Samlexpower Evolution EVO-1212F, Evolution EVO-1224F, Evolution EVO-1224F-HW, Evolution EVO-1212F-HW Owner's Manual
Page 1
EvolutionTM Series
Inverter/Charger
Pure Sine Wave
Models:
EVO-1212F
EVO-1212F-HW
EVO-1224F
EVO-1224F-HW
Please read this
manual BEFORE
operating.
Firmware:
Rev 0.74
Owner's
Manual
Page 2
2 | SAMLEX AMERICA INC.
EVOTM INVERTER/CHARGER MANUAL | Index
SECTION 1
Safety Instructions & General Information ............................ 3
SECTION 2
Components & Layout ....................................................... 25
SECTION 3
Installation ......................................................................... 30
SECTION 4
General Description and Principles of Operation ................. 71
SECTION 5
Battery Charging in EvolutionTM Series ................................ 80
SECTION 6
Operation, Protections and Troubleshooting ...................... 97
SECTION 7
Specications .................................................................... 105
SECTION 8
Warranty ...................................................................... 108
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 Inc 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 © 2016 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.
Page 3
SECTION 1 | Safety Instructions & General Information
1.1 IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS. THIS MANUAL CONTAINS IMPORTANT INSTRUCTIONS FOR
MODELS: EVO-1212F, 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:
WARNING!
Indicates possibility of physical harm to the user in case of non-compliance.
MISE EN GARDE!
Il y a une possibilité de faire du mal physique à l'utilisateur si les consignes de sécurités
sont pas suivies
!
CAUTION!
Indicates possibility of damage to the equipment in case of non-compliance.
ATTENTION!
Il y a une risque de faire des dégâts à l'équipement si l'utilisateur ne suit pas les instructions
i
INFO
Indicates useful supplemental information.
Please read these instructions BEFORE installing or operating the unit to prevent personal injury or damage to the unit.
WARNING!
!
CAUTION!
1.
W
ARNING! 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 weatherdeck installation. To reduce risk of electrical shock, do not expose to rain or spray.
3.1 CAUTION! EVO
TM
Inverter/Charger with fully automatic charging circuit charges properly
rated 12V / 24V Lead Acid Batteries. When EVO
TM
Inverter/Charger is in Charge Mode,
Green LED marked "ON" will be blinking.
3.2 CAUTION! Option is available to use 12V / 24V nominal Lithium 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. When
the EVO
TM
Inverter/Charger is in Charge Mode, Green LED marked "ON" will be blinking.
Page 4
4 | SAMLEX AMERICA INC.
4. CAUTION! For indoors use only.
5.
W
ARNING! 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 for sizing of
conductors for AC INPUT circuits and Table 1.2 for sizing of conductors for AC OUTPUT
circuits.
7.
W
ARNING! Over current protection (AC Breakers) for the AC input / output circuits
has NOT been provided for EVO-1212F-HW / 1224F-HW and has to be provided by the
installer / user. See guidelines at Table 1.1 for sizing of breakers for AC INPUT circuits
and Table 1.2 for sizing of breakers for AC OUTPUT circuits. National and Local Electrical
Codes will supersede these guidelines.
8.
CAUTION!
The battery terminals are intended for eld connection using Copper
conductors that are sized based on 90°C. See Table 1.3 for recommended sizes for
installation in free air and conduit respectively.
9.
W
ARNING! 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 1.3
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 1.4.
11.
This unit has been pr
ovided 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 cir
cuit operating at more than 150 Volts to Ground.
Do not connect to AC Load Center (Cir
cuit 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 r
emove 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 1.5.
Other types may fail to operate properly when connected to this unit.
14.
GROUNDING: The Gr
ounding 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.
Grounding Symbol / Défaut à la terre
SECTION 1 | Safety Instructions & General Information
Page 5
15. WARNING! Precautions When Working With Batteries.
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 Hydr
ogen 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.
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 r
emove 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 Batteries
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 to the EVO
TM
Inverter/Charger under conditions of (i) over voltage /
over heating (to stop charging) and (ii) deep discharge (to stop inverting).
TABLE 1.1 SIZING OF AC INPUT WIRING AND BREAKERS (Refer to Table 3.2 for more details)
Model No.
(Rated Output
Power in
Inverter Mode)
(Column 1)
Rated
AC Pass
Through
Current
(Column 2)
Maximum
AC Side
Charging
Current
(Column 3)
Maximum
AC Input
Current
Limit
(Parameter
"GRID MAX
CURRENT")
(Column 4)
NEC Ampac-
ity = 125%
of Column 4
(Column 5)
Conductor
Size Based
on NEC
Ampacity at
Column 5
(Column 6)
Size of
Breaker
Based on
Column 4
(Column 7)
EVO-1212F
(1200VA)
10A 11.2A 20A 25A AWG# 12 20A
EVO-1212F-HW
(1200VA)
10A 11.2A 20A 25A AWG# 12 20A
EVO-1224F
(1200VA)
10A 11.2A 20A 25A AWG# 12 20A
EVO-1224F-HW
(1200VA)
10A 11.2A 20A 25A AWG# 12 20A
SECTION 1 | Safety Instructions & General Information
Page 6
6 | SAMLEX AMERICA INC.
Table 1.2 AC OUTPUT WIRING AND BREAKERS (Refer to Table 3.3 for more details)
Model No.
(Rated Power in
Inverter Mode)
(Column 1)
Rated AC Output
Current in
Inverter Mode
(Column 2)
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-1212F
(1200VA)
10A 12.5A AWG# 14 15A
EVO-1212F-HW
(1200VA)
10A 12.5A AWG# 14 15A
EVO-1224F
(1200VA)
10A 12.5A AWG# 14 15A
EVO-1224F-HW
(1200VA)
10A 12.5A AWG# 14 15A
TABLE 1.3 SIZING OF BATTERY SIDE CABLES AND EXTERNAL BATTERY SIDE FUSES
(Refer to Table 3.1 for more details)
Model No.
(Column 1)
Rated
Continuous
DC Input
Current
(Column 2)
NEC Ampac-
ity = 125%
of Rated
DC Input
Current at
Column 2
(Column 3)
90°C Copper Conductor. Size Based
on NEC Ampacity at Column (3) or
2%Voltage Drop, whichever is Thicker
External
Fuse Based
on NEC
Ampacity at
Column (3)
(Column 9)
Cable Running Distance
between the Unit
and the Battery
(Cable Routing In Free Air)
Cable Running Distance
between the Unit and
the Battery
(Cable Routing In Raceway)
Up to 5 ft.
(Column 5)
Up to 10 ft.
(Column 6)
Up to 5 ft.
(Column 7)
Up to 10 ft.
(Column 8)
EVO-1212F
152 190 AWG# 2 AWG# 2/0 AWG# 2/0 AWG# 2/0 200A
EVO-1212F-HW
EVO-1224F
76 95 AWG# 6 AWG# 4 AWG# 3 AWG# 3 100A
EVO-1224F-HW
External
Charger 50A 63A
AWG# 6
(2% voltage
drop is thicker)
AWG# 2
(2% voltage
drop is thicker)
AWG# 6
AWG# 2
(2% voltage
drop is thicker)
70A
TABLE 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 1.5 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
SECTION 1 | Safety Instructions & General Information
Page 7
MISE EN GARDE!
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.
A
TTENTION! Cet appareil est conçu pour une installation PAS Météo-pont. Pour réduire les risques de choc élec-
trique, ne pas exposer à la pluie ou à la neige.
3.1
A
TTENTION! L'onduleur / chargeur EVO
TM
avec circuit de charge entièrement automatique charge des batteries au
plomb 12V / 24V correctement dimensionnées. Lorsque l'onduleur / chargeur EVO
TM
est en mode de charge, la
DEL verte marquée «ON» clignote.
3.2 ATTENTION! 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
TM
est alors en mode de charge, le voyant vert 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 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 pour le dimensionnement des disjoncteurs pour les circuits d’entrée CA et le tableau 1.2
pour le dimensionnement des disjoncteurs pour les circuits de sortie AC. Codes électriques nationaux et locaux
remplaceront ces lignes directrices.
8.
A
TTENTION! 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 1.3 pour les tailles recommandées pour l’installation à
l’air libre et conduit respectivement.
9.
M
ISE 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 1.3 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 1.4.
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. Utilisez uniquement les GFCIs suivantes. 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
SECTION 1 | Safety Instructions & General Information
Page 8
8 | SAMLEX AMERICA INC.
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.
Grounding Symbol / Défaut à la terre
15.
MISE EN GARDE! Précautions lorsque vous travaillez avec des piles.
Batteries au plomb
Les piles contiennent très corrosif acide sulfurique dilué comme électrolyte. Des précau
tions doivent être prises
pour empêcher tout contact avec la peau, les yeux ou les vêtements. Porter des lunettes de protection.
Batterie au lithium
S'assurer que la tension, le courant et les paramètres de prol de charge le chargeur sont conformes à ce que
le système de gestion de la batterie (BMS) de la batterie est en mesure de fournir de la fermeture du contact à
l'EVO
TM
onduleur/chargeur dans des conditions de (i) surtension / plus de chauffage (d'arrêter le chargement) et (ii)
une décharge profonde (pour arrêter l'inversion).
Les batteries produisent de l’hydrogène et de l’oxygène lors de la charge résultant de l’évolution du mélange
de gaz explosif. Il faut prendre soin de ventiler la zone de la batterie et de suivre les recommandations du
fabricant de la batterie.
Ne jamais fumer ou permettre une étincelle ou une amme près des batteries.
Faites preuve de prudence an de réduire le risque de chute d’un outil métallique sur la batterie. Il pourrait
provoquer un court-circuit ou la batterie ou d’autres pièces électriques et pourrait causer une explosion.
T
oujours utiliser des outils isolés
Retirez les articles métalliques tels que des bagues, des bracelets et des montres lorsque vous travaillez avec
des batteries. Les batteries peuvent produire un court-circuit sufsamment élevé pour souder une bague ou
autre métal et ainsi causer de graves brûlures.
Si vous devez retirer la batterie, retirez toujours la borne de terre de la batterie. Assurez-vous que tous les
accessoires sont hors de sorte que vous ne causent pas une étincelle.
1.2 DEFINITIONS
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
SECTION 1 | Safety Instructions & General Information
Page 9
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
L
), Capacitive Reactance (XC) and Reactance (X): Reactance is the
opposition of a circuit element to a change of electric current or voltage due to that element’s
inductance or capacitance. Inductive Reactance (X
L
) is the property of a coil of wire in resisting
any change of electric current through the coil. It is proportional to frequency and inductance
and causes the current vector to lag the voltage vector by Phase Angle (φ) = 90°. Capacitive reactance (X
C
) is the property of capacitive elements to oppose changes in voltage. XC is 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
L
and XC is “Ohm” - also denoted as “”.
The effects of inductive reactance X
L
to cause the current to lag the voltage by 90° and that of
the capacitive reactance X
C
to cause the current to lead the voltage by 90° are exactly oppo-
site and the net effect is a tendency to cancel each other. Hence, in a circuit containing both
inductances and capacitances, the net Reactance (X) will be equal to the difference between
the values of the inductive and capacitive reactances. The net Reactance (X) will be inductive if
X
L
> XC and capacitive if XC > XL.
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.
SECTION 1 | Safety Instructions & General Information
Page 10
10 | SAMLEX AMERICA INC.
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.
• 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.
SECTION 1 | Safety Instructions & General Information
Page 11
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.
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
TIME
180
160
140
120
100
80
60
40
20
0
20
40
60
80
100
120
140
160
180
Modied Sine
Wave sits at
ZERO for some
time and then
rises or falls
Pure Sine Wave
crosses zero V
instantaneously
Modied Sine Wave
• V
RMS
= 120V
• V
peak
= 140 to 160V
Sine Wave
• V
RMS
= 120VAC
• V
peak
= 169.68V
16.66 ms
VOLTS − VOLTS +
V
peak
= 169.68V
V
peak
= 140 to 160V
V
RMS
= 120 VAC
Fig 1.1 Pure and Modied Sine Waveforms for 120V, 60 Hz
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12 | SAMLEX AMERICA INC.
The 120V output waveform of the EvolutionTM series inverters is a Pure Sine Wave like the waveform of Utility / Grid power. Please see Sine Waveform represented in the Fig. 1.1 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 singlephase induction motors as start and run capacitors. Thus, Modied and Square Wave Inverters
may shut down due to overload when powering these devices.
1.3.2 Advantages of Pure Sine Wave Inverters
The output waveform is a Sine Wave with very low harmonic distortion and cleaner power
like Grid / Utility supplied electricity.
Inductive loads like micr
owaves, motors, transformers etc. run faster, quieter and cooler.
More suitable for powering uorescent lighting xtures containing Power Factor Improve-
ment 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 har
d drives.
Built-in clocks in devices such as clock radios, alarm clocks, cof
fee 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.
SECTION 1 | Safety Instructions & General Information
Page 13
Devices that use radio frequency signals carried by the AC distribution wiring.
Some new fur
naces 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
i
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”
i
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.
Table 1.6 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.
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14 | SAMLEX AMERICA INC.
TABLE 1.6 INVERTER SIZING FACTOR
Type of Device or Appliance
Inverter Sizing Factor
(See Note 1)
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
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)
NOTES FOR TABLE 1.6:
1 Multiply the Maximum Continuous Power Rating (Active Power Rating in Watts) of the appli-
ance / 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 B. 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 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 wir
es 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.
SECTION 1 | Safety Instructions & General Information
Page 15
• 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. 1.2. 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.
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 recom-
mended 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.
SECTION 1 | Safety Instructions & General Information
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16 | SAMLEX AMERICA INC.
Input voltage
Peak Inrush Current
Inrush current
Rated Steady State
Input RMS Current
NOTE: Voltage and
Current scales
are dierent
Fig 1.2 Inrush current in an SMPS
TIME
Peak Current
RMS Current
Non-linear
Input Current
Input Sine
Wave Voltage
CREST FACTOR = PEAK CURRENT = 3
RMS CURRENT
NOTE: Voltage and
Current scales
are dierent
Volatge − Voltage +
Current − Current +
Fig 1.3 High Crest Factor of current drawn by SMPS
1.4 GENERAL INFORMATION - LEAD ACID BATTERIES
i
INFO
For complete background information on Lead Acid Batteries and Charging Process, visit www.
samlexamerica.com>Support>White Papers>Whitepaper - Batteries, Chargers and Alternators.
Lead-acid batteries can be categorized by the type of application:
1. Automotive service - Starting/Lighting/Ignition (SLI, a.k.a. cranking), and
2. Deep cycle service.
Deep Cycle Lead Acid Batteries of appropriate capacity are recommended for powering of
inverters.
SECTION 1 | Safety Instructions & General Information
Page 17
1.4.1 Deep Cycle Lead Acid Batteries
Deep cycle batteries are designed with thick-plate electrodes to serve as primary power sources,
to have a constant discharge rate, to have the capability to be deeply discharged to up to 80 %
capacity and to repeatedly accept recharging. They are marketed for use in recreation vehicles
(RV), boats and electric golf carts – so they may be referred to as RV batteries, marine batteries
or golf cart batteries. Use Deep Cycle batteries for powering inverters.
1.4.2 Rated Capacity 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 1.4.5) 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 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.
1.4.3 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
1.4.4 Typical Battery Sizes
Table 1.7 shows details of some popular battery sizes:
TABLE 1.7 POPULAR BATTERY SIZES
BCI* Group Battery Voltage, V Battery Capacity, Ah
27 / 31 12 105
4D 12 160
8D 12 225
GC2** 6 220
* Battery Council International; ** Golf Cart
SECTION 1 | Safety Instructions & General Information
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18 | SAMLEX AMERICA INC.
