ChargeMaster
USERS MANUAL / GEBRUIKERSHANDLEIDING / BETRIEBSANLEITUNG
MANUEL UTILISATEUR / MANUAL DE UTILIZACION / INSTRUZIONI PER L’USO
ChargeMaster
12/25-3, 24/12-3
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 21
SEITE 41
PAGINA 61
PÁGINA 81
PÁGINA 101
Copyright © 2011 Mastervolt v 1.5 September 2011
CONTENTS
CONTENTS:
v 1.5 September 2011
1
GENERAL INFORMATION.............................................................................................................................................. 3
1.1
Use of this manual.............................................................................................................................................. 3
1.2
Validity of this manual ........................................................................................................................................ 3
1.3
Use of pictograms .............................................................................................................................................. 3
1.4
Identification label............................................................................................................................................... 3
1.5
Liability ............................................................................................................................................................... 3
2
IMPORTANT SAFETY INSTRUCTIONS ......................................................................................................................... 4
2.1
General .............................................................................................................................................................. 4
2.2
Explosive gases ................................................................................................................................................. 4
2.3
Warnings regarding the use of batteries............................................................................................................. 5
2.4
Warning regarding life support applications........................................................................................................ 5
2.5
Guarantee specifications .................................................................................................................................... 5
3
OPERATION .................................................................................................................................................................... 6
3.1
Features ............................................................................................................................................................. 6
3.2
Display ............................................................................................................................................................... 6
3.3
Setting mode ...................................................................................................................................................... 6
3.4
Failures............................................................................................................................................................... 6
3.5
Three Step charge algorithm .............................................................................................................................. 6
3.6
Maintenance....................................................................................................................................................... 7
4
INSTALLATION ............................................................................................................................................................... 8
4.1
Unpacking .......................................................................................................................................................... 8
4.2
Environment ....................................................................................................................................................... 8
4.3
Wiring and batteries ........................................................................................................................................... 8
4.4
Overview connections ........................................................................................................................................ 9
4.5
Things you need................................................................................................................................................. 9
4.6
Connections ....................................................................................................................................................... 9
4.7
Commissioning after installation....................................................................................................................... 10
4.8
Decommissioning ............................................................................................................................................. 10
4.9
Storage and transportation ............................................................................................................................... 10
5
MASTERBUS................................................................................................................................................................. 11
5.1
What is MasterBus? ......................................................................................................................................... 11
5.2
How to set up a MasterBus network................................................................................................................. 11
5.3
MasterBus functions ......................................................................................................................................... 12
6
TROUBLE SHOOTING .................................................................................................................................................. 16
6.1
Fault finding table ............................................................................................................................................. 16
7
TECHNICAL DATA........................................................................................................................................................ 17
7.1
Specifications ................................................................................................................................................... 17
7.2
Dimensions....................................................................................................................................................... 18
7.3
Characteristics.................................................................................................................................................. 19
8
ORDERING INFORMATION.......................................................................................................................................... 20
9
EC DECLARATION OF CONFORMITY ........................................................................................................................ 20
2
September 2011 / ChargeMaster 12/25-3, 24-12-3 / 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 ChargeMaster to enable its safe and
effective operation, maintenance and possible correction
of minor malfunctions.
It is therefore obligatory that every person who works on or
with the ChargeMaster is completely familiar with the
contents of this manual, and that he/she carefully follows
its instructions and important safety instructions.
Copyright © 2011 Mastervolt. All rights reserved.
Reproduction, transfer, distribution or storage of part or all
of the contents in this document in any form without the
prior written permission of Mastervolt is prohibited.
1.2
VALIDITY OF THIS MANUAL
Serial number
V822A001
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 model:
Part number
Apparatus version “A”
Figure 1: Identification label
Part number
Model
44010250
44020120
ChargeMaster 12/25-3
ChargeMaster 24/12-3
This model is referred to as “ChargeMaster” further in this
manual.
