Mastervolt MLI Ultra 12/1250 Operating manual

MLI Ultra
LITHIUM-ION BATTERY
12/1250, 24/1250
USER AND INSTALLATION MANUAL
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MLI Ultra
12/1250, 24/1250 – User and Installation Manual
Table of contents
1. SAFETY INSTRUCTIONS .................... 3
Warnings and symbols.......................... 3
Safety warnings..................................... 3
Safety guidelines................................... 5
2. GENERAL INFORMATION ................... 6
Liability .................................................. 6
Warranty ............................................... 6
Life cycles and C-rate............................ 6
Disclaimer ............................................. 6
Identification label ................................. 7
Correct disposal of this product............. 7
3. PRODUCT DESCRIPTION ................... 8
Status LEDs .......................................... 9
Battery switch-button (safety
disconnect).......................................... 10
Battery Management System (BMS) ... 10
Charging ............................................. 11
4. BASIC INSTALLATION ....................... 12
Unpacking ........................................... 12
Location .............................................. 12
Materials needed................................. 13
Installation procedure for a single unit. 13
Adding the MLI Ultra to a MasterBus
network ............................................... 15
Adding the MLI Ultra to a CZone
network ............................................... 16
Auxiliary connector.............................. 17
5. CONFIGURATION .............................. 18
DIP switch settings.............................. 18
How to change the DIP switch
settings............................................. 18
MasterBus DIP switch settings......... 19
CZone DIP switch settings ............... 19
Configuration in a MasterBus network. 20
Monitoring tab .................................. 20
Alarms tab ........................................21
History tab ........................................21
Configuration tab ..............................21
Events tab.........................................23
Events sources .................................24
Event commands..............................25
Stop Charge event............................25
Configuration in a CZone network........26
6. BUILDING A BATTERY BANK ............32
Series and parallel connections ...........32
Configuration of a battery bank............33
Battery bank configuration with DIP
switches (MasterBus only)................33
Battery bank configuration with
MasterAdjust.....................................35
Battery bank configuration with the
CZone Configuration Tool.................36
7. STORAGE AND CARE........................37
8. TROUBLESHOOTING.........................38
9. SPECIFICATIONS...............................40
Technical specifications.......................40
CZone specifications ...........................41
Battery switch – automatic behavior ....41
Characteristics.....................................42

MLI Ultra 12/1250, 24/1250 – User and Installation
Manual
3
1. SAFETY INSTRUCTIONS
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
Warnings and symbols
Safety instructions and warnings are marked in this manual by the
following pictograms:
CAUTION!
Special information, commands and prohibitions in order to
prevent damage.
WARNING!
A WARNING refers to possible injury to the user or installer or
significant material damage to the MLI Ultra if the installer /
user does not (carefully) follow the stated procedures.
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 neverthe-
less 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

4
MLI Ultra
12/1250, 24/1250 – User and Installation Manual
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;
- when the battery was over-charged.
If in doubt, contact your Mastervolt 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).

MLI Ultra 12/1250, 24/1250 – User and Installation
Manual
5
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
ASG. 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 t
o indemnify and not hold
ASG
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.

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MLI Ultra
12/1250, 24/1250 – User and Installation Manual
2. GENERAL INFORMATION
Liability
ASG 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.
Life cycles and C-rate
The C-rate indicates how fast a battery can be (dis)charged. The capacity (C) of a battery is
commonly expressed in numbers that look like 1C, 2C, or C/2. A C-rate of C/2 is also known as
0.5C. A fully charged battery rated at 100Ah, provides 100A for one hour. The same battery
discharging at C/2 provides 50A for two hours. At 2C it provides 200A for 30 minutes. Charge and
discharge rates can have an impact on the number of life cycles. The MLI Ultra batteries provide
3500 cycles at an ambient temperature of 25ºC [77ºF] and a DoD set to 80%. To reach the specified
number of cycles, we advise a maximum charge rate of C/2 and a discharge rate of C. This
corresponds to the following values:
MLI Ultra 12/1250
MLI Ultra 24/1250
Recommended charge current
≤ 50 A
≤ 25 A
Recommended discharge current
≤ 100 A
≤ 50 A
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.

MLI Ultra 12/1250, 24/1250 – User and Installation
Manual
7
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 (x2)
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

MLI Ultra 12/1250, 24/1250 – User and Installation
Manual
9
Status LEDs
Figure 2: status LEDs
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 dealer.
B
Yellow
Battery
state
During normal operation the LED is off.
1 short blink
●●●
State of Charge (SoC) low. Charge the
battery.
2 short blinks
●● ●● ●●
CZone network identification (during
installation).
3 short blinks
●●● ●●●
Auto cluster configuration error. See section
"Battery bank configuration with DIP
switches" on page 33.
4 short blinks
●●●● ●●●●
Battery is executing a recovery 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).

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MLI Ultra
12/1250, 24/1250 – User and Installation Manual
Battery switch-button (safety disconnect)
CAUTION!
This built-in battery switch is to safely disconnect the battery. It also disconnects
from the charger!
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.
Note: If the battery was switched-off manually, it must be switched-on manually.
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.