ME Series Inverter / Chargers Operator’s Manual
IMPORTANT SAFETY INSTRUCTIONS This manual contains important safety instructions that must me followed during the installation and operation of this product. 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.
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 lif ting 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.
Magnum Energy ME Series Inverter / Chargers Table of Contents Section Description Page 1. 1. 2. 3. 4. 5. Introduction Features and Benefits Standard Features How an Inverter/Charger Works Appliances and Run Time The ME Series Inverter/Charger 1 1 1 3 3 5 2. 1. 2.
Table of Contents, continued Section 2. 4. Description Page Installation, continued Options Battery Temperature Sensor Installation and Wiring R e m o t e C o n t r o l In s t a l l a t i o n a n d W i r i n g AGS Module Smart Shunt Stacking Cable Kit Start-up and Test Connecting the Batteries to the Inverter F i n a l I n s p e c t i o n a n d P o w e r-u p Configuring the Inverter 25 25 25 25 25 25 26 26 26 27 3. 1.
1. INTRODUCTION 1. Features and Benefits Congratulations on your purchase of the ME Series inverter/charger from Magnum Energy. The ME Series is a “new generation” inverter designed especially for rugged recreational vehicle usage. Powerful, yet simple to use, the Magnum Energy inverter will provide you with years of trouble-free performance so you can enjoy the all of the comforts you have come to expect from your RV, all backed by our limited 3 year (36-month warranty).
1. INTRODUCTION Figure 1 ME Series Inverter / Charger Ó 2003 - Magnum Energy, Inc.
1. INTRODUCTION 3. How an Inverter/Charger Works A n inverter takes direct current (DC) from your batteries and turns it into alternating current (AC), exactly like you use at home. It also takes alternating current when your motor coach is connected to shore power and transforms it into direct current to recharge your batteries.
Power ON/OFF Switch 1. INTRODUCTION Charging / Inverting LED Stack Port M a g n u m 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 4 Ó 2003 - Magnum Energy, Inc.
1. INTRODUCTION 5. The ME Series Inverter/Charger The ME Series inverter/charger is designed to allow easy access to wiring, circuit breakers, controls and LED status indicator. Its die cast baseplate with one piece aluminum cover ensures maximum durability with minimum weight, as well as cooler more efficient operation. The inverter is equipped with the following features: ON / OFF Switch - used to manually switch the inverter ON and OFF.
2. INSTALLATION 1. Unpacking and Inspection Carefully remove the ME Series inverter from its shipping container and inspect all contents. If items appear to be missing or damaged, contact Magnum Energy at (425) 353-8833 or your authorized Magnum Energy dealer. If at all possible, retain the shipping container in the event the unit ever needs to be returned for factory service. ATTENTION: Electrostatic Sensitive Devices. Observe precautions for handling. 2.
2. INSTALLATION 2. Pre-Installation, continued Hardware / Materials Required Conduit, strain - r e l i e f s a n d a p p r o p r i a t e f i t t i n g s 1/4" mounting bolts and lock washers Electrical tape Wire ties Tools Required Misc screw drivers Drill and drill bits Level Level Pliers Pencil or Marker 1/2" wrench Wire strippers Multimeter Wiring Pre-plan the wire and conduit runs. For maximum safety, run both AC and DC wires/cabling in (separate) conduit.
2. INSTALLATION 2. Pre-Installation, continued Torque Requirements Tor q u e a l l A C w i r i n g c o n n e c t i o n s t o 1 6 i n c h p o u n d s . T o r q u e D C c a b l e c o n n e c t i o n s to 10-12 foot pounds. AC Main Panel I f t h e i n s t a l l a t i o n w i l l b e p o w e r i n g a w i d e -r a n g e o f a p p l i a n c e s t h r o u g h o u t t h e vehicle, an AC main panel is often recommended.
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10 Ó 2003 - Magnum Energy, Inc.
2. INSTALLATION 3. Installation NOTE: Read all instructions and cautionary markings located at the beginning of this m a n u a l a n d i n t h e p r e - i n s t a l l a t i o n s e c t i o n , b e f o re i n s t a l l i n g t h e i n v e r t e r a n d batteries. CAUTION: Do not mount the inverter or the batteries near the vehicle’s gasoline or propane fuel tanks. Mount the inverter only on a “non-combustable” surfaces. Maximum abient temperature MUST NOT exceed 113 °F (45 °C).
2. INSTALLATION 3. Installation, continued Battery Cables and Sizing Select the correct battery cables for the installation from the table. It is important to use the correct cable to achieve maximum efficiency from the system and reduce fire hazards associated with overheated cables. Undersized cables can also l o w e r t h e i n v e r t e r ’ s p e a k o u t p u t v o l t a g e a s w e l l a s r e d u c e its surge power capability.
