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1. PE 295116 En Ta WI av i Bb J a mW BULK ABS FLOAT an i 2 X Our m e 2 MASTERVOLN ol E Wes ALPHA PRO Il a T e j i 1 SOF e ely i 109 4 30 e Figure 18 Dimension drawings of the Alpha Pro Il regulator in mm inch M S TERVOLT THE POWER TO BE INDEPENDENT I F Snijdersbergweg 93 1105 AN Amsterdam The Netherlands Tel 31 20 3422100 Fax 31 20 6971006 Email info mastervolt com
2. E changes the status to On at the first signal Input sa Sort longer signal 1 0 Off ct anges the status to Off at the first signal Copy lets the status follow the input Copy Invert lets the status follow the opposite of the input Toggle changes the status at the first signal and back at the second signal It is often used in Copy combination with a pulse switch Copy Invert Toggle Fiaure 17 Event data 6 3 5 Alpha Pro Il event source list Alpha Pro Il as event source Device state A change in device state Bulk The charging process switches to Bulk phase Absorption The charging process switches to Absorption phase Float The charging process switches to Float phase RPM event The alternator number of revs reaches a certain level 6 3 6 Alpha Pro Il event target list Alpha Pro Il as event target Bulk The charging process switches to Bulk phase Absorption The charging process switches to Absorption phase Float The charging process switches to Float phase 22 January 2013 Alpha alternator Alpha Pro Il regulator EN MASTERVOLT MASTERBUS 6 3 7 Keep alive function The Keep alive function is meant to keep the field current at least at a value that is detectable by the rpm meter So if the number of revolutions decreases the field current does not drop below this level 6 3 8 Small engine function If you h
3. tett 5 2 4 Maintenance amp repair eenen Nesten Mc Sessa A e A 5 2 5 General safety and installation precautions 6 2 6 Warni ng regarding life support applicatio s AEn ELI mE gr 6 2 7 Wemrorecaing the use of batteries ennen venne eneee POMMES 6 a p Se S 3 HOW IT ee P B NO 7 3 1 Alph altermator rra n M 7 3 2 Alpha Pro Il regulator nnee eennenerennennerevenenneeeennneeerennnnervenenneevennnneervennennverenndeervennnnenenn 7 3 2 1 Three step charging system nnn oenen enneneeeeennneevennennerevennnneevenneeeerennnnvene vennen 7 3 2 2 Temperature compensated charging nanne eenen neennnnerevenneneeevenneeerennnnnene vennen 8 3 2 3 ECLIPSE 8 4 INS TALE ATION e HM 9 4 1 UNPACKING oireena DEL 9 4 2 Important tO KMOW E E 9 4 3 ullum a 9 4 4 Mounting of the alternator annen eeneeerennnnnerserennenerennneeerennnensen eeens eeenennnneervenenneeeeennen 10 441 ET PR 10 4 4 2 Rotating direction nanne eenennnnnnneeneneneenennnnneneneeree een ennennenneeneeeneerennnnnnnnnneneneen 10 4 4 3 Mounting step by step nennen eenn eereenennnerevenneneeeennneeerennnneeneeenneereennnneervennnneen 10 4 5 Electrical connections eire Ee
4. Fig 1 Basic charging system consisting of the Alpha Alternator and the Alpha Pro Il regulator 3 1 ALPHA ALTERNATOR Mastervolt Alpha alternators are specially designed to provide high power even at low RPM A pulley ratio of 1 2 1 3 and an engine idle speed of around 700 800 rpm will generate substantial current for charging the battery sets and powering the connected equipment Mastervolt alternators are resistant to the high temperature of the engine room allowing the engine to serve as the energy source for onboard consumers and as a quick charger for the service and starter batteries N CNT 345 V E D lt TIME p i CURRENT i Figure 2 Three step plus charge system See figure 2 The first step of the three step plus charge system is the BULK phase A in which the output current of the charging system is limited by the maximum output current of the alternator and the engine RPM At this stage the major part of the battery capacity is rapidly charged The current charges the batteries and the voltage will rise to the absorption voltage Refer to the specifications for the charging voltages for different batteries The duration of this phase depends on the ratio of charging capacity to battery capacity and on the degree to which the batteries were discharged to begin with The bulk phase is followed by the absorption phase B The absorption charge starts when the voltage on the
5. aU ur charge voltage p ann UN N loads e use setting of the ch haf a x voltage v K m Battefy C nns edi not connected or notattached to the batteries 1 Check the battery temperature sensor e With non Mastervolt alternators terminal D is not isolated from ground Check voltage on terminal D It should measure nominal battery voltage If this voltage is OV check whether the terminal D is isolated from ground Charge voltage stays in absorption mode too long too short e Wrong setting of the absorption timer Adjust the absorption timer see section 5 2 6 Alpha Pro II regulator is in float mode but battery voltage is still at absorption or bulk level e Any other device is charging the batteries Switch off all other charging devices and check battery voltage again No display function e Display has switched off e Error in the network wiring Switch on display Check wiring for errors MasterView display shows no Alpha Pro II e No terminating device placed at the ends of the network MasterBus needs a terminating device on both ends of the network Check if available See section 4 2 26 January 2013 Alpha alternator Alpha Pro Il regulator EN MASTERVOLT TECHNICAL DATA 9 TECHNICAL DATA 9 1 SPECIFICATIONS ALPHA ALTERNATOR Model 12 90 12 130 Part number
6. EN Alpha alternator Alpha Pro Il regulator January 2013 17 COMMISSIONING MASTERVOLT 5 2 3 Voltage Settings The Alpha Pro Il regulator uses the reg on terminal figure 16 connection 4 and the gnd terminal for measurement of the battery voltage As the field current flows through the gnd terminal as well a voltage drop may occur on the black cable which is connected to the gnd terminal This will affect the charge voltage To minimize this voltage drop a 4mm black cable is used Under all circumstances the voltage drop may not exceed 0 01 Volts 5 2 4 Absorption voltage adjustment The factory settings for the absorption voltage are 14 25V for 12V battery and 28 50V for 24V batteries 25 C 77 F These settings can be changed with the mode selector in MasterBus position and the configuration unlocked Refer to section 6 3 4 Do not adjust the charge voltage above the recommended limits of the battery manufacturer Also note that too high voltages may damage sensitive equipment that is connected to the batteries 5 2 7 Temperature compensation The battery temperature sensor included compensates the charge voltage for deviating battery temperatures See section 3 2 2 for details When the temperature sensor is not connected the 25 C settings are taken High temperatures are destructive to batteries If your batteries are regularly subjected to temperatures above 30 C 100 F you should relocat
7. Tun the engine with full load connected to Hig al amat r for approximately 15 minutes Then check the b p and adjust it if o ary M di 24 January 2013 Alpha alternator Alpha Pro Il regulator EN MASTERVOLT TROUBLE SHOOTING 8 TROUBLE SHOOTING In case of any issue we recommend consulting the Maintenance section first see section 1 If you cannot solve a problem with the aid of the table below contact your local Mastervolt Service Centre See www mastervolt com ISSUE POSSIBLE CAUSE SOLUTION The three LED s of the Alpha Pro Il are blinking together e This is the start up mode of the Alpha Pro Il After this the Alpha Pro Il starts regulating This is a normal situation Wait until the LED s stop blinking The three LED s of the Alpha Pro Il are blinking alternately e The Alpha Pro Il selector is on a blank spot The MasterBus alarm Invalid System is shown Check the selector and correct its position The three LED s of the Alpha Pro Il are blinking twice alternately e The Alpha Pro Il MasterBus configuration was unlocked it has stopped regulating Adjust the settings and relock the configuration The Alpha Pro Il enters the start up mode after this Your oil pressure light if installed is blinking twice each time e The selector is in the 12V position while your alternator and battery are 24V The Alpha Pro II is not regulating Check the sel
