User Manual - Magnum Dimensions
Contents
1. 15A Trips to protect the inverter from hardwire AC output short circuit or overload 4 GFCI Outlets Two outlets 120 VAC 60 Hz out put power 5 Field Wiring Compartment Cover Remove the faceplate to access the AC output lead wires and the DC input connectors 6 Bonding Lug Connects to the ground system 7 Water resistant DC input strain Clamp the DC input cables for mechanical protection reliefs 8 Water resistant cover Protects the inside electronics from the elements 9 LED Status Control Panel Provides system status See next page Dimensions 6 122142B 4 1 1 LED Control Panel Description Low battery 2 Overload High temp FIGURE 2 LED Front Control Panel 1 External power Disabled Not available with this inverter model 2 Inverter power The green LED indicates that the inverter is operating from batteries in inverter mode 3 Low battery The red LED indicates that the inverter is in a low battery voltage condition 4 Overload The red LED indicates that the inverter is in an overload condition 5 High temp The red LED indicates that the inverter has a high internal temperature 4 2 NATO Connector Plug Optional 1 Pin Connector Plugs to the female connector for DC input power 2 Black Wire Negative DC input voltage from batteries 3 Red Wire Positive DC input voltage from batteries 4 Cover Protects the plug from dust when not plugged Figure 3 NATO2. Parkway St Paul MN 55110 freight prepaid THERE ARE NO EXPRESS WARRANTIES COVERING THESE GOODS OTHER THAN AS SET FORTH ABOVE THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE ARE LIMITED IN DURATION TO ONE YEAR FROM DATE OF PURCHASE SENSATA TECHNOLOGIES ASSUMES NO LIABILITY IN CONNECTION WITH THE INSTALLATION OR USE OF THE PRODUCT EXCEPT AS STATED IN THIS LIMITED WARRANTY SENSATA TECHNOLOGIES WILL IN NO EVENT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WARNING LIMITATIONS ON USE Dimensions products are not intended for use in connection with Life Support Systems and for Avionic use Sensata makes no warranty or representation in connection with their products for such uses Dimensions 15 122142B
3. 53 Output Rating np 7 Input Current Amps DC _Uptoso Weight bs 3 oo Dimensions n ame Boro 122142B Technical Description 3 1 Power Inverter System 3 1 1 Overview A DC to AC power inverter system converts DC current storage in batteries to usable 120 VAC 60Hz power The inverter have a main On Off switch to control the inverter operation it also have LED indication lights built on the front of the inverter to provide system status The inverter can also be controlled by a customer supplied remote On Off switch connected to the violet wire labeled remote switch hook up located in the field wiring compartment 3 1 2 Theory of Operation The inverter converts DC power from batteries to usable 120 VAC 60 Hz power The direct current DC that enters the inverter system is filtered by a large input capacitor and switched On and Off by the Metal Oxide Silicon Field Effect Transistors MOSFET at a rate of 60 cycles per second and directed into the transformer which steps the voltage up to 120 volts The inverter has a 16 bit 5MHz Digital System Processor DSP to control the output voltage and frequency as the DC input voltage and or output load varies The signal output waveform shape is sinusoidal it has a total harmonic distortion of less than 5 A thermally controlled cooling fan triggers when the temperature inside the electronics circuitry reaches a preset temperature limit keepin
4. C or fault in the remote On Off circuit Low battery Red LED indicator light Indicates that the inverter will shut off due to a low battery voltage condition Check the in line fuses for continuity Make sure the DC wires are clean and tight Check the DC voltage at the inverter DC input Check or bypass the remote On Off circuit Fault in the battery wiring battery capacity and voltage or the in line fuse This message will automatically clear or the inverter will shut off Overload Red LED indicator light Indicates that the inverter will shut off due to an overload condition The inverter output wiring is shorted or loads exceed the inverter rating This message will automatically clear or the inverter will shut off Remove the short circuit or excessive load from the output and then switch the inverter Off then On High Temp Red LED indicator light Indicates that the inverter has shut off due to high internal temperature The unit will automatically turn back on when it has cooled to 40 C 104 F Verify that the inverter is in a vented compartment and that the fan is not blocked High ambient temperatures combined with poor ventilation may also contribute to the shut down Dimensions 14 122142B Warranty SHI PPI NG TERMS F 0 8 St Paul Minnesota Freight prepaid and billed subject to prior credit approval MINIMUM ORDER 50 00 Net Price LOSS OR DAMAGE Loss or damage in transit is the
