BATTERY CHARGER

INSTRUCTION MANUAL
SERIAL NO.

MODEL NO.

MBC7X-24V-30A-LA

PART NO.

652292

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

MASTER CONTROL SYSTEMS, INC.

P.O. BOX 276 • 910 NORTH SHORE DRIVE • LAKE BLUFF, ILLINOIS 60044, USA
TELEPHONE: 847-295-1010 • FAX: 847-295-0704
www.mastercontrols.com
 SAFETY INSTRUCTIONS

1. This manual contains important safety and operating instructions for the specific Model Number
battery charger described on the front cover.

2. Before using battery charger, read all instructions and cautionary marking on (1) battery charger, (2)
battery, and (3) product using battery.

3. CAUTION – To reduce risk of injury, charge only the type rechargeable battery which is indicated
by the last suffix in the charger model number located on the front cover.

SUFFIX TYPE OF RECHARGEABLE BATTERY

LA Automotive lead acid (sp. Gr. 1.265-1.285)
FL Float service lead acid (sp. Gr. 1.200-1.220)
NC Nickel Cadmium
LAC, LAS, L3A, LAR Represents different types of “maintenance free”
or low maintenance lead acid.

Note:

1) Additional numbers following suffix indicate the number of cells in the battery.
2) Other types of batteries may burst causing personal injury and damage.

4. Do not expose charger to rain or snow.

5. Use of an attachment not recommended or sold by the battery charger manufacturer may result in a
risk of a fire, electric shock, or injury to persons.

6. Do not operate charger if it has received a sharp blow, been dropped, or otherwise damaged in any
way; take it to a qualified serviceman.

7. Do not disassemble charger; take it to a qualified serviceman when service or repair is required.
Incorrect reassembly may result in a risk of electric shock or fire.

8. To reduce risk of electric shock, disconnect charger from A.C. supply before attempting any
maintenance or cleaning. Turning off controls will not reduce this risk.

9. WARNING – RISK OF EXPLOSIVE GASES

a. WORKING IN VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS.
BATTERIES GENERATE WORKING EXPLOXIVE GASES DURING NORMAL
BATTERY OPERATION.

b. To reduce risk of battery explosion, follow these instructions and those published by battery
manufacturer and manufacturer of any equipment you intend to use in vicinity of battery.
Review cautionary marking on these products and on engine.

MBC6/7 1
 SAFETY INSTRUCTIONS
(Continued)

10. PERSONAL PRECAUTIONS

a. Someone should be within range of your voice or close enough to come to your aid when
you work near a lead acid battery.
b. Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing or
eyes.
c. Wear complete eye protection and clothing protection. Avoid touching eyes while working
near battery.
d. If battery acid contacts skin or clothing, wash immediately with soap and water. If acid
enters eye, immediately flood eye with running cold water for at least 10 minutes and get
medical attention immediately.
e. NEVER smoke or allow a spark or flame in vicinity of battery or engine.
f. Be extra cautious to reduce risk of dropping a metal tool onto battery. It might spark or short
circuit battery or other electrical part that may cause explosion.
g. Remove personal metal items such as rings, bracelets, necklaces and watches when working
with a lead acid battery. A lead acid battery can produce a short-circuit high enough to weld
a ring or the like to metal, causing a sever burn.
h. NEVER charge a frozen battery.

11. PREPARING TO CHARGE

a. If necessary to remove battery, always remove grounded terminal from battery first. Make
sure all accessories are off, so as not to cause an arc.
b. Be sure area around battery is well ventilated while battery is being charged.
c. Clean battery terminals. Be careful to keep corrosion from coming in contact with eyes.
d. Add distilled water in each cell until battery acid reaches level specified by battery
manufacturer. This helps purge excessive gas from cells. Do not overfill. For a battery
without cell caps, carefully follow manufacturer’s recharging instructions.
e. Study all battery manufacturer’s specific precautions such as removing or not removing cell
caps while charging and recommended rate of charge.

12. CHARGER LOCATION

a. Never place charger directly above battery being charged; gases from battery will corrode
and damage charger.
b. Never allow battery acid to drop on charger when reading gravity or filling battery.
c. Do not operate charger in a closed-in area or restrict ventilation unless charger is an integral
part of a fire pump controller.

