MASTERVOLT 12/100-3 Chargemaster Plus User Manual

MASTERVOLT 12/100-3 Chargemaster Plus

GENERAL INFORMATION

Use of this manual

This manual serves as a guideline for the safe and effective operation and maintenance of the following Charge Master Plus models:

Part number          Model
44310355                12/35-3
44310505                12/50-3
44320205                24/20-3
44320305                24/30-3
These models are further referred to as “ChargeMaster Plus”.

Liability

Advanced Systems Group can accept no liability for:

• Consequential damage resulting from the use of the ChargeMaster Plus.
• Possible errors in the included manual and the consequences of these.
• Use that is inconsistent with the purpose of the product.

Warranty

The Advanced Systems Group product warranty covers the ChargeMaster Plus for the first two years after the purchase date, on the condition that the product is installed and used according to the instructions in this manual.
Installation or use that do not comply with these instructions may result in under performance, damage or failure of the product and may void this warranty. The warranty is limited to the cost of repair and/or replacement of the product. Costs of labor or shipping are not covered by this warranty.

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.

Identification label

The following picture is only an example!
The identification label is located at the right-hand side of the ChargeMaster Plus. Important technical information required for service, maintenance & secondary delivery of parts can be derived from the identification label.
CAUTION!
Never remove the identification label. This will void the warranty.
Correct disposal of this product

• This product is designed and manufactured with high quality materials and components, which can be recycled and reused.
• 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. The correct disposal of your old product will help prevent potential negative consequences to the environment and human health.

SAFETY INSTRUCTIONS

IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS
WARNING!
Read the entire manual before using the ChargeMaster Plus. Keep this manual in a secure place.
This chapter describes important safety and operating instructions for use of a ChargeMaster Plus in residential, recreational vehicle (RV) and marine applications.

General

1. The appliance is not to be used by children or persons with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction.
2. This appliance can be used by children aged from 8 years and above and persons with reduced physical, sensory or mental capa-bilities or lack of experience and knowledge, if they have been given supervision or instruction concerning use of the appliance in a safe way and understand the hazards involved.
3. Children shall not play with the appliance.
4. Cleaning and user maintenance shall not be made by children without supervision.
5. To reduce the risk of electric shock – Do not expose the ChargeMaster Plus 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 ChargeMaster Plus in a non-ventilated room, as overheating may result.
6. Use of an attachment or spare part not recommended or sold by Advanced Systems Group may result in a risk of fire, electric shock, or personal injury.
7. UL 1236 requirements do not cover investigation of charging Lithium-ion type batteries.
8. The ChargeMaster Plus is designed to be permanently connected to an AC and DC electrical system. Installation of, and work on the ChargeMaster Plus, may be carried out only by qualified and trained personnel,  consistent with the locally applicable standards and regulations.
9. Make sure that all wiring is properly installed, in good electrical condition, and correctly sized to match the AC ampere rating of the ChargeMaster Plus. Check the wiring on a regular base, at least once a year. Do not use the ChargeMaster Plus when the wiring is undersized or damaged.
10. Do not operate the ChargeMaster Plus if it has received a sharp blow, been dropped, or otherwise damaged in any way; take it to a qualified serviceman.
11. Except for the connection compartment, see chapter 3, the ChargeMaster Plus 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.
12. To reduce risk of electric shock, disconnect the ChargeMaster Plus from both AC and DC electrical system before attempting any maintenance or cleaning. Turning off controls will not reduce this risk. Be sure that third parties cannot reverse the measures taken.
13. The ChargeMaster Plus 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.
14. Short circuiting or reversing polarity will lead to serious damage to batteries, ChargeMaster Plus, wiring as well as accessories. Fuses cannot prevent damage caused by reversed polarity and the warranty will be void.
15. In case of fire, you must use the fire extinguisher which is appropriate for electrical equipment.
16. If applied in a marine application in the United States, external connections to the ChargeMaster Plus shall comply with the United States Coast Guard Electrical Regulations (33CFR183, Sub part I).

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 ChargeMaster Plus, 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 and on engine.
3. DANGER : To reduce the risk of explosion – Never use the ChargeMaster Plus in situations where there is danger of gas or dust explosion or area in which ignition-protected equipment is required.

Personal precautions

1. Consider having someone close enough by 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 eye 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 battery or engine.
6. Be extra cautious to reduce risk of dropping a metal tool onto battery. It might spark or short-circuit battery or other electrical part that may cause explosion.
7. Do not wear watches, bracelets, necklaces or other metal objects when working on batteries.

