MasterVolt Masterlink MICC Charger Control Manual
Contents
1. gt PRESS SET UP November 2004 Masterlink MICC EN 25 MASTERVOLT TAILOR MADE ENERGY 10 ADVANCED SETTINGS After pressing and holding the Select and Set up buttons simultaneously for 5 seconds several adjustments can be made to set the Masterlink MICC according the users requirements However under normal circumstances these adjustments should not be changed Refer to figure 9 for more the set up drawing of these advanced settings The numbers below between brackets correspond with this drawing CAREFUL Adjustments in the Advanced settings menu can result in deviation in the functioning of the MICC when incorporated incorrectly For more information see also the set up drawing 10 1 Testing alarm function At this level the low battery function can be tested without draining the battery This menu can be entered by pressing and holding the Select and Set up buttons simultaneously for 5 seconds until the Set up LED and the Select LED flash Testing alarm function M06 TEST LOW BAT OFF Volt Amp Press the Volt Amp button to enter the menu With the Set up button you can toggle the alarm function between ON and OFF independently of the state of charge to test the alarm functions Return to users menu M07 EXIT LEVEL gt PRESS SET UP By pressing the Select button you can scroll to the EXIT LEVEL If this level is entered you can return to the user menu by means of the2. Distortion on the shunt wiring Replace wiring by twisted pair cable between the shunt and pin 3 and 4 chapter 3 3 step 4 Rerun the wires and keep them away from equipment that might cause noise Time remaining function indicating during discharge Shunt wiring reversed Check installation drawing and correct the wiring Pay extra attention to the distinction between battery side and system side chapter 3 3 Back light switches off after 15 seconds Unit in sleep mode Press one of the buttons or refer to chapter 9 step F01 to disable the sleep mode No accurate time remaining function Wrong setting of the installed Ah Refer to chapter 8 step A01 for the correct setting of the battery capacity Voltage low Ah alarm not functioning correctly Wrong setting of the parameters Refer to chapter 7 for the correct setting of the parameters Voltage low Ah alarm not functioning correctly Testing alarm function is switched on Switch off the Testing alarm function chapter 10 1 step M06 External voltage low Ah alarm not functioning correctly Wrong connection of relay contact Connect the external relay to the correct pins chapter 3 4 Voltage low Ah alarm not functioning Alarm setting in the off position Switch on the alarm function chapter 10 1 step F02 Voltage reading shows 0 00 Battery voltage below 7 volt Charge the battery Power sh
3. respectively system side of the shunt Install a fuse holder in the plus line The maximum length of this cable must not exceed 25 meters 80 ft 6 Run a normal cable 2x0 25 mm from pin 5 and 6 service battery voltage sense of the Masterlink MICC to the plus pole of the main battery respectively system side of the shunt Install a fuse holder in the plus line The maximum length of this cable must not exceed 25 meters 80 ft 7 Run a normal cable 2x0 25 mm from pin 7 and 8 start battery voltage sense of the Masterlink MICC to the plus respectively the minus pole of the secondary battery Install a fuse holder in the plus line The maximum length of this cable must not exceed 25 meters 80 ft 57 Please note that the 2 fuses should only be installed after the installation is completed Note for the above mentioned cables wires also a 8 wire cable 8x 0 25 mm with twisted pair wires can be used see also chapter 3 2 November 2004 Masterlink MICC EN MASTERVOLT TAILOR MADE ENERGY 8 Run a 6 pole modular communication cable RJ12 cross wired and connect the RJ12 connector to the socket on the right hand side see figure 2 connector I at the backside of the Masterlink MICC To connect the other RJ12 connector to the apparatus Refer to the chargers installation manual to connect the RJ12 connecter Mass Combi You must connect the RJ12 connecter to the QRS 232 in
4. 2 of the installed battery capacity If all the above parameters are met for a few minutes the reading of the Ah s consumed will be reset to 100 Time remaining function 702 Ah Time If you press the Ah Time button again the display shows how long the battery can be used before it will be empty and needs to be recharged The remaining time is automatically compensated with the Peukert exponent if the battery is discharged above the 20h rating see chapter 11 for more information about the Peukert exponent Ah consumed T03 e CAP CONSUMED If Ah Time button is pressed again information is shown on how many amp hours are consumed from the battery During charging this value shows how many Ah s are still necessary to bring the battery up to a 100 96 state of charge 0 Ah consumed This value is compensated by the Charge Efficiency Factor C E F TIME REMAIN 25 HR 14 MN November 2004 Masterlink MICC EN 17 MASTERVOLT TAILOR MADE ENERGY 6 HISTORICAL DATA To know the history of your battery can be very useful It will help you to check if the battery is has the right capacity for the application and how long the battery can be used before it need to be replaced This can be done by reading the number of cycles the battery has used and the efficiency C E F of the battery The memory back up system of the MICC makes this data available even if the power supply of the meter r
5. as well A WARNING Above operation is not applicable for the chargers IVO Smart 12 25 12 35 12 40 12 50 and 24 15 IVO Compact 12 25 and 24 10 and MASS 12 30 24 15 and 24 25 When the charger is switched off by means of the Masterlink MICC the Charger LED is not illuminated the maximum output current is reduced to 10 To switch off the battery charger completely the ON OFF switch of the battery charger must be set to the OFF position The meaning of the illuminating LEDs is explained beneath Refer to the charger s users manual for additional information about the e Charger hoger Ah Time Figure 6 Operation of the Masterlink MICC 14 November 2004 Masterlink MICC EN MASTERVOLT TAILOR MADE ENERGY three stage charge characteristic The LEDs A B C and D represent the following information see figure 6 for the references indicated between brackets Bulk A Main charge Batteries are charged with full charger output current at a voltage between 12V resp 24V and 14 4V resp 28 8V Absorption B absorption charge The batteries are almost approx 85 charged Charging continues with decreasing current until the batteries are full Float C trickle charge The batteries accept only a small current Voltage is lowered to 13 2V resp 26 4V to keep the battery fully charged without formation of gases AC present D The AC present LED illuminates
6. if the charger is in operation 230V supply Besides the inverter there is an external 230V AC source available 5 3 Adjustment of the maximum charge current When the available current from the AC source is limited for instance to avoid the shore fuse from tripping the output current of the charger can be reduced and accordingly the AC power consumption of the battery charger Press the Select button for 5 seconds until the green Select indication LED flashes Press the Charger button Charger shortly to display CURRENT CONT CURRENT CONT 100 Adjust the desired output current 10 100 by pressing the Set up button If the Select button is held for five seconds the arrow s direction in the right part of the display will change If the arrow is pointing downwards WV the set value can be changed into lower values by means of the Set up button If the arrow is pointing upwards 1 the set value can be changed into higher values After adjusting the output current to the desired value press the Select button shortly until EXIT LEVEL is displayed EXIT LEVEL gt PRESS SET UP Now it is possible to return to the user menu by means of the Set up button Also if none of the buttons was used for 15 seconds the Masterlink MICC returns to the users menu 5 4 Adjustment of the Power sharing Power support level Mass Combi only When the available current from t
