Mastervolt MASS 24/50-2, MASS 3-24/100, MASS 24/100, MASS 24/75, MASS 48/50 Installation Manual

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Mass Charger

MASS 24/50-2; 24/75; 24/75 (120V);

24/100; 3-24/100; 48/25; 48/50

FULLY AUTOMATIC BATTERY CHARGER

USER AND INSTALLATION MANUAL

10000001888/02

To download this manual in other languages, please

visit our website: www.mastervolt.com

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Mass Charger 24/50-2, 24/75, 24/75 (120V), 24/100, 3-24/100, 48/25, 48/50 – User and Installation Manual

TABLE OF CONTENTS

1 GENERAL INFORMATION ........................................ 3

1.1 Use of this manual .............................................. 3

1.2 Validity of this manual ......................................... 3

1.4 Disclaimer ........................................................... 3

1.5 Identification label ............................................... 3

1.6 Correct disposal of this product .......................... 3

2 SAFETY INSTRUCTIONS .......................................... 4

2.1 General ............................................................... 4

2.2 Explosive gases .................................................. 4

2.3 Warnings regarding the use of batteries ............. 4

2.4 Warning regarding life support applications ........ 5

2.5 Guarantee specifications ................................ .... 5

3 PRODUCT DESCRIPTION ......................................... 6

3.1 The 3-step+ charge process ............................... 6

3.2 Dimensions ......................................................... 6

4 INSTALLATION .......................................................... 7

4.1 Location .............................................................. 7

4.2 Connections ........................................................ 7

4.3 Wiring 7

4.3.1 AC wiring ................................................. 7

4.3.2 AC safety grounding ................................ 7

4.3.3 DC wiring ................................................. 8

4.3.4 Connection of main batteries ................... 8

4.4 Battery capacity .................................................. 8

4.5 Battery isolator .................................................... 8

4.6 Connection of second battery (3A output) .......... 8

4.7 Temperature sensor ........................................... 8

4.8 Voltage sense ..................................................... 9

4.9 Alarm function ..................................................... 9

4.9.1 Standard alarm mode .............................. 9

4.9.2 DC alarm mode ....................................... 9

4.10 RJ12 splitter for enclosure C2 ............................. 9

4.11 Overview connection compartment ................... 10

4.12 Things you need ................................................ 10

4.13 Connection ........................................................ 11

4.14 Installation step-by-step..................................... 12

4.15 Commissioning after installation ........................ 13

4.15.1 General .................................................. 13

4.15.2 MasterBus .............................................. 13

4.16 Decommissioning .............................................. 13

4.17 Storage and transportation ................................ 13

5 DIP SWITCH SETTINGS ........................................... 14

5.1 DIP switch operation ......................................... 14

5.2 DIP switch functions .......................................... 14

6 OPERATION ............................................................. 15

6.1 Switching on/off ................................................. 15

6.2 Reset the Mass Charger.................................... 15

6.3 Equalize mode ................................................... 15

6.4 LED indicators ................................................... 15

7 MASTERBUS ............................................................ 16

7.1 About MasterBus ............................................... 16

7.2 Event based commands .................................... 16

7.3 How to set up a MasterBus network .................. 16

7.4 MasterBus Settings ........................................... 16

8 TROUBLE SHOOTING ............................................. 19

9 TECHNICAL DATA ................................................... 20

9.1 Specifications .................................................... 20

9.2 Characteristics ................................................... 22

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Mass Charger 24/50-2, 24/75, 24/75 (120V), 24/100, 3-24/100, 48/25, 48/50 – User and Installation Manual

1 GENERAL INFORMATION

1.1 Use of this manual

This manual contains important safety and operating instructions for the safe and effective operation, maintenance and possible correction of minor malfunctions of the Mass Charger. It is therefore obligatory that every person who works on or with this product is completely familiar with the contents of this manual, and that he/she carefully follows the instructions and important safety instructions contained herein.

1.2 Validity of this manual

All of the specifications, provisions and instructions contained in this manual apply solely to standard versions of the Mass Charger delivered by Mastervolt.

This manual is valid for the following models:

Part no

Model

Enclosure type

40020506

Mass 24/50-2 230V/50-60Hz

40020756

Mass 24/75 230V/50-60Hz

40120756

Mass 24/75 120V/60-50Hz

40021006

Mass 24/100 230V/50-60Hz

40031006

Mass 3-24/100 400V 3 phase

40040256

Mass 48/25 230V/50-60Hz

40040506

Mass 48/50 230V/50-60Hz

These models are further mentioned as “Mass Charger”. Mastervolt offers a wide range of products for your

electrical installation. For an extensive overview of all our products, please visit our website www.mastervolt.com.

1.3 Liability

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

Charger.

 Use that is inconsistent with the purpose of the

product.

 Possible errors in the manuals and their results.

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.

1.4 Identification label

Part number Serial number K201R0010 with device version “R”

Figure 1. Identification label

The identification label is located at the right-hand side of the Mass Charger. Important technical information required for service and maintenance can be derived from the identification label.

CAUTION!

Never remove the identification label.

1.5 Correct disposal of this product

This product is designed and manufactured with high quality materials and components, which can be recycled and reused. When this crossed-out wheeled bin symbol is attached to a product, it means the product is covered by the European Directive 2012/19/EU.

Please be informed about the local separate collection system for electrical and electronic products. Please act according to your local rules and do not dispose of your old products with your normal household waste.

CERTIFICATES

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Mass Charger 24/50-2, 24/75, 24/75 (120V), 24/100, 3-24/100, 48/25, 48/50 – User and Installation Manual

2 SAFETY INSTRUCTIONS

Read the entire manual before using the Mass Charger.

Keep this manual in a secure place.

