Samlexpower SAM-250-12 User manual

SAM Series
Power
Inverters
SAM-250-12
SAM-450-12
SAM-800-12
Please read this
manual BEFORE
installing your
inverter
Owner's
Manual

SAMLEX AMERICA INC.
MANUAL | Index
SECTION 1:
Important Safety Instructions ................................................................. 1
SECTION 2:
Description........................................................................................... 3
Features ............................................................................................. 3
Principle of Operation ............................................................................ 4
SECTION 3:
Product Layout ...................................................................................... 6
SECTION 4:
Installation ............................................................................................. 7
SECTION 5:
Operation ........................................................................................... 13
SECTION 6:
Protections ........................................................................................... 14
Monitoring & Troubleshooting............................................................. 16
SECTION 7
Specications ....................................................................................... 18
SECTION 8
Warranty ........................................................................................... 20

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. 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 only
interrupt power 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 12 VDC Power Plug (Cigarette Plug) connections
and terminal connections.
5. This is not a toy - keep away from children.
6. Do NOT insert object into the air vents.

2 | SAMLEX AMERICA INC.
!Caution!
1. The metal chassis of the inverter and the Grounding Terminal of the NEMA5-15R
outlet(s) are internally bonded (connected) to the Negative DC Input Terminal on the
inverter. In a vehicle / boat, the Negative Terminal of the battery is bonded to vehicle
chassis / boat’s hull. Hence, the metal chassis of the inverter and the AC loads will be
automatically grounded (bonded to the vehicle chassis / boat’s hull).
2. Please ensure that the Negative DC Input Terminal on the inverter or the Battery Neg-
ative Terminal on the battery itself is bonded to Earth Ground WHEN THE INVERTER IS
USED ON LAND.
3. The Line and Neutral Terminals of the NEMA5-15R AC outlets are 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. The Grounding Terminal
of the AC outlet is connected to the input section of the Electronic Ground Fault Pro-
tection Circuit on the Power Circuit Board. Due to the above implementation, the volt-
age on the Neutral and Line Terminals of the AC outlet with respect to the chassis of
the inverter / chassis of the AC loads will be pulsing DC voltage with average DC value
of up to 50V (will 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 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

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Description
The inverter converts 12 VDC voltage from battery or from other suitable 12 VDC source
to115V,60HzACvoltage.ThewaveformoftheoftheACoutputvoltageisModied
Sine Wave.
Features
• Highpeakefciencyof90%
• Veryhighpowertoweightratio-compactandlightweight
• SoftStartTechnologyforbettersurgeperformance 
• LatesthighpowerUSBChargingPort,USB3.0,TypeA:5VDC,2.1A
• Loadcontrolledcoolingfanforbetterefciency
• CoolSurfaceTechnologyforcoolerandsafertouchtemperature
• UniversalProtectioncircuitforlow/highDCinputvoltage,overload/shortcircuit,
over temperature and Ground Fault
• LowInterferenceTechnologyforcontrolledRFnoise
• DetachableDCinputcableswith12VPowerPlug(CigarPlug)-
not for SAM-800-12 model / Battery Clamps
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 will ramp up
and reduce inrush / starting surge current in the load as above.
• Similaroverloadreductionwillbeinitiatedduringanyothermomentaryoverload
condition.
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.
SECTION 2 | IntroductionSECTION 1 | Safety

4 | SAMLEX AMERICA INC.
SECTION 2 | Introduction
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 at the following
loads:
• SAM-250-12andSAM-450-12: Atloadof8Wto12W
• SAM-800-12:   Atloadof35Wto45W
Thiswillreduceenergyconsumptionbythefanandwillincreaseoverallefciency
Principle of Operation
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)
Modied 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
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

4 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 5
SECTION 2 | IntroductionSECTION 2 | Introduction
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.
!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 Modied 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 in this inverter. 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volt-
age, 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.

