BATTLE BORN BATTERIES BB1250 Deep Cycle Battery Installation Guide
- June 4, 2024
- BATTLE BORN BATTERIES
Table of Contents
BATTLE BORN BATTERIES BB1250 Deep Cycle Battery
Please read this manual prior to installation and use.
Thank you for investing in a Battle Born Batteries system and welcome to the
Battle Born Batteries family. This manual provides important information on
how to install, operate, and care for your Battle Born Batteries. If you have
purchased with us before, you will find this manual useful as a reference
tool. If this is your first purchase with Battle Born Batteries, this manual
can serve as an educational tool on how to properly use and care for your
investment.
If you have a heat-enabled model, please refer to the additional Heat-Enable
Instruction manual prior to use and installation.
QR Codes will appear throughout the manual linking to FAQ videos that may
be useful.
To use the QR code, open a QR reader or the camera on your smartphone. Hold
your device over the QR code so that the code is clearly visible within the
device’s screen. Your phone will automatically scan the code and pull in the
corresponding weblink.
Caution: Risk of Fire and Burns. Do Not Open, Crush, Heat Above 150ºF or incinerate. Follow Manufacturer’s Instructions
What is in the Box?
Included with your purchase is:
- (1) BB1250 Battle Born Battery
- Dimensions (L x W x H): 10.49” x 7.11” x 8.93”
- Weight: 22 lbs.
- Operating Temp Range: -4°F (-20°C) to 140°F (60°C) BB1250 Assembly Drawing
- Absorption Time: 15 Minutes per 50Ah Battery Bank
- Water Resistant and Sealed (Batteries should not be submerged)
- Built-in BMS (Battery Management System)
- Made with Cylindrical Cells
- Comes with standard flag style terminal posts with a 3/8” hole to accommodate either a 3/8” or a 5/16” bolt
- (1) Finishing Hardware Kit
- (2) ‘18-8 Stainless Steel’ 5/16-18 x 1” Bolts
- (2) ‘18-8 Stainless Steel’ 5/16-18 x 1 1/4” Bolts
- (4) Washers
- (2) Nylok Nuts
What Do I Need for Installation?
If you already have your system set up and are ready to drop in your
batteries, you will need a torque wrench that is able to fit to and properly
torque your 5/16” finishing hardware. This is REQUIRED to make sure that you
torque to the specification of 9 to 11 ft-lbs., otherwise you may cause system
failures and damage.
Connecting Load Specified Cables to the Batteries
-
Identify the positive and negative terminals. These are labeled and color-coded red for positive (+), black for negative (–).
-
Determine which finishing hardware set you will use. Verify that your bolt can fully
seat into the nylok insert of the nut. If multiple lugs are used, longer bolts may be required for the bolt to fully seat into the nylok insert of the nut. -
Connect your cable lugs to your battery terminal with the previously identified finishing hardware set. Make sure to connect your positive load specified cable lug to the positive terminal and the negative load specified cable lug to the negative terminal. The proper order to connect to your terminal with a finishing kit is shown in Fig. 1. Figure 1: Proper order of hardware to connect cables. When going from left to right in the diagram the correct order is: bolt, washer, lug, terminal, washer, and nut. If multiple lugs are used, they should be on the same side of the terminal.
-
When connecting to your battery terminals, DO NOT finger tighten. Use a torque wrench to torque your hardware to the specification of 9 to 11 ft lbs. Failure to adequately secure connections can result in severe damage and will void your warranty. Fig. 2 below demonstrates proper and improper connections. Figure 2: Proper and Improper Terminal Connections
Safety
While LiFePO4 batteries are inherently safe, as with all batteries, energy
storage devices, and electrical equipment, safety and electrical hazards do
exist. Failure to follow these safety instructions may result in electrical
shock, injury, or death, or may damage the battery or other equipment or
property.
Installation.
- The battery should be installed as per national and local codes.
- The battery should only be installed in locations approved by local building codes.
- Electrical and shock hazards can be minimized by covering the solar array and using insulated tools.
- Do not short the battery terminals.
- Do not install the battery if there are any signs of physical damage.
- Do not install the battery in a location that may be flooded.
Operation
- Use only approved battery chargers for charging the battery.
- Do not disassemble the battery.
Emergency
- Disconnect the battery from the system.
- Wear a respirator, eye protection, and rubber gloves where appropriate.
- Use an ABC type dry chemical fire extinguisher.
- Dispose of as per local regulations.