WARNING

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

2.1 General

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

Mass Charger 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 Mass Charger in a non-ventilated room, overheating may result.

2 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.

3 The Mass Charger is designed to be permanently

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

4 Make sure that all wiring is properly installed and in

good electrical condition; and that wire size is large enough for AC current rating of the Mass Charger. Check the wiring on a regular base, at least once a year. Do not use the Mass Charger when the wiring is undersized or damaged.

5 Do not operate the Mass Charger if it has received a

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

6 Except for the connection compartment (see section

Overview connection compartment4.11 on page 10), the Mass Charger may not be opened or disassembled. There are no serviceable parts inside the cabinet. Take it to qualified, authorized and trained service personnel when service or repair is required. Incorrect reassembly may result in a risk of electric shock or fire. Only qualified, electrician installers are authorized to open the connection compartment.

7 To reduce risk of electric shock, disconnect the Mass

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

8 The Mass Charger 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.

9 Short circuiting or reversing polarity will lead to

serious damage to batteries, Mass Charger, wiring as well as accessories. Fuses cannot prevent damage caused by reversed polarity and the warranty will be void.

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

which is appropriate for electrical equipment.

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

external connections to the Mass Charger 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 Mass Charger, 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.

3 DANGER: To reduce the risk of explosion – Never

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

2.3 Warnings regarding the use of batteries

1 Someone should be within range of your voice or

close enough to come to your aid when you work near a lead-acid battery.

2 Have plenty of fresh water and soap nearby in case

battery acid contacts skin, clothing, or eyes.

3 Wear complete eye protection and clothing protection.

Avoid touching eyes while working near battery.

4 If battery acid contacts skin or clothing, wash

immediately with soap and water. If acid enters eye, immediately flood eye with running cold water for at least 10 minutes and get medical attention immediately.

5 NEVER smoke or allow a spark or flame in vicinity of

a battery or engine.

6 Do not short circuit batteries, as this may result in

explosion and fire hazard! Be extra cautious to reduce risk of dropping a metal tool onto a battery. It might

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Mass Charger 24/50-2, 24/75, 24/75 (120V), 24/100, 3-24/100, 48/25, 48/50 – User and Installation Manual

spark or short-circuit battery or other electrical part and may cause explosion.

7 Remove personal metal items such as rings,

bracelets, necklaces, and watches when working with a battery. A battery can produce a short-circuit current high enough to weld a ring or the like to metal, causing a severe burn.

8 Only use the Mass Charger for charging Lead-acid,

NiCad and Li-ion batteries and the supply of users attached to these batteries, in permanent systems. Do not use the Mass Charger for charging dry-cell batteries that are commonly used with home appliances. These batteries may burst and cause

injury to persons and damage to property. 9 NEVER charge a frozen battery. 10 Excessive battery discharge and/or high charging

voltages can cause serious damage to batteries. Do

not exceed the recommended limits of discharge level

of your batteries. 11 If it is necessary to remove a battery, always remove

the grounded terminal from the battery first. Make

sure all accessories are off, so as not to cause an arc. 12 Be sure that the area around the battery is well

ventilated while the battery is being charged. Refer to

the recommendations of the battery manufacturer. 13 Batteries are heavy! It may become a projectile if it is

involved in an accident! Ensure adequate and secure

mounting and always use suitable handling equipment

for transportation. 14 Study all battery manufacturer’s specific precautions

while charging and recommended rates of charge.

Note that the Mass Charger 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.

2.4 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.

2.5 Guarantee specifications

Mastervolt guarantees that this unit has been built according to the legally applicable standards and specifications. Should work take place, which is not in accordance with the guidelines, instructions and specifications contained in this user manual, then damage may occur and/or the unit may not fulfil its specifications. All of these matters may mean that the guarantee becomes invalid. The guarantee is limited to the costs of repair and/or replacement of the product. Costs for installation labour or shipping of the defective parts are not covered by this guarantee.

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Mass Charger 24/50-2, 24/75, 24/75 (120V), 24/100, 3-24/100, 48/25, 48/50 – User and Installation Manual

3 PRODUCT DESCRIPTION

The Mass charger is a fully automatic, high efficiency battery charger/rectifier. The Mass Charger not only charges batteries rapidly and safely, it supplies the connected consumers at the same time. In addition, the Mass Charger is secured against short circuit, overload and high temperatures in an industrial environment.

3.1 The 3-step+ charge process

The Mass charger is equipped with an intelligent 3-step+ charge characteristic which takes care of an optimal charge of your batteries. See Figure 2 and Figure 9 (page

22) for more details. Figure 2. the 3-step+ charge process.

3.2 Dimensions

C2 enclosure (Mass 24/50 and 48/25)

C3 enclosure (other models)

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Mass Charger 24/50-2, 24/75, 24/75 (120V), 24/100, 3-24/100, 48/25, 48/50 – User and Installation Manual

4 INSTALLATION

During installation and commissioning of the Mass Charger, the important safety instructions are applicable at all times. See chapter 2 on page 4.

Please check the contents of the box before you start with the installation. The contents of the box need to be:

 the Mass battery charger;  battery temperature sensor (incl. 6m cable);  a MasterBus terminator;  the user manual.

If one of these items is missing, please contact your supplier.

4.1 Location

Choosing a location to install:  Install the Mass Charger in a well-ventilated room

protected against rain, snow, spray, vapour, bilge, moisture and dust.

 Ambient temperature: 0…60°C/32°F…140°F; (power

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

 Humidity: 0-95% non-condensing.  Never use the Mass Charger at a location where there

is danger of gas or dust explosions

 Mount the Mass Charger in such a way that

obstruction of the airflow through the ventilation openings is prevented. No objects must be located within a distance of 10cm/4inch around the Mass Charger.

