Mastervolt IVO SMART 12/30-2, IVO SMART 12/50-2 User Manual

Page 1

MASTERVOLT Snijdersbergweg 93, 1105 AN Amsterdam, The Netherlands Tel. +31-20-3422100 / Fax +31-20-6971006

USERS MANUAL

V2.0 March 2004

1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

2 Safety guidelines & measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

4 Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

7 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

8 Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

10 EC declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

11 Data sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Appendix A

12 Installation sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Appendix B

IVO SMART 12/30-2 & 12/50-2

117 Volt battery charger

-export models / U.S.A. version-

Page 2

2 March 2004

GENERAL INFORMATION / SAFETY GUIDELINES & MEASURES

1 GENERAL INFORMATION

GUARANTEE SPECIFICATIONS

Mastervolt guarantees that this unit has been built according to the legally applicable standards & specifications. Should work take place, which is not in accordance with the guidelines, instructions and specifications contained in this user's manual and the supplementary installation manual, then damage may occur and/or the unit may not fulfil its specifications. All of these matters may mean that the guarantee may become invalid.

QUALITY

During production and prior to their delivery, all our units are exhaustively tested and inspected.

The guarantee period is two years.

LIABILITY

Mastervolt can accept no liability for:

• damage due to use of the battery charger;

• possible errors in the manual and the results thereof.

2 SAFETY GUIDELINES & MEASURES

USE FOR INTENDED PURPOSE

The battery charger is constructed as per the applicable safety-technical guidelines. Use the battery charger only:

• for the charging of 12V lead acid batteries and the supply of users attached to these batteries, in permanent systems;

• connected to a dedicated double pole circuit breaker (MCB);

• with a fuse, protecting the wiring between charger output and battery;

• in a technical correct condition;

• in a closed, well-ventilated room, protected against rain, moist, dust and not condensing circumstances.

Never use the battery charger at locations where there is danger of gas- or dust explosion!

Use other than as mentioned under 2 is not considered to be consistent with the intended purpose. MASTERVOLT is not liable for any damage resulting from the above.

MAINTENANCE & REPAIR

If the battery charger is switched off during maintenance and/or repair activities, it should be secured against unexpected and unintentional switching on:

• switch off the connection with the AC power supply by unplugging the battery charger;

• switch off the AC circuit breaker;

• switch off the connection with the batteries or remove the charger fuse;

• be sure that third parties cannot reverse the measures taken.

If such are required, use only original spare parts.

WARNING FOR SPECIAL DANGERS

1 Use only fuses with the prescribed current level:

• AC supply fuse not greater than required for the current consumption;

• The charger fuse must be large enough for the maximum charger current and small enough to protect the charger‘s output cables.

2 Check the wiring at least once a year. Defects such as

loose connections, burned cables etc. must be corrected immediately.

3 Do not work on the charger or the system if it is still

connected to a current source. Only allow changes in your electrical system to be caried out by qualified electricians.

4 Connection and protection must be done in accor-

dance with local standards.

5 Do not open the cabinet of the charger. No serviceable

parts inside.

Page 3

March 2004 3

TECHNICAL DATA / TECHNOLOGY

3 TECHNICAL DATA

GENERAL

Model IVO 12/30-2 IVO 12/50-2 Function apparatus battery charger/rectifier Manufacturer Mastervolt, Amsterdam

INPUT

Voltage 117 Volt AC, -10+15% 117V AC, -10+15% Frequency 50/60 Hz, ± 5 Hz 50/60 Hz, ± 5 Hz Current 4.6A 6.4A Power factor 1 1 Efficiency 88% 88%

OUTPUT

Main output + Slave 3A 1 + Slave 1 + Slave Output voltage nominal: 12V DC nominal: 12V DC Charge characteristic three-step, fully automatic, IUoUo Kind of batteries open and sealed lead acid batteries Charge voltages 14.25V-13.25V 14.25V-13.25V Ripple voltage max. 100mV rms, resistive load, full power Current 30 Amps 50 Amps Short circuit current 30 Amps 50 Amps

ENVIRONMENTAL CHARACTERISTICS

Operating ambient temperature 0-100°F (-20 to +40°C); 100% output power Cooling forced, by means of a fan with variable speed Humidity max. 95% RV, not condensing

ENCLOSURE

Dimensions (hxwxd) 4’ x 8.3’ x 12.3’ (82 x 187 x 313 mm) Protection degree IP 21 Weight 5.7 lbs (2.6 kg)

Safety IEC 335-2-29

4 TECHNOLOGY

INTRODUCTION

The IVO battery charger is a fully-automatic high-efficiency battery charger/rectifier,developed and produced by Mastervolt Amsterdam. The IVO series goes with a family of advanced quality battery chargers. Mastervolt distributes these products worldwide. The battery charger posseses an outstanding charging technique in order to charge batteries rapidly, safely and in the same time supply the connected consumers. In addition, the charger is secured against short circuit, overload and high temperatures in an industrial enviroment.

CHARGING TWO OR MORE BATTERIES WITH BATTERY ISOLATORS

If two or more batteries needs to be charged at the same time, a battery isolator can be used. The battery isolator divides the various battery sets from one other, in order to

avoid one set discharging the other. Because there is always a voltage drop across the isolator of 0,7V the output voltage needs to be compensated. We can compensate this voltage drop by removing the “diode compensation” jumper on the front panel (see chapter 5).