How to Properly Charge the Batteries
To properly charge your Battle Born batteries, you will want to verify that
any charging component in your system is capable of being programmed for the
following specifications. Charging components can include, but are not limited
to converters, inverter chargers, solar charge controllers, DC to DC chargers,
etc.
- Bulk/Absorption: 14.2V – 14.6V
- Absorption Time: Two batteries in parallel connections require 30 minutes 100Ah
- Float: 13.4V – 13.8V
- Equalization: 14.4V/ Disabled
- Temperature Compensation: 0/Disabled
- Charge Rate: 50% of the battery or battery bank capacity
- Battery Charge Temperature Range: 32°F (0°C) to 131°F (55°C)
- Battery Discharge Temperature Range: -4°F (-20°C) to 140°F (60°C)
- Cell Charge Temperature: 32°F (0°C) to 131°F (55°C)
- Cell Discharge Temperature: 68°F (20°C) to 140°F (60°C)
NOTE: Not all chargers are capable of multistage charging. If yours is not, you will want to verify it can be programmed for the Bulk/Absorption voltage and have the other items mentioned disabled if applicable. Consult your charger’s manual or the manufacturer.
Connecting the Batteries in Parallel
Why Connect in Parallel?
Multiple BB1250 batteries may be connected in parallel to increase the
capacity and current of the system. When batteries are connected in parallel,
the voltage of the system does not change, but the capacity and current limits
are additive. For example, two BB1250 batteries connected in parallel (shown
in Fig. 3) create a 12V 100Ah bank that can deliver 120A continuously and 200A
for 30 seconds.
How to Make a Parallel Connection
NOTE: All cables and connections MUST be able to accommodate the high
currents that can be delivered by the battery. Appropriate fuses and circuit
breakers are highly recommended to protect downstream components from current
spikes and short circuits.
- Identify the positive and negative terminals. These are labeled and color-coded red for positive (+), black for negative (–).
- Determine the appropriate finishing hardware set you will use. Verify that your bolt can fully seat into the nylok insert of the nut. If multiple lugs are used, longer bolts may be required for the bolt to fully seat into the nylok insert of the nut.
- Make the proper cable connections to the positive of the first battery. Please reference Fig. 1 for the proper order of hardware.
- When connecting to your battery terminals, DO NOT finger tighten. Use a torque wrench to torque your hardware to the specification of 9 to 11 ft-lbs. Failure to adequately secure connections can result in severe damage and will void your warranty.
- Connect the other end of your positive cable to the positive terminal of the other battery you are connecting to. Repeat step 4.
- Repeat steps 3-5 for the negative connections.
- Repeat steps 3-6 for additional batteries in the system. An example of a finished connection can be found below in Fig. 3.1 and Fig. 3.2. Figure 3.1: Two 1250 Batteries connected in Parallel to create a 12V 100Ah Battery Bank Figure 3.2: Four 1250 Batteries connected in Parallel to create a 12V 200Ah Battery Bank
Connecting the Batteries in Series
Why Connect in Series?
When batteries are connected in series, current capacities remain the same,
but the system voltage is additive. For example, two BB1250 batteries
connected in series form a 24V 50Ah bank (shown in Fig. 4) and should be
charged using a bulk and absorption voltage of 28.8V, and a float voltage of
27.2V.
How to Make a Series Connection
Note: Battle Born 1250 Batteries are capable of being connected in series
up to 48V. DO NOT exceed a 48V setup or you will void the batteries’ warranty.
- Before making any connections, make sure to charge each battery up to 14.2V – 14.6V with a proper lithium charger. ALL BATTERIES SHOULD BE AT THE SAME STATE OF CHARGE PRIOR TO CONNECTING, otherwise you will encounter balance issues within your system. You can check your battery’s state of charge with a multimeter.
- Identify the positive and negative terminals. These are labeled and color-coded red for positive (+), black for negative (–).
- Determine the appropriate finishing hardware set you will use. Verify that your bolt can fully seat into the nylok insert of the nut. If multiple lugs are used, longer bolts may be required for the bolt to fully seat into the nylok insert of the nut.
- Make the proper cable connections to the negative of the first battery. Please reference Fig. 1 for the proper order of hardware.
- When connecting to your battery terminals, DO NOT finger tighten. Use a torque wrench to torque your hardware to the specification of 9 to 11 ft-lbs. Failure to adequately secure connections can result in severe damage and will void your warranty.
- Connect the other end of your cable to the positive terminal of the other battery you are connecting to. Repeat step 4.
