Magnum Energy CSW1012 - Manual (Page 13)

© 2013 Magnum Energy, Inc. 9
2.0 Installation
• Crimped and sealed copper ring terminal lugs with at least a 6mm (1/4”)
bolt hole to connect the DC wires to the inverter’s DC terminals.
• The battery bank voltage MUST be between 10.5-15.5 for the inverter
to operate. If the voltage exceeds 16.0V, the inverter may be damaged.
• To ensure the maximum performance from the inverter, all connections
from the battery bank to the inverter should be minimized. The
exceptions are the DC fuse and disconnect or the DC circuit breaker—
required at the battery to protect the DC wiring—in the positive line. Any
other additional connection will contribute to additional voltage drops,
and these extra connection points may loosen during use.
• All wiring to the battery terminals should be checked periodically (once
a month) for proper tightness. The torque requirement for the DC
terminals is between 79 to 96 lbf-in (8.9 to 10.9 N-m). If you don’t have
a torque wrench, ensure all DC terminals are tight.
• Be aware that overtightening or misthreading the nuts on the DC
terminals can cause the bolts to strip and snap/break off.
• Make sure cables have a smooth bend radius and do not become kinked.
Follow existing wire runs where possible.
• A brief spark or arc may occur when connecting the battery cables to the
inverter DC terminals; this is normal and due to the inverter’s internal
capacitors being charged.
• Before routing the wiring, color code the DC cables/wires with colored
tape or heat shrink tubing: RED for positive (+); WHITE for negative (–);
and GREEN (or bare copper) for DC ground, to avoid polarity problems.
• Do not attempt to use the chassis in place of the battery negative
connection for grounding. The inverter requires a reliable return path
directly to the battery.
2.4.1 DC Wire Sizing
It is important to use the correct sized DC wire to achieve maximum effi ciency
from the system and to reduce fi re hazards associated with overheating.
Always keep your wire runs as short as practical to prevent low voltage
shutdowns and to keep the DC breaker from nuisance tripping (or open
fuses) because of increased current draw. The correct minimum DC wire
size (and corresponding overcurrent device) is required in order to reduce
stress on the inverter, minimize voltage drops, increase system effi ciency,
and ensure the inverter’s ability to surge heavy loads.
If the distance from the inverter to the battery bank is ≤5 feet, use a minimum
DC wire size of #2 AWG (33.6 mm 2 ). If the distance between the inverter
and the battery is >5 feet, the DC wire will need to be increased. Longer
distances cause an increase in resistance, which affects the performance of
the inverter. From 5-10 feet, use a minimum wire size of #1/0 AWG (53.5
mm 2 ) wire; from 10-15 feet, use a minimum wire size of #2/0 AWG (67.4
mm 2 ) wire.
Table 2-1, DC Wire/Overcurrent Device for Rated Use
Inverter
Model
Minimum DC Wire
Size [rating]*
Maximum DC
Fuse Size
DC Grounding
Wire Size*
CSW1012
#2 AWG (33.6 mm 2 )
[170 amps]
150 amps
with time delay
#2 AWG
(33.6 mm 2 )
* Copper wire rated with 75°C (167°F) insulation at an ambient temperature
of 30°C (86°F) in free air.