RD-E Series Modified Sine Wave Inverters/Chargers Owner’s Manual
Disclaimer of Liability The use of this manual and the conditions or methods of installation, operation, use, and maintenance of the RD-E Series Inverter/Charger is beyond the control of Magnum Energy Inc. Therefore, this company assumes no responsibility and expressly disclaims any liability for loss, damage, or expense whether direct, indirect, consequential, or incidental that may arise out of or be in anyway connected with such installation, operation, use, or maintenance.
IMPORTANT SAFETY INSTRUCTIONS • This manual contains important safety instructions that must be followed during the installation and operation of this product. • All electrical work must be performed in accordance with local, state and federal electrical codes. • Read all instructions and safety information contained in this manual before installing or using this product. • This product is designed for indoor/compartment installation.
IMPORTANT BATTERY SAFETY INSTRUCTIONS • Be very careful when working around batteries, they can produce extremely high currents if short-circuited. Read the battery supplier’s precautions before installing the inverter and batteries. • 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.
Table of Contents 1.0 Introduction ..................................................................................1 2.0 Installation ...................................................................................7 3.0 Operation ....................................................................................30 4.0 Maintenance and Troubleshooting ...............................................37 1.1 1.2 1.3 1.4 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 4.1 4.
List of Figures Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure 1-1, Power Switch, Status LED, and Accessory Connection Ports ................................................3 1-2, Electrical Connection Points ...........................................................................................3 1-3, Left Side Features ......................
Introduction 1.0 Introduction Congratulations on your purchase of the RD-E Series inverter/charger from Magnum Energy. The RD-E Series is a modified sine wave inverter designed especially for renewable energy systems. Powerful, yet simple to operate, this inverter/charger will provide you with the years of troublefree performance you have come to expect from Magnum Energy, all backed by our limited 2 year warranty. Installation is easy.
Introduction 1.1 Features and Benefits The RD-E Series inverter/charger is designed to allow easy access to wiring, circuit breakers, and controls. Its die cast baseplate with one-piece aluminum cover ensures maximum durability with minimum weight, as well as cooler more efficient operation. The front of the RD-E Series is equipped with the following features (see Figures 1-1 and 1-2): 1 Power ON/OFF Switch - a momentary pushbutton switch that alternately turns the inverter On or Off.
Introduction 1 POWER ON/OFF SWITCH 2 STATUS (CHARGING/INVERTING) LED 3 STACK/ACCESSORIES PORT (RED LABEL - RJ11 CONNECTION) 4 NETWORK PORT (GREEN LABEL - RJ11 5 REMOTE PORT (BLUE LABEL - RJ11 6 BATTERY TEMPERATURE SENSOR PORT (YELLOW LABEL - RJ11 CONNECTION) CONNECTION) CONNECTION) Figure 1-1, Power Switch, Status LED, and Accessory Connection Ports INTAKE AIR VENTS (AND ON RIGHT SIDE) 9 10 8 POSITIVE (+) DC TERMINAL COVER) AC INPUT/ OUTPUT (UNDER CONNECTIONS 11 7 NEGATIVE (-) DC TER
Introduction The left side of the RD-E Series is equipped with the following features (see Figure 1-3): 13 Exhaust Air Vent - ventilation openings that allow heated air to be removed by the internal cooling fan. 14 Model/Serial Number Label - includes model/serial number information, date of manufacture, and inverter and charger specifications. See the RD-E Specifications in Appendix A for more information and the different models that are available.
Introduction 1.2 How an Inverter/Charger Works An inverter takes direct current (DC) from your batteries and turns it into alternating current (AC). It also takes alternating current (when connected to a generator or to utility power) and transforms it into direct current to charge your batteries.
Introduction Depending on your inverter capacity, electrical appliances that use larger loads such as coffee pots and hair dryers can be used for short durations. However, loads that are used for longer periods (stoves, water heaters, etc.) can quickly drain your batteries and are not recommended for inverter applications. All electrical appliances are rated by the amount of power they consume (see Table 1-1).
