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2.3 AC BREAKERS

2.3.a Remove top cover per 2.1
2.3.b Remove 4- #6 x ½ Torx screws from corners of ac board and lift board slightly

(see 2.2 for screw location) 2.3.c Loosen knurled nut on breaker shaft and pull

breaker out

2.3.d Reinstall new breaker in reverse order 2.3.e

Reinstall Top Cover

2.4 CONTROL BOARD

2.4.a

Remove top cover per 2.1

2.4.b

Remove 2 - #6 x ½ Torx screws from lower L brackets in control board

2.4.c

Pull control board straight up to disconnect from FET board

2.4.d

Remove ribbon cable from control board. Note orientation of ribbon cable

on connector. (colored cable has brown wire facing rear, gray cable has

red wire facing rear).

Содержание ME Series

Страница 1: ...ME Series Inverter Chargers Operator s Manual ...

Страница 2: ...rmed in accordance with local state and federal electrical codes Read all instructions and safety information contained in this manual before installing or using this product This product is designed for indoor compartment installation It must not be exposed to rain snow moisture or liquids of any type Use insulated tools to reduce the chance of electrical shock or accidental short circuits Remove...

Страница 3: ...asses For compartment 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 inverter Use insulated tools at all...

Страница 4: ...g 8 AC Connections 8 DC Connections 8 AC Grounding 8 DC Grounding 8 Torque Requirements 9 AC Main Panel 9 Circuit Protection 9 Wire Routing 9 3 Installation 11 Inverter Mounting 11 Battery Installation 11 Battery Cables and Sizing 12 DC Wiring 12 DC Grounding 12 Negative Cable 12 Positive Cable 12 Battery Wiring 13 Parallel Connection 13 Series Connection 15 Series Parallel Connection 15 DC Fuse B...

Страница 5: ...and Power up 26 Configuring the Inverter 27 3 Operation 28 1 Operating the Inverter 29 Search 29 Inverter Mode 29 AC Shore Power Mode 29 Bulk Charge Mode 29 Absorption Charge Mode 29 Float Charge Mode 29 Battery SaverTM Mode 29 Fault or Alarm Conditions 31 Low Battery 31 High Battery 31 Overload 31 Overtemperature 31 4 Troubleshooting 33 1 Basic Troubleshooting 33 5 Preventive Maintenance 34 1 Rec...

Страница 6: ...d then switch on the power Using the optional remote control you can easily operate your inverter from anywhere within your motor coach 2 Standard Features Four Power Models ME1512RV ME2012RV ME2512RV and ME3012RV Shelf Bulkhead or Upside Down Mounting Modified Sine Wave Output Power Factor Corrected Charger Sine Wave RS485 Communication Port Remote Port Flash Programming ON OFF Inverter mounted S...

Страница 7: ...1 INTRODUCTION Figure 1 ME Series Inverter Charger Ó 2003 Magnum Energy Inc 2 ...

Страница 8: ... and the type of appliance the type of batteries installed in your recreational vehicle as well as the battery s capacity and age Other factors such as the battery s state of charge and temperature can also affect the length of time your appliances can run Appliances such as TVs VCRs stereos computers coffee pots incandescent lights and toasters can all be successfully powered by your inverter Lar...

Страница 9: ...rging Inverting LED Stack Port Magnum Net Port Remote Port Battery Temp Sensor Port Figure 2 ME Series Inverter Charger Switch LED and Connection Ports Figure 3 ME Series Inverter Charger Electrical Connection Points Ó 2003 Magnum Energy Inc ...

Страница 10: ...loat charge when batteries are fully charged and the inverter is connected to shore power LED off Indicates a fault condition such as low battery overload or over temperature Remote Control Port accepts connector for Magnum remote control cable BTS Port accepts connector for remote battery temperature sensor cable MagnumNet Communication Port accepts connector for Auto Gen Start or Smart Shunt DC ...

