MASTERVOLT ALPHA PRO Advanced 3 Step Charge Regulator For Standard Instruction Manual

: July 15, 2024
: MASTERVOLT

Table of Contents

MASTERVOLT ALPHA PRO Advanced 3 Step Charge Regulator For Standard
SAFETY INSTRUCTIONS
GENERAL INFORMATION
PRODUCT DESCRIPTION
INSTALLATION
COMMISSIONING
MASTERBUS
MAINTENANCE
TROUBLESHOOTING
TECHNICAL DATA
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MASTERVOLT ALPHA PRO Advanced 3 Step Charge Regulator For Standard

For the latest version of this manual, visit our website

www.mastervolt.com

THIS MANUAL HAS TO BE READ IN COMBINATION WITH THE “MASTERVOLT ALTERNATORS” MANUAL

SAFETY INSTRUCTIONS

READ AND SAVE THESE INSTRUCTIONS

Installation of, and work on the Alpha Pro charge regulator, must be carried out by qualified, authorized and trained personnel, consistent with the locally applicable standards and taking into consideration the safety instructions.

WARNINGS AND SYMBOLS
Safety instructions and warnings are marked in this manual and on the product by the following pictograms:

USE FOR INTENDED PURPOSE

The Alpha Pro charge regulator is constructed as per the applicable safety-technical guidelines.
Use the Alpha Pro charge regulator only:
- for the charging of lead acid or Lithium-ion batteries and the supply of loads connected to these batteries, in permanent systems;
- with fuses, protecting the wiring between the alternator / Alpha Pro charge regulator output and battery;
- in a technical correct condition;
- protected from rain, moist, dust, and condensation;
- observing the instructions in this user manual.
  WARNING!
  Never use the Alpha Pro charge regulator in locations where there is a danger of gas or dust explosion or potentially flammable products!
Use of the Alpha Pro charge regulator other than that mentioned in point 2 is not considered to be consistent with the intended purpose. Mastervolt is not liable for any damage resulting from the above.

MAINTENANCE & REPAIR

If the Alternator, Alpha Pro charge regulator, and engine are switched off during maintenance and/or repair activities, they should be secured against unexpected and unintentional switching on:
- remove the key from the engine ignition switch;
- switch off the connection with the batteries or remove the DC fuse(s);
- ensure that third parties cannot reverse the measures taken.
  WARNING!
  When service must be carried out while the engine is running, be aware of moving parts like V-belts.
If maintenance and/or repairs are required, only use original spare parts.

GENERAL SAFETY AND INSTALLATION PRECAUTIONS

Before using the Alpha Pro charge regulator, read all instructions and cautionary markings on the Alternator /Alpha Pro charge regulator, the batteries, and all appropriate sections of this manual.
The Alpha Pro charge regulator is designed to be permanently connected to your DC electrical systems. Mastervolt recommends that all wiring be done by a certified technician or electrician to ensure adherence to proper electrical wiring regulations.
Wrong use of the charging mode selector will lead to serious damage to batteries, the Alternator, the Alpha Pro charge regulator charge regulator and the cabling.
Wrong MasterBus settings will lead to serious damage to batteries, the Alternator, the Alpha Pro charge regulator, and the cabling.
Selection of a MasterShunt connected to a battery with a different nominal voltage will lead to serious damage to the batteries, the Alternator, the Alpha Pro charge regulator, and the cabling.
Be aware of parts that can be hot: not only engine parts but the alternator as well.
In case of fire, you must use the fire extinguisher which is appropriate for electrical equipment.
Short-circuiting or reversing polarity will lead to serious damage to batteries, the Alternator, the Alpha Pro charge regulator and the cabling. Fuses between the batteries and the electrical installation cannot prevent damage caused by reversed polarity and the warranty will be void.
Secure the DC wiring with a fuse, according to the guidelines in this manual. Connection and protection must be done in accordance with local standards.
Do not work on the Alternator, Alpha Pro charge regulator or parts of the electrical system if it is still connected to a power source.

