64-0035 Rev A (MM-AE Series)

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Owners Manual

MM-AE SeriesInverter/Chargers

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2010 Magnum Energy, Inc.

Disclaimer of Liability

The use of this manual and the conditions or methods of installation,operation, use, and maintenance of the MM-AE Series Inverter/Charger are beyond the control of Magnum Energy, Inc. Therefore,this company assumes no responsibility and expressly disclaimsany liability for loss, damage, or expense whether direct, indirect,

consequential, or incidental that may arise out of or be in any wayconnected with such installation, operation, use, or maintenance.

Due to continuous improvements and product updates, the imagesshown in this manual may not exactly match the unit purchased.

Restrictions on Use

The MM-AE Series Inverter/Charger may only be used in life-supportdevices or systems with the express written approval of MagnumEnergy. Failure of the MM-AE Series Inverter/Charger can reasonablybe expected to cause the failure of that life-support device or system,

or to affect the safety or effectiveness of that device or system. If theMM-AE Series Inverter/Charger fails, it is reasonable to assume thatthe health of the user or other persons may be endangered.

Contact Information

Magnum Energy, Inc.2211 West Casino Rd.Everett, WA 98204Phone: (425) 353-8833 / Fax: (425) 353-8390Web: www.magnumenergy.com

Record the units model and serial number in case you need to providethis information in the future. It is much easier to record this informationnow, instead of trying to gather it after the unit has been installed.

Model: Serial Number:

MM612AE Q1

MM1512AE AG

MM1524AE S1

Conventions Used in this Manual

i

Terminology

AC source or External AC power - refers to Alternating Current(AC) provided by the utility electric power grid or from a generator.

AE application - typically refers to using the inverter in a system thatuses Alternative Energy (e.g., solar, wind, or hydro). This term is alsoused to refer to inverters used in a home, office, or cabin installation.

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IMPORTANT PRODUCT SAFETY INSTRUCTIONS

This manual contains important safety instructions that must be fol-lowed during the installation and operation of this product. Read allinstructions and safety information contained in this manual beforeinstalling or using this product.

All electrical work must be performed in accordance with local,state, and federal electrical codes.

This product is designed for indoor/compartment installation.DO NOT expose to rain, snow, moisture, or liquids of any type.

Use insulated tools to reduce the chance of electrical shock or

accidental short circuits.

Remove all jewelry such as rings, watches, bracelets, etc., wheninstalling or performing maintenance on the inverter.

Always disconnect the batteries or energy source prior toinstalling or performing maintenance on the inverter. Live powermay be present at more than one point since an inverter utilizesboth batteries and AC. Turning off the inverter may not reducethis risk. As long as AC power is connected, it will pass throughthe inverter regardless of the ON/OFF power switch setting.

Always verify proper wiring prior to starting the inverter.

Do not operate the inverter if it has been damaged.

Do not dismantle the inverter; there are no user-serviceableparts contained in this product. Attempting to service the unityourself could cause electrical shock. Internal capacitors remaincharged after all power is disconnected.

No AC or DC disconnects are provided as an integral part of thisinverter. Both AC and DC disconnects must be provided as partof the system installation.

ii

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 aspecified action could result in damage to the equipment.

Info:This symbol indicates information that emphasizesor supplements important points of the main text.

Safety symbols

To reduce the risk of electrical shock, fire, or other safety hazard, thefollowing safety symbols have been placed throughout this manualto indicate dangerous and important safety instructions.

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No overcurrent protection for the battery supply is provided asan integral part of this inverter. Overcurrent protection of thebattery cables must be provided as part of the installation.

No overcurrent protection for the AC output wiring is provided asan integral part of this inverter. Overcurrent protection of the ACoutput wiring must be provided as part of the installation.

IMPORTANT BATTERY SAFETY INSTRUCTIONS

Wear eye protection (safety glasses) when working with

batteries.

Remove all jewelry such as rings, watches, bracelets, etc., wheninstalling or performing maintenance on the inverter.

Never work alone. Always have someone near you when workingaround batteries.

Use proper lifting techniques when working with batteries.

Never use old or untested batteries. Check each batterys labelfor age, type, and date code to ensure all batteries are identical.

Batteries are sensitive to changes in temperature. Always installbatteries in a stable environment.

Install batteries in a well ventilated area. Batteries can produceexplosive gasses. For compartment or enclosure installations,always vent batteries to the outside.

Provide at least one inch of air space between batteries toprovide optimum cooling.

Never smoke when in the vicinity of batteries.

To prevent a spark at the battery and reduce the chance ofexplosion, always connect the cables to the batteries first. Thenconnect the cables to the inverter.

Use insulated tools at all times.

Always verify proper polarity and voltage before connecting thebatteries to the inverter.

To reduce the chance offire or explosion, do not short-circuit thebatteries.

In the event of accidental exposure to battery acid, washthoroughly with soap and water. In the event of exposure to theeyes, flood them for at least 15 minutes with running water andseek immediate medical attention.

Recycle old batteries.

SAVE ALL INSTRUCTIONS

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Table of Contents

1.0 Introduction ..................................................................1

MM-AE Series Models ............................................................ 1

How an Inverter/Charger Works ............................................. 2

Appliances that will run from a Modified Sine Inverter ............... 2

Appliances and Run Time ....................................................... 2Standard Features and Benefits .............................................. 3

Battery Temperature Sensor .............................................. 5

2.0 Instal lation ....................................................................6

Pre-Installation .................................................................... 6

Unpacking and Inspection ...................................................... 6

Locating and Mounting the Inverter ......................................... 8

Wiring Guidelines ................................................................10

DC Wiring ...........................................................................11

DC Wire Sizing and Overcurrent Protection .........................11

DC Overcurrent Protection ................................................13DC Grounding .................................................................13

DC Cable Connections ......................................................14

Battery Bank Wiring ............................................................15

Inverter to Battery Bank Wiring ............................................15

DC Ground Wire ..............................................................16

DC Negative Wire ............................................................16

Battery Temperature Sensor .............................................16

DC Positive Wire .............................................................16

AC Wiring ...........................................................................17

Neutral to Safety Ground Bonding .....................................17AC Wiring Connections .....................................................18

AC Wire Size and Overcurrent Protection ............................18

AC Input Wiring ..............................................................19

AC Output Wiring ............................................................20

Ground-Fault Circuit Interruption Breakers .........................21

Functional Test ....................................................................21

3.0 Operat ion ................................................................... 23

Operating Modes .................................................................23

Inverter Mode .................................................................23

Standby Mode ................................................................24Protection Circuitry Operation ...............................................28

Inverter Start-up .................................................................29

ON/OFF Switch ...............................................................29

Status LED Indicator .......................................................29

Factory Default Settings .......................................................304.0 Maintenance and Troubleshooting ...............................32Recommended Inverter and Battery Care ...............................32Resetting the Inverter ..........................................................32

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List of Figures

Figure 1, MM-AE Series Inverter/Charger .................................. 1Figure 2, Top Side Features ..................................................... 3Figure 3, Front and Back Side Features ..................................... 4Figure 4, Left Side Features .................................................... 5Figure 5, Battery Temperature Sensor (BTS) ............................. 5Figure 6, Basic Installation Diagram ......................................... 7Figure 7, Approved Mounting Orientations ................................. 9Figure 8, MM-AE Series Inverter/Charger Dimensions ................10Figure 9, DC Cable to Battery Terminals ...................................14Figure 10, DC Cable to Inverters DC Terminals .........................14

Figure 11, AC Wiring Connections ...........................................20Figure 12, Automatic 4-Stage Charging Graph ..........................26Figure 13, BTS Temperature to Charge Voltage Change ..............27Figure 14, Series Battery Wiring .............................................36Figure 15, Parallel Battery Wiring ............................................37Figure 16, Series-Parallel Battery Wiring ..................................37Figure 17, Battery Bank Wiring Examples (12-volt) ...................38Figure 18, Battery Bank Wiring Examples (24-volt) ...................39

List of Tables

Table 1, Recommended DC Wire/Overcurrent Device .................12Table 2, DC Wire Size For Increased Distance ...........................13Table 3, Wire Color to AC Wire Connection ...............................18Table 4, Minimum Wire Size to Circuit-breaker Size ...................19Table 5, Inverter Battery Turn On/Off Levels .............................29Table 6, Inverter/Charger Default Settings ...............................31Table 7, Troubleshooting Guide ...............................................33Table 8, MM-AE Series Specifications .......................................34

Table of Contents

5.0 Specifications ..............................................................34Appendix A - Optional Equipment and Accessories ............35Appendix B - Battery Information .....................................36Battery Bank Sizing .............................................................36

Battery Types .....................................................................36Battery Configuration ...........................................................36Series Wiring ..................................................................36Parallel Wiring ................................................................37Series-Parallel Wiring.......................................................37

Appendix C - Warranty/ Service Information .....................40How to Receive Repair Service ..............................................41

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1.0 Introduction

1.0 Introduction

Congratulations on your purchase of an MM-AE Series inverter/char-ger from Magnum Energy, Inc. This product is designed especially foryour back-up power or standalone application. Powerful, yet simpleto use, the Magnum Energy inverter will provide you with years of

trouble-free use.Please read this chapter to familiarize yourself with the features andbenefits of your particular MM-AE Series model.