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.
USE OF PICTOGRAMS
CAUTION!
Never remove the identification label.
Safety instructions and warnings are marked in this
manual by the following pictograms:
WARNING
1.5
LIABILITY
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.
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.
EN / ChargeMaster 12/20-3 / September 2011
etc
which
3
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
4
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, should
be carried out 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.
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.
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.
The ChargeMaster has been approved ignition
protected according to SAE J1171 / ISO 8846, only
when
installed
and
in
normal
operation!
DANGER: To reduce the risk of explosion DURING
INSTALLATION OF THE CHARGEMASTER - avoid
situations where there is danger of gas or dust
explosion and disable all devices in areas in which
ignition-protected equipment is required.
September 2011 / ChargeMaster 12/25-3, 24-12-3 / EN
IMPORTANT SAFETY INSTRUCTIONS
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 the ChargeMaster for charging the following
battery types: Lead acid, AGM, Spiral, Gel , Deep
cycle or Li-ion batteries. 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.
EN / ChargeMaster 12/25-3, 24-12-3 / September 2011
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 the battery is well
ventilated while the 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
Do not use the ChargeMaster for applications in any
medical equipment intended for use as a component of
any life support system!
2.5
GUARANTEE SPECIFICATIONS
Mastervolt guarantees that this unit has been built
according to the legally applicable standards and
specifications. If work takes place which is not in
accordance with the guidelines, instructions and
specifications contained in this user’s 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, labour or
shipping of the defective parts are not covered by this
guarantee.
5
OPERATION
3 OPERATION
3.1
FEATURES
external AC source connected, the ChargeMaster charger
also serves the function of an AC to DC converter to
supply DC loads which are connected to the batteries.
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 the
following battery types: Lead acid, AGM, Spiral, Gel, Deep
cycle batteries and Mastervolt Li-ion batteries (MLI). It has
an auto-ranging input facility which makes it feasible to
operate on almost any AC power source in the world. It
operates on both 230V and 120V without compromising
the output current. The three-step Plus charging method
guarantees 100% charged batteries. In some cases
however, a 2-step charging method is more convenient.
This method can be selected in the setting mode. With an
Meaning Load bar
+ POWER LED + POWER LED
green
blinking red
Current
Temperature
100%
error
Current 75% Charger
failure
Current 50% Wrong AC
voltage
Current 25% Battery
voltage high
_
Current 5%
(Float, Abs,
Bulk: On)/
Battery low
(Float, Abs,
Bulk: Off)
3.3
In
Setting mode
Connected to
MasterBus
MLI
Li-ion battery *
2-Step charge
Off = 3-Step
Wet battery
Gel/AGM
battery
Load
bar
3.2
DISPLAY
The ChargeMaster is equipped with a multicolour LED
display. Different LED colours and combinations have
different meanings, see below.
POWER LED
(NO BUTTON)
Illuminating
green = on,
red = standby.
MLI**
2-step
Set button
Press Set for 5
seconds to
start the setting
mode. See
section 3.3.
Wet
Gel/AGM
Figure 2: Display operation of the ChargeMaster
* function available from firmware version 4.06
** display available from revision D
SETTING MODE
CAUTION!
We recommend you to check if your system is
up to the higher Li-ion (charging) voltages!
FAILURES
The ChargeMaster is protected against overload, short
circuit, over heating and under and over voltage. If a fault
condition occurs, the Power LED illuminates red and a
load bar segment illuminates. The segment position
6
The Li-ion charging voltages on this charger fit
the Mastervolt Li-ion (MLI) batteries and do
not necessarily fit other Li-ion batteries!
Actual state of the 3-step charging method:
Float, Absorption and Bulk.
Press Set for 5 seconds to start the setting mode. Done
so, you see a blinking LED next to the actual setting.
