Evolution Series Inverter Charger Pure Sine Wave TM Models: EVO-2212 EVO-3012 EVO-2224 EVO-4024 Owner's Manual Please read this manual BEFORE operating.
EVO INVERTER CHARGER MANUAL | Index SECTION 1 Safety Instructions & General Information............................. 3 SECTION 2 Components & Layout ........................................................ 24 SECTION 3 Installation .......................................................................... 28 SECTION 4 General Description and Principles of Operation.................. 59 SECTION 5 Battery Charging in Evolution Series ...................................
SECTION 1 | Safety Instructions & General Information 1.1 IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS. THIS MANUAL CONTAINS IMPORTANT INSTRUCTIONS FOR MODELS: EVO-2212, EVO-2224, EVO-3012, EVO-4024 THAT SHALL BE FOLLOWED DURING INSTALLATION & MAINTENANCE OF THE INVERTER CHARGER. THE FOLLOWING SYMBOLS WILL BE USED IN THIS MANUAL TO HIGHLIGHT SAFETY AND IMPORTANT INFORMATION: WARNING! Indicates possibility of physical harm to the user in case of non-compliance.
SECTION 1 | Safety Instructions & General Information 6. The AC input / output wiring terminals are intended for field connection using Copper conductors that are to be sized based on 75°C and NOT larger than AWG #1(42.4 mm2). See Tables 1.1(a), 1.1 (b) and 1.1 (c) for sizing of conductors for AC INPUT circuits and Table 1.2 for sizing of conductors for AC OUTPUT circuits. 7.
SECTION 1 | Safety Instructions & General Information • • • • • Batteries generate Hydrogen and Oxygen during charging resulting in evolution of explosive gas mixture. Care should be taken to ventilate the battery area and follow the battery manufacturer’s recommendations. Never smoke or allow a spark or flame near the batteries. Use caution to reduce the risk of dropping a metal tool on the battery. It could spark or short circuit the battery or other electrical parts and could cause an explosion.
SECTION 1 | Safety Instructions & General Information Table 1.2 AC OUTPUT WIRING AND BREAKERS Item Rated AC Output NEC Ampacity = Wire Size based on NEC Breaker Size Current in In125% of Column Ampacity at Column 3 (Based on NEC Amverter Mode 2 and 75°C Copper Conduc- pacity at Column 3) tor in Conduit (Column 1) (Column 2) (Column 3) (Column 4) (Column 5) EVO-2212 18.33A 22.91 AWG #10 25A EVO-2224 18.33A 22.91 AWG #10 25A EVO-3012 25A 31.25 AWG #8 35A EVO-4024 33.33A 41.
SECTION 1 | Safety Instructions & General Information 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 Pass & Seymour 2095W NEMA5-20, Duplex, 20A Pass & Seymour 1595W NEMA5-15, Duplex, 15A Leviton 7899-W NEMA5-20, Duplex, 20A Leviton T7599W NEMA5-15, Duplex, 15A Leviton 7599W NEMA5-15, Duplex, 15A ATTENTION! 1.
SECTION 1 | Safety Instructions & General Information 13. 14. ATTENTION! Risque de choc électrique. Utilisez uniquement les GFCIs suivantes. D’autres types peuvent ne pas fonctionner correctement lorsqu’il est connecté à cet appareil. MISE À LA TERRE: Le symbole de mise à la terre ci-dessous est utilisé pour identifier uniquement l’équipement terminal de terre-câblage. Toutefois, ce symbole est utilisable avec le cercle omis pour identifier divers points de l’unité qui sont liés à la masse.
SECTION 1 | Safety Instructions & General Information consisting of a combination of resistances, inductances and capacitances, the Phase Angle (φ) of the net current vector will be > 0° < 90° and may lag or lead the voltage vector. Resistance (R), Ohm, Ω: It is the property of a conductor that opposes the flow of current when a voltage is applied across it. In a resistance, the current is in phase with the voltage. It is denoted by “R” and its unit is “Ohm” - also denoted as “Ω”.
SECTION 1 | Safety Instructions & General Information capacitive elements and hence, its value will be > 0 <1. Normally it ranges from 0.5 to 0.8. Load: Electrical appliance or device to which an electrical voltage is fed. Linear Load: A load that draws sinusoidal current when a sinusoidal voltage is fed to it. 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.
SECTION 1 | Safety Instructions & General Information The 120V output waveform of the Evolution series inverters is a pure sine wave like the waveform of the grid power. Please see sine waveform represented in the Fig. 1.1 that also shows equivalent modified waveform for comparison. In a sine wave, the voltage rises and falls smoothly with a smoothly changing phase angle and also changes its polarity instantly when it crosses 0 Volts.
SECTION 1 | Safety Instructions & General Information • Devices that use radio frequency signals carried by the AC distribution wiring. • Some new furnaces with microprocessor control / Oil burner primary controls. • High intensity discharge (HID) lamps like Metal Halide lamps. These may get damaged. Please check with the manufacturer of these types of devices for suitability. • Some fluorescent lamps / light fixtures that have power factor correction capacitors.
SECTION 1 | Safety Instructions & General Information TABLE 1.
SECTION 1 | Safety Instructions & General Information • • • • Shield the DC side wires with metal sheathing / copper foil / braiding. Use coaxial shielded cable for all antenna inputs (instead of 300 ohm twin leads). Use high quality shielded cables to attach audio and video devices to one another. Limit operation of other high power loads when operating audio / video equipment. 1.3.
SECTION 1 | Safety Instructions & General Information NOTE: Voltage and Current scales are different Input voltage RMS Current Inrush current Fig 1.2 Inrush current in an SMPS Current − Volatge − Current + Voltage + Non-linear Input Current Peak Current NOTE: Voltage and Current scales are different RMS Current Input Sine Wave Voltage TIME CREST FACTOR = PEAK CURRENT = 3 RMS CURRENT Fig 1.3 High Crest Factor of current drawn by SMPS 1.
SECTION 1 | Safety Instructions & General Information 1.4.1 Deep Cycle Lead Acid Batteries Deep cycle batteries are designed with thick-plate electrodes to serve as primary power sources, to have a constant discharge rate, to have the capability to be deeply discharged to up to 80 % capacity and to repeatedly accept recharging. 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.
SECTION 1 | Safety Instructions & General Information 1.4.5 Specifying Charging / Discharging Currents: C-Rate Electrical energy is stored in a cell / battery in the form of DC power. The value of the stored energy is related to the amount of the active materials pasted on the battery plates, the surface area of the plates and the amount of electrolyte covering the plates.
SECTION 1 | Safety Instructions & General Information Typical Flooded Lead-Acid Battery Chart - 80˚F / 26.7˚C 24V 12V 33.0 16.5 C/5 C/10 32.0 16.0 CHARGE C/20 31.0 15.5 C/40 Battery Voltage in VDC 30.0 15.0 29.0 14.5 28.0 14.0 27.0 13.5 26.0 13.0 C/100 C/20 C/10 25.0 12.5 C/5 24.0 12.0 DISCHARGE C/3 23.0 11.5 22.0 11.0 21.0 10.5 20.0 10.0 19.0 9.5 18.0 9.0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 Battery State of Charge in Percent (%) Fig 1.