Figu re 1 , MM-AE Ser ies I nve r t e r / Charge r

MM-AE Series Models

MM612AE - a 600 watt inverter/charger with 7 amp AC transfer

capability and 30 amp/12 VDC, 4-stage PFC charger. The AC inputand output are provided with pigtail wires to allow hardwiring to amain AC distribution panel and to an inverter sub-panel. Includes a15 battery temperature sensor.

MM1512AE - a 1500 watt inverter/charger with 12 amp AC transfercapability and 70 amp/12 VDC, 4-stage PFC charger. The AC inputand output are provided with pigtail wires to allow hardwiring to amain AC distribution panel and to an inverter sub-panel. Includes a15 battery temperature sensor.

MM1524AE - a 1500 watt inverter/charger with 12 amp AC transfer

capability and 35 amp/24 VDC, 4-stage PFC charger. The AC inputand output are provided with pigtail wires to allow hardwiring to amain AC distribution panel and to an inverter sub-panel. Includes a15 battery temperature sensor.

Info: These units have common input/output neutralsfor uses in AE applications (i.e., homes/cabins/offices).If your installation is for a mobile application (RV, truck,or boat), the appropriate model for these applications isthe MM or MMS Series inverter.

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1.0 Introduction

How an Inverter/ Charger Works

An inverter takes direct current (DC) from your batteries and turnsit into alternating current (AC), like you use at home. With MM-AESeries models, it also takes alternating current (when connected toa generator or to utility power) and transforms it into direct currentto recharge your batteries.

The two modes of operation associated with this inverter/charger arereferred to in this document as:

Inverter Mode: DC from the batteries is transformed into modifiedsine wave AC for powering your AE applications.

Standby Mode: The unit operates as a battery charger to convertincoming AC power into DC power to recharge the batteries while con-tinuing to pass the incoming AC power directly to the inverters outputto power any AC loads.

Appliances that will run from a Modified Sine Inverter

Todays inverters come in two basic output waveforms: modified sine(actually a modified square wave) and pure sine wave. Modified sinewave inverters approximate a pure sine waveform.

The output of a modified sine wave inverter will run most electronicand household items including but not limited to TV, VCR, satellite dishreceiver, computers, and printers. Some devices such as rechargeablepower supplies for phones, drills, and other like devices may not runor be damaged by modified sine wave inverters.

Appliances and Run Time

The MM-AE Series inverter/charger can power a wide range of house-

hold appliances. As with any appliance using batteries for power, thereis a certain length of time that it can run this is called run time.Actual run time depends on several variables including the size andthe type of appliance, the type of batteries installed in your applica-tion, as well as the batterys capacity and age. Other factors suchas the batterys state of charge and temperature can also affect thelength of time your appliances can run.

Depending on your inverter capacity, larger electrical appliances suchas coffee pots and hair dryers can be used for short durations. How-ever, loads that are used for longer periods such as stoves or water

heaters can quickly drain your batteries and are not recommendedfor inverter applications.

All electrical appliances are rated by the amount of power they con-sume. The rating is printed on the products nameplate label, usu-ally located on its chassis near the AC power cord. Even though it isdifficult to calculate exactly how long an inverter will run a particularappliance, the best advice is trial and error. Your MM-AE Series in-verter/charger has a built-in safeguard that automatically protectsyour batteries from being over-discharged.

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21

3

4

6

5

8 7

Figur e 2 , Top Side Featu res

Standard Features and Benefits

The MM-AE Series inverter/charger converts 12 or 24 volts (de-pending on model) direct current (VDC) power from your battery to120 volts alternating current (VAC) power. The multi-stage batterycharger optimizes incoming AC power using Power Factor Correction(PFC) technology to keep the inverters battery bank fully charged.This inverter is designed to allow easy installation and use, and withits die-cast aluminum baseplate it ensures maximum durability andcooler more efficient operation.

The inverter/charger provides the following:

600 or 1500 watts continuous (depending on model) at 25C.

Numerous protection features to provide a safe andpeace-of-mind operation.

AC transfer switch circuitry; allowing incoming AC power tocontinue to pass-thru to power loads even if the inverter is off.

Dead battery charging for batteries that are extremely low.

Automatic 4-stage battery charger with power factor correctionand temperature compensation for optimum battery charging(using the temperature sensor).

Modern and aesthetically pleasing design with large AC wiringcompartment (provides easy access to AC wiring for simple andquick connections) and 360 DC connection terminals with colorcoded insulating covers.

True RMS output voltage regulation to ensure the inverter will

deliver the correct amount of power within the DC input volt-age range and the continuous output power level.

Quick connection accessory and remote ports easily acceptsseveral optional remote controls and the Battery TemperatureSensor.

1.0 Introduction

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1.0 Introduction

1. Inverter Status Indicator - this green LED illuminates toprovide information on the inverters operation.

2. Pow er Sw itch -momentary pushbutton switch that turns theinverter on or off.

3. Negative DC Terminal (black) - the inverters connection tothe negative terminal on the battery bank.

4. Positive DC Terminal (red) - the inverters connection to thepositive terminal on the battery bank.

5. Input Circuit Breaker - this circuit breaker protects the unitsinternal wiring and pass-thru relay.

6. Output Circuit Breaker -this circuit breaker provides anotherlayer of overload protection. This is not a branch-circuit ratedbreaker. Separate AC output breakers are required on the output.

7. Mounting Flanges (x4) - secures the inverter to shelf/wall.

8. AC Wiring Compartment - provides access for all AC inputand output connections on the inverter.

Figu re 3 , Fron t an d Back Side Featu res

9. Warning and Information Label -provides pertinentinformation for safely using the inverter.

10. REMOTE Port Connection -a RJ11 connector that allows anoptional remote control to be connected.

11. ACCESSORY PORT Connection -a RJ11 connector to allowthe Battery Temperature Sensor (BTS) or MM-AE accessories (e.g.,MM-DCLD) to be connected.

12. Intake Vent -ventilation openings to pull in air to help keepthe inverter cool for peak performance.

13. Exhaust Vent -ventilation openings that allow heated air tobe removed by the internal cooling fan.

14. Model/ Serial Number Label -includes model/serial numberand provides specifications and information on the inverter andcharger. See the MM-AE SeriesSpecificationson page 34 formore information and the different models available.

10

11

12

Front Side

9

Back Side

14

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15. AC Output Connection -AC knockout (output) forhardwiring.

16. AC Input Connection -AC knockout (input) for hardwiring.

17. DC Ground Terminal -this connection is used to tie theexposed chassis of the inverter to the DC grounding system. Thisterminal accepts CU/AL conductors from #14 AWG to #6 AWG.

Battery Temperature Sensor

A plug-in external Battery Temperature Sensor (BTS) is providedfor units with the battery charger feature. When installed, theBTS automatically adjusts the battery chargers BULK, ABSORB,and FLOAT voltage set-points (based on temperature) for bettercharging performance and longer battery life. If the temperaturesensor is NOT installed and the batteries are subjected to largetemperature changes, battery life may be shortened.

Figur e 4 , Le f t S ide Featu res

FRO NT V IEW

SIDE VIEW

~2" ~1"

~

0.375" diameterCable

~

16 17

15

5

1.0 Introduction

Figu re 5 , Ba t te ry Tem pera tu re Sensor ( BTS)

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2.0 Installation

2.0 Installation

Pre-Installation

Before installing the inverter, read the entire Installation section. Themore thorough you plan in the beginning, the better your inverterneeds will be met.

WARNING:Installations should be performed by qualifiedpersonnel, such as a licensed or certified electrician. Itis the installers responsibility to determine which safetycodes apply, and to ensure that all applicable installationrequirements are followed. Applicable installation codesvary depending on the specific location and the type ofinstallation.

Info:Review the Important Product Safety Informationon page ii and the Important Battery Safety Instructionson page iii before any installation.

The basic system diagram shown in Figure 6 should be reviewed toassist you in planning and designing your installation.

Unpacking and Inspection

Carefully remove the MM-AE Series inverter/charger from its ship-ping container and inspect all contents. Verify the following itemsare included:

MM-AE Series inverter/charger Red and black DC terminal covers AC access cover with two screws Two 1/2 hex-head kep nuts (installed on the DC terminals) Battery Temperature Sensor (BTS) MM-AE Series Owners Manual

If items appear to be missing or damaged, contact your authorizedMagnum Energy dealer or Magnum Energy.

