Mastervolt MLi Ultra 12/2500 User manual

USERS MANUAL / GEBRUIKERSHANDLEIDING
BETRIEBSANLEITUNG / MANUEL D’UTILISATION
MANUAL DE UTILIZACION / INSTRUZIONI PER L’USO
Lithium-ion Battery
MLi Ultra 12/2500
MLi Ultra 12/5000
MLi Ultra 24/5000
MASTERVOLT
Snijdersbergweg 93
1105 AN Amsterdam
The Netherlands
Tel.: [phone]
Fax.: [phone]
www.mastervolt.com Copyright © 2014 Mastervolt, 10000005784/04 April 2014
ENGLISH: PAGE 1
NEDERLANDS: PAGINA 33
DEUTSCH: SEITE 65
FRANÇAIS: PAGINA 97
CASTELLANO: PAGINA 129
ITALIANO: PAGINA 161

DELIVERY CONTENTS - OVERVIEW
2Copyright © 2014 Mastervolt / April 2014 / Lithium-ion Battery MLi Ultra / EN
DELIVERY CONTENTS
OVERVIEW
Positive battery terminal at the right with M8 thread
Balance line for serial connection
Connector for safety relay
MasterBus connectors
Negative battery terminal at the left with M8 thread
The two lifting handles cover the battery terminals and
protect the wiring when folded down
The MLi Ultra 12/2500, MLi Ultra 12/5000 and MLi Ultra 12/5000 are part of the Mastervolt MLi Ultra 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 (communication by means of MasterBus)
Battery temperature monitoring (integrated temperature sensor)
Communication with other MasterBus devices like chargers and alternators
Li-ion battery
MasterBus
cable (3m)
MasterBus
terminato
r
Battery terminal
2x M8 bolt + washer +
spring washer Users manual
Connectors for
safety relay + Balance line

TABLE OF CONTENTS
EN / April 2014 / Lithium-ion Battery MLi Ultra / Copyright © 2014 Mastervolt 3
Copyright © 2014 Mastervolt. All rights reserved. Reproduction, transfer, distribution or storage of part or all of the contents in
this document in any form without the prior written permission of Mastervolt is prohibited.
TABLE OF CONTENTS: 10000005784/04 April 2014
DELIVERY CONTENTS.............................................................................................................................................................. 2
OVERVIEW ................................................................................................................................................................................. 2
1SAFETY GUIDELINES AND MEASURES ...................................................................................................................... 5
1.1General rules......................................................................................................................................................5
1.2Transportation warnings.....................................................................................................................................5
1.3Disposal of li-ion batteries ..................................................................................................................................5
2GENERAL INFORMATION.............................................................................................................................................. 6
2.1Use of this manual..............................................................................................................................................6
2.2Use of pictograms ..............................................................................................................................................6
2.3Validity of this manual ........................................................................................................................................6
2.4Warranty specifications ......................................................................................................................................6
2.5Liability ............................................................................................................................................................... 6
2.6Identification label...............................................................................................................................................6
2.7Use for intended purpose...................................................................................................................................7
2.8Organizational measures ...................................................................................................................................7
2.9Maintenance and repair...................................................................................................................................... 7
2.10General safety and installation precautions........................................................................................................7
2.11Warning regarding life support applications........................................................................................................ 7
3OPERATION.................................................................................................................................................................... 8
3.1Charging and discharging...................................................................................................................................8
3.2Cell management system...................................................................................................................................8
3.3Safety features ...................................................................................................................................................8
3.3.1Reduce charge / discharge................................................................................................................8
3.3.2Stop charge / discharge event...........................................................................................................8
3.3.3Battery safety event........................................................................................................................... 9
3.4Alarm messages.................................................................................................................................................9
3.5MasterBus functionality ......................................................................................................................................9
3.6Maintenance, decommissioning and storage ..................................................................................................... 9
3.7Manual operation of the safety relay ..................................................................................................................9
4INSTALLATION............................................................................................................................................................. 10
4.1Unpacking ........................................................................................................................................................10
4.2Required tools:.................................................................................................................................................10
4.3Location to install..............................................................................................................................................10
4.4General installation guidelines..........................................................................................................................10
4.5Minimum safety requirements ..........................................................................................................................11
4.6Safety relay and battery fuse............................................................................................................................ 12
4.6.1Required materials .......................................................................................................................... 12
4.6.2Connection......................................................................................................................................12
4.7Charger settings...............................................................................................................................................13
