Mastervolt MASS 12/80-2, MASS 24/100-C, MASS 12/60-2, MASS 24/75-C, MASS 3-24/100 User Manual

USERS MANUAL / GEBRUIKERSHANDLEIDING / BETRIEBSANLEITUNG

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

Mass Charger

MASS 12/60-2; 12/80-2; 24/50-2; 24/75-C;

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

FULL AUTOMATIC BATTERY CHARGER

MASTERVOLT
Snijdersbergweg 93,
1105 AN Amsterdam
The Netherlands
Tel.: [phone]
Fax.: [phone]
www.mastervolt.com

ENGLISH: PAGE 1

NEDERLANDS: PAGINA 29
DEUTSCH: SEITE 57
FRANÇAIS: PAGINA 85
CASTELLANO: PÁGINA 113
ITALIANO: PÁGINA 141

Copyright © 2010 Mastervolt, v 2.2 July 2010

CONTENTS

CONTENTS: v 2.2 July 2010

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

1

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

1.2 Validity of this manual ........................................................................................................................................ 4

1.3 Use of pictograms .............................................................................................................................................. 4

1.4 Identification label............................................................................................................................................... 4

1.5 Liability ............................................................................................................................................................... 4

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

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

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

2.3 Warnings regarding the use of batteries............................................................................................................. 6

2.4 Warning regarding life support applications........................................................................................................ 6

2.5 Guarantee specifications.................................................................................................................................... 6

3 OPERATION .................................................................................................................................................................... 7

3.1 Introduction.........................................................................................................................................................7

3.1.1 Switching on ......................................................................................................................................7

3.1.2 Switching off:..................................................................................................................................... 7

3.2 Theory of operation ............................................................................................................................................ 7

3.3 Front panel ......................................................................................................................................................... 7

3.3.1 Bulk (LED 1 illuminates) .................................................................................................................... 8

3.3.2 (LED 1 and 2 illuminate).................................................................................................................... 8

3.3.3 Absorption (LED 1, 2 and 3 illuminate).............................................................................................. 8

3.3.4 (LED 1 to 4 illuminate)....................................................................................................................... 8

3.3.5 Float (LED 1 to 5 illuminate) .............................................................................................................. 8

3.4 Temperature compensated charging.................................................................................................................. 8

3.5 Compensation of the cable losses...................................................................................................................... 8

3.6 alarm function..................................................................................................................................................... 8

3.7 Charging a second battery ................................................................................................................................. 8

3.8 Equalize mode.................................................................................................................................................... 8

4 INSTALLATION ............................................................................................................................................................... 9

4.1 Mounting the Mass charger ................................................................................................................................ 9

4.2 Connections ....................................................................................................................................................... 9

4.3 Wiring ................................................................................................................................................................. 9

4.3.1 AC wiring........................................................................................................................................... 9

4.3.2 AC safety grounding........................................................................................................................ 10

4.3.3 DC wiring......................................................................................................................................... 10

4.4 Battery capacity................................................................................................................................................ 10

4.5 Battery isolator ................................................................................................................................................. 10

4.6 Connection of second battery (3A output) ..................................................................................................... 11

4.7 Temperature sensor ......................................................................................................................................... 11

4.8 Voltage sense................................................................................................................................................... 11

4.9 Alarm function .................................................................................................................................................. 11

4.9.1 Standard alarm mode ...................................................................................................................... 11

4.9.2 DC alarm mode ............................................................................................................................... 11

4.10 Connection of accessories ............................................................................................................................... 11

4.11 Overview connection compartment .................................................................................................................. 12

4.12 Things you need............................................................................................................................................... 12

4.13 Connection ....................................................................................................................................................... 13

4.14 Installation step-by-step ................................................................................................................................... 14

4.15 Commissioning after installation....................................................................................................................... 15

2 July 2010 / Mass Charger 12/60-2; 12/80-2; 24/50-2; 24/75; 24/100; 3-24/100; 48/25; 48/50 / EN

CONTENTS

4.15.1 General............................................................................................................................................ 15

4.15.2 MasterBus (optional) ....................................................................................................................... 15

4.16 Decommissioning ............................................................................................................................................. 15

4.17 Storage and transportation............................................................................................................................... 15

4.18 Re-installation................................................................................................................................................... 15

5 DIP SWITCH SETTINGS ............................................................................................................................................... 16

5.1 DIP Switch operation........................................................................................................................................ 16

5.2 DIP switch functions ......................................................................................................................................... 16

5.2.1 Force Float (DIP switch 1)............................................................................................................... 16

5.2.2 Traction setting (DIP switch 2)......................................................................................................... 16

5.2.3 Gel batteries (DIP switch 3)............................................................................................................. 16

5.2.4 Diode setting (DIP switch 4) ............................................................................................................ 16

6 MASTERBUS................................................................................................................................................................. 17

6.1 What is MasterBus? ......................................................................................................................................... 17

6.2 How to set up a MasterBus network................................................................................................................. 17

7 MASTERBUS SETTINGS.............................................................................................................................................. 18

7.1 Device .............................................................................................................................................................. 18

7.2 Presets ............................................................................................................................................................. 18

7.3 General ............................................................................................................................................................ 18

7.4 Bulk .................................................................................................................................................................. 18

7.5 Absorption ........................................................................................................................................................ 18

7.6 Float ................................................................................................................................................................. 19

7.7 Alarm setpoints................................................................................................................................................. 19

7.8 Traction settings ............................................................................................................................................... 19

7.9 Nicad settings................................................................................................................................................... 19

7.10 Li-ion settings ................................................................................................................................................... 19

7.11 Events .............................................................................................................................................................. 20

7.11.1 Mass Charger event source list (Mass Charger as event source)................................................... 20

7.11.2 Mass Charger event target list (Mass Charger as event target) ...................................................... 20

8 TROUBLE SHOOTING.................................................................................................................................................. 21

8.1 Fault finding table ............................................................................................................................................. 21

9 TECHNICAL DATA........................................................................................................................................................ 22

9.1 Specifications ................................................................................................................................................... 22

9.2 Dimensions....................................................................................................................................................... 24

9.3 Characteristics (230 V AC) ............................................................................................................................... 26

10 ORDERING INFORMATION.......................................................................................................................................... 27

11 EC DECLARATION OF CONFORMITY ........................................................................................................................ 28

EN / Mass Charger 12/60-2; 12/80-2; 12/150; 24/50-2; 24/75; 24/100; 48/25; 48/50; 3-24/100 / July 2010 3

GENERAL INFORMATION

1 GENERAL INFORMATION

1.1 USE OF THIS MANUAL

Copyright © 2010 Mastervolt. All rights reserved.
Reproduction, transfer, distribution or storage of part or all
of the contents in this document in any form without the
prior written permission of Mastervolt is prohibited.