Installation 2.0 Installation WARNING: Installations should be performed by qualified personnel, such as a licensed or certified electrician. It is the installer’s responsibility to determine which safety codes apply and to ensure that all applicable installation requirements are followed. Applicable installation codes vary depending on the specific location and application of the installation.
Installation G e n e ra to r P o w e r 2 3 0 V A C O u tp u t U tility P o w e r 2 3 0 V A C O u tp u t F ul x C a pa c oti r M E - A G S -N A u to G en S tart C o n tro ller ( M ag n u m A ccesso ry ) G e ne ra t or M E - A R C50 M E -R C50 AC T ra n s fe r S w itc h P WR FA U LT S E L E CT C H G IN V ON / OF F CHARG ER ON / OF F I NVERTER SHO RE AG S M ETER SETUP TECH R em o te C o n tro ls ( M ag n u m A ccesso ries ) M a in P a n e l O FF OF F OF F O FF OF F OF F ON ON ON ON
Installation 2.1.3 Locating the Inverter Only install the inverter in a location that meets the following requirements: Clean and Dry - The inverter should not be installed in an area that allows dust, fumes, insects, or rodents to enter or block the inverter’s ventilation openings. This area also must be free from any risk of condensation, water, or any other liquid that can enter or fall on the inverter. The inverter uses stainless steel fasteners, plated copper busbars, and a power-coated aluminum base.
Installation Accessible - Do not block access to the inverter’s remote control and accessory ports, as well as the inverter’s controls and status indicator. Also allow enough room to access the AC and DC wiring terminals and connections, as they will need to be checked and tightened periodically. See Figure 2-3 for the RD-E Series’ inverter/charger dimensions. Away from sensitive electronic equipment - High-powered inverters can generate levels of RFI (Radio Frequency Interference).
Installation TOP SIDE LEFT SIDE 8" RIGHT (20.3 cm) SIDE 6 5/8" (16.8 cm) FRONT SIDE BOTTOM SIDE BACK SIDE LEFT SIDE TOP SIDE RIGHT SIDE 4 7/8" (12.4 cm) 2" (5.1 cm) Keyhole slots (x4) and mounting holes (x4) accept up to 9/32" (7 mm) screw/bolt 13 3/4" (34.9 cm) 4 7/8" (12.4 cm) 12" (30.5 cm) 12 5/8" (32.
Installation 2.3 Wiring the Inverter - General Requirements This section describes the requirements and recommendations for wiring the RD-E Series inverter/ charger. Before wiring the inverter/charger, read all instructions. All wiring should meet all local codes and industry standards, and be performed by qualified personnel such as a licensed electrician. Info: This document uses the term “ground”, or “grounding”; the European equivalent is “earth”, or “earthing”.
Installation 2.3.4 • 2.4 Torque Requirements Torque all AC wiring connections to 16 in lbf (1.8 N-m). Torque DC cable connections from 10 to 12 ft lbf (13.6 to 16.3 N-m). DC Wiring This section describes the inverter’s required DC wire sizes, the recommended disconnect/overcurrent protection, and how to make the DC connections to the inverter and the battery bank. Refer to Figure 2-4 when connecting the DC wires.
Installation RD -E Series Inverter /Charger front view B TS B TS Inv e rte r’s D C N e ga tiv e C onne c tion Inv e rte r’s D C P os itiv e C onne c tion Inv e rte r’s E quipm e nt G round W ire B a tte ry Te m p S e ns or C a ble M M P e nc los ure – for s ingle inv e rte r ins ta lla tions (inc lude s D C dis c onne c t bre a k e r, D C s hunt for ba tte ry m onitor, a nd inv e rte r D C bus ba rs).
Installation 2.4.1 DC Wire Sizing It is important to use the correct DC wire to achieve maximum efficiency from the system and reduce fire hazards associated with overheating. Always keep your wire runs as short as practical to help prevent low voltage shutdowns and keep the DC breaker from nuisance tripping (or open fuses) because of increased current draw. See Table 2-1 to select the required minimum DC wire size (and corresponding overcurrent device) based on your inverter model.
