Magnum Energy MS-PAE Series Owner'S Manual Download

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Page 19

2009 Magnum Energy Inc

5/16 - 18”

LANGE

NUT

5 ft or less

5 to 10 ft

10 to 15 ft

MS4024PAE

#2/0 AWG x 2

#4/0 AWG x 2

not recommended

MS3748PAEJ

& MS4448PAE

#2/0 AWG

#4/0 AWG

#4/0 AWG x 2

Minimum Recommended DC Wire Size (one way)*

Table 2-4, DC Wire Size For Increased Distance

Figure 2-9, Battery Hardware

Installation

Figure 2-10, Inverter DC Hardware

Installation

2.3.3 DC Cable Connections

Do not put anything between the DC cable ring lug and the battery terminal post or the

at metal

part of the inverter’s DC terminal. When connecting the DC cable to the battery or inverter DC

terminals, the cable should be placed directly against the inverter or battery terminals. Incorrectly

installed hardware causes a high resistance connection which could lead to poor inverter/charger

performance and may melt the cable and terminal connections.
Follow

gures 2-9 and 2-10 on how to connect the DC cables and stack the hardware correctly.

Tighten the terminal connections from 10 to 12 ft lbf (13.6 to 16.3 Nm).

CAUTION:

The DC terminal bolt and nut are made of stainless steel which have a high

likelihood of seizure. To help prevent the bolt and nut from seizing - causing the bolt 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 tighten.

Info:

A 1/2-inch wrench or socket is used to tighten the 5/16 SAE Flange or Kep nuts.

* Copper wire rated with 90°C (194°F) insulation at an ambient temperature of 30°C (86°F).

Installation

CAUTION:

NSURE

NOTHING

PLACED

BETWEEN

THE

TERMINAL

AND

RING

LUG

CAUTION:

NSURE

NOTHING

PLACED

BETWEEN

THE

CABLE

RING

LUG

AND

BATTERY

POST

BATTERY

CABLE

(

WITH

RING

LUG

)

NVERTER

TERMINAL

(5/16 - 18”

BOLT

5/8”

LENGTH

)

BATTERY

CABLE

(

WITH

RING

LUG

)

BATTERY

TEMPERATURE

SENSOR

NUT

SPLIT

WASHER

FLAT

WASHER

BATTERY

POST

Summary of Contents for MS-PAE Series

Page 1: ...MS PAE Series Pure Sine Wave Inverter Charger Owner s Manual TM ...

Page 2: ... in this manual may not exactly match the unit purchased Restrictions on Use The MS PAE Series Inverter Charger shall not be used in connection with life support systems life saving or other medical equipment or devices Using the MS PAE Series Inverter Charger with this particular equipment is at your own risk Contact Information Magnum Energy Inc 2211 West Casino Rd Everett WA 98204 Phone 425 353...

Page 3: ... the inverter There are no user serviceable parts contained in this product This unit is provided with integral protection against overloads 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 Both AC and DC overcurrent protection must be provided as part of the installation C...

Page 4: ...teries can produce explosive gasses For compart ment or enclosure installations always vent batteries to the outside Provide at least one inch of air space between batteries to provide optimum cooling Never smoke when in the vicinity of batteries To prevent a spark at the battery and reduce the chance of explosion always connect the cables to the batteries first Then connect the cables to the inve...

Page 5: ... 4 Protection Circuitry Operation 32 3 5 Start Up 33 3 6 Factory Default Values 34 Troubleshooting 4 0 Troubleshooting 35 4 1 Performing an Inverter Reset 36 Parallel Operation 5 0 Parallel Operation 37 5 1 Overview 37 5 2 Conditions for Parallel Operation 37 5 3 Parallel System Connections and Components 39 Appendix Specifications A 1 Specifications 40 A 2 Efficiency Graphs 41 Optional Equipment ...

Page 6: ...od 2 14 Figure 2 7 Single Connection to DC Ground Rod Method 3 14 Figure 2 8 DC and Battery Temperature Sensor Wiring 17 Figure 2 9 Battery Hardware Installation 19 Figure 2 10 Inverter DC Hardware Installation 19 Figure 2 11 Battery Temperature Sensor 20 Figure 2 12 AC Terminal Block 23 Figure 2 13 AC Wiring 24 Figure 2 14 Warning Label 26 Figure 2 15 AC Voltage Checks 27 Figure 3 1 Power Flow In...