WARNING 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 battery.
Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.
Wear complete eye protection and clothing protection. Avoid touching your eyes while working near the battery.
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.
NEVER smoke or allow a spark or flame in the vicinity of the battery or engine.
Do not short-circuit batteries, as this may result in an explosion and fire hazard! Be extra cautious to reduce the risk of dropping a metal tool onto a battery. It might spark or short-circuit battery or another electrical part may cause an explosion.
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.
Do not use the Alpha Pro charge regulator for charging non-rechargeable batteries that are commonly used with home appliances. These batteries may burst and cause injury to persons and property damage.
NEVER charge a frozen battery.
Excessive battery discharge and/or high charging voltages can cause serious damage to batteries. Do not exceed the recommended limits of the discharge level of your batteries.
If it is necessary to remove a battery, always remove the grounded terminal from the battery first. Ensure that all accessories are off, so as not to cause an arc.
Ensure that the area around the battery is well-ventilated while the battery is being charged. Refer to the recommendations of the battery manufacturer.
Batteries are heavy! It may become a projectile if it is involved in an accident! Ensure that adequate and sure mounting and always use suitable handling equipment for transportation.

WARNING REGARDING LIFE SUPPORT APPLICATIONS
Do not use the Alpha Pro charge regulator for applications in any medical equipment intended for use as a component of a life support system. For this type of use a specific written agreement between the customer and Mastervolt is required.

GENERAL INFORMATION

USE OF THIS MANUAL
This manual serves as a guideline for the safe and effective operation and maintenance of the following Alpha Pro charge regulator models:

Model Product code / Part no.

Alpha Pro III 45513000
Alpha Pro II 45512000

Note: This manual applies to Alpha Pro charge regulators running on Firmware Version 4.0 and higher. For older firmware versions, some of the described settings in section 6.3 may look different. These models are further referred to as “Alpha Pro charge regulator” or “Alpha Pro”. The Alpha Pro charge regulator can be purchased individually, or as part of a kit that includes a Mastervolt alternator and/or a pulley. For available models or other accessories, see the Mastervolt website.

LIABILITY
Mastervolt can accept no liability for:

Consequential damage resulting from the use of the Alpha Pro charge regulator.
Possible errors in the included manual and the consequences of these.
Use that is inconsistent with the purpose of the product.

WARRANTY
The Mastervolt product warranty covers the Alpha Pro charge regulator 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 does not comply with these instructions may result in underperformance, 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
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.

PRODUCT DESCRIPTION

This user manual describes the installation and operation of the Alpha Pro charge regulator. Together with the Mastervolt alternators, this charging regulator is designed to provide a high output power at low RPM, which is typical for marine applications. It consists of the following main components (See Figure 2):

Mastervolt alternator
Alpha Pro charge regulator
Battery fuses
Batteries (not included)
Battery temperature sensor

Figure 2: Basic charging system consisting of an alternator and the Alpha Pro charge regulator

OVERVIEW OF THE ALPHA PRO CHARGE REGULATOR

Charging mode selector switch
Yellow LED to indicate Bulk phase
Yellow LED to indicate Absorption phase
Yellow LED to indicate Float phase
Green LED to indicate MasterBus traffic

When LEDs 2, 3 and 4 are all on, the battery is in float phase.

Figure 3: Overview of the Alpha Pro charge regulator (front view)

THE 3-STEP+ CHARGE PROCESS
The Alpha Pro charge regulator controls the alternator’s output voltage. It is designed for optimal charging of flooded, GEL, AGM, and Lithium-ion batteries. Battery charging is accomplished in three automatic stages: BULK, ABSORPTION, and FLOAT.

See Figure 5. The first step of the 3-step+ charge process is the BULK phase, in which the output current of the charging system is limited by the maximum output current of the alternator and the engine RPM. At this stage, the greater part of the battery capacity is rapidly charged. The current charges the batteries and the voltage will rise to the absorption voltage. Refer to the specifications for the charging voltages for different batteries. The duration of this phase depends on the ratio of charging capacity to battery capacity and on the degree to which the batteries were discharged to begin with.

