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1. 12 volts 100 AHrs 12 volt battery bank total capacity 2 400 AHrs Figure 15 Parallel Battery Wiring Series Parallel Wiring A series parallel configuration increases both voltage to match the inverter s DC requirements and capacity to increase run time for operating the loads using smaller lower voltage batteries In the example below Figure 16 four 6 VDC 200 AHr batteries are com bined into two strings resulting in a 12 VDC 400 AHr battery bank overcurrent e protection 12 VDC Inverter 6 volts 200 AHrs 6 volts String 1 200 AHrs String 2 200 AHrs 200 AHrs 12 volt battery bank total capacity 400 AHrs Figure 16 Series Parallel Battery Wiring 2010 Magnum Energy Inc 37 Appendix B Battery Information overcurrent protection S to 12 VDC tring 12 VDC inverter 12 VDC 100 AH battery total capacity 100 AH 100 AH 12 volt battery bank one string of one 12 volt battery overcurrent protection to 12 Series String inverter 6 VDC 6 VDC battery battery total capacity 200 AH 200 AH 200 AH overcurrent protection lt gt to 12 Parallel String inverter 100 AH 100 AH total capacity 200 AH 12 volt battery bank parallel two 12 volt batteries Parallel String 200 AH 200 AH overcurrent protection Series Strin 6 VDC 6 VDC 6 VDC SE battery
2. 400 AmpHrs Battery AmpHrs Absorb Time 120 minutes Default Settings Flooded Liquid Lead Acid Battery Type Bulk 14 6 VDC Float 13 4 VDC MM1524AE Bulk 29 2 VDC Float 26 8 VDC Charge Rate 100 VAC dropout 80VAC 2010 Magnum Energy Inc E 4 0 Maintenance and Troubleshooting 4 0 Maintenance and Troubleshooting Recommended Inverter and Battery Care The MM AE Series inverter charger is designed to provide you with years of trouble free service Even though there are no user service able parts it is recommended that every 6 months you perform the following maintenance steps to ensure optimum performance and extend the life of your batteries WARNI NG Prior to performing these checks switch both the AC and DC circuits OFF e Visually inspect the batteries for cracks leaks or swelling replace if necessary e Use baking soda to clean and remove any electrolyte spills or buildups e Check and tighten all battery holddown clamps e Clean and tighten 10 to 12 foot pounds all DC terminals battery and inverter and connecting cables e Check and fill battery water levels Liquid Lead Acid batteries only e Check individual battery voltages replace those that vary more than 0 3 VDC of each other e Check all cable runs for signs of chafing replace if necessary e Check the inverter s cooling vents clean as necessary Resetting the nverter Under some fault conditions i e
3. an internal fault the inverter will need to be reset To reset the inverter 1 Press and hold the Power ON OFF pushbutton for approximately 15 seconds or until the status LED comes on and flashes rapidly see Figure 2 Items 1 and 2 2 Release the Power ON OFF pushbutton once the rapid flashing has begun The status LED will go off 3 Press the Power ON OFF pushbutton again to turn the inverter on type switch which operates by lightly pressing and H I nfo The Power ON OFF pushbutton is a small momentary releasing 32 2010 Magnum Energy Inc 4 0 Maintenance and Troubleshooting Troubleshooting The MM AE Series inverter charger is a fairly simple device to trouble shoot There are only two active circuits AC and DC as well as a charging circuit The following chart is designed to help you quickly pinpoint the most common inverter and charger faults Table 7 Troubleshooting Guide Low Battery Voltage the status indicator blinks on 1 time every 4 secs High Battery Voltage the status indicator blinks on 2 times every 4 secs Over temperature condition the status indicator blinks on 3 times every 4 secs AC Overload the status indicator blinks on 4 times every 4 secs Internal fault the status indicator blinks on 5 times every 4 secs I nverter s status light is off AC input won t connec AC IN on remote blinks Appliances turn off and on or there is
4. nected load remains on but now is powered by the inverter If the inverter passes all the steps the inverter is ready for use If the inverter fails any of the steps refer to the Troubleshooting section 22 2010 Magnum Energy Inc 3 0 Operation 3 0 Operation Operating Modes The MM AE Series inverter charger has two normal operating rou tines Inverter Mode which powers your loads using the batteries and Standby Mode which transfers the incoming AC power utility power or a generator to power your loads and also uses this incoming power to recharge the batteries This inverter also includes an extensive protection circuitry that shuts down the inverter under certain fault conditions I nverter Mode When the inverter is first powered up it defaults to the OFF mode The momentary ON OFF power switch Figure 2 Item 2 must be lightly pressed to turn the inverter ON Subsequently pressing this switch alternately turns the inverter OFF and ON e Inverter OFF When the inverter is OFF no power is used from the batteries to power the AC loads and the status LED will be OFF If AC power from an external source utility or generator is connected and qualified on the inverter s AC input this AC in put power will pass through the inverter to power the AC loads However if this AC power is lost the AC loads will no longer be powered because the inverter is OFF When the inverter is turned ON it operates eith
5. 200 AH 200 AH to 12 VDC inverter total capacity 400 AH Series String 6 VDC 6 VDC 6 VDC battery battery 200 AH 200 AH Figure 17 Battery Bank Wiring Examples 12 volt 38 2010 Magnum Energy Inc Series String 12 VDC 12 VDC Series String 6VDC 6VDC 6 VDC 6 VDC C Series String 12 VDC 12 VDC Series String 12 VDC 12 VDC Series String 6VDC 6VDC 6 VDC 6 VDC Series String 6 6 6 VDC 6 Appendix B Battery Information 12 VDC battery 100 AH 6 VDC battery 6 VDC battery 200 AH 12 VDC battery 100 AH 12 VDC battery 100 AH 6 VDC battery 6 VDC battery 200 AH overcurrent protection to 24 VDC inverter total capacity 100 AH 12 VDC battery 100 AH overcurrent protection 6 VDC battery 200 AH 6 VDC battery 200 AH to 24 VDC inverter total capacity 200 AH overcurrent protection to 24 VDC inverter total capacity 200 AH 12 VDC battery 100 AH overcurrent E protection battery 200 AH 6 VDC battery 200 AH to 24 VDC inverter total capacity 400 AH S 24 volt battery bank two strings of four 6 volt batteries wired in series and connected in parallel Figure 18 Battery Bank Wiring Examples 24 volt 2010 Magnum Energy Inc 39 Appendix C Warranty Service Information Appendix C Warranty Servic
6. refer to Table 2 to determine the minimum DC wire size you need for various distances based on your inverter model Note 1 Maximum Continuous Current is based on the inverter s continuous power rating at the lowest input voltage with an inefficiency factor Note 2 Per the NEC the DC grounding electrode conductor can be a 6 AWG conductor if that is the only connection to the grounding electrode and that grounding electrode is a pipe rod or plate electrode Note 3 Wire size is based on the requirements needed to increase efficien cy and reduce stress to the inverter Note 4 The next larger standard size overcurrent device may be used if the de rated cable ampacity falls between the standard overcurrent devices found in the NEC 12 2010 Magnum Energy Inc 2 0 Installation Table 2 DC Wire Size For Increased Distance Minimum recommended DC wire size one way 3 ft or less 3 60 5 ft 5 to 10 ft 10 to 15 ft MMIS12AE 1 0 AWG 1 0 AWG 2 0 AWG 4 0 AWG 1524 7 1 0 AWG 1 0 AWG 2 0 AWG 4 0 AWG DC Overcurrent Protection For safety and to comply with NEC National Electrical Code electrical code regulations you must install a DC overcurrent protection device in the positive DC cable line to protect your DC cables This DC overcurrent device can be a fuse or circuit breaker but must be DC rated It must be correctly sized according to the size of DC cables being used which means it is requi
7. Blinks on 1 time every four seconds Low Battery fault e Blinks on 2 times every four seconds High Battery fault e Blinks on 3 times every four seconds Over temperature fault e Blinks on 4 times every four seconds AC Overload fault e Blinks on 5 times every four seconds Internal fault Charge Mode The green LED status indicator provides additional information e Blinks off every four seconds The unit is charging the batteries connected to the inverter The external AC power utility power or generator connected to the inverter s input is passing through the inverter and is powering the AC loads connected to the inverter s output Factory Default Settings The MM AE Series inverter charger uses default settings that are ad equate for most installations see Table 6 However you can adjust these parameters using Magnum s optional ME RC50 remote The settings once programmed are saved in non volatile memory and are preserved until changed even if DC power to the inverter is lost the ME RC50 must always be connected The following information can help you determine if you need the ME RC50 remote 01 Search Watts This setting allows you to turn off the power saving Search Mode circuitry and to adjust the power level at which the inverter will wake up and start inverting 02 Low Battery Cut Out This setting determines when the inverter will turn off based on low battery voltage The inverter turns off automati
8. DC wire connections to batteries inverter and fuse lugs DC circuit breaker are flush on the surface of the DC terminals and the hardware lock washer and nut used to hold these connections are stacked correctly see Figures 9 and 10 Verify all DC connections are torqued from 10 to 12 foot pounds Once the DC connections are completely wired and tested coat the terminals with an approved anti oxidizing spray Press the red and black terminal covers onto the inverter s DC con nectors to secure them in place If batteries are in an enclosure perform a final check of the hold down brackets and all connections Close and secure the battery enclosure AC Wiring This section describes the required AC wire size and the overcurrent protection needed It also provides information on how to make the AC connections person or a licensed electrician following all local NEC j WARNING All wiring should be done by a qualified codes Neutral to Safety Ground Bonding The NEC National Electric Code provides the standards for safely wiring AE house cabin or office installations in the United States These wiring standards require the AC source inverter utility power Or a generator to have the neutral conductor tied to ground These standards also require that the AC neutral be connected to safety ground often called a bond in only one place at any time If more than one bond is established currents can circulate betwe