Page 7: ...he following High wattage output in a small footprint less weight and area needed for install Ability to parallel up to four identical MS PAE inverters to increase output power capability requires ME RTR Pure sine wave output 5 THD 120 240 VAC Split phase output in a single inverter PFC Power Factor Corrected multi stage battery charger RS485 standard communication protocol Remote and Network port...

Page 8: ...ER ON OFF SWITCH STATUS CHARGING INVERTING LED PARALLEL STACK PORT RED LABEL RJ45 CONNECTION NETWORK PORT GREEN LABEL RJ11 CONNECTION REMOTE PORT BLUE LABEL RJ11 CONNECTION BATTERY TEMPERATURE SENSOR PORT YELLOW LABEL RJ11 CONNECTION POSITIVE DC TERMINAL NEGATIVE DC TERMINAL MOUNTING FLANGE DC EQUIPMENT GROUND TERMINAL AC ENTRY EXIT CONNECTIONS INTAKE AIR VENTS AND ON RIGHT SIDE ...

Page 9: ...parallel without in stalling the optional ME RTR 4 Magnum Net Connection Port green label a RJ11 port that accepts optional Net work capable accessories i e Auto Gen Start or Battery Monitor 5 Remote Connection Port blue label a RJ11 port that allows optional remote control displays i e ME RC ME ARC ME RTR to be connected 6 BTS Connection Port yellow label RJ11 port that accepts the remote Battery...

Page 10: ...block is used to hardwire all inverter AC input and output wiring connections Remove the two screws to access the AC wiring terminal block 16 Input circuit breakers these circuit breakers protect the unit s internal wiring and pass thru relay on each input L1 and L2 while in the standby mode These input circuit breakers are not branch circuit rated These circuit breakers pop out when they open pre...

Page 11: ...equal to or in many cases better than the grid 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 MS PAE Series provides you with all of the advantages of a pure sine wave inverter at a much lower c...

Page 12: ...Use proper lifting techniques during installation to prevent personal injury 2 1 Pre Installation 2 1 1 Unpacking and Inspection Carefully remove the MS PAE Series inverter from its shipping container and inspect all contents Verify the following items are included The MS PAE Inverter Charger Red and black DC terminal covers with Phillips screws AC access cover with two Phillips screws Two 5 16 Ke...

Page 13: ...0VA C OUTPUT F l u x C a p a c it o r G e n e r a t o r O N O F F O N O FF O N O F F O N O FF O N O F F O N O FF ON OFF O N O F F O N O FF O N O FF O N O F F O N O F F O N O FF B TS M E SB C Sm art B attery C om biner M agnum A ccessory M E A GS N A uto Gen Start C ontroller M agnum A ccessory O N O F F O N O F F O N O FF O N O F F O N O F F O N O F F O N O F F O N O FF 240 VAC 120 VAC 120 VAC SUB...

Page 14: ...f the inverter is 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 will allow cool air from the outside to flow into the inverter and heated air to exit from the inverter and out of the enclosure When mounted in an enclosed compart ment airflow mus...

Page 15: ...to the inverter Info Magnum provides a backplate with a suitable surface for mounting the inverter These backplates also provide the ability to mount either the MMP Series enclosure PN BP MMP or the MP Series Enclosure PN BP S Single Plate or BP D Dual Plate 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...

Page 16: ...2 3 MS PAE Series Dimensions Installation 12 5 8 12 4 7 8 2 4 7 8 Keyhole slots x4 and mounting holes x4 accept up to 9 32 screw bolt 13 3 4 8 6 5 8 BOTTOM SIDE RIGHT SIDE BACK SIDE RIGHT SIDE LEFT SIDE TOP SIDE LEFT SIDE TOP SIDE FRONT SIDE ...

Page 17: ...y code to comply with residential and commercial installations This is normally done by feeding the wires through conduit Magnum provides a DC conduit box ME CB a single inverter enclosure MMP Series or a multiple inverter enclosure MP Series that includes the necessary AC and DC inverter breakers that can be purchased to allow both the AC and DC conduit to be connected to the inverter 2 1 7 Wirin...

Page 18: ...ical system and the equipment grounding conductor at a separately derived system There are two types of grounding equipment grounding and system grounding The exposed metal parts of the equipment in the system usually don t carry electricity However if the exposed metal becomes electrified by a live wire a person touching this live part could complete the electrical circuit and receive a shock Equ...

Page 19: ...e 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 Table 2 1 AC G...

Page 20: ... 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 volt age with respect to earth and the other properly sized conductors in each electrical system will safely carry any fault c...

Page 21: ...occur In accordance with the NEC use Table 2 2 to size the equipment grounding 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 equipme...