8. Imax 20 below Field current turns to 20 belowrpm 1000 7 0 20000 Imax 100 Field current turns to 100 above Y rpm 2000 0 20000 above Battery Type Battery type selection Wet cell See specifications Temp Voltage change at temperature rise 0 030V C 1 000 1 000 compensate Bulk Voltage Bulk voltage 14 25 28 50 57 00V 0 00 16 00 16 00 32 00 32 00 64 00V Minimum time Minimum bulk voltage timer 4 min 0 600 min Start time at Voltage at which to start the minimum bulk voltage timer 13 80 27 60 55 2V 0 00 16 00 16 00 32 00 32 00 64 00V Maximum time Maximum bulk voltage timer 360 min 0 600 min Return voltage Return to bulk voltage 12 80 25 60 51 2V 0 00 16 00 16 00 32 00 32 00 64 00V Return time Adjustable Return to Bulk time after the 30 sec 0 255 sec Return to Bulk voltage has been reached Absorption Voltage Absorption voltage 14 25 28 50V 0 15 50 0 31 00V Maximum time Maximum absorption timer 4h 0 24 h Float Voltage Float voltage 13 25 26 50V 0 15 50 0 31 00V Alarm levels High alarm on Alarm DC High on 16 00 32 00V 0 16 00V0 32 00V High alarm off Alarm DC High off 15 00 30 00V 0 16 00V0 32 00V Low alarm on Alarm DC low on 10 00 20 00V 0 16 00 0 32 00V Low alarm off Alarm DC low off 11 00 22 00V 0 16 00 0 32 00V Alarm delay Alarm delay ti
9. Alpha Pro Il regulator January 2013 13 INSTALLATION MASTERVOLT 4 5 6 Use of a battery isolator optional When two or more battery banks need to be charged simultaneously using a battery isolator is recommended See figure 12 for installation details See APPENDIX figures A 11 A 13 and A 14 for installation examples CAUTION If there is a battery isolator between the B terminal of the alternator and the positive pole of the battery both the red bat wire and the brown reg on lines must be connected to the positive pole of the battery Do not connect these wires to the input of the battery isolator NOTE Ux As battery voltage sensing is performed by the Alpha Pro II regulator you can use a battery isolator that has no voltage sense connection e ooo 2 D L BULK ABS FLOAT j J Field c MASTERVOUT do ALPHA PRO I B conn 5 P zi B ela rHrhre ey 3 T I 4 Mu Val gt je is d raus 10A D V RE UN N D Jo tm E D 6 4 E OS QQ Figure 12 Installation of the Alpha Pro Il 33 8 ONO SUE ON Alternator Alpha Pro Il regulat
10. 2 5 See reference Attach the temperature sensor to the battery and connect the RJ12 connecter to the Alpha Pro Il regulator as indicated 12 January 2013 Alpha alternator Alpha Pro Il regulator EN MASTERVOLT INSTALLATION 4 5 4 Connection of a tachometer optional If a tachometer is used it should be connected between the W terminal of the alternator see reference and the B terminal of the alternator or the NEG pole of the battery See figure 9 Ux NOTE With some alternators the W terminal is marked by an R instead of a W Ux NOTE The operation of the tachometer can not be guaranteed when the Alpha Pro Il regulator switches from absorption mode to float mode Switching on some loads during operation will solve this problem 4 5 5 Connection of an alternator indication lamp optional To check the correct operation of the alternator often an indication lamp is used This lamp will go off when the alternator is charging The Alpha Pro Il regulator has this function integrated in MasterBus so at an alternator failure a MasterBus alarm is shown refer to section 6 3 2 Figure 9 Connection of a tachometer position of the terminals may differ see APPENDIX figures A 6 till A 9 The Alpha Pro Il regulator has the same function integrated in its MasterBus functionality so the number of revs can be shown on a MasterBus connected display too EN Alpha alternator
11. 5 GENERAL SAFETY AND INSTALLATION PRECAUTIONS e Before using the Alpha alternator Alpha Pro II regulator read all instructions and cautionary markings on the Alpha alternator Alpha Pro II regulator the batteries and all appropriate sections of the manual If you do not follow these instructions danger may occur or the unit could be damaged e The Alpha alternator Alpha Pro Il regulator is designed to be permanently connected to your DC electrical systems Mastervolt recommends that all wiring be done by a certified technician or electrician to ensure adherence to proper electrical wiring regulations e Wrong use of the mode selector will lead to serious damage to batteries the Alpha alternator the Alpha Pro Il regulator and the cabling e Wrong MasterBus settings will lead to serious damage to batteries the Alpha alternator the Alpha Pro Il regulator and the cabling e Selection of a MasterShunt connected to a battery with a different nominal voltage will lead to serious damage to CI uk the Alpha _ 2 6 WARNING REGARDING LIFE SUPPORT APPLICATIONS Mastervolt products are not sold for applications in any medical equipment intended for use as a component of any life support system unless a specific written agreement pertaining to such intended use is executed between the manufacturer and Mastervolt Such agreement will require the equipment manufacturer either to contract for additional reliability testing of the Mastervo
12. If you have passed the above mentioned tests the charging system is ready for operation Else check trouble shooting Depending on your settings the regulator can switch to Float before a 10096 SOC has been reached refer to section 6 3 4 16 January 2013 Alpha alternator Alpha Pro Il regulator EN MASTERVOLT COMMISSIONING gt POOF onda BULK ABS FLOAT OG d 00 jo MASTERVOLYL ALPHA PRO il 7 SSL at ea Figure 15 Overview of the Alpha Pro Il regulator Settings selector 12 24V MasterBus Yellow LED to indicate Bulk phase Yellow LED tot indicate Absorption phase Yellow LED to indicate Float phas Green LED to indicate M sterBus tafe e 9 ME EO CJ Z oO MASTERVYOET 4 Reg on brown j ALPHA PROW 3 D lamp yellow T see 2 W white j zs T 7 1 Not used e Temperature Kilasterdus sensor LL _ Cable assembly Reg on D Field coil W Field coil sk Figure 16 Connections of the Alpha Pro Il regulator
13. Il regulator and engine are switched off during maintenance and or repair activities they should be secured against unexpected and unintentional switching on moving dn C USE FOR INTENDED D PURPOSE IN The Alpha alterhator F A I regulato d constructed as per the applicable safety technical guidelines Use the Alpha alternator Alpha Pro Il regulator only e for the charging of lead acid or li ion batteries and the supply of loads connected to these batteries in permanent systems e with fuses protecting the wiring between Alpha alternator Alpha Pro Il regulator output 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 Never use the Alpha alternator Alpha Pro II regulator in locations where there is danger of gas or dust explosion or potentially flammable products VY A 2 pu the key from the engine ignition smon switch hen with the batteries or remove the DC C fuse s be sur gt that third parties cannot reverse the measures taken WARNING When service has to be carried out while the engine is running be aware of moving parts like V belts If maintenance and or repairs are required only use original spare parts EN Alpha alternator Alpha Pro Il regulator January 2013 SAFETY GUIDELINES AND MEASURES MASTERVOLT 2
