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
2
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
4
August 2007 / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / EN
GENERAL INFORMATION
1 GENERAL INFORMATION
1.1
USE OF THIS MANUAL
1.4
IDENTIFICATION LABEL
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
IP 23
Part no : 44020800
Type : ChargeMaster 24/80-3
Input : 120/230V AC 50/60 Hz 26A/13A
Output : 28.5V - 80A
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:
Serial no: V822A0001
Serial number
V822A001
Design by
Mastervolt
Manufactured in China
Part number
Apparatus version “A”
Part number
44010700
44011000
44020400
44020600
44020800
44021000
Model
Chargemaster 12/70-3
Chargemaster 12/100-3
Chargemaster 24/40-3
Chargemaster 24/60-3
Chargemaster 24/80-3
Chargemaster 24/100-3
Figure 1: Identification label
These models are further mentioned as “Chargemaster”
For other models see other manuals available on our
website: www.mastervolt.com
1.3
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.
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.
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.
CAUTION!
Special data, restrictions and rules with regard
to preventing damage.
A procedure, circumstance,
deserves extra attention.
etc
which
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
1
2
3
4
5
6
7
8
6
GENERAL
Before using the Chargemaster, read all instructions
and cautionary markings on the Chargemaster, the
batteries, and all appropriate sections of the manual.
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.
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.
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.
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.
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.
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.
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
1
2
3
EXPLOSIVE GASES
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.
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.
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.
August 2007 / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / EN
IMPORTANT SAFETY INSTRUCTIONS
2.3
1
WARNINGS REGARDING THE USE OF
BATTERIES
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.
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
SOURCE
Press SOURCE to select the
battery bank (1, 2 or 3) that you
want to monitor
LCD-display
See section 3.3
Figure 2: operation of the Chargemaster
3.1
FEATURES
3.2
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.
8
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.
August 2007 / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / EN
OPERATION
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.
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.
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.
3.3
LCD-DISPLAY
The display at the front side of the Chargemaster enables
you to monitor the charging process. See figure 3.
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.
If no switch is touched during 20 seconds, the
display will go to the initial readings, showing
the charge voltage and charge current.
Actual charge voltage (Volts).
CHARGEMASTER
POWER
FLOAT
ABS
INFO
FAILURE
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.
BULK
SOURCE
Highlighted if the Chargemaster is
connected to the Masterbus network.
Selected battery bank (1, 2 or 3).
Press SOURCE to alter.
Highlighted if AC voltage is not
available.
Hours and minutes indication.
Actual stage of the Three Step charge
algorithm. See section 3.4.
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
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.
CHARGE CURRENT
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.
10
3.4.1
Temperature compensated charging
By installing the battery temperature sensor the charge
voltages are automatically adapted for deviating
temperatures.
24V
12V
charge voltage (V)
TIME
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.
August 2007 / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / EN
OPERATION
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.
EN / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / August 2007
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.
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.
3.6
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
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.
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.
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
Software version
Version of the installed software.
MASTERBUS (OPTIONAL)
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!
12
August 2007 / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / EN
INSTALLATION
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
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.
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.
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):
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).
AC-Current
Minimum cross section:
in mm²
AWG
6-12 Amp
12-20 Amp
1.5 mm²
2.5 mm²
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.
AWG 15
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
12/100-3
24/40-3
24/60-3
24/80-3
24/100-3
25mm² / AWG3
35mm² / AWG2
16mm² / AWG5
25mm² / AWG3
35mm² / AWG2
35mm² / AWG2
35mm² / AWG2
50mm² / AWG0
25mm² / AWG3
35mm² / AWG2
50mm² / AWG0
50mm² / AWG0
• Charge output (output 2 and 3)
Model
DC Cable cross section:
Chargemaster <3m / 10ft
3-5m / 10ft
All models
4mm² / AWG11
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.
14
• 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
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
• 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
12/70-3
12/100-3
24/40-3
24/60-3
24/80-3
24/100-3
4.3.4
Minimum required battery
capacity
140Ah
200Ah
80Ah
120Ah
160Ah
200Ah
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.