 Mount the Mass Charger vertically, with the connecting

cables downwards.

 Do not install the Mass Charger in the same

compartment as the batteries. Do not mount the Mass Charger straight above the batteries because of possible corrosive sulphur fumes.

4.2 Connections

Before making the connection between the battery charger and the system, be sure that the AC and DC system are switched off. Remove the fuses in order to protect yourself against unexpected start up.

4.3 Wiring

CAUTION!

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

4.3.1 AC wiring

Check if the voltage of your mains source or generator corresponds with the AC input voltage of the battery charger as mentioned on the type number plate. See section 1.4 on page 3.

It is important that the green/ yellow earth wire is ± 1 cm (0.4 inch) longer than the other wires. By accidentally pulling at the cable, the earth wire stays connected to the Mass Charger longer which offers additional safety.

For a safe installation the correct wire cross section must be applied. Do not 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):

AC Current

Minimum cross section:

6-12A

1.5mm²

14AWG

12-20A

2.5mm²

12AWG

20-32A

4.0mm²

10AWG

Connection of AC wiring and recommended colours

 230V [120V] installations:

Wire colour

Meaning

Must be connected to:

Brown or black [black]

Phase

L1 Blue [white]

Neutral

Green/yellow [green]

Earth

PE/GND

 400V installations (Mass 3-24/100):

Wire colour

Meaning

Must be connected to:

Brown/black/grey

Phase

L1, L2, L3

Green/yellow

Earth

PE/GND

4.3.2 AC safety grounding

WARNING

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

CAUTION!

For safe installation it is necessary to insert a RCD (Residual Current Device; earth leakage switch) in the AC input circuit of the Mass Charger.

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Mass Charger 24/50-2, 24/75, 24/75 (120V), 24/100, 3-24/100, 48/25, 48/50 – User and Installation Manual

4.3.3 DC wiring

Keep the cable connection between charger and batteries as short as possible. If available, use coloured battery cables. If this is not possible, mark the plus and the minus cables with coloured insulating tape (e.g. red for plus and blue/black for minus). Use the following diameters:

Mass Charger

Length <3 m

Length 3-6 m

Mass 24/50-2 MB

25mm²

35mm²

Mass 24/75 MB

35mm²

50mm²

Mass 24/75 (120V) MB

35mm²

50mm²

Mass 24/100 MB

50mm²

70mm²

Mass 3-24/100 MB

50mm²

70mm²

Mass 48/25 MB

10mm²

16mm²

Mass 48/50 MB

25mm²

35mm²

4.3.4 Connection of main batteries

1 Pull the cables through the cable glands of the Mass

Charger.

2 Crimp on ring terminals to the cable:

 ring M6 for 24/50-2 and 48/25;  ring M8 for 24/75, 24/75 (120V), 24/100, 48/50

and 3-24/100.

3 Connect the cables to the terminals of the Mass

Charger. Pay attention to the polarity, positive on positive/negative on negative.

4 Integrate a suitable fuse (charger fuse) in the positive

cable. When using a DC distribution with fuses, no additional fuse is necessary.

5 Cut the cables to length and crimp on the ring

terminals. Connect the cable to the DC distribution or batteries.

CAUTION!

Reversing the positive and negative battery poles will severely damage the Mass Charger.

Lay the positive and negative cables next to each other to limit the electromagnetic field around the cables. The negative cable should be connected directly to the negative post of the battery bank or the ground side of a current shunt. Do not use the hull or chassis frame as the negative conductor.

4.4 Battery capacity

Always follow the instructions published by the battery manufacturer.

Mass Charger

Recommended battery capacity

Mass 24/50-2

100Ah

–

500Ah

Mass 24/75

150Ah

–

750Ah

Mass 24/75 (120V)

150Ah

–

750Ah

Mass 24/100

200Ah

–

1000Ah

Mass 3-24/100

200Ah

–

1000Ah

Mass 48/25

50Ah

–

250Ah

Mass 48/50

100Ah

–

500Ah

4.5 Battery isolator

If one or more batteries or battery sets must be charged at the same time via one output, a battery isolator should be used. This isolates the different battery sets to prevent one discharging the other. Mastervolt offers several Battery Isolators. Please refer to www.mastervolt.com .

A battery isolator causes a voltage drop of 0.6V. This can be compensated in two ways:

 By changing DIP switch 4 to On (Diode enabled);  By using the voltage sense function (see section 4.8

on page 9);

CAUTION!

Never use both methods. Your batteries will be overcharged and severely damaged!

If you use a ‘voltage drop free’ battery isolator, like the

Mastervolt Battery Mate, no compensation is needed. For a proper installation, see the connection diagram that

comes with the battery isolator.

4.6 Connection of second battery (3A output)

The Mass 24/50-2 MB is standard equipped with a second charge output which can be used to give a maintenance charge to a small second battery set like a starter battery. The maximum charge current of the second output is 3A, which comes from the main output.

 Use 2.5 to 4mm2 cable for the connection.  Connect the minus of the second battery to the minus

of the main battery.

 Connect the plus of the second battery to the +3A

terminal of the Mass Charger (Figure 4 and Figure 5).

 Integrate a 10A slow blow fuse in the plus cable.

4.7 Temperature sensor

The standard temperature sensor is provided with 6m cable and a double-sided tape for easy installation.

1. Make sure that the side of the battery that you want to

place the sensor, is clean and grease-free.

2. Remove the piece of paper from the tape and stick

the sensor on the battery.

3. Plug the modular cable into the terminal at the right of

the Mass Charger (see Figure 4 on page 10). For the C3 enclosure (refer to specifications) both "RS232" and "analog" are suitable.

