Mastervolt CHARGEMASTER PLUS 12/100-3, CHARGEMASTER PLUS 2/75-3, CHARGEMASTER PLUS 24/40-3, CHARGEMASTER PLUS 24/60-3 Installation Manual

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DE

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CHARGEMASTER PLUS

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

ALL-IN-ONE BATTERY CHARGER

USER AND INSTALLATION MANUAL

10000015492/01

2

ChargeMaster Plus 12/75-3, 12/100-3, 24/40-3, 24/60-3 – User and Installation Manual

ChargeMaster Plus 12/75-3, 12/100-3, 24/40-3, 24/60-3 – User and Installation Manual

3

TABLE OF CONTENTS

1 GENERAL INFORMATION ........................................ 4

1.1 Use of this manual .............................................. 4

1.2 Liability ................................................................ 4

1.3 Warranty ............................................................. 4

1.4 Disclaimer ........................................................... 4

1.5 Identification label ............................................... 4

1.6 Correct disposal of this product .......................... 4

2 SAFETY INSTRUCTIONS .......................................... 5

2.1 General ............................................................... 5

2.2 Explosive gases .................................................. 5

2.3 Personal precautions .......................................... 5

2.4 Warnings regarding the use of batteries ............. 5

2.5 Charger location ................................................. 6

2.6 DC connection precautions ................................. 6

2.7 When battery is installed in vehicle ..................... 6

2.8 When battery is outside vehicle .......................... 6

2.9 Preparing to charge ............................................ 6

2.10 Grounding instructions ........................................ 6

2.11 Warning regarding life support applications ........ 6

3 INSTALLATION .......................................................... 7

3.1 Unpacking ........................................................... 7

3.2 Location .............................................................. 7

3.3 Wiring ................................................................. 7

3.3.1 DC wiring ................................................. 7

3.3.2 AC wiring ................................................. 8

3.3.3 AC safety grounding ................................ 8

3.3.4 Network wiring (CZone/MasterBus) ......... 8

3.4 Batteries ............................................................. 8

3.5 Things you need ................................................. 8

3.6 Overview of the connection compartment ........... 9

3.7 Connection example ......................................... 10

3.8 Installation step-by-step .................................... 11

3.9 Commissioning after installation ....................... 12

4 SETTINGS ................................................................. 13

4.1 DIP switch settings ............................................ 13

4.2 MasterBus configuration .................................... 13

4.2.1 Monitoring .............................................. 13

4.2.2 Alarms .................................................... 14

4.2.3 History .................................................... 14

4.2.4 Configuration settings ............................ 15

4.2.5 Events – System automation ................. 16

4.2.6 Current control ....................................... 17

4.3 MasterShunt ...................................................... 17

4.4 Li-ion Battery MLI Ultra ...................................... 17

4.5 CZone configuration .......................................... 17

5 OPERATING INSTRUCTIONS .................................. 19

5.1 Introduction ........................................................ 19

5.2 Switching on / off ............................................... 19

5.3 Status display .................................................... 19

5.4 The 3-step+ charge process .............................. 21

5.4.1 Charge voltages ..................................... 21

5.4.2 Pre-float ................................................. 21

5.4.3 Temperature compensated charging ..... 21

5.4.4 Flat battery support ................................ 21

5.5 DC 3 IN/OUT ..................................................... 22

5.6 Maintenance ...................................................... 22

5.7 Storage .............................................................. 22

6 TROUBLE SHOOTING ............................................. 23

7 TECHNICAL DATA ................................................... 24

7.1 Specifications 12V models ................................ 24

7.2 Specifications 24V models ................................ 25

7.3 Dimensions ........................................................ 26

7.4 3-step+ charging characteristics of flooded

batteries............................................................. 27

4

ChargeMaster Plus 12/75-3, 12/100-3, 24/40-3, 24/60-3 – User and Installation Manual

Part number

Model

44310755

12/75-3

44311005

12/100-3

44320405

24/40-3

44320605

24/60-3

CAUTION!

Never remove the identification label.
This will void the warranty.

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.

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 following
ChargeMaster Plus models:

These models are further mentioned as “ChargeMaster
Plus”.

1.2 Liability

Mastervolt can accept no liability for:
 Consequential damage resulting from the use of the

ChargeMaster Plus.

 Possible errors in the included manual and the

consequences of these.

 Use that is inconsistent with the purpose of the

product.

1.3 Warranty

Mastervolt assures the product warranty of the
ChargeMaster Plus during two years after purchase, on
the condition that the product is installed and used
according to the instructions in this manual.

1.5 Identification label

Part number Serial number with device version "E".

Figure 1: Identification label

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

1.6 Correct disposal of this product

Installation or use not according to these instructions may
result in under performance, damage or failure of the
product and may void this warranty. The warranty is
limited to the cost of repair and/or replacement of the
product. Costs of labor or shipping are not covered by this
warranty.

1.4 Disclaimer

Our products are subject to continual development and
improvement. Therefore, additions or modifications to the
products may cause changes to the technical data and
functional specifications. No rights can be derived from
this document. Please consult our most current Terms &
Conditions of Sale.

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.

