Kapal

GEBRUIKERSHANDLEIDING / USERS MANUAL
BETRIEBSANLEITUNG / MODE D’EMPLOI
MASS 12/30-2, 24/15-2, 24/25-2

battery charger
1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2 Safety guidelines & measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4 Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
7 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
8 Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
10 EC declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
11 Data sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Apendix A
12 Installation sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Apendix B
MASTERVOLT
Snijdersbergweg 93, 1105 AN Amsterdam, The Netherlands
Tel. +31-20-3422100 / Fax +31-20-6971006 V1.1 September 1999
GENERAL INFORMATION / SAFETY GUIDELINES EN MEASURES
1 GENERAL INFORMATION
GARANTEE SPECIFICATIONS QUALITY

Mastervolt quarantees the performance of this Mass char- During their production and prior to their delivery, all of our
ger according to the specifications given in the data units are exhaustively tested and inspected.
sheets, if installed and used as described in this manual.
Should work take place, which is not in accordance with
the guidelines, instructions and specifications contained LIABILITY
in this user's manual and the supplementary installation Mastervolt can accept no liability for:
manual, then damage may occur and/or the unit may not
fulfil its specifications. All of these matters may mean that • damage due to use of the battery charger;
the guarantee may become invalid. • possible errors in the manual and the results thereof.
The guarantee period is two years.
2 SAFETY GUIDELINES & MEASURES
USE FOR INTENDED PURPOSE

The battery charger is contructed as per the applicable 2 Check the wiring at least once a year. Defects such as
safety-technical guidelines. Use the battery charger only: loose connections, burned cables etc. must be correc-
ted immediately.
• for the charging of lead acid batteries and the supply of
users attached to these batteries, in permanent sys- 3 Do not work on the charger or the system if it is still
tems; connected to a current source. Only allow changes in
your electrical system to be caried out by qualified
• connected to a dedicated double pole circuit breaker electricians.
(MCB);
4 Connection and protection must be done in accor-
• with a fuse, protecting the wiring between charger out- dance with local standards.
put and battery;
5 Before opening the cabinet of the charger, switch off
• in a technical correct condition; the 230V mains and remove the charger fuse.
• in a closed, well-ventilated room, protected against rain,

moist, dust and not condensing circumstances. MAINTENANCE & REPAIR
If the battery charger is switched off during maintenance
Never use the battery charger at locations and/or repair activities, it should be secured against unex-
where there is danger of gas- or dust explo- pected and unintentional switching on:
sion!
• switch off the AC circuit breaker;
Use other than as mentioned under 2 is not considered to
be consistent with the intended purpose. Mastervolt is not • disconnect the charger;
liable for any damage resulting from the above.
• switch off the connection with the batteries or remove
SAFETY the charger fuse;
1 Use only fuses with the prescribed current level: • be sure that third parties cannot reverse the measures
taken.
• AC supply fuse not greater than is required for the
current consumption; If such are required, use only original spare parts.
• The charger fuse must be large enough for the ma-

ximal charger current and small enough to protect
the charger‘s output cables.
10 August 1999 / MASS battery charger / EN

TECHNICAL DATA / TECHNOLOGY
3 TECHNICAL DATA
GENERAL
Model MASS 12/30-2 MASS 24/15-2 MASS 24/25-2
Function apparatus battery charger/rectifier
Manufacturer Mastervolt, Amsterdam
INPUT
Voltage 230V, -10% +15% 230V AC, -10% +15% 230V, -10% +15%
Frequency 50/60 Hz, ± 5 Hz 50/60 Hz, ± 5 Hz 50/60 Hz, ± 5 Hz
Current 2.5A 2.5A 3.6A
Power factor 1 1 1
Efficiency 88% 88% 88%
OUTPUT
Output voltage nominal: 12V DC nominal: 24V DC nominal: 24V DC
Output current (total max) 30A 15A 25A
Outputs 2 (1x30A max. 1xA max.) 2 (1x15A max. 1x3A max.) 2 (1x25A max. 1x3A max.)
Charge characteristic three-step, fully automatic, IUoUo
Kind of batteries open and sealed lead acid batteries / wet or gel
Charge voltages (depending of phase) 14.4V-13.25V 28.7V-26.5V 28.7V-26.5V
Ripple voltage max. 100mV rms, resistive load, full power
Current 30 Amps 15 Amps 25 Amps
Short circuit current 30 Amps 15 Amps 25 Amps
Polarity control. polarity protected by means of a breaker
ENVIRONMENTAL CHARACTERISTICS
Operating ambient temperature -20 to +40°C; 100% output power
Cooling forced, by means of a fan with variable speed
Humidity max. 95% RV, not condensing
ENCLOSURE
Dimensions (hxwxd) 325x220x111 mm
Protection level IP 23
Weight 2.6 kg
Safety IEC 335-2-29
4 TECHNOLOGY
INTRODUCTION
The MASS battery charger is a fully automatic high-effi-
cient battery charger/rectifier,developed and produced by
Mastervolt Amsterdam. The MASS series goes with a
family of advanced quality battery chargers. Mastervolt
distributes these products worldwide. The battery charger
posseses an outstanding charging technique in order to
charge batteries rapidly, safely and in the same time sup-
ply the connected consumers. In addition, the charger is
secured against short circuit, overload and high tempera-
tures in an industrial enviroment.
THEORY OF OPERATION
The MASS battery charger has a three-step charge
characteristic (see fig. 1). Fig. 1 Example:
Charge caracteristic MASS 12/15. (For other
models V/A according to data sheets).
EN / MASS battery charger / August 1999 11

