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Summary of Contents for MG Master LV
- Page 1 Innovation in energy storage Version 2.0 – 20-04-2023 MG Master LV Battery management controller - Manual - MG Master LV 12V (all models) MG Master LV 24-48V (all models) MG Master LV 72-96V (all models) MG Energy Systems B.V. www.mgenergysystems.eu...
- 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 product at all times in the future.
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Page 3: Table Of Contents
Basic 12 V system ......................9 4.3.2 Basic 48 V system ......................9 4.3.3 Basic 96 V propulsion system ..................10 4.3.4 Basic ESS system ......................10 DEVICE MODELS ..........................11 Models and configurations ....................11 5.1.1 Master LV for 12 V systems................... 11... - Page 4 Innovation in energy storage Version 2.0 – 20-04-2023 5.1.2 Master LV for 24 V and 48 V systems ................11 5.1.3 Master LV for 72 V and 96 V systems ................11 Identification label ........................ 12 5.2.1 Additional labels ......................12 Approvals and standards ......................
- Page 5 Connecting the allow-to-charge and allow-to-discharge ............. 34 Connecting a remote Start/stop button ................34 CONFIGURATION ........................... 35 Basic configuration and checks ..................... 35 MG Diagnostic Tool software ....................36 Bluetooth ..........................37 Updating firmware ........................ 38 COMMISSIONING ........................39 OPERATION ..........................40 11.1...
- Page 6 Innovation in energy storage Version 2.0 – 20-04-2023 14.4 PCBA master temperature ....................45 14.5 Private CAN-bus communication timeout ................45 14.6 Pre-charge DC-bus only for PC+ devices ................45 14.7 Pre-charge DC-bus only for 72-96V devices ................45 TECHNICAL SPECIFICATIONS ..................... 46 DIMENSIONS ..........................
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Page 7: General
1 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... -
Page 8: Table Of Contents
1.3 This revision This revision replaces all previous revisions of this document. MG Energy Systems B.V. has made every effort to ensure that this document is complete and accurate at the time of writing. In accordance with our policy of continuous product improvement, all data in this document is subject to change or correction without prior notice. -
Page 9: Safety Instructions
Innovation in energy storage Version 2.0 – 20-04-2023 2 SAFETY 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. -
Page 10: Qualifications And Training
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. 2.2.3 Non-compliance risks Failure to comply with all safety precautions can result in the following conditions: ... -
Page 11: Transport, Storage, Unpacking And Handling
Special instructions need to be considered when storing a fully connected system. In a fully connected system the Master LV will always draw a small current. This can drain the batteries and damage them. To prevent this, consider the following instructions for longer periods of storage. - Page 12 Example storage time calculation 1 (50% SOC): A system with 1x MG Master LV 12V and 2x a MG LFP 12V battery module. When the batteries are at 50% State-Of-Charge there will be 210Ah x 2 x 50% = 210 Ah available capacity.
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Page 13: Unpacking And Handling
1x Quick installation guide – MG Master LV NOTICE: Not within the scope of delivery: Fuses. Power cables and connectors. Communication cables and connectors. Detailed information about the MG Master LV can be found in our Download Center. -
Page 14: General Description
Battery monitoring The Master LV is easy to install in your MG battery system, thanks to the integrated safety components. Therefore it requires less cables and external equipment. This results in a quick Plug and Play installation. The integrated CAN-Bus automatically detects the configuration and updates... -
Page 15: Example Systems
Version 2.0 – 20-04-2023 4.3 Example systems The Master LV is a versatile battery management controller. Different system configurations can be made, from a small 12 V system up to a parallel redundant propulsion or ESS system. Contact MG Energy Systems B.V. for more information about possible configurations. -
Page 16: Basic 96 V Propulsion System
Innovation in energy storage Version 2.0 – 20-04-2023 4.3.3 Basic 96 V propulsion system 4.3.4 Basic ESS system... -
Page 17: Device Models
5 DEVICE MODELS 5.1 Models and configurations The Master LV consists of a complete range of models used for different system voltages. On all models are RJ45 CAN-Bus connectors available. The models with “(M12)” indications shows that this product has additional M12 CAN-Bus connectors. -
Page 18: Identification Label
Innovation in energy storage Version 2.0 – 20-04-2023 5.2 Identification label The identification label of the MG Master LV is located at the left side of the device. Example identification label: Figure 1 - Example identifications label The identifications label shown in figure 1 contains written information about the product. The explanation of the symbols used on the identification label is stated in table 5. -
Page 19: Approvals And Standards
Innovation in energy storage Version 2.0 – 20-04-2023 5.3 Approvals and standards The MG Master LV certificates and tests can be found in the Download Center. -
Page 20: Overview
Innovation in energy storage Version 2.0 – 20-04-2023 6 OVERVIEW This chapter shows and overview of the MG Master LV. 6.1 General overview... - Page 21 Innovation in energy storage Version 2.0 – 20-04-2023 Part Description Main fuse for control electronics Battery fuses (MEGA fuse size) Positive power terminals for battery connections (M8 bolt connections) Negative power terminals for battery connections (M8 bolt connections) (located under the insulation caps) Insulation caps Shunt Main safety contactor...
