Mastervolt MLi Ultra 12/5000 Installation And Commissioning Manual

INSTALLATION AND COMMISSIONING OF MULTIPLE BATTERIES

Li-ion Battery

MLi Ultra 12/2500

MLi Ultra 12/5000

MLi Ultra 24/5000

MASTERVOLT

Snijdersbergweg 93

1105 AN Amsterdam

The Netherlands

Tel.: +31-20-3422100

Fax.: +31-20-6971006

ENGLISH: PAGE 1

NEDERLANDS: PAGINA 17

DEUTSCH: SEITE 33

FRANÇAIS: PAGINA 49

CASTELLANO: PAGINA 65

ITALIANO: PAGINA 81

TABLE OF CONTENTS

this document in any form without the prior written permission of Mastervolt is prohibited.

TABLE OF CONTENTS: 10000005933/03 January 2014

1IMPORTANT INFORMATION .......................................................................................................................................... 3

1.1Unpacking .......................................................................................................................................................... 3

1.2Needed for installation: ....................................................................................................................................... 3

1.2.1Ventilation .......................................................................................................................................... 3

1.3External cut-off relay .......................................................................................................................................... 3

1.4General installation guidelines ............................................................................................................................ 3

1.5Connection module ............................................................................................................................................ 4

2INTRODUCTION TO MLI GROUPS ................................................................................................................................ 5

2.1Definition of an mli GROUP ................................................................................................................................ 5

2.2mli Group features .............................................................................................................................................. 5

2.2.1Balance line for 48 volt systems ........................................................................................................ 5

2.2.2Cluster functionality when using MasterBus ...................................................................................... 5

2.2.3Reduction of the installation requirement .......................................................................................... 5

2.3MasterBus Cluster functionality .......................................................................................................................... 5

2.3.1Setup Li-ion battery clusters. ............................................................................................................. 5

2.4BALANCE LINE FOR TWO BATTERIES IN SERIES ........................................................................................ 7

2.4.1Advantages of using the Balance line................................................................................................ 7

2.4.2Requirements for using the Balance line ........................................................................................... 7

2.5Matching MLi batteries in your system ............................................................................................................... 7

3INSTALLATION AND COMMISSIONING ........................................................................................................................ 8

3.1Minimum safety requirements, multiple battery installation ................................................................................ 8

3.2Installation and commissioning ........................................................................................................................... 8

3.3Charger settings ................................................................................................................................................. 8

4MULTIPLE BATTERY SYSTEM EXAMPLES ................................................................................................................. 9

4.1Parallel connection, total maximum SYSTEM current < 500 amps .................................................................... 9

4.1.1Schematic installation (parallel connection, total maximum current < 500 Amps) ............................. 9

4.1.2Required materials (parallel connection, total maximum current < 500 Amps) .................................. 9

4.1.3MasterBus configuration (parallel connection, total maximum current < 500 Amps) ....................... 10

4.1.4Commissioning (parallel connection, total maximum current < 500 Amps) ..................................... 10

4.2Parallel connection, total maximum current > 500 a, max 500 a per battery .................................................... 11

4.2.1Schematic installation (parallel connection, total maximum current > 500 Amps) ........................... 11

4.2.2Required materials (parallel connection, total maximum current > 500 Amps) ................................ 11

4.2.3MasterBus configuration (parallel connection, total maximum current > 500 Amps) ....................... 12

4.2.4Commissioning (parallel connection, total maximum current > 500 Amps) ..................................... 12

4.3Serial connection 48V, using one charger for two batteries ............................................................................. 13

4.3.1Schematic installation (Serial connection 48V, one charger for two batteries) ................................ 13

4.3.2Required materials (Serial connection 48V, one charger for two batteries) ..................................... 13

4.3.3MasterBus configuration (Serial connection 48V, one charger for two batteries) ............................ 14

4.3.4Commissioning (Serial connection 48V, one charger for two batteries) .......................................... 14

4.4Serial connection maximum 10 batteries .......................................................................................................... 15

4.4.1Schematic installation (Serial connection, maximum 10 batteries) .................................................. 15

