Mastervolt Mass Combi Pro Installation and Operation Manual

1 General Information

1.1 Product Description

The Mass Combi Pro is a multifunctional battery charger/inverter combination. It draws power from an external AC source (e.g., a generator or shore power connection) to supply your AC loads and charge your batteries.

1.2 How to Use This Manual

This manual serves as a guide for the safe and effective installation and operation of the Mass Combi Pro. It is intended for electricians (installation, operation, and commissioning) and end-users (operation, maintenance, and troubleshooting of minor malfunctions). Ensure all personnel working with the unit are familiar with and follow the instructions provided.

1.3 Manual Validity

This manual applies to the following models: Mass Combi Pro 12/3000-150 and Mass Combi Pro 24/3500-100. All specifications are for the standard Mastervolt configuration.

1.4 Disclaimer

Mastervolt products are continuously developed. Changes may occur without prior notice. No rights can be derived from this document. Refer to the general terms and conditions of sale.

1.5 Warranty

Mastervolt provides a two-year warranty, provided the unit is installed and operated according to this manual, by a qualified electrician, and without unauthorized modifications or repairs.

1.6 Modifications to the Mass Combi Pro

Modifications require written approval from Mastervolt, except for DIP-switch settings for user configuration.

1.7 Liability

Mastervolt is not liable for consequential damages or errors in this manual.

1.8 Type Label

The type label, located on the right side of the Mass Combi Pro, contains essential product information. Do not remove it.

1.9 Correct Disposal of Old Equipment

This product complies with European Directive 2012/19/EU. Dispose of old equipment according to local regulations.

2 Safety Guidelines and Warnings

2.1 Warnings and Symbols

Pay attention to the following symbols:

• !: Indicates a procedure or situation requiring special attention.
• CAUTION!: Provides specific information, instructions, and prohibitions to prevent damage.
• WARNING: Indicates potential user injury or significant material damage if instructions are not followed.

Read this manual before installation and use. The product complies with EU directives and standards.

Protection Class: IP23 (protected against finger contact and falling spray water at 60° angles). Class 1 product, requires grounding.

2.2 Intended Use

The Mass Combi Pro is designed for charging batteries and supplying AC loads in fixed installations. It converts DC battery voltage to AC voltage. Ensure it is connected via a suitable double-pole circuit breaker and residual current device, protected by appropriate fuses, and is in good technical condition. Install in a closed, well-ventilated area, protected from moisture and dust.

2.3 Organizational Measures

Ensure access to and understanding of this manual. Follow all safety guidelines.

2.4 Warning of Special Dangers

Never use the Mass Combi Pro in potentially explosive atmospheres (gas or dust). Do not use it for purposes other than intended.

2.5 General Safety Precautions

• Do not expose to rain, snow, or excessive moisture.
• Do not block ventilation openings.
• Install in a well-ventilated area to prevent overheating.
• Ensure proper grounding of the unit.
• Use appropriate fire extinguishers for electrical fires.
• Prevent short circuits and reverse polarity.
• Protect DC wiring with a suitable fuse.
• Ensure all connections comply with local standards.
• Do not perform work on the unit while connected to a power source.
• Inspect wiring and connections annually.
• Do not touch the unit with wet hands.
• Secure the unit properly, especially in vehicles, to prevent it from becoming a projectile in an accident.
• Do not open the housing except for the connection area.

2.6 Warning Regarding Life-Support Applications

Mass Combi Pro products are not intended for use in medical devices that are part of life-support systems unless a specific written agreement is in place with Mastervolt.

2.7 Warning Regarding Battery Use

Avoid excessive battery discharge and high charging voltages. Prevent battery short circuits, which can lead to explosions and fire. Installation and battery settings should only be performed by authorized personnel.

3 Technology

3.1 How it Works

The Mass Combi Pro is a multifunctional inverter, battery charger, and AC transfer switch. It manages AC power flow, charges batteries, and converts DC to AC.

Diagram Description: A schematic shows the flow of power from Generator (GEN), Mains, and Battery to the unit, and out to AC Output 1 (OUT-1) and AC Output 2 (OUT-2, switched). The unit contains an inverter/charger (3), an AC transfer switch (2), and a user interface (1).

3.2 Battery Charger

The integrated battery charger is electronically controlled and designed for lead-acid (flooded, Gel, AGM) and Lithium-ion batteries. It uses Mastervolt's three-stage Plus charging algorithm. When an external AC source is connected, the charger also acts as an AC-DC converter for DC loads.

3.2.1 Three-Stage Plus Charging System

The charging process consists of three stages:

• BULK: Maximum charging current (100%) to rapidly charge the battery. Voltage gradually increases.
• ABSORPTION: Constant voltage stage where the battery is topped off. Current decreases as the battery reaches full charge.
• FLOAT: Maintains the battery at optimal charge with a stable voltage.

