Matson Programmable Voltage Sensitive Relay

MA98411

Matson Programmable Voltage Sensitive RelayThe MPVSR is a ‘solid state’ electronic relay which is activated by sensing the voltage of the circuits it is connected to. The voltages at which it will either open or close are able to be programmed by the user, meaning this product is suitable for a huge variety of applications. An example of this is variable voltage output alternators increasingly found in modern vehicles. This unit can be programmed to suit the characteristics of almost all 12 volt charging systems, and handle currents of up to 150amps continuous (at 12VDC). The ‘cut in’ and ‘cut out’ activations are also able to be time delayed to prevent VSR ‘chatter’, as well as being able to program an alarm activation at a user defined voltage level. The MPVSR is truly the next generation of charging control.

Primary ApplicationsParallel Charging – Combining separate batteries or banks of batteries together to charge from a single source or power.Low Voltage Disconnect – Automatically switching off an electrical load once the battery reaches a user defined voltage. Automatic paralleling of batteries – Automatically combines two battery banks for emergency power situations.Automatic load switching – Using the control terminals, the MPVSR can be a switch that will allow a load through it as long as the supply voltage is between the user defined ranges.A Heavy Duty Relay – For switching loads up to 150Amps.

FEATURES• Solid state design means no moving parts to fail• Fully user programmable to set voltage and time delays• User programmable to set as either normally open or normally closed• Isolated design means circuit cannot ‘backfeed’• Isolation between control and load circuits• LED indicators and display• Alarm output for remote peace of mind• Water and dust resistant enclosure• Can be mounted in any orientation• Over temperature protection• Separate emergency over-ride connection• 5 year warranty

WARNING• Make sure you are familiar with the operation and installation

requirements of the MPVSR before installing or using.• Please take into account the environmental limitations of the product.

The device is water and dust resistant, but is not designed to be installed in wet or excessively dusty environments. These influences may shorten the life of the product and are not covered by warranty.

• Never leave the load terminals uncovered, there is a high risk of short circuit, which may damage the device and it’s surroundings, including people.

• The device should not be operated by children.• Electricity can be dangerous! Short circuits can create sparks which

will ignite any present flammable substances. It is critical to ensure the unit is installed in a well ventilated area AWAY FROM ANY SOURCES OF FLAMMABLE SUBSTANCES. This includes batteries and fuel!

LAYOUT

INSTALLATIONCorrect installation is critical for trouble free operation of the MPVSR. Failure to properly install the unit may cause it to not work correctly, and may also void its warranty. For best results please observe the following instructions.Choose a suitable location where the MPVSR can be mounted. Make sure there is adequate ventilation to allow the unit to dissipate heat, and try to install it in an area that is not too hot. Engine bays are not ideal, but if adequately mounted it is an alternative. If mounting in an engine bay, be sure to shield the unit from heat, dust and water. In other applications, avoid moisture, dust and high vibration areas. The unit can be mounted in any orientation (even upside down) but must be on a hard flat surface. Make sure you maintain at least 5cm of clearance between the unit and any other objects. Utilise all four mounting points, using appropriate fasteners for the application. Do not over tighten.

WIRINGIt is very important to use the correct cable for your application. If the cable gauge is too small you will suffer voltage drop, reduced current, over heating of cabling and general poor performance, even failure. If you have any doubts, consult the place of purchase for the cable, the cable manufacturer, or an auto electrician. They will advise you on the continuous load the cable can carry. This MUST match the load of your application. Generally, when it comes to cable, bigger is better, and there is no substitute for good quality cable and terminals.Make sure the supply current or power is disconnected before connecting anything to the MPVSR!It is recommended that you install an inline fuse or circuit breaker as the load protection. The fuse or circuit breaker should be rated to suit the application, and should not exceed 150amps or the maximum rating of the load cable being used.Connect the required wiring to the control terminals, MAKING SURE TO USE THE CORRECT POLARITY! Connecting the polarity incorrectly will damage the unit and it will either need to be repaired or replaced. This is not covered by warranty. Note; if you do not require an alarm or manual over-ride switch, you do not need to connect anything to these terminals.

Note: It is very important to use appropriate terminations on your cables. Poor connections can result in overheating, damaging the MPVSR. For advice on termination please contact the place of purchase, an auto electrician, or The Matson Group. See below for termination examples.

CRIMP TERMINALS FOR CONTROL TERMINATION

COPPER LUG FOR LOAD TERMINATION

INITIAL SET UPOnce the control wires are connected to the MPVSR and a power source, the device is ready to be programmed to the user’s desired settings. It is worth keeping in mind that you may not need to alter the factory settings, which are listed in the table below.

