Mastervolt Mass Sine 24/5000 Operating manual

USERS- AND INSTALLATION MANUAL
MASTERVOLT B.V.
Snijdersbergweg 93
1105 AN Amsterdam
The Netherlands
Tel.: [phone]
Fax.: [phone]
e-mail: [email protected]
WEB-site: www.mastervolt.com
Mass Sine 24/5000 230V AC
Mass Sine 24/4000 117V AC
Inverter
Language : English
Version : V1.1-050209
ENGLISH: PAGE 1
NEDERLANDS: PAGINA 25
DEUTSCH: SEITE 49
FRANÇAIS: PAGE 73

2 February 2005 / Mass Sine 5000 / EN

February 2005 / Mass Sine 5000 / EN 3
CONTENTS V1.1 February 2005
1GENERAL INFORMATION ................................................................ 5
1.1 Use of this manual .......................................................................5
1.2 Warranty specifications ................................................................5
1.3 Quality .......................................................................................5
1.4 Validity of this manual..................................................................6
1.5 Liability ......................................................................................6
1.6 Identification label .......................................................................6
1.7 Changes to the product ................................................................6
2SAFETY GUIDELINES AND WARNINGS............................................ 7
2.1 Warnings and symbols .................................................................7
2.2 Use for intended purpose ..............................................................7
2.3 Organizational measures ..............................................................7
2.4 Installation, maintenance and repair ..............................................8
2.5 Warning of special dangers ...........................................................8
2.6 Warning regarding life support applications .....................................8
3OPERATION .................................................................................... 9
3.1 Introduction................................................................................9
3.2 Switching on and off ....................................................................9
3.3 Indicator lights ............................................................................9
3.4 On the remote control ................................................................ 11
3.5 Maintenance ............................................................................. 11
4INSTALLATION ............................................................................. 12
4.1 Environment ............................................................................. 12
4.2 Wiring...................................................................................... 12
4.3 Mounting of the cabinet .............................................................. 12
4.4 Connecting ............................................................................... 13
4.4.1 Opening the front panel ........................................................ 13
4.4.2 Connecting AC wiring & earth wiring ....................................... 13
4.4.3 DC wiring............................................................................ 14
4.4.4 Battery cable connections...................................................... 14
4.5 Connecting the remote control panel ............................................ 15
4.6 Commissioning after installation .................................................. 15
4.7 Automatic switching between Mass inverter, the AC generator
and / or shore power.................................................................. 15
5TROUBLE SHOOTING .................................................................... 16
6TECHNICAL DATA ......................................................................... 17
6.1 230V Inverters .......................................................................... 17
6.2 117V Inverters .......................................................................... 18
7DIMENSIONS ................................................................................ 19
8INSTALLATION DRAWINGS .......................................................... 20

4 February 2005 / Mass Sine 5000 / EN

February 2005 / Mass Sine 5000 / EN 5
1GENERAL INFORMATION
1.1 Use of this manual
This manual serves as a guideline for the safe and effective operation,
maintenance and possible correction of minor malfunctions of the
Mastervolt Mass Sine. This manual is valid for the following models:
1. Mass Sine 24/5000 230V AC-50Hz, art. No 24095100.
2. Mass Sine 24/5000 230V AC-60Hz, art. No 24195100.
3. Mass Sine 24/4000 117V AC-60Hz, art. No 25024000.
4. Mass Sine 24/4000 117V AC-50Hz, art. No 25124000.
It is therefore obligatory that every person who works on or with the
Mass Sine must be completely familiar with the contents of this manual,
and that he/she carefully follows the instructions contained herein.
Installation of, and work on the Mass Sine, may once be carried out by
qualified, authorized and trained personal, consistent with the locally
applicable standards and taking into consideration the safety guidelines
and measures (chapter 2 of this manual).
Save this manual at a secure place!
1.2 Warranty specifications
Mastervolt guarantees that this product has been built according to the
legally applicable standards and specifications. Should work take place,
which is not in accordance with the guidelines, instructions and
specifications contained in this users manual, then damage may occur
and/or the unit may not fulfil its specifications. All of these matters may
mean that the guarantee may become invalid.
The warranty is limited to the costs of repair and/or replacement of the
product. Costs for installation labour or shipping of the defective parts
are not covered by this warranty.
1.3 Quality
During their production and prior to their delivery, all of our units are
exhaustively tested and inspected.
The warranty period is two years after date of purchase.

