Mastervolt MLi 24/160, MLi 12/320 User Manual

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USERS MANUAL / GEBRUIKERSHANDLEIDING

BETRIEBSANLEITUNG / MANUEL D’UTILISATION

MANUAL DE UTILIZACION / INSTRUZIONI PER L’USO

Li-ion Battery

Model MLi 12/320 / MLi 24/160

MASTERVOLT Snijdersbergweg 93 1105 AN Amsterdam The Netherlands Tel.: +31-20-3422100 Fax.: +31-20-6971006 www.mastervolt.com

ENGLISH: PAGE 1

NEDERLANDS: PAGINA 37 DEUTSCH: SEITE 73 FRANÇAIS: PAGINA 109 CASTELLANO: PAGINA 145 ITALIANO: PAGINA 181

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DELIVERY CONTENTS/ OVERVIEW

DELIVERY CONTENTS

MasterBus cable (6m)

Battery terminal

Li-ion battery

2x M10 bolt (12V)

2x M8 bolt (24V)

MasterBus terminato

This manual

OVERVIEW

The Li-ion battery MLi 12/320 is a 8 cell Lithium Ion energy storage device with a nominal voltag e of 12V The Li-ion battery MLi 24/160 is a 8 cell Lithium Ion energy storage device with a nominal voltag e of 24V It contains a cell management system which features:

• Cell balancing

• Battery voltage monitoring

• Battery current monitoring

• Pre warning when battery is almost empty (commincation by means of MasterBus)

• Battery temperature monitoring (integrated temperature sensor)

• Communication with other MasterBus devices like chargers and alternators

The battery casing contains two lifting handles that cover the MasterBus connectors and battery terminals. The handles protect the wiring when folded down.

Cell management system

Lifting handle

MasterBus connectors

Battery terminal with M10 thread (12V)

M8 thread (24V)

Negative terminal

MasterBus connectors

Positive terminal

(-, black)

No MasterBus

connectors

(+, red)

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TABLE OF CONTENTS

Copyright © 2011 Mastervolt. All rights reserved. Reproduction, transfer, distribution or storage of part or all of the contents in th is docume nt in any form without the prio r written permission of Mastervolt is prohibited.

TABLE OF CONTENTS: v 3.3 April 2011

DELIVERY CONTENTS.............................................................................................................................................................. 2

OVERVIEW .................................................................................................................................................................................2

1 SAFETY GUIDELINES AND MEASURES ......................................................................................................................5

1.1 General rules......................................................................................................................................................5

1.2 Transportation warnings.....................................................................................................................................5

1.3 Disposal ofLi-ion batteries.................................................................................................................................. 5

2 GENERAL INFORMATION..............................................................................................................................................6

2.1 Use of this manual..............................................................................................................................................6

2.2 Validity of this manual........................................................................................................................................ 6

2.3 Guarantee specifications.................................................................................................................................... 6

2.4 Liability...............................................................................................................................................................6

2.5 Identification label...............................................................................................................................................6

2.6 Important to know............................................................................................................................................... 6

2.7 Use for intended purpose................................................................................................................................... 7

2.8 Organizational measures ...................................................................................................................................7

2.9 Maintenance and repair......................................................................................................................................7

2.10 General safety and installation precautions........................................................................................................ 7

2.11 Warning regarding life support applications........................................................................................................ 7

2.12 Warning regarding the use of batteries. ............................................................................................................. 7

3 HOW IT WORKS.............................................................................................................................................................. 8

3.1 Introduction.........................................................................................................................................................8

3.2 Cell management system................................................................................................................................... 8

4 OPERATION.................................................................................................................................................................... 9

4.1 Charging.............................................................................................................................................................9

4.2 Discharging........................................................................................................................................................ 9

4.3 Battery safety Event........................................................................................................................................... 9

4.4 MasterBus powering...........................................................................................................................................9

4.5 MasterBus functionality......................................................................................................................................9

4.6 Temperature....................................................................................................................................................... 9

4.7 Manual operation of the Latching Relay............................................................................................................. 9

5 MASTERBUS................................................................................................................................................................. 10

5.1 What is MasterBus?......................................................................................................................................... 10

5.2 How to set up a MasterBus network................................................................................................................. 11

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TABLE OF CONTENTS

BEFORE YOU START................................................................................................................................................... 12

6.1 Unpacking........................................................................................................................................................12

6.2 Required tools:................................................................................................................................................. 12

6.3 Location to install..............................................................................................................................................12

6.3.1 General............................................................................................................................................12

6.3.2 Ventilation........................................................................................................................................ 12

6.4 External cut-off relay ........................................................................................................................................ 12

6.5 Battery temperature sensor.............................................................................................................................. 12

6.6 General installation guidelines.......................................................................................................................... 12

7 INSTALLATION AND COMMISSIONING......................................................................................................................13

7.1 STEP 1: Installation.......................................................................................................................................... 13

7.1.1 Single battery installation.................................................................................................................13

7.1.2 Parallel connection, total maximum current < 200 Amps................................................................. 15

7.1.3 Parallel connection, total maximum current > 200 Amps................................................................. 17

7.1.4 Serial connection, using one charger to charge all batteries........................................................... 19

7.1.5 Serial connection, using one charger per battery............................................................................ 22

7.2 STEP 2: Commissioning .................................................................................................................................. 25

7.2.1 Charger settings..............................................................................................................................25

7.2.2 General............................................................................................................................................25

7.2.3 Configuration of the Multi Purpose Contact interface (“INT DC Relay”)........................................... 25

7.2.4 Configuration of the Battery Safety Event........................................................................................26

8 USER INTERFACE (VIA MASTERBUS)....................................................................................................................... 27

8.1 MasterBus menus ............................................................................................................................................ 27

8.2 MasterBus Event data...................................................................................................................................... 28

8.3 Exchanging MasterBus devices ....................................................................................................................... 28

8.4 Basic MasterBus events: Battery Safety Event ................................................................................................ 28

8.5 ADVANCED MasterBus Events ....................................................................................................................... 29

8.6 Events with the Li-ion battery as target ............................................................................................................ 29

9 TROUBLE SHOOTING.................................................................................................................................................. 30

10 MAINTENANCE............................................................................................................................................................. 31

10.1 Battery maintenance ........................................................................................................................................31

10.2 Taking out of operation..................................................................................................................................... 31

10.3 Storage............................................................................................................................................................. 31

10.4 Battery replacement......................................................................................................................................... 31

11 ORDERING INFORMATION.......................................................................................................................................... 32

12 TECHNICAL INFORMATION ........................................................................................................................................ 33

12.1 Specifications................................................................................................................................................... 33

12.2 Dimensions....................................................................................................................................................... 34

12.3 Charge, discharge characteristic...................................................................................................................... 34

12.4 Fuse to wire...................................................................................................................................................... 34

13 EC DECLARATION OF CONFORMITY ........................................................................................................................ 35

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SAFETY GUIDELINES AND MEASURES

1 SAFETY GUIDELINES AND MEASURES

1.1 GENERAL RULES

Observe these instructions and keep them located near the Li-ion Battery for future reference. Work on the Li-ion Battery should be carried out by qualified personnel only.

Do not smoke near the battery! Do not use any naked flame or other sources of ignition. Risk of explosion and fire.

While working on the Li-ion Battery wear protective eye-glasses and clothing.

Any uncovered battery material such as electrolyte or powder on the skin or in the eyes must be flushed with plenty of clean water immediately. Then seek medical assistance. Spillages on clothing should be rinsed out with water.