The bulk phase is followed by the absorption phase. The absorption charge starts when the voltage on the batteries has reached the absorption voltage and ends when the battery is fully charged. Battery voltage remains constant throughout this stage, and the charge current decreases during charging of the battery. With a flooded battery, this stage lasts about four hours, with GEL and AGM around three, and with Lithium-ion batteries about 30 minutes. Once the maximum absorption timer has passed, the Alpha Pro charge regulator automatically switches over to the float phase. During the float phase the Alpha Pro charge regulator switches to float voltage, refer to specifications, and stabilizes this voltage to maintain the batteries in an optimum condition. Connected loads are powered directly by the charging system. If the load is higher than the capacity of the charging system, the required additional power comes from the battery, which will be progressively discharged. The Alpha Pro charge regulator will start a new cycle when the engine is started again or when the battery voltage drops below a predefined threshold.

TEMPERATURE-COMPENSATED CHARGING
A battery temperature sensor is included in the delivery of the Alpha Pro charge regulator. By installing this battery temperature sensor, the charge voltages are automatically adapted for deviating temperatures. When the temperature-sensor is not connected, the 25°C [77ºF] settings are taken.

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. This will extend the life of your batteries. Consult your battery manufacturer for recommended charging voltages.

Notes: – Temperature-compensated charging does not prevent the batteries from overcharging situations.

Lithium-ion batteries do not require an external temperature sensor or temperature compensation!

CAUTION!
High temperatures are destructive to batteries. If your batteries are regularly subjected to temperatures above 30ºC [100ºF], you should relocate them, or supply forced fresh air ventilation.

ALTERNATORS FROM OTHER BRANDS
You may want to equip a non-Mastervolt alternator with the optional temperature sensor (Product code: 41500400) that measures the housing temperature of the alternator. The MasterAdjust Temperature feature in MasterBus keeps track of the housing temperature and reduces and stops the charge of the alternator, if necessary, see section 5.4. The configuration can be done in MasterAdjust, from a PC connected to the Alpha Pro charge regulator via a Mastervolt USB Interface. MasterAdjust software is available as free to download software on the Mastervolt website: www.mastervolt.com.

CAUTION!
The alternator must be suitable to handle its power continuously. Refer to the alternator supplier for details regarding the maximum allowed temperature and the best spot to place this sensor. Mastervolt does not accept any liability for consequential damage.

The alternator temperature sensor is potted in a metal cable lug to make it more resistant to higher temperatures and provide a way to attach it to the alternator housing. The installer should find a way where and how to attach the sensor to the alternator housing.

CAUTION!
Do not attach the cable lug to one of the alternator connection bolts. These bolts are often located in the airflow of the alternator and this will affect the measurement.

INSTALLATION

During the installation and commissioning of the Alpha Pro charge regulator, the Safety Guidelines & Measures are applicable at all times. See section 1 of this manual.

UNPACKING
The Alpha Pro charge regulator ships with the following items:

Wiring loom for Mastervolt alternators
Battery temperature sensor
MasterBus terminator
User manual

After unpacking, check the contents for possible damage. Do not use the product if it is damaged. If in doubt, contact your Mastervolt dealer.

WIRING INSTRUCTIONS

General

WARNING!
Let installation work be done by a licensed electrician. Before beginning with the connection of the wiring, make the DC distribution voltage free and ensure that the engine is off.

CAUTION!
Short-circuiting or reversing polarity may lead to serious damage to the batteries, the alternator, the Alpha Pro charge regulator, the cabling, and/or the terminal connections. Fuses cannot prevent damage caused by reversed polarity. The damage as a result of reverse polarity 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, to limit transition resistance as far as possible. Use cables of the correct size. See specifications (Chapter 9) for recommended wire sizes and torque values.

Use the supplied wiring loom for the connection of the Alpha Pro charge regulator.
DC Cables to connect the battery to the alternator are not included in the delivery.
The Mastervolt alternator wiring is electrically isolated from the ground.
A DC fuse must be integrated in the positive cable between the battery and the alternator (see section 9 for specifications). Do not install the DC fuse of the DC distribution before the entire installation is completed.
The two-pole connector of the wiring loom goes into the field connector of the alternator. Take adequate measures to ensure strain relief for this connector.