4.8Charging systems.............................................................................................................................................13
4.8.1System with a Mastervolt Mass Charger or ChargeMaster .............................................................14
4.8.2System with Mastervolt Alpha Pro II regulator.................................................................................15
4.8.3System with a Mastervolt Mass Combi............................................................................................ 16
4.8.4Non-Mastervolt charging devices up to 6A AC................................................................................ 17
4.8.5Non-Mastervolt charging devices of more than 6A AC.................................................................... 18

TABLE OF CONTENTS
4Copyright © 2014 Mastervolt / April 2014 / Lithium-ion Battery MLi Ultra / EN
5COMMISSIONING ......................................................................................................................................................... 19
6MASTERBUS................................................................................................................................................................. 20
6.1What is MasterBus?.........................................................................................................................................20
6.2How to set up a MasterBus network................................................................................................................. 20
6.3MasterBus: Monitoring and Configuration of the Li-ion battery.........................................................................21
6.3.1Monitoring........................................................................................................................................21
6.3.2Alarms............................................................................................................................................. 22
6.3.3History.............................................................................................................................................22
6.3.4Configuration...................................................................................................................................22
6.3.5Events ............................................................................................................................................. 23
6.3.6List of events sources......................................................................................................................24
6.3.7List of list of event commands.........................................................................................................25
6.4Battery safety event threshold levels................................................................................................................25
7TROUBLE SHOOTING.................................................................................................................................................. 26
8MAINTENANCE, DECOMMISSIONING AND STORAGE............................................................................................. 27
8.1Maintenance..................................................................................................................................................... 27
8.2Taking out of operation.....................................................................................................................................27
8.3Battery replacement.........................................................................................................................................27
8.4Exchanging MasterBus devices .......................................................................................................................27
8.5Storage.............................................................................................................................................................27
9ORDERING INFORMATION.......................................................................................................................................... 28
10TECHNICAL INFORMATION ........................................................................................................................................ 29
10.1Specifications...................................................................................................................................................29
10.2Dimensions.......................................................................................................................................................30
10.3Charge, discharge characteristic......................................................................................................................31
10.4Fuse to cable size ............................................................................................................................................31
11EC DECLARATION OF CONFORMITY ........................................................................................................................ 32

SAFETY GUIDELINES AND MEASURES
EN / April 2014 / Lithium-ion Battery MLi Ultra / Copyright © 2014 Mastervolt 5
1 SAFETY GUIDELINES AND MEASURES
1.1 GENERAL RULES
Observe these instructions and keep them
located near the Li-ion Battery for future
reference.
Work on the Li-ion Battery should be carried out
by qualified personnel only.
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 CO2fire 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.
Too deep discharges damage the Li-ion battery
seriously and can even be dangerous.
Therefore, use of an external safety relay is
obligatory. Refer to chapter 4.
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 (29.2 V). On the other hand, Li-ion
batteries can be discharged down to 11.0
(22.0V). Note that this voltage range (11.0-
14.6V or 22.0-29.2V) 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 DISPOSAL OF LI-ION BATTERIES
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.
non-s
p
illable

GENERAL INFORMATION
6Copyright © 2014 Mastervolt / April 2014 / Lithium-ion Battery MLi Ultra / EN
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-Ultra 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.
Only the SINGLE battery installation is described. For
systems with more than one single battery, please
refer to www.mastervolt.com/batteries.
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!
2.2 USE OF PICTOGRAMS
Safety instructions and warnings are marked in this
manual by the following pictograms:
WARNING
A WARNING refers to possible injury to the
user or significant material damage to the
battery if the user does not (carefully) follow
the procedures.
CAUTION!
Special data, restrictions and rules with regard
to preventing damage.
2.3 VALIDITY OF THIS MANUAL
All of the specifications, provisions and instructions
contained in this manual apply solely to the following
products:
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
2.4 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 means 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
period and conditions of this warranty are laid down in the
general conditions of delivery as registered with the
Chamber of Commerce and Industries in Amsterdam
number 33279951 and are available on request.
Warranty will void if you fail to use an external
safety relay controlled by the Li-ion Battery.
2.5 LIABILITY
Mastervolt accepts no liability for:
consequential damage due to use of the Li-ion
Battery;
possible errors in the manuals and their results.
2.6 IDENTIFICATION LABEL
The identification label is located at the top side of the Li-
ion Battery, next to the grip handle (see figure 2-1).
Important technical information required for service,
maintenance & secondary delivery of parts can be derived
from the identification label.
CAUTION!
Never remove the identification label.
Figure 2-1:
Identification label

GENERAL INFORMATION
EN / April 2014 / Lithium-ion Battery MLi Ultra / Copyright © 2014 Mastervolt 7
2.7 USE FOR INTENDED PURPOSE
1 The Li-ion Battery is constructed as per the applicable
safety-technical guidelines.