Installation Table 2-2, DC Wire Size For Increased Distance Inverter Model Minimum Recommended DC Wire Size (one way)* 5 feet (1.5m) or less 5 to 10 feet (1.5-3m) 10-15 feet (3-4.5m) In Conduit In Free Air In Conduit In Free Air In Conduit in Free Air RD2624E #4/0 AWG (107.2 mm2) #2/0 AWG (67.4 mm2) #4/0 AWG x2 (107.2 mm2 x2) #4/0 AWG (107.2 mm2) not recommended #4/0 AWG x2 (107.2 mm2 x2) RD4024E #4/0 AWG (107.2 mm2) #4/0 AWG (107.2 mm2) #4/0 AWG x2 (107.2 mm2 x2) #4/0 AWG x2 (107.
Installation 2.4.4 Wiring the Battery Bank WARNING: Lethal currents will be present if the positive and negative cables attached to the battery bank touch each other. During the installation and wiring process, ensure the cable ends are insulated or covered to prevent touching/shorting the cables.
Installation 2.4.6 Wiring the Inverter to the Battery Bank CAUTION: The inverter is NOT reverse polarity protected. If this happens, the inverter will be damaged and will not be covered under warranty. Before connecting the DC wires from the batteries to the inverter, verify the correct battery voltage and polarity using a voltmeter. If the positive terminal of the battery is connected to the negative terminal of the inverter and vice versa, severe damage will result.
Installation 2.5 AC Wiring This section provides information on how to make the AC connections to the inverter using the correct AC wire size and the corresponding overcurrent protection. 2.5.
Installation AC Input/ Output Strain Relief Clamp AC Input/ Output Strain Relief Clamp Figure 2-8, RD-E Series Inverter/Charger - AC Wiring AC Access Cover AC Input Circuit Breaker (CB3) Figure 2-9, RD-E Series Inverter/Charger - AC Wiring (Access Cover) © 2010 Magnum Energy, Inc.
Installation 2.5.3 AC Terminal Block Connections The inverter has a four-pole AC terminal block and one AC ground terminal to connect the inverter’s AC input and output wiring. To access and view the AC terminal block and ground terminal, remove the two Phillips screws holding the AC Access Cover plate (see Figure 1-3, Item 15). Each connection on the AC terminal block is rated to accept one #14 to #6 AWG (2.1 to 13.3 mm2) CU stranded wire, or two #12 AWG (3.3 mm2) CU stranded wires.
Installation 2.5.4 AC Conductor Wiring The following steps are basic guidelines for installing and connecting the AC wiring into and out of the inverter. Refer to Section 2.5.5 and Figure 2-11 before beginning. WARNING: Before making any AC connections, make sure the inverter is disconnected from the battery and there is no other source of live power connected to the inverter. Wiring the Inverter AC Input 1.
Installation A C T e rm in a l B lo c k ( A C in p u t a n d o u tp u t w irin g ) R D-E S e rie s In v e rte r BLUE B R OW N B R OW N A C N EU T IN (f rom M ain P ane l) A C H O T IN (f rom M ain P ane l) AC NE UT O UT (t o Sub- Pa ne l) A C HO T O UT (to S ub-P a nel) BLUE AC G RO UNDS (to /fro m b o th p a n e ls) S IN G L E IN / S IN G L E O U T w irin g ON ON OFF OF F ON O FF ON O FF ON OF F ON ON O FF O FF ON OF F O FF ON OF F ON ON OF F ON ON O FF ON ON ON O FF OF
Installation 2.6 Grounding Inverters The inverter/charger should always be connected to a permanent, grounded wiring system. An inverter system that is properly grounded will limit the risk of electrical shock, reduce radio frequency noise from the inverter and minimize excessive surge voltages induced by lightning. This is done by ensuring there is a well-defined, very low-resistance path from the electrical system to the grounding system.
Installation 2.6.1 Sizing the Grounding Electrode Conductors AC Side - The size of the AC Grounding Electrode Conductor (GEC –AC) depends on the size of the largest ungrounded conductor feeding the AC load center. One #8 AWG (8.4 mm2) copper conductor will serve as an AC Grounding Electrode Conductor (GEC –AC) for AC power conductors smaller than and including #2 AWG (33.6 mm2) copper. See Table 2-4 for additional values.
