Magnum Energy MPX User Manual

MPX Series Extension Kit

Owner’s Manual

Disclaimer of Liability

The use of this manual and the conditions or methods of installation, operation, use, and maintenance of the MPX Extension Kit is beyond the control of Magnum Energy, Inc. Therefore, this company does not assume responsibility and expressly disclaims liability for loss, damage or expense, whether direct, indirect, consequential or incidental, arising out of or in anyway connected with such installation, operation, use, or maintenance.

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

Restrictions on Use

The MPX Extension Kit may only be used in life-support devices or systems with the express written approval of Magnum Energy. F ailure of the MPX can reasonably be expected to cause failure of that life-support device or system, or to affect the safety or effectiveness of that device or system. If the MPX fails, it is reasonable to assume the health of the user or other persons may be endangered.

Copyright Notice

Copyright © 2011 by Magnum Energy, Inc. All rights reserved. Permission to copy, distribute, and/ or modify this document is prohibited unless express written permission from Magnum Energy , Inc. is provided.

Contact Information

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

Statement of Appreciation

From all of us at Magnum Energy Thank you for purchasing this Magnum Extension Kit (MPX). We understand that you have many purchasing options in the marketplace, and are pleased that

you have decided on a Magnum Energy product. This MPX was proudly assembled and tested in the United States at our Everett, Washington facility.

At Magnum, we are committed to providing you with quality products and services; and hope that your experience with us is pleasant and professional.

Magnum Energy® is a registered trademark of Magnum Energy, Inc.

ii 2011 Magnum Energy, Inc.

Table of Contents

1.0 Safety Information ........................................................................... 1

1.1 Safety Symbols .........................................................................................1

1.2 General Safety ..........................................................................................1

1.3 Battery Safety ...........................................................................................2

2.0 Introduction ..................................................................................... 3

2.1 MPX Series Kit...........................................................................................3

2.2 Available MPX Models .................................................................................5

3.0 Installation ....................................................................................... 7

3.1 Installing the MPX ......................................................................................7

3.1.1 Preparation .......................................................................................7

3.1.2 Attaching the MPX to the MP Enclosure ................................................10

3.1.3 Mounting the MP Enclosure (and Attached MPX) to a Backplate/Wall ........10

3.1.4 Attaching the DC and AC Breakers ...................................................... 11

3.1.5 Connect and Separate Inverter AC Wires ............................................. 13

3.1.6 Mounting the Second Inverter onto the MPX ........................................... 13

3.1.7 Attaching the Inverter Hood ...............................................................14

3.1.8 Attaching the Router Bracket .............................................................16

3.1.9 Attaching the Router to the Bracket ....................................................16

3.2 Wiring the MPX .......................................................................................17

3.2.1 Wiring Guidelines .............................................................................17

3.2.2 Wiring the MPXS-30D .......................................................................20

3.2.3 Wiring the MPXS-60S ........................................................................33

3.2.4 Wiring the MPXD-30D .......................................................................43

3.3 Installation Checklist ................................................................................52

3.4 Functional Test ........................................................................................52

3.5 Attaching Labels and Covers .....................................................................52

4.0 Warranty and Service ..................................................................... 58

4.1 Limited Warranty .....................................................................................58

4.2 How to Receive Repair Service...................................................................58

List of Tables

Table 2-1, MPX AC Wire Kit Part Numbers ...............................................................4

Table 2-2, DC 2/0 Battery Cable Lengths ................................................................5

Table 2-3, MPX Models .........................................................................................5

Table 3-1, MPX Wiring Table ................................................................................17

List of Figures

Figure 2-1, MPX Series Kit ....................................................................................3

Figure 2-2, MPX Kit Labels and Hardware ................................................................4

Figure 2-3, MPXS-60S Installation Conﬁ gurations .....................................................5

Figure 2-4, MPXS-30D Installation Conﬁ gurations ....................................................6

Figure 2-5, MPXD-30D Model Installation Conﬁ guration ............................................6

Figure 3-1, MPX Series Dimensions and Knockout Locations/Sizes ..............................8

Figure 3-2, Removing a Knockout ..........................................................................9

List of Figures (cont.)

Figure 3-3, Removing MPX Knockouts ....................................................................9

Figure 3-4, MPX with RTR Bracket .........................................................................9

Figure 3-5, Attaching the MPX to an MP Enclosure ................................................. 10

Figure 3-6, Mounting the MPX to a Backplate/Wall.................................................10

Figure 3-7, Removing Breaker Screws ................................................................. 11

Figure 3-8, Attaching the New DC Breaker ........................................................... 11

Figure 3-9, Attaching the New AC Breaker Within a MP Single Enclosure .................. 12

Figure 3-10, Attaching the New AC Breaker Within a MP Dual Enclosure ................... 12

Figure 3-11, Mounting the Second Inverter on the MPX.......................................... 13

Figure 3-12, Mounting Multiple Inverters on the MPX ............................................. 14

Figure 3-13, Attaching the Inverter Hood ............................................................. 15

Figure 3-14, Attaching Multiple Inverter Hoods ..................................................... 15

Figure 3-15, Attaching the Router Bracket ............................................................ 16

Figure 3-16, Mounting the Router to the Bracket ................................................... 16

Figure 3-17, DC Cable Connections ..................................................................... 19

Figure 3-18a, MPXS-30D / MPSL-30D Inverter AC Wiring ....................................... 23

Figure 3-18b, MPXS-30D / MPSL-30D External AC Wiring ....................................... 24

Figure 3-18c, MPXS-30D / MPSL-30D Inverter DC Wiring ....................................... 25

Figure 3-18d, MPXS-30D / MPSL-30D Battery Bank DC Wiring ................................ 26

Figure 3-18e, MPXS-30D / MPSL-30D Communication Wiring .................................. 27

Figure 3-19a, MPXS-30D / MPSH-30D Inverter AC Wiring ....................................... 28

Figure 3-19b, MPXS-30D / MPSH-30D External AC Wiring ...................................... 29

Figure 3-19c, MPXS-30D / MPSH-30D Inverter DC Wiring ....................................... 30

Figure 3-19d, MPXS-30D / MPSH-30D Battery Bank DC Wiring ............................... 31

Figure 3-19e, MPXS-30D / MPSH-30D Communication Wiring ................................. 32

Figure 3-20a, Inverter AC Input and Output Wiring Diagram .................................. 34

Figure 3-20b, MPXS-60S / MPSL-60S AC Breaker Input Wire Transition .................... 35

Figure 3-21a, MPXS-60S / MPSL-60S Inverter AC Wiring ........................................ 38

Figure 3-21b, MPXS-60S / MPSL-60S External AC Wiring ........................................ 39

Figure 3-21c, MPXS-60S / MPSL-60S Inverter DC Wiring ........................................ 40

Figure 3-21d, MPXS-60S / MPSL-60S Battery Bank DC Wiring ................................. 41

Figure 3-21e, MPXS-60S / MPSL-60S Communication Wiring .................................. 42

Figure 3-22a.1, MPXD-30D / MPDH-30D Inverter AC Wiring ................................... 46

Figure 3-22a.2, MPXD-30D / MPDH-30D Inverter AC Wiring (Closeup) ..................... 47

Figure 3-22b, MPXD-30D / MPDH-30D External AC Wiring ...................................... 48

Figure 3-22c, MPXD-30D / MPDH-30D Inverter DC Wiring ...................................... 49

Figure 3-22d, MPXD-30D / MPDH-30D Battery Bank DC Wiring ............................... 50

Figure 3-22e, MPXD-30D / MPDH-30D Communication Wiring ................................. 51

Figure 3-23, Attaching the Interior DC Labels ....................................................... 52

Figure 3-24, Attaching the MP Enclosure Cover ..................................................... 53

Figure 3-25, Attaching the MPX Cover ................................................................. 54

Figure 3-26, Attaching the Router Cover .............................................................. 55

Figure 3-27, Attaching the Exterior Labels MPSL/MPSH .......................................... 56

Figure 3-28, Attaching the Exterior Labels MPDH .................................................. 57

iv 2011 Magnum Energy, Inc.

1.0 Safety Information

IMPORTANT SAFETY INSTRUCTIONS

This manual contains important safety instructions that must be followed during the installation and operation of this product. Before using the MPX, read all instructions and cautionary markings in this manual for: the MPX extension, the inverter/charger, the MP enclosure, and the batteries – as well as the individual manuals provided for each component of the system.

These installation instructions are for use by qualiﬁ ed personnel only. Do not perform any installation or servicing other than that speciﬁ ed in this owner’s manual unless you are qualiﬁ ed to do so. Incor- rect installation or servicing may result in a risk of electric shock, ﬁ re, or other safety hazard.

1.1 Safety Symbols

The following safety symbols have been placed throughout this manual to indicate dangerous conditions and important safety instructions.

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

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

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

1.2 General Safety

• All electrical work must be performed in accordance with local and national electrical codes.

• This product is designed for indoor/compartment installation. It must not be exposed to rain, snow, moisture, or liquids of any type.

