Magnum MMS Series Man

8/13/2019 Magnum MMS Series Man

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Owners Manual

MMS SeriesInverters/Chargers

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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 MMS Series Inverter/Chargerare beyond the control of Magnum Energy, Inc. Therefore, this companyassumes no responsibility and expressly disclaims any liability forloss, damage, or expense whether direct, indirect, consequential, or

incidental that may arise out of or be in any way connected with suchinstallation, operation, use, or maintenance.

Due to continuous improvements and product updates, the imagesshown in this manual may not exactly match the unit purchased.

Restrictions on Use

The MMS Series Inverter/Charger may only be used in life-supportdevices or systems with the express written approval of MagnumEnergy. Failure of the MMS Series Inverter/Charger can reasonablybe 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 theMMS Series Inverter/Charger fails, it is reasonable to assume thatthe health of the user or other persons may be endangered.

Contact Information

Magnum Energy, Inc.2211 West Casino Rd.Everett, WA 98204Phone: (425) 353-8833Fax: (425) 353-8390Web: www.magnumenergy.com

Record the units model and serial number in case you need to providethis information in the future. It is much easier to record this informationnow, instead of trying to gather it after the unit has been installed.

Model: Serial Number:

MMS1012 U1

MMS1012-G U1

Conventions Used in this ManualTerminology

Shore power or External AC power- refers to alternating current(AC) provided by the utility electric power grid or from a generator.

Mobile application- refers to inverters used in a recreational vehicle(RV), boat, or a truck installation.



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Safety symbols

To reduce the risk of electrical shock, fire, or other safety hazard, thefollowing safety symbols have been placed throughout this manualto indicate dangerous and important safety instructions.

WARNING:This symbol indicates that failure to take aspecified action could result in physical harm to the user.

CAUTION:This symbol indicates that failure to take aspecified action could result in damage to the equipment.

Info:This symbol indicates information that emphasizesor supplements important points of the main text.

IMPORTANT PRODUCT SAFETY INSTRUCTIONS

This manual contains important safety instructions that must be fol-lowed during the installation and operation of this product. Read allinstructions and safety information contained in this manual beforeinstalling 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. DONOT 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., wheninstalling or performing maintenance on the inverter.

Always disconnect the batteries or energy source prior to install-ing or performing maintenance on the inverter. Live power maybe present at more than one point since an inverter utilizes bothbatteries and AC. Turning off the inverter may not reduce thisrisk. As long as AC power is connected, it will pass through theinverter 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 partscontained in this product. Attempting to service the unit yourselfcould cause electrical shock. Internal capacitors remain chargedafter all power is disconnected.

No AC or DC disconnects are provided as an integral part of thisinverter. Both AC and DC disconnects must be provided as partof the system installation.



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No overcurrent protection for the battery supply is provided as anintegral part of this inverter. Overcurrent protection of the batterycables must be provided as part of the installation.

No overcurrent protection for the AC output wiring is provided asan integral part of this inverter. Overcurrent protection of the ACoutput wiring must be provided as part of the installation.

IMPORTANT BATTERY SAFETY INSTRUCTIONS

Wear eye protection (safety glasses) when working with bat-teries.

Remove all jewelry such as rings, watches, bracelets, etc., wheninstalling or performing maintenance on the inverter.

Never work alone. Always have someone near you when workingaround batteries.

Use proper lifting techniques when working with batteries.

Never use old or untested batteries. Check each batterys label forage, type, and date code to ensure all batteries are identical.

Batteries are sensitive to changes in temperature. Always installbatteries in a stable environment.

Install batteries in a well ventilated area. Batteries can produceexplosive gasses. For compartment or enclosure installations,always vent batteries to the outside.

Provide at least one inch of air space between batteries to provideoptimum cooling.

Never smoke when in the vicinity of batteries.

To prevent a spark at the battery and reduce the chance of ex-plosion, always connect the cables to the batteries first. Thenconnect the cables to the inverter.

Use insulated tools at all times.

Always verify proper polarity and voltage before connecting thebatteries to the inverter.

To reduce the chance of fire or explosion, do not short-circuitthe batteries.

In the event of accidental exposure to battery acid, wash thor-oughly with soap and water. In the event of exposure to the eyes,

flood them for at least 15 minutes with running water and seekimmediate medical attention.

Recycle old batteries.

SAVE ALL INSTRUCTIONS

ii



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2010 Magnum Energy, Inc. iii

Table of Contents

1.0 Introduction ..................................................................1

MMS Series Models ............................................................... 1

How an Inverter/Charger Works ............................................. 2

Inverter Applications for Mobile Installations ............................ 2

Advantages of Pure Sine Wave vs Modified Sine Wave Inverter ... 2Appliances and Run Time ....................................................... 2

Standard Features and Benefits .............................................. 3

Battery Temperature Sensor .............................................. 6

2.0 Installation ....................................................................7

Pre-Installation .................................................................... 7

Unpacking and Inspection ...................................................... 7

Locating and Mounting the Inverter ........................................10

Wiring Guidelines ................................................................13

DC Wiring ...........................................................................14

DC Wire Sizing and Overcurrent Protection .........................14

DC Overcurrent Protection ................................................15DC Grounding .................................................................16

DC Cable Connections ......................................................17

Battery Bank Wiring ............................................................18

Inverter to Battery Bank Wiring ............................................18

DC Ground Wire ..............................................................19

DC Negative Wire ............................................................19

Battery Temperature Sensor .............................................19

DC Positive Wire .............................................................19

AC Wiring ...........................................................................20

Neutral to Safety Ground Bonding .....................................20AC Wiring Connections .....................................................21

AC Wire Size and Overcurrent Protection ............................21

AC Input Wiring ..............................................................22

AC Output Wiring ............................................................24

Ground-Fault Circuit Interruption Breakers .........................25

Functional Test ....................................................................25

3.0 Operation ................................................................... 27

Operating Modes .................................................................27

Inverter Mode .................................................................27

Standby Mode ................................................................28

Protection Circuitry Operation ...............................................32Inverter Start-up .................................................................33

ON/OFF Switch ...............................................................33

Status LED Indicator .......................................................33

Factory Default Settings .......................................................34

4.0 Maintenance and Troubleshooting ...............................36

Recommended Inverter and Battery Care ...............................36

RV/Marine Off-Season Storage ..............................................36

Resetting the Inverter ..........................................................37



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List of Figures

Figure 1, MMS1012 Model Inverter/Charger .............................. 1Figure 2, MMS1012-G Model Inverter/Charger ........................... 1Figure 3, Top and Left Side Features ........................................ 4Figure 4, Front and Back Side Features ..................................... 5Figure 5, Battery Temperature Sensor (BTS) ............................. 6Figure 6, MMS1012 Model Basic Installation Diagram ................. 8Figure 7, MMS1012-G Model Basic Installation Diagram .............. 9Figure 8, Approved Mounting Orientations ................................12Figure 9, MMS1012 Model Inverter/Charger Dimensions ............12Figure 10, MMS1012-G Model Inverter/Charger Dimensions .......13Figure 11, DC Cable to Battery Terminals .................................17

Figure 12, DC Cable to Inverters DC Terminals .........................17Figure 13, AC Wiring Connections (MMS1012 model) .................23Figure 14, AC Hardwiring Connections (MMS1012-G model) .......23Figure 15, Automatic 4-Stage Charging Graph ..........................30Figure 16, BTS Temperature to Charge Voltage Change ..............31Figure 17, Resetting the Inverter ............................................37Figure 18, Series Battery Wiring .............................................41Figure 19, Parallel Battery Wiring ............................................42Figure 20, Series-Parallel Battery Wiring ..................................42Figure 21, Battery Bank Wiring Examples (12-volt) ...................43

List of TablesTable 1, Recommended DC Wire/Overcurrent Device .................15Table 2, DC Wire Size For Increased Distance ...........................16Table 3, Wire Color to AC Wire Connection ...............................21Table 4, Minimum Wire Size to Circuit-breaker Size ...................22Table 5, Inverter Battery Turn On/Off Levels .............................33Table 6, Inverter/Charger Default Settings ...............................35Table 7, Troubleshooting Guide ...............................................38Table 8, MMS Series Specifications ..........................................39

Table of Contents

Troubleshooting ..................................................................385.0 Specifications ..............................................................39Appendix A - Optional Equipment and Accessories ............40Appendix B - Battery Information .....................................41Battery Bank Sizing .............................................................41

Battery Types .....................................................................41Battery Configuration ...........................................................41

Series Wiring ..................................................................41Parallel Wiring ................................................................42Series-Parallel Wiring.......................................................42

Appendix C - Warranty/Service Information .....................44Limited Warranty .................................................................44How to Receive Repair Service ..............................................45



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2010 Magnum Energy, Inc. 1

1.0 Introduction

Congratulations on your purchase of an MMS Series inverter/chargerfrom Magnum Energy, Inc. This product is designed especially foryour mobile application. Powerful, yet simple to use, this product willprovide you with years of trouble-free use.