ChargeMaster Plus 12/75-3, 12/100-3, 24/40-3, 24/60-3 – User and Installation Manual

5

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

WARNING!

Read the entire manual before using the
ChargeMaster Plus. Keep this manual in a
secure place.

2 SAFETY INSTRUCTIONS

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 The appliance is not to be used by children or persons

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

2 This appliance is not intended for use 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 concerning use of the appliance by a
person responsible for their safety.

3 Children should be supervised to ensure that they do

not play with the appliance.

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

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 qualified and trained personnel, consistent
with the locally applicable standards and regulations.

7 Make sure that all wiring is properly installed, in good

electrical condition, and correctly sized to match the 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 the 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 3,

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.

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. Be sure that
third parties cannot reverse the measures taken.

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 cannot 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.

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 eye 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 Do not wear watches, bracelets, necklaces or other metal

objects when working on batteries.

2.4 Warnings regarding the use of batteries

1 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

ChargeMaster Plus 12/75-3, 12/100-3, 24/40-3, 24/60-3 – User and Installation Manual

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 Never place charger directly above battery being charged;

gases from battery will corrode and damage charger.

2 Never allow battery acid to drip on charger when reading

electrolyte specific gravity or filling battery.

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

ventilation in any way.

4 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 section

2.7, steps 5 and 6, and 2.8 steps 2 through 4.

2.7 When battery 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 sheet­metal 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 sheet­metal 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.

2.8 When battery is outside vehicle

A SPARK 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.

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.
Note that the ChargeMaster Plus charge specifications
are based on Mastervolt batteries. Specifications for a
given chemistry of a different manufacturer may vary. If
connecting batteries of a different manufacturer make
sure the manufacturer's recommendations are met.

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

Mastervolt products are not designed to be used as
component of medical equipment, unless negotiated in the
form of a written agreement between customer and/or
manufacturer and Mastervolt. Such agreement will require the
equipment manufacturer either to contract additional reliability
testing of the Mastervolt parts 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 Mastervolt parts in the life support equipment.

ChargeMaster Plus 12/75-3, 12/100-3, 24/40-3, 24/60-3 – User and Installation Manual

7

WARNING!

The wire sizes stated in this manual are given
as guideline only. Always refer to rules.

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

Wire color

Meaning

Connect to:

Red

Positive

+ (POS)

Black

Negative

– (NEG)

0

20

40

60

80

100

120

-50

-40

-30

-20

-10

0

102030405060708090

100

Output Power (%)

Temperature (°C)

Output Power vs Temperature

3 INSTALLATION

During installation and commissioning, the safety
instructions are applicable at all times.

3.1 Unpacking

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

wall;

 Battery temperature sensor;
 Drop cable CZone/MB (1m);
 MasterBus Terminator;
 User 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 1.2)
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).

3.2 Location

 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).

 If added to a CZone or MasterBus network, take the

network powering into consideration.

 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.

3.3 Wiring

3.3.1 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:

 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.

Use the following wire colors for DC wiring color or at least
different colors to make a clear distinction between the
positive and negative wire from the battery:

Run 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.

8

ChargeMaster Plus 12/75-3, 12/100-3, 24/40-3, 24/60-3 – User and Installation Manual

Model

DC fuse

Model

DC fuse

12/75-3

85A 24/40-3

50A

12/100-3

125A

24/60-3

80A

WARNING!

On first connecting to power, make sure the
ChargeMaster Plus is in a well-ventilated area
as it might spark.

AC Current
Minimum cross section:

in mm²

AWG

6-12A

1.5mm²

AWG14

12-20A

2.5mm²

AWG12

20-32A

4.0mm²

AWG10

Wire color

Meaning

Must be connected to:

Brown or black

Phase

L1

Blue

Neutral

N

Green/Yellow

Earth

PE / GND

Wire color

Meaning

Must be connected to:

Black

Hot or Line

L1

White

Neutral

N

Green

Ground

PE / GND

Wire color

Meaning

Must be connected to:

Black

Hot or Line

L1

Red

Hot or Line

L2

Green

Ground

PE / GND

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 an RCD/Breaker
(also known as GFCI) must be placed in the
AC input circuit of the ChargeMaster Plus.

For Australia and New Zealand, the wiring
rules are in accordance with AS/NZS 3000.

Model

Minimum battery capacity

12/75-3

150 Ah

12/100-3

200 Ah

24/40-3

80 Ah

24/60-3

120 Ah

The recommended DC fuses for DC 1 OUT, DC 2 OUT
and DC 3 in/OUT are:

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

3.3.2 AC wiring

For a safe installation the correct wire cross section must

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

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

Connection of AC wiring and recommended wire colors:

 240VAC, 50/60Hz installations:

 120VAC, 50/60Hz installations (single phase):

3.3.4 Network wiring (CZone/MasterBus)

The ChargeMaster Plus can be connected to a CZone or
MasterBus network. Use an RJ45 Drop cable CZone/MB
or MasterBus cable and daisy chain the ChargeMaster
Plus to the other devices, forming a local data network.
Both networks need a terminating device on both ends of
the network. Do not make ring networks or T-connections.

 CZone network
Points to consider:
˗ Up to 40 devices can be connected together on a

single backbone.