• Use insulated tools to reduce the chance of electrical shock or accidental short circuits.

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

• Both AC and DC overcurrent protection must be provided as part of the installation.

• Use Class 1 wiring methods for ﬁ eld wiring connections to terminals of a Class 2 circuit.

• Listed or labeled equipment shall be installed and used in accordance with any instructions included in the listing or labeling.

• To reduce risk of electric shock, disconnect all wiring before attempting any maintenance or cleaning. Turning off the inverter will not reduce this risk, the inverter bypass must be used or the panel should be totally disconnected from all sources.

• All wiring must have a minimum rating of 150V, 75°C when using 120V AC inverters; or 300V, 75°C when using 120V/240V AC inverters.

• AC wiring must be no less than 10 AWG (5.3 mm2) gauge copper wire.

• Battery cables should be no less than #4/0 AWG unless fused close to the battery bank for smaller sized cables.

• Crimped and sealed copper ring terminal lugs with a 3/8” hole should be used to connect to the DC terminals inside the MP enclosure. Soldered cable lugs are also acceptable.

• Torque all AC wiring connections and DC cable connections to the required torque values.

READ AND SAVE THESE INSTRUCTIONS

1

1.0 Safety Information

1.3 Battery Safety

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 and connecting 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 batteries.

• Never work alone. Always have someone near you when working around batteries.

• Use proper lifting techniques when working with batteries.

• Never use old or untested batteries. Check each battery’s label for age, type, and date code to ensure all batteries are identical.

• Batteries are sensitive to changes in temperature. Always install batteries in a stable environment.

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

• Provide at least one inch of air space between batteries to provide optimum cooling.

• Never smoke when in the vicinity of batteries.

• To prevent a spark at the battery and reduce the chance of explosion, alwa ys connect the cables to the batteries ﬁ rst. Then connect the cables to the MP enclosure/inverter system.

• Use insulated tools at all times.

• Always verify proper polarity and voltage before connecting the batteries to the MP enclosure/ inverter system.

• To reduce the chance of ﬁ re or explosion, do not short across the battery terminal.

• In the event of accidental exposure to battery acid, wash thoroughly with soap and water . In the event of exposure to the eyes, ﬂ ood them for at least 15 minutes with running water and seek immediate medical attention.

• Recycle old batteries.

• Be extra cautious to reduce the risk of dropping a metal tool onto batteries. It could short-circuit the batteries or other electrical parts, resulting in sparks that could cause an explosion.

• Cover the terminals to prevent accidental shorting.

READ AND SAVE THESE INSTRUCTIONS

2

2.0 Introduction

C

E

G

H

F

I

J

K

D

A

B

2.0 Introduction

The MPX Series Extension Kit provides the necessary equipment to mount and connect an additional Magnum inverter to a MP Series enclosure and panel. The MPX is designed to allow a Magnum inverter to ﬁ t seamlessly into the top.

IMPORTANT: If you have not yet installed any of your system (i.e., MP enclosure, ﬁ rst inverter), refer to the MP Owner’s Manual (PN: 64-0028) for initial setup instructions.

2.1 MPX Series Kit

Carefully remove the MPX from its shipping container and inspect all contents. Verify the below items are included. Contact your authorized Magnum Energy dealer or Magnum Energy if anything is missing. Save your proof-of-purchase as a record of your ownership (needed for in-warranty service).

The MPX kit includes (see Figure 2-1):

A

MPX extension box

Inverter hood - for vertically mounting an

B

inverter

C

DC disconnect breaker - 250 ADC See Note* on stacking cables below.

Remote cable (300V) - for installing remote

G

control or router Stacking cable - for series stacking MS4024

H

inverters or parallel stacking MS-PAE inverters

AC breaker - 30 AAC double-pole

D

(60 AAC single-pole with MPXS-60S) DC positive/negative 2/0 AWG battery

E

cables (see Table 2-1) MPX AC Wiring Kit - for wiring to the AC

F

terminals in MP panels (see Table 2-1)

Note* - The supplied parallel stacking cables must be used when installing the router. They are like standard CAT 5 cables, but are rated for 300V to allow their use with the MS-PAE inverters and to meet electrical safety code requirements.

I

Labels and mounting hardware (Figure 2-2)

J

MPX Series Owner’s Manual Series Stacking Manual (MPXS-60S models

K

only)

Figure 2-1, MPX Series Kit

3

2.0 Introduction

1

- (x4) ⅜”-16 x ¾” Hex bolts

4

2

- (x4) ⅜” split washers

1

2

3

TOP CONNECTION

OF

DC BREAKER

DC

POS

DC POS Top

Connection

MASTER

INVERTER

MASTER

INVERTER

MASTER

INVERTER

MASTER

INVERTER

TO

IN V

7

5

6

BOTTOM CONNECTION

OF

DC BREAKER

DC

POS

DC POS Bottom

Connection

SLAVE 1

INVERTER

SLAVE 1

INVERTER

SLAVE 1

INVERTER

SLAVE 1

INVERTER

8

TO

BAT

- (x2) ⅜”-16 nuts

3 4

- (x4) #8-32 x ¼” (T20) Torx screws

5

- (x1) #10-32 x ⅜” (T25) Torx screw

6

- (x1) #10 lock washer

7

- (x2) #10-32 x 3½” (T25) Torx screws

8

- (x2) DC breaker mounting straps

INVERTER

AC INPUT

SWITCH ON

TO CHARGE /

P

ASS-THRU

Inverter AC Input Label

SLAVE 2

INVERTER

SLAVE 2

INVERTER

SLAVE 2

INVERTER

SLAVE 2

INVERTER

INVERTER DC DISCONNECT

SWITCH ON

TO INVERT

Inverter DC

Disconnect Label

SLAVE 3

INVERTER

SLAVE 3

INVERTER

SLAVE 3

INVERTER

SLAVE 3

INVERTER

Master/Slave Labels

Figure 2-2, MPX Kit Labels and Hardware

TABLE 2-1, MPX AC WIRE KIT PART NUMBERS

AC Wire Function A80-MPXS-30D A80-MPXS-60S A80-MPXD-30D

INV HOT 1 IN #10 AWG Black (45”)* NA #10 AWG Black (55”)*

INV HOT 2 IN #10 AWG Red (45”)* #6 AWG Red (45”)* #10 AWG Red (55”)* INV HOT 1 OUT #10 AWG Black w/Stripe (45”)* NA #10 AWG Black w/Stripe (55”)* INV HOT 2 OUT #10 AWG Red w/Stripe (45”)* #6 AWG Red w/Stripe (45”)* #10 AWG Red w/Stripe (55”)*

INV NEUTRAL IN #10 AWG White (38”) #6 AWG White (38”) #10 AWG White (48”)

INV NEUTRAL OUT NA #6 AWG White (38”) NA

INV AC GROUND #10 AWG Green (38”) #10 AWG Green (38”) #10 AWG Green (48”)

* this wire is longer than needed to allow at least 7” to be cut and used for connecting to the inverter AC input

breakers

4

2011 Magnum Energy, Inc.

2.0 Introduction

TABLE 2-2, DC 2/0 BATTERY CABLE LENGTHS

Model Black Cable Red Cable

MPXS-30D-L 23.25” 21.00”

MPXS-30D-R 15.25” 16.50”

MPXS-60S-L 23.25” 21.00”

MPXS-60S-R 15.25” 16.50” MPXD-30D-L 39.00” 26.75” MPXD-30D-R 14.75” 24.25”

2.2 Available MPX Models

The three models in the MPX Series are: the MPXS-30D, MPXS-60S, and the MPXD-30D (see Figures 2-3 to 2-5). The MPXS-30D model is designed for use with a single MP enclosure (MPSL-30D and MPSH30D), the MPXS-60S is only used with the MPSL-60S, while the MPXD-30D is designed for use with a dual MP enclosure (MPDH-30D). Each model comes in a left (L) and right (R) version. The ‘right’ version (MPXS-30D-R, MPXS-60S-R, or MPXD-30D-R) is used when the MPX is mounted to the right of the MP enclosure, and the ‘left’ version (MPXS-30D-L, MPXS-60S-L, or MPXD-30D-L) is used when the MPX is mounted to the left of the MP enclosure. The left version differs from the right only in that the length of the supplied DC cables are different to accommodate the difference in distance from the MP’s DC breaker to the new installed inverter.

Info: The MPXS-60S model is unique in that it provides #6 AC wiring and a single-pole 60 AAC breaker, rather than the #10 AC wiring and 30 AAC double-pole breaker that comes with the MPXS-30D and MPXD-30D models.

