Samlexpower SAM-1500C-12 User manual

SAM Series
Inverter /
Charger
SAM-1500C-12
Please read this
manual BEFORE
installing your
inverter
Owner's
Manual

2 | SAMLEX AMERICA INC.
MANUAL | Index
SECTION 1:
Safety ............................................................................................. 1
SECTION 2:
Features, Applications & Principle of Operation ..................................... 3
SECTION 3:
Layout ............................................................................................. 8
SECTION 4:
Installation .......................................................................................... 10
SECTION 5:
Operation ........................................................................................... 19
SECTION 6:
Protections, Monitoring & Troubleshooting.......................................... 22
SECTION 7
Specications ....................................................................................... 27
SECTION 8
Warranty ........................................................................................... 28

2 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 1
SECTION 1 | Safety
IMPORTANT SAFETY INSTRUCTIONS
This manual contains important information regarding safety, operation, maintenance
and storage of this product. Before use, read and understand all cautions, warnings, in-
structions and product labels, plus your vehicle’s battery manufacturer’s guidelines. Failure
to do so could result in injury and / or property damage. The following safety symbols will
be used in this manual to highlight safety and information:
Warning!
Indicates possibility of physical harm to the user in case of non-compliance.
!Caution!
Indicates possibility of damage to the equipment in case of non-compliance
i
Info
Indicates useful supplemental information.
Warning!
To reduce the risk of re, electric shock, explosion or injury
1. Do not connect in parallel with another AC source e.g. Utility AC Distribution Wiring /
generator. This is NOT a Grid Tied Inverter!
2. When working with Multiple Outlet Power Strips, disconnect appliance plug from outlet
strip or turn off the inverter before working on the appliance. Multiple Outlet Power Strips
with switches and circuit breakers interrupt power only to the “Hot” receptacle terminals.
3. Precautions when working with batteries
• BatteriescontainverycorrosivedilutedSulphuricAcidaselectrolyte.Precautionsshouldbe
taken to prevent contact with skin, eyes or clothing.
• 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manu-
facturer’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.
• Removemetalitemslikerings,braceletsandwatcheswhenworkingwithbatteriesandalso
use caution when working with metal tools. Batteries can produce a short circuit current
high enough to melt / weld metals and thus, cause severe burn.
• Ifyouneedtoremoveabattery,alwaysremovethegroundterminalfromthebatteryrst.
Make sure that all the accessories are off so that you do not cause a spark.
4. Do not make any electrical connections or disconnections in areas designated as
IGNITION PROTECTED. This includes 12VDC Power Plug (Cigarette Plug) connections and
terminal connections.
5. This is not a toy - keep away from children.
6. Do NOT insert objects into the ventilation air vents.

2 | SAMLEX AMERICA INC.
!Caution!
1. Please ensure the following when using the unit as Backup AC Power Source (UPS)
• ThattheUtilityACPowerinputisfedfrom15A/20AGFCIprotectedoutlettoprovide
Ground Fault Protection.
• DonotgroundusingexternalChassisGroundConnection(15,Fig3.1).Theunitgets
grounded to the Earth Ground of the Utility Grounding System automatically through the
Grounding Wire of the AC Input Power Cord (10A, B- Fig 3.1). Use of multiple Grounds is
not desirable.
2. When the unit is being used as a stand-alone inverter (Utility AC Power input is not con-
nected),connecttheexternalChassisGroundConnection(15,Fig3.1)toEarthGroundusing
at least AWG #8 wire.
3. When Inverter is supplying AC loads, the voltage on the Neutral and Line Terminals of the
NEMA5-15R AC outlet with respect to the chassis of the inverter / chassis of the AC loads
will be a pulsing DC voltage with average DC value of up to 50V (will falsely read 75 VAC on
AC scale of the Voltmeter because of pulsing nature of DC voltage). DO NOT TOUCH THE
NEUTRAL TERMINAL / NEUTRAL CONDUCTORS!
4. Do not connect AC output from NEMA5-15R outlets(s) to AC distribution wiring where the
Neutral is bonded to Ground. The inverter will see this as abnormal condition of Ground
Fault and will shut down.
5. Do not use with Positive Grounded Electrical Systems (the majority of modern automobiles,
RVs, trucks and boats use Negative Grounded Electrical Systems).
6. Observe correct polarity when connecting the DC input terminals of the inverter to the
battery. Connect Positive of the battery to the Positive input connector of the inverter and
the Negative of the battery to the Negative input terminal of the inverter. Reverse polarity
connection will result in a blown fuse and may cause permanent damage to the inverter.
Damage due to reverse polarity is not covered under warranty.
7. Thisinverterwillnotoperatehighwattageappliancesthatexceedtheoutputpowerlimit
or the surge power limit.
8. Do not operate this inverter if it is wet.
9. Do not install in engine compartment – please install in a well-ventilated area.
10. This inverter is not tested for use with medical devices.
SECTION 1 | Safety

