Magnum Energy MM Series Operating instructions

Installation and
Operation Guide
MM Series
Inverters
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©2006 Magnum Energy Inc.
Disclaimer of Liability
Since the use of this manual and the conditions or methods of
installation, operation, use and maintenance of the MM Series
inverter are beyond the control of Magnum Energy Inc., this company
does not assume responsibility and expressly disclaims liability for
loss, damage or expense, whether direct, indirect, consequential or
incidental, arising out of or anyway 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 Series Inverter shall not be used in connection with life
support systems, life saving or other medical equipment or devices.
Use of this particular equipment is at your own risk.
Contact Information
Magnum Energy, Inc.
1111 80th Street SW - Suite 250
Everett, WA 98203
phone: [phone]
fax: [phone]
web: www.magnumenergy.com
Conventions Used in this Manual
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.
Warning - Indicates a dangerous voltage or condition exists.
Caution - Indicates a critical step necessary for the safe
installation and operation of the unit.
Note - Indicates an important statement.
Terminology
AC source or External AC power - refers to Alternating Current (AC)
provided by the utility electric power grid or from a generator. In
some applications this is referred to as shorepower.
AE application - typically refers to using the inverter in an system
that also uses Alternative Energy (i.e. solar, wind or hydro). This term
is also used to refer to inverters used in a home, office or cabin
installation.
Mobile application - refers to inverters used in a Recreation Vehicle
(RV), boat or truck installation.
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IMPORTANT PRODUCT SAFETY INSTRUCTIONS
This manual contains important safety instructions that must be
followed 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. 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 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 thru the inverter regardless of the ON/OFF
power switch.
• 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.
• 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 system 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 system installation.
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IMPORTANT
BATTERY SAFETY INSTRUCTIONS
• Wear eye protection such as 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 explo-
sion, 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 even 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.
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©2006 Magnum Energy Inc.iv
Table of Contents
1.0 Introduction ..........................................................................1
MM Series Models .......................................................................... 2
How an Inverter/Charger Works..................................................... 2
What Appliances 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 ......................................................................... 11
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 (Battery Charger Models Only).... 16
DC Positive Wire..................................................................... 16
AC Wiring .................................................................................... 17
Neutral to Safety Ground Bonding ........................................... 17
AC Wiring Connections............................................................ 17
AC Wire Size and Overcurrent Protection ................................ 18
AC Input Wiring ...................................................................... 19
AC Output Wiring .................................................................... 20
Recommended Ground-Fault Circuit Interruption Breakers....... 20
Functional Test............................................................................. 21
3.0 Operation .............................................................................22
Operating Modes.......................................................................... 22
Invert Mode ............................................................................ 22
Transfer Mode......................................................................... 22
Protection Mode ...................................................................... 23
Charger Mode (not available on all models)............................. 23
Start-up ...................................................................................... 25
ON/OFF Switch ........................................................................ 25
Status Indicator ...................................................................... 25
Normal Operation ................................................................... 25
Protection Operation ............................................................... 25
Charger Operation.................................................................. 25
Factory Default Settings ............................................................... 26
4.0 Troubleshooting ..................................................................27
5.0 Specifications ......................................................................28
Appendix A - Remote Control and Monitoring ........................30
Using the MM Remotes ................................................................. 30
ON/OFF Switch ............................................................................. 31
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List of Figures
Figure 1, MM Series Inverter ........................................................... 1
Figure 2, Top Side Features ............................................................. 3
Figure 3, Front and Back Side Features............................................ 4
Figure 4, Bottom Side Features........................................................ 5
Figure 5, BTS .................................................................................. 5
Figure 6, Basic Installation Diagram ................................................ 7
Figure 7, Approved Mounting Orientations ........................................ 9
Figure 8, MM Series Inverter 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 ................................................. 19
Figure 12, Automatic 4-Stage Charging Graph ............................... 23
Figure 13, MM Remotes ................................................................. 30
Figure 14, Series Battery Wiring .................................................... 34
Figure 15, Parallel Battery Wiring .................................................. 35
Figure 16, Series-Parallel Battery Wiring........................................ 35
List of Tables
Table 1, Recommended DC Wire/Overcurrent Device .................... 12
Table 2, DC Wire Size For Increased Distance ............................... 12
Table 3, Wire Color to AC Wire Connection .................................... 17
Table 4, Minimum Wire Size to Circuit-breaker Size ....................... 18
Table 5, Factory Default Settings ................................................... 26
Table 6, Troubleshooting Guide ...................................................... 27
Table 7, MM600 Specifications ....................................................... 28
Table 8, MM1200 Specifications...................................................... 29
Tables Of Contents
Appendix A - Remote Control and Monitoring (continued)
Monitoring the LED Indicators....................................................... 31
MM-R and MM-RC Remotes...................................................... 31
INVERT (green) .................................................................... 31
AC IN (green) ...................................................................... 32
FAULT (red)........................................................................... 32
MM-RC Remote Only ............................................................... 33
BULK (yellow)....................................................................... 33
ABSORB (yellow) .................................................................. 33
FLOAT (green) ...................................................................... 33
Appendix B - Battery Information ...........................................34
Battery Bank Sizing ..................................................................... 34
Battery Types .............................................................................. 34
Battery Configuration................................................................... 34
Series Wiring .......................................................................... 34
Parallel Wiring ........................................................................ 35
Series-Parallel Wiring.............................................................. 35
Appendix C - Preventive Maintenance ....................................36
Recommended Inverter and Battery Care .................................... 36
RV/Marine Off-Season Storage..................................................... 36
Appendix D - Warranty/Service Information.........................37
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1.0 Introduction
1.0 Introduction
Congratulations on your purchase! The MM Series inverter from
Magnum Energy, Inc. is designed to be powerful, yet simple to use,
and provide you with years of trouble-free use.