Press Set again to scroll through the settings. Press and
hold the button for 5 seconds to save the selected setting
or do not touch the button for 60 seconds to leave the
settings unchanged. Press Set shortly to see the new
setting.
3.4
WARNING
indicates the
explanation.
failure
cause.
See
section
3.2
for
CAUTION!
The ChargeMaster is not protected against:
•
reversing polarity of the DC-output,
•
three phase AC on the AC-input.
3.5
THREE STEP CHARGE ALGORITHM
See figure 3. Battery charging is accomplished in three
automatic stages: BULK, ABSORPTION and FLOAT.
The first step of the three step 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 BULK voltage 14.4V (Li-ion:14.6V)
resp. 28.8V (Li-ion: 29.2V) at 25°C / 77°F.
The duration of this phase depends on the ratio of battery
to charger capacity, and the battery state of charge.
September 2011 / ChargeMaster 12/25-3, 24-12-3 / EN
OPERATION
BATTERY VOLTAGE
BULK
ABSORPTION
3.5.1
FLOAT
Temperature compensated charging
By installing the battery temperature sensor (optional) the
charge voltages are automatically adapted for deviating
temperatures.
CHARGE CURRENT
TIME
Figure 3: Three step charge system
The bulk phase is followed by the ABSORPTION phase.
Absorption charging starts when the voltage on the
batteries has reached the BULK voltage, and ends when
the battery is completely full. Battery voltage remains
constant at 14.25V (Li-ion: 14,6V) / 28.5V (Li-ion: 29.2V) 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 approx. 4h,
with gel and AGM around 3h. Once the battery is 100%
full, the ChargeMaster automatically switches over to the
float phase. At FLOAT (for Gel/AGM, Wet batteries) the
ChargeMaster switches to a stabilised 13.25V (Li-ion:
13.5V) or 26.5V (Li-ion: 27.0V) at 25°C / 77°F.
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 during 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.
Figure 4: Temperature compensated charging
See figure 4. 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.
3.5.2
Connection of a second and third battery
The ChargeMaster is equipped with three equal outputs.
The total output current is divided over these three
outputs. See section 4.6 for connections.
3.6
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.
See also section 7.3 for detailed characteristics
of the three step Plus charge system.
EN / ChargeMaster 12/25-3, 24-12-3 / September 2011
7
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
UNPACKING
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.
• Operating ambient temperature: -25°C ... 60°C / -13°F
… 140°F (power derating above 25°C / 77 °F to
decrease the internal temperature).
• Humidity: 0-95% non condensing.
• Mount the ChargeMaster preferably to a vertical wall,
with the connecting cables downwards.
• Make sure that the hot air developed during operation
can be discharged. The ChargeMaster must be
mounted so that obstruction of the airflow through the
ventilation openings will be prevented.
• No objects must be located within a distance of 10 cm /
4 inches 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.
4.3
4.3.1
DC wiring
Keep in mind that high current will pass through the DC
wiring. Keep the cable lengths shortest possible for
highest system efficiency. The recommended minimum
cross section of maximum 3m/ 9ft length battery cables for
output 1, 2 and 3 is:
Model ChargeMaster
DC cable cross section
12/25-3
24/12-3
6.0 mm² / 9 AWG
4.0 mm² / 11 AWG
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 colour
Meaning
Connect to:
Red
Black
Positive
Negative
+ (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.
The recommended cable fuses for outputs 1, 2 & 3 and
minimum battery capacities are:
WIRING AND BATTERIES
Model ChargeMaster
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.
12/25-3
24/12-3
4.3.2
Fuse
32A
16A
Battery Capacity
55Ah
25Ah
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.