SECTION 1 | Safety Instructions & General Information TABLE 1.9 BATTERY CAPACITY VERSUS RATE OF DISCHARGE – C-RATE C-Rate Discharge Current C/20 C/10 C/8 C/6 C/5 C/3 C/2 1C Usable Capacity (%) 100% 87% 83% 75% 70% 60% 50% 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).
SECTION 1 | Safety Instructions & General Information Check the individual cell voltages / specific gravity. If the inter-cell voltage difference is more than a 0.2V, or the specific gravity difference is 0.015 or more, the cells will require equalization. Please note that only non-sealed / vented / flooded / wet cell batteries are equalized. Do not equalize sealed / VRLA type of AGM or Gel Cell Batteries. 1.4.
SECTION 1 | Safety Instructions & General Information 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.
SECTION 1 | Safety Instructions & General Information 1.4.12 Depth of Discharge of Battery and Battery Life The more deeply a battery is discharged on each cycle, the shorter the battery life. Using more batteries than the minimum required will result in longer life for the battery bank. A typical cycle life chart is given in the Table 1.12 below: TABLE 1.
SECTION 1 | Safety Instructions & General Information Now, the capacity of the batteries is determined based on the run time and the usable capacity. From Table 1.9 “Battery Capacity versus Rate of Discharge”, the usable capacity at 3 Hour discharge rate is 60%. 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.
SECTION 2 | Components & Layout 2.1 MAIN UNIT: LAYOUT-FRONT (FIG 2.1) Status Relay NO Common NC 12 13 3 4 11 10A 1 14 15 16 10B 2 10C 9A 9B 9C 9D 6 7 1a Red 1b Black 8 5 Fig 2.1 Layout-Front Protection Covers for Battery Terminals 1. Battery Positive (+) Input Connector – M10 x 1.25 Nut & Bolt (RED Protection Cover 1(a) is Removed) 1a. RED Protection Cover For Battery Positive (+) Input Connector 2. Battery Negative (-) Input Connector – M10 x 1.
SECTION 2 | Components & Layout 15. +12V Input Terminals for “Remote On Off” (9 to 15V, 3mA) - Screw M 2.5; AWG #30 to #12 16. Output Terminals for +12VDC source (up to 100mA) (available only when unit is ON) - Screw M 2.5; AWG #30 to #12 2.2 MAIN UNIT: LAYOUT-BACK (FIG 2.2) 1. Air outlet vents for 2 internal fans 1 Fig 2.2 Layout-Back 2.3 MAIN UNIT: LAYOUT-AC SIDE (FIG 2.3) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
SECTION 2 | Components & Layout 2.4 REMOTE CONTROL EVO-RC (FIG 2.4) [OPTIONAL] 1 9 3 5 2 6 7 8 Fault 4 Fig 2.4(a) Optional Remote Control EVO-RC 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. LCD Screen - 2 rows of 16 characters each ON/OFF Key Green LED “Status” Red LED “Fault" Navigation Key “Back” Navigation Key “Up” Navigation Key “Down” Navigation Key “Enter” SD Card Slot - FAT16/32 format; Up to 16GB RJ-45 Jack (At the back-not shown) RJ-45 Data Cable (Straight Wired), 10 meter/33 feet length {Fig 2.
SECTION 2 | Components & Layout 2.5 BATTERY TEMPERATURE SENSOR EVO-BCTS [FIG 2.5 (a)] 1. 2. 3. Temperature Sensor: Mounting hole: 10mm/0.39” suitable for 3/8” or 5/16” battery studs RJ-45 Plug 5 meter/16.5 ft cable Note: Mount the sensor on the Positive or Negative terminal stud on the battery as shown in Fig 2.5(b) 2 1 3 Fig 2.5(a) Temperature Sensor Model EVO-BCTS Fig 2.5(b) Temperature Sensor Installation 2.6 CONTENTS OF PACKAGE Inverter Charger Temperature Sensor EVO-BCTS [Fig 2.
SECTION 3 | Installation 3.1 SAFETY OF INSTALLATION WARNING! Please ensure safety instructions given under Section 1 are strictly followed. ATTENTION! Se il vous plaît assurer consignes de sécurité fournies à la section 1 sont strictement suivies. 3.2 OVERALL DIMENSIONS The overall dimensions and the location of the mounting holes are shown in Fig. 3.1. 426 380 13 7 7 Slope of top surface should be minimum 115˚ 7 Mounting Holes: 7mm/0.
SECTION 3 | Installation 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: • Mount horizontally on a horizontal surface (e.g. table top or a shelf). Please see Fig. 3.2. Wall 115° Top surface of Drip Shield 10 mm Gap 55 mm (a) Non Marine Installation (b) Marine Installation Fig 3.
SECTION 3 | Installation • Mount vertically on a vertical surface, see Fig. 3.4. Protect against possibility of small objects or water entering the ventilation openings on the top. (If necessary, install a suitable sloping guard at least 200mm from the top surface). Also, ensure there is no combustible material directly under the unit. Wall 115° Top surface of Drip Shield 10 mm Gap (a) Non Marine Installation (b) Marine Installation Fig 3.4 Mounting Arrangement 2: On Vertical Surface 3.
SECTION 3 | Installation 3.4.2 Parallel Connection Cable “A” 12V Inverter or 12V Charger Battery 1 Battery 2 Battery 3 Battery 4 12V 12V 12V 12V Cable “B” Fig 3.6 Parallel Connection When two or more batteries are connected in parallel, their voltage remains the same but their Ah capacities add up. Fig. 3.6 above shows 4 pieces of 12V, 100 Ah batteries connected in parallel to form a battery bank of 12V with a capacity of 400 Ah.
SECTION 3 | Installation 3.4.4 Wiring Order in Parallel Connection of Batteries CAUTION! When 2 or more batteries / battery strings are connected in parallel and are then connected to inverter/charger (See Figs 3.6 and 3.7), attention should be paid to the manner in which the inverter/charger is connected to the battery bank. Please ensure that if the Positive output cable of the inverter/charger (Cable “A”) is connected to the Positive battery post of the first battery (Battery 1 in Fig 3.
SECTION 3 | Installation Quand il y a 2 batteries/fils de batterie ou plus qui sont liés en parallèle et branché à la fois, à un chargeur (Voir Figs. 3.6 et 3.7), il faut faire attention à la manière dont le chargeur est branché à la banque de batterie. Veuillez assurer que le câble positif de sortie du chargeur de batterie (Câble A) est lié à la borne positive de la première batterie (La batterie 1 dans la Fig. 3.
SECTION 3 | Installation 3.5 DC SIDE CONNECTIONS Status Relay NO Common NC 3 4 1 2 6 1a Red 1b Black 5 FIG 3.8 DC Side Connections Protection Covers for Battery Terminals 1. Battery Positive (+) Input Connector – M10 x 1.25 Nut & Bolt (RED Protection Cover 1(a) is Removed) 1a. RED Protection Cover For Battery Positive (+) Input Connector 2. Battery Negative (-) Input Connector – M10 x 1.25 Nut & Bolt (Black Protection Cover 1(b) is Removed) 2a.