6 | SAMLEX AMERICA INC.
78 9
1
2
3
4
5
6
1
2
3
4
5 6
7
89
1
2
45
6
3
78 9
Fig. 3.1 – SAM-250-12 Inverter
Fig 3.3 – SAM-800-12 Inverter
Fig. 3.2 – SAM-450-12 Inverter
4
5
6
45 6
4
5
6
11a
11b
11c
10
10
SECTION 3 | Layout
1. ON/OFF Switch
2. NEMA5-15R Outlet
3. USB Port 3.0, Type "A", 2.1A
4. RED LED "Fault"
5. GREEN LED "Power"
6. YELLOW LED "Input Fault"
7. (+) Positive DC Input Terminal
(M4 Thumb Screw)
8. (-) Negative DC Input Terminal
(M4 Thumb Screw)
9. Opening for fan ventilation
10. Battery Cable with 12V Power Plug
11. Battery Cable with Battery Clamps
- 11(a) For SAM-250-12 (AWG#14)
- 11(b) For SAM-450-12 (AWG#12)
- 11(C) For SAM-800-12 (AWG#8)
LEGEND

6 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 7
SECTION 4 | InstallationSECTION 3 | Layout
Safety of Installation
Please read safety instructions on pages 1-2 before commencing installation.
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 inverter 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 it 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 pow-
er. 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inverteronornearaheatingventoranypieceofequipment,whichis
generating heat above room temperature. Keep the inverter away from direct sunlight.
Ventilated - The unit is cooled by load-controlled fan. The fan will be off up to certain thresh-
old of power and automatically switch on thereafter. The fan sucks cool air in from the venti-
lation slots on the AC outlet side and discharges hot air out of the fan opening (9) 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 ventilation slots and fan opening on the
sides are not blocked. Do not place items on or over the inverter during operation.
Mounting Orientation
SAM-250-12 Model (Fig 3.1) is not provided with mounting arrangement. SAM-450-12 (Fig
3.2)andSAM-800-12(Fig3.3)Modelsareprovidedwith2angesonthebottomwith2
mounting slots each.
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forfanairow.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 consider-
ations. If mounted as in Fig 4.1(b), metallic or other conductive object(s) may accidentally fall
inside the unit 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.
(a) (c)(b)
Fig 4.1
Mounting Orientation
on Wall

8 | SAMLEX AMERICA INC.
SECTION 4 | Installation
DC Side Connections
General Information
1. The metal chassis of the inverter and the Grounding Terminal of the NEMA5-15R
outlet(s) are internally bonded (connected) to the Negative DC Input Terminal on the
inverter. In a vehicle / boat, the Negative Terminal of the battery is bonded to vehicle
chassis / boat’s hull. Hence, the metal chassis of the inverter and the AC loads will be
automatically grounded (bonded to the vehicle chassis / boat’s hull).
2. Please ensure that the Negative DC Input Terminal on the inverter or the Battery Nega-
tive Terminal on the battery itself is bonded to Earth Ground WHEN THE INVERTER IS
USED ON LAND.
3. Do not use with Positive Grounded Electrical Systems (the majority of modern automo-
biles, RVs, trucks and boats use Negative Grounded Electrical Systems).
4. 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.
Requirements of DC Input Power Source
Approx. DC Input Current required by Inverter = Power consumed by the AC Load in
Watts ÷ 10.
DC input currents at Continuous Rated Power Output will be:
• SAM-250-12 25A
• SAM-450-12 45A
• SAM-800-12 80A
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
capacity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 techni-
cal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 M4 Nut / Thumb Screw arrangement have been
provided for connecting DC input cables (7, 8 in Fig 3.1 to 3.3).
Important Wiring Information
Inadequately sized DC input wiring of inverters produces higher voltage drop resulting
inhigherpowerlossandreducedbattery-operatingtime.VoltageDrop=Currentx
Resistance.Wiresshouldbesizedbasedon(a)maximumallowablecurrent(Ampacity)
and (b) allowable voltage drop in the wiring resistance (Wiring resistance is the sum of

