Magnum Energy RD SERIES Owner`s manual
MS Series
Pure Sine Wave
Inverter/Charger
Owner’s Manual
TM
Disclaimer of Liability
The use of this manual and the conditions or methods of installation, operation, use and maintenance
of the MS Series inverter/charger is beyond the control of Magnum Energy, Inc. Therefore, this
company does not assume responsibility and expressly disclaims liability for loss, damage, or
expense whether direct, indirect, consequential or incidental that may arise out of or be 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 MS Series inverter/charger may only be used in life support devices and systems with the
express written approval of Magnum Energy. Failure of this inverter can reasonably be expected
to cause failure of that life support device or system, or to affect the safety or effectiveness of
that device or system. If the MS inverter fails, it is reasonable to assume the health of the user
or other persons may be endangered.
Copyright Notice
Copyright © 2012 by Magnum Energy, Inc. All rights reserved. Permission to copy, distribute, and/or
modify this document is prohibited without express written permission from Magnum Energy, Inc.
Document Information
Description – MS Series Owner’s Manual
Part Number and Revision – 64-0007 Rev C
Date Published – April 2012
This entire manual is available for download—with many of the diagrams available in color—under
the Document Library tab at: www.magnumenergy.com.
Contact Information
Magnum Energy, Inc.
2211 West Casino Rd.
Everett, WA 98204
Phone: 425-353-8833
Fax: 425-353-8390
Web: www.MagnumEnergy.com
Statement of Appreciation
Thank you from all of us at Magnum Energy for purchasing this MS Series inverter/charger.
We understand that you have many purchasing options in the marketplace, and are pleased that
you have decided on a Magnum Energy product. This MS Series inverter/charger was proudly
assembled and tested in the United States in our Everett, Washington, facility.
At Magnum, we are committed to providing you with quality products and services, and hope that
your experience with us is pleasant and professional.
Record unit’s model & serial number in case you need to provide this information in the future.
Model:
Serial Number:
MS2000 (-15B/-20B)
T1
MS2012 (-15B/-20B)
J1
MS2812
H1
MS4024
K1
Magnum Energy® is a registered trademark of Magnum Energy, Inc.
Page i
© 2012 Magnum Energy, Inc.
Safety Information
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
THIS MANUAL CONTAINS IMPORTANT INSTRUCTIONS FOR THE MS SERIES INVERTER/CHARGER
THAT SHALL BE FOLLOWED DURING THE INSTALLATION AND OPERATION OF THIS PRODUCT.
Before using the MS Series, read all instructions and cautionary markings. Also, be sure to review
the individual manuals provided for each component of the system. The installation instructions
are for use by qualified personnel only. Do not perform any installation or servicing other than
that specified in this owner’s manual unless you are qualified to do so. Incorrect installation or
servicing may result in a risk of electric shock, fire, or other safety hazard.
Safety Symbols
The following safety symbols have been placed throughout this manual to indicate dangerous and
important safety instructions.
WARNING: This symbol indicates that failure to take a specified action could result in
physical harm to the user.
CAUTION: This symbol indicates that failure to take a specified action could result in
damage to the equipment.
Info: This symbol indicates information that emphasizes or supplements important
points of the main text.
Safety Precautions
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All electrical work must be performed in accordance with local and national electrical codes.
This product is designed for indoor/compartment installation. It must not be exposed to rain,
snow, moisture, or liquids of any type.
Use insulated tools to reduce the chance of electrical shock or accidental short circuits.
There are no user-serviceable parts contained in this product.
This unit is provided with integral protection against overloads.
Live power may be present at more than one point since an inverter utilizes both DC (batteries,
PV, etc.,) and AC (utility or generator) power. To reduce risk of electric shock, ensure all DC
and AC wiring is disconnected prior to installing or performing maintenance on the inverter.
Turning off the inverter will not reduce this risk, the inverter must be totally disconnected from
all sources.
Use Class 1 wiring methods for field wiring connections to terminals of a Class 2 circuit.
Listed or labeled equipment shall be installed and used in accordance with any instructions
included in the listing or labeling.
Always verify proper wiring prior to starting the inverter.
Use only copper wires with a minimum temperature rating of 90°C.
AC wiring must be no less than 10 AWG (5.3 mm²) gauge copper wire.
Battery cables should be no less than #4/0 AWG for 12 and 24-volt systems and #2/0 AWG
gauge for 48-volt systems. Crimped and sealed copper ring terminal lugs with a 5/16 hole
should be used to connect to the DC terminals on the inverter.
Torque all AC wiring connections and DC cable connections to the required torque values.
The inverter must be properly mounted, see Section 2.2 “Mounting the Inverter” in this
manual.
Overcurrent protection for the battery supply is not provided as an integral part of this
inverter. Overcurrent protection of the battery cables must be provided as part of the system
installation. Refer to Section 2.4 “DC Wiring” for more information.
© 2012 Magnum Energy, Inc.
Page ii
Safety Information
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Overcurrent protection for the AC output wiring is not provided as an integral part of this
inverter. Overcurrent protection of the AC output wiring must be provided as part of the
system installation. Refer to Section 2.5 “AC Wiring” for more information.
The AC output neutral conductor and the DC negative conductors are not connected (bonded)
to the inverter chassis. Both the input and output conductors are isolated from the enclosure
and each other. System grounding, if required, is the responsibility of the system installer and
must comply with local and national electrical codes and standards. Refer to the Section 2.6
“Grounding Inverters” for more information.
Battery Safety
1. Use insulated tools and be very careful when working around batteries, they can produce
extremely high currents if short-circuited (e.g., dropping a metal tool across the battery
terminal), which could cause a fire or explosion.
2. Read and follow the battery manufacturer’s safety precautions before installing the inverter
and batteries. Always verify proper polarity and voltage before connecting the batteries
to the inverter. Once the batteries are connected to the inverter, ensure the maintenance
and charging requirements (i.e., charge voltage and charge rate) provided by the battery
manufacturer are followed to extend the life of the batteries and to prevent damage to the
batteries while charging.
3. Wear eye protection such as safety glasses, and avoid touching your eyes and face when
working with batteries to keep any fluid/corrosion on the battery from coming in contact
with eyes and skin. Have plenty of fresh water and soap nearby and thoroughly wash in case
battery acid contacts skin, clothing, or eyes. In the event of exposure to the eyes, flood them
for at least 15 minutes with running water and seek immediate medical attention. Baking soda
neutralizes lead acid battery electrolyte and vinegar neutralizes spilled NiCad and NiFe battery
electrolyte; depending on your battery type, keep a supply on hand near the batteries.
4. Remove all jewelry such as rings, watches, bracelets, etc., when installing or performing
maintenance on the batteries and inverter. A battery can produce a short-circuit current high
enough to weld metal jewelry, causing severe burns.
5. Never work alone. Always have someone within the range of your voice or close enough to
come to your aid when working around batteries.
6. Use proper lifting techniques when working with batteries.
7. Never use old or untested batteries. Check each battery’s label for age, type, and date code
to ensure all batteries are identical.
8. Batteries are sensitive to changes in temperature. Always install batteries in a stable
environment.
9. Batteries can produce explosive gasses, so install batteries in a well-ventilated area. For
compartment or enclosure installations, always vent batteries from the highest point to the
outside. Design the battery enclosure to prevent accumulation and concentration of hydrogen
gas in “pockets” at the top of the compartment.
10. Provide at least one inch of air space between batteries to provide optimum cooling.
11. Never smoke or allow a spark near batteries.
12. 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.
13. Never charge a frozen battery.
Page iii
Safety Information
CONSIGNES DE SÉCURITÉ IMPORTANTES
CONSERVER CES INSTRUCTIONS
CE MANUEL CONTIENT DE IMPORTANTES POUR LA SÉRIE MS ONDULEUR/CHARGEUR QUI DOIVENT
ETRE SUIVIES PENDANT L’INSTALLATION ET FONCTIONNEMENT DE CE PRODUIT. Avant d’utiliser la
série MS, lire toutes les instructions etles mises en garde. Aussi, n’oubliez pas depasser en revue les
différents manuels fournispour chaque composant du système. Lesinstructions d’installation sont pour
une utilisationpar du personnel qualifié. Ne pas effectuer une installation ou d’entretien autres que
ceux spécifiés dans ce manuel, sauf si vous êtes qualifié pour le faire. Une mauvaise installation ou
d’entretien peut entraîner un risque de choc électrique, un incendie ou autre danger pour la sécurité.
Symboles de sécurité
Les symboles de sécurité suivants ont été placéstout au long de ce manuel pour indiquer des
conditions dangereuses et les consignes de sécurité importantes.
AVERTISSEMENT: Ce symbole indique que le défaut de prendre une action spécifiée
pourraitcauser des dommages physiques à l’utilisateur.
ATTENTION: Ce symbole indique que le défaut de prendre une action spécifiée peut
entraîner des dommages à l’équipement.
Info: Ce symbole indique une information qui met l’accent ou des suppléments points
importants du texte principal.
Consignes de sécurité
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Tous les travaux électriques doivent être effectués en conformité avec les codes locaux et
nationaux électriques.
Ce produit est conçu pour l’installation / du compartiment intérieur. Il ne doit pas être exposé
à la pluie, la neige, l’humidité ou des liquides de tout type.
Utiliser des outils isolés pour réduire le risque de choc électrique ou courts-circuits accidentels.
Il n’y a pas réparable par l’utilisateur contenues dans ce produit.
Cet appareil est fourni avec une protection intégrale contre les surcharges.
Puissance en direct peuvent être présents à plus d’un point depuis un onduleur utilise à la fois
DC (piles, PV, etc) et AC (utilitaire ou générateur) d’alimentation. Pour réduire le risque de
choc électrique, assurez-vous que tout le câblage DC et AC est débranchée avant l’installation
ou la maintenance sur le variateur. Mise hors tension de l’onduleur ne réduira pas ce risque,
l’onduleur doit être totalement déconnectée de toutes les sources.
Utiliser des méthodes de câblage classe 1 pour les connexions de câblage sur le terrain aux
bornes d’un circuit de Classe 2.
Coté ou étiquetés équipement doit être installé et utilisé conformément aux instructions
figurant dans la liste ou l’étiquetage.
Toujours vérifier le câblage avant de commencer l’onduleur.
Utilisez des fils de cuivre seulement avec une cote de température minimale de 90 ° C.
AC câblage ne doit pas être inférieure à 10 AWG (5,3 mm2) de cuivre de calibre.
Les câbles de batterie ne doit pas être inférieur à # 4/0 AWG pour 12 et 24 volts systèmes
et # 2/0 AWG pour calibre 48 volts systèmes. Frisées et scellé cosses en cuivre anneau des
bornes avec un trou de 5/16 doit être utilisé pour se connecter à des bornes de courant
continu sur l’onduleur.
Couple toutes les connexions de câblage ca et les connexions de câbles à courant continu à
des valeurs de couple nécessaires.
L’onduleur doit être correctement monté, voir le montage de la section onduleur dans le
chapitre Installation de ce manuel.
Protection contre les surintensités pour l’alimentation de la batterie n’est pas fourni en tant
que partie intégrante de cet inverseur. La protection contre les surintensités des câbles de
batterie doivent être fournis dans le cadre de l’installation du système. Reportez-vous à la
section Câblage cc dans le chapitre d’installation pour plus d’informations.
© 2012 Magnum Energy, Inc.
Page iv
Safety Information
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Protection contre les surintensités pour le câblage de sortie AC n’est pas fourni en tant que
partie intégrante de cet onduleur. Protection contre les surintensités du câblage de sortie CA
doit être fournie dans le cadre de l’installation du système. Reportez-vous à la section Câblage
ca dans le chapitre d’installation pour plus d’informations
Le conducteur de sortie CA conducteurs neutre et continue négative ne sont pas connectés
(servitude) au châssis inverseur. La fois l’entrée et des conducteurs de sortie sont isolés de
l’enceinte et l’autre. La terre du système, si nécessaire, est de la responsabilité de l’installateur
du système et doit se conformer à des codes locaux et nationaux et les normes électriques.
Reportez-vous à la section Mise à la terre Onduleurs dans le chapitre d’installation pour plus
d’informations.
Sécurité de la batterie
1. Utiliser des outils isolés et être très prudent lorsque vous travaillez près des batteries, elles
peuvent produire des courants extrêmement élevés si en court-circuit (par exemple, échapper
un outil métallique à travers la borne de la batterie), ce qui pourrait provoquer un incendie
ou une explosion.
2. Lisez et suivez les consignes de sécurité du fabricant de la batterie avant d’installer l’onduleur
et des batteries. Toujours vérifier la polarité et la tension avant de brancher les batteries à
l’onduleur. Une fois que les batteries sont connectées à l’onduleur, assurer la maintenance et
les exigences de charge (c.-à-tension de charge et taux de charge) fournis par le fabricant de
la batterie sont suivies pour prolonger la vie des batteries et pour éviter d’endommager les
batteries pendant la charge.
3. Porter des lunettes de protection tels que des lunettes de sécurité, et évitez de toucher vos
yeux et le visage lorsque l’on travaille avec des piles de garder tout fluide / corrosion sur
la batterie d’entrer en contact avec les yeux et la peau. Ayez suffisamment d’eau fraîche et
de savon à proximité et se laver dans le cas d’acide contact avec la peau de la batterie, les
vêtements ou les yeux. Dans le cas d’exposition pour les yeux, les inonder pendant au moins
15 minutes à l’eau courante et consulter immédiatement un médecin.Le bicarbonate de soude
neutralise l’acide de plomb électrolyte de la batterie et le vinaigre neutralise renversé NiCad
et NiFe batterie à électrolyte; en fonction de votre type de batterie, gardez sous la main près
des batteries.
4. Enlevez tous les bijoux tels que bagues, montres, bracelets, etc, lors de l’installation ou la
maintenance sur les batteries et l’onduleur. Une batterie peut produire un court-circuit assez
de courant élevé pour souder les bijoux en métal, provoquant de graves brûlures.
5. Ne jamais travailler seul. Toujours avoir quelqu’un au sein de la gamme de votre voix ou
suffisamment près pour vous venir en aide lorsque vous travaillez près des batteries.
6. Utiliser des techniques de levage appropriées lorsque vous travaillez avec des piles.
7. Ne jamais utiliser de piles usagées ou non testés. Vérifiez l’étiquette de chaque batterie à
l’âge, le type et le code de date afin d’assurer toutes les batteries sont identiques.
8. Les batteries sont sensibles aux changements de température. Toujours installer les piles
dans un environnement stable.
9. Les batteries peuvent produire des gaz explosifs, etc installer les piles dans un endroit bien
ventilé. Pour les installations compartiment ou une enceinte, toujours évacuer les piles du
plus haut point à l’extérieur. Concevoir le boîtier de piles pour éviter l’accumulation et la
concentration de gaz d’hydrogène dans “poches” en haut du compartiment.
10. Fournir au moins un pouce de l’espace aérien entre les batteries pour fournir un refroidissement
optimal.
11. Ne jamais fumer ou laisser une étincelle près des batteries.
12. Pour éviter une étincelle à la batterie et de réduire le risque d’explosion, toujours connecter
les câbles aux batteries en premier. Ensuite, connectez les câbles à l’onduleur.
13. Ne jamais charger une batterie gelée.
Page v
Table of Contents
Important Safety Information ...............................................................ii
1.0
Introduction ..................................................................................1
2.0
Installation ...................................................................................7
3.0
Operation ....................................................................................42
4.0
Maintenance and Troubleshooting ...............................................50
1.1
1.2
1.3
1.4
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3.1
3.2
3.3
3.4
3.5
3.6
3.7
4.1
4.2
4.3
4.4
Features and Benefits ................................................................................. 2
How an Inverter/Charger Works................................................................... 5
Advantages of a Pure Sine Wave vs Modified Sine Wave Inverter ...................... 5
Appliances and Run Time ............................................................................ 6
Pre-Installation.......................................................................................... 7
Mounting the Inverter ...............................................................................10
Wiring the Inverter - General Requirements .................................................12
DC Wiring ................................................................................................13
AC Wiring ................................................................................................20
Grounding Inverters ..................................................................................33
Inverter Notification Requirements ..............................................................40
Final Inspection ........................................................................................40
Functional Test .........................................................................................41
Inverter Mode ..........................................................................................42
Standby Mode ..........................................................................................43
Battery Temperature Sensor Operation ........................................................45
Protection Circuitry Operation .....................................................................46
Inverter Startup .......................................................................................47
Factory Default Values ...............................................................................48
Inverter Fan Operation ..............................................................................49
Recommended Inverter and Battery Care .....................................................50
Storage for Mobile Installations...................................................................50
Resetting the Inverter ...............................................................................50
Troubleshooting ........................................................................................51
Appendix A – Specifications and Optional Equipment ..........................52
A-1
A-2
A-3
A-4
Inverter/Charger Specifications ..................................................................52
Inverter Efficiency.....................................................................................53
AC Input Voltage to Output Charge Amps ........................................................... 53
Optional Equipment and Accessories............................................................54
Appendix B – Battery Information .......................................................55
B-1
B-2
B-3
B-4
B-5
B-6
Battery
Battery
Battery
Battery
Battery
Battery
Location .......................................................................................55
Types ...........................................................................................55
Temperature .................................................................................55
Bank Sizing ..................................................................................55
Bank Sizing Worksheet ...................................................................56
Wiring Configurations .....................................................................57
Appendix C – Inverter/Charger Terminology.......................................60
Limited Warranty ................................................................................63
How to Receive Repair Service ............................................................63
© 2012 Magnum Energy, Inc.
Page vi
List of Figures
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
1-1, Power Switch, Status LED, and Accessory Connection Ports ................................................3
1-2, Electrical Connection Points ...........................................................................................3
1-3, Left Side Features ........................................................................................................4
2-1, Simplified Installation Diagram for Permanent Installations ................................................8
2-2, Approved Mounting Positions ....................................................................................... 10
2-3, MS Series Dimensions and Side Reference ..................................................................... 11
2-4, DC and Battery Temperature Sensor Wiring ................................................................... 14
2-5, Battery Hardware Installation ...................................................................................... 16
2-6, Inverter DC Hardware Installation ................................................................................ 16
2-7, Battery Temperature Sensor ........................................................................................ 18
2-8, AC Terminal Block ...................................................................................................... 21
2-9, AC Wiring for Single In – Single Out (30 A) Configurations ............................................... 24
2-10, AC Wiring for Single In – Single Out (60 A) Configurations ............................................. 25
2-11, AC Wiring for Single In – Dual Out Configurations ......................................................... 26
2-12, AC Wiring for Dual In – Single Out Configurations ......................................................... 27
2-13, AC Wiring for Dual In – Dual Out Configurations ........................................................... 28
2-14, AC Wiring for Single In – Single Out (MS2000 models) Configurations ............................. 31
2-15, AC Wiring for Single In – Dual Out (MS2000-15B/-20B models) Configurations ................. 32
2-16, Grounding System for MS Series ................................................................................ 33
2-17, Multiple Connections to DC Ground Rod (Method 1)....................................................... 34
2-18, Multiple Connections to DC Ground Rod (Method 2)....................................................... 35
2-19, Single Connection to DC Ground Rod (Method 3) .......................................................... 35
2-20, Neutral-to-Ground Connection (Inverter Mode) ............................................................. 38
2-21, Neutral-to-Ground Connection (Standby Mode)............................................................. 38
2-22, Disconnecting the Neutral-to-Ground Connection .......................................................... 39
2-23, Large Ground Wire Connected to MS Series.................................................................. 39
2-24, Warning Label .......................................................................................................... 40
2-25, AC Voltage Checks .................................................................................................... 41
3-1, Power Flow – Inverter Mode......................................................................................... 42
3-2, Power Flow – Standby Mode ........................................................................................ 43
3-3, Automatic 4-Stage Charging Graph ............................................................................... 44
3-4, BTS Temperature to Charge Voltage Change .................................................................. 45
3-5, Power Switch and Status Indicator................................................................................ 47
A-1, MS Series Efficiency Chart ........................................................................................... 53
A-2, MS Series Output Charger Current Chart ....................................................................... 53
B-1, Series Battery Wiring .................................................................................................. 57
B-2, Parallel Battery Wiring ................................................................................................ 57
B-3, Series-Parallel Battery Wiring....................................................................................... 57
B-4, Battery Bank Wiring Examples (12-volt) ........................................................................ 58
B-5, Battery Bank Wiring Examples (24-volt) ........................................................................ 59
C-1, AC Waveforms ........................................................................................................... 61
List of Tables
Table
Table
Table
Table
Table
Table
Table
Table
Table
Table
Table
1-1,
2-1,
2-2,
2-3,
2-4,
2-5,
2-6,
3-1,
3-2,
4-1,
A-1,
Page vii
Typical Appliance Power Consumption ...............................................................................6
Recommended DC Wire/Overcurrent Device for Rated Use ................................................ 15
DC Wire Size For Increased Distance .............................................................................. 16
AC Input/Output Wiring Configurations ........................................................................... 23
AC Input/Output Wiring Configurations (MS2000 models).................................................. 30
AC Grounding Electrode Conductor Sizing ....................................................................... 34
Equipment Grounding Conductor Sizing .......................................................................... 36
Inverter Battery Turn On/Off Levels................................................................................ 46
Inverter/Charger Default Values .................................................................................... 48
Basic Troubleshooting ................................................................................................... 51
Inverter/Charger Specifications ..................................................................................... 52
© 2012 Magnum Energy, Inc.