Страница 11: ...as possible Longer battery cable runs tend to loose efficiency and reduce the overall performance of an inverter If you are planning to install dedicated batteries other than the vehicle s make sure they are in a dedicated compartment that has ventilation to the outside Also it is important that you never mount the inverter directly above the batteries as they emit corrosive fumes which could dama...

Страница 12: ... one way for 12 VDC systems Crimped and sealed copper ring terminal lugs with a 5 16 hole should be used to connect the battery cables to the inverter s DC terminals AC Grounding The ME Series inverter charger contains an internal neutral to ground switching circuit for the AC electrical system WARNING The AC shore power neutral must be grounded ONLY through the shore power cable Do not ground AC ...

Страница 13: ...outing Determine all wire routes throughout the vehicle both to and from the inverter Conductors that are at risk to physical damage must be protected by conduit tape or pla ced in a raceway Conductors passing through walls bulkheads or other struc tural members must be protected to minimize insulation damage such as chafing During the installation always avoid placing conductors near sources of c...

Страница 14: ...arger Base Plate Inverter ME1512 ME2012 ME2512 ME3012 DC Rating 150 amps 200 amps 250 amps 300 amps 1 to 3 ft 2 0 AWG 2 0 AWG 4 0 AWG 4 0 AWG 3 to 5 ft 4 0 AWG 4 0 AWG 4 0 AWG 4 0 AWG 5 to 10 ft 4 0 AWG 4 0 AWG 4 0 AWG consult code Table 2 Recommended Battery Cable Sizing ...

Страница 15: ...10 Ó 2003 Magnum Energy Inc ...

Страница 16: ... to the mounting surface using appropriate screws and lockwashers Remove the inverter s AC access panel in accommodate the AC Input and Output wiring and conduit Battery Installation NOTE To ensure the best performance from your inverter system do not use old or untested batteries Batteries must be of the same size type rating and age NOTE For optimum performance Magnum Energy recommends using AGM...

Страница 17: ...WARNING De energize all sources of power including batteries DC shore power AC and AC generator if applicable CAUTION Inverter is NOT polarity protected Verify proper polarity BEFORE connecting the battery cables NOTE DO NOT connect the battery cables to the inverter until all wiring is complete and the correct DC voltage and polarity has been verified NOTE Make sure cables have a smooth bend radi...

Страница 18: ... string A parallel connection combines overall battery capacity by the number of batteries in the string Even though there are multiple batteries the voltage remains the same In the example on the next page Figure 7 four 12 VDC 100 AHr batteries are combined into a single string resulting in a 12 VDC 400 AHr bank Connect the negative battery terminals together using short cables Connect the positi...

Страница 19: ...C combined battery capacity 400 AHr 12 VDC Figure 8 Series Battery Wiring individual battery capacity 200 AHr 6 VDC combined battery capacity 200 AHr 24 VDC TO 12 VDC INVERTER Figure 9 Series Parallel Battery Wiring individual battery capacity 200 AHr 6 VDC 12 VDC 12 VDC 12 VDC 12 VDC 6 VDC 6 VDC 6 VDC 6 VDC ...

Страница 20: ...combined battery capacity 400 AHr 12 VDC 14 Ó 2003 Magnum Energy Inc ...

Страница 21: ...2 VDC bank A series parallel connection increases both voltage and capacity using smaller lower voltage batteries In the example at the left Figure 9 four 6 VDC 200 AHr batteries are combined into two pairs resulting in a 12 VDC 400 AHr bank Connect the negative battery terminal of one 6 VDC battery to the positive of the next creating a pair using a short battery cable Connect the negative batter...

Страница 22: ...10 Parallel Battery Wiring Fuse Placement Figure 11 Series Battery Wiring Fuse Placement 6 VDC 6 VDC 6 VDC 6 VDC Figure 12 Series Parallel Battery Wiring Fuse Placement 16 Ó 2003 Magnum Energy Inc 12 VDC 12 VDC 12 VDC 12 VDC In line fuse TO 12 VDC INVERTER ...

