User Manual for Mastervolt models including: Mastervolt, Chargemaster, battery charger, 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3, 24/100-3, user manual, installation guide, technical specifications, safety instructions, operation manual, troubleshooting
ManualChargemaster070821EN
JanB
CHARGEMASTER
The English version has 36 pages. 1.2 VALIDITY OF THIS MANUAL. All of the specifications, provisions and instructions contained in this manual apply solely to ...
1.2 VALIDITY OF THIS MANUAL All of the specifications, provisions and instructions contained in this manual apply solely to standard versions of the Chargemaster delivered by Mastervolt. This manual is valid for the following models: Part number Model 44010700 Chargemaster 12/70-3 44011000 Chargemaster 12/100-3 44020400 Chargemaster 24/40-3
USERS MANUAL / GEBRUIKERSHANDLEIDING / BETRIEBSANLEITUNG MANUEL UTILISATEUR / MANUAL DE UTILIZACION / INSTRUZIONI PER L'USO
CHARGEMASTER
12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3
FULL AUTOMATIC BATTERY CHARGER
MASTERVOLT Snijdersbergweg 93, 1105 AN Amsterdam The Netherlands Tel.: +31-20-3422100 Fax.: +31-20-6971006 www.mastervolt.com
ENGLISH: NEDERLANDS: DEUTSCH: FRANÇAIS: CASTELLANO: ITALIANO:
PAGE 1 PAGINA 37 SEITE 73 PAGINA 109 PÁGINA 145 PÁGINA 181
v 1.1 August 2007
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August 2007 / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / EN
CONTENTS
CONTENTS:
v 1.1 August 2007
1
GENERAL INFORMATION.............................................................................................................................................. 5
1.1 Use of this manual.............................................................................................................................................. 5
1.2 Validity of this manual ........................................................................................................................................ 5
1.3 Use of pictograms .............................................................................................................................................. 5
1.4 Identification label............................................................................................................................................... 5
1.5 Liability ............................................................................................................................................................... 5
2
IMPORTANT SAFETY INSTRUCTIONS ......................................................................................................................... 6
2.1 General .............................................................................................................................................................. 6
2.2 Explosive gases ................................................................................................................................................. 6
2.3 Warnings regarding the use of batteries............................................................................................................. 7
2.4 Warning regarding life support applications........................................................................................................ 7
2.5 Guarantee specifications .................................................................................................................................... 7
3
OPERATION .................................................................................................................................................................... 8
3.1 Features ............................................................................................................................................................. 8
3.2 Switching on / stand-by ...................................................................................................................................... 8
3.3 LCD-display........................................................................................................................................................ 9
3.4 Three Step charge algorithm ............................................................................................................................ 10
3.4.1 Temperature compensated charging............................................................................................... 10
3.4.2 Connection of a second and third battery ........................................................................................ 10
3.5 Historical data................................................................................................................................................... 11
3.6 Masterbus (optional)......................................................................................................................................... 12
3.7 Maintenance..................................................................................................................................................... 12
3.8 Failures............................................................................................................................................................. 12
4
INSTALLATION ............................................................................................................................................................. 13
4.1 Unpacking ........................................................................................................................................................ 13
4.2 Environment ..................................................................................................................................................... 13
4.3 Wiring ............................................................................................................................................................... 13
4.3.1 AC-wiring......................................................................................................................................... 13
4.3.2 DC wiring......................................................................................................................................... 14
4.3.3 Battery capacity ............................................................................................................................... 14
4.3.4 AC safety grounding ........................................................................................................................ 14
4.4 Overview connection compartment .................................................................................................................. 15
4.5 Things you need............................................................................................................................................... 16
4.6 Connection ....................................................................................................................................................... 16
4.7 Installation step-by-step ................................................................................................................................... 18
4.8 Commissioning after installation....................................................................................................................... 20
4.8.1 General............................................................................................................................................ 20
4.8.2 MasterBus (optional) ....................................................................................................................... 20
4.9 Decommissioning ............................................................................................................................................. 20
4.10 Storage and transportation ............................................................................................................................... 20
4.11 Re-installation................................................................................................................................................... 20
EN / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / August 2007
3
CONTENTS
5
SETTINGS ..................................................................................................................................................................... 21
5.1 DIP Switch settings .......................................................................................................................................... 21
5.1.1 DIP-switch 1: Battery type ............................................................................................................... 21
5.1.2 DIP switch 2: Charge algorithm ....................................................................................................... 21
5.1.3 DIP-switch 3:Stand-by mode for display.......................................................................................... 21
5.1.4 DIP switch 4: Equalize mode........................................................................................................... 21
5.2 Settings at the LCD-display .............................................................................................................................. 22
5.2.1 Settings menu for models 12/70-3 and 12/100-3............................................................................. 22
5.2.2 Settings menu for models 24/40-3, 24/60-3, 24/80-3 and 24/100-3 ................................................ 23
6
MASTERBUS................................................................................................................................................................. 24
6.1 What is MasterBus? ......................................................................................................................................... 24
6.2 How to set up a MasterBus network................................................................................................................. 25
6.3 MasterBus: Monitoring and Programming of the ChargeMaster....................................................................... 26
6.3.1 Level 2: Monitoring .......................................................................................................................... 26
6.3.2 Level 3: Alarms................................................................................................................................ 26
6.3.3 Level 3: History................................................................................................................................ 26
6.3.4 Level 3: Configuration...................................................................................................................... 27
6.3.5 List of list of events sources ............................................................................................................ 28
6.3.6 List of list of event commands ......................................................................................................... 28
7
TROUBLE SHOOTING .................................................................................................................................................. 29
7.1 Fault finding table ............................................................................................................................................. 29
7.2 Fault indication ................................................................................................................................................. 29
8
TECHNICAL DATA........................................................................................................................................................ 30
8.1 Specifications 12V models ............................................................................................................................... 30
8.2 Specifications 24V models ............................................................................................................................... 31
8.3 Characteristics.................................................................................................................................................. 32
9
ORDERING INFORMATION.......................................................................................................................................... 34
9.1 MasterBus installation components.................................................................................................................. 34
9.2 Miscellaneous................................................................................................................................................... 34
10 EC DECLARATION OF CONFORMITY ........................................................................................................................ 35
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August 2007 / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / EN
1 GENERAL INFORMATION
1.1 USE OF THIS MANUAL
This manual contains important safety and operating instructions for the safe and effective operation, maintenance and possible correction of minor malfunctions of the Chargemaster.
It is therefore obligatory that every person who works on or with the Chargemaster must be completely familiar with the contents of this manual, and that he/she carefully follows the instructions and important safety instructions contained herein. The English version has 36 pages.
1.2 VALIDITY OF THIS MANUAL
All of the specifications, provisions and instructions contained in this manual apply solely to standard versions of the Chargemaster delivered by Mastervolt. This manual is valid for the following models:
Part number Model
44010700
Chargemaster 12/70-3
44011000
Chargemaster 12/100-3
44020400
Chargemaster 24/40-3
44020600
Chargemaster 24/60-3
44020800
Chargemaster 24/80-3
44021000
Chargemaster 24/100-3
These models are further mentioned as "Chargemaster"
For other models see other manuals available on our
website: www.mastervolt.com
1.3 USE OF PICTOGRAMS
Safety instructions and warnings are marked in this manual by the following pictograms:
WARNING
A WARNING refers to possible injury to the user or significant material damage to the charger if the user does not (carefully) follow the procedures.
CAUTION!
Special data, restrictions and rules with regard to preventing damage.
A procedure, circumstance, etc which deserves extra attention.
GENERAL INFORMATION
1.4 IDENTIFICATION LABEL
Part no : 44020800
IP 23
Type : ChargeMaster 24/80-3
Input : 120/230V AC 50/60 Hz 26A/13A
Output : 28.5V - 80A
Serial no: V822A0001
Design by Mastervolt Manufactured in China
Serial number V822A001
Part number
Apparatus version "A"
Figure 1: Identification label
The identification label is located at the right-hand side of the Chargemaster. (see figure 1) Important technical information required for service, maintenance & secondary delivery of parts can be derived from the identification label.
CAUTION!
Never remove the identification label.
