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Mastervolt 12/2000-100, User And Installation Manual

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CombiMaster 120V Series – User and Installation Manual 

  

 

7.4  DC wiring 

Notes:

 

–

  DC wiring is the same for parallel and split-phase systems.

 

– 

Use ONE battery bank whose capacity is suitable for the application. 

– 

Always use the same length cables! Be aware that to keep the drawings in this chapter 
clear and easy to read, the cable lengths have not been drawn in proportion to each other. 

* Integrate a fuse holder in the positive battery wire but do not place the fuse yet! 

 

Figure 10: DC wiring example 

Primary 

Replica 1 

Replica 2 

(RED) 

(BLACK) 

BATTERY BANK 

* 

*

 

* 

Summary of Contents for 12/2000-100

Page 1: ...48 5000 70 INVERTER CHARGER COMBINATION WITH AC IN SUPPORT USER AND INSTALLATION MANUAL For the latest version of this manual visit our website Para descargar este manual en otros idiomas visite nues...

Page 2: ...b System automation 31 5 3 CZone configuration 32 6 OPERATION 34 6 1 Switching on charge only 34 6 2 Status LEDs 34 6 3 Remote control 35 6 4 3 step charge process 35 6 5 Temperature compensated charg...

Page 3: ...ances 4 Use of an attachment not recommended or sold by Mastervolt may result in a risk of fire electric shock or injury to persons 5 Except for making the electrical connections the CombiMaster Inver...

Page 4: ...allow a spark or flame in vicinity of battery or engine vi Do not short circuit battery Be extra cautious to reduce risk of dropping a metal tool onto battery It might spark or short circuit battery o...

Page 5: ...Charger wiring as well as accessories Fuses cannot prevent damage caused by reversed polarity and the warranty will be void 2 EXTERNAL CONNECTIONS TO CombiMaster Inverter Charger SHALL COMPLY WITH THE...

Page 6: ...er 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...

Page 7: ...t side with open connection compartment Bottom side Figure 2 Connections for models with product code 35511500 35512000 35513000 35522000 35523000 1 Neutral ground bonding 2 AC input 3 Status LEDs 4 M...

Page 8: ...mperature sensor connection 14 Current sharing parallel unit configuration 15 Cluster communication ports multi unit configuration For information on multi unit configurations see chapter 7 3 2 Operat...

Page 9: ...ircuit breaker Load on AC OUT AC IN Limit Load on AC OUT AC IN Limit AC input support mode If the demand for AC power still increases the AC input circuit breaker may still trip if nothing is done Thi...

Page 10: ...r is too high the inverter shuts down or the charger will reduce power This will trigger the status LEDs and optionally a remote alarm High temperature is most likely caused by heavy loads operating f...

Page 11: ...unt that the fan s of the CombiMaster Inverter Charger can produce noise when operating The CombiMaster Inverter Charger can be tabletop mounted IP 21 as well as wall mounted IP 23 The CombiMaster Inv...

Page 12: ...If connecting batteries of a different manufacturer make sure the manufacturer s recommendations are met 12V 1500W 60A 120 600 Ah 12V 2000W 100A 200 1000 Ah 12V 3000W 160A 320 1600 Ah 12V 3500W 200A...

Page 13: ...alone CombiMaster Inverter Charger in a circuit It is not meant to provide detailed wiring instructions for any particular electrical installation For information on multi unit configurations see chap...

Page 14: ...14 CombiMaster 120V Series User and Installation Manual 4 4 2 Models 3500W 4500W 5000W Figure 5 Installation drawing for models with product code 35513500 35523500 35524500 35545000...

Page 15: ...eets the battery voltage Especially for a 48V system because most fuses do not exceed 32V Use cable lugs on the ends of the wires These lugs should be crimped with a proper crimping tool Recommended w...

Page 16: ...C input choose a transformer with at least 2x the total inverter power of the units Too small a transformer causes unstable behavior For a safe installation the correct wire cross section must be appl...

Page 17: ...situations However depending on national or local regulations neutral to ground bonding may not be allowed In that case this automatic switching feature must be disabled Models 1500W 2000W 3000W The s...

Page 18: ...ible to reduce voltage drop Each device on the CZone network has a unique CZone address the Dipswitch This number is usually assigned automatically during configuration and must match the DIP switch s...

Page 19: ...iMaster Inverter Charger to a surface Use mounting materials which are suited to carry the weight of the CombiMaster Inverter Charger AC cable to connect the AC input to an AC power source See section...

Page 20: ...e holes for the mounting bracket and secure the mounting bracket to the surface Wall mounted Tabletop mounted Note Make sure that the mounting surface and material can support the weight of the CombiM...