Reg on
The “reg on” wire should be interrupted with a relay or an ungrounded oil pressure switch. If you use a relay, this relay can be powered from the ignition switch.

CAUTION!
The “reg on” wire should run to the positive pole of the battery being charged, as this is also the voltage measurement for the regulator. Otherwise, the batteries may be overcharged and damaged. See Figure 8. If the engine is not running switch “S1” must be open, otherwise, the field windings of the alternator will be damaged due to overheating by lack of cooling-air flow.

Brown wire
Ignition switch
Relay
Positive battery pole of the battery being charged
Normally open oil pressure switch

Figure 8: Connection options

Connection of the battery temperature sensor (included)
Attach the temperature sensor on the battery and connect to the Alpha Pro charge regulator as indicated.

Notes:

If there are multiple batteries, attach the sensor to the main battery, or to the one that will run the warmest.
High temperatures are destructive to batteries. If your batteries are regularly subjected to temperatures above 30°C [100°F], you should relocate them or supply forced fresh air ventilation.
Lithium-ion batteries do not require an external temperature sensor or temperature compensation!

Connection of a tachometer (optional)
If a tachometer is used, it should be connected between the W terminal of the alternator and the B– terminal of the alternator (or the negative battery pole). See Figure 10. The Alpha Pro charge regulator has the same function integrated in its MasterBus functionality, so the number of revolutions per minute (revs or RPM) can be shown on a MasterBus-connected display too. To enable this, connect the white wire from the cable loom to the alternator, and set the number of pole pairs in MasterAdjust.

Note: With some alternators the W terminal is marked by an “R” instead of a “W”.

Connection of a D+ lamp (optional)
A standard alternator and engine have a charge indicator lamp. This lamp will go off when the alternator is charging. The Alpha Pro charge regulator offers the same function. To enable this, connect the yellow and white wires from the cable loom to the alternator, and select the RPM option in MasterAdjust.

Note: With some alternators the W terminal is marked by an “R” instead of a “W”.

The D+ control is also used for alarm indications:

3 short blinks every 2 seconds: field current too high
2 short blinks every 2 seconds: battery voltage too high
1 short blink every 2 seconds: field current too low

Figure 11: Connection of a D+ lamp (see the “Mastervolt Alternators” manual for detailed installation drawings)

Connection of a battery isolator (optional)
When two or more battery banks (of the same chemistry) need to be charged simultaneously, a battery isolator is recommended. See Figure 12 for installation details. Also, see the “Mastervolt Alternators” manual for installation examples.

CAUTION!
If there is a standard battery isolator between the B+ terminal of the alternator and the positive (+) pole of the battery, both the red [+bat] wire and the brown [reg on] lines must be connected to the positive (+) pole of the battery. Do not connect these wires to the input of the battery isolator.

Note: As battery voltage sensing is performed by the Alpha Pro charge regulator, you can use a battery isolator that has no voltage sense connection.

COMMISSIONING

CAUTION!
Fuses between the batteries and the Alpha Pro charge regulator cannot prevent damage caused by reversed polarity. The damage as a result of reverse polarity is not covered by the warranty. Commissioning of the Mastervolt alternator and the Alpha Pro charge regulator involves two major parts:

Selecting the charging mode
Testing and adjusting

SELECTING THE CHARGING MODE
The Alpha Pro charge regulator has a three-position selector switch featuring standard settings for a 12V or 24V (lead acid) system and advanced settings via MasterBus.

Note: The default setting is MasterBus. The configuration can be done in MasterAdjust, from a PC connected to the Alpha Pro charge regulator via a Mastervolt USB Interface. MasterAdjust software is available as free to download software on the Mastervolt website: www.mastervolt.com.