12 Volt DCUpper Voltage Limit 13.7 VoltsUpper Time Delay 5 SecondsLower Voltage Limit 12.8 VoltsLower Time Delay 5 SecondsAlarm Voltage Limit 12.0 VoltsAlarm Time Delay 10 SecondsState of Contacts Normally Open (n - o)

CONTROL PANEL

To adjust the settings, observe the following procedure: NOTE; the buttons need to be pressed firmly in the centre or they will not register. This is to avoid accidental changes to programming by bumping the buttons.Press the “SET” button once, the screen will show “OFF”Press the “SET” button a second time. The screen will show the current setting, relating to whichever LED is illuminated around the screen. The first to come up will be the UPPER LIMIT IN VOLTS. If this setting does

STATE

SET SELECTED CONTROL ACTIONS

RESET

PUSH BUTTONS TO SELECT CONTROL

ACTIONS

LCD DISPLAY

not need to be changed you can cycle through the parameters using the “UP” and “DOWN” arrows.

To change a value:When the value you want to change is displayed on the LED screen, press the “SET” button and the value on the screen will begin to flash. While the screen is flashing, use the “UP” and “DOWN” buttons to change the value. Pressing “SET” again will stop the screen flashing and save the value. Use the “UP” and “DOWN” buttons to cycle through to the next setting you would like to change, and repeat the process.Once you have set all the values to your requirements, take your hands off the unit. After 10 seconds of inactivity the unit will switch off.To reset the unit to the factory settings, follow the procedure above, cycle through the settings until you reach “RESET”. Press the “SET” button and see “NO” flashing. If you would like to reset the unit, use the “UP” or “DOWN” button to cycle through to see “YES” and press “SET”. This will restore the unit to factory settings and the screen will read “RST”.

COMMON APPLICATIONSDual Battery ChargingOne of the major uses of the MPVSR is in dual battery charging applications. The MPVSR is used to put the two batteries or banks of batteries into parallel once the primary battery or bank reaches a certain voltage. In a 4x4 application, where a secondary battery is used for accessories such as lights, fridges or winches, it is important to protect the vehicles starting battery from being flattened by the accessories, making sure you can always start the vehicle and drive away. The MPVSR, installed between the starting battery and the secondary battery, can put the batteries in parallel once the starting battery is charged, or reaches a user defined voltage, allowing charging of both batteries to occur while the vehicle is driving. If a load is placed on the batteries whilst in parallel, and the starting battery drops to a pre-determined voltage, the MPVSR will disconnect the two batteries, allowing the secondary battery to power the accessories and protecting the starting battery.The ability to determine the cut-in and cut-out voltages of the MPVSR, specific to the vehicle, makes this product perfect for modern vehicles with VARIABLE VOLTAGE OUTPUT ALTERNATORS.Setting Guide: (note, this setup requires the MPVSR bet programmed ‘normally open’)UPPER LIMIT IN VOLTS: This is the voltage that, when reached by the starting/primary battery, the MPVSR will put the batteries in parallel and charge both batteries. For vehicles with a VARIABLE VOLTAGE ALTERNATOR, this will need to be set relatively low, at a point just below the higher voltage output of the alternator. You will need to contact the manufacturer or dealership to find this information.LOWER LIMIT IN VOLTS: This is the voltage level that, when reached by the starting/primary battery, the MPVSR will disconnect the batteries from the parallel circuit and isolate the starting/primary battery. This needs to be set at a voltage level greater than the minimum voltage level required to start the vehicleUPPER DELAY IN SECS: This setting, in seconds, is the amount of delay the MPVSR will wait to put the batteries in parallel, after the primary/starting battery reaches the UPPER LIMIT IN VOLTS. This delay stops VSR ‘chatter’, caused by the primary battery voltage dropping when the batteries are put in parallel and the VSR continuously connecting and

disconnecting the batteries. If VSR chatter is experienced, increase the delay in 20 second increments.LOWER DELAY IN SECS: This setting determines how long the primary/starting battery will be allowed to remain at the lower limit in volts before the MPVSR cuts out and isolates the primary/starting battery. A delay is useful here because the voltage of the starting battery may drop below this point for a few seconds when starting the vehicle, but return to a safe level quickly. In this scenario you would not need to isolate the primary/starting battery.