4.4.2Required materials (Serial connection, maximum 10 batteries) ...................................................... 15

4.4.3MasterBus configuration (Serial connection, maximum 10 batteries) .............................................. 16

4.4.4Commissioning (Serial connection, maximum 10 batteries) ............................................................ 16

5ORDERING INFORMATION .......................................................................................................................................... 17

6TECHNICAL INFORMATION MULTIPLE BATTERIES ................................................................................................ 18

6.1Specifications ................................................................................................................................................... 18

IMPORTANT INFORMATION

1 IMPORTANT INFORMATION

During installation and commissioning of the Li-

ion batteries, the Safety Guidelines & Measures

are applicable at all times. See chapter 1 of the

single battery manual. For more info like

operation, single battery schemes and

installation environment, refer to the other

chapters of the user's manual.

1.1 UNPACKING

After unpacking, check the contents for possible damage.

Do not use the product if it is damaged. If in doubt, contact

your supplier.

1.2 NEEDED FOR INSTALLATION:

 Hexagon socket wrench 13mm (M8 screw) to connect

the battery cables to the Li-ion battery (torque: see

single battery manual section 6.6)

 Tools to install the wiring

 2 mm flat blade screwdriver to fasten the relay wiring

 4 mm flat blade screwdriver to fasten the balance line

wiring

 For adjustment of setpoints: A MasterBus control panel

or laptop with configuration software and MasterBus -

USB interface.

1.2.1 Ventilation

Place the battery in a sufficiently ventilated room.

1.3 EXTERNAL CUT-OFF RELAY

For safety purposes installation of a safety relay

controlled by the battery is obligatory!

Installation and commissioning of the Li-ion

battery requires programming of events in a

MasterBus communication network to control

the battery charger. The installer must be

familiar with the programming of such events.

For nominal voltages above 48V an alternative

relay must be used.

1.4 GENERAL INSTALLATION GUIDELINES

Refer to the single battery manual.

IMPORTANT INFORMATION

1.5 CONNECTION MODULE

The connection module consists of three parts,

refer to figure 1-1:

 Relay Controls (1-6)

 MasterBus (7)

 Balance line for two batteries (8,9)

Figure 1-1: Connection module

Figure 1-2: Shared relay for multiple batteries (max 2 in series)

See figure 1-2. Terminals 1 to 4 of the first battery (I) are

connected to the relay, terminals 1 and 2 of the second

battery (II) are connected to 5 and 6 of the first battery (I).

This way the two batteries can be protected by one relay,

battery II leaving the option to open the relay only. Battery

I can open and close the relay.

1. Relay Control (RC) minus

2. Open relay pulse (12/24V)

3. Close relay pulse (12/24V)

4. RC positive (12/24V)

5. RC minus from other battery

6. RC open relay from other battery

7. MasterBus connectors

8. Balance line minus

9. Balance line positive

123456

78 9

R. Mastervolt safety relay with four cables used:

A. Black relay wire (-)

B. Orange relay wire (open)

C. Brown relay wire (close)

D. Red relay wire (+)

E. Yellow relay wire (not used)

I. First battery, able to open and close the relay.

II. Second battery, linked to battery I. Able to open the relay only.

1234

A B C D E

INTRODUCTION TO MLI GROUPS

2 INTRODUCTION TO MLI GROUPS

2.1 DEFINITION OF AN MLI GROUP

With “MLI group”, we decribe a system that contains up to

10 MLi Ultra batteries connected in series or an unlimited

number of MLI Ultra batteries in parallel connection.

2.2 MLI GROUP FEATURES

The MLi Ultra Li-ion battery offers more features than

standard Li-ion batteries, for both single and group

configurations. It facilitates group connection by

1. A balance line for 48 volt systems (refer to chapter

Balance line)

2. Cluster functionality when using MasterBus (refer to

chapter MasterBus)

3. Reduction of the installation requirement (refer to

chapter System examples)

2.2.1 Balance line for 48 volt systems

The balance line is to be used between two 24V batteries

connected in series. It balances all cells in this series

connection and it saves one battery charger. It also

avoids the necessity of a MasterBus system using a

MasterBus interface and converter.

