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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.
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Table of Contents
Summary of Contents for MG HE Series
- Page 1 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.
- Page 2 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...
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Page 3: Table Of Contents
Innovation in energy storage Version 2.3 – 21-9-2022 TABLE OF CONTENTS GENERAL ............................1 Document history ........................1 Terms, abbreviations, and definition ..................1 SAFETY INSTRUCTIONS ........................3 Safety message level definition ....................3 User health and safety ......................3 Qualifications and training .................... - Page 4 Innovation in energy storage Version 2.3 – 21-9-2022 Connection overview ......................15 Overview of all models ....................17 Connections details ....................... 21 RJ45 CAN-bus connector details ................... 21 M12 CAN-bus connector details ................... 22 Power connections ......................23 Status indication ........................25 Indication showing the LED states and its meaning .............
- Page 5 Innovation in energy storage Version 2.3 – 21-9-2022 CAN-bus connection procedure ..................50 Installing the top ingress protection cover ................53 Placing the cover ......................54 Removing the cover ...................... 56 Cutting the cover ......................56 Fuse replacing procedure ...................... 58 Non-fused battery pole ....................
- Page 6 Innovation in energy storage Version 2.3 – 21-9-2022 CONTACT DETAILS ........................69...
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Page 7: General
Version 2.3 – 21-9-2022 GENERAL 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. - Page 8 Innovation in energy storage Version 2.3 – 21-9-2022 C-rate C-Rate; the current (A) used to charge/discharge the battery system divided by the rated ampere-hours (Ah). Energy Management System; The EMS controls all power sources and consumers in a system. HVIL High Voltage Interlock Loop;...
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Page 9: Safety Instructions
Innovation in energy storage Version 2.3 – 21-9-2022 2 SAFETY 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. -
Page 10: Qualifications And Training
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: ... -
Page 11: Transport, Storage, Unpacking And Handling
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 when not connected to any equipment, including MG Master LV or MG Master HV. Recharging is required when the voltage is in the range of the cut-off voltage. -
Page 12: Unpacking And Handling
Innovation in energy storage Version 2.3 – 21-9-2022 NOTICE: Check the MG Master LV or MG Master HV manual for storage of a connected system. NOTICE: Check the voltage of the stored battery module every year. When the battery module voltage is < 24 VDC, recharging is required. Contact MG Energy Systems for specific instructions and tools. -
Page 13: Scope Of Delivery
5. Quick installation guide: HE100-150-200 HE300 Top ingress protection cover HE Series (article number: MG4000267) Non-fused battery pole (article number: MG4000034). NOTICE: Not within the scope of delivery: Power cables and connectors (details can be found in chapter 6.2.3). -
Page 14: General Description
(optional); 4.2 Functional description MG’s system philosophy is to have one master BMS, e.g. a MG Master LV or MG Master HV, per bank of battery modules which communicates with one or more slave BMSs integrated in the Lithium-Ion battery module(s). -
Page 15: Example Systems
Low voltage systems up to 96 VDC are setup with the MG Master LV series. For more information about the MG Master LV, please refer to the data sheet and manual. The example in Figure 1 is a simplified schematic which is not showing all the details. -
Page 16: High Voltage Systems
High voltage systems up to 144 VDC are setup with the MG Master HV series. For more information about the MG Master HV, please refer to the data sheet and manual. The example in Figure 2 is a simplified schematic which is not showing all the details. -
Page 17: Models
Innovation in energy storage Version 2.3 – 21-9-2022 MODELS The HE Series has different models and configurations available. The main differences are battery module capacity, maximum system voltage and CAN-Bus connector types. 5.1 Models and configurations Table 4, Table 5 and Table 6 lists the available battery module configurations. -
Page 18: Battery Designation