2. INSTALLATION 3. Installation, continued Battery Wiring WARNING: During the installation and wiring process, cover exposed battery cable ends with electrical tape to prevent shorting the cables. NOTE: DO NOT connect the positive cable to the inverter at this time. Depending upon the type of battery you use in the installation (6 or 12 VDC), the b a t t e r i e s m u s t b e w i r e d i n s e r i e s , p a r a l l e l o r s e r i e s / p a r a l l e l t o p r o v i d e 1 2 V D C .
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combined battery capacity = 400 AHr @ 12 VDC 14 Ó 2003 - Magnum Energy, Inc.
2. INSTALLATION 3. Installation, continued Series Connection (four 6 VDC batteries to create a 24 VDC bank) A s e r i e s c o n n e c t i o n c o m b i n e s o v e r a l l b a t t e r y v o l t a g e b y t h e n u m b e r o f b a t t e r i e s in the string. Even though there are multiple batteries, the capacity remains the same. In the example at the left (Figure 8), four 6 VDC, 100 AHr batteries are comb i n e d i n t o a s i n g l e s t r i n g r e s u l t i n g i n a 2 4 VDC, 200 AHr bank.
2. INSTALLATION In - l i n e f u s e ~ + + + > + + 12 VDC 12 VDC 12 VDC 12 VDC - - - - TO 12 VDC INVERTER > Figure 10 Parallel Battery Wiring - Fuse Placement Figure 11 Series Battery Wiring - Fuse Placement + + + > + In - l i n e f u s e ~ + 6 VDC 6 VDC - 6 VDC - > 6 VDC - - TO 12 VDC INVERTER Figure 12 Series/Parallel Battery Wiring - Fuse Placement 16 Ó 2003 - Magnum Energy, Inc.
2. INSTALLATION 3. Installation, continued DC Fuse Block A fuse or circuit breaker must be located within 18 inches of the battery to protect the DC wiring system. The device must be rated to match the size of the cable, but can be rounded up to the next larger size (i.e., a cable rated at 150 amps can accept a 175 amp fuse) as necessary. Mount the fuse block (or circuit breaker assembly) as near as practical to the batteries.
Ó 2003 - Magnum Energy, Inc.
2. INSTALLATION DC Chassis Ground Figure 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.
2. INSTALLATION 3. Installation, continued AC Wiring WARNING: De -energize all sources of power including batteries ( D C ) , shore power ( A C ) , and AC generator (if applicable). AC wiring must be performed by a qualified person or licensed electrician. DO NOT connect the inverter’s output to an AC power source. WARNING: Risk of electric shock.
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.
2. INSTALLATION 3. Installation, continued Wiring the Inverter AC Input (refer to diagrams on the following pages) Remove the chassis AC access cover to access the internal terminal block. Route the cable and conduit from the main panel, approved bypass selector switch or main AC panel to the inverter’s AC INPUT conduit clamp. Tighten the clamp securely on the conduit. Always leave a little extra slack in the wiring.
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.
2. INSTALLATION Inverter/Charger AC Sub-panel AC Main Breaker Panel AC Input Wiring 30 Amp AC Output 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.
2. INSTALLATION Stack Port M a g n u m Net Port Remote Port Battery Temp Sensor Port Figure 20 ME Series Inverter / Charger - Option Connection Ports 24 Ó 2003 - Magnum Energy, Inc.
2. INSTALLATION 4. Options Battery Temperature Sensor Installation and Wiring Attach the ring terminal end of the Battery Temperature Sensor to the negative battery terminal. Route the sensor’s cable to the inverter following existing wire runs. Connect the cable to the 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).
Ó 2003 - Magnum Energy, Inc.
2. INSTALLATION 5. Start-up and Test Connecting the Batteries to the Inverter After all electrical connections have been completed, connect the batteries to the inverter to begin the start-up process. CAUTION: Verify correct battery voltage and polarity before connecting the cables to the inverter. Replace the fuse or (close the breaker) at the DC disconnect. Remove the electrical tape from the cable lugs and verify 12 VDC at the cable connectors using a multimeter.
Configuring the Inverter The ME Series inverter/charger must be configured for Low Battery Cutoff (LBCO), Shore Power Current, Charger Amps, Battery Size and Battery Type. These operational parameters must be configured using the optional remote control.
Table 5 - Factory Default Settings Function Search LBCO Battery Bank Battery Type Charge Rate Contr a s t Ó 2003 - Magnum Energy, Inc.
3. OPERATION Charging / Inverting LED Figure 21 ME Series Inverter / Charger - LED Indicator 28 Ó 2003 - Magnum Energy, Inc.