TABLE 2-3, MPX MODELS

MPX

Model

MPXS-30D

(left or right installation)

MPXS-30D-L/MPXS-30D-R MPSL-30D/MPSH-30D

Versions

Used With:

MP Enclosure Inverters

MS4024PAE or MS4448PAE

stacked in parallel

MPXS-60S MPXS-60S-L/MPXS-60S-R MPSL-60S MS4024 stacked in series

MPXD-30D MPXD-30D-L/MPXD-30D-R MPDH-30D

MS4024PAE or MS4448PAE

stacked in parallel

MPXS-60S on left side (MPXS-60S-L) MPXS-60S on right side (MPXS-60S-R)

MS4024

I

NVERTER

MPXS-60S-L

MS4024

I

NVERTER

OR

MS4024

I

NVERTER

MS4024

I

NVERTER

MPXS-60S-R

MPSL-60S

Figure 2-3, MPXS-60S Installation Conﬁ gurations

5

2.0 Introduction

MPXS-30D on left side (MPXS-30D-L)

MS

-PAE

I

NVERTER

MS-PAE

NVERTER

I

MPXS-30D-L

MPSL-30D

MPXS-30D on both sides (MPXS-30D-L & MPXS-30D-R)

MS-PAE

NVERTER

I

OR

MS-PAE I

NVERTER

MPXS-30D on right side (MPXS-30D-R)

MS-

PAE

I

NVERTER

MS-PAE

I

NVERTER

MPXS-30D-R

MPSL-30D

MS-PAE

NVERTER

I

MPXS-30D-L

MPXS-30D-R

MPSH-30D

Figure 2-4, MPXS-30D Installation Conﬁ gurations

MPXD-30D on both sides (MPXD-30D-L & MPXD-30D-R)

MS-PAE

I

NVERTER

MPXD-30D-L

MS-PAE

I

NVERTER

MS-PAE

I

NVERTER

MS-PAE I

NVERTER

MPXD-30D-R

MPDH-30D

Figure 2-5, MPXD-30D Installation Conﬁ guration

6

2011 Magnum Energy, Inc.

3.0 Installation

3.1 Installing the MPX

Info: Installations should be performed by qualiﬁ ed personnel, such as a licensed or

certiﬁ ed 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 location and application of the installation.

WARNING: This manual does not cover all the relevant safety instructions for your entire MP/MPX system. Review the safety information on pages 1 and 2 of this manual. Refer to the MP Owner’s Manual (PN: 64-0028) prior to installing the MPX extension.

CAUTION: The MPX/MP enclosures and the inverters are heavy . Remember to use proper lifting techniques during installation to prevent personal injury.

3.1.1 Preparation

Before proceeding, read the entire Installation section to determine how you are going to install your MPX extension. The more thorough you plan in the beginning the more time you will save. Proper planning will also help you avoid common, costly mistakes.

Required Materials and Tools

Materials

• Conduit, strain-reliefs, and appropriate ﬁ ttings • 1/4” mounting bolts & lock washers

• Electrical tape • Wire ties

• Conductors/cables for wiring

Tools

• Miscellaneous screwdrivers • Insulated pliers • Wire cutters/strippers

• Drill and drill bits • Pencil or marker • Multimeter

• Level • 1/2” wrench • Torx driver (T20,T25)

• Torque wrenches • Ratchet drives

Location

Info: When possible, Magnum Energy recommends that if you are installing only one MPX

it should be mounted to the left of the MP enclosure. Mounting the MPX on the right may prevent you from adding certain manufacturers’ charge controllers in the future.

Only install your enclosure/inverter system in a location that meets the following requirements:

Clean and Dry - System must be mounted indoors in a relatively cool, clean, and dry en vironment. Ventilation - If installed on the MP enclosure or MPX, the inverters pull in air through the intake

vents. In order to provide full output power and avoid over-temper ature fault conditions do not cover or block the MPX/MP enclosures’ ventilation openings, or install it in an area with limited airﬂ ow. At the minimum, allow 3 inches of clearance to the left and right sides of the MPX/MP enclosures.

Close to the Battery Bank - Locate system as close to the batteries as possible. This ensures the battery cable length is kept as short as possible. Long DC wires tend to lose efﬁ ciency and reduce the overall performance of an inverter. However, the MPX/MP enclosures, inverter, and any other equipment that can spark (or that corrosion could damage) should not be installed in the same compartment/room as the batteries or mounted where it will be exposed to battery gases. These gases are corrosive and will damage this equipment; also, if these gases are not ventilated and if allowed to collect, they could ignite and cause an explosion. Consult your battery supplier for proper installation requirements.

Info: Consult your inverter owner’s manual to determine the proper inverter-to-battery cable size for the distance that is used. However, this cable must not be sized any smaller than 0000 (4/0) AWG if the DC disconnect breaker in the MP enclosure will also be used as the overcurrent device. If a cable smaller than 4/0 AWG is used, an appropriately sized fuse must be installed to provide overcurrent protection to this smaller cable.

7

3.0 Installation

Safe - Keep any ﬂ ammable/combustible material (e.g., paper, cloth, plastic, etc.,) that may be

ignited by heat, sparks or ﬂ ames at a minimum distance of 12 feet away from the MP/inverter system. Do not install the MPX/MP/inverter system in any area that contains extremely ﬂ ammable liquids like gasoline or propane, or in locations that require ignition-protected devices. Sparks from relays, circuit breakers, etc., could ignite the fumes or spills.

Accessible - Do not block access to the front of your system. Maintain at least a 36” (91 cm) clear space in front to access the AC and DC wiring terminals and connections inside the MPX/MP enclosure, as they will need to be checked and tightened periodically.

Removing the MPX’s Front Cover

Remove the front cover on the MPX extension using a T25 Torx screwdriver. The screws are #10-32 x 3/8” Pan head, T25 Torx drive, thread cutting screws and the washers are #10 external tooth Star washers. You will need to reattach the MPX cover once all wiring is completed and tested.

TOP VIEW

BBB

8 1/16"

CC

AABBB

8 15/

64"

LEFT SIDE VIEW

A

8

1/16"

8 1/16"

CONDUIT KNOCKOUTS:

A = ½" and ¾" (x6) B = ¾" and 1" (x6) C = 1½" and 2" (x4)

7 15/64"

1

2"

4"

1/8

16"

FRONT VIEW

BOTTOM VIEW

AAABBB

C

BB

C

BACK VIEW

1

14"

RIGHT SIDE VIEW

A

8 15/64"

A

8 15/64"

C

B

1

KEYHOLE DETAIL

(x4)

0.2

8"

0.412"

0.8145"

0.525"

Figure 3-1, MPX Series Dimensions and Knockout Locations/Sizes

8

3.0 Installation

Conduit Knockouts

Info: Knockouts can be easily removed by tapping the edge with a straight bladed screw-

driver and a hammer, then twist out with pliers; refer to Figure 3-2. Ensure that no debris

remains inside the MPX after removing the knockouts.

The MPX

3-1 for the location of these conduit knockouts. Select the appropriate knockout that is closest to the terminal to which you are running the cable/wire (see Figures 3-1 and 3-3).

comes standard with knockouts for 1/2”, 3/4”, 1”, 1 1/2”, and 2” conduits. Refer to Figure

Info: Identify and remove whatever MPX knockouts you will need for your installation prior to attaching the MPX to the MP enclosure. It is much easier to do this now rather than once the MPX is attached.

Figure 3-2, Removing

a Knockout

Remove one of these knockouts in order to run the communication cables from the router to the inverters.

Do not remove any these front knockouts if the router* is attached to the MPX (see also Figure 3-4).

Note: The RTR bracket below is shown mounted on the right side of the MPX. The bracket can also be mounted on the left side of the MPX.

Do not attach the RTR bracket to the MPX/ MP enclosure at this time (the bracket will be attached later in Section 3.1.8).

Bottom of MPX

RTR

* The router and bracket are only used if inverters are to be parallel stacked.

bracket

Figure 3-3, Removing MPX Knockouts Figure 3-4, MPX with RTR Bracket

9

3.0 Installation

3.1.2 Attaching the MPX to the MP Enclosure

The MPX attaches to the MP enclosure. This provides unit stability when the MP enclosure is mounted to a backplate/sheathing, and also ensures good metal-to-metal contact for grounding the MPX and the MP enclosure together.

1. On the upper side of the MP enclosure, remove the side access plate – the side to which you will attach the MPX (see Figure 3-5).

2. Using the same screw and lock washer (see Item A), attach the side access plate to the side of the MPX (opposite the side of the MPX that attaches to the MP).

Note: Before attaching the MPX to the MP enclosure you should have already removed a knockout from the bottom of the MPX (see Figure 3-3). This knockout is needed for running the communication cables from the router to the inverters.

Use the supplied (B) #1032 x 3/8” (T25) T orx screw and #10 lock washer (Figure 2-2, Items 5 & 6) to attach the MPX to the MP enclosure.

A

MPX

B

3. Use the supplied screw and lock washer (see Item B) to attach the MPX to the MP enclosure. The attachment hole is located towards the front of the (lower) side of the MPX.

Figure 3-5, Attaching the MPX

to an MP Enclosure

3.1.3 Mounting the MP/MPX Enclosure to a Backplate/Wall

The MP enclosure and attached MPX can be mounted on a Magnum backplate or a wall (see the MP Owner’s Manual for wall requirements).

1. Using eight bolts, screw them halfway into the backplate/wall in the locations that the MP enclosure and attached MPX will be mounted (align with each unit’s four keyhole slots).