2.2.2 Cluster functionality when using MasterBus

MasterBus cluster functionality introduces an easier

overview of your multiple battery system, displaying the

master only and hiding the slave battery on your

MasterBus display.

2.2.3 Reduction of the installation requirement

The MLI Ultra balance line contains a fuse to protect your

wiring, further the safety relay can be connected to the

battery directly, avoiding extra MasterBus cables and

devices.

2.3 MASTERBUS CLUSTER FUNCTIONALITY

In MasterBus Configuration, a Cluster can be configured

for communication between the batteries in an MLI group.

The number of batteries in series (S) can be set and the

number of batteries in parallel (P). Topology is the name

for the total of batteries in series and parallel respectively.

The topology must be confirmed so MasterBus is able to

approve it.

Depending on the number of batteries in parallel and in

series, the ID’s (or names, if you set them) of the batteries

connected will show in the next window. You still need to

activate the cluster. The cluster state is displayed.

2.3.1 Setup Li-ion battery clusters.

Shown the configuration page of one of the batteries involved.

Enter the number of batteries in series (1) and the number of series strings in parallel (2). IMPORTANT: 2 batteries in parallel

are considered to be 2 strings of batteries, each string consisting of 1 battery.

INTRODUCTION TO MLI GROUPS

For example we create a cluster of 2 batteries in series and 3 strings in parallel:

A cluster can be up to 10 devices in total, in any configuration (Multiply #series by #parallel).

Press ‘Confirm topology’ (1) when you are satisfied with the chosen topology.

Notice the status of the cluster topology (2). The status can be “Approved”, “Needs approval”, and “Too many devices”. “Needs

approval” means the topology was confirmed but is not possible. “Too many devices” means the proposed topology needs

more devices than available in the system or is over 10 devices in total.

After approval of the topology, it is shown as subsequent Series strings. The

example shows three Series strings of two batteries in series each. Series string 1 is

the first string in the configuration page. It shows

S: 1, P:1 (-) = the battery in Series string 1, located at the Minus side of the string;

S: 2, P: 1 (+)= the battery in Series string 1, located at the Plus side of the string;

The first battery has been selected already, this is the battery you are configuring at.

The other batteries have yet to be selected. Selectable batteries:

 have an equal article code AND

 have equal software version.

“Cluster state Incomplete” (1) means not enough batteries have been selected for

the cluster configured OR one battery was selected twice.

“Activate cluster” (2) will make this battery the master and the selected batteries the

slaves. Cluster creation will fail when:

 the battery you activate the cluster on, is already ‘slave’ in another cluster

 A selected unit has a topology other than 1*1 confirmed, i.e. it consists of

more than one battery.

To access the individual battery’s, one can unfold the cluster using the “+” (3).

INTRODUCTION TO MLI GROUPS

2.4 BALANCE LINE FOR TWO BATTERIES IN SERIES

The MLi Ultra is equipped with a balance line that keeps

all cells in the series connection balanced during loading

and charging.

2.4.1 Advantages of using the Balance line

You can save one charger per two batteries in series, as

all cells in these batteries are balanced during loading and

charging. Otherwise you would need one charger per

battery. No fuses in the balance lines are needed as these

are included in the connection compartment.

2.4.2 Requirements for using the Balance line

 Maximum wire size is 4 mm2.

 For optimal connection a ferrule is recommended.

 The balance line only works if it is applied

between two subsequent batteries in the series

connection*.

* If your system contains 6 batteries, three balance lines

can be used: between battery 1-2, 3-4 and 5-6.

NOTE: a balance line between battery 6-1 is NOT

functional as the voltage between these two batteries is

too large! See section 5.4.

2.5 MATCHING MLI BATTERIES IN YOUR SYSTEM

When installing batteries:

A. Only mix batteries of the same type (12V or

24V) and capacity

B. In case of replacing, make sure the batteries

have been charged and have equal voltages.

When combining the MLi 12/320 or 24/160 with the MLi

Ultra batteries, keep in mind that:

A. The batteries do not work to their full capacity

as the MLi Ultra batteries have a larger

capacity;

B. You can use the cluster or balance line

functionality between the MLi Ultra batteries

only;

C. The MLi Ultra is 1 cm higher than its

predecessor;

D. There are no operational problems when

combining these two MLi versions.