CAUTION!
Invalid settings can cause serious damage to your batteries. Adjustments of settings may be undertaken by authorized personnel only! Keep a record of setting changes in this manual. When MasterBus is selected, by default the configuration of the Alpha Pro charge regulator will be unlocked, resulting in a device that remains inactive (shown by LEDs blinking twice, one after the other). Two parameters need to be selected via MasterAdjust before the configuration can be locked and the Alpha Pro charge regulator made operational (see Chapter 6 for more extensive explanation on using MasterBus). The following procedure describes how to commission with MasterAdjust.

Go to the Configuration page.
Go to group “System” and select the “System voltage” present in your system.
Figure 14: Selecting “System voltage” through MasterAdjust
Go to group “Battery” and select the “Battery type” present in your system.
Figure 15: Selecting “Battery type” through MasterAdjust
Go to group “Alpha Pro setup” and select “Lock setup”.

Now the Alpha Pro charge regulator is ready for testing. Or configure the following optional setting(s) first.

KEEP ALIVE FUNCTION (OPTION)
This feature can keep a connected RPM meter functional if the alternator field current drops. It will only function if the White wire is connected to the W or R point of the alternator. Two situations can override this feature:

if the alternator temperature reaches its “Stop charging @”temperature or
if the charger receives a “Stop charge” event.

POWER CURVE (OPTION)
This option limits the charge current in a selected number of revs intervals. This prevents slipping as a result of the high torque required to provide the charge current. Up to the lower rev limit, the charge current will not exceed 20%. From the higher rev limit, it allows a maximum charge current of 100%. Revs in between the limit, result in a proportional maximum charge current.

Note: All RPMs here are Alternator RPMs.

TEMPERATURE CONFIGURATION (OPTION)

There are two options in the Alpha Pro temperature settings: “Battery” and “Alternator”.

By selecting “Battery”, the Alpha Pro expects the (lead acid) battery temperature sensor to be connected to its temperature input. The measured temperature will be used to compensate for the voltage output of the alternator. When charging batteries that need temperature-compensated charge (like lead acid), this temperature sensor always has the priority, to charge the batteries safely and efficiently. The battery temperature sensor (Product code: 41500500) is included in the delivery of the Alpha Pro.
By selecting “Alternator”, two temperature levels can be entered. At the first temperature level, the alternator will start reducing its output power. At the second temperature level, the alternator will stop charging. Reducing will follow a linear line between the two temperature levels. The alternator temperature sensor (Product code: 41500400) is optional. It can be used to measure the housing temperature of an alternator.For non-Mastervolt alternators, consult the manufacturer to discuss the correct temperature values to reduce and stop the charge, considering a difference in temperature between the temperatures given by the manufacturer and the spot where the sensor will be installed.

Note: The Alpha Pro has one temperature input. If both temperatures need to be measured, a MasterShunt (Product code: 77020100) could be added to the system. The MasterShunt temperature sensor input can be used to measure the batteries and this data can be used by the Alpha Pro, see sections 6.3.1, 6.3.4, and 6.3.8.

CAUTION!
Please note that this solution will not protect the alternator against damage due to overheating. Mastervolt cannot be held responsible for any damage to a third-party alternator! The only accurate measurement is on the internal windings and this can in no way be covered by this sensor. Therefore, this measurement is only an indication!

TESTING

Test before starting the engine
Before starting the engine, follow all steps in order of succession as described below:

Check whether all indication lights on the Alpha Pro charge regulator are off.
Energize the [reg on] terminal by either turning on the ignition switch (DO NOT START THE ENGINE) or by putting a jumper across switch S1 (see Figure 17). Check whether the 3 yellow LEDs start to blink. After approximately 10 seconds, the yellow bulk LED will illuminate.
Check whether the alternator field is energized by touching the shaft of the alternator with a screwdriver. It should be strongly magnetic.
De-energize the [reg on] terminal by turning off the ignition switch or by removing the jumper across switch S1 again. All LEDs should go off and the field should no longer be strongly magnetic.

CAUTION!
If you fail to de-energize the [reg on] terminal, the field windings of the alternator will be damaged due to overheating. If you cannot pass the tests mentioned above, remove the DC fuses and double-check the wiring. Refer to the Troubleshooting section (section 8).