TECHNOLOGY / INSTALLATION
Phase 1: Main charge (“BULK”) The charger has been programmed in such a way that a
The first step “BULK” starts after switching on the MASS seperate sense connection to the battery is not necessa-
charger. In this phase, the charger supplies the maximum ry.
current until the battery reaches 14.40V. The battery is
now 80% charged. When the battery reaches this limita- CHARGING TWO OR MORE BATTERIES VIA
tion area the charge current wil decrease. Bulk duration is ONE OUTPUT
maximum 6 hours, depending on the battery’s condition If two or more batteries need to be charged at the same
and charge rate. The yellow “bulk” LED on the front panel time and output, a battery isolator should be used. The
will light up during this phase. battery isolator divides the various battery sets from one
other, in order to avoid one set discharging the other. Be-
Phase 2: “ABSORPTION” cause there is always a voltage drop across the isolator of
The second step “ABSORPTION” begins automatically 0,7V the output voltage needs to be compensated. You
with a voltage of 14.25V. The current consumption in the can compensate this voltage drop by removing the “diode
absorption mode is depending on the capacity of the compensation” jumper on the front panel.
batteries and will decrease slowly. The charger remains in
this “absorption” phase untill the charge current drops for CHARGING A CRANKING BATTERY
a periode of 15 minutes below 2.5A. If the charge current In certain situations, it may occur that in addition to the
will not drop below 2.5A, a clock will switch the “absorp- main battery(ies) a cranking battery with the same voltage
tion” mode off after 6 hours. During the absorption phase is used. The battery charger can charge a cranking batte-
the yellow “ABSORPTION” LED on the front panel will ry at the same time as the main battery, by using the 3A
light up. output.
Phase 3: Trickle charge (“FLOAT”) The second output has the same output voltage
The third stage, “FLOAT”, starts when the “absorption” as the main output, 3 Amps maximal !
phase has been completed. In the “float” mode, the char-
ger automatically switches back to a lower output voltage
of 13,25V. This voltage is sufficient to maintain the battery THE BATTERY CHARGER AS FLOAT CHARGER
at a 100% charge. During this phase, the capacity of the It is possible to use the charger as a “trickle” charger. The
charger can be entirely used for the supply of the users charger then supplies a constant output voltage of 13.25V
connected to the battery. During this mode the yellow (26.5V). For this mode you can remove a jumper on the
“float” LED will light up. If necessary the charger automa- front.
tically switches back to the “absorption” mode.
SELECTION WET OR GEL BATTERIES
The optimal charge voltage for a wet lead acid battery dif-
Current consumption from mains or generator fers from the gel battery. Therefore it is possible to switch
The charger produces no phase shift, because the input over to a higher float voltage (13.8V for 12V and 27.6V for
current follows the AC voltage waveform so a power 24V) necessary for gel batteries. You increase this output
factor of 1.0 or “unity” is achieved. The shape of the input voltage by removing a jumper on the front panel.
current waveform is the same as the input voltage e.g.
sinusoïdal. Therefore the input current is very low compa-
red to conventional chargers.
5 INSTALLATION
Low ripple on output
The charger has a very low ripple on the output, which pre- Install the MASS battery charger in a dry, well ventilated
vents interference in the DC circuit. The ripple is less than area, as close as possible to the batteries. Although the
100 mV with maximum output current. battey charger has a high efficiency, some heat will be
produced. This heat will be discharged by a fan with varia-
Automatic compensation of charge voltage with ble speed. At installation of the battery charger be sure
battery temperature that:
If the temperature sensor is connected the MASS charger
will charge its output voltage -30mV/°C (12V) or -60mV/°C • the air flow is not obstructed;
(24V). The temperature sensor should give a good inter- • no water and/or dust can enter the cabinet.
pretation of the battery temperature.
MOUNTING THE MASS CHARGER
Automatic voltage sense compensation The charger can be either horizontal or vertical mounted.
The charger compensates automatically for the normal We recommend vertical, because the heat convection is
voltage drop across the cable connection to the battery. from bottom to top.

INSTALLATION
WIRING AND CONNECTIONS Steps:

When connecting any auxiliary equipment and/or a batte-
ry isolator, proceed as follows: 1 Check if the charger, the main supply and the DC
• switch off the charger; divider are switched off.
• switch off the AC mains or generator supply; 2 Connect the battery isolator(s) using cables with the
• isolate the DC distribution from the battery. same diameter as the battery cables.
3 Compensate the voltage drop over these diodes by re-
Battery wires moving the “diode compensation” jumper on the front
Keep the cable connection between charger and battery of the charger.
as short as possible. If possible use coloured battery 4 Switch the charger on.
cables. I f this is not possible, mark the plus and the minus
cables with coloured insulating tape, e.g. red for plus and Connection of cranking battery (3A output)
blue for minus. Use the following diameters: The distance between charger and cranking battery de-
termines the required, minimal cable diameter. For cable
lenght up to 3 meter lenght above 3 meter lenghts up to 6 meters 2,5 qmm must be used. When
6 qmm 10 qmm using long thin cables, it will take proportionately longer
before a crancking battery is entirely charged. Therefore
use, for longer distances, a larger diameter. The maximal
Connection of main batteries charging current for the cranking battery is 3A. The char-
The minus cable (blue) on the -battery (minus connection) ging current for the main battery will in this case be 3A
of the battery charger. The plus cable (red) on the + main lower.
battery (plus-connection) of the charger. • Connect the minus of the cranking battery to the minus
The other side of the cable has to be connected to the of the main battery.
battery or the DC distributor. The minus cable (blue) on • Connect the plus of the cranking battery to the “BAT2”
the min-connection of the battery or DC divider. The plus plus terminal of the charger.
cable (red) on the plus-connection of the battery or DC
divider. AC power supply
Check the voltage of your mains source or generator. This
Reversing the plus and the minus wil blow the must be between 190 and 250 VAC.
fuse near to the minus connector ( the red LED Connect the mains cable on one side on the MASS
above the fuse wil light up ). Before you replace charger and the opposite side to the mains or generator.
the fuse check the polarity of the connections. Replace
the fuse only for a 20A fuse.
ACCESSORIES
Too thin cables and/or loose connections can When connecting accessories, first switch the charger
cause dangerous overheating of the cables and/ „OFF” and disconnect from AC.
or terminals. Therefore tighten all connections
properly, in order to limit as much as possible transition Temperature sensor
resistance, and use the battery cables with the correct Mount the sensor at a location that gives a good indication
diameter. of the battery temperature. Plug the connection cable into
one of the input jacks of the charger.
Battery isolator Basic remote panel