Explosion and fire hazard. Avoid short circuits, too deep discharges and too high charge currents. Use insulated tools. Do not place tools or other items on the Li-ion Battery. Do not wear any metallic items such as watches, bracelets, et cetera. In case of fire, you must use a type D, foam or CO

Never try to open or dismantle the Li-ion Battery. Electrolyte is very corrosive. In normal working conditions contact with the electrolyte is impossible. If the battery casing is damaged do not touch the exposed electrolyte or powder because it is corrosive.

Too deep discharges damage the Li-ion battery seriously and can even be dangerous. Therefore, use of a MasterBus controlled external cut off relay is obligatory. Refer to chapter 6 and 7.

Li-ion Batteries are heavy. If involved in an accident they can become a projectile! Ensure adequate and secure mounting and always use suitable handling equipment for transportation. Handle with care because Liion Batteries are sensitive to mechanical shock.

Li-ion batteries can be charged with a voltage up to 14.6 V (29.2 V). On the other hand, Li-ion batteries can be discharged down to 11.0 (22.0V). Note that this voltage range (11.0-

fire extinguisher.

Non-compliance with operating instructions, repairs made with other than original parts, or repairs made without authorization render the guarantee void.

1.2 TRANSPORTATION WARNINGS

1.3 DISPOSAL OFLI-ION BATTERIES

Batteries marked with the recycling symbol should be processed via a recognized recycling agency. By agreement, they may be returned to the manufacturer. Batteries must not be mixed with domestic or industrial waste

14.6V or 22.0-29.2V) is larger than you may expect from other battery types such as leadacid batteries. Be aware that these voltages may exceed the permitted voltages of the connected load(s). Therefore appropriate measures must be taken to avoid damage to the connected load(s).

Caution! Terminals of the Li-ion Battery are always alive; therefore do not place items or tools on the Li-ion Battery.

If charged after the Li-ion battery was discharged below the Discharge cut-off voltage, or when the Li-ion battery is damaged or overcharged, the Li-ion battery can release a harmful mixture of gasses such as phosphate.

The Li-ion battery must be transported in its original or equivalent package and in an upright position. If the battery is in its package, use soft slings to avoid damage. Do not stand below a Li-ion battery when it is hoisted. Never lift the battery at the terminals. Only lift the battery at the handles. The batteries must be protected against short circuits, slipping, upsetting or damaging. Li-ion Batteries must be suitably stacked and secured on pallets (ADR and RID, special provision

598). Stacking of pallets is only allowed only if the Liion battery is stored in its original packaging.

Li-ion non-spillable

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GENERAL INFORMATION

2 GENERAL INFORMATION

2.1 USE OF THIS MANUAL

This manual serves as a guideline for the safe and effective installation, operation and maintenance of the Mastervolt Li-ion Battery, models MLi 12/320 and MLi 24/160, further mentioned as “Li-ion Battery” or “Li-ion Batteries”. It is therefore obligatory that every person who works on or with the Li-ion Battery must be completely familiar with the contents of this manual, and that he/she carefully follows the instructions contained herein. Installation of, and work on the Li-ion Battery, may only be carried out by qualified, authorized and trained personnel, consistent with the locally applicable standards and takin g into consideration the safety guidelines and measures (chapter 1 of this manual). Keep this manual at a secure place!

2.2 VALIDITY OF THIS MANUAL

All of the specifications, provisions and instructions contained in this manual apply solely to the following products:

Part number Description

66010320 Li-ion Battery MLi 12/320 66020160 Li-ion Battery MLi 24/160

2.3 GUARANTEE SPECIFICATIONS

Mastervolt guarantees that the Li-ion Battery has been built according to the legally applicable standards and specifications. Acting not conform instructions and specifications contained in this manual, may damage the battery or it may not fulfill its specifications. All of these matters means that the guarantee becomes invalid. The guarantee is limited to the costs of repair and/or replacement of the product. Costs for installation labor or shipping of the defective parts are not covered by this guarantee. Battery damage as a result of over and undercharging is not compensated. You must take measures to disconnect the Li-ion battery based on MasterBus alarms generated by this battery, otherwise guarantee becomes invalid. Use of a MasterBus co ntrolled external cut off relay is obligatory. (refer to chapter 7). The period and conditions of this guarantee are laid down in the general conditions of delivery as registered with the Chamber of Commerce and Industries in Amsterdam number 33279951 and are available on request.

Guarantee will void if you fail to use a MasterBus controlled external cut off relay

2.4 LIABILITY

Mastervolt accepts no liability for:

• consequential damage due to use of the Li-ion Battery;

• possible errors in the manuals and their results.

2.5 IDENTIFICATION LABEL

Figure 1: Identification label

The identification label is located at the top side of the Liion Battery, under the grip handles (see figure 1) Important technical information required for service, maintenance & secondary delivery of parts can be derived from the identification label.

Never remove the identification label

2.6 IMPORTANT TO KNOW

Li-ion Batteries do not require topping up water. Never open the battery. Do not add acid or distilled water.

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GENERAL INFORMATION

2.7 USE FOR INTENDED PURPOSE

1 The Li-ion Battery is constructed as per the applicab le

safety-technical guidelines.

2 Use the Li-ion Battery only:

• in a technical correct condition;

• in a closed, well-ventilated area, protected

against rain, moist, dust and condensation;

• observing the instructions and specifications in this manual.

WARNING

Never use the Li-ion Battery in locations where there is danger of gas or dust explosion or potentially flammable products!.

3 Use of the Li-ion Battery other than m enti oned in point

2 is not considered to be consistent with the intended purpose. Mastervolt is not liable for any damage resulting from the above.

2.8 ORGANIZATIONAL MEASURES

The user must always:

• have access to the user's manual;

• be familiar with the contents of this manual. This

applies in particular to chapter Safety Guidelines and Measures.

2.9 MAINTENANCE AND REPAIR

1 If the electrical installation is switched off during

maintenance and/or repair activities, it should be secured against unexpected and unintentional switching on:

• switch off all charging systems;

• switch off the connection with the batteries;

• be sure that third parties cannot reverse the

measures taken.

2 If maintenance and repairs are required, only use

original spare parts.

2.10 GENERAL SAFETY AND INSTALLATION PRECAUTIONS

• Do not expose the Li-ion Battery to rain, snow, spray,

moisture, excessive pollution and condensing circumstances. To reduce risk of fire hazard, do not cover or obstruct the ventilation openings. Do not install the Li-ion Battery in a non-ventilated area, overheating may result.

• The Li-ion Battery must be provided with a MasterBus

controlled external cut off relay (refer to chapter 7)

• Short circuiting or reversing polarity will lead to

serious damage to the Li-ion Battery, equipment connected to the Li-ion Battery and the wiring. Fuses between can not prevent damage caused by reversed polarity and the warranty will be void.

• Protect the wiring with fuses, according to the

guidelines in this manual.

• Connection and protection must be done in

accordance with local standards.

• Do not work on the Li-ion Battery or system if it is still

connected to a power source. Only allow changes in your electrical system to be carried out by qualified electricians.

• Check the wiring at least once a year. Defects such as

loose connections, burned cables etc. must be corrected immediately.

2.11 WARNING REGARDING LIFE SUPPORT APPLICATIONS

The Li-ion Battery is 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 additional reliability testing of the Li-i on Battery parts and/or to commit to undertake such testing as a part of the manufacturing process. In addition the manufacturer must agree to indemnify and not hold Mastervolt responsible for any claims arising from the use of the Liion Battery in the life support equipment.

2.12 WARNING REGARDING THE USE OF BATTERIES.

Excessive battery discharge and/or high c harging volta ges can cause serious damage to batteries. Do not exceed the recommended limits of discharge level of your batteries. Avoid short circuiting batteries, as this may result in explosion and fire hazard. Installation and adjustments of the Li-ion Battery and its connected components should only be undertaken by authorised personnel!