1.4.5 Specifying Charging / Discharging Currents: C-Rate
Electrical energy is stored in a cell / battery in the form of DC power. The value of the stored
energy is related to the amount of the active materials pasted on the battery plates, the surface
area of the plates and the amount of electrolyte covering the plates. As explained above, the
amount of stored electrical energy is also called the Capacity of the battery and is designated by
the symbol “C”.
The time in Hours over which the battery is discharged to the “End Point Voltage” for purposes
of specifying Ah capacity depends upon the type of application. Let us denote this discharge
time in hours by “T”. Let us denote the rate of discharge current of the battery as a multiple of
Ah capacity "C" and call it as the "C-Rate”. If the battery delivers a very high discharge current,
the battery will be discharged to the “End Point Voltage” in a shorter period of time. On the
other hand, if the battery delivers a lower discharge current, the battery will be discharged to
the “End Point Voltage” after a longer period of time. Mathematically, C-Rate is dened as:
“C-RATE” = CAPACITY “C” in Ah ÷ DISCHARGE TIME “T”
Table 1.8 gives some examples of C-Rate specications and applications:
TABLE 1.8 DISCHARGE CURRENT RATES - “C-RATES”
Hours of discharge time “T” till the
“End Point Voltage”
“C-Rate” Discharge Current in
Amps = Capacity “C” in Ah ÷
Discharge Time “T” in Hrs.
Example of C-Rate
Discharge Currents
for 100 Ah battery
0.5 Hrs. 2C 200A
1 Hrs. 1C 100A
5 Hrs. (Inverter application) C/5 or 0.2C 20A
8 Hrs. (UPS application) C/8 or 0.125C 12.5A
10 Hrs. (Telecom application) C/10 or 0.1C 10A
20 Hrs. (Automotive application) C/20 or 0.05C 5A
100 Hrs. C/100 or 0.01C 1A
NOTE: When a battery is discharged over a shorter time, its specied “C-Rate” will be higher. For example, the “C-Rate” at 5 Hour discharge period i.e. C/5 Amps will be 4 times higher than the “C-Rate” at
20 Hour discharge period i.e. C/20 Amps.
1.4.6 Charging / Discharging Curves
Fig. 1.4 shows the charging and discharging characteristics of a typical 12V / 24V Flooded
Lead Acid battery at electrolyte temperature of 80°F / 26.7°C. The curves show the % State
of Charge (X-axis) versus terminal voltage (Y-axis) during charging and discharging at different
C-Rates. Please note that X-axis shows % State of Charge. State of Discharge will be =
100% - % State of Charge. These curves will be referred to in the subsequent explanations.
SECTION 1 | Safety Instructions & General Information
Page 19
Fig 1.4 Charging / Discharging Curves for Typical Flooded Lead Acid Battery
1.4.7 Reduction in Usable Capacity at Higher Discharge Rates – Typical in
Inverter Application
As stated earlier, the Ah capacity of automotive battery is normally applicable at a discharge rate
of 20 Hours. As the discharge rate is increased as in cases where the inverters are driving higher
capacity loads, the usable Ah capacity reduces due to “Peukert Effect”. This relationship is not
linear but is more or less according to the Table 1.9.
SECTION 1 | Safety Instructions & General Information
Typical Flooded Lead-Acid Battery Chart - 80˚F / 26.7˚C
Battery Voltage in VDC
Battery State of Charge in Percent (%)
0 10 20 30 40 50 60 70 80 90 100 110 120 130
16.5
16.0
15.5
15.0
14.5
14.0
13.5
13.0
12.5
12.0
11.5
11.0
10.5
10.0
9.5
9.0
C/5
C/40
C/20
C/10
DISCHARGE
CHARGE
C/20
C/3
C/5
C/10
C/100
33.0
32.0
31.0
30.0
29.0
28.0
27.0
26.0
25.0
24.0
23.0
22.0
21.0
20.0
19.0
18.0
24V 12V
Page 20
20 | SAMLEX AMERICA INC.
TABLE 1.9 BATTERY CAPACITY VERSUS RATE OF DISCHARGE – C-RATE
C-Rate Discharge Current Usable Capacity (%)
C/20 100%
C/10 87%
C/8 83%
C/6 75%
C/5 70%
C/3 60%
C/2 50%
1C 40%
Table 1.9 shows that a 100 Ah capacity battery will deliver 100% (i.e. full 100 Ah) capacity if it
is 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 1.9 above shows that for 2 Hours discharge
rate, the capacity is reduced to 50% i.e. 50 Ah. Therefore, at 50 Ampere discharge rate (500W
output for a 12V inverter and 1000W output for a 24V inverter) the battery will actually last for
50 Ah ÷ 50 Amperes = 1 Hour.
1.4.8 State of Charge (SOC) of a Battery – Based on “Standing Voltage”
The “Standing Voltage” of a battery under open circuit conditions (no load connected to it)
can approximately indicate the State of Charge (SOC) of the battery. The “Standing Voltage”
is measured after disconnecting any charging device(s) and the battery load(s) and
letting the battery “stand” idle for 3 to 8 hours before the voltage measurement is
taken. Table 1.10 shows the State of Charge versus Standing Voltage for a typical 12V/24V
battery system at 80°F (26.7ºC).
TABLE 1.10 SOC VERSUS STANDING VOLTAGE (TYPICAL FLOODED BATTERY)
Percentage of
Full Charge
Standing Voltage
of Individual Cells
Standing Voltage of
12V Battery
Standing Voltage
of 24V Battery
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
SECTION 1 | Safety Instructions & General Information
Page 21
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.
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.
1.4.9 State of Discharge of a Loaded Battery – Low Battery / DC Input Voltage
Alarm and Shutdown in Inverters
Most inverter hardware estimate the State of Discharge of the loaded battery by measuring
the voltage at the inverter’s DC input terminals (considering that the DC input cables are thick
enough to allow a negligible voltage drop between the battery and the inverter).
Inverters are provided with a buzzer alarm to warn that the loaded battery has been deeply
discharged to around 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:
-
T
emperature 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 curr
ent 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 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).
1.4.10 Low DC Input Voltage Alarm in Inverters
As stated earlier, the buzzer alarm is triggered when the voltage at the DC input terminals of
the inverter has dropped to around 10.5V for a 12V battery or 21V for 24V battery at C-Rate
discharge current of C/5 Amps. Please note that the terminal voltage relative to a particular
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 1.11 (Refer to Fig. 1.4 for parameters and values
shown in Table 1.11):
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22 | SAMLEX AMERICA INC.
TABLE 1.11 TERMINAL VOLTAGE AND SOC OF LOADED BATTERY
Discharge
Current:
C-Rate
Terminal Voltage at 80% State of
Discharge (20% SOC)
Terminal Voltage When Completely
Discharged (0% SOC)
12V 24V 12V 24V
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 11.95V 23.9V 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
In the example given above, the 10.5V / 21.0V Low Battery / DC Input Alarm would trigger
at around 80% discharged state (20% SOC) when the C-Rate discharge current is C/5 Amps.
However, for lower C-Rate discharge current of C/10 Amps and lower, the battery will be almost
completely discharged when the alarm is sounded. Hence, if the C-Rate discharge current
is lower than C/5 Amps, the battery may have completely discharged by the time the
Low DC Input Alarm is sounded.
1.4.11 Low DC Input Voltage Shut-down In Inverters
As explained above, at around 80% State of Discharge of the battery at C-Rate discharge
current of around C/5 Amps, the Low DC Input Voltage Alarm is sounded at around 10.5V for
a 12V battery (at around 21V for 24V battery) to warn the user to disconnect the battery to
prevent further 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 (20V for 24V battery). Referring to the Discharge Curves given in Fig 1.4, the State
of Discharge for various C-Rate discharge currents for battery voltage of 10V / 20V is as follows:
(Please note that the X-Axis of the curves shows the % 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 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 and shut-down functions are
designed to protect the inverter from excessive current drawn at the lower voltage.
SECTION 1 | Safety Instructions & General Information
Page 23
1.4.12 Depth of Discharge of Battery and Battery Life
The more deeply a battery is discharged on each cycle, the shorter the battery life. Using more
batteries than the minimum required will result in longer life for the battery bank. A typical cycle
life chart is given in the Table 1.12 below:
TABLE 1.12 TYPICAL CYCLE LIFE CHART
Depth of Discharge
% of Ah Capacity
Cycle Life of Group
27 /31
Cycle Life of Group 8DCycle 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%.
1.4.13 Series and Parallel Connection of Batteries
Refer to details at Section 3.4.
1.4.14 Sizing the Inverter Battery Bank
One of the most frequently asked questions is, “how long will the batteries last?” This question
cannot be answered without knowing the size of the battery system and the load on the
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 W
atts (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.
SECTION 1 | Safety Instructions & General Information
Page 24
24 | SAMLEX AMERICA INC.
Now, the capacity of the batteries is determined based on the run time and the
usable capacity.
From Table 1.9 “Battery Capacity versus Rate of Discharge”, the usable capacity at 3 Hour
discharge rate is 60%. 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.
1.14.15 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). Also, for complete charging
(return of 100% capacity), it is recommended that 4-Stage Charger may be used as follows:
Float Application Charging (2-Stage)
Stage 1 (Bulk Stage at constant curr
ent) " 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
TM
Series Inverter/Charger.
SECTION 1 | Safety Instructions & General Information
Page 25
SECTION 2 | Components & Layout
2. LAYOUT
2.1 LAYOUT OF EVO-1212F AND EVO1224F – FRONT VIEW
1
2
3 4
5
6
8
7
9
10
11
1213
14 15
Fig 2.1 Layout of Front side EVO-1212F / EVO-1224F
16
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 " ") – Hole Diameter 6.5 mm for AWG #4 to #6; Set screw M6 (Pitch 0.75 mm)
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
(see Pin layout, 19) 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
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/Of
f Push Button
12.
Blue LED “ON”
13. Red LED “Fault”
14. AC output Br
eaker, 15A
15.
AC Input Breaker, 20A
16.
Connector (marked "Remote On/Of
f") for On/Off Control through external +12V signal (9 – 15V, < 10mA):
Screw M2.5; Wire size AWG#30 to AWG#12
• 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. Pin No layout for RJ-45 Jack.
10d
10a 10b10c
17
18
1a
Red
2a
Black
1 2 3 4 5 6 7 8
19
RJ-45 Jack – Layout of Pins
Page 26
26 | SAMLEX AMERICA INC.
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, temperatur
e controlled cooling fans (fans are not shown).
2.3 LAYOUT OF EVO-1212F-HW AND EVO-1224F-HW – FRONT VIEW
1
2
3 4
5
6
8
7
10
11
1213
21
16
2223242526 27
28
19a
Fig 2.3 Hardwired AC Input and output connections: EVO-1212F-HW and EVO-1224F-HW
17
18
19b
1a
Red
2a
Black
Page 27
SECTION 2 | Components & Layout
LEGEND for Fig 2.3
1.
Battery Positive (+) Input Connector (marked "BA
TTERY POSITIVE"): Stud and Nut, M8 (Pitch 1.25mm)
•
1a Red Pr
otective Cover for Battery Positive (+) Input Connector – mounted using 2 pcs of M3
(Pitch 0.5mm) x 10mm 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 0.5mm) 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 "
") – Hole Diameter 6.5mm for AWG #4 to #6; Set screw M6
(Pitch 0.75mm)
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
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 AWG#30 to AWG#12
• 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).
The plate has 2 holes (27.8 mm /13/32” dia.) for ¾” Trade Size Fitting for conduit / cable entry
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 Pitch) x 6 mm long
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 Sections 4.5.1 to 4.5.3 and Fig 3.12(a) and 3.12(b)
28. AC Input and Output Ground connection to metal chassis: Stud and Nut; M4 (Pitch 0.7mm)
Page 28
28 | SAMLEX AMERICA INC.
SECTION 2 | Components & Layout
2.4 REMOTE CONTROL EVO-RC-PLUS
RJ-45
Plug
11
12
Fig 2.4(b) Cable for Remote Control
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)]
Fault
2
5
3
4
6
7
8
9
1
10 11
RJ-45
Plug
Page 29
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: Pin 4
Ò + NTC ; Pin 5 Ò – NTC
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
3
1
2
2.6 CONTENTS OF PACKAGE
Inverter/Charger
Temperature Sensor EVO-BCTS [Fig 2.5(a)]
DC Terminal Covers (1a, 2a: 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
Wire End Terminals for AC Wiring (Fig 3.11) for EVO-1212F-HW / EVO-1224-HW
Model AWG#12
(for input wiring)
AWG #14
(for output wiring)
EVO-1212F-HW and EVO-1224-HW 4 4
Owner's Manual
Quick Start Guide
Page 30
30 | SAMLEX AMERICA INC.
3.1 SAFETY OF INSTALLATION
WARNING!
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.
3.2 OVERALL DIMENSIONS
The overall dimensions and the location of the mounting holes are shown in Fig. 3.1.
1200
Model
EVO -1212F
Inverter Charger
Pure Sin e Wave
120 0 Watt s
12 VDC Input
120 VAC Output
380
415
35
303.5
324
40.7 123.90 50.80
298.6
123.90
7.40
dia
20.90
7.40
dia
Hole dia
13.40
Mounting Holes: 7.4 mm / 0.29”
Mounting Bolts: M6 or /”
Height: 148 mm
NOTE: All dimensions are in mm
Fig. 3.1 Mounting Dimensions
SECTION 3 | Installation
Page 31
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 and back for cooling and ventilation. Ensure that
these openings are not blocked or restricted. Install in cool, dry and well ventilated area.
!
CAUTION!
Ensure there is OVER 200 mm clear space surrounding the inverter for
ventilation.
!
ATTENTION!
Assurer qu’il y a PLUS QUE 200 mm d’espace DÉGAGÉ entourant l’onduleur pour faciliter la ventilation.
Mounting Orientation:
•
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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32 | SAMLEX AMERICA INC.
• 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
SECTION 3 | Installation
Page 33
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
6V 6V
Battery 4 Battery 3
6V
Battery 2
6V
Battery 1
24V Inverter
or 24V Charger
Cable “A”
Cable “B”
Fig 3.5 Series Connection
When two or more batteries are connected in series, their voltages add up but their Ah capacity
remains the same. Fig. 3.5 shows 4 pieces of 6V, 200 Ah batteries connected in series to form a
battery bank of 24V with a capacity of 200 Ah. The Positive terminal of battery 4 becomes the
Positive terminal of the 24V bank. The Negative terminal of battery 4 is connected to the Positive
terminal of battery 3. The Negative terminal of battery 3 is connected to the Positive terminal of
battery 2. The Negative terminal of battery 2 is connected to the Positive terminal of battery 1.
The Negative terminal of battery 1 becomes the Negative terminal of the 24V battery bank.
3.4.2 Parallel Connection
12V 12V 12V 12V
Battery 1 Battery 3Battery 2 Battery 4
Cable “A”
Cable “B”
12V Inverter
or 12V Charger
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.
SECTION 3 | Installation
Page 34
34 | SAMLEX AMERICA INC.
3.4.3 Series – Parallel Connection
6V 6V 6V 6V
12V String 1 12V String 2
Battery 1 Battery 3Battery 2 Battery 4
12V Inverter
or 12V Charger
Cable “A”
Cable “B”
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
SECTION 3 | Installation
Page 35
of the rst battery (Battery 1 as in Fig. 3.6) or to the Negative Post of the rst battery
string (Battery 1 of Battery String 1 as in Fig 3.7), the following abnormal conditions
will result:
-
The r
esistances 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 dif
ferent charging/discharg-
ing 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
-
T
outes 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.