13. MARINE CHARGERS – EXTERNAL CONNECTIONS TO CHARGER SHALL COMPLY WITH

UNITED STATES COAST GUARD ELECTRICAL REGULATIONS (33CFR183, SUB PART 1).

14. GROUNDING INSTRUCTIONS – This battery charger should be connected to a grounded, metal,
permanent wiring system; or an equipment grounding conductor should be run with circuit conductors
and connected to equipment – grounding terminal or lead on battery charger. Connections to battery
charger should comply with all local codes and ordinances.

MBC6/7 2
 INSTALLATION INSTRUCTIONS FOR

MODELS MBC6 & MBC7 BATTERY CHARGERS

CABINET MOUNTING:

INDOOR VERSION: The Charger cabinet must be mounted in a vertical position, preferable on a wall
in close proximity to the battery. The areas above and below the Charger (vent screens) must be clear
for at least 5 inches (13 cm) to allow free air flow for cooling. The Charger must not be located in areas
subject to falling or spraying water.

The cabinet should not be subject to shock or vibration. If it is necessary, install suitable vibration
dampers. The six mounting holes or slots are 5/16 inch diameter to accept ¼ inch bolts. See
“MOUNTING DIMENSIONS” Drawing for details.

WIRING: For wiring, use wire having insulation which is unaffected by the environment or by
moisture. Ring lug wire terminations are preferred especially with stranded wire. Copper wire
preferred, aluminum wire is note recommended.

The bushings, if supplied, are in 7/8 inch (2.2 cm) diameter holes for ½ inch (1.3 cm) nominal conduit
fittings. Discard bushing(s) when conduit(s) is used.

The A.C. Supply source (mains) to the Charger must have branch circuit protection.

TABLE 1 – LOWER CHASSIS TERMINAL STRIP WIRING

TERMINAL MINIMUM WIRE SIZE DESIGNATION

GND As Required Chassis Ground – Connect to ground wire of a three
prong line cord when used. Connect to ground wire in
a conduit wired installation when a wired ground is
required. (The Chassis is not insulated from the
cabinet.)
AC-H Nameplate
Input Amperes AWG
1 thru 8 amps #14 A.C. Power Input Terminal (Line Side) –Connect to
9 thru 12 amps #12 high side of A.C. supply which has branch circuit
13 thru 20 amps #10 protection capable of supplying the nameplate listed
21 thru 30 amps #8 current requirements.
AC-N Same as ‘AC-N’ A.C. Power Input (Return) Terminal (Line or Low
Side) – Connect to line or neutral side of A.C. supply
as required to provide nameplate listed input voltage.
Branch circuit protection required if line side.
+BAT --Table 2-- Positive Charge Current Output—Connect to battery
positive terminal.
-BAT --Table 2-- Charge Current Return Terminal—Connect to battery
negative terminal.

MBC6/7 (10121) 1
 INSTALLATION INSTRUCTIONS FOR MODELS MBC6 & MBC7 BATTERY CHARGERS
Continued)

NOTE: Neither battery output terminal is grounded in the Charger. Therefore, the unit may be used in
positive ground, negative ground, or ungrounded installations.

TABLE 2

BATTERY MINIMUM WIRE SIZE (COPPER WIRE

CHARGER WITHOUT REMOTE SENSE WITH REMOTE SENSE

Rated D.C. Max. Wire Min. Wire Total Loop Min. Wire Total Loop
Current Run Length Size Drop Size Drop
10 FT 16 AWG 0.4V 16 AWG 0.4V
5 AMP 25 FT 14 AWG 0.6V 14 AWG 0.6V
50 FT 12 AWG 0.8V 14 AWG 1.2V
10 FT 12 AWG 0.3V 12 AWG 0.3V
10 AMP 25 FT 12 AWG 0.8V 12 AWG 0.8V
50 FT 8 AWG 0.6V 10 AWG 1.0V
10 FT 10 AWG 0.4V 10 AWG 0.4V
20 AMP 25 FT 8 AWG 0.6V 10 AWG 1.0V
50 FT 6 AWG 0.8V 8 AWG 1.2V
10 FT 4 AWG 0.25V 4 AWG 0.25V
50 AMP 25 FT 4 AWG 0.6V 4 AWG 0.6V
50 FT 2 AWG 0.8V 4 AWG 1.2V

Note that while the wire size shown for the AC wiring is based on wire current carrying capacity
(‘ampacity’), the wire sizes shown for the battery wiring are based on wiring resistance. In addition,
splices or junctions in the wiring path must be low in resistance.

