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Manual Mass Combi 20004000

1. Figure 24 Dimensions in mm inch of the Mass Combi 12 2500 o a 100 12 4000 200 24 2500 60 and 24 4000 120 a R6 5 R0 26 i 118 5 4 7 39 1 5 _ 110 4 3 _ Figure 25 Dimensions in mm inch of the mounting box of the ICC remote panel and the APC remote panel 128 5 0 140 5 5 EN Mass Combi May 2012 23 INSTALLATION MASTERVOLT 5 7 MOUNTING OF THE CABINET Bolts can be used for the mounting of the cabinet Take the following steps to mount the cabinet 1 Determine for the four mounting spots on the basis of the outline drawings figure 24 2 Screw the topmost bolts somewhat into the wall 3 Hang the cabinet with its key holes over the two bolts and screw these bolts finger tight so that some shifting is still possible 4 Place the two lowermost bolts 5 Fasten all bolts securely Masten ce 3 EE Figure 26 mounting of the cabinet 5 8 WIRING INSTRUCTIONS WARNING Let installation work be done by a licensed electrician Before beginning with the connection of the wiring make the AC distribution as well as the DC distribution voltage free Move the main switch see figure 15 to the Off position CAUTION Short circuiting or reversing polarity may lead to serious damage to the batteries the Mass
2. Service Starter battery Batteries optional Incoming AC source Circuit breaker RCD Temperature sensor Max 50Amps 30mA This schematic is to illustrate the general placement of the Mass Combi in a circuit It is not meant to provide detailed wiring instructions for any particular electrical installation Figure 27 installation drawing for one Mass Combi stand alone operation 25 EN Mass Combi May 2012 INSTALLATION MASTERVOLT 5 8 1 Wiring instructions for one Mass Combi stand alone operation See figure 27 See reference Connect the external AC source to the AC input of the Mass Combi Integrate a fuse value depending on the used wire diameter with a maximum of 50Amps and a Residual Current Device RCD into this wiring See reference Connect the AC output POWER of the Mass Combi to the power distribution group See reference Connect the output SHORT BREAK of the Mass Combi to the SHORT BREAK distribution group Integrate a Residual Current Device RCD into this wiring See reference O Run the DC cables between the DC distribution and the Mass Combi Connect the red cable to the plus connection the black cable to the minus connection Do not install the DC fuse of the DC distribution before the entire installation is completed see chapter 7 See reference Attach the temperature sensor to the battery and run the cable into the
3. AC input Negative battery terminal wed r ET Second 5A SS Sp z charger output ASIN E SSS e E M A y Hy AC INPUT Combi fuse Combi fuse H DC distribution To alternator Battery fuse To alternator lll II Fuse UE Il ii 25A T Starter battery Starter battery A optional B optional This schematic is to illustrate the general placement of the Mass Combi in a circuit It is not meant to provide detailed wiring instructions for any particular electrical installation Figure 28 installation drawing for two Mass Combi s parallel operation See also figure 29 NOTE See also section 6 1 1 for DIP switch settings EN Mass Combi May 2012 27 INSTALLATION MASTERVOLT 5 8 2 Wiring instructions for two Mass Combi s parallel operation CAUTION Only two units of the Mass Combi 12 2500 100 or the Mass Combi 24 2500 60 can be connected in parallel Parallel operation of two units of the Mass Combi 12 4000 200 or the Mass Combi 24 4000 120 is not possible In the text below the Mass Combi that is designated as A must be configured as Master while the Mass Combi that is designated as B must be configured as Slave see section 6 1 1 for adjustment Designation must be configured as Combi A Master
4. Connector for Remote temperature connection ICC panel PARALLEL connection REMOTEQ S 2SENS MasterBus Serial interface Communication cable for parallel operation Service Batteries Temperature sensor v MasterBu S Figure 29 Connection of remote control panels battery temperature sensors and communication cable for parallel operation 5 8 3 Alarm contacts Connectors 1 to 4 are internally linked as follows 1 C Common 2 NC Normally Closed O 3 NO Normally Open O 4 Not used Figure 30 alarm contacts The alarm contact is switched to Normally Open in case of an alarm situation see section 3 5 Maximum switching current 1 Amp The Mass Combi 12 4000 200 and 24 4000 120 are provided with two sets of alarm contacts These two sets operate simultaneously 5 9 SETTINGS See chapter 6 for DIP switch settings NOTE Adjust the commissioning NOTE When using a Masterlink MICC remote panel e See section 6 2 5 for DIP switch setting at the Mass Combi e See section 4 4 of the users manual of the Masterlink MICC to enable the Mass Combi setting DIP s
5. SHORT BREAK output Please note that if the power consumption of the POWER output exceeds the setting of the power support function the external AC fuse will still trip If the total current from the POWER output and SHORT BREAK output is less then the Power support setting during approx 10 minutes the Mass Combi connects the SHORT BREAK output back to the AC input again The charger commences charging again when the load reduces further and the total current drops below the Power sharing setting 16 En A NOTE You can either choose the Generator than available from the incoming AC AC INPUT SHORT BREAK mains support function or the Power support TA E i function not both simultaneously Max 10A AC A SUPPORT FUNCTION H 200A DC 12V Figure 3 BATTERIES Power support function 3 3 6 Summary of the AC operation modes Function DIP switch What is it used for How is this achieved Power Sharing B SW3 To protect the incoming AC By reducing the charge current and thus the AC input from overload current Generator Mains B SW5 To deliver more AC power The AC output of the inverter is connected in parallel support than available from the with the incoming AC This means that energy from the incoming AC batteries is added to the incoming AC Power support B SW4 To deliver more AC power The load which is connected to the POWER output is supplied by the incoming AC while t
6. selectable If the demand for AC power still increases the external AC circuit breaker may still trip if nothing is done This problem can be solved by the Generator mains support function If the total demand for energy exceeds the maximum external power supply energy can be added to the AC outputs POWER and SHORT BREAK by means of the inverter This appliance can be automatically connected in parallel with the external power supply AC OUTPUT POWER AC OUTPUT SHORT BREAK AC INPUT GENERATOR MAINS SUPPORT FUNCTION Figure 8 Generator mains support function See figure 8 Here the AC input is still limited to 10 Amps This is not enough to supply the total load 7 17A 24A connected to the AC outputs When the Generator mains support function is enabled the inverter will supply the remaining 24 10 14A This means that the restricted amount of external AC power will be compensated by energy which is stored in the batteries Later when the AC load has dropped below the setting of the Power sharing function again the battery charger of the Mass Combi will commence to recharge the batteries For safety reasons the transfer relay is immediately switched off when incoming AC power fails in operation so that there will never be a high voltage on the shore cable inlet when it is not connected SHARING Approx CONTROL gt 0A DC 12V BATTERIE nee e Power shari
7. Combi the wiring and or the terminal connections Fuses between the batteries and the Mass Combi can not prevent damage caused by reversed polarity The damage as a result of reverse polarity is not covered by the warranty 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 far as possible Use cables of the correct size NOTE EE Feed the cables through the cable glands of the cabinet before you fix the cable lugs to the wire ends Continue with section 5 8 1 for wiring instructions of one Mass Combi in stand alone operation or section 5 8 2 for wiring instructions of two Mass Combis in parallel operation 24 May 2012 Mass Combi EN INSTALLATION MASTERVOLT Mg AC output Meu gak Negative batt Second 5A io SHORT BR mias charger output uo Positive batter y terminal Second 5A 7 LA charg er output A L Lo
8. s or micro waves are most likely not to work on this mode Economy The inverter reduces the output voltage to 104V AC if the connected load drops below 250VA The output mode voltage will return to 120V AC if the connected load rises above 250 VA Small loads as clocks in VCR s and micro waves will perform equal whether the inverter is running in the economy state or is on The energy saving from your batteries is approximately 10 For detailed specifications see section 9 1 DC no load power consumption Table 1 Mass Combi energy saving modes May 2012 Mass Combi EN MASTERVOLT HOW IT WORKS 3 3 OPERATION MODES The Mass Combi is not just a combination of an inverter and a battery charger It has many additional features which can be used to increase the total available AC power even when external AC power is limited 3 3 1 Basic operation When there is no external AC power available the inverter of the Mass Combi provides AC power on the SHORT BREAK output from the batteries There is no AC power available on the POWER output Now the Mass Combi is in Inverter mode See figure 4 AC OUTPUT POWER AC OUTPUT SHORT BREAK AC INPUT Figure 4 Inverter mode When external AC power comes available the transfer relay switches on See figure 5 Both outputs as well as the battery charger are supplied by the external AC power The batteries are recharged now Now the M
9. 135VAC 0 135VAC O 135VAC 0 135VAC Input frequency range 45 65Hz 45 65Hz 45 65Hz 45 65Hz Absolute maximum frequency range 0 70Hz 0 70Hz 0 70Hz 0 70Hz Nominal input current 120V 14 5 A 29 A 17 A 29 A Input phase Single phase 3 wire system Insulation class Class Class Class Class Power factor gt 0 98 gt 0 98 gt 0 98 gt 0 98 Harmonic distortion THD 3 3 3 3 Efficiency at full output gt 85 gt 85 gt 85 gt 85 No load power consumption lt 15W lt 30W lt 15W lt 30W Model Mass Combi 120VAC 12 2500 100 12 4000 200 24 2500 60 24 4000 100 DC output Nannaa voltage 12VDC 12VDC 24VDC 24VDC 0 15 5VDC 0 15 5VDC 0 31 0VDC 0 31 0VDC Max total output current 100A 200A 60A 120A U lt 14 25VDC U lt 14 25VDC U lt 28 5VDC U lt 28 5VDC Second charge output 5A 2x5A 5A 2x5A Charge characteristic Three stage fully automatic lUoUo Equalize Equalize mode output current 10A 20A 6A 12A Equalize mode max output voltage 15 5VDC 15 5VDC 31 0VDC 31 0VDC Equalize mode maximum duration 6 hrs 6 hrs 6 hrs 6 hrs EN Mass Combi May 2012 39 TECHNICAL DATA MASTERVOLT Model Mass Combi 120VAC 12 2500 100 12 4000 200 24 2500 60 24 4000 100 Factory settings Return Amps 6 of maximum output current Max bulk abs timer 6 hours 6 hours 6 hours 6 hours Return amps timer 15 minutes 15 minutes 15 minutes 15 minutes Return to bul