9. application e g split bolt twist on wire connectors etc Ensure the wire connectors used are rated for the size and number of wires you are connecting After connecting the wires together gently pull on the wires to ensure they are securely held together In a proper connection no bare wire should be exposed e Romex or an SO flexible cord with listed strain reliefs are allowed to be used to connect to the inverter conduit connections are not allowed D Info Per UL certification non metallic sheathed cable After all AC wiring in the inverter is complete and before reattach ing the AC access cover ensure all connections are correct and secure AC Wire Size and Overcurrent Protection The AC input and output wiring must be sized per the NEC and local electrical safety code requirements to ensure the wire s ability to safely handle the inverter s maximum load current After determining the proper AC wire sizes the inverter s AC input unless you are using a flexible cord and output wires are required to be protected against overcurrent and have a means to disconnect the AC circuits 18 2010 Magnum Energy Inc 2 0 Installation Overcurrent protection must be provided by fuses or circuit breakers and must be properly sized and rated for the wire they are protecting and the appliances being powered An external disconnect device is required for both the AC input and AC output wiring Most inverter s that ar
10. extremely low e Automatic 4 stage battery charger with power factor correction and temperature compensation for optimum battery charging using the temperature sensor e Modern and aesthetically pleasing design with large AC wiring compartment provides easy access to AC wiring for simple and quick connections and 360 DC connection terminals with color coded insulating covers e True RMS output voltage regulation to ensure the inverter will deliver the correct amount of power within the DC input volt age range and the continuous output power level e Quick connection accessory and remote ports easily accepts several optional remote controls and the Battery Temperature Sensor Figure 2 Top Side Features 2010 Magnum Energy Inc 3 1 0 Introduction 1 Inverter Status Indicator this green LED illuminates to provide information on the inverter s operation 2 Power Switch momentary pushbutton switch that turns the inverter on or off 3 Negative DC Terminal black the inverter s connection to the negative terminal on the battery bank 4 Positive DC Terminal red the inverter s connection to the positive terminal on the battery bank 5 Input Circuit Breaker this circuit breaker protects the unit s internal wiring and pass thru relay 6 Output Circuit Breaker this circuit breaker provides another layer of overload protection This is not a branch circuit rated breaker Separate AC output break
11. internal battery charger when operating in the Standby Mode The Standby Mode begins whenever AC power utility or generator is connected to the inverter s AC input Once the AC voltage and frequency of the incoming AC power is within the AC input limits an automatic AC transfer relay is activated This transfer relay passes the incoming AC power through the inverter to power the AC loads on the inverter s output This incoming power is also used to activate a powerful in ternal battery charger to keep the battery bank charged in case of a power failure Battery charging The MM AE Series models are equipped with an active Power Factor Corrected PFC multi stage battery charger The PFC feature is used to control the amount of power used to charge the batteries in order to obtain a power factor as close as possible to 1 or unity This causes the battery charger to look like a resistor to the line forces the charge current waveshape to mirror the voltage waveshape This feature maximizes the real power available from the AC power source utility or generator which translates into less power wasted and a greater charging capability than most chargers available today When an AC source utility power or generator is connected to an inverter that has a battery charger the inverter monitors the AC input for acceptable voltage Once the inverter has accepted the AC input the AC transfer relay will close and charging will begin Once chargi
12. inverter to provide full output power and avoid over temperature fault conditions do not cover or block the inverter s ventilation openings or install this inverter in an area with limited airflow Allow as much clearance around the inverter s intake and exhaust ventilation openings as possible see Items 12 and 13 in Figure 3 At the minimum allow an airspace clearance of 6 15 cm at the front and back and 3 7 5 cm everywhere else to provide adequate ventilation If installed in an enclosure a fresh air intake opening must be pro vided directly to the front side intake vent and an exhaust open ing on the back side exhaust vent of the inverter This will allow cool air from the outside to flow into the inverter and heated air to exit away from the inverter and the enclosure When mounted in an enclosed compartment airflow must be at least 59 cfm in order to maintain no more than a 68 F 20 C rise in compartment tem perature Minimum clearances can be reduced if airflow is increased but in no case should clearance around the inverter be less than 2 5 cm on all sides 8 2010 Magnum Energy Inc 2 0 Installation Safe Keep any flammable combustible material e g paper cloth plastic etc that may be ignited by heat sparks or flames at a minimum distance of 2 feet 60 cm away from the inverter Do not install this inverter in any area that contains extremely flammable liquids like gasoline or propane or in loc
13. low AC output power an AC voltmeter While charging the DC charge voltage is higher or lower than expected below the Low Battery Cut Out LBCO set point for more than one minute 10 0VDC LBCO default setting he battery voltage is above 15 5 VDC The inverter automatically resets and resumes operation when the battery voltage drops below 15 5 VDC he internal temperature of the inverter has risen above acceptable limits caused by loads too great for the inverter to operate continuously or by lack of ventilation to the inverter When the unit has cooled it will automatically reset and resume operation he inverter has turned off because the connected loads are larger than the inverters output capacity or the output wires are shorted his fault occurs when an internal fault is detected Inverter is switched OFF or there is no DC voltage battery connected to inverter he incoming AC voltage will not be accepted if it is below the VAC Dropout setting 80VAC VAC Dropout default setting he battery voltage level has dropped Battery voltage is too low Check fuses circuit breakers and cable connections Check battery voltage at the inverter s terminals Your batteries may need to be charged this fault condition will automatically clear when the battery voltage exceeds 12 5VDC his condition usually occurs only when an additional charging source alternator solar panels or other exte
14. not short circuit the batteries In the event of accidental exposure to battery acid wash thoroughly with soap and water In the event of exposure to the eyes flood them for at least 15 minutes with running water and seek immediate medical attention Recycle old batteries SAVE ALL INSTRUCTI ONS iii 2010 Magnum Energy Inc Table of Contents LO anionin ennaa kE CEN GC CQ XR E E ROC ER C DR 1 MM AE Series lee TEEN 1 How an Inverter Charger Works ENNEN nnne nnn 2 Appliances that will run from a Modified Sine Inverter 2 Appliances and Run Time ENEE ENN ENNEN ENN AA 2 Standard Features and 3 Battery Temperature arn ENK NEEN 3 230 1 stall atroci GRO WIERIFRROEOR EOE ACCOCN PRO ICD NC A C NOR EE OC 6 Big EU el Let WEEN 6 Unpacking and JNSDSCUON E ER aa Wa 6 Locating and Mounting the Inverter seen mmn 8 Wiring eee eMe TETTE 10 VIG RETI T TIU 11 DC Wire Sizing and Overcurrent Protection 11 DC Overcurrent ge e RE 13 OUI elln Te VE 13 DC Cable 5 14 Battery Bank Wiring EE 15 Inverter to Battery Bank Wiring ENEE ENNEN ANA 15 DC Ground Wire E 16 DC Negative E EN 16 Battery Temperature SenSoOr sesssenssersrusoennnonnnsennnsnnnennne 16 DE POSIUVS EE 16 AC NINO NE
15. turn determines the VAC D dropout threshold I nfo When switching from Inverter Mode to Standby Mode the inverter waits approximately 15 seconds to ensure the AC source is stable before transferring 26 2010 Magnum Energy Inc 3 0 Operation Battery Temperature Sensor Operation The plug in Battery Tem perature Sensor BTS is used to determine the battery temperature around the batteries This information allows the multi stage battery charger to automatically adjust the battery charge voltages for opti mum charging performance and longer battery life When the BTS is installed if the temperature around the BTS is below 77 F 25 C the absorb and float charge voltage increases If the temperature around the BTS is higher than 77 F 25 C the absorb and float charge voltage decreases See Figure 13 to determine how much the charge voltage changes increases or decreases as the temperature reading of the BTS changes For example the nominal absorb charge voltage for a flooded battery at 77 F 25 C on a 24 volt model is 29 2 VDC If the battery temperature is 95 F 35 C the absorb charge voltage would decrease to 28 6 VDC 29 2 VDC 0 6 change If the temperature sensor is NOT installed the charge voltages will not be compensated and the battery will maintain the charge it had at a temperature of 77 F 25 C The life of the batteries may be reduced if they are subjected to large temperature changes when the
16. BTS is not installed uses a value of 5mV C Cell from 0 50 to change the D Info When the BTS is connected the battery charger charge voltage based on temperature Temperature Compensation using BTS 12 VDC units 24VDC units 0 75V 1 5V LL 4045V NA oo 0 3V 0 6V 0 15V 0 3V No Change 0 15V 0 3V 0 45V 0 6V 0 75V 0C 5C 10 15C 20C 25C 30C 35C 40C 45C 50C 32F 41F 50F 59F 68 77F 86F 95 104F 113F 122F C O gt C C C gt _ lt Q O _ C cc C O Temperature reading from BTS Figure 13 BTS Temperature to Charge Voltage Change 2010 Magnum Energy Inc 27 3 0 Operation Protection Circuitry Operation The inverter is protected against fault conditions and in normal usage it will be rare to see any However if a condition occurs that is outside the inverter s normal operating parameters then it will shut down and attempt to protect itself the battery bank and your AC loads If there is a condition that causes the inverter to shut down it may be one of the conditions listed below Refer also to the Troubleshooting section to diagnose and clear the fault e Low Battery The inverter will shut off whenever the battery voltage falls to the Low Battery Cut Out LBCO level to protect the batteries from being over discharged After the inverter has reached the LBCO level and turned off the inverter will automatic