14. MASTERVOLT 4 5 3 Wiring instructions 1 See reference Run the DC cables between the battery set and the alternator A DC fuse must be integrated in the positive cable see section 9 for specifications Do not install the DC fuse of the DC distribution before the entire installation is completed Connect the red cable between the B terminal of the alternator and the positive pole of the battery Connect the black cable between the B terminal of the alternator and the negative pole of the battery 2 See reference Connect the black wire of the cable assembly between the gnd terminal of the Alpha Pro Il regulator and the B terminal of the alternator 3 Insert the two pole connector of the cable assembly into the field connector of the alternator See reference Take adequate measures to assure a strain relief for this connector D windings of the alternator will be damaged due to overheating NOTE An additional toggle switch may be added in series with switch S1 to shut down the alternator manually when increased propulsion is needed 2 reg on reg on S1 2A 4 See reference Connect th red wire of the cable assembly betweei the bat terminal of the Alpha Pro i egulator and the positive pole of the battery or the Be terminal the alternator La m EPI d US NOTE If a battery isolator is used to charge more than one battery the red wire of the cable assemb
15. batteries has reached the absorption voltage and ends when the battery is fully charged Battery voltage remains constant throughout this stage and the charge current depends on the state of charge of the battery the battery type the ambient temperature and so on With a wet cell battery this stage lasts about four hours with gel AGM and li ion batteries around three EN Alpha alternator Alpha Pro Il regulator January 2013 TECHNOLOGY MASTERVOLT Once the battery is fully charged the Alpha Pro II regulator automatically switches over to the float phase After Absorption phase C the Alpha Pro Il regulator Switches to Float voltage and stabilises this voltage to maintain the batteries in an optimum condition Connected loads are powered directly by the charging system If the load is higher than capacity of the charging system the required additional power comes from the battery which will be progressively discharged The Alpha Pro Il regulator will start a new cycle when the engine is started again 3 2 2 Temperature compensated charging A battery temperature sensor is not included in the delivery of the Alpha Pro Il regulator By installing this battery temperature sensor the charge voltages 12V 24V charge voltage V 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
16. 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 Consult your battery manufacturer for recommended charging voltages 3 2 3 MasterBus nabli g communication with a MasterShunt for The Alpha di H regulator features MasterBus terShunt can be selected in the enu after which it transmits battery instance This configuration d state data to the Alpha Pro Il More MasterBus devices can be connected are automatically adapted for deviating temperatures pU C RE M d J 8 January 2013 Alpha alternator Alpha Pro Il regulator EN MASTERVOLT INSTALLATION 4 INSTALLATION During installation and commissioning of the Alpha Alternator and Alpha Pro Il regulator the Safety Guidelines amp Measures are applicable at all times See section 2 of this manual 4 1 UNPACKING In addition to the Alpha Pro II alternator the delivery includes e The Alpha Pro Il regulator e A cable assembly for Mastervolt and Bosch alternators e A Bosch adapter e Battery temperature sensor e MasterBus terminator e This user s manual appendix After unpacking check the contents for possible damage Do not use the product if it is damaged If in doubt contact your supplier 4 2 IMPORTANT TO KNOW CAREFUL A Any changes to the alte
17. the field connector e Blue field wire is loose Check blue wire reference 6 on the installation drawings e Field windings of the alternator are defective Check resistance of field windings Replace alternator No output power All LED s of the Alpha Pro II regulator are off Voltage on the reg on and the bat terminal of the regulator are both 12 24V e Black gnd wire is loose Check black gnd wire reference 2 on the installation drawings e Alpha Pro Il regulator defective Replace Alpha Pro Il regulator Tachometer indication is too low or fluctuates e An alternator driven tachometer may reduce its reading or fluctuate when the Alpha Pro II regulator makes a transition from absorption to float if the battery is fully charged with no loads or if the float voltage is set quite low Nothing this is a normal situation To avoid this you may switch on some loads e Engine speed is too low Increase engine speed e Wrong calibration of the tachometer Adjust tachometer according to pulley ratio EN Alpha alternator Alpha Pro Il regulator January 2013 25 TROUBLE SHOOTING MASTERVOLT ISSUE POSSIBLE CAUSE SOLUTION Regulator stays in bulk mode all the time Bulk LED stays on e Alternator is overloaded Switch off a load part off consumers e Defective batteries short circuit between cells Check batteries and
18. the field should no longer be strongly magnetic CAUTION After performing this test be sure to turn de energize the reg on terminal otherwise the field windings of the alternator will be damaged due to overheating If you cannot pass the tests mentioned above remove the DC fuses and double check the wiring Refer to the Trouble shooting section section 8 6 Check whether all bolts are securely mounted Check both the aligning and tension of the V belts 5 2 2 In operation test To check for proper operation you will need a hand held digital meter If you have installed a battery monitor such as the MasterShunt or any other digital voltage measuring device you can use this as well an F ulator wsop ed illuminates indicating that the charger cycle begins Measure end record rie battery voltage The battery voltage should b e higher than measured before at step 1 The battery voltage rises until the yellow abs LED illuminates 6 When the yellow abs LED illuminates the absorption mode commences Measure and record the voltage at which the battery stabilizes 25 C 77 F 7 An absorption timer starts to keep the Alpha Pro Il regulator in the absorption mode The factory setting of this timer is 4 hours US ns For testing you might want to reduce the absorption time temporarily 8 When absorption time has elapsed the green float LED will illuminate This means that the float mode has started
19. the lamp connection current too high Invalid system Selector on a blank spot The selector has two blank spots to separate 12V MasterBus 24V The yellow LEDs are blinking twice alternately Battery high Battery high voltage warning generated by the Alpha Pro II Battery low Battery low voltage warning generated by the Alpha Pro II High field current Field current too high Alpha Pro Il stops regulating and retries after 5 seconds repeatedly Low field current Field current too low there is a disconnection in the field wiring Cable losses Cable between alternator and battery is too thin causing voltage drop Shunt mismatch Different voltage settings of MasterShunt and Alpha Pro II 6 3 3 History Value Meaning Factory setting Adjustable range Completed cycles Total number of completed charging cycles 0 0 200000 x Restarted cycles Total number of aborted charging cycles 0 0 200000 x Total charge time Total regulator charge time since commissioning 0 min 0 2000000 min Temp alarms Total number of temperature alarms 0 0 65535 High DC alarms Total number of high DC voltage alarms 0 0 65535 Low DC alarms Total number of low DC voltage alarms 0 0 65535 20 January 2013 Alpha alternator Alpha Pro Il regulator EN MASTERVOLT MASTERBUS 6 3 4 Configuration Below parameters can be changed via the MasterBus network by means of a MasterView panel or by
