Magnum Energy MM AE Series User manual

Owner’s Manual
MM-AE Series
Inverter/Chargers

© 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 disclaims
any liability for loss, damage, or expense whether direct, indirect,
consequential, or incidental that may arise out of or be in any way
connected with such installation, operation, use, or maintenance.
Due to continuous improvements and product updates, the images
shown 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-support
devices or systems with the express written approval of Magnum
Energy. Failure of the MM-AE 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
MM-AE Series Inverter/Charger fails, it is reasonable to assume that
the health of the user or other persons may be endangered.
Contact Information
Magnum Energy, Inc.
2211 West Casino Rd.
Everett, WA 98204
Phone: [phone] / Fax: [phone]
Web: www.magnumenergy.com
Record the unit’s model and serial number in case you need to provide
this information in the future. It is much easier to record this information
now, 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 that
uses Alternative Energy (e.g., solar, wind, or hydro). This term is also
used to refer to inverters used in a home, office, or cabin installation.

© 2010 Magnum Energy, Inc.
IMPORTANT PRODUCT SAFETY INSTRUCTIONS
This manual contains important safety instructions that must be fol-
lowed during the installation and operation of this product. Read all
instructions and safety information contained in this manual before
installing 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., when
installing or performing maintenance on the inverter.
• Always disconnect the batteries or energy source prior to
installing or performing maintenance on the inverter. Live power
may be present at more than one point since an inverter utilizes
both batteries and AC. Turning off the inverter may not reduce
this risk. As long as AC power is connected, it will pass through
the 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-serviceable
parts contained in this product. Attempting to service the unit
yourself could cause electrical shock. Internal capacitors remain
charged after all power is disconnected.
• No AC or DC disconnects are provided as an integral part of this
inverter. Both AC and DC disconnects must be provided as part
of 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 a
specified action could result in damage to the equipment.
Info: This symbol indicates information that emphasizes
or supplements important points of the main text.
Safety symbols
To reduce the risk of electrical shock, fire, or other safety hazard, the
following safety symbols have been placed throughout this manual
to indicate dangerous and important safety instructions.

© 2010 Magnum Energy, Inc.
• No overcurrent protection for the battery supply is provided as
an integral part of this inverter. Overcurrent protection of the
battery cables must be provided as part of the installation.
• No overcurrent protection for the AC output wiring is provided as
an integral part of this inverter. Overcurrent protection of the AC
output 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., when
installing or performing maintenance on the inverter.
• Never work alone. Always have someone near you when working
around batteries.
• Use proper lifting techniques when working with batteries.
• Never use old or untested batteries. Check each battery’s label
for age, type, and date code to ensure all batteries are identical.
• Batteries are sensitive to changes in temperature. Always install
batteries in a stable environment.
• Install batteries in a well ventilated area. Batteries can produce
explosive gasses. 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 times.
• Always verify proper polarity and voltage before connecting the
batteries to the inverter.
• To reduce the chance of fire or explosion, do not short-circuit the
batteries.
• In the event of accidental exposure to battery acid, wash
thoroughly with soap and water. In the event of exposure to the
eyes, flood them for at least 15 minutes with running water and
seek immediate medical attention.
• Recycle old batteries.
SAVE ALL INSTRUCTIONS
iii

© 2010 Magnum Energy, Inc.iv
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....................................................... 2
Standard Features and Benefits.............................................. 3
Battery Temperature Sensor .............................................. 5
2.0 Installation....................................................................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................................................13
DC 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 .....................................17
AC 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 Operation ................................................................... 23
Operating Modes .................................................................23
Inverter Mode.................................................................23
Standby Mode ................................................................24
Protection Circuitry Operation ...............................................28
Inverter Start-up.................................................................29
ON/OFF Switch ...............................................................29
Status LED Indicator .......................................................29
Factory Default Settings .......................................................30
4.0 Maintenance and Troubleshooting...............................32
Recommended Inverter and Battery Care ...............................32
Resetting the Inverter..........................................................32