August 2007 / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / EN
INSTALLATION
4.4
OVERVIEW CONNECTION COMPARTMENT
3
4
5
1
6
7
2
8
1
2
3
4
5
6
7
8
9
10
11
9
10
11
Screw terminals AC input
Cable gland for AC-wiring
Isolation caps for DC connections
Positive terminal charge output 1 (main output)
Common negative output terminal
Positive terminal charge output 2
Positive terminal charge output 3
Ventilation openings
DIP-switches
Temperature sensor jack
MasterBus connector
Figure 6: overview connection compartment
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
CAUTION!
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.
16
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.
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
DC distribution
Charger fuse
+
POSITIVE (+)
NEGATIVE (–)
Battery
fuse
–
Battery
fuse
Battery
fuse
Temperature sensor
BATTERY BANK 1
(main battery bank)
BATTERY
BANK 2
BATTERY
BANK 3
OPTIONAL
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
2
3
18
4
Open the connection compartment by
loosening the four screws.
5
Feed the AC wiring through cable gland and
connect the wiring to the screw terminals.
Tighten the cable gland firmly.
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 – .
Mark the position of the mounting spots by
using the mounting bracket. Then Fix the
mounting bracket to the wall.
Place the ChargeMaster over the mounting
bracket and then move it downwards until it is
suspended from the mounting bracket.
Fix the cabinet to the wall by fastening two
screws at the lower side of the cabinet as
well.
August 2007 / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / EN
INSTALLATION
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).
8
Attach the battery temperature sensor to the
casing of battery bank 1.
Plug the temperature sensor cable into the
“temp.sensor” jack.
9
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.
11
Check all wiring; see also figure 7 for wiring
details.
12
Close the connection compartment by fixing
the four screws.
13
Continue with section 4.8 for commissioning
of the ChargeMaster.
Option: Connect the ChargeMaster to the
MasterBus network. See chapter 6.
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).
4.9
If it is necessary to put the Chargemaster out of operation,
follow the instructions in order of succession as described
below:
1
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.
3
4
5
NOTE:
The DIP-switches must be adjusted prior to
commissioning; all other settings can only be
made after commissioning.
DECOMMISSIONING
6
Switch the Chargemaster to stand-by (see section
3.2).
Remove the DC-fuse(s) of the DC-distribution and/or
disconnect the batteries.
Remove the AC-fuse(s) of the AC-input and/or
disconnect the AC-mains.
Open the connection compartment of the
Chargemaster.
Check with a suitable voltage meter whether the
inputs and the outputs of the Chargemaster are
voltage free.
Disconnect all the wiring.
Now the Chargemaster can be demounted in a safe way.
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.
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).
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.
20
August 2007 / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / EN
SETTINGS
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
Figure 8: DIP-switches
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)
5.1.2
OFF
ON
DIP switch 2: Charge algorithm
IUoUo, fully automatic / 3step+ (factory setting)
Constant voltage charging (Float = 13.25/26.5V)
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.
5.1.4
OFF
ON
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.