2 Use the Li-ion Battery only:
in a technical correct condition;
in a closed, well-ventilated area, protected
against rain, moist, dust and condensation;
observing the instructions and specifications in
this manual.
WARNING
Never use the Li-ion Battery at locations
where there is danger of gas or dust explosion
or potentially flammable products!
3 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.
2.8 ORGANIZATIONAL MEASURES
The user must always:
have access to the user's manual;
be familiar with the contents of this manual. This
applies in particular to chapter Safety Guidelines and
Measures.
2.9 MAINTENANCE AND REPAIR
1 If the electrical installation is switched off during
maintenance and/or repair activities, it should be
secured against unexpected and unintentional
switching on:
switch off all charging systems;
switch off the connection with the batteries;
be sure that third parties cannot reverse the
measures taken.
2 If maintenance and repairs are required, only use
original spare parts.
2.10 GENERAL SAFETY AND INSTALLATION
PRECAUTIONS
Do not expose the Li-ion Battery to rain, snow, spray,
moisture, excessive pollution and condensing
circumstances. Do not install the Li-ion Battery in a
non-ventilated area, overheating may result.
The Li-ion Battery must only be used in combination
with a controlled external safety relay (refer to chapter
4).
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.
2.11 WARNING REGARDING LIFE SUPPORT
APPLICATIONS
The Li-ion Battery is not sold for applications in any
medical equipment intended for use as a component of
any life support system unless a specific written
agreement pertaining to such intended use is executed
between the manufacturer and Mastervolt. Such
agreement will require the equipment manufacturer either
to contract additional reliability testing of the Li-ion Battery
parts and/or to commit to undertake such testing as a part
of the manufacturing process. In addition the manufacturer
must agree to indemnify and not hold Mastervolt
responsible for any claims arising from the use of the Li-
ion Battery in the life support equipment.

OPERATION
8Copyright © 2014 Mastervolt / April 2014 / Lithium-ion Battery MLi Ultra / EN
3 OPERATION
3.1 CHARGING AND DISCHARGING
Use the Li-ion Battery within the specifications as stated in
chapter 10.
3.2 CELL MANAGEMENT SYSTEM
The Mastervolt Li-ion battery 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 the 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. But to avoid this kind of
premature failure, the Mastervolt Li-ion battery is provided
with a Cell Management System. With this system, each
cell is conditioned individually.
Features of the Cell Management System:
Balancing between the different cells. Normally, cells
in a series string receive identical currents. With the
Cell Management System current from stronger cells
will be transferred to the weaker cells during the
charging/ discharging process and idle mode;
Protection of each separate cell from 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 Li-ion battery, it must be
installed and commissioned in accordance
with the instructions stated in chapters 4 and
5 of this manual!
3.3 SAFETY FEATURES
Under- and over-charging, cell imbalances and excessive
temperatures may lead to permanent damage to the Li-ion
battery and even to dangerous situations. Therefore the Li-
ion battery is provided with several advanced safety
features.
WARNING
Alarms and warnings generated by the Li-ion
battery should not be neglected. It is the
user’s responsibility to take adequate
measures.
There are three levels of protection:
Reduce charge / discharge: reduction of the charge /
discharge current
Stop charge / discharge: Interruption of the charge /
discharge current
Battery safety event: an “emergency stop” of the
battery
3.3.1 Reduce charge / discharge
This is the lowest level of protection. Use of this level of
protection is optional.
It is triggered if the battery voltage, the voltage of one of
the individual cells or the temperature of one of the cells is
getting close to the allowed operation specifications.
MasterBus events can be programmed to display warnings
or to intervene on the electrical system, for instance by
reducing the charge voltage (Reduce charge) or by
disconnecting peripheral loads (Reduce discharge). See
section 6.3 and continued for programming of events.
3.3.2 Stop charge / discharge event
At this second level of protection, the Li-ion battery is
getting too close to the allowed operation specifications.
The Li-ion battery will generate MasterBus controlled
event commands to which the electrical installation should
respond. Programming of the Stop charge event command
is obligatory; programming of the Stop discharge event
command is optional. Refer to section 6.3 and continued.
If the Li-ion battery generates the Stop charge event, it
forces to Mastervolt Mass Charger or ChargeMaster to
switch to the float stage, in which a lower charge voltage is
used. Other (for instance non-Mastervolt) charging devices
will be switched off for 10 minutes before they resume
charging.