CHARGING A 12V CRANKING BATTERY

In certain situations, it may occur that in addition to the main battery(ies) a cranking battery is used as well. The battery charger can charge a cranking battery at the same time as the main battery.

The second output has the same output voltage as the main output, 3 Amps maximum !

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TECHNOLOGY / INSTALLATION

THE BATTERY CHARGER AS FLOAT CHARGER

It is possible to use the charger as a “trickle” charger. The charger supplies a constant output voltage of 13.25V (26.5V). For this mode you can remove a jumper on the front (see chapter 5).

BATTERY SELECTION

The optimal charge voltage for a wet lead acid battery differs from the gel battery. Therefore it is possible to switch over to a higher float voltage (13,8V for 12V) necessary for gel batteries. You increase this output voltage by removing a jumper on the front panel (see chapter 5).

THEORY OF OPERATION

The IVO battery charger has a three-step charge characteristic (see fig. 1).

Phase 1: Main charge, “BULK”

The first step “BULK” starts after switching on the IVO charger. In this phase, the charger supplies the maximum current until the battery reaches 14.40V . When the battery reaches this limitation area the charge current wil decrease. Bulk duration is maximum 6 hours, depending on the battery’s condition and charge rate. The yellow “bulk” LED will light up during this phase.

Phase 2: “ABSORPTION”

The second step “ABSORPTION” starts automatically after the battery has reached a voltage of 14.25V. The battery is in this case charged approx. 80% or more.The charger remains in this “absorption” phase untill the charge current drops for a periode of 15 min. below 2.5A. If the charge current will not drop below 2.5A, a clock will switch the “absorption” mode off after 6 hours, while the battery is charged with a constant voltage up to 100% in “trickle charge”. The current consumption in the absorption mode depends on the capacity of the batteries and will decrease slowly. During the absorption phase both the “bulk” LED and the “absorption” LED will light up.

Phase 3: Trickle charge, “FLOAT”

The third stage, “FLOAT”, starts when the “absorption” phase has been completed. In the “float” mode, the charger automatically switches back to a lower output voltage of 13,25V. This voltage is sufficient to maintain the battery at a 100% charge. During this phase, the charge voltage can be entirely used for the supply of the users connected to the battery. If necessary the charger automatically switches back to the “absorption” mode. During this mode all yellow LED’s will light up.

Current consumption from mains or generator

The charger produces no phase shift, because the input current follows the AC voltage waveform so a power factor of 1.0 or “unity” is achieved. The shape of the input current waveform is the same as the input voltage e.g. sinusoïdal. Therefore the input current is very low compared to conventional chargers.

Low ripple on output

The charger has a very low ripple on the output, which prevents interference in the DC circuit. The ripple is less than 100 mV with a maximum battery load.

Automatic temperature charge voltage compensation

When a temperature sensor is connected to the start or service battery, the IVO Smart will automatically adjust the charge voltage with 30mV/ºC. The temperature sensor shall be mounted in such a way that a sensible indication is given from the battery temperature.

Automatic voltage sense compensation

The IVO Smart will automatically compensate for the voltage drop across the cable connection to the battery. The charger is programmed in such a way that a separate sense connection is no longer necessarily.

5 INSTALLATION

Install the IVO battery charger in a dry, well ventilated area, as close as possible to the batteries. Although the battey charger has a high efficiency, some heat will be produced. This heat will be discharged by a fan with variable speed. At installation of the battery charger be sure that:

• the air flow is not obstructed;

• no water and/or dust can enter the cabinet.

MOUNTING THE IVO CHARGER

The charger can be either horizontal or vertical mounted. We recommend vertical, because the heat convection is from bottom to top.

Fig. 1 Charge caracteristic IVO Smart.

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INSTALLATION

WIRING AND CONNECTIONS (see also chapter 12)

When connecting any auxiliary equipment and/or a battery isolator, proceed as follows:

• switch off the charger;

• switch off the AC mains or generator supply;

• isolate the DC distribution from the battery.

Battery wires

Keep the cable connection between charger and battery as short as possible. Use for the connections between the charger and battery or DC distribution the cable which is con-nected to the charger. If the lenght is not sufficient, then replace the whole cable for a longer one. In such a case, use cables with a larger diameter. If possible use coloured battery cables. I f this is not possible, mark the plus and the minus cables with coloured insulating tape, e.g. red for plus and blue for minus. Use the following diameters:

lenght up to 3 meter lenght above 3 meter

6 qmm / AWG 9 10 qmm / AWG 7

Connection of main batteries

The M5 cable connectors have to be connected to the charger. The minus cable (blue) on the -battery (min connection) of the battery charger. The plus cable (red) on the + main battery (plus-connection) of the charger. The M8 cable connectors have to be connected to the bat-tery or the DC distribution. The min cable (blue) on the min-connection of the battery or DC distribution. The plus cable (red) on the plus-connection of the battery or DC distribution.

Reversing the plus and the minus will damage the charger seriously.