DUAL BATTERY WIRING EXAMPLE

+ SENSE WIRE

12 Volt Primary Battery

(Sensing)

12 Volt Secondary Battery

(Charging)

BUZZER

MUTE SWITCH

(OPTIONAL)

REMOTE OVERRIDE

SWITCH

Low Voltage DisconnectThe MPVSR can be used as a low voltage cut-out device when wired in line between the load and the power source. This would be used in situations where it is important to make sure the power source is not drained too far, like a starting battery in a car, or a lithium battery being used as a power supply. In the car example, a flattened battery means you can’t start the engine and you are stuck. The lithium battery power supply can be destroyed easily if it is discharged too far. In both case, low voltage protection will allow for peace of mind and longer life expectancy for the products involved.Setting Guide: (note, this setup requires the MPVSR bet programmed ‘normally open’)UPPER LIMIT IN VOLTS: This is the setting that determines when the power would be re-connected and allow operation to resume once the power source has returned to an acceptable level. In the car example, this would be when the battery has been charged back to a safe voltage to start the vehicle. It can be as little as 0.1V above the LOWER LIMIT IN VOLTS.LOWER LIMIT IN VOLTS: This is the voltage level where you want to disconnect the load from the power source to prevent it getting too low. In the car scenario, this would be the voltage level where if it got any lower the battery would not be able to start the car. UPPER DELAY IN SECS: This is the delay setting for re-connecting the load to the power source. Delaying the re-connection allows the voltage at the power source to stabilise before the load is connected again. This is more important when the power supply is a battery.LOWER DELAY IN SECS: This is the delay setting for disconnecting the load. In the car scenario, without a delay set, the MPVSR might disconnect the load when you try to start the vehicle, as the large load when starting can drop the battery voltage significantly for a few seconds. After starting the voltage would generally rise again to a safe level, meaning it would not be necessary to disconnect the load from the battery. In this situation it could even prevent you starting the vehicle.

LOW VOLTAGE DISCONNECT WIRING EXAMPLE

12 Volt Primary Battery

(Sensing)

BUZZER

LOAD 150AMAX

MUTE SWITCH

(OPTIONAL)

REMOTE OVERRIDE

SWITCH

+ SENSE WIRE

AUTOMATIC PARALLELING OF BATTERIESThe MPVSR can be programmed to connect two batteries or banks together in parallel if the voltage of the primary battery gets to a pre-determined voltage. For example, if the starting battery on a boat was going flat, the MPVSR could automatically connect it to the secondary or house batteries to enable it to start the motor. CAUTION: This functionality must be thought through carefully. If your starting battery is going flat, and you automatically connect your house batteries to it, and it continues to go flat without you knowing, you will be stuck with two flat battery banks! It is highly recommended to use an alarm when using this function, so you know when the batteries are in parallel.Setting Guide: (note, this setup requires the MPVSR bet programmed ‘normally closed’)UPPER LIMIT IN VOLTS: This is the setting where the batteries will be disconnected from each other after the primary battery reaches a sufficient charge voltage. LOWER LIMIT IN VOLTS: This is the setting that determines when the batteries will be connected in parallel. This should be set at the point where the starting battery might no longer be able to start the motor, and would require assistance from another battery bank.UPPER DELAY IN SECS: This is the delay, in seconds, before the batteries are disconnected after the starting battery reaches a sufficient voltage level. LOWER DELAY IN SECS: This is the delay, in seconds, before the batteries are connected into parallel. This should be around the 10 second mark to accommodate for the voltage sag of the battery under a starting load.

AUTOMATIC PARALLELING WIRING EXAMPLE

+ SENSE WIRE

12 Volt Primary Battery

(Sensing)

12 Volt Secondary Battery

(Charging)

BUZZER

MUTE SWITCH

(OPTIONAL)

AUTOMATIC LOAD SWITCHINGThe MPVSR can be programmed to perform automatic load switching, by using the control terminals for sensing a desired voltage range. This is particularly useful in remote or unmanned situation where equipment needs to be operated, but also protected from over-voltage and under-voltage damage scenarios. For example, a flashing light on a remote tower needs to be activated at night, but it is powered by a lithium battery bank that is very expensive. Wiring the light switch in series with the control terminals (positive or negative) and setting the upper and lower voltage limits to the desired range means that the light can be switched on and off as needed, but only if the battery voltage is within the safe range set by the user.Setting Guide: (note, this setup requires the MPVSR bet programmed ‘normally open’)UPPER LIMIT IN VOLTS: This is the setting where the voltage would be re-connected to the light to allow it to operate as required again. In this example it would be the safe voltage level for the batteries to operate again.LOWER LIMIT IN VOLTS: This is the voltage level at which the light would be disconnected from the power source so as not to over-discharge the battery bank. This setting would be determined by the battery manufacturers guidelines.UPPER DELAY IN SECS: This is the delay setting for re-connecting the load to the power source. Delaying the re-connection allows the voltage at the power source to stabilise before the load is connected again.LOWER DELAY IN SECS: This is the delay, in seconds, before the power is disconnected from the light after the voltage reaches the LOWER LIMIT IN VOLTS. A delay here can be useful to prevent VSR chatter due to transient voltages and slight dips in power levels.