8
September 2011 / ChargeMaster 12/25-3, 24-12-3 / EN
INSTALLATION
4.4
OVERVIEW CONNECTIONS
1. AC cable
2. Earth connector
3. Positive charge output terminal (3x)
4. MasterBus connector (2x)
5. Common negative output terminal
6. Temperature sensor jack
1
4.5
2
3
4
5 6
Figure 5: Overview connections
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)
Quantity
1
1
MasterBus terminator
MasterBus cable
DC cable to connect the positive DC connection (+) of the ChargeMaster to the positive pole of the DCdistribution; for specifications see section 4.3.1. Cable 1250 mm, 6.0 mm² / 4.10 ft, 9 AWG.
DC-cable to connect the negative DC connection (–) of the ChargeMaster to the negative pole of the DCdistribution; for specifications see section 4.3.1. Cable 1250 mm, 6.0 mm² / 4.10 ft, 9 AWG.
DC-fuse holder with a DC-fuse, to be integrated in the positive DC-cable. For specifications see section 4.3.1.
Screws / bolts (Ø 5mm) (with plugs) to mount the cabinet to a surface. Use mounting materials which are
suitable to carry the weight of the ChargeMaster.
1.5 m AC cable to connect the AC input to an external power source (e.g. a shore connection or a generator set).
Batteries. See section 4.3.1 for recommended capacity.
Appropriate and reliable cable terminals, cable lugs, battery terminals and cord end terminals
See also chapter 8 Ordering Information.
4.6
CONNECTIONS
WARNING
Let installation work be done by a licensed
electrician. Before connecting the wiring,
make the AC distribution as well as the DC
distribution voltage free.
CAUTION!
Short circuiting or reversing polarity may
seriously
damage
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. Reverse polarity
damage is detectable by the service
department and not covered by the warranty.
EN / ChargeMaster 12/25-3, 24-12-3 / September 2011
1
1
1
4
1
X
X
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 an option.
9
INSTALLATION
4.6.1
Connection example
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.
MasterBus
network,
see chapter 5.
RCD
AC Input
DC fuse
Battery
fuse
Temperature
sensor
Battery
fuse
Battery
fuse
BATTERY
BANK 1
BATTERY
BANK 2
BATTERY
BANK 3
Figure 6: installation example of the ChargeMaster
4.7
COMMISSIONING AFTER INSTALLATION
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.
10
Now the ChargeMaster is ready for operation. After
switching on the AC power supply the ChargeMaster will
initiate the charging process.
4.8
DECOMMISSIONING
To put the ChargeMaster out of operation, follow these
instructions in order of succession:
1
2
3
4.9
Switch Off the AC supply for the ChargeMaster.
Remove the DC-fuse(s) and disconnect the batteries.
Disconnect all the wiring.
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.
September 2011 / ChargeMaster 12/25-3, 24-12-3 / EN
MASTERBUS
5 MASTERBUS
5.1
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 CAN-bus based 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 enables 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. As only a few
MasterBus cables are needed, installation and material
costs are reduced importantly. New devices can be added
to the existing network easily. Consequently the
MasterBus network is highly flexible for extended system
configuration. Mastervolt also offers several interfaces like
the Modbus interface, making even non-MasterBus
devices suitable to operate in the MasterBus network.
For central monitoring and control of the connected
devices Mastervolt offers four different panels, 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.
CAUTION: Never connect a non-MasterBus
device to the MasterBus network directly! This
will void warranty of all MasterBus devices
connected.
5.2
Connections between the devices are made by
standard straight UTP patch cables.
OK
At least one device in the network must be MasterBus
powering (see specifications). As all powering devices
are galvanically isolated, multiple powering devices
are allowed.
OK
Do not make ring networks.
HOW TO SET UP A MASTERBUS
NETWORK
Every MasterBus device is equipped with two data ports.
When two or more devices are connected via these ports,
a local data network called the MasterBus is formed.
Keep the following rules in mind:
Place a terminating device on both network ends.
Do not make T-connections in the network.
OK
Terminating
device
EN / ChargeMaster 12/25-3, 24-12-3 / September 2011
Terminating
device
11
MASTERBUS
5.3
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.
