Mastervolt Chargemaster 12-35-3 Manual
Mastervolt Chargemaster 12-35-3 Manual
Mastervolt Chargemaster 12-35-3 Manual
CHARGEMASTER
12/35-3, 12/50-3, 24/20-3, 24/30-3
FULL AUTOMATIC BATTERY CHARGER
TABLE OF CONTENTS
1 GENERAL INFORMATION.............................................................................................................................................. 3
1.1 Use of this manual.............................................................................................................................................. 3
1.2 Validity of this manual ........................................................................................................................................ 3
1.3 Use of pictograms .............................................................................................................................................. 3
1.4 Identification label ............................................................................................................................................... 3
1.5 Liability ............................................................................................................................................................... 3
2 OPERATION .................................................................................................................................................................... 4
2.1 Features ............................................................................................................................................................. 4
2.2 Switching on / stand-by ...................................................................................................................................... 4
2.3 LED display ........................................................................................................................................................ 5
2.4 Three Step charge algorithm .............................................................................................................................. 6
2.5 Masterbus (optional) ........................................................................................................................................... 7
2.6 Maintenance ....................................................................................................................................................... 7
2.7 Failures............................................................................................................................................................... 7
3 INSTALLATION ............................................................................................................................................................... 8
3.1 Unpacking .......................................................................................................................................................... 8
3.2 Environment ....................................................................................................................................................... 8
3.3 Wiring ................................................................................................................................................................. 8
3.4 Batteries ............................................................................................................................................................. 9
3.5 Things you need ................................................................................................................................................. 9
3.6 Overview connection compartment .................................................................................................................. 10
3.7 Connection ....................................................................................................................................................... 10
3.8 Installation step by step .................................................................................................................................... 12
3.9 Commissioning after installation ....................................................................................................................... 14
3.10 Decommissioning ............................................................................................................................................. 14
3.11 Storage and transportation ............................................................................................................................... 14
3.12 Re-installation................................................................................................................................................... 14
2
GENERAL INFORMATION
1 GENERAL INFORMATION
1.1 USE OF THIS MANUAL
This manual serves as a guideline for the safe and CAUTION!
effective operation, maintenance and possible correction Special data, restrictions and rules with regard
of minor malfunctions of the ChargeMaster to preventing damage.
It is therefore obligatory that every person who works on or
with the ChargeMaster must be completely familiar with A procedure, circumstance, etc which
the contents of this manual and the Important Safety deserves extra attention.
Instructions, and that he/she carefully follows the
instructions contained herein. 1.4 IDENTIFICATION LABEL
Installation of, and work on the ChargeMaster may be
carried out only by qualified, authorised and trained
personnel, consistent with the locally applicable standards
and taking into consideration the Important Safety
Instructions.
3
OPERATION
2 OPERATION
POWER
See section 2.2.
INFO
Press INFO shortly to switch
display: Current (A), Voltage (V).
SOURCE
Press SOURCE to select the
battery bank (1, 2 or 3) you want to
monitor.
WARNING WARNING
The MLi charging voltages on this charger fit Switching the ChargeMaster to “stand-by”
the Mastervolt Li-ion (MLi) batteries and do does not cut off the connection to the batteries
not necessarily fit other Li-ion batteries!. or the AC-source. This means that voltages
Always follow the instructions provided by the are still available inside the apparatus.
battery manufacturer!
4
OPERATION
Load bar
Yellow LED “A” = on Yellow LED “V” = on Actual stage of the three step
Charge voltage charge algorithm.
Charge current
12V 24V
5
OPERATION
BATTERY VOLTAGE
6
OPERATION
2.6 MAINTENANCE
Load bar Red LED
No specific maintenance to the ChargeMaster is required. Fault condition
Examine your electrical installation on a regular base, at
least once a year. Defects such as loose connections, Wrong AC voltage**
burnt wiring etc. must be corrected immediately.
Charger failure**
If necessary, use a soft clean cloth to clean enclosure of
the ChargeMaster. Do not use any liquids or corrosive Battery voltage too high**
substances, such as solvents, alcohol, petrol or abrasive
components. Internal temperature too high**
Battery low, short circuit*.
Blinking: AC not available
CAUTION!
The ChargeMaster is not protected against:
reversed polarity on the DC-output,
over voltage on the AC-input.