10. LED indicators If two Mass Combis are installed in parallel the slave unit will only operate properly after the master unit was switched on first Er If you use a remote control panel press the on off button on the remote control panel See section 4 4 After switching on expect a three till five second delay before the unit is activated The LED indicators will blink several times indicating the installed software version see section 8 2 for explanation If AC power is available on the AC input and within the specified limits the Mass Combi will switch to Charger Mode and will commence to charge the batteries At the same time the internal transfer relay will pass the AC power to the AC output SHORT BREAK If the AC power from the external AC source is unavailable or outside the specified limits the unit will come on as an inverter Inverter overload protection built in idle mode circuitry transfer switching power sharing and battery charger regulation will all function automatically 14 May 2012 Mass Combi EN MASTERVOLT OPERATION 4 2 2 Switching Off Move the main switch to the Off position to switch off the Mass Combi If you use a remote control panel press the on off button on the remote control panel See section 4 4 The Mass Combi stops and all the indicators go off The Short break output is disconnected and will become powerless WARNING Switching off the Mass Combi
11. and Mass Combi See figure 28 reference O Fix the cable with an insulated faston to the 5A connection Integrate a 25 Amps T fuse in this wire The negative pole of this battery must be connected to the negative pole of the main battery See figure 29 reference If you want to install the ICC remote control panel run the communication cable between Mass Combi A and the panel Connect the RJ12 connector to the REMOTE input Data Bus Connections of Mass Combi A WS NOTES e The Mass Combi can also be operated without the ICC remote control panel connected e With two Mass Combi s installed in parallel each Combi can also have its own ICC remote control panel Other panels than the ICC remote control panel must be connected to the QRS232 connection reference Refer to the applicable installation manual for detailed instructions Continue with section 5 8 3 28 May 2012 Mass Combi EN MASTERVOLT INSTALLATION Mass Combi A Master Mass Combi B Slave Connector for Remote temperature QRS232 connection aansluiting PARALLEL ICC panel o ICC panel optional O connection a
12. be set to match A nd are f A aA to id se T oe Att the circuit breaker value of the incoming i C GaSe ME KEY SOUS OBES ME DESSE vaUe ls CHOSEN ANET AC 3 seconds the value is stored and the indicator stops blinking Power sharing indicates the value of the input current limit With this adjustment you can set maximum input Figure 18 Operation of the APC remote panel 4 6 MAINTENANCE 4 7 PROBLEM SOLVING No specific maintenance is required If necessary use a Refer to chapter 8 if a problem occurs soft clean cloth to clean the Mass Combi Never use any liquids acids and or scourers EN Mass Combi May 2012 17 INSTALLATION MASTERVOLT 5 INSTALLATION During installation and commissioning of the Mass Combi the Safety Guidelines amp Measures are applicable at all times See chapter 2 of this manual 5 1 UNPACKING In addition to the Mass Combi the delivery includes e abattery temperature sensor e aremote control panel Inverter Charger Control ICC with grey mounting box and communication cable 6m e this user s manual After unpacking check the contents for possible damage Do not use the product if it is damaged If in doubt contact your supplier Check from the identification label see section 1 6 whether the battery voltage is the same as the DC input voltage of the Mass Combi e g 24V battery set for a 24V input voltage Also check that the AC output voltage and output power of the Mass Co
13. ho lz lo lso lso leo Battery temperature in C Figure 37 Temperature compensation characteristic charge voltage versus temperature 42 May 2012 Mass Combi EN MASTERVOLT ORDERING INFORMATION 10 ORDERING INFORMATION Part number Description 6384012500 Industrial DC fuse 125A DIN 00 6384512500 Industrial DC fuse 125A DIN 1 6384525000 Industrial DC fuse 250A DIN 1 6384640000 Industrial DC fuse 400A DIN 2 6381001000 Fuse base DIN 00 max 160A 6381002000 Fuse base DIN 1 max 250A 6381003000 Fuse base DIN 2 max 400A 79009006 Battery switch 250A with knob 79009005 Battery switch 250A with key 77030100 MasterBus USB interface 77030475 MasterBus Combi Interface 6502001030 Modular communication cable cross wired 6 pole 6 meter 19 ft 6502100100 Modular communication cable cross wired 6 pole 10 meter 33 ft 6502100150 Modular communication cable cross wired 6 pole 15 meter 49 ft 130010905 Modular communication cable cross wired 8 pole 1 meter 3 ft 130010906 Modular communication cable cross wired 8 pole 5 meter 16 ft 130010910 Modular communication cable cross wired 8 pole 10 meter 33 ft 130010915 Modular communication cable cross wired 8 pole 15 meter 49 ft 41500500 Battery temperature sensor incl 6 meter 19 ft cable 70405000 Inverter Charger Control Remote ICC See section 3 4 1 704050
14. is only valid for the following models with apparatus version M and higher see section 1 6 Description Part number Mass Combi 12 2500 100 120V 37012505 Mass Combi 12 4000 200 120V 37014005 Mass Combi 24 2500 60 120V 37022505 Mass Combi 24 4000 100 120V 37024005 For other models see other manuals available on our website www mastervolt com 1 4 QUALITY During their production and prior to their delivery all of our units are tested and inspected The standard guarantee period is two years after date of purchase 1 5 LIABILITY Mastervolt can accept no liability for e consequential damage due to use of the Mass Combi e possible errors in the manuals and the results thereof 1 6 IDENTIFICATION LABEL ASTERVOLT Part No 37024005 Type Mass Combi 24 4000 100 120V Charger Input 90 135V Output 24V 100A Inverter Input 24V 200A Output 120V 60 50Hz UAM ECN Serial No C ezameoozds CE es IP23 U823M0026 Apparatus version M Figure 1 Identification label The identification label is located at the right hand side of the Mass Combi see figure 1 Important technical information required for service maintenance amp secondary delivery of parts can be derived from the identification label CAUTION Never remove the identification label 1 7 CHANGES TO THE MASS COMBI Changes to the Mass Combi may be carried out only after obtainin
15. mode or Generator Mains support mode active No error 2 solid yellow 8 solid red Charger Temperature Compensation TC error The temperature sensor on the battery gives an incorrect value Disconnect the sensor and if the LED s go off then replace the battery temperature sensor 3 solid yellow 8 solid red DC voltage error The battery voltage is too high or too low Check the batteries EN Mass Combi May 2012 35 TROUBLE SHOOTING MASTERVOLT Mode lIlluminating LEDs Explanation Possible cause What to do 4 solid yellow 8 solid red Short circuit error The battery voltage is far too low The charger reduces the output current till 25 of the maximum output current Check the batteries and the wiring 5 solid yellow 8 solid red Overheating error The charger current is reduced to zero in case of extreme overheating until the Mass Combi is cooled down Check whether the air flow of the Mass combi is blocked or whether the ambient temperature is too high 2 3 4 5 6 blinking yellow 8 9 solid green Equalizing mode is activated See chapter 6 2 6 2 blinking yellow 3 4 5 6 solid yellow 8 9 solid green Charger runs a compensation cycle for self discharge of the batteries Nothing See figure 28 for charging characteristics Inverter 1 solid yellow 7 solid red Overload error The inverter is loaded with mor
16. of Certain Hazardous Substances in Electrical and Electronic Equipment e 2002 96 EC from 27 01 2003 The Directive on Waste Electrical and Electronic Equipment Amsterdam P F Kenninck General Manager MASTERVOLT MASTERVOLT Snijdersbergweg 93 1105 AN Amsterdam The Netherlands Tel 31 20 3422100 Fax 31 20 6971006 Email info mastervolt com
17. or potentially flammable products 3 Use of the Mass Combi other than mentioned in point 2 is not considered to be consistent with the intended purpose Mastervolt is not liable for any damage resulting from the above 2 3 ORGANIZATIONAL MEASURES The user must always e have access to the user s manual e be familiar with the contents of this manual This applies in particular to chapter 2 Safety Guidelines and Measures 2 4 MAINTENANCE amp REPAIR If the Mass Combi is switched off during maintenance and or repair activities it should be secured against unexpected and unintentional switching on e remove the AC supply e remove the connection to the batteries e be sure that third parties cannot reverse the measures taken 2 f maintenance and repairs are required use only original spare parts 2 5 GENERAL SAFETY AND INSTALLATION PRECAUTIONS e Do not expose the Mass Combi 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 Mass Combi in a non ventilated area overheating may result e The Mass Combi must be provided with an equipment grounding conductor to the AC input ground terminal Grounding and all other wiring must comply with local codes and ordinances e Incase of fire you must use the fire extinguisher which is appropriate for electrical equipment e Short circuiting or rever
18. output Nominal voltage 5 120VAC 90 135VAC Wave form True sine wave max 5 distortion 22 typical Frequency 60Hz 0 05 adjustable by DIP switch Maximum continuous output power AC out 120V resistive load 2500VA 3750VA 2500VA 3750VA pes PAS DC in 211 0V DC in 211 0V DC in 222 0V DC in 222 0V 2000VA 3600VA 2000VA 3600VA OTE ambient sd DC in 211 0V DC in 211 0V DC in 222 0V DC in 222 0V Output power vs ambient temperature gt 25 C 77 F derating 0 65 per C 1 15 per F Shutdown at 80 C 176 F internal temperature Surge capability 5 sec resistive load 4000W 7500W 4000W 7500W Efficiency 100VA up to 2000VA 290 Load power factor range All power factor allowed Protections Over temperature overload short circuit AC on output high battery low battery adjustable by means of MasterAdjust software 38 May 2012 Mass Combi EN MASTERVOLT TECHNICAL DATA 9 2 SPECIFICATIONS CHARGER Model Mass Combi 120V 12 2500 100 12 4000 200 24 2500 60 24 4000 100 AC input Nominal voltage frequency 120V 60 50Hz 120V 60 50Hz 120V 60 50Hz 120V 60 50Hz Input voltage 100 output 105 135VAC 105 135VAC 105 135VAC 105 135VAC Input voltage reduced output power 90 105VAC 90 105VAC 90 105VAC 90 105VAC Absolute maximum voltage range 0
