USERS MANUAL / GEBRUIKERSHANDLEIDING / BETRIEBSANLEITUNG MANUEL UTILISATEUR / MANUAL DE UTILIZACION / INSTRUZIONI PER L’USO CHARGEMASTER 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 FULL AUTOMATIC BATTERY CHARGER MASTERVOLT Snijdersbergweg 93, 1105 AN Amsterdam The Netherlands Tel.: +31-20-3422100 Fax.: +31-20-6971006 www.mastervolt.com ENGLISH: NEDERLANDS: DEUTSCH: FRANÇAIS: CASTELLANO: ITALIANO: PAGE 1 PAGINA 37 SEITE 73 PAGINA 109 PÁGINA 145 PÁGINA 181 v 1.
August 2007 / Chargemaster 12/70-3, 12/100-3, 24/40-3, 24/60-3, 24/80-3 & 24/100-3 / EN
CONTENTS CONTENTS: v 1.1 August 2007 1 GENERAL INFORMATION.............................................................................................................................................. 5 1.1 Use of this manual.............................................................................................................................................. 5 1.2 Validity of this manual ..............................................................................................................
CONTENTS 5 SETTINGS ..................................................................................................................................................................... 21 5.1 DIP Switch settings .......................................................................................................................................... 21 5.1.1 DIP-switch 1: Battery type ............................................................................................................... 21 5.1.
GENERAL INFORMATION 1 GENERAL INFORMATION 1.1 USE OF THIS MANUAL 1.4 IDENTIFICATION LABEL This manual contains important safety and operating instructions for the safe and effective operation, maintenance and possible correction of minor malfunctions of the Chargemaster.
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 Chargemaster in residential, recreational vehicle (RV) and marine applications. 2.1 1 2 3 4 5 6 7 8 6 GENERAL Before using the Chargemaster, read all instructions and cautionary markings on the Chargemaster, the batteries, and all appropriate sections of the manual.
IMPORTANT SAFETY INSTRUCTIONS 2.3 1 WARNINGS REGARDING THE USE OF BATTERIES 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.
OPERATION 3 OPERATION POWER Hold POWER pressed for 3 seconds to switch the charger on or stand-by Green illuminated = on Orange illuminated = stand-by INFO Press INFO shortly to show historical data of the Chargemaster; see section 3.5 SOURCE Press SOURCE to select the battery bank (1, 2 or 3) that you want to monitor LCD-display See section 3.3 Figure 2: operation of the Chargemaster 3.1 FEATURES 3.2 The Mastervolt Chargemaster is a fully automatic battery charger.
OPERATION By holding the POWER switch pressed again for approx. 3 seconds, the Chargemaster will switch back to stand-by: the Chargemaster stops and the POWER switch illuminates orange. Only if DIP-switch #3 was adjusted to ON and the charger was switched on, the indication light stays blinking orange, indicating that the AC-power supply fails in operation. Note that this blinking LED may slowly drain your batteries.
OPERATION 3.4 THREE STEP CHARGE ALGORITHM BATTERY VOLTAGE BULK ABSORPTION FLOAT As the Chargemaster is equipped with a three-step Plus charge system, the batteries can also remain connected to the Chargemaster in winter. One hour every 12 days the charger automatically switches to absorption to keep the battery running properly and prolong its life span. The three-step Plus charge system is also safe for all the connected equipment. See also section 8.
OPERATION 3.5 HISTORICAL DATA Press INFO shortly to scroll through the levels as described below. When no button is touched during 20 seconds, or if you hold SOURCE pressed for at least two seconds, the display returns to the initial readings. See section 5.2 if you want to reset the below mentioned historical data. Number of completed cycles Total number charging cycles that were entirely completed, i.e. from bulk to float. See section 3.4 for detailed information of the three step charge algorithm.
OPERATION Lowest detected DC voltage Shows the lowest DC-voltage that was recorded for battery bank 1, 2 or 3 (press SOURCE to select the battery bank). This value should never be below the final discharge voltage as specified by the battery manufacturer. 3.6 The Chargemaster is compatible with the MasterBus network: a fully decentralized data network for communication between the different Mastervolt system devices such as the inverter, battery charger, generator, batteries and many more.
INSTALLATION 4 INSTALLATION During installation and commissioning of the Chargemaster, the important safety instructions are applicable at all times. See chapter 2 of this manual. 4.1 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.
