Mastervac MLI Ultra Operating manual

MLI Ultra
LITHIUM-ION BATTERY
12/1250, 24/1250
USER AND INSTALLATION MANUAL
10000018055 /01
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2
MLI Ultra 12/1250, 24/1250 –User and Installation Manual
Table of contents
1. SAFETY INSTRUCTIONS .................... 3
Safety warnings..................................... 3
Safety guidelines................................... 4
2. GENERAL INFORMATION................... 5
Liability.................................................. 5
Warranty ............................................... 5
Disclaimer............................................. 5
Identification label ................................. 5
Correct disposal of this product............. 5
3. PRODUCT DESCRIPTION................... 6
Battery Management System (BMS)..... 6
Status LEDs.......................................... 7
Battery switch-button (safety
disconnect)........................................... 7
Heat pad ............................................... 8
Charging ............................................... 8
4. BASIC INSTALLATION......................... 9
Unpacking............................................. 9
Location ................................................ 9
Materials needed................................. 10
Installation procedure for a single unit. 10
Adding the MLI Ultra to a
MasterBus network ............................ 11
Adding the MLI Ultra to a CZone
network .............................................. 12
Auxiliary connector.............................. 13
5. CONFIGURATION.............................. 13
DIP switch settings.............................. 13
MasterBus DIP switch settings...........14
CZone DIP switch settings..................14
How to change the DIP switch
settings..............................................14
Configuration in a MasterBus network .15
Monitoring tab.....................................15
Alarms tab..........................................15
History tab..........................................16
Configuration tab................................16
Events tab ..........................................17
Events sources...................................18
Event commands................................19
Stop Charge event..............................19
Capacity Very Low event....................20
How to activate MasterBus powering..20
Configuration in a CZone network........21
6. MULTIPLE BATTERIES ......................23
Series and parallel connections...........23
Clustering multiple batteries.................24
Using DIP switches (MasterBus only).24
Using MasterAdjust ............................25
Using CZone Configuration Tool.........26
7. STORAGE AND CARE........................27
8. TROUBLESHOOTING.........................28
9. SPECIFICATIONS...............................30
Technical specifications.......................30
Battery switch –automatic behavior ....31

MLI Ultra 12/1250, 24/1250 –User and Installation Manual
3
1. SAFETY INSTRUCTIONS
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
Safety warnings
WARNING!
The battery contains hazardous materials that are stored safely
during normal use. Do not crush, open or drop the battery
housing. Do not touch or ingest any of the released materials or
inhale released gasses when accidental leakage of the battery
occurs. Should skin contact, eye contact or inhalation
nevertheless occur, take the necessary first aid measures
immediately. Refer to the Material Safety Data Sheet for
Mastervolt Lithium-Ion batteries, which is available on
www.mastervolt.com.
WARNING!
Avoid short circuiting batteries as this may result in fire,
explosion, electric shock or release of toxic gas. Use insulated
tools only and keep metal objects away from the battery. Do not
wear watches, bracelets, necklaces or other metal objects when
working on the battery. In case of fire, take the necessary
firefighting measures immediately. Refer to the Material Safety
Data Sheet for Mastervolt Lithium-Ion batteries, which is
available on www.mastervolt.com.
WARNING!
Short circuits, too deep discharges and too high charge currents
will damage the battery and may result in fire, explosion, electric
shock or release of toxic gas. Never charge a battery:
- after it was discharged below the Battery Safety voltage;
- when the battery is damaged;

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MLI Ultra 12/1250, 24/1250 –User and Installation Manual
- when the battery was over-charged.
If in doubt, contact your Mastervolt distributor/dealer.
CAUTION!
When transported, make sure that:
- the battery is in its original package or equivalent;
- the battery is in upright position;
- soft slings are used to avoid damage;
- the battery is only lifted at the handles;
- the battery is handled with care.
Note: The voltage range (12.0-14.6V or 24.0-29.2V) is larger than you may expect from other
battery types such as lead-acid batteries. Be aware that these voltages could exceed
the permitted voltages of the connected load(s).
Warning regarding life support applications
Mastervolt products are not designed to be used as component of medical equipment, unless
negotiated in the form of a written agreement between customer and/or manufacturer and
Mastervolt. Such agreement will require the equipment manufacturer either to contract
additional reliability testing of the Mastervolt parts and/or to commit to undertake such testing
as a part of the manufacturing process. Furthermore, the manufacturer must agree to
indemnify and not hold Mastervolt responsible for any claims arising from the use of the
Mastervolt parts in the life support equipment.
Safety guidelines
- Use the MLI Ultra following the instructions and specifications stated in this manual.
- Work on the MLI Ultra should be carried out by qualified personnel only.
- Non-compliance with operating instructions, repairs made with other than original parts, or repairs
made without authorization render the warranty.
- If programming of events in a MasterBus or CZone network is required, the installer must be
familiar with the programming of such events.
- Connections and safety features must always comply with all local rules and regulations.
- Use cables with an appropriate size.
- Never use the MLI Ultra in situations where there is danger of gas or dust explosion or potentially
flammable products!
- Only use the MLI Ultra in a technical correct condition.
- Only use the MLI Ultra in a well-ventilated area and protect the connectors from moisture and
dust.
- Switch off all charging systems and disconnect the MLI Ultra from the electrical installation during
maintenance and/or repair activities.