20. used as power management system for all connected devices such as the inverter battery charger generator and many more This enables communication between the connected devices for instance to start the generator when the batteries are low MasterBus reduces complexity of electrical systems by using UTP patch cables All system components are simply chained together Therefore each device is equipped with two MasterBus data ports As only a few MasterBus cables are needed installation and material costs are reduced importantly New devices can be added to the existing network easily Consequently the MasterBus network is highly flexible for extended system configuration Connections between the devices are made by standard straight UTP patch cables c oo01 amp o0onm At least one device in the network must be MasterBus powering see specifications As all powering devices are galvanically isolated multiple powering devices are allowed devices suitable to operate in the Ma terBus network For central monitoring and control of the connected devices M tervolt offers four different panels from the small Mastervisior compatible 20 x 65 mm LCD screen up to the full colour MasterView System panel All monitoring panels can be used for monitoring control and configuration of all connected MasterBus equipment A 6 2 Mastervolt also offers several interfaces like the Modbus int
21. 48512090 48512130 Type enclosure see APPENDIX A B Charge current 90A 130A Recommended DC fuse 125A 160A Recommended DC wire size up to 3 m AWG2 35mm _ AWGO 50mm 3mupto5m AWGO 50mm AWG2 0 70mm Nominal voltage 12V 12V Charge regulator Alpha Pro ll 12V Alpha Pro Il 12V Pulley diameter 73mm 88 mm Belt tread 2x 2x Isolated from ground Yes Yes Rotating directions 2 2 Maximum speed 8000 rpm 8000 rpm Pulley Double Double Required transmission belt A type A type Weight 5 0 kg 12 1 Ibs 10 1kg 22 3 Ibs Number of mounting positions 3 A CUT dli De 7 5 m a J L 7 NT 24V models ic Tk t Model IN xr 2475 24 110 24 150 Part number 4 48524075 48524110 48524150 Type enclosure see APPENDIX B B C Charge current 75A 110A 150A Recommended DC fuse 100A 160A 200A Recommended DC wire size up to 3 m AWG3 25mm AWG2 35mm AWGO 50mm 3mupto5m AWG2 35mm AWGO0 50mm AWG2 0 70mn Nominal voltage 24V 24V 24V Charge regulator Alpha Pro ll 24V Alpha Proll 24V Alpha Pro Il 24V Pulley diameter 88 mm 88 mm Q 92 mm Belt tread 2x 2x 2x Isolated from ground Yes Yes Yes Rotating directions 2 2 2 Maximum speed 8000 rpm 8000 rpm 8000 rpm Pulley Double Double Double Required transmission belt A type A type A type Weight 10 1kg 22 3 lbs 10 1kg 223lbs 13 1kg 28 9 Ibs Number of mounting po
22. 5 3 oleum 18 6 gg iy 19 6 1 What is MasterBuS irrena ooa nna aa e aaa iae iaaa raaa EEDE 19 6 2 How to set up a MasterBus network annen eere nereenneneerennenneeereneeeerennnneervennnneeeeeneen 19 6 3 Mast rBUS fUNCHONS e Rl Sac die GHA Bes N ete 20 6 3 1 Llevo ETE 20 6 3 2 Pk DEP 20 6 3 3 jj EE 20 6 3 4 ISrerrifeUcnM E 21 6 3 5 Alpha Pro Il event source list Alpha Pro Il as event source nanne eenen 22 6 3 6 Alpha Pro II event target list Alpha Pro Il as event target 22 6 3 7 Keep alive fUNCUOM MT 23 6 3 8 Smallengine f n GOTT pets p e td 23 6 3 9 Unlocking configuration TL EEn E cacaecs e 23 6 3 10 a E Nun oae PREMO NM r7 PEN ten pete E d uiis ini 23 6 3 Hh Start Float soc 7 MANTENAN dE cnr iE m ET ENEN 7 1 Electrical COMMGCHONS eee PEE 7 2 Cleaning of the alternator 7 3 Mounting of the alternator nennen eerennennersereneeeerennneeerennnnnnereeenneeenennnneervenenneeeennenn 24 7 4 Tension and condition of V belts nuur ennneneeennneeerennennserennneerennnnnenrevennevenennneeerenen 24 8 TROUBLE SHOOTING 25 9 TECHNICAL DAT 27 9 1 Specifications Alpha alternator unne oenen nerennnenervennenverenneeeerennnnenrerenneeeeennnneervennnneeeeennen 27 9 2 Speci
23. I ears figure 5 referen Sis B on th mounting bracke t with a nator mounting bolts Note n ear at a rear side of the alternator housing should be fixed in such way that it can freely 1 move ir a arrow see figure 5 reference A This is to avoid mechanical stress due to possible high temperatures of the alternator in the Ahe direction of the FgueS th engin a drive pulley 2 and tighten the bracket mounting bolts securing the mounting bracket 4 to the engine S l 8 See ww alternator pulley 3 with Figure 6 Alignment 10 January 2013 Alpha alternator Alpha Pro Il regulator EN MASTERVOLT INSTALLATION 4 Loosely attach the alternator adjustment strap Figure 5 and 6 reference D to the alternator adjustment ear figure 5 reference C with the bolt lockwasher and flat washer 5 Tighten the V belt by applying pressure to the alternator front housing only and tighten the bolt to the adjustment ear figure 5 reference C Set belt tension per belt manufacturer s recommended specifications If manufacturer s specifications are not readily available set V belt tension tight enough so that the V belt on alternator fan pulley will not slip when attempti
24. M STERVOLT USERS MANUAL GEBRUIKERSHANDLEIDING BETRIEBSANLEITUNG MANUEL UTILISATEURS ALPHA ALTERNATOR 12 90 12 130 24 75 24 110 amp 24 150 HIGH OUTPUT ALTERNATORS WITH ALPHA PRO II REGULATOR MASTERVOLT Snijdersbergweg 93 1105 AN Amsterdam The Netherlands Tel 31 20 3422100 Fax 31 20 6971006 www mastervolt com 100000000002887 02 CONTENTS MASTERVOLT THIS MANUAL HAS TO BE READ IN COMBINATION WITH THE APPENDIX ALPHA ALTERNATOR CONTENTS 100000000002887 02 1 GENERAL INFORMATION M 4 1 1 USS OR MUS VAN WA ses ett Em 4 1 2 Guarantee specifications ennen eneen venneneerenneeeerennenverereneeeeenne nere vennnnveevenneeerennnnnere vennen 4 1 3 OTE EEE 4 1 4 Validity Of THiS Nen e 4 1 5 EC 4 1 6 Changes to the Alpha alternator Alpha Pro II regulator nanne enneneee venne eerennnnnereeenneen 4 2 SAFETY GUIDELINES AND MEASURES 110 entree reiecta runc te ruta due xr annm tne aaa n me Eua aa naE Cua Eun Dra uuu ERR CIAR sane 5 2 1 Warnings and symbols nnen eener vennenneneneerenenenenennnnneneneeree nanne nnnnnnerenenenenennenneneneerenenennn 5 2 2 Use for intended purpose nonnen nrnnnn neren ennnerenennnenrnennnnneeenennere vennnneneeennnnereeennenevennnnneeen 5 2 3 Organizational PERG ASUPER x c
25. age to the batteries the alternator the Alpha Pro Il regulator the cabling and or the terminal connections Fuses can not prevent damage caused by reversed polarity The damage as a result of reverse polarity is not covered by the warranty CAUTION A 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 See specifications section 9 for recommended wire sizes OAh wey load connected woe hat all above rec endations are given as example only mc correct alternator battery capacity depends on many factors such as daily engine running hours load connected to the batteries during charging other charging equipment etcetera Therefore Mastervolt strongly advises to make an energy balance for the entire electrical installation 4 5 2 Installation drawings Ux NOTE From the text below is often referred to a reference These references are shown in the installation drawings of the loose supplied APPENDIX Keep the APPENDIX on hand during installation e For Alpha alternator model 12 90 see APPENDIX figure A 6 e For Alpha alternator models 12 130 24 75 and 24 110 see APPENDIX figure A 7 e For Alpha alternator model 24 150 see APPENDIX figure A 8 EN Alpha alternator Alpha Pro Il regulator January 2013 11 INSTALLATION
26. arantee period is two years 1 4 VALIDITY OF THIS MANUAL All of the specifications provisions and instructions contained in this manual apply solely to standard versions of the Alpha alternator Alpha Pro Il regulator delivered by Mastervolt 1 5 LIABILITY Mastervolt can accept no liability for 45512000 Alpha Pro Il regulator for ae consequential damage due to use of the results thereof 48524150 Alpha afternator 24 150 incl 3 stage Alpha Iternator Alpha Pro II regulator Alpha Pro II regulator MasterBu ible p Tt g e possible rrors in the manuals and the c and Bosch alternator LT V Every person who works on or with the Alpha alternator Alpha Pro Il regulator must be completely familiar with the contents of this manual and must follow its instructions Installation of and work on the Alpha alternator Alpha Pro Il regulator must be carried out by qualified authorised and trained personnel consistent with the locally applicable standards and taking into consideration the safety guidelines and measures section 2 of this manual Keep this manual at a secure place 1 2 GUARANTEE SPECIFICATIONS Mastervolt guarantees that this unit has been built according to the legally applicable standards and PE B P CAREFUL Never remove the type number plate Important technical information required for service maintenance amp secondary delivery of parts can be derived