6 February 2005 / Mass Sine 5000 / EN
1.4 Validity of this manual
All of the specifications, provisions and instructions contained in this
manual apply solely to the Mastervolt-delivered standard versions of the
product.
1.5 Liability
Mastervolt can accept no liability for any consequential damage due to
use of the product, possible errors in the manual and the results
thereof.
1.6 Identification label
The identification labels are located at the backside and in the
connection compartment of the product. Important technical
information required for service, maintenance & secondary delivery of
parts can be derived from the identification label. Therefore the
identification label must not be removed!
1.7 Changes to the product
Modifications to the product may only be carried out by Mastervolt or
after the written permission of Mastervolt.

February 2005 / Mass Sine 5000 / EN 7
2SAFETY GUIDELINES AND WARNINGS
2.1 Warnings and symbols
Safety instructions and warnings are marked in this manual by the
following symbols:
CAUTION!
Special data, restrictions and rules with regard to preventing damage.
WARNING!
A WARNING refers to possible injury to the user or significant material
damage to the product if the installer / user does not (carefully) follow
the procedures.
2.2 Use for intended purpose
•The product is constructed as per the applicable safety-technical
guidelines.
•Use the product only:
−with a fuse, protecting the wiring between product intput and
battery;
−in a technical correct condition;
−in a closed, well-ventilated room, protected against rain,
moisture, dust and non condensing circumstances;
−observing the instructions in this manual.
WARNING!
Never use the product in situations where there is danger of gas or dust
explosion!
•Use other than as mentioned above is not considered to be
consistent with the intended purpose. Mastervolt is not liable for any
damage resulting from unintended use.
2.3 Organizational measures
The installer / user must always:
•have access to this manual;
•be familiar with the contents of this manual. This applies particularly
to Chapter 2, Safety Guidelines & Warning.

8 February 2005 / Mass Sine 5000 / EN
2.4 Installation, maintenance and repair
If the product is switched off during maintenance and/or repair
activities, it should be secured against unexpected and unintentional
switching on:
•switch off the connection with the batteries and remove the battery
fuse of the product;
•be sure that third parties cannot reverse the measures taken.
2.5 Warning of special dangers
•Connect the earth of the inverter output to the central ground and
use an RCCB switch in the inverter output.
•Secure the DC wiring with a fuse, according to the guidelines in this
user manual.
•Connection and protection of your electrical system must be done in
accordance with local standards.
•Do not work on the product or the electrical installation if it is
connected to a power source. Only allow changes in your electrical
system to be carried out by qualified electricians.
•Check the wiring at least once a year. Defects such as loose
connections, heat damaged cables etc. must be corrected
immediately.
•Not only the batteries, but the product as well can become a
projectile if your transport is involved in an accident! Ensure
adequate and secure mounting and always use suitable handling
equipment for transportation.
•Except for the connection compartment the cabinet of the product
must not be opened. There are no serviceable parts inside the
cabinet. Only qualified, authorized and trained electrician installers
are authorized to open the connection compartment.
2.6 Warning regarding life support applications
Mastervolt products are not sold for applications in any medical
equipment intended for use as a component of any life support system
unless a specific written agreement pertaining to such intended use is
executed between the product manufacturer and Mastervolt. Such
agreement will require the equipment manufacturer either to contract
for additional reliability testing of the Mastervolt parts and/or to commit
to undertake such testing as a part of the manufacturing process. In
addition such manufacturer must agree to indemnify Mastervolt from
any claims arising from the use of Mastervolt parts in the life support
equipment.

February 2005 / Mass Sine 5000 / EN 9
3OPERATION
3.1 Introduction
The Mass SINE inverter is a fully automatic high efficiency inverter
developed and produced by Mastervolt Amsterdam. The MASS SINE
inverter is part of a series of advanced quality battery chargers and
inverters supplied by Mastervolt all over the world. The MASS SINE
inverter converts DC voltage to 230VAC~50/60Hz or 117VAC~60/50Hz.
The AC output voltage has a sinusoidal waveform for reliable and
trouble free operation of connected equipment. The inverter is protected
against overload, short circuit and over temperature. In case of
overload, the inverter will reduce its output power.
3.2 Switching on and off
Switching on: Put the on/off/remote switch on the front of the inverter
on "on". The green lamp “inverter on” lights up, and the inverter will
start. If you use a remote control panel, put the on/off/remote switch to
“remote”, and put the on/off switch on the remote control panel to “on”.
Switching off: Put the on/off/remote switch on the front of the inverter
on "off". The inverter stops and all the lights that are on, go off.
CAUTION! Switching off the inverter with the switch on the front or via
the remote does not break the connection to the mains or the batteries.
3.3 Indicator lights
The functions of the indicator lights on the front are:
LED Meaning Short description
Inverter on Inverter is
switched on
The green light shows when the
inverter is switched on.
Overload Inverter is
overloaded
Glows if the inverter is overloaded.
When the inverter is overloaded,
the power limit reduces the output
voltage. Depending on the load, the
inverter will shut down after a short
period.