© 2010 Magnum Energy, Inc.v
List of Figures
Figure 1, MM-AE Series Inverter/Charger .................................. 1
Figure 2, Top Side Features..................................................... 3
Figure 3, Front and Back Side Features..................................... 4
Figure 4, Left Side Features .................................................... 5
Figure 5, Battery Temperature Sensor (BTS) ............................. 5
Figure 6, Basic Installation Diagram ......................................... 7
Figure 7, Approved Mounting Orientations................................. 9
Figure 8, MM-AE Series Inverter/Charger Dimensions ................10
Figure 9, DC Cable to Battery Terminals...................................14
Figure 10, DC Cable to Inverter’s DC Terminals.........................14
Figure 11, AC Wiring Connections ...........................................20
Figure 12, Automatic 4-Stage Charging Graph ..........................26
Figure 13, BTS Temperature to Charge Voltage Change..............27
Figure 14, Series Battery Wiring .............................................36
Figure 15, Parallel Battery Wiring............................................37
Figure 16, Series-Parallel Battery Wiring..................................37
Figure 17, Battery Bank Wiring Examples (12-volt) ...................38
Figure 18, Battery Bank Wiring Examples (24-volt) ...................39
List of Tables
Table 1, Recommended DC Wire/Overcurrent Device .................12
Table 2, DC Wire Size For Increased Distance ...........................13
Table 3, Wire Color to AC Wire Connection ...............................18
Table 4, Minimum Wire Size to Circuit-breaker Size ...................19
Table 5, Inverter Battery Turn On/Off Levels.............................29
Table 6, Inverter/Charger Default Settings ...............................31
Table 7, Troubleshooting Guide ...............................................33
Table 8, MM-AE Series Specifications .......................................34
Table of Contents
5.0 Specifications ..............................................................34
Appendix A - Optional Equipment and Accessories............35
Appendix B - Battery Information .....................................36
Battery Bank Sizing .............................................................36
Battery Types .....................................................................36
Battery Configuration...........................................................36
Series Wiring..................................................................36
Parallel Wiring ................................................................37
Series-Parallel Wiring.......................................................37
Appendix C - Warranty/Service Information .....................40
How to Receive Repair Service ..............................................41

© 2010 Magnum Energy, Inc.
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 for
your back-up power or standalone application. Powerful, yet simple
to use, the Magnum Energy inverter will provide you with years of
trouble-free use.
Please read this chapter to familiarize yourself with the features and
benefits of your particular MM-AE Series model.
Figure 1, MM-AE Series Inverter/Charger
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 input
and output are provided with pigtail wires to allow hardwiring to a
main AC distribution panel and to an inverter sub-panel. Includes a
15’ battery temperature sensor.
MM1512AE - a 1500 watt inverter/charger with 12 amp AC transfer
capability and 70 amp/12 VDC, 4-stage PFC charger. The AC input
and output are provided with pigtail wires to allow hardwiring to a
main AC distribution panel and to an inverter sub-panel. Includes a
15’ 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 input
and output are provided with pigtail wires to allow hardwiring to a
main AC distribution panel and to an inverter sub-panel. Includes a
15’ battery temperature sensor.
Info: These units have common input/output neutrals
for 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 is
the MM or MMS Series inverter.
1

© 2010 Magnum Energy, Inc.2
1.0 Introduction
How an Inverter/Charger Works
An inverter takes direct current (DC) from your batteries and turns
it into alternating current (AC), like you use at home. With MM-AE
Series models, it also takes alternating current (when connected to
a generator or to utility power) and transforms it into direct current
to recharge your batteries.
The two modes of operation associated with this inverter/charger are
referred to in this document as:
Inverter Mode: DC from the batteries is transformed into modified
sine wave AC for powering your AE applications.
Standby Mode: The unit operates as a battery charger to convert
incoming AC power into DC power to recharge the batteries while con-
tinuing to pass the incoming AC power directly to the inverter’s output
to power any AC loads.
Appliances that will run from a Modified Sine Inverter
Today’s inverters come in two basic output waveforms: modified sine
(actually a modified square wave) and pure sine wave. Modified sine
wave inverters approximate a pure sine waveform.
The output of a modified sine wave inverter will run most electronic
and household items including but not limited to TV, VCR, satellite dish
receiver, computers, and printers. Some devices such as rechargeable
power supplies for phones, drills, and other like devices may not run
or 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, there
is a certain length of time that it can run – this is called “run time”.
Actual run time depends on several variables including the size and
the type of appliance, the type of batteries installed in your applica-
tion, 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.
Depending on your inverter capacity, larger electrical appliances such
as 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 recommended
for inverter applications.
All electrical appliances are rated by the amount of power they con-
sume. The rating is printed on the product’s nameplate label, usu-
ally located on its chassis near the AC power cord. Even though it is
difficult to calculate exactly how long an inverter will run a particular
appliance, the best advice is trial and error. Your MM-AE Series in-
verter/charger has a built-in safeguard that automatically protects
your batteries from being over-discharged.