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Page 22: Connector Overview
Innovation in energy storage Version 2.0 – 20-04-2023 6.2 Connector overview Part Description I/O connector ‘A’ Start/stop button I/O connector ‘B’ BMS CAN-Bus connectors M12 BMS CAN-Bus connectors RJ45 AUX. CAN-Bus connectors RJ45 AUX. CAN-Bus connectors M12... -
Page 23: Connection Details
Innovation in energy storage Version 2.0 – 20-04-2023 6.3 Connection details This chapter will highlight the different connections for power, communication and IOs. 6.3.1 I/O connectors Figure 3 and Table 6 shows the pinout of the I/O connectors. Figure 3 - Pinout of IO connectors Table 6 - IO Connector specification Connector pins and specifications Conn. -
Page 24: Can-Bus Connections
CAN-Bus need to be taken into account. For example if the batteries are connected to the BMS CAN-Bus M12 connection of the Master LV, it can be terminated in the last battery with an M12 terminator and in the MG Master LV with a RJ45 terminator. - Page 25 Innovation in energy storage Version 2.0 – 20-04-2023 6.3.2.1 RJ45 Connector details Typical cables that are used for the RJ45 CAN-Bus connections are standard CAT 5 Ethernet network patch cables. Table 7 – RJ45 connector details Description Connector view T-568B CAN-H CAN-L NOTICE:...
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Page 26: Power Connections
The power connections consist of M8 bolts. There is a positive bus bar and a negative bus bar to mount the cables to. Four sets of cable can be mounted to the left side of the Master LV and four sets of cables can be mounted to the right side of the Master LV. -
Page 27: Fuses
6.5 Status indication The status indicators are a two colour LED and a buzzer. These indicate the state of the Master LV. For example it is in failsafe mode it will blink in a particular way and beeps in sync with this. The... -
Page 28: Main Safety Contactor
The MG Master LV contains a main safety contator. Chapter 6.1 show the location of the safety contator inside the MG Master LV. This contactor is of a non-latching type which means that if it is not powered it will be open and the batteries are isolated from any charging or discharging equipment. - Page 29 Innovation in energy storage Version 2.0 – 20-04-2023 Figure 5 - Example schematic with a solid state switch for the DC consumers...
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Page 30: Integration Requirements And Instructions
Take into account the placement requirements of the particular battery type. 7.2.1 Environment The MG Master LV has an IP rating of IP22 and must be placed in a space that is moisture and dust free, non-condensing and protected against fluid (water, oil etc.) ingress from top and bottom. WARNING: Moisture or water can damage the MG Master LV and its electronics. -
Page 31: Placement
7.4.1 Control of chargers The control of chargers by the MG Master LV can be achieved using CAN-Bus or IO-level control. 7.4.2 Control of loads The control of loads by the MG Master LV can be achieved using CAN-Bus or IO-level control. -
Page 32: Communication Protocol For 3 Rd Party Integration
10 minutes. One of the use cases is that the MG SmartLink MX is powered from this supply or even from multiple MG Master LVs in redundant systems. -
Page 33: Installation
Innovation in energy storage Version 2.0 – 20-04-2023 8 INSTALLATION Read the installation instructions in this chapter before commencing installation activities. Additional information for installation: Installation video’s: MG Master LV Quick installation guide: MG Master LV Technical drawings ... -
Page 34: Installation Procedure
5. Connecting CAN-Bus communication cables to an external CAN network; 6. Connection IO cables (optional); 8.3 Mounting procedure Before mounting first remove the top cover of the device. Figure 7 - Remove cover Mount the MG Master LV using the mounting holes indicated in chapter 6.1 item “O”. -
Page 35: Connecting The Power Cables For The Chargers And Loads
The power cables to the chargers and loads should be connected first. These must be connected at the chargers and loads side of the Master LV (right side) as shown in Figure 8. Figure 8 - Chargers and loads power connections... - Page 36 Innovation in energy storage Version 2.0 – 20-04-2023 2. Place the negative power cable on the bolt and place washer, spring washer and nut back on the bolt. Tighten the nut with 10 Nm. 3. Remove the nut, spring washer and washer from the positive bolt connections.
- Page 37 Innovation in energy storage Version 2.0 – 20-04-2023 4. Place the fuse on the positive connection bolts first. WARNING: Use proper sized fusing. See chapter 6.4 for fuse options. 5. Place the positive power cable on the bolt and place washer, spring washer and nut back on both bolts.