2 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 3
i
Info
For additional technical and operational information on Inverters, Battery Chargers and
related topics, please refer to www.samlexamerica.com/Support/Application Notes/
White Papers.
ThisunitisaModiedSineInverter/ChargerwithaTransferRelaywithprimaryfunction
of Backup AC Power Source or Off-Line AC UPS (Un-interruptible Power Supply). The unit
consists of the following 3 component integrated into a single unit:
• ModiedSineWaveInverterforACbackupwhenutilityACPowerfails:
• Input:12VNominalLeadAcidBattery(10.5Vto15.5V)
• Output:1500W(AtPowerFactor=1)at115VAC,60Hz
• ACBatteryChargertochargebatterieswhenUtilityACPowerisavailable:
• Input:120VAC,60Hz
• Output:13.8VDC,15Atocharge12VLeadAcidBatteries-Flooded,AGMorGelCell
• 2-StageCharging-BulkandFloat
• ACInputPassThroughtoloadwhenUtilityACPowerisavailable
• Input:120VAC,60Hz
• TransferRelay:30A
The primary function of the unit is a 1500W, 120 VAC Backup AC Power Source or Off-Line
AC UPS (Un-interruptible Power Supply) with combined operation of the Inverter, the
Battery Charger and the Transfer Relay. Secondary functions can be a 1500W stand alone
inverter OR a 15A, 12V stand alone Lead Acid Battery Charger.
Features
• Integrated1500WModiedSineWaveInverter,30ATransferswitch,and2Stage12VDC,
15A Battery Charger
• Highinverterpeakefciencyof90%,lightweight,andcompactforeasyinstallation
• SoftStartTechnologyforbettersurgeperformance
• SeparateON/OFFcontrolforInverterandBatteryChargerforselectableoperation
as inverter, charger or UPS function
• 4LEDindicatorstomonitoroperationalstatus
• Loadcontrolledfanforefcientcoolingwhenrequired
• Allowsuseofhighercapacityexternal12Vbatterybankforlongerbackuptime
• CoolSurfaceTechnologyforcoolerandsafertouchtemperature
• ElectronicprotectionsincludingGFCIwheninInverterMode
• LowInterferenceTechnologyforcontrolledRFnoise
• IdealforRV’s,Trucksandremotehousing 
SECTION 2 | Features, Applications &
Principle of Operation
SECTION 1 | Safety

4 | SAMLEX AMERICA INC.
SECTION 2 | Features, Applications &
Principle of Operation
Applications
• BackupACPowerSourceorOff-LineACUPS(Un-interruptiblePowerSupply)to
provide AC power during power outages
• 12VLeadAcidBatterycharging
• RVs,trucksandremotehousing
SOFT START TECHNOLOGY
This feature offers the following advantages:
• WhentheinverterisswitchedON,thevoltagerampsupto115VACinaround2sec.Ifthe
load was already ON at the time of switching ON of the inverter, starting surge current
demanded by certain reactive devices like motors etc. will be reduced and there will be less
likelihood of the inverter shutting down due to overload.
• IftheinverterisswitchedONrstandthenaloadwithhigherstarting/inrushcurrentlike
SMPS / motor is switched ON, the voltage will dip momentarily and then recover to reduce
inrush / starting surge current in the load as above.
• Similaroverloadreductionwillbeinitiatedduringanyothersuddenhigher
loading conditions.
LOW INTERFERENCE TECHNOLOGY
InnovativecircuitdesignandnoiseltrationcircuitryreducesRFinterferenceinTV
picture,audioandradioequipment.
COOL SURFACE TECHNOLOGY
Normally, heat dissipating components are mounted directly on internal metal chassis
surface of the inverter and hence, the chassis surface may rise to unsafe touch-tempera-
ture. In this inverter, heat-dissipating components are not mounted directly on the chassis
of the unit but on PCB (Printed Circuit Board) mounted heat sink and, there is air gap
between the heat sink and the chassis surface. The heat sink is cooled by load-controlled
fan. As there is no direct contact between the heat sink and the chassis, the chassis surface
remains much cooler and is safer to touch.
LOAD CONTROLLED COOLING FAN
Cooling is carried out by convection and by forced air circulation by load-controlled fan.
The fan will normally be OFF and will be switched ON automatically as follows:
• InvertersupplyingACload(s):Whenload(s)≥85W
• BatteryCharging/ACPassThroughMode:Whenchargingcurrent≥3A
Thiswillreduceenergyconsumptionbythefanandwillincreaseoverallefciency.