17. Bulk Charging This is the initial stage of charging While bulk charging the charger supplies the battery with constant current The charger remains in bulk charge until the absorption charge voltage is achieved 14 6 VDC 12 volt models or 29 2 VDC 24 volt models as determined by the Battery Type selection e Absorb Charging This is the second charging stage and begins after the bulk voltage has been reached Absorb charging pro vides the batteries with a constant voltage and reduces the DC charging current in order to maintain the absorb voltage setting The absorb charging time is 120 minutes as determined by the Battery AmpHrs selection e Float Charging The third charging stage occurs at the end of the absorb charging time While float charging also known as a main tenance charge the batteries are kept fully charged and ready if needed by the inverter The Float Charging stage reduces battery gassing minimizes watering requirements for flooded batteries and ensures the batteries are maintained at optimum capacity In this stage the charge voltage is reduced to the float charge voltage 13 4 VDC 12 volt models or 26 8 VDC 24 volt models as determined by the Battery Type selection which can maintain the batteries indefinitely e Full Charge Battery Saver mode The fourth stage occurs after four hours of float charging The Full Charge stage maintains the batteries without overcharging preventing excessi
18. I NGS AN e Do not mount the inverter near any flammable or combustible fluid or components e Provide adequate clearance ventilation to the inverter e Mount only on a non combustible surface e Maximum ambient temperature around the inverter must not exceed 77 F 25 C to meet power specifications The inverter should only be installed in a location that meets the following requirements Clean and Dry The inverter should not be installed in an area that allows dust fumes insects or rodents to enter or block the inverter s ventilation openings The area also must be free from any risk of condensation water or any other liquid that can enter or fall on the inverter The inverter uses stainless steel fasteners plated copper busbars and a power coated aluminum base Also the internal circuit boards are conformal coated The above measures are undertaken to help fight the harmful effects of corrosive environments However the life of the inverter is uncertain if used in any of these types of environments and inverter failure under these conditions is not covered under warranty Cool The inverter should be protected from direct exposure to the sun or any equipment that produces extreme heat The ambient air temperature should be between 32 F 0 C and 104 F 40 C keep in mind that the inverter s output specifications are rated at 77 F 25 C so the cooler the better within this range Ventilated In order for the
19. RO ENEE reed 17 Neutral to Safety Ground Bonding 17 AC Wiring Gel Du e gl e n LE 19 AC Wire Size and Overcurrent 18 AC APUCA AGING EE 19 ne Ou DUE VP e E 20 Ground Fault Circuit Interruption Breakers 21 Slletegleit RE 21 SG Reie d Le UE 23 Operating 23 Inverter 23 IER ele AC e gt E 24 Protection Circuitry Operation esee enr ENER ENN NENNEN 28 Inverter HEEN 29 ONOFF OWUC EE EE 29 Status LED 29 Factory 5 0 99 30 4 0 Maintenance and Troubleshooting 32 Recommended Inverter and Battery 32 Resetting the ThWePtel E TO URP FEEDS 32 2010 Magnum Energy Inc IV Table of Contents 5 0 SpecificationS soasexitVrkX iin teeter anes UR EUER AUR ROV VOR EN 34 Appendix A Optional Equipment and Accessories 35 Appendix B Battery I nformation 36 Battery Bank SIZING sese eR OU ERI RIDE PI ER CVM RE 36 battery de E 36 Battery Configuration WEE 36 Series N eea EE EA EEE REE EE 36 Parallel Wiring EEN ENEE ENNEN 34 Series Parallel WIM kt s akt ve ci a Ob dca Ee EE a o ea 37 Appendix C Warranty Service I nfo
20. TEE Va TUE VES EVE E E Y Series Inverter Chargers Owner s Manual Disclaimer of Liability The use of this manual and the conditions or methods of installation operation use and maintenance of the MM AE Series Inverter Charger are beyond the control of Magnum Energy Inc Therefore this company assumes no responsibility and expressly disclaims any liability for loss damage or expense whether direct indirect consequential or incidental that may arise out of or be in any way connected with such installation operation use or maintenance Due to continuous improvements and product updates the images shown in this manual may not exactly match the unit purchased Restrictions on Use The MM AE Series Inverter Charger may only be used in life support devices or systems with the express written approval of Magnum Energy Failure of the MM AE Series Inverter Charger can reasonably be expected to cause the failure of that life support device or system or to affect the safety or effectiveness of that device or system If the MM AE Series Inverter Charger fails it is reasonable to assume that the health of the user or other persons may be endangered Contact nformation Magnum Energy Inc 2211 West Casino Rd Everett WA 98204 Phone 425 353 8833 Fax 425 353 8390 Web www magnumenergy com Record the unit s model and serial number in case you need to provide this inform
21. ally restart after one of the following conditions 1 AC power is applied and the inverter begins operating as a battery charger 2 Battery voltage rises to the Low Battery Cut In LBCI level The inverter s status LED turns off when a low battery fault con dition occurs Refer to Table 5 to determine the LBCO and LBCI levels for your particular inverter model e High Battery In the event the battery voltage approaches the High Battery Cut Out HBCO level the inverter will automatically shut down to prevent the inverter from supplying unregulated AC output voltage The inverter s status LED turns off when a high battery fault condition occurs The inverter will automatically restart when the battery falls to the High Battery Cut In HBCI level Refer to Table 5 to determine the HBCO and HBCI levels for your particular inverter model uses a value of 5mV C Cell from 0 50 to change the D Info When the BTS is connected the battery charger charge voltage based on temperature e Overload During Inverter and Standby operation modes the inverter monitors the DC and AC current levels In the event of a short circuit or an overload condition for more than a few seconds the inverter will shut down To start operating after this fault the inverter would need to be restarted turned back on after the inverter s AC loads are reduced removed e Over temperature If internal power components begin to exceed their safe ope
22. ation in the future It is much easier to record this information now instead of trying to gather it after the unit has been installed Conventions Used in this Manual Terminology AC source or External AC power refers to Alternating Current AC provided by the utility electric power grid or from a generator AE application typically refers to using the inverter in a system that uses Alternative Energy e g solar wind or hydro This term is also used to refer to inverters used in a home office or cabin installation 2010 Magnum Energy Inc Safety symbols To reduce the risk of electrical shock fire or other safety hazard the following safety symbols have been placed throughout this manual to indicate dangerous and important safety instructions WARNI NG This symbol indicates that failure to take a specified action could result in physical harm to the user CAUTI ON This symbol indicates that failure to take a specified action could result in damage to the equipment I nfo This symbol indicates information that emphasizes or supplements important points of the main text I MPORTANT PRODUCT SAFETY INSTRUCTI ONS This manual contains important safety instructions that must be fol lowed during the installation and operation of this product Read all instructions and safety information contained in this manual before installing or using this product All electrical work must be performed in accordance wit
23. ations that require ignition protected devices Close to the battery bank As with any inverter it should be located as close to the batteries as possible Long DC wires tend to lose efficiency and reduce the overall performance of an inverter However the unit should not be installed in the same compartment as the batteries or mounted where it will be exposed to gases produced by the batteries These gases are corrosive and will damage the inverter Also if these gases are not ventilated and allowed to collect they could ignite and cause an explosion Accessible Do not block access to the inverter s remote control and accessory ports Also allow enough room to access the AC and DC wiring connections as they will need to be checked and tightened periodically See Figure 8 for the MM AE Series inverter dimensions Mounting Orientation To meet regulatory requirements the MM AE Series inverter charger can only be mounted on a horizontal surface shelf or table or a vertical surface wall or bulkhead either right side up or upside down as shown in Figure 7 The inverter must be mounted on a non combustible surface and this surface and the mounting hardware must be capable of supporting at least twice the weight of the inverter After determining your mounting position use the base of the inverter s chassis as a template to mark your mounting screw locations Remove the inverter and drill pilot holes into the mounting surface Aft
24. batteries and are not recommended for inverter applications All electrical appliances are rated by the amount of power they con sume The rating is printed on the product s nameplate label usu ally located on its chassis near the AC power cord Even though it is difficult to calculate exactly how long an inverter will run a particular appliance the best advice is trial and error Your MM AE Series in verter charger has a built in safeguard that automatically protects your batteries from being over discharged 2 2010 Magnum Energy Inc 1 0 Introduction Standard Features and Benefits The MM AE Series inverter charger converts 12 or 24 volts de pending on model direct current VDC power from your battery to 120 volts alternating current VAC power The multi stage battery charger optimizes incoming AC power using Power Factor Correction PFC technology to keep the inverter s battery bank fully charged This inverter is designed to allow easy installation and use and with its die cast aluminum baseplate it ensures maximum durability and cooler more efficient operation The inverter charger provides the following e 600 or 1500 watts continuous depending on model at 25 C e Numerous protection features to provide a safe and peace of mind operation e AC transfer switch circuitry allowing incoming AC power to continue to pass thru to power loads even if the inverter is off e Dead battery charging for batteries that are