Страница 23: ...t breaker and connect a short cable same rating as the battery cables to one end of the fuse block Connect the short cable to the positive battery terminal Connect the positive cable RED fro m the inverter to the assembly DO NOT connect the positive cable to the inverter at this time Securely tighten the fuse block s lugs Once the entire installation is complete reinsert the fuse into the fuse blo...

Страница 24: ...Ó 2003 Magnum Energy Inc 17 ...

Страница 25: ...e 13 ME Series Inverter Charger AC Wiring AC Output 2 Circuit Breaker on dual output models only AC Output 1 Circuit Breaker on dual output models only Figure 14 ME Series Inverter Charger AC Wiring Access Panel 18 Ó 2003 Magnum Energy Inc ...

Страница 26: ...nstallation section before installing the inverter a n d b a t t e r i e s The minimum wire size for all ME Series models must be 10 AWG The installer must provide the appropriate circuit protection for the wire size used Refer to appropriate electrical codes for wire sizing and circuit protection AC Input Shore Power Routing Route a 30 amp service shore power to the inverter If the installation i...

Страница 27: ...2 INSTALLATION Figure 15 ME Series Inverter Charger AC Wiring Diagram located on back of cover plate Figure 16 ME Series Inverter Charger AC Terminal Block 20 Ó 2003 Magnum Energy Inc ...

Страница 28: ...ollowing pages Route the cable and conduit from the AC distribution panel to the inverter s AC OUTPUT conduit clamp Tighten the clamp securely on the conduit Connect the hot BLACK wire to the AC OUTPUT 1 HOT terminal Tighten the terminal to 16 inch pounds NOTE If using dual outputs connect the RED wire to the AC OUTPUT 2 HOT terminal Connect the neutral White wire to the AC OUTPUT NEU terminal Tig...

Страница 29: ...Figure 17a Typical Wiring Single IN Single OUT 120 VAC Figure 18a Typical Wiring Single IN Dual OUT 120 VAC Figure 19a Typical Wiring Dual IN Dual OUT 120 VAC 240 VAC 22 Ó 2003 Magnum Energy Inc ...

Страница 30: ...t Wiring Air Conditioning Water Heater Microwave Outlets 30 Amp Outlet TV Entertainment Inverted Outlets Figure 17b Typical Wiring Single IN Single OUT 120 VAC Figure 18b Typical Wiring Single IN Dual OUT 120 VAC Figure 19b Typical Wiring Dual IN Dual OUT 120 VAC 240 VAC Ó 2003 Magnum Energy Inc 23 ...

Страница 31: ...2 INSTALLATION Stack Port Magnum Net Port Remote Port Battery Temp Sensor Port Figure 20 ME Series Inverter Charger Option Connection Ports 24 Ó 2003 Magnum Energy Inc ...

Страница 32: ...he BTS port on the inverter s chassis Remote Control Installation and Wiring Mount the remote control in a convenient location using four mounting screws refer to the ME Series Remote Control Operator s Manual Route the cable to the inverter following existing wire runs Connect the cable to the remote port on the inverter s chassis AGS Module future option available soon Smart Shunt future option ...

Страница 33: ...Ó 2003 Magnum Energy Inc ...

Страница 34: ...orque the connection to 10 to 15 foot pounds Verify all cables and connectors are properly secured Place the red and black terminal covers on the inverter s DC connector Secure the covers with enclosed hardware If the batteries are in an enclosure perform a final check of the hold down brackets and all connections Close and secure the battery enclosure Final Inspection and Power up Prior to starti...

Страница 35: ... AGS OFF Enable Meter DC AC Setup Search LBCO Battery Bank Battery Type Charge Rate Contrast Factory Reset Tech Temps Fault Record The ME Series inverter charger also allows you to select an equalize charge for the batteries Press and hold the Charger ON OFF switch for 4 seconds The Equalize EQ function will be initiated and the correct code will be sent to the remote The EQ function automatically...