19. the appliances connected to the AC outputs The Power Sharing level should be set to match the value of the external circuit breaker which protects the incoming AC power For instance when the external AC power is limited by a 10A fuse the Power Sharing level must be set to 10A AC OUTPUT POWER AC OUTPUT SHORT BREAK Max 10A AC POWER i l SHARING gt 30A DC CONTROL dea a Power sharing See figure 6 EN Mass Combi May 2012 HOW IT WORKS MASTERVOLT Here the Power Sharing level is set to a 10 Amps while the AC outputs consume a total of 2 4 6 Amps This means that only 10 6 4 Amps is left over for charging With 12V batteries this will result in a maximum charge current of approx 30A DC Although the Power Sharing level can be set by means of the DIP switches locally on the Mass Combi see section 6 2 1 we recommend the use of an optional remote control panel like the Remote APC or Masterlink MICC With this remote panel you can select the available shore current fuse of each marina or camping site in a very easy way When the total connected AC load reaches the level of the Power Sharing setting 6A there will be no power left over to charge the battery This means that the charge current of the Mass Combi will be reduced to 0A See figure 7 AC OUTPUT POWER AC OUTPUT SHORT BREAK Max 10A AC 3 3 4 Generator mains support function
20. voltage See specifications in section 9 2 The Mass Combi will switch to inverter mode if the AC input voltage is out of operating range and will switch back if the AC input voltage is present again The DC input of the Mass Combi is also within limits protected against over and under voltage See specifications in section 9 1 The Mass Combi switches off if the DC input voltage is out of range 4 4 INVERTER CHARGER CONTROL PANEL The Inverter Charger Control ICC remote control panel is standard included with the delivery of each Mass Combi See figure 17 With this panel you can operate and check the actual status of the Mass Combi remotely Inverter LED Green LED the Mass Combi is operating in inverter mode Red an error is detected Inverter mode Displays the approximate battery Failure LED When illuminated red a failure is detected The cause 1 of failure is explained in section 15 Inverter Charger Control AC Input Illuminates when the incoming AC power is Mastenvorr 4 available On Off switch Note this switch will not operate if the main switch on the Mass Combi is set to Off 16 May 2012 Mass Combi EN MASTERVOLT OPERATION sr NOTE The setting for maximum input current 4 5 AC POWER CONTROL PANEL OPTIONAL can never be adjusted to a level that is higher The optional AC Power Control remote panel enables you than set by DIP switches B1 and B2 of the to limit the incoming AC
21. with the main switch on the front of the cabinet does not cut off the connection to the batteries or the AC source Therefore the POWER output is still active NOTE When the main switch is in the Off gt os position it overrides the remote control panel In this off state it is not possible to start the Mass Combi remotely 4 23 Switching Ch Charger only When the main switch is set to the Ch position the Mass Combi is only able to work as a charger This means that the inverter mode is disabled This setting is useful if you want to keep your batteries charged and maintained in case you are away i e in the winter time Now your batteries are spared when the incoming AC source fails in operation If you use the remote panel ICC MICC or MasterBus Interface you can still switch on off the charger remotely even if the incoming AC source is not available If the AC source is available and the Mass Combi is operating in the charger mode the user panel shows the actual status of the system See section 4 4 for detailed operation instructions of the remote panel ICC 4 3 PROTECTIONS The Mass Combi is protected against overload short circuit over heating and under and over voltage The user can detect failures from the local user panel or from one of the optional remote control panels by means of the indicators See section 8 1 for explanation of this readout CAUTION The Mass Combi is not prote
22. 5 for more information If you want DIP switch B SW4 To disable the Power support function OFF To enable the Power support function ON 6 2 3 Generator mains support function See section 3 3 4 for more information If you want DIP switch B SW5 To disable the Generator mains support function OFF To enable the Generator mains support function ON 6 2 4 Setting for Power Quality at incoming AC If a generator with distorted output waveform too low frequency is used as AC source the allowed frequency window for the incoming AC power can be enlarged If you want DIP switch B SW6 To set the frequency window for the incoming AC power at 45Hz lt f lt 65Hz OFF To set the frequency window for the incoming AC power at 35Hz lt f lt 65Hz ON CAUTION Adjustment of the frequency window at a too low level may cause damage to the connected AC load Refer to the AC input specifications of the connected loads 32 May 2012 Mass Combi EN MASTERVOLT SETTINGS 6 2 5 Combi inverter control The ON OFF switch at the Inverter Charger Control ICC panel and the Inverter switch at the Masterlink MICC have different functions depending on the setting of DIP switch number 7 When the Mass Combi is switched off by means of the main switch at the front then it is completely off see 4 2 However in this off state it is not possible to start the Mass Combi remotely via the ICC rem
23. 50 AC Power Control Panel Remote APC for 120VAC installations See section 3 4 2 70603250 M 3 R1 Adapter for the mounting of a Remote ICC or APC in a Mastervision panel 70403080 Masterlink MICC remote control panel for Mass Combi Features On Off status read out Power Support extended battery monitoring functions See section 3 4 3 These parts are standard included with the delivery of the Mass Combi Mastervolt can offer a wide range of products for your electrical installation including automatic AC transfer switches remote control panels and DC distribution kits See our website www mastervolt com for an extensive overview of all our products EN Mass Combi May 2012 43 EC DECLARATION OF CONFORMITY MASTE RVO LT 11 EC DECLARATION OF CONFORMITY Manufacturer Mastervolt Address Snijdersbergweg 93 1105 AN Amsterdam The Netherlands Herewith declares that Product 37012505 Mass Combi 12 2500 100 120V 37014005 Mass Combi 12 4000 200 120V 37022505 Mass Combi 24 2500 60 120V 37024005 Mass Combi 24 4000 100 120V Is in conformity with the following provisions of the EC e 2004 108 EC EMC directive The following harmonized standards have been applied o Generic emission standard EN61000 6 3 2007 o Generic immunity standard EN61000 6 1 2007 e 2006 95 EC Safety directive with the following standard o Low voltage standard EN60950 2000 e 2002 95 EC ROHS Directive on the Restriction of the Use
24. Combi B Slave See figure 27 reference Connect the external AC source to the AC input terminals of Mass Combi A Integrate a fuse value depending on the used wire diameter with a maximum of 50Amps and a Residual Current Device RCD into this wiring See reference Connect the AC output POWER of Combi A to the power distribution group See reference Connect the AC output SHORT BREAK of both Mass Combi A and Mass Combi B to the SHORT BREAK distribution Beware that the L N and PE GND wiring may not be exchanged See reference O Run the DC cables between the DC distribution and each Mass Combi Connect the red cable to the plus connection the black cable to the minus connection Do not install the DC fuses of the DC distribution before the entire installation is completed see chapter 7 See figure 29 reference O Run the modular 8 pole communication cable between Mass Combi A and Mass Combi B Connect this cable to the PARALLEL connectors See reference O Attach the temperature sensor to the battery and run the cable into Mass Combi A and connect the RJ12 connecter to the TEMP SENS connector Data Bus Connections Option if you want to make use of the possibility to give a maintenance charge to a small battery set like a starter battery run a 6mm AWG10 red cable with a fuse holder between the positive pole of the starter battery
25. MASTERVOLT USERS MANUAL MASS COMBI 12 2500 100 120V 12 4000 200 120V 24 2500 60 120V 24 4000 100 120V SINE WAVE INVERTER CHARGER COMBINATION WITH GENERATOR MAINS SUPPORT MASTERVOLT Snijdersbergweg 93 1105 AN Amsterdam The Netherlands Fax 31 20 6971006 www mastervolt com Copyright O 2012 Mastervolt v 4 1 May 2012 MASTERVOLT CONTENTS CONTENTS v 4 1 May 2012 1 GENERAL INFORMATION a eee 4 1 1 Use of this Mantaliiiian incida ar a a a ak 4 1 2 GuaranteespeciticationS tica nario iii cacas 4 1 3 Validity of this Malicia is Acs 4 1 4 UA erde ct Ashlea doe ablated le decal ta lr ei Ds tb de 4 1 5 Biabilitszs2uno reren attente A aide ed ie ee ee a ee eend 4 1 6 laefithcatonlabel itn eae ied atti aN ta A okra 4 1 7 Changes to the Mass Comisi n 4 2 SAFETY GUIDELINES AND MEASURES naan oa sannerseorseasennenseneerwinvenane e meden oewdndenanndennerese 5 2 1 Warnings nd SymbolS sydney ennaa edere ie eee ide da 5 2 2 Use for intended purpose 2 3 Organizational measures 2 4 Maintenance amp repair 2 5 General safety and installation precautions nnen vennenenerennerenenenverenerenverenerenenenerenenenenenenendenn 5 2 6 Warning regarding life support applications nennen ernnnenveneneerennenerreneneerenneerennenerreneneeeenneeveenenenvenenn 6 2 7 Warning regarding the use of batteries nvanserneeonerenenneernenneerenensenennnanenennnanrenenserenenaneneennenenen
26. Mass Combi Link the RJ12 connector to the TEMP SENS connector Data Bus Connections Option if you want to make use of the possibility to give a maintenance charge to a small battery set like a starter battery run a 6mm AWG10 red cable with a fuse holder between the positive pole of the starter battery and Mass Combi See figure 27 reference Fix the cable with an insulated faston to the 5A connection Integrate a 25 Amps T fuse in this wire The negative pole of this battery must be connected to the negative pole of the service battery See reference If you want to install the ICC remote control panel run the communication cable between the Mass Combi and the panel Connect the RJ12 connector to the REMOTE input Data Bus Connections NOTE BSS The Mass Combi can also be operated without the ICC remote control panel connected Other panels than the ICC remote control panel must be connected to the QRS232 connection reference Refer to the applicable installation manual for instructions Continue with section 5 8 3 26 May 2012 Mass Combi EN MASTERVOLT INSTALLATION Mass Combi A Mass Combi B Master Slave AC output Be eis SHORT BREAK ositive battery A terminal el T AC output ona SHORT BREAK Positive battery nd 5A terminal charger output AC output POWER
27. Thermal fuse Negative battery terminal AC output ROWER Cooling fan AC output Positive battery SHORT BREAK terminal Cable glands for AC wiring Cable glands for main DC wiring Grommets for wiring of remote panels Figure 22 Overview connection compartment Mass Combi 12 2500 100 and 24 2500 60 Connector for Remote DIP switches connection temperature QRS232 ICC panel Senor connector Alarm contacts 2x AC input Second 5A charger output 2x an Thermal fuse MAA Y O Y i Negative battery AC output terminal POWER AC output Cooling fan SHORT 2x BREAK Positive battery terminal Figure 23 Overview connection compartment Mass Combi 12 4000 200 and 24 4000 120 Bottom plate removed 22 May 2012 Mass Combi EN ts MAST E RVO LT INSTALLATION Mass Combi 2500 156 6 1 318 12 5 ho Mass Combi 4000 279 11 0 9 300 11 8 L_9 0 35 0 35 es i TT 1 EE ES EN ETT I br S Y tt en tt EE JA Se tr Nh NY a a Ld LN 5 ENE Y lt S EY g E E CC t ESE Y HT E E EA CO A DE TJ Nr A n NX IN NEE CD cm A ARAN a Si T 3 I I g qm gg 3 Y PPPE R3 25 R0 13