INSTALLATION AND COMMISSIONING

3 INSTALLATION AND COMMISSIONING

Figure 4-1: Battery system overview

Before the Li-ion battery can be used, it must be installed

and commissioned.

CAUTION! The Li-ion battery is a special

battery and it needs special safety precautions

in the installation!

3.1 MINIMUM SAFETY REQUIREMENTS, MULTIPLE

BATTERY INSTALLATION

To prevent hazardous situations YOU MUST:

E. Install a safety relay to disconnect the battery

under abnormal circumstances

F. Install a charger that stops charging if the

battery indicates so

G. Use properly sized fuses and wiring

H. Use cables of same length for batteries in

parallel

I. Configure the MasterBus Stop charge event

The graph in Figure 4-1 shows a simplified overview of a

safe Li-ion battery system.

1. Multiple MLI Ultra 12/2500, MLI Ultra 12/5000 or MLi

Ultra 24/5000 batteries.

2. Fuse in the positive battery cables to protect DC cabling

and batteries. It must correspond with the cable diameters

up to maximum 500A. The IR must be at least 15000A.

3. Safety Relay(s), must be able to disconnect the loads

and the charging devices when the battery enters an

unsafe situation.

4. Battery charging device, must be able to stop charging

or switch to the Float stage at a MasterBus event when the

battery detects a “stop charge” condition. It has to be

configured to charge a Li-ion battery, refer to charger

settings in the MasterBus configuration.

5. DC loads.

If the charger is stopped, battery power is still available for

the loads (5). If the safety relay (3) disconnects, there is no

battery power available for the loads. Refer to single

battery manual chapter 8 for advanced functionality,

explanation of the Battery Safety event and the Stop

charge event.

3.2 INSTALLATION AND COMMISSIONING

Installation and commissioning depend on the system in

which the Li-ion battery is used.

CAUTION!

With MasterBus Power enabled, the

MasterBus network will drain the Li-ion

Battery slowly, even if the battery has been

disconnected from the system. Refer to the

MasterBus configuration in the single battery

manual.

We describe four multiple Li-ion battery systems:

1 two or more batteries in parallel, total maximum

current < 500 Amps, section 3.1

2 two or more batteries in parallel, total maximum

current > 500 Amps, section 3.2

3 two batteries in series, using one charger,

section 3.3

4 up to 10 batteries in series, using a charger per

battery, section 3.4

Select one of these options and continue with the

corresponding section for installation and commissioning.

3.3 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

For higher voltages an alternative charger is necessary.

Refer to the user’s manual of the battery charger for Li-ion

charge settings.

1. Multiple Li-ion batteries

2. Fuse to wire size

3. Safety Relay to disconnect all loads and

chargers when needed

4. Battery charger with a provision to stop

charging when needed

5. Loads

123

MULTIPLE BATTERY SYSTEM EXAMPLES

4 MULTIPLE BATTERY SYSTEM EXAMPLES

4.1 PARALLEL CONNECTION, TOTAL MAXIMUM SYSTEM CURRENT < 500 AMPS

4.1.1 Schematic installation (parallel connection, total maximum current < 500 Amps)

1. Safety relay

2. Main fuse in positive busbar

3. Connection module

4. MasterBus display

5. Battery fuse in positive line

6. MasterBus connection to charger

7. Busbar

8. Relay cable

9. MasterBus cable

10. MasterBus terminator

11-14. MLi Ultra battery

A-E. Refer to figure 1-2.

Follow next steps to install the safety relay:

1 Move the safety relay in the LOCK OFF position. See single battery manual section 4.8.

2 Connect the DC main wiring as indicated but do not place the Main fuse yet.

3 Connect the wiring for the control circuit of the safety relay as indicated.

4 Connect the MasterBus cabling between the devices as indicated. Keep the rules in mind as described in single battery

manual section 5.2.

