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Mass Charger 24/50-2, 24/75, 24/75 (120V), 24/100, 3-24/100, 48/25, 48/50 

– User and Installation Manual

 

 

 

11

 

 

 

 

 

4.13  Connection 

 

WARNING 

Let installation work be done by a licensed 
electrician.  Before  beginning  with  the 
connection  of  the  wiring,  make  the  AC 
distribution  as  well  as  the  DC  distribution 
voltage free. 

 

 

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.

 

Note: 

If  the  battery  temperature  remains  within 
15-25°C, the battery temperature sensor is 
optional. 

 

Note:

  The  Mass  Charger  supports  MasterBus  and  RS  232 

compatible remote control panels. 

The  following  schematic  illustrates  the  general  placement  of  the  Mass  Charger.  It  is  not  meant  to  provide  detailed  wiring 
instructions for any particular electrical installation. 

 

Figure 5. Installation drawing of the Mass Charger 

 

BATTERY BANK 1

(main battery bank)

Temperature sensor

BATTERY BANK 2

Battery
fuse

Battery
fuse

Charger
fuse

L

N

PE/GND

RCD

Summary of Contents for MASS 24/100

Page 1: ...S 24 50 2 24 75 24 75 120V 24 100 3 24 100 48 25 48 50 FULLY AUTOMATIC BATTERY CHARGER USER AND INSTALLATION MANUAL 10000001888 02 To download this manual in other languages please visit our website www mastervolt com ...

Page 2: ...attery capacity 8 4 5 Battery isolator 8 4 6 Connection of second battery 3A output 8 4 7 Temperature sensor 8 4 8 Voltage sense 9 4 9 Alarm function 9 4 9 1 Standard alarm mode 9 4 9 2 DC alarm mode 9 4 10 RJ12 splitter for enclosure C2 9 4 11 Overview connection compartment 10 4 12 Things you need 10 4 13 Connection 11 4 14 Installation step by step 12 4 15 Commissioning after installation 13 4 ...

Page 3: ...our products please visit our website www mastervolt com 1 3 Liability Mastervolt can accept no liability for Consequential damage due to use of the Mass Charger Use that is inconsistent with the purpose of the product Possible errors in the manuals and their results Disclaimer Our products are subject to continual development and improvement Therefore additions or modifications to the products ma...

Page 4: ...ng any maintenance or cleaning Turning off controls will not reduce this risk 8 The Mass Charger 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 9 Short circuiting or reversing polarity will lead to serious damage to batteries Mass Charger wiring as well as accessories Fuses cannot pre...

Page 5: ...ent for transportation 14 Study all battery manufacturer s specific precautions while charging and recommended rates of charge Note that the Mass Charger 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 2 4 Warning...

Page 6: ...nnected consumers at the same time In addition the Mass Charger is secured against short circuit overload and high temperatures in an industrial environment 3 1 The 3 step charge process The Mass charger is equipped with an intelligent 3 step charge characteristic which takes care of an optimal charge of your batteries See Figure 2 and Figure 9 page 22 for more details Figure 2 the 3 step charge p...

Page 7: ...re switched off Remove the fuses in order to protect yourself against unexpected start up 4 3 Wiring CAUTION The wire and fuse sizes stated in this manual are given as example only Prescribed wire and fuse sizes may be different due to local applicable regulations and standards 4 3 1 AC wiring Check if the voltage of your mains source or generator corresponds with the AC input voltage of the batte...

Page 8: ...tery sets must be charged at the same time via one output a battery isolator should be used This isolates the different battery sets to prevent one discharging the other Mastervolt offers several Battery Isolators Please refer to www mastervolt com A battery isolator causes a voltage drop of 0 6V This can be compensated in two ways By changing DIP switch 4 to On Diode enabled By using the voltage ...

Page 9: ... 10 The alarm function has two modes standard factory setting and DC alarm mode continuous mode The maximum switch current of the relay is 1A Exceeding the setpoints will activate the alarm see page 17 4 9 1 Standard alarm mode In this mode the relay responds to all fault conditions that the Mass Charger can detect such as no AC input voltage low DC voltage voltage sense failure temperature sense ...

Page 10: ... Charger to the negative pole of the DC distribution for specifications see section 4 3 3 on page 7 1 DC fuse holder with a DC fuse to be integrated in the positive DC cable 1 Screws bolts Ø 6mm with plugs to mount the cabinet to a surface Use mounting materials which are suitable to carry the weight of the Mass Charger 4 AC cable to connect the AC input to an external power source e g a shore con...

Page 11: ...nnections well in order to limit transition resistance as far as possible Use cables of the correct size Note If the battery temperature remains within 15 25 C the battery temperature sensor is optional Note The Mass Charger supports MasterBus and RS 232 compatible remote control panels The following schematic illustrates the general placement of the Mass Charger It is not meant to provide detaile...