SECTION 3 | Installation
Page 36
36 | SAMLEX AMERICA INC.
3.5 DC SIDE CONNECTIONS
1
2
3 4
5
6
1a
Red
2a
Black
Fig 3.8 DC Side Connections
LEGEND for Fig 3.8
1.
Battery Positive (+) Input Connector (marked "BA
TTERY POSITIVE"): Stud and Nut, M8 (Pitch 1.25 mm)
(RED Protection Cover 1(a) is removed)
1a. RED Pr
otection 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 "
") Hole Dia 6.5 mm for up to 25 mm2 (AWG #4). Set Screw
M-8. This is internally 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
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 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 T
emperature 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 3.14 and 3.15)
SECTION 3 | Installation
Page 37
3.5.1 Preventing DC Input Over Voltage
It is to be ensured that the DC input voltage of this unit does not exceed 17 VDC for the 12V battery version
EVO-1212F / 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!
Quand vous faites des connexions à la batterie du côté d’entrée, veuillez assurer que les polarités sont mise
du bon côté (Lié le positif de la batterie à la borne positive de l’appareil et le négatif de la batterie à la borne
négative de l’appareil. Si les polarité de l’entrée sont mise à l’envers, le fusible CC externe du côté d’entrée va
s’exploser et peut causer des dégâts permanent à l’onduleur.
Des dégats causés par un renversement des polarités n’est pas couverts 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
TM
→ Negative input terminal of the EVOTM
→ 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.
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
SECTION 3 | Installation
Page 38
38 | SAMLEX AMERICA INC.
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.
MISE EN GARDE!
La section d’entrée de l’onduleur a des condensateurs de grande valeur qui sont connecté aux bornes
d’entrées. Tant que le boucle de connexion d’entrée CC (la borne (+) de la batterie → le fusible la
borne → d’entrée positive du EVOTM → la borne d’entrée négative du EVOTM → la borne (-) de la
batterie est complèt, les condesateurs commençeront à recharger. L’appareil prendra un courant fort
brièvement pour s’alimenter qui va produire une étincelle sur le dernier contact du boucle d’entrée
même si l’interrupteur ON/OFF du l’onduleur est dans la position OFF.
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.
Le ux du courant dans un conducteur est opposé par la résistance du conducteur. La résistance du conducteur
est corrélative à la longueur du conducteur et inversement corrélatif à son diamètre (l’épaisseur). La résistance
dans un conducteur produit des effects indésirables comme une perte de tension et une surchaffe. La taille
(l’épaisseur) des conducteurs est classée par le AWG (American Wire Guage). Les conducteurs qui sont plus épais
que la taille AWG #4/0 sont classé par MCM/kcmil.
SECTION 3 | Installation
Page 39
Les conducteurs sont protègés par des matériaux isolants classés pour une température spécique, par
exemple,une température de 90˚C/194˚F. Le ux de courant produit de la chaleur et affecte l’isolation. Alors, il y
a une valeur de courant maximale (aussi appellé « L’ampacité ») qui est permise pour chaque taille de conducteur
et pour la classication température de l’isolation. Les matériaux isolants des câbles seront aussi affecter par la
température de fonctionnement élèvée des bornes, à qui ils sont connectés. L’ampacité des câbles est basé sur
UL-1741 et la Norme Nationale Électrique (NEC)-2014. « Notes for table 3.1 »
Le circuit d’entrée CC doit subir à des courants CC forts et ainsi, il faut que la taille des câbles et des connecteurs
est sélectionnée pour réduire la perte de tension entre la batterie et l’onduleur. Avec des câbles moins épais et des
connexions lâches la performance de l’onduleur est diminuée et en plus, ça pourrait produire une réchauffement
anormale qui risque de fondre l’isolation ou commencer un incendie. Normalement, il faut que le câble soit
assez épais pour réduire la perte de tension, dû au courant/ la résistance du câble, à moins que 2%. Utilisez des
câble multiliares (ls en cuivre et résistant à l’huile) qui sont classés au moins à 90º C. N’utilisez pas des câbles
en aluminium car ils ont une résistance plus haute (par la longueur de l’unité). On peut achèter des câbles aux
magasins de fournitures pour marin/soudage.
Les effets d’une faible tension pour des charges électriques communes
-
Circuits d’allumage
- incandescent et Halogène Quartz: Une perte de tension à 5% causera une perte de
10% de la lumière émise. Cet effet est grâce à deux choses, non seulement l’ampoule reçoive moins de
puissance mais, aussi le lament refroidi change de la chaleur-blanc à la chaleur-rouge, qui émet moins de
lumière visible.
-
Circuits d’allumage
- uorescent: la perte de tension est presque proportionelle à la perte de la lumière émise.
-
Moteurs à Induction CA
- Souvent, Ils font partie des outils électriques, des dispositifs, pompe à puits, etc.
Au démarrage, ils exigent une surcharge de puissance. Si la tension baisse trop, ils pourraient pas marcher et
même seront endommager.
-
Circuit de rechargement de batterie PV -
La perte de tension pourrais causer une perte de puissance
disproportionée. Par exemple, une perte de tension à 5% peut réduire le courant de charge par une
pourcentage beaucoup plus grande que 5%.
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.
SECTION 3 | Installation
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40 | SAMLEX AMERICA INC.
WARNING!
It is mandatory to use appr
opriately 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 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.
-
T
ightening torque for the Thumb Nut is 35 kgf.cm (2.5 lbf.ft)
-
Use 70A fuse in series with the Positive wir
e 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.
TABLE 3.1 SIZING OF BATTERY SIDE CABLES AND EXTERNAL BATTERY SIDE FUSES
Model No.
(Column 1)
Rated
Continuous
DC Input
Current
(See
Note 1)
(Column 2)
NEC
Ampac-
ity = 125%
of Rated
DC Input
Current at
Column 2
(See
Note 2)
(Column 3)
90°C Copper Conductor. Size Based on NEC
Ampacity at Column (3) or 2%Voltage Drop,
whichever is Thicker (See Note 3)
External
Fuse Based
on NEC
Ampacity at
Column (3)
(See
Note 4)
(Column 8)
Cable Running Distance
between the Unit and the
Battery
(Cable Routing In Free Air)
Cable Running Distance
between the Unit and the
Battery
(Cable Routing In Raceway)
Up to 5 ft.
(Column 4)
Up to 10 ft.
(Column 5)
Up to 5 ft.
(Column 6)
Up to 10 ft.
(Column 7)
EVO-1212F
152 190 AWG #2 AWG #2/0 AWG #2/0 AWG #2/0 200A
EVO-1212F-HW
EVO-1224F
76 95 AWG #6 AWG #4 AWG #3 AWG #3 100A
EVO-1224F-HW
External
Charger
50A 63A
AWG #6
(2% voltage
drop is thicker)
AWG #2
(2% voltage
drop is thicker)
AWG #6
AWG #2
(2% voltage
drop is thicker)
70A
SECTION 3 | Installation
Page 41
NOTES FOR TABLE 3.1 - SIZING OF BATTERY SIDE CABLES AND EXTERNAL BATTERY
SIDE FUSES
1)
Column 2 indicates the Rated Continuous DC Input Curr
ent drawn from the battery in
Inverter Mode
2)
Column 3 indicates NEC Ampacity based on which cable conductor sizes (Columns 4 to 7)
ar
e determined. NEC Ampacity is not less than 125% of the Rated Continuous DC Input
Current (Column 2) - Refer to NEC-2014 (National Electrical Code) - Section 215.2(A)(1)(a)
for Feeder Circuits.
3)
Columns 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 exter
nal 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
3.5.7 Using Proper DC Cable Termination & Tightening Torques
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)
35 kgf.cm
(2.5 lbf.ft)
7 to 12 kgf.cm
(0.5 to 0.9 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.
SECTION 3 | Installation
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42 | SAMLEX AMERICA INC.
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.
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).
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
10
9
14 15
10d
10a 10b
10c
Fig 3.9.1 AC Input and Output Connections – EVO-1212F and EVO-1224F
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.
SECTION 3 | Installation
Page 43
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.
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!
1. N'alimentent pas la sortie de la prise GFCI à un Panel de sélection / Charger Centre où la
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)
SECTION 3 | Installation
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44 | SAMLEX AMERICA INC.
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).
28
19a
20
26 25 24 23 22 21
27
19b
Fig 3.9.2(a) Pocket for AC Input and
Output Connections for EVO-1212F-HW
and EVO1224F-HW
Fig 3.9.2(b) Cover Plate for Pocket for
AC input and Output Connections
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 scr
ews - 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
- T
erminal 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 Panelboar
d
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 Gr
ound 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
SECTION 3 | Installation
2 holes (27.8 mm / 1 /32" diameter) for 3/4"
Trade Size Fitting for cable or conduit entry.
50 mm 30 mm
27.8 mm
1 /
32
"
Hole for
M3 screws
Page 45
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 Gr
ound 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.
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 EVOTM 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
SECTION 3 | Installation
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46 | SAMLEX AMERICA INC.
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.
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 Multi-wire 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).
SECTION 3 | Installation
Page 47
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/1224FHW, 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 / 1
3/
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 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
SECTION 3 | Installation
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48 | SAMLEX AMERICA INC.
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.
Stripped Wire End
Wire End Terminal
Crimp Barrel Portion
↓
→
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 overcurrent 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 / l'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.
3.8.1 Tables 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.
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).
SECTION 3 | Installation
Page 49
TABLE 3.2 SIZING OF AC INPUT WIRING AND BREAKERS
Model No.
(Rated Output Power
in Inverter Mode)
(Column 1)
Maximum AC Input
Current Limit (Parameter
"GRID MAX CURRENT")
(See Note 1)
(Column 2)
NEC Ampacity = 125%
of Column 2
(See Note 2)
(Column 3)
Conductor Size Based
on NEC Ampacity
at Column 5
(See Note 3)
(Column 4)
Size of Breaker
based on Column 4
(See Note 4)
(Column 5)
EVO-1212F
(1200VA)
20A 25A AWG #12 20A
EVO-1212F-HW
(1200VA)
20A 25A AWG #12 20A
EVO-1224F
(1200VA)
20A 25A AWG #12 20A
EVO-1224F-HW
(1200VA)
20A 25A AWG #12 20A
NOTES FOR TABLE 3.2 - SIZING OF GRID AND BREAKERS
1.
Column 2 indicates the Maximum AC Input Curr
ent which is equal to the maximum internal current limit of 20A programmable through parameter "GRID CURRENT" (Refer to
Section 4.5.2.2 of Remote Control EVO-RC-PLUS Manual).
2.
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 curr
ent
(Column 2) - Refer to NEC-2014 (National Electrical Code) - Section 210.19(A)(1)(a)
regarding minimum Ampacity and size of Branch Circuit Conductors.
3. 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)
4. 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. T
ype 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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50 | SAMLEX AMERICA INC.
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-1212FHW 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.
(Rated Output
Power in In-
verter Mode )
(Column 1)
Rated AC Out-
put Current in
Inverter Mode
(See Note 1)
(Column 2)
NEC Ampacity
= 125% of
Column 2
(See Note 2)
(Column 3)
Conductor Size
based on NEC
Ampacity at
Column 3
(See Note 3)
(Column 4)
Size of Breaker
(Column 5)
EVO-1212F-HW
(1200VA)
10A 12.5A AWG #14
External Breaker
15A
EVO-1224F-HW
(1200VA)
10A 12.5A AWG #14
External Breaker
15A
SECTION 3 | Installation
Page 51
NOTES FOR TABLE 3.3 - AC OUTPUT WIRING AND BREAKERS
1)
Column 2 indicates the Rated AC Output Curr
ent in Inverter Mode
2) Column 3 indicates NEC Ampacity based on which the output-wiring conductor is sized.
This NEC Ampacity is not less than 125% of the Rated Output Current in Inverter Mode
(Column 2). - Refer to NEC-2014 (National Electrical Code) - Section 215.2(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
/ Panel Board on the load side. Hence, the AC output circuit of the unit is considered to be a
Feeder Circuit for purposes of NEC-2014.
3)
Column 4 indicates conductor size for the output side wiring. The size is based on NEC-2014
(National Electrical Code) - Ampacity Table 310.15(B)(16) for Raceway. Conductor size is
based on (i) NEC Ampacity (Column 3), (ii) conductor temperature of 75°C and (iii) ambient
temperature of 30°C / 86°F.
4)
Column 5 indicates the Amp rating of br
eaker. Following should be considered:
a)
Amper
e 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 Standar
d 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 Standar
d 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) r
egarding over current
devices rated 800 Amps or less
d) T
ype of breaker: Standard circuit breaker for 120 VAC Load Center /Breaker Panel
e)
EVO-1212F and EVO-1224F use built-in Br
eaker (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
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
TM
, “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
TM
or (ii) to the metal chassis of the devices connected to EVOTM or (iii) to the metal frame/
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52 | SAMLEX AMERICA INC.
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
TM
/ 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.
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”
3.12 GROUNDING ARRANGEMENT
Internally, EVOTM 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
TM
, 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
TM
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
TM
being used). This recommendation
on sizing of the DC Side Grounding Wire will be superseded by the National / Local
Electrical Codes.
!
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
TM
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.
SECTION 3 | Installation
Page 53
!
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
TM
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.
i
INFO
As described at Section 3.14, the metal frame / chassis of the EVOTM [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
TM
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
TM
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
TM
will all be bonded to the Earth Ground.
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
TM
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
TM
will be bonded to Earth Ground for
protection against Ground fault on the DC side of EVO
TM
.
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54 | SAMLEX AMERICA INC.
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 EVO1224F at Fig 3.12.
(a)
AC Input Gr
ounding: The metal chassis of EVO
TM
gets bonded to the Grounding Electrode
(GE) / Ground Rod of the premises as follows:
• The metal chassis of EVO
TM
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.
(b) AC Output Grounding: The metal chassis of the AC load(s) get connected to the Ground-
ing 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
TM
through the Grounding Conductor of the load connection
• Grounding socket (G) of GFCI outlet “10” in EVO
TM
is connected to the metal chassis of
EVO
TM
.
• The metal chassis of EVO
TM
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
SECTION 3 | Installation
Page 55
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 Gr
ounding: The metal chassis of EVO
TM
gets bonded to the Grounding Electrode
(GE) / “Ground Rod” of the premises as follows:
•
The metal chassis of EVO
TM
is connected to the “INPUT GND” Terminal (23) of the AC
Input / Output Terminal Block (20) in EVO
TM
•
The “INPUT GND” T
erminal (23) of the AC Input / Output Terminal Block (20) in EVO
TM
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 Gr
ounding: 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 Gr
ounding Bus Bar (G-B) of the
Electrical Sub Panel for EVO
TM
Output
•
Grounding Bus Bar (G-B) of the Electrical Sub Panel for EVO
TM
Output is connected to
metal chassis of EVO
TM
through the “OUTPUT GND” Terminal (26) of the AC Input /
Output Terminal Block (20) in EVO
TM
.
•
The metal chassis of EVO
TM
is connected to the “INPUT GND” Terminal (23) of the AC
Input / Output Terminal Block (20) in EVO
TM
•
The “INPUT GND” T
erminal (23) of the AC Input / Output Terminal Block (20) in EVO
TM
gets connected to the Grounding Bus Bar (G-B) in the Grid Electrical Panel through the
grounding wire of AC input connection
•
The Gr
ounding 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 EVO1224F at Fig 3.14.
(a) AC Input Grounding: The metal chassis of EVO
TM
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
TM
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.
SECTION 3 | Installation
Page 56
56 | SAMLEX AMERICA INC.