It is not necessary to shorten the cable. When you want to shorten it anyway please notice the polarity of the plug and use the old connector as an example. Now when the battery temperature is low, the charge voltage increases and when the battery temperature is high, the charge voltage is decreased. This prevents

overcharge, and gassing, which increases the battery’s life

time substantially.

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Mass Charger 24/50-2, 24/75, 24/75 (120V), 24/100, 3-24/100, 48/25, 48/50 – User and Installation Manual

Figure 3. Temperature compensated charging

4.8 Voltage sense

If required, DC cable losses can be compensated by using the sense function. This will shorten the charge time.

1. Use 0,75mm2, preferably red and black wire and

secure these with fuses of 2A slow blow.

2. Connect the wires with the two upper terminals of the

green connector at the right side of the cabinet (see Figure 4 on page 10). Pay extra attention to the polarity of the wires, red on +S and black on -S.

3. Now connect the other side of the wires: black on the

minus of the battery and red on the plus of the battery.

4.9 Alarm function

To control external equipment, the charger is equipped with a potential free contacts alarm relay; see Figure 4 on page 10. The alarm function has two modes: standard (factory setting) and DC alarm mode (continuous mode). The maximum switch current of the relay is 1A. Exceeding the setpoints will activate the alarm (see page 17).

4.9.1 Standard alarm mode

In this mode the relay responds to all fault conditions that the Mass Charger can detect such as: no AC input voltage, low DC voltage, voltage sense failure, temperature sense failure.

4.9.2 DC alarm mode

To enable this mode a DIP switch setting needs to be changed (switch 1 and 2 at ON). The alarm now works as a DC alarm and responds to the battery voltage only.

Note: In the DC alarm mode the electronics stay active

permanently and drain a very small current of ±25mA, also when the Mass Charger is switched off.

4.10 RJ12 splitter for enclosure C2

The RJ12 connector (QRS232 communication port) can be used to connect the battery temperature sensor or the remote panel (not included). Use a RJ12-splitter to connect both at the same time (not included).

Charge voltage (V)

Battery temperature (°C)

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Mass Charger 24/50-2, 24/75, 24/75 (120V), 24/100, 3-24/100, 48/25, 48/50 – User and Installation Manual

4.11 Overview connection compartment

C2 ENCLOSURE

1 Screw terminals AC input: L1, N, PE

(24/100-3ph: L1, L2, L3, PE) 2 Earth stud 3 MasterBus connector 4 MasterBus connector 5 Output (battery) positive connector

(maximum 3A) 6 RS232/Temperature sensor connector 7 Analog/Temperature sensor connector 8 Output (battery) positive connector 9 Output (battery) negative connector 10 Voltage sense/ potential free alarm

contact

C3 ENCLOSURE

Figure 4. Overview connections Mass Charger

4.12 Things you need

Make sure you have all the parts you need to install the Mass Charger:

Product

Quantity

Mass Charger (included)

Battery temperature sensor with cable and plug (included)

DC cable to connect the positive DC connection (+) of the Mass Charger to the positive pole of the DC distribution; for specifications see section 4.3.3 on page 7

DC cable to connect the negative DC connection (–) of the Mass Charger to the negative pole of the DC distribution; for specifications see section 4.3.3 on page 7

DC fuse holder with a DC fuse, to be integrated in the positive DC cable

Screws/bolts (Ø 6mm) (with plugs) to mount the cabinet to a surface. Use mounting materials which are suitable to carry the weight of the Mass Charger

AC cable* to connect the AC input to an external power source (e.g. a shore connection or a generator set)

Batteries. See section 4.4 on page 8 for recommended capacity

Appropriate and reliable cable terminals, cable lugs, battery terminals and cord end terminals

* Double insulated three-wire cable with wire colours according to the locally applicable regulations. The applicable length and wire diameter depend on the electrical installation (see section 4.3.1 on page 7).

We recommend as a minimum tool kit:

 Socket wrench 13mm to fix the DC input (battery) cables  Flat blade screw driver 1.0 x 4.0mm to fix the screw terminals  Tools to fix the screws/bolts (Ø 6mm) with plugs to mount the cabinets to a surface  Philips screw driver to open the connection area of the Mass Charger  2mm flat blade screw driver for the sense terminal (see Figure 4, point 10).

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Mass Charger 24/50-2, 24/75, 24/75 (120V), 24/100, 3-24/100, 48/25, 48/50 – User and Installation Manual

4.13 Connection

WARNING

Let installation work be done by a licensed electrician. Before beginning with the connection of the wiring, make the AC distribution as well as the DC distribution voltage free.

CAUTION!

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

Note:

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

Note:

The Mass Charger supports MasterBus and RS 232 compatible remote control panels.

The following schematic illustrates the general placement of the Mass Charger. It is not meant to provide detailed wiring instructions for any particular electrical installation.

Figure 5. Installation drawing of the Mass Charger

BATTERY BANK 1

(main battery bank)

Temperature sensor

BATTERY BANK 2

Battery fuse

Charger fuse

L N

PE/GND

RCD

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Mass Charger 24/50-2, 24/75, 24/75 (120V), 24/100, 3-24/100, 48/25, 48/50 – User and Installation Manual

4.14 Installation step-by-step

Mark the position of the mounting spots using

the drilling dimensions.

Place the four screws first and

hang the Mass Charger over them. Then fix the Mass to the

wall by securing the screws.

Open the connection compartment by loosening the two screws.

Feed the AC wiring through the

cable gland and connect the wiring to the screw terminals. Tighten the cable gland firmly.

Connect the DC cabling of the house bank,

positive to +, negative to – .