10 February 2005 / Mass Sine 5000 / EN
LED Meaning Short description
Overload +
on slow
Overload in wait
state
When the inverter is in a state of
overload for a long period of time
the inverter will switch off and the
overload + on indicators will flash
slowly. This takes approx. 20
seconds after which the inverter
automatically will restart. This so
called wait state gives the inverter
time to recover from any heavy
surge loads and the battery time to
recover in case of an empty
battery. When the inverter is
switched of 10 times with intervals
no more than 30 seconds apart the
inverter will switch off permanently
and the “overload” and ON
indicators will flash fast. To switch
the inverter on again, you must
manually switch the inverter off and
on. When the output is short
circuited, the inverter will go into
overload. The “overload” and ON
indicators will flash slowly. The
inverter will try to start up ten
times.
Overload +
on fast
Inverter is
switched off
If the short circuit is not removed,
the inverter will switch off
permanently. Remove the short
circuit and reset the inverter by
switching it off and on.
Low battery Battery voltage is
too low
The inverter is switched off if the
battery voltage is too low (see table
below). If the voltage rises above
the values given below, the inverter
restarts automatically.
Switching off voltage: 19V
Switching on voltage: 22V
Temperature Inverter is
overheated
The inverter switches off in high
ambient temperatures and / or
sustained overload. After cooling
down, the inverter restarts
automatically.

February 2005 / Mass Sine 5000 / EN 11
3.4 On the remote control
If you use a remote control panel, put the on/off switch to “remote”,
and put the on/off switch on the remote control panel to ON. The
meaning of the illuminated LED’s is:
•inverter on: inverter is switched on
•failure: inverter is overloaded, overheated or battery voltage is too
low
If the failure lamp is lit you can check the nature of the failure on the
inverter front.
3.5 Maintenance
For reliable and optimum function examine your electrical installation on
a regular base, at least once a year. Defects such as loose connections,
burnt wiring etc. must be corrected immediately. Keep the inverter dry,
clean and dust-free, in order to ensure good heat discharge. If
necessary, use a soft clean cloth to clean the cabinet. Never use any
liquids, acids and/or scourers.

12 February 2005 / Mass Sine 5000 / EN
4INSTALLATION
During installation and commissioning of the MASS inverter, the Safety
Guidelines and Measures are applicable at all times. See chapter 2 of
this manual.
4.1 Environment
Install the MASS inverter in a dry, well ventilated, dust free situation.
Locate the inverter as close as possible to the DC distribution in order to
keep the battery cables short. Do not locate the inverter in the same
compartment as the batteries. The heat of the inverter is discharged by
a fan with a variable speed, from the top and side of the cabinet to the
bottom of the cabinet. When fitting the inverter be sure that:
•the air flow is not obstructed;
•the inverter is mounted vertically;
•no water and / or dust can enter the cabinet.
WARNING! Never use the inverter in locations where there is gas or
explosion danger!
4.2 Wiring
The routing of the wires has influence on the EMC behavior of the
system in which the inverter is a component. This is caused by the fact
that wires are excellent receivers and transmitters of radio frequency
electro magnetic interference. Most problems originate from mutual
interference between wires and cables. Therefore you should separate
AC and DC cables and lay the cables in metal cable trunk and connect
this trunk to ground. The metal of the trunk offers a low resistance to
interference currents, so that these currents run via the trunk to
ground. A compromise would be to lay the cables besides a metal strip.
If this solution is also not workable then make a cable loom.
4.3 Mounting of the cabinet
Use suitable screws and dowels to fix the MASS inverter to the wall. To
mount the MASS inverter follow the described instructions:
1. Determine the mounting points (see Figure 7-1).
2. Drill mounting holes for the cabinet.
3. Mount the MASS inverter with four screws or bolts (M6) to the wall.
4. Fasten all screws or bolts securely.