If one or more batteries or battery sets must be charged Plug the connection cable into the analog input jack.
at the same time via one output, a battery isolator should
be used. A battery isolator isolates the different battery Standard remote panel
sets from one another, in order to prevent one discharging Plug the connection cable into the digital input jack.
the other. A consequence of the battery isolator is a volta- The communication protocol is based on quasi RS 232.
ge drop of 0.7 Volt. This voltage drop can be compensa-
ted by removing a jumper on the front panel of the char- Adjustment Interface & advanced remote panel
ger. Plug the connection cable into the digital input jack.
Choose isolator type: The communication protocol is based on quasi RS 232.
2 battery set 3 battery set

MV 702 MV 703 ADJUSTMENTS
On the front of the charger you find three jumpers, each
For proper installation, see the connection diagram inclu- for a specific application. You can easily remove the jum-
ded with the battery isolator. pers with a pincet or a small pincer.

INSTALLATION / OPERATION / USING THE CHARGER WITH YOUR BATTERIES
Switching off:
The IVO charger will be switched off by the OFF switch.
7 USING THE CHARGER WITH YOUR

Forced float BATTERIES
For industrial applications only.
Gel/wet battery CHARGING EFFICIENCY

By removing this jumper the output will be a constant For a good performance your batteries should not be
“trickle charge” voltage of 13,8V. discharged below 30-40% of their capacity. Therefore al-
ways start charging at this level.
Diode compensation As in marine and mobile systems often a limited charging
By removing this jumper the output voltage will be increased time is desired, batteries are with generator use charged
with 0,7 Volt. up to 85-90%. Charging up to 100% would take too long.
This means that normally about 50% of the theoretical
battery capacity can be used.
In case a mains connection is present, charging time is
less important. Then charging up to 100% is advised.
6 OPERATION
TIPS TO INCREASE THE BATTERY LIFETIME:
1 Check if the charger is „OFF”.
2 Connect DC output with batteries or place fuse. • Install the batteries at a cool place. The acid in the bat-
3 Switch on AC source. teries will damage the plates in a high temperature en-
vironment. A normal life time of 5 year at 20°C, will go
Switching on: down to 2.5 years at 30°C.
The MASS charger will be switched on by the ON switch.
One of the front LEDS will light up now and the charging • Charge the battery immediately after a consistent deep
starts immediately. discharge.Especially at high environment temperatures,
sulfating occurs very fast. If the state of sulfating is not
too bad, the battery will regain a part of its capacity af-
INDICATOR LIGHTS float charge 80 - 100 %
ter a number of charge/recharge cycles.
FLOAT:
CHARGE INDICATOR
The battery charger is

in a “trickle charge” mo- absorption 50 %
de, batteries are 100%

charged.
bulk charge - on
ABSORPTION:
The batteries are still
charging, charge level off
is approx. 80%.
on
BULK:
The charger supplies charge failure
the maximal voltage,
the battery charge is
less than 80%.
MASS
AUTOMATIC
BATTERY CHARGER

TROUBLE SHOOTING
8 TROUBLE SHOOTING
Malfunction Possible cause What to do

No output voltage and/or current No AC mains or fuse blowes Check fuse, replace if necessary.
Mains or generator output too low Check input voltage, must be between
190 and 260V (nominal 230V).
Output voltage too low but Battery load consumes more than the Reduce the battery load taken from
charger supplies max. current charger can supply, the battery voltage batteries.
cannot increase more
Batteries not 100% charged Measure the battery voltage after a

while, this will be higher.
Charge current too low Batteries almost fully charged Check if the charger is in the absorp-
tion mode. In this mode, the charge
current will slowly decrease.
High ambient temperature If the ambient temperature is more than

40°C, the maximum charge current
automatically will be reduced.
Mains too low When the mains is lower than 190V,

the charger will regulate the current
down.
Batteries not fully charged Charge current too low See “charge current too low”;
Current to load too high Decrease the battery load;
Charge time too short Increase type of charger;
Battery temperature too low Use temperature sensor;
Defective battery (short circuit in cell) Replace the battery;
Defective battery charger Check the charger.
Battery very fast empty Battery capacity reduced because:

• wastage Replace the batteries;
• sulphating/stagnation Charge/discharge for several times, this
might help, otherwise replace batteries.
Batteries are warm/gassing Defective batteries (short circuit in cell) Replace batteries;
Battery temperature too high Use temperature sensor;
Charge voltage too high Check jumper ‘battery isolator’
on front panel.
If you cannot solve the problem with this fault finding table, contact your Mastervolt Service Centre.
For a detailed distributor list, please contact our main office in Amsterdam, tel. +31-20-3422100.