1.5 LIABILITY
Mastervolt can accept no liability for: · consequential damage due to use of the Chargemaster; · possible errors in the manuals and the results thereof.
EN / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / August 2007
5
IMPORTANT SAFETY INSTRUCTIONS
2 IMPORTANT SAFETY INSTRUCTIONS
READ AND SAVE THESE INSTRUCTIONS
WARNING
This chapter describes important safety and operating instructions for use of a Chargemaster in residential, recreational vehicle (RV) and marine applications.
2.1 GENERAL
1 Before using the Chargemaster, read all instructions and cautionary markings on the Chargemaster, the batteries, and all appropriate sections of the manual.
2 To reduce the risk of electric shock Do not expose Chargemaster to rain, snow, spray, moisture, excessive pollution and condensing circumstances. To reduce risk of fire hazard, do not cover or obstruct the ventilation openings. Do not install the Chargemaster in a non-ventilated room, overheating may result.
3 Use of an attachment or spare part not recommended or sold by Mastervolt may result in a risk of fire, electric shock, or injury to persons.
4 The Chargemaster is designed to be permanently connected to an AC and DC electrical system. Installation of, and work on the Chargemaster, may be carried out only by a qualified, authorised and trained technician or electrician, consistent with the locally applicable standards and regulations.
5 Make sure that all wiring is properly installed and in good electrical condition; and that wire size is large enough for AC ampere rating of the Chargemaster. Check the wiring on a regular base, at least once a year. Do not use the Chargemaster when the wiring is undersized or damaged.
6 Do not operate Chargemaster if it has received a sharp blow, been dropped, or otherwise damaged in any way; take it to a qualified serviceman.
7 Except for the connection compartment, see chapter 4, the Chargemaster may not be opened or disassembled. There are no serviceable parts inside the cabinet. Take it to a qualified, authorized and trained serviceman when service or repair is required. Incorrect reassembly may result in a risk of electric shock or fire. Only qualified, electrician installers are authorized to open the connection compartment.
8 To reduce risk of electric shock, disconnect the Chargemaster from both AC and DC electrical system
before attempting any maintenance or cleaning. Turning off controls will not reduce this risk. 9 The Chargemaster must be provided with an equipment-grounding conductor to the AC-input ground terminal. Grounding and all other wiring must comply with local codes and ordinances. 10 Short circuiting or reversing polarity will lead to serious damage to batteries, Chargemaster, wiring as well as accessories. Fuses can not prevent damage caused by reversed polarity and the warranty will be void. 11 In case of fire, you must use the fire extinguisher which is appropriate for electrical equipment. 12 If applied in a marine application in the United States, external connections to the Chargemaster shall comply with the United States Coast Guard Electrical Regulations (33CFR183, Sub part I).
2.2 EXPLOSIVE GASES
1 WARNING RISK OF EXPLOSIVE GASES. WORKING IN VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS. BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION. FOR THIS REASON, IT IS OF UTMOST IMPORTANCE THAT EACH TIME BEFORE USING THE CHARGEMASTER, YOU READ THIS MANUAL AND FOLLOW THE INSTRUCTIONS EXACTLY.
2 To reduce risk of battery explosion, follow these instructions and those published by battery manufacturer and manufacturer of any equipment you intend to use in vicinity of the battery. Review cautionary marking on these products.
3 DANGER: To reduce the risk of explosion Never use the Chargemaster in situations where there is danger of gas or dust explosion or area in which ignition-protected equipment is required.
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August 2007 / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / EN
2.3 WARNINGS REGARDING THE USE OF BATTERIES
1 Someone should be within range of your voice or close enough to come to your aid when you work near a lead-acid battery.
2 Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.
3 Wear complete eye protection and clothing protection. Avoid touching eyes while working near battery.
4 If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters eye, immediately flood eye with running cold water for at least 10 minutes and get medical attention immediately.
5 NEVER smoke or allow a spark or flame in vicinity of battery or engine.
6 Do not short circuit batteries, as this may result in explosion and fire hazard! Be extra cautious to reduce risk of dropping a metal tool onto battery. It might spark or short-circuit battery or other electrical part that may cause explosion.
7 Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a lead-acid battery. A lead-acid battery can produce a short-circuit current high enough to weld a ring or the like to metal, causing a severe burn.
8 Only use Chargemaster for charging a LEAD-ACID batteries and the supply of users attached to these batteries, in permanent systems. Do not use Chargemaster for charging dry-cell batteries that are commonly used with home appliances. These batteries may burst and cause injury to persons and damage to property.
9 NEVER charge a frozen battery. 10 Excessive battery discharge and/or high charging
voltages can cause serious damage to batteries. Do not exceed the recommended limits of discharge level of your batteries. 11 If it is necessary to remove a battery, always remove grounded terminal from battery first. Make sure all accessories are off, so as not to cause an arc.
IMPORTANT SAFETY INSTRUCTIONS
12 Be sure that the area around battery is well ventilated while battery is being charged. Refer to the recommendations of the battery manufacturer.
13 Batteries are heavy! It may become a projectile if it is involved in an accident! Ensure adequate and secure mounting and always use suitable handling equipment for transportation.
2.4 WARNING REGARDING LIFE SUPPORT APPLICATIONS
The Chargemaster is not sold for applications in any medical equipment intended for use as a component of any life support system unless a specific written agreement pertaining to such intended use is executed between the manufacturer and Mastervolt. Such agreement will require the equipment manufacturer either to contract additional reliability testing of the Chargemaster and/or to commit to undertake such testing as a part of the manufacturing process. In addition the manufacturer must agree to indemnify and not hold Mastervolt responsible for any claims arising from the use of the Chargemaster in the life support equipment.
2.5 GUARANTEE SPECIFICATIONS
Mastervolt guarantees that this unit has been built according to the legally applicable standards and specifications. Should work take place, which is not in accordance with the guidelines, instructions and specifications contained in this users manual, then damage may occur and/or the unit may not fulfil its specifications. All of these matters may mean that the guarantee becomes invalid. The guarantee is limited to the costs of repair and/or replacement of the product. Costs for installation labor or shipping of the defective parts are not covered by this guarantee.
EN / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / August 2007
7
OPERATION
3 OPERATION
POWER Hold POWER pressed for 3 seconds to switch the charger on or stand-by Green illuminated = on Orange illuminated = stand-by
INFO Press INFO shortly to show historical data of the Chargemaster; see section 3.5
LCD-display See section 3.3
SOURCE Press SOURCE to select the battery bank (1, 2 or 3) that you want to monitor
Figure 2: operation of the Chargemaster
3.1 FEATURES
The Mastervolt Chargemaster is a fully automatic battery charger. This means that under normal circumstances it may stay switched on with the AC power and batteries connected. The Chargemaster is suitable for charging of lead-acid batteries which may include maintenance-free, low maintenance, AGM/spiral, gel or deep-cycle batteries. It has an auto-ranging input facility which makes it feasible to operate on almost any AC power source in the world. It operates smoothly on both 230V as well as on 120V without any compromises for the output current. The threestep Plus charging method guarantees that the batteries are always charged to 100%. With an external AC source connected, the Chargemaster charger also serves the functions of an AC to DC converter to supply DC loads which are connected to the batteries.
3.2 SWITCHING ON / STAND-BY
The Chargemaster is activated by holding the POWER switch pressed for approx. 3 seconds. The POWER switch will illuminate green. After switching on, the installed software version is shown for 10 seconds. The state of charge (which is stored in the memory of the Chargemaster) will be displayed. If necessary and if AC power is available, the Chargemaster will start to charge the batteries.
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August 2007 / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / EN
By holding the POWER switch pressed again for approx. 3 seconds, the Chargemaster will switch back to stand-by: the Chargemaster stops and the POWER switch illuminates orange.
WARNING
Switching the Chargemaster to "stand-by" does not cut off the connection to the batteries or the AC-source. This means that voltages are still available inside the apparatus.
If the Chargemaster was switched to stand-by or AC power became unavailable, the POWER switch starts to blink orange. After approximately 2 minutes the blinking will stop and the display will switch off, so that the batteries will not be loaded by the indication light.
