 1 sec,
the AC side charging current is clawed back to ensure that GRID MAX CURRENT value is not exceeded. If
the value of pass through load current increases to a value of 1A more than the programmed value of GRID
MAX CURRENT for 5 sec, input over current protection will be activated based on option to either transfer
to Inverting Mode or to shut down in FAULT MODE [Refer to details of these 2 options under parameter
“INPUT OC PROTECT” at Section 4.5.2.10 in the EVO-RC-PLUS Owner’s Manual]
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SECTION 4 | General Description & Principles of Operation
EXAMPLE:
1) Assume EVO-1212F is connected to the Grid input with Grid input supply circuit breaker capacity of 20A.
Parameter settings are as follows:
a) “GRID MAX CURRENT” setting = the Default value of 20A.
b) “BULK CURRENT” setting = 60A (DC). When charging at 60A on the DC side, the corresponding
AC side input current will be 11.2A (Based on Conversion Factor of 1A DC side charging current =
0.19A AC side charging current).
2) Assume that the AC pass-through load current is 5A. The total AC input current will be 16.2A i.e. 5A AC
pass-through load current + 11.2A AC input side current corresponding to 60A DC side charging current
[see 1(b) above)]. Under this condition, the EVO will operate normally because the net AC input current of
16.2A will be below 20A Default setting for parameter “GRID MAX CURRENT”
3) If now, the AC pass-through load current is increased to 15A for more than 5 sec, the total AC input
current will be 26.2A i.e. 15A pass through load current + 11.2A AC side charging current corresponding
to 60A DC side charging current [see 1(b) above)]. As the total AC input current will be 6.2A more than
the “GRID MAX CURRENT” for more than 1 sec, the AC input side charging current will be clawed back
from 11.2A to 8.8A within less than 5 sec so that the total AC input current is limited to 20A. At reduced
AC side charging current of 8.8A, the corresponding DC side charging current will be 46.3 A DC (Based on
Conversion Factor of 1A DC side charging current = 0.19A AC side charging current).
4) If now, the AC pass-through load current is increased to 22A for more than 5 sec, the total AC input
current will be 30.8A (22A pass through load current + 8.8A AC side charging current corresponding to
46.3A DC side charging current) . The AC side charging current will be automatically reduced from 8.8A
(corresponding to 46.3A DC side charging current) to 0A (corresponding to 0A DC side charging current).
However, now the AC input current will be still be 22A i.e. 2A more than the “GRID MAX” current setting
of 20A for more than 5 sec. After 5 sec of operation under this condition, the EVO will operate as follows
based the option selected through parameter “INPUT OC PROTECT” [See details of this parameter under
Section 4.5.2.10 in EVO-RC-PLUS Owner’s Manual]
o Parameter “INPUT OC PROTECT” set in the Default option “0=Inverter”: The EVO will switch over
to Inverter Mode to ensure that 22A AC load is maintained. If subsequently, the load reduces to 1A less
than the 20A setting of GRID MAX CURRENT for 5 sec, the EVO will switch back to Charging Mode
o Parameter “INPUT OC PROTECT” set for option “1= Shutdown”: EVO will be shut down.
• There will be no AC output because the Transfer Relay will be de-energized, charging will be stopped
and PWM drive to the Inverter Section will be switched off
• Fault message “Input over current” will be displayed on the LCD screen, Blue LED marked “Status”
will be switched off and Red LED marked “Fault” will be switched on
• The unit will be latched in OFF condition and will require manual reset by powering off
the unit, waiting for 1 min and then powering on again
5.3 AUTOMATIC REDUCTION OF CHARGING CURRENT IN HIGHER AMBIENT TEMPERATURES
In order to protect against over temperature shut down when operating in higher ambient temperatures of around
50C to 60C, the BULK CURRENT setting [See section 4.4.2.1 of EVO-RC-PLUS Remote Control Manual] is automatically
reduced as follows based on temperature sensed at the Power Transformer and at the Heat Sink for the Power Mosfets:
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SECTION 5 | Battery Charging in Evolution™ Series
• Power Transformer: In case the temperature is >130C, the BULK CURRENT setting is automatically reduced by
0.2% every 20 sec.
• Heat Sink: In case the temperature is >90C, the BULK CURRENT setting is automatically reduced by 0.2% every
20 sec.
