Discover AES 42-48-6650 LiFePO4 Battery Low Wholesale Instruction Manual

Discover AES 42-48-6650 LiFePO4 Battery Low Wholesale

Introduction

The AES LiFePO4 is a battery that can operate on its own or in a battery bank configuration where multiple batteries are connected in parallel.
This manual covers serial numbers for part number 42-48-6650 greater than DET424820275xxxx.

AUDIENCE, WARNINGS, MESSAGES, GENERAL SAFETY, PERSONAL PROTECTIVE

EQUIPMENT

Audience

Configuration, installation, service, and operating tasks should only be performed by qualified personnel in consultation with local authorities having jurisdiction and authorized dealers. Qualified personnel should have training, knowledge, and experience in the:

• Installation of electrical equipment
• Application of applicable installation codes
• Analysis and reduction of hazards involved in performing electrical work
• Installation and configuration of batteries
• Installation and configuration of systems activated by relays

Warning, Caution, Notice, and Note Messages

Messages in this manual are formatted according to this structure.

Additional information concerning important procedures and features of the product. Read all the instructions before installation, operation, and maintenance.
Important information regarding hazardous conditions.

WARNING

Important information regarding hazardous conditions that may result in personal injury or death.

CAUTION

Important information regarding hazardous conditions that may result in personal injury.

NOTICE Important information regarding conditions that may damage the equipment but not result in personal injury.

NOTE  Ad hoc information concerning important procedures and features unrelated to personal injury or equipment damage.

General Warnings

Do not crush, disassemble, or dispose of the battery in a fire or the garbage.
This product is made of recyclable materials and must be recycled.

WARNING

ELECTRIC SHOCK AND FIRE HAZARD

• This equipment must only be installed as specified.
• Do not install the batteries in series.
• Do not disassemble or modify the battery.
• If there is damage to the battery case, do not touch exposed contents.
• There are no user-serviceable parts inside.
  Failure to follow these instructions may result in death or serious injury

WARNING

CHEMICAL HAZARD
Do not touch the exposed contents of a Lithium cell.
Failure to follow these instructions may result in death or serious injury.

WARNING

ELECTRIC SHOCK AND FIRE HAZARD
Do not lay tools or other metal parts on the battery or across the terminals.
Failure to follow these instructions may result in death or serious injury.

CAUTION

ELECTRIC SHOCK HAZARD

• Do not touch the energized surfaces of any electrical component in the battery system.
• Before servicing the battery, follow all procedures to fully de-energize the battery system.
• Follow the “Safe Handling Procedures” below when working with the battery.
  Failure to follow these instructions may result in injury.

NOTICE

• The AES Battery has a Battery Management System (BMS) with an integrated solidstate relay that reduces the fire risk.
• The primary suppression for a lithium battery fire is water. The secondary suppression is CO2 powder and halon.

Safe Handling Procedures

Before using the battery, read all instructions and cautionary markings on the unit and all appropriate sections of this manual.

• Use personal protective equipment when working with batteries.

• Do not dispose of the battery in a fire.

• Promptly dispose of or recycle used batteries following local regulations.

• Do not disassemble, open, crush, bend, deform, puncture, or shred.

• Do not modify, re-manufacture, or attempt to insert foreign objects into the battery, immerse or expose the battery to water or other liquids, fire, explosion, or other hazards. If the user suspects damage to the battery due to water, heat, or other reason, take it to a service center for inspection.

• Only use the battery for the system for which it is specified.

• Do not lift or carry the battery while in operation.

• The battery is heavy. When lifting the battery, follow appropriate standards.

• Only lift, move, or mount following local regulations.

• Take care when handling battery terminals and cabling.

• Do not expose the battery to high temperatures.

• Do not submerge the battery.

• Do not install the battery module with the top face pointed down.

• Only use the battery with a charging system that meets specifications. Using a battery or charger that does not meet specifications may present a risk of fire, explosion, leakage, or other hazards.

• Do not short-circuit a battery or allow metallic conductive objects to contact battery terminals.

• Replace the battery with only another one that meets the system’s specifications.
  Using a battery that does not meet specifications may present a risk of fire, explosion, leakage, or other hazards.

• Do not drop the device or battery. If the device or battery is dropped, especially on a hard surface, and the user suspects damage, take it to a service center for inspection.

Personal Protective Equipment

When handling or working near a battery:

• Use Personal Protective Equipment, including clothing, glasses, insulated gloves, and boots.
• Do not wear rings, watches, bracelets, or necklaces.