OPERATION
Only if DIP-switch #3 was adjusted to ON and the charger was switched on, the indication light stays blinking orange, indicating that the AC-power supply fails in operation. Note that this blinking LED may slowly drain your batteries.
3.3 LCD-DISPLAY
The display at the front side of the Chargemaster enables you to monitor the charging process. See figure 3.
If no switch is touched during 20 seconds, the display will go to the initial readings, showing the charge voltage and charge current.
CHARGEMASTER
FLOAT
POWER
ABS
FAILURE
BULK
INFO SOURCE
Selected battery bank (1, 2 or 3). Press SOURCE to alter.
Actual stage of the Three Step charge algorithm. See section 3.4.
Actual charge voltage (Volts).
Actual charge current (Amps).
Battery capacity in %. Only displayed when the Chargemaster is connected to a MasterShunt by means of the MasterBus network (see chapter 6). This readout shows the actual amount of energy that is in the battery.
Highlighted if a failure was detected See section 3.8.
Highlighted if the Chargemaster is connected to the Masterbus network.
Highlighted if AC voltage is not available.
Hours and minutes indication.
Figure 3: Initial readings at the LCD-display (displayed values may differ)
EN / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / August 2007
9
OPERATION
3.4 THREE STEP CHARGE ALGORITHM
BATTERY VOLTAGE
BULK
ABSORPTION
FLOAT
CHARGE CURRENT
TIME
Figure 4: Three step Plus charge system
See figure 4. Battery charging is accomplished in three automatic stages: BULK, ABSORPTION and FLOAT. The first step of the three step Plus charge system is the BULK phase, in which the output current of the charger is 100%, and the greater part of the capacity of the battery is rapidly charged. The current charges the batteries and gradually the voltage rises to the absorption voltage of 14.4V (12V models) or 28.8V (24V models) at 25°C / 77°F. The duration of this phase depends on the ratio of battery to charger capacity, and also on the degree to which the batteries were discharged to begin with.
The bulk phase is followed by the ABSORPTION phase. Absorption charging starts when the voltage on the batteries has reached 14.4V (12V models) / 28.8V (24V models) at 25°C / 77°F, and ends when the battery is completely full. Battery voltage remains constant at 14.25V (12V models) / 28.5V (24V models) at 25°C / 77°F throughout this stage, and the charge current depends on the degree to which the battery was initially discharged, the battery type, the ambient temperature, and so on. With a wet cell battery this stage lasts some four hours, with gel and AGM around three. Once the battery is 100% full, the Chargemaster automatically switches over to the float phase.
During the FLOAT phase the Chargemaster switches to 13.25V (12V models) or 26.5V (24V models) at 25°C / 77°F and stabilises this voltage to maintain the batteries in an optimum condition. Connected DC-loads are powered directly by the charger. If the load is higher than charger capacity, the required additional power comes from the battery, which will be progressively discharged until the charger automatically switches back to the bulk phase. Once consumption decreases, the charger goes back to normal operation of the three-step charge system.
As the Chargemaster is equipped with a three-step Plus charge system, the batteries can also remain connected to the Chargemaster in winter. One hour every 12 days the charger automatically switches to absorption to keep the battery running properly and prolong its life span. The three-step Plus charge system is also safe for all the connected equipment.
See also section 8.3 for detailed characteristics of the three step Plus charge system.
3.4.1 Temperature compensated charging By installing the battery temperature sensor the charge voltages are automatically adapted for deviating temperatures.
12V
24V
charge voltage (V)
battery temperature (°C)
Figure 5: Temperature compensated charging
See figure 5. When the battery temperature is low, the charge voltage increases. On the other hand, when the battery temperature is high, the charge voltage is decreased. Over charge and gassing are prevented this way. This will extend the life of your batteries.
3.4.2 Connection of a second and third battery The Chargemaster is equipped with a second and a third charge output which can be used to give a maintenance charge to small battery sets like a starter battery. Maximum output current: 10 Amps (± 10%). Output voltage: same as the main charger. See section 4.6 for connection.
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August 2007 / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / EN
3.5 HISTORICAL DATA
Press INFO shortly to scroll through the levels as described below. When no button is touched during 20 seconds, or if you hold SOURCE pressed for at least two seconds, the display returns to the initial readings.
See section 5.2 if you want to reset the below mentioned historical data.
Number of completed cycles Total number charging cycles that were entirely completed, i.e. from bulk to float. See section 3.4 for detailed information of the three step charge algorithm.
Number of aborted cycles Each time the charge cycle was not entirely finished, this counter is increased by 1. Operation of the Chargemaster might be interrupted because of AC grid failure. A large number of aborted cycles may indicate too short charging periods or an undersized charging system. Be aware that incomplete charges can reduce the expected lifetime of your batteries dramatically.
Total Ampere hours charged Total amount of charged Amphours or kAh for battery bank 1, 2 or 3 (press SOURCE to select the battery bank).
Total runtime in charger mode Total number of hours that the Chargemaster was charging.
Highest AC input voltage Here the highest recorded AC input voltage is shown. To avoid damaging the charger this value may never be higher than the absolute maximum AC-input voltage (see figure 9). High AC-input voltages are often caused by generator sets that have a poor voltage regulation. Have your electrical installation examined by a qualified installer if this value is higher than 260VAC.
OPERATION
Number of temperature shutdowns If the internal temperature of the Chargemaster is too high, it shuts down automatically. After cooling down, the Chargemaster will switch on again. A large number of temperature shutdowns might indicate too hot environmental conditions or bad cooling due to obstruction of the air flow around the charger.
Number of low DC voltage shutdowns If the battery voltage is too low the ChargeMaster will limit the charge current to 25% of the nominal charge current (see specifications). This counter shows the number of times that this happened. Have your electrical installation examined by a qualified installer if this has happened more than once.
Number of high DC voltage shutdowns Also if the battery voltage is too high the ChargeMaster shuts down automatically. This counter shows the number of times that this happened. Have your electrical installation examined by a qualified installer if this has happened more than once.
Number of high AC voltage shutdowns This value shows the number of times that the Chargemaster was shut off due to too high AC input voltage. High AC-input voltages are often caused by generator sets that have a poor voltage regulation. Have your electrical installation examined by a qualified installer if this has happened more than once.
Number of low AC voltage shutdowns Number of times that the Chargemaster was shut off due to too low AC input voltage (see figure 9). Low AC-input voltages may be caused by generator sets that have a poor voltage regulation or by thin AC-wiring. In some marinas or camping sites the AC power supply sometimes drops too low when there is a large demand of electric power.
EN / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / August 2007
11
OPERATION
Lowest detected DC voltage Shows the lowest DC-voltage that was recorded for battery bank 1, 2 or 3 (press SOURCE to select the battery bank). This value should never be below the final discharge voltage as specified by the battery manufacturer.
Highest detected DC-voltage Shows the highest DC-voltage that was recorded for battery bank 1, 2 or 3 (press SOURCE to select the battery bank) This voltage should never be higher than the maximum charging voltage as specified by the battery manufacturer. Too high voltages may also damage the connected DC-loads.
Software version Version of the installed software.
Lock - Unlock To protect the ChargeMaster against unintended adjustment of set points, the lock mode is activated every time you leave the Settings menu. When activated ("ON"), it is not possible to change settings. Default setting: ON Press SOURCE to toggle the lock mode.
3.6 MASTERBUS (OPTIONAL)
The Chargemaster is compatible with the MasterBus network: a fully decentralized data network for communication between the different Mastervolt system devices such as the inverter, battery charger, generator, batteries and many more. See chapter 6 for details.
3.7 MAINTENANCE
No specific maintenance to the Chargemaster is required. Examine your electrical installation on a regular base, at least once a year. Defects such as loose connections, burnt wiring etc. must be corrected immediately. If necessary, use a soft clean cloth to clean cabinet of the Chargemaster. Never use any liquids, acids and/or scourers.
3.8 FAILURES
The Chargemaster is protected against overload, short circuit, over heating and under and over voltage. If a fault condition occurs, text FAILURE is shown on the LCDdisplay. The cause of the failure is displayed by means of an error code. See section 7.2 for explanation.
CAUTION!
The Chargemaster is not protected against reversing polarity of the DC-output and serious over voltage (>265VAC) on the ACinput .