Battery designation As per IEC 62620 it is required to state a standard designation per battery module configuration. For the HE series lithium-ion battery these are given in table 7. Table 7 - Battery module designation as per IEC 62620... -
Page 19: Identification Label
Innovation in energy storage Version 2.3 – 21-9-2022 5.2 Identification label The identification label of the MG HE battery module is located at the top of the enclosure under the lid. Example identification label: Figure 3 - Example identifications label The identifications label shown in figure 3 contains written information about the product. -
Page 20: Approvals And Standards
Innovation in energy storage Version 2.3 – 21-9-2022 Approvals and standards The HE battery conforms to an extensive list of standards and tests. Declaration of Conformity Material safety datasheet UN38.3 certificate A complete list of all performed tests can be found at the following link: HE List of Standards and Tests... -
Page 21: Overview
Innovation in energy storage Version 2.3 – 21-9-2022 6 OVERVIEW This chapter shows an overview of the HE battery. Each battery module contains the following common parts: Negative battery pole connection; Positive battery pole connection; BMS CAN-bus connection, either RJ45 or M12; ... - Page 22 Innovation in energy storage Version 2.3 – 21-9-2022 Table 9 - Module connection overview Part Description Positive power connection (including fuse). M8 bolt connection. Equipotential bonding connection (only available on the (M12-HV) option). CAN-Bus communication, either RJ45 or M12. Negative power connection. M8 bolt connection. Cooling fans (not for HE 300Ah)
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Page 23: Overview Of All Models
Innovation in energy storage Version 2.3 – 21-9-2022 Overview of all models An overview of every battery model is shown below. For dimension check chapter 13. MGHE240100, MGHE241100, MGHE242100 (HE 100Ah) Rear Front Side... - Page 24 Innovation in energy storage Version 2.3 – 21-9-2022 MGHE240150, MGHE241150, MGHE242150 (HE 150Ah) Rear Front Side...
- Page 25 Innovation in energy storage Version 2.3 – 21-9-2022 MGHE240200, MGHE241200, MGHE242200 (HE 200Ah) Rear Front Side...
- Page 26 Innovation in energy storage Version 2.3 – 21-9-2022 MGHE240300, MGHE241300, MGHE242300 (HE 300Ah) Rear Front Side...
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Page 27: Connections Details
Innovation in energy storage Version 2.3 – 21-9-2022 6.2 Connections details Each battery module contains two CAN-Bus connectors to connect to the MG Master BMS and to the next battery, if any. This CAN-Bus connection is used for several functions: ... -
Page 28: M12 Can-Bus Connector Details
Innovation in energy storage Version 2.3 – 21-9-2022 M12 CAN-bus connector details The HE Series have the option to contain M12 CAN-Bus connectors. Connector details The connectors used for connecting the CAN-bus are all of the same type, namely a circular M12 connector with 5 positions and A-coded keying. -
Page 29: Power Connections
Innovation in energy storage Version 2.3 – 21-9-2022 Power connections The power connections on the battery module consists of two M8 bolt connections. One is the positive battery pole and one is the negative battery pole. Figure 6 - Battery pole connection overview Part Description Spring washer... - Page 30 Innovation in energy storage Version 2.3 – 21-9-2022 Fuse types to use: MG Fuse article Fuse current Fuse manufacturer article number number MGFUSE1580150 150 A Little fuse CF8 - 155.0892.6151 MGFUSE1580200 200 A Little fuse CF8 - 155.0892.6201 MGFUSE1580225 225 A Little fuse CF8 - 155.2892.6221...
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Page 31: Status Indication
Innovation in energy storage Version 2.3 – 21-9-2022 6.3 Status indication Figure 8 shows the location of the status indication LEDs. They are located next to the CAN-bus connections. Figure 8 - Status LEDs overview Part Description Green LED Red LED Indication showing the LED states and its meaning Table 12 - Status indication Green LED... -
Page 32: Integration Requirements And Instructions
Moisture or water can damage the battery and its electronics. This might lead to dangerous situations. Thermal management The HE Series battery modules are air cooled. Therefore ambient temperature needs to be taken into account when selecting a space for the installation of the batteries. ... - Page 33 Innovation in energy storage Version 2.3 – 21-9-2022 NOTICE: Take into account the heat rejection of other equipment in the same space of the batteries. NOTICE: A significant decrease of cycle life will occur when the battery modules are used at high ambient temperatures.