Introduction
1.0 Introduction
Congratulations on your purchase of a MS Series inverter/charger from Magnum Energy. The MS
Series is a “pure” sine wave inverter designed especially for rugged mobile applications, home
backup power, and standalone applications. Powerful, yet simple to use, this inverter/charger will
provide you with years of trouble-free performance you have come to expect from Magnum Energy.
Installation is easy. Simply connect the inverter’s output to your distribution circuits or electrical
panel, connect your utility or AC generator power to the inverter’s easy-to-reach terminal block,
connect the batteries, and then switch it on for power.
Info: This is a sizable manual and much of it is fairly technical. Terms may be used
throughout the manual that are unfamiliar to you. Refer to the Inverter/Charger
Terminology glossary in Appendix C for clarification.
The MS Series inverter/charger includes the following:
• 2000, 2800, or 4000 watt inverter and charger in a small footprint installation
• Pure sine wave output
• Automatic PFC (Power Factor Corrected) multi-stage battery charging
• RS485 standard communication protocol
• Remote and Network ports (easy connection for optional accessories)
• Inverter-mounted ON/OFF switch with LED indicator
• 60-amp AC pass-thru capability (30-amp AC pass-thru for MS2000 models)
• Large AC access and terminal block [wire size: 14 to 6 AWG (2.1 to 13.3 mm2) CU]
• Field serviceable for qualified personnel – tested repair kits available
• Automatic battery temperature compensation (when using the Battery Temperature Sensor)
for optimum charging even during extreme temperature changes
• Overcurrent, over-temperature, and high/low battery voltage protection
The following accessories are also available for use with the MS Series inverter/charger:
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•
ME-ARC (Advanced Remote Control) – easy to read LCD display panel that allows advance
inverter set up, control, and troubleshooting.
ME-RC (Basic Remote Control) – easy to read LCD display panel that allows standard inverter
set up, control, and troubleshooting.
ME-AGS-N (Automatic Generator Start Module – Network version) – automatically starts/
stops your generator.
ME-BMK (Battery Monitor Kit - with Shunt) – provides precise DC voltage/current measurements
and information on your battery’s State of Charge (SOC) condition.
Regulatory Compliance
The MS Series inverter/charger is designated as a Standalone (non grid-interactive) power
inverter with an internal battery charger. It can be connected to the utility grid (or to a generator)
to allow the inverter batteries to be charged, and to power inverter loads while connected. The
MS series is not a grid-interactive (also known as utility-interactive) inverter and does not have
the capability to export (or sell) power back into the utility grid.
The MS Series has been tested and listed to UL 458, 5th Edition (Power Converters/Inverters
and Power Converter/Inverter Systems for Land Vehicles and Marine Crafts) and UL 1741, 2nd
Edition¹ (Inverters, Converters and Controllers for Use in Independent Power Systems) for use
in the US; and is also certified to CSA C22.2 No. 107.1-01 (General Use Power Supplies) for use
in Canada. It has been tested and certified to these product safety standards by Intertek Testing
Services (known as ETL), which is a Nationally Recognized Testing Laboratory (NRTL). NRTL’s
are qualified organizations that meet Occupational Safety and Health Administration (OSHA)
regulations to perform independent safety testing and product certification.
The MS Series also meets the KKK-A-1822E standard for use in ambulances.
Note¹ – The MS2000 models are not listed to the UL 1741 standard.
© 2012 Magnum Energy, Inc.
Page 1
Introduction
1.1 Features and Benefits
The MS Series inverter/charger is designed to allow easy access to wiring, circuit breakers, and
controls. Its die cast baseplate with one-piece aluminum cover ensures maximum durability with
minimum weight, as well as a cooler, more efficient operation.
The front of the MS inverter is equipped with the following features (refer to Figures 1-1 and
1-2):
1
Power ON/OFF Switch – a momentary pushbutton switch that alternately turns the
inverter on or off.
2
Status LED Indicator – this green LED illuminates to provide information on inverter
or charger operation.
3
Stack/Accessories Connection Port (red label) – a RJ11 port that allows seriesstacking, and accepts the optional RSAs (Remote Switch Adapters) for remote on/off
switch operation.
Info: The series-stacking capability—which allows two units to provide 120/240 VAC
output—is only available on the MS4024 inverter/charger. See the ME-SSI owner’s
manual (PN: 64-0009) for additional information on stacking.
4
Magnum Network Connection Port (green label) – a RJ11 port that accepts optional
network capable accessories (i.e., Auto Gen Start or Battery Monitor).
5
Remote Connection Port (blue label) – a RJ11 port that allows an optional remote
control (ME-RC, ME-ARC, or ME-RTR) to be connected.
6
Battery Temperature Sensor Connection Port (yellow label) – a RJ11 port that
accepts the remote Battery Temperature Sensor (BTS) accessory.
7
DC Equipment Ground Terminal – this connection is used to tie the exposed chassis
of the inverter to the DC grounding system. This terminal accepts CU/AL conductors from
#14 to #2 AWG (2.1 to 33.6 mm2).
8
AC Entry/Exit Connections – two 3/4” knockouts provided with cable-clamp strain
reliefs to accommodate and secure the AC input and output field wiring.
9
Intake Air Vents – ventilation openings to pull in air to help keep the inverter cool for
peak performance.
10
Positive DC Terminal – provides a 360 degree connection point for the positive (+)
cable from the battery bank; consists of a 5/16-18 x 5/8” bolt with a Kep or Flange nut
that holds the battery cable to the DC terminal.
11
Negative DC Terminal – provides a 360 degree connection point for the negative (-)
cable from the battery bank; consists of a 5/16-18 x 5/8” bolt with a Kep or Flange nut
that holds the battery cable to the DC terminal.
12
Mounting Flange – used to secure the inverter to a shelf or wall.
Page 2
© 2012 Magnum Energy, Inc.
Introduction
1 POWER ON/OFF SWITCH
2 STATUS (CHARGING/INVERTING) LED
STACK/ACCESSORIES PORT
LABEL - RJ11 CONNECTION)
3 (RED
4 NETWORK PORT
(GREEN
LABEL
- RJ11
5 REMOTE PORT
(BLUE
LABEL
- RJ11
CONNECTION)
CONNECTION)
6 BATTERY TEMPERATURE SENSOR PORT
(YELLOW
LABEL
- RJ11
CONNECTION)
Figure 1-1, Power Switch, Status LED, and Accessory Connection Ports
INTAKE AIR VENTS
(AND ON RIGHT SIDE)
9
10
POSITIVE (+) DC
TERMINAL
COVER)
(UNDER
8
11
AC ENTRY/EXIT
CONNECTIONS
NEGATIVE (-)
DC TERMINAL
(UNDER COVER)
7
12
DC
EQUIPMENT
GROUND
TERMINAL
MOUNTING
FLANGE
Figure 1-2, Electrical Connection Points
© 2012 Magnum Energy, Inc.
Page 3
Introduction
The left side of the MS Series inverter is equipped with the following features (Figure 1-3):
13
Exhaust Air Vents – ventilation openings that allow heated air to be removed by the
internal cooling fan.
14
Model/Serial Number Label – includes model/serial number information, date of
manufacture, and inverter and charger specifications. See the MS Specifications in
Appendix A for more information and a list of available models.
15
AC Access Cover – provides access to the internal AC wiring terminal block. This terminal
block is used to hardwire all inverter AC input and output wiring connections. Remove the
two screws to access the AC wiring terminal block.
AC Input Circuit Breaker (CB3) – this circuit breaker protects the unit’s internal
charger wiring and pass-thru relay while in Standby mode. The circuit breaker pops out
when it opens – press in to reset. The input circuit breaker is not branch-rated, therefore
branch-rated circuit breakers must be installed in the inverter’s input wiring.
16
AC Output Circuit Breakers (CB1 & CB2) – these circuit breakers are branch-rated
and allow the inverter AC loads to be connected directly to the inverter’s output without
requiring an inverter sub-panel. These circuit breakers pop out when they open – press
in to reset. They can also be manually pulled to disconnect the inverter’s loads.
17
Info: The output breakers (CB1 and CB2) are only available on models MS2000-15B,
MS2000-20B, MS2012-15B, and MS2012-20B.
CAUTION: Inverter models without the output circuit breakers (CB1 and CB2) must
have branch-rated circuit breakers installed in the inverter’s output wiring.
CAUTION: The inverter’s internal AC transfer relay is rated for 30 amps per leg (30
amps for AC HOT 1 and 30 amps for AC HOT 2). The pass-thru current must be no
greater than 30 amps per leg or damage to the relays may occur.
Model/Serial
Number Label
14
15
AC Access Cover
13
Exhaust
Air Vents
(each side)
CB1
CB2
AC Output Circuit Breakers
(on -15B, -20B output
breaker models only)
17
CB3
16 AC Input Circuit Breaker
Figure 1-3, Left Side Features
Page 4
© 2012 Magnum Energy, Inc.
Introduction
1.2
How an Inverter/Charger Works
There are two modes of operation associated with this inverter/charger:
•
Inverter Mode:
When the inverter is properly connected to batteries and turned on, the direct current
(DC) from the batteries is transformed into a pure sine wave alternating current (AC).
This AC is similar to the voltage provided by your utility and is used to power any electrical
appliances (i.e., AC loads) connected to the inverter’s output.
•
Standby Mode:
When an external source of AC power (i.e., utility power or generator) is connected and
qualified on the inverter’s AC input, it operates in Standby mode. In Standby mode,
the unit operates as a battery charger to convert the incoming AC power into DC power
to recharge the batteries; and at the same time, automatically closes an internal
AC transfer relay to pass the incoming AC power directly to the inverter’s output to continue
powering the connected electrical appliances.
1.2.1
Inverter Applications for Permanent Installations
An inverter can be used for backup power in a permanent location that normally uses utility power,
such as a home or office. When the utility power is available, the inverter keeps the batteries
charged. When the utility power fails, the inverter comes on automatically to supply AC power to
your home or office during the power failure. For a home or business, reliable backup power is
needed to prevent lost computer data, or to maintain lights and keep food fresh in the refrigerator/
freezer.
In some areas, where utility power is not available, this inverter can be used in a standalone
renewable power system. The inverter allows AC electrical appliances to be run from the storage
battery bank. When the battery bank becomes discharged, either renewable DC sources (solar,
wind, or hydro power) can be used to recharge the batteries, or a generator can be connected to
the inverter to power the system while the batteries recharge.
1.2.2
Inverter Applications for Mobile Installations
Inverters can also be used to provide power in mobile situations, such as in an RV, truck, or boat.
In these applications, the inverter provides power to the AC loads using the energy stored in the
batteries and recharges the batteries when shore power or an onboard generator is available.
1.3
Advantages of a Pure Sine Wave vs a Modified Sine Wave Inverter
Today’s inverters come in two basic output waveforms: modified sine wave (which is actually a
modified square wave) and pure sine wave. Modified sine wave inverters approximate a pure sine
wave form and will run most appliances and electronics without any problems. These inverters
are less expensive, and therefore, offer a viable alternative to more expensive pure sine inverters.
The output of a pure sine wave inverter is equal to, or in many cases, better than the utility power
used in your home. Virtually any electronic device will operate from a pure sine wave inverter.
Motors run cooler, microwaves usually cook faster, and clocks keep better time just to name a
few examples. Without compromising quality or performance, the MagnaSine provides you with
all the advantages of a pure sine wave inverter at a much lower cost than many on the market.
The MS Series is built on the same platform as our popular ME and RD Series modified sine wave
inverters – allowing for an easy upgrade from the original ME or RD Series installation. This
standard platform also helps reduce cost by using standard parts/accessories across many models.
All Magnum accessories such as: the Advanced Remote Control (ME-ARC), Basic Remote Control
(ME-RC), Automatic Generator Start - Networked (ME-AGS-N), Battery Monitor Kit (ME-BMK),
and network accessories can be used with the ME, RD, MS, and MS-PAE Series inverters (some
advanced features may not be available in every inverter).
© 2012 Magnum Energy, Inc.
Page 5
Introduction
1.4
Appliances and Run Time
The MS Series inverter/charger can power a wide range of household appliances including small
motors, hair dryers, clocks, and other electrical devices. 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 application, 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.
Appliances such as TVs, VCRs, stereos, computers, coffee pots, incandescent lights, and toasters
can all be successfully powered by your inverter. Larger electrical appliances, however, such as
stoves, water heaters, etc., can quickly drain your batteries and are not recommended for this
application.
All electrical appliances are rated by the amount of power they consume. The rating is printed
on the product’s nameplate label, usually 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 MS Series inverter has a built-in safeguard that automatically
protects your batteries from over-discharge.
Info: For optimum performance, a minimum battery bank of 200 AH is recommended
for moderate loads (<1000W) and greater than 400 AH for heavy loads (≥1000W).
Table 1-1, Typical Appliance Power Consumption
Page 6
Device
Load
Device
Load
Blender
400W
Coffee Maker
1200W
Computer
300W
Color TV
150W
Drill
500W
Hair Dryer
1000W
Hot Plate
1800W
Iron
1000W
Light (Flo)
10W
Light (Inc)
100W
Microwave
1000W
Refrigerator
500W
© 2012 Magnum Energy, Inc.
Installation
2.0 Installation
Info: Installations should be performed by qualified 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 application of
the installation.
CAUTION: Review the “Important Product Safety Information” on pages ii-v before
any installation.
CAUTION: The inverter is heavy. Use proper lifting techniques during installation to
prevent personal injury.
The simplified system diagram shown in Figure 2-1 should be reviewed to assist you in planning
and designing your installation. This drawing is not intended to override or restrict any national
or local electrical codes. This drawing should not be the determining factor as to whether the
installation is compliant, that is the responsibility of the electrician and the on-site inspector.
2.1
Pre-Installation
Before proceeding, read the entire Installation section to determine how best to install your MS
inverter/charger. The more thorough you plan in the beginning, the better your inverter needs
will be met.
2.1.1
Unpacking and Inspection
Carefully remove the MS Series inverter/charger from its shipping container and inspect all contents.
Verify the following items are included:
• The MS inverter/charger
• Red and black DC terminal covers with Phillips screws
• AC access cover with two Phillips screws
• Two 5/16” Kep or Flange nuts (installed on the DC terminals)
• Battery Temperature Sensor
• Warning label
• MS 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 to 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.
2.1.2
Required Tools and Materials
Hardware/Materials
•
Conduit, strain-reliefs and appropriate fittings
•
1/4” mounting bolts and lock washers
•
Electrical tape
•
Wire ties
Tools
•
Miscellaneous screwdrivers
•
Pliers
•
Wire strippers
•
Drill and drill bits
•
Pencil or marker
•
Multimeter
•
Level
•
1/2” wrench
© 2012 Magnum Energy, Inc.
Page 7
Installation
Generator Power
120/240VAC Output
Utility Power
120/240VAC Output
Flux Capacit
or Genera
ME-AGS-N
Auto Gen Start
Controller
(Magnum
Accessory)
tor
ME-ARC
ME-RC
AC
Transfer
Switch
PWR
FAULT
CHG
SELECT
INV
ON/OFF
CHARGER
ON/OFF
INVERTER
SHORE
AGS
METER
SETUP
TECH
Remote Controls (Magnum Accessories)
Main Panel
OFF
OFF
OFF
OFF
OFF
OFF
ON
ON
ON
ON
OFF
OFF
OFF
ON
ON
ON
ON
ON
ON
OFF
ON
ON
ON
ON
ON
ON
OFF
ON
ON
ON
ON
OFF
OFF
ON
OFF
ME-BMK
Battery Monitor
with shunt
(Magnum
Accessory)
120
VAC
30A
OFF
ON
OFF
DC
Overcurrent
Protection
(breaker or
fuse/switch)
DC
Shunt
OFF
OFF
OFF
MS Series
Inverter/
Charger
OFF
OFF
120/240VAC
power to
inverter
OFF
30A
ON
OFF
Sub-Panel
120VAC inverter power
(or 120/240VAC pass-thru power)
to sub-panel
240
VAC
120
VAC
BTS
Battery Bank
ME-SBC
Smart Battery
Combiner
(Magnum
Accessory)
Figure 2-1, Simplified Installation Diagram for Permanent Installations
Page 8
© 2012 Magnum Energy, Inc.
Installation
2.1.3
Locating the Inverter
Only install the inverter 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. This 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, a powder-coated aluminum base
and the internal circuit boards are conformal coated – to help fight the harmful effects of corrosive
environments. However, the inverter’s life is uncertain if used in these type of environments, and
inverter failure under these conditions is not covered under warranty.
Info: If the inverter is installed in an area where moisture may occur, we recommend
putting silicone dielectric grease compound into the electrical ports (Items 3-6 as
shown in Figure 1-1). Before installing the cables, or if leaving any ports open, squirt a
liberal amount into each port. Silicone dielectric compound makes an effective moisture
and corrosive barrier to help protect and prevent corrosion to the RJ11 connections.
Cool – The inverter should be protected from direct sun exposure or equipment that produces
extreme heat. The ambient temperature around the inverter must not exceed 77°F (25°C) to
meet power specifications.
Ventilation – In order for the inverter to provide full output power and to 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. The inverter uses two fans to provide forced air cooling, these fans
pull in air through the intake vents (see Item 9, Figure 1-2) and blow out air through the exhaust
vents (see Item 13, Figure 1-3). Allow at the minimum an airspace clearance of 6” at the intake
and exhaust vents, and 3” everywhere else to provide adequate ventilation.
If installed in an enclosure, a fresh air intake opening must be provided directly to the front side
(intake vents) of the inverter and an exhaust opening on the back side (exhaust vents) of the
inverter. This allows cool air from the outside to flow into the inverter and heated air to exit the
inverter and the enclosure. When mounted in an enclosed compartment, airflow must be ≥ 100
cfm in order to maintain no more than a 68°F (20°C) rise in compartment temperature.
CAUTION: Do not mount this inverter in a zero clearance compartment, nor cover or
obstruct the ventilation openings – overheating may result.
Safe – Keep any flammable/combustible material (i.e., paper, cloth, plastic, etc.) that may be
ignited by heat, sparks, or flames at a minimum distance of 2 feet away from the inverter. Do not
install this inverter in any area that contains extremely flammable liquids like gasoline or propane,
or in locations that require ignition-protected devices.
WARNING: The MS Series inverter/charger is not ignition protected and may not be
located in an engine compartment with gasoline fueled engines under any circumstance.
