MG Energy Systems MGHE240100 Manuale utente

MG Energy Systems B.V. | Foeke Sjoerdswei 3 | 8914 BH Leeuwarden | The Netherlands

+31 (0)58 750 89 47 | [email protected] | www.mgenergysystems.eu

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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)

MG Energy Systems B.V.

Revision: 2.2

Date: 11-01-2021

MG Energy Systems B.V. | Foeke Sjoerdswei 3 | 8914 BH Leeuwarden | The Netherlands

+31 (0)58 750 89 47 | [email protected] | www.mgenergysystems.eu

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Copyrights 2020 MG Energy Systems B.V.

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.

MG Energy Systems B.V. | Foeke Sjoerdswei 3 | 8914 BH Leeuwarden | The Netherlands

+31 (0)58 750 89 47 | [email protected] | www.mgenergysystems.eu

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TABLE OF CONTENTS

1 GENERAL ...................................................................................................................................................... 6

1.1 Document history ................................................................................................................................ 6

1.2 Terms, abbreviations, and definition................................................................................................... 6

2 SAFETY INSTRUCTIONS................................................................................................................................. 8

2.1 Safety message level definition ........................................................................................................... 8

2.2 User health and safety ......................................................................................................................... 8

General precautions..................................................................................................................... 8

Qualifications and training........................................................................................................... 9

Non-compliance risks................................................................................................................... 9

Unacceptable modes of operation .............................................................................................. 9

3 TRANSPORT, STORAGE AND UNPACKING.................................................................................................. 10

3.1 Transport............................................................................................................................................ 10

3.2 Storage............................................................................................................................................... 10

3.3 Unpacking .......................................................................................................................................... 11

Scope of delivery........................................................................................................................ 11

4 GENERAL DESCRIPTION.............................................................................................................................. 12

4.1 Battery system components .............................................................................................................. 12

4.2 Functional description ....................................................................................................................... 12

4.3 Example systems................................................................................................................................ 13

Low voltage systems .................................................................................................................. 13

High voltage systems ................................................................................................................. 14

5 MODELS ..................................................................................................................................................... 15

5.1 Models and configurations ................................................................................................................ 15

RJ45 connectors and systems up to 96 V................................................................................... 15

M12 connectors and systems up to 96 V................................................................................... 15

M12 connectors and systems up to 460 V systems (M12, HV) ................................................. 15

Battery designation.................................................................................................................... 16

5.2 Identification label ............................................................................................................................. 17

6 OVERVIEW.................................................................................................................................................. 18

6.1 Connection overview ......................................................................................................................... 18

Overview of all models............................................................................................................... 20

6.2 Connections details............................................................................................................................ 24

RJ45 CAN-bus connector details ................................................................................................ 24

MG Energy Systems B.V. | Foeke Sjoerdswei 3 | 8914 BH Leeuwarden | The Netherlands

+31 (0)58 750 89 47 | [email protected] | www.mgenergysystems.eu

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M12 CAN-bus connector details ................................................................................................ 25

Power connections..................................................................................................................... 26

6.3 Status indication ................................................................................................................................ 28

Indication ................................................................................................................................... 28

7 INTEGRATION REQUIREMENTS AND INSTRUCTIONS ................................................................................ 29

7.1 Risk assessment ................................................................................................................................. 29

7.2 Location.............................................................................................................................................. 29

Environment............................................................................................................................... 29

Thermal management................................................................................................................ 29

7.3 Placement .......................................................................................................................................... 32

Positioning the battery .............................................................................................................. 32

Positioning considering air flow................................................................................................. 33

Mounting considerations........................................................................................................... 34

Battery module spacing requirements ...................................................................................... 35

Placement in sealed spaces or compartments .......................................................................... 36

7.4 Electrical............................................................................................................................................. 37

Power cables .............................................................................................................................. 37

Parallel configuration................................................................................................................. 37

Paralleling using the Distributor LV............................................................................................ 41

Series configuration ................................................................................................................... 42

Charger....................................................................................................................................... 43

8 INSTALLATION............................................................................................................................................ 44

8.1 Installation procedures ...................................................................................................................... 44

8.2 Mounting procedure.......................................................................................................................... 45

8.3 Equipotential bonding connection procedure................................................................................... 45

8.4 Electrical connection procedure ........................................................................................................ 46

Power connection procedure .................................................................................................... 46

CAN-bus connection procedure................................................................................................. 48

8.5 Installing the top ingress protection cover ........................................................................................ 49

Placing the cover........................................................................................................................ 49