4 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 5
SECTION 2 | Features, Applications &
Principle of Operation
SECTION 2 | Features, Applications &
Principle of Operation
Principle of Operation - Inverter
Conversion of 12 VDC from the battery / other DC source to 115 VAC takes place in 2
stages.Intherststage,the12VDCisconvertedtohighvoltageDC(around160VDC)
usinghighfrequencyswitchingandPulseWidthModulation(PWM)technique.Inthe
2ndstage,the160VhighvoltageDCisconvertedto115V,60HzModiedSineWaveAC.
(NOTE:115VistheRMSvalueoftheModiedSineWaveACvoltage.Thepeakvalueof
theModiedSineWaveACvoltagewillbeequaltothevalueoftheabovehighvoltage
of around 160V. See the Fig 2.1 below).
MODIFIED SINE WAVEFORM - CHARACTERISTICS
& COMPARISON WITH PURE SINE WAVEFORM
PleaserefertoFig2.1belowwhichshowsonecycleofModiedSineWaveandPureSine
Wave for comparison.
Fig 2.1 Modied Sine Wave and Pure Sine Wave - Comparison
TheoutputwaveformoftheinverterisaModiedSineWave.InaModiedSineWave,
thevoltagewaveformconsistsofrectangularpulsesthatapproximatesinewavepulses
of a Pure Sine Wave. The voltage rises and falls abruptly at a particular phase angle and
sits at 0 Volts for some time before changing its polarity. In a Pure Sine Wave, the voltage
rises and falls smoothly with respect to phase angle and the voltage changes its polarity
instantly when it crosses 0 Volts.
TIME
180
160
140
120
100
80
60
40
20
0
20
40
60
80
100
120
140
160
180
Modified Sine
Wave sits at
0V for some
time and then
rises or falls
Sine Wave
Modified Sine Wave
Pure Sine Wave
crosses 0V
instantaneously
Legend
V +
V -
115 RMS

6 | SAMLEX AMERICA INC.
SECTION 2 | Features, Applications &
Principle of Operation
!Caution!
Certaindevices(fewexamplesgivenbelow)maymalfunctionwhenpoweredfromModi-
edSineWave.Checkwiththemanufacturerofthedeviceforsuitabilityofpowering
withModiedSineWave:
• Devicesutilizingzerovoltagecrossingfortimingcontrol:Someclocksusedinconsumer
electronic items (will not keep accurate time)
• DevicesusingmodulationofRFsignalsonAClinesduringzerocrossinge.g.X-10System
for Home Automation
• DevicesutilizingTriacbasedphasecontrolfortransformerlessvoltagestepdowne.g.:
• Smallbatterychargersforhandtools,ashlights,night-lights,shaversetc.
• Variablemotorspeedcontrolinhandtools
• Lightdimmers
• Temperaturecontrollerse.g.:
• TemperatureControlledElectricBlankets
• Devicesusinghighcapacitancebasedvoltagemultipliersforgeneratinghighvoltage
(will create very high surge currents) e.g.:
• PhotographicStrobeLights
• LaserPrinters
MEASURING MODIFIED SINE-WAVE VOLTAGE WITH
A “TRUE RMS” VOLTMETER
Asmentionedabove,ModiedSineWavevoltageisatypeofsquarewavethathasan
RMS(RootMeanSquare)valueof115VAC.Ageneral-purposeACvoltmeteriscalibrated
toaccuratelymeasuretheRMSvalueofaPureSineWaveandNOTofaModiedSine
Wave.Ifthisgeneral-purposevoltmeterisusedtomeasureModiedSinewavevoltage,it
will indicate a lower value (96 VAC to 104 VAC). For accurately measuring the voltage of a
ModiedSineWave,useavoltmeterwhichisdesignedtomeasure“TrueRMSValues”like
Fluke 87, Fluke 8060A, Fluke 77 / 99, Beckman 4410 etc.
PRINCIPLE OF OPERATION AND CHARGING ALGORITHM - BATTERY CHARGER
The battery charger is a 2 Stage, Switched Mode Design using Fly Back Topology.
120VACfromtheACInputisrectiedtohighvoltageDCofaround170VDC,whichis
thenconvertedtohighfrequencypulsesusingMOSFETSwitchandthensteppeddown
throughswitchingtransformer.Thetransformedvoltageisrectiedandltered.Asample
of the output voltage is used as feedback signal for the drive circuit for the switching
Mosfet to achieve desired voltage regulation of 13.8 VDC using Pulse Width Modulation
(PWM).Itisdesignedtoprovidemaximumchargingcurrentof15A.