Please read this chapter to familiarize yourself with the features and
benefits of your particular MM Series model.
Figure 1, MM Series Inverter
MM Series Models
MM612 - 600 watt inverter with 7 amp AC transfer relay. The AC input
and output are provided with pigtail wires to allow hardwiring to an AC
distribution panel. Features neutral-to-ground switching for Mobile
applications.
MM612G - 600 watt inverter with 7 amp AC transfer relay. The AC
input is provided with a flexible cord and a GFCI outlet on the output
for easy connection to your AC appliances; ready to use after
connecting to your batteries. Features neutral-to-ground switching for
Mobile applications.
MM612AE - 600 watt inverter/charger with 7 amp AC transfer relay
and 30 amp, 4-stage PFC charger. AC input and output provided with
pigtail wires to allow hardwiring to a main AC distribution panel and
inverter sub-panel. Features common input/output neutrals for AE
applications. Includes 15’ battery temperature sensor.
MM1212 - 1200 watt inverter/charger with 12 amp AC transfer relay
and 70 amp, 4-stage PFC charger. The AC input and output are
provided with pigtail wires to allow hardwiring to a main AC distribution
panel and inverter sub-panel. Features neutral-to-ground switching for
Mobile applications. Includes 15’ battery temperature sensor.
MM1212AE - 1200 watt inverter/charger with 12 amp AC transfer
relay and 70 amp, 4-stage PFC charger. The AC input and output are
provided with pigtail wires to allow hardwiring to a main AC distribution
panel and inverter sub-panel. Features common input/output neutrals
for AE applications. Includes 15’ battery temperature sensor.
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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 Series
models that have the battery charger feature, it also takes alternating
current (when connected to utility or generator power) and transforms it
into direct current to recharge your batteries.
There are three modes of operation associated with this inverter:
Inverter Mode: Direct Current (DC) from the batteries is transformed
into Alternating Current (AC) for powering your household electrical
appliances.
Transfer Mode: Alternating Current (AC) is taken directly from utility
power (or other AC sources) and passes through the inverter directly to
your household appliances.
Charger Mode (not available on all models): The incoming AC from
utility power (or other AC sources) is converted to DC to recharge the
batteries connected to the inverter.
What Appliances will run from a Modified Sine Inverter
Today’s inverters come in two basic output waveforms: modified sine
(which is actually a modified 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, Satellite dish
receiver, computers and printers. Some devices such as rechargeable
power supplies for phones, drills, and such devices may not run or be
damaged by modified sine wave inverters.
Appliances and Run Time
The MM Series inverter can power a wide range of household appliances
including small motors, clocks and other electrical devices. 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 application, 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 and lights can all be
successfully powered by your inverter. Depending on your inverter
capacity, larger electrical appliances such as coffee pots and hair dryers
can be used for short durations. However, 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, usually
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 Series inverter has a built-in
safeguard that automatically protects your batteries from being over-
discharged.
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3
4
6
5
87
Figure 2, Top Side Features
Standard Features and Benefits
The MM Series inverter converts 12 Volts Direct Current (VDC) power
from your battery to 120 Volts Alternating Current (VAC) power. On
models with the multistage battery charger feature, the incoming AC
power is optimized using Power Factor Correction (PFC) technology to
keep the inverter’s battery bank fully charged. This inverter is de-
signed to allow easy installation and use and with its die-cast aluminum
baseplate, which ensures maximum durability and cooler more
efficient operation.