Runs may be two of the next smaller even wire size, e.g., two #12 AWG wires may be used in place of a
#10 AWG wire, etc. Aluminum wire NOT recommended.

MBC6/7 (10121) 2
 OPERATING PROCEDURES FOR MODEL MBC7 BATTERY CHARGER

GENERAL - The Model MBC7 Battery Chargers are constant voltage, manually switched, two
rate (float-equalize), current limited, regulated (line compensated) battery chargers. This model
was designed for "floating" type application requiring precise regulation and current limiting. In
these systems the Charger will provide the load current while maintaining the charge in the
battery. Upon power outage the batteries supply the load. On power restoration, the Charger
again supplies the load current and charges the battery with the remaining available output
current until the battery is charged. The Charger is capable of equalizing properly sized
batteries. When the Charger is in the "float" mode, the battery water consumption will be low.

OUTPUT CAPACITY - These Chargers are capable of supplying up to 100% of their DC rated
output current without allowing the battery to be depleted. Loads across the battery which are
less than the Charger's rated current will be supplied by the Charger with the remaining charger
output being available to charge the battery, as required. For loads greater than the rated output,
the charger will supply its rated output with the battery supplying the remainder. These units
current limit at their rated output current.

LINE REGULATION - The Charger is regulated (line compensated) and requires no tap
settings. The line voltage regulation (output change) is 0.2% maximum for a 10% line voltage
change. The Charger will operate with line changes of up to + 15% of nominal with reduced
current rating on low line voltages.

LOAD REGULATION - The Charger will maintain its output voltage to within + 0.2% for
output currents from zero to rated current in both the "float" and "equalize" modes at nominal
line voltages.

WATER CONSUMPTION - In the "float" mode water consumption will be low. If left in the
"equalize" mode the Charger will produce considerable gassing and subsequently high water
consumption once the battery is fully charged. THE CHARGER SHOULD NOT BE LEFT IN
THE "EQUALIZE" MODE FOR EXTENDED PERIODS OR BATTERY DAMAGE WILL
OCCUR. The battery water level should be checked at least every three months due to climatic
changes. Longest battery life will be obtained when distilled water is used to fill batteries.

FLOAT MODE - This is the NORMAL operating mode of the charge, n this mode the Charger
will maintain the battery charge level, supply external loads up to the charger output current
rating and will bring the battery up to a charged condition after a discharge. Water consumption
will be low in this mode. With no external loads the final or maintaining current into a fully
charged battery will be less than 5% of rated current with a properly sized battery.

EQUALIZE MODE - For batteries within the recommended range of capacity (ampere hour
capacity of 5 to 20 times the charger output current rating) the charger will have sufficiently high
output voltage and current to equalize a battery to eliminate charge level differences between
individual cells. The equalize mode can also be used to charge the battery more rapidly. Most
applications do not require equalizing the battery more than once a month.

MBC7B 1 of 2
 OPERATING PROCEDURES FOR MODEL MBC7 BATTERY CHARGER
(Continued)

NOTE: THE CHARGER SHOULD NOT BE LEFT IN THE EQUALIZE MODE

FOR MORE THAN 24 HOURS OR EXCESSIVE WATER
CONSUMPTION AND BATTERY HEATING WILL OCCUR.

BATTERY CONDITION - A fully charged battery will be indicated by a low Charger output
current and, for lead acid batteries, a full charge specific gravity hydrometer reading in all cells.
A battery which has approached end of life will have a reduced ampere hour capacity (something
less than the battery's rated capacity). An adequate check of a battery for capacity is to subject
the battery to a worst case discharge while monitoring the battery voltage (with Charger
disabled). In order to maintain the required voltage during discharge, a battery must both have
adequate capacity and be fully charged.