5.4 PARALLEL CHARGING USING EXTERNAL SOLAR CHARGER
The batteries feeding the EVOTM can also be charged using appropriately sized external solar charging system. The
output of the solar panels will feed to an appropriately sized external Solar Charge Controller. Output of the external
Solar Charge Controller is fed to the input terminals marked “EXT Charger” (3,4 in Fig 2.1). Maximum charging
current on these terminals is to be limited to 50A. This limit should not be exceeded!
The charging current received from the external Solar Charge Controller is directly fed to the battery terminals (1,2
in Fig 2.1) through a series connected Hall-effect Current Sensing IC with integrated shunt. The value of this current
is displayed as “BATT EXT” on the optional Remote Control EVO-RC-PLUS. Refer to following display screens from
EVO-RC-PLUS Remote Control Manual.
• During Inverting Mode: Screen No.7 in Fig 3.2(a) under Section 3.6.3.2 of EVO-RC-PLUS Remote Control Manual
• During Charging Mode: Screen No.1 in Fig 3.3(a) of EVO-RC-PLUS Remote Control Manual
• During Power Save Mode: Screen No.5 in Fig 3.4(a) of EVO-RC-PLUS Remote Control Manual
The net Bulk Charging Current fed to the battery bank will, thus, be as follows:
• Net Bulk Charging Current fed to the battery bank= Adjusted Bulk Charging Current from the internal Battery
Charging Section + Current available from the external Solar Charge Controller
Normally, Lead Acid batteries should not be charged at very high Bulk Charging Current as this will damage the
batteries due to overheating and cell degradation. Normal Bulk Charging Current is in the range of 10% to 20% of the
Ah capacity of the battery bank at C/20 Discharge Rate. Check with the battery manufacturer regarding recommended
Bulk Charging Current for your battery bank. This value of “Bulk Charging Current” should be programmed as “BULK
CURRENT” using the optional Remote Control EVO-RC-PLUS [Refer to Section 4.4.2.1 in the Owner’s Manual for EVO-
RC-PLUS Remote Control].
The measured value of the charging current received from the external Solar Charge Controller is monitored by the
control circuitry of the internal Battery Charging Section. The amount of Bulk Charging Current produced by the
internal Battery Charging Section is adjusted in real time to satisfy the following condition:
• Internal Bulk Charging Current = Programmed Value of “Bulk Current” – External Charging Current
For example, if the “Bulk Current” in the EVO
Controller is generating 15A, the internal Battery Charging Section will reduce its current from 40A to 25A so
that the net charging current is equal to the programmed value of 40A.
In other Inverter Chargers where this design feature is not available and the Bulk Charging Current of the internal
Battery Charger Section is xed, the batteries are likely to be charged at high Bulk Charging Current = Fixed value
of Bulk Charging Current from the internal Battery Charging Section + Current available from the External Charge
Controller.
TM
is programmed at say 40A and the external Solar Charge
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CAUTION!
TM
Ensure that charging voltage related parameters of EVO
(iii) FLOAT VOLTAGE and (iv) Temperature Compensation (COMPENSATE) are set / programmed to match
the programmed parameters of the external charge controller. [Please refer to (i) Table 6.2, Section 6 and (ii)
Sections 4.4.2.2 to 4.4.2.5 of the EVO-RC-PLUS Remote Control Manual].
ATTENTION!
S'assurer que la charge de tension, les paramètres connexes d'EVO
(ii) EQUALIZE VOLTAGE, (iii) Tension d'égaliser et (iv) La compensation de température (COMPENSATE) est
réglée / programmée pour correspondre aux paramètres programmés du contrôleur de charge externe.
[Veuillez consulter (i) le tableau 6.2, section 6 et (ii) les sections 4.4.2.2 à 4.4.2.5 du manuel d'utilisation de la
télécommande EVO-RC-PLUS].
like (i) ABSORP VOLTAGE, (ii) EQUALIZE VOLTAGE,
TM
comme (i) La tension d'absorption,
5.5 BATTERY TEMPERATURE COMPENSATION USING TEMPERATURE SENSOR:
MODEL NO. EVO-BCTS
5.5.1 General Description – Battery Temperature Compensation
Please refer to Section 1.4.5 for general information on temperature compensation of battery charging voltages.
Battery Temperature Sensor Model EVO-BCTS [Fig 2.5(a)] has been provided to ensure optimum charging of Lead Acid
and Nickel Zinc (Ni-Zn) Batteries by negative temperature compensation of the charging voltages based on the battery
electrolyte temperature. The charging voltage is reduced when electrolyte temperature rises above the reference
temperature of 25°C / 77°F and increased when electrolyte temperature falls below the reference temperature of
25°C / 77°F.