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 the Mass Charger 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

40010606 Mass 12/60-2 (230 V)
40010806 Mass 12/80-2 (230 V)
40020506 Mass 24/50-2 (230V)
40020756 Mass 24/75-C (230V)
40021006 Mass 24/100-C (230V)
40031006 Mass 24/100 3-phase (3x400V)
40040256 Mass 48/25 (230 V)
40040506 Mass 48/50 (230 V)

These models are further mentioned as “Mass Charger”
For other models see other manuals available on our
website: www.mastervolt.com

1.3 USE OF PICTOGRAMS

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

WARNING

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

CAUTION!

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

A procedure, circumstance, etc which deserves
extra attention.

1.4 IDENTIFICATION LABEL

Part no : 44020800

40021006

Type : ChargeMaster 24/80-3

Mass Charger24/100-C

Input : 120/230V AC 50/60 Hz 26A/13A
Output : 28.5VDC - 80A

Serial no: V822C0001

220-240V 16A 50-60Hz

28.50V 100A

XD10A0005

Serial number

XD10A

0005

Apparatus version “A”

Figure 1: Identification label

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

IP 23

Design by
Mastervolt

Manufactured in China

Part number

CAUTION!

Never remove the identification label.

1.5 LIABILITY

Mastervolt can accept no liability for:

• consequential damage due to use of the Mass
Charger;

• possible errors in the manuals and their results.

4 July 2010 / Mass Charger 12/60-2; 12/80-2; 24/50-2; 24/75; 24/100; 3-24/100; 48/25; 48/50 / EN

IMPORTANT SAFETY INSTRUCTIONS

2 IMPORTANT SAFETY INSTRUCTIONS

READ AND SAVE THESE INSTRUCTIONS

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 Before using the Mass Charger, read all instructions

and cautionary markings on the Mass Charger, the
batteries, and all appropriate sections of the manual.

2 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.

3 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.

4 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.

5 Make sure that all wiring is properly installed and in

good electrical condition; and that wire size is large
enough for AC ampere rating of the 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.

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

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

7 Except for the connection compartment, see chapter

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

8 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.

9 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.

10 Short circuiting or reversing polarity will lead to

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

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

which is appropriate for electrical equipment.

12 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.

EN / Mass Charger 12/60-2; 12/80-2; 24/50-2; 24/75; 24/100; 3-24/100; 48/25; 48/50 / July 2010 5

IMPORTANT SAFETY INSTRUCTIONS

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
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.

2.4 WARNING REGARDING LIFE SUPPORT
APPLICATIONS

The Mass Charger is not sold for applications in any
medical equipment intended for use as a component of
any life support system unless a specific written
agreement pertaining to such intended use is executed
between the manufacturer and Mastervolt. Such
agreement will require the equipment manufacturer either
to contract additional reliability testing of the Mass Charger
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 Mass Charger 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 users manual, then
damage may occur and/or the unit may not fulfil its
specifications. All of these matters may mean that the
guarantee becomes invalid.
The guarantee is limited to the costs of repair and/or
replacement of the product. Costs for installation labor or
shipping of the defective parts are not covered by this
guarantee.

6 July 2010 / Mass Charger 12/60-2; 12/80-2; 24/50-2; 24/75; 24/100; 3-24/100; 48/25; 48/50 / EN

OPERATION

3 OPERATION

3.1 INTRODUCTION

The MASS battery charger is a full-automatic high
efficiency battery charger/rectifier, developed and
produced by Mastervolt Amsterdam. The MASS series
features a family of advanced quality battery chargers. 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.

3.1.1 Switching on

The battery charger will be switched on by the ON/OFF
switch. One of the front LEDs will light up now and the
charging starts immediately.

3.1.2 Switching off:

The battery charger will be switched off by the ON/OFF
switch.

The connection between the mains and the
battery charger will not be severed with the
switch.

3.2 THEORY OF OPERATION

The battery charger is equipped with an intelligent 3-stage
charge characteristic which takes care of an optimal
charge of your batteries (see fig. 2). When switched on,
the Mass Charger always starts in Bulk phase.

LEDs in charge

BULK ABSORPTION FLOAT

Fig. 2: Example: charge characteristic MASS 12/60-2.
(For other models V/A according to specifications).

To prevent your batteries from overcharging a new cycle
only starts when the battery voltage has been under the
level of 12.8/25.6 or 51.2V for longer than 30 seconds or
after a hard reset by switching the on/off switch back and
forward.

stage, see fig. 3

charge
voltage (V)

charge
current (A)

charge time

3.3 FRONT PANEL

On the front of the Mass Charger a so called "capacity
meter" (figure 3, LED 9 to 13) gives you information about
the battery state like a fuel meter of a car. The more LEDs
are illuminated the more power is in the battery.

Fig 3: Front panel of the battery charger

Illuminating LED’s Meaning

Normal operation, LED 6 illuminates green
1 Charger On
1+2 Uout> 13.8/27.6/55.2V
1+2+3 Uout = abs. (14.25/28.5/57.0V)
1+2+3+4 3 hrs after start max bulk timer,

or I < return amps

1+2+3+4+5 6 hrs after start max bulk timer,

or I < return amps for 15 min or longer
9 Charge current 0-5% of full current
9+10 Charge current 5-25% of full current
9+10+11 Charge current 25-50% of full current
9+10+11+12 Charge current 50-75% of full current
9+10+11+12+13 Charge current 75-100% of full current
6 Green: normal operation, Red: fault

condition, Off: standby or off
7 Green: MasterBus communication,

Off: no MasterBus communication

Fault condition, LED 6 illuminates red

6 red +1 Battery sense error
6 red +2 Charger temperature too high
6 red +3 Short circuit indication, charger will

reduce the charge current to 25%
6 red +4 DC error, DC voltage too low or too high
6 red +5 Temperature sense error

EN / Mass Charger 12/60-2; 12/80-2; 24/50-2; 24/75; 24/100; 3-24/100; 48/25; 48/50 / July 2010 7

OPERATION

3.3.1 Bulk (LED 1 illuminates)

The battery is empty when only the first LED Bulk/ON
illuminates. In this stage the Mass Charger gives full
current (see fig. 4 phase A) and the battery voltage will
slowly increase. After reaching the level of 13.8V (12V
charger), 27.6V (24V charger) or 55.2V (48V charger) the
battery is charged for about 25% and the second LED will
also illuminate.