7. it has cooled down sufficiently Make sure that the charger is ventilated properly E5 Charger switched off because of a battery sense error The battery voltage sense wires are connected wrong or the charger has reached the maximum compensation value The charger compensates the voltage loss with a maximum of 2 5V E6 Inverter error The inverter is in overload reduce load Inverter temperature is too high inverter will automatically switch off and on if temperature has dropped sufficiently Make sure that the inverter is ventilated DC supply voltage to high switch off charger The following error code is displayed when the Masterlink MICC detects a communication problem with the battery charger Code Description Action NO COMM Communication error with the battery Switch on the battery charger or adjust the charger The battery charger is switched charger s DIP switch correctly refer to the off or the AC input is disconnected charger s operation manual ContMon REMARK When the ContMon function is enabled while the battery charger is switched off energy is withdrawn from the battery connected to the battery charger NO COMM Communication error with the battery Check the wiring of the 6 pole modular charger The battery charger is communication cable Chapter 3 2 and 3 3 step disconnected from the Masterlink MICC 9 or connected by a wrong modular communication cable RJ12 cross wired 3
8. off The alarm status will still be shown in the display but the external alarm contact of the MICC will not be activated check chapter section for more information about alarm settings If this mode is entered the alarm function can be switched on or off by means of the Set up button The factory default for this level is off Adjustment of the charger inverter LED indication F03 LED IS SWITCH With the third and last level it is possible to change the function of the LED indication of the charger and inverter buttons Factory settings for this function is OFF which means that the charger LED and the inverter LED will only illuminate when the battery charger respectively the inverter are actually switched on and that they are operating without failures With the Set up button you can switch this function to ON When switched ON the indication LED will illuminate as soon as the Battery charger or the inverter is switched on by means of the Charger button respectively the Inverter button Then the LED will illuminate immediately whether the charger is operating without failures or not Activate Mass Combi setting F04 You only have to activate ON this setting if you are using the Masterlink MICC in combination with the Mass Combi The default setting is HFC MODE Return to users menu F05 If this level is entered you can return to the user menu by means of the Set up button EXIT LEVEL
9. 2 November 2004 Masterlink MICC EN ADDITIONAL INFORMATION MASTERVOLT TAILOR MADE ENERGY 14 TECHNICAL DATA Model Article number Function of instrument Manufacturer Voltage Measurement Amperage Measurement Amp Hours Measurement Time remaining Supply voltage Supply current Shunt Accuracy Dimensions Hole cut out size Weight Dept required Masterlink MICC 70403105 Battery monitor for 12 and 24 volt battery banks Remote control for a Mastervolt inverter and battery charger or Mass Combi Mastervolt Amsterdam the Netherlands 7 35 volts 0 01 volt resolution 0 500 Amp 0 2A resolution 0 42A 2A resolution 42 500A 0 2000 Ah 1 Ah resolution 0 255 hours 1 min resolution 9 35 Volt DC 100mA 12V 50mA 24V Normal operation 28mA 12V 16mA 24V Sleep mode 500 Amp 50 mV supplied with the product Voltage 0 6 1 digit Current 0 8 of reading 1 digit See chapter 15 See chapter 15 250 gr 65 mm minimum November 2004 Masterlink MICC EN 33 MASTERVOLT ADDITIONAL INFORMATION TAILOR MADE ENERGY 15 DIMENSIONS Panel Minimum required dimensions for installing panel only width x height x depth 120 x 65 x 40mm 279 108 B St IND 31 32 119 50 Grey mounting box Dimensions grey mounting box width x height x depth 140 x 85 x 50mm Dimensions for cut out width x height 120 x 68mm use the packing as mounting temp
10. 3 Set level full charge Return amps f DEPT 3 80 of C ahr 6 of C ahr par rud 70 90 1 10 A04 F04 Set min require run time DEPT 4 oain ra Float level HFC mode 5 min 90 min 13 1V 26 2V On Off AUS F05 Reset Ahr to 0000 DEPT 5 M05 Press setup Exit level Exit level A06 DEPT 6 Battery type 12 24V A07 DEPT 7 Exit level Figure 8 Set up drawing installer level Program level advanced settings Hold select amp setup 2 to 4 sec untill both leds flashes SELECT amp SETUP Inverter Volt amp Ahr time Charger Set up M06 A08 F06 No function Change Peukert No function Reset to factory setting DEPT 1 level 2 me mode exponent 1 27 level 2 Press setup 1 01 to 1 50 09 M07 F07 Change C E F Manual A DEPT 2 Exit level actual read Out Reset all historical data 0 7 0 99 up F08 A10 DEPT 3 Exit level Exit level DEPT 4 DEPT 5 DEPT 6 Figure 9 Set up drawing advanced settings 20 November 2004 Masterlink MICC EN MASTERVOLT TAILOR MADE ENERGY 7 LOW BATTERY ALARM MENU The Masterlink MICC checks the state of charge of the battery continuously and gives an alarm when the battery is reaching a low voltage set point or a low discharge floor The Masterlink MICC is provided with a relay to control an external alarm check also chapter 3 4 for more information To enter the Alarm menu hold the Select button for 5 seconds until the Select LED flash
11. ISATION AND SETTING THE BATTERY CAPACITY Ux See also chapter 8 4 1 Synchronisation Although the meter is for many items self learning it is necessary for a quick start up to set the meter according to the voltage and capacity of the installed batteries To synchronise the meter with the installed batteries charge the batteries after the installation of the Masterlink MICC for at least 24 hours with an appropriate charger to be sure the batteries are 10096 charged After this time the FLOAT LED will be lit indicating the battery is fully charged The Masterlink MICC can now be synchronised with the installed battery 4 2 Setting the battery capacity The factory default for the battery capacity is set at 200 Ah For high accuracy of the time remaining function and the percentage charged indication the meter must be set according to the battery capacity installed The following steps will make sure that the right battery capacity is set and the readings are as accurate as possible lr Note the capacity of the battery can only be set if the batteries are 100 96 charged The time remaining function and the Ah consumed will be reset if the battery capacity settings are changed Press the Select button for 5 seconds until the green Select indication LED flashes e Press the Ah Time button Ah Time shortly to display the battery capacity BATTERY CAP 200 Ah Set up Adjust the requi
12. MASTERVOLT TAILOR MADE ENERGY USERS MANUAL MASTERLINK MICC MASS INVERTER CHARGER CONTROL r ASTERVOLT MASS Irverte Wor Amp Aber glenn MASTERVOLT Snijdersbergweg 93 1105 AN Amsterdam The Netherlands Tel 31 20 3422100 Fax 31 20 6971006 Language English www mastervolt com Version V4 0 301104 MASTERVOLT TAILOR MADE ENERGY November 2004 Masterlink MICC EN MASTERVOLT TAILOR MADE ENERGY CONTENTS V4 0 November 2004 1 GENERAL INFORMATION 5 1 1 Wse of this Manual venne between tee S A 5 1 2 Guarantee Specifications inre 5 1 32 Qualily aie edi ea ral RR tee ees 5 1 4 Validity of this 5 1 5 ees celle eee a 5 2 SAFETY GUIDELINES amp 6 2 4 Warnings and symbols 5 cientes eee ee eR aces dinar den ase ee dd Re nen UR eR Ve dado 6 2 2 iUse forintended purpose tie RR eee p IE eee ien 6 2 3 Organisational measures nnn unnenerenenennen sensoren eenneereneeenneernensvennensenneeenerenneeeeneenneeenen 6 2 4 Warming for speclial dangers as zeerover sense hed cuca day Rt dee ne Doe kan dede baud ae eap Rer dateen 6 Soi INSTALLATION ERE 7 31 Tools and equipment re
13. NFORMATION Congratulations You are one step ahead to install the most advanced battery monitor the Masterlink MICC from Mastervolt This instrument will tell you at a glance e Exact state of charge of your battery e System voltage and system charge or discharge current e Amp hours consumed from the battery e Time of operation remaining until your battery is empty e Remote operation of your inverter your battery charger or Mass Combi 1 1 Use of this manual This manual serves as a guideline for the safe and effective operation installation maintenance and possible correction of minor malfunctions of the Masterlink MICC It is therefore obligatory that every person who works with the Masterlink MICC must be completely familiar with the contents of this manual and that he she carefully follows the instructions contained herein The manual must be immediately accessible to the user This manual has 16 chapters 1 2 Guarantee Specifications Mastervolt guarantees that this unit has been built in accordance with the legally applicable standards and specifications Should work take place which is not in accordance with the guidelines instructions and specifications contained in the user manual damage may occur and or the unit may not fulfil its specifications All of these matters may mean that the guarantee may become invalid 1 3 Quality During the production and prior to their delivery all our un