- Page 34 Innovation in energy storage Version 2.3 – 21-9-2022 Air cooling Each HE battery excluding the HE 300Ah is equipped with fans for active cooling. Figure 9 shows the air flow direction through the battery module. Figure 9 - Air flow through module The fans will turn on/off at certain battery temperatures.
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Page 35: Placement
Innovation in energy storage Version 2.3 – 21-9-2022 7.3 Placement This chapter will explain the design requirements for placement of the battery modules. Placement in battery box It is mandatory to place the battery modules in a steel box or sealed compartment with fire retardant properties. -
Page 36: Positioning The Battery
Innovation in energy storage Version 2.3 – 21-9-2022 Positioning the battery The battery module may be placed upwards and on its side. Figure 10 and Figure 11 shows the possible positions that are allowed. Figure 10 - Mounting positions of the HE100, HE150 and HE200 models Figure 11 - Mounting positions of the HE300 model... -
Page 37: Positioning Considering Air Flow
Innovation in energy storage Version 2.3 – 21-9-2022 Positioning considering air flow The airflow of the battery modules must be considered when positioning the battery modules certain positions. The airflow of one battery may not be used as input flow for the next battery. This will cause temperature differences and thus imbalance in the modules. -
Page 38: Battery Module Spacing Requirements
Innovation in energy storage Version 2.3 – 21-9-2022 Battery module spacing requirements Figure 13 shows the minimum spacing of the battery modules. It is mandatory to maintain a clearance of 10 mm from all sides of the battery module. There is a keep out clearance of 50 mm at the front and back of the modules with fans installed. - Page 39 Innovation in energy storage Version 2.3 – 21-9-2022 Spacing requirements HE300 model Figure 15 - Battery spacing requirements applicable to HE300 model...
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Page 40: Electrical
Parallel configuration The battery module can set in parallel to create a larger system capacity. The MG Master BMS can handle up to 96 HE battery modules. Meaning that a 24 VDC system can have 96 HE battery modules in parallel. - Page 41 Innovation in energy storage Version 2.3 – 21-9-2022 Figure 16 - Four battery module connected in parallel on a single Master LV. Cables must have matching lengths. There are multiple options when connecting more than four batteries in parallel. 1. Paralleling at the battery modules. 2.
- Page 42 Innovation in energy storage Version 2.3 – 21-9-2022 Paralleling at the battery modules Paralleling at the battery modules makes it possible to connect more than four battery modules to a Master LV or other DC distribution. Important is that the cable lengths of the battery modules must be as equal as possible to prevent too much differences during charging and discharging.
- Page 43 Innovation in energy storage Version 2.3 – 21-9-2022 Figure 18 shows the same paralleling method, but used for a 48 V system where battery modules are connected in series. Figure 18 - Example of 48 V system with paralleled groups...
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Page 44: Paralleling Using The Distributor Lv
Version 2.3 – 21-9-2022 Paralleling using the Distributor LV Another option to parallel battery modules is to use the MG Distributor LV (MGLVDIST01001). Basically this DC distribution box has a positive and negative bus bar with the possibility to place fuses. -
Page 45: Series Configuration
Version 2.3 – 21-9-2022 Series configuration The battery modules can be connected in series up to 144 VDC which requires the use of the MG Master HV. Table 14 shows the maximum number of battery modules in series per battery type. - Page 46 Innovation in energy storage Version 2.3 – 21-9-2022 Figure 20 shows an example system of 6 battery modules in series connected to a MG Master HV. Figure 20 – Series configuration example WARNING: In systems with voltages > 58 V an insulation monitor is required.