Note: If you have purchased a Magnum dual or single backplate, you will be supplied with the necessary Hex head bolts (1/4-20 x 3/4”) to mount the MP and MPX units to the backplate. If you are mounting to a wall, the installer must provide the appropriate mounting bolts.

2. Hang the MP enclosure and attached MPX onto the eight bolts using each unit’s keyhole slots (see Figure 3-6).

3. Tighten the bolts to secure the MP enclosure and MPX onto the backplate/wall.

BP-S Magnum

Single Backplate

MP Enclosure

Figure 3-6, Mounting the MPX to a Backplate/Wall

10

3.0 Installation

3.1.4 Attaching the DC and AC Breakers

Info: The holes on the breaker mounting plate inside the MP enclosure — for Torx screws

that hold the new DC and AC breakers — are NOT pre-threaded. Use a power driver to screw these self-threading screws into the mounting plate.

WARNING: During normal operation the terminals, busbars, and electrical components

inside the MP enclosure may be energized - DO NOT TOUCH. Disconnect all power sources before removing the cover.

DC Breaker

CAUTION: The DC break ers must be mounted in a vertical position to meet the speciﬁ ed

trip current and trip delay curve.

The DC breaker is attached within the MP enclosure and functions as the inverter’s DC disconnect switch. The DC breaker can be used as the battery-to-inverter circuit protection in most installations.

1. Using a T25 screwdriver, remove two of the #10-32 x 3½” Torx screws that secure the existing DC breaker to the mounting plate – the removed screws should be the two that are adjacent to where the new DC breaker will be mounted (see Figure 3-7).

2. Place the new DC breaker against the MP’s mounting plate and next to the existing DC breaker where the two mounting straps are loose.

3. While holding the new DC breaker in place, ﬁ t two new mounting straps over the new DC breaker. Ensure the holes on the new mounting straps — that are over the new DC breaker — line up with the holes of the adjacent two existing mounting straps (see Figure 3-8).

4. Insert the two Torx screws that were removed in Step 1 into the aligned holes of the new and existing mounting straps on the adjacent sides of the breakers, and then tighten to secure the existing DC breaker. Insert two new #10-32 x 3½” Torx screws into the other side of the new mounting straps and tighten enough to hold the new DC breaker in place. Do not fully tighten the screws, that will be done in Step 5 after being aligned.

5. Check for proper breaker alignment by temporarily placing the MP’s front panel co ver over the DC breakers. If ﬁ t and alignment are correct, tighten all T orx screws to secure the new DC break er.

CAUTION: Be careful not to over-tighten to the point of bending down the tabs on the

mounting straps.

Mounting Plate

(location for

new breaker)

Leave

existing

mounting

straps

(x2)

in place

Note: Figure 3-8 in-

cludes the new breaker’s DC wire connections. Actual connec-

New

mounting

straps

(x2)

tions occur in Section

3.2.

New

torx

screws

(x2)

Remove

screws

adjacent

to new breaker location

New

DC

breaker

Existing

mounting

straps

(x2)

Existing

torx

screws

(x2)

Existing

DC

breaker

Fig. 3-7, Removing Breaker Screws Fig. 3-8, Attaching the New DC Breaker

11

3.0 Installation

AC Breaker

The AC breaker is attached within the MP enclosure and functions as the inverter’s AC input disconnect switch.

1. While holding the new AC breaker against the MP’s mounting plate, align the breaker’s four mounting holes with the enclosure’s mounting holes (see Figure 3-9). Note: The AC breakers are always installed in the left enclosure of a MP dual enclosure (see Figure 3-10).

2. Use the supplied four #8-32 x 1/4” T20 screws (Figure 2-2, Item 4) to hold the AC breaker in place. Do not fully tighten the screws, that will be done in the next step after ensuring proper alignment with the MP enclosure’s cover.

3. Check the AC breaker alignment by temporarily placing the MP’s front panel cover over the AC breakers. If the ﬁ t and alignment are correct, tighten all Torx screws to secure the new AC breaker.

Use four #8-32 x ¼” (T20) Torx screws

Figure 3-9, Attaching the New AC Breaker Within a MP Single Enclosure

Figure 3-10, Attaching the New AC Breaker Within a MP Dual Enclosure

12

3.0 Installation

3.1.5 Connect and Separate Inverter AC Wires

Prior to mounting the second inverter on the MP enclosure, connect the AC wires provided in the MPX AC wire kit (see Figure 2-1, Item F and Table 2-1) to the inverter’s AC wiring terminal (see the inverter owner’s manual or the MP Owner’s Manual for guidance in connecting the AC wires inside the inverter). Before connecting the AC wires, separate them into two wire bundles (inverter AC input and inverter AC output) to help ensure they are connected correctly after the inverter is mounted on the MP enclosure.

It is possible to connect these wires after the inverter is mounted. However, you have more space and easier access to the wiring terminal when the inverter’s AC wires are connected before mounting – especially when installing multiple inverters side-by-side on an MP enclosure system. Replace the AC wiring access plate once you have connected the wires inside the inverter.

3.1.6 Mounting the Second Inverter onto the MPX

The additional inverter ﬁ ts on top the MPX and is secured to the backplate/wall (Figures 3-11 & 3-12). Note: Before mounting, pull the unconnected ends of the AC wiring outside of the inverter and

through the MPX enclosure (see Figure 3-12).

1. Place the Magnum inverter on top of the MPX.

2. Secure it to the backplate/wall using four Hex head bolts and the inverter’s keyhole slots.

3. Tighten the Hex head bolts to secure the inverter to the backplate/wall.

Note: Prior to mounting, connect the AC input and output wires within the new inverter (refer to your inverters owner’s manual), and then route the wiring through the MPX.

Figure 3-11, Mounting the Second Inverter on the MPX

13

3.0 Installation

Note: Prior to mounting,

connect the AC input and output wires within each new inverter (refer to your inverter owner’s manual), and then route the wiring through the MPX.

Figure 3-12, Mounting Multiple Inverters on the MPX

IMPORTANT: If the inverter is ever removed from the top of the MPX for service and the AC bypass breaker is used to continue to power the inverter loads, attach the knockout plate (provided with the MP enclosure) to the top of the MPX for use as a safety plate to prevent accidental access to live electrical circuits inside the MPX.

WARNING: If the knockout plate is used as a safety plate, the battery cables from the

top of the DC disconnect must be prevented from touching the metal knockout plate or a short circuit to the battery bank may occur – causing lethal currents. Either remove these cables or isolate them (i.e., using electrical tape/rubber caps), do not rely ONLY on turning the DC disconnect switch to OFF.

3.1.7 Attaching the Inverter Hood

The inverter hood is designed to prevent objects from falling inside the top vents of the inverter, which can cause damage. For installations where the inverter is mounted on a vertical surface (DC terminals facing down) — such as a MP enclosure — the hood must be mounted above the inverter in order to meet UL regulatory requirements.

Info: The inverter hood does not mount to the inverter chassis, it must be mounted to the backplate/wall. Mounting bolts are included if a Magnum backplate has been purchased. If no backplate, the installer must supply the bolts – the mounting slots on the hood will accept up to a maximum 1/4” screw/bolt.

CAUTION: The inverter hood is not to be used as a drip shield to prevent water drops from entering the inverter.

Refer to Figures 3-13 & 3-14 to install the hood. The bottom edge of the hood must be mounted ﬂ ush against the top of the inverter. This is the optimal position for minimizing the risk of objects falling into the inverter, and at the same time providing the clearance needed for air ﬂ ow from the top vents of the inverter. Do not place anything on top of the inverter hood that might cause it to bend downward, or place anything on the sides that might restrict air ﬂ ow through the inverter.

1. Screw two bolts/screws halfway into the backplate/wall where the hood will be mounted.

2. Place the inverter hood on these screws, and then tighten securely.

14

3.0 Installation

Figure 3-13, Attaching the Inverter Hood

Figure 3-14, Attaching Multiple Inverter Hoods

15

3.0 Installation

3.1.8 Attaching the Router Bracket

The Magnum router can be easily attached to the MP and MPX enclosures using the router bracket. The router bracket comes with four screws (#8 x 32 x 3/8” T15 drive) for mounting; one for attaching the bracket to the MPX, and three for attaching the bracket to the MP enclosure (router br acket and hardware provided with MP enclosure). Refer to Figure 3-15.

Use the Torx drive screws

provided with the router bracket

Figure 3-15, Attaching the Router Bracket

3.1.9 Attaching the Router to the Bracket

The router is easily attached to the router bracket using the four screws (#8-32 x 1/2” Phillips drive) in the router bracket kit provided with the MP enclosure. Refer to Figure 3-16 to attach the router to the bracket.

Use the four Phillips screws

provided to attach the router

to the router bracket

Figure 3-16, Attaching the Router to the Bracket

16

3.0 Installation

3.2 Wiring the MPX

This section covers installing AC, DC, and communication wiring for each MPX model (Table 3-1).