MAINTENANCE / EC DECLARATION
9 MAINTENANCE
The battery charger requires no specific maintenance. For

a reliable and optimal function of the MASS battery char-
ger only the following is required:
• Check at least ones a year the wire and cable connec-

tions (loosen joints etc.).
• Keep the MASS charger dry, clean and in a dust-free

area, in order to ensure a good heat discharge.
10 EC DECLARATION OF CONFORMITY
Manufacturer: MASTERVOLT
Address: Snijdersbergweg 93
1105 AN AMSTERDAM Z.O.
The Netherlands
Herewith declares that:

Product: MASS battery charger
Model: MASS 12/30-2
MASS 24/15-2
MASS 24/25-2
Is in conformity with the provision of the EC EMC directive 89/336/EEC and

amendments 92/31/EEC and 93/68/EEC.
The following harmonized standards have been applied:

Generic emission standard EN 50081-1:1992
Generic immunity standard EN 50082-1:1992
Amsterdam,
Dr. F.J. ter Heide,

Managing director MASTERVOLT

APENDIX A & B
MASS 12/30-2, 24/15-2, 24/25-2

battery charger
MASTERVOLT
Tel. +31-20-3422100 / Fax +31-20-6971006 V1.1 September 1999
34
DATA SHEETS
11 DATA SHEETS MASS 12/30-2
MAIN INFORMATION
Design : by MASTERVOLT
Manufacturer : ISO 9001 certified
Model / name : MASS 12/30-2
Product : battery charger/rectifier
Article no : 04-00-10300
Colour : • RAL 5021, wasserblau
• RAL 7037, grey
Weight excl. packing : 2.6 kg
Shipping weight : 4 kg
Cabinet typ : MASS 1 cabinet
Dimensions : hxwxd. 325 x 220 x 111 mm
Carton dimensions : hxwxd. 350 x 250 x 160 mm
Type of packing : carton recycable
Available : 230V / 50-60Hz
Availability : normally from stock, from July ‘99 onwards
Mass 12/30-2 battery charger/rectifier, art.no 04-00-10300,
in new ‘high tech’ enclosure.
TECHNICAL SPECIFICATIONS
Function apparatus : charging of 12V lead acid batteries and power simultanously loads
Nominal input voltage : 230V AC, 1ph, 3wire, 50/60 Hz
Input voltage range full specs : 190..250V, 50/60 Hz, ± 5%
Input voltage range no-defects : 0..250V, 33-80 Hz
Input current : at 230V AC: 2.5A
Inrush current : no inrush current, soft start, according to IEC 1003-3
Power factor : 1, power factor controlled, IEC 555-2
Max. input power : 550 Watt
Efficiency : > 88%
Output voltage : nominal 12V DC
Output current : nominal 30 Amps
Charge characteristic : three-step, fully automatic, IUoUo, programmable
float charge 80 - 100 %
Kind of batteries : open & sealed lead acid batteries
Charge voltage 25°C : • bulk voltage 14.40V • absorption 14.25V
CHARGE INDICATOR
• wet float 13.25V • gel float 13.8V
Return Amps : 2.5A absorption 50 %
Min. Absorption time : 15 minutes
Max. Bulk/abs. time : 6 hours
Return new cycle voltage : 12.8V, delay 30 seconds
Temperature compensation : 30 mV/°C, by temperature sensor bulk charge - on
Voltage sense : fully automatic compensation

Ripple voltage : max. 100mV rms, resistive load, full power
Voltage accurancy : voltage ± 2% off
Current accurancy : current ± 3%

Maximum output : • 30 Amps at 14.25 Volt at 25°C ambient on
• 30 Amps at 13.25V at 40°C ambient
DC leakage drain : < 10 mA charge failure
Number of outputs : one main outputs and one 3 Amps Slave Charger
AC/DC connections : internal,
min. AC cable size: 2.5 mm2 / min. DC cable size: 16 mm2
Jumper selections : • gel/wet battery selection
• forced to float
MASS
• battery isolator compensation AUTOMATIC
Remote indication : status bulk, absorption, float BATTERY CHARGER
Remote connection : by telephone plug-in jack - RJ45
Temperature connection : by telephone plug-in jack - RJ45 Standard control on unit.
Smart controls : QRS232 output by telephone plug - RJ45
Apendix A 35
DATA SHEETS
Short circuit proctection : yes, reduced output max. 30 Amps
Reverse polarity protection : yes, by internal fuses
Over heat : yes, derating output and shut off by 80°C temperature on heatsink
Storage temperature : -25°C to 80°C

Operating ambient temperature : -20°C to 40°C, derating with 2.5% / °C > 40°C
Humidity : maximum 95%, not condensing
Vibration : according IEC 68-2-6
Cooling : mix of conventional and forced air cooling
Forced cooling : by one variable speed maintenance free DC fan
Environmental protection : IP23
Reliability/life time : • MTBF 30.000 hours

• 1/4 life time period, Uin = 207V AC, Uout = 14,25, Iout = 30 Amps at Tamb 40°C
• 3/4 life time period, Uin = 207V Ac, Uout = 13,25, Iout = 30 Amps at Tamb 25°C
ELECTRO MAGNETIC COMPATBILITY

Electro Magnetic Emission : better than EN 50081-1 (gen. emmission standard, scope; residiential, commercial & light industry)
Electro Magnetic Immunity : better than EN 50082-1 (gen. emmission standard, scope; residiential, commercial & light industry)
Safety : according to IEC 335-2-29, polarity protected by means of a breaker, short break
WHAT TO DO IN CASE OF A DEFECT?