˗ Make sure the CZone network has two terminating

resistors, one at each open end of the backbone.

˗ The electric power for the network comes from a

battery or power supply. Make sure that it delivers
enough power and is positioned as close to the middle
of the backbone as possible to reduce voltage drop.

 MasterBus network
Points to consider:
˗ Connections between the devices are made by

standard MasterBus cables (straight UTP). Mastervolt
can supply these cables.

˗ Up to 63 MasterBus devices can be connected

together.

˗ The electric power for the network comes from the

connected devices according to the rule: 1powering / 3
non-powering. Spread the powering devices over the
network.

For more details on networks, please contact your
Mastervolt supplier.

3.4 Batteries

 240VAC, 50/60Hz (split phase 120/240VAC):

Note: An accessible disconnection device (switch or

circuit breaker for example) must be incorporated in
the AC wiring, in accordance with wiring rules.

3.3.3 AC safety grounding

Always follow the instructions published by the battery
manufacturer.

Minimum based on Mastervolt Gel batteries. If connecting
batteries of a different manufacturer make sure the
manufacturer's recommendations are met.

3.5 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 3.3.1 for
specifications.

ChargeMaster Plus 12/75-3, 12/100-3, 24/40-3, 24/60-3 – User and Installation Manual

9

Front side with open connection compartment

Bottom side

1

Common negative output terminal

7

Strain relief for AC wiring

2

Positive terminal charge output 3; DC 3 IN/OUT

8

Safety ground connection

3

Isolation walls for DC connections

9

Network connection (CZone/MasterBus)

4

Positive terminal charge output 2; DC 2 OUT

10

Temperature sensor connection

5

Positive terminal charge output 1; DC 1 OUT

11

DIP switches

6

Screw terminals AC input

12

Ventilation openings

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

positive DC cable; see section 3.3.1 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 0.

 Batteries. See section 3.4.
 Appropriate and reliable cable terminals, cable lugs,

battery terminals and cord end terminals.

 For CZone setup, an RJ45-M12 Drop cable CZone/MB

(included) and a tee connector (not included). When
connecting several drop cables in a similar location,
use a 2-way or 4-way tee connector

3.6 Overview of the connection compartment

 For MasterBus setup, an RJ45 MasterBus cable (not

included).

We recommend as a minimum tool kit:

 Socket wrench 13mm to fix the main DC cables.
 Socket wrench 10mm to fix the Safety ground

connection.

 Flat blade screw driver 1.0 × 4.0mm 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 number 2 to open the connection

compartment.

Figure 2: Connections

10

ChargeMaster Plus 12/75-3, 12/100-3, 24/40-3, 24/60-3 – User and Installation Manual

WARNING

All electrical systems (AC and DC) must be
disconnected from any power source during
the entire installation!

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.

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.

3.7 Connection example

This schematic illustrates 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 3: Installation drawing of the ChargeMaster Plus

Notes:

- If the battery temperature remains within 15-25°C, connection of the battery temperature sensor is optional.

- Lithium-ion batteries require no temperature sensor.

- If creating a parallel system of multiple ChargeMaster Plus units, the units should be excluded from any isolation
measurement system.

ChargeMaster Plus 12/75-3, 12/100-3, 24/40-3, 24/60-3 – User and Installation Manual

11

1

2

3

Fix the enclosure to the wall by fastening two

4

Open the connection compartment by

5

Connect the wiring to the screw terminals.

6

Integrate a fuse holder in the positive battery

positive to +, negative to – .

Repeat steps for output 2 and 3.

3.8 Installation step-by-step

loosening the two screws.

screws at the lower side of the enclosure as
well.

Fasten the cable with the strain relief.

wire but do not place the fuse yet!
Fit crimp-on cable lugs to the DC cables.
Connect the DC cabling of battery bank 1,

12

ChargeMaster Plus 12/75-3, 12/100-3, 24/40-3, 24/60-3 – User and Installation Manual

WARNING

When placing this fuse, a spark might
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.

7

Attach the battery temperature sensor to the

“Temp sense” jack.

Option: Connect the ChargeMaster to the
CZone or MasterBus network.

8

Adding to a CZone network

Ensure that the network is properly terminated.

9

If required, use a small screw driver to

.

10

Check all wiring; see also Figure 3 for wiring

fuses.

11

Close the connection compartment by fixing
the screws.

12

Continue with section 3.9 for commissioning
of the ChargeMaster Plus.

casing of battery bank 1.
Plug the temperature sensor cable into the

details. If all wiring is OK: Place the DC

1 Disconnect the backbone at the closest

backbone connection and add in a tee
connector.

2 Reconnect the backbone connection(s) with

the new tee connector in place.

3 Connect the RJ45 CZone/MB drop cable to

the black coupler on the tee and then connect
to the ChargeMaster Plus.

Adding to a MasterBus network

1 Disconnect a MasterBus cable or Terminator

from the closest MasterBus device and
connect it to the ChargeMaster Plus.

2 Connect the new MasterBus cable to the

other MasterBus device and then connect to
the ChargeMaster Plus.

change DIP switch settings. See section 4.1

3.9 Commissioning after installation

DIP switches, if required, must be set prior to
commissioning. All other settings can only be set after
commissioning. See chapter 4.

