Mastervolt MLI-E 12/1200 Operating manual

Lithium-ion Battery
MLI-E 12/1200
USER AND INSTALLATION MANUAL
10000013074_03

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MLI-E 12/1200 –User and Installation Manual
DELIVERY CONTENTS
1. (1x) MLI-E 12/1200 Battery
2. (1x) Tool (combined 2.5mm/6mm Allen hex key)
3. (2x) Hex bolt M8 x 16mm
4. (2x) Bolt M8 x 20mm
5. (4x) Spring washer M8
6. (2x) Plain washer M8
7. (1x) Removable automotive battery pole positive
8. (1x) Removable automotive batty pole negative
9. (2x) Removable handles
10. (1x) USB drive with manual
The MLI-E 12/1200 is part of the Mastervolt MLI series of Lithium Ion batteries. These batteries are
equipped with an integrated cell management system which features:
•Cell balancing
•Battery voltage monitoring
•Battery current monitoring
•Pre warning when battery is almost empty
•Battery temperature monitoring (integrated temperature sensor)
•Communication with other devices like chargers and alternators
Figure 1: Delivery contents

MLI-E 12/1200 –User and Installation Manual
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TABLE OF CONTENTS
DELIVERY CONTENTS.............................................................................................................................................................. 2
1SAFETY GUIDELINES AND MEASURES ......................................................................................................................... 4
1.1 General rules........................................................................................................................................................... 4
1.2 Transportation warnings .......................................................................................................................................... 4
1.3 Correct disposal of this product ............................................................................................................................... 4
2GENERAL INFORMATION ................................................................................................................................................ 5
2.1 Use of this manual................................................................................................................................................... 5
2.2 Disclaimer................................................................................................................................................................ 5
2.3 Warranty specifications............................................................................................................................................ 5
2.4 Liability..................................................................................................................................................................... 5
2.5 Identification label.................................................................................................................................................... 5
2.6 Use for intended purpose ........................................................................................................................................ 5
2.7 Organizational measures......................................................................................................................................... 5
2.8 Maintenance and repair........................................................................................................................................... 6
2.9 General safety and installation precautions............................................................................................................. 6
2.10 Warning regarding life support applications............................................................................................................. 6
3OPERATION....................................................................................................................................................................... 7
3.1 Charging and discharging........................................................................................................................................ 7
3.2 Cell management system ........................................................................................................................................ 7
3.3 Safety features......................................................................................................................................................... 7
3.4 MasterBus functionality............................................................................................................................................ 7
3.5 Connections and battery controls ............................................................................................................................ 7
3.6 LED indicators ......................................................................................................................................................... 8
3.7 Operation modes..................................................................................................................................................... 8
4INSTALLATION.................................................................................................................................................................. 9
4.1 Unpacking................................................................................................................................................................ 9
4.2 Required tools.......................................................................................................................................................... 9
4.3 Location to install..................................................................................................................................................... 9
4.4 General installation guidelines................................................................................................................................. 9
4.5 Connecting power cables with automotive type terminals ....................................................................................... 9
4.6 Connecting shrink fit type of power cables .............................................................................................................10
4.7 Connecting power cables with automotive type terminals and placing protective caps..........................................11
4.8 Set battery in normal operation mode.....................................................................................................................12
4.9 Charger settings .....................................................................................................................................................12
4.10 Fuse to cable size...................................................................................................................................................12
4.11 Battery balancing....................................................................................................................................................12
4.12 Commissioning.......................................................................................................................................................12
5COMMUNICATION........................................................................................................................................................... 13
5.1 Bluetooth app..........................................................................................................................................................13
5.2 Basic NMEA Components and how to use them....................................................................................................14
5.2.1 Adding additional NMEA 2000 devices....................................................................................................... 14
5.2.2 NMEA 2000 Network limits......................................................................................................................... 14
5.3 What is MasterBus?................................................................................................................................................14
5.3.1 How to set up a MasterBus network ........................................................................................................... 14
5.3.2 Monitor and configure the MLI-E with MasterBus....................................................................................... 14
6TROUBLE SHOOTING..................................................................................................................................................... 16
7MAINTENANCE, DECOMMISSIONING AND STORAGE................................................................................................ 17
7.1 Maintenance...........................................................................................................................................................17
7.2 Taking out of operation...........................................................................................................................................17
7.3 Battery replacement................................................................................................................................................17
7.4 Storage...................................................................................................................................................................17
8TECHNICAL INFORMATION ........................................................................................................................................... 18
8.1 Specifications..........................................................................................................................................................18
8.2 Dimensions.............................................................................................................................................................19