Page 22: ...duces the effects of induc tance 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 m...

Page 23: ...ive C onnection Inverter s Equipm ent Ground Wire B TS B TS Battery Bank B attery B ank s Equipm ent Ground Wire B attery B ank s N egative C able B attery B ank s Positive C able M M P enclosure for single inverter installations includes D C disconnect breaker D C shunt for battery m onitor and inverter D C bussbars If m ultiple inverters will be installed see the M P enclosures which are designe...

Page 24: ...aker 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 allow for momentary current surges from the inverter without opening However because the fuse can be energized from both dire...

Page 25: ...ections Follow figures 2 9 and 2 10 on how to connect the DC cables and stack the hardware correctly Tighten the terminal connections from 10 to 12 ft lbf 13 6 to 16 3 Nm CAUTION The DC terminal bolt and nut are made of stainless steel which have a high likelihood of seizure To help prevent the bolt and nut from seizing causing the bolt to strip or snap break off the use of anti seize lubricant is...

Page 26: ...atteries 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 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 CAUTION Install batteries in a well ventilated are...

Page 27: ...ire Mount the circuit breaker assembly as near as practical to the batteries and open the circuit breaker WARNING DO NOT close the DC circuit breaker 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 d...

Page 28: ... circuits and overloads by an overcurrent protection device and have a means to disconnect the AC circuits Overcurrent protection is not included in the inverter and must be provided as part of the instal lation The overcurrent protection device must be a circuit breaker or a fuse and be properly sized and branch circuit rated for the wire it is protecting and the appliances being powered The MS P...

Page 29: ...wiring To access and view the AC terminal block and ground termi nals remove the two Phillips screws holding the AC access cover plate see figure 1 3 item 15 Each connection on the AC terminal block is rated for 105 C and can accept one 18 to 2 AWG 0 82 to 33 6 mm2 CU stranded wire or two 14 to 8 AWG 2 1 to 8 7 mm2 CU stranded wires Each connection uses a 1 4 28 screw and the maximum tightening to...

Page 30: ...output wiring AC HOT 1 IN from Main Panel AC HOT 2 IN from Main Panel AC HOT 1 OUT to Sub Panel Loads AC NEUTRAL to from either Panel AC GROUND to from either Panel AC NEUTRAL to from either Panel AC HOT 2 OUT to Sub Panel Loads Inverter s A C input and output wiring goes through A C bypass switch assembly when using MMP enclosure M S PA E Inverter C harger Sub Panel and Outlets Inverter A C Loads...

Page 31: ...e conduit connectors Feed all AC wiring through the enclosure and into the in verter AC terminal block be sure to leave several extra inches of wire to work with At least two sets of conductor wiring will be needed one from the AC source or Main Panel to the inverter input and another from the inverter output to the sub panel Wiring the Inverter AC Input from the main panel 3 a For a 120 240VAC in...

Page 32: ...ystem 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 read ily 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 ...

Page 33: ... correct Info The inverter s AC output voltage will not be correct until a 5 watt load 5 watts is default setting is connected to the inverter or the search mode is turned OFF with a remote display The 10 watt or greater light bulb is used because it is a sufficient load to bring the inverter out of search mode up to full voltage 6 Check the AC output voltage of the inverter by connecting an AC vo...

Page 34: ...re 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...

Page 35: ... 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 the Charge Mode begins After Charge Mode begins the DC voltage is monitored to determine the charging stage If the DC voltage is low 25 6 24 volt models or 51 2 48 volt models the charger begins Bulk Charging If the DC v...

Page 36: ...ssing 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 peri ods and prevent excessive loss of water in flooded batteries or drying out of GEL AGM batteries In...

Page 37: ...able output may nuisance transfer This commonly happens when powering loads that are larger than the generator can handle causing the generator s output to constantly fall below the inverters input VAC dropout threshold Info When switching from Inverter Mode to the Standby Mode the inverter waits ap proximately 15 seconds to ensure the AC source is stable before transferring 3 3 Battery Temperatur...

Page 38: ...erter 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 cur rent ...

Page 39: ... fault condition such as low battery high battery overload overtemperature 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 inverters input is passing thru the inverter and is powering the AC loads ...

Page 40: ...ads from unregulated power brown outs 03 Batt AmpHrs 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 04 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 05 Charge Rate This setting can be us...

Page 41: ...erter reset is required Remove DC power to the inverter or press and hold down the power switch on the inverter for 15 seconds until the green Status LED comes on If this fault does not clear the unit will need to be serviced No output power Green LED is flashing Unit is in Search Mode which means load is too small for search mode circuit detection Turn on load greater than 5 watts to bring invert...