3.3.2 (LED 1 and 2 illuminate)

The battery has been charged for 25%. The Mass Charger
still gives the maximum output current and the voltage will
increase till the absorption voltage level (see fig. 2 phase
A). The time of phase A is 6 hours default.

3.3.3 Absorption (LED 1, 2 and 3 illuminate)

The battery has been charged for 50% (fig. 2 phase B).
The Mass Charger limits the charge voltage to a safe level
and the charge current shall slowly decrease.

3.3.4 (LED 1 to 4 illuminate)

The battery is charged for 75%. The charge voltage is
limited at the absorption level, because the battery is
almost full, the current consumption will further decrease.

3.3.5 Float (LED 1 to 5 illuminate)

When all LEDs are illuminated the battery is fully charged.
The float/trickle charge program gives a lower output
voltage, sufficient enough to maintain the batteries at
100% charge but low enough to prevent your batteries
from unnecessary stress. In this stage the Mass Charger
is able to supply full current to the connected users/loads.

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

3.4 TEMPERATURE COMPENSATED
CHARGING

By installing the battery temperature sensor the charge
voltages are automatically adapted for deviating
temperatures. This can increase the battery’s life time
substantially and save you a lot of money.

Charge voltage (V)

Battery temperature (°C)

Figure 4:
Temperature compensated charging

See figure 4. When the battery temperature is low, the
charge voltage increases. On the other hand, when the
battery temperature is high, the charge voltage is
decreased. Over charge and gassing are prevented this
way. This will extend the life of your batteries.

3.5 COMPENSATION OF THE CABLE LOSSES

The Mass Charger can compensate the voltage drop
occurring over the DC cables. For this purpose the Mass
Charger is provided with terminals for sense wires. The
sense wires are connected closest possible to the
batteries in order to charge them with the right voltage.
When only the minus sense wire is connected only the
losses of the minus DC cable will be compensated.
Connecting both cables produces the best result, all
losses will be compensated until a maximum of 3V in total.

3.6 ALARM FUNCTION

The battery charger is equipped with an integrated alarm
function. External equipment can be controlled by the
potential free contacts of this alarm. The maximum switch
current of the relay is 1A. Exceeding the setpoints (refer to
section 6.7) will activate the alarm.

3.7 CHARGING A SECOND BATTERY

Some installations have a main battery set and besides
this a smaller (cranking) battery with the same voltage. It is
possible to maintain this second battery with the 3A output
of the battery charger. This function is standard available
on the models 12/60-2, 12/80-2 and 24/50-2.

3.8 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 wet type
batteries and will damage gel/AGM/Spiral type
batteries!
Incorrect use of the equalize mode may lead to
hazardous situations. Do not smoke or use any
naked flame or other sources of ignition due to
risk of explosion. Always ventilate the battery
room during equalizing to clear the air.

During equalizing the batteries are brought into the gas
state and permitted load voltages may be exceeded.
Therefore appropriate measures must be taken, e.g.
disconnect all loads from the battery and ventilate the
room. 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 operation. To start the equalize mode, select
Equalize in the MasterBus device settings (section 7.2).

8 July 2010 / Mass Charger 12/60-2; 12/80-2; 24/50-2; 24/75; 24/100; 3-24/100; 48/25; 48/50 / EN

INSTALLATION

4 INSTALLATION

During installation and commissioning of the Mass
Charger, the important safety instructions are applicable at
all times. See chapter 2 of this manual.
Please check the contents of the box before you start with
the installation. The contents of the box need to be:

• battery charger;

• battery temperature sensor (incl. 6 mtr cable);

• a MasterBus terminating device;

• users manual;

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

Install the MASS battery charger in a dry, well ventilated
area, closest possible to the batteries. Although the battery
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.

4.1 MOUNTING THE MASS CHARGER

Obey the following stipulations during installation:

• The Mass Charger is designed for indoor use only.

• 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.

• Mount the Mass Charger vertically, with the connecting

cables downwards.

• Make sure that the hot air that is developed during

operation can be discharged. The Mass Charger must
be mounted in such a way that obstruction of the
airflow through the ventilation openings will be
prevented.

• No objects must be located within a distance of 10 cm /

4 inch around the Mass Charger.

• Do not locate the Mass Charger in the same

compartment as the batteries.

• Do not install 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

WARNING!

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

4.3.1

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.
Cut the cable in accordance to fig. 5a. 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. Connect the green/yellow
wire to PE, brown to L1 and the blue wire to the N
terminal.

brown

Connect the 3-24/100 according to fig. 5b. The three black
wires to L1, L2 and L3. Connect the green/yellow wire to
the PE. For a safe installation the correct wire cross
section must be applied. Don’t use a cross section that is
smaller than indicated. See table below to select the
appropriate cross section for the AC wiring (up to 6m / 20ft
length):

AC Current Minimum cross section:

6-12 Amp 1.5 mm² AWG 14
12-20 Amp 2.5 mm² AWG 12
20-32 Amp 4.0 mm² AWG 10

Connection of AC-wiring and recommended wire colours.

• 230V/50Hz installations, see figure 5a:

Wire color Meaning

Brown or black Phase L1
Blue Neutral N
Green/Yellow Earth PE / GND

• 400V/50Hz installations, see figure 5b:

Wire color Meaning

Black Phase L1, L2, L3
Green/Yellow Earth PE / GND

AC wiring

green/yellow

blue

Fig5a

minimal

black

black

minimal

1 cm

green/yellow

black

Fig5b

Must be
connected to:

Must be
connected to:

EN / Mass Charger 12/60-2; 12/80-2; 24/50-2; 24/75; 24/100; 3-24/100; 48/25; 48/50 / July 2010 9

INSTALLATION

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
Residual Current Device (earth leakage switch)
in the AC input circuit of the Mass Charger.

4.3.3 DC wiring

Keep the cable connection between charger and batteries
shortest 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:

Model Mass Charger Length <3 m Length 3-6 m

Mass 12/60-2 (230 V) 25 mm² 35 mm²
Mass 12/80-2 (230 V) 35 mm² 50 mm²
Mass 24/50-2 (230V) 25 mm² 35 mm²
Mass 24/75-C (230V) 35 mm² 50 mm²
Mass 24/100-C (230V) 50 mm² 70 mm²
Mass 24/100 3-phase
(3x400V)
Mass 48/25 (230 V) 10 mm² 16 mm²
Mass 48/50 (230 V) 25 mm² 35 mm²

Connection of main batteries
1 Pull the cables through the cable glands of the Mass

Charger.

