Magnum Energy ME Series Use and care manual

Service Instructions: 64-1002
DC Terminal Plate
Removal and Replacement
(ME, MS or RD Series Inverter/Charger)
© 2006 Magnum Energy, Inc. Page 1 of 2 Service Instructions: 64-1002 (7/06)
1.0 Description
These instructions provide information on removing and
replacing the DC terminal plate in a ME, MS or RD Series
inverter/charger. This is required when some internal
components are replaced or when the DC terminal plate
has been damaged and needs to be replaced with a new
DC terminal plate (kit part number: TDC-Plate).
Note: This document is part of a series of Service
Instructions to help qualified personnel replace
components that have failed or been damaged.
2.0 Installation Preparation
Before removing or replacing the DC terminal plate, read
this entire document carefully and follow all instructions.
2.1 Safety Precautions
Follow all electrical safety precautions and ESD
prevention guidelines below and in the Electrical Safety
Precautions and ESD Prevention, Service Instructions:
64-1000.
Warning: Hazardous voltages are present within
the inverter when power is applied. Do not work
inside the inverter without first turning off and
disconnecting all AC and DC power to the inverter.
Warning: The capacitors inside the inverter store
electric energy even after all AC and DC power is
removed. After disconnecting all AC and DC power
to the inverter, short the positive and negative DC
terminals together to dissipate this energy.
Figure 1, DC Terminal Plate
2.2 Included Materials
Before dismantling your inverter/charger, inspect the DC
terminal plate and confirm that there is no obvious
physical damage. Ensure the DC terminal plate kit
contains the items listed below; and if any item appears
to be damaged, missing or incorrect, contact Magnum
Energy.
•DC terminal plate kit – includes an insulated plate
with positive and negative DC terminals, and two
5/16” nuts; as shown in figure 1.
Note: All removed items must be returned if
repair is for warranty consideration; save the
packing material and shipping container to use
when returning the removed items.
2.3 Required Tools and Equipment
Before disassembling the inverter, ensure you have the
following tools and equipment to remove and replace
the DC terminal plate:
•T25 Torx head screwdriver (≥6” shaft recommended).–
for #10-32 screws.
•7/16” socket with ≥6” extension and socket wrench
– for ¼-20 bolts.
•7/16” open end wrench - for ¼-20 nuts (only needed
on inverters with the small FET board).
•Torque wrench (130 in-lbs torque required) – for ¼-
20 bolts with 7/16” head.
3.0 Removing/Replacing the DC Plate
3.1 Removing the DC Terminal Plate
3.1.1 Remove the inverter’s top cover and familiarize
yourself with the inverter’s internal components as
described in the Top Cover Removal and Replacement
with Internal Component Identification (ME, MS or RD
Series Inverter/Charger), Service Instructions: 64-1001.
3.1.2 Ensure all cables are removed from the positive
and negative terminals on the DC terminal plate.
3.1.3 Remove the two ¼-20 bolts (7/16” head) on
the back of the DC terminal plate (see figures 2 and 3).
Note: Record how this hardware is removed, it
will need to be reconnected in the same way.
Note: While unscrewing the ¼-20 bolts on buss-
wires, use a 7/16” wrench to hold the nut.
3.1.4 Remove the two #10-32 screws (T25 head)
holding the DC terminal plate to the front wall of the
inverter base (see figure 4, item B).
3.1.5 Remove the DC terminal plate by firmly lifting it
straight-up from the inverter base.

© 2006 Magnum Energy, Inc. Page 2 of 2 Service Instructions: 64-1002 (7/06)
3.2 Replacing the DC Terminal Plate
The steps below assume the DC terminal plate has been
damaged and is being replaced by a “new” DC terminal
plate. If replacing the same DC terminal plate, ignore
the reference to the “new” DC terminal plate.
3.2.1 Slide the new DC terminal plate down the front
wall of the inverter base; make sure the slots on the side
of the new DC terminal plate are aligned correctly (see
figure 4, item A).
Note: The DC terminal plate has a slight V-shape
(the top is slightly wider than the bottom) and
can only be correctly installed one way.
3.2.2 Firmly push down on the new DC terminal plate
until it sits flush against the base of the inverter.
3.2.3 Screw in the two #10-32 screws (T25 head) that
hold the front of the new DC terminal plate to the
inverter base (see figure 4, item B).
3.2.4 Connect the new DC terminal plate to the DC
buss-bars/buss-wires using the two ¼-20 bolts (7/16”
head). Refer to figure 2 or 3, depending on the inverter’s
FET board. Torque these connections to 130 in. lbs.
Caution: Ensure these ¼-20 bolts are reconnected
in the same way as they were removed and are
correctly torqued. These connections are required
to carry very high DC current and an improper
connection will affect the performance of the
inverter and may cause damage.
3.2.5 The DC terminal plate is now installed; review all
the connections a final time to ensure they are correct.
Figure 2, DC Terminal Plate to Small FET Board
Figure 3, DC Terminal Plate to Large FET Board
Figure 4, Front-of the DC Terminal Plate
3.2.6 If you have no other internal repairs to
perform, reinstall the top cover as described in the Top
Cover Removal and Replacement with Internal Component
Identification (ME, MS or RD Series Inverter/Charger),
Service Instructions: 64-1001.