27. ave a small engine this option limits the charge current in a selected number of revs interval This enables a smaller engine to rev up so it will not stall as a result of the high torque required to provide the charge current At the lower limit of this interval the charge current is 20 at the higher limit it is 100 6 3 9 Unlocking configuration To change the Alpha Pro II MasterBus configuration it must be unlocked With the configuration unlocked the regulator has stopped regulating and its LEDs start blinking twice alternately After you finished configuration you need to lock it before the regulator restarts regulating 6 3 11 Start Float SOC Percentage of the maximum State of Charge to enter Float stage This setting can be used to save the batteries at higher SOCs as they are not constantly subject to the higher Absorption voltage Further during a long trip the engine can be reserved for propulsion rather than charging the batteries immediately LR 6 3 10 MasterShunt Mm VN With a MasterShunt connected iu things ar different using the Alpha EE 1 There are two options to p to p lace a lace 4 tempera re sensor The MasterShunt temperature C is preferably placed onto the battery the Alpha Pro sensor onto the alternator 2 In the Alpha Pro Il configuration the MasterShunt must be selected 3 Absorption Return Amp is added in the configuration This is the charge current at which the regulator starts the minim
28. e Ere ED EE pe he Ra Ra dE rese naar 11 4 5 1 Battery Capacity PENA IcEE 11 4 5 2 Installation drawings nnen nerennennerevenneeeveennneeerennnnvereeneeervenne meere venneneeeenneeerennn 11 4 5 3 Wri INSTFUCHIONS er canara 12 4 5 4 Connection of a tachometer Optional naaa ennenneeereneeereenenneerennennve nennen 13 4 5 5 Connection of an alternator indication lamp optional nanne enn eeenne nennen eenn 13 4 5 6 Use of a battery isolator optional nnn eneeneeeeenneeerennnneneneneeneevennneeerennnnnen 14 January 2013 Alpha alternator Alpha Pro Il regulator EN MASTERVOLT CONTENTS 5 del IEiecmemm M 15 5 1 Selecting the charging mode sisirin aaa Ea daaa aa aar a E aiaia 15 5 1 1 Commissioning when selecting MasterBus aanne eeeeenenneerveneenve rennen 15 5 2 i um ER 15 5 2 1 Test prior to starting engine sss nennen nenne 15 5 2 2 In Operation 1eSt aec Hc 16 5 2 3 Voltage EI p Ee TE 18 5 2 4 Absorption voltage adjustment nnee eene nerenneenseeeenenerveneneerevenneneevenneeeeennn 18 5 2 5 Float voltage adjustment nnen nennen venenneeevennenerennnnnerenenneneveennnenerennnnnen 18 5 2 6 Absorption time adjustment nnn ennenneeeneerrerennenennenneneneer ven ennnnnennnnenenenn 18 5 2 7 Temperature compensation essen nnne nnne n nnn en nennen nnn 18
29. e them or supply forced fresh air ventilation 5 3 OPERATION After starting the engine the Alpha alternator and the Alpha Pro Il regulator will switch on automatically The regulator will wait for the engine to rev up before it starts charging the battery Refer to section 5 2 2 Start Up mode There is no need for adjustment or operation If the engine is stopped the Alpha alternator and the Alpha Pro Il regulator will switch off again When switched off all LED s of the Alpha Pro Il regulator are off An exception is when the Alpha Pro II is set to power the MasterBus network It will then stay switched on even after switching off the e engine 5 2 5 Float voltage adjustment ee The factory settings for the float UNA are 13 25V C anda P for 12V battery and 26 50V for 24V batteries Ne er disconnect any wiring during These settings canbe changed with the oe of engine selector in MasterBus position and t the NDA tion unlocked Refer to section 6 3 4 If the float voltage is set near 13 0V you may have to Switch on some DC loads to get the alternator to turn on because it takes some time for the voltage to settle from the higher absorption voltage 5 2 6 Absorption time adjustment Factory setting of the absorption timer 4 hours This is appropriate for most systems Exceptions might be e Extension of the absorption time to do some intentional overcharging to regain lost capacity e Shorten the time if you stop and sta
30. ector and correct its position No voltages at all All LED s of the Alpha Pro II regulator are off e Battery fuse has blown Investigate the cause of this malfunction Then replace the fuse e Battery connections are corroded or bad Clean and tighten the connections If the cables are burned replace them e Black gnd wire is loose Check black gnd wire No output power all LED s e Engine is not running Start the engine of the Alpha Pro Il regulator um e 2 Amps Bd di n wip is are off Voltage on the a terminal is 12 24V Vo on the reg on termi inal of the regulator is OV N pe blown s fuse and replace if Check the 2 Am necessary brown reg on e Problem with the oil p ure 5 switch or ignition relay S4 or ireis loose Check voltage on reg on terminal of the Alp a Pro II regulator Check brown reg on Check the oil pressure contact or ignition relay for correct operation No output power one of the LED s of the Alpha Pro I regulator is on Voltage on the field terminal of the regulator is OV e 10 Amps fuse in the red wire blown Check the 10 Amps fuse and replace if necessary e Two pole field connector of the cable assembly is loose red and blue wire Check field connector on the alternator reference 3 on the installation drawings e Problem in the wiring Check red and blue wires to
31. erface making even hon M CAUTION Never connect a non MasterBus device to the MasterBus network directly This will void warranty of all MasterBus devices connected HOW TO SET UP A MASTERBUS NETWORK Every MasterBus device is equipped with two data ports When two or more devices are connected via these ports a local data network called the MasterBus is formed Keep the following rules in mind Place a terminating device on both network ends Terminating device Terminating device x P dgio EN Alpha alternator Alpha Pro Il regulator January 2013 19 MASTERBUS MASTERVOLT 6 3 connected software 6 3 1 MASTERBUS FUNCTIONS Adjustment of the settings of the Alpha Pro II can be made via the MasterBus network by means of a remote control panel or a MasterBus USB interface to a PC with MasterView System Monitoring CAUTION Invalid settings of the Alpha Pro Il can cause serious damage to your batteries and or the connected load Adjustments of settings may be undertaken by authorised personnel only A Value Meaning General Device state Shows the state of the Alpha Pro Il Standby Charging Alarm Charger state Shows the state of the internal charger Off Bulk Absorptio
32. fications Alpha Pro Il regulator nnen enneneernenneneerenneeeerennnnneenvenneeerennnneervenenneeeeennen 28 EN Alpha alternator Alpha Pro Il regulator January 2013 3 GENERAL INFORMATION MASTERVOLT 1 GENERAL INFORMATION 1 4 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 Alpha alternator and the Alpha Pro Il regulator This manual is valid for the following models Part Description number 48512090 Alpha alternator 12 90 incl 3 stage Alpha Pro Il regulator MasterBus 48512130 Alpha alternator 12 130 incl 3 stage Alpha Pro II regulator MasterBus 48512131 Alpha alternator 12 130 MG 3 stage Alpha Pro II regulator MasterBus 48524075 Alpha alternator 24 75 incl 3 stage Alpha Pro Il regulator MasterBus 48524076 Alpha alternator 24 75 MG 3 stage Alpha Pro Il regulator MasterBus 48524110 Alpha alternator 24 110 incl 3 stage Alpha Pro Hregulator M sterBus 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 1 3 QUALITY During their production and prior to their delivery all of our units are exhaustively tested and inspected The standard gu