As long as FAILURE isn't shown, no failure is detected: the Chargemaster is operating normally!
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August 2007 / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / EN
4 INSTALLATION
During installation and commissioning of the Chargemaster, the important safety instructions are applicable at all times. See chapter 2 of this manual.
4.1 UNPACKING
In addition to the Chargemaster the delivery includes: · A mounting bracket to mount the chargemaster to a
wall; · a battery temperature sensor; · a MasterBus terminating device (see chapter 6); · a cable gland for UL-compliant AC-connection (see
section 4.4); · this user's manual.
After unpacking, check the contents for possible damage. If in doubt, contact your supplier. Check from the identification label (see section 1.4) whether the battery voltage is the same as the nominal output voltage of the Chargemaster (e.g. 24V battery set for a 24V battery charger).
4.2 ENVIRONMENT
Obey the following stipulations during installation: · The Chargemaster is designed for indoor use only. · Ambient temperature: 0 ... 60°C / 32°F ... 140°F;
(power derating above 40°C / 104°F to decrease the internal heat sink temperature). · Humidity: 0-95% non condensing · Mount the Chargemaster vertically, with the connecting cables downwards. · Make sure that the hot air that is developed during operation can be discharged. The Chargemaster must be mounted in such a way that obstruction of the airflow through the ventilation openings will be prevented. · No objects must be located within a distance of 10 cm / 4 inch around the Chargemaster. · Do not locate the Chargemaster in the same compartment as the batteries. · Do not install the Chargemaster straight above the batteries because of possible corrosive sulphur fumes.
INSTALLATION
4.3 WIRING
WARNING!
The wire and fuse sizes stated in this manual are given as example only. Prescribed wire and fuse sizes may be different due to local applicable regulations and standards.
4.3.1 AC-wiring For a safe installation the correct wire cross section must be applied. Don't use a cross section that is smaller than indicated. See table below to select the appropriate cross section for the AC wiring (up to 6m / 20ft length):
AC-Current
6-12 Amp 12-20 Amp
Minimum cross section:
in mm²
AWG
1.5 mm²
AWG 15
2.5 mm²
AWG 13
Connection of AC-wiring and recommended wire colours
· 230V/50Hz installations:
Wire color Brown or black Blue Green/Yellow
Meaning Phase Neutral Earth
Must be connected to: L1 N PE / GND
· 120V/60Hz installations (single phase):
Must be
Wire color
Meaning
connected to:
Black
Hot or Line
L1
White
Neutral
N
Green
Ground
PE / GND
· 240V/60Hz installations (dual phase 2x120VAC):
Must be
Wire color
Meaning
connected to:
Black
Hot or Line
L1
Red
Hot or Line
L2
Green
Ground
PE / GND
EN / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / August 2007
13
INSTALLATION
4.3.2 DC wiring Keep in mind that high current will pass through the DC wiring. Keep the cable length as short as possible, this will keep the system efficiency as high as possible. The recommended minimum cross section of the battery cables is:
· Main charge output (output 1)
Model
DC Cable cross section:
Chargemaster <3m / 10ft
3-5m / 10ft
12/70-3
25mm² / AWG3
35mm² / AWG2
12/100-3
35mm² / AWG2
50mm² / AWG0
24/40-3
16mm² / AWG5
25mm² / AWG3
24/60-3
25mm² / AWG3
35mm² / AWG2
24/80-3
35mm² / AWG2
50mm² / AWG0
24/100-3
35mm² / AWG2
50mm² / AWG0
· Charge output (output 2 and 3)
Model
DC Cable cross section:
Chargemaster <3m / 10ft
3-5m / 10ft
All models
4mm² / AWG11
6mm² / AWG9
Use ring terminals on the ends of the wires. The terminals must be crimped with a proper crimping tool. Use the following wire colours for DC wiring colour or at least different colours to make a clear distinction between the positive and negative wire from the battery:
Wire color Red Black
Meaning Positive Negative
Must be connected to: + (POS) (NEG)
Lay the positive and negative cables next to each other to limit the electro magnetic field around the cables. The negative cable should be connected directly to the negative post of the battery bank or the ground side of a current shunt. Do not use the chassis frame as the negative conductor. Tighten securely. The positive battery cable must be fused and connected to the positive post of the battery bank.
· Main charge output (output 1)
Model Chargemaster Recommended charger fuse
12/70-3
80A
12/100-3
125A
24/40-3
50A
24/60-3
80A
24/80-3
100A
24/100-3
125A
· Charge output (output 2 and 3)
Model Chargemaster Recommended charger fuse
All models
16A
The fuse with the fuse-holder is available from your local Mastervolt distributor or Customer Service Representative.
4.3.3 Battery capacity The minimum required battery capacity is as follows:
Model Chargemaster
12/70-3 12/100-3 24/40-3 24/60-3 24/80-3 24/100-3
Minimum required battery capacity 140Ah 200Ah 80Ah 120Ah 160Ah 200Ah
4.3.4 AC safety grounding
WARNING!
The ground wire offers protection only if the cabinet of the Chargemaster is connected to the safety ground. Connect the ground terminal (PE / GND) to the hull or the chassis.
CAUTION!
For safe installation it is necessary to Insert a Residual Current Device (earth leakage switch) in the AC input circuit of the Chargemaster.
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August 2007 / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / EN
4.4 OVERVIEW CONNECTION COMPARTMENT
1 2
INSTALLATION
3 4
5 6
7
8
9
1 Screw terminals AC input 2 Cable gland for AC-wiring 3 Isolation caps for DC connections 4 Positive terminal charge output 1 (main output) 5 Common negative output terminal 6 Positive terminal charge output 2 7 Positive terminal charge output 3 8 Ventilation openings 9 DIP-switches 10 Temperature sensor jack 11 MasterBus connector
Figure 6: overview connection compartment
10
11
EN / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / August 2007
15
INSTALLATION
4.5 THINGS YOU NEED
Make sure you have all the parts you need to install the Chargemaster:
Chargemaster (included) Battery temperature sensor with cable and plug (included). DC-cable to connect the positive DC connection (+) of the Chargemaster to the positive pole of the DCdistribution; for specifications see section 4.3.2, DC-cable to connect the negative DC connection () of the Chargemaster to the negative pole of the DCdistribution; for specifications see section 4.3.2. DC-fuse holder with a DC-fuse, to be integrated in the positive DC-cable. For specifications see section 4.3.2. Screws / bolts (Ø 6mm) (with plugs) to mount the cabinet to a surface. Use mounting materials which are suitable to carry the weight of the Chargemaster AC cable* to connect the AC input to an external power source (e.g. a shore connection or a generator set); Batteries. See section 4.3.3 for recommended capacity Appropriate and reliable cable terminals, cable lugs, battery terminals and cord end terminals
Quantity 1 1 1
1
1 4
1 X X
* Double insulated three wire cable with wire colours according to the locally applicable regulations. The applicable length and wire diameter depend on the electrical installation (see section 4.3.1).
We recommend as a minimum tool kit: · Socket wrench 13mm to fix the DC-input (battery) cables · Flat blade screw driver 1.0 x 4.0 mm to fix the screw terminals · Tools to fix the screws / bolts (Ø 6mm) with plugs to mount the cabinets to a surface · Philips screw driver to open the connection area of the Chargemaster
4.6 CONNECTION
WARNING
Let installation work be done by a licensed electrician. Before beginning with the connection of the wiring, make the AC distribution as well as the DC distribution voltage free.
CAUTION!
Short circuiting or reversing polarity may lead to serious damage to the batteries, the Chargemaster, the cabling and/or the terminal connections. Fuses between the batteries and the Chargemaster can not prevent damage caused by reversed polarity. The damage as a result of reverse polarity is detectable by the service department and is not covered by the warranty.
CAUTION!
Too-thin cables and/or loose connections can cause dangerous overheating of the cables and/or terminals. Therefore tighten all connections well, in order to limit transition resistance as far as possible. Use cables of the correct size.
NOTE: If the battery temperature remains within 1525°C, connection of the battery temperature sensor is optional.
NOTE: The Chargemaster is only feasible for the connection of MasterBus compatible remote control panels.