Page 21: ...ng the two screws at the bottom and then lifting the front cover plate Step 7 Connect the AC wiring to the screw terminals Fasten the cables with a strain relief For larger cables rotate the strain re...

Page 22: ...perature sensor to the casing of the battery bank Then plug the temperature sensor cable into the temp sensor jack Note Lithium ion batteries require no temperature sensor Step 10 On the left side of...

Page 23: ...he network is properly terminated Step 12 Option use a small screwdriver to change DIP switch settings See section 5 1 on page 25 Note if added to a CZone network the DIP switches are used to set the...

Page 24: ...r use both contacts to connect an external switch In this case the CombiMaster Inverter Charger s On Charge only switch must be in the on position I External switch closed On external switch open Char...

Page 25: ...Tool Instructions manual At least one of DIP switches from 3 to 10 must be ON In a MasterBus network DIP switch 1 ON DIP switch 2 ON MasterBus Powering on OFF MasterBus Powering off Figure 6 DIP switc...

Page 26: ...On On Off Charger button Button to switch off on the charger On On Off DC IN OUT Charger state Charger state Off Bulk Absorption Float read only Battery voltage Battery voltage read only Battery curre...

Page 27: ...put current Mains input current of the cluster on L1 Input frequency Mains input frequency of the cluster on L1 Cluster L1 OUT Output voltage Total AC output voltage of the cluster on L1 Output curren...

Page 28: ...Battery Temp Battery temperature too high too low DC high voltage Battery voltage is too high DC low voltage Battery voltage is too low Overload The loads exceed the nominal inverter power Device erro...

Page 29: ...Frequency Inverter frequency 60Hz 50 60Hz DC Low on Voltage level at which the inverter switches on DC Low off alarm 11 5 1 10 7 12 5 1 DC Low off Voltage level at which the inverter switches off 10 2...

Page 30: ...100 Delay on Delay on 5s 0 300 seconds Delay off Delay off 5s 0 300 seconds Cluster installer level models 3500W 4500W 5000W only Phase system Multi unit configuration type Single phase Single phase S...

Page 31: ...MasterBus Event source Description Inverting The CombiMaster Inverter Charger is in Inverter mode Charging The CombiMaster Inverter Charger is in Charger mode Supporting The CombiMaster Inverter Charg...

Page 32: ...e following steps 3 Enter an understandable Module Name 4 Each device on a CZone network has a unique CZone address the Dipswitch This number must match the physical DIP switch settings When connected...

Page 33: ...ed in section 9 4 13 Press OK to return to the Advanced Settings window 14 Check and adjust the DC settings Note that this is only possible if in step 5 the option User defined is selected 15 Press OK...

Page 34: ...inverter off by the On Charge only switch 6 2 Status LEDs Figure 7 status LEDs Off No AC input Inverter off Charger off Green on AC input OK Inverter on Charger on Charger in bulk phase Charger in ab...

Page 35: ...d ends when the battery is completely full Battery voltage remains constant throughout this stage and the charge current depends on the degree to which the battery was initially discharged the battery...

Page 36: ...erter Charger against overload Models 1500W 2000W 3000W have a 30A fuse Models 3500W 4500W 5000W have a 50A fuse If the status LEDs indicate an overload proceed as follows Step 1 Turn off AC power Ste...

Page 37: ...power off Step 2 Remove the DC fuse s and disconnect the batteries Step 3 Remove the AC fuse s of the AC input and or disconnect the AC IN Step 4 Open the connection compartment of the CombiMaster Inv...

Page 38: ...Configuration type 12V 3500W 200A 24V 3500W 100A 24V 4500W 120A 48V 5000W 70A Single phase parallel Up to 3 units 120V 10 5kW Up to 7 units 120V 24 5kW Up to 7 units 120V 31 5kW Up to 7 units 120V 35k...

Page 39: ...tween units n 1 1 3 Communication cable n 2 4 Current Sharing cable n 0 4 Cable Strain Relief Bracket n 0 4 Mastervolt offers various cable kits that contain this item See the Mastervolt website for d...

Page 40: ...y is suitable for the application Always use the same length cables Be aware that to keep the drawings in this chapter clear and easy to read the cable lengths have not been drawn in proportion to eac...

Page 41: ...stribution through the CombiMaster Inverter Charger The following figure shows that cables with the same marking are the same length Be aware that to keep the drawings further on in this chapter clear...

Page 42: ...AC input L PE and N wires to the AC IN screw terminals Figure 12 wiring single phase AC IN Connect the AC output L PE and N wires to the AC OUT screw terminals Figure 13 wiring single phase AC OUT Pri...

Page 43: ...unit in split phase by means of a busbar An Equipment Leakage Circuit Interrupter ELCI must be installed with or in addition to the main shore power disconnect circuit breaker Check locally applicable...

