MG HE Series User manual

Innovation in energy storage
Version 2.3 –21-9-2022
Lithium-Ion HE battery module
- Manual -
MGHE240100, MGHE241100, MGHE242100 (HE 100Ah)
MGHE240150, MGHE241150, MGHE242150 (HE 150Ah)
MGHE240200, MGHE241200, MGHE242200 (HE 200Ah)
MGHE240300, MGHE241300, MGHE242300 (HE 300Ah)
Also applicable to older series HP and UHE
MG Energy Systems B.V.

Innovation in energy storage
Version 2.3 –21-9-2022
Copyrights 2022 MG Energy Systems B.V.
All Rights Reserved
This publication or parts thereof, may not be reproduced in any form, by any method, for any
purpose.
For conditions of use and permission to use this manual for publication in other than the English
language, contact MG Energy Systems B.V..
MG ENERGY SYSTEMS B.V. MAKES NO WARRANTY, EITHER EXPESSED OR IMPLIED, INCLUDING BUT
NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE, REGARDING THESE MG ENERGY SYSTEMS B.V. PRODUCTS AND MAKES SUCH MG ENERGY
SYSTEMS B.V. PRODUCTS AVAILABLE SOLELY ON AN “AS IS” BASIS.
IN NO EVENT SHALL MG ENERGY SYSTEMS B.V. BE LIABLE TO ANYONE FOR SPECIAL, COLLATERAL,
INCIDENTAL, OR CONSEQUENTIAL DAMAGES IN CONNECTION WITH OR ARISING OUT OF PURCHASE
OR USE OF THESE MG ENERGY SYSTEMS B.V. PRODUCTS. THE SOLE AND EXCLUSIVE LIABILITY TO MG
ENERGY SYSTEMS B.V.., REGARDLESS OF THE FORM OF ACTION, SHALL NOT EXCEED THE PURCHASE
PRICE OF THE MG ENERGY SYSTEMS B.V. PRODUCTS DESCRIBED HERE IN.
MG Energy Systems B.V. reserves the right to revise and improve its products as it sees fit. This
publication describes the state of this product at the time of its publication and may not reflect the
product at all times in the future.

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TABLE OF CONTENTS
1 GENERAL .........................................................................................................................................1
1.1 Document history ...................................................................................................................1
1.2 Terms, abbreviations, and definition......................................................................................1
2 SAFETY INSTRUCTIONS....................................................................................................................3
2.1 Safety message level definition ..............................................................................................3
2.2 User health and safety ............................................................................................................3
Qualifications and training..............................................................................................4
Non-compliance risks......................................................................................................4
Risk assessment ..............................................................................................................4
Unacceptable modes of operation .................................................................................4
3 TRANSPORT, STORAGE, UNPACKING AND HANDLING ...................................................................5
3.1 Transport.................................................................................................................................5
3.2 Storage....................................................................................................................................5
3.3 Unpacking and handling..........................................................................................................6
Lifting the battery module ..............................................................................................6
Scope of delivery.............................................................................................................7
4 GENERAL DESCRIPTION...................................................................................................................8
4.1 Battery system components ...................................................................................................8
4.2 Functional description ............................................................................................................8
4.3 Example systems.....................................................................................................................9
Low voltage systems .......................................................................................................9
High voltage systems ....................................................................................................10
5 MODELS ........................................................................................................................................11
5.1 Models and configurations ...................................................................................................11
RJ45 connectors and systems up to 96 V......................................................................11
M12 connectors and systems up to 96 V......................................................................11
M12 connectors and systems up to 144 V systems (M12-HV) .....................................11
Battery designation.......................................................................................................12
5.2 Identification label ................................................................................................................13
Other labels...................................................................................................................13
5.3 Approvals and standards ......................................................................................................14
6 OVERVIEW.....................................................................................................................................15