6 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 7
SECTION 2 | Features, Applications &
Principle of Operation
SECTION 2 | Features, Applications &
Principle of Operation
Fig. 2.2 Battery Charger Stages and Voltage/Current Curves
2 Stage Charging
Workingofa2StageChargerisexplainedbelow.PleaserefertoFig2.2.
2 Stages of Charging are Bulk and Float Stages. A 2-Stage Charger is able to recharge a
batterytoaround80%capacity.ThistypeofchargerisusedinBackup/UPSapplications
wherethebatteryremainscharged,isoatingmostofthetimesandwilldischargeat
lesserfrequencyonlyduringpoweroutages.Chargingdetailsaregivenbelow:
• Thecharger’soutputvoltagewillbe13.8Vforchargingcurrent<theBulkChargeCurrent
of 15A.
• Ifthebatterywasdischargedtoalevelthatdrawshighercurrent>theBulkchargeCurrent
of 15A, the charger will limit the charging current to 15A, its voltage will drop and will be
clamped at the actual battery voltage when charging was started (Points 1 to 2, Fig 2.1).
Charging will take place at constant current limit of 15A, the battery voltage will start rising
and the current demand will start reducing. When the current reduces to less than 15A, the
chargerwillexitcurrentlimit/BulkChargeStage(Point2,Fig2.1)andwilloutputaxed
Float Voltage of 13.8V thereafter (Points 2 to 3 on the Voltage Curve in Fig 2.2). Battery’s in-
trinsic voltage will continue to rise towards 13.8V and charging current will start to taper off
(Points 2 to 3 on the Current Curve in Fig 2.2). When the battery voltage has reached almost
13.8V,itwouldhavechargedtoaround80%capacityandthecurrentdrawwillbereduced
tofewhundredmilliamps(around0.1%ofbatteryAhcapacity)tocompensateselfdischarge
(Point 3 on the Current Curve in Fig 2.2).
• IfthedischargedlevelatthetimeofswitchingONwassuchthatthechargingcurrentdrawn
was<15A,thechargerwillnotbeundercurrentlimitandwilloutputFloatVoltageof13.8V
(Points 2 to 3 on the Voltage Curve in Fig 3.2). Battery’s intrinsic voltage will continue to rise
towards 13.8V and charging current will start to taper off (Points 2 to 3 on the Current Curve
in Fig 2.2). When the battery voltage has reached almost 13.8V, it would have charged to
around80%capacityandthecurrentdrawwillbereducedtofewhundredmilliamps(around
0.1%ofbatteryAhcapacity)tocompensateselfdischarge(Point3ontheCurrentCurvein
Fig 2.2)
Bulk Charge
Stage Float Charge Stage
Charger Current Curve
Charger Voltage Curve
Time
Voltage
Current
9
10
11
12
13
14
1
1
2
2
3
3
15A
0A
LEGEND
1. Charging Starts
1 to 2. Bulk Charge Stage: Constant Current = 15A
2. Exits Bulk & Enters Float
2 to 3. Foat Stage: Constant Voltage = 13.8V
Current Tapers to 0.1% of Ah Capacity
13.8V
5A
10A
20A

8 | SAMLEX AMERICA INC.
SECTION 3 | Layout
Fig 3.1 Layout and Input/Output Connections
AC INPUT/OUTPUT SIDE
5
41
14
2 3
6 7 8 9
10A
LEGEND
1. AC Outlet - NEMA5-15R
2. ON/OFF Switch - Charger
3. ON/OFF Switch - Inverter
4. Breaker for AC Input - 15A
5. Fuse for Charger Section - 5A, 125V / 250V
6. YELLOW LED for Input Fault
7. GREEN LED for Charger ON
8. GREEN LED for Inverter ON
9. RED LED for Fault
10A. & 10B.
AC Input Cord - 6 ft. 10A with
NEMA5-15P Plug (10B)
11. Negative Input Terminal (M9) for 12V
Battery Negative
11a. BLACK plastic cover for Negative
Input Terminal
12. Positive Input Terminal (M9) for
12V Battery Positive
12A. RED plastic cover for Positive
Input Terminal
13. Opening for cooling fan discharge
14. Ventilation slots for air inlet
15. Chassis Ground Connection, M5
16. 200A, Class-T / MRBF Fuse (within 7”
of Positive Battery Terminal)*
17. AWG#2 Battery Cables (see Table 4.1
for voltage drops)
* Not Supplied.
1
DC INPUT SIDE
13
15
13
11A 12A
11 12
+–
12V Battery
16 1717
10B
15A/20A GFCI
Protected Outlet -
Utility AC Power

8 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 9
SECTION 3 | Layout SECTION 3 | Layout
12
6
SAM-1500C-12 Dimensions: 345 mm x 202 x 84 mm 13.54 x 7.87 x 3.35 inch Weight: 4 kg / 8.8 lb
302 345
120
202
Fig 4.1: Dimensions of Mounting Arrangement
Fig 3.2 Dimensions & Mounting Arrangement