28. able length and wire diameter depend on the electrical installation see section 5 3 1 We recommend as a minimum tool kit e Socket wrench 13mm to fix the DC input battery cables e Flat blade screw driver 1 0 x 4 0 mm to fix the screw terminals e Tools to fix the screws bolts 1 4 with plugs to mount the cabinets to a surface e Philips screw driver to open the connection area of the Mass Combi 20 May 2012 Mass Combi EN MASTERVOLT INSTALLATION ouahWN Figure 19 Modular communication cable 6 pole cross wired For connection of remote control panels I Figure 20 Modular communication cable 8 pole cross wired For communication between two Mass Combi s parallel operation 5 5 REMOVAL OF THE FRONT PANEL Figure 21 See figure 21 Steps 1 Loosen the two Phillips screws that secure the front cover plate for two turns 2 Slide the front cover plate from the cabinet downwards The connectors for the battery the AC and the remote panel are now visible See figures 22 and 23 WARNING The front panel may never be removed while the Mass Combi is still connected to a power source EN Mass Combi May 2012 21 INSTALLATION MAST E RVO LT 5 6 OVERVIEW CONNECTION COMPARTMENT Connector for Remote temperature DIP switches connection sensor QRS232 ICC panel connector Alarm contacts PARALLEL connector AC input Second 5A charger output
29. al fuse O 25 C 77 F BULK ABSORPTION FLOAT BULK min bulk timer 2 min min abs timer 15 min Bulk 14 40VDC T 1 14 25VDC Absorption rn e 13 25VDC F loat fe start mex bulk e 12 80VDC 7 Return to bulk 12 80VDC gt Imax 100 Imax lt Imax Return amps 6 Imax voltage max bulk max absorption repeated 85 30 return to timer 8 hr timer 4 hr every 336 hr min sec bulk timer cCcurrent Figure 35 Charge characteristic of the three step Plus charging method 25 77 F EN Mass Combi May 2012 41 TECHNICAL DATA MAST E RVO LT FLOAT EQUALIZE FLOAT Float voltage 2 25V 15 50VDC Float voltage 13 25VDC 10 of Imax Max equalize time 6hr Start equalize cycle by jumper change disabled when Gel voltage current Figure 36 Charge characteristic of the equalize charge cycle see section 6 2 6 25 77 F Limited by voltage setting ev 25 C REFERENCE Temperature variation gt 15 0 E TEMPERATURE Temperature variation T standard 5 0 mV C 2 ig Reference voltage 25 C pe Battery Charging is not allowed above 55 C 310 and under 20 C S 12 Volt system 30mV C 13 5 i 24 Volt system 60mV C 5 0mv C per cell 13 0 i 4 125 Uref 25 C 12 0 l 30 l 20 l 10 lo
30. and negative cables next to each other to limit the electro magnetic field around the cables The negative cable should be connected directly to the negative post of the battery bank or the ground side of a current shunt Do not use the chassis frame or hull of the ship as the negative conductor Tighten connections securely 15 20 Nm 130 175 In Lbs The positive battery cable must be fused according to local applicable regulations and connected to the positive post of the battery bank Model Mass Combi Recommended Combi fuse 12 2500 100 250A 12 4000 200 2 x 250A 24 2500 60 125A 24 4000 120 250A The fuse with the fuse holder is available from your local Mastervolt distributor or Customer Service Representative 5 3 3 AC safety grounding WARNING The ground wire offers protection only if the cabinet of the Mass Combi is connected to the safety ground Connect the earth terminal PE GND to the hull or the chassis CAUTION For safe installation it is necessary to e connect the neutral conductor N of the AC output to the earth PE GND only during inverter operation of the Mass Combi e insert a Residual Current Device earth leakage switch of 30mA in AC output SHORT BREAK of the Mass Combi e Insert a Residual Current Device earth leakage switch of 30mA in AC input of the Mass Combi Refer to local regulations on these issues For safety purposes the neutral conductor N of the AC
31. ass Combi is in Charger mode AC OUTPUT POWER AC OUTPUT SHORT BREAK AC INPUT Figure 5 Charger mode BATTERIES 3 3 2 The transfer switch The Mass Combi has two AC outputs available e SHORT BREAK output The SHORT BREAK output switches between the AC input and the output of the inverter The AC input has the highest priority In principle AC power is always available on this output However during a switchover the loads connected to this output are not supplied with AC power for a very short period of time short break It is the ideal output for loads that need AC power permanently like personal computers interior lighting and the refrigerator e POWER output This output is always internally connected to the AC input It is therefore only available when an external AC source like shore power a generator or an outlet is present Larger loads like a hot water boiler electric cooking appliance or washing machine should be connected to this output 3 3 3 Power sharing function selectable If the available power at the AC input is limited and the load connected to the AC output increases the external AC circuit breaker may trip if nothing is done To avoid this the Mass Combi can automatically reduce the battery charger output and thus the AC power consumption This Power sharing feature constantly senses the incoming AC current which is used to supply both the battery charger and
32. ate iii ee de 19 5 4 THINGS VOU NCEA ia entend verreden tene dt ies 20 5 5 Removal of the front panel anssen vennerenenserrenensenenenserenensernenenserenenanenenenserenennordennnnerevensenrvensoeeennnnenenn 21 5 6 Overview connection compartment nnen enenneneenevenneeeenerenneeeenevennereenenenneeeeneeenneerenevenneeennevenneeveneeeneeenn 22 5 7 Mounting of the cabinet itched ls soi ai A A haters nee 24 5 8 WIFINQINSTUCUON Scirocco he ceed ele 24 5 8 1 Wiring instructions for one Mass Combi stand alone operation nennen eneen 26 5 8 2 Wiring instructions for two Mass Combi s parallel operation nnee oenen neereene neren 28 5 8 3 Alarm CONTAC suit ol it 29 5 9 A Ne 29 SET A A A A T 30 6 1 DIP SWItCH 5 Zator noni eenander neen 30 6 1 1 Parallel mode s acar va ervoer ere tre a amedee vlee tet 30 6 1 2 Gutput frequency Verter cuina ao 30 6 1 3 Energy SAVING MONO rater verken a cn pa 31 6 1 4 Battery Aypi rnst ranee di ate eis 31 6 1 5 Ground relay cia dd a ee ti 31 6 2 BIN ln ceri ete e a o A etc Nae ee ae aes es 32 6 2 1 Power sharing UNC ste ee seve ee i A eee es 32 6 2 2 Power Support FUNCTIONS niet eenden etna dae ed greta 32 6 2 3 Generator mains support FUNCTION oooocccnncccnonccnnocanoncncnnncnnnn cnn nn crac nana rra 32 6 2 4 Setting for Power Quality at incoming AC oooocncccinnccnocccnnnncnonnnnnnnnnnncn conan nnnnn cnn nn nr nn 32 6 2 5 Combilinverter control ixocii iaa 33 6 2 6 Eg
33. ays ventilate the room were the batteries are located and equalized to clear the air gt The equalizing mode can only be started when the Mass Combi is in operation This means that the connection compartment of the Mass Combi must be opened while connected to the mains and the batteries Take adequate measures for protection against short circuits and electrical shocks During equalizing the batteries are brought into the gas state and is it possible that the permitted load voltages are exceeded See chapter 9 4 for characteristics Therefore appropriate measures must be taken e g disconnect all loads from the battery and ventilate the room For these reasons use of the equalizing mode should only be executed by trained technical engineers An equalizing charge can be necessary after very deep discharges and or inadequate charges This has to be carried out according to the specifications of the manufacturer of the batteries If you want DIP switch B SW8 To start the equalize mode Off On Off pulse EN Mass Combi May 2012 33 START UP AFTER INSTALLATION MASTERVOLT 7 START UP AFTER INSTALLATION 7 1 COMMISSIONING CAUTION Check the polarity of all wiring before commissioning plus connected to plus red cables minus connected to minus black cables NOTE The DIP switches must be adjusted prior to commissioning see chapter 6 Follow the steps described below to switch on the Mass C
34. bi EN MASTERVOLT HOW IT WORKS The APC panel has extended functions such as setting remotely the Power sharing value and monitoring your AC load This APC remote panel is optional see chapter 10 for ordering information 3 4 3 Masterlink MICC panel T MASS INVERTER CHARGER CONTROL NE Bulk Absorption Float AC present Figure 13 Masterlink MICC panel The Masterlink MICC panel art no 70403105 is a digital remote panel that has additional features compared to the ICC and APC panel This sophisticated panel is not only a remote control panel to switch on and off your Mass Combi but also a battery consumption meter for read out of the exact state of charge of your battery by means of a shunt included with the delivery of the Masterlink MICC When the battery is reaching a low voltage set point or a low state of charge an alarm can be raised This can be used to start up the generator The information provided includes reading voltage current consumed Ah time remaining and remaining capacity as a percentage of the maximum available battery capacity A well lit LCD screen also displays direct online data or historical information A protective back box 3 4 4 MasterBus Combi Interface Figure 14 MasterBus Combi Interface With this optional interface you can connect your Mass Combi to the MasterBus network a fully decentralized data network for communication between the different Mastervolt system dev
35. ble size IN amp OUTPUT 13 AWG 9 AWG Depending on your electrical installation Battery connections Bolt M8 13mm diameter Slave charger output 5 amps Faston is switched off in inverter mode Environmental Specifications Max dimensions HxWxD 496 x 318 x 496 x 318 x 496 x 318 x 496 x 318 x 156 mm 279 mm 156 mm 279 mm Weight 11kg 24lbs 21kg 46lbs 11kg 24lbs 21kg 46lbs Operating temperature range SPECIFIED will meet specified tolerances ALLOWED may not meet specified tolerances NON OPERATING storage 0 C to 25 C 32 to 77 F 25 C to 60 C 13 to 140 F 25 C to 85 C 13 to 185 F Humidity Max 95 relative humidity not condensing Environment class IP 23 Cooling Mix of conventional and forced air cooling by DC fans with variable speed Fan operation The fan does operate on a temperature current control related PWM variable speed control DC maintenance free fan 40 May 2012 Mass Combi EN 3 MAST E RVO LT TECHNICAL DATA 9 4 CHARACTERISTICS 1000 900 800 700 600 Percentaae of rated current 500 400 300 200 150 100 0 1 1 10 100 1000 10000 Trip time in seconds Figure 34 Switch off characteristic of the internal therm