5. Form 122142B J anuary 2007 4467 White Bear Parkway St Paul MN 55110 800 553 6418 I SO 9001 2008 Registered Company Dimensions DC to AC Power Inverter System Owners Manual for Models MIL 24U10AN Dimensions 1 122142B Table of Contents Section Description Page 1 Safety Instructions 05H u0u0 anna 3 1 1 Warning and Danger Symbols uueeeesssnnnsennnnnennenennnnnnnn non 3 1 2 Inverterr System Precautions uunnnssensnnnnnnnnnnnnnnnnnnnnn anne 3 1 3 Battery Precautions ernnsineeieleeseeeiin 3 2 Spetifications zu nn 4 3 Technical description kan 5 3 1 Power Inverter Systems nusnssssnnsnenennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 5 3 1 1 Overview anche 5 3 1 2 Theory of Operation nannte 5 3 2 Available Options and Features suumnn nennen nn 5 3 2 1 GFCI Protected AC Output A Option 5 3 2 2 Remote On Off Swtich urn veanadenestenczcea erecta beets 5 4 Inverter Physical Description uau20un0nannunannunannnnannunann ann nn 6 4 1 Inverter Module 2er sei 6 4 1 1 LED Control Panel Description 4r seers 7 4 2 NATO Connector Plug Optional 2rr4 nn Rn nn 7 5 Installation asien EEE 8 5 1 Tools Needed for Installation _ sennrsnnnnnennennnnnn nennen 8 5 2 System COMpONeNtS einen ene 8 5 3 Mounting the Inverter zu ee een setae etd 8 5 3 1 Chassis Bonding Lug 8 6 Inverter Wiring nr 9 6 1 DC MATING ses nsein theta aepuoctn peauer acteenas
6. M engine battery Use 2 gauge cables and 250A fuse for small OEM alternators and 1 0 gauge and 350A for heavy duty alternators 6 1 3 NATO Connector If the inverter comes with a NATO connector option plug the pin male connector extending from the inverter to the female connector for 24 volt DC input power 6 1 4 Connecting the DC wires A Damage to the inverter not covered under warranty will occur if correct polarity is not observed when installing the DC input cables Refer to Figure 5A DC wiring diagram Open the inverter field wiring compartment to access the DC input lugs Unscrew the DC input lug POS and NEG screws Remove the fuse from the fuseholder for cable installation Remove 1 inch of insulation from the un terminated ends of the red and black cables e Insert the stripped end of the red wire into the DC input lug labeled POS and the stripped end of the black wire into the DC input lug labeled NEG Tighten the lug screws to 10 Ft Lbs e Tighten the cover DC cable strain relief screws to 1 Ft Lb e Connect the end of the short red cable to a POS battery post e Connect the terminated end of the black cable neg return cable directly to a battery NEG post DO NOT connect to the chassis e Install the in line fuse in the fuseholder that is within 18 of the positive post of the battery bank a one time spark will occur when this final DC connection is made To determine the fus
7. Plug Optional item Dimensions 7 122142B Installation 5 1 Tools for Installation Tools required for installation Straight screwdriver connectors butt type and insulated drill Crimpers for insulated and non insulated connectors electrical tape 2 Phillips screwdriver wire cutters wire strippers cable ties tape measure 5 2 System Components VE Inverter Nite 24U10AN amp ea Optional Figure 4 System components 5 3 Mounting the Inverter The inverter mounting location should provide adequate ventilation and clearance to maintain room temperature during operation At least 1 2 inch of clearance is required on all sides e Locate a suitable secure vertical or horizontal mounting surface as close to the batteries as possible without being in the same airtight compartment e If mounting the inverter on a vertical surface it is recommended that the front control panel be pointing down whenever _ E HERE possible e Locate the mounting holes on the chassis 13 2 flanges and fasten them using inch diameter screws to secure the inverter All dimensions are in inches See figure 5 Figure 5 Inverter footprints 5 3 1 Chassis Bonding Lug Connect the bonding lug located at the right side of the inverter chassis to the earth grounding system using an 8 gauge copper wire Figure 6 Inverter grounding Dimensions 8 122142B Inverter Wiring 6 1 DC Wiring 1 Itis recommended in all cas