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August 2007 / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / EN
INSTALLATION
"temp.sensor"
RCD 30mA L N PE/GND
POSITIVE (+) NEGATIVE ()
Charger fuse
DC distribution
+
Battery fuse
Battery fuse
Battery fuse
Temperature sensor
BATTERY BANK 1 (main battery bank)
BATTERY BANK 2
OPTIONAL
BATTERY BANK 3
This schematic is to illustrate the general placement of the Chargemaster in a circuit. It is not meant to provide detailed wiring instructions for any particular electrical installation.
Figure 7: installation drawing of the Chargemaster
EN / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / August 2007
17
INSTALLATION
4.7 INSTALLATION STEP-BY-STEP
1 Mark the position of the mounting spots by using the mounting bracket. Then Fix the mounting bracket to the wall.
4 Open the connection compartment by loosening the four screws.
2 Place the ChargeMaster over the mounting bracket and then move it downwards until it is suspended from the mounting bracket.
5 Feed the AC wiring through cable gland and connect the wiring to the screw terminals. Tighten the cable gland firmly.
3 Fix the cabinet to the wall by fastening two screws at the lower side of the cabinet as well.
6 Remove the isolation cap from the DC terminals. Attach crimp-on ring terminals to both DC-cables. Connect the DC-cabling of battery bank 1, positive to +, negative to .
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August 2007 / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / EN
7 Option: Connect the DC-wiring of the second and third battery bank. These battery banks should have a common negative with the main battery (see figure 7).
INSTALLATION
10 The factory setting of the ChargeMaster is
optimal for most installations. In some applications however, it is desirable to change these settings. See section 5.1 for adjustment. Use a small screw driver for adjustment of the DIP-switches.
8 Attach the battery temperature sensor to the
casing of battery bank 1.
Plug the temperature sensor cable into the
"temp.sensor" jack.
11 Check all wiring; see also figure 7 for wiring
details.
12 Close the connection compartment by fixing
the four screws.
9 Option: Connect the ChargeMaster to the MasterBus network. See chapter 6.
13 Continue with section 4.8 for commissioning
of the ChargeMaster.
EN / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / August 2007
19
INSTALLATION
4.8 COMMISSIONING AFTER INSTALLATION
When your ChargeMaster is not new, you have to take into account that former users may have changed the settings. Reset the ChargeMaster back to factory settings when there is any doubt (see section 5.2).
4.8.1 General
The factory settings of the ChargeMaster are optimal for most installations. With some applications however, it is desirable to change these settings. Therefore several adjustments can be made. See chapter 5.
NOTE: The DIP-switches must be adjusted prior to commissioning; all other settings can only be made after commissioning.
CAUTION!
Check the polarity of all wiring before commissioning: positive connected to positive (red cables), negative connected to negative (black cables).
If all wiring is OK, place the DC-fuse(s) of the DCdistribution to connect the batteries to the Chargemaster.
WARNING
When placing this fuse, a spark can occur, caused by the capacitors used in the Chargemaster. This is particularly dangerous in places with insufficient ventilation, due to the gassing of the batteries an explosion can occur. Avoid having flammable materials close by.
Now the Chargemaster is ready for operation. After switching on the AC power supply the Chargemaster will initiate the charging process.
4.8.2 MasterBus (optional)
During first commissioning the Chargemaster will be recognized by the MasterBus network automatically. The remote control panel of the MasterBus network will indicate that a new device was found.
Some settings can only be changed via the MasterBus interface. See section 6.3 for an overview of all available MasterBus settings. Refer to the user's manual of the remote control panel to change these settings.
4.9 DECOMMISSIONING
If it is necessary to put the Chargemaster out of operation, follow the instructions in order of succession as described below:
1 Switch the Chargemaster to stand-by (see section 3.2).
2 Remove the DC-fuse(s) of the DC-distribution and/or disconnect the batteries.
3 Remove the AC-fuse(s) of the AC-input and/or disconnect the AC-mains.
4 Open the connection compartment of the Chargemaster.
5 Check with a suitable voltage meter whether the inputs and the outputs of the Chargemaster are voltage free.
6 Disconnect all the wiring.
Now the Chargemaster can be demounted in a safe way.
4.10 STORAGE AND TRANSPORTATION
When not installed, store the Chargemaster in the original packing, in a dry and dust free environment.
Always use the original packing for transportation. Contact your local Mastervolt Service Centre for further details if you want to return the apparatus for repair.
4.11 RE-INSTALLATION
To reinstall the Chargemaster, follow the instructions as described in this chapter (chapter 4).
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August 2007 / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / EN
5 SETTINGS
Adjustment of the settings of the ChargeMaster can be made in three different ways: · By means of DIP-switches; see section 5.1; · By means of settings at the LCD-display; see section
5.2; · Via the MasterBus network (by means of a remote
control panel or an interface connected to a PC with MasterAdjust software); see section 6.3.
CAUTION!
Invalid settings of the ChargeMaster can cause serious damage to your batteries and/or the connected load! Adjustments of settings may be undertaken by authorised personnel only.
5.1 DIP SWITCH SETTINGS
The ChargeMaster has four DIP switches at the bottom side of the housing. See figure 8.
OFF ON
1 2 3 4
Figure 8: DIP-switches
5.1.1 DIP-switch 1: Battery type
The factory default for the battery type is optimal for most installations. In some applications however, it is desirable to change this setting.
Standard open lead/acid battery (factory setting) Gel / AGM / spiral battery (see specifications)
OFF ON
5.1.2 DIP switch 2: Charge algorithm
IUoUo, fully automatic / 3step+ (factory setting) Constant voltage charging (Float = 13.25/26.5V)
OFF ON
SETTINGS
5.1.3 DIP-switch 3:Stand-by mode for display
By default the LCD-display will switch off after 2 minutes if either the Chargemaster is switched to Stand-by or the AC power supply is disconnected.
LCD-display will switch off when Chargemaster is switched to stand-by mode (factory setting) LCD-display will stay on when Chargemaster is switched to stand-by mode. Note that the LCDdisplay is powered by the batteries.
OFF ON
5.1.4 DIP switch 4: Equalize mode
WARNING
Incorrect use of the equalize mode may lead to hazardous situations. Do not smoke; use any naked flame or other sources of ignition due to risk of explosion. Always ventilate the room were the batteries are located and equalized to clear the air. Equalization is ONLY applicable for wet type batteries and will damage gel and AGM type batteries.
An equalizing charge can be necessary after very deep discharges and/or inadequate charges. This has to be carried out according to the specifications of the manufacturer of the batteries.
During equalizing the batteries are brought into the gas state and is it possible that the permitted load voltages are exceeded. Therefore appropriate measures must be taken, e.g. disconnect all loads from the battery and ventilate the room. For these reasons use of the equalizing mode should only be executed by trained technical engineers.
The equalizing mode can only be started when the Chargemaster is in operation and in Float. This means that the connection compartment of the Chargemaster must be opened while connected to the mains and the batteries. Take adequate measures for protection against short circuits and electrical shocks.
To start the equalize mode: move DIP switch 4 to the ON postion and back to the OFF position.
EN / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / August 2007
21
SETTINGS
5.2 SETTINGS AT THE LCD-DISPLAY
· Hold SOURCE pressed for three seconds to get access to the settings menu. · Then press SOURCE repeatedly to scroll through the settings menu as described below. · To change a displayed setting, press INFO repeatedly. Hold INFO pressed for three seconds to switch between increasing/
decreasing a value. When the correct value is set, continue scrolling through the levels by pressing SOURCE repeatedly.
When no button is touched during 2 minutes, the display returns to the initial readings (section 3.3).
To protect the ChargeMaster against unintended adjustment of set points, the lock mode must be disabled before changing a setting. See section 3.5 ("Lock - Unlock") to disable the lock mode.