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6.1 Connection overview ............................................................................................................15
Overview of all models..................................................................................................17
6.2 Connections details...............................................................................................................21
RJ45 CAN-bus connector details ...................................................................................21
M12 CAN-bus connector details ...................................................................................22
Power connections........................................................................................................23
6.3 Status indication ...................................................................................................................25
Indication showing the LED states and its meaning .....................................................25
7 INTEGRATION REQUIREMENTS AND INSTRUCTIONS ...................................................................26
7.1 Risk assessment ....................................................................................................................26
7.2 Location.................................................................................................................................26
Environment..................................................................................................................26
Thermal management...................................................................................................26
7.3 Placement .............................................................................................................................29
Placement in battery box..............................................................................................29
Positioning the battery .................................................................................................30
Positioning considering air flow....................................................................................31
Mounting considerations..............................................................................................31
Battery module spacing requirements .........................................................................32
7.4 Electrical................................................................................................................................34
Power cables .................................................................................................................34
Parallel configuration....................................................................................................34
Paralleling using the Distributor LV...............................................................................38
Paralleling using a custom bus bar connection system ................................................38
Series configuration ......................................................................................................39
Charger..........................................................................................................................41
8 INSTALLATION...............................................................................................................................42
8.1 Tooling...................................................................................................................................42
8.2 Installation procedures .........................................................................................................43
8.3 Mounting procedure.............................................................................................................43
8.4 Electrical connection procedure ...........................................................................................43
Equipotential bonding connection procedure..............................................................44
Positive and negative power connection procedure ....................................................45

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CAN-bus connection procedure....................................................................................50
8.5 Installing the top ingress protection cover ...........................................................................53
Placing the cover...........................................................................................................54
Removing the cover ......................................................................................................56
Cutting the cover...........................................................................................................56
8.6 Fuse replacing procedure......................................................................................................58
Non-fused battery pole.................................................................................................58
Replacement instructions .............................................................................................58
9 COMMISSIONING..........................................................................................................................60
10 SERVICE .....................................................................................................................................61
10.1 Maintenance .........................................................................................................................61
Cleaning.........................................................................................................................61
10.2 End-of-life..............................................................................................................................61
10.3 Disposal.................................................................................................................................61
11 BOUNDARY LIMITS....................................................................................................................62
11.1 HE 25.2 V / 100-150-200 Ah Battery Module .......................................................................62
Cell voltage....................................................................................................................62
Cell temperature charging ............................................................................................63
Cell temperature discharging........................................................................................63
Power terminal temperature........................................................................................63
Current ..........................................................................................................................64
Balancing.......................................................................................................................64
Deviation voltages and temperatures...........................................................................64
11.2 HE 25.2 V / 300 Ah Battery Module......................................................................................65
Cell voltage....................................................................................................................65
Cell temperature charging ............................................................................................66
Cell temperature discharging........................................................................................66
Power terminal temperature........................................................................................66
Current ..........................................................................................................................67
Balancing.......................................................................................................................67
Deviation voltages and temperatures...........................................................................67
12 TECHNICAL SPECIFICATIONS .....................................................................................................68
13 DIMENSIONS .............................................................................................................................68

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14 CONTACT DETAILS.....................................................................................................................69

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1
1GENERAL
Before continuing read the instructions in this chapter carefully and be sure the instructions are fully
understood. If there are questions after reading the instructions please consult MG Energy Systems.
1.1 Document history
Table 1 - Document history
Rev.
Date
Changes
Revision author
2.0
13-01-2019
Initial document.
Mark Scholten
2.1
24-11-2020
Major changes: Text, images, added new chapters
etc.
Mark Scholten
2.2
11-01-2020
- Update schematic in Figure 1. Fixed minor typos.
- Removed image on page 27. This was not intended
to be there.
Mark Scholten
26-08-2021
Updated battery designation in section 5.1.4.
Frank van Son
2.3
21-09-2022
- Updated images
- Extended storage notes text in chapter 3.2.
- Changed voltage levels and number of battery
modules in series to 144V and 6 modules in series.
- Added chapter risk assessment to chapter 2.2.3.
- Added "Other labels" to chapter 5.2.
- Updated dummy fuse article number in chapter
6.2.3.1.
- Removed 2C heat rejection from chapter 7.2.2.1.
- Added chapter 7.3.1 Placement in battery box.
- Changed float voltage to 28,0 V in chapter 7.4.6.1.
- Added chapter 8.1 Tooling.
- Updated connection of positive and negative
power cables and CAN-Bus connections.
- Extended the commissioning in chapter 9.
- Extended the maintenance in chapter 10.
- Changed "Dummy fuse" to non-fused battery pole
in the complete document
Mark Scholten
1.2 Terms, abbreviations, and definition
Table 2 - Terms, abbreviations, and definitions
Battery cell
Battery cell; the smallest building block in a battery, a chemical unit.
Cell is the bare Lithium-Ion battery cell.
Battery module
Battery module; is an assembly of submodules, BMS and outer
enclosure.
Battery stack
Battery stack; is a set of multiple cells in cell cassettes constructed as
one.
BMS
Battery Management System; The BMS is the electronics that
monitors the battery cell parameters to keep it within the operation
specifications.
CAN-bus
Controller Area Network bus; CAN-bus is a standard serial data-bus
that provides data communication between two or more devices.

