Mastervolt ChargeMaster Plus 12/35-3 Operating manual

CHARGEMASTER PLUS
ChargeMaster Plus 12/35-3, 12/50-3, 24/20-3, 24/30-3
AUTOMATIC BATTERY CHARGER
USER AND INSTALLATION MANUAL
10000016594/04
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ChargeMaster Plus 12/35-3, 12/50-3, 24/20-3, 24/30-3 –User and Installation Manual
TABLE OF CONTENTS
1GENERAL INFORMATION ......................... 3
1.1 Use of this manual.................................... 3
1.2 Liability....................................................... 3
1.3 Warranty .................................................... 3
1.4 Disclaimer.................................................. 3
1.5 Identification label .................................... 3
1.6 Correct disposal of this product............. 3
2SAFETY INSTRUCTIONS........................... 4
2.1 General ...................................................... 4
2.2 Explosive gases ........................................ 4
2.3 Personal precautions ............................... 5
2.4 Warnings regarding the use of batteries5
2.5 Charger location....................................... 5
2.6 DC connection precautions .................... 5
2.7 When battery is installed in vehicle ....... 6
2.8 When battery is outside vehicle ............. 6
2.9 Preparing to charge ................................. 6
2.10Grounding instructions ............................ 7
2.11Warning regarding life support
applications ............................................... 7
3INSTALLATION .......................................... 8
3.1 Unpacking ................................................. 8
3.2 Location ..................................................... 8
3.3 Wiring......................................................... 8
3.3.1 DC wiring......................................... 8
3.3.2 AC wiring......................................... 9
3.3.3 AC safety grounding...................... 9
3.3.4 Network wiring
(CZone/MasterBus)................................ 10
3.4 Batteries................................................... 10
3.5 Material needed...................................... 10
3.6 Overview of the connection
compartment........................................... 11
3.7 Connection example.............................. 12
3.8 Installation step-by-step......................... 13
3.9 Commissioning after installation .......... 15
4SETTINGS.................................................16
4.1 DIP switch settings ................................. 16
4.2 MasterBus configuration ....................... 16
4.2.1 Monitoring ..................................... 16
4.2.2 Alarms............................................ 17
4.2.3 History............................................ 17
4.2.4 Configuration settings.................. 18
4.2.5 Events –System automation ...... 19
4.2.6 Current control ............................. 20
4.3 MasterShunt............................................ 20
4.4 Lithium-ion Battery MLI Ultra................ 20
4.5 CZone configuration .............................. 20
5OPERATING INSTRUCTIONS ..................22
5.1 Introduction ............................................. 22
5.2 Switching on / off.................................... 22
5.3 Status display.......................................... 22
5.4 The 3-step+ charge process................. 23
5.4.1 Charge voltages ........................... 24
5.4.2 Pre-float ......................................... 24
5.4.3 Temperature compensated
charging................................................... 24
5.4.4 Flat battery support...................... 24
5.5 DC OUT ................................................... 24
5.6 Maintenance............................................ 24
5.7 Storage .................................................... 25
6TROUBLE SHOOTING..............................26
7TECHNICAL DATA ...................................28
7.1 Specifications 12V models.................... 28
7.2 Specifications 24V models.................... 29
7.3 Dimensions.............................................. 30
7.4 Characteristics........................................ 30

ChargeMaster Plus 12/35-3, 12/50-3, 24/20-3, 24/30-3 –User and Installation Manual
3
1GENERAL INFORMATION
1.1 Use of this manual
This manual serves as a guideline for the safe
and effective operation and maintenance of the
following ChargeMaster Plus models:
Part number
Model
44310355
12/35-3
44310505
12/50-3
44320205
24/20-3
44320305
24/30-3
These models are further referred to as
“ChargeMaster Plus”.
1.2 Liability
Advanced Systems Group can accept no liability
for:
•Consequential damage resulting from the use
of the ChargeMaster Plus.
•Possible errors in the included manual and
the consequences of these.