+ -

Option for model 24/50:

Connect the DC wiring of

the second battery bank (max. 3A). This bank has a common negative with the main battery.

Attach the battery temperature sensor to the

casing of the main battery bank. Plug the temperature sensor cable into the “Temp.Sensor” jack. See also Figure 4 on page 10.

Option: Connect the Mass Charger to the MasterBus network.

The factory setting of the Mass Charger is

optimal for most installations. Sometimes however, it is desirable to change these settings. See chapter 5 (page 14) and

section 7.4 (page 16).

Check all wiring. If everything is all right,

close the connection compartment by fixing the two screws.

Continue with section 4.15 for commissioning of the Mass Charger.

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Mass Charger 24/50-2, 24/75, 24/75 (120V), 24/100, 3-24/100, 48/25, 48/50 – User and Installation Manual

4.15 Commissioning after installation

Note: When your Mass Charger is not new, you have to

take into account that former users may have changed the settings. Reset the Mass Charger to factory settings when there is any doubt (see section 7.4 on page 16).

4.15.1 General

The factory settings of the Mass Charger are optimal for most installations. With some applications however, it is desirable to change these settings. Therefore several adjustments can be made. See chapters 5 and 7.4.

Note: The DIP switches must be adjusted prior to

commissioning; all other settings can only be configured after commissioning.

CAUTION!

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

If all wiring is OK, place the DC fuse(s) of the DC distribution to connect the batteries to the Mass Charger.

WARNING

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

Now the Mass Charger is ready for operation. After switching on the AC power supply the Mass Charger will initiate the charging process.

4.15.2 MasterBus

Adjustment of the settings of the Mass Charger can be made by means of DIP switches or via the MasterBus network (by means of an USB interface connected to a PC with MasterAdjust software). Some settings can only be changed via the MasterBus interface. See section 7.4 on page 16 for an overview of all available MasterBus settings.

4.16 Decommissioning

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

1 Switch the Mass Charger to off. 2 Remove the DC fuse(s) of the DC distribution and/or

disconnect the batteries.

3 Remove the AC fuse(s) of the AC input and/or

disconnect the AC mains.

4 Open the connection compartment of the Mass

Charger.

5 Check with a suitable voltage meter whether the

inputs and the outputs of the Mass Charger are voltage free.

6 Disconnect all wiring. Now the Mass Charger can be demounted in a safe way.

4.17 Storage and transportation

When not installed, store the Mass Charger in the original packing, in a dry and dust free environment.

Always use the original packing for transportation. Contact your local Mastervolt Service Centre for further details if you want to return the apparatus for repair.

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Mass Charger 24/50-2, 24/75, 24/75 (120V), 24/100, 3-24/100, 48/25, 48/50 – User and Installation Manual

5 DIP SWITCH SETTINGS

The Mass Charger settings can be adjusted in two ways:

 By means of DIP switches;  Via the MasterBus network (by means of a remote

control panel or an interface connected to a PC with MasterAdjust software); see section 7.4 on page 16.

Note: Once a DIP switch has been set to On, MasterBus

presets are disabled but people can still change the settings!

CAUTION!

Invalid settings of the Mass Charger can cause serious damage to your batteries and/or the connected load! Adjustments of settings may be undertaken by qualified personnel only!

5.1 DIP switch operation

The Mass Charger has six DIP switches. These switches are operated by flipping the levers to the other position, using a small screw driver.

Figure 6. DIP switches

5.2 DIP switch functions

See the table for the functional overview of the DIP switches (Switch 5 and 6 are reserved for future use).

Force Float (DIP switch 1)

For special applications a fixed charge voltage can be required. The battery charger allows you to change the 3step+ charge program to a single stage program by activating the function "Force Float", switching DIP switch 1 to "ON". The charge voltage will be fixed at 26.5V (24V charger) or 53V for a 48V charger.

Traction setting (DIP switch 2)

Setting for traction charging: +0.7/1.4V during bulk and +0.4/0.8V in absorption for 24/48V batteries.

Gel/AGM batteries (DIP switch 3)

Some Gel/AGM batteries need a higher float voltage for optimal charge. Changing the float voltage can be done by setting DIP switch 3 to "ON". The float voltage will increase to 27.6V (24V charger) or 55.2V for a 48V charger.

Diode setting (DIP switch 4)

Setting for +0.6V voltage compensation in case a battery isolator is used.

DIP SWITCH

4 3 2

Standard

0 0 0

Diode

1 0 0

Gel/AGM

0 1 0

Diode + Gel/AGM

1 1 0

Traction

0 0 1

Traction + Diode

1 0 1

ContMon + Traction

0 1 1

ContMon + Traction + Diode

1 1 1

ForceFloat

0 0 0

ForceFloat + Diode

1 0 0 1 ForceFloat + Gel/AGM

0 1 0

ForceFloat + Diode +

Gel/AGM

1 1 0

ContMon

0 0 1

ContMon + Diode

1 0 1

ContMon + Gel

0 1 1 1 ContMon + Diode + Gel/AGM

1 1 1

1 = On; 0 = Off

ContMon:

Continuous monitor mode. MasterBus, RS232 and DC alarm stay functioning at mains failure. Remote stays functioning if it has its own power source.

Diode:

Diode compensation on (+0.6V)

Gel/AGM:

Gel/AGM compensation on (during float +1.1V or 2.2V)

Traction

Traction charging (+0.7 or 1.4V during bulk and +0.4 or 0.8V in absorption).

Force float:

One step charge program with fixed float voltage.

Page 15

Mass Charger 24/50-2, 24/75, 24/75 (120V), 24/100, 3-24/100, 48/25, 48/50 – User and Installation Manual

6 OPERATION

6.1 Switching on/off

Activate the Mass Charger by switching the main switch to the on position. When no error is present, the charger LED illuminates green and the Mass Charger starts charging.