2 Crimp on the ring terminals to the cable:

• ring M6 for 12/60-2, 12/80-2, 24/50-2 and 48/25;

• ring M8 for 24/75, 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 at length and crimp on the ring

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

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

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

Lay the positive and negative cables next to each other to
limit the electro magnetic field around the cables. The

50 mm² 70 mm²

negative cable should be connected directly to the
negative post of the battery bank or the ground side of a
current shunt. Do not use the chassis frame as the
negative conductor.

4.4 BATTERY CAPACITY

The minimum required battery capacity is as follows:

Model Mass Charger Minimum required

battery capacity

Mass 12/60-2 (230 V) 140Ah
Mass 12/80-2 (230 V) 200Ah
Mass 24/50-2 (230V) 120 Ah
Mass 24/75-C (230V) 160 Ah
Mass 24/100-C (230V) 250 Ah
Mass 24/100 3-phase (3x400V) 250 Ah
Mass 48/25 (230 V) 60 Ah
Mass 48/50 (230 V) 120 Ah

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. It isolates the different battery sets from one
another, in order to prevent one discharging the other. A
consequence of the battery isolator is a voltage drop of 0.6
Volt. This voltage drop can be compensated in two ways:

1 By changing DIP-switch 4 to On (Diode enabled);
2 By MasterBus configuration (Diode compensate);

Warning!
DIP-switch settings overrule MasterBus
settings!

Mastervolt offers several Battery Isolators, refer to

www.mastervolt.com

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

Steps:
1 Check if the Mass Charger, the main supply and the

DC distribution are switched off.
2 Check if the Dc fuses have been removed.
3 Connect the battery isolator(s) using cables with the

same diameter as the battery cables.
4 Compensate the voltage drop over the battery isolator

by changing the setting of dip switch 4 (see fig. 5). Not

suitable when using the voltage sense function.
5 Switch on the Mass Charger.

.

10 July 2010 / Mass Charger 12/60-2; 12/80-2; 24/50-2; 24/75; 24/100; 3-24/100; 48/25; 48/50 / EN

INSTALLATION

4.6 CONNECTION OF SECOND BATTERY
(3A OUTPUT)

The battery chargers 12/60-2, 12/80-2 and 24/50-2 are
standard equipped with a second charge output of 3A in
order to give a small second battery set like a starter
battery a maintenance charge. The maximum charge
current of the second output is 3A, which comes from the
main output.

• Use 2.5 to 4 mm

2

cable for 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 (see fig. 2 and 3).

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

4.7 TEMPERATURE SENSOR

The standard temperature sensor is provided with 6 m
cable and a double-sided tape for easy installation.
Determine the warmest place on the battery set and make
it clean and grease free. Remove the piece of paper from
the tape and stick the sensor on the battery. Plug the 6way
cable into a terminal at the right of the Mass Charger (see
fig. 7). 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.

4.8 VOLTAGE SENSE

To shorten the charge time substantially, the battery cable
losses can be compensated by using the sense function.
Use 0,75 mm

2

, preferably red and black wire and secure
these with fuses of 2A slow blow. Connect the wires with
the two upper terminals of the green connector at the right
side of the cabinet (see fig. 7). Pay good attention to the
polarity of the wires, red on +S and black on -S. Now
connect the other side of the wires: black on the minus of
the battery and red on the battery side of the Mass
Charger fuse.

4.9 ALARM FUNCTION

The battery charger is equipped with a potential free
contacts alarm relay, see figure 7. The alarm function has
two modes: standard (factory setting) and DC alarm mode
(continuous mode).

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, too 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 CONNECTION OF ACCESSORIES

The battery charger is equipped with several terminals for
accessories. Cable to connect the accessories is not
delivered as a standard. Accessories can be plugged in at
all times. For C3 enclosure (refer to specifications): when
using a remote panel and the temperature sensor use the
specified plug for the panel and the other (free) one for the
temperature sensor.

Figure 6: Standard remote panel C3-RS,
art. no 07-04-03040

The standard remote panel must be connected with an
appropriate communication cable.

4.11 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 splitter to connect both
at the same time (not included).

EN / Mass Charger 12/60-2; 12/80-2; 24/50-2; 24/75; 24/100; 3-24/100; 48/25; 48/50 / July 2010 11

INSTALLATION

4.12 OVERVIEW CONNECTION COMPARTMENT

C2
enclosure

1 Screw terminals AC input: L1, N, PE

(24/100-3ph: L1, L2, L3, PE)

2 Earth stud

C3
enclosure

3 MasterBus connector
4 MasterBus connector
5 Output (battery) positive connector

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

contact

Figure 7: Overview connections Mass Charger

4.13 THINGS YOU NEED

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

Product Quantity

Mass Charger (included) 1
Battery temperature sensor with cable and plug (included). 1
DC-cable to connect the positive DC connection (+) of the Mass Charger to the positive pole of the DC­distribution; for specifications see section 4.3.3.
DC-cable to connect the negative DC connection (–) of the Mass Charger to the negative pole of the DC­distribution; for specifications see section 4.3.3.
DC-fuse holder with a DC-fuse, to be integrated in the positive DC-cable. 1
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); 1
Batteries. See section 4.4 for recommended capacity X
Appropriate and reliable cable terminals, cable lugs, battery terminals and cord end terminals X

* 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).

We recommend as a minimum tool kit:

• Socket wrench 13mm to fix the DC-input (battery) cables

• Flat blade screw driver 1.0 x 4.0 mm 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

• 2 mm flat blade screw driver for the sense terminal (figure 9 point 10).

1

1

4

12 July 2010 / Mass Charger 12/60-2; 12/80-2; 24/50-2; 24/75; 24/100; 3-24/100; 48/25; 48/50 / EN

g

INSTALLATION

4.14 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!

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

CAUTION!

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

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

NOTE:
The Mass Charger is feasible for the connection
of MasterBus and RS 232 compatible remote
control panels.

This schematic is to
illustrate the general
placement of the Mass
Charger in a circuit. It is
not meant to provide
detailed wiring
instructions for any
particular electrical
installation.

Charger fuse

Fi

ure 8: Installation drawing of the Mass Charger

EN / Mass Charger 12/60-2; 12/80-2; 24/50-2; 24/75; 24/100; 3-24/100; 48/25; 48/50 / July 2010 13

p

INSTALLATION

4.15 INSTALLATION STEP-BY-STEP

Attach the battery temperature sensor to the

Mark the position of the mounting spots using

1

the drilling dimensions .