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, as well
as the inverter’s controls and status indicator. Allow enough room to access the AC and DC wiring
terminals and connections, as they will need to be checked and tightened periodically. See Figure
2-3 for the MS Series inverter/charger’s dimensions.
Away from sensitive electronic equipment – High powered inverters can generate levels of RFI
(Radio Frequency Interference). Locate any electronic equipment susceptible to radio frequency
and electromagnetic interference as far away from the inverter as possible.
© 2012 Magnum Energy, Inc.
Page 9
Installation
2.2 Mounting the Inverter
The inverter base can reach a temperature up to 90°C (194°F) and should be mounted on a
noncombustible surface*. This surface and the mounting hardware must also be capable of
supporting at least twice the weight of the inverter. To meet regulatory requirements, the MS
Series must be mounted in one of the following positions as shown in Figure 2-2:
•
•
•
above or under a horizontal surface (shelf or table),
on a vertical surface (wall) with the DC terminals to the right,
on a vertical surface (wall) with the DC terminals toward the bottom, the MP-HOOD (inverter
hood) installed on the top, and either the ME-CB (Conduit box), MMP series (single inverter
enclosure), or MP Series (multiple inverter enclosure) installed on the inverter’s bottom.
Info: The ME-CB, MMP and MP Series enclosures prevent material from falling out the
bottom in the event of an internal fire, and also allow sufficient ventilation to prevent the
inverter from overheating under normal operating conditions. The MP-HOOD inverter
hood helps prevent items from falling inside causing damage to the inverter.
Info: Magnum provides a backplate for mounting the inverter. These backplates (PN:
BP-S single plate or BP-D, dual plate) also provide the ability to mount either the MMP
Series enclosure (PN: BP-MMP) or the MP Series Enclosure (PN: BP-MP).
After determining the mounting position, refer to the physical dimensions as shown in Figure
2-3, or use the base of the inverter as a template to mark your mounting screw locations. After
marking the mounting screw locations, mount the unit with appropriate mounting hardware.
* Noncombustible surface – A surface made of material that will not ignite, burn, support combustion, or
release f ammable vapors when subjected to f re or heat as per the ASTM E136 standard. For the most
part, these are materials that are largely comprised of inorganic materials such as stone, steel, iron, brick,
tile concrete, slate, and glass. Common building materials such as gypsum board as well as any paint, wall
coverings, and certainly wood will not pass.
SHELF OR TABLE MOUNTED
(UP SIDE DOWN)
30
30
SHELF OR TABLE
MOUNTED
(RIGHT SIDE UP)
WALL MOUNTED
(DC TERMINALS
FACING DOWN*)
*WHEN
THE INVERTER
IS MOUNTED IN THIS
POSITION, THE
MP-HOOD
(INVERTER HOOD ON
TOP), AND THE ME-CB
(CONDUIT BOX ON BOTTOM)
OR MP/MMP SERIES
ENCLOSURES MUST BE
USED.
(DC
WALL MOUNTED
TERMINALS TO THE RIGHT)
Figure 2-2, Approved Mounting Positions
Page 10
© 2012 Magnum Energy, Inc.
Installation
Model: MS2000 Inverter/Charger
Inverter Operation:
LEFT
SIDE
6 ⅝"
Date Code Qtr 1 2 3 4 Year 06 07 08 09 10
8"
Continuous output power: 2000 Watts @ 25°C
Peak output current 29.0AAC, 10 sec surge (unregulated)
Output provided with integral protection against overload
DC Input: 10.0-15.5VDC
Continuous input current: 225A @ 12.6VDC
AC current distortion at rated power <5% THD
Charger Operation:
Continuous Charger current: 100ADC @ 11-14VDC
AC Input: 120VAC/60Hz @ 30 Amps Max
(Charger can use up to 16 amps of 120VAC)
Power Factor: @ 10% to 100% charge > .95
Engineered and Manufactured in the U.S.A.
Magnum Energy Inc.
1111 80th St S.W. Suite 250
Everett, WA 98203
Serial Number
CB1
OUTPUT 1
T1-00001
CB2
OUTPUT 2
30
30
LEFT
SIDE
CB3
INPUT 30 A
30
MS2000 model
MS2012/MS2812/MS4024 models
Note: MS2000 models have the same
dimensions as those shown below.
13 ¾"
4 ⅞"
RIGHT
SIDE
BACK
SIDE
TOP
SIDE
4 ⅞"
2"
FRONT
SIDE
12"
12 ⅝"
LEFT
SIDE
Keyhole slots (x4) and mounting holes
(x4) accept up to 9/32" screw/bolt
Figure 2-3, MS Series Dimensions and Side Reference
© 2012 Magnum Energy, Inc.
Page 11
Installation
2.3
Wiring the Inverter - General Requirements
This section describes the requirements and recommendations for wiring the MS Series inverter/
charger. Before wiring the MS Series inverter/charger, carefully read all instructions.
Wiring should meet all local codes and standards and be performed by qualified personnel
such as a licensed electrician.
The NEC (National Electric Code, ANSI/NFPA 70) for the United States and the CEC (Canadian
Electrical Code) for Canada provide the standards for safely wiring residential and commercial
installations. The NEC/CEC lists the requirement for wire sizes, overcurrent protection, and
installation methods and requirements.
Inverter/charger systems involve power from multiple sources (inverter, generator, utility, batteries,
solar arrays, etc.) which make the wiring more hazardous and challenging.
The input and output AC and DC circuits are isolated from the inverter chassis. The inverter system
grounding is the responsibility of the installer in accordance with the NEC/CEC.
WARNING: Ensure all sources of DC power (i.e., batteries, solar, wind, or hydro) and
AC power (utility power or AC generator) are de-energized (i.e., breakers opened,
fuses removed) before proceeding – to prevent accidental shock.
2.3.1
Protecting Wire – Conduit Box
The AC and DC wires to and from the inverter must be protected as required by code. This can
be done by using jacketed wires or by feeding the wires through conduit. Magnum offers a DC
conduit box (ME-CB), a single inverter enclosure (MMP Series), and a multiple inverter enclosure
(MP Series) that include the necessary AC and DC inverter breakers that allow both the AC and
DC conduit to be connected to the inverter.
Info: The strain reliefs can be removed and replaced with 3/4” grommets if you are using
either the ME-CB conduit box, MMP or MP enclosure, and the AC wires are individual
conductors (i.e., not jacketed),.
2.3.2
•
•
•
•
•
•
Wiring Requirements
All conductors that are at risk for physical damage must be protected by conduit, tape, or
placed in a raceway.
Always check for existing electrical, plumbing, or other areas of potential damage prior to
making cuts in structural surfaces or walls.
Do not mix AC and DC wiring in the same conduit or panel unless specifically approved/
designed for both AC and DC wiring. Where DC wiring must cross AC or vice-versa, try to
make the wires at the crossing point perpendicular (90 degrees) to one another.
Both AC and DC overcurrent protection must be provided as part of the installation.
The inverter requires a reliable negative and ground return path directly to the battery.
Use only copper wires with a minimum temperature rating of 90°C.
2.3.3
Wire Routing
Before connecting any wires, determine all wire routes to and from the inverter. Typical routing
scenarios are:
• AC input wiring from the main AC panel to the inverter.
• AC input wiring from a generator (optional) to the inverter.
• DC input wiring from the batteries to the inverter.
• AC output wiring from the inverter to the AC sub-panel or to dedicated circuits.
• Battery Temperature Sensor cable from the inverter to the batteries.
• Remote control cable (optional) to the inverter.
• Ground wiring to and from the inverter.
2.3.4
Torque Requirements
Torque all AC wiring connections to 16 in lbf (1.8 N-m). Torque DC cable connections from 10 to
12 ft lbf (13.6 to 16.3 N-m).
Page 12
© 2012 Magnum Energy, Inc.
Installation
2.4
DC Wiring
This section describes the inverter’s required DC wire sizes, the recommended disconnect/
overcurrent protection, and how to make the DC connections to the inverter and the battery bank.
Refer to Figure 2-4 when connecting the DC wires.
WARNING: Even though DC voltage is “low voltage”, significant hazards may be
present, particularly from short circuits of the battery system.
CAUTION: The inverter is NOT reverse polarity protected – which means that if the
negative and positive battery voltage is connected backwards to the inverter, the
inverter will likely be damaged. You should verify the correct voltage polarity using a
voltmeter BEFORE connecting the DC wires.
CAUTION: Before wiring the DC cables, review the safety information at the beginning
of this manual and the information below to ensure a safe and long-lived system.
Info: DO NOT connect the battery cables to the inverter until all wiring is complete and
the correct DC voltage and polarity have been verified.
•
When the inverter is installed in a Photovoltaic System, the NEC requires that the DC circuit
conductors and overcurrent devices to the inverter be sized to carry not less than 125% of
the inverter’s maximum current rating.
•
The DC positive and negative cables connected to the inverter from the battery bank 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 the wear of the inverter’s filter capacitors.
•
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.
•
The battery bank voltage MUST match the DC voltage required by the inverter (i.e., 24-volt
battery bank for a 24-volt inverter) or the inverter may be damaged.
•
To ensure the maximum performance from the inverter, all connections from the battery bank
to the inverter should be minimized. The exception is the DC overcurrent disconnect in the
positive line and a shunt in the negative line. Any other additional connection will contribute
to additional voltage drops, and these extra connection 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 ft lbf (13.6 to 16.3
N-m). If you don’t have a torque wrench, ensure all DC terminals are tight and cannot move.
•
Be aware that overtightening or misthreading the nuts on the DC terminals can cause the
bolts to strip and snap/break off.
•
Make sure cables have a smooth bend radius and do not become kinked. Place long cable runs
in conduit and follow existing wire runs where possible.
•
A brief spark or arc may occur when connecting the battery cables to the inverter DC terminals;
this is normal and due to the inverter’s internal capacitors being charged.
•
Color code the DC cables/wires with colored tape or heat shrink tubing: RED for positive (+);
WHITE for negative (-); and GREEN for DC ground, to avoid polarity problems.
© 2012 Magnum Energy, Inc.
Page 13
Installation
MS Series
Inverter/Charger
(front view)
BTS
BTS
Inverter’s DC Negative Busbar
Inverter’s DC Positive Busbar
Inverter’s Equipment Ground Wire
Battery Temp Sensor Cable*
MMP enclosure – for single inverter installations
(includes DC disconnect breaker, DC shunt for
battery monitor, and inverter DC busbars). If
multiple inverters will be installed, see the MP
enclosures - designed to allow up to four
inverters to be connected together.
Battery Bank’s Equipment Ground Wire
Battery Bank’s Negative Cable
Battery Bank’s Positive Cable
DC System Grounding point
[Electrode Conductor
(i.e., ground busbar)]
Battery Bank
Figure 2-4, DC and Battery Temperature Sensor Wiring
Page 14
© 2012 Magnum Energy, Inc.
Installation
2.4.1
DC Wire Sizing
It is important to use the correct sized DC wire to achieve maximum efficiency from the system
and to reduce fire hazards associated with overheating. Always keep your wire runs as short as
practical to prevent low voltage shutdowns and to keep the DC breaker from nuisance tripping (or
open fuses) because of increased current draw. See Table 2-1 to select the minimum DC wire size
(and corresponding overcurrent device) required based on your inverter model. The cable sizes
listed in Table 2-1 are required in order to reduce stress on the inverter, minimize voltage drops,
increase system efficiency, and ensure the inverter’s ability to surge heavy loads.
If the distance from the inverter to the battery bank is >5 feet, the DC wire will need to be increased.
Longer distances cause an increase in resistance, which affects the performance of the inverter.
Use the overcurrent device previously determined from Table 2-1 and then refer to Table 2-2 to
determine the minimum DC wire size needed for various distances, based on your inverter model.
2.4.2
DC Overcurrent Protection
DC overcurrent protection is not included in the inverter—for safety reasons and to comply with
electrical code regulations—it must be provided as part of the installation. The DC overcurrent
protection device must be installed in the positive DC cable line, it can be a fuse or a circuit
breaker and must be DC rated. It must be correctly sized according to the size of DC cables being
used, which means it is required to open before the cable reaches its maximum current carrying
capability, thereby preventing a fire. In a residential or commercial electrical installation, the NEC
requires both overcurrent protection and a disconnect switch. If a circuit breaker is used as the
overcurrent protection device, it can also be used as the required DC disconnect.
If a fuse is used as an overcurrent device, a Class-T type or equivalent is recommended. This fuse
type is rated for DC operation, can handle the high short-circuit currents and has a time delay
that allows for momentary current surges from the inverter without opening the fuse. However,
because the fuse can be energized from both directions, if it is accessible to unqualified persons,
the NEC requires that it be installed in a manner that the power must be disconnected on both
ends of the fuse before servicing.
Use Table 2-1 to select the DC overcurrent device needed based on the recommended minimum
wire size for your particular inverter model (may not meet all local code or NEC requirements).
Table 2-1, Recommended DC Wire/Overcurrent Device for Rated Use
Using Conduit
Inverter
Model
Maximum
Continuous
Current1
NEC
Current2
MS2000
222 amps
MS2012
In Free Air
DC
Grounding
Electrode
Wire Size5
Minimum DC
Wire Size
(rating)3
Recommended
DC Breaker
Size4
Minimum DC
Wire Size
(rating)3
Maximum DC
Fuse Size4
278 amps
#4/0 AWG
(260 amps)
250 amps6
#2/0 AWG
(300 amps)
300 amps with
time delay
#6 AWG
222 amps
278 amps
#4/0 AWG
(260 amps)
250 amps6
#2/0 AWG
(300 amps)
300 amps with
time delay
#6 AWG
MS2812
311 amps
388 amps
#4/0 AWG
(260 amps)
250 amps6
#4/0 AWG
(405 amps)
400 amps with
time delay
#6 AWG
MS4024
222 amps
278 amps
#4/0 AWG
(260 amps)
250 amps6
#2/0 AWG
(300 amps)
300 amps with
time delay
#6 AWG
Note1 – Maximum continuous current is based on the inverter’s continuous power rating at the lowest input voltage.
Note2 – NEC current is based on the maximum continuous current rating with a 125% NEC de-rating for sizing the overcurrent device (when not continuous duty) to prevent it from being operated at more than 80% of rating.
Note3 – Copper wire rated with 90°C (194°F) insulation at an ambient temperature of 30°C (86°F), with a multiple cable
f ll factor (0.8) de-rating (if needed).
Note4 – The next larger standard size overcurrent device may be used if the derated cable ampacity falls between the
standard overcurrent devices found in the NEC.
Note5 – 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 rod, pipe, or plate electrode.
Note6 – May not allow continuous operation at full rated power as def ned by the NEC.
© 2012 Magnum Energy, Inc.
Page 15
Installation
Table 2-2, DC Wire Size For Increased Distance
Inverter
Model
Minimum Recommended DC Wire Size (one way)*
5 feet or less
In Conduit
In Free Air
5 to 10 feet
In Conduit
10 to 15 feet
In Free Air
In Conduit
In Free Air
#4/0 AWG x2
MS2000
#4/0 AWG
#2/0 AWG
#4/0 AWG x2
#4/0 AWG
not
recommended
MS2012
#4/0 AWG
#2/0 AWG
#4/0 AWG x2
#4/0 AWG
not
recommended
#4/0 AWG x2
MS2812
#4/0 AWG
#4/0 AWG
#4/0 AWG x2
#4/0 AWG x2
not
recommended
not
recommended
MS4024
#4/0 AWG
#2/0 AWG
#4/0 AWG x2
#4/0 AWG
not
recommended
#4/0 AWG x2
* Copper wire rated with 90°C (194°F) insulation at an ambient temperature of 30°C (86°F).
2.4.3
DC Cable Connections
Do not put anything between the battery cable ring lug and the battery post or the flat metal part
of the inverter’s DC terminal. When connecting the battery cable to the battery post or inverter
DC terminal, the cable should be placed directly against the inverter terminal or battery post.
Incorrectly installed hardware causes a high resistance connection which could lead to poor inverter/
charger performance, and may melt the cable and terminal connections.
Refer to Figures 2-5 and 2-6 to connect the DC cables and to stack the hardware correctly. Tighten
the terminal connections from 10 to 12 ft lbf (13.6 to 16.3 N-m).
CAUTION: The DC terminal and Flange/Kep nuts are made of stainless steel which have
a high likelihood of seizure. To help prevent the bolt and nut from seizing—causing the
bolts to strip or snap/break-off—the use of anti-seize lubricant is highly recommended.
Info: If antioxidant grease or spray is used, apply it after all the connections have been
made and are properly tightened.
Info: A 1/2-inch wrench or socket is used to tighten the 5/16 SAE Flange/Kep nuts.
nut
CAUTION:
ENSURE NOTHING
split washer
Battery
Temperature
Sensor
flat washer
CAUTION:
ENSURE NOTHING IS
battery cable
(with ring lug)
PLACED BETWEEN
THE CABLE RING LUG
battery
post
Figure 2-5, Battery Hardware
Installation
Page 16
RING LUG.
Inverter DC
terminal
(5/16–18 x 5/8" bolt)
AND BATTERY POST.
IS
PLACED BETWEEN THE
DC TERMINAL AND
5/16-18
Flange or
Kep nut
battery cable
(with ring lug)
Figure 2-6, Inverter DC Hardware
Installation
© 2012 Magnum Energy, Inc.
Installation
2.4.4
Wiring the DC Overcurrent Protection Device
A fuse/disconnect or circuit breaker must be provided in the DC positive line between the battery
and the inverter to protect the DC wiring system. Mount the fuse block (or circuit breaker assembly)
as near as practical to the batteries. For maximum protection, install it within 18 inches (45 cm)
of the battery.
1. Open the fuse disconnect (or open the circuit breaker) and connect a short cable (same rating
as the battery cables) to one end of the fuse block.
2. Connect the short cable to the positive battery terminal.
3. Connect the positive cable (RED) from the inverter to the fuse/disconnect (or circuit breaker)
assembly. DO NOT connect the positive cable to the inverter at this time.
4. Securely tighten the fuse/disconnect (or circuit breaker) connection lugs. Once the entire
installation is complete and all connections are verified, close the fuse disconnect (or circuit
breaker) to provide power to the inverter.
2.4.5
Wiring the Battery Bank
WARNING: Lethal currents 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 touching/shorting the cables.
Info: DO NOT connect the DC wires from the battery bank to the inverter until 1) all
DC and AC wiring is complete, 2) the correct DC and AC overcurrent protection has
been installed, and 3) the correct DC voltage and polarity have been verified.
Info: For the MS Series inverter/charger to perform optimally, a minimum battery
bank of 200 AH is recommended for moderate loads (<1000W) and greater than 400
AH for heavy loads (≥1000W).
Depending upon the voltage of the batteries you use in the installation (6 or 12 VDC), the batteries
must be wired in series, parallel, or series-parallel to provide the correct voltage (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 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.
CAUTION: Install batteries in a well ventilated area. Batteries can produce explosive
gasses. For compartment or enclosure installations, always vent batteries to the
outside.
Info: To ensure the best performance from your inverter system, batteries should be of
the same size, type, rating, and age. Do not use old or untested batteries.
© 2012 Magnum Energy, Inc.
Page 17
Installation
2.4.6
Battery Temperature Sensor Installation and Wiring
The Battery Temperature Sensor (shown in Figure 2-7) provides the inverter with precise battery
temperature information to automatically adjust the ABSORB and FLOAT charge voltage set-points.
This allows the batteries to be correctly charged under extreme temperature changes.
If the temperature sensor is NOT installed and the batteries are subjected to large temperature
changes, the batteries’ lives may be shortened.
The BTS cable may be extended—using a RJ11 connector (female to female) and a standard phone
cable with RJ11 connectors—to a maximum length of 40 feet. However, your inverter to battery
cable length should not exceed the recommended distance provided in Table 2-2.
To install the BTS:
1. Attach the ring terminal end of the Battery Temperature Sensor to the negative battery terminal;
see Figure 2-5 for proper connection to the battery terminal.