If at all possible, keep your shipping box. It will help protect your

inverter from damage if it ever needs to be returned for service.

Save your proof-of-purchase as a record of your ownership; it willalso be needed if the unit should require in-warranty service.

Record the units model and serial number in the front of this manualin case you need to provide this information in the future. It is mucheasier to record this information now, instead of trying to gather itafter the unit has been installed.

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Figu re 6 , Bas ic I ns ta l l a t i on D iag ram

ACMain Panel

MM-AE Series Inverter

DCdisconnect

andovercurrent

device

Battery

Bank

A C IN

AC LoadsVCR

TV Tools

AC

Sub-Panel

AC

Outlet

A COU T

DCGround

2.0 Installation

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2.0 Installation

8

Locating and Mounting the Inverter

WARNINGS:

Do not mount the inverter near any flammable orcombustible fluid or components.

Provide adequate clearance/ventilation to the inverter.

Mount only on a non-combustible surface. Maximum ambient temperature around the inverter must

not exceed 77 F (25 C) to meet power specifications.

The inverter should only be installed in a location that meets thefollowing requirements:

Clean and Dry - The inverter should not be installed in an area thatallows dust, fumes, insects, or rodents to enter or block the invertersventilation openings. The area also must be free from any risk ofcondensation, water, or any other liquid that can enter or fall on theinverter. The inverter uses stainless steel fasteners, plated copper

busbars, and a power-coated aluminum base. Also, the internal circuitboards are conformal coated. The above measures are undertakento help fight the harmful effects of corrosive environments. However,the life of the inverter is uncertain if used in any of these types ofenvironments, and inverter failure under these conditions is not coveredunder warranty.

Cool - The inverter should be protected from direct exposure to thesun or any equipment that produces extreme heat. The ambient airtemperature should be between 32 F (0 C) and 104 F (40 C);keep in mind that the inverters output specifications are rated at 77

F (25 C), so the cooler the better within this range.Ventilated - In order for the inverter to provide full output powerand avoid over-temperature fault conditions do not cover or blockthe inverters ventilation openings, or install this inverter in an areawith limited airflow. Allow as much clearance around the invertersintake and exhaust ventilation openings as possible, see Items 12and 13 in Figure 3. At the minimum, allow an airspace clearance of6 (15 cm) at the front and back, and 3 (7.5 cm) everywhere elseto provide adequate ventilation.

If installed in an enclosure, a fresh air intake opening must be pro-vided directly to the front side (intake vent) and an exhaust open-ing on the back side (exhaust vent) of the inverter. This will allowcool air from the outside to flow into the inverter, and heated air toexit away from the inverter and the enclosure. When mounted in anenclosed compartment, airflow must be at least 59 cfm in order tomaintain no more than a 68 F (20 C) rise in compartment tem-perature. Minimum clearances can be reduced if airflow is increased,but in no case should clearance around the inverter be less than 2(5 cm) on all sides.

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Safe - Keep any flammable/combustible material (e.g., paper, cloth,plastic, etc.) that may be ignited by heat, sparks, or flames at aminimum distance of 2 feet (60 cm) away from the inverter. Do notinstall this inverter in any area that contains extremely flammableliquids like gasoline or propane, or in locations that require ignition-protected devices.

Close to the battery bank - As with any inverter, it should belocated as close to the batteries as possible. Long DC wires tend tolose efficiency and reduce the overall performance of an inverter.However, the unit should not be installed in the same compartment asthe batteries or mounted where it will be exposed to gases producedby the batteries. These gases are corrosive and will damage theinverter. 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 inverters remote control andaccessory ports. Also, allow enough room to access the AC and DC wiringconnections, as they will need to be checked and tightened periodically.See Figure 8 for the MM-AE Series inverter dimensions.

Mounting Orientation - To meet regulatory requirements, theMM-AE Series inverter/charger can only be mounted on a horizontalsurface (shelf or table) or a vertical surface (wall or bulkhead) eitherright-side up or upside-down, as shown in Figure 7. The inverter mustbe mounted on a non-combustible surface, and this surface and themounting hardware must be capable of supporting at least twice theweight of the inverter. After determining your mounting position, usethe base of the inverters chassis as a template to mark your mountingscrew locations. Remove the inverter and drill pilot holes into the

mounting surface.After the inverter has been properly mounted, proceed to the DCWiring section.

Figu re 7 , Approved Moun t ing Or ien ta t ions

Wall Mounted (right-side up)

Wall Mounted (up-side down)

Shelf Mounted

(right-side up)

Shelf Mounted

(up-side down)

2.0 Installation

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2.0 Installation

Figu re 8 , MM-AE Ser ies I nve r t e r / Charge r D im ens ions

Mounting holes x 4

[ (0.25") diameter ]

10.0"~ 16 5/8"

(16.59")

~ 6 3/4" (6.71")

~ 8 7/16" (8.41")

~ 7 " (7.51")

~ 4 11/16"

(4.66")

Wiring Guidelines

Before connecting any wires, determine all wire routes to andfrom the inverter throughout the home or cabin.

Conductors passing through walls or other structural membersmust be protected to minimize insulation damage such aschafing, which can be caused by vibration or constant rubbing.

Always check for existing electrical, plumbing, or other areasof potential damage prior to making cuts in structural surfaces orwalls.

Make sure all wires have a smooth bend radius and do not be-come kinked.

Both AC and DC overcurrent protection must be provided as partof the installation.

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DC wires and cables should be tied together with wire ties orelectrical tape approximately every 6 inches. This helps improvethe surge capability and reduces the effects of inductance, whichimproves the inverter waveform and reduces wear on theinverters filter capacitors.

Use only copper wires with a minimum temperature rating of

75C. To ensure the maximum performance from the inverter, all

connections from the battery bank to the inverter should beminimized; the exceptions are the DC overcurrent disconnect inthe positive line and a shunt in the negative line. Any other ad-ditional connection will contribute to additional voltage drops,and these extra connections points may loosen during use.

All wiring to the battery terminals should be checked periodically(once a month) for proper tightness. The torque requirementfor the DC terminals is between 10 to 12 foot-pounds. If youdont have a torque wrench, ensure all DC terminals are tightand cannot move.

CAUTION:Be aware that overtightening and misthreadingthe nuts on the DC terminals can cause the bolts to stripand snap/break off.

DC Wiring

This section describes the inverters required DC wire sizes and therecommended disconnect/overcurrent protection, and how to makethe DC connections to the inverter and the battery bank.

DC Wire Sizing and Overcurrent Protection

It is important to use the correct DC wire to achieve maximum ef-ficiency from the system and reduce fire hazards associated withoverheating. See Table 1 to select the minimum DC wire size neededbased on your inverter model. If the distance from the inverter to thebattery bank is greater than 3 feet, use Table 2 to help determinethe minimum recommended cable sizes for longer distances. Alwayskeep your wire runs as short as practical to help prevent low volt-age shutdowns, and keep the DC breaker from nuisance tripping (oropen fuses) because of increased current draw. Undersized cables

can also lower the inverters peak output voltage, as well as reduceits ability to surge heavy loads.

2.0 Installation

11

Info: The DC wires must be color coded with coloredtape or heat shrink tubing; RED for positive (+), BLACKfor negative (-), and GREEN for DC ground.

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2.0 Installation

The DC wires must have soldered and crimped lugs, crimped coppercompression lugs, or aluminum mechanical lugs. Soldered connec-tions alone are not acceptable for this application.

Table 1, Recommended DC Wire/ Overcurrent Device

If the inverter is expected to operate at a distance greater thanthree feet from the battery bank, the DC wire size will need to be

increased to overcome the increase in resistance which affects theperformance of the inverter. Continue to use the overcurrent deviceand DC ground wire previously determined from Table 1 and then,refer to Table 2 to determine the minimum DC wire size you need forvarious distances based on your inverter model.

Note 1 - Maximum Continuous Current is based on the inverters continuouspower rating at the lowest input voltage with an inefficiency factor.Note 2 - Per the NEC, the DC grounding electrode conductor can be a #6

AWG conductor if that is the only connection to the grounding electrode andthat grounding electrode is a pipe, rod, or plate electrode.Note 3 - Wire size is based on the requirements needed to increase efficien-cy and reduce stress to the inverter.Note 4 - The next larger standard size overcurrent device may be used ifthe de-rated cable ampacity falls between the standard overcurrent devicesfound in the NEC.

Info: The term in free air is defined by the NEC as notencased in conduit or raceway.