5 Add a MasterBus control panel to the MasterBus network.

4.1.2 Required materials (parallel connection, total maximum current < 500 Amps)

Quantity Mastervolt

Part number Description

@ 12V @ 24V

n -- 66012500 Li-ion Battery MLi Ultra 12/2500

n -- 66015000 Li-ion Battery MLi Ultra 12/5000

-- n 66025000 Li-ion Battery MLi Ultra 24/5000

1 -- 79007700 Safety relay 12V/500A, part # 7700

-- 1 79007702 Safety relay 24V/500A, part # 7702

1 1 77049000 500A Fuse to protect the DC Main Wiring*

1 1 778T2S600

T-Fuse holder for 77049000

1 1 MasterBus control panel (see single battery manual section 6.2)

** ** DC Main Wiring, with Main Fuse depending on system current

** ** Wiring for the safety relay control circuit, minimum cross section: 0.5mm²

** ** MasterBus communication cables

n number of MLi batteries

*Any other fuse can be applied as long as the voltage/current ratings are fitting the installation and the IR (Interrupt Rating) of

the fuse is at least 15000Amps.

** Installation dependent

Figure 5-1: Parallel connection, current under 500A

555 5

13 14

11 12

MULTIPLE BATTERY SYSTEM EXAMPLES

4.1.3 MasterBus configuration

(parallel connection, total maximum current < 500 Amps)

Refer to the single battery manual for explanation of the Stop Charge event.

CAUTION!

Configuration of the Stop Charge event is mandatory to prevent major damage to the MLi Ultra batteries!

4.1.4 Commissioning

(parallel connection, total maximum current < 500 Amps)

During commissioning, first the functioning of the connected cut off relay must be checked. Important is, the relay reacts

correctly on a MasterBus event, in this case by operating the buttons in the MasterBus monitoring screen. Further, a wiring

check is necessary. This is done by reading the current measured by the battery, in the monitoring screen. Make sure the

batteries have approximately equal states of charge before connecting in parallel. Follow next steps.

1 UNLOCK the relay, refer to single battery manual section 4.8.

2 Enter on the MasterBus control panel the MasterBus MLi Ultra monitoring page. Operate the Close Relay button at the

bottom of this page. If the relay is closed (On), the knob position must be shifted inwards. See Figure 5-2.

3 Operate the Open Relay button on the last battery (Figure 5-1, battery 14). If the relay is open (Off), the knob position

must be outwards. Keep the relay open.

4 Install all fuses.

5 Switch On the load.

6 Verify on the MLi Ultra monitoring page that there is no current flow. See Figure 5-3.

7 Close the relay with the first battery (Figure 5-1, battery 11). Verify that a current is flowing out of the battery (negative

value).

8 Switch Off the load, switch On the charger and verify that a current is flowing into the battery (positive value).

9 If necessary, check if the battery is in MasterBus Powering mode. See single battery manual section 8.1 Configuration:

MasterBus Power.

10 If necessary, remove the MasterBus control panel from the MasterBus network.

Figure 5-2: Buttons for closing and opening the relay

OFF

Figure 5-3: Checking zero current

MULTIPLE BATTERY SYSTEM EXAMPLES

4.2 PARALLEL CONNECTION, TOTAL MAXIMUM CURRENT > 500 A, MAX 500 A PER BATTERY

4.2.1 Schematic installation (parallel connection, total maximum current > 500 Amps)

1. Safety relay

2. Main fuse in positive bus bar

3. Communication module

4. MasterBus display

5. Fuse in positive battery line

6. MasterBus connection to charger

7. Busbar

8. Relay cable

9. MasterBus cable

10. MasterBus terminator

11-14. MLi Ultra battery

A- E. Refer to figure 1-2.