8 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 9
SECTION 4 | Installation
resistance of Positive and Negative cables = 2 times the distance between the inverter and
thebattery).Upto5%voltagedrophasbeenconsidered.
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condi-
tionsundershortcircuit,fusewithAmpererating≥themaximumcontinuouscurrent
drawn by the inverter but ≤ the Ampacity of the connecting cable should be used in the
battery connection. The fuse should be fast acting e.g. Blade Types AGC / ATO / MAXI 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.
Detachable Cables Provided for Battery Connection
Table 4.1 below provides information on battery cables that have been provided for mak-
ing temporary / detachable connection to the 12V battery. The Table also provides rating
ofexternalfuses(fusesnotprovided)tobeusedwhenusingcableswithbatteryclamp.
Thecablesareterminatedwithcustomized12.5mmx8.5mmlugsforconnectiontothe
inverter with the help of customized terminal using M4 Nut / Thumb Screw arrangement
(7, 8 in Fig 3.1 to 3.3). The other end for battery side has either 12V Power Plug (with 8A
fuse) or battery clamps.
Table 4.1 Cables Supplied with the Inverter
Model No.
3 ft. Cable with 12V Power Plug /Cigarette Plug
(with 8A Fuse protection) 3 ft. Cable with Battery Clamps
SAM-250-12 Fig 3.1 (10) Fig 3.1 (11a) Recommended Fuse:
30A (Not supplied)
SAM-450-12 Fig 3.2 (10) Fig 3.2 (11b) Recommended Fuse:
60A (Not supplied)
SAM-800-12 -Fig 3.3 (11c) Recommended Fuse:
100A (Not supplied)

10 | SAMLEX AMERICA INC.
Making DC Side Connections using Detachable Cable with
12V Power Plug (Cigarette Plug)
Table 4.1 above gives details of cable with 12V Power Plug (Cigarette Plug) that has been
provided for making detachable, temporary connection to the vehicle battery through
the 12V Power Outlet (Cigarette Receptacle). With this arrangement, AC power draw is
limitedtomaximumof80W.
Please ensure that the 12V Power Plug is fully and rmly inserted in the receptacle.
!Caution!
12V Power Outlet (Cigarette Receptacle) in vehicles and the mating 12V Power Plug (Cig-
arette Plug) create electrical connection by spring-loaded contacts. This type of electrical
connection is not very rm. In addition to issues with incompatible sizes of outlets, the
plug can vibrate out of the socket under normal driving conditions owing to inadequate
retention. Loose electrical contact, especially at the Positive contact at the tip of the plug,
causes sparking and excessive heating at higher currents. Hence, for safety against risk of
re, current supplied by 12V Power Outlet circuit in the vehicle is limited and is normally
fused at 12A to 15A depending upon the type / model of the vehicle. The supplied cable
with 12V Power Plug is protected by replaceable 250V, 8A, Fast Blow Fuse (Bussmann
Type AGC-8, installed under the tip of the plug) and will allow maximum continuous
power draw of 80W. If device > 80W is used, 8A fuse in the tip of the Power Plug will
blow to prevent blowing of vehicle fuse. Replace the fuse with the rated fuse only (Fuse
is accessed by unscrewing the top portion).
Making DC Side Connections using Cable with Battery Clamps
Table 4.1 above gives details of DC input cables with battery clamps that have been pro-
vided for making temporary, detachable connection to a 12V battery.
!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.
Making Hardwired, Permanent DC Side Connections
For hard wiring / permanent connection to the battery, recommended cable and fuse sizes
are given in Table 4.2.
Themaximumcurrentforcablesizing/fuseratinghasbeenconsideredat1.25timesthe
maximumcontinuouscurrentdrawattheratedoutputpower(Approximately=ACload
in Watts “10):
• 30AforSAM-250-12Inverter
• 60AforSAM-450-12Inverter
• 100AforSAM-800-12Inverter
SECTION 4 | Installation