Page 12: ...bank positive to negative to 6 Option for model 24 50 Connect the DC wiring of the second battery bank max 3A This bank has a common negative with the main battery 7 Attach the battery temperature sensor to the casing of the main battery bank Plug the temperature sensor cable into the Temp Sensor jack See also Figure 4 on page 10 7 Option Connect the Mass Charger to the MasterBus network 8 The fac...

Page 13: ...After switching on the AC power supply the Mass Charger will initiate the charging process 4 15 2 MasterBus Adjustment of the settings of the Mass Charger can be made by means of DIP switches or via the MasterBus network by means of an USB interface connected to a PC with MasterAdjust software Some settings can only be changed via the MasterBus interface See section 7 4 on page 16 for an overview ...

Page 14: ... Force Float switching DIP switch 1 to ON The charge voltage will be fixed at 26 5V 24V charger or 53V for a 48V charger Traction setting DIP switch 2 Setting for traction charging 0 7 1 4V during bulk and 0 4 0 8V in absorption for 24 48V batteries Gel AGM batteries DIP switch 3 Some Gel AGM batteries need a higher float voltage for optimal charge Changing the float voltage can be done by setting...

Page 15: ...During equalizing the batteries are brought into the gas state and permitted load voltages may be exceeded refer to Figure 10 on page 23 for characteristics For these reasons the equalizing mode should only be used by trained technical engineers The equalizing mode can only be started when the Mass Charger is in float operation To start the equalize mode select Equalize in the MasterBus device set...

Page 16: ...ring 3 non powering Do not make ring networks Do not make T connections in the network 7 4 MasterBus Settings Meaning Factory setting Adjustable range Device settings Language Language that is displayed on a monitoring device connected to the MasterBus English EN NL DE FR ES IT Name Name for the Mass Charger CHG Mass type 0 12 characters Device Device name recognized by MasterBus Mass Charger Batt...

Page 17: ...2 00 64 00V DC Alrm high off Alarm DC High off 30 00 60 00V 16 00 32 00 32 00 64 00V DC Alrm low on Alarm DC low on 20 00 40 00V 16 00 32 00 32 00 64 00V DC Alrm low off Alarm DC low off 22 00 44 00V 16 00 32 00 32 00 64 00V DC Alrm delay Alarm delay time 30 sec 0 255 sec Traction settings Bulk voltage Bulk voltage 29 20 58 40V read only Max bulk time Maximum bulk time 360 min read only Min bulk t...

Page 18: ...data Data is linked to the command 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 1 st signal and back at the 2 nd signal It is used in combination with a pulse switch Off Off On Copy Copy Invert Toggle Event x 1 The ...

Page 19: ...s will be higher Charge current too low Batteries almost fully charged Nothing this is normal when the battery is almost fully charged High ambient temperature Nothing if ambient temperature is more than 40 C the charge current is automatically reduced Low AC input voltage At lower AC input voltages the charge current is reduced See Figure 8 on page 22 Check AC input voltage Batteries not fully ch...

Page 20: ...section 7 4 for settings Default charge voltages at 25 C Absorption voltage 28 5V 28 5V 28 5V Float voltage 26 5V 26 5V 26 5V Voltage ripple max 100mV RMS with resistive load full power Short circuit current 1 4 of Imax 12 5A 18 75A 18 75A Wire gauge up to 3m length 25mm 35mm 35mm Charger fuse external 63A 80A 80A ENVIRONMENTAL Ambient temperature 20 to 40 C 100 output power derated with 2 5 C abo...

Page 21: ...l AGM lead acid NiCad Mastervolt MLI settings section 7 10 Default charge voltages at 25 C Absorption voltage 28 5V 28 5V 57V 57V Float voltage 26 5V 26 5V 53V 53V Voltage ripple max 100mV RMS with resistive load full power Short circuit current 1 4 of Imax 25A 25A 6A 12 5A Cable size within 3 m 35mm 35mm 16mm 25mm Charger fuse external 125A 125A 32A 63A ENVIRONMENTAL Ambient temperature 20 to 40 ...

Page 22: ...4 50 2 24 75 24 75 120V 24 100 3 24 100 48 25 48 50 User and Installation Manual 9 2 Characteristics Figure 8 Charge current versus input voltage Figure 9 Charge characteristic of the 3 step charging method at 25 C 77 F ...

Page 23: ...24 75 120V 24 100 3 24 100 48 25 48 50 User and Installation Manual 23 Figure 10 Charge characteristic of the equalize charge cycle at 25 C 77 F Figure 11 Temperature compensation characteristic charge voltage versus temperature ...

Page 24: ...20 3422100 Email info mastervolt com Web www mastervolt com Copyright 2018 Mastervolt All rights reserved Reproduction transfer distribution or storage of part or all of the contents in this document in any form without the prior written permission of Mastervolt is prohibited ...

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