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Page 47: Charger
Therefore the charger needs to have the ability to stop and start it remotely with a contact. There are also a number of chargers available that are digitally controlled by the MG Master BMS. Refer to the MG Master LV or MG Master HV manual for more details. Charger settings Chargers that are controlled with on/off need to use the following voltage settings. -
Page 48: Installation
Innovation in energy storage Version 2.3 – 21-9-2022 8 INSTALLATION Read the installation instructions in this chapter before commencing installation activities. Additional information for installation: Installation video: HE100-150-200 HE300 Quick installation guide: HE100-150-200 HE300 Technical drawings Application Notes WARNING: Before continuing make sure the following instructions are met: ... -
Page 49: Installation Procedures
The battery module can be used in combination with other battery modules of the same type and always in combination with a MG Master BMS. Before any electrical connection can be performed, the top covers from the battery module must be removed. -
Page 50: Equipotential Bonding Connection Procedure
Innovation in energy storage Version 2.3 – 21-9-2022 Equipotential bonding connection procedure The equipotential bonding connection is located on top of the battery module next to the positive power connection as shown in chapter 6.1. Equipotential bonding connection scheme and the required wire cross-section depend on local standards and regulation. -
Page 51: Positive And Negative Power Connection Procedure
Innovation in energy storage Version 2.3 – 21-9-2022 Positive and negative power connection procedure Before connecting any power cable make sure the routing of the power cables is made properly. Figure 23 shows a wrong connection of the power cable which will interfere with the CAN-Bus connectors and protection cover. - Page 52 Innovation in energy storage Version 2.3 – 21-9-2022 Below the procedure for connecting the power cables to the battery. 1. Remove the nut, spring washer and washer from the positive battery pole. NOTICE: When removing the nut and washers from the battery pole, it will become loose. This is normal.
- Page 53 Innovation in energy storage Version 2.3 – 21-9-2022 3. Depending on the system voltage or specific system design the battery fuse must be removed. In case of system voltage > 58 Vdc: replace battery pole + fuse with non-fused battery pole. 4.
- Page 54 Innovation in energy storage Version 2.3 – 21-9-2022 5. Remove the nut, spring washer and washer from the negative battery pole. 6. Clean the battery pole and the cable lug’s contact surfaces for a low resistance connection. 7. Connect the negative power cable with M8 cable lug to the M8 bolt as shown and place back the washer, spring washer and nut.
- Page 55 Innovation in energy storage Version 2.3 – 21-9-2022 WARNING: Make sure the cable lug is directly mounted to the battery pole without any washers or nuts in between. WARNING: Stacking of multiple cable lugs is possible however we strongly advise against it. Connection resistance increases which, in time, might lead to excessive heat generation.
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Page 56: Can-Bus Connection Procedure
RJ45 or M12 connectors depending on the battery type. The same topology is used for both connector types. However, the MG Master LV and MG Master HV can have different connection configurations. For more information about the CAN-bus communication connection possibilities, refer to the MG Master LV, MG Master HV manual. - Page 57 Basic connection The most basic connection is as following: 1. Start with a CAN-bus cable at the MG Master BMS, the Battery CAN-Bus, and go to the first battery. 2. Connect from the first to the second battery. Repeat this until the last battery module.
- Page 58 Innovation in energy storage Version 2.3 – 21-9-2022 Example including MG Energy Monitor In this example an MG Energy Monitor is connected to the battery system using M12 to RJ45 converter cables. WARNING: Use the termination resistors delivered with the MG Master BMS.
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Page 59: Installing The Top Ingress Protection Cover
The top ingress protection cover is used to protect the battery module against the ingress of liquids from the top. This chapter describes the installation of the cover. Figure 27 - Top ingress protection cover for HE series The two black covers needs to be mounted before the top ingress protection cover can be mounted. -
Page 60: Placing The Cover
Innovation in energy storage Version 2.3 – 21-9-2022 Placing the cover The cover can be placed over the modules even when the cables are connected. The flexibility of the cover makes it to fit to almost every existing installation. In some cases the cover must be cut to make it fit. - Page 61 Innovation in energy storage Version 2.3 – 21-9-2022 Figure 30 shows an example of a cover installed on a battery module. Figure 30 - Example of cover in installation...