INSTALLATION 4.3.2 DC wiring Keep in mind that high current will pass through the DC wiring. Keep the cable length as short as possible, this will keep the system efficiency as high as possible.
INSTALLATION 4.
INSTALLATION 4.5 THINGS YOU NEED Make sure you have all the parts you need to install the Chargemaster: Chargemaster (included) Battery temperature sensor with cable and plug (included). DC-cable to connect the positive DC connection (+) of the Chargemaster to the positive pole of the DCdistribution; for specifications see section 4.3.2, DC-cable to connect the negative DC connection (–) of the Chargemaster to the negative pole of the DCdistribution; for specifications see section 4.3.2.
INSTALLATION “temp.sensor” RCD 30mA L N PE/GND DC distribution Charger fuse + POSITIVE (+) NEGATIVE (–) Battery fuse – Battery fuse Battery fuse Temperature sensor BATTERY BANK 1 (main battery bank) BATTERY BANK 2 BATTERY BANK 3 OPTIONAL This schematic is to illustrate the general placement of the Chargemaster in a circuit. It is not meant to provide detailed wiring instructions for any particular electrical installation.
INSTALLATION 4.7 INSTALLATION STEP-BY-STEP 1 2 3 18 4 Open the connection compartment by loosening the four screws. 5 Feed the AC wiring through cable gland and connect the wiring to the screw terminals. Tighten the cable gland firmly. 6 Remove the isolation cap from the DC terminals. Attach crimp-on ring terminals to both DC-cables. Connect the DC-cabling of battery bank 1, positive to +, negative to – . Mark the position of the mounting spots by using the mounting bracket.
INSTALLATION 7 Option: Connect the DC-wiring of the second and third battery bank. These battery banks should have a common negative with the main battery (see figure 7). 8 Attach the battery temperature sensor to the casing of battery bank 1. Plug the temperature sensor cable into the “temp.sensor” jack. 9 10 The factory setting of the ChargeMaster is optimal for most installations. In some applications however, it is desirable to change these settings. See section 5.1 for adjustment.
INSTALLATION 4.8 COMMISSIONING AFTER INSTALLATION When your ChargeMaster is not new, you have to take into account that former users may have changed the settings. Reset the ChargeMaster back to factory settings when there is any doubt (see section 5.2). 4.9 If it is necessary to put the Chargemaster out of operation, follow the instructions in order of succession as described below: 1 2 4.8.1 General The factory settings of the ChargeMaster are optimal for most installations.
SETTINGS 5 SETTINGS Adjustment of the settings of the ChargeMaster can be made in three different ways: • By means of DIP-switches; see section 5.1; • By means of settings at the LCD-display; see section 5.2; • Via the MasterBus network (by means of a remote control panel or an interface connected to a PC with MasterAdjust software); see section 6.3.
SETTINGS 5.2 • • • SETTINGS AT THE LCD-DISPLAY Hold SOURCE pressed for three seconds to get access to the settings menu. Then press SOURCE repeatedly to scroll through the settings menu as described below. To change a displayed setting, press INFO repeatedly. Hold INFO pressed for three seconds to switch between increasing/ decreasing a value. When the correct value is set, continue scrolling through the levels by pressing SOURCE repeatedly.
SETTINGS 5.2.2 Settings menu for models 24/40-3, 24/60-3, 24/80-3 and 24/100-3 Display Stage BULK BULK BULK ABS ABS ABS Display Text BULK VOLT MAX TMR MIN TMR ABS VOLT MAX TMR MIN TMR ABS RET AMP ABS FLOAT RET AMP FLT VOLT FLOAT CONST FLT Setting min default max unit resolution 0.00 0 0 0.00 0 0 28.80 8h 120sec 28.50 4h 15min 31.00 24h 240sec 31.00 24h 240min V h / min sec V h / min h / min 0.05 1min 1sec 0.05 1min 1min 0% 6% 50% % 1% 0 0.00 30sec 26.50 26.50 240sec 31.00 31.
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 a CAN-bus based communication network 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.
MASTERBUS 6.2 HOW TO SET UP A MASTERBUS NETWORK Each device that is suitable for the MasterBus network is equipped with two data ports. When two or more devices are connected to each other through these ports, they form a local data network, called the MasterBus. Keep the following rules in mind: The electric power for the network comes from the connected devices. At least one device in the network should have powering capabilities (see specifications).
MASTERBUS 6.3 MASTERBUS: MONITORING AND PROGRAMMING OF THE CHARGEMASTER 6.3.1 Level 2: Monitoring Value State of charger Voltage output 1 Current output 1 Voltage output 2 Current output 2 Voltage output 3 Current output 3 6.3.