25. bly causing the connections to melt Follow Figures 9 and 10 to stack the hardware correctly Tighten the terminal connections from 10 to 12 foot pounds CAUTI ON Do not put anything between the DC cable ring AN lug and the battery terminal post or inverter s DC terminal If antioxidant grease or spray is used apply it after all the connections have been made and are properly tightened CAUTI ON Overtightening or misthreading nuts on the DC terminals will cause the bolts to strip and snap break off Temperature sensor gt DC cable nut 4 with ring lug a OCK washer O eier terminal H flat washer Verify that the DC cable lugs are flush with the battery terminals Torque the battery terminals from 10 to 12 foot pounds BATTERY battery POI post Figure 9 DC Cable to Battery Terminals negative and positive connected backwards You must verify the correct voltage polarity BEFORE connecting the DC wires or damage may occur 0 CAUTI ON The inverter is NOT reverse polarity protected Crimped and sealed copper ring terminal lugs with a 5 16 hole should be used to connect the DC wires to the inverter s DC terminals DC cable with ring lug DC terminal cover snaps Inverter s DC terminal Figure 10 DC Cable to I nverter s DC Terminals 14 2010 Magnum Energy Inc 2 0 Installation Battery Bank Wiring N D WARNI NG Lethal cu
26. cally after the battery voltage has been below this setting for more than one minute This protects the batteries from over discharge and the AC loads from unregulated power brown outs Visit www magnumenergy com for more information 30 2010 Magnum Energy Inc 3 0 Operation 03 Battery AmpHrs This setting allows you to input the battery bank size in amp hours This provides information to the charger on how long to charge the batteries in the Absorb Charging stage 04 Battery Type This setting identifies the type of batteries being used in the system This provides information to the charger to determine what voltage level to use to charge the batteries 05 Charge Rate This setting can be used to turn off the charger limit the amount of current that the charger can use leaving more current available to power loads or to ensure small battery banks are not overheated because of a charge rate that is too high 06 VAC Dropout Sets the minimum AC voltage that must be pres ent on the AC input before the unit transfers from Standby Mode to Inverter Mode This protects the AC loads from utility outages and brown outs The ME RC50 remote also provides the following features e allows you to enable an equalize charge for certain battery types e displays the inverter charger s operating status e provides fault information for troubleshooting Table 6 I nverter Default Settings LowBatCutOut 10 0 VDC MM1524AE 20 0 VDC
27. cated on the battery Battery Configuration The battery bank must be wired to match the inverter s DC input volt age specifications In addition the batteries can be wired to provide additional run time The various wiring configurations are Series Wiring Wiring batteries in a series increases the total battery bank output voltage A series connection combines each battery in a string until the voltage matches the inverter s DC requirement Even though there are multiple batteries the capacity remains the same In the example below Figure 14 two 6 VDC 200 AHr batteries are combined into a single string resulting in a 12 VDC 200 AHr bank overcurrent protection Ee E To 6 volts 12 VDC 200 AHrs 200 AHrs Inverter 12 volt battery bank total capacity 200 AHrs Figure 14 Series Battery Wiring 36 2010 Magnum Energy Inc Appendix B Battery Information Parallel Wiring Wiring the batteries in parallel increases the total run time the bat teries can operate the AC loads A parallel connection combines overall battery capacity by the number of batteries in the string Even though there are multiple batteries the voltage remains the same In the example below Figure 15 four 12 VDC 100 AHr batteries are combined into a single 12 VDC 400 AHr battery bank 12 volts overcurrent 100 AHrs protection 12 volts 100 AHrs TO 12 VDC I rt 12 volts bod 100 AHrs
28. d lightly press and release the inverter s ON OFF power switch located on the top of the inverter to turn the inverter on Verify the inverter s status indicator is blinking indicating the in verter is providing AC power 5 Check the output voltage of the inverter by connecting a true RMS multimeter to the outlets powered by the inverter Verify the voltage is 120 VAC 5 VAC If not using a true RMS meter the output AC voltage could indicate from 90 to 130 VAC depending on the battery voltage 6 Turn on or connect a load to the outlets and verify it comes on Continue to keep the load connected and turned on 7 Press the remote ON OFF switch to turn the inverter off If the remote is not used press and release the inverter s ON OFF power switch to turn the inverter off The inverter s status indicator and the connected load should go off 8 Apply AC power to the inverter s AC input After the AC input power is qualified approximately 15 seconds the incoming AC power will transfer through the inverter to the inverter s AC output and power the connected load Verify the inverter s status indicator and the connected load comes on 9 Even though the connected load is on the inverter is currently disabled off Press the remote s ON OFF switch or press and re lease the ON OFF power switch on the inverter to enable turn on the inverter 10 Disconnect the incoming AC power to the inverter Verify the con
29. dercharging Basic Remote Control The ME RC50 Remote Control Panel is simple to use an LCD screen and at a glance LEDs display complete inverter charger status Soft keys provide simple access to menus and a rotary encoder knob al lows you to scroll through and select a wide range of settings Auto Generator Start Controller The ME AGS N Automatic Generator Start controller Network ver sion is designed to automatically start your generator based on low battery condition or high temperature The AGS controller includes an input voltage jumper for 12 24 and 48 volt battery banks and a 4 position DIP Dual In line Package switch which provides the ability to change the relay timing configurations to allow compatibility with a wider range of generators Battery Monitor Kit The ME BMK Battery Monitor Kit is a single battery bank amp hour meter that monitors the condition of the battery and provides infor mation to let you know how much energy you have available and let you plan your electrical usage to ensure the battery is not being over discharged The ME BMK NS version does not include a DC shunt order the ME BMK to receive a 500A 50mv DC shunt Fuse Block Fuses The Magnum Fuse Fuse blocks are used to protect the battery bank inverter and cables from damage caused by DC short circuits and overloads They include a slow blow fuse with mounting block and protective cover The 125 and 200 amp models use an ANL type fuse and
30. e hardwired use a service distribution panel wired to the inverter s input main panel and a dedicated panel between the inverter s output wiring and the AC loads sub panel These systems use the circuit breakers provided in the panels as the overcurrent protection and the AC disconnect If fuses are used then separate AC disconnect switches will be needed Based on information from the NEC Table 4 provides the minimum AC wire size and the suggested breaker size based on the inverter model However larger wire size may be required because of volt age drop The AC wire sizes provided in this table assume using only copper wire and a temperature rating of 759 C or higher A minimum of 14 AWG is required for all AC wiring Table 4 Minimum Wire Size to Circuit breaker Size AC Input AC Output Inverter Suggested Suggested Model Input Breaker Output Breaker Breaker Breaker Size Size 12 7 amps 14 AWG 10 amps 8 amps Fis AWG 10 amps 1512 20 amps 12 20 amps 12 amps 14 awe 15 amps 1524 20 amps 12 20 amps 12 amps 14 AWG AC Input Wiring Your inverter has an AC transfer feature that passes the AC input power to the inverter s output Connection to the AC input is made by hardwiring from a distribution panel as described below 1 Run an appropriately sized 2 conductor plus ground cable from the AC distribution panel through a strain relief on the AC IN openin
31. e I nformation 24 Month Limited Warranty Magnum Energy Inc warrants this MM AE Series Inverter Charger to be free from defects in material and workmanship that result in product failure during normal usage according to the following terms and conditions 1 The limited warranty for the product extends for 24 months beginning from the product s original date of purchase 2 The limited warranty extends to the original purchaser of the product and is not assignable or transferable to any subsequent purchaser 3 During the limited warranty period Magnum Energy will repair or replace with factory new or rebuilt replacement items at Magnum Energy s option any defective parts or any parts that will not properly operate for their intended use if such repair or replacement is needed because of product malfunction or failure during normal usage The limited warranty does not cover defects in appearance cosmetic or decorative or any structural or non operative parts Magnum Energy s limit of liability under the limited warranty shall be the actual cash value of the product at the time the original purchaser returns the product for repair determined by the price paid by the original purchaser Magnum Energy shall not be liable for any other losses or damages 4 Upon request from Magnum Energy the original purchaser must prove the product s original date of purchase by a dated bill of sale itemized receipt 5 The original purchaser s