Warnings regarding the use of batteries

1. Only use the ChargeMaster Plus for charging Lead-Acid or lithium-ion batteries and the  supply of consumers attached to these batteries, in permanent systems. Do not use the ChargeMaster Plus 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. Make sure lithium-ion batteries used for this charger are certified to EN standards.
2. NEVER charge non-rechargeable batteries.
3. NEVER charge a frozen battery.
4. 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.
5. If it is necessary to remove a battery, always remove grounded terminal from battery first. Make sure all accessories are off, so as not to cause an arc.
6. Be sure that the area around battery is well ventilated while battery is being charged. Refer to the recommendations of the battery manufacturer.
7. 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.

Charger location

1. Never place charger directly above battery
   being charged; gases from battery will corrode and damage charger.

2. Never allow battery acid to drip on charger when reading electrolyte specific gravity or filling battery.

3. Do not operate charger in a closed-in area or restrict ventilation in any way.

4. Do not set a battery on top of charger.

DC connection precautions

1. Connect and disconnect DC output clips only after setting any charger switches to “off” position and removing AC cord from electric outlet. Never allow clips to touch each other.
2. Attach clips to battery and chassis as indicated in section 2.7, steps 5 and 6, and 2.8 steps 2 through 4.

When battery is installed in vehicle
A SPARK MAY CAUSE BATTERY EXPLOSION.
To reduce risk of a spark near battery:

1. Position AC and DC cords to reduce risk of damage by hood, door, or moving engine part.
2. Stay clear of fan blades, belts, pulleys, and other parts that can cause injury to persons.
3. Check polarity of battery posts. POSITIVE (POS, P, +) battery post usually has larger  diameter than NEGATIVE (NEG, N, –) post.
4. Determine which post of battery is grounded  (connected) to the chassis. If negative post is grounded to chassis (as in most vehicles), see (5). If positive post is grounded to the chassis, see (6).
5. For negative-grounded vehicle, connect POSITIVE (RED) clip from battery charger to POSITIVE (POS, P, +) ungrounded post of battery. Connect NEGATIVE (BLACK) clip to vehicle chassis or engine block away from battery. Do not connect clip to carburetor, fuel lines, or sheet-metal body parts. Connect to a heavy gage metal part of the frame or engine block.
6. For positive-grounded vehicle, connect NEGATIVE (BLACK) clip from battery charger to NEGATIVE (NEG, N, –) ungrounded post of battery. Connect POSITIVE (RED) clip to vehicle chassis or engine block away from battery. Do not connect clip to carburetor, fuel lines, or sheet-metal body parts. Connect to a heavy gage metal part of the frame or engine block.
7. When disconnecting charger, turn switches to off, disconnect AC cord, remove clip from vehicle chassis, and then remove clip from battery terminal.
8. See operating instructions for length of charge information.

When battery is outside vehicle
A SPARK MAY CAUSE BATTERY EXPLOSION.
To reduce risk of a spark near battery:

1. Check polarity of battery posts. POSITIVE (POS, P, +) battery post usually has a larger diameter than NEGATIVE (NEG, N, –) post.

2. Attach at least a 24-inch-long 6-gauge (AWG) insulated battery cable to NEGATIVE (NEG, N, –) battery post.

3. Connect POSITIVE (RED) charger clip to POSITIVE (POS, P, +) post of battery.

4. Position yourself and free end of cable as far away from battery as possible – then connect NEGATIVE (BLACK) charger clip to free end of cable.

5. Do not face battery when making final
   connection.

6. When disconnecting charger, always do so in reverse sequence of connecting procedure and break first connection while as far away from battery as practical.

Preparing to charge

1. If it is necessary to remove battery from vehicle to charge, always remove grounded terminal from battery first. Make sure all accessories in the vehicle are off, so as not to cause an arc.

2. Be sure area around battery is well ventilated while battery is being charged.

3. Clean battery terminals. Be careful to keep corrosion from coming in contact with eyes.

4. Add distilled water in each cell until battery acid reaches level specified by battery manufacturer. Do not overfill. For a battery without removable cell caps, such as valve regulated lead acid batteries, carefully follow manufacturer’s recharging instructions.

5. Study all battery manufacturer’s specific precautions while charging and recommended rates of charge.
   Note that the ChargeMaster Plus 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.

6. Determine voltage of battery by referring to car owner’s manual and make sure that output voltage selector switch is set at correct voltage. If charger has adjustable charge rate, charge battery initially at lowest rate. Exception: For a charger not having an output voltage selector switch, determine voltage of battery by referring to car owner’s manual and make sure it matches output rating of battery charger.

Grounding instructions

This battery charger should be connected to a grounded, metal, permanent wiring system; or an equipment-grounding conductor should be run with circuit conductors and connected to equipment-grounding terminal or lead on battery charger. Connections to battery charger should comply with all local codes and ordinances.