14. Set up button 10 2 Exponent adjustment With this menu the Peukert exponent and the C E F Charge Efficiency Factor can be in accordance with the type of battery installed refer to chapter 11 for additional information It is advisable to only change these setting if extended knowledge of the installed battery is available This menu can be entered by and holding the Select and Set up buttons simultaneously for 5 seconds until the Set up and Select LEDs flash Setting the Peukert exponent A08 e CHANGE PEUKERT Press the Ah Time button to enter the menu With the Set up button the value can be changed from 1 01 to 1 50 The factory default setting is 1 27 Note If the Select button is held for five seconds the arrow in the right part of the display will change If the arrow is pointing downwards Y the set value can be decreased by means of the Set up button If the arrow is pointing upwards the set value can be increased Setting the Charge efficiency factor A09 In the second the C E F Charge Efficiency Factor can be changed The C E F is 26 November 2004 Masterlink MICC EN MASTERVOLT TAILOR MADE ENERGY recalculated automatically by the Masterlink MICC every time the battery makes a cycle The calculated value is checked with the C E F as stored in the memory of the Masterlink MICC If the calculated value is differs from the stored value only 50 of the difference is
15. TAILOR MADE ENERGY Press and hold the Select button for 5 seconds until the green Select indication LED flashes Press the Select button five times shortly until BATTERY BANK is displayed BATTERY BANK 24V Set the required voltage of the main batteries using the Set up button The Masterlink MICC will now be synchronised and set in accordance with the installed batteries 4 4 Activate Mass Combi setting You only have to activate ON this setting if you are using the Masterlink MICC in combination with the Mass Combi The default setting is OFF This menu can be entered by holding the Select button for 5 seconds until the Select LED is flashing Now press the Set up button shortly to enter the program menu Press the Select button 4 times shortly until the HFC MODE is displayed HFC MODE OFF Select the required setting using the Set up button EXIT LEVEL gt PRESS SET UP If this level is entered you can return to the user menu by means of the Set up button 4 5 case you are lost If it is necessary to reset to factory defaults go to the PROGRAM LEVEL by holding the Select button and Set up button simultaneously until both the Select LED and the Set up LED are flashing Next press the Set up button shortly until RESET FACTORY is displayed RESET HISTORY PRESS SET 5sec After holding the Set up button for 5 seconds the unit will be r
16. arged battery The more a battery is charged the less current it requires If this current drops below 2 of the installed battery capacity C 20 rating the battery can be considered as fully charged provided the charged voltage is met as well If the battery becomes a lot older beyond its normal lifetime it might start to consume more current when the battery is fully charged so the meter can not be reset to zero and efficiency can not be calculated correctly This means that this set point needs to be changed to a higher value if old batteries are used which are beyond their economical life but can not yet be replaced The charged amps can be changed between 1 and 10 of the installed capacity and the factory default is 2 Setting the charged voltage A04 FLOAT LEVEL In order to check if the battery is fully charged several parameters must be met before the MICC will consider the battery fully charged One of the parameters is the minimum voltage that must be reached This voltage must be set according to the lowest voltage of all the charging devices in the system This means for example if the voltage of the battery charger is 14 25 volt and the alternator is 14 volt the voltage must be set just below the lowest voltage i e below 14 volt The above mentioned voltages are measured at the output terminals of the charging system and therefore it is necessary for these voltages to be set approx 0 4 volt lower
17. aring Power support can not be adjusted Mass Combi setting not activated Check and if necessary activate the Mass Combi setting in the Masterlink MICC menu see chapter 9 step F04 Check and if necessary activate the Power sharing Power support function on the Mass Combi See also the manual of the Mass Combi November 2004 Masterlink MICC EN 31 MASTERVOLT ADDITIONAL INFORMATION TAILOR MADE ENERGY 13 2 Error codes The following error codes are displayed when the Masterlink MICC detects a problem The display alternates between the selected monitoring function and the error code The error code continues to flash until the error is corrected Code Description Action E1 Battery Temperature error the batteries are too warm to be charged safely The charger will stop charging until the battery temperature is within the safe margin Make sure that the batteries are ventilated properly E2 DC error automatic charger shut down due to too low or too high DC Voltage DC system voltage has dropped below 10 5V 12V system 21 0V 24V system or has risen above 15 5V 12V system 31 0V 24Vsystem E3 Short circuit of the charger output Possible short circuit on the output The charge current will be reduced to a quarter of the maximum value E4 Charger is too hot automatic charger shutdown due to too high temperature The charger switches automatically on after
18. asic installation such as you would find on an average boat RV or in a solar application First gather all the tools you need for the installation of the Masterlink MICC We recommend as a minimum tool kit e saw to make the panel cut out e A 10 mm drill to make holes for feeding through the wiring between the panel the shunt and the batteries e A 14 mm spanner for shunt connections e Wire stripper and crimper 2mm and 5 mm flat blade screwdrivers A complete set of spanners pliers and wrenches may be helpful during the installation of the Masterlink MICC 3 2 Materials needed for installation Make sure you have all the parts you need for the job e A 500A 50mV shunt supplied with the Masterlink MICC e Cable s long enough to easily reach from the batteries to the Masterlink MICC maximum length of the cables 25 meters 80ft e Either One cable 4x2x0 25 mm shielded twin twisted pair e Or One cable 2x0 25 mm shielded twisted pair and three normal 2 core cables 2x0 25 mm e Two 6 pole modular communication cables RJ12 cross wired see figure 1 to connect the Masterlink MICC to the Mass Sinus inverter and the Mass charger e Three inline fuse holders with 2 Amp fuses do not install the fuses before the installation is completed An as short as possible heavy duty battery cable to run from one shunt bolt to the main battery The size of this cable is usually 35 70 mm but can vary depending
19. ays connect the cables between batteries and charger and inverter before you connect the Masterlink MICC to the charger or inverter If it is necessary to disconnect batteries and charger inverter then first disconnect Masterlink MICC from the charger inverter For an appropriate operation of the Masterlink MICC the ON OFF switch of the inverter must be set to the REMOTE position If you are using a Mass Combi then the ON OFF CH switch on the front of the Mass Combi must be set in the ON or Ch Position See chapter 4 of the manual of the Mass Combi gt AC CONNECTIONS INPUT OUTPUT OUTPUT GEN SHORE POWER SHORT BREAK HI 50A MAX 50A MAX 25A MAX x L N PE L N PE L N PE 25A SHORT BREAK PUSH TO RESET Step 8 6 pole modular cable RJ12 cross wired Step 9 optional 6 pole modular cable RJ12 cross wired Figure 4 Connection between the Masterlink MICC panel and the Mass Combi 10 November 2004 Masterlink MICC EN ENERGY MASTERVOLT TAILOR MADE uonejjesul G 4 OPA pZ JO ZL JO ZL B A DDIN paliddns jou s1ejew Gz jo wnwxew YOLVNYSLIV IES SORES depuis UJM 9JIM 9109 9 JO x pu