10 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 11
The thickness of the cables is required to be determined appropriately. The recommended
cable sizes are based on the following 2 considerations (thicker of the two cable sizes has
been recommended):
• Excessiveheatingmayleadtoriskofinsulationmeltdownandre.Sizeisbasedon
themaximumcurrentcarryingcapacity(Ampacity)forconductortemperaturesof
105°C in free air at 30°C ambient.
• Excessivevoltagedropwillalarmandthenshutdowntheinverterprematurelydue
tolowDCinputvoltageprotectionoftheinverter(10.5V±0.3V).Sizeisbasedon5%
voltagedropfromthebatterytotheinverterat1.25timesthemaximumcontinuous
current draw at the rated output power.
Table 4.2 Recommended Cable and Fuse Sizes for Hard Wiring
Inverter
Wattage
Cable Size for 5% Voltage Drop for Distance Between
Battery and Inverter =
Recommended
Fuse (Not Supplied)
3 ft.
(Wire length = 6 ft.)
6 ft.
(Wire length = 12 ft.)
10 ft.
(Wire length = 20 ft.)
SAM-250-12 AWG #14 AWG #12 AWG #10 30A
SAM-450-12 AWG #10 AWG #8 AWG #6 60A
SAM-800-12 AWG #6 AWG #6 AWG #4 100A
As stated above, the 3 ft. battery cables provided with the unit are terminated with
customized12.5mmx8.5mmlugsforconnectiontotheinverterwiththehelpofcustom-
ized terminal using M4 Nut /Thumb Screw arrangement (7,8 in Fig 3.1 to 3.3). For connect-
ingthelonger/thickercablestotheinverter,usethecustomized12.5mmx8.5mmtab
with 4.5 mm hole provided with the set of cable with battery clamps. Cut the cable a few
inches from the Tab Terminal and splice it with the thicker / longer cable. As the length of
the thinner end piece will be only a few inches, there will be no appreciable drop of volt-
age along the short end section.
!Caution!
• PleaseensurethattherecommendedexternalfusespeciedinTable4.2above(Fuse
is not supplied) is installed in series with the Positive cable and is as close to the Bat-
tery (+) terminal as possible (preferably within 7”).
•. Pleaseensurethatalltheconnectionsaretight.Looseconnectionsmaycauseover-
heated wires and melted insulation.
AC Side Connections
General Information
1. The metal chassis of the inverter and the Grounding Terminal of the NEMA5-15R
outlet(s) are internally bonded (connected) to the Negative DC Input Terminal on the
inverter. In a vehicle / boat, the Negative Terminal of the battery is bonded to vehicl-
chassis / boat’s hull. Hence, the metal chassis of the inverter and the AC loads will be
automatically grounded (bonded to the vehicle chassis / boat’s hull).
SECTION 4 | Installation

12 | SAMLEX AMERICA INC.
2. The Line and Neutral Terminals of the NEMA5-15R AC outlets are 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. The Grounding Terminal
of the AC outlet is connected to the input section of the Electronic Ground Fault Pro-
tection Circuit on the Power Circuit Board. Due to the above implementation, the volt-
age on the Neutral and Line Terminals of the AC outlet with respect to the chassis of
the inverter / chassis of the AC loads will be pulsing DC voltage with average DC value
of up to 50V (will read 75 VAC on AC scale of the Voltmeter because of pulsing nature
of DC voltage). DO NOT TOUCH THE NEUTRAL TERMINAL / NEUTRAL CONDUCTORS!
3. Do not connect 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.
Connecting AC Loads
Connect the AC loads to the NEMA5-5R outlet(s) (2, Fig 3.1, 3,2, 3.3)
!Caution!
Do not connect 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.
SECTION 4 | Installation

12 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 13
Connecting Loads, Switching ON & Switching OFF
Connecting Loads
1. Make sure that single load or the combined load requirement of your equipment
doesnotexceedtheinverter'soutputrating.
2. Switch OFF the inverter.
3. Switch OFF the load.
4. Plug the cord(s) from the load(s) into the AC receptacle(s) of the inverter
5. Switch ON the inverter. Wait for a few seconds.
6. The GREEN LED indicator "Power" (5, Fig 3.1 to 3.3) will be lit to indicate that the
inverter is operating normally.
7. Switch ON the load(s).
Switching ON
1. Switch OFF the load connected to the inverter. Avoid switching ON the inverter with
load in ON condition.
2. Switch ON the inverter, wait for a few seconds and then switch ON the load.
3. When using high capacitive loads with inadequate inrush current limiting like
cheaper quality of Compact Flourescent Lamps (CFL) etc., wait for 10 seconds before
switching ON such loads. If the inverter is switched ON with these types of loads in
ON condition, the inverter may shut down or the loads may not switch ON. Some-
times, adding a small resisitive load (like incandescent lamp) in parallel with such
devices may prevent such shut down.
Switching OFF
1. Switch OFF the load connected to the inverter
2. Switch OFF the inverter.
Rated Versus Actual Current Draw of Equipment
Most electrical tools, appliances and audio/video equipment have labels that indicate the
power consumption in Amps or Watts. Be sure that the power consumption of the item
you wish to operate is less than inverter's power (if the power consumption is rated in
AmpsAC,simplymultiplybytheACVolts(115)todeterminetheapproximatewattage).
The inverter will shut down if it is overloaded. The overload must be removed before
the inverter will restart. Resistive loads are the easiest for the inverter to run. However,
larger resistive loads, such as electric stoves or heaters, usually require more wattage
than the inverter can deliver. Inductive loads, such as TV's and stereos, require more cur-
rent to operate than do resistive loads of the same wattage rating. Induction motors, as
well as some televisions, may require 2 to 6 times their wattage rating to start up. The
most demanding in this category are those that start under load, such as compressors
and pumps. To restart the unit after a shutdown due to overloading, remove the cause
of overload, turn the power switch OFF, wait for at least 3 minutes and then switch
ON again.
SECTION 5 | Operation