36. cations 100 75 50 25 AC Present Inverter charger combination Charge cycle Charger mode Displays the status of the charge cycle bulk absorption or float see section 3 1 1 Inverter mode Displays the approximate battery voltage mo float m o abs Inverter LED When illuminated green the Mass Combi is operating in inverter mode Inverter Charger Charger LED When illuminated green the Mass Combi is operating in charger mode When one of the indicators flashes or illuminates red a failure is detected The cause of failure is explained in section 8 1 The Mass Combi is a fully automatic inverter charger system Under normal circumstances there is no need for adjustment or operation besides switching on and off A 4 1 INDICATORS See figure 15 The operation of the Mass Combi is displayed by means of LED indicators at the front side of the housing If the Mass Combi is activated and as long as none of the red indicators are illuminated no failure is detected and the unit is operating normally WARNING Never disconnect any of the wiring during operation of the Mass Combi 4 2 SWITCHING ON AND OFF The only control on the Mass Combi itself is the main switch see figure 15 on the front of the unit This switch controls On Off and Ch Charger only 4 2 1 Switching on The Mass Combi can be activated by switching the main switch to the ON position Figure 15
37. cted against reversing polarity of the DC input AC voltage on the DC input and serious over voltage gt 135VAC at 120V on the AC input or AC outputs 4 3 1 Transfer switch overload protection The transfer switch of the Mass Combi is protected against overload and short circuit When the current through the transfer switch of the Mass Combi is too high see figure 34 the thermal fuse figure 22 or 23 will switch off and the Mass Combi shuts down To correct this situation proceed as follows 1 Move the main switch of the Mass Combi to the OFF position 2 Disconnect the Mass Combi from any power source Disconnect all loads from the Mass Combi 3 Investigate the cause of failure of the thermal fuse like overload or short circuits 4 Refer to section 5 5 to open the connection compartment 5 Wait for at least two minutes and then reset the thermal fuse by pushing the button inside the connection compartment see figure 16 YAPUT GEN SHORE BOA MAX v N PE ge t THERMAL FUSE Figure 16 Reset of the thermal fuse o Close the connection compartment again Connect the Mass Combi to the power sources again 8 Switch on the Mass Combi see section 4 2 N 4 3 2 Output overload or short circuit In case of overload or short circuit in the inverter mode the 100 LED of the Power bar see figure 15 is illuminated red and the output voltage of the Mass Combi is limited The Mass Combi
38. d See table below to select the appropriate cross section for the AC wiring AC Current Minimum cross section in mm AWG 15 20 Amp 2 5 mm AWG 13 20 32 Amp 4 mm AWG 11 32 48 Amp 6 mm AWG 9 48 80 Amp 10 mm AWG 7 Recommended wire colours refer to local rules 120V AC installations Must be Wire color Meaning connected to Black Hot or Line L1 White Neutral N Green Ground PE GND The maximum current passing the Mass Combi must be limited Therefore the AC input must be protected by a fuse as specified below Model Mass Combi Maximum rating of the AC input fuse All models 50Amps 18 May 2012 Mass Combi EN MASTERVOLT INSTALLATION 5 3 2 DC wiring Keep in mind that high current will pass through the DC wiring Keep the cable length as short as possible this will keep the system efficiency as high as possible The recommended minimum cross section for battery cables up to 3m 10ft length is Model Mass Combi DC Cable cross section 12 2500 100 2x 70mm AWG2 0 12 4000 200 4x 70mm AWG2 0 24 2500 60 2x 50mm AWGO 24 4000 120 2x 70mm AWG2 0 Use cable lugs terminals on the ends of the wires These lugs should be crimped with a proper crimping tool Use the following wire colours for DC wiring refer to local rules Must be Wire color Meaning connected to Red Positive POS Black Negative NEG Lay the positive
39. e discharged to begin with The bulk phase is followed by the absorption phase Absorption charging starts when the voltage on the batteries has reached 14 4V 12V models 28 8V 24V models 25 C 77 F and ends when the battery is completely full Battery voltage remains constant at 14 25V 12V models 28 5V 24V models 25 C 77 throughout this stage and the charge current depends on the degree to which the battery was initially discharged the battery type the ambient temperature and so on With a wet cell battery this stage lasts some four hours with gel and AGM around three Once the battery is 100 full the Mastervolt charger automatically switches over to the float phase During the float phase the Mass Combi switches to 13 25V 12V models or 26 5V 24V models 25 C 77 F and stabilises this voltage to maintain the batteries in an optimum condition Connected DC loads are powered directly by the charger If the load is higher than charger capacity the required additional power comes from the battery which will be progressively discharged until the charger automatically switches back to the bulk phase Once consumption decreases the charger goes back to normal operation of the three step charge system As the Mass Combi is equipped with a three step Plus charge system the batteries can also remain connected to the Mass Combi in winter One hour every 12 days the charger automatically switches to absorption t
40. e panel AP Cuisine A its 12 3 4 3 Masterlink MICC Panel isolated and 13 3 4 4 MasterBus Combi INterface oooonoconncccnncconocnnnnaconannnnnnnonoronnnn cn narco nnn crac 13 3 5 Alarmi Contacts idiota lira Pee ce Metered 13 4 OPERATION ici 14 4 1 IndiGators ici A a Se ta A ete 14 4 2 Switching On and Our als bis 14 4 2 1 SWITCHING ROTE 14 4 2 2 SWITCHING O f iii alt a Soa 15 4 2 3 Switching Eh Charger OY a cod cie 15 4 3 Proteccion A a as 15 4 3 1 Transfer switch overload protection nnen eee veeneneneenenensennneerennnerreneneevenneereenenenrenenn 15 4 3 2 Output overload or short circuit nnee nennerennenennerennerennerenenenverenerenverenenensenenerenvenenn 15 4 3 3 A arb retentie ban tkn ede dele adil Pals oh Gee ih elias 16 4 3 4 Under and over Voltage Sle estes bee Blended erect oe lederen 16 4 4 Inverter Charger Control panel 21 in cinta pr toi ban eze 16 2 May 2012 Mass Combi EN MASTERVOLT CONTENTS 10 4 5 AC Power Control panel Optional naven zenrnerennenre deerne weenie rvan drenten rt eee egret 17 4 6 Maintenance smarter ath aig Me ATA a 17 4 7 Problem SOWING iii a pia tej a Se ee a eet ee eee 17 INSTALLATION soie eeneserenerensnerensnorteerndanaanadherbmedandnanaddans denied tene dedononnvnddwagen A 18 5 1 Unpacking EAEE AE A lis idtd 18 5 2 ENVIO MON ttio mia os 18 5 3 WIG ENE 18 5 3 1 AG WINING 2 05 Resi needa Za ada aia 18 5 3 2 DEMIAN aL e AETAT 19 5 3 3 AG s tety grounding en c
41. e than 2500W 4000W Reduce the connected load by switching off some equipment 3 solid yellow DC voltage error The battery Check the batteries and the wiring 7 solid red voltage is too high or too low 4 solid yellow The inverter output voltage is less Reduce the connected load 7 solid red than 90V AC 5 solid yellow Overheating error The inverter is off Reduce the connected load and let the 7 solid red because of high temperature Mass Combi cool down 7 flashing red The inverter is permanently off until a manual reset by means of the main switch Disconnect all loads and restart the Mass Combi by switching the unit manually off and on with the main switch 6 flashing yellow 7 solid green The battery voltage is running too low but the inverter is still on Check the batteries The inverter will switch off if the battery voltage stays low 3 4 5 6 solid yellow 7 solid green 2 flashing yellow The battery voltage is running too high but the inverter is still on Check the DC input voltage The inverter will switch off if the battery voltage rises too high Table 4 Failure codes of the Mass Combi If you cannot solve a problem with the aid of this table contact your local Mastervolt Service Centre See www mastervolt com Make sure you have the following information present if you have to contact your local Mastervolt Service Center to solve a problem Ar
42. en when limited external AC power is available External AC power can be supplied by a public grid or a generator DC power can be delivered by charged batteries 3 1 THE BATTERY CHARGER The built in battery charger is electronically controlled It is designed for optimal recharging of both wet cell gel cell and AGM deep cycle batteries Battery charging is accomplished in three automatic stages BULK ABSORPTION and FLOAT With an external AC source connected the Mass Combi charger also serves the functions of an AC to DC converter to supply DC loads which are connected to the battery Simple automatic operation is made possible by the microprocessor that is the brain of the inverter charger combination In most cases the unit is left on and no attention or maintenance is required BATTERY VOLTAGE ABSORPTION gt am E CHARGE CURRENT TIME Figure 2 Three step charge system 3 1 1 Three step Plus charge system See figure 2 The first step of the three step Plus charge system is the BULK phase in which the output current of the charger is 100 and the greater part of the capacity of the battery is rapidly charged The current charges the batteries and gradually the voltage rises to the absorption voltage of 14 4V 12V models or 28 8V 24V models 25 77 F The duration of this phase depends on the ration of battery to charger capacity and naturally also on the degree to which the batteries wer
43. g the written permission of Mastervolt This is not applicable for DIP switches see chapter 6 which are used for making user settings May 2012 Mass Combi EN MASTERVOLT SAFETY GUIDELINES AND MEASURES 2 SAFETY GUIDELINES AND MEASURES 2 1 WARNINGS AND SYMBOLS Safety instructions and warnings are marked in this manual by the following pictograms A procedure circumstance etc which re A deserves extra attention 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 charger if the user does not carefully follow the procedures 2 2 USE FOR INTENDED PURPOSE 1 The Mass Combi is constructed as per the applicable safety technical guidelines 2 Use the Mass Combi only e for the charging of lead acid batteries and the supply of users attached to these batteries in permanent systems e for the conversion of a DC voltage from a battery to an AC voltage e connected to a dedicated double pole circuit breaker and earth leakage switch e with a fuse protecting the wiring between Mass Combi and battery e ina technical correct condition e in a closed well ventilated room protected against rain moist dust and condensation e observing the instructions in the users manual WARNING A Never use the Mass Combi in situations where there is danger of gas or dust explosion