20. ber 2004 Masterlink MICC EN 3 MASTERVOLT TAILOR MADE ENERGY 6 HISTORICAL DATA 18 LOW BATTERY ALARM MENU ree 21 8 INSTALL LEVE E 23 9 PROGRAM oi er edes ia RE era sie ra eve e 25 10 ADVANCED SETTINGS eene eU a oen aka no 26 10 1 Testing alarm TumCtion oo EE EURO UAE ro Me ee esd 26 10 2 Exponent adjustment 5 eene E Ec ea ree 26 10 3 Reset tri amp riu aude Eee E ER ede ce vaderen den 27 11 ADDITIONAL INFORMATION 28 11 1 The PeU e Exponeht 1 m M ee a Ma bist teed ed ie eet 28 11 2 Time Remaining amp History sss enne enne nnne nnns nenne 29 12 GENERAL BATTERY 30 13 TROUBLE SHOOTING AND ERROR CODES noo eenen nnne nnne nnne nnne 31 13 1 Troubleshooting nsi eenen ie do Foe dete tbe ec eee ee neers 31 13 2 Ertor Codes oe gae da E LU Eel se aS 32 14 TECHNICAL DATA LEES 33 15 DIMENSIONS ctm M 34 16 CE DECLARATION OF CONFIRMITY 35 4 November 2004 Masterlink MICC EN MASTERVOLT TAILOR MADE ENERGY 1 GENERAL I
21. compensated This is to avoid the C E F being changed too much by incorrect wrong settings or an incorrect calculation of the MICC For an accurate calculation of the C E F the Masterlink MICC needs approx 6 10 cycles after power up If the C E F of the battery is known the C E F can be set manually to give an accurate reading directly after power up of the MICC but even if the C E F is set manually the Masterlink MICC continues to calculate the C E F and will automatically adjust it if necessary The C E F can be set by means of the Set up button between 70 and 90 The factory default is set at 90 96 Note If the Select button is held for five seconds the arrow in the right part of the display will change If the arrow is pointing downwards Y the set value can be decreased by means of the Set up button If the arrow is pointing upwards the set value can be increased Return to users menu A10 If this level is entered you can return to the user menu by means of the Set up button EXIT LEVEL gt PRESS SET UP 10 3 Reset menu The reset menu is used to reset the Masterlink MICC to its factory settings and to reset all historical data This menu can be entered by and holding the Select and Set up buttons simultaneously for five seconds until the Set up and Select LED s flash Return to the factory default settings F06 RESET FACTORY PRESS SET 5sec Now press the Set up button to enter th
22. e ES euoude a 8409 9 OM JO SJSISUOI BIGeD yx Sesni YIM Jepjoy esnJ o u jeubis Aleneg OL O 206108 ou jeubis Aiayyeq MoT apeg eoues eDejoA M peq HeIS 250A ooues eDeyoA Ayayeq HEIS eoues H yeq epis yunys 9pis peo JUNYS 6 8 Z 9 eyon M yeq soes 6 v Kjddns Jamog OO OIOIOIOIOUQO IOIO jddns Jomod HH Hg wesaid gy e eondisqy Mg qiz U U NEN YADYVHO 2 H to SSOJO JSPSAU yy m JOHLNOO HAIHVHI YSLYSANI SSVIA 2 EL 2 3 Q U Q U SOI MNI TH31SVIN LIOAYSLSVW 9NIMV G NOILVIVLSNI 11 November 2004 Masterlink MICC EN MASTERVOLT TAILOR MADE ENERGY 4 SYNCHRON
23. e menu With the first level of the reset menu the MICC can be returned to the factory settings by holding the Set up button for 5 seconds Resetting the historical data F07 RESET HISTORY PRESS SET 5sec If new batteries are installed the historical data of the old batteries needs to be erased to leave only historical data from the newly installed batteries By holding the Set up button for 5 seconds the old data will be erased and a new cycle for historical data will be started Return to users menu F08 EXIT LEVEL gt PRESS SET UP If this level is entered you can return to the user menu by means of the Set up button November 2004 Masterlink MICC EN 27 MASTERVOLT TAILOR MADE ENERGY 11 ADDITIONAL INFORMATION 11 1 The Peukert Exponent Deep cycle battery capacity is usually stated as a 20 hour discharge rate A 100 Ah battery will provide 5A for 20 hours At discharge rates above 5A the battery will not supply 100 Ah For example if you are drawing 100A out of the battery it will last less than one half hour A scientist named Peukert discovered this in 1897 The Peukert equation describes the effect of different discharging rates on the capacity of a battery This effect is that with increasing discharge rate the capacity of a battery decreases Table 3 and the examples give you an idea of this effect and show how to estimate a value for the Peukert exponent in your situation The Masterli
24. emoved or if the battery completely discharged to 0 volts For more information see also the set up drawing figure 7 The numbers of the mentioned levels correspond with this drawing Battery history data H01 To enter the historic data menu press the Set up button once With the Select button you can scroll trough a total of 6 information levels BATTERY HIS DATA Deepest discharge H02 By touching the Select button once the deepest discharge of the battery is displayed This value lets you know the deepest discharge of the battery since power up of the MICC or after a historic data reset For an optimum lifetime of your battery it is advised not to discharge a battery below 80 of its rated capacity If a battery is frequently discharged below this value premature failure of the battery can be expected DEEPEST DIS 99 Ah Peukert exponent H03 PEUKERT EXP The second level shows the Peukert exponent Standard batteries are rated for a 20 hour discharge This means that a 100 Ah battery can supply 5 amps for 20 hours before a voltage of 1 75 volt cell 10 5 volt for 12 volt batteries and 21 volt for 24 volt batteries is reached If the discharge current is higher for example 10 amps the battery will not be able to supply the full 100 Ah In this case the voltage of 1 75 volt cell or 10 5 21 volt is reached before the battery has supplied its full 20 h rated capacity Frequently discharging the batt
25. en the average current is much lower than the C 20 rate this set point can be set higher for example 12 24 volt For solar applications this voltage alarm can set higher to avoid too deeply discharged batteries Low Ah set point M02 At the second level of this alarm menu the alarm can be set according to the Ah consumed Battery voltage is not always correct to set an alarm The voltage of a battery is not only affected by the state of charge of the battery but is also affected by the load connected to the battery during discharge The alarm for the low Ah discharge floor is factory set at 35 of the total capacity of the battery For an average battery installation this value is normally ok but the alarm for low Ah can be set according to the requirements of the application For solar applications this value is often set to 50 and for cyclic applications forklifts the value is often set at 20 DIS FLOOR Alarm delay The alarm is delayed for 30 sec This means that if the voltage is lower than the setting for low battery voltage the alarm will be activated after 30 seconds This prevents the alarm being activated during a small dip in the battery voltage Low battery alarm off setting M03 The fourth level is used to reset the alarm if the battery reaches 80 state of charge This means with the factory default settings of 35 for low alarm and 80 for switching of the alarm the alarm is activated i
26. ery below this voltage and or capacity will shorten the life of the battery dramatically The maximum time the battery can be used in the above mentioned example is approx 8 hour i e 80 Ah A German scientist Dr Peukert has found an exponent that can be used to calculate the capacity of the battery if it is used above its 20 h rating This exponent is used by the MICC to calculate the time the battery can be used time remaining function The Peukert exponent is also used to calculate the state of charge in percentage In normal circumstances the Peukert exponent is no needs to change only if traction batteries e g on a forklift are used and a high level of accuracy is required The Peukert exponent can be changed in the program mode See section for how to calculate the Peukert exponent and section how to set the MICC according to the exponent found 18 November 2004 Masterlink MICC EN MASTERVOLT TAILOR MADE ENERGY Charge Efficiency Factor C E F H04 C E F The third level is the C E F Charge Efficiency Factor Every combination of battery and charger has an total efficiency This means that there must be more Ah charged into the battery than are used A standard wet type lead acid battery has an efficiency of approx 80 a gel type battery has an efficiency of approx 90 The efficiency of a battery is improved after it has been used for 5 10 cycles For the rest of the lifetime of the batt