32. ed lt 13 Table 3 Wire Color to AC Wire Connection 18 Table 4 Minimum Wire Size to Circuit breaker Size 19 Table 5 Inverter Battery Turn On Off Levels eese 29 Table 6 Inverter Charger Default Settings 31 Table 7 Troubleshooting Guide enn mmn nmn nnn 33 Table 8 MM AE Series Specifications 34 V 2010 Magnum Energy Inc 1 0 Introduction 1 0 I ntroduction Congratulations on your purchase of an MM AE Series inverter char ger from Magnum Energy Inc This product is designed especially for your back up power or standalone application Powerful yet simple to use the Magnum Energy inverter will provide you with years of trouble free use Please read this chapter to familiarize yourself with the features and benefits of your particular MM AE Series model Figure 1 MM AE Series I nverter Charger MM AE Series Models MM612AE a 600 watt inverter charger with 7 amp AC transfer capability and 30 amp 12 VDC 4 stage PFC charger The AC input and output are provided with pigtail wires to allow hardwiring to a main AC distribution panel and to an inverter sub panel Includes a 15 battery temperature sensor MM1512AE 1500 watt inverter charger with 12 amp AC transfer capability and 70 amp 12 VDC 4 stage PFC charger The AC in
33. en neutral and ground and cause ground loop currents These ground loops can trip GFCIs and cause an electric shock hazard In AE installations the neutrals are connected together and are always connected to Safety ground at the main AC panel never at the inverter Series inverter charger Non AE versions are designed I nfo For AE application you must use an MM AE for use in mobile applications 2010 Magnum Energy Inc 17 2 0 Installation AC Wiring Connections For all hardwired inverter models the AC input and output wiring is performed in the AC wiring compartment This compartment is located on the top panel see Figure 2 Item 8 If installed remove the two Phillips screws on the cover to access the AC wiring compartment and locate the inverter s AC wiring There is a label located in the AC access compartment which gives information on which wires are used for the AC input and output You can also refer to Table 3 to match the inverter s AC wires to the appropriate AC wire connection Table 3 Wire Color to AC Wire Connection Wire color label Wire connection Black HOT IN AC IN White NEUT IN Neutral In Red HOT OUT Hot Out AC OUT White with black stripe NEUT OUT Neutral Out AC Ground Green GROUND AC IN amp AC OUT Ground The AC wires inside the AC compartment are 16 AWG with a tem perature rating of 105 C All AC connections should be made using an approved connector for your
34. er by Searching or Inverting depending on the connected AC loads e Searching When the inverter is first turned ON the automatic Search feature is enabled This feature is provided to conserve battery power when AC power is not required In this mode the inverter pulses the AC output looking for an AC load i e electrical appliance Whenever an AC load greater than 5 watts is turned on the inverter recognizes the need for power and automatically starts inverting When there is no load or less than 5 watts de tected the inverter automatically goes back into search mode to minimize energy consumption from the battery bank When the inverter is Searching the inverter s green LED flashes fast 4 is 5 watts it can be turned off or adjusted from 5 to 50 D I nfo The factory default value for the Search feature watts using the ME RC50 remote display e nverting When a load greater than 5 watts is connected to the inverter output the MS Series inverts the DC power from the bat tery and supplies 120 VAC power to your sub panel The inverter s green LED flashes once every 2 seconds medium flash to indicate it is inverting The amount of time the inverter can be inverting and providing power is directly related to the amount of AC loads that are connected and the capacity of the battery bank 2010 Magnum Energy Inc 23 3 0 Operation Standby Mode The MM AE Series features an automatic transfer relay and an
35. er the inverter has been properly mounted proceed to the DC Wiring section Shelf Mounted right side up Shelf Mounted Wall Mounted up side down up side down Figure 7 Approved Mounting Orientations 2010 Magnum Energy Inc 9 2 0 Installation Mounting holes x 4 4 0 25 diameter J mH 5 A 9 amp LI TC SM CS C7040 CO IZ UE 10 0 LU U 6 6 71 7 1 7 51 8 8 41 Figure 8 MM AE Series I nverter Charger Dimensions Wiring Guidelines Before connecting any wires determine all wire routes to and from the inverter throughout the home or cabin Conductors passing through walls or other structural members must be protected to minimize insulation damage such as chafing which can be caused by vibration or constant rubbing Always check for existing electrical plumbing or other areas of potential damage prior to making cuts in structural surfaces or walls Make sure all wires have a smooth bend radius and do not be come kinked Both AC and DC overcurrent protection must be provided as part of the installation 10 2010 Magnum Energy Inc 2 0 Installation e DC wires and cables should be tied together with wire ties or electrical tape approximately every 6 inches This helps improve the surge capability and reduces the effects of inductance which improves the inverter waveform and reduces wear on the inverter s filter capacitors e Use o
36. ers are required on the output 7 Mounting Flanges x4 secures the inverter to shelf wall 8 AC Wiring Compartment provides access for all AC input and output connections on the inverter Front Side Back Side SE Mode MMISMAE PR Seni E ODDO Figure 3 Front and Back Side Features 9 Warning Information Label provides pertinent information for safely using the inverter 10 REMOTE Port Connection a RJ11 connector that allows an optional remote control to be connected 11 ACCESSORY PORT Connection a RJ11 connector to allow the Battery Temperature Sensor BTS or MM AE accessories e g MM DCLD to be connected 12 Intake Vent ventilation openings to pull in air to help keep the inverter cool for peak performance 13 Exhaust Vent ventilation openings that allow heated air to be removed by the internal cooling fan 14 Model Serial Number Label includes model serial number and provides specifications and information on the inverter and charger See the MM AE Series Specifications on page 34 for more information and the different models available 4 2010 Magnum Energy Inc 1 0 Introduction Figure 4 Left Side Features 15 AC Output Connection AC knockout output for hardwiring 16 AC Input Connection AC knockout input for hardwiring 17 DC Ground Terminal this connection is used to tie the exposed chassis of the inverter to the DC grounding s
37. g Refer to Table 4 for minimum wire size and overcurrent protection required for the AC input wiring 2 Remove about two inches of the insulating jacket from the AC cable and then separate the three wires and strip about 3 4 of insulation from each wire 3 Using approved AC wire connectors connect the incoming Hot In Neutral In and Ground wires to the MM AE Series AC wires colored black HOT IN white NEU IN and green AC GROUND respectively 4 After making the AC input connections secure the AC input cable by tightening the strain relief The AC input wiring in the inverter is complete Review all AC wiring to ensure all connections are correct and secure 2010 Magnum Energy Inc 19 2 0 Installation Neutral Out Neutral white w black In white stripe AC IN AC OUT Figure 11 AC Wiring Connections AC Output Wiring nected to an AC power source This will cause severe damage to the inverter and is not covered under war ranty 0 CAUTI ON The inverter s AC output must never be con When hardwiring the output of the inverter a cable must be routed from the inverter s output to an AC distribution panel sub panel that provides overcurrent protection to the loads powered by the in verter Connect the AC output to this distribution panel as described below 1 Remove the 1 2 knockout on the AC Output Connection see Figure 4 Item 15 use a utility knife to cut thru the round Slot 2 D
38. h local state and federal electrical codes This product is designed for indoor compartment installation DO NOT expose to rain snow moisture or liquids of any type Use insulated tools to reduce the chance of electrical shock or accidental short circuits Remove all jewelry such as rings watches bracelets etc when installing or performing maintenance on the inverter Always disconnect the batteries or energy source prior to installing or performing maintenance on the inverter Live power may be present at more than one point since an inverter utilizes both batteries and AC Turning off the inverter may not reduce this risk As long as AC power is connected it will pass through the inverter regardless of the ON OFF power switch setting Always verify proper wiring prior to starting the inverter Do not operate the inverter if it has been damaged Do not dismantle the inverter there are no user serviceable parts contained in this product Attempting to service the unit yourself could cause electrical shock Internal capacitors remain charged after all power is disconnected No AC or DC disconnects are provided as an integral part of this inverter Both AC and DC disconnects must be provided as part of the system installation 2010 Magnum Energy Inc ii e No overcurrent protection for the battery supply is provided as an integral part of this inverter Overcurrent protection of the battery cables must be provided as pa
39. hall return the product prepaid to Magnum Energy in Everett WA After the completion of service under this limited warranty Magnum Energy will return the product prepaid to the original purchaser via a Magnum selected non expedited surface freight within the contiguous United States and Canada this excludes Alaska and Hawaii 6 If Magnum repairs or replaces a product its warranty continues for the remaining portion of the original warranty period or 90 days from the date of the return shipment to the original purchaser whichever is greater All replaced products and parts removed from repaired products become the property of Magnum Energy 7 This limited warranty is voided if e the product has been modified without authorization e the serial number has been altered or removed e the product has been damaged through abuse neglect accident high voltage or corrosion e the product was not installed and operated according to the owner s manual BEFORE RETURNI NG ANY UNIT CONTACT MAGNUM ENERGY FOR A RETURN MATERI AL AUTHORI ZATI ON RMA NUMBER 40 2010 Magnum Energy Inc Appendix C Warranty Service Information How to Receive Repair Service If your product requires warranty service or repair contact either 1 An Authorized Service Center as listed on the Magnum Energy website at www magnumenergy com servicecenters htm or 2 Magnum Energy Inc at Telephone 425 353 8833 Fax 425 353 8390 Email warranty magnumenerg