Inverter Model

MM612AE MM1512AE MM1524AE

Maximum ContinuousCurrent

80 amps 200 amps 100 amps

DC GroundingElectrode Wire Size

# 6 AWG # 6 AWG # 6 AWG

Minimum DC Wire Size(90C rating in free air)

# 2 AWG(190 amps)

# 1/0 AWG(260 amps)

# 1/0 AWG(260 amps)

Maximum DC

Fuse Size

200 amps with

time delay

300 amps with

time delay

300 amps with

time delay

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DC Overcurrent Protection

For safety and to comply with NEC (National Electrical Code) electricalcode regulations, you must install a DC overcurrent protection device

in the positive DC cable line to protect your DC cables. This DCovercurrent device can be a fuse or circuit-breaker, but must be DCrated. It must be correctly sized according to the size of DC cablesbeing used, which means it is required to open before the cablereaches its maximum current carrying capability, thereby preventinga fire. See Table 1 to select the DC overcurrent device based on theminimum wire size for your inverter model.

If using a fuse, we recommend using a class-T type or equivalent.This fuse type is rated for DC operation, can handle the high short-circuit currents, and allows for momentary current surges from theinverter without opening.

DC Grounding

The inverter/charger should always be connected to a permanent,grounded wiring system. The idea is to connect the metallic chassisof the various enclosures together to have them at the same voltagepotential, which reduces the possibility for electric shock. For themajority of installations, the inverter chassis and the negative batteryconductor are connected to the systems ground bond via a safety-grounding conductor (bare wire or green insulated wire) at only onepoint in the system. Per the NEC, the size for the grounding conductoris usually based on the size of the overcurrent device used in the DC

system. Refer to Table 1 to select the appropriate DC ground wirebased on the overcurrent device used for your inverter model.

2.0 Installation

13

Table 2, DC Wire Size For Increased Distance

Minimum recommended DC wire size (one way)

3 ft or less 3 to 5 ft 5 to 10 ft 10 to 15 ft

MM612AE #2 AWG #1 AWG #1/0 AWG #2/0 AWG

MM1512AE # 1/0 AWG #1/0 AWG #2/0 AWG #4/0 AWG

MM1524AE # 1/0 AWG #1/0 AWG #2/0 AWG #4/0 AWG

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2.0 Installation

14

Figu re 9 , DC Cab le to Bat te r y Term ina ls

DC Cable Connections

When connecting the DC cable to the battery or to the inverters DCterminals, the hardware should be installed in the correct order toprevent high resistance connections from heating up and possiblycausing the connections to melt. Follow Figures 9 and 10 to stackthe hardware correctly. Tighten the terminal connections from 10 to

12 foot-pounds.

CAUTION: Do not put anything between the DC cable ringlug and the battery terminal post or inverters DC terminal.If antioxidant grease or spray is used, apply it after all theconnections have been made and are properly tightened.

CAUTION: Overtightening or misthreading nuts on the DCterminals will cause the bolts to strip and snap/break-off.

CAUTION:The inverter is NOT reverse polarity protected(negative and positive connected backwards). You mustverify the correct voltage polarity BEFORE connecting theDC wires or damage may occur.

Crimped and sealed copper ring terminal lugs with a 5/16 hole shouldbe used to connect the DC wires to the inverters DC terminals.

Figu re 10 , DC Cab le to I nv er t e r s DC Term ina ls

B A T T E R Y

DC cablewith ring lug

bolt

flat washer

nut

lock washer

batterypost

battery terminal

Temperature sensor

Verify that theDC cable lugs are flush

with the battery terminals.T orque the battery terminals

from 10 to 12 foot-pounds.

DC cablewith ring lug

DCterminal cover

(snaps on)

InvertersDC terminal

5/16 (Kepnut with star-washer) or

Flange nut

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Battery Bank Wiring

WARNING: Lethal currents will be present if the positiveand negative cables attached to the battery bank touch eachother. During the installation and wiring process, ensurethe cable ends are insulated or covered to prevent touch-

ing/shorting the cables.Info: DO NOT connect the DC wires from the battery bankto the inverter until: 1) all DC/AC wiring is complete, 2)the correct DC and AC overcurrent protection have beeninstalled, and 3) the correct DC voltage and polarity havebeen verified.

Info: For optimum performance, a minimum battery bankof 200 AHr is recommended.

Depending upon the type of batteries you use in the installation (6or 12 VDC), the batteries must be wired in series, parallel, or series-parallel (see Appendix B - Battery Information, for guidance on wiringbatteries together). The interconnecting DC wires must be sized andrated exactly the same as those that are used between the batterybank and the inverter.

Place the batteries as close as practical to the inverter, preferably inan insulated and ventilated enclosure. Allow adequate space abovethe batteries to access the terminals and vent caps (as applicable).Also, allow at least 1 of space between the batteries to provide goodair flow. DO NOT mount the batteries directly under the inverter.

Info: To ensure the best performance from your invertersystem do not use old or untested batteries. Batteriesshould be of the same size, type, rating, and age.

CAUTION: Install batteries in a well ventilated area. Bat-teries can produce explosive gasses. For compartmentor enclosure installations, always vent batteries to theoutside.

Inverter to Battery Bank Wiring

WARNING: Ensure all sources of DC power (i.e., batter-ies, solar, wind, or hydro) and AC power (utility power orAC generator) are de-energized (i.e., breakers opened,fuses removed) before proceeding.

2.0 Installation

15

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2.0 Installation

CAUTION: The inverter is NOT reverse polarity pro-tected. If this happens, the inverter will be damaged andwill not be covered under warranty. Before connectingthe DC wires from the batteries to the inverter, verifythe correct battery voltage and polarity using a voltme-ter. If the positive terminal of the battery is connected

to the negative terminal of the inverter and vice versa,severe damage will result. If necessary, color code thecables with colored tape or heat shrink tubing; RED forpositive (+), and BLACK for negative (-) to avoid polar-ity confusion.

Info: The DC overcurrent device (i.e., fuse or circuitbreaker) must be placed in the positive (RED) DC cableline between the inverters positive DC terminal andthe batterys positive terminal (RED); as close to thebattery as possible.

DC Ground W ireRoute an appropriately sized DC grounding wire (GREEN or barewire) from the inverters DC Ground Terminal (see Figure 4, Item 17)to a dedicated system ground. Recommended tightening torque is45 in. lbs.

DC Negative Wire

Route an appropriately sized DC negative wire (BLACK) from thenegative terminal of the first battery string to the inverters negativeterminal (see Figure 16 for reference).

Battery Temperature Sensor

Connect the RJ11 connector end of the BTS to the ACCESSORY PORT(see Figure 3, Item 11) on the inverter. Connect the other end of theBTS to the negative terminal of the first battery string (in same place asthe negative DC wire above); refer to Figure 9 for the correct hardwareplacement.

DC Positive W ire

Mount the DC fuse block and disconnect (or circuit breaker assembly)as near as practical to the batteries, and then open the disconnect(or circuit breaker).

WARNING: DO NOT close the DC fuse/DC disconnect (orclose the DC circuit breaker) to enable battery power tothe inverter at this time. This will occur in the FunctionalTest after the installation is complete.

Route and connect an appropriately sized DC positive wire (RED) fromthe DC fuse block (or circuit breaker assembly) to the inverters posi-tive DC terminal.

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Neutra l to Safety Ground Bonding

The NEC (National Electric Code) provides the standards for safelywiring AE (house, cabin, or office) installations in the United States.These wiring standards require the AC source (inverter, utility power,or a generator) to have the neutral conductor tied to ground. Thesestandards also require that the AC neutral be connected to safetyground (often called a bond) in only one place at any time. If morethan one bond is established, currents can circulate between neutraland ground and cause ground-loop currents. These ground-loopscan trip GFCIs and cause an electric shock hazard. In AE installations,

the neutrals are connected together and are always connected tosafety ground at the main AC panel never at the inverter.

Info: For an AE application, you must use an MM-AESeries inverter/charger. Non AE versions are designedfor use in mobile applications.

AC Wiring

This section describes the required AC wire size and the overcurrentprotection needed. It also provides information on how to make theAC connections.

WARNING: All wiring should be done by a qualifiedperson or a licensed electrician following all local/NECcodes.

17

2.0 Installation

Connect a short wire (same rating as the DC wires) to one end of thefuse block and the other end of the short wire to the positive terminalof the last battery string (see Figure 16). This is essential to ensureeven charging and discharging across the entire battery bank.

Ensure the DC wire connections (to batteries, inverter, and fuse lugs/DC circuit breaker) are flush on the surface of the DC terminals, andthe hardware (lock washer and nut) used to hold these connectionsare stacked correctly (see Figures 9 and 10).

Verify all DC connections are torqued from 10 to 12 foot-pounds.

Once the DC connections are completely wired and tested, coat theterminals with an approved anti-oxidizing spray.

Press the red and black terminal covers onto the inverters DC con-nectors to secure them in place.

If batteries are in an enclosure, perform a final check of the holddown brackets and all connections. Close and secure the batteryenclosure.