OPERATION
EN / April 2014 / Lithium-ion Battery MLi Ultra / Copyright © 2014 Mastervolt 9
3.3.3 Battery safety event
This is the highest level of protection. It occurs if the
commands generated at the second level of protection
were neglected. The Battery safety event will trigger the
safety relay to cut off the Li-ion battery from the electrical
installation.
There are two kinds of Battery safety events: a resettable
and a non-resettable. See section 6.4 for threshold levels.
WARNING
If a non-resettable Battery safety event
occurs, the Li-ion battery is damaged. It shall
be secured against further use.
If the safety relay has been triggered, act as follows:
1 Disconnect all loads and all charging devices from the
Li-ion Battery.
2 Reset the safety relay(s) to reconnect the Li-ion
battery. To do so, move the safety relay in the
REMOTE ON position. See section 3.7.
3 Wait for 1 minute. If the Battery Safety Event triggers
again, a non-resettable battery safety event occurred.
Do not try to reset the safety relay(s) again. In this
case the Li-ion battery is damaged and should not be
used anymore. Move the safety relay(s) in the LOCK
OFF position and contact a Mastervolt representative
for assistance.
4 If the Battery Safety Event was not triggered again, a
resettable battery safety event occurred. Check the
battery voltage with a suitable voltage meter. If the
battery voltage is below 13V (26V for 24V battery),
keep the loads disconnected and start charging the Li-
ion battery. If the battery voltage is over 13V (26V for
24V battery), check the output voltage of the charging
devices. If OK, discharge the Li-ion battery for a while.
Additional MasterBus events can be programmed when
the Battery safety event occurs. Refer to section 6.3 and
continued.
3.4 ALARM MESSAGES
The Li-ion Battery may generate the following Alarm
messages that may appear on a MasterBus display:
Message What to do?
Battery Safety Battery Safety Event occurred. See
section 3.3.3.
Overtemperature The internal temperature of one of
the cells is too high. This will also
generate a Battery Safety Event. See
section 3.3.3
Overcurrent Battery current is >600A for more
than 30 seconds. Reduce load
immediately
3.5 MASTERBUS FUNCTIONALITY
Refer to chapter 6 for advanced MasterBus functionality.
The Li-ion battery is able to power the MasterBus network.
Refer to section 6.3.4, Configuration: MasterBus Power for
setting the battery to MasterBus powering.
CAUTION!
The safety systems and the MasterBus
network will slowly drain the Li-ion Battery,
even if the battery has been disconnected
from the electrical system. Refer to section
6.3.4 if you want to disable these control
systems for instance when the battery will be
put out of operation for a longer time
3.6 MAINTENANCE, DECOMMISSIONING AND
STORAGE
Refer to chapter 8
3.7 MANUAL OPERATION OF THE SAFETY RELAY
Function Description Action
REMOTE ON To connect the Li-ion Battery to load and
charging devices Push button on top of the safety relay until latched
REMOTE OFF To disconnect the Li-ion Battery from
load and charging devices Rotate knob on top of the safety relay to right to release button; then rotate
knob to left
LOCK OFF To prevent remote operation Rotate knob on top of the safety relay
to right

INSTALLATION
10 Copyright © 2014 Mastervolt / April 2014 / Lithium-ion Battery MLi Ultra / EN
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 within the following range:
Model Allowed open clamp voltage
12V models 11.0 – 14.5 Volt
24V models 22.0 – 29.0 Volt
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.
2 mm flat blade screwdriver to fasten the wiring of the
safety relay;
4 mm flat blade screwdriver to fasten the balance line
wiring
A MasterBus control panel (for adjustment of setpoints
and programming of obligatory MasterBus events).
Select one from the table below:
Part number Model
77010305 MasterView Easy MkII
77010400 MasterView System panel
77030100 MasterBus USB interface
(required as interface between your
PC and the MasterBus network)
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.
The Li-ion battery must be installed in upright position
or on the long side, although upright mounting is
recommended
Keep at least 1 cm between two Li-ion batteries for air
flow.
The Li-ion battery must be secured to its foundation.
4.4 GENERAL INSTALLATION GUIDELINES
Switch off all loads and chargers before starting
installation.
The Li-ion battery is a special kind of battery which
requires special safety precautions in the installation
Installation and commissioning of the Li-ion battery
requires programming of MasterBus events in a
MasterBus communication network to control the
battery charger. The installer must be familiar with the
programming of such MasterBus events. See
chapters 4 and 6 of this manual
Additional measures must be taken when
installing Li-ion batteries in series or parallel.