✔ Consult factory in Amsterdam, tel. +31-20-3422100, or your local Repair Center.
200
58
48
6
111.2
101
83
41
10
10
Main PCB of the MASS 12/30-2. 220
Dimensions of the new cabinet and PCB.
COMPLIANCES
• CE:
Is in conformity with the provision of the EC EMC directive 89/336/EEC and amendments 92/31/EEC, 93/68/EEC.
The following harmonized standards have been applied: • Generic emission standard : EN 50081-1:1992
• Generic immunity standard : EN 50082-1:1992
• LLOYDS, DNV, ABS:

MASTERVOLT has constructed this product for rugged circumstances in professional or leisure situations.
This product can be type-approved individually. Price approx. US $ 1500 per certification.
• MANUFACTURED UNDER ISO 9001.
36 Apendix A
DATA SHEETS
Main PCB of the MASS 12/30-2.
New ‘high tech’ enclosure.

ACCESSORIES & REMOTES
Article no description
04-15-00100 basic remote control LED’s
-- standaard remote contol LED’s current control
-- advanced remote control display with owner’s settings
04-15-00300 MASS 1 temperature sensor
-- MASS 1 cable set
-- MASS 1 remote cable set
00-17-05000 Adjustment Interface
-- Smart alarm control box
SERVICE INFORMATION
-- sub assy, main PCB board
-- complete aluminium heatsink
-- cover module
-- connection module
Adjustment Interface, art. no 02-17-05000.
-- front indicator module The below mentioned data can be adjusted with this
-- installation blocks digital instrument:
• adjustment charge voltage (e.g. traction)
• ‘return’ Amps etc.
OPERATING PRINCIPLE
Fully automatic power factor switch mode battery charger, suitable as power supply using a separate non-isolated pre regulator
boost converter for power factor correction, followed by a double forward converter controlled by a combination of analogue
hardware and microprocessor control.
AC input DC output
PFC DC/DC
Aux. power supply
HARDWARE CONTROL
SOFTWARE CONTROL
remote select RS232
Apendix A 37
DATA SHEETS
Set points register Setpoint

1 Min. bulk time 30 sec. • Temperature variation
5.0 mV/°C per cell
5.0 mV/°C
2 Temperature variation 30 mV/C
• Reference voltage 25°C
3 Return to bulk time 30 sec. • Battery charging is not allowed
4 Return to bulk voltage 12.80 V above +50°C and under -20°C
• 12 Volt 30 mV/°C
5 Max. bulk/abs time 360 min. • 24 Volt 60 mV/°C Uref 25°C
6 Min. abs time 15 min.
7 Return Amps 2.5 Amps
8 Max. charge current 30 Amps
9 Bulk voltage 14.40 V
ion
10 Abs voltage 14.25 V
at
ns
ry
11 Float voltage 13.25 V
tte
pe
at
ba
m
flo
12 Forced to float voltage 13.25 V
co
et
ed
de
l/w
13 Gel voltage setting 550 mV
dio
ge
for
14 Diode compensation setting 600 mV standard IUU characteristic
15 DC high alarm on 15.00 V IUU char. increased with 0.6V
16 DC high alarm off 14.50 V IUU char. high float level
17 DC low alarm on 10.00 V IUU char. high float, increased with 0.6V
18 DC low alarm off 11.00 V
IU char. low float level
19 Alarm delay time 30 sec.
IU char. low float, increased with 0.6V
IU char. high float level
IU char. high float, increased with 0.6 V
TEMPERATURE COMPENSATED CHARGING

25°C reference
temperature
CHARGING CHARACTERISTICS
15.0
charging voltage in V
14.5
absorption
14.0
13.5
float
13.0
12.5
12.0
-30 -20 -10 0 10 20 30 40 50 60
battery temperature in °C min. bulk time min. abs time

MAX. BULK return to bulk time
BULK TIME ABS TIME FLOAT TIME
TOTAL CHARGE TIME CYCLE NEW CYCLE
MAX. OUTPUT VERSUS INPUT VOLTAGE

25°C reference 25°C reference
temperature temperature
40
Tamb= 25°C
current in Amps
35
14.25V Tamb= 40°C

30
230V model
25
20
15
80 100 120 140 160 180 200 220 240 260 0 20 30 40
input voltage output current in Amps
38 Apendix A
DATA SHEETS
11 DATA SHEETS MASS 24-15-2
MAIN INFORMATION
Article no : 04-00-20150
• RAL 7037, grey
Cabinet type : MASS 1 cabinet
Efficiency : > 88%
float charge 80 - 100 %
Charge characteristic : three-step, fully automatic, IUoUo, programmable
CHARGE INDICATOR
Charge voltage 25°C : • bulk voltage 28.7V • absorption 28.5V absorption 50 %
Return Amps : 1.25A
Max. Bulk/abs. time : 3 hours bulk charge - on

Temperature compensation : 60 mV/°C, by temperature sensor
Voltage sense : fully automatic compensation off
Voltage accurancy : voltage ± 2% on
Maximum output : • 15 Amps at 28.5 Volt at 25°C ambient charge failure
DC leakage drain : < 5 mA
MASS
Jumper selections : • gel/wet battery selection AUTOMATIC
• forced to float BATTERY CHARGER
• battery isolator compensation
Remote indication : status bulk, absorption, float Standard control on unit.