27. ery the efficiency will slowly decline depending on its age and the number of discharge cycles If an efficiency of 70 is reached it will basically mean that the battery is at the end of its lifetime and needs to be replaced The changing of the efficiency means that it is necessary to calculate the efficiency every charge and discharge cycle The C E F is not only for the reading of the charge and discharge information of the MICC but also for the calculation of the time remaining function Number of cycles H05 NUMBER CYCLES 10 The fourth level gives information about the number of 35 low battery set point cycles used from the battery after the Masterlink MICC was set up or after the Masterlink MICC was reset to factory settings The number of cycles a battery can handle depends strongly on the type of battery and its quality One cycle is reached if the battery is discharged from 100 state of charge down to 0 followed by a charge up to 100 One cycle is also reached if a battery is discharged twice to 50 96 and charged back to 100 96 or discharged four times 25 and charged to 100 96 etc A normal cranking battery can perform approx 50 80 cycles before the end of its cycle life is reached A semi traction battery can perform about 200 250 cycles and full traction batteries can handle 1000 1500 cycles before the end of their cycle lifetime is reached The number of cycles the battery is used together with
28. es Now press the Volt Amp button Volt Amp to enter the low batter alarm menu 11 0 22 0V With the Select button you can now scroll through the levels of this menu and adjust several alarm set points For more information see also the set up drawing figure 8 and figure 10 The numbers that are mentioned behind the levels correspond with this drawing Note If the Select button is held for five seconds the arrow in the right part of the display will change If the arrow is pointing downwards W the set value can be decreased by means of the Set up button If the arrow is pointing upwards the set value can be increased Battery voltage Battery status FULL CHARGE M03 LOW BATTERY M01 LOW BAT DELAY 30s Battery voltage Battery status MAX RUN TIME 6h DIS FLOOR M02 Time MIN RUN TIME M04 Figure 10 battery alarm settings November 2004 Masterlink MICC EN 21 MASTERVOLT TAILOR MADE ENERGY Low battery alarm voltage set point M01 LOW BATTERY The MICC automatically detects a 12 or a 24 volt system The factory default for the low battery alarm is 11 volt if a 12 volt system is used or 22 volt if a 24 volt system is used These values are correct if the battery is discharged by the C 20 rate If the discharged rate is higher i e if the current is high the low voltage alarm may set slightly lower for example 10 20 volts Wh
29. eset to factory defaults November 2004 Masterlink MICC EN 13 MASTERVOLT TAILOR MADE ENERGY 5 OPERATION 5 1 General By means of the Masterlink MICC you can switch on and off your inverter and charger remote controlled and read the exact state of charge of your battery The dis charge current is measured by means of a shunt and on demand made visible on the display From the starting point of fully charged batteries the Masterlink MICC calculates the actual battery capacities For this calculation the measured dis charge currents are used as well as assumptions about their effect on battery capacity The accuracy of the results of this calculation depends on the correctness of these assumptions These assumptions are partly set up by the user possibly after a test and partly set up by the Masterlink MICC itself after a number of charge discharge cycles The operation of the Masterlink MICC can be separated into three major parts remote control of the battery charger remote control of the inverter and retrieving information you re your batteries see figure 6 Inverter LCD Display MAGS CHARGER 5 2 Remote control of the battery charger By pressing the Charger Charger switch the battery charger can be switched on off After a few seconds the Charger LED illuminates when the charger is in operation 230V supply The AC present LED illuminates
30. f the secondary starter battery and the system side figure 3 of the shunt 13 Connect the battery side of the shunt figure 3 to the minus terminal of the main battery s NOTE if several minus cables are connected to the minus terminal of the main battery all of these cables must be connected to the system side of the shunt On the battery side only one cable between shunt and main battery is used 14 Reconnect the positive terminals of the batteries to the system 15 Double check the wire connection of the meter and install the three 2 amp fuses November 2004 Masterlink MICC EN MASTERVOLT TAILOR MADE ENERGY Directly after power up by installing the two 2 amp fuses the LED s will light and after approximately five seconds the display will show the volt amps state of charge and the time remaining of the main battery If this is not the case check the wire connections for errors Consult to the trouble shooting chapter if the wires are connected correctly but the meter is not showing the display chapter 13 3 4 Installation of an external alarm The switching current of the alarm relay normally open contact may never exceed 1A 30VDC The switching contacts of the relay are available on pin 9 and 10 Rear view of the Masterlink MICC panel a O Connection compartment of the Mass Combi See chapter 5 of the manual of the Mass Combi 3 5 Connection of the charger and the inverter Alw
31. f the Ah consumed drops below 35 and it is reset when the batteries have been charged up to 80 of their capacity The value can be set between 70 and 90 according to the requirements of the system Minimum alarm time setting M04 MIN RUN TIME The fifth level of this alarm setting is used to set the minimum time that the alarm will stay activated If for example the battery drops below the settings for voltage and Ah but is charged directly afterwards the alarm will stay activated for 10 minutes factory setting even if the battery is charged above the settings for voltage and Ah This time can be adjusted between 5 and 90 minutes by means of the Set up button Maximum alarm time The maximum alarm time is set for 6 hours and used to set the maximum time the alarm will stay activated If for example the battery is discharged below the settings for voltage and Ah and will not be charged the alarm will stay activated for a maximum of 6 hours Return to users menu M05 If this level is entered it is possible to return to the user menu by means of the Set up button Also if none of the buttons are touched for 15 seconds the Masterlink MICC will return to the users menu EXIT LEVEL gt PRESS SET UP 22 November 2004 Masterlink MICC EN MASTERVOLT TAILOR MADE ENERGY 8 INSTALL LEVEL This menu is used to set the Masterlink MICC according to the voltage and capacity of the batteries instal
32. he AC source is limited for instance to avoid the shore fuse from tripping the maximum current can be limited In case of the Mass Combi you can adjust the Power sharing Power support level Press the Select button for 5 seconds until the green Select indication LED flashes See chapter 7 7 of the manual of the Mass Combi to enable Power sharing Power support function November 2004 Masterlink MICC EN 15 MASTERVOLT TAILOR MADE ENERGY MICC User level Direct access by pressing desired function button shortly Select gt Inverter Volt amp Ahr time Charger Set up 101 Vor T01 C01 Voltage amp Current Battery Status Charger switch status H01 DEPT 1 oe ore TAS read out present in ON OFF Battery historical data Service Battery full 02 T02 DEPT 2 Voltage read out Time remaing H02 Starter battery present in Deepest Discharge hours T03 Battery Capacity H03 DEPT 3 Consumed read out in Peukert Exponet Ahr H04 DEPT4 C E F H05 DEPT 5 Numbers of cycles detected H6 DEPT 6 Software version H07 DEPT 7 Error status e Press the Charger button Charger shortly to display CURRENT CONT CURRENT CONT You can adjust the Power sharing Power support level between 2 5A and 25A in steps of a 0 5A by pressing the Set up button If the Select button is held for five seconds the arrows direction in the right part of the display wi
33. its are exhaustively tested and inspected The guarantee period is two years 1 4 Validity of this manual All of the specifications provisions and instructions contained in this manual apply solely to the MASTERVOLT delivered standard versions of the Masterlink MICC 1 5 Liability MASTERVOLT can accept no liability for e Consequential damage due to use of the Masterlink MICC e Possible errors in the manuals and the results thereof CAREFUL Never remove the type and number plate Important technical information required for service maintenance amp secondary delivery of parts can be found from the type and number plate November 2004 Masterlink MICC EN MASTERVOLT TAILOR MADE ENERGY 2 SAFETY GUIDELINES amp MEASURES 2 1 Warnings and symbols Safety instructions and warnings are marked in this manual by the following symbols and pictograms a procedure circumstance etc which deserves extra attention A CAREFUL Special data restrictions and rules with regard to the prevention of damage A WARNING a WARNING refers to possible injury to the user or significant material damage to the MICC if the user does not carefully follow the procedures 2 2 Use for intended purpose 1 The Masterlink MICC is constructed as per the applicable low voltage directive 2 Use the Masterlink MICC only e ina technically correct condition e in a closed room protected against rain moisture du