Refer to www.mastervolt.com/batteries for our manual
on multiple Li-ion battery systems and system
examples
Use properly sized and reliable, cables, cable lugs
and battery terminals. Tighten all connections. For the
main DC connections use 14.7 to 19.6 Nm / 130 to
170 InLbs torque. Do not over torque as this will
damage the Li-ion Battery beyond repair.
Unused wiring should be insulated properly to avoid
accidental contact.
Connect the battery with the correct polarity to the
charger and load(s) (positive pole to positive
terminal). Note that the position of the battery poles
may differ from previously installed batteries! In
installations with a negative earth, connect the
negative cable last of all to prevent short circuiting.
After connecting the battery cable, close the
protection lids (grip handles of the Li-ion battery) to
prevent incidental touching of the terminals.

INSTALLATION
EN / April 2014 / Lithium-ion Battery MLi Ultra / Copyright © 2014 Mastervolt 11
1 Li-ion battery
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
Figure 4-1: Single battery system overview
4.5 MINIMUM SAFETY REQUIREMENTS
WARNING
To prevent hazardous situations YOU MUST:
A. Install a safety relay which
disconnects the battery under
abnormal circumstances (section 4.6)
B. Install a charger that stops charging if
the battery indicates so by means of a
Stop charge event (section 4.8 and
continued)
C. Configure the MasterBus Stop charge
event (section 4.8 and continued)
D. Check the correct operation of the
safety relay (chapter 5)
E. Use properly sized fuses and wiring
Figure 4-1 shows a simplified overview of a safe Li-ion
battery system.
1 MLi 12/2500, MLi 12/5000 or MLi 24/5000 Li-ion
battery.
2 Fuse in the positive battery cable to protect DC
cabling and battery. It must correspond with the
cable diameter up to maximum 500A for the 24V
battery and the 12V battery.
The DC breaking capacity (IR) must be at least 15kA.
3 Safety relay, must be able to disconnect loads and
charging devices when battery enters an unsafe
situation.
4 Battery Charger, must be able to stop charging or
switch to the Float stage at the MasterBus Stop
charge event when the battery detects a “stop
charge” condition. It has to be configured to charge a
Li-ion battery, refer to the user’s manual of the
battery charger, section MasterBus configuration
(charger settings).
5 DC loads.
If the charger is stopped due to a Stop charge event,
battery power is still available for the loads (5). If the safety
relay (3) disconnects due to a Battery Safety event, there
is no battery power available for the loads.
.
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INSTALLATION
12 Copyright © 2014 Mastervolt / April 2014 / Lithium-ion Battery MLi Ultra / EN
4.6 SAFETY RELAY AND BATTERY FUSE
4.6.1 Required materials
Quantity Mastervolt
Part number Description
@ 12V @ 24V
1 -- 79007700 Safety relay 12V/500A, part # 7700
-- 1 79007702 Safety relay 24V/500A, part # 7702
1 1 77049000 T-Fuse to protect the DC Main Wiring*, max. 500A.
Minimum DC breaking capacity (IR): 15kA
1 1 778-T2S-600 T-Fuse holder for 77049000
** ** DC Main Wiring, cross section depending on maximum system current
** ** Wiring for the control circuit of the safety relay, minimum cross section: 0.5mm²
*Any other fuse can be applied as long as the voltage/current ratings satisfy installation requirements.
** Installation dependent
4.6.2 Connection
See figure 4-2. Follow next steps to install the safety relay:
1 Move the safety relay in the LOCK OFF position. See section 3.7.
2 Connect the safety relay, fuse holder and DC main wiring as indicated but do not place the battery fuse yet.
3 Connect the wiring for the control circuit of the safety relay as indicated. Note that the yellow wire is not connected.
1. Li-ion battery A. Black relay wire (-)
2. Battery fuse in positive battery line B. Orange relay wire, UDC open
3. Safety relay C. Brown relay wire, UDC close
D. Red relay wire (+)
E. Yellow relay wire (not used)
Figure 4-2: Connection of the Safety relay and battery fuse
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4.7 CHARGER SETTINGS
A single Mastervolt Li-ion battery can be charged with any
standard Mastervolt battery charger. These chargers
feature the MLi charging option. Without this option, IUoUo
charge settings must be as follows:
Li-ion battery
model Bulk / absorption voltage setting Float voltage setting
MLi Ultra 12/2500 14.25 V 13.5 V
MLi Ultra 12/5000 14.25 V 13.5 V
MLi Ultra 24/5000 28.5 V 27.0 V
Refer to the user’s manual of the battery charger for
adjustment.
The temperature of each cell as well as the temperature of
the entire Li-ion battery is monitored by the cell
management system. Therefore, do not use a sensor for
temperature compensated charging.