14 | SAMLEX AMERICA INC.
NOTE: Please refer to Table 6.1 for status of monitoring LEDs and Buzzer for various
protections / operational conditions explained below.
Over Temperature Protection
The unit is cooled by load-controlled fan. In case the fan fails or if the cooling is inad-
equateduetohigherambienttemperatureorrestrictedairow,thetemperatureinside
theinverterwillexceedthesafetemperaturethresholdandtheunitwillautomatically
shut down. The unit will reset automatically on cooling down.
Low Battery Voltage Protection
This condition is not harmful to the inverter but could damage the 12Vbattery. The
inverter automatically shuts down when input voltage drops to 10.5 ± 0.3V.
Over Voltage Protection
Theinverterwillautomaticallyshutdownwhentheinputvoltageexceeds15.5V±0.3V.
Inputvoltageexceeding16voltscoulddamagetheinverter.
Overload / Short Circuit Protection
The inverter will automatically shut down under short circuit conditions and when the
continuous/surgepowerexceedsratedwatts.Theunitwilllatchinshutdowncondition.
To reset, switch OFF the ON/OFF switch, wait for 3 minutes and switch ON again.
i
Info
Some high capacitive loads like compact uorescent lamp (CFL) or Switched Mode
Power Supply (SMPS) will draw very high inrush current due to very fast volt-
age rise of the square wave nature of the Modied Sine Wave and shut down the
inverter. Try using a small resistive load in parallel to reduce high inrush current and
prevent overloading.
Low Input Voltage Alarm
An alarm will sound when the voltage at the input terminals of the inverter drops to
10.8V ± 0.3V. This is an indication that either the battery terminal voltage has dropped
duetoitsdischargedconditionandneedstobere-chargedorthereisanexcessivevolt-
age drop across the wires connecting the inverter to the battery (due to use of thinner
and longer length of wires that will produce higher voltage drop at higher loads or due
to loose connections). The user should stop operation of the electronic device at this time
since the inverter will shut down automatically shortly thereafter, when the input voltage
at the inverter further drops to 10.5V ± 0.3V. In case the alarm is due to the discharged
condition of the battery, start your engine to recharge the battery / use an appropriate
battery charger.
SECTION 6 | Protections Monitoring
& Troubleshooting