SECTION 3 | Installation • External charging source, if any, is connected to the connectors (3) and (4) as shown above. The maximum capacity of the external charging source is 50A. Battery Temperature Sensor EVO-BCTS is connected to the RJ-45 Jack (6). See Fig 2.5 (a) and 2.5 (b) for details. • 3.5.
SECTION 3 | Installation The DC input circuit is required to handle very large DC currents and hence, the size of the cables and connectors should be selected to ensure minimum voltage drop between the battery and the inverter. Thinner cables and loose connections will result in poor inverter performance and will produce abnormal heating leading to risk of insulation melt down and fire.
SECTION 3 | Installation Les conducteurs sont protègés par des matériaux isolants classés pour une température spécifique, par exemple,une température de 90˚C/194˚F. Le flux de courant produit de la chaleur et affecte l’isolation. Alors, il y a une valeur de courant maximale (aussi appellé « L’ampacité ») qui est permise pour chaque taille de conducteur et pour la classification température de l’isolation.
SECTION 3 | Installation It is mandatory to use appropriately sized external fuse in the battery and External Charger Circuits. If external fuse is not used and reverse polarity connection is made by oversight, the input section of the unit will be damaged/burnt. Warranty will be voided in such a situation. Il est obligatoire d’utiliser un fusible externe de taille appropriée à la batterie et les circuits chargeur externe .
SECTION 3 | Installation TABLE 3.1 Item (Column 1) SIZING OF BATTERY SIDE CABLES AND EXTERNAL BATTERY SIDE FUSES Rated Continuous DC Input Current (See Note 1) NEC Ampacity = 125% of Rated DC Input Current at Column 2 (See Note 2) (Column 2) (Column 3) 90°C Copper Conductor.
SECTION 3 | Installation 4) Column 9 indicates the size of external fuse in the battery circuit. It is mandatory to install this fuse within 7” of the battery Positive terminal to protect the internal DC Input Section of the unit and also to protect the battery cables against short circuit. Amp rating of the fuse is based on the following considerations: a) 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.
SECTION 3 | Installation 3.6 AC INPUT AND OUTPUT - LAYOUT AND CONNECTION ARRANGEMENT AC side layout and connection arrangement are shown in Fig 3.9. 1. Cover plate for pocket for AC Input/Output terminals 2. Pocket for AC Input/Output Terminals (behind cover plate 1) 3. AC Input/Output Terminal Block - Terminal hole diameter: 6mm for up to AWG #6 - Set Screw: M4 4. Grid Input - Line 5. Grid Input - Ground 6. Grid Input - Neutral 7. Generator Input - Line 8. Generator Input - Ground 9.
SECTION 3 | Installation 3.6.1 System Grounding and Output Neutral to Chassis Ground Bond Switching WARNING! • In "Inverting Mode" (default condition), the Neutral of the AC output of the unit gets bonded to the metal chassis of the unit through the internal “Neutral to Chassis Switching Relay” [Relay K4 in Figs 4.1(a) and 4.1(b)]. • In “Charging Mode”, the internal “Output Neutral to Chassis Switching Relay” disconnects the Neutral of the AC output connection from the chassis of the unit.
SECTION 3 | Installation damage the output section of the unit and may also pose a fire and safety hazard. If an electrical breaker panel / load center is fed from this unit and this panel is also required to be powered from additional alternate AC source, the AC power from the additional AC source should first be fed to a suitable Manual/Automatic Transfer Switch and the output of the transfer switch should be connected to the electrical breaker panel / load center.
SECTION 3 | Installation primaire de ce transformateur et les deux sorties chaud (120 VAC divisé phases) et le neutre du secondaire de ce transformateur doit être relié au panneau de disjoncteur électrique / Centre de gravité. Se il vous plaît voir les détails en ligne sous Livre blanc intitulé “120/240 VAC Split système phase et multi-fils Circuits de dérivation” à: www.samlexamerica.com (Accueil> Support> Livres blancs). 3.
SECTION 3 | Installation Strip adequate insulation from the end of the wire (Fig. 3.11). Avoid nicking the wire when stripping the insulation. Wire End Terminals have been provided (see Section 2.6, page 27) for firm connection under the set screw. Insert the bare end of the wire into the barrel portion of the Wire End Terminal & crimp barrel portion using suitable crimping tool (Fig 3.11). Insert the terminated end of the wire fully into the terminal slot till it stops. Tighten the screw firmly.
SECTION 3 | Installation capacity of the specific model when operating in Inverter Mode (Column 1 ). • When Grid / Generator input is available and the unit is operating in Charging / Pass Through Mode, the AC Input Current will be determined as follows: • The maximum possible AC Input Current (Column 4) for a particular model will be equal to the sum of the Rated AC Side Battery Charging Current (Column 3) and the Rated Pass Through current (Column 2).
SECTION 3 | Installation TABLE 3.2.2 SIZING OF GRID AND GENERATOR INPUT WIRING AND BREAKERS (FOR INPUT CURRENT LIMIT PROGRAMMED AT 45A FOR EVO-3012 AND EVO-4024) Model No.
SECTION 3 | Installation Electrical Code) - Section 210.19(A)(1)(a) regarding minimum Ampacity and size of Branch Circuit Conductors. 6) Column 7 indicates the wiring conductor size that has been determined based on NEC-2014 (National Electrical Code) - Ampacity Table 310.15(B)(16) for Raceway. This conductor size is based on (i) NEC Ampacity (Column 6) (ii) conductor temperature of 75°C and (iii) ambient temperature of 30°C / 86°F.
SECTION 3 | Installation Table 3.3 SIZING OF AC OUTPUT WIRING AND BREAKERS Item Model No. and Rated Output Power in Inverter Mode (Column 1) Rated AC Output Current in Inverter Mode (See Note 1) 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) External Breaker Size based on NEC Ampacity at Column 3 (See Note 3) (Column 5) (Column 2) EVO-2212 (2200VA, 18A) 18.33A 22.91 AWG #10 25A EVO-2224 (2200VA, 18A) 18.33A 22.
SECTION 3 | Installation 3.10 GFCI PROTECTION FOR VEHICLE APPLICATION When this unit is installed in vehicles, ensure that Ground Fault Circuit Interrupter(s) are installed in the vehicle wiring system to protect all branch circuits. Details of tested and approved GFCI’s are given in Table 3.4. 3.11 GROUNDING TO EARTH OR TO OTHER DESIGNATED GROUND For safety against electrical shock, the metal chassis of unit is required to be grounded to the Earth Ground or to the other designated ground.
SECTION 3 | Installation The connections must be tight against bare metal. Use star washers to penetrate paint and corrosion. As the Equipment Grounding Bus Bar (G3) in the DC Panel is bonded to the Grounding Electrode (GE), the chassis of the EVO / DC side will be bonded to Earth Ground. WARNING! For application of EVO on a boat, the size of the Equipment Grounding Conductor (EGC) from the Grounding Terminal on the EVO (G2) to the boat’s system Ground, should be the same size as the battery cable.
SECTION 3 | Installation • When in Charging Mode, the Neutral conductor of the Grid power/Generator will be connected to the Output Neutral connector of the Inverter Charger. At the same time, the “Output Neutral to Chassis Ground Bond Switching Relay” [K4 in Figs 4.1(a) and 4.1(b)] will unbond (disconnect) the Output Neutral connector of the Inverter Charger from the chassis of the Inverter Charger.
