Mastervolt chargemaster plus 12/100-3, chargemaster plus 24/40-3, chargemaster plus 12/75-3, 44310750, 44320400 User Manual

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USERS MANUAL / GEBRUIKERSHANDLEIDING / BETRIEBSANLEITUNG

MANUEL UTILISATEUR / MANUAL DE UTILIZACION / INSTRUZIONI PER L’USO

CHARGEMASTER PLUS

12/75-3, 12/100-3, 24/40-3, 24/60-3

FULLY AUTOMATIC BATTERY CHARGER

MASTERVOLT Snijdersbergweg 93, 1105 AN Amsterdam

The Netherlands Tel.: +31-20-3422100 Fax.: +31-20-6971006 www.mastervolt.com

ENGLISH

NEDERLANDS: See www.mastervolt.com/chargemaster DEUTSCH: Siehe www.mastervolt.com/chargemaster FRANÇAIS: Voir www.mastervolt.com/chargemaster CASTELLANO: Vea www.mastervolt.com/chargemaster ITALIANO: Vedere www.mastervolt.com/chargemaster

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TABLE OF CONTENTS:

1 GENERAL INFORMATION 4

1.1 USE OF THIS MANUAL 4

1.2 VALIDITY OF THIS MANUAL 4

1.3 USE OF PICTOGRAMS 4

1.4 IDENTIFICATION LABEL 4

1.5 LIABILITY 4

2 IMPORTANT SAFETY INSTRUCTIONS 5

2.1 GENERAL 5

2.2 EXPLOSIVE GASES 5

2.3 PERSONAL PRECAUTIONS 6

2.4 WARNINGS REGARDING THE USE OF BATTERIES 6

2.5 CHARGER LOCATION 6

2.6 DC CONNECTION PRECAUTIONS 6

2.7 FOLLOW THESE STEPS WHEN BATERY IS INSTALLED IN VEHICLE 6

2.8 FOLLOW THESE STEPS WHEN BATTERY IS OUTSIDE VEHICLE 7

2.9 PREPARING TO CHARGE 7

2.10 GROUNDING INSTRUCTIONS 7

2.11 WARNING REGARDING LIFE SUPPORT APPLICATIONS 7

2.12 GUARANTEE SPECIFICATIONS 7

2.13 CORRECT DISPOSAL OF THIS PRODUCT 7

3 OPERATING INSTRUCTIONS 8

3.1 FEATURES 8

3.2 LOCAL USER INTERFACE 9

3.2.1 SWITCHING ON / STAND-BY 9

3.3 STATUS-DISPLAY 10

3.3.1 STATUS 10

3.3.2 OUTPUT POWER 10

3.3.3 ERROR 10

3.4 THREE STEP PLUS CHARGE ALGORITHM 11

3.4.1 PRE-FLOAT 11

3.4.2 TEMPERATURE COMPENSATED CHARGING 11

3.4.3 FLAT BATTERY SUPPORT 11

3.5 SMART TERMINAL - OUTPUT 3 12

3.5.1 10A STARTER 12

3.5.2 STARTER 12

3.5.3 STARTER + ALTERNATOR 12

3.5.4 FOLLOW MAIN 12

3.5.5 FOLLOW MAIN + ALTERNATOR 12

3.5.6 12V CONSTANT VOLTAGE 12

3.5.7 24V CONSTANT VOLTAGE (24V MODEL ONLY) 12

3.5.8 12V 3 STEP+ (24V MODEL ONLY) 12

3.6 MAINTENANCE 12

3.7 FAILURES 12

3.8 HISTORICAL DATA 12

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4 INSTALLATION 13

4.1 UNPACKING 13

4.2 ENVIRONMENT 13

4.3 WIRING 13

4.3.1 DC WIRING 13

4.3.2 AC-WIRING 14

4.3.3 AC SAFETY GROUNDING 14

4.4 BATTERIES 14

4.5 THINGS YOU NEED 14

4.6 OVERVIEW CONNECTION COMPARTMENT 15

4.7 CONNECTION 16

4.7.1 GENERAL 16

4.7.2 CONNECTION EXAMPLE 17

4.8 INSTALLATION STEP-BY-STEP 18

4.9 COMMISSIONING AFTER INSTALLATION 19

4.9.1 GENERAL 19

4.9.2 COMMISSIONING STEP-BY-STEP 19

4.9.3 MASTERBUS (OPTIONAL) 20

4.10 DECOMMISSIONING 20

4.11 STORAGE AND TRANSPORTATION 20

4.12 RE-INSTALLATION 20

5 SETTINGS 21

5.1 DIP SWITCH SETTINGS 21

5.2 MASTERBUS FUNCTIONS 21

5.2.1 MASTERBUS COMMUNICATION 21

5.2.2 CURRENT CONTROL 21

5.2.3 MASTERSHUNT 21

5.2.4 LI-ION BATTERY MLI ULTRA 22

5.2.5 IN USE 22

5.2.6 MONITORING 22

5.2.7 ALARM 22

5.2.8 HISTORY 23

5.2.9 CONFIGURATION 23

5.2.10 EVENTS 25

5.2.11 EVENTS SOURCE 25

5.2.12 EVENT TARGET 26

6 TROUBLE SHOOTING 27

7 TECHNICAL DATA 28

7.1 SPECIFICATIONS 12V MODELS 28

7.2 SPECIFICATIONS 24V MODELS 29

7.3 DIMENSIONS 30

8 ORDERING INFORMATION 31

8.1 MASTERBUS INSTALLATION COMPONENTS 31

8.2 MISCELLANEOUS 31

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1 GENERAL INFORMATION

1.1 USE OF THIS MANUAL

This manual serves as a guideline for the safe and effective operation and maintenance of the ChargeMaster Plus It is therefore obligatory that every person who works on or with the ChargeMaster Plus must be completely familiar with the contents of this manual and the Important Safety Instructions, and that he/she carefully follows the instructions contained herein. Installation of, and work on the ChargeMaster Plus may be carried out only by qualified, authorised and trained personnel, consistent with the locally applicable standards and taking into consideration the Important Safety Instructions.

Copyright © 2017 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

All of the specifications, provisions and instructions contained in this manual apply solely to standard versions of the ChargeMaster Plus delivered by Mastervolt. This manual is only valid for the following models with apparatus version “A” and higher (see section 1.4):

Part number

Model

44310750

ChargeMaster Plus 12/75-3

44311000

ChargeMaster Plus 12/100-3

44320400

ChargeMaster Plus 24/40-3

44320600

ChargeMaster Plus 24/60-3

x = OEM Customer specific number

These models are further mentioned as “ChargeMaster Plus”

1.3 USE OF PICTOGRAMS

Safety instructions and warnings are marked in this manual by the following pictograms:

WARNING

A WARNING refers to possible injury to the user or significant material damage to the charger if the user does not (carefully) follow the procedures.

CAUTION!

Special data, restrictions and rules with regard to preventing damage.

A procedure, circumstance, etc which deserves extra attention.

1.4 IDENTIFICATION LABEL

Figure 1: Identification label

The identification label is located at the right-hand side of the ChargeMaster Plus. (see figure 1) Important technical information required for service, maintenance & secondary delivery of parts can be derived from the identification label.