Automatic temperature compensation will be carried out over temperature range of -20°C to +60°C based on the
programmed value of the negative “Temperature Coefcient of Battery Charging Voltage”. In EVO, this parameter is
called “COMPENSATE” and is specied in “mV/C/Cell”. For programming details of this parameter, please refer to the
following Sections of EVO-RC-PLUS Remote Manual:
INFO
Charging voltages of Lithium Ion Battery are not affected by temperature and hence, Battery Temperature
Sensor Model EVO-BCTS is not required to be used when Lithium Ion batteries are used.
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SECTION 5 | Battery Charging in Evolution™ Series
• Parameter Setup Menu Map at Fig 4.2: Screen 5
• Programming range and defaults: Screen No. 5 of Table 4.3
• Programming procedure: Section 4.4.2.5
In addition to compensating Absorption, Float and Equalization voltages, the voltage thresholds of parameters “LOW
VOLTAGE ALARM”, “BATTERY LOW VOLTAGE”, “RESET VOLTAGE”, “BATTERY OVER VOLTAGE” and “RESET TO
BULK” are also temperature compensated.
5.5.2 Constructional Details of Battery Temperature Sensor Model EVO-BCTS and Installation
The Temperature Sensor consists of 5 meters / 16.5 ft cable with Temperature Sensor Head for the battery end [1 in Fig
2.5(a)] and RJ-45 Plug [2 in Fig 2.5(a)] for EVO end.
Temperature Sensor Head [1 in Fig 2.5(a)]: The Temperature Sensor Head is installed on the Positive / Negative
battery Stud [Fig 2.5(b)] to monitor the temperature of the battery electrolyte. The Sensor Head contains an embedded
Negative Temperature Coefcient (NTC) Resistor with 2 internal terminals “NTC+” and “NTC -”. Internal terminal
“NTC+” is wired to Pin 4 of the RJ-45 Plug [2 in Fig 2.5(a)] and internal terminal “NTC -” is wired to Pin 5 of the RJ-45
Plug.
RJ-45 Plug [2 in Fig 2.5(a)]: The RJ-45 Plug is required to be plugged into the RJ-45 Jack marked “Battery Temp
Sensor” on the front panel of EVO (6 in Fig 2.1). Pinout of this RJ-45 Jack is shown in Fig 5.0.
RJ-45 Jack on the Front Panel of EVO
TM
(6, Fig 2.1) for Connecting Battery Temperature Sensor
Pinout of this RJ-45 Jack [marked “Battery Temp Sensor” on the front panel of EVO (6 in Fig 2.1)] is shown at Fig 5.0
below (also shown at Fig 3.13):
+5V
1K
5.1K
Batt Temp
to DSP
Internal
Schematic
TM
of EVO
1 2 3 4 5 6 7 8
Fig 5.0 Pinout of RJ-45 Jack marked “Battery Temp Sensor” on the front panel of EVO (6 in Fig 2.1).
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SECTION 5 | Battery Charging in Evolution™ Series
5.6 CHARGING PROFILES
Please refer to Section 1.4.3 regarding general information on 4 stages of battery charging. Depending upon the type
of batteries to be charged and its application, 2/3/4 charging stages may be used based on the appropriate Charging
Prole.
When AC input within the programmed window of voltage and frequency is available, EVO will operate as a battery
charger. Option is available for 7 charging proles as follows:
• 6 options for the following 3-Stage / 2-Stage charging proles through programming parameter “CHARGING
PROFILE” designed to cover various charging requirements for Lead Acid, Nickel-Zinc (Ni-Zn) and Lithium Ion
Batteries.
o 0 = 3 Stage Adaptive (Default)
o 1 = 3 Stage Type 1
o 2 = 3 Stage Type 2
o 3 = 2 Stage Type 1
o 4 = 2 Stage Type 2
o 5 = 2 Stage Type 3
• 1 option for 4-Stage Adaptive
Charging Prole for Equalization
for Lead Acid Batteries
CAUTION!
The Battery Management System (BMS) that comes with the type of Lithium Battery being used may need to
have control over charging and discharging of the battery. For this, Pins 4 and 5 of the Temperature Sensor Jack
(6, Fig 2.1; Pinout at Fig 5.0) may be used to feed potential free contact closing signal from the BMS to “Stop
Charging” or “Stop Inverting” Refer to Section 5.11.2 for details.