February 2005 / Mass Sine 5000 / EN 13
4.4 Connecting
The Mastervolt Service Centres have all accessories available, e.g.
battery terminals and supply cables in all sizes.
Refer to the installation drawings during installation (chapter 8)
WARNING! Before beginning to connect the wiring, make the AC and
DC distribution voltage-free.
4.4.1 Opening the front panel
Loosen the two Philips screws that secure the front cover plate for two
turns. Pull the grey front panel away from the cabinet (downwards).
The terminals and cable glands are now accessible.
4.4.2 Connecting AC wiring & earth wiring
The inverter is protected against overload and short circuit, so it is not
necessary to install a fuse in the output of the inverter.
CAUTION! For safe installation it is necessary to:
•connect the earth (PE) and neutral (N) of the inverter output to the
central ground;
•insert a RCCB (earth leakage) switch of 30mA in the inverter output.
Please acquaint yourself with the local regulations on this issue!
WARNING! Check whether the voltage from the inverter is the same
as the connected equipment.
WARNING! The earth wire offers protection only if the inverter cabinet
is connected to the earth. Connect the inverter's earth terminal (at the
right hand side of the AC terminal block) to the hull or chassis via the
earth stud.
To connect the Mass SINE inverter to the mains:
1. Switch the on/off/remote switch to 'off'. The L1, N and PE terminals
are situated on the left hand side inside the cabinet.
2. Connect the AC on-board system brown phase 4mm/AWG 11 wire
to terminal L1, the blue neutral wire to terminal N and the
green/yellow earth wire to terminal PE.

14 February 2005 / Mass Sine 5000 / EN
4.4.3 DC wiring
Keep the cable length as short as possible, this will keep the system
efficiency as high as possible. The recommended minimum size of the
battery cables is 4 x 50mm/AWG 0 (see Figure 8-2) or 2 x
70mm/AWG 2/0 with two jumpers (included, see Figure 8-3). The
recommended length is a maximum of 3 meters. When longer cables
are required, use thicker cables. When possible, use coloured (red and
black) battery cables. If this is not possible, mark the cables with red
and black isolation tape or heat shrink sleeve.
4.4.4 Battery cable connections
To connect the Mass SINE inverter to the batteries:
1. Pull the battery cables through the glands at the bottom side of the
inverter. Keep the cable connection between batteries and inverter
as short as possible (maximum 3 meters).
2. Connect the black negative battery cable to the negative connection
bolt (right) and the red positive battery cable to the positive bolt
(left) of the inverter.
3. Cut the cables to the right length and fix, if necessary; connect
cable clamps to both ends.
4. Connect the negative cable to the negative battery pole and the
positive cable via the inverter fuse to the positive red pole.
CAUTION! Pull the battery cables through the glands before you install
the cable clamps.
CAUTION! Reversing positive and negative will cause major damage to
the inverter. This damage is not covered by the guarantee.
CAUTION! Too-thin cables and/or loose connections can cause
dangerous overheating of the cables and/or terminals. Therefore tighten
all connections well, in order to limit transition resistance as much as
possible. Use DC cables of the correct size.

February 2005 / Mass Sine 5000 / EN 15
4.5 Connecting the remote control panel
The remote control panel C4-RI for the MASS inverter comprises an
off/on switch and two LED’s. The LED 'inverter on' indicates proper
functioning of the inverter and the availability of 230/117V AC output
voltage. The LED 'failure' indicates overload, over temperature or too
low voltage. Connect the remote control panel by means of a telephone
cable (not supplied with the panel).
4.6 Commissioning after installation
Carefully check the polarity of the connections.
CAUTION! Only insert the inverter fuse if the polarity is correct.
Switching on with incorrect polarity will damage the inverter irreparably.
The inverter fuse cannot prevent this.
If the connections are correct:
•check whether the on/off switch is in the OFF position;
•when inserting the inverter fuse, a spark will occur, caused by the
capacitor used in the inverter. This is normal.
The inverter is now ready for use.
4.7 Automatic switching between Mass inverter, the AC
generator and / or shore power
Please contact your Mastervolt supplier if you intend to use the inverter
with a generator or shore power connection. Hand switched or simple
relay switching systems could damage your inverter, because of the
lack off time delay. This kind of damage is not covered by the warranty.