CAUTION!

Never remove the identification label.

1.5 LIABILITY

Mastervolt can accept no liability for:  consequential damage due to use of the

ChargeMaster Plus;

 possible errors in the manuals and the results thereof.

Serial number

YMDDA0001

Device version “A”

Part number

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2 IMPORTANT SAFETY INSTRUCTIONS

READ AND SAVE THESE INSTRUCTIONS

WARNING

This chapter describes important safety and operating instructions for use of a ChargeMaster Plus in residential, recreational vehicle (RV) and marine applications.

2.1 GENERAL

1 Before using the ChargeMaster Plus, read all

instructions and cautionary markings on the ChargeMaster Plus, the batteries, and all appropriate sections of the manual.

2 The appliance is not to be used by persons (including

children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction

3 Children being supervised not to play with the

appliance

4 To reduce the risk of electric shock – Do not expose

ChargeMaster Plus 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 Plus in a non-ventilated room, overheating may result.

5 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.

6 The ChargeMaster Plus is designed to be

permanently connected to an AC and DC electrical system. Installation of, and work on the ChargeMaster Plus, may be carried out only by a qualified, authorised and trained technician or electrician, consistent with the locally applicable standards and regulations.

7 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 Plus. Check the wiring on a regular base, at least once a year. Do not use the ChargeMaster Plus when the wiring is undersized or damaged.

8 Do not operate ChargeMaster Plus if it has received a

sharp blow, been dropped, or otherwise damaged in any way; take it to a qualified serviceman.

9 Except for the connection compartment, see chapter

4, the ChargeMaster Plus 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.

10 To reduce risk of electric shock, disconnect the

ChargeMaster Plus from both AC and DC electrical system before attempting any maintenance or cleaning. Turning off controls will not reduce this risk.

11 The ChargeMaster Plus 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.

12 Short circuiting or reversing polarity will lead to

serious damage to batteries, ChargeMaster Plus, wiring as well as accessories. Fuses can not prevent damage caused by reversed polarity and the warranty will be void.

13 In case of fire, you must use the fire extinguisher

which is appropriate for electrical equipment.

14 If applied in a marine application in the United States,

external connections to the ChargeMaster Plus shall comply with the United States Coast Guard Electrical Regulations (33CFR183, Sub part I).

2.2 EXPLOSIVE GASES

1 WARNING – RISK OF EXPLOSIVE GASES.

WORKING IN VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS. BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION. FOR THIS REASON, IT IS OF UTMOST IMPORTANCE THAT EACH TIME BEFORE USING THE CHARGEMASTER PLUS, YOU READ THIS MANUAL AND FOLLOW THE INSTRUCTIONS EXACTLY.

2 To reduce risk of battery explosion, follow these

instructions and those published by battery manufacturer and manufacturer of any equipment you intend to use in vicinity of the battery. Review cautionary marking on these products and on engine.

3 DANGER: To reduce the risk of explosion – Never

use the ChargeMaster Plus in situations where there is danger of gas or dust explosion or area in which ignition-protected equipment is required.

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2.3 PERSONAL PRECAUTIONS

1 Consider having someone close enough by 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 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.

2.4 WARNINGS REGARDING THE USE OF BATTERIES

1 Only use ChargeMaster Plus for charging a LEAD-

ACID batteries and the supply of users attached to these batteries, in permanent systems. Do not use ChargeMaster Plus 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.

2 NEVER charge non-rechargeable batteries. 3 NEVER charge a frozen battery. 4 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.

5 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.

6 Be sure that the area around battery is well ventilated

while battery is being charged. Refer to the recommendations of the battery manufacturer.

7 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.

2.5 CHARGER LOCATION

1 Locate charger as far away from battery as dc cables

permit.

2 Never place charger directly above battery being

charged; gases from battery will corrode and damage charger.

3 Never allow battery acid to drip on charger when

reading electrolyte specific gravity or filling battery.

4 Do not operate charger in a closed-in area or restrict

ventilation in any way.

5 Do not set a battery on top of charger.

2.6 DC CONNECTION PRECAUTIONS

1 Connect and disconnect dc output clips only after

setting any charger switches to “off” position and removing ac cord from electric outlet. Never allow clips to touch each other.

2 Attach clips to battery and chassis as indicated in §2.7

(5), §2.7 (6), and §2.8 (2) through §2.8 (4).

2.7 FOLLOW THESE STEPS WHEN BATERY IS INSTALLED IN VEHICLE

A SPARK MAY CAUSE BATTERY EXPLOSION. TO REDUCE RISK OF A SPARK NEAR BATTERY:

1 Position ac and dc cords to reduce risk of damage by

hood, door, or moving engine part.

2 Stay clear of fan blades, belts, pulleys, and other

parts that can cause injury to persons.

3 Check polarity of battery posts. POSITIVE (POS, P, +)

battery post usually has larger diameter than NEGATIVE (NEG, N,–) post.

4 Determine which post of battery is grounded

(connected) to the chassis. If negative post is grounded to chassis (as in most vehicles), see (5). If positive post is grounded to the chassis, see (6).

5 For negative-grounded vehicle, connect POSITIVE

(RED) clip from battery charger to POSITIVE (POS, P, +) ungrounded post of battery. Connect NEGATIVE (BLACK) clip to vehicle chassis or engine block away from battery. Do not connect clip to carburetor, fuel lines, or sheet-metal body parts. Connect to a heavy gage metal part of the frame or engine block.

6 For positive-grounded vehicle, connect NEGATIVE

(BLACK) clip from battery charger to NEGATIVE (NEG, N, –) ungrounded post of battery. Connect POSITIVE (RED) clip to vehicle chassis or engine block away from battery. Do not connect clip to carburetor, fuel lines, or sheet-metal body parts. Connect to a heavy gage metal part of the frame or engine block.

7 When disconnecting charger, turn switches to off,

disconnect AC cord, remove clip from vehicle chassis, and then remove clip from battery terminal.

8 See operating instructions for length of charge

information.

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2.8 FOLLOW THESE STEPS WHEN BATTERY IS OUTSIDE VEHICLE

A SPARK NEAR THE BATTERY MAY CAUSE BATTERY EXPLOSION. TO REDUCE RISK OF A SPARK NEAR BATTERY:

1 Check polarity of battery posts. POSITIVE (POS, P, +)

battery post usually has a larger diameter than NEGATIVE (NEG, N, –) post.

2 Attach at least a 24-inch-long 6-gauge (AWG)

insulated battery cable to NEGATIVE (NEG, N, –) battery post.

3 Connect POSITIVE (RED) charger clip to POSITIVE

(POS, P, +) post of battery.

4 Position yourself and free end of cable as far away

from battery as possible – then connect NEGATIVE

(BLACK) charger clip to free end of cable. 5 Do not face battery when making final connection. 6 When disconnecting charger, always do so in reverse

sequence of connecting procedure and break first

connection while as far away from battery as practical. 7 A marine (boat) battery must be removed and

charged on shore. To charge it on board requires

equipment specially designed for marine use.

2.9 PREPARING TO CHARGE

1 If necessary to remove battery from vehicle to charge,

always remove grounded terminal from battery first.