Refer to the following for more details:
• Section 5.7 for description and charging curves for
3-Stage Charging Proles
• Section 5.10 for description and charging curves for
2-Stage Charging Proles
• Programming procedure at Section 4.4.2.21 in the
EVO-RC-PLUS Remote Control Manual
Refer to the following for more details:
• Section 5.8 for description and charging proles
• Programming procedure at Section 4.4.2.12 in the
EVO-RC-PLUS Remote Control Manual
ATTENTION!
Le système de gestion de la batterie (BMS) qui vient avec le type de batterie au lithium utilisé aura besoin
d'avoir le contrôle de charge et décharge de la batterie. Pour cela, les broches 4 et 5 du capteur de
température (6, Fig. 2.1; Pinout à la Fig. 5.0) peut être utilisé pour l'alimentation contact libre de signal de
fermeture de la BMS à "arrêter la charge" ou "arrêter d'inverser". Se reporter à la Section 5.11.2 pour plus
de détails.
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SECTION 5 | Battery Charging in Evolution™ Series
5.7 3-STAGE CHARGING PROFILE - DETAILED EXPLANATION
Refer to 3 types of 3-Stage Charging Prole options at Srls. 1 to 3 in TABLE 5.2.
Fig. 5.1 shows the voltage and current charging curves with respect to time and different charging stages associated
with these proles.
INFO
4-Stage Adaptive Charging Prole for Equalization is also available and can be activated at any time during
charging taking place under these 3-stage proles. Procedure to activate 4-Stage Adaptive Charging Prole
for Equalization is described under programming parameter "EQUALIZE-4 STAGES" at Section 4.4.2.12 in
the EVO-RC-PLUS Remote Control Manual.
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TABLE 5.2 3 TYPES OF CHARGING PROFILE OPTIONS FOR 3-STAGE CHARGING
Options under Programming
Parameter “CHARGING PROFILE”
Srl
(See Section 4.4.2.21 in EVO-RC-PLIS
No.
Remote Control Manual)
Charging Stages Battery Type
0 = 3 Stage Adaptive
1
NOTES:
1.This is the default, 3-Stage Adaptive
Type of Charging Prole with Adaptive
Time Algorithm for Absorption Stage
1. Stage 1 – Bulk Stage (See Section 5.7.1.1 for details)
• Charge at constant current (CC) = the programmed value
of parameter “BULK CURRENT” (Default value is 20A. For details
of programming range & procedure, refer to Section 4.4.2.1 of EVO-RC-PLUS
Remote Control Manual)
• Transition to Absorption Stage when voltage rises to the
set value for programming parameter “ABSORP VOLTAGE”
(Default value is 14.4V for EVO-1212F/1212F-HW and 28.8V for EVO-
1224F/1224F-HW. For details of programming range & procedure, refer to
Section 4.4.2.2 of EVO-RC-PLUS Remote Control Manual)
2. Stage 2 - Absorption Stage (See Section 5.7.2 for details)
• Charge at constant voltage (CV) = the programmed value
for parameter “ABSORP VOLTAGE”. (Default value is 14.4V for
EVO-1212F/1212F-HW and 28.8V for EVO-1224F/1224F-HW. For details
of programming range & procedure, refer to Section 4.4.2.2 of EVO-RC-PLUS
Remote Control Manual)
• Adaptive Time Algorithm: Time in Absorption Stage is
computed automatically based on time in Bulk Stage (See
Section 5.7.2 for details).
• Transition to Float Stage thereafter.
3. Stage 3 - Float Stage (See Section 5.7.3 for details)
• Charge at constant voltage (CV) = the programmed value
of parameter “FLOAT VOLTAGE”. (Default value is 13.5V for
EVO-1212F/1212F-HW and 27.0V for EVO-1224F/1224F-HW. For details
of programming range & procedure, refer to Section 4.4.2.4 of EVO-RC-PLUS
Remote Control Manual)
• Reset to Bulk Stage under the following conditions:
i. If the AC input is disconnected and is reconnected.
ii. If battery voltage falls to the programmed value of
parameter "RESET TO BULK" (Default value is 12.0V for
EVO-1212F/1212F-HW and 24.0V for EVO-1224F/1224F-HW. For
details of programming range & procedure, refer to Section 4.4.2.15 of
EVO-RC-PLUS Remote Control Manual)
iii. If the charger remains in the Float Stage for 10 days
− Lead Acid: Flooded and sealed –
AGM/Gel Cell
− ENSURE that there are no other
DC load(s) on the batteries.