1 Check the wiring; positive connected to positive (red

cables), negative connected to negative (black
cables).

2 When all wiring is OK, place the DC fuse(s) to

connect the batteries to the ChargeMaster Plus.

3 Switch on the AC power supply.
4 Press and hold the MODE button (Figure 5) for 3

seconds to switch the charger on and initiate the
charging process.

ChargeMaster Plus 12/75-3, 12/100-3, 24/40-3, 24/60-3 – User and Installation Manual

13

CAUTION!

Invalid settings of the ChargeMaster Plus can
cause serious damage to your batteries and/or
the connected load! Only authorised personnel
may adjust settings.

DIP switch

3 4 5

MasterBus settings (Flooded)1

0 0 0

Flooded (fixed)

0

0

1

AGM (fixed)

0 1 0

Gel (fixed)

0

1

1

Lithium-ion (fixed)

1

0

0

Constant voltage (13,25/26,50V)2

1 1 1

DIP switch

6

7

12V battery

1

Current limit 10A

1

Parameter

Meaning

Value range

General

Device state

Shows charger state (On / Stand-by / Alarm / Off)

(read only)

Charger state

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

(read only)

'Toggle' button

Button to toggle the charger state.
This button does not work when the ChargeMaster Plus is switched off manually. In

that case it can only be switched on with the MODE button.

On / off
Input current

Option to set the maximum AC input current level to prevent a generator or shore
fuse from overload. See section 4.2.6 for more information. Default 20.

0-20A
Battery temp.

Temperature of the main battery bank (in °C)

(read only)

4 SETTINGS

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

 By means of DIP switches.
 From a laptop or notebook connected to the

ChargeMaster Plus via a USB Interface. Some settings
can only be changed in this way.

In a MasterBus network:

DIP switch 1 must always be set to the ON position (1).
DIP switch 2 is MasterBus Powering ON (1) or OFF (0).
DIP switches 3 to 5 are used for battery type selection:

When required, the ChargeMaster Plus can be restored to
factory settings (see section 4.2.1).

4.1 DIP switch settings

Use a small screwdriver to carefully set the required
settings.

Figure 4: DIP switches

DIP switch 1 = CZone (0) or MasterBus (1) network.
DIP switch 2 = MasterBus powering off (0) or on (1)
DIP switches 3 to 10 are either used as CZone 'address'

or for MasterBus battery and 3rd output settings.
In a CZone network:

DIP switch 1 must always be set to the OFF position (0).
DIP switch 2 must always be set to the OFF position (0).
DIP switches 3 to 10 must match the unique number used

in the CZone network; the dipswitch. See the CZone Con-
figuration Tool Instructions manual for more information.

1

If all DIP switches are in the OFF position (0 ), the settings suit

a Flooded battery but can be changed in MasterAdjust.

2

Constant voltage has no temperature compensation

DIP switches 6 and 7 are used for DC 3 IN/OUT:

These two options cover the most used applications. Other
options can be selected via the configuration tool.

See section 5.4 for more information on charge voltage
settings and section 5.5 for DC 3 IN/OUT.

4.2 MasterBus configuration

MasterBus is a CAN based data network for communica­tion between Mastervolt devices. When the ChargeMaster
Plus is connected, open MasterAdjust on a Windows
laptop or notebook connected to the MasterBus network
via a MasterBus USB interface. MasterAdjust software is
available as free to download software on the Mastervolt
website: www.mastervolt.com. This tool runs on a
Windows laptop or notebook.

4.2.1 Monitoring

A remote panel, like the SmartRemote, Touch 5 (CZone) or EasyView 5 (MasterBus), can be used for reading battery
information. See applicable user manuals for details. The following table lists the parameters as shown in MasterAdjust.

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ChargeMaster Plus 12/75-3, 12/100-3, 24/40-3, 24/60-3 – User and Installation Manual

Parameter

Meaning

Value range

DC 1 OUT

Output 1

Output state (Off/pre-float/on)

(read only)

Output 1 V

Voltage of charge output 1

(read only)

Output 1 A

Output current of charge output 1

(read only)

Shunt device

A connected MasterShunt can be chosen for feedback on the charged battery.
Default not selected.

(read only)
DC 2 OUT

Output 2

Output state (Off/pre-float/on)

(read only)

Output 2 V

Voltage of charge output 2

(read only)

Output 2 A

Output current of charge output 2

(read only)

DC 3 IN/OUT

Output 3

Output state (Off/pre-float/on/smart input DC 3 IN/OUT)

(read only)

Output 3 V

Voltage of charge output 3

(read only)

Output 3 A

Output current of charge output 3

(read only)

Parameter

Meaning

Alarm status

Bat. temp. high

Battery temperature too high / too low

TS error

Temperature sensor error

AC error

AC input (mains) error

DC 1 OUT

Shunt mismatch

Setting for nominal voltage (12/24V) at the MasterShunt or the nominal voltage of the MLI batteries differs
from nominal voltage detected by the ChargeMaster Plus. Check battery voltage and settings of the
MasterShunt or voltage of the MLI Ultra battery.