7
INSTALLATION
3 INSTALLATION
During installation and commissioning of the Although the ChargeMaster fully complies with all
ChargeMaster, the important safety instructions are applicable EMC limits, it may still cause harmful
applicable at all times. interference to radio communication equipment. If such
interference appears, it is recommended to increase
3.1 UNPACKING the separation between the ChargeMaster and the
In addition to the ChargeMaster the delivery includes: equipment, to relocate the receiving antenna or to
Mounting bracket to mount the ChargeMaster to a wall; connect the equipment to a circuit different from that to
Battery temperature sensor; which the ChargeMaster is connected.
MasterBus terminating device (see APPENDIX);
This User’s manual 3.3 WIRING
Important Safety Instructions
WARNING!
After unpacking, check the contents for possible damage. The wire and fuse sizes stated in this manual
Do not use the product if it is damaged. If in doubt, contact are given as example only. Prescribed wire
your supplier. and fuse sizes may be different due to local
Check from the identification label (see section 1.4) applicable regulations and standards.
whether the battery voltage is the same as the nominal
output voltage of the ChargeMaster (e.g. 24V battery set 3.3.1 DC wiring
for a 24V battery charger). Keep in mind that high current will pass through the DC
wiring. Keep the cable length as short as possible, this will
3.2 ENVIRONMENT keep the system efficiency as high as possible. The
Obey the following stipulations during installation: recommended minimum cross section of the battery
The ChargeMaster is designed for indoor use only. cables for output 1, 2 and 3 is:
Ambient operating temperature: -25°C ... 60°C / -13°F
… 140°F (power de-rating above 25°C / 77 °F to Model DC Cable cross section:
decrease the internal temperature). ChargeMaster <2m / 6ft 2-5m / 6ft
Humidity: 0-95% non condensing. 12/35-3 16mm² / 4AWG 25mm² / 2AWG
Mount the ChargeMaster preferably to a vertical wall, 12/50-3 25mm² / 2AWG 35mm² / 1AWG
with the connecting cables downwards. 24/20-3 10mm² / 6AWG 16mm² / 4AWG
Do not expose the ChargeMaster to excessive dust, 24/30-3 16mm² / 4AWG 25mm² / 2AWG
aggressive environments, ammonia or salt.
Make sure that the hot air that is developed during Use ring terminals on the ends of the wires. The terminals
operation can be discharged. The ChargeMaster must must be crimped with a proper crimping tool. Use the
be mounted in such a way that obstruction of the following wire colours for DC wiring colour or at least
airflow through the ventilation openings will be different colours to make a clear distinction between the
prevented. positive and negative wire from the battery:
No objects must be located within a distance of 10 cm /
4 inch around the ChargeMaster. Wire colour Meaning Connect to:
Do not locate the ChargeMaster in the same Red Positive + (POS)
compartment as the batteries. Black Negative – (NEG)
Do not install the ChargeMaster straight above the
batteries because of possible corrosive sulphur fumes.
If the ChargeMaster is installed in the immediate
vicinity of living areas, take into account that the fan of
the ChargeMaster can produce noise when operating.
8
INSTALLATION
Lay the positive and negative cables next to each other to 3.4 BATTERIES
limit the electromagnetic field around the cables. The Always follow the instructions published by battery
negative cable should be connected directly to the manufacturer. The minimum required battery capacity for
negative post of the battery bank or the ground side of a Mastervolt gel batteries (MVG series) is as follows:
current shunt. Do not use the chassis frame as the
negative conductor. Tighten securely. The positive battery Model Minimum required battery
cable must be fused and connected to the positive post of ChargeMaster capacity (MVG series)
the battery bank. 12/35-3 85Ah
12/50-3 120Ah
The recommended DC fuses for outputs 1, 2 and 3 are:
24/20-3 55Ah
24/30-3 85Ah
Model ChargeMaster DC fuse
12/35-3 40A
See section 4.1.4 for minimum required
12/50-3 63A
battery capacity to meet the requirements of
24/20-3 32A the CEC regulations (USA only).
24/30-3 40A
3.5 THINGS YOU NEED
The fuse with the fuse-holder is available from your local
Make sure you have all the parts you need to install the
Mastervolt distributor or Customer Service Representative.
ChargeMaster:
3.3.2 AC wiring
ChargeMaster (included);
Battery temperature sensor with cable and plug
The AC cable and is pre-assembled to the ChargeMaster.
(included);
The following wiring colours apply:
DC cables to connect the ChargeMaster to the DC-
distribution; see section 3.3.1 for specifications;
Wire color Meaning Connect to:
DC-fuse holder with a DC-fuse, to be integrated in the
Brown Hot/Line/ Phase L1
positive DC-cable; see section 3.3.1 for specifications;
Blue Neutral N
Screws / bolts (Ø 4.5mm) (with plugs) to mount the
Green/Yellow PE / Ground PE / GND enclosure to a surface. Use mounting materials which
are suitable to carry the weight of the ChargeMaster;
3.3.3 AC safety grounding Batteries; see section 3.4;
Appropriate and reliable cable terminals, cable lugs,
WARNING! battery terminals and cord end terminals.
