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

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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
5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
7 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
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-
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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.
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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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4
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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5
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.
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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.
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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.
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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
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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
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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).
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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
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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.
6
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
25°C reference temperature
0 44 50
output current in Amps
Tamb= 25°C
charging voltage in V
CHARGING CHARACTERISTICS
30
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)
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 12/50-2 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
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 12/50-2 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
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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.
6
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
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.
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 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)
on
failure
Inverter Control
on
failure
float
bulk
absorption
Charger Control
Charger Output
current control
on
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
C
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
on
failure
Inverter Control
on
failure
float
bulk
absorption
Charger Control
Charger Output
current control
on
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
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