34. late 140 amp 34 November 2004 Masterlink MICC EN MASTERVOLT ADDITIONAL INFORMATION TAILOR MADE ENERGY 16 CE DECLARATION OF CONFIRMITY Manufacturer Mastervolt Snijdersbergweg 93 1105 AN Amsterdam The Netherlands Herewith declares that Product Masterlink MICC Is in conformity with the following provisions of the EC EMC directive EMC 89 336 EEG 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 1997 Safety directive 73 23 EEC and amendment 93 68 EEC with the following standard Low voltage standard EN 60950 2000 Amsterdam Dr F J ter Heide General Manager MASTERVOLT November 2004 Masterlink MICC EN 35 MASTERVOLT TAILOR MADE ENERGY Snijdersbergweg 93 1105 AN Amsterdam The Netherlands Tel 31 20 3422100 Fax 31 20 6971006 Email info mastervolt com
35. led To enter the install level press the Select button for 5 seconds until the Select LED is flashing e Next press the Ah Time button Ah Time to enter the installer menu With the Select button you can scroll through the levels of this menu Ux For more information see also the set up drawing figure 8 The numbers of the mentioned levels below correspond with this drawing Note If the Select button is held for five seconds the arrow in the right part of the display will change If the arrow is pointing downwards Y the set value can be decreased by means of the Set up button If the arrow is pointing upwards the set value can be increased Setting the battery capacity A01 The first level is used for setting the battery capacity For an accurate reading of the time remaining function and the capacity consumed in 96 of the installed capacity this level must be set according the capacity of the battery installed The set value is the capacity of the battery with a 20 hour rating C 20 If traction batteries are installed with a different rating such as C 10 or C 8 ask your battery supplier what the capacity of the battery will be if the battery is discharged according the 20 hour rating and set the MICC according this value BATTERY CAP 200 Ah For 12 volt systems the capacities of all the installed batteries of the main battery bank can be added If a 24 volt battery system will be used all
36. ll change If the arrow is pointing downwards x the set value can be changed into lower values by means of the Set up button If the arrow is pointing upwards the set value can be changed into higher values Figure 7 Set up drawing user ievei After adjusting the output current to the desired value press the Select button shortly until EXIT LEVEL is displayed EXIT LEVEL gt PRESS SET UP Now it is possible to return to the user menu by means of the Set up button Also if none of the buttons was used for 15 seconds the Masterlink MICC returns to the users menu 5 5 Remote control of the Inverter e By pressing the Inverter Inverter switch the inverter can be switched on and off After a few seconds the Inverter LED illuminates when the inverter is in operation AC output 16 November 2004 Masterlink MICC EN MASTERVOLT TAILOR MADE ENERGY 5 6 User menu Functions like battery voltage current consumption and time remaining are displayed by means of the LCD display This information can also used to control an optional Battery Alarm relay Refer to chapter 7 8 9 and 10 for adjusting and programming functions of the Power System Control Panel For more information see also the set up drawing figure 7 The numbers of the mentioned levels correspond with this drawing Battery voltage and current V01 VOLT amp CHG AMP Volt Amp 28 56V 29 3A B
37. nk MICC uses Peukert s equation only for the calculation of Time Remaining The number in the display in Ah is always the actual number of used Ah This means that if you discharge the battery very fast the Time Remaining can be zero before the meter indicates that the total capacity has been used Executing two discharge tests one at a high and one at a low discharge rate which are about the minimal and maximal discharge rate for your situation enables you to calculate a value for the Peukert exponent which fits best to your situation The Masterlink MICC uses 1 27 as default value for which will give good results for most batteries At low to moderate discharge rates around the 20 hr discharge rate the logarithmic effect of the Peukert equation is small At lower discharge rates the effect is almost linear For this reason battery manufacturers specify the capacity for a 20 hour discharge rate Peukert s equation for battery capacity Cp reads n t log t2 log t1 where nz log 11 log 12 By doing two discharge tests and knowing I1 and I2 discharge current in one of the two tests and t1 and t2 time in hours of the two tests you can calculate n For this calculation you need a calculator that has a logarithmic function You can use Table 3 for a better understanding of the effect of high discharge rates on the capacity of your batteries You can use the table also
38. on the system Consult your Mastervolt dealer if dw UR Figure 1 Modular cable cross wired the wire size is unknown This cable is commonly available from your Mastervolt dealer or at marine and auto shops Cable terminals and cord end terminals If an external low battery alarm is required a normal cable 2x0 25 mm The maximum Mastervolt part number Description 68 01 601100 Cable 3x2x0 25 mm twisted stranded wires per meter 68 01 601200 Cable 4x2x0 25 mm twisted stranded wires per meter 65 02 001030 Modular RJ 12 cross wired communication cable 6 m 19 ft 65 02 100100 Modular RJ 12 cross wired communication cable 10 m 33 ft 65 02 100150 Modular RJ 12 cross wired communication cable 15 m 48 ft Table 1 Ordering information for cables November 2004 Masterlink MICC EN MASTERVOLT TAILOR MADE ENERGY current consumption of the relay must not exceed 1A 30VDC 3 3 Step by Step installation IS During installation check also the installation drawing on page 11 Ideally you should install the Masterlink MICC where it is possible to gain easy access to the instrument For good visibility avoid installing the meter in direct sunlight The maximum cable distance between the meter and the shunt must not exceed 25 meters 80ft WARNING Be sure that all the charging systems in the installation are switched off or
39. ount the fact that batteries are not 100 efficient You have to put in more energy than you take out All our meters learn the efficiency of the battery system The CEF is used to correct the rate at which Amp hours are counted back during charging The CEF is also displayed a falling CEF is an indication of a failing battery Additionally the historic data available in the Meter includes the number battery cycles and the deepest discharge November 2004 Masterlink MICC EN 29 MASTERVOLT TAILOR MADE ENERGY 12 GENERAL BATTERY INFORMATION The lifetime and performance of batteries depend for a great deal on how they are cared for and used Below we have listed some influences on the lifetime and some more information about charging and calculating the right capacity for your system Temperature A high temperature is disastrous for the lifetime of your batteries If they are regularly subjected to temperatures above 40 C you should relocate them or supply forced fresh air ventilation Discharge Regularly discharging below 20 of battery capacity has a negative effect on lifetime For long life of the batteries it is best not to discharge the battery below 50 Charging Special care must be taken if wet type batteries are used During charging they produce dangerous hydrogen gas This means that special care must be take for ventilation to avoid the danger of explosion To keep their capacity batte