TABLE 3-1, MPX WIRING TABLE

MPX Model MP Enclosure

Used With:

MPXS-30D MPSL-30D Figure 3-18a Figure 3-18b Figure 3-18c Figure 3-18d Figure 3-18e MPXS-30D MPSH-30D Figure 3-19a Figure 3-19b Figure 3-19c Figure 3-19d Figure 3-19e

MPXS-60S MPSL-60S Figure 3-21a Figure 3-21b Figure 3-21c Figure 3-21d Figure 3-21e

MPXD-30D MPDH-30D Figure 3-22a Figure 3-22b Figure 3-22c Figure 3-22d Figure 3-22e

*- ‘External’ refers to wiring that is required outside the MP/MPX panel (i.e., wiring to loads, grid/gen input wiring)

3.2.1 Wiring Guidelines

This section provides general information on the AC wiring to/from the new inverter, from the incoming AC source, and to the outgoing AC distribution panel (i.e., inverter sub-panel).

IMPORTANT: All wiring should meet local codes and standards and be performed by qualiﬁ ed personnel such as a licensed electrician.

CAUTION: Before installing any AC wiring, review all safety information in the MP Owner’s

Manual (PN: 64-0028) and at the beginning of this manual, and the information below to ensure a safe system:

• The AC wires must be appropriately sized, and must be no less than #10 AWG (5.3 mm2) gauge copper wire and be approved for residential wiring.

• DO NOT connect the Magnum inverter’s output to an AC power source. This could cause severe damage to the inverter and is not covered under warranty.

Inverter

AC Wiring

External* AC Wiring

Inverter

DC Wiring

Battery Bank

DC Wiring

Communica-

tions Wiring

WARNING: To reduce the risk of ﬁ re, do not connect a 120V AC only inverter to both

busbars in an AC load center (circuit breaker panel) having multi-wire branch circuits connected. Every circuit connected to a 120V AC panel must have its own neutral; otherwise, currents on shared neutrals will add rather than subtract – ov erloading the neutral conductor.

The AC and DC wires into and out of the MP enclosure and the MPX extension must be protected as required by code. This can be done by using jacketed wires or by feeding wires through conduit.

Info: If using a Magnum inverter, and the AC wires are individual conductors (i.e., not jacketed), the strain reliefs on the inverter can be replaced with 3/4” grommets.

• Use proper clamps or other approved methods for securing the cable/conduit to the enclosure.

• The MP enclosure is speciﬁ cally approved/designed for both AC and DC wiring. However, where DC wiring must cross AC or vice-versa, try to make the wires at the crossing point 90° to one another.

• Use only copper wires with a minimum rating of 150V , 75°C if only 120V AC power is being used; or, with a minimum rating of 300V, 75°C if 120/240V AC power is being used.

• In a system where one conductor is grounded, the wire colors on the DC side and the AC side are the same. The insulation on all grounded conductors (DC negative/AC neutral) must be white, gray, or any color except green if marked with white at each termination (marking only allowed on 6 AWG or larger conductors). The equipment grounding conductors must be bare (no insulation), or have green or green with yellow-striped insulation or identiﬁ cation. The hot ungrounded conductor (DC positive/AC hot) is usually red or black.

• Terminals containing more than one conductor must be listed for multiple conductors.

• The connectors or terminals used on ﬂ exible, ﬁ ne-stranded conductors must be speciﬁ cally marked or labeled for use with ﬁ ne-stranded conductors.

• The MPX/MP enclosures include wires (along with communication cables) with insulation rated for at least 300 volts, which allows 120/240V AC inverters to be installed. If installing a 120/240V AC inverter, the installer must also provide wires (both power and communication) with the insulation rated for at least 300 volts.

17

3.0 Installation

AC Connections

To view the AC connection points inside the MP enclosures, review Figures 3-18a/b and 3-19a/b for the MPSL-30D and MPSH-30D models, Figure 3-21a/b for the MPSL-60S model, or Figure 3-22a/b for MPDH-30D model.

If using an MS-PAE Series inverter, the full AC continuous pass-thru capacity of these inverters is 30 amps for each AC leg (AC LEG 1 and AC LEG 2), and requires a maximum 30 amp breaker on each AC input to protect the inverter’s inputs. This correlates with the MPSL-30D, MPSH-30D, and the MPDH-30D enclosures, which include a dual 30 amp input inverter breaker and a minimum cable size of #10 AWG in conduit.

In MS4024 inverters, the AC LEG 1 and AC LEG 2 may be combined to obtain a 60 amps pass-thru capability. When tying the AC LEG 1 and AC LEG 2 together for a 60 amp continuous pass-thru capability, the AC input to the inverter requires a 60 amp breaker. This correlates with the MPSL-60S model, which includes a single 60 amp breaker and requires a minimum cable size of #6 AWG in conduit. Refer to Figure 3-20a for info on wiring to the MS4024 inverter.

If you are using other circuit breakers/wire sizes, refer to the appropriate electrical codes for proper sizing requirements.

DC Cable Connections

Before proceeding with the DC wiring, review the instructions in Figure 3-17 to ensure proper DC cable stacking and connections. Do not put anything between the DC cable ring lug and the battery terminal post or the ﬂ at metal part of the inverter’s DC terminal. When connecting the DC cable to the battery or inverter DC terminals, the cable should be placed directly against the inverter or battery terminals. Incorrectly installed hardware causes a high resistance connection which could lead to poor inverter/charger performance, and may melt the cable and terminal connections.

Make sure to properly connect the DC cables and correctly stack the hardware. Tighten the terminal connections from 10 to 12 ft lbf (13.6 to 16.3 N-m).

CAUTION: The DC terminal and Flange/Kep nuts supplied with the inverter are made of stainless steel, which have a high likelihood of seizure. To help prevent the bolt and nut from seizing — causing the bolts to strip or snap/break-off — the use of anti-seize lubricant is highly recommended.

Info: If antioxidant grease or spray is used, apply it after all the connections have been made and are properly tightened.

Info: A 1/2-inch wrench or socket is used to tighten the 5/16-18 SAE Flange/Kep nuts.

IMPORTANT: Magnum accessories (ME-ARC, ME-RTR, ME-AGS, and ME-BMK) each use a

communication chip to talk with the inverter. This communication chip is powered through the communication lines using the B+ (battery positive) and B- (battery negative) supply. We hav e found that customers are removing the battery negative circuit (B-) while the battery positive circuit (B+) is still connected; or, they are connecting the battery positive (B+) before connecting battery negative (B-). When accessories are connected to the inverter and B+ is connected or disconnected to the inverter without a return path (i.e., B-), the communication chips/lines become the DC return path to the battery – causing permanent damage to all connected accessories on the network.

You should not ha ve any issue with communication circuits when using the MP/MPX panels. This is because when you open the Inverter Disconnect Breaker on the MP to power-down the system you are opening the B+ circuit while all B- circuits remain connected. Once the system is powered-down, you can connect and disconnect communication cables as needed. When you are ﬁ nished removing/adding accessories and comm cables, you can turn the Inverter Disconnect Breaker back on to resume operation, which connects the B+ circuits (with B- circuits already connected).

In summary: Ensure all battery negative (B-) circuits are connected before connecting or disconnecting battery positive (B+).

18

MPX

Inverter

#2

Enclosure

MP

Inverter

#1

3.0 Installation

INVERTER DC NEGATIVE AND POSITIVE CONNECTIONS

Inverter Hardware Stack-up:

Inverter DC terminals

1

2

3

INVERTER NEGATIVE TO SHUNT BUSBAR (TOP) DC POSITIVE CONNECTION

2

3

4

5

1

INVERTER POSITIVE TO INVERTER DC BREAKER (TOP) CONNECTION

3

2

4

1

BATTERY POSITIVE TO INVERTER DC BREAKER (BOTTOM) CONNECTION

1

3

2

4

1

Inverter cable lugs

2

[(-) to shunt busbar, (+) to inverter DC breaker]

5/16-18 nut (Flange or Kep)

3

DO NOT place anything

between the inverter DC

terminals and the inverter

cable lugs

Top of Shunt Busbar Hardware

1 2 3 4 5

between the DC shunt busbar

and the negative inverter cable

Top of DC Breaker Hardware

1 2 3 4

Bottom of DC Breaker Hardware

1 2 3 4

Stack-up:

DC shunt busbar (top) Hex bolt (3/8-16-3/4") Negative (-) battery cable lug Split-lock washer 3/8-16 nut

DO NOT place anything

Stack-up:

DC breaker (top) terminal Positive (+) inverter cable lug Split-lock washer Hex bolt (3/8-16-3/4")

DO NOT place anything

between the DC breaker

terminal and the positive

inverter cable lug.

Stack-up:

DC breaker (bottom) terminal Positive (+) battery cable lug Split-lock washer Hex bolt

between the DC breaker

terminal and the positive

(3/8-16-3/4")

DO NOT place anything

battery cable lug.

.

lug.