MMS Series ModelsMMS1012 - a 1000 watt inverter/charger with 20 amp AC transfercapability and a 50 amp, 4-stage Power Factor Correction (PFC)charger. The AC input and output are provided with pigtail wires toallow hardwiring to a main AC distribution panel and to an invertersub-panel. Features isolated input/output neutrals for mobileapplications. Includes a 15 battery temperature sensor.

Fi g u r e 1 , MMS 1 0 1 2 M o d e l I n v e r t e r / Ch a r g e r

MMS1012-G - a 1000 watt inverter/charger with 20 amp AC transfer

capability and a 50 amp, 4-stage PFC charger. The AC input isprovided by a standard 3 ft. plug-in power cord, and the AC outputis provided by a standard GFCI two plug outlet. Features isolatedinput/output neutrals for mobile applications. Includes a 15 batterytemperature sensor.

Fi g u r e 2 , MMS 1 0 1 2 - G M o d e l I n v e r t e r / Ch a r g e r

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1.0 Introduction

How an Inverter/Charger Works

An inverter takes direct current (DC) from your batteries and turnsit into alternating current (AC), like you use at home. With MMSSeries models, it also takes alternating current (when connected toa generator or to shore power) and transforms it into direct currentto recharge your batteries.

The two modes of operation associated with this inverter/charger arereferred to in this document as:

Inverter Mode: DC from the batteries is transformed into pure sinewave AC for powering your mobile applications.

Standby Mode: The unit operates as a battery charger to convertincoming AC power into DC power to recharge the batteries while con-tinuing to pass the incoming AC power directly to the inverters outputto power any AC loads.

Inverter Applications for Mobile Installations

Inverters can be used to provide power in mobile situations, such asin an RV, truck, or boat. In these applications, the inverter providespower to the AC loads using the energy stored in the batteries andrecharges the batteries when shore power or an onboard generatoris available.

Advantages of a Pure Sine Wave vs Modified Sine WaveInverter

Todays inverters come in two basic output waveforms: modified sinewave (which is actually a modified square wave) and pure sine wave.

Modified sine wave inverters approximate a pure sine waveform andwill run most appliances and electronics without any problems. Theseinverters are less expensive and, therefore, offer a viable alternativeto more expensive pure sine wave inverters.

The output of a pure sine wave inverter is equal to or, in manycases, better than the shore power used in your home. Virtuallyany electronic device will operate from a pure sine wave inverter.Motors run cooler, microwaves usually cook faster, and clocks keepbetter time just to name a few examples. Without compromisingquality or performance, the MagnaSine provides you with all of theadvantages of a pure sine wave inverter at a much lower cost thanmany on the market.

Appliances and Run TimeThe MMS Series inverter/charger can power a wide range of householdappliances. As with any appliance using batteries for power, thereis a certain length of time that it can run this is called run time.Actual run time depends on several variables including the size andthe type of appliance, the type of batteries installed in your applica-tion, as well as the batterys capacity and age. Other factors such asthe batterys state of charge and temperature can also affect the lengthof time your appliances can run.



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1.0 Introduction

3

Depending on your inverter capacity, larger electrical appliances suchas coffee pots and hair dryers can be used for short durations. How-ever, loads that are used for longer periods such as stoves or waterheaters can quickly drain your batteries and are not recommendedfor inverter applications.

All electrical appliances are rated by the amount of power they

consume. The rating is printed on the products nameplate label,usually located on its chassis near the AC power cord. Even thoughit is difficult to calculate exactly how long an inverter will run a par-ticular appliance, the best advice is trial and error. Your MMS Seriesinverter/charger has a built-in safeguard that automatically protectsyour batteries from being over-discharged.

Standard Features and Benefits

The MMS Series inverter/charger converts 12 volts of 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 invertersbattery bank fully charged. This inverter is designed to allow easyinstallation and use, and with its die-cast aluminum baseplate it en-sures maximum durability and cooler, more efficient operation.

The inverter/charger provides the following:

1000 watts continuous at 25C.

Numerous protection features to provide a safe and peace-of-mind operation.

AC transfer switch circuitry; allowing incoming AC power to con-tinue 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 correctionand temperature compensation for optimum battery charging(using the temperature sensor).

Modern and aesthetically pleasing design with large AC wiringcompartment (provides easy access to AC wiring for simple andquick connections) and 360 DC connection terminals with colorcoded insulating covers.

True RMS output voltage regulation to ensure the inverter will

deliver the correct amount of power within the DC input voltagerange and the continuous output power level.

Quick connection accessory and remote ports easily acceptseveral optional remote controls and the Battery TemperatureSensor.



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Fi g u r e 3 , To p a n d L e f t S i d e Fe a t u r e s

1.Inverter Status Indicator - this green LED illuminates to provideinformation on the inverters operation.

2.Power Switch -momentary pushbutton switch that turns theinverter on or off.

3.Negative DC Terminal (black) - the inverters connection to thenegative terminal on the battery bank.

4.Positive DC Terminal (red) - the inverters connection to thepositive terminal on the battery bank.

5.Input Circuit Breaker - this circuit breaker protects the unitsinternal wiring and pass-thru relay.

6.Output Circuit Breaker -this circuit breaker provides anotherlayer of overload protection. Not a branch circuit-rated breaker.Separate AC output breakers may be required on the output.

7.Mounting Flanges (x4) - secures the inverter to shelf/wall.

8.AC Wiring Compartment - provides access for all AC input andoutput connections on the inverter.

9. AC Output Connection - AC knockout for hardwiring ACoutput.

10.AC Input Connection -Strain relief clamp for hardwiring ACinput. Strain relief comes with an attached flexible AC input powercord on the MMS1012- G model.

11.DC Ground Terminal -this connection is used to tie the exposedchassis of the inverter to the DC grounding system. This terminalaccepts CU/AL conductors from #14 AWG to #6 AWG.

12. GFCI Outlet- Ground Fault Circuit Interrupter outlet (with testand reset capability). Only available on MMS1012-G model.

4

1.0 Introduction

1 2

3

4

5

6

7

8

10 9

11

12



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1.0 Introduction

5

Fi g u r e 4 , Fr o n t a n d B a c k S i d e Fe a t u r e s

13. Warning and Information Label - provides pertinentinformation for safely using the inverter.

14.REMOTE Port Connection -a RJ11 connector that allows anoptional remote control to be connected.

15.ACCESSORY PORT Connection-a RJ11 connector to allow theBattery Temperature Sensor (BTS) or MMS accessories (e.g., MM-DCLD, MM-ISA) to be connected.

16.Intake Vent -ventilation openings to pull in air to keep theinverter cool for peak performance.

17.Exhaust Vent -ventilation openings that allow heated air to beremoved by the internal cooling fan.

18.Model/Serial Number Label -includes model/serial number andprovides specifications and information on the inverter and charger.See the MMS SeriesSpecificationson page 38 for more informa-tion and the different models available.

Front Side

14

13

15

16

Back Side

17

18



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Battery Temperature Sensor

A plug-in external Battery Temperature Sensor (BTS) is providedfor units with the battery charger feature. When installed, the BTSautomatically adjusts the battery chargers BULK, ABSORB, andFLOAT voltage set-points (based on temperature) for better chargingperformance and longer battery life. If the temperature sensor is

NOT installed and the batteries are subjected to large temperaturechanges, battery life may be shortened.

F R ON T V IEW

SIDE VIEW

~2" ~ 1"

~

0.375" diam eterCable

~

Fi g u r e 5 , B a t t e r y T em p e r a t u r e S e n s o r ( B T S)

6

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2.0 Installation

2.0 Installation

Pre-Installation

Before installing the inverter, read the entire Installation section. Themore thorough you plan in the beginning, the better your inverterneeds will be met.