Installation Method 2 (see Figure 2-14): When the AC and DC service panels are near each other, then the AC Grounding Electrode Conductor (GEC – AC) and DC Grounding Electrode Conductor (GEC – DC) can be connected to a single grounding electrode. In this method — since there are multiple connections to the DC Grounding Electrode (GEC – DC) — the size of the DC grounding electrode conductor can not be smaller than the largest conductor in the DC system (usually the batteryto-inverter cable).
Installation 2.6.2 System Bonding Jumper The RD-E Series inverter does not include an internal bond between the grounded conductor (AC neutral/DC negative) and the equipment grounding terminals. This bond [System Bonding Jumper (SBJ)] is usually done in the main distribution panel for each electrical system. CAUTION: There should be one and only one point in each electrical system (both AC and DC) where the grounded conductor is attached to the grounding electrode conductor.
Installation 2.7 Inverter Notification Requirements When an inverter is installed in a building, facility, or structure, standard safety practices require a label or plaque be present. This label/plaque is required to be readily visible and provide information that informs personnel to the location of all electrical system disconnects. This is to ensure all power to a building is quickly located and shut down in an emergency.
Installation 2.9 Functional Test After all electrical connections to the inverter, batteries, AC source, and sub-panel have been completed, follow these steps to test the installation and the inverter operation. CAUTION: Use a multimeter to verify the correct DC voltage for your particular inverter model (i.e.
Installation 3.0 Operation The RD-E Series inverter has two normal operating routines; Inverter mode, which powers your loads using the batteries, and Standby mode, which transfers the incoming AC power (e.g., utility power or a generator) to power your loads and also uses this incoming power to recharge the batteries. This inverter also includes an extensive protection circuitry to shut down the inverter under certain fault conditions. 3.
Operation 3.2 Standby Mode The RD-E Series features an automatic transfer relay and an internal battery charger when operating in Standby mode. Standby mode begins whenever AC power (utility power or generator) is connected to the inverter’s AC input. Once the AC voltage and frequency of the incoming AC power is within the AC input limits, an automatic AC transfer relay is activated. This transfer relay passes the incoming AC power through the inverter to power the AC loads on the inverter’s output.
Operation The Charge mode provides up to four separate charging stages: Bulk Charging, Absorb Charging, Float Charging, and Full Charge (see Figure 3-3). Bulk Charging: This is the initial stage of charging. While bulk charging, the charger supplies the battery with constant current. The charger will remain in bulk charge until the absorption charge voltage (determined by the battery type selection*) is achieved. The inverter’s green LED stays ON (solid) to indicate bulk charging.
Operation 3.4 Transfer Time While in Standby mode, the AC input is continually monitored. Whenever AC power falls below the VAC dropout voltage (160 VAC, default setting), the inverter automatically transfers back to the Inverter mode with minimum interruption to your appliances – as long as the inverter is turned on. The transfer from Standby mode to Inverter mode occurs in approximately 16 milliseconds.
Operation 3.6 Protection Circuitry Operation The inverter is protected against fault conditions, and in normal usage it will be rare to see any. However, if a condition occurs that is outside the inverter’s normal operating parameters, it will shut down and attempt to protect itself, the battery bank, and your AC loads. If there is a condition that causes the inverter to shut down, it may be one of the following conditions [also refer to the Troubleshooting section (Section 4.
Operation 3.7 Inverter Startup ON/OFF Switch - The inverter can be turned on and off by lightly pressing and releasing the Power ON/OFF switch on the front of the inverter (see Figure 3-5). When the inverter is first connected to the batteries, or when its automatic protection circuit has turned the inverter off, the ON/OFF switch will need to be pressed to start the unit (or reset per Section 4.3).
Operation 3.8 Factory Default Values Your RD-E Series inverter/charger uses default values for the adjustable settings (see Table 3-2) that are adequate for most installations. If some of your operating parameters need to be changed from the default values, the optional ME-RC50 or ME-ARC50 remote control can be used to make those changes. To help you determine if you need a remote display, information on the inverter/ charger settings that can be changed is provided below.