The inverter is equipped with the following features:
• 600 or 1200 watts continuous (depending on model) at 25° Celsius.
• Equipped with numerous protection features to provide a safe and
peace-of-mind operation.
• Unique 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 (battery charger models) allows charging
batteries that are extremely low.
• Automatic 4-stage battery charger with Power Factor Correction and
Temperature compensation - for optimum battery charging (models
with battery charger and using 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 voltage range
and continuous output power level.
• Quick connection accessory and remote ports - easily accepts
several optional remote controls and the Battery Temperature Sensor.
1.0 Introduction
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1.0 Introduction
1, Inverter Status Indicator - this green LED (Light Emitting
Diode) illuminates to provide information on the inverter’s operation.
2, Power switch - momentary push-button switch that turns the
inverter On or Off.
3, Negative DC terminal (black) - the inverters connection to the
negative terminal on the 12 VDC battery bank.
4, Positive DC terminal (red) - the inverters connection to the
positive terminal on the 12 VDC 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,
unless you are using the GFCI outlet version.
7, Mounting flanges (x4) - used to secure the inverter to a shelf or
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 (available
only models with the battery charger) to allow the Battery
Temperature Sensor (BTS) to be connected. The BTS provides
information that enables the multistage PFC battery charger to “fine
tune” the battery charge voltages for better charging performance
and longer battery life.
12, Intake vent - ventilation openings to pull in air to help keep the
inverter cool for peak performance.
13, Exhaust vent - ventilation opening that allows 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 Specifications on pages 28 and 29 for more information and
the different models available.
10
11
12
Front Side
9
Back Side
14
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15, AC output connection -
Hardwire versions - AC knockout (output) for hardwiring.
GFCI versions - provided with a Ground Fault Circuit-
Interrupter outlet (with test and reset capability).
16, AC input connection -
Hardwire versions - AC knockout (input) for hardwiring.
GFCI versions - provided with a flexible AC input cord for direct
connection to an AC outlet.
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 (Battery Charger Models Only)
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 chargers BULK, ABSORB and
FLOAT voltage setpoints based on
temperature. If the temperature
sensor is NOT installed and if the
batteries are subjected to large
temperature changes, the battery
life may be shortened.
Figure 4, Bottom Side Features
Figure 5, BTS
16 17
Hardwire version
(input & output hardwired)
TEST
RESET
TEST
RESET
GFCI version
(input cord & GFCI outlet)
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1.0 Introduction
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2.0 Installation
2.0 Installation
Pre-Installation
Before installing the inverter, read the entire installation section to
determine how you are going to install your MM. The more thorough
you plan in the beginning, the better your inverter needs will be met.
Note: Installations should be performed by qualified person-
nel, 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 require-
ments are followed. Applicable installation codes vary
depending on the specific location and application of the
installation.
Note: 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 Series inverter from its shipping container
and inspect all contents. Verify the following items are included:
-The MM Inverter
-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 (battery charger models only)
-MM Series Inverters, Installation and Operation Guide.
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.
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Figure 6, Basic Installation Diagram
AC
Main Panel
MM Series Inverter
DC
disconnect
and
over-current
device
Battery
Bank
AC IN
AC Loads
VCR
TV Tools
AC
Sub-Panel
AC
Outlet
AC
OUT
Cord
(GFCI versions)
Hardwire
or
DC
Ground
Hardwire Outlet
(GFCI versions)
or
2.0 Installation
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2.0 Installation
8
Locating and Mounting the inverter
Warnings:
• Do not mount the inverter near any flammable or combus-
tible fluid or components.
• Provide adequate clearance and ventilation to the inverter
• Mount the inverter only on a “noncombustible” 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. This 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
buss-bars, a power-coated aluminum base and the internal circuit
boards are conformal coated all done to help fight the harmful effects
of corrosive environments. However, the life of the inverter is
uncertain if used in these type 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 equipment that produces extreme heat. The ambient air
temperature should be between 32° F (0° C) and 104° F (40° C);
realize that the inverters 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 overtemperature fault conditions; do not cover or block the
inverters ventilation openings or install this inverter in an area with
limited airflow. Allow as much clearance around the inverters intake
and exhaust ventilation openings as possible, see items 12 and 13 in
figure 3. At the minimum, 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 opening
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 from
the inverter and out of 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 temperature. Minimum
clearances can be reduced if airflow is increased, but in no case should
clearance around inverter be less than 2" (5 cm) on all sides.
Safe - Keep any flammable/combustible material (i.e. 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.
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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
loose 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 if 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 tighten
periodically. See figure 8 for the MM Series inverter dimensions.