Reverse polarity

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

DC 2 OUT

Reverse polarity

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

DC 3 IN/OUT

Reverse polarity

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

Parameter

Meaning

Charger

Days running

Total run time in charger mode

DC 1 / 2 OUT

Highest voltage

Highest detected DC voltage output 1 / 2

Lowest voltage

Lowest detected DC voltage output 1 / 2

Total Ah’s

Total charged Ah’s

DC 3 IN/OUT

Highest voltage

Highest detected DC voltage DC 3 IN/OUT

Lowest voltage

Lowest detected DC voltage DC 3 IN/OUT

Total Ah’s

Total charged Ah’s

Total Ah’s in

Total charged Ah’s using DC 3 IN/OUT as input

 Parameters marked with a  are not available in CZone.

4.2.2 Alarms

The following table lists the parameters as shown in MasterAdjust.

4.2.3 History

The history data shows the absolute maximum readings. The following table lists the information as shown in MasterAdjust.

ChargeMaster Plus 12/75-3, 12/100-3, 24/40-3, 24/60-3 – User and Installation Manual

15

Parameter

Meaning

Factory setting

Value 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 network

CHG
ChargeMaster

0-12 characters

Powersave
mode

If Powersave mode is ON, the charger will switch
itself off when no AC power is available.
If Powersave mode is OFF, the charger stays ON
even when no AC power is available.

On

On, Off

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,
Lithium-ion

Temp.
compensate

Temperature depended charge voltage
compensation

-0,030V/°C /

-0,060V/°C

-1,000/+1,000V/°C

Smart terminal

Charge method DC 3 IN/OUT

Follow DC 1

Follow DC 1, Follow DC 1 +
Alternator, Constant 12V,
Constant 24V*, 12V 3-Step+*,
12V Battery*

Full Current

Select if 3rd output is a full output

On

On, off

Maximum
current

DC 3 IN/OUT maximum DC output current

40/20A

5-40/20A

Input threshold

Voltage threshold used to switch over when DC 3
IN/OUT acts as VSR

13,75/27.50V

8-16/16-32V

Input current

DC 3 IN/OUT maximum DC input current (see
also section 4.2.6)

40/20A

5-40/20A

Bulk

Voltage

Bulk voltage (@ 25°C); see section 5.4

14.40/28.80V

8-16/16-32V

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 5.4

14.25/28.50V

8-16/16-32V

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

)

6%

0-50%
Minimum time

Minimum absorption timer

15min

0-240min

Float

Voltage

Float voltage (@ 25°C); see section 5.4

13.25/26.50V

8-16/16-32V

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

8-16/16-32V
Return to bulk

Return to bulk delay time, see Return to bulk
voltage

30sec

0-240sec

4.2.4 Configuration settings

The configuration can be done in MasterAdjust, from a laptop or notebook connected to the ChargeMaster Plus via a
Mastervolt USB Interface. See applicable user manuals for details. The following table lists the parameters as shown in
MasterAdjust. Parameters marked with a  are not available in CZone.

Note: DIP switch settings overrule MasterBus settings. If DIP switches are not in their default setting, the corresponding

MasterBus setting is grayed out.

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ChargeMaster Plus 12/75-3, 12/100-3, 24/40-3, 24/60-3 – User and Installation Manual

Parameter

Meaning

Factory setting

Value range

Alarms

Alarm delay

Delay time before the alarm is triggered

30sec

5-60sec

DC 1 OUT

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

Not selected

Not selected,
MSH + Product Name

DC 2 OUT

Name

Name of this output

Output 2

0-16 chars

DC 3 IN/OUT

Name

Name of this output

Output 3

0-16 chars

Installer menu

DIP Switch

DIP switch settings

1100000000

0 / 1

Factory
settings
button

Button to reset the ChargeMaster Plus to default
settings (requires installer rights)

Not applicable

Not applicable

Field

Meaning

Value

Event x source

Select an event that triggers an action, for example Battery pre low.

See Event source list

Event x target

Select the device that should take action, for example the generator

Selectable targets are system
dependent

Event x command

Select the parameter that must be changed on the target device, for
example Activate.

See command list of the selected
device

Event x data

Data, for example On, is linked to the command.

Off, On, Copy, Copy Invert,
Toggle

Event source

Meaning

Charger state

State of the ChargeMaster Plus serves as an 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

Failure

Any fault condition of the ChargeMaster Plus serves as an event source

Event command

Meaning

On

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 MLI Ultra Li-ion battery, this event is obligatory. Refer to the MLI Ultra manual.

*24V models only

4.2.5 Events – System automation

A CZone/MasterBus device can be programmed to initiate an action at another connected device. This is very helpful in
automation of your system but is not required.

In MasterBus this is done by means of event based commands. In the Events tab you can program the ChargeMaster Plus to
act as an event source. Events which occur during the operation of the ChargeMaster Plus will then trigger actions from other
products. The following tables list the parameters as shown in MasterAdjust.

Table 1: MasterBus event parameters

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.

Table 2: ChargeMaster Plus MasterBus Event sources

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.

Table 3: ChargeMaster Plus MasterBus Event commands

ChargeMaster Plus 12/75-3, 12/100-3, 24/40-3, 24/60-3 – User and Installation Manual

17

WARNING!

