Mase Generators STAR 70 Series User manual

STAR70
STAR80
STAR90
STAR100
STAR110
STAR120
STAR140
in: 230V
out: 12V-24V
Rev.0 A.A. 30/06/2014
cod.43301
Tipo modello
N° matricola
Codice
USE, MAINTENANCE AND INSTALLATION MANUAL GB
HIGH FREQUENCY BATTERY CHARGERS

This manual has to be preserved for all through life of the
gen set to which ago reference
Thankyouforhavingchosenaproductmase.
Asaleadinggeneratormanufacturer,maseGeneratorsoffersawiderangeofgeneratorswithanoutputfrom1KVA
portablegeneratorsto1600KVAunitsforspecialapplications.
Foundedin1970,theCesena-basedcompanyextendsoveraareaof16,000squaremeters,includinga9,000sq.mtr.
manufacturingfacility.
MaseGeneratorsbeganasacompanyproducing500Watt,lightandcompactportablegenerators.Thesegenerators
madetheMaseGeneratorsnamewellknownthroughouttheworld.maseGeneratorsisaleaderinhigh
quality,reliableproducts,andinnovativeresearchperformedbyResearchandDevelopmentDepartment.
Thegeneratoryouhavepurchasedisthefruitofyearsof experienceinthesectorandforthemodernconception,the
strongsizing,thematerialsemployees,thecontinuousupdatings,constitutesaneffectiveanswertotheoperators’
demandsofthesector.
ThisManualinstructionswillfurnishyou usefulinformationandprecioussuggestionsso you canfullyexploit
allthepossibilitiesthatthegeneratorsoffersyou.
If anypartofthemanualresultedincomprehensible, pleasecontactus.
Intorenewourthankswecordiallygreetyou.
MASE GENERATORS S.p.A. Via Tortona, 345
47522 Cesena (FC) Italy
Tel.[phone] Fax.[phone]
Technicaldata,informations,layoutsof thetextsandgraphicpreparations:editedbytheTechnicalOffice
maseGenerators.
THECOMPANYMASEGENERATORSSPARESERVESALLRIGHTSTOIMPLEMENTMODIFICATIONSTOTHISPRESENTMANUALWITHOUT
ADVANCENOTICEORNOTIFICATION,WHENNECESSARY,INACCORDANCEWITHITSPOLICYOFCONTINUALPRODUCTIMPROVEMENT.
THEMASEGENERATORSSPA,RESERVESALLTHERIGHTSONTHEMANUALPRESENT.ANYTOTALORPARTIALREPRODUCTIONIS
PERMITTEDWITHOUTWRITTENAUTHORIZATIONOFTHEMASEGENERATORSSPA.

CONTENTS
1) USEAND OPERATING ................................................................................................ 5
2) INSTALLATIONANDSAFETYWARNINGS.................................................................. 5
3) TECHNICAL FEATURES ............................................................................................. 6
4) CONNECTTO MAINS.................................................................................................. 7
5) CONNECT TO BATTERY PACK .................................................................................. 7
6) VISUALSIGNALS......................................................................................................... 8
7) BATTERYCHARGER SETTINGS.............................................................................. 10
8) TRASPORT, PACKAGINGAND STORAGE............................................................... 11
9) GUARANTEEANDRESPONSABILITY...................................................................... 12
10) DISPOSAL ................................................................................................................. 12
11) BATTERYCHARGERS - STAR series - general infos................................................ 13

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Before connecting the battery chargerto the mains and to the battery, READTHE
FOLLOWING INSTRUCTIONS CAREFULLY.
WARNING!This is an EMC complying product in classA+B asdefined by the CEI
EN 61000-6-2, CEIEN 61000-6-3 and CEIEN 61000-6-4 regulations, inother words
both for use in RESIDENTIAL ENVIRONMENTS and in INDUSTRIAL
ENVIRONMENTS