• 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 Gr
ounding: 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
TM
through the Grounding Conductor of the load connection
•
Grounding socket (G) of GFCI outlet “10” in EVO
TM
is connected to the metal chassis of EVOTM.
•
The metal chassis of EVO
TM
is connected to the Grounding Pin (G) of the AC Power Inlet
Plug (9)
•
The gr
ounding 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 Gr
ounding 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
TM
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
TM
is connected to the “INPUT GND” Terminal (23) of the AC
Input / Output Terminal Block (20) in EVO
TM
• The “INPUT GND” Terminal (23) of the AC Input / Output Terminal Block (20) in
EVO
TM
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 Gr
ounding 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:
SECTION 3 | Installation
Page 57
SECTION 3 | Installation
• The metal chassis of the AC load(s) is connected to the Grounding Bus Bar (G-B) of the
Electrical Sub Panel for EVO
TM
Output
•
Grounding Bus Bar (G-B) of the Electrical Sub Panel for EVO
TM
Output is connected to
metal chassis of EVO
TM
through the “OUTPUT GND” Terminal (25) of the AC Input /
Output Terminal Block (20) in EVO
TM
.
•
The metal chassis of EVO
TM
is connected to the “GRID GND” Terminal (22) of the AC
Input / Output Terminal Block (20) in EVO
TM
•
The “INPUT GND” T
erminal (23) of the AC Input / Output Terminal Block (20) in EVO
TM
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 r
equirements, the AC Grounds of EVO
TM
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
TM
.
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
TM
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
TM
is bonded to the metal chassis of
EVO
TM
by the “Output Neutral to Chassis Ground Bond Switching Relay” (RY2 in Fig 4.1). As
the metal chassis of EVO
TM
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
TM
. 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
TM
from the metal chassis of EVOTM. 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
TM
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
Page 58
58 | SAMLEX AMERICA INC.
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(a)] 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)
The Battery Charger Section is designed to charge either Lead Acid Batteries or Lithium 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 Battery, programmable 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. Pease 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
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. 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:
SECTION 3 | Installation
Page 59
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
Scr
een 1
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
• EVO in Inverting Mode: Inverting will stop. EVOTM 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:
Scr
een 1
For 2 sec
Scr
een 1
For 2 sec
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
Page 60
60 | SAMLEX AMERICA INC.
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 thr
ough DC Electrical Panel with an ap-
propriate fuse to protect the DC input cables against short circuit
Battery Charger Temperature Sensor Model EVO-BCTS is installed on the Positive or Nega-
tive 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
TM
is fed from the Grid. Alternatively, AC input may be fed from a generator.
AC output fr
om the EVO
TM
is fed to the AC Electrical Sub-Panel for EVO
TM
WARNING!
In case generator is used to feed AC input to the EVO, the following should be ensured:
•
Ensur
e 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
TM
, 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
TM
(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'EVOTM (EVO va transférer à l'inversion de mode).
SECTION 3 | Installation
Page 61
SECTION 3 | Installation
+
-
+
-
+
-
+
-
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
321
5
J6
RY2
J7
J1
J2
J9
J4
14
15
9
Metal Chassis
G
G
G
NL
27
10
BCTS
Fig 3.12 Installation Diagram for Typical Shore Based Installation for EVO-1212F and EVO-1224F
Page 62
62 | SAMLEX AMERICA INC.
SECTION 3 | Installation
LEGEND for Fig 3.12
NOTE:
For sizing of wiring and fuses, refer to the following:
(a) DC side wiring: T
able 3.1
(b) AC side wiring: Table 3.2
L.
Line T
erminal
L-B. Line Bus Bar
N. Neutral Terminal
N-G.
Neutral to Gr
ound 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 T
emperature 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 Exter
nal Charge Controller (4, Figs 2.1 / 3.8)
5.
DC Side Grounding Terminal on EVO
TM
(5, Figs 2.1 / 3.8)
6.
RJ-45 Jack for T
emperature Sensor (6, Fig 2.1)
GE.
Gr
ounding 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 Br
eaker 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)
Cir
cuit breaker
Fuse
120 VAC Leg, Phase A
120 VAC Leg, Phase B (180° out of phase with Phase A Leg)
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.
B
A
Page 63
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 EVO-1212F-HW and EVO-1224F-HW
Page 64
64 | SAMLEX AMERICA INC.
LEGEND for Fig 3.13
NOTE:
For sizing of wiring and fuses, refer to the following:
(a) DC side wiring: T
able 3.1
(b) AC side wiring: Table 3.2 for AC input and Table 3.3 for AC output.
L.
Line T
erminal
L-B. Line Bus Bar
N. Neutral Terminal
N-G.
Neutral to Gr
ound 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 T
emperature 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 Exter
nal Charge Controller (4, Figs 2.1 / 3.8)
5.
DC Side Grounding Terminal on EVO
TM
(5, Fig 2.1)
6.
RJ-45 Jack for T
emperature Sensor (6, Fig 2.1)
GE.
Gr
ounding 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 V
AC Leg, Phase A
120 V
AC Leg, Phase B (180° out of phase with Phase A Leg)
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
SECTION 3 | Installation
B
A
Refer to AC Input / Output
Connections for EVO-1212F-HW
/ 1224F-HW at Fig 3.9.2(a)
Page 65
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
TM
(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:
• 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.
Page 66
66 | SAMLEX AMERICA INC.
SECTION 3 | Installation
• 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 EVO1212F / 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 fr
om 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
TM
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
TM
can be fed from either
of the 2 Split Phase Legs of the 50A RV Panel (through suitable breaker).
AC output from the EVO
TM
is fed to the Electrical Sub-Panel for EVOTM (Use 120V version and
NOT 120/240 Split Phase version of the Electrical Sub-panel)
Page 67
+
-
+
-
+
-
A.C. Section
D.C. Section
+
-
Battery
Bank
EVO INVERTER CHARGER: EVO-1212F AND EVO-1224F
External
Charge
Controller
RJ-45
6
J6
RY2
J7
J1
J2
J9
J4
9
Metal Chassis
G
G
G
NL
+ + +
- +
Battery Isolator
Engine Starter
Battery
Alternator
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
See LEGEND on the next page
4
3
2
1
5
10
15
BCTS
27
Fig 3.14 Installation Diagram for Typical RV / Mobile
Installation for EVO-1212F and EVO-1224F
SECTION 3 | Installation
Page 68
68 | SAMLEX AMERICA INC.
SECTION 3 | Installation
LEGEND for Fig 3.14
NOTE:
For sizing of wiring and fuses, refer to the following:
(a) DC side wiring: T
able 3.1
(b) AC side wiring: Table 3.2
L.
Line T
erminal
L-B. Line Bus Bar
N. Neutral Terminal
N-G.
Neutral to Gr
ound 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 T
emperature 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 Exter
nal Charge Controller (4, Figs 2.1 / 3.8)
5.
DC Side Grounding Terminal on EVO
TM
(5, Figs 2.1 / 3.8)
6.
RJ-45 Jack for T
emperature Sensor (6, Fig 2.1)
GE.
Gr
ounding 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 Br
eaker 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)
Cir
cuit breaker
Fuse
120 VAC Leg, Phase A
120 VAC Leg, Phase B (180° out of phase with Phase A Leg)
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.
B
A
Page 69
SECTION 3 | Installation
ELECTRICAL
SUB-PANEL FOR
EVO (SINGLE
PHASE: 120 VAC)
N-B
G-B
To loads
backed up
by EVO
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
Fig 3.15 Installation Diagram for Typical RV / Mobile
Installation for EVO-1212F-HW and EVO-1224F-HW
Page 70
70 | SAMLEX AMERICA INC.
LEGEND for Fig 3.15
NOTE:
For sizing of wiring and fuses, refer to the following:
(a) DC side wiring: T
able 3.1
(b) AC side wiring: T
able 3.2 for AC input and Table 4.3 for AC output.
L.
Line T
erminal
L-B.
Line Bus Bar
N.
Neutral T
erminal
N-G.
Neutral to Gr
ound Bond
N-B.
Neutral Bus Bar
G-B.
Gr
ounding Bus Bar
SBJ.
System Bounding Jumper
J1, 2, 4, 7, 9
Male T
ab Terminals on internal Circuit Board
RY2.
Relay for Neutral to Gr
ound Bond Switching (Section 4.4.2)
BCTS.
Battery Charger T
emperature 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 Exter
nal Charge Controller (3, Figs 2.1 / 3.8)
4.
Negative Input Connector for Exter
nal Charge Controller (4, Figs 2.1 / 3.8)
5.
DC Side Gr
ounding Terminal on EVO
TM
(5, Fig 2.1)
6.
RJ-45 Jack for T
emperature Sensor (6, Fig 2.1)
GE.
Gr
ounding 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
120 VAC Leg, Phase B (180° out of phase with Phase A Leg)
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
SECTION 3 | Installation
B
A
Refer to AC Input / Output
Connections for EVO-1212F-HW
/ 1224F-HW at Fig 3.9.2(a)
Page 71
4.1 GENERAL DESCRIPTION
EVOTM is a Pure Sine Wave, Bi-directional, Single-Phase Inverter / Charger with a Transfer Relay
that operates either as an inverter OR as a smart battery charger. It uses a common Converter
Section that can work in two directions – in one direction it converts external AC input power to
DC power to charge the batteries using Grid / Generator (Charging Mode) and in the other direction, it converts DC power from the battery to AC power (Inverting Mode). This allows the same
power components to be used in both directions resulting in high-energy transfer efciency with
fewer components. Please note that it can NOT work in both the directions at the same time (i.e.
it cannot work as an inverter and as a charger at the same time).
High performance 100 MHz DSP (Digital Signal Processing) type of micro-controller and Pulse
Width Modulated (PWM) conversion circuits are used for the above implementation.
4.2 COMPONENTS OF THE SYSTEM
It consists of 3 Sections – Inverter Section, Battery Charger Section and AC Input/Transfer Relay
Section. The unit is fed with the following inputs:
120 V
AC / 60 Hz Grid input. Good quality Inverter Generator with stable 120 VAC / 60 Hz
output may also be used if Grid is not available.
DC Battery Source consisting of 12V/24V battery bank. - 4 versions of EVO
TM
are available. 2
versions for 12 VDC battery input (EVO-1212F 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 Bulk Charging 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
The low DC voltage from the DC Battery Source is inverted to the AC voltage in two steps. The
low DC voltage from the DC Battery Source is rst converted to low frequency (60 Hz), low voltage synthesized sine wave AC using an H-bridge conguration and high frequency PWM (Pulse
Width Modulation) technique. The low frequency, low voltage synthesized sine wave is then
stepped up to 120 VAC pure sine wave voltage using a low frequency Isolation Transformer and
ltration circuit. This type of DC to AC inversion is called Hybrid Type – a combination of low
frequency and high frequency implementation. Other distinctive features of the Inverter Section
are given below:
Soft Start: The inverter design incorporates “Soft Start” feature with the following advantages and protections:
SECTION 4 | General Description & Principles of Operations
Page 72
72 | SAMLEX AMERICA INC.
- 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 pr
otects
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 sec
•
120% for 10 min
• 110% for 30 min
4.4 TRANSFER RELAY SECTION
Transfer Relay Section is used to either feed AC power to the Battery Charger Section and at the
same time, pass through the AC power from the external AC input power source to the load (As
long as the external AC input power 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 Grid/Generator to Inverter and <1ms from Inverter to
Grid / Generator. Heavy duty 30A. Transfer Relay (RY1, Fig 4.1) is used for reliable transfer of up to
300% surge power. A separate Relay (RY2, Fig 4.1) is used for Neutral to Ground Bond Switching.
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 Output
Neutral and Chassis Ground has been provided in EVO
TM
through “Output Neutral to Chassis
Ground Bond Switching Relay” (RY2 in Figs 4.1). Switching of bonding is carried out as follows:
• When operating as an inverter, the current carrying conductor of the Inverter Section that is connected to the Output Neutral terminal of EVO
TM
is bonded to the metal chassis of EVOTM by the
“Output Neutral to Chassis Ground Bond Switching Relay” (RY2 in Figs 4.1). As the metal chassis of EVO
TM
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
SECTION 4 | General Description & Principles of Operations
Page 73
carrying conductor of the Inverter Section (connected to the output 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/Generator will be con
-
nected to the Output Neutral terminal of EVO
TM
. At the same time, the “Output Neutral
to Chassis Ground Bond Switching Relay” (RY2 in Figs 4.1) will unbond (disconnect) the
Output Neutral connector of EVO
TM
from the metal chassis of EVOTM. This will ensure that the
Grounded Conductor (GC) i.e. the Neutral of the Grid power/Generator is bonded to the
Earth Ground at one single point at the location of the AC Power Distribution System of the
Marina/RV Park/Shore Power.
• Disabling Neutral to Ground Bond: In some applications, the Output Neutral of EVO
TM
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 Insulated Male/Female
Quick Disconnect located in the AC wiring compartment of EVO-1212F-HW / 1224F-HW.
[Please see (i) 27, Fig 3.9.2(a) and (ii) 27, Fig 4.1]. In EVO-1212F / 1224F, this Insulated Male
/ Female Quick Disconnect is accessible after opening the top cover of the unit.
Please read the following on-line White Papers for more details at www.samlexamerica.com
(Home > Support > White Papers):
-
“Neutral to Gr
ound 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
30A 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.
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.
Switching of Bonding of Output Neutral to Chassis Ground
o 30A 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
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
SECTION 4 | General Description & Principles of Operations
Page 74
74 | SAMLEX AMERICA INC.
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-1212F-HW / 1224F-HW. In EVO-1212F / 1224F, the Insulated
Male / Female Quick Disconnect is accessible after opening the top cover of the unit.
NEUTRAL
BI-DIRECTIONAL
TRANSFORMER
LINE
RY2
RY1
METAL CHASSIS
GROUND OF THE EVO
TM
3
4
5
3
4
5
INVERTING
CHARGING
OUTPUT N
INPUT L
INPUT
GND
INPUT N
OUTPUT L
OUTPUT
GND
27
Fig 4.1 Operation of Transfer Relay and Neutral to Ground Bond Switching
LEGEND for Fig 4.1
RY1 Transfer Relay (30A) (Shown in de-energized state). Transfers the 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.
RY2 Relay (30A) 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
Insulated Male / Female Quick Disconnect [27, Fig 3.9.2(a)] for disconnecting
Output Neutral to Chassis Ground bond in Inverting Mode (Default - connected)
NOTE: Relays are de-energized in Inverting Mode and are energized in Charging Mode
4.4.3 Synchronized Transfer of Power – Inverter to AC Input Source
Assume that AC input power source (from Grid / Generator) is not available and the unit is
working in "Inverting Mode".
When AC input power becomes available, its voltage and frequency are checked if these are
within the programmed limits. If yes, the frequency and phase of the Inverter Section are
SECTION 4 | General Description & Principles of Operations
Page 75
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 seamless transfer and for better protection
of Transfer Relay contacts. The unit now operates in “Charging Mode”. In "Charging Mode",
AC input power from the Grid / Generator is used to charge the batteries and is also passed
through to power the AC loads.
4.4.4 Synchronized Transfer From AC Input Source to Inverter
When the unit is operating in “Charging Mode” as described above, the phase and frequency
of AC input power are tracked continuously. In case AC input power fails or is disconnected, the
inverter will be forced into transfer at voltage which is at the same phase and frequency at which
the AC input power 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 6 programmable
charging proles as detailed at Table 5.2, Section 5.6. The same Isolation Transformer and the HBridge 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 ooded, AGM, Gel Cell, Lead Calcium and Lithium.