Page 44: ...put of each unit must be protected by means of properly sized circuit breakers 85A max that switch off simultaneously L1 L2 and Neutral Figure 15 wiring split phase AC OUT All AC loads must be protect...

Page 45: ...means of a busbar The cables length and wire gauge must be identical The AC input of each unit must be protected by means of properly sized circuit breakers 50A max that switch off simultaneously L a...

Page 46: ...off simultaneously L1 L2 and Neutral Figure 17 wiring split phase parallel AC OUT All AC loads must be protected by means of properly sized circuit breakers and a Ground Fault Circuit Interrupter GFC...

Page 47: ...us or CZone network is properly terminated 7 6 3 Network wiring of split phase units Figure 20 Two units in split phase MasterBus network wiring In case of a CZone network connect drop cables instead...

Page 48: ...In case of a MasterBus network the MasterBus Terminator may be located somewhere else in the network Ensure that the MasterBus or CZone network is properly terminated 7 7 Configuration and initial sta...

Page 49: ...on 0 1 AC voltage input window wide AC voltage input window narrow 0 1 Energy saving mode off Energy saving mode on 0 1 Parallel operation off Parallel operation on 0 1 Step 6 First install the DC fus...

Page 50: ...list select Split phase or Single phase Step 14 With the Dev per phase stepper select PER PHASE the number of units in parallel Primary Replica In our example this is 2 Step 15 Click the Confirm topol...

Page 51: ...and DC are turned off Step 2 Make sure the AC IN and AC OUT breakers are open Step 3 Make sure the On Charge only switch position is Charge only on all units Step 4 Check all connections are firmly ti...

Page 52: ...rge only Step 22 Wait for 60 seconds and switch the units on again Step 23 Check the status of the LEDs during start up to verify the configuration LED 1 green blinking 5 seconds single phase standalo...

Page 53: ...rn to fewer units per phase change the Dev per phase value and click Confirm topology again To breakdown a cluster select Single phase and 1 Device per phase and click the Confirm topology button To r...

Page 54: ...only switch or the remote setting of the Inverter button Output voltage too low charger supplies maximum current Load connected to the batteries is larger than charger can supply Reduce load taken fro...

Page 55: ...place if necessary Batteries are too warm gassing Defective battery short circuit in cell Check battery and replace if necessary Battery temperature too high Use the battery temperature sensor Charge...

Page 56: ...2600W 3500W 3500W 4500W 5000W Continuous power Tamb 140 F 60 C 750W shutdown above 140 F 1000W shutdown above 140 F 1500W shutdown above 140 F 1000W shutdown above 140 F 1500W shutdown above 140 F 175...

Page 57: ...000W 160A 24V 2000W 60A 24V 3000W 70A 12V 3500W 200A 24V 3500W 100A 24V 4500W 120A 48V 5000W 70A Product code 35511500 35512000 35513000 35522000 35523000 35513500 35523500 35524500 35545000 Input vol...

Page 58: ...ion Tool Charging specifications Battery type Flooded default GEL AGM Li Ion MLI Bulk voltage 14 40V 28 80V 14 40V 28 80V 14 40V 28 80V 14 25 28 50 V Max bulk time 480 min 480 min 480 min 480 min Min...

Page 59: ...35523500 35524500 35545000 AC input switched 30A 30A 30A 30A 30A 50A 50A 50A 50A AC output Max connected continuous load 40A 40A 40A 40A 40A 85A 85A 85A 85A AC input fuse Yes resettable thermal breake...

Page 60: ...5000W only Split phase configuration Models 3500W 4500W 5000W only 3 phase configuration No MasterBus powering Yes Protections Ignition protected Yes conforming to SAE J1171 ISO 8846 AC input AC IN li...

Page 61: ...s Output power Temperature F Figure 22 Output power vs temperature for models 1500W 2000W and 3500W Output power Temperature F Figure 23 Output power vs temperature for models 3000W Output power Tempe...

Page 62: ...00A 120V CombiMaster 12V 3000W 160A 120V CombiMaster 24V 2000W 60A 120V CombiMaster 24V 3000W 70A 120V 35512000 35513000 35522000 35523000 17 6 11 2 6 0 448 284 153 20 9 CombiMaster 12V 3500W 200A 120...

Page 63: ...Master 120V Series User and Installation Manual 63 Figure 26 Dimensions in inches mm of models 2000W 3000W strain relief for parallel stacking Figure 27 Dimensions in inches mm of models 3500W 4500W 5...

Page 64: ...0 800 307 6702 E tech mastervolt OneASG com Location Shipping Advanced Systems Group US N85 W12545 Westbrook Crossing Menomonee Falls WI 53051 United States Asia Pacific Technical Support T 64 9 415 7...

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