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2.0 Installation

18

The AC wires inside the AC compartment are #16 AWG with a tem-perature rating of 105 C. All AC connections should be made usingan approved connector for your application (e.g., split bolt, twist-onwire connectors, etc.). Ensure the wire connectors used are rated forthe size and number of wires you are connecting.

After connecting the wires together, gently pull on the wires to ensurethey are securely held together. In a proper connection, no bare wireshould be exposed.

Info: Per UL certification, non-metallic sheathed cable(i.e., Romex) or an SO flexible cord with listed strainreliefs are allowed to be used to connect to the inverter;conduit connections are not allowed.

After all AC wiring in the inverter is complete (and before reattach-ing the AC access cover), ensure all connections are correct and

secure.

Table 3, Wire Color to AC W ire Connection

AC Wiring Connections

For all hardwired inverter models, the AC input and output wiring isperformed in the AC wiring compartment. This compartment is locatedon the top panel (see Figure 2, Item 8). If installed, remove the twoPhillips screws on the cover to access the AC wiring compartment

and locate the inverters AC wiring. There is a label located in the ACaccess compartment which gives information on which wires are usedfor the AC input and output. You can also refer to Table 3 to matchthe inverters AC wires to the appropriate AC wire connection.

AC Wire Size and Overcurrent Protection

The AC input and output wiring must be sized per the NEC and localelectrical safety code requirements to ensure the wires ability tosafely handle the inverters maximum load current. After determiningthe proper AC wire sizes, the inverters AC input (unless you are usinga flexible cord) and output wires are required to be protected againstovercurrent and have a means to disconnect the AC circuits.

Wire co lor ( label) Wire connection

AC INBlack (HOT IN) Hot In

White (NEUT IN) Neutral In

AC OUT

Red (HOT OUT) Hot Out

White with blackstripe (NEUT OUT)

Neutral Out

AC Ground Green (GROUND) AC IN & AC OUT Ground

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AC Input W iring

Your inverter has an AC transfer feature that passes the AC inputpower to the inverters output. Connection to the AC input is madeby hardwiring from a distribution panel as described below:

1. Run an appropriately sized 2-conductor plus ground cable (from theAC distribution panel) through a strain relief on the AC IN opening.Refer to Table 4 for minimum wire size and overcurrent protectionrequired for the AC input wiring.

2. Remove about two inches of the insulating jacket from the ACcable, and then separate the three wires and strip about 3/4 ofinsulation from each wire.

3. Using approved AC wire connectors, connect the incoming HotIn, Neutral In, and Ground wires to the MM-AE Series AC wirescolored black (HOT IN), white (NEU IN), and green (AC GROUND)respectively.

4. After making the AC input connections, secure the AC input cableby tightening the strain relief.

The AC input wiring in the inverter is complete. Review all AC wiringto ensure all connections are correct and secure.

19

Table 4, Minimum W ire Size to Circuit-breaker Size

2.0 Installation

Overcurrent protection must be provided by fuses or circuit-breakers,and must be properly sized and rated for the wire they are protectingand the appliances being powered.

An external disconnect device is required for both the AC input andAC output wiring. Most inverters that are hardwired use a service/distribution panel wired to the inverters input (main panel), and a

dedicated panel between the inverters output wiring and the AC loads(sub-panel). These systems use the circuit breakers provided in thepanels as the overcurrent protection and the AC disconnect. If fusesare used, then separate AC disconnect switches will be needed.

Based on information from the NEC, Table 4 provides the minimumAC wire size and the suggested breaker size based on the invertermodel. However, larger wire size may be required because of volt-age drop. The AC wire sizes provided in this table assume using onlycopper wire and a temperature rating of 75 C or higher. A minimumof #14 AWG is required for all AC wiring.

InverterModel

AC Input AC Output

InputBreaker

MinimumWire Size

SuggestedBreaker

Size

OutputBreaker

MinimumWire Size

SuggestedBreaker

Size

MM612AE 7 amps #14 AWG 10 amps 8 amps #14 AWG 10 amps



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2.0 Installation

AC Output Wiring

CAUTION: The inverters AC output must never be con-

nected to an AC power source. This will cause severedamage to the inverter and is not covered under war-ranty.

When hardwiring the output of the inverter, a cable must be routedfrom the inverters output to an AC distribution panel (sub-panel)that provides overcurrent protection to the loads powered by the in-verter. Connect the AC output to this distribution panel as describedbelow:

1. Remove the 1/2 knockout on the AC Output Connection(see Figure 4, Item 15) use a utility knife to cut thru the round

slot.

2. Discard this knockout and install a 1/2 strain relief in the AC OUTopening. You may need to file the opening edge for proper fit.

3. Run a 2-conductor plus ground cable through the strain relief inthe AC OUT opening. Refer to Table 4 for the minimum wire size andthe overcurrent protection required for the AC output wiring.

A C IN A C O UT

Strainreliefs

ACGroundIn/Out(green)

NeutralIn (white)

HotOut(red)

Neutral Out(white w/black

stripe)

HotIn(black)

Figur e 11, AC W ir in g Conn ect ion s

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2.0 Installation

21

4. Remove about two inches of the insulating jacket from the ACcable, and then separate the three wires and strip about 3/4 ofinsulation from each wire.

5. Using approved AC wire connectors, connect the outgoing HotOut, Neutral Out, and AC Ground wires to the MM-AE Series ACwires colored red (HOT OUT), white with black stripe (NEU OUT), andgreen (AC GROUND) respectively. Gently pull on the wires to ensurethey are securely held together, and check to see that no bare wireis exposed.

6. After making the AC output connections, secure the AC outputcable by tightening the strain relief.

7. Connect the outgoing AC wires to an AC load panel equipped withovercurrent protection (e.g., circuit breakers).

The AC output wiring in the inverter should be complete. Beforereattaching the AC access cover, review all AC wiring to ensure all

connections are correct and secure.

Ground-Fault Circuit Interruption (GFCI) Breakers

Some electrical safety codes require GFCIs to be installed in AEapplications (home/cabin/office). In compliance with UL standards,Magnum Energy has tested the following GFCIs and find that theyfunction properly when connected to the inverters AC output.

Shock SentryTM #XGF15V-SPLeviton Smart Lock #8899-AHubbel #GF520EMBKA

WARNING: Risk of electric shock. Use only the GF-CIs [receptacles or circuit breaker(s)] specified in thismanual. Other types may fail to operate properly whenconnected to this inverter.

Functional Test

After all electrical connections to the inverter, batteries, AC source,and loads (using a sub-panel) have been completed, follow thesesteps to test the installation and the inverters operation.

1. Check the battery voltage and polarity before connecting thebatteries to the inverter. Use a multimeter to verify 10 to 14 VDC(12-volt models) or 20 to 28 VDC (24-volt models) at the batteriespositive and negative terminals.

2. Apply battery power to the inverter by switching the DC disconnectON (or close the DC circuit-breaker). The inverter will remain OFF,but the green status indicator on the front of the inverter will quicklyblink once to indicate that DC power has been connected and is readyto be turned on.

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3. Prior to turning on the inverter, make sure all connected loads (e.g.,appliances) are switched OFF or disconnected from the AC outlets.

4. a. If a remote switch is connected, press the ON/OFF switch toturn the inverter on.

b. If there is not a remote switch connected, lightly press andrelease the inverters ON/OFF power switch located on the top ofthe inverter to turn the inverter on.

Verify the inverters status indicator is blinking indicating the in-verter is providing AC power.

5. Check the output voltage of the inverter by connecting a trueRMS multimeter to the outlets powered by the inverter. Verify thevoltage is 120 VAC +/- 5 VAC. If not using a true RMS meter theoutput AC voltage could indicate from 90 to 130 VAC, depending onthe battery voltage.

6. Turn on or connect a load to the outlets and verify it comes on.

Continue to keep the load connected and turned on.

7. Press the remote ON/OFF switch to turn the inverter off. If theremote is not used, press and release the inverters ON/OFF powerswitch to turn the inverter off. The inverters status indicator and theconnected load should go off.

8. Apply AC power to the inverters AC input. After the AC input poweris qualified (approximately 15 seconds), the incoming AC power willtransfer through the inverter to the inverters AC output and powerthe connected load. Verify the inverters status indicator and theconnected load comes on.

9. Even though the connected load is on, the inverter is currentlydisabled/off. Press the remotes ON/OFF switch (or press and re-lease the ON/OFF power switch on the inverter) to enable/turn onthe inverter.

10. Disconnect the incoming AC power to the inverter. Verify the con-nected load remains on, but now is powered by the inverter.

If the inverter passes all the steps, the inverter is ready for use.

If the inverter fails any of the steps, refer to the Troubleshootingsection.

2.0 Installation

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3.0 Operation

Operating Modes

The MM-AE Series inverter/charger has two normal operating rou-tines; Inverter Mode, which powers your loads using the batteries,and Standby Mode, which transfers the incoming AC power (i.e.,

utility power or a generator) to power your loads and also uses thisincoming power to recharge the batteries. This inverter also includesan extensive protection circuitry that shuts down the inverter undercertain fault conditions.