Make sure all accessories in the vehicle are off, so as

not to cause an arc. 2 Be sure area around battery is well ventilated while

battery is being charged. 3 Clean battery terminals. Be careful to keep corrosion

from coming in contact with eyes. 4 Add distilled water in each cell until battery acid

reaches level specified by battery manufacturer. Do

not overfill. For a battery without removable cell caps,

such as valve regulated lead acid batteries, carefully

follow manufacturer’s recharging instructions. 5 Study all battery manufacturer’s specific precautions

while charging and recommended rates of charge. 6 Determine voltage of battery by referring to car

owner’s manual and make sure that output voltage

selector switch is set at correct voltage. If charger has

adjustable charge rate, charge battery initially at

lowest rate. Exception: For a charger not having an

output voltage selector switch, determine voltage of

battery by referring to car owner’s manual and make

sure it matches output rating of battery charger.

2.10 GROUNDING INSTRUCTIONS

This battery charger should be connected to a grounded, metal, permanent wiring system; or an equipment-

grounding conductor should be run with circuit conductors and connected to equipment-grounding terminal or lead on battery charger. Connections to battery charger should comply with all local codes and ordinances.

2.11 WARNING REGARDING LIFE SUPPORT APPLICATIONS

The ChargeMaster Plus 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 Plus 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 Plus in the life support equipment.

2.12 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 user 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.

2.13 CORRECT DISPOSAL OF THIS PRODUCT

(Waste Electrical & Electronic Equipment)

This product is designed and manufactured with high quality materials and components, which can be recycled and reused. When this crossed-out wheeled bin symbol is

attached to a product, it means the product is covered by the European Directive 2012/19/EU. Please be informed about the local separate collection system for electrical and electronic products. Please act according to your local rules and do not dispose of your old products with your normal household waste. The correct disposal of your old product will help prevent potential negative consequences to the environment and human health.

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3 OPERATING INSTRUCTIONS

3.1 FEATURES

The Mastervolt ChargeMaster Plus 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 Plus is suitable for charging of Li-ion and lead-acid batteries, which may include maintenance-free, low maintenance, AGM/spiral, gel or deep-cycle batteries.

WARNING

The MLi charging voltages on this charger fit the Mastervolt Li-ion (MLi) batteries but do not necessarily fit other Li-ion batteries! Always follow the instructions provided by the battery manufacturer!

Battery’s Best Friend

REVIVAL MODE

 Automatically charges flat batteries, see section

3.4.3.

MULTI CHEMISTRY

 When using different battery sizes or chemistries

(eg. the starter battery differs from the service bank), the Smart terminal avoids damage/ overcharge by limiting the current and/or by selecting a different chemistry

MULTI BATTERY

 Charge 1 to 3 batteries at the same time

MULTI VOLTAGE

 Charge 12V auxiliary battery from a 24V charger

THREE OUTPUTS

 Full charge power available for each battery. The

ChargeMaster Plus is capable of delivering full output power on all three outputs. Ensuring on demand power for the battery that needs it most

PRIORITY CHARGE

 Redirects power to the battery with the lowest

state of charge

 The ChargeMaster Plus has the ability to

individually move each battery from absorption to pre-float stage. See section 3.4.1.

SAFE CHARGE

 Quickly recognizes the State of Charge The

ChargeMaster Plus will prevent unnecessary charging (overcharge) of your batteries. The ChargeMaster Plus will detect previous charges and will reduce the Absorption timer so batteries are not overcharged.

3 STEP + ALGORITM

 Fast charging and extended battery life

 The three-step Plus charging method guarantees

that the batteries are always charged to 100%. See section 3.4

Global Charging

GLOBAL AC

 The ChargeMaster Plus 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

RUGGED POWER

 Works under extreme conditions; Operating

range -25°C ... 80°C / -13°F … 176°F. See section 4.2

Power On The Move

SMART TERMINAL – OUTPUT 3

 Charge 3 batteries from a single alternator  When charging from an alternator, the Smart

input acts as a voltage sensitive relay. While the battery coupled to the smart input, is being charged, the Smart terminal distributes the current to the other batteries (up to 40A). See section 3.5

Powerful Connections

MASTERSHUNT READY

 Seamless integration with MasterShunt. See

section 5.2.3

POWER SUPPLY MODE

 With an external AC source connected, the

ChargeMaster Plus charger also serves the functions of an AC to DC converter to supply DC loads with or without batteries connected

CURRENT CONTROL

 Prevent blown shore fuses by adjusting the AC

input power

MasterBus Compatible

MASTERBUS INSIDE

 For intelligent power systems and easy

monitoring. See section 5.2

System Simplicity

STATUS DISPLAY

 Shows charger- and batteries status at a glance

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3.2 LOCAL USER INTERFACE

The status display at the front side of the ChargeMaster Plus enables you to control the charger and monitor the charging process.

3.2.1 Switching on / stand-by

The ChargeMaster Plus is activated by holding the MODE switch (see figure 2) pressed for approx. 3 seconds. The MODE LED will illuminate green. If necessary and if AC power is available, the ChargeMaster Plus will start to charge the batteries.

Once switched on, the ChargeMaster Plus automatically resumes operation after it was disconnected from an AC-source temporarily.

By holding the MODE switch pressed again for approx. 3 seconds, the ChargeMaster Plus will switch back to standby: the ChargeMaster Plus stops and the MODE LED illuminates red.

WARNING

Switching the ChargeMaster Plus to “stand-

by” does not cut off the connection to the

batteries or the AC-source. This means that voltages are still present inside the apparatus.

Figure 2: ChargeMaster Plus status display

The ChargeMaster Plus can also be operated and monitored remotely by means of a MasterBus remote control panel. See section

5.2 for details.

MODE switch

Hold MODE pressed for 3 seconds to

switch the charger on or stand-by

LED-display

See section 3.3

MASTERBUS

Blinks when there is MasterBus

communication

MODE

Indicates ChargeMaster Plus

status

Battery 1, 2 & 3

Battery charge status

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3.3 STATUS-DISPLAY

The status display has a 3 level menu. Menu navigation is done by shortly pressing the MODE switch. After each press the next menu level is shown. The MODE LED color indicates the level that is being shown.

MODE LED color

Meaning

Level 1

Green

Status menu

Level 2

Orange

Output power menu

Level 3

Red

Error menu

3.3.1 Status

Display

LED

State

Meaning

MODE Solid green

ChargeMaster Plus on

Solid red

ChargeMaster Plus stand-by

Blink fast red

Error, navigate to error menu

Battery I Blinking medium fast green

Battery in bulk stage

Blinking slow green

Battery absorption stage

Solid green

Battery in float stage

Battery II Blinking medium fast green

Battery in bulk stage

Blinking slow green

Battery absorption stage

Solid green

Battery in float stage

Battery III Blinking medium fast green

Battery in bulk stage

Blinking slow green

Battery absorption stage

Solid green

Battery in float stage

MasterBus

Blinking green

MasterBus communication

3.3.2 Output power

Display

LED

State

Meaning

MODE

Solid orange

Output power menu Battery I

Solid orange

Total output power 0-25%

Battery II

Solid orange

Total output power 26-50%

Battery III

Solid orange

Total output power 51-75%

MasterBus

Solid orange

Total output power 76-100%

3.3.3 Error

Error

LED

State

Meaning

What to do

MODE

Blink fast red

Error menu Battery I

Blink fast red

Reverse polarity

Check battery connection

Battery II

Blink fast red

AC error

Check AC voltage/frequency

Battery III

Blink fast red

DC error

Check battery voltage

MasterBus

Blink fast red

Temperature sense error

Check temperature sensor

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3.4 THREE STEP PLUS CHARGE ALGORITHM

See Figure 3. 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 BULK voltage 14.4V (MLi:14.25V) resp. 28.8V (MLi: 28.5V) 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.