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MLI-E 12/1200 –User and Installation Manual
1 SAFETY GUIDELINES AND MEASURES
1.1 General rules
Observe these instructions and keep them
located near the MLI-E for future reference.
Work on the Li-ion Battery should be carried
out by qualified personnel only.
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. Terminals of the
Li-ion Battery are always alive; therefore do
not place items or tools on the Li-ion
Battery. Avoid short circuits, too deep
discharges and too high charge currents.
Use insulated tools. Do not wear any
metallic items such as watches, bracelets,
et cetera. In case of fire, you must use a
type D, foam or CO2 fire extinguisher.
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.
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 Li-
ion Batteries are sensitive to mechanical
shock.
Li-ion batteries can be charged with a
voltage up to 14.6 V. On the other hand, Li-
ion batteries can be discharged down to
11.0 V. Note that this voltage range (11.0-
14.6V) is larger than you may expect from
other battery types such as lead-acid
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).
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.
Non-compliance with operating instructions, repairs
made with other than original parts, or repairs made
without authorization render the warranty void.
1.2 Transportation warnings
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.
Batteries are tested according to UN Handbook of Tests
and Criteria, part III, sub section 38.3
(ST/SG/AC.10/11/Rev.5).
For transport the batteries belong to the category UN3480,
Class 9, Packaging Group II and have to be transported
according to this regulation. This means that for land and
sea transport (ADR, RID & IMDG) they have to be packed
according to packaging instruction P903 and for air
transport (IATA) according to packaging instruction P965.
The original packaging satisfies these instructions.
1.3 Correct disposal of this product
This product is designed and manufactured with high
quality materials and components, which can be recycled
and reused. Batteries marked with the recycling symbol
must 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.
Figure 2: Disposal and recycling symbols
Please be informed about the local separate collection
system for electrical and electronic products. Please 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.
non-spillable

MLI-E 12/1200 –User and Installation Manual
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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 MLI-E series of lithium ion batteries 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 is 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 taking
into consideration the safety guidelines and measures
(chapter 1 of this manual). Keep this manual at a secure
place!
All of the specifications, provisions and instructions
contained in this manual apply solely to the following
products:
Part number
Description
66011200
Li-ion Battery MLI-E 12/1200
2.2 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 most current Terms &
Conditions of Sale.
2.3 Warranty 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 mean that the warranty becomes invalid.
The warranty 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
warranty. 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) generated alarms by this battery, otherwise
warranty becomes invalid. Use of a battery controlled
external safety relay is obligatory (refer to chapter 4). The
correct functioning of this product is subject to warranty.
The period and conditions of this warranty are laid down in
Mastervolt Warranty Terms and Conditions which can be
downloaded from www.mastervolt.com/support.
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.
•Use that is inconsistent with the purpose of the
product.
2.5 Identification label
The identification label is located at the top side of the Li-
ion Battery, next to the grip handle (see Figure 3).
Important information required for service or maintenance
can be derived from the identification label.
CAUTION!
Never remove the identification label.
2.6 Use for intended purpose
The Li-ion Battery is constructed as per the applicable
safety-technical guidelines.
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 at locations
where there is danger of gas or dust explosion
or potentially flammable products!
Use of the Li-ion Battery other than mentioned in point 2 is
not considered to be consistent with the intended purpose.
Mastervolt is not liable for any damage resulting from the
above.
2.7 Organizational measures
The user must always:
•have access to the user manual;
•be familiar with the contents of this manual. This
applies in particular to chapter Safety Guidelines and
Measures.
Figure 3: Identification label

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MLI-E 12/1200 –User and Installation Manual
2.8 Maintenance and repair
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.
If maintenance and repairs are required, only use original
spare parts.
2.9 General safety and installation precautions
•Do not expose the Li-ion Battery to rain, snow, spray,
moisture, excessive pollution and condensing circum-
stances. Do not install the Li-ion Battery in a non-
ventilated area, overheating may result.
•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 batteries and equipment cannot prevent
damage caused by reversed polarity and the warranty
will be void.
•Protect the wiring with fuses, according to the local
standards.
•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.
2.10 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. In addition 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.

MLI-E 12/1200 –User and Installation Manual
7
3 OPERATION
3.1 Charging and discharging
Use the MLI-E within the specifications as stated in section
8.1.
3.2 Cell management system
The MLI-E consists of a pack of battery cells. As with all
kind of batteries, there is always some kind of unbalance
present between the individual cells. During charging of an
unbalanced battery pack, one or more cells will reach the
maximum state of charge before the other cells. During
discharge the cells that are not fully charged will be
depleted prior to the other cells, causing early
undervoltage shutdown of the pack. Normally spoken,
these early charge and discharge limits reduce the usable
capacity of the battery and will shorten the expected
lifetime of the pack. To avoid this kind of premature failure,
the MLI-E is provided with a Cell Management System
(BMS). 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 under- and over-
charging by voltage monitoring of each individual cell;
•Prevention of too deep battery discharges;
•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.
WARNING
Before using the MLI-E, it must be installed
and commissioned in accordance with the
instructions stated in chapter 4 of this manual!
3.3 Safety features
Under- and over-charging and excessive temperatures
may lead to permanent damage to the MLI-E and even to
dangerous situations. Therefore the Li-ion battery is
provided with several advanced safety features.
WARNING
Alarms and warnings generated by the MLI-E
should not be neglected. It is the user’s
responsibility to take adequate measures.
There are two levels of protection:
•Warning: The yellow LED of the MLI-E will be lit.
•Alarm: The red LED of the MLI-E will be lit. This is an
“emergency stop” of the battery. The battery will
disconnect itself from the system.
3.4 MasterBus functionality
Refer to chapter 1 for advanced MasterBus functionality.
The Li-ion battery is not able to power the MasterBus
network. A proper amount of powering devices should be
placed in the MasterBus network.
CAUTION!
Make sure to place the MLI-E batteries on the
end of a MasterBus network.
3.5 Connections and battery controls
Figure 4: Connections and battery controls
Port/connection
Description
J1
RJ45 (CAN1)
J2
Inputs 4-pins
J3
Monitor 6-pins
J4
Outputs 8-pins
J5
RJ45 (CAN2)
S1
Red push button
S2
Configuration switches
X1
Battery negative (−) terminal
X2
Battery positive (+) terminal