- Repeat steps 3-6 for additional batteries, but DO NOT exceed 48V. An example of a correct series connection can be found below in Fig. 4.1 and Fig. 4.2. Figure 4.1: Two 1250 Batteries Connected in Series to create a 24V 50Ah Battery Bank Figure 4.2: Four 1250 Batteries Connected in Series to create a 48V 50Ah Battery Bank
Individually charge each battery to 100% prior to connecting your battery bank in series
How Does the BMS Protect the Batteries?
All Battle Born Batteries come with a built-in battery management system (BMS)
that protects the cells from many strenuous circumstances to protect the life
cycles of the cells and your electrical system from potential damage. The BMS
in the BB1250 allows for 60 Amps continuous, 100 Amp surge for 30 seconds, and
1/2 second surge for loads over 100 Amps. All of our BMS’ protect against the
following conditions:
High Voltage Disconnect ( > 14.7V)
If an individual cell voltage exceeds a prescribed threshold during charging,
the BMS will prevent a charge current from continuing. Discharge is always
allowed under this condition. If the batteries have not been balanced for a
long time, high voltage disconnect could occur at a lower voltage. The
batteries will rebalance after several full charges.
Low-Voltage Disconnect ( < 10.6V)
If an individual cell falls below a prescribed threshold during discharge, the
BMS will prevent further discharge. Although
the battery is in “low-voltage disconnect” mode, it will still allow a
charging current.
NOTE: Many chargers must detect a voltage over 10V to send a charge to
the battery. Please be aware that some chargers may not sense a battery in
low-voltage
disconnect and you may need to jump it with a 12V source to “wake up” the
battery. You should jump your battery within 24hrs of entering low-voltage
disconnect otherwise you risk damaging your battery and voiding the warranty.
High Temperature Charging and Discharging
The BMS will not allow a charging current if the internal temperature of the
battery has reached 131°F (55°C).
If the internal temperature of the battery has reached 140°F (60°C), the BMS
will not allow a discharging current.
Low Temperature Charging
The BMS will not allow a charging current under 32°F (0°C) but will continue
to discharge down to -4°F (-20°C).
NOTE: The BB1250 has an operating temperature range of -4°F (-20°C) to
131°F (55°C).
High Current Discharge Surges
The BMS will not allow a current that exceeds 100 (+/- 5%) Amps for more than
30s, or anything larger for 0.5s. After a high current disconnection, the
battery will automatically reconnect after 5 seconds.
Short Current Discharge Surges
Our BMS has built-in short circuit protection. If the short circuit protection
is tripped, the BMS will shut the battery down and will remain disconnected
until you remove the battery cables. While the battery cables are
disconnected, we suggest taking the voltage of the battery with a voltmeter.
If it reads above 10V, reconnect the battery cables. If you are unsuccessful
at obtaining a voltage reading above 10V, please give our technical support
team a call.
Balancing of Cells
A passive balancing process is activated by the BMS at the top of each charge
cycle when the battery voltage exceeds around 14.2V. This ensures that all the
cells remain at the same state of charge, which helps pack longevity and
performance.
Voltage vs. Capacity
For a Single Battery
How to Properly Size Cables for System Install
When considering cable sizing there are a few factors to consider. First,
what is the size of the load you are powering with the battery bank? Second,
how far away from the battery is the load? You can do voltage drop
calculations to see if you need to step up your cable size. Fig. 5 is a chart
to use for reference. Do keep in mind that cables are only capable of carrying
a certain amperage and you should verify the specifications of your cable and
the power draws before implementing them into your system to avoid potential
failures and damage.
Cable QR Code
Figure 5: As a rule of thumb, you can use these numbers as a guideline.
How to Incorporate Fuses into System Install
ANL fuses are designed to melt and separate into two pieces for the purpose of
breaking a circuit in the event of excessive current. These fuses are
essential components for protecting against a catastrophic event and are
typically placed between Battle Born Batteries and the inverter/load.
Fuse QR Code
How to Properly Store Batteries
We recommend bringing the Battle Born batteries to a 100% state of charge.
Then, disconnect the battery from any loads by removing the negative cable
from one battery. On average, the batteries lose approximately 2-3% capacity
per month. This is subject to increasing if stored in extreme environmental
conditions.
Storage QR Code
How to Maintain the Batteries
Battle Born Batteries require very little maintenance. If your batteries are
in series and not being charged by a multi-bank charger it is recommended that
you fully charge the batteries individually once a year if the system is used
frequently. This will internally balance your batteries to ensure that they
will reach their expected life span and allow you to get the full power out of
them with each use. If your batteries are in parallel this is not necessary,
just make sure the batteries are charged to 14.2V – 14.6V frequently for
internal balance. Our BMS has a built-in passive balancing system that will
take care of this for you.