Fig 3.12 Grounding Arrangement - EVO Series G3 Neutral Bus bar Bus bar for Equipment Grounding Conductors (EGC) A.C. Ground of EVO System Bonding Jumper (SBJ) Grounding Terminal on EVO (5, Fig 3.8) GRID LINE GRID GND GRID NEUTRAL Refer to AC GENERATOR LINE Input/Output GENERATOR GND Connectors GENERATOR NEUTRAL at Fig 3.9 OUTPUT LINE OUTPUT GROUND OUTPUT NEUTRAL Quick Disconnect Ground Electrode (Ground Rod) Pos. (+) Bus Neg. (-) Bus 120 VAC Leg, Phase B (180º out of phase with Phase A Leg) N. G3. G1.
SECTION 3 | Installation 3.15 SHORE BASED INSTALLATION 3.15.1 Typical Shore Based Installation Fig. 3.
SECTION 3 | Installation A NO - Normally Open Contact B Common To Remote Start/Stop C NC - Normally Closed Contact Terminals on the Generator 14 A B Optional Generator Auto Start/Stop Module + Fuse C - Optional Remote Control EVO-RC (Within 7” of battery terminal) Fuse 3 14 6 Battery Temperature Sensor - Model EVO-BCTS - + Deep Cycle Battery Bank 4 LINE N 1 7 AC DISTRIBUTION PANEL To Loads 2 5 Ground Terminal (5) FRONT (See Fig 2.1) G AC SIDE (See Fig 2.
SECTION 3 | Installation 3.16 MOBILE INSTALLATION - GENERAL INFORMATION 3.16.1 GFCI Protection For Vehicle Application When this unit is installed in vehicles, it is to be ensured that Ground Fault Circuit Interrupter(s) [GFCI] are installed in the vehicle wiring system to protect all branch circuits. WARNING! Please ensure that Ground Fault Circuit Interrupter(s) [GFCI] are installed in the vehicle wiring system to protect all branch circuits. GFCIs listed in Table 1.
SECTION 3 | Installation • For EVO-3012: The maximum continuous DC current required is 373A. The capacity of the Battery Isolator should be more than 373A or more than the capacity of the alternator, whichever is higher • For EVO-4024: The maximum continuous DC current required is 266A. The capacity of the Battery Isolator should be more than 266A or more than the capacity of the alternator, whichever is higher 3.16.
SECTION 3 | Installation A NO - Normally Open Contact B Common To Remote Start/Stop C NC - Normally Closed Contact Terminals on the Generator 14 A B + Optional Generator Auto Start/Stop Module - + Fuse C - Battery Temperature Sensor - Model EVO-BCTS Deep Cycle Battery Bank (Within 7” of battery terminal) + + - + Battery Isolator + Engine Starting Battery Fuse Optional Remote Control EVO-RC 3 14 6 4 1 7 2 5 Grounding Terminal (5) FRONT (See Fig 2.1) Alternator AC SIDE (See Fig 2.
SECTION 4 | General Description & Principles of Operations 4.1 GENERAL DESCRIPTION This unit is a Pure Sine Wave Bi-directional, Single-Phase Inverter / Charger with a Transfer Relay that operates either as an inverter OR as a smart battery charger.
SECTION 4 | General Description & Principles of Operations Soft Start: The inverter design incorporates “Soft Start” feature with the following advantages and protections: - When the unit powers up, it starts in Inverting Mode first. 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.
SECTION 4 | General Description & Principles of Operations 4.5.1 AC Transfer and Output Neutral To Chassis Ground Bond Switching As required by NEC and UL specification 458, AUTOMATIC Ouput Neutral to Chassis Ground bond switching arrangement has been provided in these units through “Output Neutral to Chassis Ground Bond Switching Relay” [K4 in Figs 4.1(a) and 4.
SECTION 4 | General Description & Principles of Operations o simultaneously). The Bidirectional Transformer works as a battery Charger. The Hot AC input from the Grid (GRID LINE) or from the Generator (GEN LINE) is fed to the Hot input of the Bi-directional Transformer for battery charging and at the same time, it is passed through to the Hot Out (OUTPUT LINE) for powering the AC loads When Grid / Generator power fails, relays K2 / K3 will be de-energized and contact 4 switches over to contact 3.
SECTION 4 | General Description & Principles of Operations Switching of Output Neutral to Chassis Ground Bonding o 70A rated DPDT Relay K4 is used to switch the bonding of the Output Neutral Connector (OUTPUT NEUTRAL) to the chassis of the unit. Please note that in this relay, each of the 2 poles is rated for 35A.
SECTION 4 | General Description & Principles of Operations K4 NEUTRAL 7 9 INVERTING CHARGING K2 BI-DIRECTIONAL TRANSFORMER 7 9 LINE K3 7 9 1 QD 4 3 METAL CHASSIS GROUND OF THE UNIT 6 1 4 3 6 1 4 3 6 GEN AC OUTPUT GRID LINE LINE LINE GEN GND OUTPUT GND GRID GND GEN NEUTRAL OUTPUT NEUTRAL GRID NEUTRAL K2 DPDT Transfer Relay (70A) for Grid, Line • Two 35A each poles are paralleled for 70A capacity K3 DPDT Transfer Relay (70A) for Generator, Line • Two 35A each poles are paralleled for
SECTION 4 | General Description & Principles of Operations in “Charging Mode” with the AC power from the Grid / Generator charging the batteries as well as providing power to the AC loads. 4.5.6 Transfer From Grid / Generator to Inverter When the unit is operating in “Charging Mode” with the AC power from the Grid / Generator charging the batteries as well as providing power to the AC loads, the phase and frequency of Grid / Generator is tracked continuously.
SECTION 4 | General Description & Principles of Operations When the batteries discharge to the Low Voltage Alarm threshold (Default 11V / 22V), relay contact in the Status Relay will close and the Generator will be started automatically. The Inverter is synchronized with the Generator and once synchronization is completed, the load is transferred instantly (within 1 ms) to the Generator at Zero Crossing of the voltage waveform for seamless transfer and for better protection of Transfer Relay contacts.
SECTION 4 | General Description & Principles of Operations 4.8.4 Power Saving Mode - Transfer Characteristics in Grid / Generator Mode • Transfer from Grid / Generator to Inverter: If qualified Grid or Generator AC input power is available (its voltage and frequency are within the programmed range), the Transfer Relay remains energized and the AC input power is passed through to the load and at the same time, the unit operates as a battery charger.
SECTION 4 | General Description & Principles of Operations time, the Internal AC Charger starts charging the battery. If an external charger is also connected to the External Charging Terminals, the internal AC Charger will limit the charging current to a value = (Programmed Value of Charging Current - Value of Current fed from the External Charger). When the battery voltage rises to the programmed value of “RECONNECT VOLTAGE” [12V Version: 13.50V to 16.00V (Default 14.0V); 24V Version: 27.00V to 32.