Place the four screws first and

2

hang the Mass Charger over
them. Then fix the Mass to the
wall by securing the screws.

Open the connection compartment by

3

loosening the two screws.

7

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

4

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

Connect the DC-cabling of the house bank,

5

positive to +, negative to – .

+ -

+ -

Option: Connect the Mass Charger to the

7

MasterBus network.

The factory setting of the Mass Charger is

8

optimal for most installations. Sometimes
however, it is desirable to change these
settings. See ch. 5 DIP switch adjustment
and cha

Check all wiring; see also figure 10 for wiring

9

details. If everything is all right, close the
connection compartment by fixing the two
screws.

ter 7 for MasterBus settings.

Option for models 12/60, 12/80 and 24/50:

6

Connect the DC-wiring of
the second battery bank
(max. 3A). This bank has a
common negative with the
main battery.

10

Continue with section 4.15 for
commissioning of the Mass Charger.

14 July 2010 / Mass Charger 12/60-2; 12/80-2; 24/50-2; 24/75; 24/100; 3-24/100; 48/25; 48/50 / EN

INSTALLATION

4.16 COMMISSIONING AFTER INSTALLATION

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 7.2).

4.16.1 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 chapter 7.

NOTE:
The DIP-switches must be adjusted prior to
commissioning; all other settings can only be
made 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 DC­distribution 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. This is particularly dangerous in
places with insufficient ventilation, due to the
gassing of the batteries an explosion can occur.
Avoid having flammable materials close by.

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

4.16.2 MasterBus (optional)

During first commissioning the Mass Charger will be
recognized by the MasterBus network automatically. The
remote control panel of the MasterBus network will
indicate that a new device was found.

Some settings can only be changed via the MasterBus
interface. See chapter 7 for an overview of all available
MasterBus settings. Refer to the user’s manual of the
remote control panel to change these settings.

4.17 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 (see section 3.1.2).
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 the wiring.

Now the Mass Charger can be demounted in a safe way.

4.18 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.

4.19 RE-INSTALLATION

To reinstall the Mass Charger, follow the instructions as
described in this chapter (chapter 4).

EN / Mass Charger 12/60-2; 12/80-2; 24/50-2; 24/75; 24/100; 3-24/100; 48/25; 48/50 / July 2010 15

DIP SWITCH SETTINGS

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 chapter 7.

Once a DIP switch has been set to On,
MasterBus settings are disabled.

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 authorised personnel only.

5.1 DIP SWITCH OPERATION

The Mass Charger has six DIP switches, see figure 9.
These switches are operated by flipping the levers to the
other position, using a small screw driver.

5.2 DIP SWITCH FUNCTIONS

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

4 3 2 1 DIP switches/ Settings

0 0 0 0 Standard
1 0 0 0 Diode
0 1 0 0 Gel
1 1 0 0 Diode + Gel
0 0 1 0 Traction
1 0 1 0 Traction + Diode
0 1 1 0 ContMon + Traction
1 1 1 0 ContMon + Traction + Diode
0 0 0 1 ForceFloat
1 0 0 1 ForceFloat + Diode
0 1 0 1 ForceFloat + Gel
1 1 0 1 ForceFloat + Diode + Gel
0 0 1 1 ContMon
1 0 1 1 ContMon + Diode
0 1 1 1 ContMon + Gel
1 1 1 1 ContMon + Diode + Gel

5.2.1 Force Float (DIP switch 1)

For special applications a fixed charge voltage can be
required. The battery charger allows you to change the
three stage charge program to a single stage program by
activating the function "Force Float", switching DIP switch
1 to "ON" (see fig. 2 & 3 for further information).
The charge voltage will be fixed at 13.25V (12V charger),

26.5V (24V charger) or 53V for a 48V charger.

5.2.2 Traction setting (DIP switch 2)

Setting for traction charging: +0.7/1.4/2.8V during bulk and
+0.4/0.8/1.6 V in absorption for 12/24/48V batteries.

Figure 9: DIP-switches C2 (above) and C3 enclosure

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: Gel compensation on (+0,55V during float)

or 1.1V/24V or 2.2V/ 48V
Traction Traction charging (+0.7V during bulk and

+0.4V in absorption).
Force float: One step charge program with fixed float

voltage.

5.2.3 Gel batteries (DIP switch 3)

Some gel batteries need a higher float voltage for optimal
charge. Changing the float voltage can by done by setting
DIP switch 3 to "ON". The float voltage will increase to

13.8V (12V charger), 27.6V (24V charger) or 55.2V for a
48V charger.

5.2.4 Diode setting (DIP switch 4)

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

16 July 2010 / Mass Charger 12/60-2; 12/80-2; 24/50-2; 24/75; 24/100; 3-24/100; 48/25; 48/50 / EN

MASTERBUS

6 MASTERBUS

6.1 WHAT IS MASTERBUS?

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

MasterBus is a fully decentralized data network for
communication between the different Mastervolt system
devices. It is CAN-bus based which has proven itself as a
reliable bus-system in automotive applications. MasterBus
is used as power management system for all connected
devices, such as the inverter, battery charger, generator
and many more. This enables communication between the
connected devices, for instance to start the generator
when the batteries are low.
MasterBus reduces complexity of electrical systems by
using UTP patch cables. All system components are
simply chained together. Therefore each device is
equipped with two MasterBus data ports. As only a few
MasterBus cables are needed, installation and material
costs are reduced importantly. New devices can be added
to the existing network easily. Consequently the
MasterBus network is highly flexible for extended system
configuration. Mastervolt also offers several interfaces like
the Modbus and NMEA interface, making even non­MasterBus devices suitable to operate in the MasterBus
network.
For central monitoring and control of the connected
devices Mastervolt offers four different panels, from the
small Mastervision compatible 120 x 65mm LCD screen
up to the full colour MasterView System panel. All
monitoring panels can be used for monitoring, control and
configuration of all connected MasterBus equipment.

CAUTION: Never connect a non-MasterBus
device to the MasterBus network directly! This
will void warranty of all MasterBus devices
connected.

6.2 HOW TO SET UP A MASTERBUS
NETWORK

Every MasterBus device is equipped with two data ports.
When two or more devices are connected via these ports,
a local data network called the MasterBus is formed.
Keep the following rules in mind:

Place a terminating device on both network ends.

Connections between the devices are made by
standard straight UTP patch cables.

OK

At least one device in the network must be MasterBus
powering (see specifications). As all powering devices
are galvanic isolated, multiple powering devices are
allowed.

OK

Do not make ring networks.

Do not make T-connections in the network.