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HOW IT WORKS

3 HOW IT WORKS

3.1 INTRODUCTION

This chapter describes the features of the Mastervolt Lithium Ion battery, a high capacity battery for deep cycle applications, suitable for parallel operation. Compared to the traditional lead acid battery, the Li-ion battery offers 70% weight and volume reduction, yet three times as many charging cycles.

A major advantage of Li-ion batteries is the constant available power at different discharge loads. Lead Acid battery capacity decreases at a high discharge current while the available Li-ion power remains 100%.

100%

80%

60%

40%

Available capacity

20%

20hr (8A) 10hr (16A) 5hr (32A) 3hr (53A) 1hr (160A)

Discharge time (current)

Figure 2: Available capacity versus discharge time (discharge current), Li-ion 24/160 compared to AGM

Key features of the Mastervolt Li-ion battery:

• Deep discharge cycles without noticea ble effect on the cycle life;

• No memory effect;

• No extra energy loss at high discharge levels;

• Short charging time compared to lead acid batteries;

• 90 up to 94% energetic efficiency;

• Cell management system for conditioned charge

and discharge regulation to increase safety and performance;

• Pre warnings about battery state of charge;

• Parallel connectable;

• Weighs about 30% of a comparable lead acid

battery;

• Dimensions are about 30% of a comparable lead acid battery;

• Maintenance free, no topping up of water;

• No gassing;

• MasterBus compatible;

• Integrated battery terminal isolators.

Li-Ion AGM

3.2 CELL MANAGEMENT SYSTEM

The Mastervolt Li-ion battery pack consists of eight cells. This combination offers both the voltage and power necessary for all kinds of 12V (24V) equipment. As with all kind of batteries, some kind of unbalance is always present in the battery pack. During charging in an unbalanced battery pack, one or more cells will reach the maximum charge level before the rest of the cells in the series string. During discharge the cells that are not fully charged will be depleted before the other cells in the string, causing early undervoltage shutdown of the pack. These early charge and discharge limits reduce the usa ble charge in the battery and will shorten the expected lifetime of the pack. To avoid this kind of premature failure, the Mastervolt Liion is provided with a Cell Management System. With this System, each cell is conditioned individually.

Features of the Cell Management System:

• Balancing between the different cells. Normally, cells in a series string receive identical currents. With the Cell Management System current from stronger cells will be transferred to the weaker cells during the charging/ discharging process and idle mode;

• Protection of each separate cell from overcharging or discharging by voltage monitoring of each cell;

• Protection from too deep battery discharges (with obligatory external cut-off relay);

• Monitoring of temperature. Each separate cell as well as the external temperature of the battery pack is being monitored;

• Communication with Mastervolt charge devices to maximize safety and performance;

• Pre warnings when the state of charge is becoming low. This feature is particularly useful for ships with electric propulsion. Reducing vessel speed in time ensures a safe return in the harbour.

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OPERATION

4 OPERATION

4.1 CHARGING

Charge the Li-ion Battery within the specifications as stated in chapter 12. See section 7.2 for recommended settings of the battery charger.

4.2 DISCHARGING

• Never discharge the Li-ion Battery beyond its specifications as stated in chapter 12.

• For this purpose, always use of a Latching Relay in combination with a MasterBus interface to control this cut-off relay is obligatory. Refer to installation instructions in chapter 7

4.3 BATTERY SAFETY EVENT

The Li-Ion battery must be protected by means of a Latching Relay in combination with a MasterBus interface to control this cut-off relay. This cut-off relay will be triggered when one of the following conditions is met during 30 seconds:

• The voltage of one of the Lithium Ion cells is less than

2.0 Volts;

• The voltage of one of the Lithium Ion cells is more than 4.5 Volts;

• The voltage of the Li-ion Battery is less than 10 Volts (for a 12V battery) or 20 Volts (for a 24Volt battery);

• The voltage of the Li-ion Battery is more than 15.5 Volts (for a 12V battery) or 31.0 Volts (for a 24Volt battery)

If the Battery Safety Event has been triggered, act as follows: 1 Disconnect all loads and all charging devices from the

Li-ion Battery.

2 Reset the Latching Relay(s) to reconnect the Li-ion

battery. To do so, move the Latching Relay(s) in the REMOTE ON position. See section 4.7.

4.7 MANUAL OPERATION OF THE LATCHING RELAY

Function Description Action

REMOTE ON To connect the Li-ion Battery to load and

charging devices

REMOTE OFF To disconnect the Li-ion Battery from

load and charging devices

LOCK OFF To prevent remote operation Rotate knob on top of the relay to right

3 Wait for 1 minute. If the Battery Safety Event triggers

again, do not try to reset the Latching Relay(s) again. In this case the Li-ion battery is damaged and sho uld not be used anymore. Move the Latching Relay(s) in the LOCK OFF position and contact a Mastervolt representative for assistance.

4 If the Battery Safety Event was not triggered again,

check the battery voltage with a suitable voltage meter. If the battery voltage is too low, keep the loads disconnected and start charging the Li-ion battery. If the battery voltage is too high, check the output voltage of the charging devices. If OK, discharge the Li-ion battery for a wile

4.4 MASTERBUS POWERING

The Li-ion battery is able to power the MasterBus network. Refer to section 8.1 Configuration: MasterBus Power for setting the battery to MasterBus powering. If enabled, the MasterBus network will drain the Li-ion Battery slowly.

4.5 MASTERBUS FUNCTIONALITY

Refer to chapter 8 for advanced MasterBus functionality.

4.6 TEMPERATURE

See specifications for recommended operating temperatures. Higher temperatures will seriously reduce service life. The temperature of each cell as well as the temper ature of the entire Li-ion battery is monitored by the cell management system (see section 3.2). Therefore, do not

use a sensor for temperature compensated charging.

Do not use a temperature sensor for temperature compensated charging!

Push button on top of the relay until latched

Rotate knob on top of the relay to right to release button; then rotate knob to left

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MASTERBUS

5 MASTERBUS

5.1 WHAT IS MASTERBUS?

All devices that are suitable for MasterBus are marked by the MasterBus symbol.

MasterBus is a fully decentralized data network for communication between the different Mastervolt system devices. It is a CAN-bus based communication network which has proven itself as a reliable bus-system in automotive applications. MasterBus is used as power management system for all connected devices, such as the inverter, battery charger, generator and many more. This facilitates communication between the connected devices, for instance to start the generator when the batteries are low.

MasterBus reduces complexity of electrical systems by using less cables. All system components are simply chained together. For this purpose every MasterBus device has been equipped with two MasterBus data p orts. When two or more devices are connected through these data ports, they become a local data network, called the MasterBus. The results are a reduction of installation costs as only a few electrical cables and less installation time are needed.

For central monitoring and control of the connected devices, Mastervolt offers a wide range of panels which

show full status information of your electrical system at a glance and a push of a button. Four different panels are available, from the small Mastervision compatible 120 x 65mm 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.

New devices can be added to the existing network in a very easy way by just extending the network. This makes the MasterBus a highly flexible network for extended system configuration, today and in the future.

Mastervolt also offers several interfaces, making even non-MasterBus devices suitable to operate in the MasterBus network. For direct communication between the MasterBus network and a product which is not from Mastervolt, several interfaces are available. Examples are the MasterBus NMEA interface and the MasterBus Modbus interface.

CAUTION: Never connect a non-MasterBus device to the MasterBus network directly! This will void warranty of all MasterBus devices connected.