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1) USE AND OPERATION
Inorderto usethe batterycharger, safety normscontainedin lawsand regulationsand provisions issued
by local authorities must be complied with.
“User” obligations : as per these operating instructions, the “user” is any natural or legal person who
directly uses STAR chargingdevicesorwhomsoever uses themon behalf of the aforementioned person.
Under special circumstances, for example, leasing, rental, the “user” is the person who, as per the
agreements stipulated between the owner and the user of the STAR charging devices, assumes the
followingobligations.
The “user” shallbe responsible forthe installation site of the device. He shallcheck whether particularly
sensitive equipment is disturbed by the influence of the battery charger. The installation site shall be
chosensothat usage (ahigh directcurrent produces magneticinterference)doesnot affectthe operation
of electromagnetic devices and magnetic data carriers (for example pace makers, monitors, magnetic
disks and diskettes, magnetictapes, watches etc.).
The “user” shall ensurethatthe use of STAR chargingdevices complies withregulations in forceand that
any action which could endanger the life andhealth of the useror of third parties is prevented, aswell as
the prevention of damage to property.
The “user” shall ensure that users and operators have read and understood these instructions and that
they complywith accident-prevention rules, technicalsafety rules, and useand maintenance directives.
2)INSTALLATIONANDSAFETY WARNINGS
Before connecting the battery charger to the mains and to the battery, READ THE FOLLOWING
INSTRUCTIONS CAREFULLY:
IN ORDER FOR THE BATTERY CHARGER TO OPERATE CORRECTLY AND PERFORM AT ITS
BEST ITMUST BE INSTALLED ONAWALL THE RIGHT WAYANDFIXEDWITHRAWLPLUGS USING
THE LOOPS PROVIDED; ENSURE THE VENTILATION SLITSARE NOT OBSTRUCTED.
Only specialised, authorised personnelshall be allowed to carryoutworkrequiring the batterycharger
tobe opened.
Before starting-up the battery charger check insulation on the mains cable and battery connection
connectors.
Only skilled personnel should intervene on electrical equipment.
Disconnect frommainsbefore connecting ordisconnecting the battery.
WARNING !!Charging batteries produceexplosive gas, it isthereforestrictly forbidden tosmoke in the
vicinity; naked flames and/or sparks and proximityto other equipment which could endanger people or
property are to be prevented.
Thisbatterychargercontainselectricalcomponentswhichcanproducevoltaicarcsandsparks,therefore
if it is used in confined spaces, it must be installed in a suitable location; in any case the standard battery
charger (IP 20) must be used indoors, in well-ventilated spaces, which are not exposed to rain and/or
water splashesand be positioned onsolid, level flooring, in particular dusty areas orareas where water,
heat andhumidityoriginate aretobe avoided. Furthermore, thebatterychargermust notbepositionedon
support structuresand/orshelvesmadeofwoodorotherflammablematerial,materialsmustnotbestocked
in the vicinity of the battery charger and no kind of object or container for liquids must be placed on the
cover.
In order to prevent risk of electrocution, the battery charger must be connected to an earthed
socket, furthermore the socket whichthebattery charger isconnectedtomustbe proportionate in power
to the charger and be protected by an appropriate compliantelectrical device (fuse orautomatic cut-out
switch). In order to obtain sufficientselectivity, the protection must have a calibration atleast 10% higher
than thepower absorption of thedevice, furthermore the device must be protected fromexcessive high
contact voltagein compliance with LocalAuthority provisions.
Werecommendusingappropriatebipolarconnectors.
The useof extension leads to lengthenexisting electrical connectionsmust be avoided at allcosts.
The STAR chargingdevice needs no specialmaintenance, apartfromregularcleaningprocedures,to
be carried out periodically according to the type of working environment. Before starting to clean the
device, the mainssupply cable and battery cables must be unplugged.

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3) TECHNICAL FEATURES
12VModel Voltage (V) Output (A) Weight (kg)
8-9 hours charging
time
10-12 hours charging
time
STAR 12/70 12 50+10+10 275 - 325 370 - 450 6,80
STAR 12/80 12 60+10+10 300 - 360 450 - 360 13,50
STAR 12/90 12 70+10+10 350 - 420 520 - 620 13,50
STAR 12/100 12 80+10+10 400 - 480 590 - 705 13,50
STAR 12/110 12 90+10+10 450 - 540 650 - 820 13,50
STAR 12/120 12 100+10+10 500 - 600 720 - 910 13,50
STAR 12/140 12 120+10+10 600 - 720 860 -1100 13,50
24VModel Voltage (V) Output (A) Weight (kg)
8-9 hours charging
time
10-12 hours charging
time
STAR 24/70 24 50+10+10 275 - 325 370 - 450 6,80
STAR 24/80 24 60+10+10 300 - 360 450 - 360 13,50
STAR 24/90 24 70+10+10 350 - 420 520 - 620 13,50
STAR 24/100 24 80+10+10 400 - 480 590 - 705 13,50
STAR 24/110 24 90+10+10 450 - 540 650 - 820 13,50
STAR 24/120 24 100+10+10 500 - 600 720 - 910 13,50
STAR 24/140 24 120+10+10 600 - 720 860 -1100 13,50
Battery range
(5 Hr Rate)
Battery range
(5 Hr Rate)

