BATTLE BORN BATTERIES BB5024H 50Ah 24V LiFePO4 Deep Cycle Battery Installation Guide
- June 13, 2024
- BATTLE BORN BATTERIES
Table of Contents
BATTLE BORN BATTERIES BB5024H 50Ah 24V LiFePO4 Deep Cycle Battery
Product Information
The Battle Born Batteries BB5024 is a high-quality battery system designed for various applications. It comes with a built-in Battery Management System (BMS) and is made with cylindrical cells. The dimensions of the battery are 12.76 x 6.86 x 8.95 inches, and it weighs 31 lbs. The absorption time for a 50Ah battery bank is 15 minutes. The batteries are water-resistant and sealed, but should not be submerged.
The package includes the following:
- Dimensions (L x W x H): 12.76 x 6.86 x 8.95
- Weight: 31 lbs.
- 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
- (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
Product Usage Instructions
- Read the manual before installation and use.
- If you have a heat-enabled model, refer to the additional Heat-Enable Instruction manual before use and installation.
- Use a QR reader or the camera on your smartphone to scan QR codes throughout the manual for FAQ videos.
- For installation, you will need a torque wrench that can properly torque your 5/16 finishing hardware to 9 to 11 ft-lbs.
- To connect load specified cables to the batteries:
- Determine which finishing hardware set to 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.
- Connect the positive load specified cable lug to the positive terminal and the negative load specified cable lug to the negative terminal.
- The proper order of hardware to connect cables is: bolt, washer, lug, terminal, washer, and nut (from left to right in Fig. 1).
- If multiple lugs are used, they should be on the same side of the terminal.
- Use a torque wrench to torque the hardware to 9 to 11 ft-lbs. Do not finger tighten.
- Improperly secured connections can result in severe damage and void the warranty (refer to Fig. 2 for proper and improper connections).
Please refer to the manual for more detailed instructions and safety precautions.
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.
What is in the Box?
Included with your purchase is:
- (1) BB5024 | BB5024H Battle Born Batteries Battery
- Dimensions (L x W x H): 76” x 6.86” x 8.95”
- Weight: 31
- Operating Temp Range: -4°F (-20°C) to 140°F (60°C)
- Absorption Time: 15 Minutes per 50Ah Battery Bank
- Water Resistant and Sealed (Batteries should not be submerged) BB5024 | BB5024H Assembly Drawing
- 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
BB5024 | BB5024H Assembly Drawing
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 These are labeled and color-coded red for positive (+), black for negative (–).
- Determine which finishing hardware set you will 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 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.
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
- The battery should only be installed in locations approved by local building
- Electrical and shock hazards can be minimized by covering the solar array and using insulated
- Do not short the battery
- Do not install the battery if there are any signs of physical
- Do not install the battery in a location that may be
Operation
- Use only approved battery chargers for charging the
- Do not disassemble the
- A CSL is required for use with inverters 3500W or
Emergency
- Disconnect the battery from the
- Wear a respirator, eye protection, and rubber gloves where
- Use an ABC type dry chemical fire
- Dispose of as per local
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: 4V – 29.2V
- Absorption Time: Two batteries in parallel connections require 30 minutes 100Ah
- Float: 8V – 27.6V
- Equalization: 8V/ 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: -4°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.
WARNING
- Do not short battery terminal.
- Do not reverse polarity.
- Do not pierce battery casing.
- Do not attempt to disassemble.
- DO not drop or mishandle.
- DO not immerse in water.
- Do not operate with loose connections.
- Do not operate battery in series or in parallel with any other type of battery.
- Do not connect more than two batteries in series.
- Do not operate using cables that cannot accommodate the maximum current that can be delivered by the batteries (Please contact technical support to verify that you are using appropriate cables and contacts.)
Connecting the Batteries in Parallel
Why Connect in Parallel?
Multiple BB5024 | BB5024H 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 BB5024 | BB5024H batteries connected in parallel (shown in Fig. 3) create a 24V 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 These are labeled and color-coded red for positive (+), black for negative (–).
- Determine the appropriate finishing hardware set you will 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 Please reference Fig. 1 for the proper order of hardware.
- When connecting to your battery terminals,do not ginger 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 Repeat step 4.
- Repeat steps 3-5 for the negative
- 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
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 BB5024 | BB5024H batteries connected in series form a 48V 50Ah bank (shown in Fig. 4) and should be charged using a bulk and absorption voltage of 57.6V, and a float voltage of 54.4V.
How to Make a Series Connection
Note : BB5024 | BB5024H 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 2V 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 These are labeled and color-coded red for positive (+), black for negative (–).