In operation test
To check for proper operation, you will need a handheld digital meter. If you have installed a battery monitor such as the MasterShunt or any other digital voltage-measuring device, you can use this as well.

WARNING!
When the engine is running, be aware of moving parts like V-belts.

Note: See section 3.2 for an explanation of the bulk, absorption, and float modes.

Ensure that no loads or any other charging sources are on!
Ensure that the battery is (almost) fully charged. This will keep the duration of the test as short as possible.

Follow all steps in order of succession as described below:

Measure and record the battery voltage before starting the engine.
Start the engine. The three LEDs on the Alpha Pro charge regulator blink together to indicate the startup mode.
Check for abnormal noise or vibration.
The yellow [BULK] LED on the Alpha Pro charge regulator (see Figure 3) illuminates, indicating that the charge cycle begins. Rev up the engine so the alternator rotates at 3000 rpm.
Measure and record the battery voltage. The battery voltage should be higher than measured before at step 1. The battery voltage rises until the yellow [ABS] LED illuminates.
When the yellow [ABS] LED illuminates, the absorption mode starts. Disconnect the temperature sensor and measure the voltage at which the battery stabilizes. When installed correctly, the result should equal the specified voltage at 25°C [77°F]. Reconnect the temperature sensor. Option: An absorption timer starts to keep the Alpha Pro charge regulator in the absorption mode. The factory setting of this timer is 4 hours. For testing, you might want to reduce the absorption time temporarily. When absorption time has elapsed, the yellow [FLOAT] LED will illuminate. This means that the float mode has started.

If the above-mentioned tests are completed, the charging system is ready for operation. Otherwise, check the troubleshooting table.

Voltage sensing
The Alpha Pro charge regulator uses the [reg on] terminal (Figure 4, connection 4) and the [gnd] terminal for measurement of the battery voltage. Measure this voltage, then measure the voltage at the battery terminals. When installed correctly, the difference will never exceed 0.01 V. See Chapter 9 for correct wire sizes.

OPERATION
After starting the engine, the alternator and the Alpha Pro charge regulator will switch on automatically. The regulator will wait for the engine to rev up before it starts charging the battery. Refer to section 5.5.2. Start-Up mode. There is no need for adjustment or operation. If the engine is stopped the alternator and the Alpha Pro charge regulator will switch off again. When switched off, all LEDs of the Alpha Pro charge regulator are off.

CAUTION!
Never disconnect any wiring during the operation of the engine.

MASTERBUS

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. MasterBus is used as a 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 the 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. New devices can be added to the existing network easily. Consequently, the MasterBus network is highly flexible for extended system configuration. 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 can damage the MasterBus and the connected devices.

HOW TO SET UP A MASTER BUS NETWORK
Every MasterBus device is equipped with two data ports (RJ-45). 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:

Connections between the devices are made by standard straight MasterBus cables. Mastervolt can supply these cables.
Up to 63 MasterBus devices can be interconnected.
MasterBus needs a MasterBus Terminator on both ends of the network.
The electric power for the network comes from the connected devices according to the rule: 1 powering / 3 nonpowering. Spread the powering devices over the network.
Do not make ring networks.
Do not make T-connections in the network.

For more details on MasterBus, please contact your Mastervolt dealer.

MASTER BUS FUNCTIONS

Note: This manual applies to Alpha Pro charge regulators running on Firmware Version 4.0 and higher. For older firmware versions, some of the described settings may look different. Adjustments to the settings of the Alpha Pro charge regulator can be made via the MasterBus network employing a MasterBus-USB interface connected to a PC with MasterAdjust. Ensure that the mode selector is in the MasterBus position. See item 1 in Figure 3 on page 6 for the position of the switch.

CAUTION!
Invalid settings of the Alpha Pro charge regulator can cause serious damage to your batteries and/or the connected load! Adjustments of settings may be undertaken by authorized personnel only.

Monitoring

Notes: – When the configuration is unlocked, only the Device state and Charger state will be shown. – “Alternator shaft” and “Engine shaft” will not be shown if the RPM group is disabled in the Configuration tab.