Do not use a temperature sensor for
temperature compensated charging!
4.8 CHARGING SYSTEMS
Installation and configuration of the Stop charge event
depend on the system in which the Li-ion battery is used.
We describe five ways to charge your Li-ion battery:
1 System with a Mastervolt Mass Charger or
ChargeMaster, refer to section 4.8.1.
2 System with a Mastervolt Alpha Pro II alternator
regulator, refer to section 4.8.2.
3 The Mastervolt Mass Combi, used to charge the
battery. Refer to section 4.8.3
4 Non-Mastervolt charging devices, up to 6A AC. Refer
to section 4.8.4.
5 Non-Mastervolt charging devices, from 6A AC up.
Refer to section 4.8.5.
Select one of these options and continue with the
corresponding section.
WARNING
If more charging devices are used to charge
the Li-ion battery (for instance when the Li-ion
battery is charged by both an AC powered
charger and an alternator), Stop charge
events must be configured for each charging
device.
WARNING
During the entire installation procedure:
The safety relay must remain in LOCK
OFF position
The battery fuse should not be placed

INSTALLATION
14 Copyright © 2014 Mastervolt / April 2014 / Lithium-ion Battery MLi Ultra / EN
4.8.1 System with a Mastervolt Mass Charger or ChargeMaster
1. Li-ion battery 5. Loads
2. Battery fuse in positive battery line 6. DC plus cable
3. Safety relay 7. DC minus cable
4 Mastervolt Mass charger or Chargemaster 8. MasterBus cable
9. MasterBus terminator
Figure 4-3: Basic system with a Mastervolt Mass Charger or Chargemaster
Follow next steps to install the Mastervolt Mass Charger or
ChargeMaster:
1 Connect the DC main wiring as indicated.
2 Connect the MasterBus cabling between the devices
as indicated. Keep the rules in mind as described in
section 6.2.
3 Add a MasterBus control panel to the MasterBus
network.
4 Configure the following Stop Charge event at the Li-
ion battery:
Configuration Event 1 (obligatory)
Event source Stop charge
Event target CHG Mass Charger /
CHG ChargeMaster
Event command Float
Event data Copy
Stop Charge event
The charger must stop charging at the Stop Charge event.
The Mass Charger or ChargeMaster is able to process the
Stop Charge event. The event source is the Li-ion battery
Stop charge. The event target is the Mass Charger or
ChargeMaster (CHG Mass Charger or CHG
ChargeMaster). At the Stop charge event, the event
command “Float” is triggered. The charger switches to
float phase and resumes charging the normal way
according to its charging characteristic.
5 Continue with chapter 5
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4.8.2 System with Mastervolt Alpha Pro II regulator
1. Li-ion battery 5. Loads
2. Battery fuse in positive battery line 6. DC plus cable
3. Safety relay 7. DC minus cable
4 Alternator with Alpha Pro II regulator 8. MasterBus cable
9. MasterBus terminator
Figure 4-4: Basic system with a Mastervolt Alpha Pro II regulator
Follow next steps to install the Mastervolt Alpha Pro II
regulator:
1 Connect the DC main wiring as indicated.
2 Connect the MasterBus cabling between the devices
as indicated. Keep the rules in mind as described in
section 6.2.
3 Add a MasterBus control panel to the MasterBus
network.
4 Configure the following Stop Charge event at the Li-
ion battery:
Configuration Event 1 (obligatory)
Event source Stop Charge
Event target APR Alpha Pro MB
Event command Suspend charge
Event data Copy
Stop Charge event
The charger must stop charging at the Stop Charge event.
The Alpha Pro II regulator is able to process the Stop
Charge event. The Event source is the Li-ion battery Stop
charge. The Event target is the Alpha Pro II (APR Alpha
Pro MB). At the Stop charge event, the Event command
“Suspend charge” is triggered. The charging process of
the regulator is interrupted and will resume once the Stop
Charge event ends.
5 Configure the following Battery safety event at the Li-
ion battery:
Configuration Event 2 (obligatory)
Event source Battery Safety
Event target APR Alpha Pro MB
Event command Suspend charge
Event data On
Battery safety event
If a Battery safety event occurs, the safety relay will
disconnect the battery from the electrical installation. This
may result in voltage fluctuations on the DC grid and
overheating of the field windings of the alternator.
Therefore at the Battery Safety event, the Event command
“Suspend charge” is triggered which will terminate the
charging process.
