Mastervolt CZONE Mac Plus Operating manual

Mac Plus
DC-DC CHARGER
12/12-50, 12/24-30, 24/12-50, 24/24-30, 24/24-50
USER AND INSTALLATION MANUAL
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Mac Plus –User and Installation Manual
TABLE OF CONTENTS
1. SAFETY INSTRUCTIONS................................................................................................... 4
Warnings and symbols................................................................................................................ 4
General....................................................................................................................................... 4
Explosive gases.......................................................................................................................... 5
Warnings regarding the use of batteries...................................................................................... 5
Warning regarding life support applications................................................................................. 6
2. GENERAL INFORMATION ................................................................................................. 7
Use of this manual ...................................................................................................................... 7
Liability........................................................................................................................................ 7
Warranty ..................................................................................................................................... 7
Disclaimer................................................................................................................................... 7
Identification label ....................................................................................................................... 8
Correct disposal of this product................................................................................................... 8
3. PRODUCT DESCRIPTION ................................................................................................. 9
Dimensions ................................................................................................................................. 9
Front panel................................................................................................................................ 10
4. INSTALLATION INSTRUCTIONS ..................................................................................... 11
5. PLACEMENT AND MOUNTING........................................................................................ 12
Adding the Mac Plus to a MasterBus network........................................................................... 12
Adding the Mac Plus to a CZone network ................................................................................. 12
6. CONNECTION .................................................................................................................. 13
Installation drawing A................................................................................................................ 13
Installation drawing B................................................................................................................ 13
Remote switch input.................................................................................................................. 14
Battery temperature sensor (included) ...................................................................................... 14
Voltage drop compensation....................................................................................................... 14
7. CONFIGURATION –DIP SWITCHES............................................................................... 15
8. OPERATION ..................................................................................................................... 17
Battery charger operation modes.............................................................................................. 17
LED indicator............................................................................................................................. 17
9. MASTERBUS.................................................................................................................... 18
What is MasterBus.................................................................................................................... 18
MasterBus on the Mac Plus ...................................................................................................... 18
Monitoring................................................................................................................................ 19
Alarm ....................................................................................................................................... 20
Configuration............................................................................................................................ 20
Events...................................................................................................................................... 23
10.CZONE.............................................................................................................................. 25
What is CZone .......................................................................................................................... 25
Adding the Mac Plus to a CZone system configuration ............................................................. 25
11.TROUBLE SHOOTING...................................................................................................... 27

Mac Plus –User and Installation Manual
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12.TECHNICAL SPECIFICATIONS ....................................................................................... 29
CZone specifications................................................................................................................. 30
Battery settings ......................................................................................................................... 30
Characteristics .......................................................................................................................... 31

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Mac Plus –User and Installation Manual
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.
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 and
replace the wiring immediately.
6 Do not operate Mac Plus if it has received a sharp blow, been dropped, or otherwise damaged
in any way; take it to a qualified service technician.
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

Mac Plus –User and Installation Manual
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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 –RISK OF EXPLOSIVE GASES. 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 or area in which ignition-protected equipment is required.
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.

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Mac Plus –User and Installation Manual
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 Only use Mac Plus for charging a LEAD-ACID or Lithium-Ion batteries and the supply of loads
attached to these batteries, in permanent systems. Do not use Mac 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.
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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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
81205105
12/12-50
81205305
12/24-30
81205205
24/12-50
81205405
24/24-30
81205505
24/24-50
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.

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Mac Plus –User and Installation Manual
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 N708F0001 with device hardware version F)
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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3. Product description
The Mac Plus charger converts a DC (battery) voltage to a regulated DC voltage. It 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.
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 –User and Installation Manual
Front panel
Front panel
1
Status LED
2
+ Output
3
Ground
4
+ Input
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: not used
Pin 4: remote switch input
Pin 5-6: battery temperature sensor input