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Page 38: Connecting The Power Cable For The Batteries
Batteries side of the Master LV (left side) as shown in Figure 9. Figure 9 - Batteries power connection Repeat step 1 to 5 from chapter 8.4 to connect the battery power cables to the Master LV. 8.6 Connecting CAN-Bus communication cables to the batteries Communication cables can be connected with M12 or RJ45 cables to the Master LV depending on the type of battery module that is used. -
Page 39: Connecting Rj45 Cables
2. Connect the next RJ45 cable from the first battery module to the next. Repeat this until the last battery module is connected. 3. Place an RJ45 terminator at the last battery module. 4. Place an RJ45 terminator at the MG Master LV’s BMS CAN-Bus. 8.6.2 Connecting using M12 cables Connecting batteries with M12 requires battery modules with M12 connections. -
Page 40: Connecting Can-Bus Communication Cables To An External Can Network
Innovation in energy storage Version 2.0 – 20-04-2023 8.7 Connecting CAN-Bus communication cables to an external CAN network The external CAN-Bus connection can either be with M12 connection as well as RJ45 connections. Refer to chapter 6.3.2 and 7.7 for detailed information. The connection of the AUX. -
Page 41: Configuration
First time configuration must always be performed without main safety contactor opened. This can be achieved by pulling a BMS CAN-Bus cable going to the batteries from the Master LV. When starting then Master LV it will go to failsafe because the lack of battery communication. -
Page 42: Mg Diagnostic Tool Software
Innovation in energy storage Version 2.0 – 20-04-2023 9.2 MG Diagnostic Tool software There is Diagnostic Tool software available to look into the detailed status, read out events, and perform settings. Figure 13 - Main screen of Diagnostic Tool The Diagnostic Tool can be downloaded from the Download Center:... -
Page 43: Bluetooth
Version 2.0 – 20-04-2023 9.3 Bluetooth The internal Bluetooth module in the MG Master LV is disabled by default. There are three ways to turn on the Bluetooth option. 1. Using the MG Diagnostic Tool. Go to Settings and enable Bluetooth. -
Page 44: Updating Firmware
Version 2.0 – 20-04-2023 9.4 Updating firmware The firmware of the MG Master LV can only be updated using the MG Diagnostic Tool. After connecting the latest version of the MG Diagnostic Tool it will notify if there is a new firmware available. -
Page 45: Commissioning
Are the location and placement requirements in chapter 7.2 and 7.3 met? Is the MG Master LV installed in a location where there is no possibility fluids can enter? For example installation under the seams of hatches. ... -
Page 46: Operation
The start/stop button should be pressed for at least 2 seconds tostart the battery system. The Master LV begins to pre-charge the DC bus until the voltage has reached a safe level to close the main safety contactor. After closing the main safety contactor the chargers and loads are activated if possible. -
Page 47: Diagnostics And Troubleshooting
Innovation in energy storage Version 2.0 – 20-04-2023 12 DIAGNOSTICS AND TROUBLESHOOTING Diagnostic and troubleshooting can be achieved in several ways. Connecting the MG Diagnostic Tool; Connecting the MG Connect App; Looking/listening at the Status indicator; 12.1 Troubleshooting procedure... -
Page 48: Status Indicator
Innovation in energy storage Version 2.0 – 20-04-2023 12.2 Status indicator Table 13 shows the meaning of the status LED and buzzer. Table 13 - Status indication reference Status LED state Description System is in standby mode. Press Start button to start up the system. -
Page 49: Service
Clean the device. Check status with the MG Diagnostic Tool, MG Connect App MG Energy Portal. ELECTRICAL HAZARD: Do not poor or spray water directly onto the device. When cleaning the device be aware that the connected battery string is a permanent energy source. Even when the device is turned off, the battery power connections might carry dangerous voltage levels. -
Page 50: Boundary Limits
Innovation in energy storage Version 2.0 – 20-04-2023 14 BOUNDARY LIMITS The boundary limits that are used for internal measurements and timeouts are listed in this chapter. A level will be triggered when a boundary condition is true for a defined period of time. The tables with the boundary limits consist of: ... -
Page 51: Battery Pack Current
Innovation in energy storage Version 2.0 – 20-04-2023 14.3 Battery pack current Name Level Boundary condition Time Hardware failure warning = invalid 30 sec. Clear = valid 30 sec. 14.4 PCBA master temperature Name Level Boundary condition Time Hardware failure warning = invalid 30 sec. -
Page 52: Technical Specifications
Innovation in energy storage Version 2.0 – 20-04-2023 15 TECHNICAL SPECIFICATIONS The technical specifications of this product can be downloaded from the MG Download Center. https://downloads.mgenergysystems.eu/masterlv 16 DIMENSIONS The dimensions of this product can be downloaded from the MG Download Center. -
Page 53: Contact Details
2. Watch the Installation Videos. Videos can be found on MG’s You Tube channel. 3. Check Your Software Version. Check and update the products software version to latest using the MG Connect App (Apple or Android) or MG Diagnostic Tool. 4. Contact MG Service Point.
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