Samlexpower SAM-250-12 Bedienungsanleitung

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

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

2 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 3

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

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

5 6

78 9

Fig. 3.1 – SAM-250-12 Inverter

Fig 3.3 – SAM-800-12 Inverter

Fig. 3.2 – SAM-450-12 Inverter

45 6

11a

11b

11c

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

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