Alarms

History

Configuration
The configuration can be done in MasterAdjust. When the Alpha Pro charge regulator is connected, open MasterAdjust on a Windows computer, connected to the MasterBus network via a Mastervolt USB Interface. MasterAdjust software is available as free to download software on the Mastervolt website: www.mastervolt.com.

Note: To be able to change the configuration of the Alpha Pro charge regulator, the configuration must be unlocked. This is done by pressing the “Unlock setup” button in the “Configuration” tab in MasterAdjust. When the configuration is unlocked, the regulator will stop regulating and its LEDs will blink twice, one after the other. When the configuration is finished, press the “Lock setup” button and the regulator starts regulating again.

Only in combination with an alternator temperature sensor.
All RPMs in this group are Alternator RPMs.
The number of Pool pairs is only needed if RPM values are required in MasterBus.
Can be modified if the battery type is “User defined”.
This will force the field current to 0%. Note: with older firmware, it would not drop below 20%. Therefore, the new behavior of this setting may affect existing installations. An external tachometer would read 0 RPM while the alternator is still spinning!
For a 24V system, multiply the voltages by two.

Events

Input is a pulse followed by a longer signal (1/0).
On changes the status to On at the first signal.
Off changes the status to Off at the first signal.
Copy lets the status follow the input.
Copy Invert lets the status follow the opposite of the input.
Toggle changes the status at the first signal and back at the second signal. It is often used in combination with a pulse switch.

Event source list (Alpha Pro as event source)

Event target list (Alpha Pro as event target)

MasterShunt connected to Alpha Pro
You can select a MasterShunt or an MLI Ultra battery in the MasterAdjust configuration menu. When this selection is active the Alpha Pro receives important data from the battery via MasterBus. This will improve the charging system and protect the battery using the following data:

Battery full determination
The MasterShunt or MLI Ultra battery measures the actual current that goes into the battery. When only a small percentage of current is measured, the Alpha Pro considers the battery to be full and switches to the float phase.

Starting in Float
Thanks to the above-mentioned mechanism the Alpha Pro will start directly with float charging if the SOC is 100%.

Use of the temperature sensor
The MasterShunt is installed closer to the battery than the alternator. The battery temperature sensor can now be connected to the MasterShunt. The MasterShunt will pass the measured battery temperature on to the Alpha Pro. This value is being used to compensate for the charge voltage as described in Section 3.3.

Compensation for the voltage losses
The Alpha Pro now uses the voltage of the MasterShunt to determine the voltage loss between the battery and the alternator. The Alpha Pro will compensate for these losses by raising the charge voltage evenly. Cable losses for MLI Ultra batteries are not compensated.

Note: The Alpha Pro uses both the shunt data and its data (via Reg on) for determination of voltage losses. Therefore, Mastervolt advises to mount the reg on wire (brown) as close to the battery as possible on the load side of the fuse.

With a MasterShunt connected, the following is different in the use of the Alpha Pro:

There are two options to place a temperature sensor. The MasterShunt temperature sensor is preferably placed onto the battery, and the optional sensor (Product code: 41500400) onto the alternator.
Absorption Return Amp is added in the configuration. This is the charge current at which the regulator starts the minimum absorption timer. This value is calculated from the MasterShunt Amp=Full percentage, multiplied by its entered Battery capacity.
The MasterShunt may have a battery voltage setting that differs from the Alpha Pro voltage setting. In this case, a MasterShunt Mismatch alarm is shown on MasterBus.

CAUTION!
If the Battery voltage was set to User-defined, there will be no MasterShunt Mismatch alarm when the MasterShunt has different voltage settings!

MAINTENANCE

During maintenance, the Safety Guidelines & Measures are applicable at all times. See section 1 of this manual. No specific maintenance to the Alpha Pro charge regulator is required. Examine your electrical installation regularly, at least every six months. Defects such as loose connections, damaged wiring etc. must be corrected immediately.

TROUBLESHOOTING

In case of any issue, we recommend consulting the Maintenance section first (see section 7). If you cannot solve a problem with the aid of the table below, contact your local Mastervolt dealer. See www.mastervolt.com.