WARNING:Installations should be performed by qualifiedpersonnel, such as a licensed or certified electrician. Itis the installers responsibility to determine which safetycodes apply and to ensure that all applicable installationrequirements are followed. Applicable installation codesvary depending on the specific location and the type ofinstallation.

Info:Review the Important Product Safety Informationon page ii and the Important Battery Safety Instructionson page iii before any installation.

The basic system diagrams shown in Figures 6 and 7 should bereviewed to assist you in planning and designing your installation.

Unpacking and Inspection

Carefully remove the MMS Series inverter/charger from its shippingcontainer and inspect all contents. Verify the following items areincluded:

MMS 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) MMS Series Owners Manual

If items appear to be missing or damaged, contact your authorizedMagnum Energy dealer or Magnum Energy.

If at all possible, keep your shipping box. It will help protect yourinverter from damage if it ever needs to be returned for service.

Save your proof-of-purchase as a record of your ownership; it willalso be needed if the unit should require in-warranty service.

Record the units model and serial number in the front of this manualin case you need to provide this information in the future. It is mucheasier to record this information now, instead of trying to gather itafter the unit has been installed.



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Fi g u r e 6 , MMS 1 0 1 2 M o d e l Ba s ic I n s t a l l a t i o n D i a g r am

A C

M a i n P a n e l

D Cd isconnect

a n d

overcurrentdev ice

Battery

Bank

A C IN

A C Loads

A C

Sub -Pane l

(optional)

A C

Out let

A C

OU T

D C

Ground

VC R

T V Tools

Installation

8



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Installation

9

Fi g u r e 7 , MMS1 0 1 2 - G Mo d e l B a si c I n s t a l l a t i o n D i a g r am

D Cdisconnec t

a n dovercurrent

dev ice

Battery

Bank

A C IN

A C Loads

A C

OU T

D CGround

VC R

T V Tools



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2.0 Installation

10

Locating and Mounting the Inverter

WARNINGS:

Do not mount the inverter near any flammable orcombustible 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 thefollowing requirements:

Clean and Dry- The inverter should not be installed in an area thatallows dust, fumes, insects, or rodents to enter or block the invertersventilation openings. The area also must be free from any risk ofcondensation, water, or any other liquid that can enter or fall on theinverter. The inverter uses stainless steel fasteners, plated copper

busbars, and a power-coated aluminum base. Also, the internal circuitboards are conformal coated. The above measures are undertakento help fight the harmful effects of corrosive environments. However,the life of the inverter is uncertain if used in any of these types ofenvironments, and inverter failure under these conditions is not coveredunder warranty.

Cool- The inverter should be protected from direct exposure to thesun or any equipment that produces extreme heat. The ambient airtemperature should be between 32 F (0 C) and 104 F (40 C);keep in mind 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 powerand avoid over-temperature fault conditions do not cover or blockthe inverters ventilation openings, or install this inverter in an areawith limited airflow. Allow as much clearance around the invertersintake and exhaust ventilation openings as possible, see Items 16and 17 in Figure 4. At the minimum, allow an airspace clearance of6 (15 cm) at the front and back, and 3 (7.5 cm) everywhere elseto 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 allowcool air from the outside to flow into the inverter, and heated air toexit away from the inverter and the enclosure. When mounted in anenclosed compartment, airflow must be at least 59 cfm in order tomaintain 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.



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Safe- Keep any flammable/combustible material (e.g., paper, cloth,plastic, etc.) that may be ignited by heat, sparks, or flames at aminimum distance of 2 feet (60 cm) away from the inverter.

WARNING: The MMS Series Inverter/Charger is notan ignition-protection rated device and should not beinstalled in any location that requires ignition-protected

equipment. To prevent fire or explosion, do not installthe MMS Series in any area with extremely flammableliquids like gasoline or propane; or, in an area thatcontains connections between components of a fuelsystem.

Close to the battery bank - As with any inverter, it should belocated as close to the batteries as possible. Long DC wires tend tolose efficiency and reduce the overall performance of an inverter.However, the unit should not be installed in the same compartment asthe batteries or mounted where it will be exposed to gases produced

by the batteries. These gases are corrosive and will damage theinverter. 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 inverters remote controland accessory ports. Also, allow enough room to access the ACand DC wiring connections, as they will need to be checked andtightened periodically. See Figure 9 & 10 for the MMS Series inverterdimensions.

Mounting Orientation -To meet regulatory requirements, the MMSSeries 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 8. The inverter must bemounted on a non-combustible surface, and this surface and themounting hardware must be capable of supporting at least twice theweight of the inverter. After determining your mounting position,use the base of the inverters chassis as a template to mark yourmounting screw locations. Remove the inverter and drill pilot holesinto the mounting surface.

If this unit is used in a mobile application, you may want to placeflexible washers or bushings between the mounting surface and theinverters mounting flanges to reduce vibration.

After the inverter has been properly mounted, proceed to the DCWiring section.

2.0 Installation

11



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2.0 Installation

Fi g u r e 9 , MMS 1 0 1 2 M o d e l I n v e r t e r / Ch a r g e r D im e n s io n s

Mount ing ho les x 4

[ (0 .25 ") d iameter ]

10 .0 "~ 16 5/8 "

(16.59")

~ 6 3/4 " (6.71")

~ 8 7/16" (8 .41")

~ 7 " (7 .51")

~ 4 "(4 .625")

Shelf Mounted

(right-side up)

Shelf Mounted

(up-side down)

Wall Mounted (up-side down)

Wall Mounted (right-side up)

Fi g u r e 8 , A p p r o v e d MMS 1 0 1 2 ( - G ) M o u n t i n g O r ie n t a t i o n s



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Wiring Guidelines

Before connecting any wires, determine all wire routes to andfrom the inverter throughout the RV, vehicle, or boat.

Conductors passing through walls or other structural membersmust 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 ofpotential damage prior to making cuts in structural surfaces orwalls.

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 partof the installation.

Fi g u r e 1 0 , MMS1 0 1 2 - G M o d e l I n v e r t e r / Ch a r g e r D i m e n s io n s

2.0 Installation

~ 16 5/8"

(16.59")

~ 6 (6.71")

10 "

~ 5 "

(5 .125")

~ 4

(4 .625")

~ 5 "

Mount ing holes x 4

[ (0.25") diameter]

~ 7 (7.51")

~ 8 7/16 (8.41")

13



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DC Wiring

This section describes the MMS Series inverters required DC wire sizesand the recommended disconnect/overcurrent protection, and how tomake 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 withoverheating. See Table 1 to select the minimum DC wire size neededbased on your inverter model. If the distance from the inverter to thebattery bank is greater than 3 feet, use Table 2 to help determinethe minimum recommended cable sizes for longer distances. Always

keep your wire runs as short as practical to help prevent low voltageshutdowns, and keep the DC breaker from nuisance tripping (or openfuses) because of increased current draw. Undersized cables can alsolower the inverters peak output voltage, as well as reduce its abilityto surge heavy loads.

Info:The DC wires must be color coded with coloredtape or heat shrink tubing; RED for positive (+), BLACKfor negative (-), and GREEN for DC ground.

14

2.0 Installation

The DC wires must have soldered and crimped lugs, crimped coppercompression lugs, or aluminum mechanical lugs. Soldered connec-tions alone are not acceptable for this application.

Do not attempt to use a vehicle metal frame in place of the nega-tive connection or DC ground. The inverter requires a reliablenegative and ground return path directly to the battery.DC wires and cables should be tied together with wire ties orelectrical tape approximately every 6 inches. This helps improvethe surge capability and reduces the effects of inductance,

which improves the inverter waveform and reduces wear on theinverters filter capacitors.Use only copper wires with a minimum temperature rating of75C.

To ensure the maximum performance from the inverter, all con-nections from the battery bank to the inverter should be mini-mized; the exceptions are the DC overcurrent disconnect in thepositive line.



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2.0 Installation

15

Table 1, Recommended DC Wire/Overcurrent Device

Info:The term in free air is defined by the NEC as notencased in conduit or raceway.

If the inverter is expected to operate at a distance greater thanthree feet from the battery bank, the DC wire size will need to beincreased to overcome the increase in resistance which affects theperformance of the inverter. Continue to use the overcurrent deviceand DC ground wire previously determined from Table 1 and then,refer to Table 2 to determine the minimum DC wire size you need forvarious distances based on your inverter model.