FAQ QR Code
For more FAQs scan the QR code.
To see what else Battle Born Batteries has to offer, scan the QR code to the
right or visit https://battlebornbatteries.com/shop/
Battery Line QR Code
How to Properly Recycle and Dispose of the Batteries
Here at Dragonfly Energy our goal is to provide our customers with long
lasting green energy that will support them for years on all their adventures.
That is why we not only build batteries that can keep up with you for a long
time but also provide industry leading customer support to help you get the
most out of your batteries. When the time does come, and your batteries have
reached the end of their lifetime it is important to recycle them responsibly.
Here are a few suggestions:
- Make sure all loads are removed from your system before removing the batteries. Once the batteries are removed cover the terminals using electrical tape. Now can be a good time to inspect any cable runs or lugs.
- Visit www.earth911.com or www.call2recycle.org/locator to find a drop off location. Be sure to call ahead of time to confirm that the drop off location is still accepting materials.
- Give us a call if you are having any trouble finding a drop off location and we can help you find one.
Limited Warranty
Our Limited Warranty applies only to all products sold and shipped within the
US and Canada. In the unlikely event you are having an
issue with one of our batteries, your Battle Born Battery has a 10-year
manufacturer’s defect warranty from the date of purchase. This warranty does
not cover negligence or misuse of the battery. If it is deemed that the
battery was used improperly, you will be subject to a $150 an hour repair
charge plus parts and shipping.
We also provide warranty support for third party products that we re-sell
(inverters, converters, chargers, etc.).
This is the Limited Warranty for your Battle Born Battery:
LIMITED WARRANTY ON BATTLE BORN LiFePO4 DEEP CYCLE BATTERIES
THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE
OTHER RIGHTS, WHICH VARY FROM STATE TO STATE. THE LIMITED WARRANTY CAN ALSO BE
FOUND IN THE DOCUMENTATION WE PROVIDE WITH THE PRODUCT. WE WARRANT THAT DURING
THE WARRANTY PERIOD, THE PRODUCT WILL BE FREE FROM DEFECTS IN MATERIALS AND
WORKMANSHIP.
WE LIMIT THE DURATION AND REMEDIES OF ALL IMPLIED WARRANTIES, INCLUDING WITHOUT LIMITATION THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE TO THE DURATION OF THIS EXPRESS LIMITED WARRANTY. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.
Who May Use This Warranty?
Dragonfly Energy Corp., dba Battle Born Batteries located at address 1190
Trademark Drive, #108, Reno, evada 89521 (“we”) extend this limited warranty
only to the consumer who originally purchased the product (“you”), and only to
products sold in the U.S. and
Canada. It does not extend to any subsequent owner or other transferee of the
product, nor does it extend to batteries outside of the U.S. and Canada.
What Does This Warranty Cover?
This limited warranty covers defects in materials and workmanship of LiFe O4
deep cycle batteries (the “product”) for the Warranty
Period as defined below.
What Does This Warranty Not Cover?
This limited warranty does not cover any damage due to: (a) transportation;
(b) storage; (c) improper use; (d) failure to follow the product instructions
or to perform any preventive maintenance; (e) modifications; (f) unauthorized
repair; (g) normal wear and tear; or (h) external causes such as accidents,
abuse, or other actions or events beyond our reasonable control. We will not
pay for shipping and handling fees to return the repaired or replacement
product to you whether we elect to repair or replace the defective product;
you are responsible for shipping and handling.
What is The Period of Coverage?
This limited warranty starts on the date your purchase is shipped to you, and
lasts for ten years (the “Warranty period”).
The Warranty Period is not extended if we repair or replace the product. We
may change the availability of this limited warranty at our discretion, but
any changes will not be retroactive.
What are Your Remedies Under This Warranty?
With respect to any defective product during the first eight years of the
Warranty Period, we will, in our sole discretion, either: (a) repair or
replace such product (or the defective part) free of charge or (b) refund the
purchase price of such product.
With respect to any defective product during the last two years of the
Warranty Period, we will, in our sole discretion, either: (a) repair or
replace such product (or the defective part) free of charge or (b) provide a
new product discount of thirty percent (30%) of the price listed at the time
your RMA is issued should you choose to replace the irreparable product. You
will have thirty (30) days from the date we notify you that the product is
irreparable to use your discount to purchase a replacement product. We will
pay for shipping and handling fees to return the repaired product to you; you
will pay customary shipping charges if the product is irreparable and replaced
at a discount.
