Magnum Energy RD Series Owner'S Manual Download

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Page 16

2010 Magnum Energy, Inc

Installation

Table 2-2, DC Wire Size For Increased Distance (in free air)

Inverter

Model

Minimum Recommended DC Wire Size (one way)

1-3 feet

3-5 feet

5-10 feet

RD2212

#4/0 AWG (107.16 mm

) #4/0 AWG x2 (107.16 mm

)

not recommended

RD1824

#2/0 AWG (67.4 mm

)

#2/0 AWG (67.4 mm

)

#4/0 AWG (107.16 mm

)

RD2824

#4/0 AWG (107.16 mm

)

#4/0 AWG (107.16 mm

)

#4/0 AWG x2 (107.16 mm

)

RD3924

#4/0 AWG (107.16 mm

) #4/0 AWG x2 (107.16 mm

)

not recommended

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

2.4.3

DC Cable Connections

Do not put anything between the 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 the examples in Figures 2-5 and 2-6 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 N-m).

CAUTION:

The DC terminal and Kep nuts are made of stainless steel, which has a high

likelihood of seizure. To help prevent the bolt and nut from seizing — causing the bolts

to strip or snap/break-off — the use of anti-seize lubricant is highly recommended.

Info:

If antioxidant grease or spray is used, apply it after all the connections have been

made and are properly tightened.

Info:

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

Figure 2-5, Battery Hardware

Installation

Figure 2-6, Inverter DC Hardware

Installation

battery cable

(w ith ring lug)

nut

split

w asher

flat

w asher

Battery

T em perature

Sensor

battery

post

C A U T ION:

Ensure nothing is

placed betw een

the cable ring lug

and the battery

post.

5/16 -18"

F lange or

Kep nut

battery cable

(w ith ring lug)

Inverter D C

term inal

(5/16 -18" bolt,

5/8" length)

C A U T ION:

Ensure nothing is

placed betw een

the D C term inal

and the ring lug.

Summary of Contents for RD Series

Page 1: ...RD Series Modified Sine Wave Inverter Chargers Owner s Manual ...

Page 2: ...Failure of the RD Series Inverter Charger can reasonably be expected to cause the failure of that life support device or system or to affect the safety or effectiveness of that device or system If the RD Series Inverter Charger fails it is reasonable to assume that the health of the user or other persons may be endangered Copyright Notice Copyright 2004 2010 by Magnum Energy Inc All rights reserve...

Page 3: ...oduct 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 CEC and local codes Both AC and DC overcurrent protection must be provided as part of the installation Use Class 1 wiring methods for field wiring connect...

Page 4: ...lways install batteries in a stable environment Install batteries in a well ventilated area Batteries can produce explosive gases For compartment or enclosure installations always vent batteries to the outside Provide at least one inch 2 5 cm of air space between batteries to provide optimum cooling Never smoke in the vicinity of batteries To prevent a spark at the battery and reduce the chance of...

Page 5: ...34 3 2 Standby Mode 35 3 3 Battery Charging 35 3 4 Transfer Time 37 3 5 Battery Temperature Sensor Operation 37 3 6 Protection Circuitry Operation 38 3 7 Inverter Startup 39 3 8 Factory Default Values 40 4 0 Maintenance and Troubleshooting 41 4 1 Recommended Inverter and Battery Care 41 4 2 Troubleshooting 42 4 3 Resetting the Inverter 43 Appendix A Specifications and Optional Equipment 44 A 1 Inv...

Page 6: ...s 28 Figure 2 16 Multiple Connections to DC Ground Rod Method 1 29 Figure 2 17 Multiple Connections to DC Ground Rod Method 2 30 Figure 2 18 Single Connection to DC Ground Rod Method 3 30 Figure 2 19 Warning Label 32 Figure 2 20 AC Voltage Checks 33 Figure 3 1 Power Flow Inverter Mode 34 Figure 3 2 Power Flow Standby Mode 35 Figure 3 3 Automatic 4 Stage Charging Graph 36 Figure 3 4 BTS Temperature...

Page 7: ...ss thru Large AC access and terminal block wire size 10 to 6 AWG 5 3 to 13 3 mm2 CU DC terminal covers with 360 degree connection Field serviceable for qualified personnel tested repair kits available ETL listed to UL STD 1741 1st edition for safety Automatic battery temperature compensation using battery temperature sensor for optimum charging even during extreme temperature changes Overcurrent o...