Removing the cover ................................................................................................................... 50

Cutting the cover........................................................................................................................ 51

8.6 Fuse replacing procedure................................................................................................................... 52

Dummy fuse............................................................................................................................... 52

MG Energy Systems B.V. | Foeke Sjoerdswei 3 | 8914 BH Leeuwarden | The Netherlands

+31 (0)58 750 89 47 | [email protected] | www.mgenergysystems.eu

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Replacement instructions .......................................................................................................... 52

9 COMMISSIONING....................................................................................................................................... 54

10 SERVICE .................................................................................................................................................. 55

10.1 Maintenance ...................................................................................................................................... 55

Connections ............................................................................................................................... 55

Cleaning...................................................................................................................................... 55

10.2 End-of-life........................................................................................................................................... 55

10.3 Disposal.............................................................................................................................................. 55

11 BOUNDARY LIMITS................................................................................................................................. 56

11.1 HE 25.2 V / 100-150-200 Ah Battery Module .................................................................................... 56

Cell voltage................................................................................................................................. 56

Cell temperature charging ......................................................................................................... 57

Cell temperature discharging..................................................................................................... 57

Power terminal temperature..................................................................................................... 57

Current ....................................................................................................................................... 58

Balancing.................................................................................................................................... 58

Deviation voltages and temperatures........................................................................................ 58

11.2 HE 25.2 V / 300 Ah Battery Module................................................................................................... 59

Cell voltage................................................................................................................................. 59

Cell temperature charging ......................................................................................................... 60

Cell temperature discharging..................................................................................................... 60

Power terminal temperature..................................................................................................... 60

Current ....................................................................................................................................... 61

Balancing.................................................................................................................................... 61

Deviation voltages and temperatures........................................................................................ 61

12 TECHNICAL SPECIFICATIONS .................................................................................................................. 62

12.1 Dimensions......................................................................................................................................... 63

13 ORDERING INFORMATION ..................................................................................................................... 67

14 CONTACT DETAILS.................................................................................................................................. 68

MG Energy Systems B.V. | Foeke Sjoerdswei 3 | 8914 BH Leeuwarden | The Netherlands

+31 (0)58 750 89 47 | [email protected] | www.mgenergysystems.eu

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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

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, fluid cooling

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.

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.

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.

MG Energy Systems B.V. | Foeke Sjoerdswei 3 | 8914 BH Leeuwarden | The Netherlands

+31 (0)58 750 89 47 | [email protected] | www.mgenergysystems.eu

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MG Energy Systems B.V. | Foeke Sjoerdswei 3 | 8914 BH Leeuwarden | The Netherlands

+31 (0)58 750 89 47 | [email protected] | www.mgenergysystems.eu

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2SAFETY INSTRUCTIONS

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

General precautions

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.

MG Energy Systems B.V. | Foeke Sjoerdswei 3 | 8914 BH Leeuwarden | The Netherlands

+31 (0)58 750 89 47 | [email protected] | www.mgenergysystems.eu

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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.

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)

MG Energy Systems B.V. | Foeke Sjoerdswei 3 | 8914 BH Leeuwarden | The Netherlands

+31 (0)58 750 89 47 | [email protected] | www.mgenergysystems.eu

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3TRANSPORT, STORAGE AND UNPACKING

3.1 Transport

The package and transport instructions provided by the manufacturer must be followed under all

circumstances.

Notes on transport:

Use original packaging materials.

Lithium-Ion batteries are dangerous goods and must be

transported according to the applicable rules.

Transportation company and shipper must be qualified to

transport and package dangerous goods.

The SoC during transport must be ≤30%.

For details on transport of this battery module see the MSDS.

CAUTION:

It is not allowed to transport, connect or operate a damaged battery.

NOTICE:

No liability can be accepted for damage during transport if the equipment is not

transported in its original packaging or if the original packaging is opened before

the destination is reached.

NOTICE:

The SoC of the battery as delivered from factory is ≤30%.

3.2 Storage

The storage instructions provided by the manufacturer must be followed in all circumstances.

Notes on storage:

Battery module must be stored in its original packaging.

Store in a dry, clean, and conditioned location.

Local regulations for storage of dangerous goods may be applicable.

Recommended storage temperature of the battery module is between +10°C to +25°C.

It is recommended to limit the battery charge between 50% and 70% SoC. This will limit calendric

aging.

The battery module’s SoC is decreasing 1% per year. Recharging is required when the voltage is in the range

of the cut-off voltage.

NOTICE:

Check the MG Master LV or MG Master HV manual for storage of a connected

system.

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