33. from the type number plate 1 6 CHANGES TO THE ALPHA ALTERNATOR ALPHA PRO II REGULATOR Changes to the Alpha alternator Alpha Pro Il regulator may be carried out only after obtaining the written permission of Mastervolt January 2013 Alpha alternator Alpha Pro Il regulator EN M ASTERVOLT 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 US AN A A 2 2 A A procedure circumstance etc which deserves extra attention CAREFUL 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 Alpha alternator Alpha Pro Il regulator if the user does not carefully follow the procedures WARNING Moving machinery This symbol nn that a poten tial hazarde exi ists caused 2 3 Use of the Alpha alternator Alpha Pro Il regulator 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 ORGANIZATIONAL MEASURES The user must always 2 4 e have access to the user s manual e be familiar with the contents of this manual This applies in particular to section 2 Safety Guidelines and Measures MAINTENANCE amp REPAIR If the Alpha alternator Alpha Pro
34. lectricians hazard Installation of the batteries and adjustments of the Alpha alternator Alpha Pro II regulator should f env b veren by authorised personnel e S c January 2013 Alpha alternator Alpha Pro Il regulator EN MASTERVOLT TECHNOLOGY 3 HOW IT WORKS This user s manual describes the installation and operation of the Alpha Alternator together with the Alpha Pro Il regulator from Mastervolt This charging system is designed to provide a high output power at low RPM which is typical for marine applications It consists of the following main components See figure 1 Alpha alternator included Alpha Pro Il charge regulator included Battery fuses 10A fuse included Batteries not included Temperature sensor included akWN The picture shows an installation without MasterShunt If you have a MasterShunt installed the Alpha Pro Il temperature sensor is better mounted on the alternator 3 2 ALPHA PRO Il REGULATOR The Alpha Pro Il voltage regulator controls the alternator s output voltage It is designed for optimal recharging of both wet gel AGM and li ion batteries Battery charging is accomplished in three automatic stages BULK ABSORPTION and FLOAT Simple automatic operation is made possible by the microprocessor that is the brain of the Alpha Pro II regulator 3 2 1 Three step charging system BATTERY VOLTAGE ABSORPTION De i
35. lt parts and or to commit to undertake such testing as a part of the manufacturing process In addition such manufacturer must agree to indemnify and hold Mastervolt non responsible from any claims arising out of the use of the Mastervolt parts in the life support equipment 2 7 WARNING REGARDING THE USE OF BATTERIES Excessive battery discharge and or high charging voltages will cause serious damage to batteries Do not exceed the recommended limits of discharge level of your batteries Avoid short circuiting batteries as tis may result in explosion and fire alternator the ony P o I Sula and th cabling e Be aware of al that can p not only engine parts butthe altern ay e In case of fire you mus st use the fire extnaudt which is appropriate vn electrical equipment e Short circuiting or reversing polarity will lead to serious damage to batteries the Alpha alternator the Alpha Pro Il regulator and the cabling Fuses between the batteries and the electrical installation can not prevent damage caused by reversed polarity and the warranty will be void e Secure the DC wiring with a fuse according to the guidelines in this manual Connection and protection must be done in accordance with local standards e Do not work on the Alpha alternator Alpha Pro II regulator or parts of the electrical system if it is still connected to a current source Only allow changes in your electrical system to be carried out by qualified e
36. ly should not be connected to the B terminal of the alternator but to the positive pole of the battery instead e di oc o 5 See reference The brown cable of the cable assembly must be connected to the reg on terminal of the Alpha Pro II regulator Connect the other wire end through a switch S1 with normally open contacts to the positive pole of the battery as indicated You can use the ignition Switch figure 7 or preferably an independent ungrounded oil pressure switch figure 8 Use a 2 5mm cable This cable must also be secured by a 2 Amp fuse As the reg on terminal is also used for voltage measurement this cable should not be shared with other loads 7 CAUTION If the engine is not running switch S1 must be open otherwise the field US DD Urs 7 Con Seton of m switch left and an independent Tou oil pressure switch with normally open contact right Brown wire Ignition switch Relay Normally open oil pressure switch Positive battery pole See reference The blue wire of the cable assembly is the field connection of the alternator Connect this wire to the field terminal of the Alpha Pro II regulator NOTE only applicable for non Mastervolt alternators With most other brands there is an internal connection between the negative field terminal of the alternator D and the alternator housing GND Be sure to remove this connection before installation See APPENDIX section
37. me 30 sec 0 240 sec EN Alpha alternator Alpha Pro Il regulator January 2013 21 MASTERBUS MASTERVOLT Value Meaning Default Adjustable range Shunt Shunt device Selection of the shunt to measure the battery voltage Alpha Pro II setup Factory settings Option to reset to factory settings Lock setup Option to lock the configuration settings With the configuration locked only the language and the device name can be changed Unlock setup Option to unlock the configuration settings only appears after Lock setup only with Alternator type and Battery voltage configured as user defined Value Meaning Default Adjustable range Events Event x source Event by the Alpha Pro Il that should result in an Disabled See Event source action another device on the MasterBus network list Nine events are available x can be 1 9 Event x Select a connected MasterBus device that should Select Selectable targets target take action due to an Alpha Pro Il event are system dependent Event x command Action to be taken by the target device Select See command list in manual of the selected device Event x data Data is linked to the command See also figure Off Off On Copy Copy 16 Invert Toggle Event x 1 See Event x I nenten dp pears after enabling Eventx Disabled EE est 17 aen meaning of the event data
38. means of an interface connected to a PC with MasterView System software Value Meaning Default Adjustable range General Language Language displayed on a MasterBus English See specifications monitoring device Name Name of this device This name will be APR Alpha Pro MB 0 12 chars recognized by all devices connected to the MasterBus MasterBus power Option to let the Alpha Pro power MasterBus Off Off On System System Startup delay Delay in seconds to allow the engine revving 10 0 60 up before the alternator starts loading it Alternator type Select the alternator type to connect this Alpha 12V 90A See specifications charging regulator to Battery voltage Nominal battery voltage 12V 12V 24V Temp sensor Location of the Alpha Pro temperature sensor Battery Battery Alternator Alternator Pole pairs Number of alternator pole pairs 6 1 16 alternator dependent Pulley ratio Motor pulley diameter relative to the alternator 1 000 0 000 4 000 pulley diameter Keep alive DC The field current is not to drop below this 6 6 25 only after percentage of maximum to keep the rpm Installer login meter functioning well RPM event at Number of revs at which an ev nt takes place 1000 rpm 200 10000 rpm Small engine Option to minimize torque load by decr asing Not checked rging current This prevents a from stalling ll engine TN DT