40. put Data bus connections see figure 4 9 Run another 6 pole modular communication cable RJ12 cross wired and connect the RJ12 connecter to the socket which is marked with Inv see figure 2 connector IT at the back of the Masterlink MICC To connect the other RJ12 connector to the apparatus Refer to the inverters installation manual to connect the RJ12 connecter Option for the Mass Combi Connect the RJ12 connecter to the REMOTE input Data bus connections see fig 4 NOTE under normal circumstances there is no need to install this optional cable If this cable is installed the total stand by power consumption will be reduced from 50mA to 30mA if the Mass Combi is switched off by means of the Inverter button on the Masterlink MICC panel When installed it is not possible to connect the ICC remote control panel to the Mass Combi OF 5 O O WIE MINE O Figure 2 Backside panel 10 Connect the wires to the connection terminals of the Masterlink MICC and mount the panel with the four factory supplied nuts and rings 11 Connect the minus wire of the system to the system side see figure 3 of the shunt Charger Inverter Battery side Secondary battery Main battery Figure 3 12 Make a connection between the minus o
41. quired recette dende ann dear eeen dend 7 3 2 Materials needed for installation ennn enne neer 7 3 9 Step by Step Installatiori e eei dieu nce quen onion 8 3 4 Installation of an external alarm sssseseseeeeeene een nee enne 10 3 5 Connection of the charger and the inverter sssssssssseeeeeeenneeeeen nnne 10 4 SYNCHRONISATION AND SETTING THE BATTERY CAPACITY 12 4 1 Synchronisation eite i a ei ERU te vende 12 4 2 Setting the battery capacity nennen enen enneeeeeereenenennneneer 12 4 3 Setting the battery voltage taper rre vasa D e eder Eee dedecore 12 4 4 Activate Mass Combi setting sss 13 4 5 1 neren Oa p E Rit duets n tint sepa 13 5 OPERATION zai uuesesnmiegesne inn nRHIREIUORINUU BE ere idis elec tie 14 51 General narren ane nn endet nn aed ea A E S 14 5 2 Remote control of the battery charger nn anannenennne eenen 14 5 3 Adjustment of the maximum charge 15 5 4 Adjustment of the Power sharing Power support level Mass Combi only 15 5 5 Remote control of the Inverter unne naaa E aE ENE EE er AE A KEEA AE AEAEE aE 16 5 6 Userimen i t ntt e ve eee ee dn 17 Novem
42. red capacity of the main battery by pressing the Set up button If the Select button is held for five seconds the arrow s direction in the right part of the display will change If the arrow is pointing downwards 4 the set value be changed into lower values by means of the Set up button If the arrow is pointing upwards the set value can be changed into higher values IS If the battery capacity is set and no buttons are used the Masterlink MICC will reset to the users menu after 15 seconds For 12 volt systems the capacities of all the installed batteries for the main battery bank can be added If a 24 volt battery system is used all the capacities of the main battery bank are added and divided by two Example A main battery bank with two batteries installed of 12 volt 100 Ah each For a 12 volt system the battery capacity must be set at 200 Ah For a 24 volt system the battery capacity must be set at 100 Ah The auxiliary starter battery capacity doesn t need not to be set 4 3 Setting the battery voltage Normally it will not be necessary to set the battery voltage the meter automatically detects a 12 or 24 volt main battery system Special care must be taken that the battery must be charged at least 50 before power up If this is not possible or the state of charge of the battery is unknown the battery voltage needs to be adjusted 12 November 2004 Masterlink MICC EN MASTERVOLT
43. removed and disconnect the plus and minus connections from the main and secondary starter batteries prior to installation 1 Make a cut out in the panel using the outline drawings of chapter 15 or integrate the Masterlink MICC in your Mastervision panel The minimum depth required for installing the Masterlink MICC is 65 mm 2 Make a hole in the black installation box on the side where it is easy to enter the cable 3 Install the shunt of the Masterlink MICC as close as possible to the main battery but avoid the shunt being in contact with the positive terminal of the batteries 27 Special must be taken that during installation of the wiring sharp bends of the cables are avoided Also be careful not to run the cable on sharp edges that could easily damage the cables and the Masterlink MICC 4 Run the twisted wired cable 2x 0 25 mm between the shunt and the Masterlink MICC Be sure that the wires are long enough to be connected at the left side of the shunt The shunt s output voltage is very low between 0 and 50mV Therefore reliable connections are essential Prevent connections and wiring from corrosion Pay attention to the correct connections 3 and 4 of the system side and the battery side see figure 3 The maximum length of this cable must not exceed 25 meters 80 ft 5 Run a normal cable 2x0 25 mm from pin 1 and 2 power supply of the Masterlink MICC to the plus pole of the main battery
44. ries must be charged fully regularly and the best way is to use a three step regulated charger To adjust the charger according to the temperature of the battery will increase the lifetime of the battery significantly Also a low voltage ripple will help to extend the lifetime of the battery Mastervolt therefore recommends the use of the Mastervolt Mass or IVO Smart chargers Charging a battery is simple if 230 V utility power is regularly available However using a generator to charge the battery up to more than 85 is not efficient The reason for this is that the charging current is strongly reduced after reaching 80 85 of the battery capacity A rule of thumb can be used that the last 20 of charge of the battery will take 3 4 hours To keep the generator time as short as possible batteries will not be charged up to the full 100 if a generator is used to charge the batteries Normally this will not harm the battery as long if they are brought back to a full 100 at least every five to seven days Real available capacity The battery capacity given by the manufacturer is based on the current the battery can deliver when fully discharged during 20 hours Using the not absolute values for charging and discharging mentioned above 50 and 100 means that about 50 of the capacity as declared by the manufacturer is really available for use If you often use a generator this can even be as low as 35 Choosing the best bat
45. st and condensing circumstances e observing the instructions in the manual A WARNING Never use the Masterlink MICC at locations where there is danger of gas or dust explosion 3 Use other than as mentioned under 2 is not considered to be consistent with the intended purpose MASTERVOLT is not liable for any damage resulting from the above 2 3 Organisational measures The user must always e Have access to the user manual Be familiar with the contents of this manual This applies particularly to Chapter 2 Safety Guidelines amp Measures 2 4 Warning for special dangers 1 Check the wiring at least once a year Defects such as loose connections burnt wiring etc must be corrected immediately 2 Do not work on the Masterlink MICC or the system if it is still connected to a power source Only allow changes in your electrical system to be carried out by qualified electricians 3 Installation must be done in accordance with local standards 4 The battery voltage can be dangerous Use caution and pay careful attention when installing the Masterlink MICC Avoid short circuiting Voltages above 34 V can be dangerous November 2004 Masterlink MICC EN MASTERVOLT TAILOR MADE ENERGY 3 INSTALLATION 3 1 Tools and equipment required Installation of the Masterlink MICC involves only eight wires and two 6 pole modular communication cables RJ12 cross wired The following sections describe a b
46. tery capacity for your situation If you are going to decide about the battery capacity that you have to install it is good to keep the above mentioned 50 in mind If the batteries are often discharged at a higher rate than 5 of the battery capacity C 20 rate as given by the manufacturer it is also useful to take the Peukert effect into account The 50 rule and Peukert effect result both in larger battery sets as expected after simply counting factory specifications However if you take both into account you will miss the often heard disappointment about the performance of batteries 30 November 2004 Masterlink MICC EN ADDITIONAL INFORMATION MASTERVOLT TAILOR MADE ENERGY 13 TROUBLE SHOOTING AND ERROR CODES 13 1 Trouble shooting Problem Possible cause What to do No display function Error in the wiring Check wiring for errors especially power supply pin 1 and 2 chapter 3 3 step 5 No amp reading Error in the wiring Check wiring for errors especially between shunt and pin 3 and 4 chapter 3 3 step 4 No volt reading Error in the wiring Check wiring for errors especially voltage sense pin 1 2 5 and 6 chapter 3 3 step 6 No voltage reading of secondary battery Secondary battery not or wrongly connected Check the wiring to pin 7 and 8 Connect wire between minus main battery and minus secondary battery chapter 3 3 step 7 Amp reading not accurate