Too thin cables and/or loose connections can cause dangerous overheating of the cables and/

or terminals. Therefore tighten all connections well, in or-der to limit as far as possible transition resistance, and use the battery cables of the correct diameter.

Connection of cranking battery

The distance between charger and cranking battery determines the required, minimal cable diameter. For cable lenghts up to 6 meters 2,5 qmm / AWG 13 must be used. When using long thin cables, it will take proportionately longer before a crancking battery is entirely charged. Therefore use, for longer distances, a larger diameter. The maximum charging current for the cranking battery is 3A. The char-ging current for the main battery will in this case be 3A less.

• Connect the minus of the cranking battery to the minus

of the main battery.

• Connect the plus of the cranking battery to the “+slave”

plus terminal of the charger (see chapter 12).

AC power supply

Check the voltage of your IVO charger and power source. This must be between 90 and 160 VAC. Connect the power cord of the IVO charger to the mains or generator.

As soon as the AC plug is connected to the mains, the charger will function immediately. The charger has no ON/OFF switch!

CONNECTION OF BATTERY ISOLATORS

If you connect options act as follows:

• unplug and remove the AC wire;

• disconnect the DC side of the battery and charger, first the battery.

CONNECTING ACCESSORIES

When connecting accessories handle as follows:

• Unplug the AC power cord

• Disconnect all DC Parts

Temperature sensor

Install the temperature sensor in such a way that an accurate measurement is given of the battery temperature. The IVO Smart battery charger is equipped with multiple modular jacks. The sensor can be connected to any of the modular jacks.

Basic remote control panel

The Basic remote control panel shall be connected by using a 6-core modular connection cable between the control panel and the modular analog remote jack.

Standard remote control panel

The standard remote panel shall be connected by using a 6-core modular connection cable between the panel and the digital remote modular jack. The communication protocol is based on a quasi RS 232 interface.

Adjustment interface & advanced remote panel

The Adjustment interface & Advanced remote panel shall be connected by using a 6-core modular connection cable between the panel and the digital remote modular jack. The communication protocol is based on a quasi RS 232 interface.

Battery isolator

If two or more batteries or battery sets must be charged simultaneously, often a battery isolator is used. A battery isolator isolates the different battery sets from one another, in order to prevent one discharging the other. A consequence of the battery isolator is a voltagedrop of 0,7 Volt. This voltage drop can be compensated by removing a jumper on the front panel of the charger.

Page 6

INSTALLATION / OPERATION / BATTERIES

2 battery set 3 battery set

BI 702 BI 703

For a proper installation, see the connection diagram included with the battery isolator. Steps:

1 Check if the charger, the main supply and the DC-

distribution are switched off.

2 Connect the battery isolator using cables with the same

diameter as the battery cables.

3 Compensate the voltage drop over these diodes by

removing the “diode compensation” jumper on the front of the charger.

4 Switch the charger on.

ADJUSTEMENTS

On the front side of the charger you find three jumpers, each for a specific application. You can easily remove the jumpers with a pincet or small pincer. Unplug the AC power cord prior to removing or placing a jumper.

Forced float

For industrial applications only.

Gel/wet battery

By removing this jumper the output voltage will be a constant “trickle charge” voltage of 13,8V.

Diode compensation

By removing this jumper the output voltage will be increased with 0,7 Volt.

6 OPERATION

The IVO charger has no ON/OFF switch!

Switching on:

The IVO charger will be switched on by plugging in the AC-power cord. One of the LED indicators will light up now and the charger starts immediately.

Turning off:

The IVO charger will be switched off by unplugging this power cord.

INDICATOR LEDS

FLOAT:

The battery charger is in a “trickle charge” mode, batteries are 100% charged.

ABSORPTION:

The batteries are still being charged, charge level is approx. 80%.

BULK:

The charger supplies the maximal voltage, the battery charge is less than 80%.

7 BATTERIES

DEFINITION OF THE BATTERY CAPACITY

Starting point is the consumption during a certain period without charging the battery. It is recommended not discharge the battery totally, but to keep 50% in spare. A consistent deep discharging decreases the lifetime of the battery. Take care of the reduced capacity on the end of the battery life (average 70%) and the temperature. According to abovementioned, the rule of thumb is:

• amps use x 2 = battery capacity.

TIPS TO INCREASE THE BATTERY LIFETIME

• Install and place the batteries in a cool and well ventilated enviroment. The acid in the batteries will damage the plates in a high tempe-rature environment. Alifetime of 5 year at 68°F (20°C), will be 2,5 at 86°F (30°C).

• Charge the battery immediately after a consistent deep discharge. Especially at high environment temperatures, sulfating occurs very fast. If the state of sulfating is not too bad, the battery will remain a part of his capacity after a few charge / recharge cycles.

Page 7

TROUBLE SHOOTING

8 TROUBLE SHOOTING

Malfunction Possible cause What to do

No output voltage and/or current No AC mains or fuse blown Check fuse, replace if necessary.

Mains or generator output voltage too low Check input voltage, must be between

90 and 160V (nominal 117V).

Output voltage too low but Battery load consumes more than the Reduce the battery load taken from charger supplies max. current charger can supply, the battery voltage batteries.

cannot increase more

Batteries not 100% charged Measure the battery voltage after a

while, this will be higher.