6 Continue with chapter 5
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INSTALLATION
16 Copyright © 2014 Mastervolt / April 2014 / Lithium-ion Battery MLi Ultra / EN
4.8.3 System with a Mastervolt Mass Combi
1. Li-ion battery 5. Loads
2. Battery fuse in positive battery line 6. DC plus cable
3. Safety relay 7. DC minus cable
4 MasterBus Combi Interface via serial cable connected to the Mass Combi 8. MasterBus cable
9. MasterBus terminator
Figure 4-5: Basic system with a Mastervolt Mass Combi
Follow next steps to install the Mastervolt Mass Combi:
1 Connect the DC main wiring as indicated.
2 Connect the MasterBus cabling between the devices
as indicated. Keep the rules in mind as described in
section 6.2
3 Add a MasterBus control panel to the MasterBus
network.
4 Configure the following Stop Charge event at the Li-
ion battery:
Configuration Event 1 (obligatory)
Event source Stop Charge
Event target INT Mass Combi
Event command Charger
Event data Copy invert
Stop Charge event
The Mass Combi must stop charging at the Stop Charge
event. Because the Mass Combi is not MasterBus
compatible, it uses the MasterBus-Combi Interface (INT
Mass Combi) for MasterBus communication. This interface
must be event configured. The Event source is the Li-ion
battery Stop charge. The Event target is the MasterBus-
Combi Interface with the command Charger Off. After10
minutes the Stop Charge event ends and charging is
resumed.
5 Continue with chapter 5
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4.8.4 Non-Mastervolt charging devices up to 6A AC
1. Li-ion battery 5. Loads
2. Battery fuse in positive battery line 6. DC plus cable
3. Safety relay 7. DC minus cable
4Non-Mastervolt charger with an AC input current less than 6A, 8. MasterBus cable
in combination with a Digital DC 1x6A relay 9. MasterBus terminator
Figure 4-6: Basic system with non-Mastervolt chargers up to 6A AC.
All charging devices other than in sections 4.8.1 till 4.8.3
with an AC input current up to 6A, must be equipped with
a MasterBus Digital AC 1x6A relay (p/n 77031500) to stop
charging.
Follow next steps to install the non-Mastervolt charger:
1 Connect the DC main wiring as indicated.
2 Connect the MasterBus cabling between the devices
as indicated. Keep the rules in mind as described in
section 6.2.
3 Add a MasterBus control panel to the MasterBus
network.
4 Configure the following Stop Charge event at the Li-
ion battery:
Configuration Event 1 (obligatory)
Event source Stop Charge
Event target INT AC 1x6A
Event command Activate
Event data Copy invert
Stop Charge event
The charger must stop charging at the Stop Charge event.
The non-Mastervolt charging devices are not able to
process the Stop Charge event itself. You need a Digital
AC 1x6A to switch off the charging device input or output.
The event source is the Li-ion battery Stop charge. The
Event target is the Digital AC 1x6A (INT AC 1x6A). Copy
invert means, at the Stop Charge event, Activate becomes
untrue and charging stops. After10 minutes the Stop
Charge event ends and charging is resumed
CAUTION
Under all circumstances, charging must be
terminated when the Li-ion battery generates
a Stop charge event
5 Continue with chapter 5
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INSTALLATION
18 Copyright © 2014 Mastervolt / April 2014 / Lithium-ion Battery MLi Ultra / EN
4.8.5 Non-Mastervolt charging devices of more than 6A AC
1. Li-ion battery 5. Loads
2. Battery fuse in positive battery line 6. DC plus cable
3. Safety relay 7. DC minus cable
4Non-Mastervolt charger with an AC input current of more than 6A, 8. MasterBus cable
in combination with a Digital DC 1x6A relay controlling another AC relay 9. MasterBus terminator
Figure 4-7: Basic system with non-Mastervolt chargers above 6A AC
All charging devices other than in sections 4.8.1 till 4.8.3
with an AC input current of more than 6A, must be
equipped with a digital AC 1x6A relay operating a high
current relay to stop charging:
Follow next steps to install the non-Mastervolt charger:
1 Connect the DC main wiring as indicated.
2 Connect the MasterBus cabling between the devices
as indicated. Keep the rules in mind as described in
section 4.6.
3 Add a MasterBus control panel to the MasterBus
network.
4 Configure the following Stop Charge event at the Li-
ion battery:
Configuration Event 1 (obligatory)
Event source Stop Charge
Event target INT AC 1x6A
Event command Activate
Event data Copy invert
Stop Charge event
The charger must stop charging at the Stop Charge event.
The non-Mastervolt charging devices are not able to
process the Stop Charge event itself. You need a Digital
AC 1x6A to switch off the charging device input or output.