10 | SAMLEX AMERICA INC.
SECTION 4 | Installation
Safety of Installation
Warning!
Please read safety instructions in Section 1 before commencing installation. When
using the unit as a backup AC Power Source, Utility AC Power Input should be fed from
15A/20A, GFCI Protected outlet.
Installation Environment
Forbestoperatingresults,theinvertershouldbeplacedonatsurface,suchastheground,
caroor,orothersolidsurface.Thepowercordallowseasypositioningoftheinverter.The
inverter should only be used in locations that meet the following criteria:
Dry-Donotallowwaterand/orotherliquidstocomeintocontactwiththepowerinverter.
In all marine applications, do not install the unit below or near the waterline and keep the
inverter away from moisture or water.
If Flooded / Wet Cell Type of battery is being used, ensure that the unit is not installed very
close to the battery to avoid contact with acid / acid vapors
Cool - Ambient air temperature should be between 0°C (32°F) to 25°C (77°F) for full rated
power. At higher temperature of 26°C (79°F) to 35°C (95°F), the output power should be
de-ratedto80%.Donotplacetheunitonornearaheatingventoranypieceofequipment,
which is generating heat above room temperature. Keep the unit away from direct sunlight.
Ventilated - The unit is cooled by load-controlled fan. The fan will switch ON automatically at
load≥85Wwhentheinverterissupplyingpower,andat3AchargingcurrentwheninBattery
Charging/AC Pass Through Mode. The fan sucks cool air from the air intake ventilation slots
on the AC outlet side (14, Fig 3.1) and discharges hot air out of the fan opening (13, Fig 3.1)
on the DC Input Terminal side. Keep the areas surrounding the inverter clear by at least 10 cm
to ensure free air circulation around the unit. Ensure that the air intake ventilation slots and
fan openings for air discharge are not blocked. Do not place items on or over the unit
during operation.
Mounting Orientation
Two(2)angesonthebottomwith2mountingslotseachareprovidedformounting,as
shown in Fig 3.2.
Iftheinverterisrequiredtobemountedonaverticalsurfacelikeawall,pleaseensurethat
thefanaxisishorizontalasshowninFig4.1(a).
The DC input side has larger ventilation openings (13, Fig 3.1) for fan air discharge. Mounting
with the fan side facing up or down as shown in Figs 4.1(b) or 4.1(c) is NOT permitted due to
safety considerations. If mounted as in Fig 4.1(b), metallic or other conductive object(s) may
accidentallyfallinsidetheunitthroughthefanventilationopeningsandcreatehazardous
condition resulting from short circuit of internal high voltage section(s). If mounted as in Fig
4.1(c), hot / molten material from damaged internal portion of the unit due to malfunction
mayfalloncombustiblematerialontheoorandmaycreaterehazard.

10 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 11
(a) (c)(b)
Fig 4.1
Mounting Orientation
on Wall
SECTION 4 | Installation
Grounding Arrangement
!Caution!
1. Forgroundingrequirements,theMETALCHASSISoftheunitisconnectedasfollows:
• TotheGroundingNutandBolt(15,Fig,3.1)forexternalEarthGroundconnection,
whenrequired.
• TotheGroundingPinofNEMA5-15PplugoftheACInputPowerCord(10A,B-Fig3.1).When
the AC Input Power Cord is plugged into 15A/20A GFCI protected outlet being fed with Utility
AC Power, the metal chassis of the inverter automatically gets bonded to the Earth Ground of
the Utility Distribution System.
• TotheGroundingTerminalofthe2xNEMA5-15Routlet(s)(1,Fig3.2)throughinternal
Normally Closed (NC) Contact of Relay R2.
2. Following conditions will be applicable when the unit is used as a Backup AC Power Source
and is connected to the Utility AC Power through AC Input Power Cord (10A, B – Fig 3.1):
• Utility AC Power is available: The metal chassis of the unit gets bonded to Earth Ground of
theUtilityDistributionSystem.InternalRelayR2willenergizeandwilldisconnectthe
Grounding Terminals of the AC Outlets from the metal chassis of the unit. IN THIS CASE, THE
METAL CHASSIS OF THE CONNECTED AC LOADS WILL BE FLOATING. PLEASE ENSURE THAT
WHEN USING THE UNIT AS BACKUP AC POWER SOURCE, THE UTILITY AC INPUT IS FED FROM
15A/20A GFCI PROTECTED OUTLET TO PROVIDE GROUND FAULT PROTECTION.
• Utility AC Power is NOT available: The metal chassis of the unit is connected to Earth Ground
oftheUtilityDistributionSystem.RelayR2isde-energizedandthemetalchassisoftheunit
gets connected to the Grounding Terminals of the two NEMA5-15R outlet(s). Thus, the metal
chassis of the loads also gets bonded to the Earth Ground of the Utility Distribution System.
• Grounding using Grounding Nut and Bolt (15, Fig, 3.1): DO NOT GROUND USING THIS NUT
AND BOLT. THE UNIT GETS GROUNDED TO THE EARTH GROUND OF THE UTILITY GROUNDING
SYSTEM AUTOMATICALLY THROUGH THE GROUNDING WIRE OF THE AC INPUT POWER CORD
(10A, B- Fig 3.1). USE OF MULTIPLE GROUNDS IS NOT DESIRABLE.
3. When the unit is being used as a stand-alone inverter (Utility AC Power input is not con-
nected),RelayR2remainsde-energizedandthemetalchassisoftheunitremainsconnected
to the Grounding Terminals of the two NEMA5-15R outlet(s). In this application, connect the
Grounding Nut and Bolt (15, Fig, 3.1) to Earth Ground using at least AWG #8 wire.
4. Following operating conditions will be applicable when the unit is being used as (i) A Stand-
alone Inverter (Utility AC Power input is NOT connected) or (ii) as a Backup AC Power Source
when Utility AC Power is OFF:
• TheLineandNeutralTerminalsoftheNEMA5-15RACoutletswillbeisolatedfromits
Grounding Terminal. Thus, the metal chassis of the AC loads and the metal chassis of the
inverter will also be isolated from the Line and Neutral of the NEMA5-15R AC outlets.

