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