Load(s) on the battery may
drain full or part of the charging
current and will upset the
“Adaptive Time Algorithm” for
Absorption Stage time
1 = 3 Stage Type 1 1. Stage 1 – Bulk Stage (See Section 5.7.1.1 for details)
2
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• Charge at constant current (CC) = the programmed value
of parameter “BULK CURRENT” (Default value is 20A. For details
of programming range & procedure, refer to Section 4.4.2.1 of EVO-RC-PLUS
Remote Control Manual)
• Transition to Absorption Stage when voltage rises to the
set value for programming parameter “ABSORP VOLTAGE”
(Default value is 14.4V for EVO-1212F/1212F-HW and 28.8V for EVO-
1224F/1224F-HW. For details of programming range & procedure, refer to
Section 4.4.2.2 of EVO-RC-PLUS Remote Control Manual)
2. Stage 2 - Absorption Stage (See Section 5.7.2 for details)
• Charge at constant voltage (CV) = the programmed value
for parameter “ABSORP VOLTAGE”.
EVO-1212F/1212F-HW and 28.8V for EVO-1224F/1224F-HW. For details
of programming range & procedure, refer to Section 4.4.2.2 of EVO-RC-PLUS
Remote Control Manual)
(Default value is 14.4V for
• Remain in Absorption Stage for time duration =
programmed value of parameter “ABSORP TIME” (Default
value is 60 min. For details of programming range & procedure, refer to Section
4.4.2.19 of EVO-RC-PLUS Remote Control Manual)
• Transition to Float Stage thereafter.
− Lead Acid: Flooded and sealed –
AGM/Gel Cell
− Lithium (See Section 5.11 for
details)
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SECTION 5 | Battery Charging in Evolution™ Series
3. Stage 3 - Float Stage (See Section 5.7.3 for details)
• Charge at constant voltage (CV) = the programmed value
of parameter “FLOAT VOLTAGE”. (Default value is 13.5V for
EVO-1212F/1212F-HW and 27.0V for EVO-1224F/1224F-HW. For details
of programming range & procedure, refer to Section 4.4.2.4 of EVO-RC-PLUS
Remote Control Manual)
• Reset to Bulk Stage under the following conditions:
i. If the AC input is disconnected and is reconnected.
ii. If battery voltage falls to the programmed value of
parameter "RESET TO BULK"
EVO-1212F/1212F-HW and 24.0V for EVO-1224F/1224F-HW. For
details of programming range & procedure, refer to Section 4.4.2.15 of
EVO-RC-PLUS Remote Control Manual).
iii. If the charger remains in the Float Stage for 10 days
(Default value is 12.0V for
2 = 3 Stage Type 2 1. Stage 1 – Bulk Stage (See Section 5.7.1.1 for details)
3
• Charge at constant current (CC) = the programmed value
of parameter “BULK CURRENT” (Default value is 20A. For details
of programming range & procedure, refer to Section 4.4.2.1 of EVO-RC-PLUS
Remote Control Manual)
• Transition to Absorption Stage when voltage rises to the
set value for programming parameter “ABSORP VOLTAGE”
(Default value is 14.4V for EVO-1212F/1212F-HW and 28.8V for EVO-
1224F/1224F-HW. For details of programming range & procedure, refer to
Section 4.4.2.2 of EVO-RC-PLUS Remote Control Manual)
2. Stage 2 - Absorption Stage (See Section 5.7.2 for details)
• Charge at constant voltage (CV) = the programmed value
for parameter “ABSORP VOLTAGE”. (Default value is 14.4V for
EVO-1212F/1212F-HW and 28.8V for EVO-1224F/1224F-HW. For details
of programming range & procedure, refer to Section 4.4.2.2 of EVO-RC-PLUS
Remote Control Manual)
• Remain in Absorption Stage till the current reduces to value
= the programmed value of parameter “ABSORP EXIT
AMPS”
(Default value is 4A. For details of programming range & procedure,
refer to Section 4.4.2.20 of EVO-RC-PLUS Remote Control Manual)
• Transition to Float Stage thereafter.
3. Stage 3 - Float Stage (See Section 5.7.3 for details)
• Charge at constant voltage (CV) = the programmed value
of parameter “FLOAT VOLTAGE”.
EVO-1212F/1212F-HW and 27.0V for EVO-1224F/1224F-HW. For details
of programming range & procedure, refer to Section 4.4.2.4 of EVO-RC-PLUS
Remote Control Manual)
• Reset to Bulk Stage under the following conditions:
i. If the AC input is disconnected and is reconnected.