BATTERY NEGATIVE TO SHUNT BUSBAR (BOTTOM) CONNECTION

Bottom of Shunt Busbar

Hardware Stack-up:

4

1

2

3

5

1

DC shunt busbar (bottom

2

Hex bolt (3/8

3

Negative (-) battery cable lug

4

Split-lock washer 3/8-16 nut

5

DO NOT place anything

between the DC shunt busbar

and the negative battery cable

-16-3/4")

lug.

Figure 3-17, DC Cable Connections

)

19

3.0 Installation

3.2.2 Wiring the MPXS-30D

The following steps are basic guidelines for installing and connecting the AC, DC, and communication wiring for the MPXS-30D (used with MPSL-30D or MPSH-30D enclosures).

WARNING: To prevent electrical shock, make sure all AC power (inverter, generator, or utility) is off before making any AC connections inside the MP enclosure.

MPXS-30D AC Wiring

This section provides information on the AC wiring to/from the inverters, and to/from the main panel and sub-panel. The MPX kit includes strand B wires for wiring to the AC terminals in the MP enclosure. The HOT 1 and HOT 2 wires into/out of the inv erter are longer than needed. This allows you to cut and use the two excess wire lengths (one black and one red, or one black w/stripe and one red w/stripe) for routing AC wires from the bottom of the AC breaker to the MP’s busbar terminals. See Table 2-1 for AC wire size, color, length, and routing location.

Inverter AC Input Wiring (see Figure 3-18a - MPSL-30D, Figure 3-19a - MPSH-30D)

1. Route and attach a black wire from the top right terminal of each of the MP enclosure’s new AC input breakers to each inverter’s AC HO T 1 IN terminal (Master, Slave 1, and if MPSH-30D enclosure, Slave 2).

2. Route and attach a red wire from the top left terminal of each of the MP enclosure’s new AC input breakers to each inverter’s AC HOT 2 IN terminal.

3. Route and attach a green wire from the MP enclosure’s GROUND busbar to each inverter’s AC GROUND terminal.

Inverter AC Output Wiring (see Figure 3-18a - MPSL-30D, Figure 3-19a - MPSH-30D)

1. Route and attach a black w/white stripe wire from the MP enclosure’s INV HO T 1 OUT busbar to each inverter’s AC HOT 1 OUT terminal (Master, Slave 1, and if MPSH-30D enclosure, Slave 2).

2. Route and attach a red w/white stripe wire from the MP enclosure’s INV HOT 2 OUT busbar to each inverter’s AC HOT 2 OUT terminal.

3. Route a white wire from the MP enclosure’ s AC NEUTRAL busbar to each inverter’s AC NEUTRAL terminal.

Bottom AC Breaker Wiring (see Figure 3-18b - MPSL-30D, Figure 3-19b - MPSH-30D)

1. Route and attach a black wire from the bottom right terminal of each of the new AC input breakers to the MP enclosure’s AC LEG 1 IN busbar (Master, Slave 1, and if a MPSH-30D enclosure, Slave 2).

2. Route and attach a red wire from the bottom left terminal of each of the new AC input breakers to the MP enclosure’s AC LEG 2 IN busbar.

External AC Main Panel Wiring (see Figure 3-18b - MPSL-30D, Figure 3-19b - MPSH-30D)

1. Route and attach a black wire from MP enclosure’s AC LEG 1 IN busbar to the main AC electrical panel.

2. Route and attach a red wire from the MP enclosure’s AC LEG 2 IN busbar to the main AC electrical panel.

3. Route and attach a green wire from the MP enclosure’s GROUND busbar to the main AC electrical panel’s Ground busbar.

4. Route and attach a white wire from the MP enclosure’s AC NEUTRAL busbar to the main AC electrical panel’s Neutral busbar.

External AC Sub-Panel Wiring (see Figure 3-18b - MPSL-30D, Figure 3-19b - MPSH-30D)

1. Route and attach a black wire from the MP enclosure’s AC LEG 1 OUT busbar to the AC electrical sub-panel.

2. Route and attach a red wire from the MP enclosure’s AC LEG 2 OUT busbar to the AC electrical sub-panel.

3. Route and attach a green wire from the MP enclosure’s GROUND busbar to the AC electrical sub-panel’s Ground busbar.

4. Route and attach a white wire from the MP enclosure’ s AC NEUTRAL busbar to the AC electrical sub-panel’s Neutral busbar.

AC Wiring Inspection

After verifying all AC connections are correct — and all AC terminal screws are torqued correctly — replace the covers on the main electrical panel/sub-panel.

20

3.0 Installation

MPXS-30D DC Wiring

This section covers the DC wiring to/from the inverters, and from the battery bank.

WARNING: During normal operation, the terminals, busbars, and electrical components inside the MP enclosure may be energized – DO NOT TOUCH. Disconnect all power sources before removing the cover.

WARNING: Use precaution when working with the DC/battery system, even though it is a “low voltage” system signiﬁ cant hazards may be present, particularly if short circuits occur.

CAUTION: DO NOT connect the battery cables to the battery bank until all wiring to the inverters and inside the MP/MPX enclosures is complete, and the correct DC voltage and polarity have been veriﬁ ed.

Installing DC Cables from Inverters to MP (see Fig. 3-18c - MPSL -30D, Fig. 3-19c - MPSH-30D)

IMPORTANT: Coordinate the DC wiring to each inverter from each DC breaker such that the

far left inverter (Master) is connected to the far left breaker (Master DC breaker), and the second inverter (Slave 1) is connected to the second DC breaker (Slave 1 break er), and so on.

1. Route a DC positive cable (red) from each inverter into the MP enclosure.

2. Connect the end of the DC positive cable (red) to the inverter’s positive DC terminal.

3. Connect the other end of the DC positive cable (red) to a DC circuit breaker’s top terminal.

4. Route a DC negative cable (black) from each inverter into the MP enclosure.

5. Connect the end of the DC negative cable (black) to the inverter’s negative DC terminal.

6. Connect the other end of the DC negative cable (black) to the top of the DC shunt’s busbar.

7. Route an appropriately sized DC equipment ground wire from each new inverter’s DC GROUND terminal to the DC GROUND busbar in the MP enclosure.

8. Verify all DC connections are torqued from 10 to 12 ft lbf (13.6 to 16.3 N-m).

9. Once the DC connections are correctly wired and tested, coat the terminals with an approved anti-oxidizing coating.

Installing the DC Cables From the Battery Bank to the MP Enclosure (see Figure 3-18d MPSL-30D, Figure 3-19d - MPSH-30D)

IMPORTANT: Damage may occur if DC power is connected to the MP enclosure before the Communication wiring is completed. DO NOT connect the DC cables from the MP enclosure to the battery bank until: 1) all DC, AC, and Comm wirings are completed, 2) the correct DC and AC overcurrent protection have been installed and, 3) the correct DC voltage and polarity

have been verified.

WARNING: Ensure all AC and DC breakers are switched OFF before connecting or disconnecting the battery cables, and that all AC and DC power is disconnected from the inverter.

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.

CAUTION: The Magnum inverter is NOT reverse polarity protected, if this happens the inverter will be damaged and will not be covered under warranty. Before making the ﬁ nal DC connection from the MP enclosure down to the battery bank, verify the correct

battery voltage and polarity by using a voltmeter. If the positive (+) terminal of the battery is connected to the negative (–) busbar of the MP enclosure and vice versa, severe damage will result. Ensure the cables are color-coded to avoid polarity confusion.

1. Route a DC positive battery cable (red) from the battery bank thru the bottom of the MP enclosure for each inverter.

2. Connect the end of each DC positive battery cable (red) to a DC circuit breaker’s bottom battery positive connection.

21

3.0 Installation

3. Route a DC negative battery cable (black) from the battery bank thru the bottom of the MP enclosure for each inverter.

4. Connect the end of each DC negative battery cable (black) to the battery negative connection (DC shunt’s bottom busbar).

5. Route an appropriately sized DC equipment ground wire from the ground terminal in the battery bank enclosure to the DC ground terminal in the MP enclosure.

6. Route an appropriately sized DC grounding wire (green or bare wire) from the DC GROUND busbar in the MP enclosure to the system ground (see the MP owner’s manual for information on sizing and connecting the system ground wire).

7. Ensure the DC wire connections (to the inverter, DC circuit breaker, and DC shunt) are ﬂ ush on the surface of the DC terminals and the hardware used to hold these connections are stacked correctly (see Figure 3-17); and then securely tighten these connections.

IMPORTANT: Only after the entire installation is complete and all connections are veriﬁ ed,

should the DC circuit breaker be closed to provide power to the inverters.

MPXS-30D Communication Wiring

Each MPXS-30D kit includes a remote cable and a stacking cable for connecting to a router. The Magnum router comes with two CAT 5 stacking cables and two RJ11 remote cables. The MP enclosure comes with an extension cable for connecting the inverter to a Battery Temperature Sensor (BTS).

Connecting Remote Cables to Router (Figure 3-18e - MPSL-30D, Figure 3-19e - MPSH-30D)

1. Using the supplied RJ11 remote cables, route a cable from each inverter through the MPX to the attached router.

2. Connect one end of each remote cable to the Remote (blue label) port on each installed inverter.

3. Connect the other end of each remote cable to its respective comm port (P1-P6) on the router.

Info: It is recommended that the Master inverter be connected to Port 1, Slave 1 to P ort 2 etc., in order to k eep tr ack of which inv erter is displayed on each port.