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Page 62: Removing The Cover
Innovation in energy storage Version 2.3 – 21-9-2022 Removing the cover 1. Pull one corner away from the battery 2. Lift the cover to release it. Cutting the cover If cutting is required use the cut lines at the inside of the cover as guide. Do not remove the flap because it prevents water drips of entering the battery module or cable. - Page 63 Innovation in energy storage Version 2.3 – 21-9-2022 Figure 31 - Example to cutting out cable release.
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Page 64: Fuse Replacing Procedure
Innovation in energy storage Version 2.3 – 21-9-2022 8.6 Fuse replacing procedure Replacement of the fuse requires the battery system to shut down. The fuse can be replaced with a new fuse or with a non-fused battery pole. WARNING: When replacing the fuse with a non-fused battery pole, the fuse for the string of batteries needs to be installed separately in the system. - Page 65 Innovation in energy storage Version 2.3 – 21-9-2022 NOTICE: When removing the nut and washers from the battery pole, it will become loose. This is normal. When the cable is connected and the nut and washers are back in place it will be tightened again. 2.
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Page 66: Commissioning
<project name> - Commissioning. NOTICE: For the system commissioning procedure, refer to the manual of the MG Master LV or MG Master HV. If no commissioning procedure is available in the manual, contact MG Energy Systems. -
Page 67: Service
Innovation in energy storage Version 2.3 – 21-9-2022 10 SERVICE 10.1 Maintenance For maintenance it will be sufficient to inspect the following points once a year: Check the electrical connections on torque. Check if all communication connections are mated. ... -
Page 68: Boundary Limits
Innovation in energy storage Version 2.3 – 21-9-2022 11 BOUNDARY LIMITS The boundary limits that are used by the master for the battery modules are listed in this chapter. A level will be triggered when a boundary condition is true for a defined period of time. Battery thresholds are compatible with the following master BMS firmware versions or higher: ... -
Page 69: Cell Temperature Charging
Innovation in energy storage Version 2.3 – 21-9-2022 Cell temperature charging Table 17 Cell temperature charging boundary limits slave BMS Boundary condition Name Level Economic Performance Time Over temperature alert >= 43 °C >= 48 °C 5 sec. Clear < 42 °C <... -
Page 70: Current
Innovation in energy storage Version 2.3 – 21-9-2022 Current Table 20 Current boundary limits slave BMS Boundary condition Name Level Economic Performance Time Charging over current warning > 0.6C > 1C 10 sec. Clear <= 0.6C <= 1C 10 sec. Discharging over current warning >... -
Page 71: He 25.2 V / 300 Ah Battery Module
Innovation in energy storage Version 2.3 – 21-9-2022 11.2 HE 25.2 V / 300 Ah Battery Module Boundary limits are defined to keep the battery within manufacturer’s specifications. The tables with the boundary limits consist of: Name, description of the situation; ... -
Page 72: Cell Temperature Charging
Innovation in energy storage Version 2.3 – 21-9-2022 Cell temperature charging Table 24 Cell temperature charging boundary limits slave BMS Boundary condition Name Level Economic Performance Time Over temperature alert >= 38 °C >= 43 °C 5 sec. Clear < 37 °C <... -
Page 73: Current
Innovation in energy storage Version 2.3 – 21-9-2022 Current Table 27 Current boundary limits slave BMS Boundary condition Name Level Economic Performance Time Charging over current warning > 0.7C 10 sec. Clear <= 0.7C 10 sec. Charging over current critical Failsafe >... -
Page 74: Technical Specifications
Innovation in energy storage Version 2.3 – 21-9-2022 12 TECHNICAL SPECIFICATIONS The technical specifications of this product can be downloaded from the MG Download Center. https://downloads.mgenergysystems.eu/he/documents/technical-specification-en 13 DIMENSIONS The dimensions of this product can be downloaded from the MG Download Center. - Page 75 Innovation in energy storage Version 2.3 – 21-9-2022 14 CONTACT DETAILS For specific questions please feel free to contact us. MG Energy Systems B.V. Foeke Sjoerdswei 3 NL-8914 BH Leeuwarden The Netherlands For support contact your local dealer: https://www.mgenergysystems.eu/dealers/...