MLI Ultra 12/1250, 24/1250 –User and Installation Manual
5
2. GENERAL INFORMATION
Liability
Mastervolt cannot be held liable for:
- Consequential damage resulting from the use of the MLI Ultra.
- Possible errors in the included manual and the consequences of these.
- Use that is inconsistent with the purpose of the MLI Ultra.
Warranty
The Mastervolt product warranty covers the MLI Ultra for the first two years after the purchase date,
on the condition that the product is installed and used according to the instructions in this manual.
Installation or use that does not comply with these instructions may result in under performance,
damage or failure of the product and may void this warranty. The warranty is limited to the cost of
repair and/or replacement of the product. Costs of labor or shipping are not covered by this
warranty.
Disclaimer
Our products are subject to continual development and improvement. Therefore, additions or
modifications to the products may cause changes to the technical data and functional specifications.
No rights can be derived from this document. Please consult our online Terms & Conditions of Sale.
Identification label
The following picture is only an example!
The identification label is located on the top side of the MLI Ultra.
Technical information required for service and maintenance (part
number, serial number and revision code) can be derived from
the identification label.
CAUTION!
Never remove the identification label.
This will void the warranty.
Correct disposal of this product
This product is designed and manufactured with high quality materials and
components, which can be recycled and reused. Act according to your local rules
and do not dispose of your old products with your normal household waste. The
correct disposal of your old product will help prevent potential negative
consequences to the environment and human health.

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MLI Ultra 12/1250, 24/1250 –User and Installation Manual
3. PRODUCT DESCRIPTION
1. M8 positive terminal
2. M8 negative terminal
3. Provision for removable handle
4. Hold down edges group 31, fit battery group size 49
5. Attachment strap support
6. Protective vent; maintain adequate ventilation around
this opening. Do not touch the membrane!
7. Auxiliary connector
8. MasterBus/CZone connectors
9. Status LEDs and DIP switch
cover
10. Battery switch-button (safety
disconnect)
Figure 1: overview of the MLI Ultra 1250
Battery Management System (BMS)
The MLI Ultra has a built-in Battery Management System (BMS) and a built-in battery switch. The
BMS protects the battery by automatically controlling the battery switch when thresholds are met.
This is called a 'battery safety'-event. See chapter "SPECIFICATIONS”for the thresholds. An
automatically switch-off is initiated after the following events:
•Cell over- or under-voltage
•Battery over-current
•Over-temperature of the MLI Ultra
•Low State of Charge (SOC)
Likewise, automatically switch-on is initiated when the conditions are safe again.
The BMS can also:
- activate the heat pad
- communicate with Mastervolt charge devices over MasterBus or CZone
- send out warnings and alarms (to a display like the SmartRemote or EasyView 5 e.g.)
For more information on system automation, see section "Events tab" on page 17.
10
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7
2
6
5
3
8
4
1

MLI Ultra 12/1250, 24/1250 –User and Installation Manual
7
Status LEDs
Figure 2: status LEDs
Note: to minimize self-discharge, LEDs B and C are off during normal operation.
LED
Color
Name
Behavior
A
Red
Error
If this LED is on, a BMS error has occurred or cells are damaged.
Check the installation and contact your Mastervolt distributor/dealer.
B
Yellow
Battery
state
During normal operation the LED is off.
1 short blink
●●●
SoC low. Charge the battery.
2 short blinks
●● ●● ●●
CZone network identification (during
installation).
3 short blinks
●●● ●●●
Auto cluster configuration error. See section
"Using DIP switches" on page 24.
4 short blinks
●●●● ●●●●
Battery is executing a recovering procedure.
Blinking slowly
▬▬▬
Battery is updating its firmware.
C
Green
Battery
switch
state
When the Battery switch-button is pressed short, this LED indicates
the status of the battery switch.
- Solid on for 1 minute: battery is on (switch is closed).
- Blinking for 1 minute: battery is off (switch is open).
Battery switch-button (safety disconnect)
CAUTION!
This built-in battery switch is to safely disconnect the battery. It also disconnects
from the charger! If the battery was switched-OFF manually, it must be switched-
ON manually.
Figure 3: Battery switch-button
Press short for status; Short press to make LED C show the
status of the Battery switch.
•Solid on for 1 minute: battery is on (switch is closed).
•Blinking for 1 minute: battery is off (switch is open).
Press 1 sec; Long press for 1 second to switch-off. LED C
will blink.
Press 5 sec; Long press for 5 seconds to switch-on. LED C
will light up for 1 minute.