Page 8: ...Connection Port blue label a RJ11 port that allows the optional remote controls ME RC50 or ME ARC50 to be connected 6 BTS Connection Port yellow label RJ11 port that accepts the remote Battery Temperature Sensor BTS accessory 7 DC Equipment Ground Terminal this connection is used to tie the exposed chassis of the inverter to the DC grounding system This terminal accepts CU AL conductors from 14 to...

Page 9: ...G LED STACK ACCESSORIES PORT RED LABEL RJ11 CONNECTION NETWORK PORT GREEN LABEL RJ11 CONNECTION REMOTE PORT BLUE LABEL RJ11 CONNECTION BATTERY TEMPERATURE SENSOR PORT YELLOW LABEL RJ11 CONNECTION INTAKE AIR VENTS AND ON RIGHT SIDE AC INPUT OUTPUT CONNECTIONS DC EQUIPMENT GROUND TERMINAL POSITIVE DC TERMINAL UNDER COVER NEGATIVE DC TERMINAL UNDER COVER MOUNTING FLANGE 6 5 4 3 2 1 11 10 12 7 8 9 ...

Page 10: ...k This terminal block is used to hardwire all inverter AC input and output wiring connections Remove the two screws to access the AC wiring terminal block 16 Input Circuit Breaker this circuit breaker protects the unit s internal charger wiring and pass thru relay while in Standby Mode This circuit breaker will pop out when it opens Press in to reset This input circuit breaker is not branch circui...

Page 11: ...ed square wave and pure sine wave Modified sine wave inverters approximate a pure sine waveform and will run most appliances and electronics without any problems These inverters are less expensive and therefore offer a viable alternative to more expensive pure sine inverters The output of a modified sine wave inverter will run most electronic and household items including but not limited to TV VCR...

Page 12: ... the best advice is trial and error Your RD Series inverter has a built in safeguard that automatically protects your batteries from over discharge Info For optimum performance a minimum battery bank of 200 AH is recommended for moderate loads 1000W and greater than 400 AH for heavy loads 1000W Table 1 1 Typical Appliance Power Consumption Device Load Device Load Blender 400W Coffee Maker 1200W Co...

Page 13: ...erter charger The more thorough you plan in the beginning the better your inverter needs will be met 2 1 1 Unpacking and Inspection Carefully remove the RD Series inverter charger from its shipping container and inspect all contents Verify the following items are included The RD Inverter Charger Red and black DC terminal covers with Phillips screws AC access cover with two Phillips screws Two 5 16...

Page 14: ...E B M K B attery M onitor with shunt M agnum A ccessory D C Shunt A C Transfer Switch Generator Power 120 240 VA C Output U tility Power 120 240 VA C Output F lu 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 FF O N O FF O N O FF O N O F F O N O F F O N O FF B TS O N O FF O N O FF 30 A 3 0A M E SB C Sm art B attery C om biner M agnum A cc...

Page 15: ...t air through the exhaust vents see Figure 1 3 Item 13 Allow at the minimum an airspace clearance of 6 15 2 cm at the intake and exhaust vents and 3 7 6 cm everywhere else to provide adequate ventilation If installed in an enclosure a fresh air intake opening must be provided directly to the front side intake vents of the inverter and an exhaust opening on the back side exhaust vents of the invert...

Page 16: ...nverter enclosure installed on the inverter s bottom Info The ME CB and the MMP Series enclosure prevent material from falling out the bottom in the event of an internal fire and also allow sufficient ventilation to prevent the inverter from overheating under normal operating conditions The MP HOOD inverter hood helps prevent items from falling inside causing damage to the inverter Info Magnum pro...

Page 17: ...Side Reference 12 5 8 32 1 cm 12 30 5 cm 4 7 8 12 4 cm 2 5 1 cm 4 7 8 12 4 cm Keyhole slots x4 and mounting holes x4 accept up to 9 32 7 mm screw bolt 13 3 4 34 9 cm 8 20 3 cm 6 5 8 16 8 cm BOTTOM SIDE RIGHT SIDE BACK SIDE RIGHT SIDE LEFT SIDE TOP SIDE LEFT SIDE TOP SIDE FRONT SIDE ...

Page 18: ...w both the AC and DC conduits to be connected to the inverter Info If using the ME CB conduit box or the MMP enclosure and the AC wires are individual conductors i e not jacketed the strain reliefs can be removed and replaced with 3 4 grommets 2 3 2 Wiring Requirements All conductors that are at risk for physical damage must be protected by tape or placed in a raceway Always check for existing ele...