Страница 36: ...Table 5 Factory Default Settings Function Search LBCO Battery Bank Battery Type Charge Rate Contrast Default 5 watts 11 VDC 400 AHr Liquid Lead Acid 100 75 Ó 2003 Magnum Energy Inc 27 ...

Страница 37: ...3 OPERATION Charging Inverting LED Figure 21 ME Series Inverter Charger LED Indicator 28 Ó 2003 Magnum Energy Inc ...

Страница 38: ...Whenever the inverter is running on nominal AC Shore Power it charges the batteries The inverter s green LED stays ON solid to indicate the first stage of charging During bulk charging the charger supplies the maximum amount of constant current to the batteries As the battery voltage rises to a set value typically 14 1 VDC for GEL 14 3 VDC for AGM and 14 6 VDC for liquid lead acid the charger will...

Страница 39: ...3 OPERATION Figure 22 ME Series Inverter Charger Fault Conditions Figure 23 Optional ME Series Remote Control Fault Conditions 30 Ó 2003 Magnum Energy Inc ...

Страница 40: ...er is charging it constantly monitors the batteries In the event the battery voltage approaches too high of level it automatically turns off the battery charger to protect the batteries from damage The inverter s LED turns OFF to indicate the fault condition NOTE High battery voltage may be caused by excessive voltage from the alternator solar panels or other external charging sources Overload Dur...

Страница 41: ...w batteries Check and recharge batteries Appliances turn OFF ON Green LED is flashing Loose or corroded battery cables Low batteries Loose AC output connections Clean and tighten all cables Recharge or replace batteries Tighten AC output connections AC output voltage seems too low when using a meter Wrong type of voltmeter used displays 80 VAC to 100 VAC Use a true RMS voltmeter Low surge power Lo...

Страница 42: ...es replace those that vary more than 0 3 VDC of each other Check all cable runs for signs of chafing replace if necessary Check the inverter s cooling vents clean as necessary Check and tighten 16 foot pounds the inverter s internal AC terminal block connections 2 Off Season Storage When placing the coach into seasonal storage it is recommended that you perform the following to ensure the system i...

Страница 43: ...rating Ambient Temp 4 F to 120 F 20 C to 50 C Max Altitude operating 15 000 feet 4 57 km Dimensions HxWxD Mounting 13 75 x 12 65 x 8 34 9 cm x 32 1 cm x 20 3 cm shelf top or bottom up or bulkhead Specifications 25 C Subject to change without notice MODEL Input Voltage nominal Input Voltage range Power Rating 45 C Surge Rating Rated Power Full Voltage Search Mode Short Circuit Inverter Efficiency C...

Страница 44: ... limit of liability under the limited warranty shall be the actual cash value of the product at the time the original purchaser returns the product for repair determined by the price paid by the original purchaser Magnum Energy shall not be liable for any other losses or damages 4 Upon request from Magnum Energy the original purchaser must prove the product s original date of purchase by a dated b...

Страница 45: ...Remote Control for ME Series Inverter Chargers Operator s Manual ...

Страница 46: ...ion 4 Front Panel 5 Rotary Knob 5 Switches 5 Chart 1 Battery Charge Voltages 6 Chart 2 Absorption Times 6 Chart 3 Factory Default Settings 6 LEDs 8 LCD Display 9 4 Troubleshooting and Specifications 11 5 Warranty 12 SAVE THESE INSTRUCTIONS This manual contains important safety instructions Ó 2003 Magnum Energy Inc 1 ...

Страница 47: ......

Страница 48: ...ger thus maximizing performance and increasing the life of your batteries The remote control has all of the programming and operation functions included in an easy to use package The remo te features soft keys as well as a rotary knob LEDs and a two line LCD readout To help save energy the automatic power saver mode turns off all LEDs as well as the LCD display five minutes after the last soft key...