DC Overcurrent ProtectionFor safety and to comply with NEC (National Electrical Code) electricalcode regulations, you must install a DC overcurrent protection devicein the positive DC cable line to protect your DC cables. This DCovercurrent device can be a fuse or circuit-breaker, but must be DCrated. It must be correctly sized according to the size of DC cablesbeing used, which means it is required to open before the cablereaches its maximum current carrying capability, thereby preventinga fire.See Table 1 to select the DC overcurrent device based on theminimum wire size for your inverter model.

Note 1 - Maximum Continuous Current is based on the inverters continuouspower rating at the lowest input voltage with an inefficiency factor.Note 2 - Per the NEC, the DC grounding electrode conductor can be a #6 AWGconductor if that is the only connection to the grounding electrode and thatgrounding electrode is a pipe, rod, or plate electrode.Note 3 - Wire size is based on the requirements needed to increase efficiencyand reduce stress to the inverter.Note 4 - The next larger standard size overcurrent device may be used ifthe de-rated cable ampacity falls between the standard overcurrent devicesfound in the NEC.

Inverter Model

MMS1012 MMS1012-G

Maximum Continuous

Current 200 amps 200 amps

DC GroundingElectrode Wire Size

# 6 AWG # 6 AWG

Minimum DC Wire Size(90C rating in free air)

# 1/0 AWG(260 amps)

# 1/0 AWG(260 amps)

Maximum DCFuse Size

300 amps withtime delay

300 amps withtime delay



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Electrical systems in mobile installations typically do not require usinga DC disconnect, although an overcurrent protection device is stillrequired. Because the DC disconnect is not required, a fuse is usuallyused as the disconnect device in these installations. These installationsalso do not normally use conduit, so the fuse must be installed in the

ungrounded conductor (usually the positive DC cable line) within 18inches 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 allows for momentary current surges from theinverter without opening.

DC Grounding

The inverter/charger should always be connected to a permanent,grounded wiring system. The idea is to connect the metallic chassisof the various enclosures together to have them at the same voltage

potential, which reduces the possibility for electric shock. For themajority of installations, the inverter chassis and the negative batteryconductor are connected to the systems ground bond via a safety-grounding conductor (bare wire or green insulated wire) at only onepoint in the system. Per the NEC, the size for the grounding conductoris usually based on the size of the overcurrent device used in the DCsystem. Refer to Table 1 to select the appropriate DC ground wirebased on the overcurrent device used for your inverter model.

If the inverter is in a vehicle, DO NOT connect the battery negative(-) cable to the vehicles safety ground. Only connect to the invertersnegative battery terminal. If there are any non-factory installedappliances onboard the vehicle, DO NOT ground them at safetyground. Only ground them at the negative bus of the DC load center(as applicable).

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

MMS1012 #1/0 AWG #1/0 AWG #2/0 AWG #4/0 AWG

MMS1012-G # 1/0 AWG #1/0 AWG #2/0 AWG #4/0 AWG

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17

Fi g u r e 1 1 , DC Ca b l e t o B a t t e r y T e r m i n a l s

DC Cable Connections

When connecting the DC cable to the battery or to the inverters DCterminals, the hardware should be installed in the correct order toprevent high resistance connections from heating up and possiblycausing the connections to melt. Follow Figures 11 and 12 to stackthe hardware correctly. Tighten the terminal connections from 10 to

12 foot-pounds.CAUTION:Dont put anything between the DC cable ringlug and the battery terminal post or the inverters DCterminal. If antioxidant grease or spray is used, apply itafter all the connections have been made and are properlytightened.

CAUTION:Overtightening or misthreading nuts on the DCterminals will cause the bolts to strip and snap/break-off.

CAUTION:The inverter is NOT reverse polarity protected(negative and positive connected backwards). You mustverify the correct voltage polarity BEFORE connecting theDC wires or damage may occur.

Crimped and sealed copper ring terminal lugs with a 5/16 hole shouldbe used to connect the DC wires to the inverters DC terminals.

Fi g u r e 1 2 , DC Ca b l e t o I n v e r t e r s DC T e r m i n a l s

B A T T E R Y

DC cablewith ring lug

bolt

flat washer

nut

lock wa sher

batterypost

battery terminal

Tem perature sensor

Verify that theDC cable lugs are flush

with the battery terminals.T orque the battery terminals

from 10 to 12 foot-pounds.

DC cablewith ring lug

D Cterminal cover

(snaps on)

InvertersDC termina l

5/16 (Kepnut with star-washer) or

Flange nut



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Battery Bank Wiring

WARNING:Lethal currents will be present if the positiveand negative cables attached to the battery bank touch eachother. During the installation and wiring process, ensurethe cable ends are insulated or covered to prevent touch-

ing/shorting the cables.Info:DO NOT connect the DC wires from the battery bankto the inverter until: 1) all DC/AC wiring is complete, 2)the correct DC and AC overcurrent protection have beeninstalled, and 3) the correct DC voltage and polarity havebeen verified.

Info:For optimum performance, a minimum battery bankof 200 AHr is recommended.

Depending upon the type of batteries you use in the installation (6or 12 VDC), the batteries must be wired in series, parallel, or series-parallel (see Appendix B - Battery Information, for guidance on wiringbatteries together). The interconnecting DC wires must be sized andrated exactly the same as those that are used between the batterybank and the inverter.

Place the batteries as close as practical to the inverter, preferably inan insulated and ventilated enclosure. Allow adequate space abovethe batteries to access the terminals and vent caps (as applicable).Also, allow at least 1 of space between the batteries to provide goodair flow. DO NOT mount the batteries directly under the inverter.

Info:To ensure the best performance from your invertersystem do not use old or untested batteries. Batteriesshould be of the same size, type, rating, and age.

CAUTION:Install batteries in a well ventilated area. Bat-teries can produce explosive gasses. For compartmentor enclosure installations, always vent batteries to theoutside.

Inverter to Battery Bank Wiring

WARNING: Ensure all sources of DC power (i.e., bat-teries) and AC power (shore power or AC generator) arede-energized (i.e., breakers opened, fuses removed)before proceeding.

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19

CAUTION: The inverter is NOT reverse polarity pro-tected. If this happens, the inverter will be damaged andwill not be covered under warranty. Before connectingthe DC wires from the batteries to the inverter, verifythe correct battery voltage and polarity using a voltme-ter. If the positive terminal of the battery is connected

to the negative terminal of the inverter and vice versa,severe damage will result. If necessary, color code thecables with colored tape or heat shrink tubing; RED forpositive (+), and BLACK for negative (-) to avoid polar-ity confusion.

Info: The DC overcurrent device (i.e., fuse or circuitbreaker) must be placed in the positive (RED) DC cableline between the inverters positive DC terminal andthe batterys positive terminal (RED); as close to thebattery as possible.

DC Ground WireRoute an appropriately sized DC grounding wire (GREEN or bare wire)from the inverters DC Ground Terminal (see Figure 3, Item 11) to adedicated system ground. Recommended tightening torque is 45 in.lbs.

DC Negative Wire

Route an appropriately sized DC negative wire (BLACK) from thenegative terminal of the first battery string to the inverters negativeterminal (see Figure 21 for reference).

Battery Temperature Sensor

Connect the RJ11 connector end of the BTS to the ACCESSORY PORT(see Figure 4, Item 15) on the inverter. Connect the other end of theBTS to the negative terminal of the first battery string (in same place asthe negative DC wire above); refer to Figure 11 for the correct hardwareplacement.

DC Positive Wire

Mount the DC fuse block and disconnect (or circuit breaker assembly)as near as practical to the batteries, and then open the disconnect(or circuit breaker).

WARNING: DO NOT close the DC fuse/DC disconnect (orclose the DC circuit breaker) to enable battery power tothe inverter at this time. This will occur in the FunctionalTestafter the installation is complete.

Route and connect an appropriately sized DC positive wire (RED) fromthe DC fuse block (or circuit breaker assembly) to the inverters posi-tive DC terminal.



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Neutral to Safety Ground Bonding

The NEC (National Electric Code)/CEC (Canadian Electrical Code)provide the standards for safely wiring mobile (RV, boat, or truck)installations. These wiring standards require the AC source (inverter,shore power, or a generator) to have the neutral conductor tied to

ground. These standards also require that the AC neutral be con-nected to safety ground (often called a bond) in only one place atany time. If more than one bond is established, currents can circulatebetween neutral and ground and cause ground-loop currents. Theseground-loops can trip GFCIs and cause an electric shock hazard.