Warning regarding life support applications

Master volt 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 Advanced Systems Group. 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. Furthermore, the manufacturer must agree to indemnify and not hold Advanced Systems Group responsible for any claims arising from the use of the Mastervolt parts in the life support equipment.

INSTALLATION

During installation and commissioning, the safety instructions are applicable at all times.

Unpacking

In addition to the ChargeMaster Plus the delivery includes:

• Mounting bracket to mount the ChargeMaster Plus to a wall;
• Battery temperature sensor;
• Drop cable CZone/MB (1m);
• MasterBus Terminator;
• User and installation manual.

After unpacking, check the contents for possible damage. Do not use the product if it is damaged. If in doubt, contact your supplier
Check from the identification label (see section 1.5) whether the battery voltage is the same as the nominal output voltage of the ChargeMaster Plus (e.g. 24V battery set for a 24V battery charger).

Location

• The ChargeMaster Plus is designed for indoor use only.

• Ambient temperature: -25°C … 80°C / -13°F …176°F; (power derating above 40°C / 104°F to decrease the internal heat sink temperature).
  

• Humidity: 0-95% non-condensing

• Mount the ChargeMaster Plus vertically, with the connecting cables downwards.

• Do not expose the ChargeMaster Plus to excessive dust, aggressive environments, ammonia or salt.

• Make sure that the hot air that is developed during operation can be discharged. The ChargeMaster Plus must be mounted in such a way that obstruction of the airflow through the ventilation openings will be prevented.

• This device requires a minimum of 100mm (4″) of clearance on every side.

• If added to a CZone or MasterBus network, take the network powering into consideration.

• Never place the ChargeMaster Plus directly above the battery being charged, as gases from battery will corrode and damage the ChargeMaster Plus.

• If the ChargeMaster Plus is installed in the immediate vicinity of living areas, take into account that even though we took the highest care, the fan of the ChargeMaster Plus can produce noise when operating.

• Although the ChargeMaster Plus fully complies with all applicable EMC limits, it may still cause harmful interference to radio communication equipment. If such interference appears, it is recommended to increase the separation between the ChargeMaster Plus and the equipment, to relocate the receiving antenna or to connect the equipment to a circuit different from that to which the ChargeMaster Plus is connected.

Wiring

WARNING!
The wire sizes stated in this manual are given as guideline only. Always comply with all local rules and regulations.

1. 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. The recommended minimum cross section of the battery cables is:
     

   • Use the following wire colors for DC wiring color or at least different colors to make a clear distinction between the positive and negative wire from the battery:
     

   • Run 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 chassis frame as the negative conductor. Tighten securely. The positive battery cable must be fused and connected to the positive post of the battery bank.

   • The recommended DC fuses for DC 1/2/3 OUT are:
     

   • The fuse with the fuse-holder is available from your local Mastervolt distributor or Customer Service Representative.

2. AC wiring
   WARNING!
   On first connecting to power, make sure the ChargeMaster Plus is in a well- ventilated area as it might spark.
   For a safe installation the correct wire cross section must be applied. Don’t 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):
   Connection of AC wiring and recommended wire colors:

   • 240VAC, 50/60Hz installations:
     

   • 120VAC, 50/60Hz installations (single phase):
     

   • 240VAC, 50/60Hz (split phase 120/240VAC):
     Note : An accessible disconnection device  (switch or circuit breaker for example) must be incorporated in the AC wiring, in accordance with wiring rules.

3. AC safety grounding
   WARNING!
   The ground wire offers protection only if the enclosure of the ChargeMaster Plus is connected to the safety ground. Connect the ground terminal (PE / GND) to the hull, chassis or Distribution Apparatus.
   CAUTION!
   According to local regulations an RCD/Breaker (also known as GFCI) must be placed in the AC input circuit of the ChargeMaster Plus.
   For Australia and New Zealand, the wiring rules are in accordance with AS/NZS

5. Network wiring (CZone/MasterBus)
   The ChargeMaster Plus can be connected to a CZone or MasterBus network. Use an RJ45 Drop cable CZone/MB or MasterBus cable and daisy chain the ChargeMaster Plus to the other devices, forming a local data network. Both networks need a terminating device on both ends of the network. Do not make ring networks or T-connections.

   • CZone network
     Points to consider:

   • Up to 40 devices can be connected together on a single backbone.

   • Make sure the CZone network has two terminating resistors, one at each open end of the backbone.

   • The electric power for the network comes from a battery or power supply. Make sure that it delivers enough power and is positioned as close to the middle of the backbone as possible to reduce voltage drop.

   • MasterBus network
     Points to consider:

   •  Connections between the devices are made by standard MasterBus cables (straight UTP). Advanced Systems Group can supply these cables.

