Menards MasterForce 260-9521 User manual

To Reduce The Risk Of Injury, User Must Read And

Understand Operator’s Manual. Save These Instructions For Future Reference.

260-9521

0099002205-00

1500W Power Converter

TABLE OF CONTENTS

Safety Symbols...............................................................................Page 3

Safety Information ..........................................................................Page 4

Important Safety Instructions .......................................................Page 5

Personal Precautions .....................................................................Page 6

Converter Location.........................................................................Page 6

Features ..........................................................................................Page 6

Speciﬁcations .................................................................................Page 7

Replacement Parts.........................................................................Page 7

Before Using Your Converter .........................................................Page 7

Fastening the Converter to a Flat Surface....................................Page 8

Connecting Converter Cables .......................................................Page 8

Battery Bank Instructions ..............................................................Page 9

Operating Instructions..................................................................Page 10

Power Source ...............................................................................Page 11

LED Indicator and Shutdown Protection ....................................Page 12

If the Converter’s Fuse Blows......................................................Page 12

Maintenance and Storage Instructions.......................................Page 12

Troubleshooting ............................................................................Page 13

Warranty ........................................................................................Page 14

Page 3

SAFETY SYMBOLS

Some of the following symbols may be used on your converter Please study

them and learn their meaning. Proper interpretation of these symbols will allow

better and safer operation of the converter.

Symbol Name Designation/Explanation

VVolts Voltage

AAmperes Current

Hz Hertz Frequency

WWatts Power

~Alternating current Type of current

Direct current Type or characteristic of current

Class II construction Double-insulated construction

Read the operator’s

manual

To reduce the risk of injury, read and

understand the operator’s manual

Warning symbol Alerts user to warning message

Electric shock symbol

Connect only to properly grounded

outlets. Replace defective cords or

wire immediately.

Page 4

SAFETY INFORMATION

The purpose of safety symbols is to attract our attention to possible dangers. The

safety symbols, and the explanations with them, deserve your careful attention and

understanding. The symbol warnings do not by themselves eliminate any danger.

The instructions and warnings they give are no substitutes for proper accident pre-

vention measures.

Be sure to read and understand all safety instructions in this

manual, including all safety alert symbols, such as “DANGER”, “WARNING” and

“CAUTION” before using this converter. Failure to follow all instructions listed

below may result in electric shock, ﬁre and/or serious personal injury.

SYMBOL MEANING

SAFETY ALERT SYMBOL: Indicates DANGER, WARNING or CAUTION.

May be used in conjunction with other symbols or pictographs.

Failure to obey this safety warning WILL result in death or serious

injury to yourself or to others. Always follow the safety precautions to reduce the risk

of ﬁre, electric shock and personal injury.

Failure to obey this safety warning CAN result in death or

serious injury to yourself or to others. Always follow the safety precautions to

reduce the risk of ﬁre, electric shock and personal injury.

Failure to obey this safety warning MAY result in personal

injury to yourself or others, or property damage. Always follow the safety precautions

to reduce the risk of ﬁre, electric shock and personal injury.

Page 5

1. IMPORTANT SAFETY INSTRUCTIONS

1.1

SAVE THESE INSTRUCTIONS – This

manual contains important safety and

operating instructions for converter

model 260-9521. This manual will

show you how to use your converter

safely and effectively. Please read,

understand and follow these instruc-

tions and precautions carefully.

RISK OF ELECTRIC SHOCK OR FIRE.

1.2

People with pacemakers should con-

sult their physician before using the

converter. Electromagnetic ﬁelds in

close proximity to a heart pacemaker

may cause pacemaker interference

or pacemaker failure.

1.3

IMPORTANT: Do not use in a marine

application.

1.4

Keep out of reach of children.

1.5

Do not expose converter to rain or

snow.

1.6

Use of an attachment not rec-

ommended or sold by the unit

manufacturer may result in a risk of ﬁre,

electric shock, or injury to persons.

1.7

Do not disassemble the unit; take it to

a qualiﬁed serviceman when service

or repair is required. Incorrect reas-

sembly may result in a risk of electric

shock or ﬁre.

1.8

To reduce risk of electric shock, unplug

unit from outlet before attempting any

maintenance or cleaning. Turning off

controls will not reduce this risk.

1.9

For the most effective use, place the

power converter on a ﬂat surface.

1.10

Keep the converter well ventilated,

in order to properly disperse heat

generated while it is use. Make sure

there are several inches of clearance

around the top and sides and do not

block the slots of the converter.