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L1 N
50A - STAR 70
60A - STAR 80
70A - STAR 90
80A- STAR 100
90A - STAR 110
100A- STAR 120
120A- STAR 140
MAIN
OUTPUT
OUTPUT10A
SECONDARY
OUTPUTS INPUT
230V
FROM
GENERATING SET
MASE 230V
4) CONNECT TO MAINS
It's absolutely necessary to connect to an electrical outlet adequate to the charger power, checking the
data information printed onthe technical label.
Performwiring connectionas shown onfollowing picture:
5) CONNECT TO BATTERY PACK
Itis recommended to use bipolarconnectorsin accordance with actual rules without possibilityof polarity
reverseonthe battery;check theproperconnection of cables oncontacts connector.
Only skilled techniciancan do this operation.
Connect asshownon following picture:
OUT1, OUT2, OUT3 indicate independent outputs,which if necessarycan beparallelate to increase
maximumoutputcurrent.

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P2
P2
P2
MONITOR1
MONITOR2
MONITOR3
1
2
3
REF DESCRIPTION
DL4 LED
(green)
DL3 LED
(yellow)
DL2 LED
(green)
DL1 LED
(red)
DISPLAY
S1 Only supply from battery OFF OFF OFF OFF OFF
S2 Only supply from mains OFF OFF OFF OFF OFF
S3 Both supply from battery and mains ON OFF OFF OFF ON
S4 Autostart running BL BL BL BL ON
F1 Phase 1 - Initial charge CI BL OFF OFF OFF ON
F2-F7 Phase 2 - Phase 7 BL ON OFF OFF ON
F8 Pause for equalization ON ON ON OFF ON
EQU ON Charge for equalization ON (running) BL BL ON OFF ON
EQU OFF Charge for equalization OFF (pause) ON ON ON OFF ON
M Maintenance BL BL ON OFF ON
END Charge terminated ON ON ON OFF ON
OFF = led turned off ON=led turned on BL= led blinking (T=1sec)
6) VISUAL SIGNALS
Visual signal on Display (ref.2):
State of 4 Leds (ref.1) during different functioning mode of batterycharger.
During charging,the battery charger offers3 monitor menus, which you can move betweenby pressing
the P2 button, and whose detailed meaningwas previouslyillustrated

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Signals Meaning
Red led fixed First phase of normal charge
Yellow led fixed Second phase of normal charge
Green led fixed End of charger or charger maintening
Signals Meaning
Not suitable battery or battery not connected
Excedeed security timer
Internal short circuit
Signals Meaning
Green led fixed Battery charged
INITIAL TEST
CHARGE
FAILURES
Red led blinking
Visualsignal referredto 10A outputs (ref.3)
Belowis a summary of the information given respectively on the 3 MONITOR displays.
MONITOR1
LINE EXAMPLE DESCRIPTION
(1) Pb 1Pb ST 48V /35ª Battery Technology, Type of Curve, Battery Charger Rating
(2) 43,3 V 35ª Battery voltage and current
(3) Ah= 8 Tc= 0h 15m 29s Ah charged, Charging Time in hours, min, sec
(4) PhI1 CHARGE Current charging phase, battery charger STATUS
(5) -- Messages (e.g. phase = auto start A0, Status= BATTERY NOT CONNECTED)
MONITOR2
LINE EXAMPLE DESCRIPTION
(1) 43,3V 35ª Battery Voltage and Current Supplied
(2)
Active charge profile with indication :
- Phases complete (thick line)
- Phase in progress (flashing line)
- Phases to execute (thin line)
(3) 7Ah PhI1 13m22s Ah charged, Charging time in hours, min, sec
(4) -- Message Possible fault or status messages
MONITOR3
LINE EXAMPLE DESCRIPTION
(1) N.CYCLE= 7 – Ph 1 Number of charge cycle and current charge phase
E.g. : charge cycle 5 and Phase 3
(2) C1ID=1PB ST_01.0001 Charging curve unique identification
(3) Vbif=1.68V/el = 40.4V Battery voltage at start of phase (Vbif) expressed first as element
voltage (V/el), then as absolute voltage (V)
(4) Vbef=1.81V/el = 43.4V Battery voltage at end of phase (current) (Vbef) expressed first as
element voltage (V/el), then as absolute voltage (V)
(5) Ibif= 36A Ibef= 35ª Current at start of phase (Ibif) and current at end of phase (Ibef)
(6) Tf =0h13m Tef=0h13m Single phase time (Tf) and Overall charge time at end of phase (Tef)
(7) Ahf= 7 AhEf= 7 Ah supplied in the selected phase (Ahf) and overall charge Ah
(AhEf)
(8) -- Message Indicates any faults occurring during the charge cycle
RED LED YELLOWLED GREENLED