Inverter Mode

When the inverter is first powered up, it defaults to the OFF mode. Themomentary ON/OFF power switch (Figure 2, Item 2) must be lightlypressed to turn the inverter ON. Subsequently pressing this switchalternately 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 beOFF. If AC power from an external source (utility or generator)is connected and qualified on the inverters AC input, this AC in-put power will pass through the inverter to power the AC loads.However, if this AC power is lost, the AC loads will no longer bepowered because the inverter is OFF.

When the inverter is turned ON, it operates either by Searchingor Inverting, depending on the connected AC loads.

Searching - When the inverter is first turned ON, the automaticSearch feature is enabled. This feature is provided to conservebattery power when AC power is not required. In this mode, the

inverter pulses the AC output looking for an AC load (i.e., electricalappliance). Whenever an AC load (greater than 5 watts) is turnedon, the inverter recognizes the need for power and automaticallystarts inverting. When there is no load (or less than 5 watts) de-tected, the inverter automatically goes back into search mode tominimize energy consumption from the battery bank. When theinverter is Searching, the inverters green LED flashes (fast).

Info: The factory default value for the Search featureis 5 watts, it can be turned off or adjusted from 5 to 50watts using the ME-RC50 remote display.

Inverting - When a load greater than 5 watts is connected to theinverter output, the MS Series inverts the DC power from the bat-tery and supplies 120 VAC power to your sub-panel. The invertersgreen LED flashes once every 2 seconds (medium flash) to indicateit is inverting. The amount of time the inverter can be invertingand providing power is directly related to the amount of AC loadsthat are connected and the capacity of the battery bank.

3.0 Operation

23

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3.0 Operation

24

Standby Mode

The MM-AE Series features an automatic transfer relay and an internalbattery charger when operating in the Standby Mode. The StandbyMode begins whenever AC power (utility or generator) is connectedto the inverters AC input. Once the AC voltage and frequency of theincoming AC power is within the AC input limits, an automatic AC

transfer relay is activated. This transfer relay passes the incoming ACpower through the inverter to power the AC loads on the invertersoutput. This incoming power is also used to activate a powerful in-ternal battery charger to keep the battery bank charged in case ofa power failure.

Battery charging - The MM-AE Series models are equipped with anactive Power Factor Corrected (PFC) multi-stage battery charger. ThePFC feature is used to control the amount of power used to chargethe batteries in order to obtain a power factor as close as possible to1 (or unity). This causes the battery charger to look like a resistor tothe line (forces the charge current waveshape to mirror the voltage

waveshape). This feature maximizes the real power available fromthe AC power source (utility or generator), which translates into lesspower wasted and a greater charging capability than most chargersavailable today.

When an AC source (utility power or generator) is connected to aninverter that has a battery charger, the inverter monitors the ACinput for acceptable voltage. Once the inverter has accepted the ACinput, the AC transfer relay will close and charging will begin. Oncecharging, the DC voltage is monitored to determine the chargingstage. If the DC voltage is low (12.9 VDC/12 volt models or 25.8

VDC/24 volt models), the charger begins bulk charging. If the DCvoltage is high (>12.9 VDC/12 volt models or >25.8 VDC/24 voltmodels), the charger skips the initial Bulk/Absorb Charging stagesand goes directly to float charging.

The multi-stage charger can use up to five different charging stagesto help monitor and keep the batteries healthy. The five stagesinclude an automatic 4-stage charging process (Bulk, Absorb, Float,and Full Charge), and a manual Equalization (EQ) charge stage. Theautomatic 4-stage charge process provides complete recharging andmonitoring of the batteries without damage due to overcharging (seeFigure 12). The Equalization stage (requires the ME-RC50 remote)

is used to stir up stratified electrolyte and reverse any battery platesulfation that might have occurred.

While charging, the unit may go into Charger Back-offprotectionwhich automatically reduces the charge current to the batteries.This is caused by:

1. The internal temperature is too hot the charger automaticallyreduces the charge rate to maintain temperature; or,

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2. The AC input voltage falls < 85 VAC the charger reduces the chargecurrent to zero to help stabilize the incoming AC voltage; or

3. FET Temperature.

The automatic 4-stage charging process includes:

Bulk Charging: This is the initial stage of charging. While bulkcharging, the charger supplies the battery with constant current.The charger remains in bulk charge until the absorption chargevoltage is achieved (14.6 VDC/12 volt models or 29.2 VDC/24 voltmodels)* as determined by the Battery Type selection**.

Absorb Charging: This is the second charging stage and beginsafter the bulk voltage has been reached. Absorb charging pro-vides the batteries with a constant voltage and reduces the DCcharging current in order to maintain the absorb voltage setting.The absorb charging time is 120 minutes as determined by theBattery AmpHrs selection**.

Float Charging: The third charging stage occurs at the end of the

absorb charging time. While float charging (also known as a main-tenance charge), the batteries are kept fully charged and ready ifneeded by the inverter. The Float Charging stage reduces batterygassing, minimizes watering requirements (for flooded batteries),and ensures the batteries are maintained at optimum capacity.In this stage, the charge voltage is reduced to the float chargevoltage (13.4 VDC/12 volt models or 26.8 VDC/24 volt models)* as determined by the Battery Type selection** which canmaintain the batteries indefinitely.

Full Charge (Battery Saver mode): The fourth stage occurs

after four hours offloat charging. The Full Charge stage maintainsthe batteries without overcharging, preventing excessive loss ofwater in flooded batteries or drying out of GEL/AGM batteries. Inthis stage, the charger is turned off and begins monitoring thebattery voltage. If the battery voltage drops low (12.7 VDC/12volt models or 25.4 VDC/24 volt models), the charger will auto-matically initiate another four hours in float charge.

* These voltage settings are based on the Battery Temperature Sensor(BTS) being disconnected, or at a temperature of 77 F (25 C). If the BTSis installed, these voltage settings will increase if the temperature aroundthe BTS is below 77 F (25 C), and decrease if the temperature around the

BTS is higher than 77 F (25 C).

** The MM-AE Series uses changeable settings (see Table 6, Inverter DefaultSettings) that are adequate for most installations. However, if you determinethat some of your operating parameters need to be changed, the ME-RC50remote control can be purchased to allow changes to those settings.

25

3.0 Operation

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ConstantCurrent

ReducedCurrent

ReducedVoltage

Absorb volts

AdjChargeRate

Setting

IncreasedVoltage

ConstantVoltage

MonitoredVoltage

No Current

Time

Floatvolts

MonitoredCurrent

Absorb Time(determined by

the Adj Batt

AmpH rs setting)

Bulk

Charging

Absorb

Charging

Float

Charging

DCVoltage

DCCurrent

Full

Charge

Goes to FullCharge after 4

hours in FloatCharge

Absorb and Float voltage settings are

determined by the Battery Type selection

Figu re 1 2 , Au tom at i c 4 -S tage Charg in g Graph

Transfer time - While in Standby Mode, the AC input is continuallymonitored. Whenever AC power falls below the VAC dropout voltage(80 VAC, default setting), the inverter automatically transfers backto Inverter Mode with minimum interruption to your appliances aslong as the inverter is turned on. The transfer from Standby Modeto Inverter Mode averages approximately 16 milliseconds. While theMM-AE Series is not designed as a computer UPS system, this transfertime is usually fast enough to hold them up. However, the VAC dropoutsetting has an effect on the ability of the loads to transfer without

resetting. The lower this setting, the longer the effective transferwill be and therefore, the higher the probability for the output loadsto reset. This occurs because the incoming AC voltage is allowed tofall to a level that is so low that when the transfer does occur, thevoltage on the inverters output has already fallen to a low enoughlevel to reset the loads.

The disadvantage of a higher VAC dropout setting is that smallergenerators (or large generators with an unstable output) may nui-sance transfer. This commonly happens when powering loads thatare larger than the generator can handle causing the generatorsoutput voltage to constantly fall below the inverters input VAC drop-out threshold.

Info: You must use the ME-RC50 remote to adjust theVAC dropout setting which in turn determines the VACdropout threshold.

Info: When switching from Inverter Mode to StandbyMode, the inverter waits approximately 15 seconds toensure the AC source is stable before transferring.

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3.0 Operation

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3.0 Operation

27

Battery Temperature Sensor Operation - The plug-in Battery Tem-perature Sensor (BTS) is used to determine the battery temperaturearound the batteries. This information allows the multi-stage batterycharger to automatically adjust the battery charge voltages for opti-mum charging performance and longer battery life.