Follow next steps to install the safety relay:

1 Move the safety relay in the LOCK OFF position. See single battery manual section 4.8.

2 Connect the DC main wiring as indicated but do not place the Main fuse yet.

3 Connect the wiring for the control circuit of the safety relay as indicated in figure 1-2.

4 Connect the MasterBus cabling between the devices as indicated. Follow single battery manual section 5.2.

5 Add a MasterBus control panel to the MasterBus network.

4.2.2 Required materials (parallel connection, total maximum current > 500 Amps)

Quantity Mastervolt

Part number Description

@ 12V @ 24V

n -- 66012500 Li-ion Battery MLi Ultra 12/2500

n -- 66015000 Li-ion Battery MLi Ultra 12/5000

-- n 66025000 Li-ion Battery MLi Ultra 24/5000

n -- 79007700 Safety relay 12V/500A, part # 7700

-- n 79007702 Safety relay 24V/500A, part # 7702

n n 77049000 500A Fuse to protect the DC Main Wiring*

n n 778T2S600

T-Fuse holder for 77049000

1 1 MasterBus control panel (see single battery manual section 6.2)

** ** DC Main Wiring, with Main Fuse depending on system current

** ** Wiring for the safety relay control circuit, minimum cross section: 0.5mm²

** ** MasterBus communication cables

n number of MLi batteries

*Any other fuse can be applied as long as the voltage/current ratings are fitting the installation and the IR (Interrupt Rating) of

the fuse is at least 15000Amps.

** Installation dependent

Figure 5-4: Parallel connection, current over 500A

11 12 13 14

1 1 1

555 5

MULTIPLE BATTERY SYSTEM EXAMPLES

4.2.3 MasterBus configuration

(parallel connection, total maximum current > 500 Amps)

Refer to the single battery manual for explanation of the Stop Charge event.

CAUTION!

Configuration of the Stop Charge event is mandatory to prevent major damage to the MLi Ultra batteries!

4.2.4 Commissioning

(parallel connection, total maximum current > 500 Amps)

During commissioning, first the functioning of the connected cut off relay must be checked. Important is, the relay reacts

correctly on a MasterBus event, in this case by operating the buttons in the MasterBus monitoring screen. Further, a wiring

check is necessary. This is done by reading the current measured by the battery, in the monitoring screen. Make sure the

batteries have approximately equal states of charge before connecting in parallel. Follow next steps.

1 UNLOCK the relay, refer to single battery manual section 4.8.

2 Enter on the MasterBus control panel the MasterBus MLi Ultra monitoring page. Operate the Close Relay button at the

bottom of this page. If the relay is closed (On), the knob position must be shifted inwards. See Figure 5-5.

3 Operate the Open Relay button. If the relay is open (Off), the knob position must be outwards. Keep the relay open.

4 Install all fuses.

5 Switch On the load.

6 Verify on the MLi Ultra monitoring page that there is no current flow. See Figure 5-6.

7 Close the relay and verify that a current is flowing out of the battery (negative value).

8 Switch Off the load, switch On the charger and verify that a current is flowing into the battery (positive value).

9 If necessary, check if the battery is in MasterBus Powering mode. See single battery manual section 8.1 Configuration:

MasterBus Power.

10 If necessary, remove the MasterBus control panel from the MasterBus network.

Figure 5-5: Buttons for closing and opening the relay

OFF

Figure 5-6: Checking zero current

MULTIPLE BATTERY SYSTEM EXAMPLES

4.3 SERIAL CONNECTION 48V, USING ONE CHARGER FOR TWO BATTERIES

4.3.1 Schematic installation (Serial connection 48V, one charger for two batteries)

Follow next steps to install the safety relay:

1 Move the safety relay in the LOCK OFF position. See section 4.8.

2 Connect the DC main wiring as indicated but do not place the Main fuse yet.

3 Connect the wiring for the control circuit of the safety relay as indicated in figure 1-2.

4 Connect the MasterBus cabling between the devices as indicated. Keep the rules in mind as described in section 5.2.

5 Add a MasterBus control panel to the MasterBus network.

4.3.2 Required materials (Serial connection 48V, one charger for two batteries)

Quantity Mastervolt

Part number Description

@ 12V @ 24V

n -- 66012500 Li-ion Battery MLi Ultra 12/2500

1 -- 66015000 Li-ion Battery MLi Ultra 12/5000

-- 1 66025000 Li-ion Battery MLi Ultra 24/5000

1 1 77031500 Digital AC 1x6A

1 -- 79007700 Safety relay 12V/500A, part # 7700

-- 1 79007702 Safety relay 24V/500A, part # 7702

1 1 77049000 500A Fuse to protect the DC Main Wiring*

1 1 778T2S600

T-Fuse holder for 77049000

1 1 MasterBus control panel (see single battery manual section 6.2)

** ** DC Main Wiring, with Main Fuse depending on system current

** ** Wiring for the safety relay control circuit, minimum cross section: 0.5mm²

** ** MasterBus communication cables

*Any other fuse can be applied as long as the voltage/current ratings are fitting the installation and the IR (Interrupt Rating) of

the fuse is at least 15000Amps.