LOW VOLTAGE SHUTDOWN - These Chargers are normally supplied with low voltage
shutdown which causes the Charger to reduce its output current any time the battery output
terminal voltage drops below +5.0 volts. The Charger will shut off completely if the output
terminal voltage drops below +2.5 volts. This provides reverse polarity and short circuit
protection. In addition, in the absence of capacitive loads, the Charger will shutdown on
"Missing battery" or open leads, if the Charger output terminals (+B & -B) have 3.0K ohms or
less of load resistance connected.

TO PUT THE CHARGER INTO OPERATION - Connect per installation instructions and
A.C. power.

CAUTION: ALWAYS DISCONNECT, TURN OFF, OR REMOVE A.C. POWER FROM

THE CHARGER BEFORE ATTEMPTING TO SERVICE THE CHARGER OR
BEFORE CONNECTING OR DISCONNECTING CHARGER OR BATTERY
LEADS. SIMILARLY, DO NOT CONNECT OR DISCONNECT BATTERY
LEADS WITH ANY LOADS CONNECTED.

NORMAL OPERATION - When power is first applied the Charger will normally supply its
rated current as indicated on the Charger ammeter. As the battery charge builds up the charge
current will reduce finally to a level required to maintain the battery charge and supply any
additional loads. The charge current should reduce to lower values within 30 hours or less for
properly sized Chargers.

When a drain is put on the battery or A.C. power in interrupted the Charger will again produce
higher output currents until the battery voltage builds up to a charged condition.

When connected to a fully discharged battery the Charger will current limit at the rated current
for most of the charge cycle. As above, a deep discharged battery can cause Charger shutdown
(if its terminal voltage is less than +5.0 volts) for up to several hours before high charge currents
to occur as above.

CHARGER MAINTENANCE - There are no field adjustments to be made on these Chargers.

The only adjustable device is the float voltage adjustment on the regulator P.C. board which is
factory set using precision equipment.

MBC7B 2 of 2
 THEORY OF OPERATION

MODEL MBC6 & MBC7 BATTERY CHARGERS

GENERAL: Refer to drawing 10357 for schematic representation. Note that while the specific
transformer wiring changes with battery type, the typical wiring shown is representative of the Charger
operation.

A.C. PATH: The A.C. Power is applied to the parallel primaries of the power transformers Tf11 and
TF12 through circuit breaker CB1. Note that the primary taps shown are factory wiring options to
accommodate different battery types. The “GND” terminal is tied directly to the chassis which is in
electrical contact with the cabinet. The primary and secondary circuits are electrically isolated from
each other and from chassis or cabinet ground. The transformers, then isolate the A.C. power and
transforms the voltage to the level required by the battery.

Control Transformer TF20 is connected through circuit breaker CB20 to the A.C. supply of CB1. The
regulator board has its own regulated power supplies (+10V, & -10V) which are supplied via
transformer TF20. The regulated +10V & -10V supplies power to: the sensing amplifiers, drive circuits,
provides reference values, and powers the voltage reference elements; providing the double regulated
voltage reference for low line regulation error.

D.C. PATH: The secondary output windings of transformers TF11 and TF12 are connected to the A.C.
input of the SCR (Silicon Controller Rectifier) assemblies Q11 and Q12. These form a full wave bridge
with the SCRs in the positive leg. The resistors and capacitors in series across the SCRs act as
“Snubber” networks to prevent false triggering due to line transients.

The positive outputs of the SCR assemblies Q11 and Q12, which control the charger current, are routed
through the Ammeter and fuse F2 to positive output terminal “+BAT” and to the battery positive
terminal. Battery charge currents will flow, then, when the SCRs are turned on and vice vesa.

The SCR turn-on signals are pulses supplied from a pulse transformer on the regulator board. The two
trigger pulse signals flow from the regulator +PT and +PT2 outputs. The pulse return paths are to –PT
and –PT2.

The charger current from the battery terminal returns to the negative output terminal “-BAT” and thru
the current sens resistor assembly R10 to the negative output of the full wave bridge Q11 and Q12.