SECTION 4 | General Description & Principles of Operations 4.12 OPTIONAL REMOTE CONTROL EVO-RC FOR PROGRAMMING OF MODES OF OPERATION AND PARAMETERS Optional Remote Control Model EVO-RC (Fig 2.4) will be required for more advanced control and monitoring. Please see separate Owner’s Manual for EVO-RC at Appendix A. The Remote Control comes with 10M / 33 ft., RJ-45 Data Cable. The Remote plugs into RJ-45 Jack on the front panel of the unit (7, Fig 2.1).
SECTION 5 | Battery Charging in Evolution Series 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 specified at battery temperature of 25˚C / 77˚F. 5.1 PRINCIPLE OF OPERATION OF BATTERY CHARGING SECTION EVO Series is a Bi-directional Inverter / Charger with a Transfer Relay that operates either as an inverter OR as a battery charger.
SECTION 5 | Battery Charging in Evolution Series value of input current from Grid/Generator can be programmed (See Appendix A under Group 2 Parameter Select for Input Setting-"Max Current". Default is 30A). The EVO will automatically reduce charging current to support the AC loads on priority and use whatever is extra for charging. This will prevent overloading of the Grid Branch Circuit/Generator. 5.
SECTION 5 | Battery Charging in Evolution Series of –20°C to + 60°C. Table 5.1 shows the programmable range. Default settings for the temperature coefficient is -4mV/°C/Cell. 5.6 3 STAGE CHARGING MODE: BULK, ABSORPTION & FLOAT FOR NORMAL CHARGING Normal day to day charging is performed in a 3 Stage Cycle—BULK, ABSORPTION and FLOAT— to provide rapid and complete charge cycles without undue battery gassing. Please see Table 6.2 for details of programmable settings and Default Values.
SECTION 5 | Battery Charging in Evolution Series The value of the Bulk Charge 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.
SECTION 5 | Battery Charging in Evolution Series 5.6.3 Float Stage Float Stage is a maintenance stage in which the output voltage is reduced to a lower level, 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 value of Float Voltage are shown in Table 6.2.
SECTION 5 | Battery Charging in Evolution Series When Equalization is selected (requires optional Remote Control Model EVO-RC (see Appendix A), the charger will first execute Bulk Stage followed by Absorption Stage. On completion of Absorption Stage, the charger will execute Equalization Stage. After completion of Equalization Stage, the charger will enter Float Stage.
SECTION 5 | Battery Charging in Evolution Series 5.8 DETAILS OF EQUALIZTION MODE CHARGING CYCLE (Fig 5.2) • During the Bulk Stage, the charger will charge at the programmed Bulk Charge Current “ Io “ (see programmable range at Table 5.1. Default value is 40A). Bulk Charge Current “Io” 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.
SECTION 5 | Battery Charging in Evolution Series 5.9 SWITCHING ON AND SWITCHING OFF OF EQUALIZATION MODE (4 STAGE CHARGING) The unit comes preset for charging in Normal Charging Profile (3 Stage Charging Profile). Equalization Profile (4 Stage Charging Profile) is required to be selected manually as follows: Using ON/OFF Push Button on the Front Panel: When the unit is in Charging Mode (qualified Grid / Generator Input is available), the Green LED “Status” will be flashing once per second.
SECTION 6 | Operation, Protections and Troubleshooting BEFORE OPERATING THE UNIT, PLEASE ENSURE THAT THE UNIT HAS BEEN INSTALLED PROPERLY AS PER INSTRUCTIONS AT SECTION 3 OF THIS MANUAL. PLEASE ENSURE THAT ALL SAFETY INSTRUCTIONS AT SECTION 1 OF THIS MANUAL ARE READ AND UNDERSTOOD BEFORE OPERATING THE UNIT.
SECTION 6 | Operation, Protections and Troubleshooting 6.2 POWERING ON / OFF BY FEEDING EXTERNAL +12V CONTROL SIGNAL TO TERMINALS MARKED “REMOTE ON/OFF” ON THE FRONT PANEL (15, FIG 2.1) Programming option is available through the Parameter Setting Menu of the optional Remote Control Model No. EVO-RC (see Appendix A) for 2 types of external +12V control signal fed through Remote ON/OFF Terminal (15, Fig 2.1). Details of these options are given below: 6.2.
SECTION 6 | Operation, Protections and Troubleshooting TABLE 6.1 Status When powered ON LED AND BUZZER INDICATIONS Green LED marked “ON” (12, Fig 2.1) Flash 3 times Red LED marked “Fault” (13, Fig 2.
SECTION 6 | Operation, Protections and Troubleshooting TABLE 6.2 PROGRAMMABLE AND DEFAULT PARAMETERS: GROUP CHARGING CURVE Parameter “BULK CURRENT” ** (Bulk Charge Current “Io”) Programming Range (Programming requires optional Remote Control Model EVO-RC) EVO2212 EVO3012 EVO2224 EVO4024 0-100A 0-130A 0-70A 0-110A Default EVO2212 EVO3012 EVO2224 EVO4024 40A “ABSORP VOLTAGE” ** (Absorption Voltage) 13.5V - 16.0V 27.0V - 32.0V 14.4V 28.8V “EQUALIZE VOLTAGE” ** (Equalization Voltage) 14.
SECTION 6 | Operation, Protections and Troubleshooting TABLE 6.3 PROGRAMMABLE AND DEFAULT PARAMETERS - GROUP "INPUT SETTING" Programming Range Parameter name Group EVO2212 EVO3012 5 – 40A 5 -70A DEFAULT FREQ MAXIMUM CURRENT INPUT SETTING EVO2224 Default value EVO4024 EVO2212 50 / 60Hz EVO3012 EVO2224 EVO4024 60Hz 5 -40A 5 -70A 30A HIGH CUT OFF 50 – 70Hz 65Hz HIGH RESET 50 – 70Hz 64Hz LOW CUT OFF 40 – 60Hz 55Hz LOW RESET 40 – 60Hz 56Hz TABLE 6.
SECTION 6 | Operation, Protections and Troubleshooting TABLE 6.6 PROGRAMMABLE AND DEFAULT PARAMETERS - GROUP "OTHER FUNCTIONS" Parameter name “POWER SAVING” Setting range 2212 3012 Default Value 2224 4024 2212 3012 1 = Enable 0 = Disable 2224 4024 Enable • “ENTER POINT” 4 – 50W 6W 8W 6W 8W • “WAKE UP POINT” 5 – 50W 7W 10W 7W 10W 0 = Button Type “REMOTE SWITCH” • For ON /OFF control through external 12V signal fed to Remote ON / OFF terminals on the Front Panel (15, Fig 2.
SECTION 6 | Operation, Protections and Troubleshooting 6.5 PROTECTIONS, FAULT MESSAGES AND TROUBLESHOOTING GUIDE The front panel of the unit has a Red LED marked “FAULT” (13, Fig 2.1). This LED will light up (steady) when the unit registers any of the FAULT MODE situations shown in Table 7.1 of EVO-RC Manual at Appendix A. Table 7.1 of EVO-RC Manual at Appendix A shows details of protections and associated Fault/ Error Messages that will be displayed on the LCD screen of the optional Remote Control EVO-RC.