Temperature connection : by telephone plug-in jack - RJ45
Apendix A 39
DATA SHEETS


• 1/4 life time period, Uin = 207V AC, Uout = 28.5, Iout = 15 Amps at Tamb 40°C
• 3/4 life time period, Uin = 207V Ac, Uout = 26.5, Iout = 15 Amps at Tamb 25°C


✔ Consult factory in Amsterdam, tel. +31-20-3422100, or your local Repair Center
200
58
48
6
111.2
101
83
41
10
10
COMPLIANCES
• CE:
Is in conformity with the provision of the EC EMC directive 89/336/EEC and amandments 92/31/EEC, 93/68/EEC.

40 Apendix A
DATA SHEETS
New ‘high tech’ enclosure.

ACCESSORIES & REMOTES
-- MASS 1 cable set
SERVICE INFORMATION
-- cover module
-- connection module The below mentioned data can be adjusted with this
-- front indicator module digital instrument:
-- installation blocks • ‘return’ Amps etc.
OPERATING PRINCIPLE
AC input DC output
PFC DC/DC
Aux. power supply
HARDWARE CONTROL
SOFTWARE CONTROL
remote select RS232
Apendix A 41
DATA SHEETS

1 Min. bulk time 30 sec. • Temperature variation
5.0 mV/°C per cell
5.0 mV/°C
2 Temperature variation 60 mV/C
• Reference voltage 25°C
3 Return to bulk time 30 sec. • Battery charging is not allowed
• 12 Volt 30 mV/°C
5 Max. bulk/abs time 360 min. • 24 Volt 60 mV/°C Uref 25°C
ion
at
ns
ry
tte
pe
at
ba
m
flo
co
et
ed
de
l/w
c
dio
ge
for
13 Gel voltage setting 1.10 V
standard IUU characteristic
14 Diode compensation setting 600 mV
IUU char. increased with 0.6V
15 DC high alarm on 30 V
IUU char. high float level
16 DC high alarm low 29 V
17 DC low alarm on 20 V IUU char. high float, increased with 0.6V
18 DC l ow alarm off 22 V IU char. low float level

19 Alarm delay time 30 sec. IU char. low float, increased with 0.6V

25°C reference
temperature 30
30 29
28
29
27
absorption
28 26
25
27 24
float
26
25
24
-30 -20 -10 0 10 20 30 40 50 60 min. bulk time min. abs time

MAX. BULK ABS TIME return to bulk time
battery temperature in °C BULK TIME
TOTAL CHARGE TIME CYCLE
ABS TIME FLOAT TIME
NEW CYCLE

30
20 29
Tamb= 25°C
current in Amps
28
Tamb= 40°C
15 27
14.25V 26
230V model
10 25
24
0 7.5 15
80 100 120 140 160 180 200 220 240 260
42 Apendix A
DATA SHEETS
11 DATA SHEETS MASS 24/25-2
MAIN INFORMATION
Article no : 04-00-20250
• RAL 7037, grey
Cabinet type : MASS 1 cabinet
Efficiency : > 88%
Charge characteristic : three-step, fully automatic, IUoUo, programmable float charge 80 - 100 %
Charge voltage 25°C : • bulk voltage 28.7V • absorption 28.5V
CHARGE INDICATOR
Return Amps : 1.25A absorption 50 %

Max. Bulk/abs. time : 6 hours
Temperature compensation : 60 mV/°C, by temperature sensor bulk charge - on
Voltage sense : fully automatic compensation

Voltage accurancy : voltage ± 2% off

Maximum output : • 25 Amps at 28.5 Volt at 25°C ambient on

DC leakage drain : < 5 mA charge failure
Jumper selections : • gel/wet battery selection
• forced to float
MASS
• battery isolator compensation AUTOMATIC
Remote indication : status bulk, absorption, float BATTERY CHARGER
Standard control on unit.
Temperature connection : by telephone plug-in jack - RJ45
Apendix A 43
DATA SHEETS


• 1/4 life time period, Uin = 207V AC, Uout = 28.5, Iout = 25 Amps at Tamb 40°C
• 3/4 life time period, Uin = 207V Ac, Uout = 26.5, Iout = 25 Amps at Tamb 25°C


✔ Consult factory in Amsterdam, tel. +31-20-3422100, or your local Repair Center.
200
58
48
6
111.2
101
83
41
10
10
COMPLIANCES
• CE:
Is in conformity with the provision of the EC EMC directive 89/336/EEC and amandments 92/31/EEC, 93/68/EEC.

44 Apendix A
DATA SHEETS
ACCESSORIES & REMOTES New ‘high tech’ enclosure.

-- MASS 1 cable set
SERVICE INFORMATION
-- cover module
-- connection module
-- front indicator module The below mentioned data can be adjusted with this
-- installation blocks digital instrument:
• ‘return’ Amps etc.
OPERATING PRINCIPLE
AC input DC output
PFC DC/DC
Aux. power supply
HARDWARE CONTROL
SOFTWARE CONTROL
remote select RS232
Apendix A 45
DATA SHEETS

1 Min. bulk time 30 sec.
• Temperature variation
2 Temperature variation 60 mV/C 5.0 mV/°C per cell
5.0 mV/°C
3 Return to bulk time 30 sec. • Reference voltage 25°C
• Battery charging is not allowed
5 Max. bulk/abs time 360 min. • 12 Volt 30 mV/°C
• 24 Volt 60 mV/°C Uref 25°C
ion
at
ns
ry
tte
pe
at
ba
m
flo
co
et
ed
de
l/w
c
13 Gel voltage setting 1.10 V
dio
ge
for
14 Diode compensation setting 600 mV standard IUU characteristic
15 DC high alarm on 30 V IUU char. increased with 0.6V
16 DC high alarm off 29 V IUU char. high float level
17 DC low alarm on 20 V IUU char. high float, increased with 0.6V
18 DC low alarm off 22 V IU char. low float level
19 Alarm delay time 30 sec. IU char. low float, increased with 0.6V