Move the switch to the off position to switch off the Mass Charger!

6.2 Reset the Mass Charger

Set the main switch to off. 1. Switch on again. 2.

The Mass Charger automatically resumes operation in Bulk stage after it was disconnected from an AC source.

6.3 Equalize mode

An equalizing charge can be necessary after very deep discharges and/or inadequate charges. This has to be carried out according to the specifications of the battery manufacturer.

WARNING!

Equalization is ONLY applicable for flooded batteries and will damage Gel/AGM/Spiral type batteries!

Incorrect use of the equalize mode may lead to hazardous situations. During equalizing the batteries are brought into the gas state and permitted load voltages may be exceeded (refer to Figure 10 on page 23 for characteristics). For these reasons the equalizing mode should only be used by trained technical engineers. The equalizing mode can only be started when the Mass Charger is in float operation. To start the equalize mode, select Equalize in the MasterBus device settings (see section 7.4 on page 16).

6.4 LED indicators

Figure 7. Front panel of the battery charger

During normal operation the charger LED (6) is green. When all charge process status LEDs (1 to 5) are on, the

battery is fully charged. For details refer to Figure 9 on page 22.

1…5

Status LEDs charge process

Charger status LED:

˗ Green = on ˗ Off = off ˗ Red = fault condition:

+

: Battery sense error

+

: Charger temperature too high

+

: Short circuit indication, charger will reduce

the charge current to 25%

+

: DC error, DC voltage too low or too high

+

: Temperature sense error

Status LED MasterBus communication:

˗ Green = MasterBus communication ˗ Off = no MasterBus communication

Main or on/off switch

9...13

Status LEDs charge current

5 4 3 2 1

7 6

Page 16

Mass Charger 24/50-2, 24/75, 24/75 (120V), 24/100, 3-24/100, 48/25, 48/50 – User and Installation Manual

7 MASTERBUS

7.1 About MasterBus

All devices that are suitable for MasterBus are marked with the MasterBus symbol.

MasterBus is a CAN based, fully decentralized data network for communication between Mastervolt devices. MasterBus is used as power management system for all connected equipment, such as the inverter, battery charger, generator and many more. Every device that is compatible with MasterBus is equipped with two data ports. The devices are simply chained together, forming a local data network. Monitoring panels such as the EasyView 5 can be used for monitoring and control of all connected MasterBus equipment.

CAUTION!

Never connect a non-MasterBus device to the MasterBus network directly! This will damage all connected MasterBus devices.

7.2 Event based commands

With MasterBus a device can be programmed to initiate an action at another connected device. This is done by means of event based commands.

7.3 How to set up a MasterBus network

 Connections between the devices are made by

standard straight MasterBus cables. Mastervolt can supply these cables.

 Up to 63 MasterBus devices can be connected

together.

 MasterBus needs a terminator on both ends of the

network.

 The electric power for the network comes from the

connected devices according to the rule: 1 powering/3 non powering.

 Do not make ring networks.  Do not make T-connections in the network.

7.4 MasterBus Settings

Meaning

Factory setting

Adjustable range

Device settings

Language

Language that is displayed on a monitoring device connected to the MasterBus.

English

EN, NL, DE, FR, ES, IT Name

Name for the Mass Charger.

CHG Mass+type*

0-12 characters

Device

Device name recognized by MasterBus.

Mass Charger

Battery name

Name for the main battery bank.

House Bank

0-16 characters

Factory settings

Option to reset the Mass Charger to default settings.

Not reset

Not reset, reset

Presets

Diode compensate

Option for charger diode +0.6V voltage compensation. If it is enabled, the compensation value is adjustable.

Disabled

Disabled, Enabled: 0-2.50V

Forced float

Option for Forced Float or constant voltage charging. If it is enabled, Forced Float voltage is adjustable.

Disabled

Disabled, Enabled Continuous mode

Option to keep MasterBus powered by the battery when the Mass Charger is disabled.

Disabled

Disabled, Enabled

Gel/AGM

Gel/ AGM settings option. It includes fully adjustable Bulk, Absorption and Float settings.

Disabled

Disabled, Enabled Traction

Traction settings option. See Traction settings.

Disabled

Disabled, Enabled

NiCad

NiCad settings option See NiCad settings.

Disabled

Disabled, Enabled

Li-ion

Li-ion settings option. See MLI settings.

Disabled

Disabled, Enabled

Equalize

Option to enable Equalizing. Shows only when no other battery type has been selected. Warning: Equalize is suitable for flooded batteries only! Do not use Equalize for other battery types!

Disabled

Disabled, Enabled

Page 17

Mass Charger 24/50-2, 24/75, 24/75 (120V), 24/100, 3-24/100, 48/25, 48/50 – User and Installation Manual

Meaning

Factory setting

Adjustable range

General

Max. current

Maximum charge current, adjustable model dependent.

(Max current)*

0 – I

max

Temp. compensate

Charge voltage compensation for temperature (V/°C).

-0.060/-0.120V/°C

-1.000 – 1.000V/°C

Bulk

Bulk voltage

28.50/57.00V

16.00-32.00/ 32.00-64.00V

Max. bulk time

Maximum bulk timer

480 min

0-600 min

Min bulk time

Minimum bulk timer

2 min

0-600 min

Start bulk time

Voltage at which to start the bulk timer.

27.60/55.20V

16.00-32.00/ 32.00-64.00V

Bulk ret. volt.

Return to Bulk voltage

25.60/51.20V

16.00-32.00/ 32.00-64.00V

Bulk ret. time

Adjustable Return to Bulk time after the Return to Bulk voltage has been reached.