Figure 3: Three step charge algorithm

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 / 28.5V 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 flooded battery this stage lasts approx. 4h, with gel and AGM around 3h. Once the battery is 100% full, the ChargeMaster Plus automatically switches over to the float phase. At FLOAT (for Gel/AGM, flooded batteries) the ChargeMaster Plus switches to a stabilised 13.25V (MLi:

13.5V) or 26.5V (MLi: 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 Plus is equipped with a three-step plus charge system, the batteries can also remain connected to the ChargeMaster Plus 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.

3.4.1 Pre-float

The ChargeMaster Plus has the ability to individually move each battery from absorption to pre-float stage. In pre-float

stage, the charge voltage is lower than in absorption stage. Pre-float ensures batteries that are nearly full don’t receive the higher charge voltage needed in the absorption stage. This prevents over-charging, extending the lifespan of the batteries.

3.4.2 Temperature compensated charging

By installing the battery temperature sensor the charge voltages are automatically adapted for deviating temperatures.

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.

3.4.3 Flat battery support

The ChargeMaster Plus automatically detects a flat battery, and will initiate the flat battery charge curve described in the table below.

UBat

Voltage

Output power

12V

0.00V - 2.50V

15%-30% of Imax

2.50V – 8.00V

25% of Imax

8.00V – 10.00V

linear from 25% - 100% of Imax

10.00V – 14.25V

100% of Imax

>14.25

Limited by Pmax

UBat

Voltage

Output power

24V

0.00V – 5.00V

15%-30% of Imax

5.00V – 16.00V

25% of Imax

16.00V – 20.00V

linear from 25% - 100% of Imax

20.00V – 28.50V

100% of Imax

>28.50

Limited by Pmax

Page 12

3.5 SMART TERMINAL - OUTPUT 3

The Chargemaster is equipped with three full outputs. The total output current is divided over these three outputs. See section 4.6 for connections.

Output 3 is the Smart terminal, which can be current limited and can serve as an output and as an input to charge battery 1 & 2.

The Smart terminal has the following operating modes:

 10A starter  Starter  Starter + alternator  Follow main  Follow main + alternator  12V constant voltage  24V constant voltage  12V 3 step+

3.5.1 10A starter

Output 1 & 2 are configured as full outputs, Smart terminal 3 is now current limited to 10A to safely charge a starter battery.

3.5.2 Starter

Output 1 & 2 are configured as full outputs, Smart terminal 3 is now current limited to be able to charge a starter battery. A 24V charger can charge a 24V or 12V starter battery with an own charging profile. Settings are configured via MasterBus, see section 5.2.

3.5.3 Starter + alternator

Output 1 & 2 are configured as full outputs, Smart terminal functions as a VSR (Voltage Sensitive Relay). When there is no AC power available and the alternator is charging the starter battery, the alternator can also be used to charge battery 1 & 2. The threshold voltage which is used to switch over can be configured via MasterBus. See section

5.2

3.5.4 Follow main

Operation mode for 3 batteries, the charger is configured with 3 full outputs. All batteries are charged with the same settings.

3.5.5 Follow main + alternator

Operation mode for 3 batteries, the charger is configured with 3 full outputs. All batteries are charged with the same settings. Smart terminal functions as a VSR (Voltage Sensitive Relay). When there is no AC power available and the alternator is charging the starter battery, the

alternator can also be used to charge battery 1 & 2. The threshold voltage which is used to switch over is configured via MasterBus. See section 5.2

3.5.6 12V constant voltage

Output 1 & 2 are configured as full outputs, Smart terminal is now current limited and set to 12V constant voltage

3.5.7 24V constant voltage (24V model only)

Output 1 & 2 are configured as full outputs, Smart terminal is now current limited and set to 24V constant voltage

3.5.8 12V 3 step+ (24V model only)

Output 1 & 2 are configured as full outputs, Smart terminal is now current limited and set to 3 step+ charge algorithm. In 12V 3 step plus configuration the following battery types can be selected: AGM, GEL, flooded, AGM Spiral.

3.6 MAINTENANCE

No specific maintenance to the ChargeMaster Plus is required. Examine your electrical installation on a regular basis, 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 enclosure of the ChargeMaster Plus. Do not use any liquids or corrosive substances, such as solvents, alcohol, petrol or abrasive components.

3.7 FAILURES

The ChargeMaster Plus is protected against overload, short circuit, overheating and under and over voltage. If a fault condition occurs, the MODE button turns red and the Battery 1, 2 & 3 LED indicate an error code. See section

3.3.3 for explanation.

CAUTION!

The ChargeMaster Plus is not protected against serious over voltage (>275VAC) on the AC-input .

As long as there is no error code shown, no failure is detected: the ChargeMaster Plus is operating normally!

3.8 HISTORICAL DATA

Connect the ChargeMaster Plus to MasterBus in order to be able to see the historical data stored in the ChargeMaster Plus.

Page 13

4 INSTALLATION

During installation and commissioning of the ChargeMaster Plus, the important safety instructions are applicable at all times.

4.1 UNPACKING

In addition to the ChargeMaster Plus the delivery includes:  Mounting bracket to mount the ChargeMaster Plus to a

wall;

 Battery temperature sensor;  MasterBus terminating device;  This user’s manual

After unpacking, check the contents for possible damage. Do not use the product if it is damaged. 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 Plus (e.g. 24V battery set for a 24V battery charger).

4.2 ENVIRONMENT

Obey the following stipulations during installation:  The ChargeMaster Plus is designed for indoor use

only.

 Ambient temperature: -25°C ... 80°C / -13°F … 176°F;

(power derating above 40°C / 104°F to decrease the internal heat sink temperature).

 Humidity: 0-95% non condensing  Mount the ChargeMaster Plus vertically, with the

connecting cables downwards.

 Do not expose the ChargeMaster Plus to excessive

dust, aggressive environments, ammonia or salt.

 Make sure that the hot air that is developed during

operation can be discharged. The ChargeMaster Plus 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 Plus.

 Do not locate the ChargeMaster Plus in the same

compartment as the batteries.

 Do not install the ChargeMaster Plus straight above

the batteries because of possible corrosive sulphur fumes.

 If the ChargeMaster Plus is installed in the immediate

vicinity of living areas, take into account that the fan of the ChargeMaster Plus can produce noise when operating.

 Although the ChargeMaster Plus fully complies with all

applicable EMC limits, it may still cause harmful interference to radio communication equipment. If such interference appears, it is recommended to increase the separation between the ChargeMaster Plus and the equipment, to relocate the receiving antenna or to connect the equipment to a circuit different from that to which the ChargeMaster Plus is connected.

4.3 WIRING

WARNING!