** Installation dependent

Figure 5-7: Serial connection with one charger for two batteries

1. MLi Ultra battery

2. Main fuse in positive battery line

3. Communication module

4. 48V relay to be operated directly like shown or via

the MasterBus operated Digital AC 1x6A on the

relay coils. See single battery manual section

7.6.1 for an example.

5. 48V MasterBus compatible charger

6. Fuse to protect the charge wiring

7. DC cable

8. Relay wiring

9. MasterBus cable.

A-E Refer to figure 1-2.

MULTIPLE BATTERY SYSTEM EXAMPLES

4.3.3 MasterBus configuration (Serial connection 48V, one charger for two batteries)

Refer to the single battery manual for explanation of the Stop Charge event.

CAUTION!

Configuration of the Stop Charge event is mandatory to prevent major damage to the MLi Ultra batteries!

Make sure this event is configured for every MLi battery in your system!

4.3.4 Commissioning (Serial connection 48V, one charger for two batteries)

During commissioning, first the functioning of the connected cut off relay must be checked. Important is, the relay reacts

correctly on a MasterBus event, in this case by operating the buttons in the MasterBus monitoring screen. Further, a wiring

check is necessary. This is done by reading the current measured by the battery, in the monitoring screen. Make sure the

batteries have approximately equal states of charge before connecting in parallel. Follow next steps.

1 UNLOCK the relay, refer to section 4.8.

2 Enter on the MasterBus control panel the MasterBus MLi Ultra monitoring page. Operate the Close Relay button at the

bottom of this page. If the relay is closed (On), the knob position must be shifted inwards. See Figure 5-8.

3 Operate the Open Relay button. If the relay is open (Off), the knob position must be outwards. Keep the relay open.

4 Install all fuses.

5 Switch On the load.

6 Verify on the MLi Ultra monitoring page that there is no current flow. See Figure 5-9.

7 Close the relay and verify that a current is flowing out of the battery (negative value).

8 Switch Off the load, switch On the charger and verify that a current is flowing into the battery (positive value).

9 If necessary, check if the battery is in MasterBus Powering mode. See single battery manual section 8.1 Configuration:

MasterBus Power.

10 If necessary, remove the MasterBus control panel from the MasterBus network.

Figure 5-8: Buttons for closing and opening the relay

OFF

Figure 5-9: Checking zero current

MULTIPLE BATTERY SYSTEM EXAMPLES

4.4 SERIAL CONNECTION MAXIMUM 10 BATTERIES

4.4.1 Schematic installation (Serial connection, maximum 10 batteries)

2 2

11 11 11

Figure 5-10: 6 MLi Ultra 24V in series, making a 144V system

1. MLi Ultra battery

2. Fuse for every two batteries

3. Fuse in positive battery line before the relay

4. Connection module

5. Battery safety relay suitable for 144V DC

6. Loads

7. Fuse in positive battery line after the relay

8. Battery DC cables

9. Communication cables

10. MasterBus cables

11. Balance line for every two batteries*

*NOTE: a balance line between the far left and right

battery is NOT functional!