   • Up to 63 MasterBus devices can be connected together.

   • The electric power for the network comes from the connected devices according to the rule: 1powering / 3 non-powering. Spread the powering devices over the network.

For more details on networks, please contact your Mastervolt supplier.
Batteries
Always follow the instructions published by the battery manufacturer.

Materials needed
Make sure you have all the parts you need to install the ChargeMaster Plus:

• ChargeMaster Plus (included).

• Battery temperature sensor with cable and plug (included).

• DC cables to connect the ChargeMaster Plus to the batteries and common negative; see section 3.3.1 for specifications.

• DC fuse holder with a DC fuse, to be integrated in the positive DC cable; see section 3.3.1 for specifications.

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

• AC cable to connect the AC input to an AC power source. See section 3.3.2.

• Batteries. See section 3.4.

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

• For CZone setup, an RJ45-M12 Drop cable CZone/MB (included) and a tee connector
  (not included). When connecting several drop cables in a similar location, use a 2-way or 4-way tee connector

• For MasterBus setup, an RJ45 MasterBus cable (not included).

We recommend as a minimum tool kit:

• Socket wrench (10mm) to fix the main DC cables.
• Socket wrench (10mm) to fix the Safety ground connection.
• Flat blade screwdriver (3mm or 1/8″) to fix the spring-clamp terminals of the AC wiring.
• Tools to fix the screws / bolts (Ø 6mm) with plugs to mount the ChargeMaster Plus to a surface.
• Philips screwdriver number 2 to open the connection compartment.

Overview of the connection compartment

1. Spring cage terminal AC input
2. Strain relief for AC wiring (M3)
3. Safety ground connection 1*
4. Safety ground connection 2*
5. M6 Positive terminal charge output 1; DC 1 OUT
6. M6 Positive terminal charge output 2; DC 2 OUT
7. M6 Positive terminal charge output 3; DC 3 OUT
8. Common negative output terminal
9. DIP switches
10. Network connection (CZone/MasterBus)
11. Temperature sensor connection

• There are two safety ground connections. Use only one of them.

Connection example

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

• Use only one of the two options.
  When installing the AC wires, keep extra length available for the PE, ensuring the PE will be the last wire to get taut if the wire slips through the anchorage.

Notes :

• If the battery temperature remains within 15-25°C (59-77°F), connection of the battery temperature sensor is optional.
• Lithium-ion batteries require no temperature sensor.
• If creating a parallel system of multiple ChargeMaster Plus units, the units should be excluded from any isolation measurement system.

WARNING!
All electrical systems (AC and DC) must be disconnected from any power source during the entire installation!
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.
• Short circuiting or reversing polarity may lead to serious damage to the batteries, the ChargeMaster Plus, the cabling and/or the terminal connections. Fuses between the batteries and the ChargeMaster Plus cannot prevent damage caused by reversed polarity. The damage as a result of reverse polarity is detectable by the service depart-ment and is not covered by the warranty.

Installation step-by-step

2. Open the connection compartment by loosening the two screws.

3. Fix the enclosure to the wall by fastening two screws at the lower side of the ChargeMaster Plus as well.

4. Connect the AC wiring to the spring-clamp terminals:

  * Push a flat-blade screwdriver (3mm / 1/8″) into the square hole to open the related wire port.  

  * 2 Insert the wire 15mm / 0.6″ into the opening.
  * Remove the screwdriver.  

Fasten the cable with the strain relief.

6. Integrate a fuse holder in the positive battery wire but do not place the fuse yet!
   Fit crimp-on cable lugs to the DC cables. Connect the DC cabling of battery bank 1, positive to +, negative to – .
   Tightening torque: 4.9 – 5.4 Nm [43 – 47 In-lb.] Repeat steps for output 2 and

8. Attach the battery temperature sensor to the casing of battery bank 1.
   Plug the temperature sensor cable into the “Temp sense” jack.

9. Option: Connect the ChargeMaster to the CZone or MasterBus network.

   • Adding to a CZone network
   • Disconnect the backbone at the closest backbone connection and add in a tee connector.
   • Reconnect the backbone  connection(s) with the new tee connector in place.
   • 3 Connect the RJ45 CZone/MB drop cable to the black coupler on the tee and then connect to the ChargeMaster Plus. Plug the connectors into either of the ports.
   • Adding to a MasterBus network
   • Disconnect a MasterBus cable or Terminator from the closest MasterBus device and connect it to the ChargeMaster Plus.
   • Connect the new MasterBus cable to the other MasterBus device and then connect to the ChargeMaster Plus. Ensure that the network is properly terminated.