1 2 3 4
5.1.1
5.1.3
OFF
ON
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
Stage
BULK
BULK
BULK
ABS
ABS
ABS
Display
Text
BULK VOLT
MAX TMR
MIN TMR
ABS VOLT
MAX TMR
MIN TMR
ABS
RET AMP
ABS
FLOAT
RET AMP
FLT VOLT
FLOAT
CONST FLT
22
Setting
min
default
max
unit
resolution
0.00
0
0
0.00
0
0
14.40
8h
120sec
14.25
4h
15min
15.50
24h
240sec
15.50
24h
240min
V
h / min
sec
V
h / min
h / min
0.05
1min
1sec
0.05
1min
1min
0%
6%
50%
%
1%
0
0.00
30sec
13.25
240sec
15.50
sec
V
1sec
0.05
0.00
13.25
15.50
V
0.05
RET BULK
RET BULK
MAX CURR
ALM DEL
HIGH DCON
HIGH DCOF
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
0.00
0
0
0
0.00
0.00
12.80
30sec
nominal
30sec
16.00
15.00
15.50
240sec
nominal
240
16.00
16.00
V
sec
A
sec
V
V
0.05
1sec
1A
1sec
0.05
0.05
LOW DCON
LOW DCOF
RES FACT
Alarm DC low on
Alarm DC low off
Reset to factory settings
0.00
0.00
10.00
11.00
NO
16.00
16.00
V
V
0.05
0.05
YES
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
Display
Text
BULK VOLT
MAX TMR
MIN TMR
ABS VOLT
MAX TMR
MIN TMR
ABS
RET AMP
ABS
FLOAT
RET AMP
FLT VOLT
FLOAT
CONST FLT
Setting
min
default
max
unit
resolution
0.00
0
0
0.00
0
0
28.80
8h
120sec
28.50
4h
15min
31.00
24h
240sec
31.00
24h
240min
V
h / min
sec
V
h / min
h / min
0.05
1min
1sec
0.05
1min
1min
0%
6%
50%
%
1%
0
0.00
30sec
26.50
26.50
240sec
31.00
31.00
sec
V
1sec
0.05
V
0.05
RET BULK
RET BULK
MAX CURR
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
0.00
0
0
26.50
30sec
nominal
31.00
240sec
nominal
V
sec
A
0.05
1sec
1A
ALM DEL
HIGH DCON
HIGH DCOF
LOW DCON
LOW DCOF
RES FACT
Alarm delay time
Alarm DC High on
Alarm DC High off
Alarm DC low on
Alarm DC low off
Reset to factory settings
0
0.00
0.00
0.00
0.00
30sec
32.00
30.00
20.00
22.00
NO
240
32.00
32.00
32.00
32.00
sec
V
V
V
V
1sec
0.05
0.05
0.05
0.05
YES
0.00
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
24
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.
August 2007 / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / EN
MASTERBUS
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:
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.
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.
OK
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
Do not make ring networks.
OK
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
Terminating
device
OK
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
6.3.2
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
Default
Adjustable range
(read only)
(read only)
(read only)
(read only)
(read only)
(read only)
(read only)
Factory setting
Adjustable range
See 6.3.4
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)
n/a
n/a
n/a
n/a
n/a
n/a
Level 3: Alarms
Value
Low batt
High batt
Low AC
High AC
Low frequency
High frequency
High temperature
Low temperature
Meaning
Battery voltage has dropped below setting DC low on, and
has not increased above setting DC low off yet
Battery voltage has increased above setting DC high on,
and has not dropped below setting DC high off yet
AC input voltage is too low
AC input voltage is too high
AC input frequency is too low
AC input frequency input is too high
Internal temperature is too high
Internal temperature is too low
* see section 8.3, figure 9 for characteristics
6.3.3
Level 3: History
This menu shows the absolute maximum readings. See section 3.5 for detailed description.
Factory
setting
Value
Meaning
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
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
Lowest DC volta
Highest DC volt
Software version
26
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)
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
Language
Meaning
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
Forced float vo.
Return to bulk
Return to bulk
Max Charge curr
Alarm setpoints
DC high on
DC high off
DC low on
DC low off
Alarm delay
Device settings
Product name on.
Traction settings
Traction Bulk v
Adjustable. range
English
English
14.40/28.80V
8h
120sec
13.25/26.50V
0-15.50/0-31.00V
0-24h
0-240sec
(read only)
14.40/28.80V
4h
15min
6%
30sec
0-15.50/0-31.00V
0-24h
0-240min
0-50%
0-240sec.