1.11

Do not place the converter in areas

such as battery compartments or

engine compartments, where fumes

or gases may accumulate.

1.12

DO NOT operate the converter if you,

the converter, the device being oper-

ated or any other surfaces that may

come into contact with any power

source are wet. Water and many other

liquids can conduct electricity, which

may lead to serious injury or death.

1.13

Do not place the converter on or

near heating vents, radiators or other

sources of heat or ﬂammable materials.

1.14

Do not place the converter in direct

sunlight. The ideal air temperature for

operation is between 50° and 80°F.

1.15

Only connect the power converter to

a 12V battery or power supply. Do not

attempt to connect the converter to

any other power source, including an

AC power source. Connecting to a 6V

or 16V battery will cause damage to

the converter.

1.16

Do not use with positive ground elec-

trical systems.

1.17

Make sure the AC plug is tight.

1.18

Do not modify the AC receptacle in

any way.

1.19

Do not try extending or otherwise

changing the 12V power cord sup-

plied with your converter. Make sure

the cord connections are tight.

1.20

Incorrect operation of your converter

may result in damage and personal

injury.

The converter output is 120V AC and

can shock or electrocute the same as

any ordinary household AC wall outlet.

1.21

Do not use the converter with a prod-

uct that draws a higher wattage than

the converter can provide, as this

may cause damage to the converter

and product.

1.22

This device does not include an in-

ternal Ground Fault Circuit Interrupter

(GFCI). For GFCI protection, use a

GFCI outlet.

Page 6

2. PERSONAL PRECAUTIONS

2.1

Restrictions on Use: This converter

may not be used with life support

devices or systems. Failure of this con-

verter 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.

2.2

Wear complete eye protection and

protective clothing when working

near lead-acid batteries. Always

have someone nearby for help.

2.3

Remove all personal metal items from

your body, such as rings, bracelets,

necklaces and watches. A lead-acid

battery can produce a short circuit

current high enough to weld a ring to

metal, causing a severe burn.

2.4

Never smoke or allow a spark or

ﬂame in the vicinity of the battery or

engine.

3. CONVERTER LOCATION

3.1

Never place unit directly above bat-

tery; gases from battery will corrode

and damage the converter.

3.2

Never allow battery acid to drip on unit

when reading gravity or ﬁlling battery.

3.3

Do not operate converter in a closed-in

area or restrict ventilation in any way.

4. FEATURES

• ON/OFF rocker switch

• LED indicator

Green indicates Power ON.

Red indicates Overload/Interruption

in power.

• 12 Volt power cord

• 120V standard AC outlets (2)

• USB ports – 5V, 2.0A (2)

• High-speed cooling fans (2)

To keep the converter cool, the fans

speed up as the load increases. The

fans do not run when the converter is

turned off.

• Positive Battery Cable Terminal (Red)

• Negative Battery Cable Terminal

(Black)

• Ground Terminal and ground wire

Grounds converter, to protect against

electrical shock.

• Thermal Protection

When the thermal resistor exceeds 80° C

(176° F), the converter shuts down until it

cools off, and then automatically restarts.

• Surge Protection

When the power input from the vehicle’s

battery exceeds 16 volts, the converter

shuts down. Once the voltage drops

down to less than 14 volts, it automati-

cally restarts.

• Low-Battery Protection

When the power input from the vehi-

cle’s battery drops to below 10.5 volts,

the alarm will sound, the red LED will

light, and the converter will shut down.

Page 7

5. SPECIFICATIONS

Nominal input voltage.....................................................................12.8-13.2 VDC

Nominal output voltage .................................................................... 110-125 VAC

Output frequency...............................................................................60 Hz ± 3 Hz

Operating input voltage..................................................................10.5-15.5 VDC

Continuous output power................................................................ Up to 1500 W

Surge output power (0.1 second).............................................................. 3000 W

Waveform ................................................................................Modiﬁed sine wave

Maximum efﬁciency........................................................................................ 90%

Maximum no load current (at nominal input voltage)............................ 0.80 ADC

Input overvoltage shutdown............................................................. 16 ± 0.5 VDC

Input undervoltage alarm .............................................................. 10.5 ± 0.5 VDC

Input low voltage shutdown ............................................................. 10 ± 0.5 VDC

Output power overload shutdown level.......................................... 1675 ± 175 W

Internal fuse ............................................................................................... 30A x 6

AC receptacles....................................................................Two, NEMA 5-15 USA

USB ports...................................................................................................Two, 2A

Battery cables......................................................................... One black, one red

Ground wire........................................................................................... One green

6. REPLACEMENT PARTS

Battery cable (black)........................................................................ 3899003409Z

Battery cable (red) ........................................................................... 3899003410Z

7. BEFORE USING YOUR CONVERTER

Do not use the converter with a product

that draws a higher wattage than the

converter can provide, as this may cause

damage to the converter and product.