When the BTS is installed, if the temperature around the BTS is below

77F (25C) the absorb and float charge voltage increases. If thetemperature around the BTS is higher than 77F (25C), the absorband float charge voltage decreases. See Figure 13to determine howmuch the charge voltage changes (increases or decreases) as thetemperature reading of the BTS changes. For example, the nominalabsorb charge voltage for a flooded battery at 77F (25C) on a 24-volt model is 29.2 VDC. If the battery temperature is 95F (35C),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 willnot be compensated and the battery will maintain the charge it had

at a temperature of 77F (25C). The life of the batteries may bereduced if they are subjected to large temperature changes whenthe BTS is not installed.

Info: When the BTS is connected, the battery chargeruses a value of -5mV/C/Cell from 0-50C to change thecharge voltage based on temperature.

-0.75

-0.6

-0.45

-0.3

-0.15

0

0.15

0.3

0.45

0.6

0.75

0 5 10 15 20 25 30 35 40 45 50

Temperature reading from BTS

T e m p e r at u r e C o m p e n s a t i o n u s i n g B T S

0C

32F

5C

41F

10C

50F

45C

113F

30C

86F

40C

104F

35C

95F

25C

77F

20C

68F

15C

59F

50C

122FChangetobatterychargingvolta

ge

no BTS

connected

12VDC units

+0.75V

+0.6V

+0.45V

+0.3V

+0.15V

No Change

-0.15V

-0.3V

-0.45V

-0.6V

-0.75V

24VDC units

+1.5V

+1.2V

+0.9V

+0.6V

+0.3V

No Change

-0.3V

-0.6V

-0.9V

-1.2V

-1.5V

Figur e 13, BTS Tem pera t ur e to Char ge Vo l tag e Chan ge

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Protection Circuitry Operation

The inverter is protected against fault conditions, and in normal usageit will be rare to see any. However, if a condition occurs that is outsidethe inverters normal operating parameters, then it will shut downand attempt to protect itself, the battery bank, and your AC loads. Ifthere is a condition that causes the inverter to shut down, it may beone of the conditions listed below. Refer also to the Troubleshootingsection to diagnose and clear the fault.

Low Battery - The inverter will shut off whenever the batteryvoltage falls to the Low Battery Cut Out (LBCO) level to protectthe batteries from being over-discharged. After the inverterhas reached the LBCO level and turned off, the inverter willautomatically restart after one of the following conditions:

1. AC power is applied and the inverter begins operating as abattery charger.

2. Battery voltage rises to the Low Battery Cut In (LBCI )

level.The inverters status LED turns off when a low battery fault con-dition occurs. Refer to Table 5 to determine the LBCO and LBCIlevels for your particular inverter model.

High Battery - In the event the battery voltage approaches theHigh Battery Cut Out (HBCO) level, the inverter will automaticallyshut down to prevent the inverter from supplying unregulated ACoutput voltage. The inverters status LED turns off when a highbattery fault condition occurs. The inverter will automaticallyrestart when the battery falls to the High Battery Cut In (HBCI)level. Refer to Table 5 to determine the HBCO and HBCI levels foryour particular inverter model.

Info: When the BTS is connected, the battery chargeruses a value of -5mV/C/Cell from 0-50C to change thecharge voltage based on temperature.

Overload - During Inverter and Standby operation modes, theinverter monitors the DC and AC current levels. In the eventof a short-circuit or an overload condition for more than a fewseconds, the inverter will shut down. To start operating after thisfault, the inverter would need to be restarted (turned back on)

after the inverters AC loads are reduced/removed.Over-temperature - If internal power components begin toexceed their safe operating temperature level, the inverter willshut down to protect itself from damage. The inverters status LEDturns OFF to indicate the over-temperature fault condition. Theinverter will automatically restart after the units cools down.

3.0 Operation

28

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Internal Fault - The inverter continually monitors several inter-nal components and the processor communications. If a conditionoccurs that doesnt allow proper internal operation, the inverterwill shut down to protect itself and the connected loads. Theinverter will need to be reset to start operating.

Table 5, Inverter Battery Turn On/ Off Levels

* - adjustable with remote

Inverter Startup

ON/ OFF Switch - The inverter can be turned on and off by lightlypressing and releasing the Power ON/OFF switch on the front of theinverter. When the inverter is first connected to the batteries, or whenits automatic protection circuit has turned the inverter off, the ON/OFFswitch will need to be pressed to start the unit. Once the inverterhas been turned on, pressing the Power ON/OFF switch alternatelyturns the inverter on and off.

WARNING: The Power ON/OFF control switch does not

turn on or off the charger feature. If AC power (utility orgenerator) is connected and qualified on the AC input,this AC power will also be available on the AC outputand is not controlled by the Power ON/OFF switch.

Status LED I ndicator - The status indicator is a green LED (LightEmitting Diode) that provides information on the operational mode ofthe inverter. Watch this indicator for at least 10 seconds to determinethe inverters operational condition from the information below:

Inverter Mode

Off- Indicates the inverter is off; there is no AC power fromthe inverter, utility, or generator at the inverters outputterminals.

Blinks On (once every second) - The inverter is on and isusing energy from the battery. The inverter is either provid-ing full power to the loads connected to the inverter, or its inSearch Mode and ready to supply AC power to the connectedloads.

3.0 Operation

29

Inverter BatteryTurn On/ Off

Levels

Inverter Model

MM612AE MM1512AE MM1524AE

HBCO >15.8 VDC >15.8 VDC >31.6 VDC

HBCI 15.5 VDC 15.5 VDC 31.0 VDC

LBCI 12.5 VDC 12.5 VDC 25.0 VDC

LBCO*(one 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

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3.0 Operation

Protection Mode

There are five fault conditions that will cause the inverter to shutdown: Low Battery, High Battery, Over-temperature, AC Overload,and Internal faults. If your inverter has shut down, monitor thestatus indicator and count the number of blinks that occur everyfour seconds to determine the particular reason for the shutdown.

Refer to the Troubleshooting section to help diagnose/clear thefault condition.

Blinks on 1 time every four seconds - Low Battery fault.

Blinks on 2 times every four seconds - High Battery fault.

Blinks on 3 times every four seconds - Over-temperaturefault.

Blinks on 4 times every four seconds - AC Overload fault.

Blinks on 5 times every four seconds - Internal fault.

Charge Mode

The green LED status indicator provides addit ionalinformation:

Blinks off every four seconds - The unit is charging thebatteries connected to the inverter. The external AC power(utility power or generator) connected to the inverters inputis passing through the inverter and is powering the AC loadsconnected to the inverters output.

Factory Default Settings

The MM-AE Series inverter/charger uses default settings that are ad-equate for most installations (see Table 6). However, you can adjustthese parameters using Magnums optional ME-RC50 remote. Thesettings once programmed are saved in non-volatile memory and arepreserved until changed even if DC power to the inverter is lost(the ME-RC50 must always be connected). The following informationcan help you determine if you need the ME-RC50 remote*.

01 Search Watts:This setting allows you to turn off the power-savingSearch Mode circuitry and to adjust the power level at which theinverter will wake up and start inverting.

02 Low Battery Cut Out:This setting determines when the inverter

will turn off based on low battery voltage. The inverter turns offautomatically after the battery voltage has been below this setting formore than one minute. This protects the batteries from over-dischargeand the AC loads from unregulated power (brown-outs).

* Visit www.magnumenergy.com for more information.

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Table 6, Inverter Default Settings

03 Battery AmpHrs:This setting allows you to input the battery banksize in amp hours. This provides information to the charger on howlong to charge the batteries in the Absorb Charging stage.

04 Battery Type: This setting identifies the type of batteries beingused in the system. This provides information to the charger todetermine what voltage level to use to charge the batteries.

05 Charge Rate:This setting can be used to turn off the charger, limitthe amount of current that the charger can use (leaving more currentavailable to power loads); or, to ensure small battery banks are notoverheated because of a charge rate that is too high.

06 VAC Dropout: Sets the minimum AC voltage that must be pres-ent on the AC input before the unit transfers from Standby Mode toInverter Mode. This protects the AC loads from utility outages andbrown-outs.

The ME-RC50 remote also provides the following features:allows you to enable an equalize charge for certain batterytypes

displays the inverter/chargers operating status

provides fault information for troubleshooting

3.0 Operation

31

Function Default Settings

Search Watts 5W

LowBatCutOut 10.0 VDC (MM1524AE- 20.0 VDC)

Battery AmpHrs400 AmpHrs

(Absorb Time = 120 minutes)

Battery Type

Flooded - Liquid Lead Acid

(Bulk = 14.6 VDC, Float = 13.4 VDC)

(MM1524AE - Bulk = 29.2 VDC, Float = 26.8 VDC)

Charge Rate 100%

VAC dropout 80VAC

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4.0 Maintenance and Troubleshooting


Recommended I nverter and Battery Care

The MM-AE Series inverter/charger is designed to provide you withyears of trouble-free service. Even though there are no user-service-able parts, it is recommended that every 6 months you perform the

following maintenance steps to ensure optimum performance andextend the life of your batteries.