40. iscard this knockout and install a 1 2 strain relief in the AC OUT opening You may need to file the opening edge for proper fit 3 Run a 2 conductor plus ground cable through the strain relief in the AC OUT opening Refer to Table 4 for the minimum wire size and the overcurrent protection required for the AC output wiring 20 2010 Magnum Energy Inc 2 0 Installation 4 Remove about two inches of the insulating jacket from the AC cable and then separate the three wires and strip about 3 4 of insulation from each wire 5 Using approved AC wire connectors connect the outgoing Hot Out Neutral Out and AC Ground wires to the MM AE Series AC wires colored red HOT OUT white with black stripe NEU OUT and green AC GROUND respectively Gently pull on the wires to ensure they are securely held together and check to see that no bare wire is exposed 6 After making the AC output connections secure the AC output cable by tightening the strain relief 7 Connect the outgoing AC wires to an AC load panel equipped with overcurrent protection e g circuit breakers The AC output wiring in the inverter should be complete Before reattaching the AC access cover review all AC wiring to ensure all connections are correct and secure Ground Fault Circuit Interruption GFCI Breakers Some electrical safety codes require GFCT s to be installed in AE applications home cabin office In compliance with UL standards Magnum E
41. istances Always keep your wire runs as short as practical to help prevent low volt age shutdowns and keep the DC breaker from nuisance tripping or open fuses because of increased current draw Undersized cables can also lower the inverter s peak output voltage as well as reduce its ability to surge heavy loads tape or heat shrink tubing RED for positive BLACK D Info The DC wires must be color coded with colored for negative and GREEN for DC ground 2010 Magnum Energy Inc 11 2 0 Installation The DC wires must have soldered and crimped lugs crimped copper compression lugs or aluminum mechanical lugs Soldered connec tions alone are not acceptable for this application Table 1 Recommended DC Wire Overcurrent Device AN 61 1 Rn A A MM612AE A MMi524 AE 6 AWG 6 AWG 6 AWG C Wire Size 2 AWG 1 0 AWG 1 0 AWG C ratin e air 190 amps 260 amps 260 amps iximum DC 200 amps with 300 amps with 300 amps with time delay time delay time delay Info The term in free air is defined by the NEC as not encased in conduit or raceway If the inverter is expected to operate at a distance greater than three feet from the battery bank the DC wire size will need to be increased to overcome the increase in resistance which affects the performance of the inverter Continue to use the overcurrent device and DC ground wire previously determined from Table 1 and then
42. le con tinuing to pass the incoming AC power directly to the inverter s output to power any AC loads Appliances that will run from a Modified Sine Inverter Today s inverters come in two basic output waveforms modified sine actually a modified square wave and pure sine wave Modified sine wave inverters approximate a pure sine waveform The output of a modified sine wave inverter will run most electronic and household items including but not limited to TV VCR satellite dish receiver computers and printers Some devices such as rechargeable power supplies for phones drills and other like devices may not run or be damaged by modified sine wave inverters Appliances and Run Time The MM AE Series inverter charger can power a wide range of house hold appliances As with any appliance using batteries for power there is a certain length of time that it can run this is called run time Actual run time depends on several variables including the size and the type of appliance the type of batteries installed in your applica tion as well as the battery s capacity and age Other factors such as the battery s state of charge and temperature can also affect the length of time your appliances can run Depending on your inverter capacity larger electrical appliances such as coffee pots and hair dryers can be used for short durations How ever loads that are used for longer periods such as stoves or water heaters can quickly drain your
43. m diagram shown in Figure 6 should be reviewed to assist you in planning and designing your installation Unpacking and Inspection Carefully remove the MM AE Series inverter charger from its ship ping container and inspect all contents Verify the following items are included MM AE Series inverter charger Red and black DC terminal covers AC access cover with two screws Two 1 2 hex head kep nuts installed on the DC terminals Battery Temperature Sensor BTS MM AE Series Owner s Manual If items appear to be missing or damaged contact your authorized Magnum Energy dealer or Magnum Energy If at all possible keep your shipping box It will help protect your inverter from damage if it ever needs to be returned for service Save your proof of purchase as a record of your ownership it will also be needed if the unit should require in warranty service Record the unit s model and serial number in the front of this manual in case you need to provide this information in the future It is much easier to record this information now instead of trying to gather it after the unit has been installed 6 2010 Magnum Energy Inc 2 0 Installation MM AE Series Inverter Ed a rm nr a ui DC disconnect and overcurrent device Main Panel AC Loads Figure 6 Basic Installation Diagram 2010 Magnum Energy Inc 7 2 0 Installation Locating and Mounting the I nverter WARN
44. nd Recommended tightening torque is 45 in Ibs DC Negative Wire Route an appropriately sized DC negative wire BLACK from the negative terminal of the first battery string to the inverter s negative terminal see Figure 16 for reference Battery Temperature Sensor Connect the RJ11 connector end of the BTS to the ACCESSORY PORT see Figure 3 Item 11 on the inverter Connect the other end of the BTS to the negative terminal of the first battery string in same place as the negative DC wire above refer to Figure 9 for the correct hardware placement DC Positive Wire Mount the DC fuse block and disconnect or circuit breaker assembly as near as practical to the batteries and then open the disconnect or circuit breaker WARNI NG DO NOT close the DC fuse DC disconnect or Ji close the DC circuit breaker to enable battery power to the inverter at this time This will occur in the Functional Test after the installation is complete Route and connect an appropriately sized DC positive wire RED from the DC fuse block or circuit breaker assembly to the inverter s posi tive DC terminal 16 2010 Magnum Energy Inc 2 0 Installation Connect a short wire same rating as the DC wires to one end of the fuse block and the other end of the short wire to the positive terminal of the last battery string see Figure 16 This is essential to ensure even charging and discharging across the entire battery bank Ensure the
45. nergy has tested the following GFCIs and find that they function properly when connected to the inverter s AC output Shock Sentry ZXGF15V SP Leviton Smart Lock 8899 A Hubbel ZGF520EMBKA WARNI NG Risk of electric shock Use only the GF Ji CIs receptacles or circuit breaker s specified in this manual Other types may fail to operate properly when connected to this inverter Functional Test After all electrical connections to the inverter batteries AC source and loads using a sub panel have been completed follow these steps to test the installation and the inverter s operation 1 Check the battery voltage and polarity before connecting the batteries to the inverter Use a multimeter to verify 10 to 14 VDC 12 volt models or 20 to 28 VDC 24 volt models at the batteries positive and negative terminals 2 Apply battery power to the inverter by switching the DC disconnect ON or close the DC circuit breaker The inverter will remain OFF but the green status indicator on the front of the inverter will quickly blink once to indicate that DC power has been connected and is ready to be turned on 2010 Magnum Energy Inc 21 2 0 Installation 3 Prior to turning on the inverter make sure all connected loads e g appliances are switched OFF or disconnected from the AC outlets 4 a If a remote switch is connected press the ON OFF switch to turn the inverter on b If there is not a remote switch connecte
46. ng the DC voltage is monitored to determine the charging stage If the DC voltage is low 12 9 VDC 12 volt models or x25 8 VDC 24 volt models the charger begins bulk charging If the DC voltage is high gt 12 9 VDC 12 volt models or gt 25 8 VDC 24 volt models the charger skips the initial Bulk Absorb Charging stages and goes directly to float charging The multi stage charger can use up to five different charging stages to help monitor and keep the batteries healthy The five stages include an automatic 4 stage charging process Bulk Absorb Float and Full Charge and a manual Equalization EQ charge stage The automatic 4 stage charge process provides complete recharging and monitoring of the batteries without damage due to overcharging see Figure 12 The Equalization stage requires the ME RC50 remote is used to stir up stratified electrolyte and reverse any battery plate sulfation that might have occurred While charging the unit may go into Charger Back off protection which automatically reduces the charge current to the batteries This is caused by 1 The internal temperature is too hot the charger automatically reduces the charge rate to maintain temperature or 24 2010 Magnum Energy Inc 3 0 Operation 2 The AC input voltage falls lt 85 VAC the charger reduces the charge current to zero to help stabilize the incoming AC voltage or 3 FET Temperature The automatic 4 stage charging process includes e
47. nly copper wires with a minimum temperature rating of Ta C e To ensure the maximum performance from the inverter all connections from the battery bank to the inverter should be minimized the exceptions are the DC overcurrent disconnect in the positive line and a shunt in the negative line Any other ad ditional connection will contribute to additional voltage drops and these extra connections points may loosen during use All wiring to the battery terminals should be checked periodically once a month for proper tightness The torque requirement for the DC terminals is between 10 to 12 foot pounds If you don t have a torque wrench ensure all DC terminals are tight and cannot move CAUTI ON Beawarethatovertightening and misthreading the nuts the DC terminals can cause the bolts to strip and snap break off DC Wiring This section describes the inverter s required DC wire sizes and the recommended disconnect overcurrent protection and how to make the DC connections to the inverter and the battery bank DC Wire Sizing and Overcurrent Protection It is important to use the correct DC wire to achieve maximum ef ficiency from the system and reduce fire hazards associated with overheating See Table 1 to select the minimum DC wire size needed based on your inverter model If the distance from the inverter to the battery bank is greater than 3 feet use Table 2 to help determine the minimum recommended cable sizes for longer d