In mobile installations, there may be multiple AC sources (i.e., shorepower, generator, or inverter), which means there may be the poten-tial of having multiple neutral to ground connections.

AC Wiring

This section describes the MMS Series required AC wire size andovercurrent protection. It also provides information on how to makethe AC connections.

Info: The MMS1012-G modelhas a power cord forAC input and dual outlets on top of the inverter for ACoutput, however, it has hardwiring capability as well.

WARNING: All wiring should be done by a qualifiedperson or a licensed electrician following all local/NECcodes.

Connect a short wire (same rating as the DC wires) to one end of thefuse block and the other end of the short wire to the positive terminalof the last battery string (see Figure 21). This is essential to ensureeven charging and discharging across the entire battery bank.

Ensure the DC wire connections (to batteries, inverter, and fuse lugs/DCcircuit breaker) are flush on the surface of the DC terminals, and the

hardware (lock washer and nut) used to hold these connections arestacked correctly (see Figures 11 and 12).

Verify all DC connections are torqued from 10 to 12 foot-pounds.

Once the DC connections are completely wired and tested, coat theterminals with an approved anti-oxidizing spray.

Press the red and black terminal covers onto the inverters DC con-nectors to secure them in place.

If batteries are in an enclosure, perform a final check of the holddown brackets and all connections. Close and secure the batteryenclosure.

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2.0 Installation

The AC wires inside the AC compartment are #16 AWG with a tem-perature rating of 105 C. All AC connections should be made usingan approved connector for your application (e.g., split bolt, twist-onwire connectors, etc.). Ensure the wire connectors used are rated forthe size and number of wires you are connecting.

After connecting the wires together, gently pull on the wires to ensurethey are securely held together. In a proper connection, no bare wireshould be exposed.

Info:Per UL certification, non-metallic sheathed cable(i.e., Romex) or an SO flexible cord with listed strainreliefs are allowed to be used to connect to the inverter;conduit connections are not allowed.

After all AC wiring in the inverter is complete (and before reattachingthe AC access cover), ensure all connections are correct and secure.

Wire color (label) Wire connection

Black (HOT IN) Hot In

White (NEUT IN) Neutral In

Red (HOT OUT) Hot OutWhite with black

stripe (NEUT OUT) Neutral Out

AC Ground Green (GROUND) AC IN and AC OUT Ground

AC IN

AC OUT

Table 3, Wire Color to AC Wire Connection

AC Wiring Connections

For the MMS1012 model, the AC input and output wiring is performedin the AC wiring compartment. This compartment is accessed viathe top panel (see Figure 3, Item 8). If the panel cover is installed,remove the two Phillips screws on the cover to access the AC wiringcompartment and locate the inverters AC wiring. There is a label

located in the AC access compartment which gives information onwhich wires are used for AC input and output. You can also refer toTable 3 to match the inverters AC wires to the appropriate AC wireconnection.

AC Wire Size and Overcurrent Protection

The AC input and output wiring must be sized per the NEC and localelectrical safety code requirements to ensure the wires ability tosafely handle the inverters maximum load current. After determiningthe proper AC wire sizes, the inverters AC input (unless you are usinga flexible cord) and output wires are required to be protected againstovercurrent and have a means to disconnect the AC circuits.



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AC Input WiringYour inverter has an AC transfer feature that passes the AC inputpower to the inverters output. Connection to the AC input is madeby hardwiring from a distribution panel as described below:

1. Run an appropriately sized 2-conductor plus ground cable (fromthe AC distribution panel) through the strain relief clamp on the ACIN opening (Figure 3, Item 10). Refer to Table 4 for minimum wiresize and overcurrent protection required for the AC input wiring.

2. Remove about two inches of the insulating jacket from the ACcable, and then separate the three wires and strip about 3/4 of

insulation from each wire.3. Using approved AC wire connectors, connect the incoming HotIn, Neutral In, and Ground wires to the MMS Series AC wirescolored black (HOT IN), white (NEU IN), and green (AC GROUND)respectively.

4. After making the AC input connections, secure the AC input cableby tightening the strain relief clamp.

The AC input wiring in the inverter is complete. Review all AC wiringto ensure all connections are correct and secure.

Table 4, Minimum Wire Size to Circuit-breaker Size

All inverter AC input and output wiring is required to be protected by anovercurrent protection device. Overcurrent protection must be providedby fuses or circuit-breakers, and must be properly sized and rated forthe wire they are protecting and the appliances being powered.

Most inverters that are hardwired use a service/distribution panelwired to the inverters input (main panel), and a dedicated panel

between the inverters output wiring and the AC loads (sub-panel).These systems use the circuit breakers provided in the panels as theovercurrent protection and the AC disconnect. If fuses are used, thenseparate AC disconnect switches will be needed.

Based on information from the NEC, Table 4 provides the minimumAC wire size and the suggested breaker size based on the invertermodel. However, a larger wire size may be required because of volt-age drop. The AC wire sizes provided in this table assume using onlycopper wire and a temperature rating of 75 C or higher. A minimumof #14 AWG is required for all AC wiring.

InverterModel

AC Input AC Output

InputBreaker

MinimumWireSize

SuggestedBreaker

Size

OutputBreaker

MinimumWireSize

SuggestedBreaker

Size

MMS1012 20 amps #12 AWG 20 amps 15 amps #14 AWG 15 amps

MMS1012-G

20 amps #12 AWG 20 amps 15 amps #14 AWG 15 amps

22



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2.0 Installation

A C IN A C O UT

Strainreliefs

A CGroundIn/Out(green)

Neutra lIn (white)

H otOut(red)

N eutra l O ut(whi te w/b lack

str ipe)

H otIn

(black)

Fi g u r e 1 3 , A C W i r i n g Co n n e c t i o n s ( MMS 1 0 1 2 m o d e l )

Info:The MMS1012-G modelhas a power cord for ACinput and a factory-installed dual outlet on top of theinverter for AC output.

Fi g u r e 1 4 , A C H a r d w i r in g Co n n e c t i o n s ( MMS 1 0 1 2 - G m o d e l )

A C IN A C O UT

Strain

reliefs

A CGround

Out (green)

NeutralIn (whi te)

H otOut( red)

NeutralOut (whi te

w/bla ck st ripe)

H otIn

(black)

A CGroundIn (green)



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2.0 Installation

24

AC Output Wiring

CAUTION:The inverters AC output must never be con-nected to an AC power source. This will cause severedamage to the inverter and is not covered under war-ranty.

Info:When using the MMS Series inverter in an RV ap-plication, under certain conditions and provided that thewire is properly sized for the protecting breaker; RVIAwiring standards will permit the breaker in the Main dis-tribution panel and/or the supplemental breakers on theinverter to provide adequate protection for the AC outputwiring. For more information on these requirements, referto the RVIA (www.rvia.org).

Follow the steps below to hardwire the AC output of the MMS Seriesinverter:

1. Remove the 1/2 knockout on the AC Output Connection (see Figure3, Item 9) use a utility knife to cut thru the round slot.

2. Discard this knockout and install a 1/2 strain relief in the AC OUTopening. You may need to file the opening edge for proper fit.

3. Run a 2-conductor plus ground cable through the strain relief inthe AC OUT opening. Refer to Table 4 for the minimum wire size andthe overcurrent protection required for the AC output wiring.

4. Remove about two inches of the insulating jacket from the ACcable, and then separate the three wires and strip about 3/4 ofinsulation from each wire.

5. Using approved AC wire connectors, connect the outgoing HotOut, Neutral Out, and AC Ground wires to the inverters AC wirescolored red (HOT OUT), white with black stripe (NEU OUT), andgreen (AC GROUND) respectively. Gently pull on the wires to ensurethey are securely held together, and check to see that no bare wireis exposed.

6. After making the AC output connections, secure the AC outputcable by tightening the strain relief.

7. Connect the outgoing AC wires to either:

a. an AC load sub-panel equipped with overcurrent protection(e.g., circuit breakers), or

b. directly to the circuit, when following RVIA requirements thatpermit using breakers from the main distribution panel or thebreakers on the inverter under certain conditions.

The AC output wiring in the inverter should be complete. Beforereattaching the AC access cover, review all AC wiring to ensure allconnections are correct and secure.