14 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 15
i
Info
It is normal for the alarm to sound while the unit is being connected to or discon-
nected from the power source. This is not indicative of a problem.
Ground Fault Protection - General
Due to loss of insulation as a result of aging of insulating materials, accident or malfunc-
tion, voltage source inside an electrical device can get connected to its metal chassis. If the
energized metal chassis is touched by a person standing on Earth Ground (considered to
be at 0V), they will get a shock due to current leaked through the body to Earth Ground
(called Leakage Current). Such condition is called “Ground Fault”. As this Leakage Current
is diverted to Earth Ground, it does not return to the electrical power source supplying
the AC device. Severity of electrical shock will depend upon the value of the fault voltage
on the metal chassis and the impedance in the current path to Earth Ground, primarily the
impedance of the human body (100 kΩ when dry and 1 kΩ when wet). Human body can
tolerate leakage current of up to 5ma for 15 to 30 msec.
Ground fault protection in this inverter is provided as follows:
• TheLineandNeutralterminalsofthe AC outlet are isolated from its grounding ter-
minal. Thus, the metal chassis of the AC loads will also be isolated from the Line and
Neutral.
• ThegroundingterminaloftheAC outlet is connected to the input section of the Elec-
tronic Ground Fault Protection Circuit on the power circuit board.
• Due to the above implementation, the Neutral voltage will be pulsing DC voltage
with average DC value of up to 50 VDC with respect to the metal chassis of the AC
loads / metal chassis of the inverter (will read 75 VAC on the AC scale of the Voltmeter
because of pulsing nature of DC Voltage). Similarly, the Line voltage will also be up to
75Vwith respect to the metal chassis of the AC loads / metal chassis of the inverter .
Do not touch the Line / Neutral!
• IfthemetalchassisoftheloaddevelopsaGroundFaultcondition,upto75Vwillbe
fed to the Electronic Ground Fault Protection Circuit and the AC output of the inverter
will shut down.
• Ground Fault protection will also operate if the Neutral and ground of the AC output
of the inverter are connected (bonded) intentionally like in Service Entrance / Load
Center for AC distribution wiring.
!Caution!
Connecting to utility AC distribution wiring with Neutral to Ground connection (bond)
is not permitted. In AC utility distribution wiring, the Neutral conductor is connected
(bonded) to the Equipment Grounding Conductor at the Load Center / Service Entrance.
Both these conductors are then bonded to the Earth Ground (Ground Rod). Thus, if the
output of the inverter is connected to the utility AC distribution wiring, it will see a Neu-
tral to Ground connection and the inverter will trip due to activation of the Ground Fault
ProtectionCircuitasexplainedabove.
SECTION 6 | Protections Monitoring
& Troubleshooting

16 | SAMLEX AMERICA INC.
Failure to Start Some Devices on Load
Some high capacitance loads like Compact Fluorescent Lamp (CFL) or Switched Mode
Power Supply (SMPS) will shut down the inverter under overload condition if the inverter
is switched ON with these loads in ON condition. However, if these loads are switched
OFFrstandswitched ON only after around 10 sec after the inverter is switched ON (as
already recommended under switching ON procedure), the inverter may not shut down.
Hence, do not switch ON the inverter with such loads in ON condition.
Monitoring of Operational Status & Protections
Normal / abnormal behavior can be monitored by observing Green LED (5, Power), Yellow
LED (6, Input Fault), Red LED (4, Fault) and Buzzer. Details are given in Table 6.1 below:
Table 6.1 Protections and Monitoring
Operating
Condition/
Protection
Threshold/
Reason
GREEN
LED (5,
Power)
YELLOW
LED (6,
Input
Fault)
RED
LED (4,
Fault)
Buzzer Remedy/Reset
Normal -ON OFF OFF OFF -
Low DC Input
Alarm
10.8V ± 0.3V ON OFF OFF ON Check battery voltage and
input voltage drop.
Auto reset when voltage
> 10.5 V ± 0.3V.
No Output
due to Low DC
Input Voltage
shutdown
10.5V ± 0.3V OFF ON OFF OFF Check battery voltage and
input voltage drop.
Auto reset when voltage rises
to >11.5V.
No output due
to High DC
Input Voltage
Shut Down
15.5 ± 0.2V OFF ON OFF OFF Check charger voltage.
Auto reset when voltage
< 15.5V.
No Output
due to High
Temperature
Shut Down
Internal hot
spot > 88°C
to 115°C
OFF ON OFF OFF Check ambient temperature,
fan and loss of cool
replacement air .
Auto reset when hot spot
cools down 10°C to 15°C
below the threshold.
SECTION 6 | Protections Monitoring
& Troubleshooting