Page 19: ...mm This helps improve the surge capability and reduces the effects of inductance which improves the inverter waveform and reduces the wear of the inverter s filter capacitors Crimped and sealed copper ring terminal lugs with a 5 16 hole should be used to connect the DC wires to the inverter s DC terminals The battery bank voltage MUST match the DC voltage required by the inverter i e 24 volt batte...

Page 20: ... attery Tem p Sensor C able Inverter s D C N egative C onnection Inverter s D C Positive 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 MMP enclosure for single inverter installations includes D C disconnect breaker D C shunt for battery m onitor and inverter D C busbars...

Page 21: ...oth overcurrent protection and a disconnect switch If a circuit breaker is used as the overcurrent protection device it can also be used as the required DC disconnect If a fuse is used as an overcurrent device a Class T type or equivalent is recommended This fuse type is rated for DC operation can handle the high short circuit currents and has a time delay that allows for momentary current surges ...

Page 22: ...verter charger performance and may melt the cable and terminal connections Follow the examples in Figures 2 5 and 2 6 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 N m CAUTION The DC terminal and Kep nuts are made of stainless steel which has a high likelihood of seizure To help prevent the bolt and nut from seizing cau...

Page 23: ...n the batteries to provide good air flow DO NOT mount the batteries directly under the inverter CAUTION Install batteries in a well ventilated area Batteries can produce explosive gases For compartment enclosure installations always vent batteries to the outside Info To ensure the best performance from your inverter system batteries should be of the same size type rating and age Do not use old or ...

Page 24: ...it breaker or fuse assembly as near as practical to the batteries and leave open i e no power to inverter WARNING DO NOT close the DC circuit breaker or connect the fuse to connect battery power to the inverter at this time This will occur in the Functional Test after the installation is complete CAUTION If connecting live battery cables to the inverter DC terminals a brief spark or arc may occur ...

Page 25: ...ed The inverter s input is wired to the service distribution panel main panel The inverter s output is then wired to a dedicated panel sub panel The inverter uses the circuit breakers provided in the panels as the overcurrent protection and the AC disconnect device AC overcurrent protection isn t included in the inverter and must be provided as part of the inverter installation The AC overcurrent ...

Page 26: ...nc Installation Figure 2 8 RD Series Inverter Charger AC Wiring Figure 2 9 RD Series Inverter Charger AC Wiring Access Cover AC Input Circuit Breaker CB3 AC Input Output Strain Relief AC Input Output Strain Relief AC Access Cover ...

Page 27: ... lbf 1 8 N m Info One of the AC wiring configurations SI SO 60A Figure 2 12 uses a 6 AWG 13 3 mm2 CU wire to carry 60 amps and splits to two wires to allow 30 amps for each leg i e AC HOT1 and AC HOT2 IDEAL Industries Inc www idealindustries com manufactures a crimp connector PN 412 and a separate insulator PN 417 that allow up to two 8 AWG 8 4 mm2 wires with one 6 AWG 13 mm2 wire to be connected ...

Page 28: ... terminal Tighten the NEUT IN terminal to 16 in lbf 1 8 N m Wiring the Inverter AC Output 1 Route the cable from the inverter s AC OUTPUT to the AC electrical sub panel through the other strain relief clamp Tighten the strain relief clamp securely on the cable 2 Connect the hot black wire from the HOT 1 OUT terminal to the sub panel main breaker Tighten the HOT 1 OUT terminal to 16 in lbf 1 8 N m ...

Page 29: ...is 30 amps Requires a separate inverter sub panel Want dedicated charging and dedicated pass thru while the AC source is on Requires a separate inverter sub panel May need to power 240 VAC loads when AC source is on requires 120 240 VAC source Requires a separate inverter sub panel Appropriate Models RD2212 RD1824 RD2824 RD3924 RD2212 RD1824 RD2824 RD3924 RD2212 RD1824 RD2824 RD3924 RD2212 RD1824 ...

Page 30: ...S ub P a nel A C N E U T IN from M a in P a nel A C N EU T O U T to S ub P a nel Sub panel and Outlets Inverter Loads 120 VA C 120 VA C AC G RO UNDS to from both P anels ON OFF O N O FF O N O F F 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 O N O FF O N O F F O N O FF O N O F F 30 Maximum 30 amp breaker single pole required to inverter AC input O N O FF O N O F F ON OFF Figure 2 11 AC ...

Page 31: ...N EU T O U T to S ub P a nel A C H O T 2 IN from M a in P a nel A C H OT 2 OU T to S ub P a nel 120 VA C Sub panel and Outlets Inverter Loads 120 VA C 120 VA C 120 VA C AC G RO UNDS to from both P a ne ls ON OFF O N O FF O N O F F 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 O N O FF O N O F F O N O FF O N O F F 60 Maximum 60 amp breaker single pole required to inverter AC input ON OFF...