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1
DP1
VALUE
DP2
VALUE
DP1
DP2
Modbus Address
ON
GEL
ON
12V
ON
ON
160
OFF
WET
OFF
24V
OFF
ON
161
ON
OFF
162
ON
ON
163
SW 2SW 1
7) BATTERY-CHARGER settings through DP switches:
With batterycharger turned off and mains disconnected, gentlydetachthe label (ref.1) and have access
to DP switches.
Set the swichesin order to features required.See chart below.

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8) TRANSPORT, PACKAGING AND
STORAGE
8.1 TRANSPORT AND STORAGE
Packaging:SupplieddirectlybyMaseGenerators.
Thetotalweightof thepackedgeneratorisgivenin
Paragraph 2.3 “Table of technical
characteristics”.
Transport:Duringtransport thegenerator(withor
without packaging) must be protected against
atmospheric agents, it must not be turned upside
downandmustbeprotectedagainstknocks.
Itisstrictlyprohibitedtopollutetheenvironment
withthepackaging
Storage:Batterychargermustbestoredinhorizontal
position and away from atmospheric agents and
humidity.
8.2 LIFTING AND HANDLING OF THE PACKED UNIT
Always check that the capacity of the lifting
means and its accessories is greater than the
weight of the generator printed on the
identificationplate.
For handling on level ground, a transpallet is
sufficient with a suitable capacity according to the
table of technical characteristics of the Use and
MaintenanceManual.
The centre of gravity of the
generatorcorrespondstoaboutthecentreofits
geometricalvolume.

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9) GUARANTEE AND RESPONSIBILITY
9.1 GUARANTEE
•masebatterycharger is guaranteed 12 months from the date of installation.
•The guaranteecovers parts found to bedefective in manufacturingor assembly.
•The guarantee does NOTcoverdamagecaused by incorrectusageand/or installation.
•The guarantee lapsesif any tampering is discovered.
•For any problems, please refer to an AUTHORISED RETAILER or directly to mase generatorsS.p.A
•Notcoveredbytheguaranteeare:failedobservanceoftheinstallationregulations,damagecausedby
naturaldisasters,accidents,defectsoftheelectricalsystemincludingtheloadtowhichthegeneratoris
connected,negligence,improperuseorabusebytheoperatoranddamagecausedbyrepairscarriedout
byunqualifiedpersonnel.
•Repairsthatcannotbecarriedoutattheplace ofinstallationcanbecarriedout at maselaboratoriesor
atauthorisedworkshops.TransportexpenseswillbebornebytheCustomer.
•UndernocircumstancesdoestheCustomerhavetherighttoclaimcompensationfordamagesorside
effectscausedbyuse ofthe machine ina manner notconformto whatisdescribed inthismanual.
9.2 LIMITS OF RESPONSIBILITY
masegeneratorsS.p.A.isresponsibleforanythingregardingthesafety,reliabilityandperformanceofthe
Generatorontheconditionthat:
• Thegeneratorisusedbypersonstrained throughtheuseandmaintenancemanual.
• The installation is carried out according to maseinstructions.
• The serviceproceduresarecarried outexclusively by masespecialised technicalpersonnel.
• Theelectricalsystemandtheloadstowhichthegeneratorisconnectedisinconformitywiththeapplicable
CEIregulations.
• The battery charger isinstalled andused inaccordance withtheinstallations providedinthis manual.
• Use originalspare partsspecificto eachmodel.
10) DISPOSAL
10.1 DISPOSAL OF THE WASTE MATERIALS DERIVING FROM MAINTENANCE AND SCRAPPING
•Thepackagingusedfortransportisbiodegradableandthuseasytodisposeofbycompaniesauthorised
forpapercollection.
•Theelectricalcomponentsmustbetakentocompaniesauthorisedforthecollectionofelectronicmaterial.
•Allthepaintedmetalpartsmustbetaken tocompaniesauthorisedforthecollectionofmetals.
Please note that the system and itscomponents contain materials that, if dispersed in the
environment,maycausesignificantecologicaldamage.
•Anyothermaterialnotlistedabovemustbetakentocompaniesauthorisedforthecollectionofindustrial
waste.