Important battery charging features are as follows:
•
Adaptive Charging Contr
ol
•
Dynamic Input Power Diversion Contr
ol
• Parallel charging through External Charge Controller
•
T
emperature compensated charging
• Programmable Charging Proles for Lead Acid and Lithium Batteries
Please see details under Section 5 titled “Battery Charging in Evolution
TM
Series”.
4.6 MODES OF OPERATION
4.6.1 Charging Mode
As long as the external AC input power from the Grid/Generator is available and is within the
programmed limits of voltage and frequency, it is passed through to the AC load through the
Transfer Relay Section. At the same time, the Battery Charger Section converts the external AC
input power from the Grid/Generator to DC power to charge the DC Battery Source.
4.6.2 Inverting Mode
If at any instant, the external AC input power from the Grid/Generator is interrupted or is not
within the programmed limits of voltage and frequency, the Transfer Relay is de-energized and
the load is transferred to the Inverter Section and internal battery charging is terminated. This is
called the Inverting Mode.
4.6.3 Power Saving Mode
When the unit is operating without any load connected to it, it requires some minimum input
power from the battery to keep all the sections inside the unit alive and ready to deliver power to
the AC load as soon as the load is switched on. This power is called the “No Load Power Draw” or
the “Idle Power” or “Self Power Consumption”. The “No Load Power Draw” of these units in the
SECTION 4 | General Description & Principles of Operations
Page 76
76 | SAMLEX AMERICA INC.
Normal Mode is around 20W. The EVOTM has a provision to minimize this “No Load Power Draw”,
if required (Applicable only when the unit is in “Inverter Mode”). This is achieved by enabling
the “Power Saving Mode”. The unit is shipped in default “Disabled” condition i.e. Power
Saving Mode will be NOT active. Optional Remote Control EVO-RC-PLUS is required to enable
this mode (Refer to Section 4.8.2.1 of the Owner's Manual for EVO-RC-PLUS). When this mode is
enabled, the unit does not provide continuous output power. Pulsing output power consisting of
only 3 cycles of reduced 48 VAC output voltage that are made available every 0.5 seconds is used
to sense if a minimum load is present or not. As continuous power is not being supplied, the
“No Load Power Draw” is reduced to less than 8W. If a load greater than the programmed
value of “Wake-up Point” (Default – 7W) is sensed, the unit exits Power Save Mode and starts
providing normal continuous output power. If the load drops to the programmed value of “Enter
Point” (Default – 6W), the unit once again reverts to Power Saving Mode. Programmable and Default Values of “Enter Point” and “Wake-up Point” are shown in Table 6.6. Further details are available at Sections 4.8.2.1 to 4.8.2.3 of the Owners Manual for the Remote Control EVO-RC-PLUS.
Power Saving Mode should be disabled for the following loads:
Low power loads that draw < 5W e.g. digital clocks, satellite r
eceivers, 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.
4.6.4 Power Saving Mode - Transfer Characteristics in Grid
• Transfer from AC input source to Inverter: If qualied Grid / Generator AC input power
is available (its voltage and frequency are within the programmed range), the Transfer Relay
remains energized and the AC input power is passed through to the load and at the same
time, the unit operates as a battery charger. If AC input power from Grid / Generator fails
or is not 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” (Default – 7W), the inverter continues in
Normal Mode. However, if it sees a load less than the programmed value of “Enter Point”
(Default – 6W) for around 5 sec, it enters Power Saving Mode.
• Transfer from Inverter to A input source: As soon as qualied AC input power from
Grid / Generator is available, the inverter will exit Power Saving Mode and will switch over
to Normal Mode. This switch over is necessary for synchronizing the AC output of the
inverter with the AC input before transfer (Synchronization can not be carried out with
pulsing wave form during Power Saving Mode). After synchronization is completed, the
load is transferred to the Grid at zero crossing of the voltage waveform.
4.6.5 Normal (Off-Line), On-Line and Charger Only Modes
i
INFO
Description given below provides general capability of this function. For details of
programming, please refer to sub-headings “ONLINE MODE” (Section 4.4.2.13) and
"ONLINE OPTION" (Section 4.4.2.14) at Section 4.4 in the Owner’s Manual for Remote
Control Model EVO-RC-PLUS.
SECTION 4 | General Description & Principles of Operations
Page 77
The EVOTM is able to operate in 3 modes – Normal (Off-line), On-line and Charger Only
Modes. Normal (Off-line) Mode is the Default Mode. Mode can be changed to Online Mode
or Charger Only Mode through optional Remote Control Model EVO-RC-PLUS (Please see
Section 4.4.2.13 in the Owner’s Manual for EVO-RC-PLUS).
Normal (Ofine) Mode: This is the Default Mode. In this mode, the AC input (from the Grid
/ Generator) is the PRIMARY source of AC power and the batteries / Inverter Section of EVO
TM
is
the BACK-UP source of DC-AC power. If qualied AC input (within the programmed voltage and
frequency limits) is available, the Transfer Relay will be switched ON (energized), the EVO
TM
will
operate in “Charging Mode” and qualied AC input from the Grid / Generator 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 and 4, Fig 2.1), the internal AC Charger will limit the charging current to a value =
(Programmed Value of "BULK CURRENT" – Value of Current fed from the external solar charge
controller). When the Grid / Generator AC input fails or, is not within the programmed values of
voltage and frequency, the Transfer Relay will be switched OFF (de-energized), the unit will change
over to “Inverting Mode” and the AC Output will be fed from the internal Inverter Section. When
Grid / Generator input is restored, the unit will revert back to “Charging Mode” to charge the
batteries and at the same time, pass through the AC input to the AC output.
Online Mode: In this mode, the Inverter Section of the EVO
TM
is the PRIMARY DC-AC source
of power. The Grid / Generator input is the BACK-UP source of AC power. Online Mode has
2 options of operation (ONLINE OPTION) that can be programmed through optional
Remote Control Model EVO-RC-PLUS (Please see Section 4.4.2.14 in the Owner’s
Manual for EVO-RC-PLUS). In this mode, even if qualied Grid / Generator AC input is
available (within the programmed voltage and frequency limits), the EVO
TM
always operates in
“Inverting Mode” and AC output is provided by the Inverter Section as long as the battery is in
charged condition above the specied programmed value of low battery voltage (This specied
value of low battery voltage is selected through programmable parameter “LOW VOLT ALARM”
- See Section 4.4.2.8 in the EVO-RC-PLUS 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, the Transfer Relay will be switched ON
(energized) and the EVO
TM
will change over to “Charging Mode” [The sustained programmed
time period is selected using parameter called “GS DETECT TIME” (0-600 sec; Default 10 sec)
- See Section 4.4.2.16 in the EVO-RC-PLUS Manual. On changing over to “Charging Mode”,
qualied AC input from the Grid / Generator is passed through to the AC Output and at the
same time, the Internal AC Charger starts charging the battery. If an external Solar Charge
Controller is also connected to the External Charging Terminals (3 and 4, Fig 2.1), the internal
AC Charger will limit the charging current to a value = (Programmed Value of Charging Current
– Value of Current fed from the external Solar Charge Controller). When the battery has been
re-charged either fully through complete, 3-Stage Adaptive Charging algorithm (ONLINE
OPTION: 0=Option 1 - See Section 4.4.2.14 in the EVO-RC-PLUS Manual) or, for a programmed
specied time period (ONLINE OPTION: 1=Option 2 - See Section 4.4.2.14 in the EVO-RC-PLUS
Manual), the Transfer Relay will be switched OFF (de-energized), charging will stop and the unit
will change over to “Inverting Mode”.
SECTION 4 | General Description & Principles of Operations
Page 78
78 | SAMLEX AMERICA INC.
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.
Charger Only Mode: In Off-grid DC powered homes, for efciency consideration, all
lighting and other loads / appliances are normally powered from 12V 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
TM
can be programmed to operate as a battery
charger ONLY. Details are given below:
When “Charger Only” Mode is selected (ONLINE MODE: 2=Charger Only - See Section
4.4.2.13 in the EVO-RC-PLUS Manual), the EVO
TM
will operate as a battery charger to charge
the batteries and pass through the AC input power to the loads as long as AC input is
available (In DC powered homes, 120 VAC pass through will normally not be used as all the
loads will be DC)
When AC input fails, the Inverter Section will NOT be activated and the EVO
TM
will operate in
“Standby Mode” as long as AC input is NOT available. In “Standby Mode”, the EVO
TM
draws
extremely low power from the batteries (< 5W)
For further details, please refer to the following Sections of the EVO-RC-PLUS Manual:
• Section 4.1.3.1: Screen No. 13 of “Select Parameter Menu Map for Group 1 – CHARGE
CURVE” at Fig 4.2
•
Section 4.4.1: Scr
een No 13 of Table 4.3 for “Group 1 Parameter Set Up: CHARGE CURVE”
• Section 4.4.2.13: “Charger Only Mode” under ONLINE MODE
4.7 TEMPERATURE SENSOR FOR BATTERY CHARGING
Battery Charger Temperature Sensor Model EVO-BCTS (Fig 2.5) has been provided to ensure
optimum charging by modifying the charging voltages based on temperature if the battery
sees very wide temperature swings. Temperature compensation can be programmed with the
help of optional Remote Control EVO-RC-PLUS (see Section 4.4.2.5 in EVO-RC-PLUS 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). Please read White Paper titled “Batteries, Chargers &
Alternators” available online at www.samlexamerica.com (Home > Support > White
Papers) and Section 5 titled “Battery Charging in EVO
TM
Series” for more details.
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 Bulk Charging Current. This improves the life of the battery. Please see Section 5.4 for more details.
SECTION 4 | General Description & Principles of Operations
Page 79
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 the Owner's Manual for
Remote Control EVO-RC-PLUS. 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 150°C and auto-reset at 80°C
•
“Heat sink over heat!” :
Shut down at 70°C and auto-reset at 40°C
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 50°C to 60°C, the BULK CURRENT setting is automatically reduced as follows based
on temperature sensed at the Power Transformer and at the Heat Sink for the Power Mosfets:
• Power Transformer: In case the temperature is >130°C, the BULK CURRENT setting is
reduced by 0.2% every 20 sec.
•
Heat Sink:
In case the temperature is >90°C, the charging current is reduced by 0.2%
every 20 sec.
4.10 OPTIONAL REMOTE CONTROL EVO-RC-PLUS 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.
i
INFO
For background information on batteries and charging process, please read
Section 1.4, “General Information - Lead Acid Batteries”. All battery charging
voltages are specied at battery temperature of 25˚C / 77˚F.
SECTION 4 | General Description & Principles of Operations
Page 80
80 | SAMLEX AMERICA INC.
5.1 PRINCIPLE OF OPERATION OF BATTERY CHARGING SECTION
EVOTM Series is a Bi-directional Inverter / Charger with a Transfer Relay that operates either as
an inverter OR as a battery charger. It uses a common Converter Section that can work in two
directions – in one direction it converts external AC power to DC power to charge the batteries
(Charging Mode) and in the other direction, it converts the DC power from the battery to AC
power (Inverting Mode). PWM design is used for both the charging and inverting sections.
Please note that it cannot work in both the directions at the same time (i.e. it cannot work as
an inverter and as a charger at the same time). High performance, 100 MHz DSP (Digital Signal
Processing) type of micro-controller and Pulse Width Modulated (PWM) conversion circuits are
used for the above implementation.
When AC input power from Grid / Generator is available within the programmed limits of
voltage and frequency, the internal Transfer Relay passes through the AC input to the AC loads
and at the same time, the AC input is fed to the Battery Charger Section.
First, the AC input voltage is stepped down by the Low Frequency Isolation Transformer and
is then rectied by 4 sets of H-Bridge Mosfets and fed to the batteries for charging. When
charging starts, the current does not rise sharply, but ramps up slowly to the full
programmed Bulk Charge current.
The Battery Charger Section of the EVO
TM
is a 2, 3 or 4 Stage Charger based on powerful, 100
MHz DSP micro-controller. Refer to Section 5.6 for details of operation.
5.2.1 Dynamic AC Input Current Diversion Control Between AC Pass Through
Current And Battery Charging Current
EVOTM Models have very powerful Battery Charger Section that will require very high AC input
current from the Grid (See Table 5.1).
TABLE 5.1 CHARGING CURRENTS AND PASS THROUGH LOAD CURRENTS
Rated Charging
Current
Maximum Pass Through
Load Power and Current
Max. DC Side
Charging
Current
Equivalent AC
Side Charging
Current
Pass Through
Power
Pass Through
Amps
EVO-1212F and
EVO-1212F-HW
60A 11.2A 1200 VA 10A
EVO-1224F and
EVO-1224F-HW
40A 11.2A 1200 VA 10A
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 Grid / Generator 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 Grid / Generator 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 desired setting (Please refer to Section 4.5.2.2 of the EVORC-PLUS Owner's Manual).
SECTION 5 | Battery Charging in Evolution
TM
Series
Page 81
“GRID MAX CURRENT” (Default = 20A) should be set equal to the Ampere rating of the external Grid / Generator supply breakers. During Battery Charging Mode, if the AC pass through
load current is increased resulting in the net AC input current increasing to a value more than
the programmed “GRID MAX CURRENT”, the EVO
TM
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 CURRENT”.
i
INFO
If the AC side charging current has been automatically reduced to 0A and the pass
through load current is still 1A more than the programmed value of the “GRID MAX
CURRENT” for 5 sec, the EVO
TM
will shut down due to FAULT MODE and display “Input
over current!”
EXAMPLE:
•
Assume EVO-1212F is being fed with input supply cir
cuit breaker capacity of 20A. The
“GRID MAX CURRENT” setting = the Default value of 20A. The “BULK CURRENT” has been
programmed at 60A (DC). When charging at 60A (DC), the corresponding AC side current
draw will be 11.2A AC (Based on Conversion Factor of 1A DC side battery charging current
= 0.19A AC side charging current).
• Assume that the AC pass through load is 5A. Total AC input current will be 16.2A (5AAC
pass through load current + 11.2A AC side charging current corresponding to 60A DC side
charging current) and will be below the set “GRID MAX CURRENT” of 20A.
• If now, the AC pass through load current is increased to say 12A, the total AC input current
will be 23.2A (12A pass through load current + 11.2A AC side charging current corresponding
to 60A DC side battery charging current). As the “GRID MAX CURRENT” is set at 20A, the AC
input side charging current will be automatically reduced to 8A AC from 12A AC so that the
total AC input current is limited to 20AAC. Correspondingly, the equivalent DC side battery
charging current will reduce from 60ADC to 42.1ADC (at conversion factor of 1ADC side battery charging current = 0.19AAC side current).
• If now, the AC pass through load current is increased to say 22A, the total AC input current
will be 30AAC (22AAC pass through load current + 8AAC AC side charging current corresponding to 42.1A DC side charging current) . The AC side charging current will be reduced
from 8AAC (corresponding to 42.1A DC side charging current) to 0AAC (corresponding to
0A DC side charging current). However, now the AC input current will be 22AAC which
in 2ACC more than the GRID CURRENT setting of 20AAC. After 5 sec, the EVO
TM
will shut
down due to FAULT MODE and display “Input over current!” (AC input current was 2A
more than the “GRID MAX” current setting of 20A for 5 sec)
5.2.2 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 50°C to 60°C, the charging current is automatically reduced as follows based
on temperature sensed at the Power Transformer and at the Heat Sink for the Power Mosfets:
• Power Transformer: In case the temperature is >130°C, the BULK CURRENT setting is
reduced by 0.2% every 20 sec.
• Heat Sink: In case the temperature is >90°C, the BULK CURRENT setting is reduced by
0.2% every 20 sec.
SECTION 5 | Battery Charging in Evolution
TM
Series
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82 | SAMLEX AMERICA INC.
