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Mastervolt CHARGEMASTER PLUS Series

Mastervolt CHARGEMASTER PLUS Series
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CHARGEMASTER PLUS
12/75-3, 12/100-3, 24/40-3, 24/60-3
FULLY AUTOMATIC BATTERY CHARGER
USER AND INSTALLATION MANUAL
10000011898/13
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Mastervolt CHARGEMASTER PLUS Series Specifications

General IconGeneral
Frequency50/60 Hz
Output Voltage12 V / 24 V
Protection RatingIP23
Temperature SensorYes
Remote ControlOptional
Parallel OperationYes
DimensionsVaries by model
Battery TypesGel, AGM, Lithium-ion
ProtectionOver temperature, short circuit, overload, reverse polarity
Operating Temperature-25 °C to 60 °C (-13 °F to 140 °F), derating above 40 °C
Charging Stages3-stage+

Summary

General Information

Use of this manual

Explains the purpose and scope of the manual for safe and effective operation.

Liability

Mastervolt's disclaimer regarding consequential damage, errors, and misuse of the product.

Warranty

Outlines the two-year warranty terms and conditions for the ChargeMaster Plus.

Disclaimer

States that products are subject to development, and rights cannot be derived from this document.

Identification Label

Locates and describes the identification label with important technical information for service.

Correct Disposal of Product

Provides instructions for environmentally responsible disposal of the product according to EU directives.

Safety Instructions

General Safety Precautions

General safety precautions for appliance use, electric shock, fire hazards, and qualified personnel.

Explosive Gases Warning

Warning about explosive gases from lead-acid batteries and the importance of following manual instructions.

Personal Precautions

Safety measures for working near batteries, including personal protection and first aid.

Battery Use Warnings

Cautions on using only lead-acid batteries, avoiding non-rechargeable or frozen batteries, and proper handling.

Charger Location Guidelines

Guidelines for selecting a safe and appropriate location for the charger, avoiding battery proximity.

DC Connection Precautions

Precautions for connecting and disconnecting DC output clips to prevent sparks and damage.

Battery Installation in Vehicle

Detailed safety steps for connecting the charger to a battery installed in a vehicle, avoiding sparks.

Battery Outside Vehicle

Safety procedures for connecting the charger to a battery located outside a vehicle.

Preparing for Charging

Steps to prepare a battery for charging, including terminal cleaning and checking electrolyte levels.

Grounding Instructions

Requirements for grounding the battery charger to a grounded metal wiring system or conductor.

Life Support Applications Warning

Disclaimer regarding the use of products in medical equipment without specific agreements.

Installation

Unpacking Contents

Lists items included in the delivery and instructions for checking for damage or missing parts.

Environment Stipulations

Stipulations for installation environment, including temperature, humidity, and ventilation requirements.

DC Wiring Guidelines

General warning and guidelines for DC wiring, emphasizing cable size and proper connection.

AC Wiring Instructions

Instructions for AC wiring, including safety warnings, RCD/Breaker requirements, and wire cross-section selection.

Battery Compatibility

Emphasizes following battery manufacturer instructions and provides recommended battery capacities.

Required Parts and Tools

Lists necessary parts and tools for installing the ChargeMaster Plus, including included items.

Connection Compartment Overview

Connection Example Schematic

Installation Step-by-Step Guide

Commissioning After Installation

MasterBus Connectivity

Decommissioning Procedure

Storage and Transportation

Re-installation Instructions

Settings Configuration

DIP Switch Settings

Details the function of each DIP switch for configuring basic settings of the ChargeMaster Plus.

MasterBus Functions Overview

Explains MasterBus communication modes, current control, MasterShunt coupling, Li-ion compatibility, monitoring, alarms, history, events, and configuration parameters.

Operating Instructions

Introduction to Operation

Introduces the ChargeMaster Plus as a fully automatic charger suitable for various battery types and voltages.

Switching On and Stand-by

Details the procedure for switching the charger on and off using the MODE button.

Status Display Interpretation

Explains how to use the front status display and LEDs to monitor the charger and charging process.

Status Display Details

Provides detailed breakdown of status indicators, LED states, and meanings for different menus.

Output Power Indicators

Explains how the output power is indicated via LEDs and their corresponding percentage ranges.

Error Indicators and Resolution

Details error indicators, LED states, meanings, and recommended actions to resolve issues.

3-Step+ Charge Process

Charge Voltages by Battery Type

Provides a table of charge voltages for different battery types (AGM, GEL, Flooded, MLI) across stages.

Pre-Float Stage Explanation

Describes the pre-float stage and its benefit in preventing over-charging and extending battery life.

Temperature Compensated Charging

Explains how the battery temperature sensor automatically adjusts charge voltages.

Flat Battery Support

Details the process for supporting deeply discharged or flat batteries.

Smart Terminal Output 3

10 A Starter Mode

Configuration for the Smart terminal as a 10A starter battery charger.

Starter Mode

Configuration for the Smart terminal to charge a starter battery.

Starter + Alternator Mode

Configuration where the alternator also charges batteries 1 & 2 when no AC power is available.

Follow Main Mode

Configuration where all batteries are charged with the same settings.

Follow Main + Alternator Mode

Similar to 'Follow main' but also utilizes the alternator to charge batteries 1 & 2.

12 V Constant Voltage Mode

Configuration for the Smart terminal to provide 12V constant voltage.

24 V Constant Voltage Mode

Configuration for the Smart terminal to provide 24V constant voltage.

12 V 3-Step+ Mode (24 V Model)

Configuration for the Smart terminal using the 12V 3-step+ charge process for various battery types.

Maintenance and Failures

Minimal Maintenance

Outlines minimal maintenance requirements and cleaning instructions for the enclosure.

Failure Detection and Indication

Describes how the ChargeMaster Plus protects against faults and how error codes are indicated.

History Data Access

Instructions on how to connect to MasterBus to view stored history data.

Troubleshooting Common Issues

No Output Voltage or Current

Troubleshooting steps for issues with no output voltage or current, checking AC input and wiring.

Low Output Voltage, Max Current

Steps to diagnose low output voltage and high current draw, checking load and battery status.

Low Charge Current

Troubleshooting for low charge current, considering battery state and ambient temperature.

Batteries Not Fully Charged

Identifies causes for batteries not reaching full charge, like wrong settings or short charge time.

Batteries Discharged Too Fast

Addresses issues where batteries discharge quickly, suggesting checks for capacity and battery health.

Batteries Overheating or Gassing

Troubleshooting for batteries overheating or gassing, checking temperature and voltage settings.

EasyView 5 Display Not Functioning

Steps to troubleshoot if the EasyView 5 display is not functioning, checking power and connections.

MasterBus Communication Issues

Solutions for slow or absent MasterBus communication, focusing on wiring and termination.

Technical Data

Specifications for 12 V Models

Detailed technical specifications for the 12V ChargeMaster Plus models (12/75-3 and 12/100-3).

Specifications for 24 V Models

Detailed technical specifications for the 24V ChargeMaster Plus models (24/40-3 and 24/60-3).

Physical Dimensions

Provides the physical dimensions of the ChargeMaster Plus models in mm and inches.

3-Step+ Charging for Flooded Batteries

Illustrates the charging stages (Bulk, Absorption, Float) and timing for flooded batteries.

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