When you turn on a device or a tool that

runs on a motor, the device goes through

two stages:

Start Up – Requiring an initial surge of

power (commonly known as the “start-

ing” or “peak” load).

Continuous Operation – Power con-

sumption drops (commonly known as

the “continuous load”).

The wattage (WATTS) or amperes (AMPS)

can normally be found stamped or printed

on most devices and equipment, or in

the user’s manual. Otherwise, contact

the manufacturer to ﬁnd out whether the

device you want to use is compatible with

a modiﬁed sine wave.

To calculate the wattage:

Wattage = AMPS x 120 (AC Voltage).

To calculate the starting load:

Starting Load = 2 x wattage.

In general, the startup load of the device

or power tool determines whether your

converter has the capability to power it.

To calculate the continuous load:

Continuous Load = AMPS x 120

(AC Voltage).

Page 8

IMPORTANT: Always run a test to establish

whether the converter will operate a par-

ticular piece of equipment or device. In the

event of a power overload, the converter is

designed to automatically shut down.

This safety feature prevents damaging

the converter while testing devices and

equipment within the wattage range of

the converter.

If a device does not operate properly when

ﬁrst connected to the converter, turn the

converter ON/OFF switch ON, OFF, and

ON again in quick succession. If this pro-

cedure is not successful, it is likely that

the converter does not have the required

capacity to operate the device in question.

IMPORTANT: This converter uses a nonsi-

nusoidal waveform (Fig. 1) which is not the

same as power company electricity (Fig 2).

Therefore, we do not recommend you use it

to power the following devices:

Switch mode power supplies

Linear power supplies

Class 2 transformers

Line ﬁlter capacitors

Shaded pole motors

Fan motors

Microwave ovens

Fluorescent and high intensity lamps

(with a ballast)

Transformer less battery chargers

Using the converter with any of these

devices may cause the device to run

warmer or overheat.

Fig. 1

Modied sine waveform

produced by converter

Fig. 2

Pure sine waveform

typical of home AC outlet

IMPORTANT: If you are using the power

converter to operate a battery charger,

monitor the temperature of the battery

charger for about 10 minutes. If the battery

charger becomes abnormally warm, dis-

connect it from the converter immediately.

8. FASTENING THE CONVERTER TO A FLAT SURFACE

For your convenience, the converter may

be fastened horizontally to a ﬂat sur-

face. The area where the converter is to

be fastened must be dry, well-ventilated

and away from any combustible material

or fumes.

Turn off and disconnect the converter.

Place the back of the converter with the

mounting bracket against a ﬂat, secure

surface.

Attach the converter, using corrosion-

resistant screws.

9. CONNECTING CONVERTER CABLES

The converter and power source must be

in the OFF mode.

IMPORTANT: Make sure to connect your

converter only to a 12 volt power supply.

To avoid electrical shock, it is necessary

to ground the converter as well as the

device powering it. The converter should

be grounded, using a 16 AWG copper

wire (included).

NOTE: Do not turn on the converter or the

power source until the converter and the

power source are grounded.

Page 9

TO GROUND THE CONVERTER

Turn off and disconnect the converter.

Locate the chassis ground screw on the

back of the converter.

Remove the outer hex nut and loosen

the second hex nut.

Attach the grounding wire’s ring con-

nector to the ground terminal of the

converter.

Tighten the hex nut securely. Then,

replace the other hex nut and tighten it

securely.

Attach the other end of the wire to a

properly grounded location:

Vehicle: Connect to the chassis, unpainted

frame part, or engine block of the vehicle.

Fixed location: Connect to a ground rod

or other appropriately rated ground.

CONNECTING CONVERTER

CABLES TO THE CONVERTER

(See Fig. 3):

Locate the Positive and Negative termi-

nals on the left side of the converter.

From the POSITIVE (RED) and the NEG-

ATIVE (BLACK) terminals, remove the

hex nut, split lock and ﬂat washer.

Place the POSITIVE (RED) ring connec-

tor onto the POSITIVE (RED) converter

terminal. Place the NEGATIVE (BLACK)

ring connector onto the NEGATIVE

(BLACK) converter terminal.

Place a ﬂat washer and split lock on top

of each ring connector. Put a hex nut

over these and tighten.