8. e between the inverter and the battery bank is 20 feet e The battery compartment must be vapor tight to the interior of the vehicle and vented directly to the exterior e Install several vent plugs within one inch of the top of the battery compartment to allow for ventilation Install a ventilation assembly as needed e Allow space around the battery and especially above the battery for inspection and maintenance purposes e The battery should not be able to move more than 1 inch in any direction 6 2 AC Wiring Remove the inverter field wiring compartment cover plate to access the 120VAC 60Hz output hardwire leads and follow the color code connections Hot Black wire Neutral White wire Ground Green wire 6 2 1 AC Output The 120 VAC 60 Hz current produced by the inverter is provided at the GFCI receptacle outlets located on front of the inverter The output is also presented behind the wiring compartment panel for direct hardwire leads The hardwire leads are GFCI protected remote outlets do not need to be GFCI outlets Do not connect another source of AC power directly to the output of the A inverter This will result in damage to the inverter that is not covered under warranty AC Wiring compartment DC wiring compartment Figure 9 AC DC Wiring compartment Dimensions 11 122142B 6 3 DC Wiring Diagram AC Output Engine Compartment Connect the charge cables directly to the vehicle alternator R
9. e size refer to section 6 1 1 6 1 5 Remote On Off Switch An optional customer supplied On Off switch may be connected to the inverter The remote switch will operate only if the main On Off switch on the face of the inverter is turned ON e Open the inverter field wiring compartment to access the DC input connector Figure 8 Remote Switch Hookup e Locate the violet wire labeled Remote Switch Hook up and remove it from the positive battery connector e Connect the violet wire to the load side of the On Off remote switch e Using an 18 gauge wire connect a fused 5 amp recommended 24VDC battery voltage to the line side of the switch e The fuse should be mounted within 18 inches of the battery s positive post e All material used for the remote switch should be UL listed and installed per code Dimensions 10 122142B 6 1 6 Deep Cycle Batteries A Do not use vehicle starting batteries deep discharge cycles typical with SPS applications can shorten the life of this type of batteries e Install at least one 24 VDC auxiliary deep cycle battery two 12 volt batteries in series or four 6 volt batteries in series to feed the inverter directly Depending on the application running time more batteries could be added if necessary The vehicle alternator will recharge the batteries e It is recommended to mount the battery bank close to the inverter The maximum recommended distanc
10. emote On Off switch and fuse is customer supplied Figure 10 DC wiring diagram Dimensions 12 Violet wire _ Charge Cable Black Vehicle Alternator Charge Cable Red oper 24 Volt Battery 122142B 6 4 AC Wiring Diagram Not used Output Branch Breaker Breaker GFCI Outlets White Wire Neutral 120VAC 60Hz Output Remote AC outlets Figure 11 AC wiring diagram Dimensions 13 122142B Operation and Troubleshooting 7 1 Operation 7 1 1 Turning the Inverter ON To turn the inverter ON set the Inverter On Off switch to the On position The green LED Inverter Power will come on If the remote switch is used the inverter is turned ON or OFF by the remote switch A Turn the inverter OFF if not in use There is an approximately 1 to 2 amps DC draw from the batteries at idle or no load 7 2 Troubleshooting Call or e mail Customer Service Department for free consultation during business hours central time zone at 1 800 553 6418 or 1 651 653 7000 fax 1 651 653 7600 e mail inverterinfo sensata com e Unplug all loads and connect a 100 watt light bulb to the inverter output Observe the LEDs light coming on at the control panel then check the troubleshooting table Table V PROBLEM POSSI BLE CAUSES OR SOLUTIONS No LEDs No power output The inverter is not connected to the batteries the battery voltage is below 18 volts D
11. es to use stranded copper wires 2 Use SGX cross linked polyurethane insulation type that complies with the high temperature insulation requirements 125 C of SAE J 1127 and vehicle manufacturer requirements 3 Wire gauge recommendations are minimum For higher temperature rated applications inside engine spaces or large motor loads and other applications with high surge currents use wire gauge 1 to 2 sizes larger than shown on table 4 Keep the wire runs between battery and SPS as short as possible 5 Use Bussmann fuse type ANN XXX and fuseblock 3576 where XXX is the size of the fuse 6 1 1 Inverter Cable This is the cable that runs from the inverter module to the batteries Estimate the inverter cable length and locate your inverter model on table I cross reference the wire gauge and fuse size Table Wire and Fusing Guide for 24VDC systems at 5 Voltage Drop at Full Output Inverter Full Load Inverter to battery estimated cable length in feet Model Amps DC T 10 11 15 16 20 24U10 50 8 gauge 100A fuse 6 gauge 150A fuse 6 gauge 150A fuse Fuse holder Cover Stripped end To inverter DC input Terminal Ring 5 16 Red wire Terminal Ring 3 8 To Battery post 20 feet max Black wire Figure 7 Inverter cable assembly Dimensions 9 122142B 6 1 2 Charge Cable This is the cable that runs from the batteries to vehicle alternator or OE