13.25/26.50V
0-15.50/0-31.00V
Float voltage
Forced float voltage
(Constant voltage charging)
Return to bulk voltage
Return to bulk time delay
Maximum charge current
13.25/26.50V
0-15.50/0-31.00V
13.25/26.50V
30sec
100%
0-15.50/0-31.00V
0-240sec
0-100%
Alarm DC High on
Alarm DC High off
Alarm DC low on
Alarm DC low off
Alarm delay time
16.00/32.00V
15.00/30.00V
10.00/20.00V
11.00/22.00V
30sec
0-16.00V0-32.00V
0-16.00V0-32.00V
0-16.00/0-32.00V
0-16.00/0-32.00V
0-240sec
Name of this device. This name will be recognized by all
devices connected to the MasterBus
CHG CM+type*
0-12 chars
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
Maximum allowed upper temperature
Maximum allowed lower temperature
Maximum voltage compensation for temperature
compensated charging,
AGM / GEL float voltage setting
Max voltage com
Factory setting
AGM / GEL floa
Hardware settings
Gel / AGM
DIP-switch 1: Battery type
Force float
DIP switch 2: Charge algorithm
Equalize
DIP switch 4: Equalize mode
August 2007 / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / EN
+300/+600mV
(read only)
+300/+600mV
480 min
(read only)
(read only)
+2.25/+4.50V
8h
(read only)
(read only)
-30mV/°C
-60mV/°C
+300/+600mV
480 min
(read only)
(read only)
+0.3/+0.6V
(read only)
+550/+1100mV
(read only)
(see section 5.1.1)
(see section 5.1.2)
(see section 5.1.4)
(read only)
(read only)
(read only)
(read only)
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,
6.3.5
Adjustable. range
(read only)
(read only)
(read only)
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.
28
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
Possible cause
What to do
No output voltage
and/or current
Output voltage too low,
charger supplies
maximum current
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
Check AC wiring, check remote control panel.
Check input voltage, check generator.
Check input voltage, check generator.
Reduce load taken from the batteries.
Charge current too low
Batteries almost fully charged
High ambient temperature
Batteries not fully
charged
Batteries are
discharged too fast
Batteries are too warm,
gassing
7.2
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
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).
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
12/70-3
12/100-3
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:
44010700
44011000
120/230V
50/60Hz
1200VA
7A
14A
12V
70A at 14.4V
3
10A +/- 10%
10A +/- 10%
120/230V
50/60Hz
1700VA
9A
18A
12V
100A at 14.4V
3
10A +/- 10%
10A +/- 10%
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
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.
Cooling
Sound level
Protection degree
Approvals
MasterBus connectivity
Powering capabilities for MasterBus
* Adjustable, see chapter 5 for settings.
** See also figure 9.
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*;
24/40-3
44020400
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
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
Cooling
Sound level
Protection degree
Approvals
MasterBus connectivity
Powering capabilities for MasterBus
24/60-3
44020600
120/230V
120/230V
50/60Hz
50/60Hz
1400VA
2000VA
8A
10A
16A
20A
24V
24V
40A at 28.8V
60A at 28.8V
3
3
10A +/- 10%
10A +/- 10%
10A +/- 10%
10A +/- 10%
IUoUo, automatic, three step plus
28.8V
28.8V
28.5V
28.5V
26.5V
26.5V
24/80-3
44020800
24/100-3
44021000
120/230V
50/60Hz
2700VA
13A
26A
24V
80A at 28.8V
3
10A +/- 10%
10A +/- 10%
120/230V
50/60Hz
3375VA
16A
32A
24V
100A at 28.8V
3
10A +/- 10%
10A +/- 10%
28.8V
28.5V
26.5V
28.8V
28.5V
26.5V
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.
* Adjustable, see chapter 5 for settings
** See also figure 9
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
`min. bulk timer: 2 min
14.40VDC
14.25VDC
13.25VDC
FLOAT
BULK
`min. abs timer: 15 min
Bulk
Absorption
Float
Start max bulk timer: 13.25VDC
12.80VDC
Return to bulk: 12.80VDC
Imax 100%
Imax
< Imax
Return amps = 6% Imax
= voltage
`max. bulk ``max. absorption
timer: 8 hr timer: 4 hr
repeated
every 336
288 hr
85
min
30 `return to
sec bulk timer
= current
Figure 10: Charge characteristic of the three-step Plus charging method (at 25°C / 77°F)
32
August 2007 / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / EN
TECHNICAL DATA
FLOAT
EQUALIZE
FLOAT
Float voltage + 2.25V
= 15.50VDC
Float voltage
= 13.25VDC
10% of Imax
= voltage
Max equalize time = 6hr
Start equalize cycle by jumper change (disabled when Gel)
= current
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
9.2
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
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