48. put and output are provided with pigtail wires to allow hardwiring to a main AC distribution panel and to an inverter sub panel Includes a 15 battery temperature sensor MM1524AE a 1500 watt inverter charger with 12 amp AC transfer capability and 35 amp 24 VDC 4 stage PFC charger The AC input and output are provided with pigtail wires to allow hardwiring to a main AC distribution panel and to an inverter sub panel Includes a 15 battery temperature sensor for uses in AE applications i e homes cabins offices If your installation is for a mobile application RV truck or boat the appropriate model for these applications is the MM or MMS Series inverter D I nfo These units have common input output neutrals 2010 Magnum Energy Inc l 1 0 Introduction How an I nverter Charger Works An inverter takes direct current DC from your batteries and turns it into alternating current AC like you use at home With MM AE Series models it also takes alternating current when connected to a generator or to utility power and transforms it into direct current to recharge your batteries The two modes of operation associated with this inverter charger are referred to in this document as I nverter Mode DC from the batteries is transformed into modified sine wave AC for powering your AE applications Standby Mode The unit operates as a battery charger to convert incoming AC power into DC power to recharge the batteries whi
49. r to correctly read the output voltage his is normal 33 5 0 Specifications 5 0 Specifications Table 8 MM AE Series Specifications MODEL MM612AE MM1512AE MM1524AE Inverter Specifications Input battery voltage range 9 to 16 VDC 9 to 16 VDC 18 to 32 VDC Nominal AC output voltage 120 VAC 5 Output frequency and accuracy 60 Hz 0 1 Hz 1msec surge current amps AC 27 42 45 100msec surge current amps AC 11 23 24 5 sec surge power real watts 1100 2100 2650 10 sec surge power real watts 1050 1900 2575 30 sec surge power real watts 1000 15750 2500 5 min surge power real watts 950 1550 2350 30 min surge power real watts 675 1525 1900 Continuous power output at 25 C 600 VA 1500 VA 1500 VA Maximum input battery current 80 ADC 200 ADC 100 ADC Inverter efficiency peak 95 95 91 ransfer time 16 msecs AC transfer capability 7A 12A 12A Search mode typical 3 watts 6 watts 4 watts No load 120 VAC output typical 10 watts 18 watts 9 watts Waveform Modified Sine Wave Charger Specifications Continuous output at 25 C 30 ADC 70 ADC 35 ADC Charger efficiency 85 88 88 Power factor EX S Input current at rated output amps AC 4 9 9 Battery temperature compensation Yes 15 ft Battery Temp Sensor standard General Features and Capabilities Protection circuitry Low High Battery Over temp amp Overload Corrosion protection PCB s conformal coated powder coated chassis Output circuit breaker 7A s
50. rating temperature level the inverter will shut down to protect itself from damage The inverter s status LED turns OFF to indicate the over temperature fault condition The inverter will automatically restart after the units cools down 28 2010 Magnum Energy Inc 3 0 Operation e Internal Fault The inverter continually monitors several inter nal components and the processor communications If a condition occurs that doesn t allow proper internal operation the inverter will shut down to protect itself and the connected loads The inverter will need to be reset to start operating Table 5 I nverter Battery Turn On Off Levels I nverter Battery I nverter Model Turn On Off Levels MM612AE MMI512AE 1524 HBCO gt 15 8 VDC gt 15 8 VDC gt 31 6 VDC HBCI 15 5 VDC 15 5 VDC 31 0 VDC LBCI 212 5 VDC 212 5 VDC 225 0 VDC LBCO 10 0 VDC 10 0 VDC 20 0 VDC one minute delay 9 0 12 2 VDC 9 0 12 2 18 0 24 4 VDC LBCO 8 5 VDC 8 5 VDC 17 0 VDC adjustable with remote Inverter Startup ON OFF Switch The inverter can be turned on and off by lightly pressing and releasing the Power ON OFF switch on the front of the inverter When the inverter is first connected to the batteries or when its automatic protection circuit has turned the inverter off the ON OFF switch will need to be pressed to start the unit Once the inverter has been turned on pressing the Power ON OFF switch alternately tu
51. red to open before the cable reaches its maximum current carrying capability thereby preventing a fire See Table 1 to select the DC overcurrent device based on the minimum wire size for your inverter model If using a fuse we recommend using a class T type or equivalent This fuse type is rated for DC operation can handle the high short circuit currents and allows for momentary current surges from the inverter without opening DC Grounding The inverter charger should always be connected to a permanent grounded wiring system The idea is to connect the metallic chassis of the various enclosures together to have them at the same voltage potential which reduces the possibility for electric shock For the majority of installations the inverter chassis and the negative battery conductor are connected to the system s ground bond via a safety grounding conductor bare wire or green insulated wire at only one point in the system Per the NEC the size for the grounding conductor is usually based on the size of the overcurrent device used in the DC system Refer to Table 1 to select the appropriate DC ground wire based on the overcurrent device used for your inverter model 2010 Magnum Energy Inc 13 2 0 Installation DC Cable Connections When connecting the DC cable to the battery or to the inverter s DC terminals the hardware should be installed in the correct order to prevent high resistance connections from heating up and possi
52. rent o Curre Figure 12 Automatic 4 Stage Charging Graph Transfer time While in Standby Mode the AC input is continually monitored Whenever AC power falls below the VAC dropout voltage 80 VAC default setting the inverter automatically transfers back to Inverter Mode with minimum interruption to your appliances as long as the inverter is turned on The transfer from Standby Mode to Inverter Mode averages approximately 16 milliseconds While the MM AE Series is not designed as a computer UPS system this transfer time is usually fast enough to hold them up However the VAC dropout setting has an effect on the ability of the loads to transfer without resetting The lower this setting the longer the effective transfer will be and therefore the higher the probability for the output loads to reset This occurs because the incoming AC voltage is allowed to fall to a level that is so low that when the transfer does occur the voltage on the inverter s output has already fallen to a low enough level to reset the loads The disadvantage of a higher VAC dropout setting is that smaller generators or large generators with an unstable output may nui sance transfer This commonly happens when powering loads that are larger than the generator can handle causing the generator s output voltage to constantly fall below the inverter s input VAC drop out threshold Info You must use the ME RC50 remote to adjust the VAC dropout setting which in
53. rmation 40 How to Receive Repair Service eee enhn nnn rn nnn 41 List of Figures Figure 1 MM AE Series 1 Figure 2 Top Side Gg DEE 3 Figure 3 Front and Back Side Features 4 Figure 4 Left Side Features 3 Figure 5 Battery Temperature Sensor BTS 5 Figure 6 Basic Installation Diagram 7 Figure 7 Approved Mounting Orientations 9 Figure 8 MM AE Series Inverter Charger Dimensions 10 Figure 9 DC Cable to Battery 14 Figure 10 DC Cable to Inverter s DC 14 Figure 11 AC Wiring ConnectionS PCR UE 20 Figure 12 Automatic 4 Stage Charging 26 Figure 13 BTS Temperature to Charge Voltage Change 27 Figure 14 Series Battery Wiring een 36 Figure 15 Parallel Battery Wiring enn nnne 37 Figure 16 Series Parallel Battery Wiring 37 Figure 17 Battery Bank Wiring Examples 12 volt 38 Figure 18 Battery Bank Wiring Examples 24 volt 39 List of Tables Table 1 Recommended DC Wire Overcurrent Device 12 Table 2 DC Wire Size For Increas
54. rnal charging sources is used to charge the battery bank Reduce or turn off any other charger to the inverter batteries to allow the voltage level to drop Reduce the number of electrical loads that you are operating this will avoid a repeat Over temp shutdown if the cause was too many loads for the ambient Check ventilation around the inverter ensure cool air is available to pass thru the inverter Reduce the AC loads connected to the inverter or remove all AC output wiring and restart the inverter clear this fault an inverter reset is required Remove DC power to the inverter or press and hold down the power switch on the inverter for 15 seconds until the green Status LED comes on If this fault does not clear the unit will need to be serviced Switch the inverter ON Connect a battery with correct voltage to the inverter Check the incoming AC voltage to the input of the inverter ensure it is present and above the VAC dropout level Loose AC output connections ighten AC output connections Loose corroded battery cables Clean and tighten all cables Wrong type of voltmeter used will on the battery voltage If the Battery Temperature Sensor is installed it will increase or decrease the DC voltage level depending on temperature around the battery sensor 2010 Magnum Energy Inc Most meters are made to read Average modified waveform which requires using a true RMS voltmete
55. rns the inverter on and off turn on or off the charger feature If AC power utility or generator is connected and qualified on the AC input this AC power will also be available on the AC output and is not controlled by the Power ON OFF switch j WARNING The Power ON OFF control switch does not Status LED Indicator The status indicator is a green LED Light Emitting Diode that provides information on the operational mode of the inverter Watch this indicator for at least 10 seconds to determine the inverter s operational condition from the information below Inverter Mode e Off Indicates the inverter is off there is no AC power from the inverter utility or generator at the inverter s output terminals e Blinks On once every second The inverter is on and is using energy from the battery The inverter is either provid ing full power to the loads connected to the inverter or it s in Search Mode and ready to supply AC power to the connected loads 2010 Magnum Energy Inc 29 3 0 Operation Protection Mode There are five fault conditions that will cause the inverter to shut down Low Battery High Battery Over temperature AC Overload and Internal faults If your inverter has shut down monitor the status indicator and count the number of blinks that occur every four seconds to determine the particular reason for the shutdown Refer to the Troubleshooting section to help diagnose clear the fault condition e