10. If required, use a small screwdriver to change DIP switch settings.

11. Check all wiring; see also Figure 3 for wiring details. If all wiring is OK: Place the DC fuses.

12. Close the connection compartment by fixing the screws.

13. Continue with section 3.9 for commissioning of the ChargeMaster Plus.

Commissioning after installation

1. Check the wiring; positive connected to positive (red cables), negative connected to negative (black cables).

2. When all wiring is OK, place the DC fuse(s) to connect the batteries to the ChargeMaster Plus.
   WARNING!
   When placing this fuse, a spark might occur, caused by the capacitors used in the ChargeMaster Plus. 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.

3. Switch on the AC power supply.
   Note : when new, the ChargeMaster Plus will not start charging batteries before activated with the ON/OFF button. See step 6.

4. Check the DIP switches.

5. Check and adjust the settings of the ChargeMaster Plus with Master Adjust (MasterBus network) or with the CZone Configuration Tool (CZone network).

6. When the settings meet the power system’s needs, press and hold the ON/OFF button for 3 seconds to switch the charger on and initiate the charging process.

SETTINGS

Adjustment of the settings of the ChargeMaster Plus can be made in two different ways:

• By means of DIP switches.
• From a laptop or notebook connected to the ChargeMaster Plus via a USB Interface. Some settings can only be changed in this way.

CAUTION!
Invalid settings of the ChargeMaster Plus can cause serious damage to your batteries and/or the connected load! Only authorized personnel may adjust settings.
When required, the ChargeMaster Plus can be restored to factory settings (see section 4.2).

DIP switch settings

Use a small screwdriver to carefully set the required settings.

In a CZone network:

• Set DIP switches 1 and 2 to OFF.
• DIP switches 3 to 10 must match the unique address used in the CZone network; the dipswitch. At least one of DIP switches 3 to 10 must be ON. See the CZone
• Configuration Tool Instructions manual for more information.

In a MasterBus network:

• Set DIP switch 1 to ON.
• DIP switch 2 is MasterBus Powering ON (1) or OFF (0).
• DIP switches 3 to 5 are used for battery type selection:

1. If all DIP switches are in the OFF position (0 ), the settings suit a Flooded battery but can be changed in Master Adjust.
2. Constant voltage has no temperature compensation
   DIP switches 6 to 10 are not used in MasterBus.

MasterBus configuration

MasterBus is a CAN based data network for communication between Mastervolt devices. When the ChargeMaster Plus is connected, open MasterAdjust on a Windows laptop or notebook connected to the MasterBus network via a MasterBus USB interface. MasterAdjust software is available as free to download software on the Mastervolt website: www.mastervolt.com. This tool runs on a Windows laptop or notebook.

1. Monitoring
   A remote panel, like the SmartRemote, Touch 5 (CZone) or EasyView 5 (MasterBus), can be used for reading battery information. See applicable user manuals for details. The following table lists the parameters as shown in MasterAdjust.

Parameter

|

Meaning

|

Value range

---|---|---
General| |
Device state| Shows charger state (On / Stand-by / Alarm / Off)| (read only)
Charger state| Actual state of charge process: Off/bulk/absorption/float/suspended| (read only)

Parameter

|

Meaning

|

Value range

---|---|---
‘Toggle’ button| Button to toggle the charger state. This button does not work when the ChargeMaster Plus is switched off manually. In that case it can only be switched on with the ON/OFF button.| On / Standby
AC IN limit| Option to set the maximum AC input current level to prevent a generator or shore fuse from overload.| 12/35-3: 0-9A

12/50-3: 0-11A0

24/20-3: 0-10A

| | 24/30-3: 0-15A
AC present û| Shows the presence of AC input| (read only)
Battery temp.û| Temperature of the main battery bank (in °C)| (read only)
DC 1 OUT| |
Output 1û| Output state| (read only)
Output 1 V| Voltage of charge output 1| (read only)
Output 1 A| Output current of charge output 1| (read only)
Batt/Shunt link| A connected Masters hunt can be chosen for feedback on the charged battery. Default not selected.| (read only)
DC 2 OUT| |
Output 2û| Output state| (read only)
Output 2 V| Voltage of charge output 2| (read only)
Output 2 A| Output current of charge output 2| (read only)
DC 3 OUT| |
Output 3û| Output state| (read only)
Output 3 V| Voltage of charge output 3| (read only)
Output 3 A| Output current of charge output 3| (read only)

Parameters marked with a  are not available in CZone.

2. Alarms
   The following table lists the available alarms in MasterAdjust.
   

3. History
   The history data shows the absolute maximum readings. The following parameters are only shown in MasterAdjust.
   