2. Route the sensor’s cable to the inverter following existing wire runs.
3. Connect the RJ11 connector end of the BTS cable to the yellow-labeled BTS port on the inverter
(Item 6, Figure 1-1).
FRONT VIEW
~1"
~2"
~¾”
0.375" diameter
Cable
~½”
SIDE VIEW
Figure 2-7, Battery Temperature Sensor
Page 18
© 2012 Magnum Energy, Inc.
Installation
2.4.7
Wiring the Inverter to the Battery Bank
CAUTION: The inverter is NOT reverse polarity protected – 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 voltmeter. 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): red for positive (+), and white for negative (-) to
avoid polarity confusion.
Info: The DC overcurrent device (i.e., circuit breaker or fuse) 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
equipment ground terminal (Item 7, Figure 1-2) to a dedicated system ground. Recommended
tightening torque is 45 in lbf (5.1 N-m). Refer to Section 2.6 for grounding information and sizing
the DC ground wires.
DC Negative Wire
Route an appropriately sized DC negative wire (marked white) from the negative terminal of the
battery bank to the inverter’s negative terminal (Item 11, Figure 1-2).
Info: If installing a battery monitor such as Magnum’s ME-BMK, install a DC shunt inline with the negative battery cable.
DC Positive Wire
Mount the circuit breaker or fuse assembly as near as practical to the batteries and leave open
(i.e., no power to inverter).
WARNING: DO NOT close the DC circuit breaker or connect the fuse to connect
battery power to the inverter at this time. This will occur in the Functional Test after
the installation is complete.
CAUTION: If connecting live battery cables to the inverter DC terminals, a brief spark
or arc may occur; this is normal and due to the inverter’s internal capacitors being
charged.
Route and connect an appropriately sized DC positive wire (red) from the inverter’s positive DC
terminal (Item 10, Figure 1-2) to one end of circuit breaker (or DC fuse block).
Connect a short wire (same rating as the DC wires) to the other side of the DC circuit breaker
(or one end of the fuse/disconnect assembly) and the other end of the short wire to the positive
terminal of the battery bank (see Figure 2-1 for reference). This is essential to ensure even charging
and discharging across the entire battery bank.
Ensure the DC wire connections (on the batteries, inverter, and DC circuit breaker/fuse lugs) 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 2-5 and 2-6). Verify all DC connections are
torqued from 10 to 12 ft lbf (13.6 to 16.3 N-m).
Once the DC connections are completely wired and tested, coat the terminals with an approved
anti-oxidizing spray.
Attach the red and black terminal covers over the inverter’s DC connectors and secure them in
place with the supplied screws.
If the batteries are in an enclosure, perform a final check of the connections to the battery terminals,
then close and secure the battery enclosure.
© 2012 Magnum Energy, Inc.
Page 19
Installation
2.5
AC Wiring
This section provides information on how to make the AC connections to the inverter using the
correct AC wire size and corresponding overcurrent protection.
2.5.1
Pre-AC Wiring Requirements
CAUTION: Before installing any AC wiring, review the safety information at the
beginning of this manual and the following to ensure a safe and long-lived system:
•
Read all instructions and cautionary markings located at the beginning of this manual
and in the pre-installation section before installing the inverter and batteries.
•
Always use properly rated circuit breakers. If using an electrical sub-panel, circuit
breakers can be moved from the main electrical panel to the sub-panel only if the
breakers are also listed to be installed in the sub-panel.
•
AC wiring must be no less than #10 AWG (5.3 mm2) gauge copper wire and be
approved for the application (i.e., residential, RV, or marine wiring).
•
DO NOT connect the inverter’s output to an AC power source. This could cause
severe damage to the inverter and is not covered under warranty.
WARNING: To reduce the risk of fire, do not connect this inverter to an AC load center
(circuit breaker panel) having multi-wire branch circuits connected.
2.5.2
AC Wire Size and Overcurrent Protection
The AC input and output wiring must be sized per the local electrical safety code requirements
to ensure the wire’s ability to safely handle the inverter’s maximum load current. The AC wiring
must be protected from short circuits and overloads by an overcurrent protection device and have
a means to disconnect the AC circuits. AC overcurrent protection is not included in the inverter
and must be provided as part of the inverter installation. The AC overcurrent protection device
must be a circuit breaker or a fuse/disconnect and be properly sized and branch circuit rated for
the wire it is protecting and the appliances being powered.
The MS Series provides a terminal block (see Figure 2-8) that allows the AC input and output wiring
to be permanently wired. This terminal block allows a service/distribution panel (main panel) to
be wired to the inverter’s input, and a dedicated panel (sub-panel)1 between the inverter’s output
wiring and the AC loads. These systems use the circuit breakers provided in the panels as the
overcurrent protection and the AC disconnect device.
When in the Standby mode, the full AC continuous pass-thru capacity of the MS Series inverter/
charger is 30 amps for each AC leg² (AC HOT 1 and AC HOT 2). However, the AC HOT 1 and AC
HOT 2 may be combined to obtain a 60-amp pass-thru capability (see Figure 2-10 for the SISO60A configuration). For a 30-amp continuous pass-thru capability, each AC HOT input to the
inverter requires a 30-amp continuous duty rated breaker³, which corresponds to a minimum
cable size of #10 AWG4 in conduit. When tying the AC HOT 1 and HOT 2 together for a 60-amp
continuous pass-thru capability, the AC input to the inverter requires a 60 amp continuous duty
rated breaker³, which corresponds to a minimum cable size of #6 AWG4 in conduit. If you are
using other circuit breakers/wire sizes, refer to the appropriate electrical codes for proper sizing
requirements.
CAUTION: The inverter’s internal AC transfer relay contacts are rated for 30 amps
(each leg), the pass-thru current for relay contact must be no greater than 30 amps
or damage to this relay may occur.
Note1 – Breaker models (-15B and -20B) do not require a dedicated inverter panel (i.e., sub-panel).
Note² – On breaker models (-15B and -20B), the pass-thru current is limited by the output breaker size.
Note³ – The breaker must be derated by 80% if not rated for continuous duty. The NEC requires that circuits
are not to be operated continuously at more than 80% of rating unless listed with a 100% continuous rating.
Note4 – Copper wire should be rated with 90°C insulation at an ambient temperature of 30°C (86°F).
Page 20
© 2012 Magnum Energy, Inc.
Installation
2.5.3
Recommended GFCI (Ground Fault Circuit Interruption) Breakers
Some electrical safety codes require the use of GFCIs. In compliance with UL standards, Magnum
Energy has tested the following GFCIs and find that they function properly when connected to the
inverter’s AC output:
• Shock SentryTM #XGF15V-SP • Leviton Smart Lock #8899-A • Hubbel #GF520EMBKA
2.5.4
AC Terminal Block Connections
The inverter has a six-pole AC terminal block and one AC ground terminal to connect the inverter’s
AC input and output wiring. To access and view the AC terminal block and ground terminal, remove
the two Phillips screws holding the AC wiring access cover plate (see Item 15, Figure 1-3).
Info: When wiring the AC input and output circuits, we highly recommend a full
system Inverter Bypass Switch. This simple item, if installed, provides a convenient
way to isolate the inverter for battery maintenance, and it could save you hours of
downtime—if you ever need to service your inverter—by enabling you to continue to
provide AC power to your AC loads without any re-wiring. Because we think it is an
essential part of an inverter system, every Magnum panel (MMP Series and MP Series)
is equipped with a full system Inverter Bypass Switch.
Each connection on the AC terminal block is rated to accept one #14 to #6 AWG (2.1 to 13.3 mm2) CU
stranded wire, or two #12 AWG (3.3 mm2) CU stranded wires. Each connection uses a M3.5 slotted
head screw, and the maximum tightening torque is 16 lbf-in (1.8 N-m).
Info: One of the AC wiring configurations [SI/SO (60A), Figure 2-10] uses a #6 AWG
wire to carry 60 amps, and splits to two wires to allow 30 amps for each leg (i.e., AC
HOT 1 and AC HOT 2). IDEAL Industries Inc. (www.idealindustries.com) manufactures
a crimp connector (PN: 412) and a separate insulator (PN: 417) that allow up to two
#8 AWG wires – with one #6 AWG wire to be connected together.
Info: To comply with ABYC requirements for marine installations, the AC terminal has
a stainless steel wire protector to prevent wire damage from the set-screw.
Info: The inverter’s NEUT IN and NEUT OUT terminals are electrically isolated from
each other while inverting. This is related to the neutral-ground bonding requirement
and helps prevent ground-loops (see Section 2.6.5 for more information). If the
installation requires the input and output neutrals to be connected together, the
inverter’s neutral-to-ground connection must be disconnected (see Section 2.6.5).
The AC ground terminal can accept one #14 to #6 AWG (2.1 to 13 mm2) CU stranded wire. It uses
a slotted head screw and has a recommended maximum tightening torque of 45 in lbf (5.1 N-m).
For multiple ground wires, use a pressure or mechanical connector to attach the single wire from
the AC ground terminal to the input and output ground connections.
HOT 2 IN
HOT 1 IN
NEUT IN
HOT 1 OUT
HOT 2 OUT
NEUT OUT
AC GROUND
(In & Out)
Figure 2-8, AC Terminal Block
© 2012 Magnum Energy, Inc.
Page 21
Installation
2.5.5
AC Conductor Wiring
The following steps are basic guidelines for installing and connecting the AC wiring to and from all
MS Series inverters (except MS2000 Series model inverters – for instructions on wiring MS2000
Series model inverters, refer to Section 2.5.7). Before proceeding, refer to Table 2-3 to determine
your AC wiring configurations.
WARNING: Before making any AC connections, make sure the inverter is disconnected
from the battery and no AC power is connected to the inverter.
Wiring the Inverter AC Input
1. Remove the two Phillips screws on the AC wiring access cover (Item 15, Figure 1-3) to access
the internal AC terminal block (see Figure 2-8).
2. Route the cable from the AC electrical main panel through one of the strain relief clamps on
the inverter (Item 8, Figure 1-2). Tighten the strain relief clamp securely on the cable. Always
leave a little extra slack in the wiring.
3. Connect the hot wire (BLACK) from the main panel’s dedicated breaker to the inverter’s AC
HOT 1 IN terminal. Tighten the AC HOT 1 IN terminal to 16 in lbf (1.8 N-m).
Info: You must connect to the AC HOT 1 IN terminal if you want to use the battery
charger.
Info: Depending on the AC wiring configuration, you may need to connect a wire to
the AC HOT 2 IN terminal – refer to your configuration drawing (Figure 2-10 to 2-13).
4. Connect the neutral (WHITE) from the main panel’s neutral busbar to the inverter’s AC NEUT
IN terminal. Tighten the AC NEUT IN terminal to 16 in lbf (1.8 N-m).
Wiring the Inverter AC Output
1. Route the cable through the unused strain relief clamp on the inverter (Item 8, Figure 1-2)
to the AC electrical sub-panel (or outlets, if using the output breaker versions). Tighten the
strain relief clamp securely on the cable.
2. Connect the hot (BLACK) wire from the inverter’s AC HOT 1 OUT terminal to the sub-panel‘s
main breaker (or to the hot connections on the outlets if using the output breaker versions).
Tighten the AC HOT 1 OUT terminal to 16 in lbf (1.8 N-m).
Info: Depending on the AC wiring configuration, you may need to connect a wire
to the AC HOT 2 OUT terminal – refer to your configuration drawing (Figure 2-10 to
2-13).
3. Connect the neutral (WHITE) from the inverter’s AC NEUT OUT terminal to the sub-panel’s
neutral busbar (or to the neutral connection on the outlets if using the output breaker versions).
Tighten the AC NEUT OUT terminal to 16 in lbf (1.8 N-m).
Wiring the Inverter AC Ground
1. Combine the ground (GREEN) wire from the main panel’s ground busbar and the ground
(GREEN) wire from the sub-panel’s ground busbar (or the ground connection on the outlets if
using the output breaker versions). After these grounds are combined, connect them to the
inverter’s AC GROUNDS terminal. Tighten the AC GROUNDS terminal to 16 in lbf (1.8 N-m).
AC Wiring Inspection
1. Verify all cables runs are secured. If installed in a mobile installation, use wire ties or other
non-conductive fasteners to prevent chafing or damage from movement and vibration.
2. Verify strain reliefs or grommets are in place to prevent damage to the wiring or conduit where
it passes through walls/bulkheads or other openings.
3. After verifying all AC connections are correct and all inverter AC terminal screws are torqued to
16 in lbf (1.8 N-m), replace the AC wiring access cover and the covers on the main electrical/
distribution panel.
Page 22
© 2012 Magnum Energy, Inc.
Installation
2.5.6
AC Wiring Configurations
The following table provides the different wiring configurations for installing and connecting the
AC conductors to and from the inverter (refer to Figures 2-9 to 2-13 for installation drawings
showing these configurations).
Table 2-3, AC Input/Output Wiring Configurations
SI/SO
(30A)
Single In/
Single Out
(30A)
SI/SO (60A)
Single In/
Single Out
(60A)
SI/DO
Single In/
Dual Out
DI/SO
Dual In/Single
Out
DI/DO
Dual In/
Dual Out
AC Source1
Required
120 VAC @ <
30 amps
120 VAC @ >
30 amps
(60 amps
maximum)
120/240 VAC (or
2 separate legs of
120 VAC)
@ < 15 amps per
leg (-15B models);
or < 20 amps per
leg (-20B models).
120/240 VAC (or 120/240 VAC (or
2 separate legs
2 separate legs
of 120 VAC)
of 120 VAC)
@ < 30 amps
@ < 30 amps per
per leg
leg
Reason to
Use
Have an 120
VAC source
that is < 30
amps.
Requires
a separate
inverter
sub-panel.
Have an 120
VAC source
that is > 30
amps.
Requires
a separate
inverter
sub-panel.
Do not want to
Want dedicated
install a separate
charging and
inverter sub-panel. dedicated passInverter pass-thru
thru while the
capability limited
AC source is on.
by model used:
Requires a
-15B = 30 amps; separate inverter
-20B = 40 amps.
sub-panel.
Appropriate
Models
MS2012
MS2812
MS4024
MS2012
MS2812
MS4024
MS2012-20B
MS2012-15B
MS2012
MS2812
MS4024
MS2012
MS2812
MS4024
Maximum
Input
Breaker
Required
Minimum
Wire Size
30A
(single pole)
#10 AWG
(In & Out)
60A
(single pole)
#6 AWG
(In & Out);
Can be split to
two #10 AWG
(for HOT 1
& HOT 2)
-15B models:
30A (single pole);
-20B models:
40A (single pole)
#10 AWG (In)
(Hot input must
be split to two
#12 AWG);
#12 AWG x2 (Out)
30A
(dual pole)
#10 AWG
(In & Out)
30A
(dual pole)
#10 AWG
(In & Out)
Maximum
Inverter
Pass-thru
capacity
3600W
(30A @ 120
VAC)
7200W
(60A @ 120
VAC)
-15B models:
3600W
(30A @ 120 VAC);
-20B models:
4800W
(40A @ 120VAC)
3600W
(30A @ 120
VAC)
7200W
(2 legs of 30A @
120/240 VAC or
2 legs of 30A @
120 VAC)2
Wiring
Diagram
Figure 2-9
Figure 2-10
Figure 2-11
Figure 2-12
Figure 2-13
May need to
power 240 VAC
loads when
AC source is
on (requires
120/240 VAC
source).
Requires a
separate inverter
sub-panel.
Note1 – AC Source is from either the utility/grid power (i.e., shore power) or an AC generator.
Note2 – If two legs of 30A @ 120 VAC are used, they must be from the same source.
© 2012 Magnum Energy, Inc.
Page 23
Installation
AC Terminal Block
(AC input and output wiring)
AC NEUT IN
(from main panel)
AC HOT 1 IN
(from main panel)
AC HOT 1 OUT
(to sub-panel)
AC NEUT OUT
(to sub-panel)
MS Series Inverter
AC GROUNDS
(to/from
both panels)
SINGLE IN / SINGLE OUT (30A) wiring
In mobile installations: neutral is typically not
connected to ground in main panel.
ON
ON
OFF
ON
OFF
ON
ON
OFF
OFF
ON
ON
OFF
ON
OFF
ON
ON
OFF
OFF
OFF
OFF
ON
ON
OFF
ON
ON
OFF
ON
ON
OFF
OFF
30
OFF
OFF
Main Panel
(Utility/Generator Input)
..Maximum..
30-amp breaker
(single pole)
required to
inverter AC input
120
VAC
120
VAC
Sub-Panel and Outlets
(Inverter Loads)
Figure 2-9, AC Wiring for Single In – Single Out (30 A) Configurations
Page 24
© 2012 Magnum Energy, Inc.
Installation
AC Terminal Block
(AC input and output wiring)
AC NEUT IN
(from main panel)
AC HOT 1 IN
(from main panel)
AC HOT 2 IN
(from main panel)
AC HOT 1 OUT
(to sub-panel)
AC HOT 2 OUT
(to sub-panel)
AC NEUT OUT
(to sub-panel)
MS Series Inverter
AC GROUNDS
(to/from
both panels)
SINGLE IN / SINGLE OUT (60A) wiring
In mobile installations: neutral is typically not
connected to ground in main panel.
ON
ON
OFF
ON
OFF
ON
ON
OFF
OFF
ON
ON
OFF
OFF
OFF
ON
OFF
ON
ON
OFF
OFF
OFF
OFF
ON
ON
OFF
ON
ON
OFF
ON
ON
OFF
ON
OFF
OFF
60
ON
OFF
Maximum..
60-amp breaker
(single pole)
required to
inverter AC input
120
VAC
Main Panel
(Utility/Generator Input)
120
VAC
120
VAC
120
VAC
Sub-Panel and Outlets
(Inverter Loads)
Figure 2-10, AC Wiring for Single In – Single Out (60 A) Configurations
© 2012 Magnum Energy, Inc.
Page 25
Installation
AC Terminal Block
(AC input and output wiring)
AC NEUT IN
(from main panel)
AC HOT 1 IN
(from main panel)
AC HOT 2 IN
(from main panel)
AC HOT 1 OUT
AC HOT 2 OUT
AC NEUT OUT
(x2)
MS2012-15B or
MS2012-20B Inverter
AC GROUNDS
(to/from
both panels)
SINGLE IN / DUAL OUT wiring
In mobile installations: neutral is typically not
connected to ground in main panel.
ON
120
VAC
120
VAC
Direct from Inverter
(Inverter Loads)
OFF
ON
OFF
ON
OFF
OFF
ON
OFF
OFF
ON
OFF
OFF
ON
ON
OFF
ON
OFF
ON
OFF
ON
30
ON
ON
OFF
ON
OFF
Maximum breaker size
required to inverter AC input
depends on model used.
MS2012-15B: 30-amp
breaker (single pole);
MS2012-20B: 40-amp
breaker (single pole).
Main Panel
(Utility/Generator Input)
Figure 2-11, AC Wiring for Single In – Dual Out Configurations
Page 26
© 2012 Magnum Energy, Inc.
Installation
AC Terminal Block
(AC input and output wiring)
AC NEUT IN
(from main panel)
AC HOT 1 IN
(from main panel)
AC HOT 2 IN
(from main panel)
AC HOT 2 OUT
(to sub-panel)
AC NEUT OUT
(to sub-panel)
MS Series Inverter
AC GROUNDS
(to/from
both panels)
DUAL IN / SINGLE OUT wiring
In mobile installations: neutral is typically not
connected to ground in main panel.
ON
ON
OFF
OFF
ON
OFF
OFF
ON
ON
OFF
ON
OFF
OFF
ON
OFF
ON
OFF
ON
ON
OFF
ON
ON
OFF
ON
OFF
30
Maximum..