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25

Ground-Fault Circuit Interruption (GFCI) Breakers

If installing this inverter in the wiring system of a mobile application(RV, boat, or truck), a Ground Fault Circuit Interrupter (GFCI) mustbe installed to protect all branch circuits powered by this inverter. Incompliance with UL standards, Magnum Energy tested the followingGFCIs and found that they function properly when connected to the

inverters AC output.

Shock SentryTM#XGF15V-SPLeviton Smart Lock #8899-AHubbel #GF520EMBKA

WARNING: Risk of electric shock. Use only the GF-CIs [receptacles or circuit breaker(s)] specified in thismanual. Other types may fail to operate properly whenconnected to this inverter.

Functional Test

After all electrical connections to the inverter, batteries, AC source,and loads (using a sub-panel) have been completed, follow thesesteps to test the installation and the inverters operation.

1. Check the battery voltage and polarity before connecting the bat-teries to the inverter. Use a multimeter to verify 10 to 14 VDC at thebatteries positive and negative terminals.

2. Apply battery power to the inverter by switching the DC disconnectON (or close the DC circuit-breaker). The inverter will remain OFF,but the green status indicator on the front of the inverter will quickly

blink once to indicate that DC power has been connected and is readyto be turned on.

3. Prior to turning on the inverter, make sure all connected loads (e.g.,appliances) are switched OFF or disconnected from the AC outlets.

4. a. If a remote switch is connected, press the ON/OFF switch toturn the inverter on.

b. If there is not a remote switch connected, lightly press andrelease the inverters ON/OFF power switch located on the top ofthe inverter to turn the inverter on.

Verify the inverters status indicator is blinking indicating the in-

verter is providing AC power.

5. Check the output voltage of the inverter by connecting a true RMSmultimeter to the outlets powered by the inverter. Verify the voltageis 120 VAC +/- 5 VAC. If not using a true RMS meter the output ACvoltage could indicate from 90 to 130 VAC, depending on the bat-tery voltage.



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6. Turn on or connect a load to the outlets and verify it comes on.Continue to keep the load connected and turned on.

7. Press the remote ON/OFF switch to turn the inverter off. If theremote is not used, press and release the inverters ON/OFF powerswitch to turn the inverter off. The inverters status indicator and theconnected load should go off.

8. Apply AC power to the inverters AC input. After the AC input poweris qualified (approximately 15 seconds), the incoming AC power willtransfer through the inverter to the inverters AC output and powerthe connected load. Verify the inverters status indicator and theconnected load comes on.

9. Even though the connected load is on, the inverter is currentlydisabled/off. Press the remotes ON/OFF switch (or press and re-lease the ON/OFF power switch on the inverter) to enable/turn onthe inverter.

10. Disconnect the incoming AC power to the inverter. Verify the con-nected load remains on, but now is powered by the inverter.

If the inverter passes all the steps, the inverter is ready for use.

If the inverter fails any of the steps, refer to the Troubleshootingsection.



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3.0 Operation

Operating Modes

The MMS Series inverter/charger has two normal operating routines;Inverter Mode, which powers your loads using the batteries, andStandby Mode, which transfers the incoming AC power (i.e., shore

power or a generator) to power your loads and also uses this incomingpower to recharge the batteries. This inverter also includes an exten-sive protection circuitry that shuts down the inverter under certainfault conditions.

Inverter Mode

When the inverter is first powered up, it defaults to the OFF mode. Themomentary ON/OFF power switch (Figure 3, Item 2) must be lightlypressed to turn the inverter ON. Subsequently pressing this switchalternately turns the inverter OFF and ON.

Inverter OFF- When the inverter is OFF, no power is used from

the batteries to power the AC loads and the status LED will beOFF. If AC power from an external source (shore power or genera-tor) is connected and qualified on the inverters AC input, this ACinput power will pass through the inverter to power the AC loads.However, if this AC power is lost, the AC loads will no longer bepowered because the inverter is OFF.

When the inverter is turned ON, it operates either by Searchingor Inverting, depending on the connected AC loads.

Searching- When the inverter is first turned ON, the automaticSearch feature is enabled. This feature is provided to conservebattery power when AC power is not required. In this mode, the

inverter pulses the AC output looking for an AC load (i.e., electricalappliance). Whenever an AC load (greater than 5 watts) is turnedon, the inverter recognizes the need for power and automaticallystarts inverting. When there is no load (or less than 5 watts) de-tected, the inverter automatically goes back into Search Mode tominimize energy consumption from the battery bank. When theinverter is Searching, the inverters green LED flashes (fast).

Info:The factory default value for the Search featureis 5 watts. It can be turned off or adjusted from 5 to 50watts using the ME-RC50 remote display.

Inverting- When a load greater than 5 watts is connected tothe inverter output, the MMS Series inverts the DC power fromthe battery and supplies 120 VAC power to your sub-panel. Theinverters green LED flashes once every 2 seconds (medium flash)to indicate it is inverting. The amount of time the inverter can beinverting and providing power is directly related to the amountof AC loads that are connected and the capacity of the batterybank.

3.0 Operation

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3.0 Operation

28

Standby Mode

The MMS Series features an automatic transfer relay and an internalbattery charger when operating in Standby Mode. Standby Modebegins whenever AC power (shore power or generator) is connectedto the inverters AC input. Once the AC voltage and frequency of theincoming AC power is within the AC input limits, an automatic AC

transfer relay is activated. This transfer relay passes the incoming ACpower through the inverter to power the AC loads on the invertersoutput. This incoming power is also used to activate a powerful in-ternal battery charger to keep the battery bank charged in case ofa power failure.

Battery charging- The MMS Series models are equipped with anactive Power Factor Corrected (PFC) multi-stage battery charger. ThePFC feature is used to control the amount of power used to chargethe batteries in order to obtain a power factor as close as possible to1 (or unity). This causes the battery charger to look like a resistor tothe line (forces the charge current waveshape to mirror the voltage

waveshape). This feature maximizes the real power available fromthe AC power source (shore power or generator), which translatesinto less power wasted and a greater charging capability than mostchargers available today.

When an AC power source is connected to an inverter that has abattery charger, the inverter monitors the AC input for acceptablevoltage. Once the inverter has accepted the AC input, the AC transferrelay will close and charging will begin. Once charging, the DC voltageis monitored to determine the charging stage. If the DC voltage is low(12.9 VDC), the charger begins bulk charging. If the DC voltage ishigh (>12.9 VDC), the charger skips the initial Bulk/Absorb Chargingstages and goes directly to float charging.

The multi-stage charger can use up to five different charging stagesto help monitor and keep the batteries healthy. The five stagesinclude an automatic 4-stage charging process (Bulk, Absorb, Float,and Full Charge), and a manual Equalization (EQ) charge stage. Theautomatic 4-stage charge process provides complete recharging andmonitoring of the batteries without damage due to overcharging (seeFigure 15). The Equalization stage (requires the ME-RC50 remote)is used to stir up stratified electrolyte and reverse any battery platesulfation that might have occurred.

While charging, the unit may go into Charger Back-offprotectionwhich automatically reduces the charge current to the batteries.This is caused by:

1. The internal temperature is too hot the charger automaticallyreduces the charge rate to maintain temperature; or,

2. The AC input voltage falls < 85 VAC the charger reduces the chargecurrent to zero to help stabilize the incoming AC voltage; or

3. FET Temperature.



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The automatic 4-stage charging process includes:

Bulk Charging:This is the initial stage of charging. While bulkcharging, the charger supplies the battery with constant current.The charger remains in bulk charge until the absorption chargevoltage is achieved (14.6 VDC)* as determined by the BatteryType selection**.

Absorb Charging:This is the second charging stage and beginsafter the bulk voltage has been reached. Absorb charging pro-vides the batteries with a constant voltage and reduces the DCcharging current in order to maintain the absorb voltage setting.The absorb charging time is 120 minutes as determined by theBattery AmpHrs selection**.

Float Charging:The third charging stage occurs at the end ofthe absorb charging time. While float charging (also known as amaintenance charge), the batteries are kept fully charged andready if needed by the inverter. The Float Charging stage reduces

battery gassing, minimizes watering requirements (for floodedbatteries), and ensures the batteries are maintained at optimumcapacity. In this stage, the charge voltage is reduced to the floatcharge voltage (13.4 VDC)* as determined by the Battery Typeselection** which can maintain the batteries indefinitely.