4. Configuration settings
   The configuration can be done in MasterAdjust, from a laptop or notebook connected to the ChargeMaster Plus via a Mastervolt USB Interface. See applicable user manuals for details. The following table lists the parameters as shown in MasterAdjust.
   Notes :
   DIP switch settings overrule MasterBus settings. If DIP switches are not in their default setting, the corresponding MasterBus setting is grayed out.
   To be able to make changes to the configuration via MasterBus, DIP switch 1 must be in the ON position. Parameter| Meaning| Factory setting| Value range
   ---|---|---|---
   Device| | |
   Language| Menu language of this device| English| EN, NL, DE, FR, ES, IT, NO, SV, FI, DA
   Name| Name of this device. This name will be recognized by all devices connected to the network| ChargeMaster| 0-12 characters
   Power save mode| If Power save mode is ON, the charger will switch itself off when no AC power is available.| On| On, Off
   | If Power save mode is OFF, the charger stays ON even when no AC power is available.| |
   CZone enabled| This checkbox is marked when the ChargeMaster Plus is setup to work in a CZone network| Off| (read only)
   DIP Switches| DIP switch settings| 11 00000000| (read only)
   Charger| | |
   Method| Charge method| 3-Step+| 3-Step+, constant voltage
   DC current limit| Maximum DC output current| Depending on model, 100%| Depending on model 20-100%
   Battery type| The battery type settings are based on Mastervolt batteries. If connecting batteries of a different manufacturer, make sure the manufacturer’s recommendations are met. Should this not be the case, then “User defined” must be selected to change the settings.| Flooded| User defined, AGM, Gel, Flooded, Lithium- ion (MLI)
   Temp. compensate| Temperature depended charge voltage compensation| -0,030V/°C /

-0,060V/°C

| -1,000/+1,000V/°C
Bulk| | |
Voltage| Bulk voltage (@ 25°C);| 14.40/28.80V| 8-16/16-32V
Minimum time| Minimum time of the Bulk phase since

Start bulk timer

| 120sec| 0-240sec
Start time at| Battery voltage trigger point to start the bulk timer| 13.25/26.50V| (read only)
Maximum time| Maximum time of the Bulk phase since

Start bulk timer

| 480 min| 0-1440min
Parameter| Meaning| Factory setting| Value range
---|---|---|---
Absorption| | |
Voltage| Absorption voltage (@ 25°C);| 14.25/28.50V| 8-16/16-32V
Maximum time| Maximum absorption timer| 240min| 0-1440min
Return Amps| Return amps. If the charge current drops below this level, the charger switches from the Absorption to the Float stage (% of Imax)| 6%| 0-50%
Minimum time| Minimum absorption timer| 15min| 0-240min
Float| | |
Voltage| Float voltage (@ 25°C);| 13.25/26.50V| 8-16/16-32V
Return to bulk V| Return to bulk voltage; If the battery voltage stays below this level for at least the Return to bulk delay time, the charger will start the Bulk stage| 12.80/25.60V| 8-16/16-32V
Return to bulk sec| Return to bulk delay time, see Return to bulk voltage| 30sec| 0-240sec
DC 1 OUT| | |
Name| Name of this output| Output 1| 0-16 chars
Batt/Shunt link| Selection of the Master Shunt to which output 1 of the ChargeMaster Plus is connected| Not selected| Not selected,

MSH + Product Name, BAT + Product Name

DC 2 / 3 OUT| | |
Name| Name of this output| Output 2 / 3| 0-16 chars
Installer menu| | |
Factory settings button| Button to reset the ChargeMaster Plus to default settings (requires installer rights)| Not applicable| Not applicable
5. Events – System automation
A CZone/MasterBus device can be programmed to initiate an action at another connected device. This is very helpful in automation of your system but is not required.
In MasterBus this is done by means of event-based commands. In the Events tab you can program the ChargeMaster Plus to act as an event source. Events which occur during the operation of the ChargeMaster Plus will then trigger actions from other products. The following tables list the parameters as shown in MasterAdjust. Field| Meaning| Value
---|---|---
Event x source| Select an event that triggers an action, for example Battery pre low.| See Event source list
Event x target| Select the device that should take action, for example the generator| Selectable targets are system dependent
Event x command| Select the parameter that must be changed on the target device, for example Activate.| See command list of the selected device
Event x data| Data, for example On, is linked to the command.| Off, On, Copy, Copy Invert, Toggle

The ChargeMaster Plus can be configured as an event source. An event source can be used to initiate an event command and an event action by another device.
When the ChargeMaster Plus is configured as an event target by another device, this device can initiate an event command and an event action to be performed by the ChargeMaster Plus.