30-amp breaker
(double pole)
required to
inverter AC input
120
VAC
Main Panel
(Utility/Generator Input)
ON
ON
OFF
ON
OFF
30
OFF
OFF
120
VAC
Sub-Panel and Outlets
(Inverter Loads)
Figure 2-12, AC Wiring for Dual In – Single Out Configurations
© 2012 Magnum Energy, Inc.
Page 27
Installation
AC Terminal Block
(AC input and output wiring)
AC NEUT IN
(from main panel)
AC HOT 1 IN
(from main panel)
AC HOT 2 IN
(from main panel)
AC HOT 1 OUT
(to sub-panel)
AC NEUT OUT
(to sub-panel)
AC HOT 2 OUT
(to sub-panel)
MS Series Inverter
AC GROUNDS
(to/from
both panels)
DUAL IN / DUAL OUT wiring
In mobile installations: neutral is typically not
connected to ground in main panel.
ON
ON
OFF
OFF
OFF
OFF
OFF
ON
OFF
ON
OFF
ON
OFF
ON
ON
OFF
ON
ON
OFF
ON
OFF
ON
..Maximum..
30-amp breaker
(double pole)
required to
inverter AC input
240
VAC only
in standby
Main Panel
(Utility/Generator Input)
OFF
ON
ON
ON
OFF
ON
ON
OFF
OFF
30
OFF
ON
OFF
30
ON
OFF
120
VAC
120
VAC
Sub-Panel and Outlets
(Inverter Loads)
Figure 2-13, AC Wiring for Dual In – Dual Out Configurations
Page 28
© 2012 Magnum Energy, Inc.
Installation
2.5.7
AC Conductor Wiring (MS2000 models)
The MS2000 offers a cost-effective alternative to the MS2012 while still providing the same features. This model has a slightly smaller height, but otherwise has the same footprint as the other
MS Series inverters. The MS2000 can be wired in a single in - single out configuration, as well as
a single in - dual out configuration (-15B & -20B).
The following steps are basic guidelines for installing and connecting the AC wiring into and out
of the inverter. Refer to Table 2-4 to determine your AC wiring configurations before beginning.
WARNING: Before making any AC connections, make sure the inverter is disconnected
from the battery and that no AC power is connected to the inverter.
Wiring the Inverter AC Input
1. Remove the two Phillips screws on the AC access cover (Item 15, Figure 1-3) to access the
internal AC wiring.
2. Route the cable from the AC electrical main panel through one of the strain relief clamps to
the AC INPUT. Tighten the strain relief clamp securely on the cable. Always leave a little extra
slack in the wiring.
3. Connect the AC hot in wire (black) from the main panel’s dedicated breaker to the inverter’s
(black) HOT IN wire using field wiring leads.
4. Connect the AC neutral in wire (white) from the main panel’s neutral busbar to the inverter’s
(white) NEUTRAL IN wire using field wiring leads.
Wiring the Inverter AC Output
1. Route the cable from the inverter’s AC OUTPUT to the AC electrical sub-panel (or outlets, if
using the output breaker versions) through the other strain relief clamp. Tighten the strain
relief clamp securely on the cable.
2. Connect the inverter’s HOT 1 OUT (blue) wire to the sub-panel main breaker (or, to the hot
connections on the outlets if using the output breaker versions) using field wiring leads.
Info: Depending on the AC wiring configuration, you may need to connect a wire to
the inverter’s HOT 2 OUT (orange) wire (see Figure 2-15).
3. Connect the inverter’s NEUTRAL OUT (white w/black) wire to the sub-panel’s neutral busbar
(or to the neutral connections on the outlets, if using the output breaker versions - see Figure
2-15) using field wiring leads.
Wiring the Inverter AC Ground
Combine the ground (green) wire from the main panel’s ground busbar and the ground (green)
wire from the sub-panel’s ground busbar (or the ground connection on the outlets, if using the
output breaker versions). After these grounds are combined, use field wiring leads to connect
them to the inverter’s AC GROUND (green) wire.
AC Wiring Inspection
1. Verify all cable runs are secured. If installed in a mobile installation, use wire ties or other
non-conductive fasteners to prevent chafing or damage from movement and vibration.
2. Verify strain reliefs or grommets are in place to prevent damage to the wiring or conduit where
it passes through walls/bulkheads or other openings.
3. After verifying all AC connections are securely fastened, replace the AC wiring access cover
and the covers to the main electrical/distribution panel.
© 2012 Magnum Energy, Inc.
Page 29
Installation
2.5.8
AC Wiring Configuration (MS2000 models)
The following table provides the different wiring configurations for installing and connecting the
AC conductors to and from MS2000 model inverters (see Figures 2-14 and 2-15 for installation
diagrams showing these configurations).
Table 2-4, AC Input/Output Wiring Configurations (MS2000 models)
SI/SO (30A)
Single In/
Single Out
(30A)
Page 30
SI/DO
Single In/
Dual Out
AC Source1
Required
120 VAC @
< 30 amps
120 VAC @
< 30 amps
@ < 15 amps per
leg (-15B models);
or < 20 amps per
leg (-20B models).
Reason to
Use
Have an 120
VAC source
that is < 30
amps.
Requires
a separate
inverter
sub-panel.
Do not want to
install a separate
inverter sub-panel.
Inverter pass-thru
capability limited
by model used.
Appropriate
Models
MS2000
MS2000-15B
MS2000-20B
Maximum
Input
Breaker
Required
Minimum
Wire Size
30A
(single pole)
#10 AWG
(In & Out)
-15B models:
30A (single pole);
-20B models:
30A (single pole)
#10 AWG (In)
(Hot input must
be split to two
#12 AWG);
#12 AWG x2 (Out)
Maximum
Inverter
Pass-thru
capacity
3600W
(30A @
120 VAC)
-15B models:
15A/leg
(30A max.);
-20B models:
20A/leg
(30A max.)
Wiring
Diagram
Figure 2-14
Figure 2-15
© 2012 Magnum Energy, Inc.
Installation
AC Terminal Block
(AC input and output wiring)
MS2000 Series Inverter
BLACK
AC HOT IN
WHITE
AC NEUT IN
GREEN
AC GROUND
AC GROUND
.WHITE w./ BLACK
AC. NEUT. OUT.
AC HOT. 1 OUT
BLUE
SINGLE IN / SINGLE OUT (30A) wiring
In mobile installations: neutral is typically not
connected to ground in the main panel.
ON
ON
OFF
ON
ON
OFF
ON
OFF
ON
ON
OFF
OFF
ON
OFF
OFF
OFF
OFF
ON
ON
OFF
ON
ON
OFF
ON
ON
OFF
ON
ON
OFF
OFF
30
OFF
OFF
..Maximum..
30 amp breaker
(single pole)
required to
inverter AC input
120
VAC
Main Panel
(Shore Power/Generator Input)
120
VAC
Sub-Panel and Outlets
(Inverter Loads)
Figure 2-14, AC Wiring for Single In – Single Out (MS2000 models)
Configurations
© 2012 Magnum Energy, Inc.
Page 31
Installation
AC Terminal Block
(AC input and output wiring)
BLACK
Has optional 15-amp or 20amp branch-rated circuit
breakers (on side of unit).
AC HOT IN
WHITE
MS2000-15B/
MS2000-20B Inverters
AC NEUT IN
GREEN
AC GROUND
AC GROUND (x2)
.WHITE w./ BLACK
AC NEUT OUT
.WHITE w./ BLACK
AC NEUT OUT
BLUE
AC HOT. 1 OUT
AC HOT. 2 OUT
ORANGE
SINGLE IN / DUAL OUT wiring
In mobile installations: neutral is typically not
connected to ground in the main panel.
ON
120
VAC
120
VAC
Direct from inverter
(Inverter Loads)
OFF
OFF
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
ON
OFF
OFF
ON
ON
OFF
ON
ON
OFF
30
ON
OFF
ON
OFF
.Maximum 30-amp breaker
(single pole) required to
inverter AC input.
Main Panel
(Shore Power/Generator Input)
Figure 2-15, AC Wiring for Single In – Dual Out (MS2000-15B/-20B models)
Configurations
Page 32
© 2012 Magnum Energy, Inc.
Installation
2.6
Grounding Inverters
The inverter/charger should always be connected to a permanent, grounded wiring system.
An inverter system that is properly grounded will limit the risk of electrical shock, reduce radio
frequency noise from the inverter, and minimize excessive surge voltages induced by lightning. This
is done by ensuring there is a well-defined, very low-resistance path from the electrical system to
the grounding system. This low-resistance path helps stabilize the electrical system voltage with
respect to ground and carries fault currents directly to ground if the electrical system malfunctions.
To understand how the conductors in the electrical circuit will be connected to the system ground,
the following terms should be understood:
•
•
•
•
•
Grounded Conductor (GC): The wire/cable in the electrical system that normally carries current (usually
the AC neutral and/or the DC negative), and is intentionally connected or “bonded” to the ground
system. This wire, or the ends of this wire, should be colored white or gray.
Equipment Grounding Conductor (EGC): A wire/cable that does not normally carry current and is used to
connect the exposed metal parts of equipment—that might be accidentally energized—to the grounding
electrode system or to the grounded conductor. This wire, or the ends of this wire, should be green or
green with a yellow stripe; this wire can be bare copper.
Grounding Electrode Conductor (GEC): The wire/cable that does not normally carry current and connects
the grounded conductor and/or the equipment grounding conductor to the grounding electrode at the
service equipment.
Grounding Electrode (GE): A ground rod or conducting element that establishes an electrical connection
to the earth.
System bonding jumper (SBJ): The connection between the grounded circuit conductor in the electrical
system and the equipment grounding conductor at a separately derived system.
The MS Series inverter/charger uses both AC and DC power; however, the AC electrical system is
isolated from the DC electrical system by an internal transformer. Although this inverter/charger
has two electrical systems, each electrical system must be properly grounded and connected to
a common “earth” reference. Refer to Figure 2-16.
For proper grounding, each electrical system must connect all exposed metal parts of equipment
(via equipment grounding conductors - EGC) and one of the current-carrying conductors (grounded
conductor - GC) together at a common point (ground busbar - GBB), usually by a system bonding
jumper (SBJ) in an electrical service disconnect panel. The common point of each electrical system
is then connected (via grounding electrode conductor - GEC) to the common ground reference,
such as a ground rod (grounding electrode - GE). This connection to earth should only be made
at one point in each electrical system; otherwise, parallel paths will exist for the currents to flow.
These parallel current paths would represent a safety hazard and are not allowed in installations
wired per the NEC/CEC.
AC Electrical System
AC Service
Panel
DC Electrical System
Positive
Hot
Neutral
GBB
DC Service
Panel
MS Series Inverter/Charger
GC
SBJ
AC
DC
Neutral
Negative
AC Ground
EGC
GEC-AC
GC
SBJ
DC Ground
Grounding
System
Negative
GBB
EGC
GEC-DC
or
or
GE
Grounding Electrode
(AC side dedicated)
GE
Grounding Electrode
(AC and DC sides shared)
GE
Grounding Electrode
(DC side dedicated)
Figure 2-16, Grounding System for MS Series
© 2012 Magnum Energy, Inc.
Page 33
Installation
2.6.1
Sizing the Grounding Electrode Conductors
AC Side – The size of the AC grounding electrode conductor (GEC – AC) depends on the size of
the largest ungrounded conductor feeding the AC load center. One #8 AWG (8.4 mm2) copper
conductor will serve as an AC grounding electrode conductor (GEC – AC) for AC power conductors
smaller than and including #2 AWG (33.6 mm2) copper. See Table 2-5 for additional values.
Table 2-5, AC Grounding Electrode Conductor Sizing
Size of Largest Ungrounded
Conductor
Minimum Size of Grounding
Electrode Conductor
#2 AWG or smaller
#8 AWG (8.4 mm2)
#1 to #1/0 AWG
#6 AWG (13.3 mm2)
#2/0 or #3/0 AWG
#4 AWG (21.1 mm2)
Over #3/0 AWG
through 350 kcmil
#2 AWG (33.6 mm2)
DC Side – To size the DC grounding electrode conductor, you must first determine which one of the
following three methods will be used to connect the DC and AC grounding points in the inverter’s
two electrical systems to the common “earth” ground:
Method 1 (Figure 2-17): This method uses a separate grounding electrode for the DC system
and the AC system. In this method—since there are multiple connections to the DC grounding
electrode (GEC – DC)—the size of the DC grounding electrode conductor cannot be smaller than
the largest conductor in the DC system (usually the battery-to-inverter cable).
The DC grounding electrode (GE – DC) must be bonded to the AC grounding electrode (GE – AC)
to make a grounding electrode system. This bonding conductor (BC) cannot be smaller than the
largest grounding electrode conductor, either AC or DC.
AC Electrical System
AC Service
Panel
DC Electrical System
Positive
Hot
Neutral
GBB
DC Service
Panel
MS Series Inverter/Charger
GC
SBJ
AC
DC
Neutral
Negative
AC Ground
EGC - AC
GEC-AC
GE
Grounding Electrode
(AC side dedicated)
GC
Negative
SBJ
DC Ground
Grounding
System
BC
GBB
EGC - DC
GEC-DC
GE
Grounding Electrode
(DC side dedicated)
Figure 2-17, Multiple Connections to DC Ground Rod (Method 1)
Page 34
© 2012 Magnum Energy, Inc.
Installation
Method 2 (Figure 2-18): When the AC and DC service panels are near each other, then the AC
grounding electrode conductor (GEC – AC) and DC grounding electrode conductor (GEC – DC) can
be connected to a single grounding electrode. In this method—since there are multiple connections
to the DC grounding electrode (GEC – DC)—the size of the DC grounding electrode conductor cannot
be smaller than the largest conductor in the DC system (usually the battery-to-inverter cable).
AC Electrical System
AC Service
Panel
DC Electrical System
Positive
Hot
Neutral
GC
AC
DC
Neutral
Negative
SBJ
GBB
DC Service
Panel
MS Series Inverter/Charger
AC Ground
EGC - AC
GC
Negative
SBJ
DC Ground
GBB
EGC - DC
Grounding
System
GEC-DC
GEC-AC
GE
Grounding Electrode
(AC and DC sides shared)
Figure 2-18, Multiple Connections to DC Ground Rod (Method 2)
Method 3 (Figure 2-19): The AC grounding electrode conductor (GEC – AC) is bonded to the
DC ground point and the DC grounding electrode conductor (GEC – DC) is the only connection to
the grounding electrode, which must be a rod, pipe, or plate electrode.
In this method, since there is only one connection to the ground rod, the DC grounding electrode
conductor is not required to be larger than #6 AWG (13 mm2) copper. The reasoning for allowing
this smaller grounding electrode conductor is that it is only required to stabilize the system voltage
with respect to earth, and the other properly-sized conductors in each electrical system will safely
carry any fault currents if they occur.
AC Electrical System
AC Service
Panel
DC Electrical System
Positive
Hot
Neutral
GBB
DC Service
Panel
MS Series Inverter/Charger
GC
SBJ
AC
DC
Neutral
Negative
AC Ground
Negative
SBJ
DC Ground
EGC - AC
GEC-AC
GC
GBB
EGC - DC
Grounding
System
GE
GEC-DC
Grounding Electrode
(DC side dedicated)
Figure 2-19, Single Connection to DC Ground Rod (Method 3)
© 2012 Magnum Energy, Inc.
Page 35
Installation
2.6.2
System Bonding Jumper
The MS Series inverter does not include an internal bond between the grounded conductor (AC
neutral/DC negative) and the equipment grounding terminals. This bond [system bonding jumper
(SBJ)] is usually done in the main distribution panel for each electrical system.
CAUTION: There should be one and only one point in each electrical system (both
AC and DC) where the grounded conductor is attached to the grounding electrode
conductor.
AC Side – The size of the system bonding jumper (SBJ) in the AC electrical system is based on
the area of the largest AC ungrounded conductor. In accordance with the NEC, use Table 2-4 to
determine the system bonding jumper size compared to the largest AC ungrounded conductor.
DC Side – The size of the system bonding jumper (SBJ) in the DC electrical system must not be
smaller than the DC grounding electrode conductor (GEC – DC) used, which is determined from
the grounding method that will be used (see Section 2.6.1).
2.6.3
Equipment Grounding Conductor
The inverter case and all other noncurrent-carrying exposed metal surfaces in the entire electrical
system that may be accidentally energized must be grounded. The equipment-grounding conductor
must be sized to safely carry the maximum ground-fault current likely to be imposed on it from
where a ground-fault may occur. In accordance with the NEC, use Table 2-6 to size the equipmentgrounding conductors. This table requires that the equipment-grounding conductor be sized
according to the rating of the overcurrent device protecting the circuit.
CAUTION: The connections and wiring for the equipment-grounding conductor must
be continuous to allow fault currents to properly operate overcurrent devices. Where
equipment is removed and this disconnects the bonding connection between the
grounding electrode conductor and exposed conducting surfaces, a bonding jumper
must be installed while the equipment is removed.
AC Side – Where the AC output from the inverter is connected to an AC load center, there should
be an equipment grounding conductor connected between the inverter case and the grounding
point in the AC load center. The AC equipment grounding conductor (EGC – AC) is sized per Table
2-6 and is connected to the inverter’s AC equipment grounding terminal shown in Figure 2-8.
DC Side – Since the currents on the DC side are higher than the AC side (10 times at 12 volts,
5 times at 24 volts), the equipment grounding needs are different. The DC equipment grounding
conductor (EGC – DC) is sized per Table 2-6 and connected to the DC equipment grounding terminal
on the inverter as shown in Item 7, Figure 1-2.
Table 2-6, Equipment Grounding Conductor Sizing
Page 36
Rating of Overcurrent
Device
Minimum Size of Copper
Ground Wire
15 amps
#14 AWG
20 amps
#12 AWG
30 - 60 amps
#10 AWG
100 amps
#8 AWG
200 amps
#6 AWG
300 amps
#4 AWG
400 amps
#3 AWG
© 2012 Magnum Energy, Inc.
Installation
2.6.4
Grounding on Boats
When installing the MS Series inverter/charger on a boat, there are several considerations that
must be followed when grounding to ensure a safe installation, prevent galvanic corrosion, and
to adhere to ABYC (American Boat and Yacht Council) standards.
Ensure a Safe Ground Connection
When AC on the boat is being supplied by shore power, the onboard neutral should be connected
to safety ground on the dock. Consequently, neutral and safety ground should not be connected
anywhere on the boat when shore power is present. When AC on the boat is being supplied by the
MS Series inverter, the inverter’s output neutral is connected to safety ground through an internal
relay, using its neutral-to-ground connection (shown in Figure 2-20).
The DC ground terminal on the MS Series must also be connected to the boat’s safety ground
bus. This ensures that both the inverter’s AC and DC ground terminals are connected to the boat’s
safety ground bus as a safety measure to provide protection against faults, and to provide a path
for AC fault currents while the boat is connected to shore power.
Preventing the Risk of Corrosion
The inverter’s AC and DC ground terminals must be connected to the boat’s safety ground to
provide an important safety feature. However, this ground connection introduces the risk of galvanic
corrosion and/or electrolysis of the boat’s underwater metallic hardware.
Two possible solutions are typically used to maintain the correct onboard grounding requirements
while greatly reducing (if not eliminating) the risk of galvanic corrosion. These solutions would be
either using a galvanic isolator or an onboard isolation transformer.
Galvanic isolators allow high AC voltage faults to pass, but block low voltage corrosion/electrolysis
currents from conducting.
Marine isolation transformers allow the shore power to be connected to one side of the transformer,
and the boat’s AC wiring system is connected to the other side. Since transformers do not allow
DC currents to pass, the problem with galvanic corrosion is eliminated.
ABYC Inverter/Charger Grounding Requirements1
• DC Grounding Connections:
1) The DC grounding conductor (equipment ground) shall be:
a) connected from the metallic case or chassis of the inverter/charger to the engine negative
terminal or its bus,
b) of an ampacity equal to that of the DC positive conductor (under certain conditions, there
is an exception to allow this conductor to be one size smaller – refer to the ABYC standard).