VOLTAGE SENSING: The regulator board is the controlling element of the entire Charger. The SCR
assembly is a “Slave” to the regulator. The regulator senses the battery terminal voltage via terminal
“+BAT”, signal fuse F3, terminals 51, +S, 26 “+V” & 27 “+RS” and the +RS regulator pin terminal.
The negative battery terminal voltage is sensed via terminal “-BAT”, signal fuse F4, terminals 54, -S, 25
“-V” and regulator pin terminal –RS. The regulator will turn on the SCRs sooner in each half line cycle
when the sensed battery voltage is below the internal regulated reference voltage. Turning on the SCRs
sooner in each half cycle will allow more charge current to flow. When the battery voltage increase
(with charge level) above the fixed reference voltage, the regulator will turn on the SCRs later in each
half cycle causing reduced charges currents.

MBC6/7 (10357) 1
When the Charger switches from the ‘FLOAT’ mode to the “EQUALIZE” mode, the regulator reference
voltage is switched to a high value. The regulator will, thus, cause higher charge currents to flow until
the ‘EQUALIZE’ voltage is reached. When the Charger switches back to the ‘FLOAT’ mode, the
reference voltage is reduced so the regulator will cause reduced charge currents to allow the battery
voltage to drop down to the “FLOAT” voltage level.

The battery voltage sensing network is high in impedance (approximately 1.0 mA) and will not cause
battery discharge on power outage.

CURRENT SENSING: The return charge current flowing from the battery negative terminal into the “-
BAT” terminal is sensed by resistor assembly R10 and the ‘+CS’ and ‘-CS’ inputs on the regulator
board. The regulator compares the actual current flow against a reference level to cause current limiting.
When the current flow exceeds the reference level, the regulator will override the voltage section and
delay the SCR turn on point (in each half cycle) to reduce the current to the rated value.

MODE SWITCHING: The mode switching decision point of the Charger is called the “Cross-Over
Current”. The current sensing portion of the regulator compares the actual current flow against a
(Cross-Over) reference level to determine whether the charge current is more than the “Cross-Over
current”. The cross-over current is normally 65% to 75% of rated D.C. output current.

Now, if the regulator senses currents above the cross-over value it will switch to the “Equalize Mode”
by altering the output voltage level to the higher value (Equalize). Conversely, when the charge current
is sensed to be less than cross-over value the regulator will switch the output voltage to the low voltage
“Float” mode. (The “Hysteresis” in this mode switch action occurs by virtue of the battery
characteristics).

SHUTDOWN: The shutdown sense line is connected to the internal SCR trigger drive signal on the
regulator board through a diode. The “SD” line does not input current and will not discharge the battery
on power outage. Thus with a shorted output the load will “Steal” the SCR trigger drive (via terminal
SD), preventing SCR turn on, to shutdown the Charger.

REMOTE SENSING: The remote sensing terminals (‘+S’ and ‘-S’) are the terminals thru which the
regulator senses the battery voltage. By removing the factory installed straps (terminal ‘+B’ to ‘+S’ and
‘-B’ to ‘-S’) the sensing can be extended closer to the battery terminals. Thus, the effect of lead
resistance on ‘51’ and ‘54’ between the Charger and the remote sense terminals is ignored by the
Charger. This improves load regulation and reduces charge time somewhat.

SIGNAL FUSES: The regulator +RS and –RS signals as well as the sense voltage for alarm assemblies
(if any) are supplied via separate signal fuses F3 and F4 which are fed directly by the “+BAT’ & “-
BAT” terminals and are not isolated by the main fuse F2. This way, the alarm module (if supplied)
senses battery voltage independent of the state of main fuse.

CAUTION: The signal fuses F3 and F3 MUST be pulled to isolate the signal circuitry.

MBC6/7 (10357) 2
 CFA/HVA CHARGER FAILURE/HIGH VOLTAGE ALARM OPTION

INSTALLATION INSTRUCTIONS FOR CFA/HVA DUAL ALARM

The only additional installation required for Chargers equipped with this option is to connect the
CFA and HVA Alarm contacts to the remote alarm circuits. The contacts provided are SPDT rated
at 0.5A amperes max. @ 115 VAC max. Consult wiring diagram 10356 for wiring information.
Note that the CFA contacts are in the ALARM state with the relay de-energized and the HVA
contacts are in the non-alarm state with the relay de-energized.