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MASTERBUS

5.2 HOW TO SET UP A MASTERBUS NETWORK

Every device that is suitable for the MasterBus net work is equipped with two data ports. When two or more devices are connected to each other through these ports, they form a local data network, called the MasterBus.

Keep the following rules in mind:

Connections between the devices are made by standard straight UTP patch cables. Mastervolt can

The electric power for the network comes from the connected devices. At least one device in the network should have powering capabilities (see specifications). One powering device can power up to three nonpowering devices. As all powering devices are isolated galvanically, multiple powering devices are allowed.

supply these cables. These cables are also commonly available at computer supply stores.

Figure 3: UTP patch cable

As with all high speed data networks, MasterBus needs a terminating device on both ends of the network.

1-8

Figure 5: Power supply

Do not make ring networks.

Figure 6: No ring networks

Do not make T-connections in the network.

Terminating

device

Terminating

device

Figure 4: Two Terminators

Figure 7: No T-connections

Page 12

BEFORE YOU START

6 BEFORE YOU START

During installation and commissioning of the Liion battery, the Safety Guidelines & Measures are applicable at all times. See chapter 1 of this manual.

6.1 UNPACKING

After unpacking, check the contents for possible damage. Do not use the product if it is damaged. If in doubt, contact your supplier.

6.2 REQUIRED TOOLS:

• Hexagon socket wrench to connect the battery

cables to the

Model Socket wrench size

Li-ion Battery MLi 12/320 Li-ion Battery MLi 24/160

• Tools to install the wiring.

• For adjustment of setpoints: A MasterBus control

panel. Select one form the table below:

Part number Model

77010305 MasterView Easy MkII 77010400 MasterView System panel 77030100 MasterBus USB interface

6.3 LOCATION TO INSTALL

6.3.1 General

• Keep the Li-io n battery away from heat sources. See specifications for allowed operating temperatures.

• Keep the Li-ion battery away from moist.

• The Mastervolt Li-ion must be installed in upright

position.

• Keep at least 1 cm between two Li-ion batteries for air flow.

• The Li-ion battery must be secured to its foundation.

6.3.2 Ventilation

The Li-ion battery is provided with ventilation o penings for natural convection. Make sure that the hot air developed during operation can be discharged. Place the batter y in a sufficiently ventilated room.

Li-ion battery

13mm: 15mm

(required as interface between your PC and the MasterBus network)

6.4 EXTERNAL CUT-OFF RELAY

For safety purposes installation of a Latching Relay in combination with a MasterBus interface to control this cut-off relay is obligatory! Installation and commissioning of the Li-ion battery requires programming of events in a MasterBus communication network to control this external cut-off relay. The installer must be familiar with the programming of such events.

6.5 BATTERY TEMPERATURE SENSOR

The Cell Management System has an integrated battery temperature sensor. See section 8.5 for more information.

Do not use an external battery temperature sensor.

6.6 GENERAL INSTALLATION GUIDELINES

• Switch off all loads and chargers before starting installation.

• Batteries in series or parallel must be of the same brand, type, capacity, nominal voltage and state of charge. Do not mix old and new batteries. Never use a Li-ion in parallel or in series with other kind of batteries, such as lead-acid batteries.

• Use properly sized and reliable, cables, cable lugs and battery terminals. Tighten all connections. For the main DC connections use 14.7 to 19.6 Nm / 130 to 170 InLbs torque. Do not over torque as this will damage the Li-ion Battery beyond repair.

• Unused wiring should be insulated properly to avoid accidental contact.

• Connect the battery with the correct polarity to the charger and load(s) (positive pole to positive terminal). Note that the position of the battery poles may differ from previously installed batteries! In installations with a negative earth, connect the negative cable last of all to prevent short circuiting.

• After connecting the battery cable, close the protection lids (grip handles of the Li-ion battery) to prevent incidental touching of the terminals.

Page 13

INSTALLATION AND COMMISSIONING

7 INSTALLATION AND COMMISSIONING

The sections in this chapter describe the minimum requirements for installation and commission ing of the Li-ion battery. Refe r to chapter 8 for advanced functionality.

Installation and commissioning of the Li-ion battery consist of the following steps:

STEP 1

STEP 2

7.1 STEP 1: INSTALLATION

The way Installation and commissioning should be executed, depends on the configuration in which the Li-ion battery is used.

Check your configuration from the table below and proceed with the indicated section

Configuration Section

Single battery 7.1.1 Parallel connection, total maximum current < 200 Amps 7.1.2 Parallel connection, total maximum current > 200 Amps 7.1.3 Serial connection, using one charger to charge all batteries 7.1.4 Serial connection, using one charger per battery 7.1.5

7.1.1 Single battery installation

7.1.1.1 Required materials

Quantity @ 12V @ 24V

1 -- 66010320 Li-ion Battery MLi 12/320

-- 1 66020160 Li-ion Battery MLi 24/160 1 1 77030500 MasterBus MPC (Multi Purpose Contact Output) 1 -- 79007700 Latching Relay 12V/300A – Blue Sea Systems, part # 7700

-- 1 79007702 Latching Relay 24V/300A – Blue Sea Systems, part # 7702 1 1 Main Fuse + Fuse base to protect the DC Main Wiring

1 1 2A-T Fuse + fuse holder to protect the wiring of the control circuit of the Latching Relay 1 1 MasterBus control panel (see section 6.2) ** ** DC Main Wiring, cross section depending on Main Fuse, max 70mm² ** ** Wiring for the c ontrol circuit of the Latching Relay, minimum cross section: 0.5mm² ** ** MasterBus communication cables ** Installation dependent

Installation

Commissioning

Mastervolt Part number

Description

Fuse rating depending on the cross section of the applied DC Main Wiring, max 200A.

Page 14

INSTALLATION AND COMMISSIONING

7.1.1.2 Installation instructions

1 Move the Latching Relay in the LOCK OFF position. See section 4.7

2 Connect the DC Main Wiring as indicated in figure 8 but do not place the Main Fuse yet

3 Connect the wiring for the con t rol circuit of the Latching Relay as indicated in figure 8

4 Connect the MasterBus cabling between the devices as indicated in figure 8. Keep the rules in mind as described in

section 5.2. Add a MasterBus control panel to the MasterBus network.

1. MasterBus MPC

BROWN*

YELLOW*

* WIRE NOT USED

ORANGE

BLACK

RED

2. Main Fuse

3. 1A-T Fuse

4. Li-ion battery

5. Latching Relay

6. MasterBus control panel

7. DC Main Wiring

8. Control circuit wiring

9. MasterBus cabling

10. MasterBus terminator or connection to another MasterBus device

Terminal 2: not connected

Figure 8: Single battery installation

5 Continue with section 7.2

Page 15

INSTALLATION AND COMMISSIONING

7.1.2 Parallel connection, total maximum current < 200 Amps

CAUTION: I

If more than 10 Li-ion batteries must be connected in parallel, please contact your Mastervolt supplier for advice.