Page 32: ... O T 2 O U T t o Sub Pa ne l A C N E U T IN from M a in P a nel A C N EU T O U T to S ub P a nel A C H O T 2 IN from M a in P a nel AC G RO UNDS to from both P a ne ls ON OFF O N O FF O N O F F 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 O N O FF O N O F F O N O FF O N O F F 30 Maximum 30 amp breaker double pole required to inverter AC input 30 ON OFF O N O F F O N O FF R D Series Inv...

Page 33: ...l A C H O T 2 IN from M a in P a nel A C H OT 2 OU T to S ub P a nel Sub panel and Outlets Inverter Loads 120 VA C 120 VA C AC G RO UNDS to from both P a ne ls ON OFF O N O FF O N O F F 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 O N O FF O N O F F O N O FF O N O F F 30 Maximum 30 amp breaker double pole required to inverter AC input 30 O N O FF O N O FF O N O F F O N O FF ON OFF 240 ...

Page 34: ...ipment Grounding Electrode GE A ground rod or conducting element that establishes an electrical connection to the earth System bonding jumper SBJ The connection between the grounded circuit conductor in the electrical system and the equipment grounding conductor at a separately derived system The RD Series inverter charger uses both AC and DC power however the AC electrical system is isolated from...

Page 35: ...grounding points in the inverter s two electrical systems to the common earth ground Method 1 see Figure 2 16 This method uses a separate grounding electrode for the DC system and the AC system In this method since there are multiple connections to the DC Grounding Electrode GEC DC the size of the DC grounding electrode conductor cannot be smaller than the largest conductor in the DC system usuall...

Page 36: ... Ground Rod Method 2 Method 3 see Figure 2 18 The AC Grounding Electrode Conductor GEC AC is bonded to the DC ground point and the DC Grounding Electrode Conductor GEC DC is the only connection to the grounding electrode which must be a rod pipe or plate electrode In this method since there is only one connection to the ground rod the DC grounding electrode conductor is not required to be larger t...

Page 37: ... from where a ground fault may occur In accordance with the NEC use Table 2 5 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 ov...

Page 38: ... inverter negative 1 Apply battery power to the inverter by closing the DC circuit breaker or inserting a fuse The inverter will remain OFF but the green status indicator on the front of the inverter will quickly blink once to indicate that DC power has been connected and is ready to be turned on 2 Prior to turning on the inverter make sure all AC loads e g appliances are NOT connected to the inve...

Page 39: ...erter s AC output voltage will not be correct until a load greater than 5 watts 5 watts is the default setting is connected to the inverter or when the Search Mode is turned OFF with a remote display ME RC50 5 Check the AC output voltage of the inverter by connecting an AC voltmeter to the output terminals see Figure 2 20 and verify the correct output voltages 6 Press and release the inverter s ON...

Page 40: ...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 e g electrical appliance Whenever an AC load greater than 5 watts is turned on the inverter recognizes the need for power and automatically starts inverting When there is no load or less than 5 watts detected the inverter automatically goes back into Search Mode to...

Page 41: ...feature allows the charger voltage and current to change independently These two features maximize the real power available from either utility power or generator AC power sources which translates into less power wasted and greater charging capabilities than most chargers available today When an AC source is connected to the AC input the inverter begins monitoring for acceptable AC voltage Once th...

Page 42: ... battery gassing minimizes watering requirements for flooded batteries and ensures the batteries are maintained at optimum capacity Full Charge Battery Saver mode The fourth stage occurs after four hours in the Float Charging stage The Full Charge stage is designed to keep batteries fully charged over long periods and prevent excessive loss of water in flooded batteries or drying out of GEL AGM ba...

Page 43: ...rature Sensor BTS is used to determine the battery temperature around the batteries This information allows the multi stage battery charger to automatically adjust the battery charge voltages for optimum charging performance and longer battery life When the BTS is installed if the temperature around the BTS is below 77 F 25 C the absorb and float charge voltage increases and if the temperature aro...

Page 44: ... to the High Battery Cut In HBCI 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 solar panels or other external charging sources Overload During inverter and standby operation the inverter monitors current levels In the event of a short circuit or an overload condition for more t...

Page 45: ...F switch there is a fault condition such as low battery high battery overload over temperature or an internal fault Refer to the Troubleshooting section to help diagnose clear the fault condition Slow flash blinks on once every 8 seconds Indicates float charging the inverter is in Standby Mode the external AC power that is connected to the inverter s input is passing through the inverter and is po...