The wire and fuse sizes stated in this manual are given as example only. Prescribed wire and fuse sizes may be different due to local applicable regulations and standards.

4.3.1 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:

ChargeMaster Plus model

DC Cable cross section:

<3m / 10ft

3-5m / 10-16ft

12/75-3

25mm² / AWG2

35mm² / AWG1

12/100-3

35mm² / AWG1

50mm² / AWG0

24/40-3

16mm² / AWG4

25mm² / AWG2

24/60-3

25mm² / AWG2

35mm² / AWG2

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

Positive

+ (POS)

Black

Negative

– (NEG)

100

120

-50

-40

-30

-20

-10

102030405060708090

100

Output Power (%)

Temperature (°C)

Output Power vs Temperature

Page 14

Lay the positive and negative cables next to each other to limit the electromagnetic 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 DC fuses for outputs 1, 2 and 3 are:

ChargeMaster Plus model

DC fuse

12/75-3

85A

12/100-3

125A

24/40-3

50A

24/60-3

80A

The fuse with the fuse-holder is available from your local Mastervolt distributor or Customer Service Representative.

4.3.2 AC-wiring

WARNING!

The ground wire offers protection only if the enclosure of the ChargeMaster Plus is connected to the safety ground. Connect the ground terminal (PE / GND) to the hull or the chassis.

CAUTION!

According to local regulations a RCD/Breaker must be placed in the AC input circuit of the ChargeMaster Plus.

For a safe installation the correct wire cross section must

be applied. Don’t use a cross section that is smaller than

indicated. See table below to select the appropriate cross section for the AC wiring (up to 6m / 20ft length):

AC-Current

Minimum cross section:

in mm²

AWG

6-12 Amp

1.5 mm²

AWG 14

12-20 Amp

2.5 mm²

AWG 12

20-32 Amp

4.0 mm²

AWG 10

Connection of AC-wiring and recommended wire colours:  230V/50Hz installations:

Wire color

Meaning

Must be connected to:

Brown or black

Phase

Blue

Neutral

Green/Yellow

Earth

PE / GND

 120V/60Hz installations (single phase):

Wire color

Meaning

Must be connected to:

Black

Hot or Line

White

Neutral

Green

Ground

PE / GND

4.3.3 AC safety grounding

WARNING!

The ground wire offers protection only if the enclosure of the ChargeMaster Plus 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 Plus.

4.4 BATTERIES

Always follow the instructions published by battery manufacturer.

ChargeMaster Plus model

Recommended battery capacity

12/75-3

140Ah

800Ah

12/100-3

200Ah

1000Ah

24/40-3

80Ah

400Ah

24/60-3

120Ah

500Ah

4.5 THINGS YOU NEED

Make sure you have all the parts you need to install the ChargeMaster Plus:

 ChargeMaster Plus (included)  Battery temperature sensor with cable and plug

(included).

 DC cables to connect the ChargeMaster Plus to the

batteries and common negative; see section 4.3.1 for specifications

 DC-fuse holder with a DC-fuse, to be integrated in the

positive DC-cable; see section 4.3.1 for specifications

 Screws / bolts (Ø 6mm) (with plugs) to mount the

enclosure to a surface. Use mounting materials which are suitable to carry the weight of the ChargeMaster Plus

 AC cable to connect the AC input to an AC power

source. See section 4.3.2.

 Batteries; see section 4.4  Appropriate and reliable cable terminals, cable lugs,

battery terminals and cord end terminals

We recommend as a minimum tool kit:  Socket wrench 13mm to fix the main DC-cables

Page 15

 Socket wrench 10mm to fix the Safety ground

connection

 Flat blade screw driver 1.0 x 4.0 mm to fix the screw

terminals of the AC wiring

 Tools to fix the screws / bolts (Ø 6mm) with plugs to

mount the enclosure to a surface

 Philips screw driver nr. 2 to open the connection

compartment

4.6 OVERVIEW CONNECTION COMPARTMENT

Screw terminals AC input

Common negative output terminal

Cable clip for AC-wiring

Ventilation openings

Isolation walls for DC connections

DIP-switches

Positive terminal charge output 1

Temperature sensor connection

Positive terminal charge output 2

MasterBus connection

Positive terminal charge Smart terminal

Safety ground connection

4 5 6

Figure 5: connection

compartment

Page 16

4.7 CONNECTION

4.7.1 General

WARNING

Let installation work be done by a licensed electrician. All electrical systems (AC and DC) must be disconnected from any power source during the entire installation!

CAUTION!

Short circuiting or reversing polarity may lead to serious damage to the batteries, the ChargeMaster Plus, the cabling and/or the terminal connections. Fuses between the batteries and the ChargeMaster Plus cannot prevent damage caused by reversed polarity. The damage as a result of reverse polarity is detectable by the service department and is not covered by the warranty.

CAUTION!

Too-thin cables and/or loose connections can cause dangerous overheating of the cables and/or terminals. Therefore tighten all connections well, in order to limit transition resistance as far as possible. Use cables of the correct size.

NOTE: If the battery temperature remains within 1525°C, connection of the battery temperature sensor is optional.

NOTE: The ChargeMaster Plus is only feasible for the connection of MasterBus compatible remote control panels.

Page 17

4.7.2 Connection example

This schematic is to illustrate the general placement of the Chargemaster Plus in a circuit. It is not meant

to provide detailed wiring instructions for any particular electrical installation.

Figure 6: installation drawing of the ChargeMaster Plus

Page 18

4.8 INSTALLATION STEP-BY-STEP

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.

Open the connection compartment by loosening the two screws.

Fix the enclosure to the wall by fastening two screws at the lower side of the enclosure as well.

Connect the wiring to the screw terminals. Fasten the cable with the cable clip.

Fit crimp-on ring terminals to the DC-cables. Connect the DC-cabling of battery bank 1,

positive to +, negative to – .

If needed repeat steps for output 2 and 3.

Page 19

4.9 COMMISSIONING AFTER INSTALLATION

4.9.1 General

When your ChargeMaster Plus is not new, you have to take into account that former users may have changed the settings. Reset the ChargeMaster Plus back to factory settings when there is any doubt (see section

5.2).

The factory settings of the ChargeMaster Plus are optimal for most installations. With some applications however, it is desirable to change these settings. Therefore several adjustments can be made. See chapter 5

NOTE: The DIP-switches must be adjusted prior to commissioning; all other settings can only be made after commissioning.

4.9.2 Commissioning step-by-step

CAUTION!

Check the polarity of all wiring before commissioning: positive connected to positive (red cables), negative connected to negative (black cables).

Attach the battery temperature sensor to the casing of battery bank 1. Plug the temperature sensor cable into the “temp.sensor” jack.

Option: Connect the ChargeMaster to the MasterBus network.

If required, change DIP-settings. See section

5.1 for adjustment. Use a small screw driver for adjustment of the DIP-switches.

Check all wiring; see also figure 6 for wiring details.

Close the connection compartment by fixing the four screws.

Continue with section 4.9 for commissioning of the ChargeMaster.

Page 20

1 If all wiring is OK, place the DC-fuse(s) to connect the

batteries to the ChargeMaster Plus.

WARNING

When placing this fuse, a spark can occur, caused by the capacitors used in the ChargeMaster Plus. 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.