25°C reference
temperature 30
30 29
28
29
absorption 27
28 26
25
27
24
float
26
25
24
-30 -20 -10 0 10 20 30 40 50 60 min. bulk time min. abs time

return to bulk time
battery temperature in °C
MAX. BULK ABS TIME
BULK TIME ABS TIME FLOAT TIME
TOTAL CHARGE TIME CYCLE NEW CYCLE

30
25 28.5V 29
Tamb= 25°C
current in Amps
230V model
20 28
Tamb= 40°C
15 27
10 26
5 25
0 24
0 12.5 25
80 100 120 140 160 180 200 220 240 260
46 Apendix A
NOTES
NOTES
Apendix B 47
panel code C-3-RS
part number 07-04-03040
MASTERVISION MODULAR SWITCHBOARDS

CAUTION SPECIFICATIONS
1. Lethal voltages exist on your vessel. Make sure all shore power, onboard
description: remote standard charger control
generating sources and batteries are disconnected before beginning
installation of your electrical panel. type: for Mass & IVO smart chargers
2. AC modules will have lethal voltages on the bus bars and terminals. The
coating on these bars is for identification only and should not be relied on as a dimensions panel (wxh): 120 x 65 mm
insulator. Additional safety enclosures may be required in some installations. panel depth: 40 mm
3. Make sure all AC modules are bonded to the shipís AC ground bus. When
grouping modules together to form your panel, a single ground may be used.
Use a resistance meter to verify ground to all modules.
Charger Control
float
The standard remote panel
The standard remote panel is a useful power device for absorption
remote control of the Mass an IVO smart Mastervolt
battery chargers. The standard remote control does indicate the
on - bulk charge current output
status of the charge control by six high power leds and control
the output current by setting the potential meter. The remote failure
control is easy to install by a plug-in standard twisted six pole
RJ45 telephone plug between the digital rs232 output of the
charger and the panel. The serial communication of the remote
control and the charger is based on rs232 technology.
The remote panel can be used as an interface for a custom external
made panel or for a dual remote indicator. current control
The standard remote panel has a CSI (csi=charger
status interface) and a DC high/low alarm.
The two potential free change-over contacts indicate if the
charger is ON or in general failure. The DC alarm set
points can be adjusted in the charger by use of the
adjustment interface.
DC alarm
Specifications normally closed external LED failure
Remote cable: normally open external LED bulk
Connector RJ45, 6 pole, male common external LED 20-40%
Max length 6 meter, max
Type twisted wire CSI alarm external LED absorption
External led drive: normally closed external LED 60-80%
Imax 5 mA normally open external LED float
Umax 2,5V common
External current control
R pot cc 0..1kOhm 0..100% 6 pole telephone jack charger
General CSI alarm RJ 45
Max rating 1 Amp, 30 VDC
NC-on When the charger is off or the charger is in
failure, the normally closed contact is closed
CSI failure
C Common
NO-on When the charger is on and no-failure is Bat TC failure Battery temperature sensor out of range <20 C & >60 C
indicated the normally open contact is closed Voltage sense failure Voltage sense out of range >3 VDC
DC-high/low alarm (combined function with CSI) Sys. temp. failure Charger is out of temperature range "overload" (>75--85 C)
Max rating 1 Amp, 30 VDC Short break indicator Charger in reduced current mode (short break mode)
NC-on When there is no DC failure, the normally Uout <4..5VDC
closed contact is closed DC alarm Battery range out of range (with standard setting of charger)
C Common
NO-on When there is a DC failure the normally open
contact is closed
12V 24V
Connectors 0,75 mm2
DC low on 10.0 20.0 VDC
DC low off 11.0 22.0 VDC
DC high on 16.0 32.0 VDC
DC high off 15.0 30.0 VDC
Delay time 30 30 SEC
48 September 1999 / MASS 12/30, 24/15 and 24/25 battery charger / EN

panel code C-4-RB
part number 07-04-04100
MASTERVISION MODULAR SWITCHBOARDS
CAUTION SPECIFICATIONS
1. Lethal voltages exist on your vessel. Make sure all shore power, onboard
generating sources and batteries are disconnected before beginning
description: remote basic charger control
installation of your electrical panel. type: for Mass & IVO smart chargers
2. AC modules will have lethal voltages on the bus bars and terminals. The
coating on these bars is for identification only and should not be relied on
as a insulator. dimensions panel (wxh): 60 x 65 mm
Additional safety enclosures may be required in some installations. panel depth: 40 mm
3. Make sure all AC modules are bonded to the shipís AC ground bus. When
grouping modules together to form your panel, a single ground may be used.
Use a resistance meter to verify ground to all modules.
The basic remote panel Charger