SECTION 7 | Specifications Models EVO-2212 EVO-3012 EVO-2224 EVO-4024 INVERTER SECTION Output Waveform Pure Sine Wave Input Battery Voltage Range >9 - 17 VDC >18 - 34 VDC Nominal AC Output Voltage 120 VAC ± 5% Output Frequency 60 Hz ± 0.
SECTION 7 | Specifications Models EVO-2212 EVO-3012 EVO-2224 EVO-4024 OPERATING MODES OFF-LINE Mode Grid/Generator Priority (Default) • Grid/Generator supplies AC loads and charges batteries • Inverter is standby ON-LINE Mode Inverter Priority (Programmable) • Inverter supplies AC loads even if Grid/Generator is available • Grid/Generator takes over when batteries are discharged to "Battery Low Alarm" to charge batteries and to power AC loads.
SECTION 7 | Specifications SAFETY AND COMPLIANCE • Intertek-ETL listed: Conforms to ANSI / UL STD. 1741 Safety Compliance EMI / EMC Compliance • Intertek-ETL listed: Certified to CAN / CSA STD. C22.2 No. 107.1-01 • Intertek-ETL listed: Conforms to ANSI / UL STD.
SECTION 8 | Warranty 2 YEAR LIMITED WARRANTY EVO Series Inverter Chargers manufactured by Samlex America, Inc. (the “Warrantor“) are warranted to be free from defects in workmanship and materials under normal use and service. The warranty period is 2 years for the United States and Canada, and is in effect from the date of purchase by the user (the “Purchaser“). Warranty outside of the United States and Canada is limited to 6 months.
Notes SAMLEX AMERICA INC.
Notes 90 | SAMLEX AMERICA INC.
Notes SAMLEX AMERICA INC.
Contact Information Toll Free Numbers Ph: 800 561 5885 Fax: 888 814 5210 Local Numbers Ph: 604 525 3836 Fax: 604 525 5221 Website www.samlexamerica.com USA Shipping Warehouse Kent WA Canadian Shipping Warehouse Delta BC Email purchase orders to orders@samlexamerica.
APPENDIX A Remote Control for Evolution Series Inverter Charger Owner's Manual Please read this manual BEFORE operating. Model: EVO-RC NOTE: REMOTE CONTROL MODEL NO. EVO-RC IS OPTIONAL AND IS REQUIRED TO BE ORDERED SEPARATELY.
EVO-RC OWNER'S MANUAL | Index SECTION 1 Safety Instructions, Introduction and Layout.......................... 3 SECTION 2 Installation ............................................................................ 4 SECTION 3 Operation ........................................................................... 6 SECTION 4 Parameter Setup ................................................................. 11 SECTION 5 SD Card ..........................................................................
SECTION 1 | Safety Instructions, Introduction and Layout APPENDIX A 1.0 INTRODUCTION AND LAYOUT The EVO-RC Remote Control allows you to monitor and customize the operating parameters of Samlex EVO Inverter Charger Models EVO-2212, 2224, 3012 and 4024. Layout is shown in Fig. 1.1(a) and (b) below. 1. LCD Screen – 2 rows of 16 characters each 2. ON/OFF Key 3. Green LED "Status" 4. Red LED "Fault" 5. Navigation Key "Back" 6. Navigation Key "Up" 7. Navigation Key "Down" 8. Navigation Key "Enter" 9.
SECTION 2 | Installation APPENDIX A 2.1 INSTALLATION GUIDELINES The remote control is provided with 10M/33ft, RJ-45 Data Cable (Straight Wired). Check the proposed routing distance of the wire and use longer wire, if necessary. • Flush mounting of the Remote requires appropriate cut-out in the wall/panel. Take necessary precautions to ensure any wiring/plumbing running behind the wall/panel is not damaged. • Route the wire to ensure there are no kinks.
SECTION 2 | Installation 4. 5. 6. APPENDIX A Take the other end of remote cable and plug it into the RJ-45 Jack at the back of the EVO-RC (Fig. 2.3). Check the remote display to ensure the Power-up self test initiates. If the self test is successful, secure the EVO-RC to the wall using the four screws. (Fig 2.2) Flush mounting the EVO-RC on the wall with 4pcs, Φ3mm self-tapping screws (flat head). Fig 2.
SECTION 3 | Operation APPENDIX A 3.0 GENERAL INFORMATION EVO-RC Remote Control provides the user with the ability to modify EVO Inverter Charger’s operating parameters. The default settings in EVO Inverter Charger are adequate for some installations but may have to be modified for others. This Section provides details on the remote functions, status and menu maps and displays, fault messages and parameter settings. 3.
SECTION 3 | Operation APPENDIX A 3.2 POWER ON / POWER OFF Power ON Press ON/OFF Key and hold for 2 seconds to turn the EVO Inverter Charger ON. POWER ON... When the EVO Inverter Charger is OFF and the ON/OFF key is pressed and held, the LCD screen shows “POWER ON…” and the Status LED flashes 3 times. After 2 seconds, EVO-RC starts to search for the communication ID of the EVO Inverter Charger it is attached to.
SECTION 3 | Operation APPENDIX A 3.5. FAULT CLEARING If any fault occurs, the LCD screen will display the Fault Message, Red LED Alarm (Fault) will be lighted. Remove cause of the fault and the unit will remain in Fault Mode. A short press (0.1 seconds) of the ON/OFF button will clear the Fault Message and the EVO Inverter Charger will return to operational status (if the fault condition no longer exists). Refer to section 7 on “Fault Messages”. 3.
SECTION 3 | Operation ò Page Up (Up key) * Fault Message Page Down (Down key) ** Fault Page 10 INVERTING BATTERY Page 11 INVERTING GRID Page 12 INVERTING GEN Page 13 INVERTING ID= 1 RC=XXX1 ò 0.0A ò 25.0C ò 0.00V ò 0.00V ò ò ò CHARGING N-CC2 INPUT PF=1.000 ò CHARGING N-CC2 OUTPUT 120.00V ò CHARGING N-CC2 OUTPUT 10.00A ò CHARGING N-CC2 OUTPUT 1200W ò CHARGING N-CC2 OUTPUT 1200VA ò CHARGING N-CC2 OUTPUT PF= 1.
SECTION 3 | Operation APPENDIX A NOTES FOR FIG 3.2: 1. The 3-digit numbers XXX in “RC-XXX” indicate the Revision No. of the firmware for the Remote Control EVO-RC 2.
SECTION 4 | Parameter Setup APPENDIX A 4.0 GROUP AND PARAMETER SETUP MENUS Up to 46 operating parameters can be programmed to suit the desired operating conditions. The operating parameters have been organized in 7 “Select Group” Menus (Groups 1 to 7) as shown in Parameter Setup Menu Maps at Fig 4.1 for Groups 1 to 4 and Fig 4.2 for Groups 5 to 7. For convenience, each Parameter Setup Screen in Figs 4.1 and 4.2 can be referenced by 2 co-ordinates: Group No. (Column) and Page No. (Row).
SECTION 4 | Parameter Setup APPENDIX A Page Down (Down Key)** Page Up (Up Key)* 4.1 PARAMETER SETUP MENU MAPS Enter Key (To Group towards the right) Back Key (To Group towards the left) Group 1 SELECT GROUP “CHARGE GROUP” Group 2 SELECT GROUP “INPUT SETTING” Group 3 SELECT GROUP “INPUT LOW LIMIT” Group 4 SELECT GROUP “INPUT HIGH LIMIT” Page 1 BULK CURRENT 40 A DEFAULT FREQ 0= 60 Hz RESET VOLTAGE 95.0 V RESET VOLTAGE 135.0 V Page 2 ABSORP VOLTAGE 14.