•Use that is inconsistent with the purpose of
the product.
1.3 Warranty
The Advanced Systems Group product warranty
covers the ChargeMaster Plus for the first two
years after the purchase date, on the condition
that the product is installed and used according
to the instructions in this manual.
Installation or use that do not comply with these
instructions may result in under 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 this
warranty.
1.4 Disclaimer
Our products are subject to continual
development and improvement. Therefore,
additions or modifications to the products may
cause changes to the technical data and
functional specifications. No rights can be
derived from this document. Please consult our
most current Terms & Conditions of Sale.
1.5 Identification label
The following picture is only an example!
Part number Serial number.
Figure 1: Identification label
The identification label is located at the right-
hand side of the ChargeMaster Plus. Important
technical information required for service,
maintenance & secondary delivery of parts can
be derived from the identification label.
CAUTION!
Never remove the identification
label. This will void the warranty.
1.6 Correct disposal of this product
This product is designed and
manufactured with high quality
materials and components,
which can be recycled and
reused.
Please be informed about the local separate
collection system for electrical and electronic
products.
Please act according to your local rules and do
not dispose of your old products with your
normal household waste. The correct disposal of
your old product will help prevent potential
negative consequences to the environment and
human health.

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ChargeMaster Plus 12/35-3, 12/50-3, 24/20-3, 24/30-3 –User and Installation Manual
2SAFETY INSTRUCTIONS
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
WARNING!
Read the entire manual before
using the ChargeMaster Plus.
Keep this manual in a secure
place.
This chapter describes important safety and
operating instructions for use of a ChargeMaster
Plus in residential, recreational vehicle (RV) and
marine applications.
2.1 General
1The appliance is not to be used by children or
persons with reduced physical, sensory or
mental capabilities, or lack of experience and
knowledge, unless they have been given
supervision or instruction.
2This appliance can be used by children aged
from 8 years and above and persons with
reduced physical, sensory or mental capa-
bilities or lack of experience and knowledge,
if they have been given supervision or instruc-
tion concerning use of the appliance in a safe
way and understand the hazards involved.
3Children shall not play with the appliance.
4Cleaning and user maintenance shall not be
made by children without supervision.
5To reduce the risk of electric shock –Do not
expose the ChargeMaster Plus to rain, snow,
spray, moisture, excessive pollution and
condensing circumstances. To reduce risk of
fire hazard, do not cover or obstruct the
ventilation openings. Do not install the
ChargeMaster Plus in a non-ventilated room,
as overheating may result.
6Use of an attachment or spare part not
recommended or sold by Advanced Systems
Group may result in a risk of fire, electric
shock, or personal injury.
7UL 1236 requirements do not cover investiga-
tion of charging Lithium-ion type batteries.
8The ChargeMaster Plus is designed to be
permanently connected to an AC and DC
electrical system. Installation of, and work on
the ChargeMaster Plus, may be carried out
only by qualified and trained personnel,
consistent with the locally applicable
standards and regulations.
9Make sure that all wiring is properly installed,
in good electrical condition, and correctly
sized to match the AC ampere rating of the
ChargeMaster Plus. Check the wiring on a
regular base, at least once a year. Do not use
the ChargeMaster Plus when the wiring is
undersized or damaged.
10 Do not operate the ChargeMaster Plus if it has
received a sharp blow, been dropped, or
otherwise damaged in any way; take it to a
qualified serviceman.
11 Except for the connection compartment, see
chapter 3, the ChargeMaster Plus may not be
opened or disassembled. There are no
serviceable parts inside the cabinet. Take it to
a qualified, authorized and trained serviceman
when service or repair is required. Incorrect
reassembly may result in a risk of electric
shock or fire.
12 To reduce risk of electric shock, disconnect
the ChargeMaster Plus from both AC and DC
electrical system before attempting any
maintenance or cleaning. Turning off controls
will not reduce this risk. Be sure that third
parties cannot reverse the measures taken.