44. h A SW4 SW5 High Power Energy saving disabled OFF OFF Idle 40VA When it detects a load that is gt 40VA it switches on the output power automatically ON OFF Idle 150VA When it detects a load that is gt 150VA it switches on the output power automatically OFF ON Economy 208V The output voltage will drop to 208V as long as the connected load stays below 250VA ON ON Note The power saving modes Idle 40VA or Idle 150VA can only be selected with a Mass Combi 12 2500 100 or a Mass Combi 24 2500 60 operating as stand alone unit These modes are not available with a Mass Combi 12 4000 100 Mass Combi 24 4000 120 or two Mass Combi s in parallel operation 6 1 4 Battery type The factory setting for the battery type is optimal for most installations In some applications however it is desirable to change this setting Adjust the Mass Combi to the applied batteries by adjusting DIP switches SW6 and SW7 Wrong adjustment can cause damage to your batteries which is not covered by the warranty The setting for traction battery should never be used with a battery bank that consists of 2V GEL cells If you want DIP switch A SW6 SW7 Standard battery factory setting OFF OFF Gel AGM spiral battery During the float stage of the charging cycle the output voltage will be higher ON OFF 0 55V O 12V 1 1V O 24V Traction battery Charging voltage will be increased during the bulk stage 0 7 V and the absorpti
45. he SHORT BREAK output is connected to the output of the inverter Table 6 Overview of the AC operationmodes see chapter 6 for adjustment of the DIP switches EN Mass Combi May 2012 11 HOW IT WORKS MASTERVOLT 3 4 PARALLEL OPERATION If 2500 kW of inverter power is not sufficient yet another identical Mass Combi can be connected in parallel to double both the inverter power and the charge power With two units in parallel the total inverter power conversion will be equally divided between the two units To achieve this one of the units must be configured by means of a DIP switch setting as master and the other as slave See figure 10 Once the configuration is established the master tells the slave apparatus what to do This communication is done by the use of a modular communication cable between the two units EF Sa Only two units of the Mass Combi 12 2500 100 Es or the Mass Combi 24 2500 60 can be connected in parallel Parallel operation of two units of the Mass Combi 12 4000 200 or the Mass Combi 24 4000 120 is not possible See section 5 8 2 for connection and settings AC OUTPUT SHORT BREAK AC INPUT AC OUTPUT POWER OUTPUT POWER OUTPUT OUTPUT POWER OUTPUT SHORT BREAK SHORT BREAK master Modular communication cable BATTERIES Figure 10 Parallel operation Mastervolt offers several possibilities for remote monitoring and co
46. ices such as the inverter battery charger generator batteries and many more This enables monitoring and configuration with a MasterView display or the MasterAdjust software 3 5 ALARM CONTACTS The Mass Combi is equipped with an integrated alarm function External equipment can be controlled by the potential free contacts of this alarm see 5 8 3 The maximum switch current of the relay is 1A By default the relay will be activated when the DC voltage is out of range after a delay of 30 seconds See table below Other functions can be programmed by means of MasterAdjust software see section Error Reference source not found easy to install is included as standard for protecting the Nominal voltage 12V 24V electronic components This panel is suitable for Under voltage ON 10 0V 20 0V MasterVision Mastervolt s modular switchboard system Under voltage OFF 11 0V 22 OV Over voltage ON 16 0V 32 0V Over voltage OFF 15 5V 31 0V Tabel 3 EN Mass Combi May 2012 13 OPERATION MASTERVOLT 4 OPERATION Power bar Charger mode Displays the actual DC charge current as a percentage of the maximum charge current Inverter mode Displays the actual AC output power as a percentage of the maximum output power Main switch AC Present Illuminates when the incoming AC power grid or generator voltage is available and according to specifications When flashing fast the incoming AC is outside specifi
47. input current By adjusting this Mass Combi Example lf the dipswitches of setting the AC input source can be protected against an the Mass Combi are adjusted to 25 Amps it is overload situation This setting is used to control the power only possible to scroll between 10 15 and 25 sharing function the generator mains support function Amps and the power support function See chapter 10 for Refer to the manual of the AC Control Panel or further ordering information information AC load gauge Indicates the actual AC load used relatively to the maximum AC Voltage available AC power indi he AC vol fth F Example Power sharing value is set at 10A At 120V the Aa MEAS llaga or the Active 100 indicator corresponds with 1200W 10Ax120V If you SOUC only use 600W 5A the AC load gauge indicates 50 If the external AC power is unavailable then the AC load gauge shows the inverter AC load AC input When an external AC source is available the AC input indicator illuminates When it blinks slowly the power support function or generator mains support function is activated Hd AC Power ew gt Control Failure LED 130V 40A When illuminated or e 120V 30A blinking a failure is E detected 110V 20A See section 8 1 100V 10A a AA Set key Easy programming of the maximum input current in three steps 1 Hold Set pressed until the power sharing indicator starts to blink current level lt should
48. ith the contents of this manual and that he she carefully follows the instructions contained herein Installation of and work on the Mass Combi may be carried out only by qualified authorised and trained personnel consistent with the locally applicable standards and taking into consideration the safety guidelines and measures chapter 2 of this manual Keep this manual at a secure place The English version has 44 pages 1 2 GUARANTEE SPECIFICATIONS Mastervolt guarantees that this unit 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 becomes invalid The guarantee is limited to the costs of repair and or replacement of the product Costs for installation labor or shipping of the defective parts are not covered by this guarantee 1 3 VALIDITY OF THIS MANUAL Copyright O 2012 Mastervolt All rights reserved Reproduction transfer distribution or storage of part or all of the contents in this document in any form without the prior written permission of Mastervolt is prohibited All of the specifications provisions and instructions contained in this manual apply solely to standard versions of the Mass Combi delivered by Mastervolt This manual
49. k delay time 30 seconds 30 seconds 30 seconds 30 seconds Battery temperature compensation 30mV per C 17mV per F 60mV per C 33mV per F Battery voltage sense automatic voltage compensation Protections Short circuit current is reduced to 25 of l max Battery types Acid Gel AGM Spiral Traction Bulk 14 40V 28 80V 14 40V 28 8V 14 60V 29 20V Charge voltage Absorption 14 25V 28 50V 14 25V 28 50V 14 45V 28 90V Charge voltage Float 13 25V 26 50V 13 80V 27 20V 13 25V 26 50V Forced to Float 13 25V 26 50V 13 80V 27 20V 13 25V 26 50V adjustable by means of MasterAdjust software traction max ABS BULK time 120min 9 3 MISCELLANEOUS Switch over system AC transfer fuse Yes by means of resetable fuse Reverse polarity protection None Overheat protection Yes derating above 80 C 176 F on Power Heat sink Type of Transfer Automatic Type of Switch 2 pole relay Continuous rating 35A 120V Transfer speed 25ms max 10ms typical Inverter synchronized to line before transfer Yes Transfer interruptible free Half seamless Power sharing mode Yes adjustable via DIP switches see 6 2 or via the remote APC see 4 5 Ground relay Ground relay included for connection of neutral of inverter to ground only at inverter mode Standard disabled See chapter to 6 1 5 to enable AC ca
50. m the battery DC cable to connect the negative DC connection of the Mass Combi to the negative pole of the DC distribution 1 2 for specifications see section 9 1 maximum recommended length 2m 6ft colour preferably black or at least a different colour to make a clear distinction between the positive and negative wire from the battery DC fuse holder with a DC fuse to be integrated in the positive DC cable For specifications see section 5 3 2 1 2 Screws bolts 1 4 with plugs to mount the cabinet to a surface Use mounting materials which are suitable to carry 4 8 the weight of the Mass Combi AC cable to connect the AC input of Combi A to an external power source e g a shore connection or a generator 1 1 set e AC cable to connect the external load to the AC Power output of Combi A AC cable to connect the external load to the AC SHORT BREAK output of Combi A e AC cable to connect the AC SHORT BREAK outputs of both Combi A and B to each other Maximum length 15m Batteries Refer to section 9 1 for specifications x px Appropriate and reliable cable terminals cable lugs battery terminals and cord end terminals Modular communication cable 8 pole maximum length 49ft for communication between the two Mass Combis See figure 20 Double insulated three wire cable with wire colours according to the locally applicable regulations The applic
51. mbi satisfies loading requirements 5 2 ENVIRONMENT Obey the following stipulations during installation e The Mass Combi is designed for indoor use only e Ambient temperature O 60 C 32 F 140 power derating above 25 C 104 F to decrease the internal heat sink temperature e Humidity 0 95 non condensing e Mount the Mass Combi on a solid surface with the connecting cables downwards e Make sure that the hot air produced during operation can be discharged The Mass Combi must be mounted in such a way that obstruction of the airflow through the ventilation openings will be prevented e No objects must be located within a distance of 10 cm 4 inch around the Mass Combi See also section 5 7 e Do not locate the Mass Combi in the same compartment as the batteries e Do not install the Mass Combi straight above the batteries because of possible corrosive sulphur fumes 53 WIRING The wiring is connected inside the connection compartment If necessary the wiring can be fed from the top to the bottom side of the cabinet along the back of the cabinet Always feed the wiring through the cable glands of the cabinet and then connect the wiring to the terminals Fix the phase line wire to terminal L the neutral wire to terminal N and the ground wire to terminal PE GND 5 3 1 AC wiring For a safe installation the correct wire cross section must be applied Don t use a cross section that is smaller than indicate