Страница 49: ... adjustment dial and to view the LEDs for troubleshooting Predrill the four 1 8 holes as necessary 2 Route the 4 wire twisted pair wiring from the inverter charger to the remote Connect the wiring to the rear of the remote and to the remote port on the inverter charger 3 Use the four 6x3 4 screws to mount the remote to the coach s wall or bulkhead Figure 1 ME Series Remote Control Ó 2003 Magnum En...

Страница 50: ...3 Operation Figure 2 Remote Control Font Panel Ó 2003 Magnum Energy Inc 4 ...

Страница 51: ...turns ON and OFF with the switch Charger ON OFF Used to switch the charger function ON and OFF The green CHARGER LED turns ON and OFF with the switch Press and hold the switch down for 5 seconds to initiate EQ Soft Keys Press the soft keys to access the required function Then use rotary SELECTOR knob to scroll through the selections Press the rotary knob to save the selection Options include Shore...

Страница 52: ... GEL Bulk 14 1 VDC Absorption 14 1 VD C Float 13 6 VDC Equalize Disabled AGM Absorbed Glass Mat Bulk Absorption Float Equalize 14 3 VDC 14 3 VDC 13 1 VDC 15 5 VDC CAUTION Never Equalize Gel batteries NOTE AGM voltages are courtesy of Lifeline TM brand batteries Chart 1 Battery Charge Voltages ...

Страница 53: ...ault Settings Ó 2003 Magnum Energy Inc Battery Size 200 AHr 400 AHr 600 AHr 800 AHr 1000 AHr Charge Time 90 minutes 120 minutes 150 minutes 180 minutes 210 minutes Function Search LBCO Battery Bank Battery Type Charge Rate Contrast Default 5 watts 10 VDC 400 AHr Liquid Lead Acid 80 75 6 ...

Страница 54: ...during battery charging See Chart 2 Battery Charge Rate Used to set the maximum charge rate during bulk absorption or float charge Selections are in 10 amp increments from 10 100 Battery Type Used to select battery type for the battery charge profile Selections are Gel AGM Absorbed Glass Mat Liquid Lead Acid Flooded and Custom future See Chart 1 Contrast Used to adjust the LCD contrast AC Dropout ...

Страница 55: ...nerator synchroniz ing to AC waveform before relay transfer ON Bulk Absorb Float Equalize or Battery Full Charge mode Slow Blink Charger Standby Charger off button was pressed with AC available from shore or generator Charger Backoff charger temperature too hot and charger automatically reduced charge rate to maintain temperature Low AC Input Voltage Input voltage below 85 VAC Charger automaticall...

Страница 56: ...setup options Absorption Absorption charge is the second stage of charging and indicates the bulk voltage for battery type selected has been reached The DC current will start to taper off in order to maintain the bulk voltage setting Absorption time is determined by battery bank size selection See Chart 2 Figure 3 Menu Map Ó 2003 Magnum Energy Inc 9 Shore 5 10 15 20 30 50 AGS Enable OFF TEST Adj S...

Страница 57: ... hours in float mode the charger is switched OFF and Battery Full is indicated When the battery voltage drops to 12 9 VDC the charger turns on and float charges the batteries to a nominal level Once that level has been reached the charger returns to Battery Full mode to monitor the batteries Equalize The battery charger is delivering equalize voltage to the batteries for a maximum of 4 hours See C...

Страница 58: ...will automatically restart after unit cools down AC Overload The unit has shut down because the AC load connected to the inverter s output exceeded its maximum output rating NOTE When this occurs reduce the load and MANUALLY restart the unit Specifications Electrical Requirements 12 VDC Controls Charger ON OFF Inverter ON OFF LED Indicators Power Fault Charger Inverter Soft Keys Shore AGS Meter Se...