Full Charge (Battery Saver mode):The fourth stage occursafter four hours of float charging. The Full Charge stage maintainsthe batteries without overcharging, preventing excessive loss ofwater in flooded batteries or drying out of GEL/AGM batteries. Inthis stage, the charger is turned off and begins monitoring thebattery voltage. If the battery voltage drops low (12.7 VDC),

the charger will automatically initiate another four hours in floatcharge.

* These voltage settings are based on the Battery Temperature Sensor(BTS) being disconnected, or at a temperature of 77 F (25 C). If the BTSis installed, these voltage settings will increase if the temperature aroundthe BTS is below 77 F (25 C), and decrease if the temperature around theBTS is higher than 77 F (25 C).

** The MMS Series uses changeable settings (see Table 6, Inverter DefaultSettings) that are adequate for most installations. However, if you determinethat some of your operating parameters need to be changed, the ME-RC50remote control can be purchased to allow changes to those settings.

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ConstantCurrent

ReducedCurrent

ReducedVoltage

Absorb volts

AdjChargeRate

Setting

IncreasedVoltage

ConstantVoltage

MonitoredVoltage

No Current

Time

Floatvolts

MonitoredCurrent

Absorb Time(determined bythe Adj Batt

AmpHrs setting)

Bulk

Charging

Absorb

Charging

Float

Charging

DCVoltage

DCCurrent

Full

Charge

Goes to FullCharge after 4

hours in FloatCharge

Absorb and F loat voltage settings are

determined by the Battery Type selection

Fi g u r e 1 5 , A u t om a t i c 4 - S t a g e Ch a r g i n g G r a p h

Transfer time- While in Standby Mode, the AC input is continuallymonitored. Whenever AC power falls below the VAC dropout voltage(80 VAC, default setting), the inverter automatically transfers backto Inverter Mode with minimum interruption to your appliances aslong as the inverter is turned on. The transfer from Standby Mode toInverter Mode averages approximately 16 milliseconds. While the MMSSeries is not designed as a computer UPS system, this transfer timeis usually fast enough to hold them up. However, the VAC dropout

setting has an effect on the ability of the loads to transfer withoutresetting. The lower this setting, the longer the effective transferwill be and therefore, the higher the probability for the output loadsto reset. This occurs because the incoming AC voltage is allowed tofall to a level that is so low that when the transfer does occur, thevoltage on the inverters output has already fallen to a low enoughlevel to reset the loads.

The disadvantage of a higher VAC dropout setting is that smallergenerators (or large generators with an unstable output) may nui-sance transfer. This commonly happens when powering loads thatare larger than the generator can handle causing the generators

output voltage to constantly fall below the inverters input VAC drop-out threshold.

Info:You must use the ME-RC50 or ME-ARC50 remoteto adjust the VAC dropout setting which in turndetermines the VAC dropout threshold.

Info:When switching from Inverter Mode to StandbyMode, the inverter waits approximately 15 seconds toensure the AC source is stable before transferring.

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Battery Temperature Sensor Operation- The plug-in Battery Tem-perature Sensor (BTS) is used to determine the battery temperaturearound the batteries. This information allows the multi-stage batterycharger to automatically adjust the battery charge voltages for opti-mum charging performance and longer battery life.

When the BTS is installed, if the temperature around the BTS is below

77F (25C) the absorb and float charge voltage increases. If thetemperature around the BTS is higher than 77F (25C), the absorband float charge voltage decreases. See Figure 15to determine howmuch the charge voltage changes (increases or decreases) as thetemperature reading of the BTS changes. For example, the nominalabsorb charge voltage for a flooded battery at 77F (25C) is 14.6VDC. If the battery temperature is 95F (35C), the absorb chargevoltage would decrease to 14.3 VDC (14.6 VDC - 0.3 change).

If the temperature sensor is NOT installed, the charge voltages willnot be compensated and the battery will maintain the charge it hadat a temperature of 77F (25C). The life of the batteries may be

reduced if they are subjected to large temperature changes whenthe BTS is not installed.

Info:When the BTS is connected, the battery chargeruses a value of -5mV/C/Cell from 0-50C to change thecharge voltage based on temperature.

-0.75

-0.6

-0.45

-0.3

-0.15

0

0.15

0.3

0.45

0.6

0.75

0 5 1 0 1 5 2 0 2 5 3 0 3 5 4 0 4 5 5 0

Tem perature reading from BTS

T e m p e ra tu r e C o m p e n s a t i o n u s i n g B T S

0C

32 F

5C

41 F

10 C

50 F

45 C

113F

30 C

86 F

40 C

104F

35 C

95 F

25 C

77 F

20 C

68 F

15 C

59 F

50 C

122FChange

tob

attery

chargingv

o

ltage

no BTS

connected

1 2 V D C u n its

+0.75V

+0.6V

+0.45V

+0.3V

+0.15V

No Change

-0.15V

-0.3V

-0.45V

-0.6V

-0.75V

Fi g u r e 1 6 , B TS T em p e r a t u r e t o Ch a r g e V o l t a g e Ch a n g e



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Protection Circuitry Operation

The inverter is protected against fault conditions, and in normal usageit will be rare to see any. However, if a condition occurs that is outsidethe inverters normal operating parameters, then it will shut downand attempt to protect itself, the battery bank, and your AC loads. Ifthere is a condition that causes the inverter to shut down, it may beone of the conditions listed below. Refer also to the Troubleshootingsection to diagnose and clear the fault.

Low Battery- The inverter will shut off whenever the batteryvoltage falls to the Low Battery Cut Out (LBCO) level to protectthe batteries from being over-discharged. After the inverterhas reached the LBCO level and turned off, the inverter willautomatically restart after one of the following conditions:

1. AC power is applied and the inverter begins operating as abattery charger.

2. Battery voltage rises to the Low Battery Cut In (LBCI)

level.The inverters status LED turns off when a low battery fault con-dition occurs. Refer to Table 5 to determine the LBCO and LBCIlevels for your particular inverter model.

High Battery - In the event the battery voltage approaches theHigh Battery Cut Out (HBCO) level, the inverter will automaticallyshut down to prevent the inverter from supplying unregulated ACoutput voltage. The inverters status LED turns off when a highbattery fault condition occurs. The inverter will automatically restartwhen the battery falls to the High Battery Cut In (HBCI) level.Refer to Table 5 to determine the HBCO and HBCI levels for yourparticular inverter model.

Info:High battery voltage may be caused by excessive orunregulated voltage from solar panels or other externalcharging sources.

Overload - During Inverter and Standby operation modes, theinverter monitors the DC and AC current levels. In the eventof a short-circuit or an overload condition for more than a fewseconds, the inverter will shut down. To start operating after thisfault, the inverter would need to be restarted (turned back on)

after the inverters AC loads are reduced/removed.Over-temperature - If internal power components begin toexceed their safe operating temperature level, the inverter willshut down to protect itself from damage. The inverters status LEDturns OFF to indicate the over-temperature fault condition. Theinverter will automatically restart after the units cools down.

3.0 Operation

32



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Internal Fault - The inverter continually monitors several inter-nal components and the processor communications. If a conditionoccurs that doesnt allow proper internal operation, the inverterwill shut down to protect itself and the connected loads. Theinverter will need to be reset to start operating.

Table 5, Inverter Battery Turn On/Off Levels

3.0 Operation

33

Inverter BatteryTurn On/Off

Levels

Inverter Model

MMS1012 MMS1012-G

HBCO >15.8 VDC >15.8 VDC

HBCI 15.5 VDC 15.5 VDC

LBCI 12.5 VDC 12.5 VDC

LBCO(one minute

delay)

10.0 VDC(9.0 - 12.2 VDC)

10.0 VDC(9.0 - 12.2 VDC)

LBCO(immediate)

8.5 VDC 8.5 VDC

Inverter Startup

ON/OFF Switch- The inverter can be turned on and off by lightlypressing and releasing the Power ON/OFF switch on the front of theinverter. When the inverter is first connected to the batteries, or whenits automatic protection circuit has turned the inverter off, the ON/OFFswitch will need to be pressed to start the unit. Once the inverterhas been turned on, pressing the Power ON/OFF switch alternatelyturns the inverter on and off.

WARNING:The Power ON/OFF control switch does notturn on or off the charger feature. If AC power (utility orgenerator) is connected and qualified on the AC input,this AC power will also be available on the AC outputand is not controlled by the Power ON/OFF switch.