Connecting Stacking Cables to Router (Figure 3-18e - MPSL-30D, Figure 3-19e - MPSH-30D)

1. Using the supplied stacking (CAT 5) cables, route a cable from each inverter through the MPX to the attached router.

2. Connect one end of each stacking cable to the Stack Port (red label) on each installed inverter.

3. Connect the other end of each stacking cable to its respective CAT 5 port on the router (MA, SL1, SL2, and SL3 ports for the appropriate number of installed inverters).

Info: At least one CAT 5 cable must be plugged into the router’s MA port in order for the router to operate any inverters.

Battery Temperature Sensors (BTS) (Figures 3-18e - MPSL-30D, Figure 3-19e - MPSH-30D) The Battery T emperature Sensor provides the inv erter with precise battery temperature information

that enables the batteries to be correctly charged under extreme temperature changes. If the BTS is not installed and the batteries are subjected to large temperature changes, battery life may be shortened.

1. Using the supplied extension cable, route the cable from the Master inverter through the MPX and the MP enclosure to the BTS.

Info: When the inverters are installed in parallel, the BTS must be connected to the Master inverter.

2. Connect one end the extension cable to the Battery Temp Sensor port (yellow label) on the Master inverter.

3. Connect the other end of the extension cable to the RJ-11 connector on the BTS.

Connecting the DC Cables from the MP Enclosure to the Battery Bank

Once all the wiring is completed, connect the DC cables from the MP enclosure to the battery bank.

22

Slave

(SL1)

Series

MS-PAE

Inverters

AC INPUT

(to Slave)

Black

Red

Green

Black w/ Stripe

White

Red w/ Stripe

AC OUTPUT

(from Slave)

3.0 Installation

Black

Red

Black

Red

Enclosure

MPSL-30D

SL1

MA

INPUT Breaker

Slave 1 Inverter AC

INPUT Breaker

Master Inverter AC

(MA)

Master

AC INPUT

(to Master)

Black

Red

Green

Black w/ Stripe

White

Red w/ Stripe

MPXS-30D

AC OUTPUT

(from Master)

TO MPSL-30D:FROM INVERTER

Router

:

WIRE

GROUND busbar

AC INPUT breaker

AC NEUTRAL busbar

INV HOT 2 OUT busbar

INV HOT 1 OUT busbar

AC INPUT

AC OUTPUT

RED

BLACK

WHITE

RED w/STRIPE

BLACK w/STRIPE

GREEN

Figure 3-18a, MPXS-30D / MPSL-30D Inverter AC Wiring

23

3.0 Installation

Master Inverter AC

INPUT Breaker

MPSL-30D

.Red

Enclosure

Slave 1 Inverter AC

INPUT Breaker

.Red

.Black

LEG

1

IN

OFF

.Red

LEG

.White

2

IN

OFF

.Green

NEU

IN

ON

.White

GND

ON

AC Sub-Panel

(Inverter Loads)

OFF

AC Main Panel

(AC Source)

.Green

.Red

NEU OUT

.Black

GND

LEG

OUT

ON

OFF

ON

LEG

2

1

OUT

OFF

120V 240V

120V

Figure 3-18b, MPXS-30D / MPSL-30D External AC Wiring

24

Red

Black

3.0 Installation

SL1

Slave

SL1

.Red cable

.Black cable

Red

Black

to positive

DC terminal

to negative

DC terminal

MA

Enclosure

MPSL-30D

(MA)

Master

DC Equipment

Ground Terminal

Series

MS-PAE

Inverters

.Red cable

to positive

DC terminal

MA inverter’s HOT 1 IN terminal

From AC Input breaker (LEG 1) to

From AC Input breaker (LEG 2) to

MPXS-30D

to negative

.Black cable

DC terminal

Figure 3-18c, MPXS-30D / MPSL-30D Inverter DC Wiring

BTS port to BTS

to GROUND busbar

MA inverter’s HOT 2 IN terminal

.From MA inverter’s ground terminal

From MA inverter’s

terminal to DC GROUND busbar

From MA inverter’s DC equipment ground

25

3.0 Installation

MPSL-30D

Enclosure

Connected to each

inverter’s DC Equipment Ground Terminal (see also

Figure 3-18c)

Connected to

DC System

Ground

BTS extension

cable (300V)

MA

Black

Red

SL1

Black

Red

Battery

Temperature

Sensor

Figure 3-18d, MPXS-30D / MPSL-30D Battery Bank DC Wiring

26

Positive (x2), negative (x2),

and ground (x1)

cables connected to

inverter battery bank

3.0 Installation

Remote (P1)

Stack (MA)

To BTS

MPXS-30D

Stacking Ports

To Router’s:

k

t

c

a

S

A

M

m

o

C

1

P

t

r

o

P

r

t

o

P

Master

(MA)

R

u

o

t

Remote Cable

(300V)

e

r

To Router’s:

r

t

o

P

k

c

a

S

1

t

S

L

r

o

t

P

m

o

C

P

2

Stack (SL1)

Remote (P2)

Slave 1

(SL1)

MA

SL1

Comm

Ports

To MA

inverter

Stacking Cables

P1 P2

S

M

L

A

1

Remote Cables

To Slave 1

inverter

Extension Cable

(300V) to BTS

M

E

S

P

L

3

-

D

0

c

n

s

o

l

r

u

e

B

S

T

Figure 3-18e, MPXS-30D / MPSL-30D Communication Wiring

27

3.0 Installation

TO MPSH-30D:FROM INVERTER:

AC NEUTRAL busbar

INV HOT 2 OUT busbar

INV HOT 1 OUT busbar

GROUND busbar

AC INPUT breaker

(SL2)

Slave 2

(SL1)

Slave 1

Black w/ Stripe

Black

Red

Green

Black w/ Stripe

White

Red w/ Stripe

(to Slave 2)

AC INPUT

AC OUTPUT

(from Slave 2)

(to Slave 1)

AC INPUT

Black

Red

Green

White

Red w/ Stripe

MPXS-30D-R

Enclosure

MPSH-30D

Black

Red

Black

Red

Black

Red

SL2

MA SL1

Slave 2

Inverter AC

INPUT Breaker

Slave 1

Inverter AC

INPUT Breaker

AC OUTPUT

WIRE

WHITE

RED w/STRIPE

BLACK w/STRIPE

AC INPUT

RED

BLACK

GREEN

Series

MS-PAE

Inverters

(MA)

Master

AC OUTPUT

(from Slave 1)

(to Master)

AC INPUT

Green Black

Red

Red w/ Stripe

Black w/ Stripe

White

Master

Inverter AC

INPUT Breaker

MPXS-30D-L

(from Master)

AC OUTPUT

Figure 3-19a, MPXS-30D / MPSH-30D Inverter AC Wiring

28

3.0 Installation

Master Inverter

AC INPUT Breaker

MPSH-30D

Enclosure

Slave 1

AC INPUT Breaker

MA SL1

.Red

.Black

.Bl

.Red

ack

Slave 2

AC INPUT Breaker

SL2

.Black

.Red

LEG

120V

.Black

.Red

.White

.Green

LEG

1

2

IN

OFF

ON

OFF

ON

OFF

ON

OFF

ON

NEU

IN

ON

GND

ON

AC Sub-Panel

(Inverter Loads)

OFF

NEU

OUT

AC Main Panel

(AC Source)

240V

120V

.Green

.White

GND

OFF

.Red

LEG

2

OUT

ON

OFF

ON

1

OUT

OFF

Figure 3-19b, MPXS-30D / MPSH-30D External AC Wiring

29

3.0 Installation

2

)

e

2 L

v a

S

l

(

S

30D-R

MPXS-

1 e

v a

l S

r e

t s

a

M

) 1

L S

(

) A

M

(

E A P

S

M

s e

i

r e S

s

r e

t

r e v n

I

l a

e

l

v

n

i

b

t

a

i

m

c

s

r

o

e

d

t

p

e

C

o

R

.

t

D

l

e

l

a

v

b

n

i

t

a c

a

m r

g

k

e

c

t

n

a

l

C

o

B

t

D

.

DC Equipment

Ground Terminal

l a

e

l

v

n

i

b

t

a

i

m

c

s

r

o

e

d

t

p

e

C

o

R

.

t

D

l

e

l

a

v

b

n

i

t

a

c

m r

g

k

e

c

t

n

a

l

C

o

B

t

D

.