52. n of the failure is displayed by means of the LEDs at the front of the Mass Combi Figure 32 LEDs at the front of the Mass Combi 100 lor S 75 o E 50 25 4x6 eed 5 o Lisz On Main switch Off Ch e gt PS AC Present Inverter e Y Charger Inverter charger combination Mode Illuminating LEDs Explanation Possible cause What to do None The Mass Combi is switched off manually Switch on the Mass Combi by means of the On Off Ch switch Also check the on off switch of the ICC remote panel DC fuse is blown Investigate the cause of the failure and replace the fuse 9 solid green all other LED s off External AC is present but the Mass Combi is switched off by means of a remote panel Switch on the Mass Combi by means of the remote panel 7 solid green 8 flashing fast red 9 flashing fast green Thermal fuse is blown Reset the thermal fuse See 4 3 1 7 solid green 9 flashing fast green Insufficient quality of AC in Shore or Generator Check AC wiring Too thin and or too long cables Check the generator if applied or change setting for Power Quality at incoming AC see section 6 2 4 7 solid red 9 solid green AC in from Shore or Generator connected to the Short Break output Disconnect the AC in cable from the Short break output 7 solid green 9 solid green Power support
53. ng 10 May 2012 Mass Combi EN MASTERVOLT HOW IT WORKS 3 3 5 Power support function selectable As explained above when the Generator mains support function is enabled the inverter will operate in parallel with the external AC power source This means that energy from the batteries is added to the AC output only Under no circumstance AC power from the inverter can be fed back into the AC grid Please mind that several countries maintain different regulations with regard to AC sources operating in parallel with the AC grid This may mean that in some situations the use of the Generator mains support function is not allowed Please acquaint yourself with local regulations on this issue Never use the Generator mains support function if this is not allowed Even if the use of the Generator mains support function is not allowed it is still possible to supply more energy than the external AC sourced can deliver This can be achieved by using the Power support function AC OUTPUT POWER AC OUTPUT See figure 9 The AC input is still limited to 10 Amps This is not enough to supply the total load 7 17A 24A connected to the AC outputs Now when the Power support function is enabled the transfer relay will open When opened the external power source will deliver 7A to supply the load connected to the POWER output only while the inverter will deliver 17 Amps for the load connected to the
54. ntrol of the Mass Combi There are three remote panels available for the Mass Combi The Inverter Charger Control ICC panel and the AC Power Control APC panel are specially designed for the Mass Combi The Mass Inverter Charger Control MICC is a universal panel The remote panels are connected to the Mass Combi via a modular communication cable with two RJ 12 connectors The maximum length of communication cable should not exceed 15m 49ft See chapter 10 for ordering information The Mass Combi can also be connected to the MasterBus network via the optional MasterBus Combi Interface Note that it is not possible to connect all panels and the Combi Interface at the same time You should choose one of the following options e No remote monitoring at all e Remote panel ICC only e Remote panels APC and ICC e Masterlink MICC panel only e MasterBus Combi Interface only e MasterBus Combi Interface and Remote panel ICC 3 4 1 Remote panel ICC Inverter Charger Control f Aasrimucar Figure 11 Remote panel ICC The ICC panel provides the same functions as the user panel on the Mass Combi However with this remote panel you have the convenience to operate the Mass Combi remotely This ICC remote panel and remote cable 6m are included with the delivery of the Mass Combi 3 4 2 Remote panel APC AC Power Control o 5 5 E Mastervort Figure 12 Remote panel APC 12 May 2012 Mass Com
55. o keep the battery running properly and prolong its life span The three step Plus charge system is also safe for all the connected equipment See also section 9 4 for detailed characteristics of the three step Plus charge system EN Mass Combi May 2012 HOW IT WORKS MASTERVOLT 3 1 2 Temperature compensated charging The Mass Combi is delivered with a battery temperature sensor By installing this battery temperature sensor the charge voltages are automatically adapted for deviating temperatures 12V 24V o 2 Ss o gt d 5 ha i i 5 30 20 10 0 10 20 30 40 50 60 battery temperature C Figure 3 Temperature compensated charging See figure 3 When the battery temperature is low the charge voltage increases On the other hand when 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 batteries See section 5 8 to connect the battery temperature sensor 3 1 3 Connection of a second battery The Mass Combi is equipped with second charge output which can be used to give a maintenance charge to a small battery set like a starter battery Maximum output current 5 Amps Output voltage same as the main charger See section 5 8 for connection 3 2 THE INVERTER 3 2 1 General The inverter provides voltage and frequency regulated AC power fr
56. of the Mass Combi 37 EN Mass Combi May 2012 TECHNICAL DATA MASTERVOLT 9 TECHNICAL DATA 9 1 SPECIFICATIONS INVERTER Model Mass Combi 120VAC 12 2500 100 12 4000 200 24 2500 60 24 4000 100 Partnumber 120VAC 37012505 37014005 37022505 37024005 DC input Nominal battery voltage 12V 12V 24V 24V Operating input voltage range 10 0 15 0V 10 0 15 0V 19 0 31 0V 19 0 31 0V ADRES MAXIMUM ge ange 0 0 16 0V 0 0 16 0V 0 0 32 0 V 0 0 32 0 V No defects Low battery switch off 1 30 sec delay 10 0V 5 10 0V 5 19 0V 5 19 0V 5 Low battery switch on 11 0V 5 11 0V 5 22 0V 5 22 0V 5 High battery switch off No delay 15 0V 5 15 0V 5 31 0V 5 31 0V 5 High battery switch on 14 5V 5 14 5V 5 29 5V 5 29 5V 5 Max ripple allowed on DC No defects 5 RMS 5 RMS 5 RMS 5 RMS Nominal current at full load 200A 400A 100A 200A Maximum peak current 400A 800A 200A 400A Recommended Fuse 250A 500A 125A 250A Wire size up to 2m 6tt 2x 70mm 4x 70mm 2x 50mm 2x 70mm AWG2 0 AWG2 0 AWGO AWGO Recommended batteries 200 600Ah 400 1200Ah 100 300Ah 200 600Ah DC No load power consumption Off mode OmA OmA OmA OmA High power mode 120V 0A out lt 9W lt 18W lt OW lt 18W Economic mode 104V 0A out lt 8W lt 16W lt 8W lt 16W Idle mode 5 pulses per 2 sec lt 0 5W lt 1W lt 0 5W lt 1W AC
57. om a battery bank Fast acting electronic circuits protect the inverter against extreme overloads low and high battery voltage and overheating of the inverter Considerable momentary surge power is available for starting up electric motors High efficiency insures long battery usage between recharges A built in energy saving feature can reduce battery power consumption when the inverter is unloaded 3 2 2 Energy saving mode selectable In the inverter mode the Mass Combi has a built in automatic energy saving feature that reduces battery power consumption when no load is present on the SHORT BREAK output Response from idle is instant In most cases the operation is not noticeable Four modes can be set by means of DIP switches see chapter 6 The inverter of the Mass Combi can operate in one of the following modes table below Mode Explanation High power This is the default setting The energy saving mode is switched off The inverter is fully operating and the output voltage is 120V AC Idle 40VA Only available with Mass Combi 12 2500 100 or 24 2500 60 operating as stand alone unit The inverter reduces below the 40VA or 150VA connected load the output voltage almost to zero The Mass Combi scans the SHORT BREAK outlet with pulses of 120V every 2 seconds When it detects a load that a is larger than 40VA or 150VA it switches on the inverter automatically Small loads such as clocks in VCR
58. ombi Tighten all cable glands to ensure the pull relief Check all wiring and connections Close the front cover plate of the connection compartment of the Mass Combi Beware that the wiring does not obstruct the cooling fans and air flow Place the DC fuse s of the DC distribution to connect the batteries to the Mass Combi WARNING When placing this fuse a spark can occur caused by the capacitors used in the Mass Combi This is particularly dangerous in places with insufficient ventilation due to the gassing of the batteries an explosion can occur and avoid having flammable materials close by Now the Mass Combi is ready for operation 7 2 DECOMMISSIONING If it is necessary to put the Mass Combi out of operation follow the instructions in order of succession as described below 1 Move the Main switch of the Mass Combi to the Off position see figure 15 2 Remove the DC fuse s of the DC distribution and or disconnect the batteries 3 Remove the AC fuse s of the AC input and or disconnect the AC mains 4 Open the connection compartment of the Mass Combi see section 5 5 5 Check with a suitable voltage meter whether the inputs and the outputs of the Mass Combi are voltage free 6 Disconnect all the wiring Now the Mass Combi can be demounted in a safe way 34 May 2012 Mass Combi EN MASTERVOLT TROUBLE SHOOTING 8 TROUBLE SHOOTING 8 1 FAULT INDICATORS If a failure occurs the origi
59. on OFF ON stage 0 4V Forced float When activated the three stage charging program is changed to a single stage program ON ON Fixed output voltage 13 8V 12V or 27 6V 24V 6 1 5 Ground relay The ground relay function allows you to connect the Neutral conductor N of the inverter output circuit to the Safety Ground PE GND automatically when the Mass Combi is working as an inverter With most electrical installations in the USA this ground relay must be set to ON Refer to local regulations on this issue If you want DIP switch A SW8 no internal connection between the Neutral N and the Safety Ground PE GND when the Mass Combi OFF is working as an inverter the Neutral wire N of the inverter output circuit connected to the Safety Ground PE GND when the ON Mass Combi is working as an inverter and disconnected when incoming AC power is applied charger transfer mode EN Mass Combi May 2012 31 SETTINGS MASTERVOLT 6 2 DIP SWITCH B 6 2 1 Power sharing function See section 3 3 3 for more information 120V Models DIP switch B If you want SW1 SW2 SW3 To limit the AC input current to 50 Amps ON To limit the AC input current to 30 Amps OFF OFF OFF To limit the AC input current to 25 Amps ON OFF OFF To limit the AC input current to 15 Amps OFF ON OFF To limit the AC input current to10 Amps ON ON OFF 6 2 2 Power Support Function See section 3 3
60. ote panel or the Masterlink MICC panel This is independent from the setting of DIP switch number 7 If you want to charge your batteries only and you do not want to start the inverter function when incoming AC fails then the main switch of the Mass Combi must be set to the Ch position Charger only see 4 2 3 In this state it is not possible to switch the Mass Combi remotely on or off This is independent from the setting of DIP switch number 7 If you want DIP switch B SW7 To switch the Mass Combi inverter and charger function remotely on or off The main switch at the front of OFF the Mass Combi has to be set to the ON position To switch the inverter function of the Mass Combi remotely on or off when AC in fails With this setting the ON charger is always active when the AC in is available The main switch at the front of the Mass Combi has to be set to the ON position NOTE The Mass Combi is not entirely off when the Mass Combi is switched off by means of the ICC remote panel or the Masterlink MICC The no load drain is less then 5mA and is used to keep the data buses connected to the remote panels active 6 2 6 Equalize mode WARNING Incorrect use of the equalize mode may lead to hazardous situations WARNING Equalization is ONLY applicable for wet type batteries and will damage gel and AGM type batteries WARNING Do not smoke use any naked flame or other sources of ignition due to risk of explosion Alw