30 sec

0-255 sec

Absorption

Abs. voltage

Absorption voltage

28.50/ 57.00V

16.00-32.00/ 32.00-64.00V

Max absorption

Maximum absorption timer

240 min

0-600 min

Min absorp. time

Minimum absorption timer

15 min

0-180 min

Return amps

Return to Float current (in A)

6.0 %*I

max

0-25% * I

max

Float

Float voltage

26.50/53.00V

16.00-32.00/ 32.00-64.00V

Equalize voltage

31.00/62.00V

16.00-32.00/ 32.00-64.00V

Equalize time

360 min

0-600 min

Alarm set points

DC Alrm high on

Alarm DC High on

32.00/64.00V

16.00-32.00/ 32.00-64.00V

DC Alrm high off

Alarm DC High off

30.00/60.00V

16.00-32.00/ 32.00-64.00V

DC Alrm low on

Alarm DC low on

20.00/40.00V

16.00-32.00/ 32.00-64.00V

DC Alrm low off

Alarm DC low off

22.00/44.00V

16.00-32.00/ 32.00-64.00V

DC Alrm delay

Alarm delay time

30 sec

0-255 sec

Traction settings

Bulk voltage

29.20/58.40V

(read only)

Max bulk time

Maximum bulk time

360 min

(read only)

Min bulk time

Minimum bulk time

4 min

(read only)

Start bulk time

27.60/55.20V

(read only)

Bulk ret. volt.

Bulk return voltage

25.60/51.20V

(read only)

Bulk return time

30 sec

(read only)

Abs. voltage

Absorption voltage

28.90/57.80V

(read only)

Max absorp. time

Maximum absorption time

480 min

(read only)

Min absorp. time

Minimum absorption time

15 min

(read only)

Return amps

Return to Bulk current (in A)

6.0 %*I max

(read only)

Float voltage

Traction float voltage

26.50/53.00V

(read only)

NiCad settings

Bulk voltage

29.00/58.00V

(read only)

Max bulk time

Maximum bulk time

480 min

(read only)

Min bulk time

Minimum bulk time

2 min

(read only)

Start bulk time

26.50/53.00V

(read only)

Bulk ret. volt.

Bulk return voltage

10.00/20.00/40.00V

(read only)

Bulk return time

30 sec

(read only)

Abs. voltage

Absorption voltage

29.00/58.00V

(read only)

Max absorp. time

Maximum absorption time

480 min

(read only)

Min absorp. time

Minimum absorption time

15 min

(read only)

Return amps

Return to Bulk current (in A)

6.0 %*I max

(read only)

Float

NiCad float voltage

26.00/52.00V

(read only)

Page 18

Mass Charger 24/50-2, 24/75, 24/75 (120V), 24/100, 3-24/100, 48/25, 48/50 – User and Installation Manual

Meaning

Factory setting

Adjustable range

MLI (Li-ion) settings

Bulk voltage

28.50/57V

(read only)

Max bulk time

Maximum bulk time

480 min

(read only)

Min bulk time

Minimum bulk time

2 min

(read only)

Start bulk time

26.50/53.00V

(read only)

Bulk ret. volt.

Bulk return voltage

26.30/52.60V

(read only)

Bulk return time

240 sec

(read only)

Abs. voltage

Absorption voltage

28.50/57V

(read only)

Max absorp. time

Maximum absorption time

240 min

(read only)

Min absorp. time

Minimum absorption time

15 min

(read only)

Return amps

Return to Bulk current (in A)

6.0 %*I max

(read only)

Forced Float

LI-ion forced float voltage

27/54V

(read only)

* Depending on model

Events

Event x source

Event-based command. Mass Charger event that should result in an action by another device on the MasterBus network.

Disabled

See Event source list. Event x target

Select a connected MasterBus device that should take action due to a Mass Charger event.

Select…

Selectable targets are system dependent.

Event x command

Action to be taken by the target device.

Select…

See command list in selected device manual

Event x data

Data is linked to the command.

On changes the status to On at the first signal. Off changes the status to Off at the first signal. Copy lets the status follow the input. Copy Invert lets the status follow the opposite of the input Toggle changes the status at the 1st signal and back at the

2nd signal. It is used in combination with a pulse switch.

Off

Off, On, Copy, Copy Invert, Toggle.

Event x+1

The next event appears after enabling Event x.

Disabled

See Event x.

Mass Charger event source list (Mass Charger as event source)

Charging

Mass Charger state is On

Bulk

Charge stage is Bulk

Absorption

Charge stage is Absorption

Float

Charge stage is Float

Failure

Charger failure MasterBus alarm

CSI

Charger Status Interface MasterBus alarm to generate an audible alarm at charger failure

Equalize

Mass Charger is in Equalize mode

TC Error

Battery temperature sensor error

Fan

MasterBus signal for an external fan to start (at 50% load/50°C)

LED Bulk

LED Bulk illuminates

LED 20-40

LED 2 illuminates (see Figure 7)

LED Abs

LED Abs illuminates

LED 60-80

LED 4 illuminates (see Figure 7)

LED Float

LED Float illuminates

LED Failure

LED Failure illuminates

Mass Charger event target list (Mass Charger as event target)

Bulk

Command to start the Bulk stage of charge

Absorption

Command to start the Absorption stage of charge

Float

Command to start the Float stage of charge

On/ Standby

Command to switch on the Mass Charger

Page 19

Mass Charger 24/50-2, 24/75, 24/75 (120V), 24/100, 3-24/100, 48/25, 48/50 – User and Installation Manual

8 TROUBLE SHOOTING

In case of a failure, the Mass Charger display shows an error ‘code’ to help you find its source. See section 6.4 LED indicators, on page 15. If you cannot solve a problem

using the following fault finding table, contact your supplier or Mastervolt. Make sure you have the part and serial number at hand (See section 1.4, on page 3).