The system automatically switches between stages based on battery voltage and charge status.

3.2.2 Charging with Temperature Compensation

A battery temperature sensor (included) adjusts charging voltage based on battery temperature to prevent overcharging and gassing, extending battery life.

3.2.3 Silent Mode

Reduces fan noise but may limit charging current and increase charging time.

3.3 Inverter

3.3.1 General

The inverter provides voltage and frequency-regulated AC power from the battery bank. Electronic circuits protect against overloads, low/high battery voltage, and overheating. It offers high surge current for inductive loads.

3.3.2 Power Saving Mode (Selectable)

Automatically reduces power consumption when no loads are connected, with instant response to increased demand. Can be configured via MasterBus or DIP switch.

3.4 Operating Modes

The Mass Combi Pro offers various operating modes that can be combined. These can be activated via the front switch, DIP switches, or MasterBus.

3.4.1 Inverter Mode

Provides AC power to the outputs when no external AC source is available.

3.4.2 Charging Mode

Charges the battery and supplies AC outputs from an external AC source (Mains or Generator).

3.4.3 Output 1 and 2

Output 1 provides continuous AC power. Output 2 is available when an external AC source is present and can be configured.

3.4.4 Power-Sharing Mode

Manages AC input current to prevent tripping of the AC fuse when loads exceed available input power. The power-sharing level should match the AC input fuse rating.

3.4.5 Generator/Mains Support

Supplements the AC input power with inverter power when demand exceeds available input. Inverter power is never fed back into the AC grid. Check local regulations regarding parallel operation with the grid.

4 Operation

4.1 LED Indicators

LEDs on the front panel indicate the status of the Mass Combi Pro:

• Generator Input LED: Indicates generator power.
• Mains Input LED: Indicates mains power.
• Power Indicator LEDs: Show charging current (during charging) or output power (during inversion). Red on the top LED indicates overload.
• AC Output 1 LED: Indicates power to Output 1.
• AC Output 2 LED: Indicates power to Output 2.
• Charge Indicator LEDs: Show charging phase or battery voltage approximation.
• Main Switch: Controls power to the unit (On, Off, Inverter Off).

4.2 Protection Devices

The Mass Combi Pro is protected against overload, short circuit, overheating, and under/over-voltage. Faults are indicated on the front panel or MasterBus.

• Output Overload/Short Circuit: Unit shuts down after 5 seconds. Attempts to restart automatically. Permanent shutdown after 5 failed restarts.
• Overheating: Inverter shuts down, charger reduces current. Unit restarts when temperature returns to normal.
• Under/Over-Voltage (AC): Unit switches to inverter mode if AC input is outside limits. Returns to normal when voltage is within limits.
• Under/Over-Voltage (DC): Unit shuts down if DC input is outside limits.

4.2.4 Dynamic DC Input Window

Adjusts shutdown based on battery voltage and current to protect batteries from damage due to low current loads causing voltage drops.

4.3 Operating Strategies

Preferred behavior for AC input and outputs can be configured via MasterBus:

4.3.1 AC Input Strategy

• Mains preferent: Prioritizes mains input.
• Gen preferent: Prioritizes generator input.
• Max fuse preferent: Selects AC source with the highest fuse rating.
• Mains only: Only uses mains input.
• Generator only: Only uses generator input.

4.3.2 AC Output 2 Strategy

• Events only: Manual control.
• Generator input: Output 2 active with generator.
• Mains input: Output 2 active with mains.
• Gen/mains input: Output 2 active with generator or mains.
• Always on: Output 2 is always active.

5 Installation

5.1 Unpacking

Check the contents of the package: Mass Combi Pro, battery temperature sensor, MasterBus termination device. Inspect for any damage.

5.2 Environment

Install in a closed room. Operating temperature: -25°C to 60°C (derating above 40°C). Max. installation altitude: 2000m. Humidity: 0-95% non-condensing. Mount on a firm surface with cable entry pointing downwards. Ensure adequate ventilation. Maintain 10cm clearance around the unit and 15cm below. Do not install near batteries.

5.3 Wiring

Wiring is done within the connection area. Use strain reliefs for cable management. Connect Phase to L, Neutral to N, and Ground to PE.

5.3.1 AC Wiring

Use correct cable cross-sections as specified in the table. Ensure AC input is protected by a fuse (max 30A for Mains, 50A for Generator). Ground wire must have the same cross-section as the phase wire.

5.3.2 DC Wiring

Use appropriate cable sizes (e.g., 95 mm² for 12/3000-150, 50 mm² for 24/3500-100). Use M8 cable lugs. Ensure cables are run parallel to minimize electromagnetic fields. Secure the positive battery cable with a fuse sized according to the cable cross-section. Tighten DC connections to 15-20 Nm.

5.3.3 AC Safety Grounding

The grounding bolt (M6) must be connected to the chassis or hull. Use a minimum 10 mm² cable. A 30 mA RCD is recommended for AC inputs and outputs.