2 Switch on the AC power supply 3 Hold the MODE button (Figure 2) pressed for 3

seconds to switch on the charger

Now the ChargeMaster Plus will initiate the charging process.

4.9.3 MasterBus (optional)

During first commissioning the ChargeMaster Plus will be recognized by the MasterBus network automatically.

Some settings can only be changed via the MasterBus interface. See section 5.2 for an overview of all available MasterBus settings. Refer to the user’s manual of the remote control panel to change these settings.

4.10 DECOMMISSIONING

If it is necessary to put the ChargeMaster Plus out of operation, follow the instructions in order of succession as described below:

1 Switch the ChargeMaster Plus to stand-by (see

chapter 3).

2 Remove the DC-fuse(s) and disconnect the batteries. 3 Remove the AC-fuse(s) of the AC-input and/or

disconnect the AC-mains.

4 Open the connection compartment of the

ChargeMaster Plus.

5 Check with a suitable voltage meter whether the

inputs and the outputs of the ChargeMaster Plus are voltage free.

6 Disconnect all the wiring.

Now the ChargeMaster Plus can be demounted in a safe way.

4.11 STORAGE AND TRANSPORTATION

When not installed, store the ChargeMaster Plus 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.

4.12 RE-INSTALLATION

To reinstall the ChargeMaster Plus, follow the instructions as described in this chapter (chapter 4).

Page 21

5 SETTINGS

Adjustment of the settings of the ChargeMaster Plus can be made in two different ways:

 By means of DIP-switches; see section 5.1;  Via the MasterBus network; see section 5.2.

CAUTION!

Invalid settings of the ChargeMaster Plus 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

If all dipswitches are in the ‘0’ position, changes can only

be made by via the MasterBus network.

After dipswitch settings have been made, the ChargeMaster Plus needs to be switched off and on, in order for the settings to take effect.

Main output 1 & 2Smart output 3

MasterBus leading

Constant voltage

AGM

GEL

Flooded

AGM spiral Flooded traction Flooded calcium

10 starter

Starter

Starter + alternator

Follow main

Follow main + alternator

12V constant voltage 24V constant voltage

12V 3 step+ AGM

12V 3 step+ GEL

12V 3 step+ flooded

12V 3 step+ AGM spiral

ChargeMaster Plus

DIP-switch settings

Example as shown above (24V ChargeMaster Plus):

Main output 1 & 2 => Charging GEL batteries

Smart output3 => Is set to 12V 3 step+

Smart output3 => Charging 12V AGM battery

1 2 3 4 5 6 7 8

CM+

Figure 7: ChargeMaster Plus DIP-switch settings

5.2 MASTERBUS FUNCTIONS

Adjustment of the settings of the ChargeMaster Plus can be made via the MasterBus network (by means of a remote control panel or an interface connected to a PC with MasterAdjust software). Some settings can only be changed via the MasterBus interface.

5.2.1 MasterBus Communication

MasterBus communication can be set to Smart on or

Always on. The table below explains the difference between these settings.

AC available

ChargeMaster Plus mode MasterBus communication

MasterBus powering

Smart

Always

Standby

Yes

Standby

Yes

As can be seen above, the ChargeMaster Plus is a MasterBus powering device only if AC is available.

5.2.2 Current Control

If the available power at the AC-input is limited. The ChargeMaster can be configured to reduce input current. The Current Control level should be set equal or lower than the value of the external circuit breaker, which protects the incoming AC power. For example, when the external AC power is limited by a 6A fuse, the Current

Control level should be set to ≤6 A. The AC input current of

the ChargeMaster Plus will be reduced to 6A. The Current Control level can be adjusted by means of MasterAdjust software or the use of an optional remote control, like the EasyView 5.

5.2.3 MasterShunt

A MasterShunt can be coupled with output 1 of the

ChargeMaster Plus. The actual measurement data of the MasterShunt will be used to charge the batteries. Refer to the manual of the MasterShunt how to configure your system.

Page 22

5.2.4 Li-ion Battery MLi Ultra

The ChargeMaster Plus is compatible to be used with a Liion battery MLi Ultra. Refer to the manual of the Li-ion battery MLi Ultra how to configure your system.

WARNING!

Before using the Li-ion battery, it must be installed and commissioned in accordance with the instruction provided in the MLi Ultra manual!

5.2.5 In use

If not all outputs of the ChargeMaster Plus are used, the unused outputs can be excluded from sending alarm messages. This is done by unchecking the in use checkbox for the output that is not used. Factory setting is all outputs in use.

5.2.6 Monitoring

Value

Meaning

Default

Adjustable range

General

Device state

Shows charger state (Charging / Stand-by / Alarm)

(read only)

Charger state

Actual state of charge algorithm: Off/bulk/absorption/float/suspended

(read only) Charger

Function to toggle the charger state

On / Stand-by

Input current

Option to set the maximum AC input current level to prevent a generator or shore fuse from overload

0-20A Battery temp.

Actual temperature of the main battery bank (in °C)

(read only)

Output 1

Output state (Off/pre-float/on)

(read only)

Output 1

Voltage of charge output 1

(read only)

Output 1

Output current of charge output 1

(read only)

Shunt device

A connected MasterShunt can be chosen for feedback on the charged battery.

Not connected

(read only) Output 2

Output 2

Output state (Off/pre-float/on)

(read only)

Output 2

Voltage of charge output 2

(read only)

Output 2

Output current of charge output 2

(read only)

Smart Terminal

Output 3

Output state (Off/pre-float/on/smart terminal)

(read only)

Output 3

Voltage of charge output 3

(read only)

Output 3

Output current of charge output 3

(read only)

5.2.7 Alarm

Value

Meaning

Adjustable range

Alarm status

Bat. Temp. high

Battery temperature too high

(read only)

TS error

Temperature sensor error

(read only)

Mains high volt.

AC Input voltage too high

(read only)

Mains low volt.

AC Input voltage too low

(read only)

Mains high freq.

AC Input frequency too high

(read only)

Mains low freq.

AC Input frequency too low

(read only)

Output 1

Battery high

DC output voltage is too high

(read only)

Battery low

DC output voltage is too low

(read only)

Shunt mismatch

(read only)

Reverse polarity

DC + and DC –are connected in reverse (this will damage the charger)

(read only)

Page 23

Value

Meaning

Adjustable range

Output 2

Battery high

DC output voltage is too high

(read only)

Battery low

DC output voltage is too low

(read only)

Reverse polarity

DC + and DC –are connected in reverse (this will damage the charger)

(read only)

Smart terminal

Battery high

DC output voltage is too high

(read only)

Battery low

DC output voltage is too low

(read only)

Reverse polarity

DC + and DC –are connected in reverse (this will damage the charger)

(read only)

5.2.8 History

This menu shows the absolute maximum readings.