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C-rate
C-Rate; the current (A) used to charge/discharge the battery system
divided by the rated ampere-hours (Ah).
EMS
Energy Management System; The EMS controls all power sources
and consumers in a system.
HVIL
High Voltage Interlock Loop; is a wire loop which is created for
protection of pulling cables from the battery system while in
operation. It shuts down the system when loop is not closed.
IC
Integrated Circuit; is a chip containing an electronics circuit;
MSDS
Material Safety Data Sheet; is a document that lists information
relating to occupational safety and health for the use of various
substances and products.
NMEA 2000
National Marine Electronics Association’s NMEA 2000 is a plug-and-
play communications standard used for connecting marine sensors
and display units within ships and boats, standardised in the IEC
61162-1.
PCB
Printed Circuit Board; is a board containing an electronic circuit;
PCBA
Printed Circuit Board Assembly; is a board containing an electronic
circuit including passive and active components;
SoC
State-of-Charge; is the remaining capacity in a battery cell or module
in percent (%).
SoH
State-of-Health; is a figure of merit of the condition of a battery (or a
cell, or a battery pack), compared to its ideal conditions.

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2SAFETY INSTRUCTIONS
Follow the safety instructions in this document to ensure your own safety.
2.1 Safety message level definition
Table 3 - Safety message levels overview
WARNING:
A hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION:
A hazardous situation which, if not avoided, could result in minor or moderate
injury.
LIMITATION:
A limitation to use which must be considered for safe use of the equipment.
ELECTRICAL HAZARD:
The possibility of electrical risks if instructions are not followed in a proper
manner.
NOTICE:
A potential situation which, if not avoided, could result in an undesirable
result or state.
A practice not related to personal injury.
2.2 User health and safety
This product is designed and tested in accordance with international standards. The equipment
should be used according the intended use only.
WARNING:
A battery is a permanent energy source which cannot be turned off.
ELECTRICAL HAZARD:
Wear applicable personal protective equipment when working on a
battery system.
Use insulated tools when working on a battery system.
Make sure the locale health and safety regulations for working on battery
systems are followed.
There is a risk of electrocution and burns when working on higher voltage
systems without proper protective gear and special training.

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Qualifications and training
The personnel responsible for the assembly, operation, inspection, and maintenance of the battery
system must be appropriately qualified. The user company must do the following tasks:
Define the responsibilities and competency of all personnel working on the battery system.
Provide instruction and training.
Ensure that the contents of the operating and safety instructions have been fully understood
by the personnel.
Check the local safety rules and guidelines they have higher preference over the
manufacturers specification in case of regulatory conflicts.
Working on higher voltages requires specific training and certification.
Instructions and training can be carried out by MG Energy Systems B.V. by order of the user
company.
Non-compliance risks
Failure to comply with all safety precautions can result in the following conditions:
Death or serious injury due to electrical, mechanical, and chemical influences.
Environmental damage due to the leakage of dangerous materials.
Product damage.
Property damage.
Loss of all claims for damages.
Risk assessment
For every integration of the battery system it is mandatory to perform a risk assessment.
Goal of the risk assessment is to identify the hazards and determine the corresponding risks for the
particular application.
The following topics need to be addressed:
Fire hazards (fire from the batteries, fire from external source etc.)
Environmental hazards (moisture, water ingress, vibration, heat etc.)
Electrical hazards (short-circuit, cable dimensioning, cable routing etc.)
Installation and operational hazards (lifting, communication, power loss etc.)
Unacceptable modes of operation
The operational reliability of this product is only guaranteed when it is used as intended. The
operating limits on the identification tag and in the data sheet may not be exceeded under any
circumstances. If the identification tag is missing or worn, contact MG Energy Systems B.V. for
specific instructions.
WARNING:
The battery modules may only be used in combination with a master BMS.
(MG Master LV or MG Master HV)