61. output must be connected to the earth PE GND when the Mass Combi is in inverter operation When utility power is available on the AC input and the Mass Combi is in charger mode this connection must be disabled again In some applications automatic connection between the neutral conductor N and earth PE GND is not required or acceptable Therefore the automatic connection between the neutral conductor N and earth PE GND is disabled by default To enable this automatic connection see section 6 1 5 EN Mass Combi May 2012 19 INSTALLATION MAST E RVO LT 5 4 THINGS YOU NEED Make sure you have all the parts you need to install the Mass Combi Quantity needed for parallel operation of two Mass Combi s Quantity needed for stand alone operation of one Mass Combi Mass Combi included 1 2 Inverter Charger Control ICC panel with a grey mounting case included 1 Modular communication cable 6 pole included 19ft maximum length 49ft to connect the inverter charger control 1 2 panel ICC panel to the Mass Combi see figure 19 Battery temperature sensor with cable and plug included 1 2 DC cable to connect the positive DC connection of the Mass Combi to the plus pole of the DC distribution for 1 2 specifications see section 9 1 maximum recommended length 2m 6ft colour preferably red or at least a different colour to make a clear distinction between the positive and negative wire fro
62. shuts down if this overload or failure lasts longer than 5 seconds The Mass Combi will automatically restart after shutdown After 5 failed start attempts the Mass Combi shuts down permanently the 100 LED is lit and the Inverter LED see figure 15 will flash You can restart the Mass Combi EN Mass Combi May 2012 15 OPERATION MASTERVOLT only by switching the unit manually off and on with the main switch on the Mass Combi after the overload is removed or failure is solved 4 3 3 Overheating In the event of overheating the Mass Combi shuts down see chapter 8 1 for illumination of indicator lights The Mass Combi is automatically powered up again when the temperature drops below the factory default threshold Overheating is most likely caused by e heavy or non resistive loads operating for a longer time e high ambient temperature e disrupted air flow dust or too less space DC load Charge cycle Charger mode Displays the DC charge current as a percentage of the maximum current Inverter mode Displays the AC power as a percentage of the maximum power section 3 1 1 voltage Charger LED Green the Mass Combi is operating in charger mode Red an error is detected Figure 17 Operation of the ICC remote panel Charger mode Displays the state of charge bulk absorption or float see 4 3 4 Under and over voltage The AC input of the Mass Combi is within limits protected against over and under
63. sing polarity will lead to serious damage to batteries Mass Combi and the wiring Fuses between the batteries and the Mass Combi can not prevent damage caused by reversed polarity and the warranty will be void e Protect the DC wiring with a fuse according to the guidelines in this manual e Connection and protection must be done in accordance with local standards e Do not work on the Mass Combi or system if it is still connected to a power source Only allow changes in your electrical system to be carried out by qualified electricians e Check the wiring and connections at least once a year Defects such as loose connections burned cables etc must be corrected immediately EN Mass Combi May 2012 SAFETY GUIDELINES AND MEASURES MASTERVOLT Do not touch the equipment when wet or if your hands are clammy Not only the batteries but the Mass Combi 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 see section 5 5 the cabinet of the Mass Combi 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 The Mass Combi products are not sold for applications in any medical equipment in
64. soee 6 3 HOW IT WORKS 300 acnet ence ance tacee ats cSeatesdeccwadencanenestteshecBesSuesscduscnscpeacuestingentecgucteannidseaedceuetvacnitauetacteetunerinie 7 3 1 The battery Chargers iniciado ariadna asada data leden hete A a aa aea a aa a Sa 7 3 1 1 Three step Plus charge system cccesecceceseeceeeeeeeeeeeseneeeeeseeeeecseesenesneeesesceeescaeeseeeseneeeseseeeeecnenaees 7 3 1 2 Temperature compensated Charging ccessscecesseceeesseeneeeeseeeeeeseeeeeenneeeeesceeeseeeeseeenenseeenseeeeetseeeens 8 3 1 3 Connection of a second battery anneer venen ccoo nora nnnn arc nnn nana nena n nana r cana n nana n rana nana nens 8 3 2 The Invenia o ree a ia 8 3 2 1 General visa ce AA ee eee A A 8 3 2 2 Energy saving mode Selectable trinon krein taaa ayi a i aiae a a 8 3 3 Op ration Mode Saiit A a A i te ed ae teed ee 9 3 3 1 Basic operallON isis pis 9 3 3 2 The transters Willis olaa 9 3 3 3 Power sharing function selectable ennn venenenrennneerrennvervenenervennneervenneervenenenvenenn 9 3 3 4 Generator mains support function Selectable nnen eenneenneneenneeeneerennereneerenneneneenenn 10 3 3 5 Power support function Selectable nennen neereeneneereneneerennneerennenereennvervennneereenn 11 3 3 6 Summary of the AC operation modes nnen ennen eeeneeenneereneeenneneenneenneereneereneenenneneneeeenn 11 3 4 Parallel operativo 12 3 4 1 Remote panel ICG cts La ld ets lan dt fa 12 3 4 2 Remot
65. tended for use as a component of any life support system unless a specific written agreement pertaining to such intended use is executed between the manufacturer and Mastervolt Such agreement will require the equipment manufacturer either to contract additional reliability testing of the Mass Combi parts and or to commit to undertake such testing as a part of the manufacturing process In addition the manufacturer must agree to indemnify and not hold Mastervolt responsible for any claims arising from the use of the Mass Combi parts in the life support equipment 2 7 WARNING REGARDING THE USE OF BATTERIES 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 Avoid short circuiting batteries as this may result in explosion and fire hazard Installation of the batteries and adjustments of the Mass Combi should only be undertaken by authorised personnel May 2012 Mass Combi EN MASTERVOLT HOW IT WORKS 3 HOW IT WORKS This chapter describes the various applications of the Mass Combi series from Mastervolt The Mastervolt Mass Combi is a battery charger a powerful sine wave inverter and an AC transfer system in one compact enclosure The three step Plus charging method guarantees that the batteries are always charged 100 The pure sine wave inverter assures that the AC output voltage is perfectly reliable ev
66. ticle and serial number Software version See section 1 6 See section 8 2 36 May 2012 Mass Combi EN MASTERVOLT TROUBLE SHOOTING 8 2 SOFTWARE VERSION The version of the installed software can be derived from the illuminating LED s on the front panel during start up The LED s at the left hand side represent the software version of the electronics at the AC side while the LED s at the right hand side represent the software version of the DC side of the combi Proceed as follows e Set the main switch of the Mass Combi to the On position e All indicators are illuminated for a second Then the LED s are showing the version number of the software by flashing Flashing one time stands for 1 flashing two times stands for 2 and so on See example below Here the software version of the of the electronics at the AC side is 2 05 the software version of the DC side is 1 32 e After showing the installed software versions the Mass Combi will switch on Software version of the electronics at Software version of the electronics at the DC side the AC side Flashes 0 times Flashes 0 times Flashes 2 times e Flashes 1 times Flashes 0 times Flashes 3 times E Flashes 2 times a Flashes 5 times 5 Software version Software version 01 3 2 Inverter O Dot AC Present Charger Dot Inverter charger combination Figure 33 Representation of the software versions
67. ualize modB vrare tenet A E edele ede ed die LA ee eh eit ies 33 START UP AFTER INSTALLATION 225 3 200cecsleceneestececeedeecsserseocensethetenenjunvenseresaneselerseaeenddcesacentibecesndcchaevesucsenesdeoeegusts 34 7 1 COMMMISSIONING reset ins deren nenten barberi es esacegecaddesetedsns dacaddadassagt sh aacadieseted TAAT 34 7 2 DeCOMMISSIONING iia A e Spee Beeldende Spee ea 34 TROUBLE SHOOTING 2 5 c cc20feacceteccescanesnenesncecunctesdecteedescnassnunnedsceentecguaceqnsidacaedcauersuen tasetsdeeerunes sdacedaeuseueerceeaneceeaneesaed 35 8 1 Fault indicators EA E AA ATEA TTA E TETT 35 8 2 Software VeriMed rada 37 TECHNICAL DATA al inci 38 9 1 Specifications AVe ET 52 3 aha seach cadet cadet sha eta aderen denn iach a AEE E eT aa a aaa Ea E SA AA ARE SETEN aS EREA 38 9 2 Specifications charge ssis be aos ete ela 39 9 3 Miscellaneous zeio ds ii a e a aS 40 9 4 Characteristics isei A lee ee en eee 41 ORDERING INFORMATION ooo tai item 43 EC DECLARATION OF CONFORMITY nnen one nenenennerensenennnvensenennnrensneennneennneennneernneennnenrennennnenenneennnenenneernn 44 EN Mass Combi May 2012 3 GENERAL INFORMATION MASTERVOLT 1 GENERAL 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 Mass Combi It is therefore obligatory that every person who works on or with the Mass Combi is completely familiar w
68. witches prior to EN Mass Combi May 2012 29 SETTINGS MASTERVOLT 6 SETTINGS The Mass Combi is provided with two groups of DIP switches to adjust the apparatus according to the specifications of the electrical installation The DIP switches are located in the connection compartment See figure 31 DIP switch A DIP switch B ON OFF Figure 31 DIP switches 6 1 DIP SWITCH A 6 1 1 Parallel mode If you want DIP switch A SW1 SW2 to configure the Combi as Master Combi A then OFF OFF to configure the Combi as Slave Combi B then ON ON to configure the Combi as Slave Combi B having its own charge characteristics then OFF ON only when both Combi A and Combi B have their own battery set NOTES e f the Combi is configured as Slave then the settings of SW3 to SW8 of DIP switch A and SW1 to SW7 of DIP switch B are denied e f the charge characteristics of the Combi that is configured as Slave Combi B are set to follow the Master DIP Switch A SW1 ON then its settings SW6 to SW7 of DIP switch A are denied 6 1 2 Output frequency inverter 120V Models DIP switch A If you want SW3 to set the output frequency to 60 Hz OFF to set the output frequency to 50Hz ON 30 May 2012 Mass Combi EN MASTERVOLT SETTINGS 6 1 3 Energy saving mode See section 3 2 2 for more information If you want DIP switc

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