Страница 59: ...iability under the limited warranty shall be the actual cash value of the product at the time the original purchaser returns the product for repair determined by the pricepaid by the original purchaser Magnum Energy shall not be liable for any other losses or damages 4 Upon request from Magnum Energy the original purchaser must prove the product s original date of purchase by a dated bill of sale ...

Страница 60: ...ervice Manual REV 1 0 12 03 INDEX 1 0 Troubleshooting 2 0 Repairing 2 1 Top Cover Removal 2 2 AC Board 2 3 AC Breakers 2 4 Fet Board 2 6 DC Terminal Plate 2 7 Transformer 2 8 Fans 2 9 Remote 3 0 Test Procedure ...

Страница 61: ...1 0 TROUBLESHOOTING 1 1 ME SERIES 1 2 RD SERIES 1 3 REMOTE ...

Страница 62: ...2 0 REPAIRING OVERVIEW ...

Страница 63: ......

Страница 64: ... 2 a Remove top cover per 2 1 2 2 b Remove4 6 x Torx screws from corners of ac board 2 2 c Use a utility knife or sharp chisel to cut temp sensor loose then clean remaining silicon from transformer 2 2 d Mark and remove ac wires from ac board being careful to note the start wire from the transformer location Also note the orientation of the black and orange wire Miswiring of these ...

Страница 65: ...CODE White Neutral IN 2 wires Black AC Hot IN 1 Red Hot IN 2 Blue Hot OUT 2 2 2 e Install wires to new ac board and install 4 6 x Torx screws 2 2 f Use silicon to glue down sensors to transformer in old location Use tape to temporarily hold sensors until silicon dries 2 2 g Re install Top Cover ...

Страница 66: ...3 d Reinstall new breaker in reverse order 2 3 e Reinstall Top Cover 2 4 CONTROL BOARD 2 4 a Remove top cover per 2 1 2 4 b Remove 2 6 x Torx screws from lower L brackets in control board 2 4 c Pull control board straight up to disconnect from FET board 2 4 d Remove ribbon cable from control board Note orientation of ribbon cable on connector colored cable has brown wire facing rear gray cable has...

Страница 67: ...e pushing down on control board 2 4 f Re install Top Cover 2 5 a Remove top cover per 2 1 2 5 b Remove 2 x 20 bolts and nuts from inside DC plate 2 5 c Remove2 10 x Torx screws from outside DC plate 2 5 d Pull firmly straight up to remove DC plate from base 2 5 e Re install DC plate in reverse order 2 5 f Re install Top Cover ...

Страница 68: ...2 6 FET BOARD 2 6 a Remove top cover per 2 1 2 6 b Remove control board per 2 4 2 6 c Remove DC Plate per 2 5 ...

Страница 69: ...rx screws from FET bar clamps 2 6 g Pull up firmly on FET board to release from base and remove black insulation material Burquist 2 6 h Install new insulation material being careful to properly align with base 2 6 i Loosely install 3 6 x screw to properly align FET board to base 2 6 j Re install FET bar clamps and alternately tighten 4 10 x Torx screws until all 4 screws are tightened to xxx ...

Страница 70: ...ylon shoulder washers into base while setting transformer in place Make sure to install start wire from transformer to correct terminal on ac board or damage will occur to FET board when ac power is applied 2 7 f Install 4 screws with nylon shoulder washers and tighten snug 2 7 g Use silicon to glue down sensors to transformer in old location Use tape to temporarily hold sensors until silicon drie...

Страница 71: ...2 6 FANS 2 8 a Remove Top Cover per 2 1 2 8 b Remove 1 6 x Torx screw from fan bracket 2 8 c Bend fan bracket upward to remove fan 2 8 d Reinstall fan in reverse order 2 8 e Reinstall Top Cover ...

Страница 72: ...E 2 8 a Remove front knob it may be necessary to pry slightly up on knob 2 8 b Remove 2 Phillips head screws from back of remote 2 8 c Remove circuit board and keypad from case 2 9 d Re assemble in reverse order ...

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