12 | SAMLEX AMERICA INC.
SECTION 4 | Installation
The Grounding Terminal of the NEMA5-15R AC outlet will be connected to the input section
of the Electronic Ground Fault Protection Circuit on the Power Circuit Board.
• Duetotheaboveimplementation,thevoltageontheNeutralandLineTerminalsofthe
NEMA5-15R AC outlet with respect to the chassis of the inverter / chassis of the AC loads
will be a pulsing DC voltage with average DC value of up to 50V (will falsely read 75 VAC
on AC scale of the Voltmeter because of pulsing nature of DC voltage). DO NOT TOUCH THE
NEUTRAL TERMINAL / NEUTRAL CONDUCTORS!
5. Do not connect AC output from the NEMA5-15 outlets to AC distribution wiring where the
Neutral is bonded to Ground. The inverter will see this as abnormal condition of Ground
Fault and will shut down.
DC Side Connections
General Information
1. Ensure that the unit is connected to 12V battery system. CONNECTION TO 24V BATTERY
SYSTEM WILL DAMAGE THE UNIT.
2. Donotuseadditionalexternalchargingsourcetochargethebatteryatvoltage>15.5V.
3. Do not use with Positive Grounded Electrical Systems (the majority of modern automobiles,
RVs, trucks and boats use Negative Grounded Electrical Systems).
4. Observe correct polarity when connecting the DC input terminals of the unit to the battery.
Connect Positive of the battery to the Positive input connector of the unit and the Nega-
tive of the battery to the Negative input terminal of the unit. Reverse polarity connection
will result in a blown fuse and may cause permanent damage to the unit. Damage due to
reverse polarity is not covered under warranty.
Requirements of DC Input Power Source
Approx. DC Input Current required by Inverter = Power consumed by the AC Load
in Watts ÷ 10.
DC current drawn from the battery when delivering the rated power of 1500W is 150A.
12 VDC input to the inverter should be fed from a 12V Battery System or from a 12.5 VDC
to 15 VDC Regulated DC Power Supply. If a DC Power Supply is used, its output current ca-
pacityshouldbemorethan2timesthemaximumDCinputcurrentdrawnbytheinverter.
Further explanation of operation is based on DC input power from a 12V battery. It is
recommended that Deep Cycle Type Batteries are used. For detailed technical information
ontypes,construction,specications,sizing,connectionsandcharging/dischargingof
Lead Acid Batteries, please read online White Paper titled “Batteries, Chargers and
Alternators” at www.samlexamerica.com under Support/White Papers.
DC Input Power Terminals
Custom made DC input terminals using M9 Nut / Bolt arrangement have been provided
for connecting DC input cables (11, 12 in Fig 3.1). The terminals are protected by plastic
covers.

12 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 13
Important Wiring/Cabling Information
Although wires and cables are good conductors of electric current, they do have some
resistance, which is directly proportional to the length and inversely proportional to the
thickness(diameter)i.e.resistanceincreasesinthinnerandlongerwires.Currentowing
through resistance produces heat. Cables and wires are covered with insulating material
thatcanwithstandaspeciedtemperatureoftheconductorunderspeciedconditions.
Toensurethattheinsulationisnotdamagedduetoexcessiveoverheating,eachwiresize
hasamaximumallowablecurrentcarryingcapacitycalled"Ampacity"whichisspecied
byNECTable31.15(B)(17).Further,NECalsospeciesthatwiresizeshouldbebasedon
Ampacity-1.25timestheratedcurrentow.
Resistance of wires and cables produces another undesirable effect of voltage drop. Volt-
agedropisdirectlyproportionaltotheresistanceandthevalueofcurrentow.Voltage
dropproduceslossofpowerintheformofheat.Inaddition,excessivevoltagedropfrom
the battery to the inverter may prematurely shut down the inverter due to activation of
the Low Input Voltage Protection Circuitry of the inverter (10.5 ± 0.5V). DC cables should
besizedtoensuremaximumvoltagedropislimitedtolessthan5%.
Effects of low voltage on common electrical loads are given below:
Lighting Circuits – Incandescent and Quartz/Halogen: Loss in light output 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 – Fluorescent: Voltage drop causes an early proportional drop in
light output.
AC Induction Motors: These are commonly found in power tools, appliances, etc. They
exhibitveryhighsurgedemandswhenstarting.Signicantvoltagedropinthesecircuits
may cause failure to start and possible motor damage.
Requirement of Fuse in Battery Connection
A battery is a very large source of current. If there is a short circuit along the length of
the cables that connect 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overheat,
theinsulationwillmeltandislikelytocausere.Topreventoccurrenceofhazardous
conditionsundershortcircuit,fusewithAmpererating≥themaximumcontinuouscur-
rent drawn by the inverter but ≤ the Ampacity of the connecting cable should be used
in the battery connection. The fuse should be fast acting Class-T or Marine Rated Battery
Fuse Type MRBF. Rating of fuse is shown in Table 4.1 below. The fuse should be installed
as close to the Battery Positive terminal as possible, preferably within 7”. Please note that
thisfuseisrequiredtoprotectthecablerunfromthebatterytotheinverteragainstshort
circuit. The inverter has its own internal DC side fuse(s) for internal DC side protection.
Making DC Side Connections
RecommendedcableandfusesizesforconnectingbatteryaregiveninTable4.1.
Themaximumcurrentforcablesizing/fuseratinghasbeenconsideredat1.25times
rated continuous current draw at the rated output power.
SECTION 4 | Installation