The ground wire offers protection only if the
enclosure of the ChargeMaster is connected We recommend as a minimum tool kit:
to the safety ground. Connect the ground Socket wrench 10mm to fix the DC-cables;
terminal (PE / GND) to the hull or the chassis. Tools to fix the screws / bolts (Ø 4.5mm) with plugs to
mount the enclosure to a surface;
CAUTION! Philips screw driver nr. 2 to open the connection
For safe installation it is necessary to insert a compartment and to fix the Safety ground connection;
Residual Current Device (earth leakage A small screw driver for adjustment of the DIP-
switch) in the AC input circuit of the switches.
ChargeMaster.
9
INSTALLATION
10
1 2 3 4 6 7 2
5
1. Cable gland for AC-wiring 6. Positive terminal charge output 2
2. Isolation caps for DC connections 7. Positive terminal charge output 3
3. Positive terminal charge output 1 8. MasterBus connectors
4. Common negative output terminal 9. Temperature sensor jack
5. Safety ground connection 10. DIP switches
3.7 CONNECTION
3.7.1 General CAUTION!
Too-thin cables and/or loose connections can
WARNING cause dangerous overheating of the cables
Let installation work be done by a licensed and/or terminals. Therefore tighten all
electrician. connections well, in order to limit transition
All electrical systems (AC and DC) must be resistance as far as possible. Use cables of
disconnected from any power source during the correct size.
the entire installation!
NOTE:
CAUTION! If the battery temperature remains within 15-
Short circuiting or reversing polarity may lead 25°C, connection of the battery temperature
to serious damage to the batteries, the sensor is optional.
ChargeMaster, the cabling and/or the terminal
connections. Fuses between the batteries and NOTE:
the ChargeMaster can not prevent damage The ChargeMaster is only feasible for the
caused by reversed polarity. The damage as connection of MasterBus compatible remote
a result of reverse polarity is detectable by the control panels.
service department and is not covered by the
warranty.
10
INSTALLATION
AC Input
RCD
DC fuse
Battery
fuse Battery
Battery
fuse fuse
Temperature
sensor
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.
11
INSTALLATION
12
INSTALLATION
Mount the isolation caps of the If required, change DIP-settings. See section
7 10
DC terminals back into position 4.1 for adjustment.
Mind the + and – markings! Use a small screw driver for adjustment of
the DIP-switches.
13
INSTALLATION
14
SETTINGS
4 SETTINGS
Adjustment of the settings of the ChargeMaster can be 4.1.4 DIP switch 4: CEC Energy saving mode
made in two different ways:
By means of DIP-switches; see section 4.1; Energy saving mode disabled (factory setting) OFF
Via the MasterBus network; see section 4.3. Energy saving mode enabled. ON
15
SETTINGS
4.3.1 Monitoring
4.3.2 Alarm
4.3.3 History
This menu shows the absolute maximum readings.
16
SETTINGS
4.3.4 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.
17
SETTINGS
4.3.5 Events
Input (pulses)
The input is represented by an on/off switch.
Output (data)
On changes the status to On at the first signal.
Off changes the status to Off at the first signal.
Copy lets the status follow the input.
Copy Invert lets the status follow the opposite of the input
Copy is used for dimming too by holding the pulse switch
pressed for a longer time.
Toggle changes the status at the first signal and back at
the second signal. It is used in combination with a pulse
switch.
18
SETTINGS
19
TROUBLE SHOOTING
5 TROUBLE SHOOTING
If you cannot solve a problem with the aid of this chapter, contact your local Mastervolt Service Centre.
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
Firmware version; double click on ChargeMaster icon in MasterView System software Configuration.
20
TECHNICAL DATA
6 TECHNICAL DATA
6.1 SPECIFICATIONS 12V MODELS
21
TECHNICAL DATA
22
TECHNICAL DATA
6.3 DIMENSIONS
23
ORDERING INFORMATION
7 ORDERING INFORMATION
7.1 MASTERBUS INSTALLATION COMPONENTS
7.2 MISCELLANEOUS
Mastervolt can offer a wide range of products for your electrical installation, including an extended program of components for
your MasterBus network, both AGM and gel batteries, shore power connections, DC distribution kits and many more.
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