39. n Float Battery Battery voltage Battery voltage measured by the MasterShunt or if no Mastershunt has been selected the battery voltage is measured by the Alpha Pro II V Battery temp Battery temperature measured by the MasterShunt or if no Mastershunt has been selected the battery temperature is measured by the Alpha Pro II C Alternator Alternator shaft Number of revolutions alternator rpm Engine shaft Number of revolutions engine rpm Sense voltage Battery voltage measured by the Alpha Pro II V Field current Current through the alternator field coil A Alternator volt Voltage measured between Bat and GND V Alternator temp Alternator temperature mount the sensor on the alternator Also refer to section 6 3 4 Shunt Status Not selected Gonnected Connection lost nn State of charge Battery state of charge calculat d by the shunt 5 Battery voltage Battery voltage V measured by the M sterShunt J Battery current Battery current A measured by the MasterShunt N Battery temp Battery temperature measured by the MasterShunt temperature sensor C ere P 6 3 2 Alarms Value Meaning TS error Temperature Compensation error Bat Temp high The battery temperature sensor measures a high temperature Dev Temp high Alpha Pro device temperature too high D overload Overload of
40. nally or internally restricting its ability to dissipate heat from its external surface or 2 when fresh airflow through the alternator is restricted e Dirt and dust The alternator operates less efficiently when buildup of dirt particles forms around wire and cable connections Dirty connections impair the flow of electrical current e Vibration If the alternator is poorly or loosely mounted the resulting vibration can damage internal components A loosely mounted alternator will also diminish the performance of the belt drives EN Alpha alternator Alpha Pro Il regulator January 2013 INSTALLATION MASTERVOLT 4 4 4 4 1 MOUNTING OF THE ALTERNATOR General Consult your engine supplier for the availability of a mounting bracket and other necessary mounting hardware to mount the alternator on the engine Mastervolt Alpha alternators require two A type V belts of equal length measured pair for transmission As every engine differs from the other Mastervolt can not give any specific mounting instructions for any particular engine 4 4 2 Rotating direction The Alpha alternator is equipped with a bidirectional fan Therefore it may rotate in either a clockwise or counter clockwise direction 4 4 3 Mounting step by step 1 Determine the alternator mounting location 2 Loosely attach the mounting bracket to the engine with the mounting engine bolts Position the alternator mounting foot between the two E
41. nd advanced settings via MasterBus See figure 13 The default setting is MasterBus 5 1 1 Commissioning when selecting MasterBus In case the MasterBus setting is selected by default the product s configuration will be unlocked resulting in an Alpha Pro Il that remains inactive shown by LEDs blinking twice alternately Two parameters need to be selected via MasterBus before the configuration can be locked and the Alpha Pro Il made operational see Chapter 6 for more extensive explanation on using MasterBus 1 Goto Configuration page 2 Goto group System and select the Alternator type present in your system System Startup delay Figure 14 10 sec Selecting Alternator type Alternator type through Alpha 12V 90A MasterAdjust p ae tter t is has een done the Alpha Pro Il is ready for testing us ie N Md CAUTION Invalid settings can cause serious damage to your batteries Adjustments of settings may be undertaken by authorised personnel only Keep a record of setting changes in this manual CAUTION Use a 0 4 x 2 5mm flat blade screwdriver to adjust the selector Do not attempt to rotate the selector past the limit You will damage the selector AN 5 2 TESTING 5 2 1 Test prior to starting engine Before starting the engine follow all steps in order of succession as described below 1 Place the DC fuse s to connect the batteries to the wiring of the Alpha alternator and the Alpha Pr
42. ng to rotate alternator by hand CAREFUL A Alternator will be permanently damaged if pressure is applied to rear housing Tighten the V belt by pressing against front casing near alternator fan 6 Tighten all remaining alternator mounting bolts and check all other bolts to secure the installation e Use the supplied cable assembly for connection of the Alpha Pro II regulator e DC Cables to connect the Battery to the alternator are not included in the delivery e The alternator wiring is electrically isolated from ground 4 5 1 Battery capacity Make sure that the alternator has the right capacity to charge the batteries and to supply the load that is connected to the batteries while charging Failure to do so may result in extended charging times increased alternator temperatures and finally a reduced lifetime of your alternator and your batteries The ratio between alternator capacity and battery capacity should be for a wet battery Type of vessel Ratio between alternator capacity and battery capacity Motor boat 20 40 Sailing boat 30 50 For example on a sailing boat an alternator type alk is suitable for charging a 24V battery bank of 4 5 mens on RM WARNING ne b L AN Let installation wok be i licensed electrician Before he di with the connection of the wiring make the DC distribution voltage free CAUTION A Short circuiting or reversing polarity may lead to serious dam
43. o II regulator N Check whether all indication lights on the Alpha Pro Il regulator are off EN Alpha alternator Alpha Pro Il regulator January 2013 15 COMMISSIONING MASTERVOLT 3 Energize the reg on terminal by either turning on the ignition switch DO NOT START THE ENGINE or by putting a jumper across switch S1 see figure 14 Check whether the 3 yellow LED s start to blink After approx 10 seconds the yellow bulk led will illuminate reg on Oil pressure switch Ignition relay Jumper fe Amp Y Positive battery pole Figure 14 Jumper across switch S1 NOTE See section 3 2 1 for explanation of the bulk absorption and float mode WARNING A When the engine is running be aware of moving parts like V belts e Be sure no loads or any other charging sources are on e Be sure the battery is almost fully charged Follow all steps in order of succession as described below 1 Measure and record the battery voltage at idle 2 Start the engine The three LEDs on the Alpha Pro Il blink together to indicate the start up mode 3 Check for abnormal noise or vibration 4 The yellow bulk LED on the Alpha Pro Il 4 Check whether the fe altefnator field is is Eu by touching the shaft of the alternator with a screwdriver It Lii d eel 5 De energize ihe pes etiem by uM the ignition switch or by removing the jumper across switch S1 again All LED s should go off and
44. or Battery isolator Auxiliary battery fuse Auxiliary batteries Main battery fuse Main batteries Minus bus bar Battery sensor on main battery 10A replaceable fuse between battery positive pole and alternator Field connector Ignition relay or oil pressure switch to be connected to Regulator On connection number 1 in cable assembly 14 January 2013 Alpha alternator Alpha Pro Il regulator EN MA STERVOLT COMMISSIONING 5 COMMISSIONING AN Commissioning of the Alpha alternator and the Alpha Pro Il regulator involves two major parts e Selecting the charging mode e Testing and adjusting CAUTION Check all wiring before commissioning positive connected to positive red cables negative connected to negative black cables 5 1 SELECTING THE CHARGING MODE Both the Alpha alternator and the Alpha Pro ll regulator are preset from the factory with settings that will work fine for most batteries ot 3 Go to group Battery and select the Battery type present in your system Battery Type Lead acid Y Figure 15 Selecting Battery type through MasterAdjust 4 Go to group Alpha Pro setup and select Lock setup Alpha Pro setup m quem 16 Selecting Lock setup via MasterAdjust P add i Figure 13 Three MT The Alpha Pro Il Pavia has a inde e positions selector featuring stan settings fof a 12V or 4 lead acid system a