CAUTION: I

If Li-ion batteries need to be replaced individually, make sure that: Before reconnection: the open circuit voltage of these batteries must equal the voltage of the parallelled batteries. After reconnection: MasterBus events need to be reprogrammed for each replaced battery

7.1.2.1 Required materials

Quantity @ 12V @ 24V

Mastervolt Part number

Description

n* -- 66010320 Li-ion Battery MLi 12/320

-- n* 66020160 Li-ion Battery MLi 24/160 1 1 77030500 MasterBus MPC (Multi Purpose Contact Output) 1 -- 79007700 Latching Relay 12V/300A – Blue Sea Systems, part # 7700

-- 1 79007702 Latching Relay 24V/300A – Blue Sea Systems, part # 7702 1 1 Main Fuse + Fuse base to protect the DC Main Wiring

Fuse rating depending on the cross section of the applied wiring, max 200A.

n* n* Fuse + Fuse base to protect the wiring to the Li-ion Battery

Fuse rating depending on the cross section of the applied wiring, max 160A. 1 1 2A-T Fuse + fuse holder to protect the wiring of the control circuit of the Latching Relay 1 1 MasterBus control panel (see section 6.2) 2 2 DC Bus bar to connect the DC Main Wiring ** ** DC Main Wiring, cross section depending on the applied fuses, max. 70mm² ** ** Wiring for the c ontrol circuit of the Latching Relay, minimum cross section: 0.5mm² ** ** MasterBus communication cables * n = Number of Li-ion Batteries installed in parallel, maximum number: 10 ** Installation dependent

Page 16

INSTALLATION AND COMMISSIONING

7.1.2.2 Installation instructions

1 Move the Latching Relay in the LOCK OFF position. See section 4.7

2 Connect the DC Main Wiring as ind icated in figure 9 but do not place the fuses yet

3 Connect the wiring for the con t rol circuit of the Latching Relay as indicated in figure 9

4 Connect the MasterBus cabling between the devices as indicated in figure 9. Keep the rules in mind as described in

section 5.2. Add a MasterBus control panel to the MasterBus network.

BROWN*

YELLOW*

* WIRE NOT USED

ORANGE

BLACK

RED

Terminal 2: not connected

Figure 9: Two or more batteries in parallel, Total maximum current < 200 Amps

5 Continue with section 7.2

1. MasterBus MPC

2. Main Fuse

3. 1A-T Fuse

4. Li-ion battery

5. Latching Relay

6. MasterBus control panel

7. DC Main Wiring

8. Control circuit wiring

9. MasterBus cabling

10. MasterBus terminator or connection to another MasterBus device

11. Fuse to protect the wiring to the Li-ion Battery

12. DC Bus-bar

Page 17

INSTALLATION AND COMMISSIONING

7.1.3 Parallel connection, total maximum current > 200 Amps

CAUTION: I

If more than 10 Li-ion batteries must be connected in parallel, please contact your Mastervolt supplier for advice.

CAUTION: I

7.1.3.1 Required materials

Quantity @ 12V @ 24V

Mastervolt Part number

Description

n* -- 66010320 Li-ion Battery MLi 12/320

-- n* 66020160 Li-ion Battery MLi 24/160 1 1 77030500 MasterBus MPC (Multi Purpose Contact Output) n* -- 79007700 Latching Relay 12V/300A – Blue Sea System s, part # 7700

-- n* 79007702 Latching Relay 24V/300A – Blue Sea System s, part # 7702 1 1 Main Fuse + Fuse base to protect the DC Main Wiring

Fuse rating depending on the cross section of the applied wiring. n* n* Fuse + Fuse base to protect the wiring to the Li-ion Battery

fuses, max 70mm². ** ** DC Main Wiri ng, cross section depending on the applied Main Fuse. ** ** Wiring for the c ontrol circuit of the Latching Relay, minimum cross section: 0.5mm² ** ** MasterBus communication cables * n = Number of Li-ion Batteries installed in parallel, maximum number: 10 ** Installation dependent

Page 18

INSTALLATION AND COMMISSIONING

7.1.3.2 Installation instructions

1 Move the Latching Relay in the LOCK OFF position. See section 4.7

2 Connect the DC Main Wiring as indicated in figure 10 but do not place the fuses yet

3 Connect the wiring for the control circuit of the Latching Relay as indicated in figure 10

4 Connect the MasterBus cabling b etween the devices as indicated in figure 10. Keep the rules in mind as described in

section 5.2. Add a MasterBus control panel to the MasterBus network.

YELLOW*

* WIRE NOT USED

YELLOW*

BROWN*

YELLOW*

BROWN*

YELLOW*

BROWN*

ORANGE

RED

BLACK

ORANGE

RED

Terminal 2: not connected

1. MasterBus MPC

2. Main Fuse

3. 2A-T Fuse

4. Li-ion battery

5. Latching Relay

6. MasterBus control panel

7. DC Main Wiring

Figure 10: Two or more batteries in parallel, Total maximum current > 200 Amps

5 Continue with section 7.2

8. Control circuit wiring

9. MasterBus cabling

10. MasterBus terminator or connection to another MasterBus device

11. Fuse to protect the wiring to the Li-ion Battery

12. DC Bus-bar

Page 19

INSTALLATION AND COMMISSIONING

7.1.4 Serial connection, using one charger to charge all batteries

When the Li-ion Batteries are connected in series, the charging process must be balanced. T his can be done by means of DC/DC-converter, model MAGIC 24/24-20. When an imbalance is recognized by the The MasterBus SBS Interface (Serial Balancing System Interface), these DC/DC-converters will be actuated aut omatically to level the imbalances. For each Li-ion Battery one DC/DC-converter is required.

CAUTION: I

Serial connection of Li-ion Batteries is only possible with two or more Li-ion Batteries type MLi 24/ 160. If more than two Li-ion batteries must be connected in series, always consult your Mastervolt supplier for advice. Serial connection of Li-ion Batteries type MLi 12/320 is not possible

CAUTION: I

If Li-ion batteries need to be replaced individually, make sure that: After reconnection: MasterBus events need to be reprogrammed for each replaced battery

7.1.4.1 Required materials

Quantity @ 24V

Mastervolt Part number

Description

n* 66020160 Li-ion Battery MLi 24/160 1 77030500 MasterBus MPC (Multi Purpose Contact Output) 1 79007702 Latching Relay 24V/300A – Blue Sea Systems, part # 7702 2 Main Fuse + Fuse base to protect the DC Main Wiring

Fuse rating depending on the cross section of the applied wiring.

** Fuses + Fuse bases to protect the wiring after each two Li-ion Batteries. Refer to local

regulations. Fuse rating depending on the cross section of the applied wiring. n* 30A-T Fuse + fuse holder to protect to the DC/DC-converters. 1 2A-T Fuse + fuse holder to protect the wiring of the control circuit of the Latching Relay 1 MasterBus control panel (see section 6.2) 1 77030500 MasterBus SBS Interface (Serial Balancing System Interface) n* 81300200 DC/DC-converter, model MAGIC 24/24-20 ** DC Main Wiring, cross section depending on the applied fuses (max 70mm²) ** DC Wiring to connect the DC/DC converters model MAGIC; cross section: 6mm² ** Wiring for the control circuit of the Latching Relay, minimum cross section: 0.5mm² ** MasterBus communication cables * n = Number of Li-ion Batteries installed in parallel, maximum number: 10 ** Installation dependent

Page 20

INSTALLATION AND COMMISSIONING

7.1.4.2 Installation instructions

1 Move the Latching Relay in the LOCK OFF position. See section 4.7

2 Connect the DC Main Wiring as indicated in figure 11 but do not place the fuses yet

3 Connect the wiring for the control circuit of the Latching Relay as indicated in figure 11

1. DC/DC converter, model MAGiC 24/24-20

2. MasterBus Serial Interface

4. 30A-T Fuse (DC/DC-converters)

5. Li-ion battery 6 Fuse after each two Li-ion Batteries

7. DC Fuse Main Wiring (Positve)

8. MasterBus MPC Interface

Figure 11: Two or more batteries in series, using one charger to charge all batteries (Only DC-wiring is shown)

* WIRE NOT USED

BLACK

ORANGE

Terminal 2: not connected

MasterBus control panel

10. MasterBus SBS Interface

11. DC Fuse Main Wiring (Negative)

12. DC main wiring

13. Control circuit wiring 14 DC wiring (DC/DC-converters)

15. DC Fuse Control circuit wiring 16 Latching Relay

YELLOW*

RED

BROWN*

Page 21

INSTALLATION AND COMMISSIONING

4 See figure 12. Connect the MasterBus cabling between the devices as indicated. Keep the rul es in mind as described in

section 5.2. Note the zigzag MasterBus cabling. This way of conn ecting prevents under powering of MasterBus devices. Add a MasterBus control panel to the MasterBus network.