12. g the inverter within the operating temperature range The water resistant cover and the fully coated circuit board protects the inverter s electronics from the elements specially from moisture and water that may rust the electronic board components The inverter cover has special venting openings that are not directly exposed to the surround ambient the venting openings are located from beneath on both sides of the inverter to allow airflow circulation to cool down the inverter for efficient operation 3 2 Available Options and Features 3 2 1 GFCI Protected AC Output A Option The inverter have one GFCI protected AC output circuit with a 15A output breaker With the A option the 120VAC 60Hz AC outlets on front of the inverter and the set of hardwire leads are both GFCI protected therefore it is not necessary to install remote GFCI protected outlets 3 2 2 Remote On Off Switch The inverter can be controlled by a customer supplied remote On Off switch connected to the 18 gauge violet wire labeled remote switch hook up which is located in the inverter s field wiring compartment the line side of the switch must be fused and connected to 24Volts Dimensions 5 122142B Inverter Physical Description 4 1 Inverter Module FIGURE 1 Inverter module physical description Item Description Function 1 On Off Switch Switches the inverter ON or OFF 2 Branch Breaker Not available 3 Output Breaker
13. lies with all the safety standards required in the USA and Canada for land vehicle inverters 1 2 Inverter System Precautions e DC to AC inverters produces hazardous voltages To avoid risk of harm or fire the unit must be properly installed e There are no user serviceable parts inside do not remove the cover e The inverter Systems should not be mounted in a location that may be exposed to rain or spray e The inverter Systems should not be installed in a zero clearance enclosure e Damage to the inverter Systems will occur if correct polarity is not observed when installing the DC input cables e Damage to the inverter Systems will occur if an external AC power source is applied to the inverter s AC hardwire output e The inverter System contains a circuit breaker and capacitor that may produce a spark Do not mount in a confined battery or gas compartment e Be Sure the inverter Systems is turned OFF during installation 1 3 Battery Precautions e Working in the vicinity of lead acid batteries is dangerous There is a risk of acid exposure Batteries generate explosive gases during operation There is risk of high current discharge from shorting a battery that can cause fire and explosion Use insulated tools during installation Remove all rings watches jewelry or other conductive items before working near the batteries Inspect the batteries once a year for cracks leaks or swelling Dispose of the batteries according
14. responsibility of the carrier Any claim should be filed with the delivering transport company Invoice Bill of Lading and Delivery receipt with damage noted therein must accompany any claims for freight damage Claims for shortage and lost shipments must be made in writing to Sensata Technologies St Paul MN within 10 days of date of shipment Claims not reported within this time frame will not be honored PRICES Prices are subject to change without notice All orders are subject to acceptance at the factory We reserve the right to invoice prices in effect at time of shipment TERMS Net 30 days with approved credit credit card or C O D en GOODS POLICY No returned materials will be accepted without an accompanying Returned Materials Authorization Number RMA from factory Credit will be issued for returned goods to the original purchaser within 60 days of purchase provided the inverter is returned to Sensata unused and not mounted The amount of credit will be issued at Sensata s discretion based on the condition of the product Customer must be in good standing with Sensata Inverters that are discontinued high voltage over 24vdc special order or used are excluded and will not be eligible for credit Non inverter items such as cable assemblies fuses and fuse holders will not be eligible for credit Support components supplied by Sensata vendors will be covered under that manufacturer s credit return policy Customer pays return freigh