2) The inverter/charger’s negative battery terminal and DC grounded conductor (negative
cable) shall not be connected to the inverter case or chassis at the inverter/charger itself.
•
AC Grounding Connections:
1) The AC grounding conductor (green) shall be connected to the inverter/charger in a manner
so that the AC ground connection will not be disconnected in servicing. This conductor is in
addition to and independent of the DC grounding conductor.
2) The neutral for AC power sources shall be grounded only at the following points:
a) the shore power neutral is grounded only through the shore power cable and not grounded
on board the boat,
b) the inverter neutral shall be grounded at the inverter, and the output neutral shall be
disconnected from ground when the inverter is operating in the charger/pass-through mode,
c) on systems using an isolation transformer or a polarization transformer, the inverter
neutral (and the transformer secondary neutral) may be grounded at the AC main grounding
bus instead of at the inverter.
Note1 – See the ABYC Standard for complete AC/DC grounding requirements.
© 2012 Magnum Energy, Inc.
Page 37
Installation
2.6.5
Neutral to Safety Ground Bonding
The standards for safely wiring residential, commercial, RV/truck, and marine installations in the
United States require the neutral and safety ground to be connected at the AC source; whether
it is the utility feed in your home, an inverter, or a generator. This is to establish a specification
that maximizes the possibility that a circuit breaker will activate if a hotwire-to-ground fault
occurs. These standards also require that the AC neutral be connected to safety ground (often
called a “bond”) in one, and only one, place at any time. The single bond is established in order
to make the electrical panel’s neutral line safe, by connecting it to ground. Without this bond,
the neutral can have up to 60 VAC with respect to ground. On the other hand, if more than one
bond is established, currents can circulate between neutral and ground and cause “ground-loop”
currents. These ground-loops can trip GFCIs, cause an electric shock hazard, and may be the reason
for other annoying side effects.
In applications where you are using an inverter as one of your AC sources along with another
AC source (i.e., utility power or generator), there is the potential of having multiple connections
(bonds) between neutral and ground. Therefore, you must ensure that the inverter does not also
connect the neutral-to-ground while the other AC source is actively powering the inverter loads.
This can be prevented if your inverter is equipped with automatic neutral-to-ground switching.
WARNING: In most electrical systems, the neutral-to-ground bond is located in the
main utility service entrance panel. Remove any bond downstream from the inverter
to prevent multiple bonds. If there is an inverter sub-panel—separate from a main
electrical panel—it should have a removable wire that allows the neutral bus to be
unbonded from the ground busbar.
All MS Series inverter/chargers have automatic neutral-to-ground switching to specifically work
in multiple source applications. The MS Series inverters use an internal relay that automatically
connects the AC neutral output terminal to the vehicle/boat’s ground while inverting (Inverter
mode) to provide the neutral-to-ground bond; as shown in Figure 2-20. However, when an external
AC source (i.e., shore power or a generator) is qualified, another neutral-to-ground connection is
introduced in the system. When the MS Series is connected to this external AC source and goes
into Standby mode, the internal relay automatically opens the neutral-to-ground connection as
shown in Figure 2-21. This design keeps two neutral-to-ground connections from occurring at the
same time, thereby preventing an electrical shock hazard between the vehicle/boat’s neutral and
the external AC source’s neutral.
Inside MS Series Inverter /Charger
(Inverter Mode)
Inside MS Series Inverter /Charger
(Standby Mode)
Neu-Gnd Relay (K1)
Neu-Gnd Relay (K1)
NEUT IN
NEUT IN
NEUT OUT
GROUND
NEUT OUT
GROUND
Neutral -to-Ground Connection
(inside AC compartment)*
Figure 2-20, Neutral-to-Ground
Connection (Inverter Mode)
Neutral -to-Ground Connection
(inside AC compartment)*
Figure 2-21, Neutral-to-Ground
Connection (Standby Mode)
* - Normally located in the AC compartment; however, on MS2000 models the neutral-to-ground is located
internally on the AC board.
Page 38
© 2012 Magnum Energy, Inc.
Installation
2.6.6
Disabling the Neutral-to-Ground Connection
All MS Series inverter/chargers have the automatic neutral-to-ground switching feature. In
some installations/jurisdictions, this feature must be disabled by disconnecting the neutral-toground connection. If you are not sure whether you must disable this feature, check your local code
requirements. The following steps will guide you in disabling the neutral-to-ground switching feature.
Note: The neutral-to-ground switching feature cannot be disabled in MS2000 models.
Info: The ground connection from the inverter’s AC and DC ground terminals should
still be connected to the system ground, even if ground switching has been disabled.
WARNING: Fire and Shock Hazard – disconnect all AC and DC sources before working
in the AC wiring compartment.
1. Locate and remove the AC access cover plate
(Item 15, in Figure 1-3) on the side of the
MS Series inverter.
2. Inside the AC wiring compartment, locate
the green wire with the insulated connector;
see Figure 2-22. This insulated connector
connects the neutral and ground inside the
inverter while inverting.
3. Pull the two ends of the insulated connector
apart to separate the green wire; this will
prevent the neutral and ground from connecting inside this inverter.
4. Move the two disconnected ends away from
each other and push back out of the way. You
must ensure that the two connector ends will
not have any contact with any other wires
within the AC compartment. You may want
to use electrical tape to insulate the ends
and secure them out of the way.
2.6.7
Neutral-toGround
Connection
(green wire)
Figure 2-22, Disconnecting the
Neutral-to-Ground Connection
Connecting a Large Ground Wire
Marine installation requires the ground wire to be the same size or one size smaller than the
negative cable. Use the following steps to allow a larger ground wire to be connected.
1. Locate the DC ground terminal (Item 7, in
Figure 1-2).
2. Locate and remove the AC access cover plate
(Item 15, in Figure 1-3) on the side of the
MS inverter.
3. Within the AC wiring area, locate the hex nut
on the back side of the DC ground terminal. After locating the hex nut, use a 7/16”
wrench/nut driver to remove the hex nut,
bolt, lock washer, and DC ground terminal –
remove them from the chassis.
4. Reverse the removed bolt and place it back
in the chassis hole to attach a correctly sized
ground cable to the MS Series chassis as
shown in Figure 2-23.
5. Place the washer and nut on the bolt over the
ground cable and securely tightened the nut
[from 4 to 5 ft lbf (5.4 to 6.8 N-m)]. Note:
The ground cable’s bolt hole size is 1/4”.
© 2012 Magnum Energy, Inc.
DC Ground
terminal bolt/nut,
reversed and
tightened.
Figure 2-23, Large Ground Wire
Connected to MS Series
Page 39
Installation
2.7
Inverter Notification Requirements
When an inverter is installed in a building, facility or structure, the NEC (National Electrical Code)
requires a label or plaque to be provided. This label/plaque is required to be easily visible and
provide information that informs personnel on the location of all electrical system disconnects.
This is to ensure all power to a building is quickly located and shut down in an emergency. There
are also specific requirements for this label/plaque depending on the inverter application, they
are as follows.
2.7.1
Facilities with Standalone Systems
Any building, facility, or structure with a photovoltaic power system that is not connected to a
utility service source and is a standalone system must have a permanent plaque or directory
installed on the exterior of the building or structure at a readily visible location acceptable to the
Authority Having Jurisdiction (AHJ). The plaque or directory must provide the location of system
disconnecting means and information regarding whether the structure contains a standalone
electrical power system.
2.7.2
Facilities with Utility Services and PV Systems
Buildings, facilities, or structures with both utility service and a photovoltaic system must have a
permanent plaque or directory providing the location of the service disconnecting means and the
photovoltaic system disconnecting means if they are not located at the same location.
2.7.3
Inverter Warning Label
A warning label as shown in Figure 2-24 is provided to inform all personnel that an inverter is
installed in your electrical system. Affix this label in a clearly visible location at the electrical panel
that is being powered by the inverter. This is because it might be falsely assumed that the panel is
no longer “hot” after the AC power has been shut off, when power may actually still be available
due to the inverter automatically powering the panel.
This electrical system is equipped with an Automatic
Generator Starting (AGS) device and/or an inverter.
Disconnect all AC and DC power to the AGS and/
or inverter before performing any service to the
electrical system. Failure to do so can result in shock
causing serious injury or death.
PN: 62-0002 Rev A
Figure 2-24, Warning Label
2.8
Final Inspection
1. Verify all cables/conduit runs are secured with wire ties or other non-conductive fasteners to
prevent chafing or damage from movement and vibration.
2. Verify strain reliefs or grommets are in place to prevent damage to the wiring or conduit where
it passes through walls, bulkheads, or other openings.
3. Verify all AC connections are correct and torqued to a maximum of 16 in lbf (1.8 N-m).
4. Replace the covers on the main electrical/distribution panel.
5. Replace the chassis access cover.
6. Verify the inverter’s front panel switch is in the “OFF” position.
Info: If required by code, have the installation inspected by an electrical inspector.
Page 40
© 2012 Magnum Energy, Inc.
Installation
2.9
Functional Test
After all electrical connections to the inverter, batteries, AC source and sub-panel have been
completed, follow these steps to test the installation and the inverter’s operation.
CAUTION: Use a multimeter to verify the correct DC voltage for your particular inverter
model (i.e., 24-volt battery bank for a 24-volt inverter) and to ensure the polarity of the
battery voltage is correct (battery positive connected to the inverter positive terminal
and the battery negative connected to the inverter negative terminal).
1. Apply battery power to the inverter by closing 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 the inverter is ready to be turned on.
2. Prior to turning on the inverter, make sure all AC loads (i.e., appliances) are NOT connected
to the inverter’s output or to any AC outlets powered by the inverter.
3. Lightly press and release the inverter’s ON/OFF switch to turn the inverter on. Verify the
inverter’s status indicator is blinking – indicating the inverter is on.
4. Connect a 10-25 watt light bulb to the inverter output and verify it comes on and shines normally.
DO NOT connect anything larger than a 25-watt light bulb until all wiring and voltages are confirmed
to be correct.
Info: The inverter’s AC output voltage will not be correct until a load greater than 5
watts (default setting) is connected to the inverter; or, Search mode is turned off with
a remote display (ME-RC, ME-ARC, or ME-RTR). A 10-25 watt light bulb is used as it is
a sufficient load to bring the inverter out of Search mode and up to full voltage.
5. Check the AC output voltage of the inverter by connecting an AC voltmeter to the output
terminals as shown in Figure 2-25 (verify the correct output voltages).
6. Press and release the inverter’s ON/OFF switch to turn the inverter off. The inverter’s status
indicator and the connected load should go off.
7. 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 light bulb. Verify that the inverter’s status indicator and the light bulb come on.
8. Even though the light bulb is on, the inverter is currently disabled (off). Press and release the
ON/OFF switch on the inverter to enable (turn on) the inverter.
9. Disconnect the incoming AC power to the inverter. Verify the light bulb remains on and is now
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 in this manual.
AC Terminal Block
AC Output
120 Vac
(± 5%)
30
30
Neutral to Ground
< 0.5 Vac
Figure 2-25, AC Voltage Checks
© 2012 Magnum Energy, Inc.
Page 41
Operation
3.0 Operation
The MS Series inverter has two normal operating routines: Inverter mode, which powers your loads
using the batteries, and Standby mode, which transfers the incoming AC current (i.e., utility power
or a generator) to power your loads and to recharge the batteries. This inverter also includes an
extensive protection circuitry to shut down the inverter under certain fault conditions.
3.1
Inverter Mode
When the MS Series is first powered up, it defaults to the OFF mode. The momentary ON/OFF
power switch (Item 1, Figure 1-1) must be lightly pressed to turn the inverter ON. Subsequently
pressing this switch alternately turns the inverter OFF and ON.
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 input 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 either by “searching” or “inverting”, depending on the
connected AC loads.
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) detected, 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).
Info: The factory default value for the Search feature is 5 watts. It can be turned off
or adjusted from 5 to 50 watts using a remote display (ME-RC, ME-ARC, or ME-RTR).
Inverting – When a load greater than 5 watts is connected to the inverter output, the MS Series
inverts the DC power from the battery 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. Refer to Figure 3-1 to see the flow
of power from the DC input to the AC output while in the Inverter mode.
CB2
(optional)
AC Hot
Transfer Relay
AC HOT 2 IN
AC HOT 1 IN
AC HOT 2 OUT
AC HOT 1 OUT
0
VAC
AC NEUTRAL OUT
120
VAC
CB1
(optional)
CB3 (30A)
AC NEUTRAL IN
INV
OUT
120
VAC
AC GROUND
Neutral-Ground
Transfer Relay
AC
DC
IN
DC NEGATIVE
DC
DC POSITIVE
FET Bridge
Power Transformer
Figure 3-1, Power Flow - Inverter Mode
Page 42
© 2012 Magnum Energy, Inc.
Operation
3.2
Standby Mode
The MS Series features an internal battery charger and an automatic transfer relay when operating
in 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 internal battery charger to keep the battery
bank charged in case of a power failure. Refer to Figure 3-2 to see the flow of power from the AC
input to the DC and AC output while in Standby mode.
AC
IN
240
VAC
120
VAC
120
VAC
CB2
(optional)
AC Hot
Transfer Relay
AC HOT 2 IN
AC HOT 1 IN
AC HOT 2 OUT
AC HOT 1 OUT
240
VAC
AC NEUTRAL OUT
120
VAC
CB1
(optional)
CB3 (30A)
AC NEUTRAL IN
AC
OUT
120
VAC
AC GROUND
Neutral-Ground
Transfer Relay
AC
DC
OUT
DC NEGATIVE
DC
DC POSITIVE
FET Bridge
Power Transformer
Figure 3-2, Power Flow - Standby Mode
3.2.1
Battery Charging
Magnum Energy’s MS Series is equipped with an active PFC (Power Factor Corrected) and PI
(Proportional-Integral) multi-stage battery charger. The PFC feature controls 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 wave
shape to mirror the voltage wave shape). The PI feature allows the charger voltage and current
to change independently. These two features maximize the real power available from either the
utility or generator AC power sources, which translates into less power wasted and greater charging
capabilities than most chargers available today.
When an AC source is connected to the AC input, the inverter begins monitoring for acceptable AC
voltage. Once the inverter has accepted this AC voltage, the AC transfer relay closes and Charge
mode begins. After Charge mode begins, the DC voltage is monitored to determine the charging
stage. If the DC voltage is low (≤12.8 VDC/12-volt models or ≤25.6 VDC/24-volt models), the
charger begins Bulk charging. If the DC voltage is high (>12.8 VDC/12-volt models or >25.6 VDC/
24-volt), the charger will skip the Bulk and the Absorb charging stages and go 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. The EQ stage (requires the a remote display – ME-RC, ME-ARC, or ME-RTR) to
enable Equalization charge) is used to stir up stratified electrolyte and to reverse any battery plate
sulfation that may 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 2) The AC input voltage
falls below 90 VAC – the charger stops charging to help stabilize the incoming AC voltage.
© 2012 Magnum Energy, Inc.
Page 43
Operation
The Charge mode provides up to four separate charging stages: Bulk Charging, Absorb Charging,
Float Charging and Full Charge.
Bulk Charging: This is the initial stage of charging. While bulk charging, the charger supplies the
battery with controlled constant current. The charger will remain in bulk charge until the absorption
charge voltage (determined by the Battery Type selection*) is achieved. The inverter’s green LED
stays ON (solid) to indicate bulk charging.
Absorb Charging: This is the second charging stage and begins after the absorb voltage has
been reached. Absorb charging provides the batteries with a constant voltage and reduces the
DC charging current in order to maintain the absorb voltage setting. The inverter’s green LED
flashes once every second (fast flash) to indicate absorption charging for 2 hours (determined by
the Battery AmpHrs selection*), then switches to float charging.
Float Charging: The third charging stage occurs at the end of the absorb charging time. While
float charging, the charge voltage is reduced to the float charge voltage (determined by the
Battery Type selection*). In this stage, the batteries are kept fully charged and ready if needed by
the inverter. The inverter’s green LED flashes once every 8 seconds (slow flash) to indicate float
charging. The Float Charging stage reduces battery gassing, minimizes watering requirements (for
flooded batteries), and ensures the batteries are maintained at optimum capacity.
Full Charge (Battery Saver™ mode): The fourth stage occurs after four hours in the Float
Charging stage. The Full Charge stage is designed to keep batteries fully charged over long periods,
and to prevent excessive 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 (12.7 VDC or less on 12-volt models or 25.4 VDC or less on 24-volt models),
the charger automatically initiates another four hours in float charge.
Info: If the battery voltage falls to the re-bulk voltage (12.1 VDC on 12-volt models or
24.2 VDC on 24-volt models) or lower, the unit will begin another bulk charge.
* These settings in the MS Series are changeable and leave the factory with default values (see Table
3-2, Inverter/Charger Default Values). These default values are adequate for most installations,
however, if you determine that some of the values need to be changed for your particular system,
the a remote control (ME-RC, ME-ARC, or ME-RTR) may be purchased to adjust these settings.
Bulk
Charging
Absorb
volts
DC
Voltage
Time
DC
Current
Absorb
Charging
Increased
Voltage
Max
Charge
Rate
Constant
Current
Constant
Voltage
Float
Charging
Float
volts
Reduced
Voltage
Monitored
Voltage
Goes to Full
Charge after
4 hours in
Float Charge
Absorb
Time
Reduced
Current
Full
Charge
Monitored
Current
No Current
Figure 3-3, Automatic 4-Stage Charging Graph
Page 44
© 2012 Magnum Energy, Inc.
Operation
3.2.2
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 occurs in approximately 16 milliseconds. While the
MS 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 low enough to reset the loads.
The disadvantage of a higher VAC dropout setting is that smaller generators (or large generators
with an unstable output) may nuisance 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 dropout threshold.
Info: When switching from Inverter mode to Standby mode, the inverter waits
approximately 15 seconds to ensure the AC source is stable before transferring.
3.3
Battery Temperature Sensor Operation
The plug-in Battery Temperature Sensor (BTS) is used to determine the battery’s temperature.
This information allows the multi-stage battery charger to automatically adjust the battery charge
voltages for optimum charging performance and longer battery life.
With a BTS installed, if the temperature around the BTS is below 77°F (25°C) the absorb and float
charge voltage increases, and if the temperature around the BTS is higher than 77°F (25°C), the
absorb and float charge voltage decreases. See Figure 3-4 to determine how much the charge
voltage changes (increases or decreases) depending on the temperature reading of the BTS. 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
charges 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 BTS is not installed.
Change to battery charging voltage
Info: When the BTS is connected, the battery charger uses a value of -5mV/°C/Cell
from 0-50°C to change the charge voltage based on temperature.
Temperature Compensation using BTS
12VDC units
24VDC units
+0.75V
0.75
+0.6V0.6
+0.45V
0.45
+0.3V0.3
+0.15V
0.15
No Change0
-0.15V
-0.15
-0.3V-0.3
-0.45
-0.45V
-0.6V-0.6
-0.75
-0.75V
+1.5V
+1.2V
+0.9V
+0.6V
+0.3V
No Change
-0.3V
-0.6V
-0.9V
-1.2V
-1.5V
0
0C
32F
no BTS
connected
5
5C
41F
10
10C
50F
15
15C
59F
20
20C
68F
25
25C
77F
30
30C
86F
35
35C
95F
40
45
50
40C
45C
50C
104F 113F 122F
Temperature reading from BTS
Figure 3-4, BTS Temperature to Charge Voltage Change
© 2012 Magnum Energy, Inc.
Page 45
Operation
3.4
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 following conditions [also
refer to the Troubleshooting section (Section 4.4) to help diagnose and clear the fault condition].
•
Low Battery – The inverter will shut off whenever the battery voltage falls to the LBCO (Low
Battery Cut Out) level to protect the batteries from being over-discharged. After the inverter
has reached the LBCO level and turned off, the inverter will automatically 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 LBCI (Low Battery Cut In) level.