© 2010 Magnum Energy, Inc.
21
3
4
6
5
87
Figure 2, Top Side Features
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 to
120 volts alternating current (VAC) power. The multi-stage battery
charger optimizes incoming AC power using Power Factor Correction
(PFC) technology to keep the inverter’s battery bank fully charged.
This inverter is designed to allow easy installation and use, and with
its die-cast aluminum baseplate it ensures maximum durability and
cooler more efficient operation.
The inverter/charger provides the following:
• 600 or 1500 watts continuous (depending on model) at 25°C.
• Numerous protection features to provide a safe and
peace-of-mind operation.
• AC transfer switch circuitry; allowing incoming AC power to
continue 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 correction
and temperature compensation – for optimum battery charging
(using the temperature sensor).
• Modern and aesthetically pleasing design with large AC wiring
compartment (provides easy access to AC wiring for simple and
quick connections) and 360° DC connection terminals with color
coded 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 accepts
several optional remote controls and the Battery Temperature
Sensor.
1.0 Introduction
3

© 2010 Magnum Energy, Inc.
4
1.0 Introduction
1. Inverter Status Indicator - this green LED illuminates to
provide information on the inverter’s operation.
2. Power Switch -momentary pushbutton switch that turns the
inverter on or off.
3. Negative DC Terminal (black) - the inverter’s connection to
the negative terminal on the battery bank.
4. Positive DC Terminal (red) - the inverter’s connection to the
positive terminal on the battery bank.
5. Input Circuit Breaker - this circuit breaker protects the unit’s
internal wiring and pass-thru relay.
6. Output Circuit Breaker -this circuit breaker provides another
layer of overload protection. This is not a branch-circuit rated
breaker. 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 input
and output connections on the inverter.
Figure 3, Front and Back Side Features
9. Warning and Information Label -provides pertinent
information for safely using the inverter.
10. REMOTE Port Connection -a RJ11 connector that allows an
optional remote control to be connected.
11. ACCESSORY PORT Connection - a RJ11 connector to allow
the 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 keep
the inverter cool for peak performance.
13. Exhaust Vent -ventilation openings that allow heated air to
be removed by the internal cooling fan.
14. Model/Serial Number Label -includes model/serial number
and provides specifications and information on the inverter and
charger. See the MM-AE Series Specifications on page 34 for
more information and the different models available.
10
11
12
FrontSide
9
BackSide
14
13

© 2010 Magnum Energy, Inc.
15. AC Output Connection -AC knockout (output) for
hardwiring.
16. AC Input Connection -AC knockout (input) for hardwiring.
17. DC 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 AWG to #6 AWG.
Battery Temperature Sensor
A plug-in external Battery Temperature Sensor (BTS) is provided
for units with the battery charger feature. When installed, the
BTS automatically adjusts the battery charger’s BULK, ABSORB,
and FLOAT voltage set-points (based on temperature) for better
charging performance and longer battery life. If the temperature
sensor is NOT installed and the batteries are subjected to large
temperature changes, battery life may be shortened.
Figure 4, Left Side Features
FRONT VIEW
SIDE VIEW
~2" ~1"
~½”
0.375"diameter
Cable
~¾”
16 17
15
5
1.0 Introduction
Figure 5, Battery Temperature Sensor (BTS)

© 2010 Magnum Energy, Inc.
6
2.0 Installation
2.0 Installation
Pre-Installation
Before installing the inverter, read the entire Installation section. The
more thorough you plan in the beginning, the better your inverter
needs will be met.
WARNING:Installations should be performed by qualified
personnel, such as a licensed or certified electrician. It
is the installer’s responsibility to determine which safety
codes apply, and to ensure that all applicable installation
requirements are followed. Applicable installation codes
vary depending on the specific location and the type of
installation.
Info:Review the “Important Product Safety Information”
on page ii and the “Important Battery Safety Instructions”
on page iii before any installation.
The basic system diagram shown in Figure 6 should be reviewed to
assist 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 items
are 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 Owner’s Manual
If items appear to be missing or damaged, contact your authorized
Magnum 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 will
also be needed if the unit should require in-warranty service.
Record the unit’s model and serial number in the front of this manual
in case you need to provide this information in the future. It is much
easier to record this information now, instead of trying to gather it
after the unit has been installed.