47. the C E F of the battery gives a reasonable indication about how long the battery can be used before it needs to be replaced Every time the battery is discharged below 35 of its rated capacity and charged back to at least 85 96 of its capacity one cycle is counted Software version H06 SOFTWARE VER 1 92 The fifth level of this menu displays the software version installed in your MICC This software version can be used for future references Error status H07 The sixth level shows the error status see the low battery alarm settings for more information ERROR STATUS NONE At this level it is possible to return to the user menu by means of the Set up button Also if none of the buttons are used for 15 sec the MICC returns to the users menu November 2004 Masterlink MICC EN 19 MASTERVOLT TAILOR MADE ENERGY MICC Installer level Hold select 2 4 sec untill led flashes and select the function below Select gt Inverter Volt Amp Ahr time Charger Set up M01 A01 c01 F01 No function Set Low Voltage Level Battery Capacity Current Control DEPT 1 level 1 Low Battery Signal 200 ah 100 amp Sleep mode 11vdc 22vdc 40 9990 ah 10 100 A02 M02 Average Time F02 DEPT 2 Set dischage Floor Consumtion C02 Low Bat Contact 35 of C ahr Exit level 20 50 0 minutes On Off s 0 10 20 30 minutes M03 A03 F0
48. the capacities of the main battery bank are added and divided by two Example a main battery bank with two batteries installed of 12 volt 100 Ah each For a 12 volt system the battery capacity must be set at 200 Ah For a 24 volt system the battery capacity must be set at 100 Ah The auxiliary starter battery capacity does not need to be set US Please note that the capacity of the battery only can be set if the batteries are 100 charged The time remaining function and the Ah consumed are reset if the battery capacity settings are changed Average time for the time remaining function A02 AVERAGE TIME With the second level it is possible to set the average time for the time remaining function If this set point is set to 0 it means that the time remaining is instantaneous and will give direct information about how long the batteries can be used in accordance with the load connected A more accurate and easier way to use value is shown if the average reading is set to 10 20 or 30 minutes If this level is entered the value can be set by means of the Set up button The factory default for this level is 10 minutes Setting the charged amperage A03 RETURN AMPS Another point that needs to be met before the Masterlink MICC considers the battery fully November 2004 Masterlink MICC EN 23 MASTERVOLT TAILOR MADE ENERGY charged is the number of amps flowing into a fully ch
49. to compensate for the voltage drop in the wiring In the above mentioned example therefore the voltage must be set for 13 6 volt Also this value will be automatically set for a 12 or a 24 volt system The factory settings are 13 6 volts for a 12 volt system or 27 2 volt for a 24 volt system Resetting the Ah consumed A05 With the fifth of this menu the consumed Ah can be reset back to zero by the Set up button for 5 sec This will only be required if the MICC is out of synchronisation caused by wrong settings or if the batteries are replaced RESET AHR gt PRESS SET UP E ny reset the consumed Ah s if you are sure the batteries are 100 charged Setting the battery voltage A06 The last level is used to set the Masterlink MICC according to the battery voltage of the main battery If the Masterlink MICC is powered up with a full or at least a reasonably charged battery the MICC will automatically set the voltage according to the nominal voltage of the main battery system If during power up of the Masterlink MICC 24 volt battery was completely discharged i e the voltage was below the 15 volts the meter is set for the wrong voltage The right voltage can be set with the Set up button The factory default setting is 12 volt BATTERY BANK 24V Return to users menu A07 If this level is entered you can return to the user menu by means of the Set up button EXIT LEVEL gt PRESS SET UP 24 No
50. to make an estimate of n of a battery after only one discharge test The values in the table are based on a 100 Ah battery but can be used for any capacity you like applying the correct ratio capacity current See the examples given 28 November 2004 Masterlink MICC EN ADDITIONAL INFORMATION MASTERVOLT TAILOR MADE ENERGY Discharge rates in A Charge 5 10 16 7 25 50 75 100 150 200 250 300 400 500 100 100 100 100 100 100 100 100 100 100 100 100 100 100 93 88 85 79 76 74 71 69 67 66 64 63 100 87 78 72 63 58 55 51 48 46 44 42 40 100 84 74 67 56 51 47 41 40 37 36 33 32 100 81 69 62 50 44 41 36 33 31 30 27 25 100 76 61 52 40 34 30 26 23 21 20 17 16 100 71 55 45 32 26 22 18 16 14 13 11 10 Table 3 Percentage of available capacity from a 100 Ah battery at different discharge rates and different values for n Peukert exponent Example 1 Suppose you have a 200 Ah battery Now discharge at a 50 A rate until the battery reaches 1 75 V per cell 10 5V for a 12 V battery This would be equivalent to a discharge rate of 25 A for a 100 Ah battery If the battery delivered 67 134 Ah the appropriate Peukert s exponent would be 1 25 Example 2 A 100 Ah battery with a Peukert s exponent of 1 3 will deliver only 41 of its capacity 41 Ah when supplying a 100A load 11 2 Time Remaining amp History The Charging Efficiency Factor CEF takes into acc
51. vember 2004 Masterlink MICC EN MASTERVOLT TAILOR MADE ENERGY 9 PROGRAM MENU The Program menu is used to set the Masterlink MICC according the users requirements This menu can be entered by and holding the Select button for 5 seconds until the Select LED is flashing Now press the Set up button shortly to enter the program menu With the Select button you can scroll through the levels of this menu For more information see also the set up drawing figure 8 The numbers of the mentioned levels below correspond with this drawing Sleep mode F01 SLEEP MODE ON The first level that can be set is the sleep mode For an even lower power consumption of the MICC as often required in solar applications the MICC can be set so that the backlight of the display will be switched off if the buttons are not used for 15 seconds In this way the power consumption is reduced till 28 mA As soon as one of the buttons will be touched the display will be lit again for an easy reading of the display This function is very useful if smaller battery capacities are used or in solar applications where as low a possible power consumption as possible is required The sleep mode can be switched on or off by means of the Set up button The factory default setting is On Setting alarm function on or off F02 LOW BAT CONT With the second level it is possible to switch the output of the alarm function on or
52. y pressing the Volt Amp button the LCD Display shows the main battery voltage and current If the battery is being charged VOLT amp CHG AMP is displayed VOLT amp DIS AMP means that the battery is being discharged with the current that is displayed Voltage secondary starter battery V02 e VOLT START BAT Volt Amp 28 53V By pressing the Volt Amp button again the voltage of the secondary starter battery is displayed Please note that if no secondary battery was installed this function is not available The Masterlink MICC automatically detects whether a secondary starter battery is connected to the meter Battery status T01 BATTERY STATUS Ah Time 42 By pressing the Ah Time button the LCD Display shows the state of charge of the main battery as a percentage of the installed battery capacity This percentage gives an exact indication of the state of charge of the battery This value is automatically compensated by the charge efficiency factor C E F and the Peukert exponent check chapter 11 for more information about the C E F and about the Peukert exponent A battery is considered fully 100 charged if 1 All of the Ah s discharged are charged back into the battery plus 1 Ah real counting without CEF 2 The charge float voltage is met the voltage is usually set around 14 0 28 0 volt 3 The charge return current is met the charged current will be usually be set for
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