Mastervolt MasterShunt 500 Operating manual

MasterShunt 500
ENHANCED BATTERY MONITOR
USER AND INSTALLATION MANUAL
10000011590/04
To download this manual in other languages, please
visit our website: www.mastervolt.com

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MasterShunt 500 –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 Use for intended purpose........................................................................................................................................... 4
2.2 Maintenance and repair.............................................................................................................................................. 4
2.3 General safety and installation precautions................................................................................................................ 4
2.4 Warning regarding battery use ................................................................................................................................... 4
3PRODUCT DESCRIPTION.................................................................................................................................................... 5
3.1 Introduction................................................................................................................................................................. 5
3.2 Exterior....................................................................................................................................................................... 5
3.3 LED indicators............................................................................................................................................................ 5
4Installation............................................................................................................................................................................ 6
4.1 Things you need for installation.................................................................................................................................. 6
4.2 Connection example................................................................................................................................................... 6
4.3 Installation step-by-step.............................................................................................................................................. 7
4.4 Placing a fuse inside................................................................................................................................................... 8
4.5 Parallel use (MasterBus only)....................................................................................................................................10
5SETTINGS........................................................................................................................................................................... 11
5.1 About MasterBus.......................................................................................................................................................11
5.1.1 Configuration................................................................................................................................................. 11
5.1.2 Events –System Automation......................................................................................................................... 14
5.1.3 Alarms ........................................................................................................................................................... 15
5.1.4 Monitoring...................................................................................................................................................... 15
5.1.5 History ........................................................................................................................................................... 15
5.2 About CZone .............................................................................................................................................................17
6MAINTENANCE................................................................................................................................................................... 19
6.1 Replacement of batteries / reset history ....................................................................................................................19
6.2 Replacement of a fuse...............................................................................................................................................19
7Trouble shooting................................................................................................................................................................ 20
8Specifications..................................................................................................................................................................... 21
8.1 Technical specifications.............................................................................................................................................21
8.2 Dimensions................................................................................................................................................................22

MasterShunt 500 –User and Installation manual
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1 GENERAL INFORMATION
1.1 Use of this manual
This manual serves as a guideline for the safe and effective operation and maintenance of the following MasterShunt 500
models:
Product code
Model
77020110
MasterShunt 500 –MasterBus only
77020115
MasterShunt 500 –CZone and MasterBus
These models are further referred to as “MasterShunt 500”.
1.2 Liability
Mastervolt cannot be held liable for:
Consequential damage resulting from the use of the MasterShunt 500.
Possible errors in the included manual and the consequences of these.
Use that is inconsistent with the purpose of the product.
1.3 Warranty
Mastervolt assures the product warranty of the MasterShunt 500 during two years after purchase, on the condition that the
product is installed and used according to the instructions in this manual.
Installation or use not according to 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 for labour 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
←Part number
CAUTION!
Never remove the identification label.
←Serial number
Figure 1: Identification label
Important information required for service or maintenance can be derived from the identification label. The identification label is
located at the bottom of the MasterShunt 500.
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. When this crossed-out wheeled bin symbol is attached to a product, it means the product is covered by the
European Directive 2012/19/EU.
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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MasterShunt 500 –User and Installation manual
2 SAFETY INSTRUCTIONS
WARNING!
Read the entire manual before using the MasterShunt 500. Keep this manual in a secure place.
Installation and work on the MasterShunt 500 may be carried out only by qualified and trained personnel, consistent with the
locally applicable standards and taking into consideration the safety guidelines and measures.
2.1 Use for intended purpose
The MasterShunt 500 is constructed according to applicable safety guidelines.
Use the MasterShunt 500 only:
in a technical correct condition;
in a closed, well-ventilated room, protected against rain, moist, dust and condensation;
observing the instructions in the user manual.
WARNING!
Never use the MasterShunt 500 in locations where there is danger of gas or dust explosion or potentially flammable
products.
2.2 Maintenance and repair
If the electrical installation is switched off during maintenance and/or repair activities, it should be secured against unexpected
and unintentional switching on:
switch off all charging systems;
switch off the connection with the batteries;
be sure that third parties cannot reverse the measures taken.
If maintenance and repairs are required, only use original spare parts.
2.3 General safety and installation precautions
Connection and protection must be done in accordance with local standards.
Do not work on the MasterShunt 500 or system if it is still connected to a current 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, burned cables etc. must be corrected
immediately.
2.4 Warning regarding battery use
Excessive battery discharge and/or high charging voltages can cause serious damage to batteries. Do not exceed the
recommended limits of battery discharge level. Avoid short circuiting batteries, as this may result in explosion and fire hazard.