15. t PLEASE SHI P FREI GHT PREPAID AUTHORI ZED RETURNS TO Sensata Technologies 4467 White Bear Parkway St Paul MN 55110 LIMITED WARRANTY Sensata warrants to the original purchaser for use that the goods or any component thereof manufactured by Sensata will be free from defects in workmanship for the period listed on the product label from date of purchase provided such goods are installed maintained and used in accordance with Dimensions and the original manufacturer s written instructions Components not manufactured by Sensata but used within the assembly provided by Sensata are subject to the warranty period as specified by the individual manufacturer of said component provided such goods are installed maintained and used in accordance with Sensata and the manufacturer s written instructions Sensata s sole liability and the Purchaser s sole remedy for a failure of goods under this limited warranty and for any and all claims arising out of the purchase and use of the goods shall be limited to the repair or replacement of the goods that do not conform to this warranty The return of the purchase price in cash is at the sole discretion of Sensata To obtain repair or replacement service under the limited warranty the purchaser must contact the factory for a Return Material Authorization RMA Once obtained send the Return Material Authorization Number along with the defective part or goods to Sensata Technologies 4467 White Bear
16. tecd aster aentretadtactstzs 9 6 1 1 Inverter Cable ahnen lett andecs slesaaieesdse 9 6 1 2 Charge Cable en eee wees 10 6 1 3 NATO COnneCIOR ee ee 10 6 1 4 Connecting the DC Wires nnneensnnnnnsnnnnnnnnnnnnnn anne 10 6 1 5 Remote On Off Switch unser 10 6 1 6 Deep Cycle Batteries ceeeeessennenennnenennnnnnnnnnnnnnnnnnnnnnennn 11 6 2 PAT T De TE EA ni at 12 6 251 AC OUD een res RE ee 12 6 3 DC Wiring Diagram ae 12 6 4 AC Wiring Diagram sn 13 7 Operation and Troubleshooting sssssssssnnnnnunnnnnnnnnnnnnnnnnnnnnnnnnn 14 7 1 OpEratiION Ssosnsdnari dee hacte ach candee aa a a a iS 14 7 1 1 Turning the Inverter On _ esesrsnsernnnennnnnnnenennnn nenn 14 7 2 Troubleshooting rs 14 8 Warranty unununnnnonunununnnununnnnnnnnananan nn nn an un nnannnnnanananununnnnnnnnnnnannnn 15 Dimensions 2 122142B Safety Instructions Important Read this manual before installation it contains important safety installation and operating instructions Save this manual and keep it in a safe place 1 1 Warning and Danger Symbols To reduce the risk of electrical shock and to ensure the safe operation of your Dimensions power inverter the following symbols are used throughout the manual ATTENTION DANGER Important operating instructions Risk of personal harm and or Follow them closely electrocution exists in this area Use extreme caution SAFETY CERTIFICATION c UL US This is a UL and CUL Certified product that comp
17. to local regulations Do not incinerate batteries risk of explosion exists Dimensions 3 122142B Specifications Millennium Series Power Inverters Output Voltage VAC 120 5 Output Frequency 60 Hz 0 05 Output Waveform Pure sine wave lt 5 THD Input Voltage VDC 22 to 30 Operating Temperature 20 to 40 C 0 to 104 F Efficiency Up to 88 Other Design Features Patented construction and cooling methods 16 bit 5 MHz DSP Digital System Processor control Thermally controlled cooling fan Enclosed AC and DC cable connections with strain relief Remote ON OFF switch hookup e GFCI outlet and hardwire output protected LED for Inverter power Low battery High temperature amp Overload Water resistant cover Fully coated circuit board Optional NATO slave plug connector with cable Built to UL 458 standards MIL 24U10AN Environmentally Friendly Quiet Reliable AC Power Unit Protection e Automatic electronic short circuit overload protection e Automatic high temperature shutdown e Output circuit breakers e DC input reverse polarity protection Battery Protection Automatic low battery shutdown at 21 VDC with in rush delay Usage Any 120 VAC 60 Hz single phase products within the inverter power rating Dimensions MODEL NUMBER mzao National Stock Number 6130 01495 0740 Output Power Watts cont 100 Output Current amps ac Uptos3 Peak Output Amps Ac
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