Follow next steps to install the safety relay:

1 Move the safety relay in the LOCK OFF position. See single battery manual section 4.8.

2 Connect the DC main wiring as indicated but do not place the Main fuse yet.

3 Connect the wiring for the control circuit of the safety relay as indicated.

4 Connect the MasterBus cabling between the devices as indicated. Follow the rules in single battery manual section 5.2.

5 Add a MasterBus control panel to the MasterBus network.

4.4.2 Required materials (Serial connection, maximum 10 batteries)

Quantity Mastervolt

Part number Description

@ 12V @ 24V

n -- 66012500 Li-ion Battery MLi Ultra 12/2500

n -- 66015000 Li-ion Battery MLi Ultra 12/5000

-- n 66025000 Li-ion Battery MLi Ultra 24/5000

n n ** Mass Charger

1 1 500A Fuse to protect the DC Main Wiring *

1 1 MasterBus control panel (see single battery manual section 6.2)

** ** High voltage safety relay

** ** DC Main Wiring, with Main Fuse depending on system current

** ** Wiring for the safety relay control circuit, minimum cross section: 0.5mm²

** ** MasterBus communication cables

n number of MLi batteries

* The voltage/current ratings must fit the installation and the IR (Interrupt Rating) of the fuse must be at least 15000Amps.

** Installation dependent

MULTIPLE BATTERY SYSTEM EXAMPLES

4.4.3 MasterBus configuration (Serial connection, maximum 10 batteries)

Refer to the single battery manual for explanation of the Stop Charge event.

CAUTION!

Configuration of the Stop Charge event is mandatory to prevent major damage to the MLi Ultra batteries!

4.4.4 Commissioning (Serial connection, maximum 10 batteries)

During commissioning, first the functioning of the connected cut off relay must be checked. Important is, the relay reacts

correctly on a MasterBus event, in this case by operating the buttons in the MasterBus monitoring screen. Further, a wiring

check is necessary. This is done by reading the current measured by the battery, in the monitoring screen.

CAUTION!

To prevent a high compensation current, make sure the batteries have approximately equal states of charge

before connecting in parallel!

Follow next steps.

1 UNLOCK the relay, refer to section 4.8.

2 Enter on the MasterBus control panel the MasterBus MLi Ultra monitoring page. Operate the Close Relay button at the

bottom of this page. If the relay is closed (On), the knob position must be shifted inwards. See Figure 5-11.

3 Operate the Open Relay button. If the relay is open (Off), the knob position must be outwards. Keep the relay open.

4 Install all fuses.

5 Switch On the load.

6 Verify on the MLi Ultra monitoring page that there is no current flow. See Figure 5-12.

7 Close the relay and verify that a current is flowing out of the battery (negative value).

8 Switch Off the load, switch On the charger and verify that a current is flowing into the battery (positive value).

9 If necessary, check if the battery is in MasterBus Powering mode. See single battery manual section 8.1 Configuration:

MasterBus Power.

10 If necessary, remove the MasterBus control panel from the MasterBus network.

Continue with chapter 8.

Figure 5-11: Buttons for closing and opening the relay

OFF

Figure 5-12: Checking zero

ORDERING INFORMATION

5 ORDERING INFORMATION

Part number Description

66012500 Li-ion Battery MLi Ultra 12/2500

66015000 Li-ion Battery MLi Ultra 12/5000

66025000 Li-ion Battery MLi Ultra 24/5000

79007700 Safety relay 12V/500A, part # 7700

79007702 Safety relay 24V/500A, part # 7702

77031500 Digital AC 1x6A

77049000 500A Fuse to protect the DC Main Wiring*

778T2S600 T-Fuse holder for 77049000

77030450 MasterBus – Serial Interface

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

77050000 Complete set to assemble MasterBus cables. Delivery includes: 100m / 330ft MasterBus cable, 50 pcs.

modular jacks and crimping tool

TECHNICAL INFORMATION MULTIPLE BATTERIES

6 TECHNICAL INFORMATION MULTIPLE BATTERIES

6.1 SPECIFICATIONS

Model MLi Ultra 12/2500 MLi Ultra 12/5000 MLi Ultra 24/5000

Article number 66012500 66015000 66025000

Maximum number of batteries in parallel No maximum No maximum No maximum

Maximum number of batteries in series

Using the balance line 2 2 2

Using one charger per battery 10 10 10

Snijdersbergweg 93, 1105 AN

msterdam, The Netherlands

Tel : + 31-20-3422100

Fax : + 31-20-6971006

Email : [email protected]

Mastervolt MLi Ultra 12/5000, MLi Ultra 12/2500, MLi Ultra 24/5000 Installation And Commissioning Manual

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