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4. Installation instructions
In addition to the Mac Plus the delivery includes:
•Battery temperature sensor;
•Drop cable CZone/MB (1m);
•MasterBus Terminator;
•User and installation manual.
Installation steps:
1 Place and mount the Mac Plus, see chapter 5;
2 Connect the Mac Plus, see chapter 6;
3 Configure the Mac Plus, see chapters 7 and 9 or 10.
CAUTION
Read the entire manual before installing the Mac Plus. Keep the manual at a safe
location for future reference.
•Operating temperature range: -20 up to +60 ºC, >40 ºC derating power
[-4 up to +140 ºF, >104 ºF derating power].
•Never use the Mac Plus at a location where there is danger of gas or dust explosions.
•Mount the Mac Plus in such a way that obstruction of the airflow through the heatsink is
prevented. This device requires a minimum of 10 cm (4") of clearance on every side.
•Do not mount the Mac Plus straight above batteries that might release corrosive sulphur fumes.
•Be sure that the output of the supplying source is switched off during installation. Also be sure
that no load is connected to the batteries during installation, to prevent hazardous situations.
•Use cables with an appropriate size, see the following table.
Recommended wire sizes DC input/output
Model
Minimum wire size Input
Minimum wire size Output
12/12-50
16 mm2[AWG 6]
16 mm2[AWG 6]
12/24-30
16 mm2[AWG 6]
10 mm2[AWG 8]
24/12-50
10 mm2[AWG 8]
16 mm2[AWG 6]
24/24-30
10 mm2[AWG 8]
10 mm2[AWG 8]
24/24-50
16 mm2[AWG 8]
16 mm2[AWG 6]
Min. 3 Nm –max. 5 Nm

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Mac Plus –User and Installation Manual
5. Placement and mounting
Mount the Mac Plus with four M5 screws to a solid flat surface.
Adding the Mac Plus to a MasterBus network
Precondition: This section assumes that a MasterBus network is already installed.
1. Disconnect a MasterBus cable or Terminator from the closest MasterBus device and connect it
to the Mac Plus.
2. Connect the new MasterBus cable to the other MasterBus device and then connect to the Mac
Plus.
Adding the Mac Plus to a CZone network
Precondition: This section assumes that a CZone backbone is already installed.
1. Disconnect the backbone at the closest backbone connection and add in a tee connector.
2. Reconnect the backbone connection(s) with the new tee connector in place.
3. Connect the RJ45 CZone/MB drop cable to the black coupler on the tee and then connect to the
Mac Plus.

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6. Connection
•Mac Plus as a battery charger, see installation drawing A.
•Mac Plus as a stabilized DC power supply, see installation drawing B.
•Use properly sized fuses and wiring.
Installation drawing A
Installation drawing B

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Mac Plus –User and Installation Manual
Remote switch input
The remote switch input (pin 4 of the Accessories connector) can be used to enable and disable the
battery charger. In a vehicle application, it is recommended to connect the engine run signal. This
way, the charger is used when the engine is running and the alternator is charging. The engine run
signal can be provided in different ways. For details contact your vehicle distributor.
The remote input accepts two different enable levels:
•active low, connect to ground (between 0 and 0.5 V)
•active high, connect to + battery voltage (between 3 and 32 V)
Active low means active when input is low. Active high means active when input is high.
The remote switch input configuration can be done by DIP switch (see chapter 7) or by MasterBus
(see chapter 9) or by CZone (see chapter 10).
Battery temperature sensor (included)
By installing the Mastervolt battery temperature sensor, the charge voltages are automatically
adapted for deviating temperatures.
Figure 1. Temperature compensated charging
When the battery temperature is low, the charge voltage increases. In case the battery temperature
is high, the charge voltage is decreased. Over charge and gassing are prevented this way. This will
extend the life of your battery.
Voltage drop compensation
The Mac Plus can compensate the voltage drop occurring over the output cables. For this purpose,
the Mac Plus is equipped with terminals for voltage sense wires. Use 0,75 mm2 [AWG 18], preferably
red and black wire and protect these with 2 A fuses slow blow. Pay good attention to the polarity of
the wires.
In order to accurately measure the battery voltage, connect the voltage sense wires as close to the
battery poles as possible. The positive and negative voltage sense wires must be connected. Cable
losses will be compensated up to a maximum of 2.5 V.