3. OPERATION 1. Operating the Inverter The ME Series inverter/charger has two modes of operation: INVERTER (providing power to your appliances from the batteries) and AC (running from shore power or a generator). Whenever the inverter is in AC mode, it passes power directly to your appliances as well as recharges the batteries using a 3-stage battery charger (Bulk, Absorption and Float).
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.
3. OPERATION 1. Operating the Inverter, continued Fault or Alarm Conditions The inverter monitors the AC Shore Power, the batteries and itself. Whenever a c o n d i t i o n o c c u r s t h a t i s o u t s i d e t h e n o r m a l o p e r a t i n g p a r a m e t e r s , t h e i n v e r t e r w i l l take the necessary steps to protect your appliances, batteries or itself from damage.
4. TROUBLESHOOTING 1. Basic Troubleshooting T h e M E Se r i e s i n v e r t e r / c h a r g e r i s a f a i r l y s i m p l e d e v i c e t o t r o u b l e s h o o t . T h e r e are only two active circuits (AC and DC) as well as a charging circuit. The following chart is designed to help you quickly pinpoint the most common inverter failures. WARNING: De -energize all sources of power including batteries ( D C ) , shore power ( A C ) , and AC generator (as applicable).
5. PREVENTIVE MAINTENANCE 1. Recommended Inverter and Battery Care T h e M E S e r i e s i n v e r t e r / c h a r g e r i s d e s i g n e d t o p r o v i d e y o u w i t h y e a r s o f t r o u b l e free service. Even though there are no user-serviceable parts, it is recommended that every 6 months you perform the following maintenance steps to ensure optimum performance and extend the life of your batteries. WARNING: Prior to performing these checks, switch both the AC and DC circuits OFF.
6. SPECIFICATIONS ME Series Specifications ME2012 ME2512 ME3012 MODEL ME1512 12 VDC 12 VDC 12 VDC Input Voltage (nominal): Input 12 VDC 10.8-15.5 10.8-15.5 VDC 10.8 -15.5 VDC 10.8-15.5 VDC Voltage (range): Power Rating @ VDC 1500 watts 2000 watts 2500 watts 3000 watts 45°C: Surge Rating: Rated Power: 3000 watts 119 4000 watts 5000 watts 6000 watts Full Vo ltage: Search Mode: amps 0.700 amps 158 amps 198 amps 238 amps Short Circuit: Inverter 0.045 amps 238 0.900 amps 0.
7. WARRANTY 36 Month Limited Warranty Magnum Energy, Inc., warrants the ME Series Inverter / Charger to be free from defects in material and workmanship that result in product failure during normal usage, according to the following terms a n d c o n d i t i o n s : 1. The limited warranty for the product extends for 36 months beginning from the product's original date of purchase. 2.
Remote Control for ME Series Inverter/Chargers Operator’s Manual
Remote Control for ME Series Inverter/Chargers Table of Contents Section Page 1. Overview 2. Installation 2 3 3. Operation 4 Front Panel 5 Rotary Knob 5 Switches 5 Chart 1 - Battery Charge Voltages 6 Chart 2 - A b s orption Times 6 Chart 3 - Factory Default Settings 6 LEDs 8 LCD Display 9 4. Troubleshooting and Specifications 11 5. Warranty 12 SAVE THESE Ó 2003 - Magnum Energy, Inc. INSTRUCTIONS This manual contains important safety instructions.
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2. Installation Installing the ME Series Remote Control 1. Determine a suitable location to mount the remote control. It must be located in a clean, dry and protected place. Allow ample room to access the remote’s adjustment dial and to v i e w t h e L E D s f o r t r o u b l e s h o o t i n g . P r e d r i l l t h e f o u r 1 / 8 ” h o l e s as necessary. 2. Route the 4 wire twisted pair wiring from the inverter/ charger to the remote.
3. Operation Figure 2 Remote Control - Font Panel Ó 2003 - M a g n u m E n e r g y , I n c .
3. Operation, continued ME Series Remote Control - Front Panel The remote control is equipped with a wide range of easy-touse switches and displays, allowing you to quickly setup your inverter/charger as well as determine its operational status. Rotary Knob The Rotary “spin” knob is similar to a dash radio knob and used to easily move between menus to select program options.
Liquid Lead Acid (Flooded) Bulk 14.6 VDC GEL Bulk 14.1 VDC Absorption 14.6 VDC Float 13.4 VDC Equalize 15.5 VDC Absorption 1 4 . 1 VD C Float 13.6 VDC Equalize Disabled* Float 13.1 VDC Equalize 15.5 VDC AGM (Absorbed Glass Mat)** Bulk Absorption 14.3 VDC 14.3 VDC * CAUTION: Never “Equalize” Gel batteries. ** NOTE: AGM voltages are courtesy of Lifeline TM brand batteries.
Chart 2 - Absorption Times (determined by battery bank size selection) Chart 3 - Factory Default Settings Ó 2003 - M a g n u m E n e r g y , I n c .