MASTERBUS FUNCTIONS
Adjustment of the settings of the ChargeMaster can be
made via the MasterBus network (by means of a remote
control panel or an interface connected to a PC with
MasterAdjust software).
5.3.1
Monitoring
Value
State
Max input power
Charger state
House bank
Charge current
House bank
Output 2
Output 3
AC input
State
System
Connect to Shunt
MasterShunt….
5.3.2
Meaning
Shows charger state: Charging/ Stand by/ No AC/ - - - (2-step)
Option to set the maximum current at the input to prevent generator or shore fuse overload
State of charge algorithm: Bulk/ Absorption/ Float
Voltage of charger output 1*
Total charge current*
Temperature of battery 1
Voltage of charger output 2*
Voltage of charger output 3*
AC input voltage
Option to switch the ChargeMaster On/ Stand by
A connected MasterShunt can be chosen for feedback on the charged battery.
Information on the MasterShunt linked to the ChargeMaster.
Alarms
Value
Battery low
Meaning
Battery voltage has dropped below setting DC low on,
and has not increased above setting DC low off yet
Battery high
Battery voltage has increased above setting DC high
on, and has not dropped below setting DC high off yet
AC low
AC input voltage is too low
AC high
AC input voltage is too high
Frequency low
AC input frequency is too low
Frequency high
AC input frequency input is too high
Temperature low
Internal temperature is too low
Temperature high
Internal temperature is too high
Temperature sensor is in failure
Temp sense error
MSH out of range
Values the MasterShunt transmits exceed the limits.
* See section 7.3, figure 14 for characteristics
5.3.3
Factory setting
See
Configuration/alarms
See
Configuration/alarms
90 V*
260 V*
40 Hz
67 Hz
-20 °C (-4 °F)
70 °C (176 °F)
Adjustable range
See
Configuration/alarms
See
Configuration/alarms
n/a
n/a
n/a
n/a
n/a
n/a
History
This menu shows the total historical readings (read only).
Value
Meaning
Charger
Charge cycles
Number of completed cycles
Charge cycles
Number of aborted charge cycles
Ah charged
Total Ampere hours charged
Total run time
Total run time in charger mode
Highest AC volt
Highest AC input voltage
Temperature
Number of temperature shutdowns
DC Low
Number of low DC voltage shutdowns
DC High
Number of high DC voltage shutdowns
AC Low
Number of low AC voltage shutdowns
AC High
Number of high AC voltage shutdowns
House bank
Lowest voltage
Lowest detected DC voltage output 1
Highest voltage
Highest detected DC voltage output 1
Output 2
Lowest voltage
Lowest detected DC voltage output 2
Highest voltage
Highest detected DC voltage output 2
Output 3
Lowest voltage
Lowest detected DC voltage output 3
12
September 2011 / ChargeMaster 12/25-3, 24-12-3 / EN
MASTERBUS
Value
Highest voltage
System
Last MPC from:
5.3.4
Meaning
Highest detected DC voltage output 3
The latest Maximum Power Control-command the ChargeMaster received as event target, see
section 5.3.6. This value shows what device controlled/ reduced the ChargeMaster.
Configuration
Below parameters can be changed via the MasterBus
network by means of a remote control panel or by means
Value
General
Language
Product name
Output 1
Output 2
Output 3
Factory settings
Charge current
AC load
Maximum current
System
System behaviour
MasterShunt
Bulk
Bulk voltage
Max. bulk timer
Min bulk timer
Start max bulk timer
Absorption
Abs. voltage
Max absorption
Min absorption
Return amps
Return amps tim
Float settings
Float voltage
Forced float vo.
Return to bulk
Return to bulk
Alarms
DC high on
DC high off
DC low on
DC low off
Alarm delay
Traction
Traction Bulk
Traction Absorpt
Traction Absorpt
of an interface connected to a PC with MasterAdjust
software. See applicable user’s manuals for details.