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 (< 180VAC).

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 that is 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.

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 40°C the charge current is automatically reduced.

Low AC input voltage. At lower AC input voltages the charge current is reduced. See Figure 8 on page 22.

Check AC input voltage.

Batteries not fully charged

Charge current too low.

See “Charge current too low”.

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.

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 section 7.4 on page 16).

Page 20

Mass Charger 24/50-2, 24/75, 24/75 (120V), 24/100, 3-24/100, 48/25, 48/50 – User and Installation Manual

9 TECHNICAL DATA

9.1 Specifications

Model

Mass 24/50-2

Mass 24/75

Mass 24/75 (120V)

Product code

40020506

40020756

40120756

INPUT

Mains voltage

230V, -10% + 15%

120V, -10% + 15%

Frequency

50-60Hz ± 5Hz

60-50Hz ± 5Hz

Inrush current

None, the battery charger is equipped with a soft start in accordance with IEC 1003-3

Input current

12A

25A

Power factor (Cos phi)

1 1 Maximum efficiency

89%

Input power

1600W

2700W

OUTPUT

Nominal voltage

24VDC

Max charge current (I

max

50A

75A

Outputs

1x50A + 1x3A

1 x 75A

Charge characteristic*

3-step+, fully automatic

Battery types:

Flooded lead acid, Gel/AGM lead acid, NiCd, Mastervolt MLI (see section 7.4 for settings)

Default charge voltages at 25°C

Absorption voltage*

28.5V

Float voltage*

26.5V

Voltage ripple

max. 100mV RMS with resistive load @ full power

Short circuit current (1/4 of I

max

)

12.5A

18.75A

Wire gauge (up to 3m length)

25mm²

35mm²

Charger fuse (external)

63A

80A

ENVIRONMENTAL

Ambient temperature

-20 to 40°C** @ 100% output power, derated with 2,5%/°C above 40°C

Cooling

Forced air, by means of a ventilator with variable speed

Humidity

Maximum 95%RV, non-condensing

MASTERBUS

MasterBus powering capability

Yes

MasterBus menu languages

English, Dutch, German, French, Spanish, Italian

ENCLOSURE TYPE

Dimensions (hxwxd)mm

See section 3.2 on page 6

Protection degree

IP23

Weight

5kg

9kg

* Adjustable, see chapter 5. ** The Mass 24/50-2 allows operation in ambient temperatures as high as 45°C. Specifications are subject to change without prior notice.

Page 21

Mass Charger 24/50-2, 24/75, 24/75 (120V), 24/100, 3-24/100, 48/25, 48/50 – User and Installation Manual

Model

Mass 24/100 MB

Mass 3-24/100 MB

Mass 48/25 MB

Mass 48/50 MB

Product code

40021006

40031006

40040256

40040506

INPUT

Mains voltage

230V, -10% + 15%

3 x 365...550V**

230V, -10% + 15%

Frequency

50-60Hz ± 5Hz

Inrush current

None, the battery charger is equipped with a soft start in accordance with IEC 1003-3

Current

16A

6.5A

16A

Power factor (Cos phi)

0.8

Efficiency

89%

Input power

3600W

3500W

1800W

3600W

OUTPUT

Nominal voltage

24VDC

48VDC

Max charge current (I

max

100A

25A

50A

Outputs

1 x 100A

1x25A

1x50A

Charge characteristic*

3-step+, fully automatic

Battery types:

Flooded lead acid, Gel/AGM lead acid, NiCad, Mastervolt MLI (settings: section 7.10)

Default charge voltages at 25°C

Absorption voltage*

28.5V

57V

Float voltage*

26.5V

53V

Voltage ripple

max. 100mV RMS with resistive load @ full power

Short circuit current (1/4 of I

max

)

25A

12.5A

Cable size (within 3 m)

35mm²

16mm²

25mm²

Charger fuse (external)

125A

32A

63A

ENVIRONMENTAL

Ambient temperature

-20 to 40°C @ 100% output power, derated with 2,5%/°C above 40°C

Cooling

Forced air, by means of a ventilator with variable speed

Humidity

Maximum 95%RV, non-condensing

MASTERBUS

MasterBus powering capability

Yes

MasterBus menu languages

English, Dutch, German, French, Spanish, Italian

ENCLOSURE TYPE

Dimensions (hxwxd)mm

See section 3.2 on page 6

Protection degree

IP23

Weight

9kg

10kg

5kg

9kg

* Adjustable, see chapter 5. ** For device versions up to J (see section 1.4 on page 3): 3x 365...440V Specifications are subject to change without prior notice.

Page 22

Mass Charger 24/50-2, 24/75, 24/75 (120V), 24/100, 3-24/100, 48/25, 48/50 – User and Installation Manual

9.2 Characteristics

Figure 8. Charge current versus input voltage

Figure 9. Charge characteristic of the 3-step+ charging method (at 25°C/77°F)

Page 23

Mass Charger 24/50-2, 24/75, 24/75 (120V), 24/100, 3-24/100, 48/25, 48/50 – User and Installation Manual

Figure 10. Charge characteristic of the equalize charge cycle (at 25°C/77°F)

Figure 11. Temperature compensation characteristic (charge voltage versus temperature)

Page 24

Mastervolt B.V. Snijdersbergweg 93 1105 AN Amsterdam The Netherlands

Tel.: +31-20-3422100 Email: info@mastervolt.com Web: www.mastervolt.com

Reproduction, transfer, distribution or storage of part or all of the contents in this

document in any form without the prior written permission of Mastervolt is prohibited.