14 | SAMLEX AMERICA INC.
Table 4.1 Recommended Cable and Fuse Sizes for Battery Connection
Rated DC
Input
Current
1.25 Times Rated
Current for
Sizing
Cable Size1
(Ampacity)
Max Fuse
Size2
Distance between Inverter,
Battery and % Voltage
Drop3
Samlex Fuse
(Optional)
Samlex Cable
+ Fuse Kit
(Optional)3 ft. 6 ft. 10 ft.
150A 187.5A AWG#2
(215A)
200A 1.2% 2.3% 3.8% DC-FA-200 DC-2000-KIT
NOTES:
1. Cable Size
• AsperNEC,sizeisbasedonAmpacity≥1.25timestheratedDCInputCurrent
• Conductor/Insulationrating:105°C
2. Fuse Size
• Type:Class-TorMarineRatedBatteryFuse(MRBF)
• TheratingofthefuseshouldnotexceedtheAmpacityoftheCable
3. Distance between Inverter and Battery and % Voltage Drop
• Voltagedropiscalculatedbasedonlengthofcable=2xDistancetoconsidertotallengthofPositive
and Negative cables
• %dropiscalculatedwithrespecttoratedbatteryvoltageof12.5V
!Caution!
• PleaseensurethattherecommendedexternalfusespeciedinTable4.1above(Fuseis
not supplied) is installed in series with the Positive cable and is as close to the Battery (+)
terminal as possible (preferably within 7”).
• Pleaseensurethatalltheconnectionsaretight.Looseconnectionsmaycauseoverheated
wires and melted insulation.
AC Side Connections
Feeding Utility AC Power - Use as Backup AC Power Source
- Power cord with NEMA5-15 Plug (10A, B in Fig 3.1) is used to feed AC input power to the
unit when the unit is used as a Backup AC Power Source.
- Use 15A/20A, GFCI protected AC outlet for this connection.
Connecting AC Loads
Connect the AC loads to the NEMA5-5R outlet(s) (1, Fig 3.1).
SECTION 4 | Installation

14 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 15
!Caution!
1. Do not connect the AC output of the unit to AC distribution wiring where the Neutral is
bonded to Ground. The inverter will see this as abnormal condition of Ground Fault and
will shut down.
2. The AC output of this unit can not be used in parallel with another AC Power Source –
SEVERE DAMAGE WILL OCCUR!
Limiting Electro-Magnetic Interference (EMI)
This unit contains internal switching devices that generate conducted and radiated elec-
tromagnetic interference (EMI). The EMI is unintentional and cannot be entirely elimi-
nated. The magnitude of EMI is, however, limited by circuit design to acceptable levels to
provide reasonable protection against harmful interference. This unit can conduct and
radiateradiofrequencyenergyand,ifnotinstalledandusedinaccordancewiththein-
struction manual, may cause harmful interference to radio communications. The effects of
EMIwillalsodependuponanumberoffactorsexternaltotheunitlikeproximityofthe
unittotheEMIreceptors,typesandqualityofconnectingwiresandcablesetc.EMIdueto
factorsexternaltotheunitmaybereducedasfollows:
- Ensurethattheunitisrmlygroundedtothegroundsystemofthebuildingor
the vehicle.
- Locate the unit 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 unit as short as possible.
- Do not keep the battery wires far apart. Keep them taped together to reduce their
inductance and induced voltages. This reduces ripple in the battery wires and improves
performanceandefciency.
- 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.
Buzzing Sound in Audio Systems
Someinexpensivesoundstereosystemsand“BoomBoxes”mayemitabuzzingsound
from their speakers when operated from this unit. This is likely to occur because the
powersupplyintheelectronicdevicedoesnotadequatelylterhigherfrequencyhar-
monicsgeneratedbyModiedSineWaveproducedbythisunit.Thesolutionistouse
higherqualitysoundsystemthatincorporateshigherqualityofinterferencesuppression
in its power supply.
SECTION 4 | Installation