OK

Terminating

device

EN / Mass Charger 12/60-2; 12/80-2; 24/50-2; 24/75; 24/100; 3-24/100; 48/25; 48/50 / July 2010 17

Terminating

device

MASTERBUS SETTINGS

7 MASTERBUS SETTINGS

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

Value Meaning Factory setting Adjustable range

7.1 DEVICE

Language Language that is displayed on a monitoring

Name Name for the Mass Charger. CHG Mass Charger See specifications
Device Device name recognized by MasterBus. Mass Charger ­Battery name Name for the main battery bank. House Bank Max 16 characters
Factory settings Option to reset the Mass Charger to default

7.2 PRESETS

Diode compensate Option for charger diode +0.6 V voltage

Forced float Option for Forced Float or constant voltage

Continuous Option to keep MasterBus powered by the

Gel / AGM Gel/ AGM settings option. It includes fully

Traction Traction settings option. See section 7.8. Disabled Disabled, Enabled
NiCad NiCad settings option See section 7.9. Disabled Disabled, Enabled
Li-ion Li-ion settings option. See section 7.10. Disabled Disabled, Enabled
Equalize Option to enable Equalizing. Shows only when

7.3 GENERAL

Max. current Maximum charge current, adjustable model

Temp. compensate Charge voltage compensation for temperature

7.4 BULK

Bulk voltage Bulk voltage 14.25/28.50/57.00 V 0.00-16.00/16.00-

Max. bulk time Maximum bulk timer 360 min 0-600 min
Min bulk time Minimum bulk timer 4 min 0-600 min
Start bulk time Voltage at which to start the bulk timer. 13.80/27.60/55.2 V 0.00-16.00/16.00-

Bulk ret. volt. Return to Bulk voltage 12.80/25.60/51.2 V 0.00-16.00/16.00-

Bulk ret. time Adjustable Return to Bulk time after the Return to

7.5 ABSORPTION

Abs. voltage Absorption voltage 14.25/28.50/ 57.00 V 0.00-16.00/16.00-

Max absorption Maximum absorption timer 360 min 0-600 min
Min absorp. time Minimum absorption timer 15 min 0-180 min
Return amps Return to Bulk current (in A) 6.0 %*I max 0-25% * I max

English EN, NL, DE, FR, ES,

device connected to the MasterBus.

IT

Not reset Not reset, reset

settings.

Disabled Disabled,

compensation. If it is enabled, the compensation

Enabled: 0-2.50 V

value is adjustable.

Disabled Disabled, Enabled
charging. If it is enabled, Forced Float voltage is
adjustable.

Disabled Disabled, Enabled
battery when the Mass Charger is disabled.

Disabled Disabled, Enabled
adjustable Bulk, Absorption and Float settings.

Disabled Disabled, Enabled
no other battery type has been selected.
Warning: Equalize is suitable for wet batteries
only! Do not use Equalize for other battery types!

Model dependent 0-100% * Imax
dependent.

-0.060 V/°C -1.000 .. 1.000 V/°C

(V/°C).

32.00/ 32.00-64.00 V

32.00/ 32.00-64.00 V

32.00/ 32.00-64.00 V

30 sec 0-255 sec
Bulk voltage has been reached.

32.00/ 32.00-64.00 V

18 July 2010 / Mass Charger 12/60-2; 12/80-2; 24/50-2; 24/75; 24/100; 3-24/100; 48/25; 48/50 / EN

MASTERBUS SETTINGS

Value Meaning Factory setting Adjustable range

7.6 FLOAT

Float voltage Float voltage 13.25, 26.50,53.00 V 0.00-16.00/16.00-

32.00/ 32.00-64.00 V

Equalize voltage Equalize voltage 15.50/ 31.00/ 62.00 V 0.00-16.00/16.00-

32.00/ 32.00-64.00 V

Equalize time Equalize time 360 min 0-600 min

7.7 ALARM SETPOINTS

DC Alrm high on Alarm DC High on 16.00/32.00/ 64.00 V 0.00-16.00/16.00-

32.00/ 32.00-64.00 V

DC Alrm high off Alarm DC High off 15.00/30.00/60.00 V 0.00-16.00/16.00-

32.00/ 32.00-64.00 V

DC Alrm low on Alarm DC low on 10.00/20.00/40.00 V 0.00-16.00/16.00-

32.00/ 32.00-64.00 V

DC Alrm low off Alarm DC low off 11.00/22.00/44.00 V 0.00-16.00/16.00-

32.00/ 32.00-64.00 V

DC Alrm delay Alarm delay time 30 sec 0-255 sec

7.8 TRACTION SETTINGS

Bulk voltage Bulk voltage 14.60/29.20/58.40 V (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 Start bulk time 13.80/27.60/55.20 V (read only)
Bulk ret. volt. Bulk return voltage 12.80/25.60/51.20 V (read only)
Bulk return time Bulk return time 30 sec (read only)
Abs. voltage Absorption voltage 14.45/28.90/57.80 V (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 13.25/26.50/53.00 V (read only)

7.9 NICAD SETTINGS

Bulk voltage Bulk voltage 14.5/29.00/58.00 V (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 Start bulk time 13.25/26.50/53.00 V (read only)
Bulk ret. volt. Bulk return voltage 10.00/20.00/40.00 V (read only)
Bulk return time Bulk return time 30 sec (read only)
Abs. voltage Absorption voltage 14.50/29.00/58.00 V (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 13.00/26.00/52.00 V (read only)

7.10 LI-ION SETTINGS

Bulk voltage Bulk voltage 14.60/29.20/58.40 V (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 Start bulk time 13.25/26.50/53.00 V (read only)
Bulk ret. volt. Bulk return voltage 13.15/26.30/52.60 V (read only)
Bulk return time Bulk return time 240 sec (read only)
Abs. voltage Absorption voltage 14.50/29.00/58.00 V (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)
Forced Float LI-ion forced float voltage 13.25/26.50/53.00 V (read only)

EN / Mass Charger 12/60-2; 12/80-2; 24/50-2; 24/75; 24/100; 3-24/100; 48/25; 48/50 / July 2010 19

MASTERBUS SETTINGS

7.11 EVENTS

Event x source See section 7.11.1 and 7.11.2 Disabled
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. See also figure 10. Off Off, On, Copy, Copy

Invert, Toggle.

Event x+1 The next event appears after enabling Event x. Disabled See Event x.

Figure 10 shows the meaning of the event data.

