Mastervolt CZONE Mac Plus Operating manual

Mac Plus
BI-DIRECTIONAL DC-DC CHARGER
48/12-50, 12/48-15, 48/24-30, 24/48-15
USER AND INSTALLATION MANUAL
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2
Mac Plus
48V Models – User and Installation Manual
TABLE OF CONTENTS
1. Safety Instructions.............................3
Warnings and symbols............................3
General ...................................................3
Explosive gases ......................................4
Warnings regarding the use of batteries..4
Warning regarding life support
applications ...........................................5
2. General Information...........................6
Use of this manual...................................6
Liability....................................................6
Warranty..................................................6
Disclaimer ...............................................6
Identification label....................................7
Correct disposal of this product...............7
3. Product Description...........................8
Dimensions..............................................9
Front panel............................................10
4. Installation Instructions ..................11
5. Placement and Mounting ................12
6. Connection.......................................13
Installation A – the Mac Plus as a Battery
charger................................................13
Installation B – the Mac Plus as a
stabilized DC power supply .................13
Remote switch input (pin 4)...................14
Battery temperature sensor (pins 5 & 6) 14
Voltage drop compensation (pins 1 & 2)15
Optional 'reverse charge direction'-switch
(pin 3)..................................................16
Adding the Mac Plus to a MasterBus
network................................................16
Adding the Mac Plus to a CZone
network................................................16
7. Configuration – DIP Switches .........17
8. Operation ..........................................19
LED indicators........................................19
Operating modes ...................................20
Bi-directional operation ..........................22
Flat battery support................................22
9. MasterBus.........................................23
What is MasterBus.................................23
MasterBus on the Mac Plus ...................23
Monitoring..........................................24
Alarm..................................................25
Configuration......................................25
Events................................................29
10. CZone.................................................31
What is CZone.......................................31
Adding the Mac Plus to a CZone
system configuration............................31
11.Trouble Shooting..............................35
12.Technical Specifications..................37
Mac Plus Specifications.........................37
CZone specifications..............................38
Battery settings......................................38
Characteristics.......................................39

Mac Plus 48V Models – User and Installation Manual
3
1. Safety Instructions
This chapter describes important safety and operating instructions for use of a Mac Plus in
residential, vehicle (RV) and marine applications.
READ AND SAVE THESE INSTRUCTIONS
Warnings and symbols
Safety instructions and warnings are marked in this manual and on the product by the following
pictograms:
CAUTION!
Special information, commands and prohibitions in order to prevent damage.
CAUTION!
The addition of this symbol to a caution indicates that the surface may be warm.
WARNING!
A WARNING refers to possible injury to the user or installer or significant material
damage to the Mac Plus if the installer / user does not (carefully) follow the stated
procedures.
General
1 Before using the Mac Plus, read all instructions and cautionary markings on the Mac Plus, the
batteries, and all appropriate sections of the manual.
2 To reduce the risk of electric shock – Do not expose the Mac 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 Mac Plus in a poorly ventilated
room, this may result in overheating.
3 Use of an attachment or spare part, not recommended or sold by Mastervolt, may result in a
risk of fire, electric shock, or injury to persons.
4 The Mac Plus is designed to be permanently connected to a DC electrical system. Installation
of, and work on the Mac Plus, may be carried out only by a qualified, authorized and trained
technician or electrician, consistent with the locally applicable standards and regulations.
5 Make sure that all wiring is properly installed and in good electrical condition; and that wire size
is large enough for DC current rating of the Mac Plus. Check the wiring on a regular base, at
least once a year. Do not use the Mac Plus when the wiring is undersized or damaged.
Replace damaged wires immediately.
6 Do not operate the Mac Plus if it has received a sharp blow, been dropped, or otherwise
damaged in any way; take it to a qualified service technician.

4
Mac Plus
48V Models – User and Installation Manual
7 Except for the connection compartment, the Mac Plus may not be opened or disassembled.
There are no serviceable parts inside the cabinet. Take it to a qualified, authorized and trained
service technician when service or repair is required. Incorrect reassembly may result in a risk
of electric shock or fire.
8 To reduce risk of electric shock, disconnect the Mac Plus from the DC electrical system before
attempting any maintenance or cleaning. Turning off controls will not reduce this risk.
9 The Mac Plus may not be used by children or by those who cannot read and understand the
manual if they are not supervised by a responsible person who can guarantee that the charger
is being used in a safe manner. Keep the charger away from children.
10 Short circuiting or reversing polarity will lead to serious damage to batteries, Mac Plus, wiring
as well as accessories. Fuses cannot prevent damage caused by reversed polarity and the
warranty will be void.
11 In case of fire, you must use the fire extinguisher which is appropriate for electrical equipment.
12 If applied in a marine application in the United States, external connections to the Mac Plus
shall comply with the United States Coast Guard Electrical Regulations (33CFR183,
Sub part I).
Explosive gases
1 WARNING – WORKING IN VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS.
BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION.
FOR THIS REASON, IT IS OF UTMOST IMPORTANCE THAT EACH TIME BEFORE USING
THE Mac Plus, YOU READ THIS MANUAL AND FOLLOW THE INSTRUCTIONS EXACTLY.
2 To 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.
3 DANGER: To reduce the risk of explosion – Never use the Mac Plus in situations where there
is danger of gas or dust explosion.
Warnings regarding the use of batteries
1 Someone should be within range of your voice or close enough to come to your aid when you
work near a battery.
2 Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or
eyes.
3 Wear complete eye protection and clothing protection. Avoid touching eyes while working near
battery.
4 If 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.
5 NEVER smoke or allow a spark or flame in vicinity of battery or engine.