One or more battery cells having Check if the battery temperature short circuits is higher than normal.

Charge current too low Batteries almost fully charged Check if the charger is in the absorp-

tion mode. In this mode, the charge current will slowly decrease.

High ambient temperature If the ambient temperature is more than

104°F (40°C), the maximum charge current will be reduced automatically.

Mains too low When the mains voltage is less than

105V, the charger will regulate the current down.

Batteries not fully charged Charge current too low See “charge current too low”;

Current to load too high Decrease the battery load; Charge time too short Increase type of charger; Battery temperature too low Use temperature sensor; Defective battery (short circuit in cell) Replace the battery; Defective battery charger Check the charger.

Battery very fast empty Battery capacity reduced because: of:

• wastage Replace the batteries;

• sulphating/stagnation Charge/discharge for several times, this might help, otherwise replace batteries.

Batteries are warm/gassing Defective batteries (short circuit in cell) Replace batteries;

Battery temperature too high Use temperature sensor; Charge voltage too high Check jumper ‘battery isolator’

on front panel.

If you cannot solve the problem with this fault finding table, contact your Mastervolt Service Center. For a detailed distributor list, see www.mastervolt.com or contact our main office in Amsterdam, tel. +31-20-3422100.

Page 8

MAINTENANCE / EC DECLARATION

9 MAINTENANCE

The battery charger requires no specific maintenance. For a reliable and optimal operation of the IVO battery charger only the following is required:

• Check at least once a year the wire and cable connections.

• Keep the IVO charger dry, clean and in a dust-free area, in order to ensure a good heat discharge.

10 EC DECLARATION OF CONFORMITY

Manufacturer: MASTERVOLT Address: Snijdersbergweg 93

1105 AN AMSTERDAM The Netherlands

Herewith declares that: Product: IVO battery charger Model: IVO Smart 12/30-2, 117V

IVO Smart 12/50-2, 117V

Is in conformity with the provision of the EC EMC directive 89/336/EEC and amendments 92/31/EEC and 93/68/EEC.

The following harmonized standards have been applied: Generic emission standard EN 50081-1:1992 Generic immunity standard EN 50082-1:1997

And the safety directive 73 / 23 / EEC and amendment 93 / 68 / EEC with the following standard: Low voltage standard EN 60950: 2000

Amsterdam,

Dr. F.J. ter Heide, Managing director MASTERVOLT

Page 9

MASTERVOLT Snijdersbergweg 93, 1105 AN Amsterdam, The Netherlands Tel. +31-20-3422100 / Fax +31-20-6971006

APPENDIX A & B

V2.0. March 2004

IVO SMART 12/30-2 & 12/50-2

117 Volt battery charger

-export models / U.S.A. version-

Page 10

10 IVO Smart Appendix A

Page 11

IVO Smart Appendix A 11

11 DATA SHEETS IVO SMART 12/30-2 - 117V

MAIN INFORMATION

Design : by MASTERVOLT Manufacturer : ISO 9001 certified Model / name : IVO Smart 12/30-2 Product : battery charger/rectifier Article no : 43113010 Colour : • RAL 5021, wasserblau

• RAL 7037, grey

• RAL 9006 silver grey Weight excl. packing : 2.6 kg Shipping weight : 4 kg Cabinet type : Smart 1 cabinet Dimensions : (hxwxd) 4’ x 8.3’ x 12.3’ 82 x 187 x 313 mm

(excl. mounting brackets) Carton dimensions : (hxwxd) 5.1’ x 8.7’ x 13.8’ 130 x 220 x 350 mm Type of packing : carton recycable Available : for 117V / 50-60Hz Availability : normally from stock

TECHNICAL SPECIFICATIONS

Function apparatus : charging of 12V lead acid batteries and power simultanously loads Nominal input voltage : 120 AC, 1ph, 3wire, 50/60 Hz Input voltage range full specs : 90..160V, 50/60 Hz, ± 5% Input voltage range no-defects : 0..160V, 33-80 Hz Input current : at 120V AC: 4.6A Inrush current : no inrush current, soft start, according to IEC 1003-3 Power factor : 1, power factor controlled Max. input power : 540 Watt Efficiency : 81% Output voltage : nominal 12V DC Output current : nominal 30 Amps Charge characteristic : three-step, fully automatic, IUoUo, programmable Kind of batteries : open & sealed lead acid batteries Charge voltage 25°C : • bulk voltage 14.40V • absorption 14.25V

• wet float 13.25V • gel float 13.8V Return Amps : 2.5A Min. Absorption time : 15 minutes Max. Bulk/abs. time : 8 hours Return new cycle voltage : 12.8V, delay 30 seconds Temperature compensation : 30 mV/°C, by temperature sensor Voltage sense : fully automatic compensation Ripple voltage : max. 100mV rms, resistive load, full power Voltage accuracy : voltage ± 2% Current accuracy : current ± 3% Maximum output : • 30 Amps at 120 Volt at 177°F (25°C) ambient

• 25 Amps at 120 Volt at 104°F (40°C) ambient DC leakage drain : < 10 mA Number of outputs : one main output and one 3 Amps Slave Charger DC connections : external Jumper selections : • gel/wet battery selection

• forced to float

• diode splitter compensation

DATA SHEETS

IVO Smart 12/30-2 battery charger.