MASTERBUS 6.3.4 Level 3: Configuration 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 Language Meaning Language that is displayed on a monitoring device connected to the MasterBus Bulk settings Bulk voltage Bulk voltage Max.
MASTERBUS Value Meaning Factory setting Display on/off DIP-switch 3:Stand-by mode for display (see section 5.1.3) Charger Switching on / stand-by (see section 3.1) Art. nr Shows the article number and the serial number of the Serial Chargemaster * Depending on model: CM12/70, CM12/100, CM24/40, CM24/60, CM24/80 or CM24/100, 6.3.5 Adjustable. range (read only) (read only) (read only) List of list of events sources With this version of the Chargemaster programming of event commands is not possible. 6.3.
TROUBLE SHOOTING 7 TROUBLE SHOOTING If you cannot solve a problem with the aid of this chapter, contact your local Mastervolt Service Centre. See www.mastervolt.com. Make sure you have the following information present if you have to contact your local Mastervolt Service Center to solve a problem: Article and serial number (See section 1.4) Software version (See section 3.5) 7.
TECHNICAL DATA 8 TECHNICAL DATA 8.1 SPECIFICATIONS 12V MODELS Model 12/70-3 12/100-3 Article no. GENERAL Nominal input voltage**: Nominal input frequency: Full load consumption: Max. AC input current (@ 230VAC) Max. AC input current (@ 120VAC) Nominal output voltage: Total charge current*: Number of battery outlets: Max. current second output: Max. current third output: 44010700 44011000 120/230V 50/60Hz 1200VA 7A 14A 12V 70A at 14.
TECHNICAL DATA 8.2 SPECIFICATIONS 24V MODELS Model Article no. GENERAL Nominal input voltage**: Nominal input frequency: Full load consumption Max. AC input current (@ 230VAC) Max. AC input current (@ 120VAC) Nominal output voltage: Total charge current*: Number of battery outlets: Max. current second output: Max. current third output: Charge characteristic*: Charge voltage Bulk*: Charge voltage Absorption*: Charge voltage Float*; 24/40-3 44020400 Max. absorption and max.
TECHNICAL DATA 8.3 CHARACTERISTICS Figure 9: Charge current versus input voltage BULK ABSORPTION `min. bulk timer: 2 min 14.40VDC 14.25VDC 13.25VDC FLOAT BULK `min. abs timer: 15 min Bulk Absorption Float Start max bulk timer: 13.25VDC 12.80VDC Return to bulk: 12.80VDC Imax 100% Imax < Imax Return amps = 6% Imax = voltage `max. bulk ``max.
TECHNICAL DATA FLOAT EQUALIZE FLOAT Float voltage + 2.25V = 15.50VDC Float voltage = 13.25VDC 10% of Imax = voltage Max equalize time = 6hr Start equalize cycle by jumper change (disabled when Gel) = current Figure 11: Charge characteristic of the equalize charge cycle (see section 5.1.
ORDERING INFORMATION 9 ORDERING INFORMATION 9.1 MASTERBUS INSTALLATION COMPONENTS Part number 77040000 77040020 77040050 77040100 77040300 77040600 77041000 77041500 77042500 77050000 77050000 77050000 77030100 77010100 77010300 77010400 77020100 9.2 Description MasterBus terminating device MasterBus connection cable (UTP patch cable), 0,2m / 0.6ft MasterBus connection cable (UTP patch cable), 0,5m / 1.6ft MasterBus connection cable (UTP patch cable), 1,0m / 3.
EC DECLARATION OF CONFORMITY 10 EC DECLARATION OF CONFORMITY Manufacturer Address Mastervolt Snijdersbergweg 93 1105 AN Amsterdam The Netherlands Herewith declares that: Product: 44010700 44011000 44020400 44020600 44020800 44021000 Chargemaster 12/70-3 Chargemaster 12/100-3 Chargemaster 24/40-3 Chargemaster 24/60-3 Chargemaster 24/80-3 Chargemaster 24/100-3 Is in conformity with the provision of the EC, EMC directive 89/336/EEC and amendments 92/31/EEC, 93/68/EEC The following harmonized standards hav
Snijdersbergweg 93, 1105 AN Amsterdam, The Netherlands Tel : + 31-20-3422100 Fax : + 31-20-6971006 Email : info@mastervolt.