5.2.1 Settings menu for models 12/70-3 and 12/100-3
Display Display
Setting
min
Stage
Text
BULK
BULK VOLT Bulk voltage
0.00
BULK
MAX TMR
Maximum bulk timer
0
BULK
MIN TMR
Minimum bulk timer
0
ABS
ABS VOLT
Absorption voltage
0.00
ABS
MAX TMR
Max. absorption timer
0
ABS
MIN TMR
Min absorption timer
0
Return amps (% of maximum
ABS
RET AMP
0%
charge current)
ABS
RET AMP
Return amps timer
0
FLOAT FLT VOLT
Float voltage
0.00
Forced float voltage
FLOAT CONST FLT
0.00
(Constant voltage charging)
RET BULK
Return to bulk voltage
0.00
RET BULK
Return to bulk time delay
0
MAX CURR Maximum charge current
0
ALM DEL
Alarm delay time
0
HIGH DCON Alarm DC High on
0.00
HIGH DCOF Alarm DC High off
0.00
LOW DCON Alarm DC low on
0.00
LOW DCOF Alarm DC low off
0.00
RES FACT
Reset to factory settings
default
14.40 8h
120sec 14.25
4h 15min
6%
30sec 13.25
13.25
12.80 30sec nominal 30sec 16.00 15.00 10.00 11.00
NO
max
15.50 24h 240sec 15.50 24h 240min
50%
240sec 15.50
15.50
15.50 240sec nominal
240 16.00 16.00 16.00 16.00
unit
V h / min
sec V h / min h / min
%
sec V
V
V sec A sec V V V V
resolution
0.05 1min 1sec 0.05 1min 1min
1%
1sec 0.05
0.05
0.05 1sec 1A 1sec 0.05 0.05 0.05 0.05 YES
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August 2007 / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / EN
SETTINGS
5.2.2 Settings menu for models 24/40-3, 24/60-3, 24/80-3 and 24/100-3
Display Stage BULK BULK BULK ABS ABS ABS
ABS
ABS FLOAT
FLOAT
Display Text BULK VOLT MAX TMR MIN TMR ABS VOLT MAX TMR MIN TMR
RET AMP
RET AMP FLT VOLT
CONST FLT
RET BULK RET BULK MAX CURR ALM DEL HIGH DCON HIGH DCOF LOW DCON LOW DCOF RES FACT
Setting
Bulk voltage Maximum bulk timer Minimum bulk timer Absorption voltage Max. absorption timer Min absorption timer Return amps (% of maximum charge current) Return amps timer Float voltage Forced float voltage (Constant voltage charging) Return to bulk voltage Return to bulk time delay Maximum charge current Alarm delay time Alarm DC High on Alarm DC High off Alarm DC low on Alarm DC low off Reset to factory settings
min
default
max
unit resolution
0.00
28.80
31.00
V
0
8h
24h
h / min
0
120sec 240sec
sec
0.00
28.50
31.00
V
0
4h
24h
h / min
0
15min 240min h / min
0.05 1min 1sec 0.05 1min 1min
0%
6%
50%
%
1%
0
30sec
240sec
sec
0.00
26.50
31.00
V
26.50
31.00
0.00
V
1sec 0.05
0.05
0.00
26.50
31.00
V
0
30sec
240sec
sec
0
nominal nominal
A
0
30sec
240
sec
0.00
32.00
32.00
V
0.00
30.00
32.00
V
0.00
20.00
32.00
V
0.00
22.00
32.00
V
NO
0.05 1sec 1A 1sec 0.05 0.05 0.05 0.05 YES
EN / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / August 2007
23
MASTERBUS
6 MASTERBUS
6.1 WHAT IS MASTERBUS?
All devices that are suitable for MasterBus are marked by the MasterBus symbol.
MasterBus is a fully decentralized data network for communication between the different Mastervolt system devices. It is a CAN-bus based communication network which has proven itself as a reliable bus-system in automotive applications. MasterBus is used as power management system for all connected devices, such as the inverter, battery charger, generator and many more. This gives the possibility for communication between the connected devices, for instance to start the generator when the batteries are low.
MasterBus reduces complexity of electrical systems by using UTP patch cables. All system components are simply chained together. Therefore each device is equipped with two MasterBus data ports. When two or more devices are connected to each other through these data ports, they form a local data network, called the
MasterBus. The results are a reduction of material costs as only a few electrical cables are needed and less installation time.
For central monitoring and control of the connected devices Mastervolt offers a wide range of panels which show full status information of your electrical system at a glance and a push of a button. Four different panels are available, from the small Mastervision compatible 120 x 65mm LCD screen up to the full colour MasterView System panel. All monitoring panels can be used for monitoring, control and configuration of all connected MasterBus equipment.
New devices can be added to the existing network in a very easy way by just extending the network. This gives the MasterBus network a high degree of flexibility for extended system configuration, not only today, but in the future as well! Mastervolt also offers several interfaces, making even non-MasterBus devices suitable to operate in the MasterBus network.
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August 2007 / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / EN
6.2 HOW TO SET UP A MASTERBUS NETWORK
Each device that is suitable for the MasterBus network is equipped with two data ports. When two or more devices are connected to each other through these ports, they form a local data network, called the MasterBus.
Keep the following rules in mind:
Connections between the devices are made by standard straight UTP patch cables. Mastervolt can supply these cables. These cables are also commonly available at computer supply stores.
MASTERBUS
The electric power for the network comes from the connected devices. At least one device in the network should have powering capabilities (see specifications). One powering device can power up to three nonpowering devices. As all powering devices are galvanically isolated, multiple powering devices are allowed.
OK
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
OK
Do not make ring networks.
As with all high speed data networks, MasterBus needs a terminating device on both ends of the network.
Do not make T-connections in the network.
Terminating device
OK
Terminating device
August 2007 / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / EN
25
MASTERBUS
6.3 MASTERBUS: MONITORING AND PROGRAMMING OF THE CHARGEMASTER
6.3.1 Level 2: Monitoring
Value State of charger Voltage output 1 Current output 1 Voltage output 2 Current output 2 Voltage output 3 Current output 3
Meaning State of charge algorithm: Bulk/absorption/float Voltage of charge output 1 (main output)* Current of charge output 1 (main output)* Voltage of charge output 2 Current of charge output 2 Voltage of charge output 3 Current of charge output 3
6.3.2 Level 3: Alarms
Default
Adjustable range (read only) (read only) (read only) (read only) (read only) (read only) (read only)
Value
Meaning
Low batt
Battery voltage has dropped below setting DC low on, and has not increased above setting DC low off yet
High batt
Battery voltage has increased above setting DC high on, and has not dropped below setting DC high off yet
Low AC
AC input voltage is too low
High AC
AC input voltage is too high
Low frequency
AC input frequency is too low
High frequency
AC input frequency input is too high
High temperature
Internal temperature is too high
Low temperature
Internal temperature is too low
* see section 8.3, figure 9 for characteristics
Factory setting Adjustable range
See 6.3.4
See 6.3.4
See 6.3.4
90V / 180V* 135V / 265V* 45Hz 65Hz 80°C (176°F) -20°C (-4°F)
See 6.3.4
n/a n/a n/a n/a n/a n/a
6.3.3 Level 3: History
This menu shows the absolute maximum readings. See section 3.5 for detailed description.
Value
Completed charg. Aborted charger. Ah charged Total run time Highest AC volt Number of tempe. Number of low D Number of High. Number of High. Number of low A
Lowest DC volta Highest DC volt Software version
Meaning
Number of completed cycles Number of aborted charge cycles Total Ampere hours charged Total run time in charger mode Highest AC input voltage Number of temperature shutdowns Number of low DC voltage shutdowns Number of high DC voltage shutdowns Number of high AC voltage shutdowns Number of low AC voltage shutdowns Output 1 Lowest detected DC voltage Highest detected DC voltage Software version
Factory setting
Adjustable. range (read only) (read only) (read only) (read only) (read only) (read only) (read only) (read only) (read only) (read only)
(read only) (read only) (read only)
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August 2007 / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / EN
MASTERBUS
6.3.4 Level 3: Configuration
Below parameters can be changed via the MasterBus network by means of a remote control panel or by means of an interface connected to a PC with MasterAdjust software. See applicable user's manuals for details.
Value
Meaning
Language
Language that is displayed on a monitoring device connected to the MasterBus
Bulk settings
Bulk voltage
Bulk voltage
Max. bulk timer
Maximum bulk timer
Min bulk timer
Minimum bulk timer
Start bulk timer
Start bulk timer
Absorption settings
Abs. voltage
Absorption voltage
Max absorption
Maximum absorption timer
Min absorption
Minimum absorption timer
Return amps
Return amps (% of maximum charge current)
Return amps tim Return amps timer
Float settings
Float voltage
Float voltage
Forced float vo.