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3 PRODUCT DESCRIPTION
3.1 Introduction
The MasterShunt 500 is a battery monitor that enables system automation and also provides power to the MasterBus network.
The battery bank is monitored in the most accurate way by measuring the voltage and the (dis)charge current through a shunt.
The extended information about the status of a battery bank includes voltage, current, State Of Charge (SOC) and indication of
the time remaining.
The SOC is expressed as a percentage. This value is automatically compensated by the charge efficiency factor (C.E.F.) and
the Peukert exponent. When the battery is fully charged, the SOC will be reset to 100%. A non Li-ion battery is considered to
be fully charged if one of the following conditions is met.
1 Parameters below are met for at least 30 seconds:
All of the Ah's discharged are charged back into the battery (real counting without CEF).
The actual charge current is less than the setting for charge amps for full battery but more than 0A.
2 For at least 4 hours the battery voltage is higher than the float voltage plus 1.0/2.0/4.0V (at nominal battery voltage
12/24/48V).
3 For at least 8 hours the battery voltage is higher than the float voltage plus 0.3/0.6/0.9V (at nominal battery voltage
12/24/48V).
4 For at least 12 hours the battery voltage is higher than the float voltage minus 0.1/0.2/0.3V (at nominal battery voltage
12/24/48V).
A display like the Touch 10 (in a CZone network) or the EasyView 5 (in a MasterBus network) can be used to show the battery
information.
3.2 Exterior
1. Positive battery pole at battery side
2. Fastening screw, on both sides (turn 90 degrees to
loosen top)
3. Negative battery pole at battery side
4. CZone/MasterBus connector
5. Temperature sensor connector
6. Mounting hole for M8 socket screw
7. CZone/MasterBus connector
8. Negative battery pole at load side
9. Status LEDs, on both sides
10. Positive battery pole at load side
11. Bus bar or optional Internal fuse
Figure 2 : Overview of the MasterShunt
3.3 LED indicators
The MasterShunt 500 features two LED indicators; one between the connectors at the battery side and one between the
connectors at the load side (item 9 in Figure 2).
Condition
Meaning
Simultaneously slow blinking
No network activity
Simultaneously irregular blinking
Network activity
Alternately fast blinking
Alarm situation

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MasterShunt 500 –User and Installation manual
4 Installation
WARNING
During installation and commissioning of the MasterShunt 500, the Safety Guidelines and Measures are always
applicable. See Chapter 2 ‘Safety guidelines and measures’.
CAUTION!
Wrong connections may cause damage to the MasterShunt 500 and other equipment as well, which is not covered
by warranty!
Notes:
- For correct measurements the MasterShunt 500 must be placed as close as possible to the batteries.
- Optionally a fuse can be placed inside the MasterShunt 500 to make your installation safer, see Section 4.5.
Otherwise make sure to place fuses on other places in your installation to guarantee its safety.
4.1 Things you need for installation
In the box:
77020115
(CZone & MasterBus)
77020110
(MasterBus only)
MasterShunt 500


MasterBus cable, 6m


RJ45-M12 Drop cable CZone/MB, 1m


Terminator for MasterBus network


Temperature sensor


Two translucent end pieces


Four DC cones


One translucent mid piece for easy connection to Mastervolt's DC Distribution 500.


Four M8 bolts with washer to fasten the DC wiring.


Tools and materials:
For CZone setup, a tee connector (not included)
A cross-head screw driver
2 mm flat blade screwdriver
Hexagonal socket wrench size 6 mm
Two heavy duty battery cables shortest possible, finished with cable lugs. Cable thickness must be in accordance with the
electrical installation
A complete set of spanners, pliers and wrenches may be helpful during the installation of the MasterShunt 500.
CAUTION!
Use isolated tools!
4.2 Connection example
The following schematics illustrate the general placement of the MasterShunt 500 in a network. It is not meant to provide
detailed wiring instructions for any particular electrical installation.
in a CZone network
MasterShunt 500
Battery bank
Charger
Remote panel
General CZone module
CAN to USB converter
CZone Backbone cable with
terminators at both ends
Drop cable CZone/MB