Meaning
Factory setting
Adjustable. range
Language displayed on MasterBus monitoring device
Name of this device. This name will be recognized by
all devices connected to the MasterBus.
Name of output 1 in the MasterBus network
Name of output 2 in the MasterBus network
Name of output 3 in the MasterBus network
Button to reset the ChargeMaster to factory settings
English
CHG CM+type*
See specifications
0-12 chars
House bank
Output 2
Output 3
12 characters max
12 characters max
12 characters max
Auto
Model depend.
System
Stand alone
Auto, MPC, manual
Model dependent
Bulk voltage Lead acid battery
Li-ion battery
Maximum bulk timer
Minimum bulk timer
Startvoltage maximum bulk timer
14.40/28.80V
14.60/29.20V
480min
120sec
13.25/ 26.50V
0-15.50/0-31.00V
Absorption voltage Lead acid battery
Li-ion battery
Maximum absorption timer
Minimum absorption timer Lead acid [Li-ion]
Return amps (% of maximum charge current)
Return amps timer Lead acid [Li-ion]
14.25/28.50V
14.60/29.20V
240min
15min [120min]
6%
30sec [240sec]
Float voltage Lead acid battery
AGM, Gel battery
Li-ion battery
Forced float voltage (Constant voltage charging)
Li-ion battery
Return to bulk voltage Lead acid battery
Li-ion battery
Return to bulk time delay for Lead acid [Li-ion] battery
13.25/26.50V
13.80/27.60V
13.50/27.00V
13.25/26.50V
13.50/27.00V
12.80/25.60V
13.25/26.50V
30sec [240sec]
0-15.50/0-31.00V
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
0-16.00/0-32.00V
0-16.00/0-32.00V
0-16.00/0-32.00V
0-16.00/0-32.00V
0-240sec
Traction bulk voltage
Traction absorption voltage
Traction absorption timer
+300/+600mV
+300/+600mV
8 hrs
0-1200mV
0-1200mV
(Read only)
Select the method to reduce the AC input power
Set the maximum charging current allowed
Set the use mode. The ChargeMaster can be
synchronized with a MasterShunt (if Connect to
MasterShunt is selected).
Select the MasterShunt to provide battery information.
EN / ChargeMaster 12/25-3, 24-12-3 / September 2011
Stand alone,
synchronized
0-24h
0-240sec
(Read only)
0-15.50/0-31.00V
0-24h
0-240min
0-50%
(Read only)
0-15.50/0-31.00V
0-15.50/0-31.00V
1-240sec
13
MASTERBUS
Value
Hardware settings
Battery type
Meaning
Factory setting
Adjustable. range
Setting for AGM/Gel batteries.
Wet
Wet, AGM/ Gel
Charge algorithm
AC Off,
MasterBus On
12V/24V power supply allowed. Off=no, On=yes
Option to keep MasterBus powered when the AC
supply is disabled and the battery is connected.
Off
Auto
Off, On
(Read only)
Disabled
See
section
5.3.5
Event source list.
Event x
target
Event x command
Event by the ChargeMaster that should result in an
action by one of the other devices on the MasterBus
network. Nine events are available: x can be 1-9.
Select a connected MasterBus device that should take
action due to a ChargeMaster event.
Action to be taken by the target device.
Select…
Event x data
Data is linked to the command. See also figure 12.
Off
Selectable targets are
system dependent.
See command list in
manual of the selected
device. ChargeMaster
section 5.3.6.
Off, On, Copy, Copy
Invert, Toggle.
See Event x.
Events
Event x source
Event x+1
The next event appears after enabling Event x.
* Depending on model: CM12/25, CM24/12
Select…
Disabled
Figure 12 shows the meaning of the event data.
Input is a pulse followed by a longer signal (1/0).
On changes the status to On at the first signal.
Off changes the status to Off at the first signal.
Copy lets the status follow the input.
Copy Invert lets the status follow the opposite of the input.