The IVO Smart can be installed in

various ways. The mounts can be

used in four different positions

(floor/wall/ceiling position).

Page 12

12 IVO Smart Appendix A

TECHNICAL SPECIFICATIONS

Remote indication : status bulk, absorption, float Remote connection : by modular plug-in jack - RJ12 Temperature connection : by modular plug-in jack - RJ12 Smart controls : QRS232 output by telephone plug - RJ42 Short circuit proctection : yes, reduced output max. 30 Amps Reverse polarity protection : yes, by internal fuse Over heat : yes, derating output and shut off by 80°C temperature on heatsink Storage temperature : -25°C to 80°C Operating ambient temperature : -20°C to 40°C, derating with 2.5% / °C > 40°C Humidity : maximum 95%, not condensing Vibration : according IEC 68-2-6 Cooling : mix of conventional and forced air cooling Forced cooling : by one variable speed maintenance free DC fan Environmental protection : IP21

Reliability/life time : • MTBF 30,000 hours, 6 years

• 1/4 life time period, Uin = 120V AC, Uout = 14,25, Iout = 30 Amps at 104°F Tamb (40°C)

• 3/4 life time period, Uin = 120V AC, Uout = 13,25, Iout = 30 Amps at 77°F Tamb (25°C)

ELECTRO MAGNETIC COMPATBILITY

Electro Magnetic Emission : better than EN 50081-1

(gen. emmission standard, scope; residiential, commercial & light industry)

Electro Magnetic Immunity : better than EN 50082-1 (gen. emmission standard, scope; residiential, commercial & light industry) Safety : according to IEC 335-2-29, polarity protected by means of a breaker, short break

WHAT TO DO IN CASE OF A DEFECT?

Consult your local Repair Center. See www.mastervolt.com for a complete listing.

COMPLIANCES

• CE

Is in conformity with the provision of the EC EMC directive 89/336/EEC and amandments 92/31/EEC, 93/68/EEC. The following harmonized standards have been applied: • Generic emission standard : EN 50081-1:1992

• Generic immunity standard : EN 50082-1:1997

• LLOYDS, DNV, ABS

Mastervolt has constructed this product for rugged circumstances in professional or leisure situations. This product can be type-approved individually. Price approx. US $ 1500 per certification.

• MANUFACTURED UNDER ISO 9001.

DATA SHEETS

DC connections of the IVO Smart 12/30-2 at the right (1x main output, 1x 3 Amps).

Main PCB of the IVO Smart.

Page 13

IVO Smart Appendix A 13

ACCESSORIES & REMOTES

Article no description 70404100 basic remote control LED’s 70403050 standaard remote contol LED’s current control

-- advanced remote control display with owner’s settings 41500500 IVO Smart temperature sensor

-- IVO Smart 12/30 cable set

-- IVO Smart remote cable set 21705000 Adjustment Interface

SERVICE INFORMATION

Article no description

-- sub assembly, main PCB board

-- complete aluminium heatsink

-- cover module

-- connection module

-- front indicator module

-- installation blocks

OPERATING PRINCIPLE

Fully automatic power factor corrected switch mode battery charger, suitable as power supply using a separate non-isolated pre regulator boost converter for power factor correction, followed by a double forward converter controlled by a combination of analogue hardware and microprocessor control.

DATA SHEETS

IVO Smart 12/30-2 battery charger. Main PCB of the IVO Smart 12/30-2.

PFC DC/DC



HARDWARE CONTROL

SOFTWARE CONTROL

remote select RS232

DC output

AC input

Aux. power supply

Adjustment Interface, art. no 21705000. The below mentioned data can be adjusted with this digital instrument:

• DC input voltage range (DC low, DC high)

• adjustment charge voltage (e.g. traction)

• ‘return’Amps

Page 14

14 IVO Smart Appendix A

DATA SHEETS

Set points register Setpoint

1 Min. bulk time 4 min. 2 Temperature variation 5.0 mV/C 3 Return to bulk time 30 sec. 4 Return to bulk voltage 13.00 V 5 Max. bulk/abs time 360 min. 6 Min. abs time 45 min. 7 Return Amps 2.5 Amps 8 Max. charge current 30 Amps 9 Bulk voltage 14.55 V 10 Abs voltage 14.35 V 11 Float voltage 13.30 V 12 Forced to float voltage 13.25 V 13 Gel voltage setting 55 mV 14 Diode compensation setting 60 mV 15 DC high alarm on 15.00 V 16 DC high alarm low 14.50 V 17 DC low alarm on 10.00 V 18 DC l ow alarm off 11.00 V 19 Alarm delay time 30 sec. 20 Reset data WWYY 21 Battery identification no 00

• Temperature variation 

5.0 mV/°C per cell

• Reference voltage 25°C

• Battery charging is not allowed  above +50°C and under -20°C

• 24 Volt 60 mV/°C  

5.0 mV/°C

Uref 25°C

forced float

gel/wet battery

diode compensation

standard IUoUo characteristic IUoUo char. increased with 0.6V IUoUo char. high float level IUoUo char. high float, increased with 0.