5.3 ADAPTIVE CHARGING CONTROL FOR LEAD ACID BATTERIES
WITH NO EXTERNAL DC LOAD ON THE BATTERIES
6 programmable "CHARGING PROFILES" are available (See Section 5.6 and Table 5.2).
For charging Lead Acid Batteries that do not have external DC loads connected to them, option is available for an automatic Adaptive Charging Algorithm to ensure that the battery is
completely charged in a safe manner for longer battery life. (For programming information,
refer to programming option "0 = 3 Stage Adaptive" for parameter "Charging Prole" under
Section 4.4.2.21 in the EVO-RC-PLUS manual). In this algorithm, the time the battery remains
in Absorption and Equalization Stages is proportional to the time the battery remains in the
Bulk Charge Stage. A battery that is deeply discharged will remain in Bulk Stage for a longer
duration and will require longer time in the Absorption and Equalization Stages for complete
charging. On the other hand, a battery that is almost completely charged will remain in the
Bulk Stage for a shorter duration and consequently, will remain in Absorption and Equalization
stages for a shorter duration. This will prevent overcharging / boiling of the battery.
Note: In other inverter chargers that execute Absorption and Equalization Stages for a xed
time, a nearly fully charged battery may overcharge / boil and hence, will reduce battery life.
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 “External: x.xxA” on the
optional Remote Control EVO-RC-PLUS (Please see display Screen No. 7 in Figs 3.1 to 3.4 of
EVO-RC-PLUS 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).
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 Charg-
ing Current
SECTION 5 | Battery Charging in Evolution
TM
Series
Page 83
For example, if the “BULK CURRENT” in the EVOTM is programmed at say 40A and the external So-
lar Charge 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.
!
CAUTION!
Ensure that charging voltage related parameters of EVO
TM
like (i) ABSORP VOLTAGE (ii)
EQUALIZE VOLTAGE (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 Owner’s Manual for Remote Control EVO-RC-PLUS).
!
ATTENTION!
S'assurer que la charge de tension, les paramètres connexes d'EVO comme (i) LA TENSION D'ABSORPTION (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).
5.5 BATTERY TEMPERATURE SENSOR
A Battery Temperature Sensor Model EVO-BCTS has been provided [Fig 2.5(a)]. It comes with
5 m / 16.5 ft cable. Connect the ring terminal end (houses the sensor) on the battery Positive
or Negative post [Fig 2.5(b)]. Connect the RJ-45 plug to the Temperature Sensor Jack (6, Fig.
2.1). The Temperature Sensor is used to ensure optimum charging by modifying the charging
voltages based on temperature if the battery sees very wide temperature swings. In addition
to compensating ABSORPTION, EQUALIZE AND FLOAT voltages, the voltage thresholds of
parameters “LOW VOLT ALARM”, “BATT LOW VOLTAGE”, “RESET VOLTAGE”, “BATTERY OVER
VOLT” and "RESET TO BULK" are also temperature compensated. Temperature compensation will
be carried out over a temperature range of –20°C to + 60°C. Table 6.2 shows the programmable
range. Default settings for the temperature coefcient is -4mV/°C/Cell.
5.6 CHARGING PROFILES
Option is available for 6 programmable charging proles that are designed to cover various
charging requirements for Lead Acid and Lithium Batteries. The proles can be programmed using
optional Remote Control EVO-RC Plus. Please refer to the following references in the manual for
EVO-RC-PLUS:
• Menu Map for Parameter “CHARGING PROFILE” : Screen No. 21 of Fig 4.2 under Section 4.1.3.1
• Setup steps for Parameter “CHARGING PROFILE”: Details under heading “CHARGING
PROFILE” under Section 4.4.2.21
NOTE: 3 Stage Adaptive Charging Prole setting “0=3 Stage Adaptive” is the default
charging prole applicable for Lead Acid Batteries (with no external DC loads
on the battery)
SECTION 5 | Battery Charging in Evolution
TM
Series
Page 84
84 | SAMLEX AMERICA INC.
Details of the 6 programmable charging proles are given in TABLE 5.2 below.
!
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 4.1) may be used to
feed potential free contact closing signal from the BMS to “Stop Charging” or “Stop
Inverting” Refer to Section 5.12 for details.
!
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.
4.1) peut être utilisé pour l'alimentation contact libre de signal de fermeture de la RBE à "arrêter la charge" ou
"Stop" inversion Se reporter à la Section 5.12 pour plus de détails.
TABLE 5.2 BATTERY CHARGER SECTION – CHARGING PROFILE OPTIONS AND CHARGING STAGES
Options under
Parameter
"CHARGING PROFILE"
Charging Stages
Battery Type and battery
loading condition
0=3 Stage Adaptive
(Default)
1. Bulk Stage: Charge at constant current
equal to programmable parameter
“BULK CURRENT”
• Transition to Absorption Stage when
voltage rises to programmable parameter “ABSORP VOLTAGE”.
2. Absorption Stage: Charge at constant
voltage at programmable parameter
“ABSORP VOLTAGE”.
• Adaptive Time Algorithm: Time in
Absorption Stage is computed automatically based on time in Bulk Stage. Transition to Float Stage thereafter.
3.
Float Stage:
Charge at constant voltage equal to programmable parameter
“FLOAT VOLTAGE”
• Reset to Bulk Stage under the follow
-
ing conditions:
-
After 10 days in Float Stage, or
- Voltage drops to programmable voltage parameter “RESET TO BULK”
-
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
Algorithm” for Absorption
Stage time
SECTION 5 | Battery Charging in Evolution
TM
Series
Page 85
TABLE 5.2 BATTERY CHARGER SECTION – CHARGING PROFILE OPTIONS AND CHARGING
STAGES (CONTINUED)
Options under
Parameter
"CHARGING PROFILE"
Charging Stages
Battery Type and battery
loading condition
1 = 3 Stage Type 1 1. Bulk Stage: Charge at constant current
equal to programmable parameter
“BULK CURRENT”
• Transition to Absorption Stage when
voltage rises to programmable parameter “ABSORP VOLTAGE”.
2. Absorption Stage: Charge at constant
voltage at programmable parameter
“ABSORP VOLTAGE”.
• Time in Absorption Stage is program-
mable through parameter “ABSORP
TIME”. Transition to Float Stage thereafter
3.
Float Stage:
Charge at constant voltage
equal to programmable parameter
“FLOAT VOLTAGE”
• Reset to Bulk Stage under the follow
-
ing conditions:
-
After 10 days in Float Stage, or
- Voltage drops to programmable voltage parameter “RESET TO BULK”
- Lead Acid: Flooded and sealed
– AGM/Gel Cell
- Lithium (See Section 5.6)
2 = 3 Stage Type 2 1.
Bulk Stage: Charge at constant current
equal to programmable parameter
“BULK CURRENT”
• T
ransition to Absorption Stage when
voltage rises to programmable parameter “ABSORP VOLTAGE”.
2.
Absorption Stage:
Charge at constant
voltage at programmable parameter
“ABSORP VOLTAGE”.
• T
ransition from Absorption to Float
when current drops to programmable
parameter “ABSORP EXIT AMPS”
3. Float Stage: Charge at constant voltage
equal to programmable parameter
“FLOAT VOLTAGE”
• Reset to Bulk Stage under the follow
-
ing conditions:
-
After 10 days in Float Stage, or
- Voltage drops to programmable voltage parameter “RESET TO BULK”
-
Lead Acid: Flooded and
Sealed – AGM/Gel Cell
- Lithium (See Section 5.6)
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TM
Series
Page 86
86 | SAMLEX AMERICA INC.
TABLE 5.2 BATTERY CHARGER SECTION – CHARGING PROFILE OPTIONS AND CHARGING
STAGES (CONTINUED)
Options under
Parameter
"CHARGING PROFILE"
Charging Stages
Battery Type and battery
loading condition
3 = 2 Stage Type 1 1. Bulk Stage: Charge at constant current
equal to programmable parameter
“BULK CURRENT”
• Transition to Absorption Stage when
voltage rises to programmable parameter “ABSORP VOLTAGE”.
2. Absorption Stage: Charge at constant
voltage at programmable parameter
“ABSORP VOLTAGE”.
• Remain in Absorption Stage for programmable parameter “ABSORP TIME”
• Switch OFF charging thereafter
• Reset to Bulk Stage under the following
conditions:
- After 10 days in Float Stage, or
- Voltage drops to programmable volt-
age parameter “RESET TO BULK”
Lithium (See Section 5.6)
4 = 2 Stage Type 2 1. Bulk Stage: Charge at constant current
equal to programmable parameter
“BULK CURRENT”
• Transition to Absorption Stage when
voltage rises to programmable parameter “ABSORP VOLTAGE”.
2. Absorption Stage: Charge at constant
voltage at programmable parameter
“ABSORP VOLTAGE”.
Lithium (See Section 5.6)
SECTION 5 | Battery Charging in Evolution
TM
Series
Page 87
TABLE 5.2 BATTERY CHARGER SECTION – CHARGING PROFILE OPTIONS AND CHARGING
STAGES (CONTINUED)
Options under
Parameter
"CHARGING PROFILE"
Charging Stages
Battery Type and battery
loading condition
Equalize -4 Stages
0 = No (Default)
1=Yes
1. Bulk Stage: Charge at constant current
equal to programmable parameter “BULK
CURRENT”
• Transition to Absorption Stage when
voltage rises to programmable parameter “ABSORP VOLTAGE”.
2. Absorption Stage: Charge at constant
voltage at programmable parameter “ABSORP VOLTAGE”.
• Adaptive Algorithm: Time in Absorption
Stage is computed automatically based
on time in Bulk Stage. Transition to
Equalization Stage thereafter.
3. Equalization Stage: Charge at constant
voltage at programmable parameter
“EQUALIZE VOLTAGE”.
• Adaptive Algorithm: Time in Equalize
Stage is computed automatically based
on time in Bulk Stage. Transition to
Float Stage thereafter.
4. Float Stage: Charge at constant voltage
equal to programmable parameter “FLOAT
VOLTAGE”
• Reset to Bulk Stage under the follow-
ing conditions:
- After 10 days in Float Stage, or
- Voltage drops to programmable volt-
age parameter “RESET TO BULK”
- Lead Acid: Flooded ONLY.
!
CAUTION!
Sealed – AGM / Gel Cell are
NOT equalized
- 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 Algorithm”
for Absorption and Equalization Stage times
5.7 3 STAGE CHARGING PROFILE
Refer to 3-Stage Charging Prole options in TABLE 5.2.
Fig. 5.1 shows the voltage and current charging curves with respect to time and different
charging stages.
NOTE: With the optional Remote Control Model EVO-RC-PLUS (see Owner's Manual), it is
possible to program and activate 4 Stage Charging Mode including the 4th Equalization Stage.
4-Stage charging is required to be carried out only on ooded / wet cell batteries. This 4
Stage Charging Mode is discussed separately under “4 STAGE ADAPTIVE CHARGING PROFILE EQUALIZE” at Section 5.8.
SECTION 5 | Battery Charging in Evolution
TM
Series
Page 88
88 | SAMLEX AMERICA INC.
5.7.1.1 Bulk Charge Stage
In the rst stage, known as the "BULK" Charge Stage, the charger delivers the maximum "BULK
CURRENT" (“Io”) that has been programmed using optional Remote Control EVO-RC-PLUS (Refer
to Section 4.4.2.1 of EVO-RC-PLUS manual). Range and Default value are shown at Table 6.2. 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-RCPLUS (Refer to parameter "ABSORP VOLTAGE" in Table 6.2 and at Section 4.2.2.2 of EVO-RCPLUS 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 (except in the manually selected Equalization Stage) since this will cause
the battery to lose electrolyte and dry out over time.
This stage is displayed as "X-Bulk Stage" in the 2
nd
line of the Charging Mode screens
in the Remote Control EVO-RC-PLUS. Character "X" denotes code for one of 6 of the
Charging Proles that is active. (For details, please see Table 3.2 at Section 3.6.4.2 of the
Owner's Manual for EVO-RC-PLUS).
15
14
13
12
11
10
0
30
28
26
24
22
20
0
Charger Voltage, VDC
TIME
To T1 10 Days
CURRENT (%) of set
BULK CURRENT “Io”
100%
60%
0%
BULK
ABSORPTION
FLOAT
V
Absorp
- 0.3V
Io
(Displayed as
“X-Bulk Stage”)
(Displayed as
“X-Absorption Stage”)
(Displayed as
“X-Float Stage”)
24V Battery
12V Battery
Fig 5.1 Charging Curves for 3 Stage Charging Prole
LEGEND for Fig 5.1
Voltage Curve
Curr
ent Curve
NOTE 1: The voltage curve shows the voltage output of charger. The intrinsic battery voltage
may be different and will be proportional to the state of charge.
The value of the "BULK CURRENT" (“Io”) 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 percent capacity as the
Gassing Voltage rises with higher charging current. As a general Rule of Thumb, the BULK
CURRENT “Io” should be limited to 10% to 20% of the Ah capacity of the battery (20
Hr Rate). Higher charging current may be used if permitted by the battery manufacturer.
Programmable range and Default values of "BULK CURRENT" (“Io”) are shown in Table 6.2.
The units are shipped with the "BULK CURRENT" set at the Default Value of 20A for EVO1212F / EVO-1212F-HW and 15A for EVO-1224F / EVO-1224-HW.
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When the unit enters Charging Mode, it starts working as a battery charger and the charger
will run at full programmed "BULK CURRENT" until the charger reaches the programmed
threshold of "ABSORP VOLTAGE".
For Adaptive Charging Prole Options (i) 0=3 Stage Adaptive and (ii) Equalize - 4 Stages
(1=Yes) [See Table 5.2], a software timer will measure the time taken from the instant the unit
enters the Bulk Charging Stage until the instant the battery voltage reaches 0.3V below the
programmed "ABSORP VOLTAGE", then registers this time as Bulk Charge Time "To" and
computes the Absorption Time "T1" as 10 times the Bulk Charge Time "To" in the internal “T1
Timer” i.e. T1 = To x 10. The “T1 Timer” is used to determine the time the charging will take
place in the next Absorption Stage in these 2 charging proles.
5.7.1.2 Automatic Adjustments of Internal AC Charger Current When External
Solar Charge Controller is Also Charging in Parallel
Please note that if an external solar charge controller is also used to charge the batteries at
the same time in parallel with the internal AC charger of the unit, the charging current of the
internal AC charger will be controlled so that the total charging current of the external charger
and the internal charger is = the programmed "BULK CURRENT (“Io”).
For example, if the programmed "BULK CURRENT (“Io”) is say 40A and the charging current of
the external charger is 30A, the internal AC charger will output only 10A (Programmed setting
of 40A – external charging current of 30A = 10A). Similarly, if the programmed setting is say
30A and the external charger is 50A, the internal AC charger will NOT provide any charging.
Please refer to Section 5.4 for more details.
5.7.2 Absorption Stage
During the Absorption Stage, the "ABSORP VOLTAGE" is held constant near the Gassing /
Absorption Voltage to ensure that the battery is further charged to the full capacity without
overcharging. Programmable range and Default values of "ABSORP VOLTAGE" are shown in
Table 6.2. Default value is 14.4V for EVO-1212F / EVO-1212F-HW and 28.8V for EVO-1224F /
EVO-1224F-HW. For programming details, refer to Section 4.2.2.2 of the EVO-RC-PLUS manual.
The Absorption Stage restores the remaining 25% of the battery’s charge. The time the charger
remains in the Absorption Stage is proportional to the depth of discharge of the battery. When
the battery is more discharged, it will take longer time in the Bulk Charge Stage to reach the
Gassing / Absorption Voltage.