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MLI Ultra 12/1250, 24/1250 –User and Installation Manual
Heat pad
The heat pad is controlled automatically. It can also be controlled through MasterBus events or
CZone circuits.
Charging
In a Mastervolt/CZone network, the charging is done automatically. The MLI Ultra can be charged
with any Mastervolt battery charger, like the ChargeMaster Plus series, or with a ProMariner
ProSport HD or ProNautic for example. Make sure that the charger is Lithium Ion compatible and
meets the MLI Ultra's charge parameters. Set the battery type to MLI or adjust the 3-step+ (also
known as IuoUo) charge characteristic as follows:
Model
Bulk / absorption voltage
Float voltage
12V
14.25 V
13.5 V
24V
28.5 V
27 V
LED B will blink yellow when the state of charge (SOC) is low. Make sure to charge when the SOC
is low to preserve the lifespan.
The MLI Ultra supports 12 V, 24V, 36V and 48V systems. Mastervolt recommends one charger for
batteries that are connected in series.
Do not use a sensor for temperature compensated charging. Temperatures of the battery and its
cells are monitored by the built-in BMS.

MLI Ultra 12/1250, 24/1250 –User and Installation Manual
9
4. BASIC INSTALLATION
Unpacking
The delivery consists of the following parts:
1. MLI Ultra battery with 2x M8 bolt + washer + spring washer, for screw connection
2. 1x automotive battery pole positive (thick) + M8 Allen bolt, for clamp connection
3. 1x automotive battery pole negative (thin) + M8 Allen bolt, for clamp connection
4. Handle
5. 2x Attachment strap
6. MasterBus terminator
7. MasterBus cable (1m)
8. Drop cable CZone/MB (1m)
9. Auxiliary cable (2m)
10. The user and installation manual
Never use a damaged battery. If in doubt, contact your supplier.
Location
- Install the MLI Ultra in a well-ventilated room protected against rain, snow, spray, vapor, bilge,
moisture and dust.
- Keep the MLI Ultra away from heat sources. See specifications for allowed operating
temperatures.
- The MLI Ultra must be installed in upright position or on the long side of the case, although upright
mounting is recommended.
Upright position
Long side position
- Keep at least 1cm [3/8"] between two Li-Ion batteries for air flow.
- The MLI Ultra must be secured. The following drawings are examples of mounting options:
With included mounting
straps
Hold-downs on long side
(group 49)
With a frame or tray
11 mm
0.4 inch

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MLI Ultra 12/1250, 24/1250 –User and Installation Manual
Materials needed
- Battery charger
- Due to Interrupt Rating, use a T-fuse or an MRBF fuse and a fuse holder
- DC wiring
MLI Ultra
12/1250
24/1250
Recommended fuse
200 A
100 A
Recommended wire size
70 mm2 [AWG 2/0]
35mm2 [AWG 2]
WARNING!
The wire and fuse sizes stated in this manual are only guidelines. Cross section
depends on the maximum system current.
Always comply with all local rules and regulations.
Installation procedure for a single unit
WARNING!
In installations with a negative earth: Connect the negative cable last of all to
prevent short circuiting.
WARNING!
Never mount a stud fuse directly to the battery terminal! If there is not enough space,
use a separate bus bar to mount the fuse on.
Step 1. Switch off all loads and chargers.
Step 2. Insert the handle into the recesses on the top of the battery.
Step 3. Out of the box, the battery is on (switch is closed). Press the Battery switch-button to
switch-off (safety disconnect). LED C will blink for 1 minute to indicate that the battery is
switched off and the switch is open.
Step 4. Secure the battery in place.
Step 5. Mount an MRBF fuse holder directly on the battery's POSITIVE terminal, add the fuse and
the POSITIVE cable. Tighten the bolt. Never mount a stud fuse directly on the battery
terminal. Always use the isolated fuse holder! Otherwise the fuse will not work! See the
following figure.