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7. Configuration –DIP switches
The Mac Plus settings can be adjusted in two ways:
•By means of DIP switches;
•From a monitoring panel, for example the EasyView 5 (MasterBus) or the Touch 10 (CZone), or
from a computer with MasterAdjust or the CZone Configuration Tool. Some settings can only be
changed in this way.
This chapter only describes the DIP switch settings. For settings in a MasterBus network, see
chapter 9. For settings in a CZone network, see chapter 10.
CAUTION!
Incorrect settings of the Mac Plus can cause serious damage to your batteries and/or
the connected load! Adjustments of settings may be undertaken by authorized
personnel only!
Use a small screwdriver to carefully set the required
settings. You may need to remove the cables (or
Terminator) to be able to access the DIP switches.
In a CZone network, set DIP switches 1 and 2 to OFF. DIP switches 3 to 10 must match the unique
address used in the CZone network; the dipswitch. At least one of DIP switches 3 to 10 must be ON.
In a MasterBus network, set DIP switches 1 and 2 to ON. Use the other DIP switches for charger
and battery settings. For an overview of the various DIP switch settings, see the following three
tables, where a 0 indicates OFF or and a 1 indicates ON or .
Note: DIP switch settings overrule MasterBus settings. If DIP switches are not in their default
setting, the corresponding MasterBus setting is grayed out.
If a DIP switch is set back to its original setting, the corresponding setting switches back to
its default value. For example: in MasterAdjust, battery type Gel was selected. Then DIP
switch 3 was set to ON, to select battery type Lithium-Ion. When DIP switch 3 is set back to
OFF, the battery type will be Flooded; the default value.

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Mac Plus –User and Installation Manual
DIP switch
MasterBus communication
2
0
Smart on; no MasterBus communication in sleep mode (no load <2mA)
1
MasterBus communication always on (no load 10mA), provided there is enough
input power
DIP switch
Battery type
3
4
5
0
0
0
Follow MasterBus setting, see chapter 9.
Default factory setting: Flooded battery
0
0
1
Flooded
0
1
0
AGM
0
1
1
Gel
1
0
0
Lithium-Ion
1
1
1
Constant voltage (13.25 V*)
DIP switch
Charger on conditions
Typical use
6
7
8
0
0
0
MasterBus settings apply, see chapter 9.
Default factory setting:
Remote switch input ‘active high’ and input
voltage greater than enable voltage setpoint
(12.50 V*)
Default factory setting:
Recommended setting for
vehicle with proper engine run
signal
0
0
1
Always on
(Remote switch input not used)
When the battery charger must
be always active
0
1
0
Remote switch input ‘active low’
Enable the battery charger by
external operating signal
0
1
1
Remote switch input ‘active high’
Enable the battery charger by
external operating signal
1
0
0
Remote switch input ‘active low’
and input voltage greater than enable
voltage setpoint (12.50 V*)
Recommended setting for
vehicle with proper engine run
signal
1
0
1
Remote switch input ‘active high’
and input voltage greater than enable
voltage setpoint (12.50 V*)
Recommended setting for
vehicle with proper engine run
signal
1
1
0
Input voltage greater than enable voltage
setpoint (13.50 V*)
(Remote switch input not used)
Higher enable voltage setpoint.
Setting for vehicle without engine
run signal
* For a 24 V battery charger, multiply the voltages by two.
DIP switches 9 and 10 are not used in MasterBus.

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8. Operation
Battery charger operation modes
Mode
Explanation
Charging
The Mac Plus is in charging mode if it meets the switch-on
conditions (see DIP switch/MasterBus/CZone settings)
Standby
The Mac Plus goes to standby when is does not meet the
switch-on conditions (see DIP switch/ MasterBus/CZone
settings)
Or
Switched off by the Standby button in a MasterBus menu, or by
a MasterBus event, or by a CZone circuit
Sleep (low no-load power
consumption)
The Mac Plus enters sleep mode when the sleep delay has
passed, to reduce the no-load power consumption
Every 5 seconds, the Mac Plus scans if the configured battery
charger meets the switch-on conditions
Alarm
Possible error, analyze the situation
LED indicator
Use the following table to understand the meaning of the LED signals.
LED color
LED indication
Meaning
What to do?
Green
Solid
On
Normal operation
Blue
Slow blinking
Sleep
Normal operation
Blue
Solid
Standby
Normal operation
Red-Blue
Fast blinking
Software update
Update is in progress
Red
Solid
Possible error
Analyze the situation