IU char. low float level IU char. low float, increased with 0.6V IU char. high float level IU char. high float, increased with 0.6 V

TEMPERATURE COMPENSATED CHARGING

charging voltage in V

15.0

14.5

14.0

13.5

13.0

12.5

12.0

-30 -20 -10 0 10 20 30 40 50 60

battery temperature in °C

float

absorption

25°C reference temperature

MAX. BULK/ABS TIME BULK TIME TOTAL CHARGE TIME CYCLE

ABS TIME FLO AT TIME

NEW CYCLE

min. bulk time

min. abs time

return to bulk time

MAX. OUTPUT VERSUS INPUT VOLTAGE

current in Amps

input voltage



50



 80 100 120 140 160 180 200 220 240 260

25°C reference temperature

0 44 50

output current in Amps

Tamb= 25°C

charging voltage in V

CHARGING CHARACTERISTICS

Page 15

IVO Smart Appendix A 15

11 DATA SHEETS IVO SMART 12/50-2 117V

MAIN INFORMATION

Design : by MASTERVOLT Manufacturer : ISO 9001 certified Model / name : IVO Smart 12/50-2 Product : battery charger/rectifier Article no : 04-31-15010 Colour : • RAL 5021, wasserblau

• RAL 7037, grey

• RAL 9006 silver grey Weight excl. packing : 2.6 kg Shipping weight : 4 kg Cabinet typ : Smart 1 cabinet Dimensions : (hxwxd) 4’ x 8.3’ x 12.3’ 82 x 187 x 313 mm

(excl. mounting brackets) Carton dimensions : (hxwxd) 5.1’ x 8.7’ x 13.8’ 130 x 220 x 350 mm Type of packing : carton recycable Available : for 117V / 60 Hz Availability : normally from stock

TECHNICAL SPECIFICATIONS

Function apparatus : charging of 12V lead acid batteries and power simultanously loads Nominal input voltage : 120V AC, 1ph, 3wire, 50/60 Hz Input voltage range full specs : 90..160V, 50/60 Hz, ± 5% Input voltage range no-defects : 0..160V, 33-80 Hz Input current : at 120V AC: 6.4A Inrush current : no inrush current, soft start, according to IEC 1003-3 Power factor : 1, power factor controlled Max. input power : 850 Watt Efficiency : 81% Output voltage : nominal 12V DC Output current : nominal 50 Amps Charge characteristic : three-step, fully automatic, IUoUo, programmable Kind of batteries : open & sealed lead acid batteries Charge voltage 25°C : • bulk voltage 14.40V • absorption 14.25V

• wet float 13.25V • gel float 13.8V Return Amps : 2.5 Amps Min. Absorption time : 15 minutes Max. Bulk/abs. time : 8 hours Return new cycle voltage : 12.8V, delay 30 seconds Temperature compensation : 30 mV/°C, by temperature sensor Voltage sense : fully automatic compensation Ripple voltage : max. 100mV rms, resistive load, full power Voltage accuracy : voltage ± 2% Current accuracy : current ± 3% Maximum output : • 50 Amps at 120 Volt at 77°F (25°C) ambient

• 45 Amps at 120 Volt at 104°F (40°C) ambient DC leakage drain : < 10 mA Number of outputs : one main output and one 3 Amps Slave Charger DC connections : external Jumper selections : • gel/wet battery selection

• forced to float

• diode splitter compensation

DATA SHEETS

IVO Smart 12/50-2 battery charger.

The IVO Smart can be installed in

various ways. The mounts can be

used in four different positions

(floor/wall/ceiling position).

Page 16

16 IVO Smart Appendix A

TECHNICAL SPECIFICATIONS

Remote indication : status bulk, absorption, float Remote connection : by modular plug-in jack - RJ12 Temperature connection : by modular plug-in jack - RJ12 Smart controls : QRS232 output by telephone plug - RJ42 Short circuit proctection : yes, reduced output max. 50 Amps Reverse polarity protection : yes, by internal fuse Over heat : yes, derating output and shut off by 80°C temperature on heatsink Storage temperature : -25°C to 80°C Operating ambient temperature : -20°C to 40°C, derating with 2.5% / °C > 40°C Humidity : maximum 95%, not condensing Vibration : according IEC 68-2-6 Cooling : mix of conventional and forced air cooling Forced cooling : by one variable speed maintenance free DC fan Environmental protection : IP23

Reliability/life time : • MTBF 30,000 hours, 6 years

• 1/4 life time period, Uin = 120V AC, Uout = 14,25, Iout = 50 Amps at 104°F Tamb (40°C)

• 3/4 life time period, Uin = 120V AC, Uout = 13,25, Iout = 50 Amps at 77°F Tamb (25°C)

ELECTRO MAGNETIC COMPATBILITY

Electro Magnetic Emission : better than EN 50081-1

(gen. emmission standard, scope; residiential, commercial & light industry)

WHAT TO DO IN CASE OF A DEFECT?

Consult your local Repair Center. See www.mastervolt.com for a complete listing.

COMPLIANCES

• CE

• Generic immunity standard : EN 50082-1:1997

• LLOYDS, DNV, ABS

Mastervolt has constructed this product for rugged circumstances in professional or leisure situations. This product can be type-approved individually. Price approx. US $ 1500 per certification.