The event source is the Li-ion battery Stop charge. The
Event target is the Digital AC 1x6A (INT AC 1x6A). Copy
invert means, at the Stop Charge event, Activate becomes
untrue and charging stops. After10 minutes the Stop
Charge event ends and charging is resumed
CAUTION
Under all circumstances, charging must be
terminated when the Li-ion battery generates
a Stop charge event
5 Continue with chapter 5
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COMMISSIONING
EN / April 2014 / Lithium-ion Battery MLi Ultra / Copyright © 2014 Mastervolt 19
5 COMMISSIONING
Follow the steps described below for commissioning of the
Li-ion battery
1 Check all wiring and connections; see also the figures
in chapter 4 for wiring details.
2 If everything is OK, move the safety relay in the
“REMOTE OFF” position. See section 3.7. Do not
place the fuses yet!
3 On the MasterBus control panel, go to the monitoring
page of the Li-ion battery
4 See figure 5-1. Operate the “Close Relay” button. The
knob on the safety relay should shift inwards.
5 Operate the “Open Relay” button. If the safety relay is
open (Off), the knob position should be outwards.
Keep the safety relay in this position.
6 Install all fuses.
7 Switch on some loads
8 On the monitoring page check that the battery current
is 0 Amps. See figure 5-2.
9 Move the safety relay in the REMOTE ON position by
pushing the button on top of the safety relay until
latched. See section 3.7.
10 Verify that a current is flowing out of the battery
(negative current)
11 Switch off the load, switch on the charger and verify
that a current is flowing into the battery (positive
value).
12 If necessary, check if the battery is in MasterBus
Powering mode. See section 6.3.4 Configuration:
MasterBus Power.
13 Depending on the installation in which the Li-ion
battery is used, programming of additional MasterBus
events may be required. See chapter 6.
14 If necessary, remove the MasterBus control panel
from the MasterBus network
15 Charge the Li-ion battery fully until the charger
switches to the float stage (maintenance charge) of
the charging algorithm
Now the Li-ion battery is ready for operation
Figure 5-1: Buttons for closing and opening the relay
ON
OFF
Figure 5-2: Checking the current

MASTERBUS
20 Copyright © 2014 Mastervolt / April 2014 / Lithium-ion Battery MLi Ultra / EN
6 MASTERBUS
6.1 WHAT IS MASTERBUS?
All devices that are suitable for MasterBus are
marked by the MasterBus symbol.
MasterBus is a fully decentralized data network for
communication between the different Mastervolt system
devices. It is a CAN-bus based communication network
which has proven itself as a reliable bus-system in
automotive applications. MasterBus is used as power
management system for all connected devices, such as
the inverter, battery charger, generator and many more.
This facilitates communication between the connected
devices, for instance to start the generator when the
batteries are low.
MasterBus reduces complexity of electrical systems by
using less cables. All system components are simply
chained together. For this purpose every MasterBus
device has been equipped with two MasterBus data ports.
When two or more devices are connected through these
data ports, they become a local data network, called the
MasterBus. The results are a reduction of installation costs
as only a few electrical cables and less installation time
are needed.
For central monitoring and control of the connected
devices, Mastervolt offers a wide range of panels which
show full status information of your electrical system at a
glance and a push of a button. Different panels are
available, like the MasterView Easy MkII and the full
colour MasterView System panel. All monitoring panels
can be used for monitoring, control and configuration of all
connected MasterBus equipment.
New devices can be added to the existing network in a
very easy way by just extending the network. This makes
the MasterBus a highly flexible network for extended
system configuration, today and in the future.
Mastervolt also offers several interfaces, making even
non-MasterBus devices suitable to operate in the
MasterBus network. For direct communication between
the MasterBus network and a product which is not from
Mastervolt, several interfaces are available. Example is
the MasterBus Modbus interface.
CAUTION!
Never connect a non-MasterBus device to the
MasterBus network directly! This will void
warranty of all MasterBus devices connected.
6.2 HOW TO SET UP A MASTERBUS NETWORK
Every device that is suitable for the MasterBus network is
equipped with two data ports. When two or more devices
are connected to each other through these ports, they
form a local data network, called the MasterBus.
Keep the following rules in mind:
Figure 6-1: UTP patch cable
Figure 6-2: Two Terminators
As with all high speed data networks, MasterBus
needs a terminating device on both ends of the
network.
Terminating
device
Terminating
device
OK
Connections between the devices are made by
standard straight UTP patch cables. Mastervolt can
supply these cables. These cables are also commonly
available at computer supply stores.
OK
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