Value

Meaning

Adjustable. Range

Charger

Days running

Total run time in charger mode

(read only)

Output 1

Highest voltage

Highest detected DC voltage output 1

(read only)

Lowest voltage

Lowest detected DC voltage output 1

(read only)

Total Ah’s

Total charged Ah’s

(read only)

Output 2

Highest voltage

Highest detected DC voltage output 1

(read only)

Lowest voltage

Lowest detected DC voltage output 1

(read only)

Total Ah’s

Total charged Ah’s

(read only)

Smart terminal

Highest voltage

Highest detected DC voltage output 1

(read only)

Lowest voltage

Lowest detected DC voltage output 1

(read only)

Total Ah’s

Total charged Ah’s

(read only)

Total Ah’s in

Total charged Ah’s using the smart terminal as input

(read only)

5.2.9 Configuration

Below parameters can be changed via the MasterBus network by means of a remote control panel or by means of an interface connected to a PC with MasterAdjust software. See applicable user’s manuals for details.

Value

Meaning

Factory setting

Adjustable. Range

Device

Language

Menu language of this device

English

EN, NL, DE, FR, ES, IT, NO, SV, FI, DA

Name

Name of this device. This name will be recognized by all devices connected to the MasterBus

CHG ChargeMaster

0-12 chars

MB communication

Select if MasterBus communication is available when only DC power is available.

Smart on

Smart on, Always on

Charger

Method

Charge method

3-Step +

3-Step+, constant voltage

Maximum current

Maximum DC output current

Depending on model, 100%

Depending on model 20-100%

Battery type

Type of battery

Flooded

User defined, AGM, GEL, Flooded, AGM Spiral, Flooded traction, Flooded calcium, Mli

Page 24

Value

Meaning

Factory setting

Adjustable. Range

Temp. compensate

Temperature depended charge voltage compensation

-0,030V/°C/

-0,060V/°C

-1,000/+1,000V/°C

Smart terminal

Smart terminal operation mode

10A Starter

Starter, Starter + alternator, Follow main, Follow main + alternator, 12V constant voltage, 24V constant voltage*, 12V 3-step +*

Maximum current

Smart terminal maximum DC input/output current

40/20A

5-40/20A

Bulk

Voltage

Bulk voltage (@ 25°C); see section 3.4

14.40/28.80V

0-15.50/0-31.00V

Minimum time

Minimum time of the Bulk phase since Start bulk timer

120sec

0-240sec

Start time at

Battery voltage trigger point to start the bulk timer

13.25/26.50V

(read only)

Maximum time

Maximum time of the Bulk phase since Start bulk timer

480 min

0-1440min

Absorption

Voltage

Absorption voltage (@ 25°C); see section 3.4

14.25/28.50V

0-15.50/0-31.00V

Maximum time

Maximum absorption timer

240min

0-1440min

Return Amps

Return amps. If the charge current drops below this level, the charger switches from the Absorption to the Float stage (% of I

max

)

0-50%

Minimum time

Minimum absorption timer

15min

0-240min

Float

Voltage

Float voltage (@ 25°C); see section 3.4

13.25/26.50V

0-15.50/0-31.00V

Return to bulk

Return to bulk voltage; If the battery voltage stays below this level for at least the Return to bulk delay time, the charger will start the Bulk stage

13.25/26.50V

0-15.50/0-31.00V

Return to bulk

Return to bulk delay time, see Return to bulk voltage

30sec

0-240sec

Alarm levels

High alarm on

Upper threshold level to trigger the Battery high alarm

15,25/30.50V

0-16.00/0-32.00V

High alarm off

Lower threshold level to stop the Battery high alarm

14,75/29,50V

0-16.00/0-32.00V

Low alarm off

Upper threshold level to stop the Battery low alarm

11.00/22.00V

0-16.00/0-32.00V

Low alarm on

Lower threshold level to trigger the Battery low alarm

10.00/20.00V

0-16.00/0-32.00V

Alarm delay

Delay time before the alarm is triggered

30sec

5-60sec

Output 1

In use

Select if the output is used

Selected

Selected/Not selected

Name

Name of this output

Output 1

0-16 chars

Shunt device

Selection of the Mastershunt to which output 1 of the ChargeMaster Plus is connected

No connection

No connection, MSH + Product Name

Output 2

In use

Select if the output is used

Selected

Selected/Not selected

Name

Name of this output

Output 2

0-16 chars

Smart terminal

In use

Select if the output is used

Selected

Selected/Not selected

Name

Name of this output

Output 3

0-16 chars

*24V models only

Page 25

5.2.10 Events

Value

Meaning

Factory setting

Adjustable. Range

Events

Event x source

Event-based command Event by the ChargeMaster Plus that should result in an action by another device on the MasterBus network.

Disabled

(See List of event sources, section

5.2.11)

Event x target

Event-based command Selection of device on the MasterBus network that should take action due to an event by the ChargeMaster Plus.

(See Device list)

Event x command

Event-based command Action to be taken by the selected device.

(See List of event commands in the manual of the selected device,)

Event x data

Event-based command Value of the action to be taken by the selected device.

(See List of event commands in the manual of the selected device,)

Event x+1

The next event appears after enabling Event x.

Disabled

See Event x.

5.2.11 Events source

The ChargeMaster Plus can be configured as an event source; an event source can be used to initiate an event command and an event action by another device that is connected to the MasterBus.

Event sources

Description

Device state

State of the ChargeMaster Plus serves as a event source

Bulk

Bulk state of charge serves as an event source

Abs

Absorption state of charge serves as an event source

Float

Float state of charge serves as an event source

Figure 8: Meaning of the event data.

Input (pulses) The input is represented by an on/off switch.

Output (data) 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 Copy

is used for dimming too by holding the pulse switch

pressed for a longer time.

Toggle

changes the status at the first signal and back at

the second signal. It is used in combination with a pulse

switch.

Page 26

5.2.12 Event target

The ChargeMaster Plus can be configured as an event target by other devices on the MasterBus network. When the ChargeMaster Plus is configured as an event target by another device, this device can initiate an event command and an event action to be performed by the ChargeMaster Plus.

Event command

Description

State

Command to switch on the ChargeMaster Plus

Bulk

Command to start the Bulk state of charge

Abs

Command to start the Absorption state of charge

Float

Command to start the Float state of charge

Suspend charging

When using a Li-ion battery MLi Ultra, programming this event is obligatory. Refer to the manual of the Li-ion battery MLi Ultra.

Page 27

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:

 Article and serial number; see section 1.4;

Malfunction

Possible cause

What to do

No output voltage and/or current

No AC-input

Check AC wiring, check remote control panel.

AC-input voltage too low (< 75VAC)

Check input voltage, check generator.

AC input frequency out of range

Check input voltage, check generator.

Output voltage too low, charger supplies maximum current

Load connected to the batteries is larger than charger can supply.

Reduce load taken from the batteries.

Batteries not 100% charged

Measure battery voltage. After some time this will be higher.

Wrong setting of the charge voltage

Check settings (see chapter 5).

Charge current too low

Batteries almost fully charged

Nothing, this is normal when the battery is almost fully charged.

High ambient temperature

Nothing; if ambient temperature is more than the setting limit, the charge current is automatically reduced.

Low AC input voltage. At lower AC input voltages the charge current is reduced.

Check AC-input voltage.

Batteries not fully charged

Charge current too low

See “Charge current too low” in this table.

Current to load is too high

Reduce load taken from the batteries.

Charge time too short

Use a battery charger with higher capacity.

Battery temperature too low

Use the battery temperature sensor.

Defective or old battery

Check battery and replace if necessary.