Page Down (Down Key)** ò ò Page Up (Up Key)* ò SECTION 4 | Parameter Setup APPENDIX A Enter Key (To Group towards the right) Back Key (To Group towards the left) ò Group 5 SELECT GROUP “OTHER FUNCTION” Group 6 SELECT GROUP “TIME SETTING” Group 7 SELECT GROUP “STOP SD CARD” Page 1 POWER SAVING 1= Enable TIME SETTING 2000/01/01 00:00 STOP SD CARD 0= No Page 2 ENTER POINT 4W Page 3 WAKE UP POINT 5W Page 4 REMOTE SWITCH 0= Button Page 5 RELAY FUNCTION 0= Charger/Other ò ò ò ò ò Page 6 ò
SECTION 4 | Parameter Setup APPENDIX A 4.2 PARAMETER SETUP PROCEDURE – GENERAL Please refer to Fig 4.3 below. The Enter key is used to enter Parameter Setup Mode from any Operating Mode Screen in Fig 3.2. Example in Fig 4.3 below starts with Inverting Mode Screen (Group 2, Page 1 in Fig 3.2). After the Enter key is pressed, the Up/Down keys are used to navigate to the different Parameter Groups (Groups 1 to 7).
SECTION 4 | Parameter Setup APPENDIX A 4.3 PASSWORD PROTECTION FOR PARAMETER CHANGE All parameters except Time and Date are protected with a Password. When the required parameter screen is reached and is displayed and Enter Key is pressed to modify the parameter value, the system will request a 4-digit Password. The Password is 8052. Once you Enter the Password correctly, you don’t need to enter the Password again until until any key is not pressed for over 60 seconds.
40 A BULK CURRENT 90 A WRITING... BULK CURRENT 50 A ! 90 A WRITING... A WRITE50 SUCCESS! WRITING... 50 A 50 A WRITE SUCCESS! A WRITE50 FAILURE! WRITE SUCCESS! 50 A 50 A WRITE FAILURE! 50RANGE! A OUT OF WRITE FAILURE! 90 A 50 A OUT OF RANGE! A BULK90 CURRENT OUT OF 50RANGE! A 90 A BULK CURRENT 50 A BULK CURRENT 50 A ! SECTION 4 | Parameter Setup APPENDIX A Flashes twice when there is a write failure. Flashes twice when the set value is out of range. (90 A is out of range for EVO-2224). End setting.
SECTION 4 | Parameter Setup 9 “BATT LOW VOLTAGE” (Battery Low Voltage Shut Down) >9.0V – 12.0V APPENDIX A >18.0V – 24.0V 10.5V 21.
SECTION 4 | Parameter Setup APPENDIX A COMPENSATE: This parameter sets the temperature compensation for the battery. The operational range of the EVO Inverter Charger is -20°C to 60°C. This compensation voltage will affect the Absorbtion Voltage/Equalize Voltage/Floating Voltage/ Batt Over Volt/Restart Voltage/Low Volt Alarm/Batt Low Voltage when the Temperature Sensor is installed on the battery (see Fig 2.5 in the Owner's Manual for EVO Inverter Charger).
SECTION 4 | Parameter Setup APPENDIX A LOW VOLT ALARM: When inverting, if battery voltage is under the set value, the Red LED marked "Alarm" flashes once per second. The buzzer in EVO Inverter Charger will beep once per second. If Relay Function is set for Generator, the relay will turn ON. If in On-Line Mode, it will transfer from Inverting Mode to Charging Mode. Up Key x 7 BULK CURRENT 40 A ò ò Enter Key SELECT GROUP CHARGE CURVE LOW VOLT ALARM 11.
SECTION 4 | Parameter Setup Up Key x 9 BULK CURRENT 40 A ò ò Enter Key SELECT GROUP CHARGE CURVE APPENDIX A LV DETECT TIME 10 sec LV CUT OFF TIME: Even when the Inverter Section is shut down due to “Battery low voltage!” fault condition as described above, there will still be some power drawn from the battery to keep the other circuitry in the EVO Inverter Charger alive so that the inverter can be switched on when the fault gets cleared automatically after the battery has been recharged to the “RESET
SECTION 4 | Parameter Setup APPENDIX A Output and at the same time, the Internal AC Charger starts charging the battery. If an external charger is also connected to the External Charging Terminals, the internal AC Charger will limit the charging current to a value = (Programmed Value of Charging Current – Value of Current fed from the External Charger).
SECTION 4 | Parameter Setup APPENDIX A DEFAULT FREQ: Default frequency sets the Inverter frequency, which is also the standard frequency for AC input. ò Enter Key SELECT GROUP INPUT SETTING ò Up Key SELECT GROUP CHARGE CURVE DEFAUT FREQ 0= 60Hz MAXIMUM CURRENT: In Charging Mode, the net AC input current from the Grid/Generator is the sum of the AC side charging current and the pass through load current.
SECTION 4 | Parameter Setup APPENDIX A LOW RESET: This is the reset frequency at which the unit will revert to "Charging Mode" after it has switched over to "Inverting Mode" due to input frequency falling below "LOW CUT OFF". Enter Key Up Key x 5 DEFAUT FREQ 0= 60 Hz LOW RESET 56.00 Hz ò SELECT GROUP INPUT SETTING ò ò Up Key SELECT GROUP CHARGE CURVE 4.6 GROUP 3 PARAMETER SET UP: INPUT LOW LIMIT Please refer to Parameters under Group 3 at Fig 4.1.
SECTION 4 | Parameter Setup APPENDIX A CUT OFF VOLT 2: If during "Charging Mode", the AC input voltage falls below "CUT-OFF VOLT 2" for period > "DETECT TIME 2", the EVO Inverter Charger will transfer to "Inverting Mode". Up Key x 3 RESET VOLTAGE 95.0 V ò Enter Key SELECT GROUP INPUT LOW LIMIT ò ò Up Key x 2 SELECT GROUP CHARGE CURVE CUT OFF VOLT 2 85.0 V DETECT TIME 2: This is the time limit in cycles up to which low AC input voltage "CUT-OFF 2" is allowed. Up Key x 4 RESET VOLTAGE 95.
SECTION 4 | Parameter Setup APPENDIX A RESET VOLTAGE: This is the reset voltage at which the unit will revert to "Charging Mode" after it has switched over to "Inverting Mode" due to input AC voltage rising to "CUT-OFF VOLT 1/CUT-OFF VOLT 2/ CUT-OFF VOLT 3. Enter Key SELECT GROUP INPUT HIGH LIMIT ò ò Up Key x 3 SELECT GROUP CHARGE CURVE RESET VOLTAGE 135.
SECTION 4 | Parameter Setup APPENDIX A 4.8 GROUP 5 PARAMETER SET UP: OTHER FUNCTIONS Please refer to Parameters under Group 5 at Fig 4.2. Details of Parameter set up are given below: TABLE 4.8. GROUP 5 PARAMETER SET UP: OTHER FUNCTIONS Page No. for Group 5 (Fig 4.