• If battery voltage falls to the programmed value of
parameter "RESET TO BULK"
1212F/1212F-HW and 24.0V for EVO-1224F/1224F-HW. For details of
programming range & procedure, refer to Section 4.4.2.15 of EVO-RC-PLUS
Remote Control Manual)
(Default value is 12.0V for EVO-
ii. If the charger remains in the Float Stage for 10 days
− Lead Acid: Flooded and sealed –
AGM/Gel Cell
− Lithium (See Section 5.11 for
details)
(Default value is 13.5V for
5.7.1.1 STAGE 1 – Bulk Charge Stage
Refer to Fig 5.1 and Srl No. 1 of TABLE 5.2
During the 1st Bulk Charge Stage, the Duty Cycle of the boosted high frequency PWM voltage pulses (Section 5.1.2)
is adjusted continuously to charge the battery at constant current (CC) = the programmed value of parameter "BULK
CURRENT" designated as"Io"(Default value is 20A. For details of programming range & procedure for parameter "BULK
CURRENT", refer to Section 4.4.2.1 of EVO-RC-PLUS Remote Control Manual)
NOTE: The current will slowly ramp up to the programmed value of "BULK CURRENT"
SAMLEX AMERICA INC. | 99
Page 100
TIME
SECTION 5 | Battery Charging in Evolution™ Series
This current is delivered to the batteries until the battery voltage approaches its Gassing Voltage i.e. Absorption Voltage
which is typically around 14.4 volts for 12 volt batteries and 28.8 volts for 24 volt batteries. The desired value can be
programmed using the optional Remote Control EVO-RC-PLUS [Refer to parameter "ABSORP VOLTAGE" in Table 6.2
and at Section 4.4.2.2 of EVO-RC-PLUS manual]. The Bulk Charge Stage restores about 75% 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 since this will
cause the battery to lose electrolyte and dry out over time.
This stage is displayed as "X-Bulk Stage" in the 2
nd
line of the Charging Mode screens in the Remote Control EVO-RC-PLUS.
Refer to the display screens shown in Fig 3.3(a) under Section 3.6.4.1 of EVO-RC-PLUS Remote Control Manual. Character
"X" denotes code for the Charging Prole that is active. (For details of codes, please see Table 3.2 under Section 3.6.4.3
of EVO-RC-PLUS Remote Control Manual).
ABSORPTION
STAGE
Displayed as:
“X-Absorption Stage”
FLOAT
STAGE
Displayed as:
“X-Float Stage”
“RESET TO
BULK”
BULK CURRENT “Io”
CURRENT (%) of set
100%
60%
0%
24V Battery
12V Battery
30
15
28
14
26
13
24
12
22
11
Charger Voltage, VDC
20
10
0
0
BULK
STAGE
Displayed as:
“X-Bulk Stage”
(V
- 0.3V)
Absorp
Io
To T1
LEGEND for Fig 5.1
—————
•••••
Io
To
T1
"X-BULK STAGE", "X-ABSORPTION
STAGE", "X-FLOAT STAGE"
Voltage (V) Curve
Current (I) Curve
Bulk Stage Current. Please see Section 5.7.1.1
Bulk Stage Time. Please see Section 5.7.1.1
Time in Absorption Stage. Please see Section 5.7.2
This coded information relates to the active Charging Prole and Charging Stage and is displayed
in the 2nd line of the Charging Mode Display Screens of EVO-RC-PLUS Remote Control. Please see
Table 3.2 under Section 3.6.4.3 of EVO-RC-PLUS Remote Control Manual
RESET TO BULK
At this point, the charger is forced to reset automatically from the operating charging stage and
restart the selected CHARGING PROFILE from the 1st Stage i.e. from the Bulk Stage. Please see
Section 5.7.4
NOTES for Fig 5.1
1. Voltage (V) and Current (I) curves show the battery voltage and current.
2. The Voltage (V) and Current (I) curves shown are based on the following operating conditions:
a) The battery is being charged exclusively by the Battery charging Section of EVO and that there is NO external charging source that is
charging the battery / battery bank
b) There is no external DC load on the battery / battery bank (the entire current delivered by the Charging Section of EVO is being used
to charge the battery / battery bank)
Fig 5.1 Charging Curves for 3-Stage Charging Prole
100 | SAMLEX AMERICA INC.
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