45. replace if necessary e Defective alternator Check alternator and replace if necessary e Capacity of the charging system is too low Use an alternator with more capacity or increase charging capacity by using an additional charger Consult your Mastervolt representative for advice e Defective Alpha Pro Il regulator Replace Alpha Pro Il regulator Alpha Pro Il regulator does not return to bulk mode when a high load is switched on e Once the regulator is in absorption mode a timer is started and after this time the regulator switches to float and will stay in this mode Nothing this is a normal situation If necessary switch off engine and start again See also section 5 3 Alternator is getting hot while engine is not running e Rotor field windings are still excited while engine is not running Switch off DC immediately to avoid field windings of the alternator being damaged due to overheating Check the oil pressure contact or ignition relay for correct operation This switch S1 must be open when the engine is not running Check wiring between battery and reg on terminal Output voltage too high e The regulator measures a too low battery voltage and tries to compensate it Check wiring between battery and reg on terminal for corrosion Check for voltage drop across the oil pressure switch S1 if applied The line between battery and reg on should not be used by other
46. rn the alternator s rotor and finally overheat the alternator The tension of new V belts must be checked after the first 50 running hours Then every 150 running hours or at least every year whatever comes first Before adjusting the V belt tension inspect it for glazing cracks or dryness A worn or damaged V belt should be replaced If the V belt is in satisfactory condition check belt tension with cricket belt tension gauge Refer to manufacturer s specifications for proper belt tension If necessary use proper tensioning gauge for your application Then adjust the tension accordingly If you replace a worn or damaged V belt the new belt should be checked for proper tension as well A new belt loses 60 of its tension during the first few ndm of operation If a new V belt has been point that they do nothave a buik maup br it grease or dust Air flow passages must also be o N clear so NE air can easily pass through the ra The alternator s bearings are grease for life m cannot be re ona Nec 7 3 MOUNTING OF THE ALTERNATOR Check the mounting of the alternator after the first 50 running hours Then every 150 running hours or at least every year whatever comes first Make sure that the alternator is securely mounted to its applicable brackets The brackets in turn need to be bolted securely to the engine Poor or loose mountings may lead to damaging vibration as well as reduced belt drive performance
47. rnator including the alternators wiring pulley and or mounting points will make the guarantee void The remaining capacity of the engine should be large enough to drive the alternator Take into consideration that the efficiency of a typical alternator including transmission V belt is approximately 50 Example At full output power the required engine power to drive Alpha Alternator model 24 75 is 75 Amps x 28 5V 50 4 3kW 4 3 ENVIRONMENT Keep the Alpha Pro Il alternator away from than alternators usu lly supplied with engine Sk As a result a single V belt is insufficient to transf r the power from the engine to the Altern hi Tero fore _ Mastervolt alternators are stand equipped s pulley for two V belts Before installing the pulley ratio between alternator and main engine need to be checked Mastervolt alternatofs ote At igh r EN Alternator model Maximum speed 12 90 12 130 24 75 24 110 24 150 8000 RPM Your engine supplier can help you choose an appropriate double pulley and advise on the bracket for the alternator Ee Note that the alternator support has to be made suitable for handling the high forces as well Excessive heat maximum alternator temperature should exceed 105 C 220 F An alternator can an become damaged if it operates too long at excessive temperatures Damaging heat levels are generated in two ways 1 when the alternator becomes dirty either exter
48. rt the engine often each day e Temporary time reduction for testing purposes Changing absorption time is possible with the mode selector in MasterBus 9 o clock position and the configuration unlocked Refer to section 6 3 4 Adjustable range 0 minutes up to 10 hours NOTE IE The new setting will only be activated after the Alpha Pro Il was powered up again E E NOTE If a heavy load is switched on during the absorption or float mode the alternator will compensate this by increasing its output power given the engine number of revs is sufficiently high Note that the regulator will not change back to bulk mode to start a new charging cycle A new charging cycle will only commence when the engine is started again See section 3 2 1 for explanation of the three step PLUS charging cycle Although the Alpha alternator is almost maintenance free still moving parts are involved that need regular service and maintenance This should be done according to the directions in section 1 18 January 2013 Alpha alternator Alpha Pro Il regulator EN MASTERVOLT MASTERBUS 6 MASTERBUS 6 1 WHAT IS MASTERBUS All devices that are suitable for M MasterBus are marked by the MasterBus symbol MasterBus is a fully decentralized data network for communication between the different Mastervolt system devices It is CAN bus based which has proven itself as a reliable bus system in automotive applications MasterBus is
49. sitions 1 1 3 See APPENDIX for dimensions EN Alpha alternator Alpha Pro Il regulator January 2013 27 TECHNICAL DATA MASTERVOLT 9 2 SPECIFICATIONS ALPHA PRO Il REGULATOR Model Alpha Pro Il Part number 45512000 Suitable for alternator type Alpha 12 90 12 130 24 75 24 110 24 150 Bosch alternators via a cable adapter included Nominal operation voltage 12V 24V selectable Li ion voltages selectable via MasterBus only with Bulk absorption voltage 12V Li ion 14 25V 14 6V Float voltage 12V Li ion 13 25V 13 5V Bulk absorption voltage 24V Li ion 28 50V 29 2V Float voltage 24V Li ion 26 50V 27 0V Adjustable range absorption Li ion 13 15V 26 30V Adjustable range float Li ion 13 13 9V 26 27 8V Battery temperature compensation 30mV C Absorption time 4 hours adjustable range 0 min up to 24 hours Cable assembly 1 5 mtr oil resistant connection cable Bosch connector included Temperature sensor Included Dimensions hxwxd See figure 18 Weight 0 4 kg 0 9 Ibs Voltage at 25 C with connected temperature sensor 14 4 28 8V at 20 C See APPENDIX for outline drawings
50. um absorption timer This value is calculated from the MasterShunt Amp Full percentage multiplied by its entered Battery capacity 4 The MasterShunt may have a battery voltage setting that differs from the Apha Pro II voltage setting In this case a MasterShunt Mismatch alarm is shown on MasterBus CAUTION If the Battery voltage was set User defined there will be no MasterShunt Mismatch alarm when the MasterShunt has different voltage settings b e S md Y PE lt lt N J NV eee EN Alpha alternator Alpha Pro Il regulator November 2012 23 MAINTENANCE MASTERVOLT 7 MAINTENANCE During maintenance of the Alpha Alternator Alpha Pro Il regulator and or the engine the Safety Guidelines amp Measures are applicable at all times See section 2 of this manual See below for preventive maintenance procedures that will contribute to many years of trouble free operation of the Alpha alternator and the Alpha Pro II regulator 7 1 ELECTRICAL CONNECTIONS Check the wiring at least every six months Defects such as loose connections corroded connections burned cables etc must be corrected immediately 7 2 CLEANING OF THE ALTERNATOR The cleaning interval of the alternator strongly depends on environmental conditions but should be maximum six months Ensure that all alternator surfaces are clean to the 7 4 TENSION AND CONDITION OF V BELTS Loose belts will slip on the pulley fail to tu

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