Mounting Orientation - To meet regulatory requirements, the MM
Series Inverter 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
“noncombustible” 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 inverters
chassis as a template to mark your mounting screw locations. Remove
the inverter and drill pilot holes into the mounting surface.
If this unit is used in a Mobile application, you may want to place
flexible washers or bushings between the mounting surface and the
inverters mounting flanges to reduce vibration.
After the inverter has been properly mounted, proceed to the DC
wiring section.
Figure 7, Approved Mounting Orientations
Wall Mounted (right-side up)
Wall Mounted (up-side down)
Shelf Mounted
(right-side up)
Shelf Mounted
(up-side down)
2.0 Installation
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2.0 Installation
Figure 8, MM Series Inverter Dimensions
Mounting holes x4
[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")
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Wiring Guidelines
• Before connecting any wires, determine all wire routes throughout
the home or vehicle/boat both to and from the inverter.
• Conductors passing through walls, bulkheads 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, bulk-
heads or walls.
• Make sure all wires have a smooth bend radius and do not become
kinked.
• Both AC and DC overcurrent protection must be provided as part
of the installation.
• Do not attempt to use a vehicle metal frame in place of the DC
negative connection or DC ground. The inverter requires a reliable
negative and ground return path directly to the battery.
• DC wires and cables should be tied together with wire ties or
electrical tape approximately every 6 inches. This helps improves the
surge capability and reduces the effects of inductance, which im-
proves the inverter waveform and reduces the wear of 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 connec-
tions from the battery bank to the inverter should be minimized, the
exception is the DC overcurrent disconnect in the positive line and a
shunt in the negative line. Any other additional 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.
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
efficiency 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 voltage
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.
• Be aware that overtightening and misthreading the nuts on the DC
terminals can cause the bolts to strip and snap/break off.
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2.0 Installation
Note: 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.
The DC wires must have soldered and crimped lugs, crimped copper
compression lugs, or aluminum mechanical lugs. Soldered connections
alone are not acceptable for this application.
Table 1, Recommended DC Wire/Overcurrent Device
*Based on NEC, NFPA 70, Table 310-17, for 75° C single-insulated
cables in free air
Table 2, DC Wire Size For Increased Distance
MM612 MM1212
Full Load DC
Input Current 60 amps 125 amps
Maximum DC
Input Current 125 amps 175 amps
Minimum
Wire Size #4AWG #1AWG
Maximum DC
Overcurrent Device* 125 amps 200 amps
DC Ground
Wire Size #6AWG #6AWG
Inverter Model
If the inverter is expected to operate at a distance greater than three
feet from the battery bank, the DC wire 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.
3 ft or less 3 to 5 ft 5 to 10 ft 10 to 15 ft
MM612 #4 AWG #2 AWG #1/0 AWG #2/0 AWG
MM1212 # 1 AWG #1/0 AWG #2/0 AWG not
recommended
Minimum recommended DC wire size (one way)
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DC Overcurrent Protection
For safety and to comply with 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 must be
DC rated and can be a fuse or circuit-breaker. 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 needed based on the minimum wire size
according to your inverter model.
For electrical systems in AE applications, the NEC (National Electrical
Code) requires an overcurrent protection device. Mobile installations
typically do not require using a DC disconnect, although an
overcurrent protection device is still required. Because the DC
disconnect is not required, a fuse is usually used as the overcurrent
device in these installations. These installations also do not normally
use conduit, so the fuse must be installed in the ungrounded
conductor (usually the positive DC cable line) within 18 inches of the
battery to protect the DC wiring system.
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 allow 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 DC ground wire needed based
on the overcurrent device used for your inverter model,
If using this inverter in a vehicle, DO NOT connect the battery negative
(-) cable to the vehicle’s safety ground. Connect it only to the
inverter’s negative battery terminal. If there are any non-factory
installed DC appliances on board the vehicle, DO NOT ground them at
the safety ground. Ground them only at the negative buss of the DC
load center (as applicable).
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2.0 Installation
14
Figure 9, DC Cable to Battery Terminals
DC Cable Connections
When connecting the DC cable to the battery or inverter DC terminals,
the hardware should be installed in the correct order to prevent high
resistance connections which will heat-up and could cause the connec-
tions to melt. Follow figure 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 tighten.
Caution: Overtightening or misthreading the 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
(for charger models)
Verify that the
DC cable lugs are flush
with the battery terminals.
Torque the battery terminals
from 10 to 12 foot-pounds.
DC cable
with ring lug
½” kep nut
(nut with star-washer)
DC
terminal cover
(snaps on)
inverter’s
DC terminal
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