© 2010 Magnum Energy, Inc.
Figure 6, Basic Installation Diagram
AC
Main Panel
MM-AE SeriesInverter
DC
disconnect
and
overcurrent
device
Battery
Bank
AC IN
AC Loads
VCR
TV Tools
AC
Sub-Panel
AC
Outlet
AC
OUT
DC
Ground
2.0 Installation
7

© 2010 Magnum Energy, Inc.
2.0 Installation
8
Locating and Mounting the Inverter
WARNINGS:
• Do not mount the inverter near any flammable or
combustible 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 the
following requirements:
Clean and Dry - The inverter should not be installed in an area that
allows dust, fumes, insects, or rodents to enter or block the inverter’s
ventilation openings. The area also must be free from any risk of
condensation, water, or any other liquid that can enter or fall on the
inverter. The inverter uses stainless steel fasteners, plated copper
busbars, and a power-coated aluminum base. Also, the internal circuit
boards are conformal coated. The above measures are undertaken
to help fight the harmful effects of corrosive environments. However,
the life of the inverter is uncertain if used in any of these types of
environments, and inverter failure under these conditions is not covered
under warranty.
Cool - The inverter should be protected from direct exposure to the
sun or any equipment that produces extreme heat. The ambient air
temperature should be between 32° F (0° C) and 104° F (40° C);
keep in mind that the inverter’s 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 power
and avoid over-temperature fault conditions do not cover or block
the inverter’s ventilation openings, or install this inverter in an area
with limited airflow. Allow as much clearance around the inverter’s
intake and exhaust ventilation openings as possible, see Items 12
and 13 in Figure 3. At the minimum, allow an airspace clearance of
6” (15 cm) at the front and back, and 3” (7.5 cm) everywhere else
to 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 allow
cool air from the outside to flow into the inverter, and heated air to
exit away from the inverter and the enclosure. When mounted in an
enclosed compartment, airflow must be at least 59 cfm in order to
maintain 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.

© 2010 Magnum Energy, Inc.
Safe - Keep any flammable/combustible material (e.g., paper, cloth,
plastic, etc.) that may be ignited by heat, sparks, or flames at a
minimum distance of 2 feet (60 cm) away from the inverter. Do not
install this inverter in any area that contains extremely flammable
liquids like gasoline or propane, or in locations that require ignition-
protected devices.
Close to the battery bank - As with any inverter, it should be
located as close to the batteries as possible. Long DC wires tend to
lose efficiency and reduce the overall performance of an inverter.
However, the unit should not be installed in the same compartment as
the batteries or mounted where it will be exposed to gases produced
by the batteries. These gases are corrosive and will damage the
inverter. 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 inverter’s remote control and
accessory ports. Also, allow enough room to access the AC and DC wiring
connections, 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, the
MM-AE Series inverter/charger can only be mounted on a horizontal
surface (shelf or table) or a vertical surface (wall or bulkhead) either
right-side up or upside-down, as shown in Figure 7. The inverter must
be mounted on a non-combustible surface, and this surface and the
mounting hardware must be capable of supporting at least twice the
weight of the inverter. After determining your mounting position, use
the base of the inverter’s chassis as a template to mark your mounting
screw locations. Remove the inverter and drill pilot holes into the
mounting surface.
After the inverter has been properly mounted, proceed to the DC
Wiring section.
Figure 7, Approved Mounting Orientations
WallMounted (right-side up)
WallMounted (up-side down)
Shelf Mounted
(right-side up)
Shelf Mounted
(up-side down)
2.0 Installation
9

© 2010 Magnum Energy, Inc.10
2.0 Installation
Figure 8, MM-AE Series Inverter/Charger Dimensions
Mounting holes x 4
[¼” (0.25") diameter]
10.0"
~ 16 5/8"
(16.59")
~ 6 3/4" (6.71")
~ 8 7/16" (8.41")
~ 7 ½" (7.51")
~ 4 11/16"
(4.66")
Wiring Guidelines
• Before connecting any wires, determine all wire routes to and
from the inverter throughout the home or cabin.
• Conductors passing through walls or other structural members
must be protected to minimize insulation damage such as
chafing, which can be caused by vibration or constant rubbing.
• Always check for existing electrical, plumbing, or other areas
of potential damage prior to making cuts in structural surfaces or
walls.
• 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 part
of the installation.