• MANUFACTURED UNDER ISO 9001.

DATA SHEETS

DC connections of the IVO Smart 12/50-2 at the right (1x main output, 1x 3 Amps).

Main PCB of the IVO Smart.

Page 17

IVO Smart Appendix A 17

ACCESSORIES & REMOTES

Article no description 70404100 basic remote control LED’s 70403050 standard remote contol LED’s current control

-- advanced remote control display with owner’s settings 41500500 IVO Smart temperature sensor

-- IVO Smart 12/50 cable set

-- IVO Smart remote cable set 21705000 Adjustment Interface

-- Smart alarm control box

SERVICE INFORMATION

Article no description

-- sub assembly, main PCB board

-- complete aluminium heatsink

-- cover module

-- connection module

-- front indicator module

-- installation blocks

OPERATING PRINCIPLE

DATA SHEETS

IVO Smart 12/50-2 battery charger. Main PCB of the IVO Smart 12/50-2.

PFC DC/DC



HARDWARE CONTROL

SOFTWARE CONTROL

remote select RS232

DC output

AC input

Aux. power supply

Adjustment Interface, art. no 21705000. The below mentioned data can be adjusted with this digital instrument:

• DC input voltage range (DC low, DC high)

• adjustment charge voltage (e.g. traction)

• ‘return’Amps

Page 18

18 IVO Smart Appendix A

DATA SHEETS

Set points register Setpoint

1 Min. bulk time 4 min. 2 Temperature variation 5.0 mV/C 3 Return to bulk time 30 sec. 4 Return to bulk voltage 13.00 V 5 Max. bulk/abs time 360 min. 6 Min. abs time 45 min. 7 Return Amps 2.5 Amps 8 Max. charge current 50 Amps 9 Bulk voltage 14.55 V 10 Abs voltage 14.35 V 11 Float voltage 13.30 V 12 Forced to float voltage 13.25 V 13 Gel voltage setting 55 mV 14 Diode compensation setting 60 mV 15 DC high alarm on 15.00 V 16 DC high alarm low 14.50 V 17 DC low alarm on 10.00 V 18 DC l ow alarm off 11.00 V 19 Alarm delay time 30 sec. 20 Reset data WWYY 21 Battery identification no 00

• Temperature variation 

5.0 mV/°C per cell

• Reference voltage 25°C

• Battery charging is not allowed  above +50°C and under -20°C

• 24 Volt 60 mV/°C  

5.0 mV/°C

Uref 25°C

forced float

gel/wet battery

diode compensation

standard IUoUo characteristic IUoUo char. increased with 0.6V IUoUo char. high float level IUoUo char. high float, increased with 0.

IU char. low float level IU char. low float, increased with 0.6V IU char. high float level IU char. high float, increased with 0.6 V

TEMPERATURE COMPENSATED CHARGING

charging voltage in V

15.0

14.5

14.0

13.5

13.0

12.5

12.0

-30 -20 -10 0 10 20 30 40 50 60

battery temperature in °C

float

absorption

25°C reference temperature

MAX. BULK/ABS TIME BULK TIME TOTAL CHARGE TIME CYCLE

ABS TIME FLO AT TIME

NEW CYCLE

min. bulk time

min. abs time

return to bulk time

MAX. OUTPUT VERSUS INPUT VOLTAGE

current in Amps

input voltage



50



 80 100 120 140 160 180 200 220 240 260

25°C reference temperature

0 44 50

output current in Amps

Tamb= 25°C

charging voltage in V

CHARGING CHARACTERISTICS

Page 19

Appendix B 19

MASTERVISION MODULAR SWITCHBOARDS

panel code

part number

CAUTION

C-3-RS

07-04-03040

1. Lethal voltages exist on your vessel. Make sure all shore power, onboard generating sources and batteries are disconnected before beginning installation of your electrical panel.

2. AC modules will have lethal voltages on the bus bars and terminals. The coating on these bars is for identification only and should not be relied on as a insulator. Additional safety enclosures may be required in some installations.

3. Make sure all AC modules are bonded to the shipís AC ground bus. When grouping modules together to form your panel, a single ground may be used. Use a resistance meter to verify ground to all modules.

The standard remote panel is a useful power device for remote control of the Mass an IVO smart Mastervolt battery chargers. The standard remote control does indicate the status of the charge control by six high power leds and control the output current by setting the potential meter. The remote control is easy to install by a plug-in standard twisted six pole RJ45 telephone plug between the digital rs232 output of the charger and the panel. The serial communication of the remote control and the charger is based on rs232 technology. The remote panel can be used as an interface for a custom made panel or for a dual remote indicator. The standard remote panel has a CSI (csi=charger status interface) and a DC high/low alarm. The two potential free change-over contacts indicate if the charger is ON or in general failure. The DC alarm set points can be adjusted in the charger by use of the adjustment interface.