SECTION 4 | Parameter Setup APPENDIX A WAKE UP POINT: If the unit is in "Power Save Mode" and the value of the AC power of the load rises to "WAKE UP POINT", the unit will quit "Power Save Mode" and will start operating in full voltage "Inverting Mode".
SECTION 4 | Parameter Setup APPENDIX A RELAY FUNCTION: This is to select the function of Status Relay. (14, Fig 2.1 in the EVO Manual) The Status Relay has 2 sets of contacts: (i) Normally Open "NO" and "Common" and (ii) Normally Closed "NC" and "Common". "NO" and "Common" contacts will be open when the Status Relay is de-energized and will close when the relay energizes. "NC" and "Common" will be closed when the Status Relay is de-energized and will open when the reay energizes.
SECTION 4 | Parameter Setup APPENDIX A DATALOG TIME AND DATALOG DISABLE: Set the time period of the data log. 0 = Disable 1 = 1 sec 4 = 60 sec 5 = 5 min 3 = 30 sec Up Key x 9 POWER SAVING 1 = Enable ò Enter Key SELECT GROUP OTHER FUNCTION ò ò Up Key x 4 SELECT GROUP CHARGE CURVE 2 = 10 sec 6 = 10 min DATALOG TIME 1 = 1 sec PARAMETER SAVE Save all parameters to SD Card.
SECTION 5 | SD Card APPENDIX A 5.1 SD CARD GENERAL INFORMATION SD Card slot has been provided for data logging and for saving the programmed parameters. SD card supports FAT16/FAT32 format up to 16GB in size. When the SD card is inserted, the LCD screen will display the following. SD card detected V2.x xxGB SD card is detected and shows the Version and capacity. "xx" is the capacity. SD card card detected SD V2.x xxGB unusable ! SD F i lcard e c r e a t i ng . . . unusable ! Not supported card.
SECTION 5 | SD Card APPENDIX A 5.3 DATA LOG FILES AND VIEWING DATA LOG FILES USING MICROSOFT EXCEL The Data Log Files are writen as Text Files (.txt) in the DATALOG Folder on the SD Card’s Root Directory. Table 5.1 is an image of the DATALOG Folder showing example of the Data Log Files. The File Name Format is month/day/hour/minute.txt (MMDDhhmm.txt). TABLE 5.1 Example of Data Log Folder Table 5.2 shows an example of one of the File’s contents opened with a general purpose Text Reader.
SECTION 5 | SD Card APPENDIX A Fig 5.1 Screen Showing .txt Files • • Click "Open" Button (Bottom right corner of Fig 5.1). Text Import Wizard – Step 1 will be shown (Fig 5.2). Choose "Delimited"File Type". Fig 5.2 Screen Shot of Step 1 of "Text Import Wizard" in Excel • Text Import Wizard – Step 2 will appear (see Fig 5.3). Choose "Semicolon" and click 'Finish' button. 32 | SAMLEX AMERICA INC.
SECTION 5 | SD Card APPENDIX A Fig 5.3 Screen Shot of Step 2 of "Text Import Wizard" in Excel • Data as in Fig 5.4 will be displayed on your Worksheet, with the Log Data stored in Columns and Rows. Fig 5.4 Screen Shot and Data Log Work Sheet SAMLEX AMERICA INC.
SECTION 5 | SD Card APPENDIX A 5.4 SAVING / UPLOADING PROGRAMMED PARAMETERS 5.4.1 Saving Programmed Parameters All the programmed parameters can be saved on an SD Card (FAT 16 / FAT 32 Format, up to 16 GB capacity). The parameters will be saved in File named “xxxx_yyy.cfg”, where the first group of 4 digits xxxx is the Model No. e.g. 2212 or 2224 or 3012 or 4024 and the second group of 3 digits YYY is the Revision No. for that Model e.g. 061. For saving, first insert the SD Card in the SD Card Slot.
SECTION 6 | Monitoring of Operation Using LED and Buzzer APPENDIX A TABLE 6.
SECTION 7 | F ault Messages and APPENDIX A Troubleshooting Guide TABLE 7.1 FAULT MESSAGES AND TROUBLESHOOTING GUIDE NOTES: 1. Please see Table 6.1 for LED indications in EVO-RC and buzzer indications in EVO Inverter Charger 2. Buzzer is available only in EVO Inverter Charger. There is no buzzer in Remote Control EVO-RC Fault Message Symptoms and Trouble Shooting • • • Battery low voltage! • • • • • Battery ultra low voltage! • • 36 | SAMLEX AMERICA INC.
SECTION 7 | F ault Messages and APPENDIX A Troubleshooting Guide Battery over voltage! EVO Inverter Charger is in FAULT MODE because the battery voltage has risen to the set upper threshold of “BATT OVER VOLTAGE” (a) AC input is not available and EVO Inverter Charger is operating in Inverting Mode: • There will be no AC output because the Inverter Section will be switched OFF. The Green LED marked “Status” will be switched OFF and the Red LED marked “Fault” will be steady ON.
SECTION 7 | F ault Messages and APPENDIX A Troubleshooting Guide Output short circuit! EVO Inverter Charger is in FAULT MODE because there is a short circuit on the output side in Inverter Mode. Short circuit protection is activated when the output current is over 18.33Arms and output voltage is less than 15 Vrms for 6 cycles (0.1 second for 60 Hz) • There is no AC output because the Inverter Section has been switched OFF.
SECTION 8 | S pecifications APPENDIX A MODEL NO. EVO-RC COMPATIBLE INVERTER CHARGERS MODEL NUMBERS EVO-2212, EVO-3012, EVO-2224, EVO-4024 DISPLAY LCD DISPLAY 2 Rows, 16 Character each, Alpha-Numeric LCD Display LED INDICATORS Green (Status); Red (Fault / Alarm) INPUT / OUTPUT CONNECTION CABLE SET RJ-45 Data Cable (Straight Wired); 10 Meters / 33 ft ENVIRONMENT OPERATING TEMPERATURE RANGE -20°C to 60°C DIMENSIONS (W X H X D), MM 144 x 114 x 35.5 (W X H X D), INCHES 5.6 x 4.5 x 1.
SECTION 9 | Warranty APPENDIX A 2 YEAR LIMITED WARRANTY EVO-RC manufactured by Samlex America, Inc. (the “Warrantor“) is warranted to be free from defects in workmanship and materials under normal use and service. The warranty period is 2 years for the United States and Canada, and is in effect from the date of purchase by the user (the “Purchaser“). Warranty outside of the United States and Canada is limited to 6 months.
APPENDIX A Notes SAMLEX AMERICA INC.
APPENDIX A Notes 42 | SAMLEX AMERICA INC.
APPENDIX A Notes SAMLEX AMERICA INC.
Contact Information Toll Free Numbers Ph: 800 561 5885 Fax: 888 814 5210 Local Numbers Ph: 604 525 3836 Fax: 604 525 5221 Website www.samlexamerica.com USA Shipping Warehouse Kent WA Canadian Shipping Warehouse Delta BC Email purchase orders to orders@samlexamerica.