Before using the Li-ion battery, it must be properly installed and commissioned!

1. Enter an understandable
Module Name.

2. Each device on a CZone
network has a unique CZone
address; the Dipswitch. This
number must match the
physical DIP switch settings.
When connected to the system:
either select one from the drop­down list or edit graphically.

3. Select the Battery Type.

4. Enter the DC Current Limit.

5. Option: press the Advanced
Settings button to configure
advanced options.

4.2.6 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 to 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 ≤6A. The
AC input current of the ChargeMaster Plus will be reduced to 6A.

How to set the DC input current in a MasterBus network

1. Open MasterAdjust.

2. Select the ChargeMaster Plus.

3. Go to the Monitoring tab.

4. In the Input Current field, enter the required value.

4.3 MasterShunt

In a MasterBus network, a MasterShunt can be coupled with output 1 (DC 1 OUT) 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 for
information on how to configure your system.

4.4 Li-ion Battery MLI Ultra

The ChargeMaster Plus can be combined with a Li-ion battery MLI Ultra. Refer to the manual of the Li-ion battery MLI Ultra for
information on how to configure your system.

4.5 CZone configuration

The CZone® network is an NMEA 2000-compliant CAN-based system. When the ChargeMaster Plus is connected, open the
CZone Configuration Tool on a Windows laptop or notebook connected to the CZone network. Either do the configuration
while connected to the network or use a prepared configuration file (.zcf). Ensure that a DIP Switch is assigned. For detailed
information on the configuration also see section 4.2.1.

Adding the ChargeMaster Plus to a CZone system configuration
Precondition: This section assumes that a CZone system is already configured and the CZone Configuration Tool is open.

In the CZone Configuration Tool, from the Modules tab, press the Add button.
From the Module Type drop-down list select Chargers.
From the Charge Type drop-down list select the required model and continue with the following steps.

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ChargeMaster Plus 12/75-3, 12/100-3, 24/40-3, 24/60-3 – User and Installation Manual

6. Select the required Charge
Method from the drop-down list.

7. Enter an understandable Name
for DC 1 OUT, DC 2 OUT and
DC 3 IN/OUT.

8. From the DC 3 Charge Method
drop-down list, select the
required charge method for DC
3 IN/OUT. See section 5.5.
Depending on the selected
charge method, additional
settings will be offered, hidden
or grayed out.

9. NMEA2000 Instances are used
to differentiate between multiple
monitoring sources.

10. Press OK to return to the
Module Modification window
and press the Alarm/Switch
Settings button.

11. Select the required Alarm
Severities.

12. Press OK.

Optionally configure digital
switching by adding Circuit
Controls in the Circuits tab (e.g. a
battery low switch can be used to
start a generator). Write the
configuration to the network to use
the new configuration.

For more information, please refer to the CZone® Configuration Tool Instruction manual.

ChargeMaster Plus 12/75-3, 12/100-3, 24/40-3, 24/60-3 – User and Installation Manual

19

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!

WARNING

Switching the ChargeMaster Plus off or “stand­by” does not cut off the connection to the

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

MODE button

switch the charger on or off

NETWORK

communication

MODE

status

Battery 1, 2 & 3

Battery charge status

5 OPERATING INSTRUCTIONS

5.1 Introduction

The Mastervolt ChargeMaster Plus is a fully automatic
battery charger. This means that under normal
circumstances it can be left switched on with 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, gel or deep-cycle batteries. It operates on both
240V and 120V.

5.2 Switching on / off

The ChargeMaster Plus is activated by keeping the MODE
button pressed for approximately 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.

Note: Once switched on, the ChargeMaster Plus

automatically resumes operation after it was
disconnected from an AC source temporarily.

By holding the MODE button pressed again for approx. 3
seconds, the ChargeMaster Plus will switch off: the
ChargeMaster Plus stops and the MODE LED illuminates
red. When the ChargeMaster Plus was switched off, it can
only be activated by pressing the MODE button again.

5.3 Status display

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

Note: The ChargeMaster Plus can also be monitored

from a remote panel like the Touch 5 (in a CZone
network) or the EasyView 5 (in a MasterBus
network). See section 04.2 for details.

Indicates ChargeMaster Plus

Hold MODE pressed for 3 seconds to

Blinks when there is network

Figure 5: ChargeMaster Plus status display

20

ChargeMaster Plus 12/75-3, 12/100-3, 24/40-3, 24/60-3 – User and Installation Manual

Menu

MODE LED color

Meaning

Level 1

Green

Status menu

Level 2

Orange

Output power menu

Level 3

Red

Error menu

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 fast green

Battery in bulk stage

Blinking slow green

Battery absorption stage

Solid green

Battery in float stage

Battery II
Blinking fast green

Battery in bulk stage

Blinking slow green

Battery absorption stage

Solid green

Battery in float stage

Battery III
Blinking fast green

Battery in bulk stage

Blinking slow green

Battery absorption stage

Solid green

Battery in float stage

Network

Blinking green

Network communication

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%

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

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

Status

Output power

Error

ChargeMaster Plus 12/75-3, 12/100-3, 24/40-3, 24/60-3 – User and Installation Manual