Forced float voltage (Constant voltage charging)
Return to bulk
Return to bulk voltage
Return to bulk
Return to bulk time delay
Max Charge curr Maximum charge current
Alarm setpoints
DC high on
Alarm DC High on
DC high off
Alarm DC High off
DC low on
Alarm DC low on
DC low off
Alarm DC low off
Alarm delay
Alarm delay time
Device settings
Name of this device. This name will be recognized by all Product name on.
devices connected to the MasterBus
Traction settings
Traction Bulk v
Traction bulk voltage
Traction Absorpt Traction absorption voltage
Traction absorpt Traction absorption timer
Equalize settingsTraction settings
Equalize voltage Equalize voltage float
Max equalize tim Max equalize timer
Fixed settings
Temperature com Temperature compensation for charge voltage
Max allowed upp Max allowed low
Max voltage com
AGM / GEL floa Hardware settings Gel / AGM Force float Equalize
Maximum allowed upper temperature Maximum allowed lower temperature Maximum voltage compensation for temperature compensated charging, AGM / GEL float voltage setting
DIP-switch 1: Battery type DIP switch 2: Charge algorithm DIP switch 4: Equalize mode
Factory setting English
Adjustable. range English
14.40/28.80V 8h 120sec 13.25/26.50V
14.40/28.80V 4h 15min 6% 30sec
13.25/26.50V
13.25/26.50V
13.25/26.50V 30sec 100%
16.00/32.00V 15.00/30.00V 10.00/20.00V 11.00/22.00V 30sec
0-15.50/0-31.00V 0-24h 0-240sec (read only)
0-15.50/0-31.00V 0-24h 0-240min 0-50% 0-240sec.
0-15.50/0-31.00V
0-15.50/0-31.00V
0-15.50/0-31.00V 0-240sec 0-100%
0-16.00V0-32.00V 0-16.00V0-32.00V 0-16.00/0-32.00V 0-16.00/0-32.00V 0-240sec
CHG CM+type* 0-12 chars
+300/+600mV +300/+600mV 480 min
(read only) (read only) (read only)
+2.25/+4.50V 8h
(read only) (read only)
-30mV/°C -60mV/°C +300/+600mV 480 min
+0.3/+0.6V
+550/+1100mV
(read only) (read only) (read only) (read only) (read only)
(see section 5.1.1) (see section 5.1.2) (see section 5.1.4)
(read only) (read only) (read only)
August 2007 / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / EN
27
MASTERBUS
Value
Meaning
Factory setting
Display on/off
DIP-switch 3:Stand-by mode for display
(see section 5.1.3)
Charger
Switching on / stand-by
(see section 3.1)
Art. nr
Shows the article number and the serial number of the
Serial
Chargemaster
* Depending on model: CM12/70, CM12/100, CM24/40, CM24/60, CM24/80 or CM24/100,
Adjustable. range (read only) (read only) (read only)
6.3.5 List of list of events sources
With this version of the Chargemaster programming of event commands is not possible.
6.3.6 List of list of event commands
With this version of the Chargemaster programming of event commands is not possible.
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August 2007 / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / EN
TROUBLE SHOOTING
7 TROUBLE SHOOTING
If you cannot solve a problem with the aid of this chapter, contact your local Mastervolt Service Centre. See
www.mastervolt.com. Make sure you have the following information present if you have to contact your local Mastervolt
Service Center to solve a problem:
Article and serial number (See section 1.4)
Software version
(See section 3.5)
7.1 FAULT FINDING TABLE
Malfunction No output voltage and/or current Output voltage too low, charger supplies maximum current Charge current too low
Batteries not fully charged
Batteries are discharged too fast Batteries are too warm, gassing
Possible cause No AC-input AC-input voltage too low (< 90VAC) AC input frequency out of range Load that is connected to the batteries is larger than charger can supply. Batteries not 100% charged
Batteries almost fully charged
High ambient temperature
Low AC input voltage. At lower AC-input voltages the charge current is reduced. See figure 9 Charge current too low Current to load is too high Charge time too short Battery temperature too low Defective or old battery Battery capacity reduced due to wastage or sulphation, stagnation Defective battery (short circuit in cell) Battery temperature too high Charge voltage too high
What to do Check AC wiring, check remote control panel. Check input voltage, check generator. Check input voltage, check generator. Reduce load taken from the batteries.
Measure battery voltage. After some time this will be higher. Nothing, this is normal when the battery is almost fully charged. Nothing; if ambient temperature is more than 40°C the charge current is automatically reduced. Check AC-input voltage.
See "Charge current too low". Reduce load taken from the batteries. Use a battery charger with higher capacity. Use the battery temperature sensor. Check battery and replace if necessary. Charge and recharge a few times, this might help. Check battery and replace if necessary. Check battery and replace if necessary. Use the battery temperature sensor. Check settings (see section 5.2).
7.2 FAULT INDICATION
If an error occurs, FAILURE is shown on the display. The origin of the error is displayed by means of an error code.
Error code INP FREQ INP VOLT HIGH VOLT LOW VOLT BATT LOW TMP SD
Explanation AC Input frequency too high or too low AC Input voltage too high or too low DC voltage too high DC voltage too low DC voltage too low Temperature shutdown
What to do Check AC frequency, check generator. Check AC voltage, check generator. Check battery voltage. Check battery voltage. Check battery voltage. Let the charger cool down. See also section 4.2.
EN / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / August 2007
29
TECHNICAL DATA
8 TECHNICAL DATA
8.1 SPECIFICATIONS 12V MODELS
Model Article no. GENERAL Nominal input voltage**: Nominal input frequency: Full load consumption: Max. AC input current (@ 230VAC) Max. AC input current (@ 120VAC) Nominal output voltage: Total charge current*: Number of battery outlets: Max. current second output: Max. current third output: Charge characteristic*: Charge voltage Bulk*: Charge voltage Absorption*: Charge voltage Float*; Max. absorption and max. bulk timer*: Minimum absorption time*: Battery type settings*: Dimensions (mm): Dimensions (inch): Weight: Recommended battery capacity: Power factor regulations Temperature compensation Voltage compensation DC consumption Temperature range
Cooling
Sound level Protection degree Approvals MasterBus connectivity Powering capabilities for MasterBus
* Adjustable, see chapter 5 for settings. ** See also figure 9.
12/70-3 44010700
12/100-3 44011000
120/230V
120/230V
50/60Hz
50/60Hz
1200VA
1700VA
7A
9A
14A
18A
12V
12V
70A at 14.4V
100A at 14.4V
3
3
10A +/- 10%
10A +/- 10%
10A +/- 10%
10A +/- 10%
IUoUo, automatic, three step plus
14.4V
14.4V
14.25V
14.25V
13.25V
13.25V
8 hours (start max. bulk timer at 13.25V)
15 min.
15 min.
Open lead / gel / traction / AGM / spiral (adjustable by means of DIP-switch)
362x277x150
362x277x150
14.3x11.0x5.9
14.3x11.0x5.9
<7kg (<16Lbs)
<7kg (<16Lbs)
160-800Ah
160-800Ah
0,98
0,98
Battery temperature sensor and cable included.
Yes, by means of automatic compensation.
<10mA
<10mA
25°C (13°F) to 60°C (140°F) derating 3%/°C (2%/°F) above 40°C (104°F) ,
90% derating under 0°C (32°F)
Vario fan and natural cooling to ensure optimized cooling when unit stored in
corners etc.
<52dBA / 1m
IP23
IP23
Fully CE and E-marking according to automotive directive 95/54/EG / UL pending
Yes
Yes
Yes, when the charger is switched on, it can power up to three non-powering
devices.
Specifications are subject to change without prior notice.