Use wire having insulation which is unaffected by the environment of the installation. Wiring
methods should conform to local codes if alarm circuit has A.C. line voltage present. Local codes
may permit low voltage wiring techniques if alarm circuit uses energy limited, isolated, low voltage
(less than 24 volts), for operation.

CFA OPERATING PROCEDURES

The CFA assembly will detect the following Charger malfunctions: 1) immediate detection of
Charger A.C. power loss or 2) detection of loss of Charger output current (detection time can vary
from instantaneous to over an hour depending on system loads and battery self discharge or leakage).
By virtue of the above, the CFA will detect open A.C. or D.C. fuses or breakers, open input or
output wires, low line voltage, or removed Charger components. Since double throw contacts are
provided either normally open alarm sensing or normally closed 'Fail-Safe' sensing may be used.

The CFA assembly is adjusted at the factory, using precision equipment, to operate with the specific
voltage and battery type for which the Charger was built and adjusted. There are no field
adjustments to be made. The unit resets automatically.

Operation of the unit is as follows:

The unit has an internal voltage reference and compares the battery terminal voltage (as sensed by
the Charger 51 and 54 terminals) to this reference voltage. If the battery voltage is above the
reference, the unit will energize the CFA failure relay (which is the normal or 'non-alarm' state). On
units equipped with an L.E.D. light emitting diode, the diode will light when this path is enabled.
The CFA failure relay is also energized from another source. This source is the 'EAL' signal from
the Charger regulator P.C. board (Pins 15 and 16). This signal will energize the CFA fail relay only
when the Charger is actually producing charge current of at least 3/4 of rated output current (7.5
amps for a 10 amp Charger).

Since the voltage reference is set for a value between the battery 'Full Charge Open Circuit' voltage
and the 'Float' voltage, the CFA will cause an alarm unless the battery is fully charged or the Charger
is putting out high rate current.

The CFA will normally reset itself after a power failure or after a Charger failure when the fault has
been corrected. The reset occurs when the Charger produces high rate output current (via the EAL
circuit) or by virtue of sufficiently high battery voltage to satisfy the CFA voltage monitor.

CFA/HVA (10356)
 CFA/HVA CHARGER FAILURE/HIGH VOLTAGE ALARM OPTION
(Continued)

CFA OPERATING PROCEDURES (Continued)

The unit draws less than 1.0mA of current from the battery under any condition; thus, it will not
cause battery discharge upon Charger failure.

HVA OPERATING PROCEDURES

The HVA Assembly will detect an excessive high battery voltage due to a charger failure causing
‘run away’ or ‘lock up’ conditions. The Alarm set point is factory adjusted to a voltage slightly
higher than the charger ‘equalize voltage’ setting.

NOTE: Heavy gassing and water consumption will necessarily precede an HVA alarm.

Since double throw (form ‘C’) contacts are provided, either normally open alarm sensing or normally
closed ‘Fail Safe’ sensing may be used.

The assembly is adjusted at the factory, using precision equipment, to operate with the specific
voltage and battery type for which the Charger was built and adjusted. There are no field
adjustments to be made. The unit resets automatically. The unit has a short time delay built in to
prevent momentary tripping on transient voltages.

Operation of the unit is as follows: The unit has an internal voltage reference and compares the
battery terminal voltage (as sensed by the Charger 51 and 53 terminals) to this reference voltage. If
the battery voltage is above the reference the unit will energize the HVA failure relay. On units
equipped with an L.E.D. light emitting diode, the diode will light when the battery voltage is above
the set point voltage.

Once the HVA relay operates, NC relay contacts wired to charger terminal 61-64 open. This opens
the firing circuit to the SCRs and shuts down the charger. To reset, A.C. power must be removed
from the charger or SW-2 must be opened and closed.

The unit draws less than 1.0 Ma of current from the battery under any condition; thus, it will not
cause battery discharge upon charger failure.

The unit will NOT alarm UNLESS Charger A.C. power is PRESENT.

CFA/HVA (10356)