© 2010 Magnum Energy, Inc.
• DC wires and cables should be tied together with wire ties or
electrical tape approximately every 6 inches. This helps improve
the surge capability and reduces the effects of inductance, which
improves the inverter waveform and reduces wear on the
inverter’s filter capacitors.
• Use only copper wires with a minimum temperature rating of
75°C.
• To ensure the maximum performance from the inverter, all
connections from the battery bank to the inverter should be
minimized; the exceptions are the DC overcurrent disconnect in
the 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 requirement
for the DC terminals is between 10 to 12 foot-pounds. If you
don’t have a torque wrench, ensure all DC terminals are tight
and cannot move.
CAUTION:Be aware that overtightening and misthreading
the nuts on the DC terminals can cause the bolts to strip
and snap/break off.
DC Wiring
This section describes the inverter’s required DC wire sizes and the
recommended disconnect/overcurrent protection, and how to make
the 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 with
overheating. See Table 1 to select the minimum DC wire size needed
based on your inverter model. If the distance from the inverter to the
battery bank is greater than 3 feet, use Table 2 to help determine
the minimum recommended cable sizes for longer distances. Always
keep your wire runs as short as practical to help prevent low volt-
age shutdowns, and keep the DC breaker from nuisance tripping (or
open fuses) because of increased current draw. Undersized cables
can also lower the inverter’s peak output voltage, as well as reduce
its ability to surge heavy loads.
2.0 Installation
11
Info: The DC wires must be color coded with colored
tape or heat shrink tubing; RED for positive (+), BLACK
for negative (-), and GREEN for DC ground.

© 2010 Magnum Energy, Inc.
12
2.0 Installation
The DC wires must have soldered and crimped lugs, crimped copper
compression 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 than
three feet from the battery bank, the DC wire size will need to be
increased to overcome the increase in resistance – which affects the
performance of the inverter. Continue to use the overcurrent device
and DC ground wire previously determined from Table 1 and then,
refer to Table 2 to determine the minimum DC wire size you need for
various distances based on your inverter model.
Note 1 - Maximum Continuous Current is based on the inverter’s continuous
power 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 and
that 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 if
the de-rated cable ampacity falls between the standard overcurrent devices
found in the NEC.
Info: The term “in free air” is defined by the NEC as not
encased in conduit or raceway.
Inverter Model
MM612AE MM1512AE MM1524AE
Maximum Continuous
Current¹ 80 amps 200 amps 100 amps
DC Grounding
Electrode Wire Size# 6 AWG # 6 AWG # 6 AWG
Minimum DC Wire Size
(90˚C 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

© 2010 Magnum Energy, Inc.
DC Overcurrent Protection
For safety and to comply with NEC (National Electrical Code) electrical
code regulations, you must install a DC overcurrent protection device
in the positive DC cable line to protect your DC cables. This DC
overcurrent device can be a fuse or circuit-breaker, but must be DC
rated. It must be correctly sized according to the size of DC cables
being used, which means it is required to open before the cable
reaches its maximum current carrying capability, thereby preventing
a fire. See Table 1 to select the DC overcurrent device based on the
minimum 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 the
inverter without opening.
DC Grounding
The inverter/charger should always be connected to a permanent,
grounded wiring system. The idea is to connect the metallic chassis
of the various enclosures together to have them at the same voltage
potential, which reduces the possibility for electric shock. For the
majority of installations, the inverter chassis and the negative battery
conductor are connected to the system’s ground bond via a safety-
grounding conductor (bare wire or green insulated wire) at only one
point in the system. Per the NEC, the size for the grounding conductor
is usually based on the size of the overcurrent device used in the DC
system. Refer to Table 1 to select the appropriate DC ground wire
based 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

© 2010 Magnum Energy, Inc.
2.0 Installation
14
Figure 9, DC Cable to Battery Terminals
DC Cable Connections
When connecting the DC cable to the battery or to the inverter’s DC
terminals, the hardware should be installed in the correct order to
prevent high resistance connections from heating up and possibly
causing the connections to melt. Follow Figures 9 and 10 to stack
the hardware correctly. Tighten the terminal connections from 10 to
12 foot-pounds.
CAUTION: Do not put anything between the DC cable ring
lug and the battery terminal post or inverter’s DC terminal.
If antioxidant grease or spray is used, apply it after all the
connections have been made and are properly tightened.
CAUTION: Overtightening or misthreading nuts on the DC
terminals will cause the bolts to strip and snap/break-off.
CAUTION: The inverter is NOT reverse polarity protected
(negative and positive connected backwards). You must
verify the correct voltage polarity BEFORE connecting the
DC wires or damage may occur.
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.
Figure 10, DC Cable to Inverter’s DC Terminals
BATTERY
DC cable
with ring lug
bolt
flat washer
nut
lock washer
battery
post
battery terminal
Temperature sensor
Verify that the
DC cable lugs are flush
with the battery terminals.
Torque the battery terminals
from10 to 12 foot-pounds.
DC cable
with ring lug
DC
terminal cover
(snaps on)
Inverter’s
DC terminal
5/16”(Kep
nut with star-washer) or
Flange nut