Wrong setting of the charge voltage

Check settings (see chapter 5).

Batteries are discharged too fast

Battery capacity reduced due to wastage or sulphation, stagnation

Charge and recharge a few times, this might help. Check battery and replace if necessary.

Batteries are too warm, gassing

Defective battery (short circuit in cell)

Check battery and replace if necessary.

Battery temperature too high

Use the battery temperature sensor.

Charge voltage too high

Check settings (see chapter 5).

No EasyView 5 display function.

Display is switched off.

Switch on display, refer to display manual.

Error in the wiring.

Check the MasterBus cables.

Slow or no MasterBus communication.

Error in the MasterBus wiring.

Check the MasterBus cables.

No terminating device placed at the ends of the network.

MasterBus needs a terminating device on both ends of the network. Check if connected.

MasterBus network is configured as a ring network.

Ring networks are not allowed. Check the connections of the network.

Page 28

7 TECHNICAL DATA

7.1 SPECIFICATIONS 12V MODELS

Model

12/75-3

12/100-3

Article no.

44310750

44311000

GENERAL

Nominal input voltage*:

120/230V

Nominal input frequency:

50/60Hz

Full load consumption:

1300VA

1700VA

Max. AC input current (@ 230VAC)

Max. AC input current (@ 120VAC)

14A

18A

Nominal output voltage:

12V

Total charge current*:

75A at 14.4V

100A at 14.4V

Number of battery outlets:

Max. current Smart terminal

75A/40A

100A/40A

Max. input voltage Smart terminal

16V

Charge characteristic*:

IUoUo, automatic, three step plus

Charge voltage Bulk*:

14.4V

Charge voltage Absorption*:

14.25V

Charge voltage Float*;

13.25V

Max. absorption and max. bulk timer*:

8 hours (start max. bulk timer at 13.25V)

Minimum absorption time*:

15 min.

Maximum ripple voltage on DC

120mV pp

Battery type settings*:

User defined/AGM/GEL/Flooded/AGM Spiral/Flooded traction/Flooded calcium/MLi

Dimensions (mm):

383x250x126

Dimensions (inch):

15.0x9.8x5.0

Weight:

<7kg (<16Lbs)

Recommended battery capacity:

140-800Ah

200-1000Ah

Power factor regulations

≥ 0,98

Temperature compensation

Battery temperature sensor and cable included.

Voltage compensation

Yes, by means of automatic compensation or MasterShunt

DC consumption

<5mA

Temperature range

–25°C (–13°F) to 80°C (176°F) Derating of 90% below 0°C (32°F) Derating 1%/°C (0,5%/°F) from 40°C (104°F) to 60°C (140°F) ; Derating 8%/°C (4,4%/°F) from 60°C (140°F) to 70°C (158°F) ; Communication available, 0% output power from 70°C (158°F) to 80°C (176°F)

Cooling

Vario fan and natural cooling to ensure optimized cooling

Sound level

<52dBA / 1m

Protection degree

IP23

MasterBus connectivity

Yes

Powering capabilities for MasterBus

Yes, when the charger is switched on, it can power up to three non-powering devices.

* Adjustable, see chapter 5 for settings.

Specifications are subject to change without prior notice.

Page 29

7.2 SPECIFICATIONS 24V MODELS

Model

24/40-3

24/60-3

Article no.

44320400

44320600

GENERAL

Nominal input voltage*:

120/230V

Nominal input frequency:

50/60Hz

Full load consumption

1400VA

2000VA

Max. AC input current (@ 230VAC)

10A

Max. AC input current (@ 120VAC)

16A

20A

Nominal output voltage:

24V

Total charge current*:

40A at 28.8V

60A at 28.8V

Number of battery outlets:

Max. current Smart terminal:

40A/20A/10A(12V)

60A/20A/10A(12V)

Max. input voltage Smart terminal

32V

Charge characteristic*:

IUoUo, automatic, three step plus

Charge voltage Bulk*:

28.8V

Charge voltage Absorption*:

28.5V

Charge voltage Float*;

26.5V

Max. absorption and max. bulk timer*:

8 hours (start max. bulk timer at 26.5V)

Minimum absorption time*:

15 min.

Maximum ripple voltage on DC

240mV pp

Battery type settings*:

User defined/AGM/GEL/Flooded/AGM Spiral/Flooded traction/Flooded calcium/MLi

Dimensions (mm):

383x250x126

Dimensions (inch):

15.0x9.8x5.0

Weight:

<7kg (<16Lbs)

Recommended battery capacity:

160-400Ah

200-500Ah

Power factor regulations

≥0,98

≥ 0,98

Temperature compensation

Battery temperature sensor and cable included.

Voltage compensation

Yes, by means of automatic compensation or MasterShunt

DC consumption

<10mA

Temperature range

Cooling

Vario fan and natural cooling to ensure optimized cooling

Sound level

<52dBA / 1m

Protection degree

IP23

MasterBus connectivity

Yes

Powering capabilities for MasterBus

Yes, when the charger is switched on, it can power up to three non-powering devices.

* Adjustable, see chapter 5 for settings

Specifications are subject to change without prior notice.

Page 30

7.3 DIMENSIONS

Dimensions in mm ChargeMaster Plus models 12/75-3, 12/100-3, 24/40-3 and 24/60-3

185

231

250

383

126

Page 31

8 ORDERING INFORMATION

8.1 MASTERBUS INSTALLATION COMPONENTS

Part number

Description

77040000

MasterBus terminating device

77040020

MasterBus connection cable (UTP patch cable), 0,2m / 0.6ft

77040050

MasterBus connection cable (UTP patch cable), 0,5m / 1.6ft

77040100

MasterBus connection cable (UTP patch cable), 1,0m / 3.3ft

77040300

MasterBus connection cable (UTP patch cable), 3,0m / 10ft

77040600

MasterBus connection cable (UTP patch cable), 6,0m / 20ft

77041000

MasterBus connection cable (UTP patch cable), 10m / 33ft

77041500

MasterBus connection cable (UTP patch cable), 15m / 49ft

77042500

MasterBus connection cable (UTP patch cable), 25m / 82ft

77050100

100m / 330ft MasterBus cable (UTP cable)

77050200

50 pcs. modular jacks

77050000

Complete set to assemble UTP patch cables. Delivery includes: 100m / 330ft UTP cable, 50 pcs. modular jacks and crimping tool

77030100

MasterConnect USB interface, required as interface between your PC and the MasterBus when using MasterAdjust software.

77010310

EasyView 5, Touch screen to control and monitor all MasterBus products

77020110

MasterShunt 500, DC-distribution module for exact readout of battery voltage, charge / discharge current, and state of charge on the display of the ChargeMaster Plus. continuous rating: 250A, peak current: 500A

8.2 MISCELLANEOUS

Part number

Description

604015

ATC Fuse 15A (2 pcs)

77049050

ANL Fuse 50A

77049080

ANL Fuse 80A

77049100

ANL Fuse 100A

77049125

ANL Fuse 125A

607006

ANL Fuse base

701

Battery switch 275A with knob

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 Plus

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

Snijdersbergweg 93, 1105 AN Amsterdam, The Netherlands

Tel : + 31-20-3422100

Fax : + 31-20-6971006

Email : info@mastervolt.com