16 | SAMLEX AMERICA INC.
Connecting Batteries
Series Connection
Fig. 4.2 Series Connection
When two or more batteries are connected in series, their voltages add up but their Ah
capacity remains the same. Fig. 4.2 above shows 4 pieces of 6V, 200 Ah batteries connect-
ed 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.
Parallel Connection
Fig. 4.3 Parallel Connection
When two or more batteries are connected in parallel, their voltage remains the same but
their Ah capacities add up. Fig. 4.3 above shows 4 pieces of 12V, 100 AH batteries connect-
ed 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 4 | Installation
6V Battery 6V Battery
12V Battery 12V Battery 12V Battery 12V Battery
6V Battery 6V Battery 6V Battery 6V Battery
12V String 1 12V String 2
Battery 1 Battery 3Battery 2 Battery 4
Battery 1 Battery 3Battery 2
Battery 4 Battery 3
Battery 4
12V
Inverter/
Charger
12V
Inverter/
Charger
Cable “A”
Cable “B”
Cable “A”
Cable “B”
Cable “A”
Cable “B”
6V Battery
Battery 2
6V Battery
Battery 1
24V
Inverter/
Charger
6V Battery 6V Battery
12V Battery 12V Battery 12V Battery 12V Battery
6V Battery 6V Battery 6V Battery 6V Battery
12V String 1 12V String 2
Battery 1 Battery 3Battery 2 Battery 4
Battery 1 Battery 3Battery 2
Battery 4 Battery 3
Battery 4
12V
Inverter/
Charger
12V
Inverter/
Charger
Cable “A”
Cable “B”
Cable “A”
Cable “B”
Cable “A”
Cable “B”
6V Battery
Battery 2
6V Battery
Battery 1
24V
Inverter/
Charger

16 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 17
SECTION 4 | Installation
Series – Parallel Connection
Fig. 4.4 Series-Parallel Connection
Figure 4.4 above shows a series – parallel connection consisting of four 6V, 200 Ah batteries
to form a 12V, 400 Ah battery bank. Two 6V, 200 Ah batteries, Batteries 1 and 2 are con-
nected 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.
!Caution!
When 2 or more batteries / battery strings are connected in parallel and are then
connected to an Inverter Charger (See Figs. 4.3 and 4.4 given above), 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.4.3)ortothePositivebatterypostoftherstbatterystring
(Battery 1 of String 1 in Fig. 4.4), 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. 4.3) or to the Negative Post of the last battery string
(Battery 4 of Battery String 2 as in Fig. 4.4). 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atthesamechargingcurrentandthus,willbe
charged to the same state at the same time.
• Noneofthebatterieswillseeanovercharge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.4.3)ortothePositive
batterypostoftherstbatterystring(Battery1ofString1inFig.4.4),andthe
Negative output cable of the Inverter Charger (Cable “B”) is connected to the
Negativebatterypostoftherstbattery(Battery1asinFig.4.3)ortothe
6V Battery 6V Battery
12V Battery 12V Battery 12V Battery 12V Battery
6V Battery 6V Battery 6V Battery 6V Battery
12V String 1 12V String 2
Battery 1 Battery 3Battery 2 Battery 4
Battery 1 Battery 3Battery 2
Battery 4 Battery 3
Battery 4
12V
Inverter/
Charger
12V
Inverter/
Charger
Cable “A”
Cable “B”
Cable “A”
Cable “B”
Cable “A”
Cable “B”
6V Battery
Battery 2
6V Battery
Battery 1
24V
Inverter/
Charger

18 | SAMLEX AMERICA INC.
NegativePostoftherstbatterystring(Battery1ofBatteryString1asinFig.4.4),
the following abnormal conditions will result:
• Theresistancesoftheconnectingcableswillnotbebalanced.
• Theindividualbatterieswillseedifferentseriesresistances.
• Alltheindividualbatterieswillbechargedatdifferentchargingcurrentandthus,will
reach fully charged state at different times.
• Thebatterywithlowerseriesresistancewilltakeshortertimetochargeascomparedto
thebatterywhichseeshigherseriesresistanceandhence,willexperienceovercharging
and its life will be reduced.
Sizing Inverter Battery Bank
Thefollowingbasicrulesareusedtodeterminethesizeofthebatterybank:
• ActivePowerinWatts(W)=
VoltageinVolts(V)xCurrentinAmperes(A)xPowerFactor ...................... Formula 1
• Foraninverterrunningfroma12Vbatterysystem,
theDCcurrentrequiredfromthe12Vbatteriesisthe
AC power delivered by the inverter to the load in Watts (W)
divided by 10 ..................................................................................................... Formula 2
• Energyrequiredfromthebattery=
DCcurrenttobedelivered(A)xtimeinHours(H) ........................................ Formula 3
• AsaRuleofThumb,Ahcapacityofthebatteriesrequired=
2xEnergyrequiredfromthebattery ............................................................. Formula 4
Anexampleofthiscalculationfora12Vinverterisgivenbelow:
Let us say that the total continuous AC Watts delivered by the 12V inverter = 1500W.
Then,usingFormula2above,theDCcurrenttobedeliveredbythe12Vbatteries=
1500W÷10=150Amperes.
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=150Amperes×3Hours=450AmpereHours(Ah).
Finally, as per Rule of Thumb at Formula 4, the Ah capacity of the batteries should be
twice the energy required by the load in Ah=450Ahx2=900Ah.
SECTION 4 | Installation