MasterShunt 500 –User and Installation manual
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Points to consider:
˗Up to 40 devices can be connected together on a single backbone.
˗Make sure the CZone network has two terminating resistors, one at each open end of the backbone.
˗The electric power for the network comes from a battery or power supply. Make sure that it delivers enough power and
is positioned as close to the middle of the backbone as possible to reduce voltage drop.
˗The CZone/MB drop cable includes a diode to prevent power from the MasterShunt 500 getting on the CZone
backbone.
in a MasterBus network
MasterShunt 500
Battery bank
Charger
Remote panel
Network wiring with MasterBus
terminators at both ends
MasterBus USB Interface
MasterBus cable
Use an RJ45 MasterBus cable (not included) and daisy chain the MasterShunt 500 to the other MasterBus devices,
forming a local data network.
Points to consider:
˗Connections between the devices are made by standard straight MasterBus cables. Mastervolt can supply these
cables.
˗Up to 63 MasterBus devices can be connected together.
˗MasterBus needs a terminating device on both ends of the network.
˗The electric power for the network comes from the connected devices according to the rule: 1 powering / 3 non-
powering. Spread the powering devices over the network
˗Do not make ring networks.
˗Do not make T-connections in the network.
CAUTION!
Never connect a non-MasterBus device to the MasterBus network directly! This will void warranty of all
MasterBus devices connected.
For more details on networks, please contact your Mastervolt supplier.
4.3 Installation step-by-step
Step 1. Disconnect the electrical power.
Switch off all consumers;
Switch off all charging systems;
Disconnect the positive battery poles;
Check with a suitable voltmeter whether the entire DC installation is voltage free.
Step 2. Position the MasterShunt 500 close to the battery, between the battery and the load/charger.
Note: Remember to put the cones around the cables before connecting!
Step 3. Connect the loose positive battery cable to the upper left connection (A) and the positive load cable to the upper right
connection (B).
Step 4. Connect the negative battery cable to (D) and the negative load cable to (C).
Use cable lugs to accomplish sufficient electrical contact between the wiring and the MasterShunt 500.
The recommended tightening torque is 15-20 Nm.
Note: The charger must be connected at the load side of the MasterShunt 500!
CAUTION!
Leave the positive battery cable disconnected from the battery.
Step 5. Option: place a fuse. See section 4.4.
Step 6. Option: connect the MasterShunt 500 to the CZone or MasterBus network.

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MasterShunt 500 –User and Installation manual
Adding the MasterShunt 500 to a CZone network
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.
If you want to add the MasterShunt 500 at the end of the backbone, remove the terminator, add the new tee
connector and attach the terminator to the side of the connector.
3 Connect the RJ45 CZone/MB drop cable to the black coupler on the tee and then connect to the MasterShunt
500.
Adding the MasterShunt 500 to a MasterBus network
1 Disconnect a MasterBus cable or Terminator from the closest MasterBus device and connect it to the
MasterShunt 500.
2 Connect the new MasterBus cable to the other MasterBus device and then connect to the MasterShunt 500.
3 Ensure that the network is properly terminated.
See section 4.2 for more information on system integration.
Step 7. Check all wiring. If all wiring is OK: (re)connect the positive battery cable.
Step 8. Proceed with chapter 5, SETTINGS.
4.4 Placing a fuse inside
By default the MasterShunt 500 is equipped with a busbar inside. If the MasterShunt 500 is installed close to the battery, this
busbar may be replaced by either an ANL type or Class T main fuse (500A), saving both space and cost. Another option is to
place a fuse elsewhere in the system.
Note: Always have the selected fuse checked by qualified personnel to prevent any unnecessary fuse melts when going fully
operational.
Execute the following procedure to replace the busbar by a fuse:
Step 1. Disconnect the electrical power:
Step 2. Remove the two transparent covers.
Step 3. Unlock and remove upper casing.

MasterShunt 500 –User and Installation manual
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Step 4. Remove the two bolts.
Step 5. Take out the busbar. Mind possible hot parts!
Step 6. Place a class T-fuse or an ANL fuse and fasten with the two removed bolts from step 4 (torque 15-20 Nm).
WARNING
When installing the T-fuse make sure it does not make any contact with the negative pole inside the MasterShunt
500, see in the drawing.
Step 7. Replace and lock the casing.
Step 8. Reconnect the battery pole.
Step 9. Store the removed busbar close to the MasterShunt 500 for future service purposes.

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MasterShunt 500 –User and Installation manual
4.5 Parallel use (MasterBus only)
For load currents which exceed 300A continuous current, more than one MasterShunt 500 can be installed to monitor the
same battery (bank). The MasterShunt 500s are then configured in parallel to the battery. The following figure shows the
parallel configuration of two MasterShunt 500s (3) and (4) and other products.
1. Remote panel
2. Bow thruster
3. MasterShunt 500 in parallel 1, in Reversed setting
4. MasterShunt 500 in parallel 2
5. DC Distribution 500
6. Digital DC 10x10A
7. Battery
8. Network wiring (MasterBus)
Figure 3 : Parallel system example
Note: When also using older versions of the MasterShunt 500 in parallel setup, make sure to select the new version
(7702011x) as master and the older version as slave.
For parallel setup of two MasterShunt 500s, execute the following steps:
1. First reset any pre-used MasterShunt 500s to factory settings.
2. During First start up select Advanced mode/ Parallel mode on one of the MasterShunt 500s, this will become the Master.
3. Select the serial number(s) of the other MasterShunt 500(s), Refer to Figure 1. These MasterShunt 500(s) will be the
slave(s).
After pressing the “Complete” button, the measurements of all paralleled MasterShunt 500s are combined and shown as one
MasterShunt 500. The currents however are shown separately! This means, renaming the MasterShunt 500s can be
convenient.