5 See figure 12. Connect the MasterBus Serial Interfaces to the communication port of the DC/DC-converters by means of

the serial communication cables.

1. DC/DC converter, model MAGiC 24/24-20

2. MasterBus Serial Interface

3. Serial communication cable

5. Li-ion battery

8. MasterBus MPC Interface

9. MasterBus control panel

10. MasterBus SBS Interface

12. MasterBus terminator or connection to another MasterBus device

Figure 12: Two or more batteries in series, using one charger to charge all batteries (Only communication wiring is shown)

6 Refer to the manual of the SBS-interface to configure the SBS-interface

7 Continue with section 7.2

Page 22

INSTALLATION AND COMMISSIONING

7.1.5 Serial connection, using one charger per battery

When the Li-ion Batteries are connected in series, the cha rging process must be balan ced. Instead of using DC/DC-converter for balancing of the charging process (section 7.1.4), c ell balancing c an also be ac hieved by connectin g each Li-ion Battery t o its own charger.

CAUTION: I

If Li-ion batteries need to be replaced individually, make sure that: After reconnection: MasterBus events need to be reprogrammed for each replaced battery

7.1.5.1 Required materials

Quantity @ 24V

Mastervolt Part number

Description

n* 66020160 Li-ion Battery MLi 24/160 1 77030500 MasterBus MPC (Multi Purpose Contact Output) 1 79007702 Latching Relay 24V/300A 2 Main Fuse + Fuse base to protect the DC Main Wiring

Fuse rating depending on the cross section of the applied wiring. ** Fuses + Fuse bases to protect the wiring after each two Li-ion Batteries. Refer to local

regulations. Fuse rating depending on the cross section of the applied wiring. n* 44020200 Mastervolt Battery charger, model ChargeMaster 24/20-3 n* Fuses + Fuse bases to protect the DC wiring to the battery chargers. Refer to the user’s

manual of the battery charger for fuse ratings. 1 2A-T Fuse + fuse holder to protect the wiring of the control circuit of the Latching Relay 1 MasterBus control panel (see section 6.2) ** DC Main Wiring, cross section depending on the applied fuses (max 70mm²) ** DC Wiring to connect the battery chargers. Refer to the user’s manual of the battery charger

for for applicable cable cross section) ** Wiring for the control circuit of the Latching Relay, minimum cross section: 0.5mm² ** MasterBus communication cables * n = Number of Li-ion Batteries installed in parallel, maximum number: 10 ** Installation dependent

Page 23

INSTALLATION AND COMMISSIONING

7.1.5.2 Installation instructions

1 Move the Latching Relay in the LOCK OFF position. See section 4.7

2 Connect the DC Main Wiring as indicated in figure 13 but do not place the fuses yet

3 Connect the wiring for the control circuit of the Latching Relay as indicated in figure 13

_ _

1. MasterBus MPC Interface

2. Mastervolt battery charger, model ChargeMaster 24/20-3

3. Fuses to protect the DC wiring to the battery chargers

Figure 13: Two or more batteries in series, using one charger to charge all batteries (DC-wiring)

4. Li-ion battery

5. DC Fuse Main Wiring (Positve)

6. DC Fuse Main Wiring (Negative)

7. DC Fuse Control circuit wiring

8. Latching Relay

9. MasterBus control panel

10. Fuse after each two Li-ion Batteries

* WIRE NOT USED

ORANGE

Terminal 2: not connected

BLACK

RED

YELLOW*

BROWN*

Page 24

INSTALLATION AND COMMISSIONING

4 See figure 14. Connect the MasterBus cabling between the devices as indicated. Keep the rul es in mind as described in

section 5.2. Add a MasterBus control panel to the MasterBus network.

1. MasterBus MPC Interface

4. Li-ion battery

9. MasterBus control panel

12. MasterBus terminator or connection to another MasterBus device

Figure 14: Two or more batteries in series, using one charger to charge all batteries (Communication w iring)

5 Continue with section 7.2

Page 25

INSTALLATION AND COMMISSIONING

7.2 STEP 2: COMMISSIONING

CAUTION: I

The configuration as described in this section is only valid when the cut-off relay and the MasterBus MPC Interface were used as specified in this manual. When an alternati ve cut-off relay and/or an alternative MasterBus Interface was used, configuration may be different. In this case, it is the installer’s responsibility to configure the MasterBus Interface an the Li-ion battery in such way that the Li-ion battery will be disconnected from all loads and chargers if the Li-ion battery generates a Battery Safety Event

Follow the steps in the order as described below.

7.2.1 Charger settings

A single Mastervolt Li-ion battery can be charged with any standard Mastervolt battery charger. Adjust charge characteristic of the IUoUo characteristic as follows:

Nominal battery voltage

Bulk / absorption voltage setting

Float voltage setting

12V 14.6 V 13.5 V 24V 29.2 V 27.0 V

Refer to the user’s manual of the battery charger for adjustment.

7.2.2 General

1 Check if all DC-wiring, MasterBus wiring and Latch ing

Relay(s) has been connected correctly, refer to

section 7.1; 2 All loads and charging device(s) must remain off. 3 Install all fuses. 4 Connect the Li-ion batteries by moving the Latching

Relay(s) in the REMOTE ON position (push the button

on top of the relay). See section 4.7 5 Switch On the MasterBus display or use a PC in

combination with a MasterBus – USB Inetrface +

MasterAdjust software;

7.2.3 Configuration of the Multi Purpose Contact

interface (“INT DC Relay”)

1 Select the Multi Purpose Contact interface (“INT DC

Relay”) 2 Select the “Configuration” page 3 Select subgroup “Timing” 4 Enable the “Pulse” option

Figure 15

Page 26

INSTALLATION AND COMMISSIONING

5 To check the correct operation of the Multi Purpose

Contact interface, select the “Monitoring” page of the

Multi Purpose Contact interface (“INT DC Relay”) 6 Select subgroup “Device” 7 Switch the Override function from “Standby” to

“Activate”

Figure 16

8 After approximately 1 second the Override function

switches back from “Activate” to “Standby” again.

Check whether the Latching Relay was activated to

switch off the Li-ion battery. Now the Latching Relay

should be is in the REMOTE OFF position (see

section 4.7). 9 If the Latching Relay is working properly, reconnect

the Li-ion batteries by moving the Latching Relay(s) in

the REMOTE ON position again (push the button on

top of the relay). See section 4.7

Repeat steps 1 to 9 for each installed Multi Purpose Contact interface.

7.2.4 Configuration of the Battery Safety Event

1 Select the Li-ion battery (“BAT Li-ion”) 2 Select the “Events” page of the Li-ion battery 3 Configure the Battery Safety Event with the

MasterBus MPC Interface (INT DC Relay) as target. See table below.

Configuration Event 1

Event source Battery Safety Event target INT DC Relay Event command Activate Event data On

CAUTION: I

Depending on the applied installation, additional programming of MasterBus events may be necessary. See chapter 8 for details

4 Repeat steps 1 till 3 for each install ed Li-ion battery 5 Connect the load. Then verify that current is flowing

out of the battery.

6 Disconnect the load and connect the charger and

verify that current is flowing into the battery;

7 If necessary, check if the battery is in MasterBus

Powering mode. See section 8.1 Configuration: MasterBus Power.