For Adaptive Prole Options (i) 0=3 Stage Adaptive and (ii) Equalize-4 Stages (1=Yes) [See Table
5.2], the T1 Timer (explained above under Bulk Stage) computes the time of charging in this
stage as follows:
Absorption T
ime "T1" = Bulk Charge Time "To" x 10 ("To" = Time from entering Bulk
Charge Stage till battery voltage rises to 0.3V below Absorption Voltage).
The “T1 T
imer” has minimum time of 1 hour and a maximum time of 12 hours.
When the "T1 T
imer" runs out, the charger will enter the next Float Stage.
Pr
ogrammable range and Default values of Absorption Voltage are shown in Table 6.2.
This stage is displayed as "X-Absorption Stage" in the 2
nd
line of the Charging Mode
screens in the Remote Control EVO-RC-PLUS. Character "x" denotes code for one of 6
Charging Proles that is active. (For details, please see Table 3.2 at Section 3.6.4.2 of
Owner's Manual for EVO-RC-PLUS).
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5.7.3 Float Stage
Float Stage is a maintenance stage in which the output voltage is reduced to a lower level, typically
about 13.5 volts, (27 volts for 24V models) to maintain the battery’s charge without losing electrolyte
through gassing and also prevent corrosion of Positive plate by maintaining proper Positive Plate
Polarization Voltage. Programmable range of values of "FLOAT VOLTAGE" are shown in Table 6.2.
Default value is 13.5V for EVO-1212F / EVO-1212F-HW and 27.0V for EVO-1224F / EVO-1224F-HW.
For programming refer to Section 4.4.2.3 of EVO-RC-PLUS Manual.
This stage is displayed as "Float" "X-Float Stage" in the 2
nd
line of the in the Charging
Mode screens in the Remote Control EVO-RC-PLUS. Character "x" denotes code for one
of 6 Charging Proles that is active. (For details, please see Table 3.2 at Section 3.6.4.2
of Owner's Manual for EVO-RC-PLUS).
5.7.4 Automatic Resetting of Charging Cycle in 3 Stage Charging Prole
The charging cycle will be reset to the Bulk Stage as follows:
-
If the AC input from the Grid / Generator is disconnected and is reconnected or the bat
tery voltage drops below 12 VDC / 24 VDC (Default). Programmable range for this voltage
is 10 to 13V for 12V battery and 20 to 26V for 24V battery (This parameter is called "RESET TO BULK". For programming information for this parameter, refer to Section 4.4.2.15
of EVO-RC-PLUS manual).
- If the charger remains in the Float Mode for 10 days.
5.8 4 STAGE ADAPTIVE CHARGING PROFILE - EQUALIZE
!
CAUTION!
4 stage Adaptive Charging Prole - Equalize should be used only on vented,
ooded (non-sealed or “wet”) batteries and not on sealed AGM / Gel Cell Lithium
batteries and only as often as recommended by the battery manufacturer.
!
ATTENTION!
Étape 4 - Prol de charge adaptative égaliser ne doit être utilisé que sur l'évacuation, inondé
(non-étanches ou "humide") et non sur les batteries AGM scellées / Gel cellules au lithium batteries
et qu'aussi souvent que recommandé par le fabricant de la batterie.
4 Stage battery Charging Cycle is used in Adaptive Equalization Charging Prole (See Table
5.2). Equalization Prole is activated using optional Remote Control EVO-RC-PLUS [Refer to
parameter "EQUALIZE-4STAGES" at Section 4.4.2.12 of EVO-RC-PLUS Owner's Manual. The
"EQUALIZE-4STAGES" option is required to be set at 1=Equalize (4-stage)] If Remote Control
EVO-RC-PLUS is not available, Equalize Cycle may be activated by presenting the On/Off Push
Button on the front panel (11, Fig 2.1) for 1 sec. The cycle can be stopped prematurely by
pressing the Push Button for 1 sec. See Section 5.10 for more dertails.
Equalization of the batteries is carried out periodically - normally once per month for
battery under heavy duty service and every two to four months for battery under light duty
service. As equalization is a deliberate overcharge of the battery for a specied time period,
equalizing your ooded / wet cell batteries will reduce sulfation, stir up the electrolyte to
remove stratication, equalize voltages of individual cells and thus, help reach and maintain
the peak capacity of the battery.
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Please read about the necessity and details of equalizing batteries under White Paper
titled “Batteries, Chargers and Alternators,” available online at www.samlexamerica.
com (Home > Support > White Papers).
The 4 stages will be - Bulk, Absorption, Equalization, and Float. Equalization is desirable for
the proper health of Wet Cell Batteries. "EQUALIZE VOLTAGE" is programmable through the
optional Remote Control Model EVO-RC-PLUS (Refer to Section 4.2.2.3 of Owner's Manual for
EVO-RC-PLUS). Programmable voltage range and default values are shown in Table 6.2.
Adaptive Equalization current and Equalization time are computed automatically. (See Section 5.9)
Fig 5.2 shows the voltage and current curves during the 4 stages of charging in this prole.
When Equalization is activated (requires optional Remote Control Model EVO-RC-PLUS – see
Section 5.9), the charger will rst execute Bulk Stage followed by Absorption Stage. On
completion of Absorption Stage, the charger will execute Equalization Stage. After completion
of Equalization Stage, the charger will enter Float Stage. The stage transitions will thus be:
Bulk Stage (Constant Current) Absorption Stage (Constant Voltage) Equalization Stage
(Constant Voltage) Float Stage (Constant Voltage).
As part of the Adaptive Equalisation Algorithm, the charging prole in the Equalization
Stage is based on time "To" which is the time the charger remains in the initial Bulk Stage. The
charger will remain in the initial Bulk Stage for a longer duration when the battery is deeply
discharged and for a shorter duration if the battery has a shallow discharge.
VDC
24V Battery
12V Battery
CURRENT (%) of Set
BULK CURRENT
“Io”
100
50
0
15
14
13
12
11
10
16
0
30
28
26
24
22
20
32
0
TIME
To T1’
T2
Io
I2 = 0.5 x lo
BULK ABSORPTION EQUALIZATION F LOAT
Set value of
Equalization Voltage
V
Absorp
- 0.3V
10 Days
(Displayed as
“E-Bulk Stage”)
(Displayed as
“E-Absorption Stage”)
(Displayed as
“O-Float Stage”)
(Displayed as
“E-Equalization
Stage”)
Fig 5.2 Charging Curve for 4 Stage Adaptive Charging Prole in Equalization Mode
LEGEND for Fig 5.1
Voltage Curve
Current Curve
NOTE 1: The voltage curve shows the voltage output of charger. The intrinsic battery voltage
may be different and will be proportional to the state of charge.
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92 | SAMLEX AMERICA INC.
!
CAUTION!
For effective equalization to take place, it is desirable that the batteries undergo
a longer Bulk Stage applicable to the deeply discharged condition of the battery.
Please ensur
e that before the batteries are equalized, they should be deeply
discharged to 20% of its capacity. The Standing Voltage (Terminal Voltage
after disconnecting charging source[s] and load[s] for at least 3 hours) at
20% capacity will be:
-
12V Battery: Ar
ound 11.7V
-
24V Battery: Ar
ound 23.4V
Do not equalize partially or fully charged batteries
!
ATTENTION!
Pour une égalisation efcace, il faut que les batteries subissent à une étape majeure plus long en
fonction de la condition déchargée de la batterie.
Veuillez assurer que les batteries sont profondément déchargées (à 20% de sa capacité), avant de
les égaliser. La tension constante (la tension de la borne après avoir déconnecter toutes sources de
charge pour un minimum de 3 heures) quand elles sont déchargées à à 20% de sa capacité, serait:
- Une batterie de 12V: Environ 11,7V
- Une batterie de 24V: Environ 23,4V
N’égalisez pas des batteries qui sont partiellement ou complètement chargées
5.9 DETAILS OF ADAPTIVE EQUALIZATION PROFILE CHARGING
CYCLE (Fig 5.2)
During the Bulk Stage, the charger will charge at the programmed "BULK CURRENT"
(“Io“) [see programmable range at Table 6.2. Default value is 20A for EVO-1212F /
EVO-1212F-HW and 15A for EVO-1224F / EVO-1224F-HW]. "BULK CURRENT" (“Io”) is
normally limited to 10%-20% of the Ah capacity of the battery (20Hr Rate). Higher current
may be used if permitted by the battery manufacturer in Equalization Mode. The Bulk
Stage is displayed as "E-Bulk Stage" in the 2
nd
line of the Charging Mode screens
of the optional Remote Control EVO-RC-PLUS (Please refer to Table 3.2 at Section
3.6.4.2 of Owner's Manual for EVO-RC-PLUS).
A Software Timer is used to measure the time taken from the time the unit enters Bulk
Stage until the battery charger reaches 0.3V below the Absorption Voltage, then registered
this time as time To. The following times are computed based on the time To:
Absorption Time T1’ = To x 0.5
Equalization Time T2 is then computed based on the following logic:
T2 = T1’ + 1 hr = 0.5 To + 1 hr ; if T1’ < 2 hrs
T2 = T1’ + 2 hrs = 0.5 To + 2 hrs ; if 2 < T1’ < 4 hrs
T2 = T1’ + 4 hrs = 0.5 To + 4 hrs ; if T1’ > 4 hrs
When the battery reaches the programmed Absorption Voltage (see programmable range
and defaults at Table 6.2), it transitions to the Absorption Stage and remains in this stage for
the computed time T1’. This stage is displayed as "E-Absorption Stage" in the 2
nd
line
of the Charging Mode screens in Remote Control EVO-RC-PLUS (Please refer to Table
3.2 at Section 3.6.4.2 of Owner's Manual for EVO-RC-PLUS).
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At the end of Absorption Stage, it transitions to the programmed "EQUALIZE VOLT-
AGE" (see programmable range and defaults at Table 6.2). It remains in this stage for the
computed time T2. This stage is displayed as"E-Equalization Stage" in the 2
nd
line of
Charging Mode screens in Remote Control EVO-RC-PLUS (Please refer to Table 3.2
at Section 3.6.4.2 of Owner's Manual for EVO-RC-PLUS).
The equalization curr
ent “I
2
” is normally 5% to 10% of the Ah capacity of the battery.
This current is indirectly computed from the programmed "BULK CURRENT" ("Io"). As
recommended under the Setting Mode for the Bulk Charge Current, the "BULK
CURRENT" (“Io”) is expected to be set at 10% to 20% of the Ah capacity of the
battery. Hence, the Equalization Current “I
2
” will be automatically computed at 50% of
the set "BULK CURRENT" (“Io”) which will effectively amount to 5% to 10% of the Ah
capacity of the battery. For example, the Equalization Current “I
2
” for a 200 Ah capacity
battery will be 10 A - 20A. The "BULK CURRENT" (“Io”) for a 200 Ah capacity at 10% 20% will be set at 20 A - 40A. The rmware will compute the Equalization Current “I
2
” at
50% of 20 A (i.e. 10A) or at 50% of 40A (i.e. 20A).
At the end of Adaptive Equalization Stage, the charger transitions to the pr
ogrammed
"FLOAT VOLTAGE" (see programmable range and defaults at Table 6.2). This stage is dis-
played as"O-Float Stage" in the 2
nd
line of the Charging Mode screens in Remote
Control EVO-RC-PLUS (Please refer to Table 3.2 at Section 3.6.4 of Owner's Manual
for EVO-RC-PLUS).
Automatic Resetting of Charging Cycle
The charging cycle will be reset to the Bulk Stage of 3 Stage Charging Prole as follows:
If the AC is r
econnected or the battery voltage drops below 12 VDC / 24 VDC (Default).
Programmable range for this voltage is 10 to 13V for 12V battery and 20 to 26V for 24V battery.
This parameter is called "RESET TO BULK". Please see Table 6.2 and Section 4.2.2.15 of the EVORC-PLUS manual.
If the charger r
emains in the Float Mode for 10 days.
5.10 SWITCHING ON AND SWITCHING OFF OF EQUALIZATION
CHARGING PROFILE (4 STAGE CHARGING)
The default charging prole is 3 stage Adaptive Prole (See Table 5.2). Equalization Prole is
required to be selected manually as follows:
Using ON/OFF Push Button (11, Fig 2.1) on the Front Panel (only if the Remote
Control EVO-RC-PLUS is not available): When the unit is in Charging Mode (qualied
Grid / Generator Input is available), the Blue LED “ON” (12, Fig 2.1) will be ashing once
per second. Press the ON/OFF Button for 1 second. The ongoing Charge Prole will be
terminated and Adaptive Equalization will be initiated. The Blue LED “ON” (12, Fig 2.1) will
start ashing 2 times per sec to show that Equalize "CHARGE MODE" is active. The unit will
complete Equalization and terminate in the last stage of the charging prole that was active
at the time the Equalize Prole was activated using the front panel On/Off Push Button (11,
Fig 2.1). Henceforth, charging will continue in the initial charging prole that was active
before equalization was initiated using the front panel On/Off Push Button (11, Fig 2.1). At
the same time, the Charging Prole Setting will again be reset to the original and the Blue
LED “ON” (12, Fig 2.1) will return to 1 ash per second. To terminate Equalization Mode
prematurely before its completion, press the ON/OFF Push Button for 1 second.
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If the unit was in Inverting Mode [Blue LED “ON” (12, Fig 2.1) steady] and the Mode
is set to Equalization as above by pressing the ON/OFF Push Button for 1 second, the
unit will undergo Equalization Mode whenever qualied AC input is available from
Grid / Generator and the unit enters Charging Mode. To terminate Equalization Mode
prematurely before its completion, press the ON/OFF Push Button for 1 second.
NOTE: Procedure described above is to be used when the optional Remote
Control EVO-RC-PLUS has NOT been plugged into the RJ-45 Remote
Control Jack (7, Fig 2.1). Please note if the Remote Control has
been plugged into the RJ-45 Jack, the above procedure cannot be
activated and the ON/OFF of Equalization Mode will be controlled
by the Remote Control EVO-RC-PLUS.
Using Optional Remote Contr
ol EVO-RC-PLUS: Please refer to the following
Sections of the Owner's Manual for EVO-RC-PLUS:
- Section 4.1.3.1, Fig 4.2, Scr
een No. 12 "EQUALIZE-4STAGES"
-
Section 4.4.2.12 , set up pr
ocedure for parameter "EQUALIZE-4STAGES" setting at "1=Yes"
5.11 TWO-STAGE CHARGING PROFILES
In 2-Stage Prole, the battery is charged in Bulk Stage rst and then in Absorption Stage.
There is no 3
rd
Stage. Please refer to Fig 5.1 for typical Voltage and Current Curves. Consider
the curves for the Bulk and Absorption stages only.
NOTE: The 2nd Stage, i.e. "Absorption Stage" may also be referred to as "Float Stage"
in some applications like in Lithium Battery charging, and charging Lead Acid
batteries with load (battery backup applications) where the voltage setting of the 2
nd
Absorption stage is lowered to the level corresponding to Float Stage level.
There are 2 options for Charging Proles for 2-Stage Charging – (i) Type 1 and (ii) Type 2.
Please refer to Table 5.2 for details.
2-Stage Charging Proles are typically used for charging Lead Acid Batteries with load
(battery backup application) and for charging Lithium Batteries. Please refer to Section 5.12
below for details on charging Lithium Batteries
5.12 CHARGING LITHIUM BATTERIES
!
CAUTION!
The Battery Management System (BMS) that comes with the 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) may be used to feed
potential free contact closing signal from the BMS to “Stop Charging” or “Stop
Inverting. See details given below.
!
ATTENTION!