5.4 What You Need for Installation

Ensure you have all necessary parts: Mass Combi Pro, battery temperature sensor, AC cables, DC cables, DC fuse holder and fuse, mounting hardware, batteries, and appropriate connectors.

5.5 Removing the Front Cover

Loosen the two screws and lift the front cover off.

5.6 Mounting the Housing on a Surface

Use M6 screws for vertical mounting. Follow the steps to ensure secure attachment.

5.7 Wiring Instructions

Have connections made by a qualified electrician. Ensure AC and DC distribution panels are de-energized before starting. Switch the main switch to 'Off'.

WARNING: Never connect shore power to the generator input.

CAUTION: Short circuits or reverse polarity can cause serious damage. Under-dimensioned cables or loose connections can lead to overheating.

5.8 Installation Overview

Diagrams show the installation of a single Mass Combi unit, illustrating connections for Generator, Mains, Output 1, and Output 2. Ensure correct polarity, cross-sections, and fuses. Connect an RCD/breaker for Output 1 and 2.

6 Configuration

6.1 DIP Switch Configuration

The Mass Combi Pro has two sets of DIP switches for configuring the unit according to electrical installation specifications. Default settings are '0'. MasterBus settings override DIP switch settings.

DIP Switch Functions:

• A1-A2: Parallel operation (0-0: Single, 1-0: Master, 0-1: Slave).
• A3: Inverter Output (50 Hz / 60 Hz).
• A4: Power Saving Mode (Off / On).
• A5-A6: Battery Charger (Voltage settings for different battery types).
• A7-A8: Battery Type (Flooded, Gel, AGM, etc.).
• B1-B2: Mains Input Fuse Setting (10A, 16A, 30A, 50A).
• B3: Generator Fuse Setting (25A).
• B4: Power-Sharing Mode (Enabled/Disabled).
• B5: Generator/Mains Support Mode (Enabled/Disabled).
• B6: AC Input Voltage Window (Wide/Narrow).
• B7: Generator AC Input Window (Wide/Narrow).
• B8: Grounding Relay (Enabled/Disabled).

6.1.1 Grounding Relay

Enables automatic connection of the inverter's neutral to the safety ground (PE/GND) when operating as an inverter. Comply with local regulations.

6.2 MasterBus Configuration

Parameters can be changed via MasterBus, but DIP switch settings take precedence. If DIP switches are not at default, corresponding MasterBus settings are grayed out.

• Language: Select display language for MasterBus devices.
• Device Name: Assign a name to the device within the MasterBus network.
• Lock Config: Lock configuration settings (Technician Login).
• Factory Settings: Reset configuration to default (Technician Login).
• MasterBus Power: Enable/disable MasterBus power supply.
• Silent Mode: Reduce fan noise, potentially affecting charge time.
• Shunt Device Select: Choose shunt device for readings.
• Main Charger Settings: Maximum current, charging method, battery type.
• Bulk Settings: Bulk voltage, minimum/maximum bulk time, return voltage/time.
• Absorption Settings: Absorption voltage, maximum absorption time.
• Float Settings: Float voltage.
• Inverter Settings: Voltage, frequency, grounding relay, power saving mode, scanning below, dynamic window settings.

6.2.1 MasterBus Alarm Messages

Lists MasterBus alarms and their descriptions (e.g., Overload, Over temperature, Battery low).

6.2.2 List of Event Sources

Lists events that can trigger actions on other MasterBus-connected devices (e.g., Inverting, Charging, Overload).

6.2.3 List of Event Commands

Lists commands that can be sent to other MasterBus-connected devices (e.g., Inverter On/Off, Charger On/Off, Bulk, Absorption, Float).

7 Commissioning, Decommissioning

7.1 Commissioning

CAUTION: Check polarity of all wiring. Set DIP switches before commissioning. Follow steps to turn on the unit: check cables, close front cover, insert DC fuses, connect batteries. A spark may occur when inserting fuses due to capacitors.

7.2 Decommissioning

To decommission the unit:

1. Switch the main switch to 'Off'.
2. Remove DC fuses and/or disconnect batteries.
3. Remove AC input fuses and/or switch off power sources.
4. Open the connection area.
5. Verify all inputs and outputs are de-energized with a voltmeter.
6. Disconnect all wiring.

The unit can now be safely removed.

7.3 Troubleshooting

Faults are indicated by LEDs on the front panel. Refer to the table for fault explanations and solutions. Contact Mastervolt Service Centre if problems persist, providing unit serial number and software version.

8 Technical Data

8.1 Specifications

Detailed specifications for the Mass Combi Pro 12/3000-150 and 24/3500-100 are provided, including inverter, battery charger, and switching system specifications.

8.2 Dimensions

Physical dimensions of the unit are provided in millimeters.