Toggle changes the status at the first signal and back at
the second signal. It is often used in combination with a
pulse switch.
Figure 12: Event data
5.3.5
On
Bulk
Abs
Float
Failure
CSI
Fan
Led 1
Led 2
Led 3
Led 4
Led 5
14
ChargeMaster event source list (ChargeMaster as event source)
ChargeMaster state is On
State of charge is Bulk
State of charge is Absorption
State of charge is Float
Charger failure MasterBus alarm
Charger Status Interface MasterBus alarm to sound a horn at charger failure
MasterBus signal for an external fan to start (at 50% load / 50°C)
Bottom yellow LED of the MasterView Read Out illuminates (see manual MasterView Read Out)
2nd yellow LED from bottom of the MasterView Read Out illuminates (see manual MasterView Read Out)
3rd yellow LED from bottom of the MasterView Read Out illuminates (see manual MasterView Read Out)
4th yellow LED from bottom of the MasterView Read Out illuminates (see manual MasterView Read Out)
Top yellow LED of the MasterView Read Out illuminates (see manual MasterView Read Out)
September 2011 / ChargeMaster 12/25-3, 24-12-3 / EN
MASTERBUS
5.3.6
ChargeMaster event target list (ChargeMaster as event target)
Mpc reduce power
Mpc stop
Bulk
Abs
Float
State
Command to reduce AC current at a 5%/sec rate
Command to reduce AC current fast
Command to start the Bulk state of charge
Command to start the Absorption state of charge
Command to start the Float state of charge
Command to switch on the ChargeMaster
EN / ChargeMaster 12/25-3, 24-12-3 / September 2011
15
TROUBLE SHOOTING
6 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:
6.1
Article and serial number: see section 1.4.
Firmware version: doubleclick on ChargeMaster icon in
MasterView System software Configuration.
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 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
Low AC input voltage. At lower AC input
voltages the charge current is reduced.
Batteries not fully
charged
Batteries are
discharged too fast
Batteries are too warm,
gassing
16
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 the
setting limit the charge current is automatically
reduced.
Check AC-input voltage.
See “Charge current too low” in this table.
Reduce load taken from the batteries.
Use a battery charger with higher capacity.
Use the optional 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 5.3.4).
September 2011 / ChargeMaster 12/25-3, 24-12-3 / EN
TECHNICAL DATA
7 TECHNICAL DATA
7.1
SPECIFICATIONS
Specifications are subject to change without prior notice.
Model
12/25-3
Article no.
44010250
Nominal input voltage:
120/230V
Nominal input frequency:
50/60Hz
Full load consumption:
450VA
Efficiency at full load (230V AC):
≥80% @ 230V input
Nominal output voltage:
12V
Total maximum charge current:
25A at 13.25V / 13.5V
Number of battery outputs:
3
Output voltage range adjustable
0 to15.5V DC
Charge characteristic:
IUoUo, automatic, three step
Charge voltage Bulk:
14.4V (MLI: 14.6V)
Charge voltage Absorption:
14.25V (MLI: 14.6V)
Charge voltage Float;
13.25V (AGM, GEL: 13.8V, MLI: 13.5V)
Max. absorption and max. bulk timer:
8 hours (start max. bulk timer at 13.25V)
Minimum absorption time:
15 min.
Battery type settings:
Wet battery/ gel/ / AGM / spiral / Li-ion
(adjustable by means of display or
MasterBus)
Dimensions in mm/ inch:
See section 7.2
Weight:
< 1.8 Kg/ 4.0Lbs including AC cable
Recommended battery capacity:
55 Ah
Power factor regulations
≤ 0.99
Temperature compensation
Yes
Voltage compensation
Yes, automatic compensation with
battery temperature sensor.
DC consumption
<2mA
Temperature range
-25°C ... 60°C / -13°F … 140°F, power
derating 2.85%/°C (5.13%/°F) above
25°C / 77 °F to decrease the internal
temperature. From -25°C to 0°C / -13°F
to 32°F, 90% derating.