8 If such is required, you may remove the MasterBus

control panel to the MasterBus network now. Not that the rules for setting up a MasterBus network still apply

Page 27

USER INTERFACE (VIA MASTERBUS)

8 USER INTERFACE (VIA MASTERBUS)

The Li-ion battery must be configured via MasterBus. For this purpose, several MasterBus displays are available, chapter 4.

8.1 MASTERBUS MENUS

Menu Description Default Range

Monitoring Battery (V) Battery voltage measured by the cell management system Battery (A) (Dis)charging current measured by the cell management system Battery (°C) Battery temperature Compensation The cell management system compensates charge and discharge

current. This value tells the current is being compensated or not. Date Date in dd-mm-yyyy Time Time in hh:mm:ss Alarm Battery Safety Single event to meet the specified safety requirements. See

section 8.4 Over current Advanced event for better battery performance and safety. See

section 8.5 Temperature Advanced event for better battery performance and safety. See

section 8.5 History Run time Total running time (since first use) in hh:mm:ss Conversion time Total cell balancing time (since first use) in hh:mm:ss Configuration, device Language Language setting of the battery. NOTE: the language of the

display may be different from this setting. Name Name of your Li-ion battery in the MasterBus system. If you have

more than one unit, changing names improves clarity. Configuration, time Minutes Time setting of the real time clock: minutes 00-59 Hour Time setting of the real time clock: hour 00-23 Day Time setting of the real time clock: day 01-31 Month Time setting of the real time clock: month January-December Year Time setting of the real time clock: year 2000-2200 MasterBus Power The Li-ion battery can be set to power the MasterBus or not. Off Off, On Events

Event 1 source

Select an event to serve as Event 1

(see sections 8.4 and 8.5 for event trigger points):

Overvoltage = battery (cell) voltage too high

Undervoltage = battery (cell) voltage too low

See section Event trigger points for more information.

Event 1 target Event 1 command Event 1 data Event 2 to 63

Select a device to perform the task if Event 1 takes place. Select… System dependent.

Select a command, depending on the target device you choose. Select… System dependent.

Data is linked to the command. See section 8.2. Off See section 8.2.

Up to 63 events are configurable on the Li-ion battery.

On, Stand by

English

Li-ion Any maximum 12

character name

Disabled See description

Page 28

USER INTERFACE (VIA MASTERBUS)

8.2 MASTERBUS EVENT DATA

Input

Output

Off

Copy

Copy Invert

Toggle

Figure 17: Event data

See figure 17. The input could be illustrated by an on/off switch.

On changes the status to On at the first signal. Off changes 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 combination with a pulse switch.

8.3 EXCHANGING MASTERBUS DEVICES

When exchanging a MasterBus device in the network, the event configuration needs to be redone for the new device. The configuration of the device itself must be done and the s urroundin g device s that us e the exc hanged dev ice as an ev ent target, have to be adjusted as well.

8.4 BASIC MASTERBUS EVENTS: BATTERY SAFETY EVENT

The Li-ion battery software helps to protect your battery from too deep discharges. If the battery has been dischar ged too deep, this software triggers an event, called the Battery Safety Event. This event must be used for configuration of the Latching Relay(s) and the MasterBus MPC Interface. Refer to chapter 7 for configuration.

The Battery Safety Event repeats every 60 seconds. It will only stop repeating if:

• all conditions in the table below are untrue;

• the battery detects a charger current when the battery voltage is low;

• the battery detects a discharge current when the battery voltage is high.

See the table below for an explanation of the Li-ion battery event sources.

Event source Condition Meaning

Battery Safety

Single event to meet the specified safety requirements. Together with the event, an alarm pop up appears.

Ucell too low The voltage of one or more cells is 2V Ucell too high The voltage of one or more cells is 4.5V Ubat too low Battery voltage is 20V (10V for 12V Li-ion) Ubat too high Battery voltage is 31V (15.5V for 12V Li-ion)

Page 29

MAINTENANCE

If the Battery Safety Event doesn’t stop, it means that the Li-ion battery is being disabused. For safety purposes, the Battery Safety Event will become non-recoverable when one of the conditions of below table is met. If such happens, do not try to reset the Latching Relay(s) again. In this case the Li-ion battery is damaged and should not be used anymore. Move the Latching Relay(s) in the LOCK OFF position and contact a Mastervolt representative for assistance

If the Battery Safety Event is not recoverable, the Li-ion battery has been damaged. It shall not be charged or discharged anymore. Contact a Mastervolt representative for assistance! These costs are not covered by guarantee.

Event source Condition Meaning

Battery Safety Event (not recoverable)

Single event to meet the specified safety requirements. Together with the event, an alarm pop up appears.

Ucell critically low The voltage of one or mor e ce lls is 1V Ucell critically high The voltage of one or more cells is 5V Ubat critically low Battery voltage is 18V (9V for 12V Li-ion) Ubat critically high Battery voltage is 32V (16V for 12V Li-ion) Tcell too high The temperature of one or more cells is 80°C

8.5 ADVANCED MASTERBUS EVENTS

Event source Condition Meaning

Advanced

Any of the following

conditions is met during 30 s: Reduce charge Advanced settings are meant to improve

Ucell high The voltage of one or more cells is 3.6V

Ubat high The voltage of one or more cells is 29V the use and safety of the Li-ion batteries.

Reduce discharge

Ucell low The voltage of one or more cells is 2.4V

Ubat low The voltage of one or more cells is 22V

Stop charge

Ucell VeryHigh T he voltage of one or more cells is 3.8V

Ubat VeryHigh The voltage of one or more cells is 30V

Stop discharge

Ucell VeryLow The voltage of one or more cells is 2.2V

Ubat VeryLow The voltage of one or more cells is 21V

Overcurrent

Ibat TooHigh The battery current is over 600A An alarm pop up appears.

Temperature

Tcell high The temperature of one or more cells is 70°C An alarm pop up appears.

8.6 EVENTS WITH THE LI-ION BATTERY AS TARGET

There are no events with the Li-ion battery as target.

Page 30

TROUBLE SHOOTING

9 TROUBLE SHOOTING

Failure Possible cause What to do

No electric power on the ship

Alarm on the MasterView Easy MasterView display shows no Li-ion battery

A fuse has blown Check all fuses and replace if necessary A cable or cable connection is defective Check all cables and their connections. Replace if

necessary. A relay has accidentally switched position. Check all relays. The Battery Safety Event has triggered the Latching Relay to switch off the battery load. Ucell High, Ubat High, Ucell VeryHigh, Ubat

Switch on the load and switch off the charger. The

battery will resume its function as soon as the over

voltage status has ceased. Refer to section 4.3 VeryHigh. The Battery Safety Event has triggered the Latching Relay to switch off the battery load. Ucell Low, Ubat Low, Ucell VeryLow, Ubat

Switch off the load and switch on the charger. The

battery will resume its function after the under voltage

status has ceased. Refer to section 4.3 VeryLow. The Battery Safety Event has triggered the Latching Relay to switch off the battery load. Tcell High, Tcell VeryHigh, Tbat High, Tbat

Switch off the load and switch off the charger. At

normal temperature the battery will resume its

function. Refer to section 4.3 VeryHigh An alarm is activated. Read the MasterView Easy pop up to find the alarm

cause to start with. Error in the wiring Check the MasterBus cables. No terminating device placed at the ends of the network. MasterBus network is configured as a ring network.

MasterBus needs a terminating device on both ends

of the network(See section 5.2). Check if available.

Ring networks are not allowed. Check the

connections of the network (Section 5.2).