Maintenance and Troubleshooting 4.0 Maintenance and Troubleshooting The following information is provided to help you keep your RD-E Series inverter/charger in optimum operational condition. 4.1 Recommended Inverter and Battery Care The RD-E Series inverter/charger is designed to provide you with years of trouble-free service.
Maintenance and Troubleshooting 4.2 Troubleshooting The RD-E Series inverter/charger is a fairly simple device to troubleshoot. There 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. Table 4-1, Basic Troubleshooting Symptom Possible Cause N o o u t p u t p o w e r / Inverter is switched OFF. Inverter LED is OFF. Battery voltage is too low.
Maintenance and Troubleshooting 4.3 Resetting the Inverter Under some fault conditions (e.g., an internal fault), the inverter will need to be reset. To reset the inverter: Press and hold the Power ON/OFF pushbutton (see Figure 4-1) for approximately fifteen (15) seconds until the Charging/Inverting Status LED comes on and flashes rapidly; once the rapid flashing has begun, release the Power ON/OFF pushbutton. The Status LED will go off after the pushbutton is released.
Appendix A - Specifications Appendix A - Specifications and Optional Equipment A-1 Inverter/Charger Specifications Models RD2624E RD4024E Input battery voltage range 18 to 31 VDC 18 to 31 VDC Absolute maximum DC input 35 VDC Inverter Specifications 35 VDC AC output voltage accuracy 230 VAC ± 5% Output frequency and accuracy Continuous power output (at 25° C) 50 Hz ± 0.
Appendix A - Specifications A-2 Optional Equipment and Accessories The following Magnum Energy components are available for use with the RD-E Series inverter/ charger. Some of these items are required depending upon the intended use of the inverter. MMP Series Enclosures The MMP175-30D, MMP175-60S, MMP250-30D, and MMP250-60S enclosures are for single inverter applications.
Appendix A - Specifications A-3 Wiring Color Codes for Europe and the U.S./Canada The following tables contrast AC and DC wiring color codes for Europe and the United States/ Canada. In the U.S., the National Electrical Code (NEC) is the mandating authority; in Canada, it’s the Canadian Electrical Code (CEC). Most of Europe abides by the International Electrotechnical Commission’s (IEC) wiring color codes.
Appendix B - Battery Information Appendix B - Battery Information B-1 Battery Location Periodic maintenance (e.g., checking connections, cleaning, watering) on batteries is required. Locate the batteries in an accessible location to perform this maintenance. Batteries must be mounted in a clean, dry, ventilated environment where they are protected from high and low temperatures. The battery bank should be located as close to the inverter as possible without limiting access to the inverter’s disconnects.
Appendix B - Battery Information B-5 Battery Bank Sizing Worksheet Complete the steps below to determine the battery bank size required to power your AC loads: 1.
Appendix B - Battery Information B-6 Battery Wiring Configurations The battery bank must be wired to match the inverter’s DC input voltage. In addition, the batteries can be wired to provide additional run time. The various wiring configurations include: B-6.1 Series Wiring Wiring batteries in series increases the battery bank’s output voltage. A series connection combines each battery in a string until the total voltage matches the inverter’s DC requirement.
Appendix B - Battery Information Series String (12 VDC + 12 VDC) 12 VDC battery (100 AH) 12 VDC battery (100 AH) overcurrent protection to 24 VDC inverter (total capacity = 100 AH) 24 volt battery bank (one string of two 12-volt batteries wired in series) Series String (6 VDC + 6 VDC + 6 VDC + 6 VDC) overcurrent protection 6 VDC battery (200 AH) 6 VDC battery (200 AH) 6 VDC battery (200 AH) 6 VDC battery (200 AH) to 24 VDC inverter (total capacity = 200 AH) 24 volt battery bank (one string of f
Appendix C - Warranty & Service Limited Warranty Magnum Energy, Inc., warrants the RD-E 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 and conditions: 1. The limited warranty for the product extends for 24 months beginning from the product’s original date of purchase. 2.
Magnum Energy, Inc. 2211 West Casino Rd. Everett, WA 98204 Phone: 425-353-8833 Fax: 425-353-8390 Web: www.magnumenergy.