Le système de gestion de la batterie (BMS) qui vient avec la batterie au lithium utilisé peut avoir besoin
d'avoir le contrôle de charge et décharge de la batterie. Pour cela, les broches 4 et 5 du capteur de
température (6, gure 2.1) peut être utilisé pour l'alimentation contact libre de signal de fermeture de la
RBE en "Stop" ou "arrêt de charge de l'inversion. Voir les détails donnés ci-dessous.
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5.12.1 Charging Proles for Lithium Batteries
There are 3 Charging Proles available for charging Lithium Batteries: (i) 3 Stage Type 1, (ii) 2
Stage Type 1 and (iii) 2 Stage Type 2. Please refer to Table 5.2 for details
Charging voltages of Lithium Battery are not affected by temperature and hence, Battery
Temperature Sensor [Fig 2.5(a)] is not required to be used.
5.12.2 Stop Charging and Stop Inverting Protections When Charging
Lithium Batteries
As mentioned under CAUTION above, the Battery Management System (BMS) of the Lithium
Battery may need to provide the following potential free, contact closure control signals to
the Inverter Charger for battery protection:
•
“Stop Charging” contr
ol signal (potential free, contact closure) to the Battery Charger
Section to prevent (i) over voltage of individual cells / over voltage of the battery pack and
(ii) over temperature of individual cells / over temperature of the battery pack
• “Stop Inverting” control signal (potential free, contact closure) to the Inverter Section so
that the battery stops discharging to prevent deep discharge of the battery
Pins 4 and 5 of the RJ-45 Jack (6, Fig 2.1) can be programmed to accept the above potentialfree relay contact closure signal from the BMS. In default condition, Pins 4 and 5 of the RJ-45
Jack (6, Fig 2.1) are programmed for temperature compensation for Lead Acid Batteries
through battery temperature information received from Battery Charger Temperature Sensor
EVO-BCTS. Parameter “BATTERY TYPE” is used to select one of the above 2 functions of the
RJ-45 Jack (6, Fig 2.1) as follows:
Programming Parameter: “BATTERY TYPE” for selecting function of RJ-45 Jack marked
“Battery Temp. Sensor” (6, Fig 2.1)
Setting 0=Lead Acid (Default) Temperature compensation through battery temperature
information from the Battery Charger Temperature sensor
EVO-BCTS
Setting 1=Lithium Connect Pins 4 and 5 to potential free contacts of the BMS
of the Lithium Battery
If the BMS of the Lithium Battery being used has the ability to provide potentialfree relay contact closure signal for stopping of charging / inverting functions as
described above, parameter “BATTERY TYPE” should be programmed for setting
1=Lithium as explained above.
For details of above programming, please refer to Section 4.2.2.22 of the EVO-RC
PLUS Remote Control Manual.
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96 | SAMLEX AMERICA INC.
When the contacts in the BMS close, Pins 4 and 5 of the RJ-45 Jack (6, Fig 2.1) will be shorted.
The following actions will be activated:
• EVO in Charging Mode: Charging will stop (charging current will be reduced to 0A).
The 2
nd
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
the example below for Screen No. 1 for EVO-1212F:
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 : 1 2 . 0 0 V 0 . 0 A
E x t e r n a l : 0 . 0 A
Screen
No. 1
For more details, refer to Section 3.6.8 and Fig 3.7 of EVO-RC-PLUS Manual.
•
EVO in Inverting Mode:
Inverting will stop. EVO
TM
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 3.1 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 for
EVO-1212F:
"Inv stop" for 2 sec
"by BMS" for 2 sec
E V O - 1 2 1 2 F I n v S t o p
O u t p u t : 0 . 0 0 V
< 0 . 1 0 A
0 . 0 0 H z
Screen
No. 1
5.13 CHARGER ONLY MODE
In Off-grid DC powered homes, for efciency consideration, all lighting and other loads /
appliances are normally powered from 12V 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
TM
can be programmed to operate as a battery charger ONLY. Details are
given below
When “Charger Only” Mode is selected (ONLINE MODE: 2=Charger Only), the EVOTM will
operate as a battery charger to charge the batteries and pass through the AC input power to
the loads as long as AC input is available (In DC powered homes, 120 VAC pass through will
normally not be used as all the loads will be DC)
When AC input fails, the Inverter Section will NOT be activated and the EVO
TM
will operate in
“Standby Mode” as long as AC input is NOT available. In “Standby Mode”, the EVO
TM
draws
extremely low power from the batteries (< 5W)
For further details, please refer to the following Sections of the EVO-RC Plus Manual:
• Section 4.1.3.1: Screen No. 13 of “Select Parameter Menu Map for Group 1 – CHARGE
CURVE” at Fig 4.2
• Section 4.4.2.13.2: “Charger Only Mode” under ONLINE MODE
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BEFORE OPERATING THE UNIT, PLEASE ENSURE THAT THE UNIT HAS BEEN INSTALLED
PROPERLY AS PER INSTRUCTIONS AT SECTION 3 OF THIS MANUAL.
PLEASE ENSURE THAT ALL SAFETY INSTRUCTIONS AT SECTION 1 OF THIS MANUAL
ARE READ AND UNDERSTOOD BEFORE OPERATING THE UNIT.
i
INFO
a) Minimum battery voltage required for initiating manual switching ON of the unit
is as follows:
•
12V units ----- Higher than 9V
•
24V units ---- Higher than 18V
b
) Please note that this unit is designed to POWER ON AUTOMATICALLY if (i) AC voltage of
70V ± 5 VAC is available at the AC Input Terminals and (ii) DC input voltage is > 12V for
EVO-1212F / EVO-1212F-HW and >24V for EVO-1224F / EVO-1224F-HW. If the AC input
voltage and frequency are within the programmed limits, the unit will automatically
operate in “Charging Mode”. If the AC input voltage and frequency are not within the
programmed limits, the unit will operate in “Inverting" Mode. Further, as long as AC input
voltage > 70 ± 5 VAC is present, the unit CANNOT BE POWERED OFF using the ON / OFF
Button on the front panel of the unit or on the optional Remote Control EVO-RC-PLUS.
Switch OFF the AC input rst if the unit is required to be powered off. However, if the unit
is in “Fault Mode”, it will be possible to power OFF the unit with the help of the ON/OFF
Push Button.
c) Before proceeding, conrm that the unit is NOT in Standby Mode by pressing ON/
OFF Button briey. (Standby Mode is used for Firmware upload through the optional
Remote Control EVO-RC-PLUS.)
o
If LED marked “ON” (12, Fig 2.1) stays OFF
, then unit is OFF.
o
If this LED is ON or is ashing, the unit was in Standby Mode and is now ON
6.1 POWERING ON USING ON/OFF BUTTON ON THE FRONT PANEL (11, Fig 2.1)
6.1.1 Powering ON the Unit: AC Input Switched OFF / Not Connected
• To power ON the unit, press and hold the ON/OFF Button (11, Fig 2.1) for 2 seconds.
Blue LED marked “ON” (12, Fig 2.1) will ash 3 times, will go off momentarily and will
then be steady Green. Now, release the ON/OFF Button. Subsequently, the lighting pattern of this LED will be controlled by various operating conditions given in Table 6.1
6.1.2 Powering OFF the Unit: AC Input Switched OFF/ Not Connected
To power OFF the unit, press and hold the ON/OFF Button (11, Fig 2.1) for 5 seconds.
• The Blue LED marked "ON" (11, Fig 2.1) will remain ON and after around 5 sec of pressing and holding the ON / OFF button, Red LED marked "Fault" will be lighted. Release
the ON / OFF button after the Red LED "Fault" (13, Fig 2.1) has lighted. The unit will
switch off thereafter. (NOTE: Power OFF will not take place unless the Power ON/OFF
Button is released)
• NOTE: As explained under paragraph (b) of “INFO” above, as long as AC input
voltage > 70 ± 5 VAC is present, the unit CANNOT BE POWERED OFF using the ON/
OFF Button on the front panel of the unit or on the optional Remote Control EVORC-PLUS. In order to power off using the Power ON/Off Button, switch OFF the AC
input rst. Further, if the unit is in “Fault Mode”, it will be possible to power OFF
the unit with the ON/OFF Push Button.
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Page 98
98 | SAMLEX AMERICA INC.
6.2 POWERING ON / OFF BY FEEDING EXTERNAL +12V SIGNAL TO
TERMINALS MARKED “REMOTE ON/OFF” ON THE FRONT PANEL
The unit can be switched ON /OFF remotely by feeding 2 specied formats of +12VDC (+9
to15VDC, < 10mA) signals to terminals marked “Remote On / Off” on the Front Panel (16, Fig
2.1). The specied +12V signal formats are “Button Type” and “Switch Type”. These 2 signal
format options can be are programmed using the optional Remote Control EVO-RC Plus. These
options are available under programmable parameter called REMOTE SWITCH grouped under
“Select Parameter Menu Map for Group 5: OTHER FUNCTION”. Please refer to the following
Sections of the of the Manual for Remote Control EVO-RC-PLUS:
• Section 4.1.3.3, Fig 4.4: Screen No. 4 – “OTHER FUNCTION, REMOTE SWITCH”
• Section 4.8.1, T
able 4.7: Srl No. 4 “REMOTE SWITCH”
-
0=Button T
ype (Default); 1=Switch Type
• Section 4.8.2.4: Detailed explanation of programmable parameter REMOTE SWITCH
6.2.1 Button Type (Default)
This type of external +12V signal format is used when the signal is fed through an external
series connected Push Button (+12V will be fed as long as the Push Button is kept pressed).
Control logic used is as follows:
• When the EVO
TM
is in OFF condition, momentary feeding of +12V signal through the
external Push Button for > 2 sec will turn the unit ON condition. The EVO
TM
will remain
ON even when the Push Button is released
•
When the EVO
TM
is in ON condition, momentary feeding of +12V signal through the
external Push Button for > 5 sec will turn the EVO
TM
to OFF condition.
NOTE:
If the external Push Button is pressed for < 5 sec, the unit will NOT switch OFF
6.2.2 Switch Type
This type of external +12V signal format is used when the +12V signal (+9 to 15 VDC, <
10mA) is fed through an external, series connected On/Off Toggle / Rocker Switch or Relay
contact (+12V signal will be fed continuously when the switch in ON condition / Relay contact
is closed and +12V signal will be removed when the external On/Off switch is in OFF condition or the Relay contact is open). Example of this type of Remote On/Off Control signal format is the Ignition Switch in a vehicle. When the Ignition Switch is ON, 12V from the vehicle
battery will be available. When the Ignition Switch is OFF, 12V will be switched OFF. Control
logic used is as follows;
•
When the exter
nal On/Off Switch is turned ON or when the Relay contact is closed,
continuous +12V control signal will be made available and the EVO
TM
will turn ON.
EVO
TM
will remain ON as long +12V control signal is available through the ON condition
of the external On/Off Switch or the closed Relay contact
•
When the exter
nal On/Off Switch is turned OFF or if the Relay contact opens, the +12V
signal will be removed and the EVO
TM
will switch OFF
!
CAUTION!
When “Switch Type” of ON/OFF control described above is selected, the ON/OFF
Button on the front panel of the unit (12, Fig 2.1) should NOT be used to turn ON
or turn OFF the unit. The front panel ON/OFF Push Button will now follow the
above “Switch Type” control logic wherein the unit will remain ON only as long
as the Button is kept pressed and will turn OFF in 2 seconds after it is released.
SECTION 6 | Operation, Protections and Troubleshooting
Page 99
!
ATTENTION!
Lorsque « Switch Type » de ON/OFF contrôle décrit ci-dessus est sélectionnée, le bouton ON/OFF sur le panneau
avant de l’unité (12, Fig 2.1) ne devraient pas servir à allumer ou éteindre l’appareil. La façade, bouton poussoir
ON/OFF suivra désormais la logique de contrôle ci-dessus « Switch Type » dans lequel l’appareil demeurera allumé
aussi longtemps que la touche est maintenue enfoncée et s’éteint après 2 secondes après que qu’il est libéré.
6.3 OPERATIONAL INFORMATION THROUGH LEDS AND BUZZER
Table 6.1 shows the operational states of the unit indicated by the following LEDs on the
front panel of the unit and Buzzer:
o
Blue LED marked “ON” (12, Fig 2.1)
o Red LED marked “Fault” (13, Fig 2.1)
Optional Remote Control Model EVO-RC-PLUS will be required for more detailed messaging that is available through its LCD display and LEDs. This remote will also be required for
programming of various parameters to suit specic requirements.
TABLE 6.1 LED AND BUZZER INDICATIONS
Status
Blue LED
marked “ON”
(12, Fig 2.1)
Red LED
marked “Fault”
(13, Fig 2.1)
Buzzer
Seen during Power-On
Sequence
Indicates completion of
Power-On Sequence after
Power ON/OFF Button is
pressed for 2 sec
Flash 3 times Off Off
Seen during Power-Off
Sequence
Indicates completion of
Power-Off Sequence after
Power ON/OFF Button is
pressed for 5 sec
On On Off
Normal charging Flash 1 time per sec Off Off
Equalization charging Flash 2 times per
sec
Off Off
Inverting (Discharging) On Off Beep per 3 second
(Default Off)
Low battery alarm On Flash 1 per sec Beep per 1 second
Power saving Flash 1 time per
3 sec
Off Off
Standby (See CAUTION!
at Section 6.7)
Off Off Off
Fault Off On On
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Page 100
100 | SAMLEX AMERICA INC.
6.4 OPTIONAL REMOTE CONTROL EVO-RC-PLUS 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 Battery.
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:
TABLE 6.2 PROGRAMMABLE AND DEFAULT PARAMETERS: GROUP "CHARGE CURVE"
Parameter
Programming Range
(Programming requires optional
Remote Control Model EVO-RC-PLUS) Default
EVO-1212F
EVO-1212F-HW
EVO-1224F
EVO-1224F-HW
EVO-1212F
EVO-1212F-HW
EVO-1224F
EVO-1224F-HW
“BULK CURRENT”
(Bulk Charge Current “Io”)
0 - 60A 0 - 40A 20A 15A
“ABSORP VOLTAGE”
(Absorption Voltage)
13.5V - 16.0V 27.0V - 32.0V 14.4V 28.8V
“EQUALIZE VOLTAGE”
(Equalization Voltage)
14.0V - 16.0V 28.0V - 32.0V 14.4V 28.8V
“FLOAT VOLTAGE"
(Float Voltage)
13.0V - 15.0V 26.0V - 30.0V 13.5V 27.0V
“COMPENSATE”
(Temperature Compensation)
-3mV to -5mV /°C/Cell -4mV /°C/Cell
“BATT OVER VOLT”
(Battery Over Voltage Shut
Down)
14.0V - 17.0V 28.0V - 35.0V 16.0V 32.0V
“RESET VOLTAGE”
(Battery Low Voltage Reset)
12.0V - 17.0V 24.0V - 35.0V 14.0V 28.0V
“LOW VOLT ALARM”
(Battery Low Voltage Alarm)
9.5V - 12.5V 19.0V - 25.0V 11.0V 22.0V
“BATT LOW VOLTAGE”
(Battery Low Voltage Shut
Down)
9.1V - 12.0V 18.1V - 24.0V 10.5V 21.0V
“LV DETECT TIME”
(Low Voltage Detect Time)
0-600 sec 10 sec
“LV CUT OFF TIME”
(Low Voltage Cut Off Time)
0-7200 sec 1200 sec
“EQUALIZE-4STAGES”
( 3 or 4 Stage Charging)
0 = No
1 = Yes
0 = No
"ONLINE MODE"
0 = Normal
1 = On Line
2 = Charger Only
0 = Normal
"ONLINE OPTION"
0 = Option 1
1 = Option 2 0 = Option 1
SECTION 6 | Operation, Protections and Troubleshooting
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