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

Output (data)
On changes the status to On at the first signal.
Off changes the status to Off at the first signal.
Copy lets the status follow the input.
Copy Invert lets the status follow the opposite of the input.
Copy is used for dimming too by holding the pulse switch

pressed for a longer time.
Toggle changes the status at the first signal and back at
the second signal. It is used in combination with a pulse
switch.

Figure 10: Event data

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

Charging Mass Charger state is On
Bulk State of charge is Bulk
Absorption State of charge is Absorption
Float State of charge is Float
Failure Charger failure MasterBus alarm
CSI Charger Status Interface MasterBus alarm to sound a horn 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 3)
LED Abs LED Abs illuminates
LED 60-80 LED 4 illuminates (see figure 3)
LED Float LED Float illuminates
LED Failure LED Failure illuminates

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

Mpc reduce Command to reduce AC current at a 5%/sec rate
Mpc off Command to reduce AC current fast
Bulk Command to start the Bulk state of charge
Absorption Command to start the Absorption state of charge
Float Command to start the Float state of charge
On/ Standby Command to switch on the Mass Charger

20 July 2010 / Mass Charger 12/60-2; 12/80-2; 24/50-2; 24/75; 24/100; 3-24/100; 48/25; 48/50 / EN

TROUBLE SHOOTING

8 TROUBLE SHOOTING

In case of a failure, the Mass Charger display shows an
error code to help you find its source. See section 3.3 for
error codes. If you cannot solve a problem with the aid of
the fault finding table, contact your local Mastervolt

8.1 FAULT FINDING TABLE

Malfunction Possible cause What to do

No output voltage
and/or current

charger supplies
maximum current

Charge current too low

Batteries not fully
charged

Batteries are
discharged too fast
Batteries are too warm,
gassing

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.
Load that is connected to the batteries is
larger than charger can supply.
Batteries not 100% charged. Measure battery voltage. After some time this will

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

High ambient temperature. Nothing; if ambient temperature is more than 40°C

Low AC input voltage. At lower AC-input
voltages the charge current is reduced.
See figure 14.
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.
Battery capacity reduced due to wastage or
sulphation, stagnation.
Defective battery (short circuit in cell). Check battery and replace if necessary.
Battery temperature too high. Use the battery temperature sensor.
Charge voltage too high. Check settings (see chapter 6).

Service Centre. See www.mastervolt.com. Make sure you
have the article and serial number present if you have to
contact your local Mastervolt Service Center to solve a
problem (See section 1.4).

Reduce load taken from the batteries. Output voltage too low,

be higher.

fully charged.

the charge current is automatically reduced.

Check AC-input voltage.

Charge and recharge a few times, this might help.

Check battery and replace if necessary.

EN / Mass Charger 12/60-2; 12/80-2; 24/50-2; 24/75; 24/100; 3-24/100; 48/25; 48/50 / July 2010 21

TECHNICAL DATA

9 TECHNICAL DATA

9.1 SPECIFICATIONS

Model 12/60-2 12/80-2 24/50-2 24/75-C

Article no. 40010606 40010806 40020506 40020756

INPUT

Mains voltage 230V, -10% + 15% 230V, -10% + 15% 230V, -10% + 15% 230V, -10% + 15%
Frequency 50 Hz ± 5 Hz 50 Hz ± 5 Hz 50 Hz ± 5 Hz 50 Hz ± 5 Hz
Inrush current None, the battery charger is equipped with a soft start in accordance with IEC 1003-3
Current 4A 6A 7A 12A
Power factor (Cos phi) 1 1 1 1
Efficiency 89% 89% 89% 89%
Input power 900W 1400W 1600W 2700W

OUTPUT

Nominal voltage 12V DC 12V DC 24V DC 24V DC
Charge current 60 A 80 A 50 A 75 A
Outputs 1x60 A and 1x3 A 1x80 A and 1x3 A 1x50 A and 1x3 A 1 x 75 A
Charge characteristic three-step plus, fully

automatic
Kind of batteries Open and closed lead acid (gel or wet), NiCad, Li-ion (settings: section 7.10)
Default charge voltages
at 25°C
absorption 14.25V 14.25V 28.5V 28.5V
float 13.25V 13.25V 26.5V 26.5V
Voltage ripple max. 100mV RMS with resistive load @ full power
Short circuit current (1/4

15A 20A 12.5A 18.75A
of max.)
Cable size (within 3 m) 25 mm2 35 mm2 25 mm2 35 mm2
Charger fuse (external) 63A 100A 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

Yes Yes Yes Yes
capability
MasterBus menu

English, Dutch, German, French, Spanish, Italian
languages

ENCLOSURE TYPE C2 C2 C2 C3

Dimensions (hxwxd) mm See figure 12 See figure 12 See figure 12 See figure 13
Protection degree IP23 IP23 IP23 IP23
Weight 5 kg 5 kg 5 kg 9 kg

* Adjustable, see chapter 5 for settings.
Specifications are subject to change without prior notice.

three-step plus, fully
automatic

three-step plus, fully
automatic

three-step plus, fully
automatic

22 July 2010 / Mass Charger 12/60-2; 12/80-2; 24/50-2; 24/75; 24/100; 3-24/100; 48/25; 48/50 / EN

TECHNICAL DATA

Model 24/100-C 3-24/100 48/25 48/50

Article no. 40021006 40031006 40040256 40040506

INPUT

Mains voltage 230V, -10% + 15% 3 x 400 V 230V, -10% + 15% 230V, -10% + 15%
Frequency 50 Hz ± 5 Hz 50 Hz ± 5 Hz 50 Hz ± 5 Hz 50 Hz ± 5 Hz
Inrush current None, the battery charger is equipped with a soft start in accordance with IEC 1003-3
Current 16 A 6.5 A 8 A 16 A
Power factor (Cos phi) 1 0.8 1 1
Efficiency 89% 89% 89% 89%
Input power 3600W 3500W 1800W 3600W

OUTPUT

Nominal voltage 24V DC 24V DC 48 V DC 48 V DC
Charge current 100 A 100 A 25 A 50 A
Outputs 1 x 100 A 1 x 100 A 1x25 A 1x50 A
Charge characteristic three-step plus, fully

automatic

three-step plus, fully
automatic

three-step plus, fully
automatic

three-step plus, fully
automatic

Kind of batteries open and closed lead acid (gel or wet),

Li-ion (settings: section 7.10)
Default charge voltages at
25°C
absorption 28.5 V 28.5 V 57 V 57 V
float 26.5 V 26.5 V 53 V 53 V
Voltage ripple max. 100mV RMS with resistive load @ full power
Short circuit current (1/4 of

25 A 25 A 6 A 12.5 A
max.)
Cable size (within 3 m) 35 mm2 35 mm2 16 mm2 25 mm2
Charger fuse (external) 125 A 125 A 32 A 63 A
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

Yes Yes Yes Yes
capability
MasterBus menu

English, Dutch, German, French, Spanish, Italian
languages

ENCLOSURE TYPE C3 C3 C2 C3

Dimensions (hxwxd) mm See figure 13 See figure 13 See figure 12 See figure 13
Protection degree IP23 IP23 IP23 IP23
Weight 9 kg 10 kg 5 kg 9 kg

* Adjustable, see chapter 5 for settings.
Specifications are subject to change without prior notice.