21

Bulk

Absorption

Float

AGM or GEL

14.25 / 28.5

14.25 / 28.5

13.80 / 27.6

Flooded

14.25 / 28.5

14.25 / 28.5

13.25 / 26.5

Lithium-ion

14.25 / 28.5

14.25 / 28.5

13.50 / 27.0

Charge voltage (V)

Battery temperature (°C)

UBat

Voltage

Output power

12V
24V

0.00V – 2.50V

0.00V – 5.00V

15%-30% of I

max

12V
24V

2.50V – 8.00V

5.00V – 16.00V

25% of I

max

12V
24V

8.00V – 10.00V

16.00V – 20.00V

linear from 25% - 100% of
I

max

12V
24V

10.00V – 14.25V

20.00V – 28.50V

100% of I

max

12V
24V

>14.25
>28.50

Limited by P

max

5.4 The 3-step+ charge process

Battery charging is accomplished in three automatic
stages: BULK, ABSORPTION and FLOAT.

The first step 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 14.25V respectively 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 6: charge process

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, etc. 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. In FLOAT,
the ChargeMaster Plus switches to a stabilized

13.25V/26.5V (Flooded), 13.8V/27.6V (Gel/AGM) or

13.5V/27V (MLI) at 25°C/77°F.
Connected DC loads are powered directly by the charger.

If the load exceeds the 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 3-step charge system.

5.4.1 Charge voltages

5.4.2 Pre-float

The ChargeMaster Plus can automatically switch each
individual output from absorption to pre-float 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.

5.4.3 Temperature compensated charging

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

Figure 7: Temperature compensated charging

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.
Overcharge and gassing are prevented this way. This will
extend the life of your batteries.

5.4.4 Flat battery support

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

As the ChargeMaster Plus is equipped with a 3-step+
charge system, the batteries can also remain connected to
the ChargeMaster Plus during winter. One hour every 14
days the charger automatically switches to absorption to
keep the battery running properly and prolong its life span.
The three-step plus charge system is also safe for all the
connected equipment. See also the 3-step+ charging
characteristics of flooded batteries on page 27.

22

ChargeMaster Plus 12/75-3, 12/100-3, 24/40-3, 24/60-3 – User and Installation Manual

5.5 DC 3 IN/OUT

The ChargeMaster Plus is equipped with three outputs;
DC 1 OUT, DC 2 OUT and DC 3 IN/OUT. The total output
current is divided over these three outputs. See section

3.6 for connections.
DC 3 IN/OUT can be current limited and can serve as an

output and as an input to charge batteries 1 & 2. DC 3
IN/OUT can operate in the following operating modes:

 12V Battery (DIP switch 6) (24V models only)

If DIP switch 6 is in the on position then DC 3 IN/OUT
is set to 12V. All batteries are charged with the same
settings. DIP switch 6 has no effect on a 12V charger.
In case of a 24V charger, DC 3 IN/OUT is current
limited (configurable).

 Current limit 10A (DIP switch 7)

If DIP switch 7 is in the on position then DC 3 IN/OUT
is current limited to 10A to safely charge a small
starter battery. When a 24V charger is used, DIP
switch 6 can also be in the on position, unless the 24V
charger must charge a 24V starter battery.

 Follow DC 1

All batteries are charged with the same settings; a
12V charger with 12V and a 24V charger with 24V.

 Follow DC 1 + Alternator

Three full outputs. All batteries are charged with the
same settings. DC 3 IN/OUT acts 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
batteries 1 & 2. The threshold voltage which is used to
switch over is set via the configuration tool.

 Constant 12V

DC 3 IN/OUT is current limited (configurable) and set
to 13,25V constant voltage.

 Constant 24V (24V models only)

DC 3 IN/OUT is current limited (configurable) and set
to 26,5V constant voltage.

 12V 3-Step+ (24V models only)

DC 3 IN/OUT can charge a 12V battery with its own
charging profile. Settings can be configured.

The operating mode can be selected in the configuration
tool. The first two can also be selected via DIP switches.

5.6 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.

5.7 Storage

If it is necessary to put the ChargeMaster Plus out of
operation, execute the following steps:

1 Switch off the ChargeMaster Plus (see section 5.2).
2 Remove the DC fuse(s) and disconnect the batteries.
3 Switch the RCD/Breaker of the AC input to the OFF

position and, if required, 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. When not installed, store the ChargeMaster Plus in a
dry and dust free environment. To return to normal
operation, after re-installation, switch on the AC.

ChargeMaster Plus 12/75-3, 12/100-3, 24/40-3, 24/60-3 – User and Installation Manual

23

CAUTION!

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

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 4)

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 4)

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 4)

Remote panel display
shows no
ChargeMaster Plus

Display is switched off

Switch on display, refer to display manual

Error in the wiring

Check the network cables

No terminating device placed at the ends of
the network

A network needs a terminating device on both
ends of the network, check if available

Network is configured as a ring network

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

ChargeMaster Plus is not configured in
CZone configuration file

Open CZone Configuration Tool and check.

ChargeMaster Plus Dipswitch not correct

Open CZone Configuration Tool and check with
Force Dipswitch for Address.

Slow or no MasterBus
communication.