16 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 17
Operating
Condition/
Protection
Threshold/
Reason
GREEN
LED (5,
Power)
YELLOW
LED (6,
Input
Fault)
RED
LED (4,
Fault)
Buzzer Remedy/Reset
No output due
to Over Load
Shut Down
Output power
is > Continu-
ous / Surge
Rating
ON OFF ON OFF Check starting surge rating
of load. If happens with low
power CFL or SMPS, try adding
small resistive load.
If happens when inverter
is switched ON with high
capacitance load already in ON
condition, try switching ON the
load 10 sec after the inverter
has been switched ON.
Manual Reset. Unit will latch in
shut down condition. To reset,
switch OFF the ON/OFF Switch,
wait for 3 minutes and switch
ON again.
No output due
to Ground Fault
Shut Down
Neutral or
Line con-
nected to
Ground
ON OFF ON OFF Check if there is Neutral to
Ground bond or Ground Fault.
Manual Reset. Unit will latch in
shut down condition. To reset,
switch OFF the ON/OFF Switch,
wait for 3 minutes and switch
ON again.
No output No DC Input
Voltage due
to Blown DC
Input Fuse
OFF OFF OFF OFF Check 8A fuse in the 12V
Power Plug or in the battery
input line.
SECTION 6 | Protections Monitoring
& Troubleshooting

18 | SAMLEX AMERICA INC.
INVERTER PARAMETER SAM-250-12 SAM-450-12 SAM-800-12
INPUT
BATTERY SYSTEM VOLTAGE 12 VDC
NOMINAL INPUT VOLTAGE 12.5 VDC
INPUT VOLTAGE RANGE > 10.8 VDC to < 15.4 VDC
INPUT CURRENT AT CONTINUOUS POWER 22.3A to 24.2A 41.3A to 43.3A 72A to 75A
INPUT CURRENT AT NO LOAD 0.2A to 0.3A 0.25A to 0.35A 0.25A to 0.35A
OUTPUT
OUTPUT VOLTAGE WAVE FORM Modied Sine Wave
OUTPUT VOLTAGE 115 VAC +10% / -2%
OUTPUT FREQUENCY 60 Hz ± 5%
OUTPUT POWER, CONTINUOUS (RESISTIVE LOAD) 250W 450W 800W
OUTPUT POWER, SURGE (<1 SEC., RESISTIVE LOAD) 500W 900W 1600W
PEAK EFFICIENCY (AT 50% OF CONTINUOUS POWER) 90%
USB CHARGING PORT USB 3.0, Connector Type "A": 5 VDC, 2.1A
PROTECTIONS
LOW INPUT VOLTAGE ALARM 10.8 VDC. ± 0.3VDC
LOW INPUT VOLTAGE SHUTDOW 10.5 VDC.± 0.3VDC
HIGH INPUT VOLTAGE SHUTDOWN 15.4 VDC.± 0.2VDC
OVERLOAD AND GROUND FAULT SHUT DOWN Yes. Latches in shutdown condition. Manual reset: Switch
OFF the ON/OFF Switch, wait 3 mins & Switch ON again.
OVER TEMPERATURE SHUTDOWN Yes. Auto reset on cooling down.
COOLING FAN
Load controlled:
Switches ON at
8W to 12W
Load controlled:
Switches ON at
35W to 45W
INPUT FUSE: 32V, AUTOMOTIVE TYPE ATC
(INSIDE THE UNIT - NOT USER ACCESSIBLE) 30A 70A (2 x 35A in
parallel)
105A (3 x 35A in
parallel)
CONNECTIONS
DC INPUT M4 Thumb Screw
AC OUTPUT - NO. OF NEMA5-15R One NEMA5-15R
Outlet
Two NEMA5-15R
Outlets
Two NEMA5-15R
Outlets
GENERAL
OPERATING TEMPERATURE RANGE 0°C to 25°C / 32°F to 77°F at 100% loading;
26°C to 35°C / 78.8°F to 95°F at 80% loading
OPERATING HUMIDITY < 80%; Non-condensing
NEUTRAL TO CHASSIS BONDING No. Neutral of the NEMA5-15R AC Outlet is
isolated from the chassis
DIMENSIONS (W x D x H) mm
DIMENSIONS (W x D x H) inches
114.4 x 150 x 46
4.5 x 5.9 x 1.8
154 x 151 x 56.5
6.1 x 6.0 x 2.2
180 x 218 x 59
7 x 8.6 x 2.4
WEIGHT 0.42 kg
0.92 lb.
0.6 kg
1.3 lb.
1.32 kg
2.91 lb.
SECTION 7 | Specications