EN / Mass Charger 12/60-2; 12/80-2; 24/50-2; 24/75; 24/100; 3-24/100; 48/25; 48/50 / July 2010 23

TECHNICAL DATA

9.2 DIMENSIONS

Figure 12: Dimensions of C2 enclosure in mm [inch]

24 July 2010 / Mass Charger 12/60-2; 12/80-2; 24/50-2; 24/75; 24/100; 3-24/100; 48/25; 48/50 / EN

TECHNICAL DATA

Figure 13: Dimensions of C3 enclosure in mm [inch]

EN / Mass Charger 12/60-2; 12/80-2; 24/50-2; 24/75; 24/100; 3-24/100; 48/25; 48/50 / July 2010 25

TECHNICAL DATA

9.3 CHARACTERISTICS (230 V AC)

Figure 14: Charge current versus input voltage

288

Float voltage + 2.25V

= 15.50VDC

Float voltage

= 13.25VDC

10% of Imax

= voltage

= current

Figure 15: Charge characteristic of the three-step Plus charging method (at 25°C / 77°F)

FLOAT EQUALIZE FLOAT

Max equalize time = 6hr

Start equalize cycle by jumper change (disabled when Gel)

Figure 16: Charge characteristic of the equalize charge cycle (at 25°C / 77°F)

26 July 2010 / Mass Charger 12/60-2; 12/80-2; 24/50-2; 24/75; 24/100; 3-24/100; 48/25; 48/50 / EN

TECHNICAL DATA / ORDERING INFORMATION

Figure 17: Temperature compensation characteristic (charge voltage versus temperature)

10 ORDERING INFORMATION

Part number Description

77040000 MasterBus terminating device
77040100 MasterBus connection cable (UTP patch cable), 1,0m / 3.3ft
77040300 MasterBus connection cable, 3.0m / 10ft
77040600 MasterBus connection cable, 6.0m / 20ft
77041000 MasterBus connection cable, 10m / 33ft
77041500 MasterBus connection cable, 15m / 49ft
77042500 MasterBus connection cable, 25m / 82ft
77050100 100m / 330ft MasterBus cable
6502001030 Modular communication cable, cross wired, 6 pole, 6 meter / 19 ft

6502100100 Modular communication cable, cross wired, 6 pole, 10 meter / 33 ft
6502100150 Modular communication cable, cross wired, 6 pole, 15 meter / 49 ft
77050200 50 pcs. modular jacks

77050000 Set to assemble MasterBus cables. Delivery: 100m / 330ft cable, 50 pcs. modular jacks and crimping tool
77030100 MasterBus USB interface, interface between your PC and the MasterBus
77010305 MasterView Easy MkII, Touch screen to control and monitor all MasterBus products
77010400 MasterView System, Full-colour touch screen to control and monitor all MasterBus products
77020100 MasterShunt 500, DC-distribution module for exact readout of battery voltage, charge / discharge current,

and state of charge on the display of the Mass Charger. continuous rating: 250A, peak current: 500A
77020200 DC Distribution 500, DC connection device with integrated fuses.
6384003200 Industrial DC fuse 32A DIN 00
6384006300 Industrial DC fuse 63A DIN 00
6384008000 Industrial DC fuse 80A DIN 00
6384010000 Industrial DC fuse 100A DIN 00
6384012500 Industrial DC fuse 125A DIN 00
6381001000 Fuse base DIN 00 (max. 160A)
79009006 Battery switch 250A with knob
79009005 Battery switch 250A with key
6387000600 Double pole automatic circuit breaker DPN 6A-B, 1P+N
6387001000 Double pole automatic circuit breaker DPN 10A-B, 1P+N
6387001600 Double pole automatic circuit breaker DPN 16A-B, 1P+N
6385401610 Double pole automatic circuit breaker and earth leakage switch DPN VIGI 16A / B / 16mA, 1P + N
41500500* Battery temperature sensor, incl. 6 meter / 19 ft cable
21730200 RJ12 splitter for C2 enclosure, refer to section 4.11

* standard included with the delivery of the Mass Charger Mastervolt can offer a wide range of products for your electrical
installation. See our website www.mastervolt.com for an extensive overview of all our products.

EN / Mass Charger 12/60-2; 12/80-2; 24/50-2; 24/75; 24/100; 3-24/100; 48/25; 48/50 / July 2010 27

EC DECLARATION OF CONFORMITY

11 EC DECLARATION OF CONFORMITY

We,

Manufacturer Mastervolt
Address Snijdersbergweg 93
1105 AN Amsterdam
The Netherlands

Declare under our sole responsibility that

Product: Mass battery charger
Model: Mass 12/60, 12/80
Mass 24/50, 24/75, 24/100 & 24/100 3phase
Mass 48/24 & 48/50

Is in conformity with the provisions of the following EC directives:

2006/95/EC (Safety directive); the following harmonized standards have been applied:

• EN 60950-1:2001+ A11:2004 (LVD)

• EN 60335-2-29: 2004

2004/108/EC (EMC directive); the following harmonized standards have been applied:

• EN 61000-6-3: 2007 Emission hold equipment

• EN 61000-6-2: 2007 Immunity industrial

• EN 55022: 2006, Class B EN 55024

• IEC 61000-3-3 voltage dip & flicker

• IEC 61000-4-11 voltage dip & flicker measurement techniques

• IEC 6100-4-2 ESD immunity

• IEC 6100-4-4 burst and surge

• IEC 6100-4-5 burst & surge measurement techniques

• IEC6100-4-3 EMC test and measurement techniques

• IEC 6100-4-6 conducted disturbance immunity

• IEC 6100-3-2 Limits for harmonic current emissions ≤16 A per phase

Amsterdam,

H.A. Poppelier
product Manager marine & mobile

10

Snijdersbergweg 93, 1105 AN Amsterdam, The Netherlands

Tel : + 31-20-3422100

Fax : + 31-20-6971006

Email : [e-mail]