56. rrents will be present if the positive and negative cables attached to the battery bank touch each other During the installation and wiring process ensure the cable ends are insulated or covered to prevent touch ing shorting the cables Info DO NOT connect the DC wires from the battery bank to the inverter until 1 all DC AC wiring is complete 2 the correct DC and AC overcurrent protection have been installed and 3 the correct DC voltage and polarity have been verified Info For optimum performance a minimum battery bank of 200 AHr is recommended Depending upon the type of batteries you use in the installation 6 or 12 VDC the batteries must be wired in series parallel or series parallel see Appendix B Battery Information for guidance on wiring batteries together The interconnecting DC wires must be sized and rated exactly the same as those that are used between the battery bank and the inverter Place the batteries as close as practical to the inverter preferably in an insulated and ventilated enclosure Allow adequate space above the batteries to access the terminals and vent caps as applicable Also allow at least 1 of space between the batteries to provide good air flow DO NOT mount the batteries directly under the inverter D AN I nfo To ensure the best performance from your inverter system do not use old or untested batteries Batteries should be of the same size type rating and age CAUTI ON In
57. rt of the installation No overcurrent protection for the AC output wiring is provided as an integral part of this inverter Overcurrent protection of the AC output wiring must be provided as part of the installation I MPORTANT BATTERY SAFETY INSTRUCTI ONS Wear eye protection safety glasses when working with batteries Remove all jewelry such as rings watches bracelets etc when installing or performing maintenance on the inverter Never work alone Always have someone near you when working around batteries Use proper lifting techniques when working with batteries Never use old or untested batteries Check each battery s label for age type and date code to ensure all batteries are identical Batteries are sensitive to changes in temperature Always install batteries in a stable environment Install batteries in a well ventilated area Batteries can produce explosive gasses For compartment or enclosure installations always vent batteries to the outside Provide at least one inch of air space between batteries to provide optimum cooling Never smoke when in the vicinity of batteries To prevent a spark at the battery and reduce the chance of explosion always connect the cables to the batteries first Then connect the cables to the inverter Use insulated tools at all times Always verify proper polarity and voltage before connecting the batteries to the inverter To reduce the chance of fire or explosion do
58. stall batteries in a well ventilated area Bat teries can produce explosive gasses For compartment or enclosure installations always vent batteries to the outside I nverter to Battery Bank Wiring N WARNI NG Ensure all sources of DC power i e batter ies solar wind or hydro and AC power utility power or AC generator are de energized i e breakers opened fuses removed before proceeding 2010 Magnum Energy Inc 15 2 0 Installation CAUTI ON The inverter is NOT reverse polarity pro A N tected If this happens the inverter will be damaged and will not be covered under warranty Before connecting the DC wires from the batteries to the inverter verify the correct battery voltage and polarity using a voltme ter If the positive terminal of the battery is connected to the negative terminal of the inverter and vice versa severe damage will result If necessary color code the cables with colored tape or heat shrink tubing RED for positive and BLACK for negative to avoid polar ity confusion Info The DC overcurrent device i e fuse or circuit D breaker must be placed in the positive RED DC cable line between the inverter s positive DC terminal and the battery s positive terminal RED as close to the battery as possible DC Ground Wire Route an appropriately sized DC grounding wire GREEN or bare wire from the inverter s DC Ground Terminal see Figure 4 Item 17 to a dedicated system grou
59. the 300 and 400 amp models use a Class T fuse DC Load Disconnect The MM DCLD DC Load Disconnect pigtail adapter is designed to provide a means to DISABLE the inverter function when a 12 volt DC signal is removed I gnition Switch Activate The MM ISA is a pigtail adapter designed to automatically ENABLE the inverter function when a 12 volt DC signal is supplied 2010 Magnum Energy Inc 35 Appendix B Battery information Appendix B Battery I nformation Battery Bank Sizing The size of the battery bank determines how long the inverter can power the AC loads without recharging The larger the battery bank the longer the run time Size your battery bank to the system s AC load requirements and the length of time required to run the load from the batteries In general the battery bank should not be dis charged more than 50 Battery Types Batteries are available in different sizes amp hour ratings voltage and chemistries they also come in liquid or gel vented or non vented etc They are also available for starting applications such as an automobile starting battery and deep discharge applications Only the deep cycle types are recommended for inverter applications Choose the batteries best suited for the inverter installation and cost Use only the same battery type for all batteries in the bank For best performance all batteries should be from the same lot and date This information is usually printed on a label lo
60. ve loss of water in flooded batteries or drying out of GEL AGM batteries In this stage the charger is turned off and begins monitoring the battery voltage If the battery voltage drops low x12 7 VDC 12 volt models or x25 4 VDC 24 volt models the charger will auto matically initiate another four hours in float charge These voltage settings are based on the Battery Temperature Sensor BTS being disconnected or at a temperature of 77 F 25 C If the BTS is installed these voltage settings will increase if the temperature around the BTS is below 779 F 25 C and decrease if the temperature around the BTS is higher than 77 F 25 C The MM AE Series uses changeable settings see Table 6 Inverter Default Settings that are adequate for most installations However if you determine that some of your operating parameters need to be changed the ME RC50 remote control can be purchased to allow changes to those settings 2010 Magnum Energy Inc 25 3 0 Operation ing 8 Charging j Charging Charge Absorb volts Absorb and Float voltage settings are determined by the Battery Type selection Monitored Voltage Constant Voltage I ncreased Voltage Voltage t Goes to Full Charge after4 Adj hours in Float DC Charge Charge Setting determined by the Adj Batt AmpHrs setting Constant Reduced Monitored N rrent Current Current Cur
61. witchable 12A switchable 12A switchable Input circuit breaker 8 AAC 20 AAC 20 AAC Internal cooling Yes 0 to 59 cfm variable speed Optional remotes available MM RC or ME RC50 UL listing NA Environmental Specifications Operating temperature 20 C to 60 C 4 F to 140 F Non operating temperature 40 C to 70 C 40 F to 158 F Operating humidity 0 to 95 RH non condensing Physical Specifications Dimensions L x W x H 16 6 x 8 4 4 7 42cm x 21cm x 12cm Mounting Shelf or wall no vents facing downward or upward Weight 16 Ibs 7 3 kg 22 lbs 10 kg 22 Ibs 10 kg Shipping weight 18 Ibs 8 2 kg 24 Ibs 10 9 kg 24 Ibs 10 9 kg Specifications 25 C Subject to change without notice 34 2010 Magnum Energy Inc Appendix A Optional Equipment and Accessories Appendix Optional Equipment and Accessories The following Magnum Energy components are available for use with the MM AE Series inverter charger Some of these items are required depending upon the intended use of the inverter Smart Battery Combiner The Smart Battery Combiner ME SBC is designed to monitor and charge a second battery using a portion of the current that is charging the main battery The ME SBC eliminates a significant voltage drop and provides automatic turn on and turn off based on adjustable volt age set points This allows different batteries to be charged from a single charging source and prevents overcharging un
62. y com If returning the product directly to Magnum Energy for repair you must e return the unit in the original or equivalent shipping container e receive a Return Materials Authorization RMA number from the factory prior to the return of the product to Magnum En ergy for repair e place RMA numbers clearly on the shipping container or on the packing slip When sending your Product for service please ensure it is properly packaged Damage due to inadequate packaging is not covered under warranty We recommend sending the Product by traceable or insured service 2010 Magnum Energy Inc 41 EE TUE VES CC E E Y YOUR a Db Owi DISTRIBUTOR SOLIGENT Soligent 800 967 6917 www soligent net Magnum Energy Inc 2211 West Casino Rd Everett WA 98204 Phone 425 353 8833 Fax 425 353 8390 Web www magnumenergy com PN 64 0035 Rev A 2010 Magnum Energy Inc
63. ystem This terminal accepts CU AL conductors from 14 AWG to 6 AWG Battery Temperature Sensor A plug in external Battery Temperature Sensor BTS is provided for units with the battery charger feature When installed the BTS automatically adjusts the battery charger s BULK ABSORB and FLOAT voltage set points based on temperature for better charging performance and longer battery life If the temperature sensor is NOT installed and the batteries are subjected to large temperature changes battery life may be shortened 34 FRONT VIEW TE ee Cable 0 375 diameter Figure 5 Battery Temperature Sensor BTS 2010 Magnum Energy Inc 5 2 0 Installation 2 0 Installation Pre I nstallation Before installing the inverter read the entire Installation section The more thorough you plan in the beginning the better your inverter needs will be met WARNI NG Installations should be performed by qualified Ji personnel such as a licensed or certified electrician It is the installer s responsibility to determine which safety codes apply and to ensure that all applicable installation requirements are followed Applicable installation codes vary depending on the specific location and the type of installation Info Review the Important Product Safety Information D on page ii and the Important Battery Safety Instructions on page iii before any installation The basic syste

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