Hex nut

Flat

washer

Split

lock

Ring

connector

and cable

Converter

terminal

Fig. 3

CONNECTING THE CONVERTER

CABLE TO A 12V BATTERY

OR 12V POWER SOURCE:

Keep hands, hair, clothing and jewelry

clear of battery terminals.

Wear eye protection and protective

clothing.

For a negative-grounded vehicle (do

not use with positive ground electrical

systems), connect the POSITIVE (RED)

ring terminal from the converter to the

POSITIVE (POS, P, +) ungrounded post

of the battery. Connect the NEGATIVE

(BLACK) ring terminal to the vehicle

chassis or engine block away from the

battery. Do not connect the terminal

to the carburetor, fuel lines or sheet-

metal body parts. Connect to a heavy

gauge metal part of the frame or

engine block.

To disconnect the converter, remove

ﬁrst the negative terminal and then the

positive terminal.

IMPORTANT: Failure to make the correct

connections will result in blown fuses and

permanent damage to the converter.

10. BATTERY BANK INSTRUCTIONS

BATTERY BANK ASSEMBLY

READ THESE SAFETY INSTRUCTIONS

BEFORE ASSEMBLING THE BATTERY

BANK.

• Connect batteries ONLY in parallel

(negative terminals together to one

cable; positive terminals together to

the other cable), as shown in the Bat-

tery Bank Example.

• Do not connect 12V batteries in a series

with the negative of one battery con-

nected to the positive of the next.

CONNECTING INCORRECTLY MAY

RESULT IN VOLTAGE HIGH ENOUGH TO

CAUSE ELECTROCUTION.

• While assembling the battery bank,

wear splash-resistant ANSI-approved

safety goggles and electrically insu-

lated gloves.

Page 10

• Connect Only similar batteries together

in a battery bank. Do not connect old

to new, ﬂooded to gel cells, or batteries

with different capacities.

• Use extension cables with the speciﬁed

gauge (or thicker).

6’ or less: 4 AWG; 6-10’: 2 AWG

RISK OF EXPLOSIVE GASES.

• Assemble the battery bank in a clean,

well-ventilated location, away from igni-

tion sources and ﬂammable materials.

• To reduce risk of battery explosion, follow

these instructions and those published

by the battery manufacturer and manu-

facturer of any equipment you intend to

use in vicinity of a battery. Review cau-

tionary markings on these products.

CONNECTING THE BATTERIES

IN PARALLEL

First, connect all of the positive termi-

nals to each other.

Next, connect all of the negative ter-

minals to each other.

Connect the negative and positive

output cables to opposite ends of the

bank. Do not allow the output cables

to touch one another.

Test the voltages at the output cables,

to make sure that the battery bank is

correctly wired.

If the voltage is higher than 13 volts,

part of the battery bank is proba-

bly connected in series (a negative

terminal of one battery attached to

a positive terminal of another) instead

of in parallel.

Carefully examine the diagram and

correct the wiring before attaching to

the converter.

Make sure the converter’s switch is

set to OFF (O).

Connect the output cables from the

battery bank to the converter.

12V

lead-acid

battery

200 Ah*

Connect additional

12V 200 Ah*

lead-acid

batteries here

to increase capacity

12V

lead-acid

battery

200 Ah*

Example:

12V/400 Ah† BATTERY BANK

OUTPUT

to NEGATIVE

converter

terminal

OUTPUT

to POSITIVE

converter

terminal

Fig. 4

†Bank Capacity =

(single battery capacity) x (# of batteries)

400 Ah capacity is for (2) 200 Ah batteries.

*200 Ah batteries shown for illustration

purposes.

11. OPERATING INSTRUCTIONS

Connect the converter (see Connect-

ing Converter Cables section.

Switch the converter’s ON/OFF switch

to the ON (I) position.

The GREEN LED indicator will light, indi-

cating the converter is receiving power.

Switch the converter’s ON/OFF switch

to the OFF (O) position. (The GREEN

LED may ﬂash brieﬂy and/or the inter-

nal speaker may make a brief “beep”.

This is normal.)

Make sure the device to be operated

is turned OFF.

Plug the device into the converter’s

AC outlet.

Switch the converter’s ON/OFF switch

to the ON (I) position.

Turn the device on.

To disconnect, reverse the above pro-

cedure.

NOTE: If more than one device is to be

powered, start one device at a time, to

avoid a power surge and overloading the

converter. The surge load of each device

should not exceed the converter’s Con-

tinuous Operation wattage rate.

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