How do you Obtain Warranty Service?
To obtain warranty service, you must call
855-292-2831, or email our Customer
Service Department at
info@battlebornbatteries.com, or submit
your request at https://battlebornbatteries.com/returns/ during the Warranty
Period to
obtain a Return Merchandise Authorization (“RMA”) number. o warranty service
will be provided without an RMA number.
Due to the hazardous nature of the products, you must make any return shipment in the original packaging. If you do not have the original packaging, you may purchase the required packaging from us. We strongly recommend you fully insure your return shipment and request proof of delivery in case it is lost during transit. If you are returning six (6) batteries or more at one time, or if you are returning models BB8D or BBGC3, you must obtain and return the batteries in their original packaging on a pallet.
All returns must include (1) a copy of your original receipt for the purchase, (2) a letter from you referencing the RMA number with a description of the problem, (3) your contact information including phone number and shipping address. Send your returned product to: Dragonfly Energy Corp.,
ATTN: Returns Department, 1190 Trademark Drive, #108, Reno, Nevada 89521.
You are responsible for all the cost of return shipping and handling, and any
related claims that may arise.
LIMITAION OF LIABILITY
THE REMEDIES DESCRIBED ABOVE ARE YOUR SOLE AND EXCLUSIVE REMEDIES AND OUR
ENTIRE LIABILITY FOR ANY BREACH OF THIS LIMITED WARRANTY. OUR LIABILITY SHALL
UNDER NO CIRCUMSTANCES EXCEED THE ACTUAL AMOUNT PAID BY YOU FOR THE DEFECTIVE
PRODUCT, NOR SHALL WE UNDER ANY CIRCUMSTANCES BE LIABLE FOR ANY CONSEQUENTIAL,
INCIDENTAL, SPECIAL OR PUNITIVE DAMAGES OR LOSSES, WHETHER DIRECT OR INDIRECT.
SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR
CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO
YOU.
Return Policy
You have 30 calendar days to return an item from the invoice date. To be
eligible for a return, your item must be in the same condition that you
received it in. You must have the receipt or proof of purchase. If an item is
new, unused, and in the original packaging, we are happy to accept a return up
to 30 days from the original invoice date with no restocking fee. The item
must be returned with its original packaging. Original packaging must be in
the same condition as it was received, otherwise you may be responsible for a
restocking fee. If the item has been installed, used, or no longer has the
original packaging, we will assess a restocking fee that will be shared when
the return merchandise authorization (RMA) is issued. Items 60 days past the
original invoice will be reviewed at Battle Born’s discretion.
Returns will not be accepted without an RMA number, which can be obtained by
filling out the return form at https://battlebornbatteries.com/returns/. To
avoid being charged restocking fees, review the full return/refund policy at
https://battlebornbatteries.com/terms- conditions/#returns.
Refund Policy
You have 30 calendar days to return an item from the invoice date. Once we
receive your item, we will inspect it and notify you that we have received
your returned item. We will immediately notify you of the status of your
refund after inspecting the item. If your return is approved, we will initiate
a refund to your credit card (or original method of payment). You will receive
the credit within a certain amount of days, depending on your card issuer’s
policies. No refund is guaranteed after the initial 30 days has passed or if
the item has been used.
Shipping
You will be responsible for paying for your own shipping costs for returning
your item. If you are returning prior to 30 days from the original ship date,
you may be eligible for a free return. In order to be eligible for free
shipping, you MUST have the original packing in which the order was shipped,
including boxes, foam, wrapping, and pallets if necessary. Not all items will
be eligible for free return shipping. Shipping costs are nonrefundable. If you
receive a refund, the cost of return shipping may be deducted from your
refund.
If you have any questions, please contact us by calling
855-292-2831 or email us at
info@battlebornbatteries.com.
Notice: Product improvements and enhancements are continuous; therefore, the specifications and information contained in this document may change without notice. Dragonfly Energy Corp. shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing, performance, or use of this material. No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of Dragonfly Energy Corp.
Copyright © 2022, Dragonfly Energy Corp., all rights reserved. Battle Born
Batteries® is a registered trademark of Dragonfly Energy Corp. All other
trademarks, trade names, service marks, and logos referenced herein belong to
their respective owners.
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References
- VRM Portal - Victron Energy
- Battery & Cellphone Drop-Off Locations | Call2Recycle
- Battle Born Batteries | Reliable Lithium-Ion Batteries
- Terms & Conditions | Battle Born Batteries | battlebornbatteries.com
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