WARNING: Prior to performing these checks, switchboth the AC and DC circuits OFF.

Visually inspect the batteries for cracks, leaks, or swelling replace if necessary.

Use baking soda to clean and remove any electrolyte spills orbuildups.

Check and tighten all battery holddown clamps. Clean and tighten (10 to 12 foot-pounds) all DC terminals

(battery and inverter) and connecting cables.

Check and fill battery water levels (Liquid Lead Acid batteriesonly).

Check individual battery voltages (replace those that varymore than 0.3 VDC of each other).

Check all cable runs for signs of chafing replace if necessary. Check the inverters cooling vents clean as necessary.Resetting the Inverter

Under some fault conditions (i.e., an internal fault), the inverter willneed to be reset.

To reset the inverter:

Press and hold the Power ON/OFF pushbutton for approximately15 seconds, or until the status LED comes on and flashes rapidly(see Figure 2, Items 1 and 2).

Release the Power ON/OFF pushbutton once the rapid flashinghas begun. The status LED will go off.

Press the Power ON/OFF pushbutton again to turn the

inverter on.

Info:The Power ON/OFF pushbutton is a smallmomentarytype switch which operates by lightly pressing andreleasing.

1.

2.

3.

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33

Symptom Possible cause Recommended Solution

Low Battery Voltage(the status indicatorblinks on 1 time every4 secs)

The battery voltage level has droppedbelow the Low Battery Cut Out(LBCO) set-point for more than oneminute (10.0VDC = LBCO defaultsetting).

Battery voltage is too low. Check fuses/circuit-breakers and cable connections.Check battery voltage at the inverter'sterminals. Your batteries may needto be charged, this fault condition willautomatically clear when the batteryvoltage exceeds 12.5VDC.

High Battery Voltage(the status indicatorblinks on 2 timesevery 4 secs)

The battery voltage is above 15.5VDC. The inverter automaticallyresets and resumes operation whenthe battery voltage drops below 15.5

VDC.

This condition usually occurs only whenan additional charging source (alternator,solar panels or other external chargingsources) is used to charge the battery

bank. Reduce or turn off any othercharger to the inverter batteries to allowthe voltage level to drop.

Over-temperaturecondition(the status indicatorblinks on 3 timesevery 4 secs)

The internal temperature of theinverter has risen above acceptablelimits; caused by loads too great forthe inverter to operate continuously,or by lack of ventilation to theinverter. When the unit has cooled, itwill automatically reset and resumeoperation.

Reduce the number of electrical loadsthat you are operating, this will avoid arepeat Over-temp shutdown if the causewas too many loads for the ambient

Check ventilation around the inverter,ensure cool air is available to pass-thruthe inverter.

AC Overload(the status indicatorblinks on 4 timesevery 4 secs)

The inverter has turned off becausethe connected loads are larger thanthe inverters output capacity or theoutput wires are shorted.

Reduce the AC loads connected to theinverter or remove all AC output wiringand restart the inverter.

Internal fault(the status indicatorblinks on 5 timesevery 4 secs)

This fault occurs when an internalfault is detected.

To clear this fault, an inverter resetis required. Remove DC power to theinverter or press and hold down thepower switch on the inverter for 15seconds (until the green Status LEDcomes on). If this fault does not clear, theunit will need to be serviced.

Inverter's status lightis off.

Inverter is switched OFF or there isno DC voltage (battery) connected toinverter.

Switch the inverter ON. Connect a batterywith correct voltage to the inverter.

AC input won't connect(AC IN on remoteblinks)

The incoming AC voltage will notbe accepted if it is below the VACDropout setting (80VAC = VACDropout default setting).

Check the incoming AC voltage to theinput of the inverter, ensure it is presentand above the VAC dropout level.

Appliances turn off

and on; or there is lowAC output power.

Loose AC output connections. Tighten AC output connections.

Loose / corroded battery cables. Clean and tighten all cables.

Inverter AC outputvoltage is too low ortoo high when usingan AC voltmeter.

Wrong type of voltmeter used (willdisplay 90 VAC to 130 VAC dependingon the battery voltage).

Most meters are made to read AverageAC voltage. The AC output of the MM is a"modified" waveform which requires usinga true RMS voltmeter to correctly readthe output voltage.

While charging, theDC charge voltage ishigher or lower thanexpected.

If the Battery Temperature Sensor isinstalled, it will increase or decreasethe DC voltage level depending ontemperature around the batterysensor.

This is normal.

Table 7, Troubleshooting Guide

Troubleshooting

The MM-AE Series inverter/charger is a fairly simple device to trouble-shoot. There are only two active circuits (AC and DC), as well as acharging circuit. The following chart is designed to help you quicklypinpoint the most common inverter and charger faults.

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5.0 Specifications

MODEL MM612AE MM1512AE MM1524AE

Inverter Specifications

Input battery voltage range 9 to 16 VDC 9 to 16 VDC 18 to 32 VDC

Nominal AC output voltage 120 VAC +/- 5%

Output frequency and accuracy 60 Hz +/- 0.1 Hz

1msec surge current (amps AC) 27 42 45

100msec surge current (amps AC) 11 23 24

5 sec surge power (real watts) 1100 2100 2650



5 min surge power (real watts) 950 1550 2350

30 min surge power (real watts) 675 1525 1900

Continuous power output at 25 C 600 VA 1500 VA 1500 VA

Maximum input battery current 80 ADC 200 ADC 100 ADC

Inverter efficiency (peak) 95% 95% 91%

Transfer time 16 msecs

AC transfer capability 7A 12A 12A

Search mode (typical) 3 watts 6 watts 4 watts

No load (120 VAC output, typical) 10 watts 18 watts 9 watts

Waveform Modified Sine Wave

Charger Specifications

Continuous output at 25 C 30 ADC 70 ADC 35 ADC

Charger efficiency 85% 88% 88%

Power factor > 0.95

Input current at rated output (amps AC) 4 9 9

Battery temperature compensation Yes, 15 ft Battery Temp Sensor standard

General Features and Capabilities

Protection circuitry Low/High Battery, Over-temp & Overload

Corrosion protection PCB's conformal coated, powder coated chassis

Output circuit breaker 7A switchable 12A switchable 12A switchable

Input circuit breaker 8 AAC 20 AAC 20 AAC

Internal cooling Yes, 0 to 59 cfm variable speed

Optional remotes available MM-RC or ME-RC50

UL listing NA

Environmental Specifications

Operating temperature -20 C to +60 C (-4 F to 140 F)

Non-operating temperature -40 C to +70 C (-40 F to 158 F)

Operating humidity 0 to 95% RH non-condensing

Physical Specifications

Dimensions (L x W x H) 16.6"x 8.4x 4.7 (42cm x 21cm x 12cm)

Mounting Shelf or wall (no vents facing downward or upward)

Weight 16 lbs. (7.3 kg) 22 lbs. (10 kg) 22 lbs. (10 kg)

Shipping weight 18 lbs. (8.2 kg) 24 lbs. (10.9 kg) 24 lbs. (10.9 kg)

Specifications @ 25 C - Subject to change without notice

Table 8, MM-AE Series Specifications

5.0 Specifications

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Appendix A - Optional Equipment and Accessories

35

Appendix - Optional Equipment and AccessoriesThe following Magnum Energy components are available for usewith the MM-AE Series inverter/charger. Some of these items arerequired depending upon the intended use of the inverter.

Smart Battery Combiner

The Smart Battery Combiner (ME-SBCTM) is designed to monitor andcharge a second battery using a portion of the current that is chargingthe main battery. The ME-SBC eliminates a significant voltage drop,and provides automatic turn-on and turn-off based on adjustable volt-age set-points. This allows different batteries to be charged from asingle charging source, and prevents overcharging/undercharging.

Basic Remote Control

The ME-RC50 Remote Control Panel is simple to use; an LCD screenand at a glance LEDs display complete inverter/charger status. Softkeys provide simple access to menus and a rotary encoder knob al-lows you to scroll through and select a wide range of settings.

Auto Generator Start Controller

The ME-AGS-N Automatic Generator Start controller (Network ver-sion) is designed to automatically start your generator based on lowbattery condition or high temperature. The AGS controller includesan input voltage jumper (for 12, 24, and 48 volt battery banks) anda 4-position DIP (Dual In-line Package) switch which provides theability to change the relay timing configurations to allow compatibilitywith a wider range of generators.

Battery Monitor Kit

The ME-BMK Battery Monitor Kit is a single battery bank amp-hour

meter that monitors the condition of the battery and provides infor-mation to let you know how much energy you have available andlet you plan your electrical usage to ensure the battery is not beingover-discharged. The ME-BMK-NS version does not include a DC shunt order the ME-BMK to receive a 5

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64-0035 Rev A (MM-AE Series)

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