Cooling
Vario fan and natural cooling to ensure
optimized cooling.
Sound level
<50dBA / 1m
Protection degree
IP23
Approvals
Fully CE and E-marking according to
automotive directive 95/54/EG.
Communication
Full MasterBus
EN / ChargeMaster 12/25-3, 24-12-3 / September 2011
24/12-3
44020120
120/230V
50/60Hz
435VA
≥80% @ 230V input
24V
12A at 26.5V / 27.0V
3
0 to 31V DC
IUoUo, automatic, three step
28.8 (MLI: 29.2V)
28.5 (MLI: 29.2V)
26.5 (AGM, GEL: 27.6V, MLI: 27.0V)
8 hours (start max. bulk timer at 26.5V)
15 min.
Wet battery/ gel/ AGM / spiral / Li-ion
(adjustable by means of display or
MasterBus)
See section 7.2
< 1.8 Kg/ 4.0Lbs including AC cable
25 Ah
≤ 0.99
Yes
Yes, automatic compensation with
battery temperature sensor.
<2mA
-25°C ... 60°C / -13°F … 140°F (power
derating 2.85%/°C (5.13%/°F) above
25°C / 77 °F to decrease the internal
temperature). From -25°C to 0°C / -13°F
to 32°F, 90% derating.
Vario fan and natural cooling to ensure
optimized cooling.
<50dBA / 1m
IP23
Fully CE and E-marking according to
automotive directive 95/54/EG.
Full MasterBus
17
TECHNICAL DATA
7.2
DIMENSIONS
Figure 13: Dimensions in mm [inch]
18
September 2011 / ChargeMaster 12/25-3, 24-12-3 / EN
TECHNICAL DATA
7.3
CHARACTERISTICS
Charge current vs input voltage
Figure 14: 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
every288
336 hr
85
min
30 `return to
sec bulk timer
= current
Figure 15: Charge characteristic of the three-step Plus charging method Lead acid (wet batteries, at 25°C / 77°F)
Figure 16: Temperature compensation characteristic
(charge voltage versus temperature)
EN / ChargeMaster 12/25-3, 24-12-3 / September 2011
19
ORDERING INFORMATION/ EC DECLARATION OF CONFORMITY
8 ORDERING INFORMATION
Part number
Description
6384001600
6384003200
6381001000
79009006
79009005
41500500
41500800
77040000
Industrial DC fuse 16A DIN 00
Industrial DC fuse 32A DIN 00
Fuse base DIN 00 (max. 160A)
Battery switch 250A with knob
Battery switch 250A with key
Battery temperature sensor, incl. 6 metres / 19 ft cable
Battery temperature sensor, incl. 15 metres / 49 ft cable
MasterBus Terminator
Mastervolt offers a wide range of products for your electrical installation, AGM, Gel and Li-ion batteries, shore power
connections, DC distribution kits and many more.
9 EC DECLARATION OF CONFORMITY
Manufacturer
Address
Mastervolt
Snijdersbergweg 93
1105 AN Amsterdam
The Netherlands
Herewith declares that product:
44010250
ChargeMaster 12/25-3
44020120
ChargeMaster 24/12-3
Is in conformity with the provision of the EC, EMC directive 2004/108/EC.
The following harmonized standards have been applied: EN 55014, EN 55022,
EN 61000-3-2, EN 61000-3-3, EN 61000-3-11, EN 61000-6-2, EN 60950, EN60335-1, EN60335-2-29, EN 68-2-6
Low Voltage Directive: 2006/95/EC
Amsterdam,
P.F. Kenninck,
General Manager MASTERVOLT
Snijdersbergweg 93, 1105 AN Amsterdam, The Netherlands
Tel : + 31-20-3422100
Fax : + 31-20-6971006
Email : info@mastervolt.com
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