Status LED Indicator- The status indicator is a green LED (LightEmitting Diode) that provides information on the operational mode ofthe inverter. Watch this indicator for at least 10 seconds to determinethe inverters operational condition from the information below:

Inverter Mode

Off - Indicates the inverter is off; there is no AC power fromthe inverter, shore power, or generator at the inverters outputterminals.

Blinks On(once every second) - The inverter is on and is usingenergy from the battery. The inverter is either providing full powerto the loads connected to the inverter, or its in Search Mode andready to supply AC power to the connected loads.



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3.0 Operation

Protection Mode

There are five fault conditions that will cause the inverter to shutdown: Low Battery, High Battery, Over-temperature, AC Overload,and Internal faults. If your inverter has shut down, monitor thestatus indicator and count the number of blinks that occur everyfour seconds to determine the particular reason for the shutdown.

Refer to the Troubleshooting section to help diagnose/clear thefault condition.

Blinks on 1 time every four seconds - Low Battery fault.

Blinks on 2 times every four seconds - High Battery fault.

Blinks on 3 times every four seconds - Over-temperaturefault.

Blinks on 4 times every four seconds - AC Overload fault.

Blinks on 5 times every four seconds - Internal fault.

Charge Mode

The green LED status indicator provides addit ionalinformation:

Blinks off every four seconds - The unit is charging thebatteries connected to the inverter. The external AC power(shore power or generator) connected to the inverters inputis passing through the inverter and is powering the AC loadsconnected to the inverters output.

Factory Default Settings

The MMS Series inverter/charger uses default settings that are

adequate for most installations (see Table 6). However, you canadjust these parameters using Magnums optional ME-RC50 re-mote. The settings once programmed are saved in non-volatilememory and are preserved until changed even if DC power tothe inverter is lost (the ME-RC50 must always be connected).The following information can help you determine if you need theME-RC50 remote*.

01 Search Watts:This setting allows you to turn off the power-savingSearch Mode circuitry and to adjust the power level at which theinverter will wake up and start inverting.

02 Low Battery Cut Out: This setting determines when the inverterwill turn off based on low battery voltage. The inverter turns offautomatically after the battery voltage has been below this setting formore than one minute. This protects the batteries from over-dischargeand the AC loads from unregulated power (brown-outs).

* Visit www.magnumenergy.com for more information.



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Table 6, Inverter/Charger Default Settings

03 Battery AmpHrs: This setting allows you to input the battery banksize in amp hours. This provides information to the charger on howlong to charge the batteries in the Absorb Charging stage.

04 Battery Type: This setting identifies the type of batteries beingused in the system. This provides information to the charger todetermine what voltage level to use to charge the batteries.

05 Charge Rate: This setting can be used to turn off the charger, orlimit the amount of current that the charger can use (leaving morecurrent available to power loads); or, to ensure small battery banksare not overheated because of a charge rate that is too high.

06 VAC Dropout: Sets the minimum AC voltage that must be pres-ent on the AC input before the unit transfers from Standby Mode toInverter Mode. This protects the AC loads from utility outages andbrown-outs.

The ME-RC50 remote also provides the following features:allows you to enable an equalize charge for certain batterytypes

displays the inverter/chargers operating status

provides fault information for troubleshooting

Function Default Settings

Search Watts 5W

LowBatCutOut 10.0 VDC

Battery AmpHrs400 AmpHrs

(Absorb Time = 120 minutes)

Battery TypeFlooded - Liquid Lead Acid

(Bulk = 14.6 VDC, Float = 13.4 VDC)

Charge Rate 100%

VAC dropout 80VAC

3.0 Operation

35



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4.0 Maintenance and Troubleshooting


Recommended Inverter and Battery Care

The MMS Series inverter/charger is designed to provide you withyears of trouble-free service. Even though there are no user-service-able parts, it is recommended that every 6 months you perform the

following maintenance steps to ensure optimum performance andextend the life of your batteries.

WARNING: Prior to performing these checks, switchboth the AC and DC circuits OFF.

Visually inspect the batteries for cracks, leaks, or swelling replace if necessary.

Use baking soda to clean and remove any electrolyte spills orbuildups.

Check and tighten all battery holddown clamps. Clean and tighten (10 to 12 foot-pounds) all DC terminals

(battery and inverter) and connecting cables.

Check and fill battery water levels (Liquid Lead Acid batteriesonly).

Check individual battery voltages (replace those that varymore than 0.3 VDC of each other).

Check all cable runs for signs of chafing replace if necessary. Check the inverters cooling vents clean as necessary.RV/Marine Off-Season Storage

When placing your coach or boat into seasonal storage, it is rec-ommended that you perform the following to ensure the system isproperly shut down (or properly configured for seasonal storage).This is especially important for maintaining the batteries.

Perform the recommended maintenance steps noted above.

Fully charge the batteries.

Connect shore power (if available) and verify that the breakerto the battery charger is switched ON.

Verify the inverter is switched OFF.

Switch OFF all unnecessary AC and DC loads.



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37

Resetting the Inverter

Under some fault conditions (i.e., an internal fault), the inverter willneed to be reset.

To reset the inverter:

Press and hold the Power ON/OFF pushbutton for approximately

15 seconds, or until the status LED comes on and flashes rapidly(see Figure 17).

Release the Power ON/OFF pushbutton once the rapid flashinghas begun. The status LED will go off.

Press the Power ON/OFF pushbutton again to turn theinverter on.

Info: The Power ON/OFF pushbutton is a smallmomentary type switch which operates by lightlypressing and releasing.

1.

2.

3.

Sta tus L ED

Indicator

Pow er ON/OFF

pushbut ton

Fi g u r e 1 7 , R es e t t i n g t h e I n v e r t e r



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Troubleshooting

The MMS Series inverter/charger is a fairly simple device to trouble-shoot. There are only two active circuits (AC and DC), as well as acharging circuit. The following chart is designed to help you quicklypinpoint the most common inverter and charger faults.

Table 7, Troubleshooting Guide

Symptom Possible cause Recommended Solution

Low Battery Voltage(the status indicatorblinks on 1 time every4 secs)

The battery voltage level has droppedbelow the Low Battery Cut Out(LBCO) set-point for more than oneminute (10.0VDC = LBCO defaultsetting).

Battery voltage is too low. Check fuses/circuit-breakers and cable connections.Check battery voltage at the inverter'sterminals. Your batteries may needto be charged, this fault condition willautomatically clear when the batteryvoltage exceeds 12.5VDC.

High Battery Voltage(the status indicatorblinks on 2 timesevery 4 secs)

The battery voltage is above 15.5VDC. The inverter automaticallyresets and resumes operation whenthe battery voltage drops below 15.5VDC.

This condition usually occurs only whenan additional charging source (alternator,solar panels or other external chargingsources) is used to charge the batterybank. Reduce or turn off any other

charger to the inverter batteries to allowthe voltage level to drop.

Over-temperaturecondition(the status indicatorblinks on 3 timesevery 4 secs)

The internal temperature of theinverter has risen above acceptablelimits; caused by loads too great forthe inverter to operate continuously,or by lack of ventilation to theinverter. When the unit has cooled, itwill automatically reset and resumeoperation.

Reduce the number of electrical loadsthat you are operating, this will avoid arepeat Over-temp shutdown if the causewas too many loads for the ambientconditions.

Check ventilation around the inverter,ensure cool air is available to pass-thruthe inverter.

AC Overload(the status indicatorblinks on 4 timesevery 4 secs)

The inverter has turned off becausethe connected loads are larger thanthe inverters output capacity or theoutput wires are shorted.

Reduce the AC loads connected to theinverter or remove all AC output wiringand restart the inverter.

Internal fault(the status indicatorblinks on 5 timesevery 4 secs)

This fault occurs when an internalfault is detected.

To clear this fault, an inverter resetis required. Remove DC power to theinverter or press and hold down thepower switch on the inverter for 15seconds (until the green Status LEDcomes on). If this fault does not clear, theunit will need to be serviced.

Inverter's status lightis off.

Inverter is switched OFF or there isno DC voltage (battery) connected toinverter.

Switch the inverter ON. Connect a batterywith correct voltage to the inverter.

AC input won't connect(AC IN on remoteblinks)

The incoming AC voltage will notbe accepted if it is below the VACDropout setting (80VAC = VACDropout default setting).

Check the incoming AC voltage to theinput of the inverter, ensure it is presentand above the VAC dropout level.

Appliances turn off

and on; or there is lowAC output power.

Loose AC output connections. Tighten AC outpu

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