The inverter’s status LED turns off when a low battery fault condition occurs. Refer to Table
3-1 to determine the LBCO and LBCI levels for your inverter model.
•
High Battery – In the event the battery voltage approaches the HBCO (High Battery Cut
Out) 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 HBCI
(High Battery Cut In) level. Refer to Table 3-1 to determine the HBCO and HBCI levels for
your inverter model.
Info: High battery voltage may be caused by excessive or unregulated voltage
from the solar panels or other external charging sources.
•
Overload – During inverter and standby operation, 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 must be
restarted (turned back on) once the inverter’s AC loads are reduced/removed.
•
Over-temperature – If internal power components begin to exceed their safe operating
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 automatically
restarts after the unit cools down.
•
Internal Fault – The inverter continually monitors several internal components and the
processor communications. If a condition occurs that does not 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 – refer to Section 4.3 for information on resetting the inverter.
Table 3-1, Inverter Battery Turn On/Off Levels
Inverter battery turn
ON/OFF Levels
MS2000/MS2012
Inverter Model
MS2812
MS4024
HBCO
>16.8 VDC
>16.8 VDC
>33.8 VDC
HBCI
16.5 VDC
16.5 VDC
33.2 VDC
LBCI
12.5 VDC
12.5 VDC
25.0 VDC
LBCO*
(1 minute delay)
10.0 VDC
(9.0 - 12.2 VDC)
10.0 VDC
(9.0 - 12.2 VDC)
20.0 VDC
(18.0 - 24.4 VDC)
LBCO (immediate)
8.5 VDC
8.5 VDC
17.0 VDC
*adjustable with remote control
Page 46
© 2012 Magnum Energy, Inc.
Operation
3.5
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 (refer to Figure 3-5). 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 (or reset per Section 4.3). Once the inverter
has been turned on, pressing the Power ON/OFF switch alternately turns the inverter on and off.
WARNING: The Power ON/OFF switch does not 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.
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 (refer to Figure 3-5) for
at least 10 seconds to determine the inverter’s operational condition from the information below:
•
Off – Indicates the inverter is off; there is no AC power (inverter, utility, or generator)
at the inverter’s output terminals. If the LED stays off after pressing the ON/OFF switch,
there is a fault condition such as: low battery, high battery, overload, over-temperature,
or an internal fault. Refer to the Troubleshooting section to help diagnose/clear the fault
condition.
•
Slow flash (blinks on once every 8 seconds) – Indicates float charging, and the inverter is
in Standby mode (the external AC power that is connected to the inverter’s input is passing
thru the inverter and is powering the AC loads connected to the inverter’s output).
•
Medium flash (blinks once every second):
When AC power is not connected to inverter input – Indicates the inverter is on and using
energy from the battery. The inverter is either: 1) Inverting – providing full power to the
loads connected to the inverter; or 2) Searching – conserving power and waiting for a load
to be turned on that meets or exceeds the Search Watts parameter (5 watts is the inverter
default setting).
When AC power is connected to inverter input – Indicates absorb charging, and the inverter
is in Standby mode (the external AC power that is connected to the inverter’s input is
passing thru the inverter and is powering the AC loads connected to the inverter’s output).
•
On (solid) – Indicates bulk charging, and the inverter is in Standby mode (the external AC
power that is connected to the inverter’s input is passing thru the inverter and is powering
the AC loads connected to the inverter’s output).
Power ON/OFF
pushbutton switch
Charging/Inverting
Status LED indicator
Figure 3-5, Power Switch and Status Indicator
© 2012 Magnum Energy, Inc.
Page 47
Operation
3.6
Factory Default Values
Your MS Series inverter/charger uses default values for the adjustable settings (shown in Table
3-2) that are adequate for most installations. If some of your operating parameters need to be
changed from the default values, your optional remote display (ME-RC, ME-ARC, or ME-RTR) can
be used to make those changes. To help you determine if you need a remote display, information
on the inverter/charger settings that can be changed is provided below. Once programmed, the
settings are saved in the remote’s non-volatile memory and are preserved until changed – even
if DC power to the inverter is lost (as long as the remote display is connected). For information
on the full range of settings for each function in your remote display, refer to its owner’s manual
at www.magnumenergy.com.
•
Shore Max/Input Amps: This setting ensures the inverter AC loads receive the maximum
current available from the utility or generator power. When the total current used to power
the AC loads and charge the batteries begins to approach the Shore Max setting, the
current that was used for charging the batteries will automatically be reduced.
•
Search Watts: This setting allows you to turn off the power-saving Search mode circuitry,
or to adjust the power level at which the inverter will “wake up” and start inverting.
•
LowBattCutOut: This setting determines when the inverter will turn off based on low
battery voltage. The inverter turns off automatically after the battery voltage has been
below this setting for more than one minute. This protects the batteries from overdischarge and the AC loads from unregulated power (brown-outs).
Batt AmpHrs/Absorption Time: This setting allows the user to input the battery bank
size in amp hours – which tells the charger how long to charge the batteries in the Absorb
Charge stage.
•
•
Battery Type: Sets the type of batteries being used in the system. This information tells
the charger what voltage level to use to charge the batteries.
•
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.
•
VAC Dropout: Sets the minimum AC voltage that must be present 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.
Using a remote display also provides the following features:
•
•
•
allows you to enable an equalize charge for certain battery types
displays inverter/charger’s operating status
provides fault information for troubleshooting
Table 3-2, Inverter/Charger Default Values
Page 48
Adjustable Settings
Default Values
Shore Max/Input Amps
30 amps
Search Watts
5 watts
LowBattCutOut
10 VDC (12-volt models), 20 VDC (24-volt models)
Batt AmpHrs/Absorption Time
600 Amp Hours (Absorb Time = 120 minutes)
Battery Type
Flooded - Liquid Lead Acid
Charge Rate
100%
VAC Dropout
80 VAC
© 2012 Magnum Energy, Inc.
Operation
3.7
Inverter Fan Operation
The inverter contains two internal cooling fans that are automatically controlled. The speed of
these fans is determined either by the internal temperature of the inverter or by the load on the
inverter. The inverter’s fans will come on under the conditions listed below:
• Fans run full speed if the internal transistors (FETS) or the power transformer reaches 80°C
degrees Celsius (176°F), or the inverter is running at 100% of its rated load.
• Fans run medium speed if the internal transistors (FETS) or the power transformer reaches
60°C (140°F), or the inverter is running at 50% of its rated load.
• Fans run low speed when the inverter is running at 25% of its rated load.
The fans shut down when none of the above conditions are met, or if the battery voltage is below
9.5V (12-volt systems).
Whenever the inverter is first connected to the battery, the fans will come on for about one
second. The inverter’s fans will not come on based on temperature sensed by the optional Battery
Temperature Sensor.
© 2012 Magnum Energy, Inc.
Page 49
Maintenance and Troubleshooting
4.0 Maintenance and Troubleshooting
The following information is provided to help you keep your MS Series inverter/charger in optimum
operational condition.
4.1
Recommended Inverter and Battery Care
The MS Series inverter/charger is designed to provide you with years of trouble-free service. Even
though there are no user-serviceable 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.
WARNING: Prior to performing any checks, switch OFF both the AC and DC circuits.
•
•
•
•
•
•
•
•
•
4.2
Visually inspect the batteries for cracks, leaks, or swelling – replace if necessary
Use baking soda to clean and remove any electrolyte spills or buildups
Check and tighten all battery hold-down clamps (if applicable)
Clean and tighten all battery terminals and connecting cables [10 to 12 ft lbf (13.6 to 16.3
N-m)]
Check and fill battery water levels (liquid lead acid batteries only)
Check individual battery voltages (load test those that have a voltage difference of more
than 0.3 VDC from each other) – replace if necessary
Check all cable runs for signs of chafing – replace if necessary
Check the inverter’s cooling vents – clean as necessary
Check and tighten the inverter’s internal AC terminal block connections [16 in lbf (1.8
N-m)]
Storage for Mobile Installations
When placing the RV, boat or truck into storage, it is recommended that you perform the following
to ensure the system is properly shut down (or properly configured for storage). This is especially
important for maintaining the batteries.
•
•
•
•
•
•
Perform the recommended maintenance steps listed in Section 4.1.
Fully charge the batteries.
Connect AC power (if available) and verify that the breaker to the inverter’s input is
switched ON (to allow battery charging).
Verify the inverter is switched OFF.
Switch OFF all unnecessary AC and DC loads.
Disable the AGS (if installed) when the RV, boat, or truck is in a confined storage area.
WARNING: If an AGS were to start and run the generator for an extended period
of time in a confined area, a potentially fatal level of CO (Carbon Monoxide) could
accumulate.
4.3
Resetting the Inverter
Under some fault conditions (i.e., an internal fault), the inverter will need to be reset.
To reset the inverter:
Press and hold the Power ON/OFF pushbutton for approximately fifteen (15) seconds until the
Charging/Inverting Status LED (see Figure 3-5) comes on and flashes rapidly; once the rapid
flashing has begun, release the Power ON/OFF pushbutton. The Status LED will go off after the
pushbutton is released.
After the inverter reset is completed, press the Power ON/OFF pushbutton to turn the inverter ON.
Info: The Power ON/OFF pushbutton is a small momentary type switch which operates
by lightly pressing and releasing.
Page 50
© 2012 Magnum Energy, Inc.
Maintenance and Troubleshooting
4.4
Troubleshooting
The MS Series inverter/charger is a fairly simple device to troubleshoot. 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 failures.
Table 4-1, Basic Troubleshooting
Symptom
Possible Cause
N o o u t p u t p o w e r. Inverter is switched OFF
Inverter LED is OFF
Battery voltage is too low. The battery
voltage level has dropped below the
Low Battery Cutout (LBCO) set-point
for more than one minute.
Recommended Solution
Switch the inverter ON.
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
the LBCI voltage.
The battery voltage is too high. The
inverter automatically resets and
resumes operation when the battery
voltage drops to the HBCI voltage or
lower.
This condition usually only occurs when an additional
charging source (alternator, solar panels, or other
external 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.
Over-temperature condition: The
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.
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 conditions.
Check ventilation around the inverter, ensure cool air is
available to pass-thru the inverter (refer to the ventilation
requirements in Section 2.1.3).
AC overload condition: The inverter Reduce the AC loads connected to the inverter, or remove
has turned off because the connected all AC output wiring and restart the inverter.
loads are larger than the inverter’s
output capacity, or the output wires
are shorted.
Internal fault: This fault occurs when To clear this fault, an inverter reset is required. Remove
an internal fault is detected.
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.
N o o u t p u t p o w e r. Unit is in Search mode, which means Turn on a load greater than 5 watts to bring inverter to
Green LED is flashing. load is too small for Search mode full output power, or turn off search with remote.
circuit detection.
Low output or surge Loose or corroded battery cables.
power. Green LED is
Low batteries.
flashing.
Loose AC output connections.
Clean and tighten all cables.
Recharge or replace batteries.
Tighten AC output connections.
Battery cables are the wrong length Verify recommended cable lengths and gauges from the
or gauge.
manual. Replace cables as necessary.
L o w c h a r g i n g ra t e Charge rate set too low.
when connected to AC
Low AC voltage (< 90 VAC).
power.
Adjust charge rate or SHORE settings on remote.
Check AC input wiring.
Low charging rate when Generator output is too low to power Reduce the load, increase the generator’s RPMs.
using a generator.
both load and charger.
Check the SHORE settings (if remote connected).
C h a r g e r d o e s n o t Loose or corroded battery cables.
charge.
Defective batteries.
While charging, the
DC charge voltage is
higher or lower than
expected.
Clean and tighten battery cables.
Replace batteries.
Wrong charger settings.
Adjust the charger settings, ensure the unit is not in
charger standby.
Wrong AC input voltage.
Verify proper AC input voltage and frequency.
If the Battery Temperature Sensor This is normal; see Section 3.3 (Battery Temperature
(BTS) is installed, the DC voltage will Sensor Operation) for more information.
increase or decrease depending on the
temperature around the BTS.
© 2012 Magnum Energy, Inc.
Page 51
Appendix A – Specifications
Appendix A – Specifications and Optional Equipment
A-1
Inverter/Charger Specifications
Models
MS2000/MS2012
MS2812
MS4024
Input battery voltage range
9.0 to 16.8 VDC
9.0 to 16.8 VDC
18.0 to 33.6 VDC
Absolute maximum DC input
25 VDC
25 VDC
35 VDC
Inverter Specifications
AC output voltage accuracy
120 VAC ±5% (≤ continuous power)
Output frequency and accuracy
60 Hz ± 0.1 Hz
Total Harmonic Distortion (THD)
< 5%
Continuous power output (at 25°C)
2000 VA
2800 VA
4000 VA
17 A
23 A
33 A
1 msec surge current (amps AC)
50
70
120
100 msec surge current (amps AC)
33
40
82
5 sec surge power (real watts)
3300
3900
5800
30 sec surge power (real watts)
3100
3800
5400
5 min surge power (real watts)
2800
3200
4900
30 min surge power (real watts)
2200
3000
4500
267 ADC
373 ADC
267 ADC
Continuous AC output current
Maximum continuous input current
Inverter efficiency (peak)
HBCO/HBCI (High Battery Cut Out/In)
LBCO/LBCI (Low Battery Cut Out/In)
Series Stacking for 120/240 VAC
90.6%
90%
93.7%
16.8 VDC/16.5 VDC
16.8 VDC/16.5 VDC
33.6 VDC/33.0 VDC
9.0 VDC (adj)/12.5 VDC
9.0 VDC (adj)/12.5 VDC
18.0 VDC (adj)/25.0 VDC
No
No
Yes, using two MS4024 units
AC Relay Transfer time (minimum)
16 msec
Power Consumption - searching
<8 watts
Power Consumption - inverting (no load)
25 watts
30 watts
Output Waveform
25 watts
Pure Sine Wave
Charger Specifications
Continuous charger output at 25°C
Input current for continuous rated output
100 ADC
125 ADC
105 ADC
15 AAC
18 AAC
29 AAC
Charger efficiency
85%
AC input frequency range
50 to 70 Hz
AC input voltage range
60 to 140 VAC (120 VAC nominal)
Power factor
> 0.95
General Features and Capabilities
Transfer relay capability
30AAC maximum each input (30AAC total on MS2000 models, 60AAC total on all other models)*
Five-stage charging capability
Bulk, Absorb, Float, Equalize (requires remote), and Battery Saver™
Battery temperature compensation
Standard with available temp sensor connected (battery temp 0 - 50 °C)
Internal Cooling
0 to 120 cfm variable speed drive using dual 92 mm brushless DC fan
Overcurrent protection
with two overlapping circuits
Over-temperature Protection
on transformer, MOSFETS, and battery
Corrosion protection
Safety Listings
PCB’s conformal coated, powder coated chassis/top, and stainless steel fasteners
ETL listed to UL/cUL 458, UL 1741, CSA C22.2 No. 107.1-01, and meets KKK-A-1822E standard**
Warranty
3 years parts and labor
Branch-rated output circuit breakers
only on MS2012 -15B (15A x2) and MS2012-20B (20A x2) models.
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
Unit Dimensions (length x width x height)
13.75” x 12.65” x 8.0” (34.9 cm x 32.1 cm x 20.3 cm) [Height on MS2000 models is 7.0”/17.8 cm]
Shipping Dimensions (length x width x height)
Mounting
18.5” x 17.5” x 12.5” (47 cm x 44.5 cm x 31.8 cm)
Shelf or wall (vents not allowed to face downward unless ME-CB or MMP/MP is installed)
Unit Weight
43 lb (19.5 kg)
53 lb (24.0 kg)
58 lb (26.3 kg)
Shipping Weight
46 lb (20.9 kg)
56 lb (25.4 kg)
60 lb (27.2 kg)
Max operating altitude
15,000’ (4570 m)
* The pass-thru capability on each leg of the -15B and -20B models is limited by the output breaker size on each output.
** The MS2000 Series models are ETL listed to UL/cUL 458, CSA C22.2 No. 107.1-01, and also meet the KKK-A-1822E standard.
Specif cations @ 25°C - Subject to change without notice.
Page 52
© 2012 Magnum Energy, Inc.
Appendix A – Specifications
A-2
Inverter Efficiency
The following curves are plotted to show the MS Series’ efficiency over the full power range and is
displayed as a percentage. This graph represents the inverter’s efficiency while operating resistive
loads. Motors and other inductive loads run less efficiently due to the impact of power factor losses.
100%
Efficiency
90%
80%
70%
60%
MS2000 / MS2012
MS2812
MS4024
50%
40%
4200
3800
3400
3000
2600
2200
1800
1400
1000
600
400
200
Wattage
Figure A-1, MS Series Efficiency Chart
A-3
AC Input Voltage to Output Charge Amps
The following chart shows the expected charger output capability of the MS Series. The maximum
charge current is dependent on the AC input voltage and the inverter battery voltage. Note: The output
charger current shown is with the inverter battery voltage at nominal (i.e., 25.2 volts for MS4024).
Output Charge Amps
160
150
140
130
120
110
100
MS2000/MS2012
90
MS2812
80
MS4024
70
60
95
105
115
125
135
AC Input Voltage
Figure A-2, MS Series Output Charger Current Chart
© 2012 Magnum Energy, Inc.
Page 53
Appendix A – Specifications
A-4 Optional Equipment and Accessories
The following Magnum Energy components are available for use with the MS Series inverter/charger.
Some of these items are required depending upon the intended use of the inverter.
MMP Series Enclosures
The MMP enclosures have been specifically designed for single inverter applications. These enclosures combine all of the major components required for a renewable energy system—inverter/
battery disconnect, AC overcurrent protection, grounding connections, and a full system inverter
bypass switch as a convenient way to isolate the inverter for battery maintenance—into a single,
easy to install pre-wired enclosure.
MP Series Enclosures
The MPSL, MPSH, MPDH enclosures have been specifically designed to easily combine multiple inverters. The MP enclosures feature convenient front-mounted AC and DC connections and easy panel
operation. Choose the MP model based on your power capacity needs. Each model is expandable.
Start with the base model and just one inverter, and in the future add another inverter—up to a
total of four inverters depending on your model—with ease, using the MPX Series expansion boxes.
Remote Switch Adapters
The ME-RSA and ME-RSA-M pigtail adapters allow the inverter to be remotely switched on and
off – with or without a remote display.
Advanced Remote Control
The ME-ARC remote control panel uses an LCD screen and at-a-glance LEDs to provide operating
information and allow advanced features to be configured (requires Magnum inverters with advanced
configurable features). This LCD remote control also provides advanced monitoring/troubleshooting
and includes a FAVS button to access your favorite features quickly.
Standard Remote Control
The ME-RC remote control panel uses an LCD screen and at-a-glance LEDs display for complete
inverter/charger status. Soft keys provide simple access to menus, and a rotary encoder knob
allows you to scroll through and select a wide range of settings such as: Inverter ON/OFF, Charger
ON/OFF, shore power breaker setting, AGS control, Meter button, Setup and Tech menus.
Auto Generator Start Controller
The ME-AGS-N Automatic Generator Start controller (Network version) 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. Adjustable settings when using the MEARC include starting the generator based on battery voltage, time of day, battery State of Charge,
or high temperature.
Battery Monitor Kit
The ME-BMK-NS Battery Monitor Kit is a single battery bank amp-hour meter that monitors the
condition of the battery, provides information to let you know how much energy you have available,
and lets you plan your electrical usage to ensure the battery is not being over-discharged. The –NS
version does not include a DC shunt. Order Part Number: ME-BMK to receive the battery monitor
that includes the 500A/50mv DC shunt.
Fuse Block/Fuses
The TFB series of 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, high
current Class-T fuse with mounting block and protective cover. The fuse sizes are available in 125,
200, 300, and 400 amps.
Page 54
© 2012 Magnum Energy, Inc.
Appendix B – Battery Information
Appendix B – Battery Information
B-1
Battery Location
Periodic maintenance (i.e., checking connections, cleaning, watering) on batteries is required.