Page 31

MAINTENANCE

10 MAINTENANCE

10.1 BATTERY MAINTENANCE

No specific maintenance of the Li-ion battery is required. Examine your electrical installation on a regular base, at least once a year. Defects such as loose connections, burnt wiring etc. must be corrected immediately. Keep the battery clean and dry to avoid leakage currents. If necessary, use a soft clean cloth to clean casing of the Li-ion battery. Never use any liquids, acids and/ or scourers.

10.2 TAKING OUT OF OPERATION

If it is necessary to take the Li-ion battery out of oper ation, follow the instructions in order of succession as described below:

Disconnect all loads and charging devices.

1 2 Move the Latching Rel ay(s) in the LOCK O FF positio n

(see section 4.7)

3 Disconnect all wiring

Now the Li-ion battery can be demounted in a safe way.

10.3 STORAGE

The Li-ion battery should be stored in a dry and well ventilated environment. The rate of self discharge is less than 3% per month. Elevated environmental temperatures increase the self-discharge rate of the batteries and natural aging.

10.4 BATTERY REPLACEMENT

CAUTION: I

Page 32

ORDERING INFORMATION

11 ORDERING INFORMATION

Part number Description

66020160 Li-ion Battery MLi 24/160 66010320 Li-ion Battery MLi 12/320 77030500 MasterBus MPC (Multi Purpose Contact Output) 79007700 Latching Relay 12V/300A – Blue Sea Systems, part # 7700 79007702 Latching Relay 24V/300A – Blue Sea Systems, part # 7702 77031700 Battery Contactor Interface for 24V Li-ion battery 77031500 Digital AC 1x6A 77010305 MasterView Easy MkII 77010400 MasterView System panel 77030100 MasterBus USB interface, required as interface between your PC and the MasterBus network 77040000 MasterBus terminator for the MasterBus network 77040100 MasterBus connection cable 1,0m / 3.3ft 77040300 MasterBus connection cable 3,0m / 10ft 77040600 MasterBus connection cable 6,0m / 20ft 77041000 MasterBus connection cable 10m / 33ft 77042500 MasterBus connection cable 25m / 82ft 77050100 100m / 330ft MasterBus cable 77050200 50 pcs. MasterBus connectors 77050000 Complete set to assemble MasterBus cables. Delivery includes: 100m / 330ft MasterBus cable, 50 pcs.

modular jacks and crimping tool

Page 33

TECHNICAL INFORMATION

12 TECHNICAL INFORMATION

12.1 SPECIFICATIONS Model MLi 12/320 MLi 24/160

Article number 66010320 66020160 Nominal voltage 13.25 V 26.5 V Nominal capacity (C1-C20) 320 Ah 160 Ah Nominal energy 4.3 kWh 4.3 kWh Approximate weight: 55 kg (121 lbs) 55 kg (121 lbs) Number of cells: 8 8 Terminal type: Bolts M10 Bolts M8 Technology Lithium iron phosphate Lithium iron phosphate

Charge parameters

Charge voltage- cut off at 0,015C Recommended 14.6 V,

Minimum 14.25 V Recommended Float voltage 13.5 V 27.0 V Discharge cut off voltage 11.0 V 22.0 V Recommended charge/ discharge current 0.3C 100 A 50 A Maximum charge/ discharge current 1C 320 A 160 A

Rated capacity

20h discharge 320 Ah 160 Ah 10h discharge 320 Ah 160 Ah 5h discharge 320 Ah 160 Ah 3h discharge 320 Ah 160 Ah 1h discharge 320 Ah 160 Ah

Cold cranking Amps

Pulse current (10 sec) < 3200 A < 1600 A

Cycle life

@ 80% DOD ~ 2000 ~ 2000

General

Parallel configuration Yes, unlimited when fused properly Series configuration Yes, up to 10 batteries in series, additional measures are required,

always contact Mastervolt Operating temperature* –20 to 60 ºC / –4 to 140 ºF –20 to 60 ºC / –4 to 140 ºF Nominal operating temperature: 25 ºC 25 ºC Storage temperature –20 to 75 ºC / –4 to 167 ºF –20 to 75 ºC / –4 to 167 ºF Self discharge < 3% per month @ 20 ºC < 3% per month @ 20 ºC Guarantee 2 years 2 years Protection degree IP 43 IP 43

Dimensions

Length (L) 623±2mm / 24.5±0.1” 623±2mm / 24.5±0.1” Width (W) 199±2mm / 7.8±0.1” 199±2mm / 7.8±0.1” Height including terminals (H) 345±2mm / 13.6±0.1” 345±2mm / 13.6±0.1” Installation angle 0º (upright) 0º (upright)

Interfacing

MasterBus connectivity Yes Yes Powering capabilities for MasterBus Yes, when the Li-ion battery is switched on, it can power up to three

non-powering devices. * Temperatures under 5 ºC and above 25 ºC may affect life time and cycle life.

Recommended 29.2 V, Minimum 28.5 V

Page 34

[

TECHNICAL INFORMATION

12.2 DIMENSIONS

623 24,5

199 7,84

12.3 CHARGE, DISCHARGE CHARACTERISTIC

345 13,6

Figure 25: Li-ion battery MLi 12/320 and MLi 24/160, dimensions in mm

inch]

320 (160) A

5.0 (2.5) A 0 A

See figure 26. The charge characteristic shows the 3-step charging of the Li-ion battery. Bulk stops when the battery voltage has reached 14.6 (29.2) V. Absorption stops a preset time after the charge current has reached 5.0 (2.5) A (return amps). The charge voltage then changes to 13.5 (27.0) V (Float) until the Return to Bulk voltage has been reached.

14.6 (29.2) V

14.0 (28.0) V

80%

1.0 C

0.5 C

0.3 C

12.0 (24.0) V

10.0 (20.0) V

Figure 27: Discharge characteristic of the Li-ion battery model MLi 12/320 (24/160)

See figure 27. The Li-ion discharge characteristic shows the voltage curve remains level for about 80% of the discharge. Before and after this, the voltage drops fast.

14.6 (29.2) V

13.5 (27.0) V

11.0 (22.0) V

Figure 26: Charge characteristic of Li-ion battery MLi 12/320 (24/160)

Self-discharge in relation to the storage temperature

100%

80%

60%

40%

% capacity

20%

0 2 4 6 8 10 12 14 16 18 20 22 24

Storage in months

Figure 28: Self discharge characteristic Li-ion battery models MLi 12/320 and MLi 24/160 versus storage time

12.4 FUSE TO WIRE

For fuses that comply with your cabling cross sections, we refer to ISO 10133:2000.

20 °C25 °C30 °C40 °C

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EC DECLARATION OF CONFORMITY

13 EC DECLARATION OF CONFORMITY

We,

Manufacturer Mastervolt International B.V.

Address Snijdersbergweg 93 1105 AN Amsterdam The Netherlands

Declare under our sole responsibility that

Product: Mass battery chargers

Model Lithium Ion Battery MLI 24/160 Lithium Ion Battery MLI 12/320

Is in conformity with the provisions of the following EC directives:

2006/95/EC (Safety directive); The following harmonized standards have been applied:

• EN 60950-1:2001+ A11:2004 (LVD)

2004/108/EC (EMC directive); The following harmonized standards have been applied:

• EN 61000-6-3: 2007 Emission hold equipment

• EN 61000-6-2: 2007 Immunity industrial

Amsterdam, 28/10/2010 Mastervolt international B.V.

H.A. Poppelier Product manager Marine & Mobile

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Snijdersbergweg 93, 1105 AN Amsterdam, The Netherlands

Tel : + 31-20-3422100

Fax : + 31-20-6971006

Email : info@mastervolt.com