The standard remote panel

Specifications

Remote cable: Connector RJ45, 6 pole, male Max length 6 meter, max Type twisted wire External led drive: Imax 5 mA Umax 2,5V External current control R pot cc 0..1kOhm 0..100% General CSI alarm Max rating 1 Amp, 30 VDC NC-on When the charger is off or the charger is in failure, the normally closed contact is closed C Common NO-on When the charger is on and no-failure is indicated the normally open contact is closed DC-high/low alarm (combined function with CSI) Max rating 1 Amp, 30 VDC NC-on When there is no DC failure, the normally closed contact is closed C Common NO-on When there is a DC failure the normally open contact is closed Connectors 0,75 mm2

description: type:

dimensions panel (wxh): panel depth:

SPECIFICATIONS

remote standard charger control for Mass & IVO smart chargers

120 x 65 mm 40 mm

on - bulk charge

failure

float

absorption

Charger Control

current output

external LED failure external LED bulk external LED 20-40% external LED absorption external LED 60-80% external LED float

6 pole telephone jack RJ 45

charger

normally closed normally open common

DC alarm

CSI alarm

external current control

normally closed normally open common

CSI failure

Bat TC failure Battery temperature sensor out of range <20°C & >60°C Voltage sense failure Voltage sense out of range >3 VDC Sys. temp. failure Charger is out of temperature range "overload" (>75--85 C) Short break indicator Charger in reduced current mode (short break mode) Uout <4..5VDC

DC alarm Battery range out of range (with standard setting of charger)

DC low on 10.0 20.0 VDC DC low off 11.0 22.0 VDC DC high on 16.0 32.0 VDC

Delay time 30 30 SEC

12V 24V

DC high off 15.0 30.0 VDC

Page 20

20 Appendix B

CAUTION

These products fully comply to the latest CE norms in force from Januari 1st 1996 and are

produced to ISO 9001 standards.

ISO 9001

1. Lethal voltages exist on your vessel. Make sure all shore power, onboard generating sources and batteries are disconnected before beginning installation of your electrical panel.

The basic remote panel is a useful power device for remote control of the Mass an Ivo smart Mastervolt battery chargers. The basic remote control does indicate the status of the charge control by six high power leds. The remote control is easy to install by a plug-in standard twisted six pole RJ45 telephone plug between the analog output of the charger and the panel. The communication of the remote control and charger is based on analog technology. The remote panel can be used as an interface for a custom made panel or for a dual remote indicator. The basic remote panel has a combined CSI-DC/alarm (csi=charger status interface). The potential free change-over contacts indicate if the charger is ON or in general failure. The DC alarm set points can be adjusted in the chargers by use of the adjustment interface.

The basic remote panel

Specifications

Remote cable: Connector RJ45, 6 pole, male Max length 6 meter, max Type twisted wire

External led drive: Imax 5 mA Umax 2,5V

General CSI alarm Max rating 1 Amp, 30 VDC NC-on When the charger is off or the charger is in failure, the normally closed contact is closed C Common NO-on When the charger is on and no-failure is indicated the normally open contact is closed Connectors 0,75 mm2

MASTERVISION MODULAR SWITCHBOARDS

panel code

part number

C-4-RB

07-04-04100

DC low on 10.0 20.0 VDC DC low off 11.0 22.0 VDC DC high on 16.0 32.0 VDC

Delay time 30 30 SEC

12V 24V

DC high off 15.0 30.0 VDC

Combined CSI failure and DC high/low alarm Bat TC failure Battery temperature sensor out of range <20°C & >60°C

Voltage sense failure Voltage sense out of range >3 VDC Sys. temp. failure Charger is out of temperature range ìoverloadî (>75--85 C) Short break indicator Charger in reduced current mode (short break mode) Uout <4..5VDC

DC alarm Battery range out of range (with standard setting of charger)

failure

Inverter Control

failure

float

bulk

absorption

Charger Control

Charger Output

current control

failure

float

bulk

absorption

Charger Control

on - bulk charge

failure

float

absorption

Charger Control

for Mass & IVO smart chargers

60 x 65 mm 40 mm



description: type:

dimensions panel (wxh): panel depth:

SPECIFICATIONS

remote basic charger control



common normal open normal closed

external LED failure

external LED bulk

external LED 20-40%

external LED absorption

external LED 60-80%

external LED float

6 pole telephone jack RJ 45

charger

NC NO

DC+CSI

alarm contact

Page 21

IVO Smart Appendix B 21

INSTALLATION SHEET

+ Slave

digital jack: smart/standard/remote

analogue jack: smart/basic/remote panel

temp. sensor

RS 232

forced to float

gel/wet type

diode compensation 0.6V

jumper selection

main output 1

common min

AC in

start

service

service 1

Slave + charger

plus

main output 1

common min

12 INSTALLATION SHEET IVO SMART

Page 22

22 IVO Smart Appendix B

AC in

start

service

service 1

Slave + charger

plus

main output 1

common min

failure

Inverter Control

failure

float

bulk

absorption

Charger Control

Charger Output

current control

failure

float

bulk

absorption

Charger Control

on - bulk charge

failure

float

absorption

Charger Control

Basic panel.

on - bulk charge

failure

float

absorption

Charger Control

current output

Standard panel.

Page 23

Page 24

MASTERVOLT

Snijdersbergweg 93, 1105 AN Amsterdam, The Netherlands

Tel.: +31-20-3422100 Fax: +31-20-6971006