6. Current control
   If the available power at the AC input is limited. The ChargeMaster can be configured to reduce input current. The Current Control level should be set equal to or lower than the value of the external circuit breaker, which protects the incoming AC power. For example, when the external AC power is limited by a 6A fuse, the Current Control level should be set to ≤6A. The AC input current of the ChargeMaster Plus will be reduced to 6A.

How to set the AC input current in a MasterBus network

1. Open MasterAdjust.
2. Select the ChargeMaster Plus.
3. Go to the Monitoring tab.
4. IN the Input Current field, enter the required value.

Master Shunt

In a MasterBus network, a Masters hunt can be coupled with output 1 (DC 1 OUT) of the ChargeMaster Plus. The actual measurement data of the MasterShunt will be used to charge the batteries. Refer to the manual of the MasterShunt for information on how to configure your system.

Lithium-ion Battery MLI Ultra

The ChargeMaster Plus can be combined with a Li-ion MLI Ultra battery. Refer to the manual of the MLI Ultra for information on how to configure your system.
WARNING!
Before using the Li-ion battery, it must be properly installed and commissioned!

CZone configuration

The CZone® network is an NMEA 2000-compliant CAN-based system. When the ChargeMaster Plus is connected, open the CZone Configuration Tool on a Windows laptop or notebook connected to the CZone network. Either do the configuration while connected to the network or use a prepared configuration file (.zcf). Ensure that a DIP Switch is assigned.
Adding the ChargeMaster Plus to a CZone system configuration
Precondition :

• This section assumes that a CZone system is already configured and the CZone Configuration Tool is open.
• In the CZone Configuration Tool, from the Modules tab, press the Add button.
• From the Module Type drop-down list select Chargers.

From the Charge Type drop-down list select the required model and continue with the following steps.

1. Enter an understandable Module Name.
2. Each device on a CZone network has a unique CZone address; the Dipswitch. This number must match the physical DIP switch settings. When connected to the system: either select one from the drop-down list or edit graphically.
3. Select the Battery Type.
4. Enter the DC Current Limit.
5. Option: press the Advanced Settings button to configure advanced options.
6. Select the required Charge Method from the drop-down list.
7. Enter an understandable Name for DC 1 OUT, DC 2 OUT and DC 3 OUT.
8. NMEA2000 Instances are used to differentiate between multiple monitoring sources. PGNs are identifiers for information that follows. See section 7.4 for an overview of supported PGNs.
9. Press OK to return to the Module Modification window and press the Alarm/Switch Settings button.
10. Select the required Alarm Severities.
11. Press OK.

Optionally configure digital switching by adding Circuit Controls in the Circuits tab (e.g. a battery low switch can be used to start a generator). Write the configuration to the network to use the new configuration.

OPERATING INSTRUCTIONS

Introduction

The Mastervolt ChargeMaster Plus is a fully automatic battery charger. This means that under normal circumstances it can be left switched on with AC power and batteries connected. The ChargeMaster Plus is suitable for charging of Li- ion and lead-acid batteries, which may include maintenance-free, low maintenance, AGM, gel or deep-cycle batteries. It operates on both 240V and 120V.
WARNING!
The MLI charging voltages on this charger fit the Mastervolt Li-ion (MLI) batteries but do not necessa-rily fit other Li-ion batteries! Always follow the instructions provided by the battery manufacturer!
Switching on / off
The ChargeMaster Plus is activated by keeping the ON/OFF button pressed for approximately 3 seconds. The MODE LED will illuminate green. If necessary and if AC power is available, the ChargeMaster Plus will start to charge the batteries.
Note : Once switched on, the ChargeMaster Plus automatically resumes operation after it was disconnected from an AC source temporarily.
By holding the ON/OFF button pressed again for approx. 3 seconds, the ChargeMaster Plus will switch off: the ChargeMaster Plus stops and the MODE LED illuminates red. When the ChargeMaster Plus was switched off, it can only be activated by pressing the ON/OFF button again.
WARNING!
Switching the ChargeMaster Plus off or “stand-by” does not cut off the connection to the batteries or the AC source. This means that voltages are still present inside the apparatus.

Status display

The status display at the front side of the ChargeMaster Plus enables you to control the charger and monitor the charging process.
Note : The ChargeMaster Plus can also be monitored from a remote panel like the Touch 5 (in a CZone network) or the EasyView 5 (in a MasterBus network). See section 4.2 for details.
The status display has a 3-level menu. Menu navigation is done by shortly pressing the ON/OFF button. After each press the next menu level is shown. The MODE LED color indicates the level that is being shown.
Status
Output power
Error

The 3-step+ charge process

• Battery charging is accomplished in three automatic stages: BULK, ABSORPTION and FLOAT. The first step is the BULK phase, in which the output current of the charger is 100%, and the greater part of the capacity of the battery is rapidly charged. The current charges the batteries and gradually the voltage rises to the BULK voltage 14.25V respectively 28.5V at 25°C/77°F.