Mac Plus 48V Models – User and Installation Manual
5
6 Do not short circuit batteries, as this may result in explosion and fire hazard! Be extra cautious
to reduce risk of dropping a metal tool onto a battery. It might spark or short-circuit battery or
other electrical part that may cause explosion.
7 Remove personal metal items such as rings, bracelets, necklaces, and watches when working
with a battery. A battery can produce a short-circuit current high enough to weld a ring or the
like to metal, causing a severe burn.
8 Do not use Mac Plus for charging non-rechargeable batteries that are commonly used with
home appliances. These batteries may burst and cause injury to persons and damage to
property.
9 NEVER charge a frozen battery.
10 Excessive 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.
11 If 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.
12 Be sure that the area around battery is well ventilated while battery is being charged. Refer to
the recommendations of the battery manufacturer.
13 Batteries are heavy! It may become a projectile if it is involved in an accident! Ensure adequate
and sure mounting and always use suitable handling equipment for transportation.
Warning regarding life support applications
Do not use the Mac Plus for applications in any medical equipment intended for use as a
component of a life support system. For this type of use a specific written agreement between the
customer and Mastervolt is required.

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Mac Plus
48V Models – User and Installation Manual
2. General Information
Use of this manual
This manual serves as a guideline for the safe and effective operation and maintenance of the
following Mac Plus models:
Product code Model
81203105 Mac Plus 48/12-50
81203205 Mac Plus 12/48-15
81203305 Mac Plus 48/24-30
81203405 Mac Plus 24/48-15
These models are further referred to as “Mac Plus”.
Liability
Mastervolt can accept no liability for:
•Consequential damage resulting from the use of the Mac Plus.
•Possible errors in the included manual and the consequences of these.
•Use that is inconsistent with the purpose of the product.
Warranty
The Mastervolt product warranty covers the Mac 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.
Disclaimer
Our products are subject to continual development and improvement. Therefore, additions or modifi-
cations 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.

Mac Plus 48V Models – User and Installation Manual
7
Identification label
Important technical information required for service, maintenance & secondary delivery of parts can
be derived from the identification label. The following picture is only an example!
(Serial number R221
A
1000 with device hardware version
A
)
CAUTION!
Never remove the identification label. This will void the warranty.
Correct disposal of this product
This product is designed and manufactured with high quality materials and components,
which can be recycled and reused.
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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Mac Plus
48V Models – User and Installation Manual
3. Product Description
The Mac Plus charger converts a DC (battery) voltage to a regulated DC voltage. The left side is the
high side (36/48V) and the right side is the low side (12/24V). The Mac Plus can use each side as
input or output. The default direction of the current flow is indicated by the product name. So a Mac
Plus 48/12-50 uses the 48V as input and the 12V as output. Selection of the direction of the current
flow is controlled through MasterBus event configuration, CZone circuit configuration, or a remote
switch. Reversing the charge direction is typically used for boosting the starter battery.
Application examples:
•situations where the electrical power system voltage is 48V but the loads are still 12V
•to charge a 48V lithium service bank, while driving/boating
•to charge a 12V starter battery, while connected to the grid
The Mac Plus can be used as:
•a 3-Step+ battery charger or
•a stabilized DC power supply.
The Mac Plus can only be used in installations with a negative ground.

Mac Plus 48V Models – User and Installation Manual
9
Dimensions
146 mm [5.7"]
198 mm [7.8"]
255 mm [10"]
66 mm [2.6"]
165 mm [6.5"]

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Mac Plus
48V Models – User and Installation Manual
Front panel
1
3
Front panel
1 Status LED (2x)
2
+
Low side (12/24V)
3 Ground
4 +High side (36/48V)
5 MasterBus/CZone connection (2x)
6 DIP switches
7 Accessories connector
Pin 1: +battery voltage sense input
Pin 2: -battery voltage sense input
Pin 3: change the charge direction trigger
Pin 4: remote switch input
Pin 5-6: battery temperature sensor input
2
4
5
6
7