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Mac Plus –User and Installation Manual
9. MasterBus
What is MasterBus
All devices that are suitable for MasterBus are marked by the MasterBus symbol
MasterBus is a fully decentralized data network for communication between the
different Mastervolt system devices. It is a CAN-bus based communication network.
MasterBus is used as power management system for all connected devices, such as the inverter,
battery charger, generator and many more. This gives the possibility for communication between the
connected devices, for instance to start the generator when the batteries are low.
MasterBus reduces complexity of electrical systems by using UTP patch cables. All system
components are simply chained together. Therefore, each device is equipped with two MasterBus
data ports. When two or more devices are connected to each other through these data ports, they
form a local data network, called the MasterBus. The results are a reduction of material costs as
only a few electrical cables are needed and less installation time.
For central monitoring and control of the connected devices Mastervolt offers a wide range of panels
which show full status information of your electrical system at a glance and a push of a button. See
www.mastervolt.com for all available options.
New devices can be added to the existing network in a very easy way by just extending the network.
This gives the MasterBus network a high degree of flexibility for extended system configuration, not
only today, but in the future as well!
Mastervolt also offers several interfaces, making even non-MasterBus devices suitable to operate in
the MasterBus network.
Keep the following rules in mind:
˗Connections between the devices are made by standard MasterBus cables (straight UTP).
Mastervolt can supply these cables.
˗As with all high-speed data networks, MasterBus needs a terminating device on both ends of
the network.
˗Up to 63 MasterBus devices can be connected together.
˗The electric power for the network comes from the connected devices. At least one device in
the network should have powering capabilities (see specifications). One powering device can
power up to three non-powering devices. As all powering devices are galvanically isolated,
multiple powering devices are allowed. Spread the powering devices over the network.
˗Do not make ring networks.
˗Do not make T-connections in the network.
For more details on networks, please contact your Mastervolt supplier.
MasterBus on the Mac Plus
When the Mac Plus is connected, open MasterAdjust on a Windows computer connected to the
MasterBus network via a MasterBus USB interface. MasterAdjust software is available as free to
download software on the Mastervolt website: www.mastervolt.com.

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The following tables list the parameters as shown in MasterAdjust.
Monitoring
Value
Meaning
Adjustable range
Status
Device state
Shows the actual operation mode:
Standby / Charging / Alarm
(read only)
Charge state
State of charge algorithm: Off / Bulk / Absorption /
Float / Constant voltage
(read only)
On/Standby
Button to toggle the device state.
Note: in the standby mode, the Mac Plus can be
switched on again automatically. This happens, for
example, after a restart.
On, Standby
DC in
Input voltage
Voltage at the input
(read only)
Input current
Current of the input
(read only)
DC out
Output voltage
Voltage at the output
(read only)
Output current
Current of the output
(read only)
Bat. volt sense
Battery voltage measured by the battery voltage
sensor.
(read only)
Remote
Remote input
Remote input signal detected. Only applicable when
Remote input mode is active low or active high
configured.
(read only)
Temperature
Battery
Actual battery temperature measured by the Battery
temperature sensor.
If no battery temperature sensor is used or when
Battery is set to “LiIon”: “---“ is shown.
(read only)
Device
Device temperature
(read only)

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Mac Plus –User and Installation Manual
Alarm
Value
Meaning
Dev. temp. high
Internal temperature is too high
Bat. temp. high
Battery temperature is too high (> 55 ºC [131 ºF])
Bat. temp. low
Battery temperature is too low (< -20 ºC [-4 ºF])
Input high
Input voltage is too high
Input low
Input voltage is too low
Output high
Output voltage is too high
Output low
Output voltage is too low
Over volt. prot.
Over Voltage Protection shutdown
Over curr. prot
Over Current Protection shutdown
HW fault
Internal hardware error
Cable loss high
Cable loss is too high (>2.5 V)
Configuration
Value
Meaning
Factory setting
Adjustable range
Device
Name
Name of this device. This name
will be recognized by all devices
connected to the network
Plus 12/12
Plus 12/24
Plus 24/12
Plus 24/24
Plus24/24-50
0-12 chars
Language
Menu language of this device
English
EN, NL, DE, FR, ES,
IT, NO, SV, FI, DA
CZone enabled
This checkbox is marked when
the Mac Plus is setup to work in
a CZone network
Off
(read only)
DIP switches
DIP switch state 0=off, 1=on
1100000000
(read only)
Factory settings
Button to reset the Mac Plus to
default settings (requires installer
rights)
Config locked
Option to lock the configuration
(requires installer rights)
Off
On, Off