AUTOMATIC LOAD SWITCHING WIRING EXAMPLE

LOAD 150AMAX

FLOATSWITCH

CONVENTIONAL HEAVY DUTY RELAYThe MPVSR can be used as a conventional heavy duty relay for switching loads up to 150Amps continuous current at 12VDC. The control device is wired in series with the control wires and activated as required. The voltage settings should be programmed out of any range that would affect operation. Also, the relay can be set to either normally closed or normally open depending on requirements.

CONVENTIONAL HEAVY DUTY RELAY WIRING EXAMPLE

LOAD 150AMAX

CONTROL SWITCH

SPECIFICATIONS

Part Number MA98411Application Voltage 12 Volt DC and 24 Volt DCOperating Voltage Sensing: 9V DC Minimum, 38V DC Maximum

Switching: 33V DC Maximum

Continuous Contact Rating

150 Amps Maximum (rated at 40oC)

Momentary Contact Rating

500 Amps DC for a period of 10 seconds at 10% duty cycle (rated at 40oC)

Contact State User selectable normally open or closedEnvironmental protection

To IP66

Electrical Protection Thermal overload shutdownStandby Current Draw 10mA at 13.5V DC and 23mA at 27.0V DCStandby Current Draw 35mA at 13.5V DC and 55mA at 27.0V DCOperating Temperature Ideally -25oC to +50oCAlarm Output Signal Equal to input voltage to 200mA maximumOperating Humidity Ideally should not exceed 95%Enclosure Housing E-coated A360 (ADC 3) die cast aluminium Enclosure Cover and Terminal Protector

Injection moulded electrical grade ABS/PC

Load Terminals Tin plated copper studControl Terminals Tin plated brass contactDimensions 135mm L x 85mm W x 65mm HWeight 0.55kg

DIMENSIONS

H65mm

L135mm

W85mm

Matson Group - Warranty Against Defects ProcedureMatson Group Pty Ltd

100 Links Rd, St Marys, NSW 2760Phone: 02 98333444

Email: sales@matson.com.auwww.matson.com.au

WarrantyMatson warrants its products to be free of defects for reasonable consumer use for a period of 12 months. Matson will repair or replace the warranted product and it will return the repaired products under warranty to the consumer at Matson’s cost.

To make a claim under this warranty, the consumer must:• advise Matson of the defect as soon as it becomes apparent within 12

months of the purchase date and obtain a return authority by phoning Matson on the above number.

• provide satisfactory proof of purchase; and• send the faulty item to the address supplied above.

Exclusions from WarrantyThis warranty does not apply to products where:• there is evidence of Improper maintenance or abuse to the products;• the products have been exposed to harsh environmental conditions or

those outside the specified operating conditions;• Unauthorised modification is evident to the products or misuse of

products;• Operation outside the products specification.

Warranty DisclaimersMatson’s liability in respect of a breach of a consumer guarantee or any warranty made under these warranty terms and conditions for any products not of a kind ordinarily acquired for personal, domestic or household use is limited, in relation to the products to the extent

permissible by law and at it’s option to:• replacing the products or the supply of equivalent goods;• the repair of the products;• the payment of the cost of replacing the products or of acquiring

equivalent goods; or• the payment of the cost of having the products repaired.

To the extent permitted by law, all other warranties whether implied or otherwise, not set out in these warranty terms and conditions are excluded and we are not liable in contract, tort (including, without limitation, negligence or breach of statutory duty) or otherwise to compensate the customer for:• any increased costs or expenses;• any loss of profit, revenue, business, contracts or anticipated savings;• any loss or expense resulting from a claim by a third party; or• any special, indirect or consequential loss or damage of any nature

whatsoever caused by Matson’s failure in complying with its obligations.

MATSON IS NOT RESPONSIBLE FOR DAMAGE THAT OCCURS AS A RESULT OF YOUR FAILURE TO FOLLOW THE INSTRUCTIONS INTENDED FOR THE MATSON PRODUCT

In the following paragraph, “Our” means Matson and “You” means the customer:Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.The benefits given to the customer in this warranty are in addition to other rights and remedies under a law in relation to the products to which this warranty applies.

The Matson Group Pty Ltd100 Links RoadSt Marys NSW 2760 AustraliaPh: (02) 9833 3444 Fax: (02) 9833 3500sales@matson.com.auwww.matson.com.au

WARRANTY CARD(To be detatched and returned with the unit to the below address)

Name:Company Name:Address:Ph: Fax: E-mail:Purchased From:Date Purchased:Product Purchased (Model No.):

This product is supplied with a 5 Year Warranty from date of purchase.

Please Note: • Should you experience any warranty related issues with

this charger please call Matson Warranty Department on (02) 9833 3444 between the hours of 8am - 4:00pm Monday - Friday.

• Our Warranty Department will issue instructions so please contact them before returning the charger.

• Proof of Purchase will be required for all warranty claims.