Charger Control
Control
The basic remote panel is a useful power device for remote Inverter
Charger Control
Control float
Charger Outputon
control of the Mass an Ivo smart Mastervolt battery chargers.
The basic remote control does indicate the status of the charge on
on
failure
absorption
control by six high power leds. failure
float
failure
The remote control is easy to install by a plug-in standard
twisted six pole RJ45 telephone plug between the analog absorption
float
on - bulk charge
output of the charger and the panel. The communication of the bulk
absorption
remote control and charger is based on analog technology. failure
The remote panel can be used as an interface for a custom bulk
made panel or for a dual remote indicator. current control
The basic remote panel has a combined CSI-DC/alarm
(csi=charger status interface).
The potential free change-over contacts indicate if the alarm contact common C
charger is ON or in general failure. The DC alarm set normal open
points can be adjusted in the chargers by use of the normal closed
adjustment interface.
NC NO
DC+CSI
Specifications
Remote cable:
Connector RJ45, 6 pole, male
external LED float
external LED 60-80%
external LED absorption
external LED 20-40%
external LED bulk
external LED failure
Max length 6 meter, max

Type twisted wire
External led drive:

Imax 5 mA 6 pole telephone jack
Umax 2,5V RJ 45
General CSI alarm

Max rating 1 Amp, 30 VDC charger
NC-on When the charger is off or the charger is in
failure, the normally closed contact is closed
C Common
NO-on When the charger is on and no-failure is
indicated the normally open contact is closed Combined CSI failure and DC high/low alarm
Connectors 0,75 mm2 Bat TC failure Battery temperature sensor out of range <20°C & >60°C
Voltage sense failure Voltage sense out of range >3 VDC
Sys. temp. failure Charger is out of temperature range ìoverloadî (>75--85 C)
Short break indicator Charger in reduced current mode (short break mode) Uout <4..5VDC
DC alarm Battery range out of range (with standard setting of charger)

These products fully comply to the latest CE
norms in force from Januari 1st 1996 and are 12V 24V
produced to ISO 9001 standards. DC low on 10.0 20.0 VDC
DC low off 11.0 22.0 VDC
ISO 9001 DC high on 16.0 32.0 VDC
DC high off 15.0 30.0 VDC
Delay time 30 30 SEC
EN / MASS 12/30, 24/15 and 24/25 battery charger / September 1999 49

NOTES
NOTES
50 September 1999 / MASS 12/30, 24/15 and 24/25 battery charger / EN

Charger Control
float
absorption
on - bulk charge current output

failure
external
current control
Charger
Charger Control
Control
Inverter
Charger Control
Control float
Charger Outputon
on
on
failure
absorption
failure
float
failure
DC alarm absorption
float
on - bulk charge
normally closed bulk
absorption
normally open external LED bulk failure
common external LED 20-40% bulk
CSI alarm external LED absorption current control
normally closed external LED 60-80%
normally open external LED float
common
alarm contact common C
6 pole telephone jack charger normal open
RJ 45 normal closed
NC NO
DC+CSI
external LED float
external LED 60-80%
external LED absorption
external LED 20-40%
external LED bulk
6 pole telephone jack

RJ 45
charger
MASTERVOLT
Tel.: +31-20-3422100
Fax: +31-20-6971006

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GEBRUIKERSHANDLEIDING / USERS MANUAL

BETRIEBSANLEITUNG / MODE D’EMPLOI

MASS 12/30-2, 24/15-2, 24/25-2

1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

GARANTEE SPECIFICATIONS QUALITY

2 SAFETY GUIDELINES & MEASURES

USE FOR INTENDED PURPOSE

• in a closed, well-ventilated room, protected against rain,

• The charger fuse must be large enough for the ma-

10 August 1999 / MASS battery charger / EN

EN / MASS battery charger / August 1999 11

12 August 1999 / MASS battery charger / EN

WIRING AND CONNECTIONS Steps:

Battery isolator Basic remote panel

2 battery set 3 battery set

EN / MASS battery charger / August 1999 13

7 USING THE CHARGER WITH YOUR

Gel/wet battery CHARGING EFFICIENCY

The battery charger is

de, batteries are 100%

14 August 1999 / MASS battery charger / EN

Malfunction Possible cause What to do

Batteries not 100% charged Measure the battery voltage after a

High ambient temperature If the ambient temperature is more than

Mains too low When the mains is lower than 190V,

Battery very fast empty Battery capacity reduced because:

EN / MASS battery charger / August 1999 15

The battery charger requires no specific maintenance. For

• Check at least ones a year the wire and cable connec-

• Keep the MASS charger dry, clean and in a dust-free

Herewith declares that:

Is in conformity with the provision of the EC EMC directive 89/336/EEC and

The following harmonized standards have been applied:

Dr. F.J. ter Heide,

16 August 1999 / MASS battery charger / EN

MASS 12/30-2, 24/15-2, 24/25-2

11 DATA SHEETS MASS 12/30-2

Voltage sense : fully automatic compensation

Current accurancy : current ± 3%

Smart controls : QRS232 output by telephone plug - RJ45

Storage temperature : -25°C to 80°C

Reliability/life time : • MTBF 30.000 hours

ELECTRO MAGNETIC COMPATBILITY

WHAT TO DO IN CASE OF A DEFECT?

Dimensions of the new cabinet and PCB.

• LLOYDS, DNV, ABS:

• MANUFACTURED UNDER ISO 9001.

Main PCB of the MASS 12/30-2.

New ‘high tech’ enclosure.

remote select RS232

Set points register Setpoint

TEMPERATURE COMPENSATED CHARGING

-30 -20 -10 0 10 20 30 40 50 60

battery temperature in °C min. bulk time min. abs time

MAX. OUTPUT VERSUS INPUT VOLTAGE

14.25V Tamb= 40°C

80 100 120 140 160 180 200 220 240 260 0 20 30 40

input voltage output current in Amps

11 DATA SHEETS MASS 24-15-2