Overview
The Mastervolt Charge Mate Pro is a current-limited electronic charge relay designed for distributing charge current between two battery banks. The battery banks are connected automatically when the voltage rises above a pre-set value for at least 5 seconds. When the voltage drops, the battery banks are isolated again. An optional remote control switch allows the Charge Mate Pro to be used for emergency engine starts, overriding the automatic function.
Diagrams and Connections
The device facilitates the distribution of charge current between two battery banks, typically originating from a battery charger or alternator. A common negative connection is utilized for both battery banks. The unit features input terminals labeled '+in', 'status', 'ground', 'switch', and '+out'.
[Diagram: Shows the Charge Mate Pro unit connected between Battery 1 and Battery 2, with input from a battery charger/alternator. A common negative connection is shown. An arrow indicates the current direction.]
The front panel of the Charge Mate Pro includes connection terminals and indicators. Options for LED indicators and switches are available for monitoring and control.
[Diagram: Front view of the Charge Mate Pro unit with terminals labeled '+in', 'status', 'ground', 'switch', '+out'. Options for LED indicators and switches are depicted.]
Note: '*' indicates fuse/zekering/Sicherung/fusible. '**' indicates resistor/weerstand/Widerstand/Résistance/resistencia/resistenza.
Specifications
| Specification | Value |
|---|---|
| Model (hardware version C and higher) | 83304002 / 83309002 |
| Weight | 0.7 kg / 1.5 lb |
| Dimensions | 157 x 140 x 80 mm / 6.2 x 5.5 x 3.1 in |
| Input Voltage | 9-32 VDC |
| Operation Temperature | -40 to 60 °C / -40 to 148 °F |
| Maximum Output Current | 40 A / 90 A |
| Maximum Voltage Drop | 0.2 V |
| Maximum Allowed Voltage Difference | 8 V @ 12 V / 16 V @ 24 V |
| Maximum Current Status Output | 1 A |
| Automatic 12/24V detection | Yes |
| Switch on voltage | >13.5 V @12 V / >27 V @ 24 V |
| Switch on delay time | 5 s |
| Switch off voltage | <12.75 V @ 12 V / <25.50 V @ 24V |
| Switch off delay time | 2.5 s |
Recommended Wire Sizes
For wire length up to 3 meters (10 ft) (DIN 47750):
| DC Current | Wire size |
|---|---|
| 25 – 75 Amp | 16 mm² (AWG 4) |
| 75 - 100 Amp | 25 mm² (AWG 3) |
| 100 - 140 Amp | 35 mm² (AWG 1-2) |
| 140 - 200 Amp | 50 mm² (AWG 0) |
Ground wire size: 4 mm²
Cable length impact:
- <5m: Recommended
- 5-20m: Might affect charging duration (see installation instructions).
- >20m: Not recommended
Safety Regulations and Measures
- Install the Charge Mate Pro according to the instructions in this manual.
- Use the Charge Mate Pro in accordance with specifications.
- Connections and safety features must comply with locally applicable regulations.
- Use cables with appropriate wire size and keep connections as short as possible.
- Use reliable terminals and tighten bolts securely, but do not over-torque.
- Inspect your electrical installation regularly (at least annually). Correct defects like loose connections or burnt wiring immediately.
⚠️ Only use battery banks with the same type of charge characteristics.
⚠️ The Charge Mate Pro can only be applied in 12 VDC or 24 VDC installations with a common negative.
Liability
Mastervolt accepts no liability for:
- Consequential damage resulting from the use of the Charge Mate Pro.
- Possible errors in the manual and their consequences.
- Use inconsistent with the product's intended purpose.
Warranty
Mastervolt warrants the Charge Mate Pro for two years after purchase, provided it is installed and used according to the manual's instructions. Improper installation or use may lead to reduced performance, damage, or failure, voiding the warranty. The warranty covers repair/replacement costs only; labour and shipping are not included.
Correct Disposal of this Product
This product is made with high-quality, recyclable materials. Please follow local regulations for separate collection of electrical and electronic products. Do not dispose of with household waste. Proper disposal helps prevent negative environmental and health consequences. [Symbol for correct disposal/recycling]
Installation
- Ensure the power source output is switched off and no consumers are connected to the batteries during installation to prevent hazardous situations.
- Install the Charge Mate Pro as close as possible to the power source and batteries. Install in a well-ventilated area, preferably on a flat metal surface with vertical fins, as high currents can generate heat. ⚠️ Do not install directly above batteries due to potential corrosive sulphur fumes.
- Use the packaging template to determine the exact location and screw holes for mounting.
- Consult the installation drawing for correct connections.
- Install the Charge Mate Pro in the positive lead between the battery banks. To prevent high cable inductance (which can reduce charge current or cause shutdown), ensure all cables are as short as possible, free from loops, and run positive and negative cables close together.
- Connect the negative of the battery banks to the Charge Mate Pro.
- Optionally, install a remote status light to the Status output and A+.
Remote Switch (Optional)
A single pole ON-OFF-ON switch can be installed for remote operation. Refer to the installation drawing on page 2.
| Switch Function | Description |
|---|---|
| ON | Switches input to 12/24 V. Battery banks are connected in parallel and bi-directional. |
| PULSE | Switches input to 12/24 V for a short duration. Emergency start (battery banks connected for 30 seconds). |
| OFF | Switches input to Ground. The Charge Mate Pro is switched off. |
| AUTOMATIC | Leaves the switch input floating (or no switch connected). Default automatic mode with 40A / 90A fixed current limit. |
LED Indicators
| LED Status | Meaning |
|---|---|
| Green (Blinking) | Starting up |
| Green (Solid on) | Operational (electrical connection between A+ and B+) |
| Red 1x blinking + Green solid on | Working with reduced charge current (likely due to long cables). Ensure cables are short, free from loops, and positive/negative wires are close together. |
| Red 1x blinking | Overvoltage: Voltage on A+ and/or B+ is above 15.5/31 V for more than 1 s. Warning clears when voltage drops below 15/30 V for more than 10 s. |
| Red 2x blinking | High voltage differential: Voltage difference between A+ and B+ detected over 8/16 V for more than 2.5 s. Warning clears when difference drops below 8/16 V for more than 2.5 s. |
| Red 3x blinking | Temperature too high (75 °C / 167 °F). Warning clears when temperature drops below 65 °C / 149 °F. |
| Red 4x blinking | Reverse current: Reverse current detected from B+ to A+ for more than 2 s. Clears after 20 s. |
| Red 5x blinking | Installation error: Unit shuts down to protect itself, likely due to long cables. Ensure cables are short, free from loops, and positive/negative wires are close together. |