Error in the MasterBus wiring

Check the network cables

No MasterBus Terminator 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 or there are T-connections

Ring networks and T-connections are not allowed.
Check the connections of the network

6 TROUBLE SHOOTING

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 Status display for an
explanation.

If you cannot solve a problem using the fault finding table, contact your supplier or Mastervolt. Make sure you have the part
and serial number at hand.

24

ChargeMaster Plus 12/75-3, 12/100-3, 24/40-3, 24/60-3 – User and Installation Manual

Model

12/75-3

12/100-3

Product code

44310755

44311005

Nominal input voltage*

120/240V

120/240V

Nominal input frequency

50/60Hz

50/60Hz

Full load consumption

1300VA

1700VA

Max. AC input current (@ 240VAC)

5.6A

7.5A

Max. AC input current (@ 120VAC)

11.8A

14.9A

Nominal output voltage

14.25V

14.25V

Total charge current*

75A at 14.25V

100A at 14.25V

Number of battery outlets

3

3

Max. current DC 3 IN/OUT

75A/40A

100A/40A

Max. input voltage DC 3 IN/OUT

16V

16V

Charge characteristic*

IUoUo, automatic, 3-step+

Charge voltage Bulk*

14.4V

14.4V

Charge voltage Absorption*

14.25V

14.25V

Charge voltage Float*;

13.25V

13.25V

Max. absorption and max. bulk timer*

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

Minimum absorption time*

15 min.

15 min.

Maximum ripple voltage on DC

120mV pp

120mV pp

Battery type settings*

Flooded (default), GEL, AGM, MLI (Li-ion), Constant voltage (13,25 V)

Dimensions (mm)

383×250×126

383×250×126

Dimensions (inch)

15.0×9.8×5.0

15.0×9.8×5.0

Weight

5,9 kg (13 lbs)

5,9 kg (13 lbs)

Recommended battery capacity

140-800Ah

200-1000Ah

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

<5mA

<5mA

Temperature range

–25°C (–13°F) to 80°C (176°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

IP 23

IP 23

CZone connectivity

Yes

Yes

MasterBus connectivity

Yes

Yes

Powering capabilities for MasterBus

Yes

Yes

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

Ignition protected

Yes, conforming to SAE J1171/ISO 8846

7 TECHNICAL DATA

7.1 Specifications 12V models

* Adjustable, see chapter 4 for settings.

Specifications are subject to change without prior notice.

ChargeMaster Plus 12/75-3, 12/100-3, 24/40-3, 24/60-3 – User and Installation Manual

25

Model

24/40-3

24/60-3

Product code

44320405

44320605

Nominal input voltage*

120/240V

120/240V

Nominal input frequency

50/60Hz

50/60Hz

Full load consumption

1400VA

2000VA

Max. AC input current (@ 230VAC)

7.1A

10.1A

Max. AC input current (@ 120VAC)

12.8A

18.7A

Nominal output voltage

28.5V

28.5V

Total charge current*

40A at 28.5V

60A at 28.5V

Number of battery outlets

3

3

Max. current DC 3 IN/OUT

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

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

Max. input voltage DC 3 IN/OUT

32V

32V

Charge characteristic*

IUoUo, automatic, 3-step+

Charge voltage Bulk*

28.8V

28.8V

Charge voltage Absorption*

28.5V

28.5V

Charge voltage Float*;

26.5V

26.5V

Max. absorption and max. bulk timer*

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

Minimum absorption time*

15 min.

15 min.

Maximum ripple voltage on DC

240mV pp

240mV pp

Battery type settings*

Flooded (default), GEL, AGM, MLI (Li-ion), Constant voltage (13,25 V)

Dimensions (mm)

383×250×126

383×250×126

Dimensions (inch)

15.0×9.8×5.0

15.0×9.8×5.0

Weight

5,9 kg (13 lbs)

5,9 kg (13 lbs)

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

<10mA

Temperature range

–25°C (–13°F) to 80°C (176°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

IP 23

IP 23

CZone connectivity

Yes

Yes

MasterBus connectivity

Yes

Yes

Powering capabilities for MasterBus

Yes

Yes

When the charger is switched on and AC is available, it can power up to three non­powering devices.

Ignition protected

Yes, conforming to SAE J1171/ISO 8846

7.2 Specifications 24V models

* Adjustable, see chapter 4 for settings

Specifications are subject to change without prior notice.

26

ChargeMaster Plus 12/75-3, 12/100-3, 24/40-3, 24/60-3 – User and Installation Manual

7.3 Dimensions

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

ChargeMaster Plus 12/75-3, 12/100-3, 24/40-3, 24/60-3 – User and Installation Manual

27

7.4 3-step+ charging characteristics of flooded batteries

EMEA

Snijdersbergweg 93
1105 AN AMSTERDAM
The Netherlands

[phone]
[e-mail]

NORTH AMERICA

N86 W12500 Westbrook Crossing
Menomonee Falls, WISCONSIN 53051
USA

[phone], Option 1
[e-mail]

ASIA/PACIFIC

42 Apollo Drive, Rosedale
AUCKLAND 0632
New Zealand

+ 64 9 415 7261
[e-mail]

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