Page 42: ...elease the Power ON OFF pushbutton The Status LED will go off after the pushbutton is released After the inverter reset is completed press the 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 Figure 4 1 Performing an Inverter Reset 1 Press and hold the Power ON OFF pushbutton 2 Watch the Cha...

Page 43: ...hey are prevented from connecting until the Master inverter has synchronized and connected After the full system has connected battery charging begins This allows a smooth transition from inverter mode to charger mode since the slave inverters are already synchronized when they transfer the loads and start battery charging 5 2 Conditions for Parallel System When connecting units in parallel the fo...

Page 44: ...R SLAVE F lu x C a p a c it o r G e n e r a t o r ELECTRICAL PANEL 120 240VA C LOADS M E R TR R equired to stack M S PA E inverters in Parallel M agnum A ccessory B ATTERY BANK M E B M K N S B attery M onitor M agnum A ccessory A C G R O U N D To B y p as s A C G R O U N D L2 O U T L1 O U T L2 IN L1 I N IN V L1 O U T IN V L2 O U T NE U TR A L N EU TR A L A C PANEL D C Panel Part of M agnum Panel S...

Page 45: ...t side of the parallel system requires an electrical panel referred to as the inverter panel that combines all the inverter outputs and be equipped with a large double pole circuit breaker rated for the total output current of the parallel system This inverter panel must provide the AC Buss Bars for the neutral and ground conductors from each inverter output If the inverter system requires isolati...

Page 46: ...ut 15 AAC at 120 VAC per leg 17 5 AAC at 120VAC per leg 8 AAC at 120VAC per leg Charger efficiency peak AC input frequency range 40 to 60 Hz AC input voltage range Power factor Transfer relay capability Five stage charging capability Battery temperature compensation Internal cooling Over current protection Over temperature protection Corrosion protection Safety Listings NA W arranty Operating temp...

Page 47: ...00 4500 Power VA Effi ciency Pe rcenta ge MS4448PAE Efficiency Graph Figure A 2 MS4448PAE Efficiency Chart Figure A 1 MS4024PAE Efficiency Chart A 2 Efficiency Graphs The following curves are plotted to show the MS PAE series efficiency over the inverter s power range and is displayed as a percentage These graphs represent a typical inverter s efficiency while operating resistive loads Motors and ...

Page 48: ...d This LCD re mote display also provides advanced monitoring troubleshooting and includes a FAVS button to access your favorite features quickly Standard Remote Control Display The ME RC Remote Control is simple to use an easy to read LCD screen and at a glance LEDs display complete inverter charger status Soft keys provide simple access to menus and a rotary encoder knob allows you to scroll thro...

Page 49: ...peratures 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 vent...

Page 50: ...rs should be multiplied by 1 2 to factor in an average 80 inverter efficiency C 2 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...

Page 51: ...ting the loads using smaller lower volt age 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 200 AH 6 VDC 200 AH 6 VDC 200 AH 6 VDC 200 AH 6 VDC 400 AH 12 VDC add voltage in series 6 VDC 200 AH 6 VDC 200 AH 6 VDC 200 AH 6 VDC 200 AH 12 VDC 400 AH 200...

Page 52: ...6 VD C battery 200 A H 6 VD C battery 200 A H Series String 6 VD C 6 VD C 6 VD C 6 VD C Parallel String 200 A H 200 A H 24 volt battery bank two strings of two 12 volt batteries wired in series and connected in parallel 12 VD C battery 100 A H over current protection to 24 VD C inverter total capacity 200 A H Series String 12 VD C 12 VD C 12 VD C battery 100 A H 12 VD C battery 100 A H 12 VD C bat...

Page 53: ...00 A hrs 6 volt battery 200 A hrs 6 volt battery 200 A hrs 6 volt battery 200 A hrs 6 volt battery 200 A hrs 6 volt battery 200 A hrs to 48 VD C inverter total capacity 400 A hrs 6 volt battery 200 A hrs 6 volt battery 200 A hrs 6 volt battery 200 A hrs 6 volt battery 200 A hrs 48 volt battery bank parallel two strings of eight 6 volt batteries wired in series 12 volt battery 100 A hrs 12 volt bat...

Page 54: ...iginal 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 contigu...

Page 55: ...Magnum Energy Inc 2211 West Casino Rd Everett WA 98204 Phone 425 353 8833 Fax 425 353 8390 Web www magnumenergy com MS PAE Series Owner s Manual PN 64 0032 Rev A ...

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