Page 46: ...l turn off based on low battery voltage The inverter turns off automatically after the battery voltage has been below this setting for more than one minute This protects the batteries from over discharge and the AC loads 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 ...

Page 47: ... the following checks switch OFF both the AC and DC circuits Visually inspect the batteries for cracks leaks or swelling replace if necessary Use baking soda to clean and remove any electrolyte spills or buildups Check and tighten all battery holddown clamps if applicable Clean and tighten all battery terminals and connecting cables 10 to 12 ft lbf 13 6 to 16 3 N m Check and fill battery water lev...

Page 48: ... The inverter has turned off because the connected loads are larger than the inverter s output capacity or the output wires are shorted Reduce the AC loads connected to the inverter or remove all AC output wiring and restart the inverter Internal fault This fault occurs when an internal fault is detected To clear this fault an inverter reset is required Remove DC power to the inverter or press and...

Page 49: ...e inverter will need to be reset To reset the inverter Press and hold the Power ON OFF pushbutton see Figure 4 1 for approximately fifteen 15 seconds until the Charging Inverting Status LED comes on and flashes rapidly once the rapid flashing has begun release the Power ON OFF pushbutton The Status LED will go off after the pushbutton is released After the inverter reset is completed press the ON ...

Page 50: ...rrent Rated Output AC amps 15 15 21 29 Charger Efficiency 85 85 85 92 AC Input Frequency Range 50 to 70 Hz AC Input Voltage Range 60 to 140 VAC 120 VAC nominal Power Factor 0 95 General Features and Capabilities Transfer Relay Capability Two input legs at 30A each or combine for 60A Five stage Charging Capability Bulk Absorb Float Equalize requires remote and Battery Saver Battery Temperature Comp...

Page 51: ...s such as Inverter ON OFF Charger ON OFF Utility Power Breaker Setting AGS Control Meter Button Setup and Tech menus Advanced Remote Control The ME ARC50 Remote Control Panel uses an LCD screen and at a glance LEDs to provide operating information and allow advanced features to be configured requires Magnum inverters with advanced configurable features This LCD remote control also provides advance...

Page 52: ... batteries best suited for the inverter installation and cost Use only the same battery type for all batteries in the bank For best performance all batteries should be from the same lot and date This information is usually printed on a label located on the battery B 3 Battery Temperature Battery performance of lead acid type batteries is greatly affected by extreme temperatures When a lead acid ty...

Page 53: ...d each day for all the loads Add the Average Daily Watt Hours Per Load together Total Daily Watt Hours Total Daily Watt Hours Total Amp Hours 3 Determine the battery Amp Hour capacity needed to run all the loads before recharging Divide the Total Daily Watt Hours by the nominal battery volt age of the inverter i e 12 24 volts and Multiply this by how many days the loads will need to run without ha...

Page 54: ...gure 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 AH 12 VDC 200 AH 12 VDC add capacity in parallel add volta...

Page 55: ...VDC inverter total capacity 100 AH String 12 VDC 100 AH 12 VDC battery 100 AH overcurrent protection overcurrent protection to 12 VDC inverter total capacity 400 AH Series String 6 VDC 6 VDC 6 VDC battery 200 AH 6 VDC battery 200 AH 12 volt battery bank two strings of two 6 volt batteries wired in series and connected in parallel Series String 6 VDC 6 VDC 6 VDC battery 200 AH 6 VDC battery 200 AH ...

Page 56: ...four 6 volt batteries wired in series and connected in parallel to 24 VDC inverter total capacity 400 AH 6 VDC battery 200 AH overcurrent protection 6 VDC battery 200 AH 6 VDC battery 200 AH 6 VDC battery 200 AH 6 VDC battery 200 AH 6 VDC battery 200 AH 6 VDC battery 200 AH 6 VDC battery 200 AH Series String 6 VDC 6 VDC 6 VDC 6 VDC Parallel String 200 AH 200 AH 24 volt battery bank two strings of ...

Page 57: ...m Energy the original purchaser must prove the product s original date of purchase by a dated bill of sale itemized receipt 5 The original purchaser shall return the product prepaid to Magnum Energy in Everett WA After the completion of service under this limited warranty Magnum Energy will return the product prepaid to the original purchaser via a Magnum selected non expedited surface freight wit...

Page 58: ...Magnum Energy Inc 2211 West Casino Rd Everett WA 98204 Phone 425 353 8833 Fax 425 353 8390 Web www magnumenergy com RD Series Owner s Manual PN 64 0006 Rev A ...

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