30
August 2007 / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / EN
TECHNICAL DATA
8.2 SPECIFICATIONS 24V MODELS
Model Article no. GENERAL Nominal input voltage**: Nominal input frequency: Full load consumption Max. AC input current (@ 230VAC) Max. AC input current (@ 120VAC) Nominal output voltage: Total charge current*: Number of battery outlets: Max. current second output: Max. current third output: Charge characteristic*: Charge voltage Bulk*: Charge voltage Absorption*: Charge voltage Float*; Max. absorption and max. bulk timer*: Minimum absorption time*: Battery type settings*: Dimensions (mm): Dimensions (inch): Weight: Recommended battery capacity: Power factor regulations Temperature compensation Voltage compensation DC consumption Temperature range
Cooling
Sound level Protection degree Approvals MasterBus connectivity Powering capabilities for MasterBus
* Adjustable, see chapter 5 for settings ** See also figure 9
24/40-3 44020400
24/60-3 44020600
24/80-3 44020800
24/100-3 44021000
120/230V
120/230V
120/230V
120/230V
50/60Hz
50/60Hz
50/60Hz
50/60Hz
1400VA
2000VA
2700VA
3375VA
8A
10A
13A
16A
16A
20A
26A
32A
24V
24V
24V
24V
40A at 28.8V
60A at 28.8V
80A at 28.8V
100A at 28.8V
3
3
3
3
10A +/- 10%
10A +/- 10%
10A +/- 10%
10A +/- 10%
10A +/- 10%
10A +/- 10%
10A +/- 10%
10A +/- 10%
IUoUo, automatic, three step plus
28.8V
28.8V
28.8V
28.8V
28.5V
28.5V
28.5V
28.5V
26.5V
26.5V
26.5V
26.5V
8 hours (start max. bulk timer at 26.5V)
15 min.
15 min.
15 min.
15 min.
Open lead / gel / traction / AGM / spiral (adjustable by means of DIP-switch)
362x277x150
362x277x150
432x277x150
432x277x150
14.3x11.0x5.9
14.3x11.0x5.9
17.0x11.0x5.9
17.0x11.0x5.9
<7kg (<16Lbs)
<7kg (<16Lbs)
<8kg (<18Lbs)
<8kg (<18Lbs)
100-500Ah
150-750Ah
200-1000Ah
200-1000Ah
0,98
0,98
0,98
0,98
Battery temperature sensor and cable included.
Yes, by means of automatic compensation.
<5mA
<5mA
<5mA
<5mA
25°C (13°F) to 60°C (140°F) derating 3%/°C (2%/°F) above 40°C (104°F),
90% derating under 0°C (32°F)
Vario fan and natural cooling to ensure optimized cooling when unit stored in
corners etc.
<52dBA / 1m
IP23
IP23
IP23
IP23
Fully CE and E-marking according to automotive directive 95/54/EG / UL pending
Yes
Yes
Yes
Yes
Yes, when the charger is switched on, it can power up to three non-powering
devices.
Specifications are subject to change without prior notice.
EN / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / August 2007
31
TECHNICAL DATA
8.3 CHARACTERISTICS
Figure 9: Charge current versus input voltage
BULK
ABSORPTION
14.40VDC 14.25VDC
`min. bulk timer: 2 min
Bulk Absorption
`min. abs timer: 15 min
13.25VDC 12.80VDC
Imax < Imax
Float
Start max bulk timer: 13.25VDC Imax 100%
FLOAT
BULK
Return to bulk: 12.80VDC
Return amps = 6% Imax
= voltage = current
`max. bulk `max. absorption timer: 8 hr timer: 4 hr
repeated
85
every 323868 hr min
Figure 10: Charge characteristic of the three-step Plus charging method (at 25°C / 77°F)
30 `return to sec bulk timer
32
August 2007 / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / EN
Float voltage + 2.25V = 15.50VDC
FLOAT
Float voltage = 13.25VDC
EQUALIZE
TECHNICAL DATA FLOAT
10% of Imax
= voltage = current
Max equalize time = 6hr Start equalize cycle by jumper change (disabled when Gel)
Figure 11: Charge characteristic of the equalize charge cycle (see section 5.1.4) (at 25°C / 77°F)
Figure 12: Temperature compensation characteristic (charge voltage versus temperature)
EN / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / August 2007
33
ORDERING INFORMATION
9 ORDERING INFORMATION
9.1 MASTERBUS INSTALLATION COMPONENTS
Part number 77040000 77040020 77040050 77040100 77040300 77040600 77041000 77041500 77042500 77050000 77050000 77050000
77030100
77010100 77010300 77010400 77020100
Description MasterBus terminating device MasterBus connection cable (UTP patch cable), 0,2m / 0.6ft MasterBus connection cable (UTP patch cable), 0,5m / 1.6ft MasterBus connection cable (UTP patch cable), 1,0m / 3.3ft MasterBus connection cable (UTP patch cable), 3,0m / 10ft MasterBus connection cable (UTP patch cable), 6,0m / 20ft MasterBus connection cable (UTP patch cable), 10m / 33ft MasterBus connection cable (UTP patch cable), 15m / 49ft MasterBus connection cable (UTP patch cable), 25m / 82ft 100m / 330ft MasterBus cable (UTP cable) 50 pcs. modular jacks Complete set to assemble UTP patch cables. Delivery includes: 100m / 330ft UTP cable, 50 pcs. modular jacks and crimping tool MasterConnect USB interface, required as interface between your PC and the MasterBus when using MasterAdjust software. MasterView Classic, Mastervision compatible display to control and monitor all MasterBus products MasterView Easy, Touch screen to control and monitor all MasterBus products MasterView System, Full-colour touch screen to control and monitor all MasterBus products MasterShunt 500, DC-distribution module for exact readout of battery voltage, charge / discharge current, and state of charge on the display of the ChargeMaster. continuous rating: 250A, peak current: 500A
9.2 MISCELLANEOUS
Part number
Description
6384001600
Industrial DC fuse 16A DIN 00
6384005000
Industrial DC fuse 50A DIN 00
6384008000
Industrial DC fuse 80A DIN 00
6384010000
Industrial DC fuse 100A DIN 00
6384012500
Industrial DC fuse 125A DIN 00
6381001000
Fuse base DIN 00 (max. 160A)
79009006
Battery switch 250A with knob
79009005
Battery switch 250A with key
6387000600
Double pole automatic circuit breaker DPN 6A-B, 1P+N
6387001000
Double pole automatic circuit breaker DPN 10A-B, 1P+N
6387001600
Double pole automatic circuit breaker DPN 16A-B, 1P+N
6385401610
Double pole automatic circuit breaker and earth leakage switch DPN VIGI 16A / B / 16mA, 1P + N
41500500*
Battery temperature sensor, incl. 6 meter / 19 ft cable
* standard included with the delivery of the Chargemaster
Mastervolt can offer a wide range of products for your electrical installation, including an extended program of components for your MasterBus network, both AGM and gel batteries, shore power connections, DC distribution kits and many more See our website www.mastervolt.com for an extensive overview of all our products
34
August 2007 / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / EN
EC DECLARATION OF CONFORMITY
10 EC DECLARATION OF CONFORMITY
Manufacturer Address
Mastervolt Snijdersbergweg 93 1105 AN Amsterdam The Netherlands
Herewith declares that:
Product:
44010700 44011000 44020400 44020600 44020800 44021000
Chargemaster 12/70-3 Chargemaster 12/100-3 Chargemaster 24/40-3 Chargemaster 24/60-3 Chargemaster 24/80-3 Chargemaster 24/100-3
Is in conformity with the provision of the EC, EMC directive 89/336/EEC and amendments 92/31/EEC, 93/68/EEC
The following harmonized standards have been applied:
EN 60950-1 EN 55022: 1998+A1 : 2000+A2: 2003 Class A EN 61000-4-2: 2001, EN 61000-4-4: 2004, EN 61000-4-5: 2001, EN 61000-4-3: 2002+A1: 2002, EN 61000-4-6: 1996+A1: 2000 EN 61000-3-2: 2000, EN 61000-6-4: 1997
Amsterdam,
P.F. Kenninck, General Manager MASTERVOLT
EN / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / August 2007
35
Snijdersbergweg 93, 1105 AN Amsterdam, The Netherlands Tel : + 31-20-3422100 Fax : + 31-20-6971006
Email : info@mastervolt.com
Acrobat Distiller 8.0.0 (Windows)
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