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MLI-E 12/1200 –User and Installation Manual
3.6 LED indicators
Figure 5: LED positions
3.7 Operation modes
•Empty mode; battery voltage is below 10V.
•Deep discharge mode; battery voltage is below 6V.
The MLI-E is not usable anymore.
•Storage mode; the MLI-E was set to storage mode
manually. In storage mode it uses no power. This
prevents the MLI-E from draining its charge during
winter for example.
•Alarm mode; the BMS detects either an internal or
external failure. If a critical alarm occurs during
operation mode, the mode management function goes
to alarm mode.
•Operation mode; the MLI-E is fully operational. No
error is detected.
•Warning mode; the MLI-E parameters are out of
specified limit(s).
D1
(Green)
D2
(Yellow)
D3
(Red)
Operating mode
Protective disconnect
device
Communication
BMS
Off
Off
Off
Empty/Deep discharge/
Storage mode
Open
No
Inactive
Off
Off
On
Alarm mode
Open
Yes
Active
On
Off
Off
Operation mode
Closed
Yes
Active
Off
On
Off
Warning mode
Closed
Yes
Active
When the battery is not charging or discharging, the green LED will blink.
Before the battery goes to Empty/Deep discharge/Storage mode, the green and the red LEDs will blink 3 times.

MLI-E 12/1200 –User and Installation Manual
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4 INSTALLATION
During installation and commissioning of the Li-
ion battery, the Safety Guidelines & Measures
are applicable at all times. See chapter 1 of this
manual.
4.1 Unpacking
After unpacking, check the contents for possible damage.
Check the open clamp voltage with a suitable voltage
meter. It should be in the range 11.0 to 14.5V. Do not use
the product if it is damaged or if the open clamp voltage is
out of range. If in doubt, contact your supplier.
4.2 Required tools
•Hexagon socket wrench 13mm (M8 bolt) to connect
the battery cables to the Li-ion battery (torque: see
section 4.4)
•Tools to install the wiring.
4.3 Location to install
•Place the battery in a sufficiently ventilated room
•Keep the Li-ion battery away from heat sources. See
specifications for allowed operating temperatures.
•Keep the Li-ion battery away from moist.
•Keep at least 1 cm between two Li-ion batteries for air
flow.
•The Li-ion battery must be secured to its foundation,
use appropriate LN5 fastening brackets.
4.4 General installation guidelines
•Switch off all loads and chargers before starting
installation.
•Use properly sized and reliable, cables, cable lugs
and battery terminals. Tighten all connections. For the
main DC connections use 13 Nm 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.
WARNING
Use properly sized fuses and wiring to prevent
hazardous situations.
4.5 Connecting power cables with automotive type
terminals
1. Connect the positive wire of the load or charger to the
positive (+) terminal of the battery, see Figure 6.
CAUTION
Do not connect the negative (−) terminal first
as this may lead to short circuits.
2. Connect the negative wire of the load or charger to
the negative (−) terminal of the battery, see Figure 6.
3. Ensure both contacts are firmly tightened.
4. Place the handle covers over the terminals.
Figure 6: Connect the X1 (-) and X2 (+) terminal of the battery (automotive terminals)

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MLI-E 12/1200 –User and Installation Manual
4.6 Connecting shrink fit type of power cables
1. Remove the automotive power terminals, see Figure
7.
2. Connect the positive wire of the load or charger to the
positive (+) terminal of the battery, see Figure 8. Use
the included M8 bolt, spring washer and plain washer
to connect the battery cable.
CAUTION
Do not connect the negative (−) terminal first
as this may lead to short circuits.
3. Connect the negative wire to the negative (−) terminal
of the battery, see Figure 8Error! Reference source n
ot found.. Use the included M8 bolt, spring washer
and plain washer to connect the battery cable.
4. Ensure both contacts are tightened to 13Nm.
5. Place the handle covers over the terminals.
Figure 7: Remove automotive power terminals
Figure 8: Connect the X1 (-) and X2 (+) terminal of the battery (shrink fit)