13 The ChargeMaster Plus 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.
14 Short circuiting or reversing polarity will lead
to serious damage to batteries, ChargeMaster
Plus, wiring as well as accessories. Fuses
cannot prevent damage caused by reversed
polarity and the warranty will be void.
15 In case of fire, you must use the fire extin-
guisher which is appropriate for electrical
equipment.
16 If applied in a marine application in the United
States, external connections to the
ChargeMaster Plus shall comply with the
United States Coast Guard Electrical
Regulations (33CFR183, Sub part I).
2.2 Explosive gases
1WARNING –RISK OF EXPLOSIVE
GASES. WORKING IN VICINITY OF A
LEAD-ACID BATTERY IS DANGEROUS.

ChargeMaster Plus 12/35-3, 12/50-3, 24/20-3, 24/30-3 –User and Installation Manual
5
BATTERIES GENERATE EXPLOSIVE
GASES DURING NORMAL BATTERY
OPERATION. FOR THIS REASON, IT IS
OF UTMOST IMPORTANCE THAT EACH
TIME BEFORE USING THE ChargeMaster
Plus, YOU READ THIS MANUAL AND
FOLLOW THE INSTRUCTIONS
EXACTLY.
2To reduce risk of battery explosion, follow
these instructions and those published by
battery manufacturer and manufacturer of
any equipment you intend to use in vicinity of
the battery. Review cautionary marking on
these products and on engine.
3DANGER: To reduce the risk of
explosion –Never use the ChargeMaster
Plus in situations where there is danger of
gas or dust explosion or area in which
ignition-protected equipment is required.
2.3 Personal precautions
1Consider having someone close enough by to
come to your aid when you work near a lead-
acid battery.
2Have plenty of fresh water and soap nearby in
case battery acid contacts skin, clothing, or
eyes.
3Wear eye and clothing protection. Avoid
touching eyes while working near battery.
4If battery acid contacts skin or clothing, wash
immediately with soap and water. If acid
enters eye, immediately flood eye with
running cold water for at least 10 minutes and
get medical attention immediately.
5NEVER smoke or allow a spark or flame in
vicinity of battery or engine.
6Be extra cautious to reduce risk of dropping a
metal tool onto battery. It might spark or short-
circuit battery or other electrical part that may
cause explosion.
7Do not wear watches, bracelets, necklaces or
other metal objects when working on
batteries.
2.4 Warnings regarding the use of
batteries
1Only use the ChargeMaster Plus for charging
Lead-Acid or lithium-ion batteries and the
supply of consumers attached to these
batteries, in permanent systems. Do not use
the ChargeMaster Plus for charging dry-cell
batteries that are commonly used with home
appliances. These batteries may burst and
cause injury to persons and damage to
property. Make sure lithium-ion batteries used
for this charger are certified to EN standards.
2NEVER charge non-rechargeable batteries.
3NEVER charge a frozen battery.
4Excessive battery discharge and/or high
charging voltages can cause serious damage
to batteries. Do not exceed the recommended
limits of discharge level of your batteries.
5If it is necessary to remove a battery, always
remove grounded terminal from battery first.
Make sure all accessories are off, so as not to
cause an arc.
6Be sure that the area around battery is well
ventilated while battery is being charged.
Refer to the recommendations of the battery
manufacturer.
7Batteries are heavy! It may become a
projectile if it is involved in an accident!
Ensure adequate and secure mounting and
always use suitable handling equipment for
transportation.
2.5 Charger location
1Never place charger directly above battery
being charged; gases from battery will
corrode and damage charger.
2Never allow battery acid to drip on charger
when reading electrolyte specific gravity or
filling battery.
3Do not operate charger in a closed-in area or
restrict ventilation in any way.
4Do not set a battery on top of charger.
2.6 DC connection precautions
1Connect and disconnect DC output clips only
after setting any charger switches to
“off” position and removing AC cord from
electric outlet. Never allow clips to touch each
other.
2Attach clips to battery and chassis as
indicated in section 2.7, steps 5 and 6, and 2.8
steps 2 through 4.