• The duration of this phase depends on the ratio of battery to charger capacity, and the battery state of charge.
  

• The BULK phase is followed by the ABSORPTION phase. Absorption charging starts when the voltage on the batteries has reached the BULK voltage and ends when the battery is completely full. Battery voltage remains constant at 14.25V/28.5V at 25°C/77°F throughout this stage, and the charge current depends on the degree to which the battery was initially discharged, the battery type, the ambient temperature, etc. With a flooded battery this stage lasts approx. 4h, with gel and AGM around 3h.

• Once the battery is 100% full, the ChargeMaster Plus automatically switches over to the FLOAT phase. In FLOAT, the ChargeMaster Plus switches to a stabilized 13.25V/26.5V (Flooded), 13.8V/27.6V (Gel/AGM) or 13.5V/27V (MLI) at 25°C/77°F.

• Connected DC loads are powered directly by the charger. If the load exceeds the charger capacity, the required additional power comes from the battery, which will be progressively discharged until the charger automatically switches back to the bulk phase. Once consumption decreases, the charger goes back to normal operation of the 3-step charge system.

• As the ChargeMaster Plus is equipped with a 3-step+ charge system, the batteries can also remain connected to the ChargeMaster Plus during winter. One hour every 14 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 Figure 9 on page 31.

1. Charge voltages

2. Pre-float
   The ChargeMaster Plus can automatically switch each individual output from absorption to pre-float stage. Pre-float ensures batteries that are nearly full don’t receive the higher charge voltage needed in the absorption stage. This prevents over-charging, extending the lifespan of the batteries.

3. Temperature compensated charging
   By installing the battery temperature sensor, the charge voltages are automatically adapted for deviating temperatures.
   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. Overcharge and gassing are prevented this way. This will extend the life of your batteries.

4. Flat battery support
   The ChargeMaster Plus automatically detects a flat battery and will initiate the flat battery charge curve described in the following table.
   

DC OUT
The ChargeMaster Plus is equipped with three full outputs; DC 1 OUT, DC 2 OUT and DC 3 OUT. The total output current is divided over these three outputs. All batteries are charged with the same settings. See section 3.6 for connections.

Maintenance

No specific maintenance to the ChargeMaster Plus is required. Examine your electrical installation on a regular basis, at least once a year. Defects such as loose connections, dam-aged wiring etc. must be corrected immediately. If necessary, use a soft, clean cloth to clean enclosure of the ChargeMaster Plus. Do not use any liquids or corrosive substances, such as solvents, alcohol, petrol or abrasive components.

Storage

If it is necessary to put the ChargeMaster Plus out of operation, execute the following steps:

1. Turn AC power off.
2. Switch off the ChargeMaster Plus
3. Remove the DC fuse(s) and disconnect the batteries.
4. Switch the RCD/Breaker of the AC input to the OFF position and, if required, disconnect the AC mains.
5. Open the connection compartment of the ChargeMaster Plus.
6. Check with a suitable voltage meter whether the inputs and the outputs of the ChargeMaster Plus are voltage free.
7. Disconnect all the wiring.

Now the ChargeMaster Plus can be demounted in a safe way. When not installed, store the ChargeMaster Plus in a dry and dust free environment. To return to normal operation, after re-installation, switch on the AC.

TROUBLE SHOOTING

The ChargeMaster Plus is protected against overload, short circuit, overheating and under and over voltage. If a fault condition occurs, the LEDs indicate an error code. See section Status display for an explanation.
CAUTION!
The ChargeMaster Plus is not protected against serious over voltage (>275VAC) on the AC input.
If you cannot solve a problem using the fault-finding table, contact your supplier or Advanced Systems Group. Make sure you have the part and serial number at hand.

TECHNICAL DATA

Specifications 12V models

• Adjustable,
• The input RCD/Fuse rating selection must be greater than 120% of the max input current (@ 120VAC) or in accordance with the requirements of national electrical regulations. Specifications are subject to change without prior notice.

Specifications 24V models

• Adjustable, see chapter 4 for settings
• The input RCD/Fuse rating selection must be greater than 120% of the max input current (@ 120VAC) or in accordance with the requirements of national electrical regulations. Specifications are subject to change without prior notice.

Dimensions

Dimensions in mm [inches] of the ChargeMaster Plus 12/35-3, 12/50-3, 24/20-3, 24/30-3.

CZone specifications

LEN (Load Equivalence Number): 0
PGNs (Parameter Group Numbers):

Characteristics

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