3. Operation, continued Soft Keys, continued: Setup – Configures the inverter/charg er. Options include: • Search Used to set the search watts at which the inverter will come out of “sleep” mode. Selections are 3-75 watts. • LBCO (Low Battery Cut Out) Used to set the DC voltage level to shut down the inverter and protect the batteries from over-discharge damage. Selections are 9.0 VDC, 10.0 VDC and 11.0 VDC. DC volts must reach and maintain LBCO setting for 1 minute before inverter shut down is initiated.
3. Operation, continued LEDs The remote contains the following LEDs to indicate various modes of operation. PWR (green): OFF - NO AC power from inverter, shore or generator at inverter output terminals ON - AC power available from inverter, shore or generator at inverter output terminals FAULT (red): OFF - Normal operation ON - Inverter or Charger shutdown from: Overtemperature (check tech menu for exact cause), Low Battery Voltage (battery voltage below LBCO setting or lower than 9.
3. Operation, continued LCD DISPLAY INVERTING: OFF Unit is “OFF” with no shore or generator AC power applied. Search – Unit is in search mode. AC loads are less than the search watts setting. Inverting – U n i t i s i n v e r t i n g p o w e r f r o m t h e b a t t e r i e s i n t o 1 2 0 V A C a t its output. CHARGING: Bulk Charge – The battery charger is delivering maximum current to the batteries. The charger will remain in bulk charge until the bulk charge voltage is achieved. See Chart 1.
3. Operation, continued Float – At the end of absorption time, the charger reduces the charge voltage to the float voltage setting for the battery type selected. See Chart 1. Battery SaverTM - “Battery Full” Battery saver mode is a new and unique setting to Magnum Energy’s inverter/chargers. It maintains the batteries without “overcharging” thus preventing excessive loss of water in flooded batteries or drying out of AGM batteries.
4. Troubleshooting and Specifications Fault Conditions Low Battery – The unit has shut down because the battery voltage is below the set point in LBCO. It will automatically restart when battery voltage rises above 12.5 VDC. High Battery – The unit has shut down because the battery voltage has exceeded 15.5 VDC. It will automatically restart when the battery voltage drops below 15.5 VDC.
5. Warranty 36 Month Limited Warranty Magnum Energy, Inc., warrants the ME Series Remote Control to be free from defects in material and workmanship that result in product failure during normal usage, according to the following terms and conditions: 1. The limited warranty for the product extends for 36 months beginning from the product's original date of purchase. 2. The limited warranty extends to the original purchaser of the product and is not assignable or transferable to any subsequent purchaser. 3.
Magnum Service 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.
1.0 TROUBLESHOOTING 1.1 ME SERIES 1.2 RD SERIES REMOTE 1.
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1.1 TOP COVER REMOVAL 2.1.a Top cover is attached with 6 - #10 x 5/8 Torx screws (#25 bit) and 1- #6 x 1/2 Torx screw (#15 bit). Remove all seven screws and pull straight up to remove top cover. 2.2.a 2.2.b Remove top cover per 2.1 Remove 4- #6 x ½ 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.
wires can lead to instant FET board failure upon connecting ac power to the unit. WIRING COLOR 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 ½ 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.
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 2.4.b Remove top cover per 2.1 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.
2.4.e Install new control board in reverse order making sure to line up connector on board edge with FET board connector before pushing down on control board. 2.4.f Re-install Top Cover 2.5.a 2.5.b Remove top cover per 2.1 Remove 2- ¼ x 20 bolts and nuts from inside DC plate 2.5.c Remove 2- #10 x ¾ 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.
2.6 FET BOARD 2.6.a 2.6.b Remove top cover per 2.1 Remove control board per 2.4 2.6.c Remove DC Plate per 2.
2.6.d Remove 2 - ¼ x 20 bolts and nuts from FET board wiring bundles to transformer lugs 2.6.e Remove 1 - #6 x ½ Torx screw from outside edge of FET board and unplug fan connectors 2.6.f 2.6.g Remove 4 - #10 x ¾ Torx screws from FET bar clamps 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 ½ screw to properly align FET board to base 2.6.
2.7.c Use a utility knife or sharp chisel to cut temp sensor loose then clean remaining silicon from transformer 2.7.d 2.7.e Remove 4 corner Phillips head screws holding down transformer Install new transformer being careful to align #10 nylon 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.
2.6 FANS 2.8.a 2.8.b Remove Top Cover per 2.1 Remove 1 - #6 x ½ 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.
2.9 REMOTE 2.8.a 2.8.b Remove front knob (it may be necessary to pry slightly up on knob) Remove 2 Phillips head screws from back of remote 2.8.c Remove circuit board and keypad from case 2.9.