- Determine the appropriate finishing hardware set you will 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 Please reference Fig. 1 for the proper order of hardware.
- When connecting to your battery terminals, DO NOT finger 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 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.
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 BB5024 | BB5024H 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 ( > 29.4V)
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 ( < 21.2V)
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 BB5024 | BB5024H 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 20V, reconnect the battery cables. If you are unsuccessful
at obtaining a voltage reading above 20V, 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 28.4V. 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
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.
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.
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.
Please Note: A CSL is required for use with inverters 3500W or higher. 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/
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 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 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
Limited Warranty
Please find Limited Warranty information online at
https://battlebornbatteries.com/limited-warranty/
or via phone at
855-292-2831.
Return Policy
You have 30 calendar days to return an item from the invoice date tem 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 returnshipping. 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.
Lithium-ion vs. Lead-Acid
Recommended Accessories (Available via battlebornbatteries.com or call us at 855.292.2831) BMV-712 With Bluetooth built-in, the BMV-712 is the most efficient way to monitor your system. Being a shunt-based device, the unit will monitor power coming in and out of your system all at the palm of your hand. This device is highly recommended to give you the most accurate reading on your batteries.
MultiPlus Compact 2000 W
The Victron MultiPlus Compact Inverter Charger, as the name suggests, is a
combined inverter and charger in one elegant package. Its many features
include a true sine wave inverter, adaptive charging, and hybrid Power Assist
technology, plus multiple system integration features.
This unit pairs well with 200Ah or more of battery capacity.
MultiPlus 3000 W
The Victron MultiPlus Inverter Charger, as the name suggests, is a combined
inverter and charger in one elegant package. Its many features include a true
sine wave inverter, adaptive charging, and hybrid Power Assist technology,
plus multiple system integration features.
This unit pairs well with 300Ah or more of battery capacity.
MultiPlus-II
With all the functionality of a MultiPlus and a MultiGrid, the MultiPlus-II
2x 120V is a great option for those with 50A 120/240VAC split-phase
applications. Whether it is supplied from shore power or a generator, the
MultiPlus-II 2x 120V can accept and pass through both lines of a 120/240V
supply, with the capability to utilize the full 50A for charging and AC loads.
This unit pairs well with 300Ah or more of battery capacity.
Solar Charge Controller 100/50
A solar charger gathers energy from your solar panels and stores it in your
batteries. Using the latest, fastest technology, SmartSolar maximizes this
energy harvest, driving it intelligently to achieve full charge in the
shortest possible time. SmartSolar maintains battery health, extending its
life.
This device pairs well with up to 700 W of solar with a 12V battery capacity.
Cerbo GX
The Cerbo GX communication center maximizes your system’s performance and
allows you to always have complete control over your system from wherever you
are. Simply connect through the Victron Remote Management
(VRM) Portal, access directly using the
separate GX Touch 50, or use the VictronConnect App with the device’s
added Bluetooth capability.
RJ45 and VE Direct wires will be required to allow other Victron items to communicate info to the performance
Orion DC-DC Charger
The Victron Orion-Tr Smart DC-DC Charger is a DC to DC adaptive 3-stage
charger with built-in Bluetooth. This device can be used in dual battery
systems in vehicles or on boats where the alternator and the start battery are
used to charge your house batteries. The unit can be monitored and programmed
via Bluetooth and can be remotely controlled via a remote on/off switch.
The Orion-Tr Smart DC-DC Charger can be used in 12V or 24V Models are available up to 400W and multiple units can be connected in parallel to increase output power.
IP65
The Blue Smart IP65 Charger is a professional battery charger with built-in
Bluetooth. The Blue Smart IP65 Charger is a 12-volt, 15-amp charger that can
be used with lithium-ion batteries in RVs, boats, and campervans.
This device is a great addition to offer a handheld charger to top off your batteries before connecting to your System capacity.
Rich Solar Panels
Coming in a variety of options, Rich Solar Panels offer Mono PERC
Technology, a lightweight, anodized aluminum frame, high transmission, anti-
reflective coated tempered glass, a plug-and-play junction box, and industry-
standard quick-connect cables that work in series or in parallel. These panels
are certified to withstand challenging environmental conditions and are
excellent with low-light performance on cloudy days, mornings, and evenings.
Battle Born Batteries BB5024 Manual | BB5024H Manual | Edition.PIM_BB5024Rev019_08282023
Caution: Risk of Fire and Burns. Do Not Open, Crush, Heat percent, Above 150ºF or incinerate. Follow the Manufacturer’s Instructions
References
Read User Manual Online (PDF format)
Read User Manual Online (PDF format) >>