Red

Black

Red

S X P

M

L

D

0 3

D 0 3

H

S P

M

e

r u

s o

l c

n E

SL1SL2A

MA

B

A – From MA inverter’s AC HOT 2 OUT to INV HOT 2 OUT busbar

C

B – From MA inverter’s AC HOT 1 OUT to INV HOT 1 OUT busbar

E

D

E – From MA inverter’s AC HOT 1 IN to MA AC INPUT breaker

D – From MA inverter’s AC GROUND to GROUND busbar

C – From MA inverter’s AC NEUTRAL to AC NEUTRAL busbar

F

nverter’s

DC GROUND busbar

From MA i

terminal to

From MA inverter’s DC equipment ground

F – From MA inverter’s AC HOT 2 IN to MA AC INPUT breaker

BTS port to BTS

Figure 3-19c, MPXS-30D / MPSH-30D Inverter DC Wiring

30

MPSH-30D

Enclosure

3.0 Installation

Connected to

each inverter’s

DC Equipment

Ground Terminal

(see also Figure

3-19c)

BTS extension

cable (300V)

Red

Black

Red

MA

SL1

SL2

Red

Black

Connected to

DC System

Ground

Positive (x3), negative (x3),

and ground (x1)

cables connected to

inverter battery bank

Battery

Temperature

Sensor

Figure 3-19d, MPXS-30D / MPSH-30D Battery Bank DC Wiring

31

3.0 Installation

To Router’s:

MA Stack Port

P1 Comm Port

Remote

Cable

(300V)

Remote (P1)

Stack (MA)

To BTS

MS-PAE

Master

(MA)

MPXS-30D-L

To Router’s:

SL1 Stack Port

P2 Comm Port

Remote (P2)

Stack (SL1)

MS-PAE

Slave 1

(SL1)

Stacking Cable

(300V)

To Router’s:

SL2 Stack Port P3 Comm Port

Remote (P3)

Stack (SL2)

MS-PAE

Slave 2

(SL2)

MPXS-30D-R

Stacking Ports

MA

SL1

SL2

Stacking Cables

Router

P1 P2 P3

Comm

Ports

To MA inverter To Slave 2 inverter

M

S

A

S

L

1

2

To Slave 1 inverter

Remote Cables

MPSH-30D

Enclosure

Extension Cable

(300V) to BTS

BTS

Figure 3-19e, MPXS-30D / MPSH-30D Communication Wiring

32

3.0 Installation

3.2.3 Wiring the MPXS-60S

The following steps are basic guidelines for installing and connecting the AC, DC, and communication cables for the MPXS-60S.

WARNING: To prevent electrical shock, make sure all AC power (inverter, generator, or utility) is off before making any AC connections inside the MP enclosure.

MPXS-60S AC Wiring

This section provides information on the AC wiring to/from the MS4024 inverters, and to/from the main panel and sub-panel. The MPXS-60S kit includes #6 AWG strand B wires for wiring to the AC terminals in the MP panel. The HOT 1 and HOT 2 wires into/out of the inv erter are longer than needed. This allows you to cut and use the two excess wire lengths (one black and one red, or one black w/ stripe and one red w/ stripe) for routing AC wires from the bottom of the AC breakers to the MP’s busbar terminals. See Table 2-1 for AC wire size, color, length, and routing location.

Inverter AC Input Wiring (see Figures 3-20a and 3-21a)

LEG 2 AC Input Wiring

1. Route and attach a red wire from the top terminal of the MP enclosure’s AC input breaker (B1) to the HOT 2/LEG 2 inverter’s AC HOT 1 IN and AC HOT 2 IN terminals.

2. Route and attach a white wire from the MP enclosure’s AC NEUTRAL busbar to the HOT 2/LEG 2 inverter’s AC NEUTRAL terminal.

3. Route and attach a green wire from the MP enclosure’s GROUND busbar to the HOT 2/LEG 2 inverter’s AC GROUND terminal.

LEG 1 AC Input Wiring

NOTE: The LEG 1 AC input wiring is shown in the MP enclosure owner’s manual. Inverter AC Output Wiring (see Figures 3-20a and 3-21a)

LEG 2 AC Output Wiring

1. Route and attach a red w/white stripe wire from the MP enclosure’s INV HOT 2 OUT busbar to HOT 2/LEG 2 inverter’s AC HOT 2 OUT and AC HOT 1 OUT terminals.

2. Route and attach a white wire w/black stripe from the MP enclosure’s AC NEUTRAL busbar to HOT 2/LEG 2 inverter’s AC NEUTRAL terminal.

LEG 1 AC Output Wiring

NOTE: The LEG 1 AC output wiring is shown in the MP enclosure owner’s manual. NOTE: For the full 60 amp AC pass-thru on MS4024 model inverters, the inverter’ s HO T 1 and HOT

2 terminals must be wired together. Each terminal (separately) is only rated for 30 amp AC. See Figure 4-1 in the MP manual (PN: 64-0028), or refer to your MS Series owner’s manual for more info on AC wiring.

33

3.0 Installation

Left side view of

inverter mounted

on MPX Enclosure

30

MS4024 Series Inverter (LEG 2) –

showing AC wires from the

internal AC wiring terminal

.AC NEUT OUT

.AC HOT 2 OUT .AC HOT 1 OUT

.AC HOT 2 IN .AC HOT 1 IN

.

.AC NEUT IN

AC

GROUND

.

GREEN

.

WHITE

.

RED

RED w/STRIPE

.

WHITE w/STRIPE

See NOTE

below

Inverter AC

Output Wires

(Leg 2 Only)

Inverter AC

Input Wires

(Leg 2 Only)

Figure 3-20a, Inverter AC Input and Output Wiring Diagram

Info: When wiring the MS4024 (or any other MS Series inverter), both the inverter input and output neutral wires must be connected to a AC NEUTRAL busbar inside the MP enclosure. This is because — depending on the inverter’s operating mode — the inv erter’ s input and output neutral terminals may not be connected together (i.e., inverter’s neutrals are not connected when “inverting”, and are combined when “charging”).

NOTE: Because a neutral to ground connection is also made in the MP enclosure, the neutral to ground connection inside the MS4024 must be disconnected. Refer to your MS4024 owner’s manual for information on how this is done.

34

3.0 Installation

Bottom AC Breaker Wiring (see Figures 3-20b & 3-21b)

Info: Before proceeding any further, disconnect the black AC LEG 1 IN cable from the

bottom left terminal of the AC breaker and reconnect to the bottom right terminal as shown in Figure 3-20b.

• Route and attach a red wire from the bottom terminal of the AC input breaker (B1) to the MP enclosure’s AC LEG 2 IN busbar.

IMPORTANT: Prior to installing the MPXS-60S’s external AC wiring, disconnect and then recon-

nect the AC LEG 1 IN black wire from the left breaker (B1) to the newly installed right breaker (B2), as shown in Figure 3-20b. This ensures that the phase relationship (LEG 1/black on right to LEG 2/ red on left) between the AC input source and the output are correct.

MPSL-60S Enclosure

B1

B2

NOTE: The AC LEG 1 IN wire is moved from the B1 position to the B2 position to ensure correct input/output phase relationship.

Figure 3-20b, MPXS-60S / MPSL-60S AC Breaker Input Wire Transition

External AC Main Panel Wiring (see Figure 3-21b)

1. Route and attach a black wire from the MP enclosure’s AC LEG 1 IN busbar to the main AC electrical panel.

2. Route and attach a red wire from the MP enclosure’s AC LEG 2 IN busbar to the main AC electrical panel.

3. Route and attach a green wire from the MP enclosure’s GROUND busbar to the main AC electrical panel’s Ground busbar.

4. Route and attach a white wire from the MP enclosure’s AC NEUTRAL busbar to the main AC electrical panel’s Neutral busbar.

External AC Sub-Panel Wiring (see Figure 3-21b)

1. Route and attach a black wire from the MP enclosure’s AC LEG 1 OUT busbar to the AC electrical sub-panel.

2. Route and attach a red wire from the MP enclosure’s AC LEG 2 OUT busbar to the AC electrical sub-panel.

3. Route and attach a green wire from the MP enclosure’s GROUND busbar to the AC electrical sub-panel’s Ground busbar.

4. Route and attach a white wire from the MP enclosure’s AC NEUTRAL busbar to the AC electrical sub-panel’s Neutral busbar.

AC Wiring Inspection

After verifying all AC connections are correct, and all AC terminal screws are torqued correctly, replace the covers on the main electrical panel/sub-panel.

35

3.0 Installation

MPXS-60S DC Wiring

This section covers the DC wiring to/from the inverters, and from the battery bank.

WARNING: During normal operation, the terminals, busbars, and electrical components inside the MP enclosure may be energized – DO NOT TOUCH.

WARNING: Disconnect all power sources before removing the cover. Even though DC voltage is “low voltage”, signiﬁ cant hazards may be present, particularly from short cir- cuits of the battery system.

CAUTION: DO NOT connect the battery cables to the battery bank until all wiring to the inverters and inside the MP/MPX enclosure is complete and the correct DC voltage and polarity have been veriﬁ ed.

Installing the DC Cables From the Inverters to the MP (see Figure 3-21c)

IMPORTANT: Coordinate the DC wiring to each inverter from each DC breaker such that the

far left inverter is connected to the far left breaker (HOT 2/LEG 2 DC breaker), and the second inverter is connected to the second DC breaker (HOT 1/LEG 1 breaker), and so on.