Locate the batteries in an accessible location to perform this maintenance.
Batteries must be mounted in a clean, dry, ventilated environment where they are protected
from high and low temperatures. The battery bank should be located as close to the inverter as
possible without limiting access to the inverter’s disconnects. Longer battery cable runs tend to
lose efficiency and reduce the overall performance of an inverter.
To ensure optimum performance, a ventilated battery enclosure is recommended. Two feet of
clearance above the batteries is recommended for access to the battery terminals and removable
caps (lead acid battery types).
WARNING: Be very careful when working around batteries, they can produce extremely
high currents if they are short-circuited. Read the important safety instructions at
the beginning of this manual and the precautions from the battery supplier before
installing the inverter and batteries.
CAUTION: Do not mount the batteries beneath the inverter (or in the same
compartment). Batteries emit corrosive fumes which could damage the inverter’s
electronics. Never locate dedicated batteries near a vehicle/home fuel tank containing
gasoline or propane.
B-2
Battery Types
Batteries are available in different sizes, amp-hour ratings, voltage and chemistries. 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; using a starting
battery in an inverter (deep cycle) application will greatly shorten their useful life. 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 located on the battery.
B-3
Battery Temperature
Battery performance of lead-acid type batteries is greatly affected by extreme temperatures. When
a lead-acid type battery is cold, its effective amp-hour capacity is reduced. When determining
the battery requirements needed for the inverter system, realize that the battery capacity will be
reduced if they will be installed in a climate where extremely cold temperatures are expected. In
this type of environment, the batteries should be located in a heated area. At the minimum, the
batteries should be installed in an insulated enclosure; which will keep the batteries warmer as
they are being charged.
The battery bank should also be protected from high temperatures, which will shorten battery
life. In high heat situations the battery room/enclosure should be ventilated to bring in cooler air
and exhaust the hotter air. The performance of the battery bank/inverter system will substantially
increase by monitoring and preventing extreme temperatures around the batteries.
B-4
Battery Bank Sizing
The size of the battery bank determines how long the inverter will power the AC loads without
recharging. The larger the battery bank, the longer the run time. Size your battery bank to the
systems AC load requirements and length of time required to run from the batteries. In general,
the battery bank should not be discharged more than 50%. Additional DC charging devices such
as solar, wind, hydro, etc., can provide longer run times by recharging the batteries in the absence
of AC utility or generator power.
Info: For the MS Series inverter/charger to perform optimally, a minimum battery
bank of 200 AH is recommended for moderate loads (<1000W) and greater than
400 AH for heavy loads (≥1000W).
© 2012 Magnum Energy, Inc.
Page 55
Appendix B – Battery Information
B-5
Battery Bank Sizing Worksheet
Complete the steps below to determine the battery bank size required to power your AC loads:
1. Determine the daily power needed for each load
a) List all AC loads required to run; and
b) List the Watt-Hours for each load (see Table B-1 for common loads/wattage); and
c)
multiply by how many hours per day (or a fraction of an hour) each load will be used; and
d) multiply by how many days per week you will use the listed loads; and
e) divide by seven = Average Daily Watt-Hours Per Load.
Average Daily Watt-Hours Per Load
AC load
Watt-Hours
(x) hours per day
(x) days per week
(÷7) = total power
2. Determine the total power needed each day for all the loads.
• Add the Average Daily Watt-Hours Per Load together = Total Daily Watt-Hours.
3. Determine the battery amp-hour capacity needed
to run all the loads before recharging.
(inverter battery voltage)
 Multiply this by how many days the loads will need to run
without having power to recharge the batteries (typically 3 to
5 days of storage) = Storage Amp-Hours.
(days of storage)
• Divide the Total Daily Watt-Hours by the nominal battery voltage of the inverter (i.e., 12, 24 volts); and
Total Daily WattHours
÷ ___ =
x ___ =
4. Determine how deeply you want to discharge your batteries.
Divide the Storage Amp-Hours by 0.2 or 0.5 to get the Total Amp-Hours:
a) 0.2 = Discharges the batteries by 20% (80% remaining), this is considered the
optimal level for long battery life; or
b) 0.5 = Discharges the batteries by 50% (50% remaining), this is considered a
realistic trade-off between battery cost and battery life.
•
Total Amp-Hours
Additional compensation:
Low battery temperature: If the batteries are installed in a location that will be exposed to low temperatures,
the available output will be less. In these instances, you will need to determine the lowest temperature the
battery bank will experience and multiply the Total Amp-Hours by the multiplier below.
Temperature
80F/27C
70F/21C
60F/15C
50F/10C
40F/4C
30F/-1C
20F/-7C
Multiplier
1.00
1.04
1.11
1.19
1.30
1.40
1.59
Inverter efficiency: When the inverter is used in a back-up power application the inverter efficiency will not
be a large concern; however, if the inverter is the primary AC source for the calculated load, the Total AmpHours should be multiplied by 1.2 to factor in an average 80% inverter efficiency.
Page 56
© 2012 Magnum Energy, Inc.
Appendix B – Battery Information
B-6
Battery Wiring Configurations
The battery bank must be wired to match the inverter’s DC input voltage. In addition, the batteries
can be wired to provide additional run time. The various wiring configurations are:
B-6.1
Series Wiring
Wiring batteries in series increases the battery bank’s output voltage. A series connection combines
each battery in a string until the total voltage matches the inverter’s DC requirement. Even though
there are multiple batteries, the capacity remains the same. In Figure B-1 below, two 6 VDC/200
AH batteries are combined into a single string resulting in a 12 VDC, 200 AH bank.
6 VDC
(200 AH)
B-6.2
6 VDC
(200 AH)
12 VDC @
200 AH
Series Battery Wiring
combines battery voltage:
200 AH @ 6 VDC
+
200 AH @ 6 VDC
=
200 AH @ 12 VDC
Figure B-1, Series Battery Wiring
Parallel Wiring
Wiring batteries in parallel increases the battery bank’s amp-hour capacity, which allows the AC loads
to operate for a longer time. A parallel connection combines the number of batteries in the string to
increase overall battery capacity; however, the voltage remains the same. In Figure B-2 below, two
12 VDC/100 AH batteries are combined into a single 12 VDC, 200 AH battery bank.
12 VDC
(100 AH)
12 VDC @
200 AH
12 VDC
(100 AH)
Parallel Battery Wiring
combines battery capacity:
100 AH @ 12 VDC
+
100 AH @ 12 VDC
=
200 AH @ 12 VDC
Figure B-2, Parallel Battery Wiring
B-6.3
Series-Parallel Wiring
A series/parallel configuration increases both voltage (to match the inverter’s DC requirements)
and amp-hour capacity (to increase run-time for operating the loads) using smaller, lower-voltage
batteries. In Figure B-3 below, four 6 VDC/200 AH batteries are combined into two strings resulting
in a 12 VDC, 400 AH battery bank.
Series/Parallel Battery Wiring
combines battery voltage and capacity:
6 VDC
(200 AH)
6 VDC
(200 AH)
6 VDC
(200 AH)
6 VDC
(200 AH)
12 VDC @
400 AH
200 AH @ 6 VDC
+
= 200 AH @ 12 VDC
200 AH @ 6 VDC
+
= 400 AH @ 12 VDC
200 AH @ 6 VDC
+
= 200 AH @ 12 VDC
200 AH @ 6 VDC
add voltage
in series
add capacity
in parallel
add voltage and
capacity together
Figure B-3, Series-Parallel Battery Wiring
© 2012 Magnum Energy, Inc.
Page 57
Appendix B – Battery Information
overcurrent
protection
String
(12 VDC @ 100 AH)
to
to12
12VDC
VDC
inverter
inverter
(total
(totalcapacity
capacity
==100
AH)
100
AH)
12 VDC
battery
(100 AH)
12-volt battery bank (one string of one 12-volt battery)
overcurrent
protection
Series String
(6 VDC + 6 VDC)
6 VDC
battery
(200 AH)
to12
12VDC
VDC
to
inverter
inverter
(total
(totalcapacity
capacity
=
=200
200AH)
AH)
6 VDC
battery
(200 AH)
12-volt battery bank (one string of two 6-volt batteries wired in series)
overcurrent
protection
Parallel String
(100 AH + 100 AH)
12 VDC
battery
(100 AH)
to
to12
12VDC
VDC
inverter
inverter
(total
(totalcapacity
capacity
=
=200
200AH)
AH)
12 VDC
battery
(100 AH)
12-volt battery bank (parallel two 12-volt batteries)
Parallel String (200 AH + 200 AH) overcurrent
protection
Series String
(6 VDC + 6 VDC)
6 VDC
battery
(200 AH)
6 VDC
battery
(200 AH)
Series String
(6 VDC + 6 VDC)
6 VDC
battery
(200 AH)
6 VDC
battery
(200 AH)
toto1212
VDC
VDC
inverter
inverter
(total
capacity
(total
capacity
==400
AH)
400
AH)
12-volt battery bank (two strings of two 6-volt batteries wired in series and connected in parallel)
Figure B-4, Battery Bank Wiring Examples (12-volt)
Page 58
© 2012 Magnum Energy, Inc.
Appendix B – Battery Information
overcurrent
protection
Series String
(12 VDC + 12 VDC)
12 VDC
battery
(100 AH)
12 VDC
battery
(100 AH)
to
VDC
to 24
24 VDC
inverter
inverter
(total capacity
(total
capacity
100 AH)
== 100
AH)
24-volt
24-voltbattery
batterybank
bank(one
(onestring
stringof
oftwo
two12-volt
12-volt batteries
batteries wired
wired in
in series)
series)
Series String
(6 VDC + 6 VDC
+ 6 VDC + 6 VDC)
overcurrent
protection
6 VDC
battery
(200 AH)
6 VDC
battery
(200 AH)
6 VDC
battery
(200 AH)
6 VDC
battery
(200 AH)
to
VDC
to 24
24 VDC
inverter
inverter
(total capacity
(total
capacity
200 AH)
== 200
AH)
24-voltbattery
batterybank
bank(one
(one string
string of
of four
four 6-volt
6-volt batteries
batteries wired
wired in
in series)
series)
24-volt
Parallel String (100 AH + 100 AH)
Series String
(12 VDC + 12 VDC)
12 VDC
battery
(100 AH)
12 VDC
battery
(100 AH)
Series String
(12 VDC + 12 VDC)
12 VDC
battery
(100 AH)
12 VDC
battery
(100 AH)
overcurrent
protection
to
VDC
to 24
24 VDC
inverter
inverter
(total capacity
(total
capacity
200 AH)
== 200
AH)
24-volt battery bank (two
24-volt
(two strings
strings of
of two
two 12-volt
12-voltbatteries
batterieswired
wiredin
inseries
series and
and connected
connected in
in parallel)
parallel)
Parallel String (200 AH + 200 AH)
Series String
(6 VDC + 6 VDC
+ 6 VDC + 6 VDC)
Series String
(6 VDC + 6 VDC
+ 6 VDC + 6 VDC)
6 VDC
battery
(200 AH)
6 VDC
battery
(200 AH)
6 VDC
battery
(200 AH)
6 VDC
battery
(200 AH)
overcurrent
protection
to 24
24 VDC
to
VDC
inverter
inverter
(total capacity
(total
capacity
400 AH)
== 400
AH)
6 VDC
battery
(200 AH)
6 VDC
battery
(200 AH)
6 VDC
battery
(200 AH)
6 VDC
battery
(200 AH)
24-volt
battery bank
bank (two
(twostrings
strings of
of four
four 6-volt
6-voltbatteries
batterieswired
wiredin
inseries
series and
andconnected
connected in
in parallel)
parallel)
24-volt battery
Figure B-5, Battery Bank Wiring Examples (24-volt)
© 2012 Magnum Energy, Inc.
Page 59
Appendix C – Inverter/Charger Terminology
Appendix C – Inverter/Charger Terminology
The following is a glossary of terms with which you may not be familiar. They appear in the
various descriptions of inverter and battery charger operation.
Absorbtion Stage – In this second stage of three stage charging, the batteries are held at a
constant voltage (the absorb voltage setting) and the battery is charged to its maximum capacity.
AC (Alternating Current) – Electrical current that varies with time (i.e., utility power). The rate
at which the voltage changes polarity is the frequency in Hertz (Hz).
Ampacity – The ampacity of a wire is its current carrying capacity with reference to the crosssectional area of the conductors, the temperature rating of the insulation and the ambient
temperature.
Automatic Transfer Relay (inside the inverter) – An automatic switch that switches between
Inverter and Standby mode depending on availability of AC input power. If AC is present, the
unit will be a battery charger and pass power thru the inverter. When the AC goes away, the unit
becomes an inverter.
Bulk Charge Stage – The first stage in three stage charging. In this stage, a constant current is
fed to the batteries and as they accept the current the battery voltage will rise.
CEC (Canadian Electrical Code) – The guidelines and acceptable practices for electrical
installations in Canada.
Current (Amps) – The amount of electricity flowing through a conductor.
DC (Direct Current) – Electrical current that does not vary with time (i.e., battery voltage).
Deep Cycle – A deep cycle occurs when a battery is discharged to less than 20% of its capacity
(80% depth-of-discharge).
Deep Cycle Battery – A battery designed to be routinely discharged to 20% of its maximum
capacity without damage. This type of battery is recommended for use with an inverter system.
Derating – As an inverter (or charger) is used above its normal temperature, it’s capacity to
power loads (or charge) continuously is decreased.
Digital Volt Meter (DVM):
True RMS – A voltmeter that incorporates a RMS converter to read true RMS for any waveform
shape.
Averaging Type – A voltmeter that requires a sine wave waveform shape to provide an
accurate reading.
Efficiency – Usually given as a percentage, efficiency is the ratio of the output to the input. The
efficiency changes with power output levels of any inverter.
Electrolyte – Typically a mixture of water and sulfuric acid that is used in lead-acid batteries; it
is commonly referred to as battery acid.
Equalization – Controlled “overcharging” of the battery causing it to bubble and mix. This helps
reduce stratification.
Float Stage – During the third stage of three stage charging, the voltage and current are reduced
to a level that will trickle charge or maintenance charge the battery. This assures the battery
remains fully charged even while sitting.
Fuse or Disconnect – When current exceeds a preset limit the fuse or disconnect will fail before
the wiring or equipment it is protecting. Disconnects are also called circuit breakers. These are
usually reset and can act as a switch to turn off power to equipment for servicing.
Grid (The grid) – Also called the utility grid, this refers to the public power distribution system.
Impedance – Slows the electrical flow of Alternating Current (AC)
LED (Light Emitting Diode) – A light made up of semi-conducting material.
Line Tie – Term used when the inverter is connected to public power or the “grid” system.
Load(s) – An electrical item that draws power (i.e., lights, radio, refrigerator, etc.) to work.
Page 60
Appendix C – Inverter/Charger Terminology
Locked Rotor Amps – The current drawn by an electric motor with the shaft or rotor stopped
and locked in position. This can be used to determine if an inverter has enough surge current to
start a motor. If the inverter is capable of producing more amperage than the locked rotor amps
rating of a motor, it will most likely start the motor easily.
Modified Sine Wave – Also referred to as a “quasi sine wave” or a “modified square wave”. This
output looks like a one-step staircase and the waveform changes its width to continually provide
the correct RMS voltage regardless of the battery voltage. Most loads that run from a sine wave
will also run from a modified sine wave. However, things such as clocks and furnace controllers
may have trouble (See Figure C-1 below).
NEC (National Electric Code) – The guidelines and acceptable practices for electrical
installations in the USA.
Off Grid – Not connected to public power in any way.
Output Waveform – Shape of the wave that alternating current makes as its voltage rises and
falls with time.
Pass Through Current – The amount of current the inverter can safely pass directly from the
AC input to the AC output.
Photovoltaic (PV) – Solar powered.
Resistance (Ohms) – Slows the electrical flow of Direct Current (DC)
RMS (Root Mean Square) – A measure of AC voltage that provides the equivalent heating
value across a resistor as would a DC source of the same voltage.
Sellback, or Selling Back To The Grid or Utility-Interactive – Some inverters have the
capability to take energy stored in batteries, or from solar panels, and put it back into the utility
grid. The local public utility company can compensate you for using this energy.
VOLTAGE
200
160
Square Wave
120
80
Sine Wave
Modified
Sine Wave
40
0
40
80
120
160
200
TIME
Figure C-1, AC Waveforms
Sine Wave – An AC waveform that looks like rolling waves on water. It rises and falls smoothly
with time. The grid puts out a sine waveform. Any plug-in AC equipment will operate from a
sine wave output (shown in Figure C-1).
Square Wave – The simplest AC waveform (shown in Figure C-1). Some types of equipment
behave strangely when run from a square wave.
© 2012 Magnum Energy, Inc.
Page 61
Appendix C – Inverter/Charger Terminology
Stacking:
Series – Two inverters operating together to produce twice the power and voltage of a single
inverter. Required when operating 240 VAC loads and separate 120 VAC loads from either
inverter.
Parallel – Two inverters operating together to provide twice the continuous capacity on a
single output circuit. Required when a single load is too large for one inverter.
Stratification – Over time, a battery’s electrolyte (liquid) tends to separate. The electrolyte at
the top of the battery becomes watery while at the bottom it becomes more acidic. This effect is
corrosive to the plates.
Sulfating – As a battery discharges, its plates become covered with lead sulfate. During
recharging, the lead sulfate leaves the plates and recombines with the electrolyte. If the lead
sulfate remains on the plates for an extended period of time (over two months), it hardens, and
recharging will not remove it. This reduces the effective plate area and the battery’s capacity.
Temperature Compensation – Peak available battery voltage is temperature dependent. As
ambient temperatures fall, the proper voltage for each charge stage needs to be increased. A
Battery Temperature Sensor (BTS) automatically re-scales charge-voltage settings to compensate
for ambient temperatures.
Voltage – The pressure that causes electrical flow in a circuit.
Watts – Measure of power output or utilization. Watts =Volts x Amps.
Page 62
Appendix D – Warranty & Service
Limited Warranty
Magnum Energy, Inc., warrants the MS Series 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 36 months beginning from the product’s
original date of purchase.
Note: You can extend the normal 3-year warranty on this MS inverter to 5 years simply by
ordering it with and installing it on one of Magnum’s MP or MMP panel systems. To be eligible
for the 5-year warranty extension, a proof-of-purchase is required at the time of repair/service
showing that the MS inverter and the MP or MMP panel system were purchased at the same time.
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 at our option any
defective parts, or any parts that will not properly operate for their intended use, with factory
new or remanufactured replacement items 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, decorative or structural parts or any non-operative parts. Magnum
Energy’s limit of liability under this 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 shall 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. This limited warranty is voided if:
• the product has been modified without authorization.
• the serial number has been altered or removed.
• the product has been damaged from abuse, neglect, accident, high voltage or corrosion.
• the product was not installed and operated according to the owner's manual.
How to Receive Repair Service
If your product requires warranty service or repair, contact either:
1. An Authorized Service Center, which are listed on the Magnum Energy website at
http://www.magnumenergy.com/Service/ServiceCenters-US.htm; or
2. Magnum Energy, Inc. at: Telephone: 425-353-8833
Fax: 425-353-8390
Email: [email protected]
If returning the product directly to Magnum Energy for repair, you must:
•
Return the unit in the original, or equivalent, shipping container.
•
Receive a Return Materials Authorization (RMA) number from the factory prior to the
return of the product to Magnum Energy for repair.
•
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.
BEFORE RETURNING ANY UNIT TO MAGNUM ENERGY INC.,
A RETURN MATERIAL AUTHORIZATION (RMA) NUMBER IS REQUIRED.
© 2012 Magnum Energy, Inc.
Page 63
Magnum Energy, Inc.
2211 West Casino Rd.
Everett, WA 98204
Phone: 425-353-8833
Fax: 425-353-8390
Web: www.magnumenergy.com
MS Series Owner’s Manual (PN: 64-0007 Rev C)
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