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11) BATTERY CHARGER STAR series: General infos
12V Models Voltage (V) Output (A) Weight (kg)
8-9 hours charging
time
10-12 hours charging
time
STAR 12/15 12 15 80 - 110 100 - 150 2,00
STAR 12/25 12 25 120 - 160 180 - 258 2,00
STAR 12/35 12 25+10 120 - 160 180 - 258 5,50
STAR 12/50 12 30+10+10 145 - 190 215 - 310 5,50
STAR 12/60 12 40+10+10 220 - 260 295 - 360 6,80
STAR 12/70 12 50+10+10 275 - 325 370 - 450 6,80
STAR 12/80 12 60+10+10 300 - 360 450 - 360 13,50
STAR 12/90 12 70+10+10 350 - 420 520 - 620 13,50
STAR 12/100 12 80+10+10 400 - 480 590 - 705 13,50
STAR 12/110 12 90+10+10 450 - 540 650 - 820 13,50
STAR 12/120 12 100+10+10 500 - 600 720 - 910 13,50
STAR 12/140 12 120+10+10 600 - 720 860 -1100 13,50
24V Models Voltage (V) Output (A) Weight (kg)
8-9 hours charging
time
10-12 hours charging
time
STAR 24/15 24 15 80 - 110 100 - 150 2,00
STAR 24/25 24 25 120 - 160 180 - 258 2,00
STAR 24/35 24 25+10 120 - 160 180 - 258 5,50
STAR 24/50 24 30+10+10 145 - 190 215 - 310 5,50
STAR 24/60 24 40+10+10 220 - 260 295 - 360 6,80
STAR 24/70 24 50+10+10 275 - 325 370 - 450 6,80
STAR 24/80 24 60+10+10 300 - 360 450 - 360 13,50
STAR 24/90 24 70+10+10 350 - 420 520 - 620 13,50
STAR 24/100 24 80+10+10 400 - 480 590 - 705 13,50
STAR 24/110 24 90+10+10 450 - 540 650 - 820 13,50
STAR 24/120 24 100+10+10 500 - 600 720 - 910 13,50
STAR 24/140 24 120+10+10 600 - 720 860 -1100 13,50
Battery range
(5 Hr Rate)
Battery range
(5 Hr Rate)
Technical features:
•High frequency battery charger system.
•ChargingparametersareinsensitivetotheACinputlinevoltage variations.
•Charging process fully controlled by microprocessor.
•Resident charging curves for lead-acid, AGM and Gel batteries.
•Protection against polarity inversions, short circuits, over-voltages or
anomalies.
•Efficiency > 85%.
•Output ripple at maximum charge lower than 100mV.
•Charge cycle begins with batteries as low as 2V.
•Thermal protection against over heating.
•Forced ventilation.
•Possibility to remote to bridge deck the charging information (optional
available upon request).
•Operating temperature: -10°C ÷ +45°C

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STAR12/50 STAR12/60
STAR12/15 STAR12/35
STAR24/35
STAR12/25
STAR24/15 STAR24/25
STAR24/50 STAR24/60 STAR12/70 STAR12/80
STAR24/70 STAR 24/80 STAR12/90 STAR 12/100 STAR24/90 STAR24/100
STAR12/110 STAR12/120
STAR24/110 STAR 24/120 STAR12/140 STAR24/140
MASE GENERATORSS.p.A. ViaTortona,345
47522 Cesena (FC) Italy
Tel.[phone]Fax.[phone]
Email : [e-mail]
www.masegenerators.com
[mm]
Dealer
In line with our continued development, innovation and voice of customer
program, we reserve the right to change data without notice. For more
information, you may contact your local mase dealer.

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STAR12-15
STAR24-15
STAR12-50
STAR24-50
STAR12-25
STAR24-25
STAR12-60
STAR24-60

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STAR12-35
STAR24-35
STAR12-35
STAR24-35
STAR 12/70
STAR 24/70
STAR 12/80
STAR 24/80
STAR 12/90
STAR 24/90
STAR 12/100
STAR 24/100
STAR 12/110
STAR 24/110
STAR 12/120
STAR 24/120
STAR 12/140
STAR 24/140