16 February 2005 / Mass Sine 5000 / EN
5TROUBLE SHOOTING
Malfunction Possible cause What to do
High output voltage Check battery voltage and
switch charger off. (LED’s
off)
DC fuse blown. Replace the fuse.
No output voltage and
no indication lights
Switch set to remote,
but no remote present.
Put switch at on.
No output voltage,
LED low batt is lit.
Flat battery. Charge the batteries, the
inverter will switch on if
the battery voltage is
above 22V.
No output voltage and
LED temp is lit.
The inverter has been
overloaded.
Reduce the load and let
the inverter cool down.
Flat battery. Disconnect load and
charge batteries.
Cables too thin. Replace with cables of
correct diameter.
Inverter goes on and
off, LED on and LED
low bat are blinking in
turn.
Connections are
corroded or bad.
Tighten the connections. If
the cables are burned,
replace them.
Inverter goes on and
off, LED on and
overload blink in turns
one time per second,
ventilator is running at
full speed.
Inverter is overloaded. Reduce the load on the
inverter.
Inverter goes on and
off, LED on and
overload blink in turns
five times per second,
ventilator is running at
full speed.
Inverter has been
switched off ten times
as a result of an
overload situation or a
short circuit.
Reduce the load or the
short circuit. Reset the
inverter manually by
means of the on/off switch.
If you cannot correct a problem with the aid of the malfunction table,
contact your Mastervolt Service Centre or Mastervolt Amsterdam for an
extended service list, telephone: INT+ 31-20-3422100.

February 2005 / Mass Sine 5000 / EN 17
6TECHNICAL DATA
6.1 230V Inverters
GENERAL
Function apparatus supplying of AC equipment
Models 24/5000
Manufacturer Mastervolt, Amsterdam
INPUT
Battery voltage nominal 24V
Switch off voltage low 19V
Switch on voltage low 22V
Switch off voltage high 32V
Switch on voltage high 30V
Maximal ripple 5%
Current (nominal load) 240A
No load 300mA/7W
Fuse 2X160A or 1x250A slow blow
DC Cable 4x50mm²/AWG 0 or 2x70 mm²/AWG 2/0 with two jumpers (included).
OUTPUT
Output voltage 230VAC, ±5%
Output waveform true sine wave
Frequency 50Hz, ±0.01% (60Hz model orderable)
Nominal power Tamb=40°C 4000W
Half hour power Tamb=25°C 5000W
Peak power 9000W
Cos phi All power factors allowed.
Efficiency nominal 90%
CLIMATE
Nominal temperature -20 till 40°C / -4°F till 104°F
Cooling Cooling partial conventional / forced with temperature regulated fan
Humidity < 95% relative humidity, non condensing.
ENCLOSURE
Dimensions (hxwxd) 470x315x254 mm / 18.5x12.4x10.0 inch
Weight 25 kg / 55 lbs
Protection degree IP 23
STANDARDS
Emission EN 50081-1:1992
Immunity EN 50082-1:1997
Safety EN 60950:2000

18 February 2005 / Mass Sine 5000 / EN
6.2 117V Inverters
GENERAL
Function apparatus supplying of AC equipment
Models 24/4000
Manufacturer Mastervolt, Amsterdam
INPUT
Battery voltage nominal 24V
Switch off voltage low 19V
Switch on voltage low 22V
Switch off voltage high 32V
Switch on voltage high 30V
Maximal ripple 5%
Current (nominal load) 200A
No load 300mA/7W
Fuse 2x160A or 1x250A slow blow
DC Cable 4x50mm²/AWG 0 or 2x70 mm²/AWG 2/0 with two jumpers (included).
OUTPUT
Output voltage 117VAC, ±5%
Output waveform true sine wave
Frequency 60Hz, ±0.01% (50Hz model orderable)
Nominal power Tamb=40°C 3500W
Half hour power Tamb=25°C 4000W
Peak power 7000W
Cos phi All power factors allowed.
Efficiency nominal 90%
CLIMATE
Nominal temperature -20 till 40°C / -4°F till 104°F
Cooling Cooling partial conventional / forced with temperature regulated fan
Humidity < 95% relative humidity, non condensing
ENCLOSURE
Dimensions (hxwxd) 470x315x254 mm / 18.5x12.4x10.0 inch
Weight 25 kg / 55 lbs
Protection degree IP 23
STANDARDS
Emission EN 50081-1:1992
Immunity EN 50082-1:1997
Safety EN 60950:2000

February 2005 / Mass Sine 5000 / EN 19
7DIMENSIONS
Figure 7-1: Dimensions inverter.
294 1110.5
21
405.5
315
254
470
241

20 February 2005 / Mass Sine 5000 / EN
8INSTALLATION DRAWINGS
Figure 8-1: Installation of the Mass SINE.
DC Fuse
DC input
AC Output
ON
OFF
+
_
+
_
1 2 3 4 5 6
L1
N
PE
BATTERY
BATTERY