ITEMS SHIPPED IN THE BOX

Table 2-1, AES LiFePO4 box contents

SPECIFICATIONS

All specifications in this document are published @25ºC / 77ºF.

Electrical Specifications

Table 3-1, AES LiFePO4 Electrical Specifications

Electrical Specifications| 42-48-6650 | 900-0028
---|---
Nominal Voltage| 51.2 V
Nominal Energy| 7.39 kWh
Usable DOD| 90%
Rated Wh Capacity (1C)| 6.65 kWh
Rated Ah Capacity (1C)| 130 Ah
Charge Bulk Voltage – Bulk VDC| 54.4 Vdc
Charge Absorption Voltage – U1 MAX| 54.4 Vdc
Charge Float Voltage – U2| 53.6 Vdc
Charge Termination Current (a)| 2 A
Low Voltage Disconnect Recommended| 48.0 V
Low Voltage Disconnect (b)| 40.0 V
Max. Continuous Discharge Current (c)| 130 Adc
Max. Continuous Charge Current (c)| 130 Adc
Peak Discharge Current (3 seconds)| 300 Adc
Fuse (Provides backup overcurrent protection)| 200 A
Maximum short circuit fault current| 6.0 kA / 5.5 ms
Arc Flash Incident Energy IEm| 0.1 cal/cm2
Arc Flash Incident Energy AFB| 9.4 cm
(a) Charge termination current is permitted to be less than specified.
(b) Under load, low Voltage Disconnect is based on 2.5 VPC. In no load conditions, do not allow the battery to self- discharge below 3.0 VPC.
(c) The effects of AC Ripple must be taken into consideration when sizing and configuring the system.

Mechanical Specifications

Table 3-2, AES LiFePO4 Mechanical Specifications

Mechanical Specifications| 42-48-6650 | 900-0028
---|---
Chemistry| LiFePO4
Cell Modules| 16S 26P
Length| 471.5 mm (18.56 in)
Width| 347.5 mm (13.68 in)
Height| 375 mm (14.76 in)
Terminal (1)| M8
Weight| 87.0 kg (191.8 lb)
IP Rating| IP55
Case Material| Powder Coated Cold Rolled Steel
(1) TERMINALTORQUE: 9 Nm +/- 3 (6.64 ft-lb) to a maximum depth of 14 mm (0.55 in).

Environmental Specifications

Table 3-3, AES LiFePO4 Environmental Specifications

Environmental Specifications| 42-48-6650 | 900-0028
---|---
Rated Altitude| Altitude does not significantly affect operating characteristics up to 2,000 m (6,561 ft)
Charge Operating Temperature Range (a)(b)| 0°C to 45°C (32°F to 113°F)
Discharge Operating Temperature Range (a)| -20°C to 50°C (-4°F to 122°F)
Storage Temperature (c)| -20°C to 45°C (-4°F to 113°F)
(a) Specifies the temperature of the cells and not the ambient temperature. Ambient temperature and cell temperature may not be the same.
(b) The Battery Management System (BMS) does not allow the charging of cells when it is below 0°C (32°F).
(c) Storage outside of specified temperatures will result in permanent capacity loss and void the warranty.

Protection Specifications

Table 3-4, AES LiFePO4 Protection Specifications

Protection Specifications| 42-48-6650 | 900-0028
---|---
Overvoltage
Protection (a)| Greater than 58.4 V for 3 seconds
Recovery (a)| Recovery after 120 seconds. Charge is permitted at 53.6 V or less.
Under voltage
Protection (b)| Less than 40 V for 5 seconds
Recovery (b)| No automatic recovery. The battery shuts down after 120 seconds.
Over-Charge Current
Protection| Greater than 143 A for 10 seconds
Recovery| Recovery after 120 seconds
Over-Discharge Current
Protection (c)| 3-second rating 300 A
Recovery (c)| Recovery after 120 seconds
Over-temperature in Discharge
Protection (d)| Cell temperature above 60°C (140°F) for 5 seconds
Recovery (d)| Cell temperature below 50°C (122°F)
Under-temperature in Discharge
Protection (d)| Cell temperature below -20°C (-4°F) for 5 seconds.
Recovery (d)| Cell temperature above -18°C (0°F)
Over-temperature in Charge
Protection (d)| Cell temperature above 60°C (140°F) for 5 seconds
Recovery (d)| Cell temperature below 50°C (122°F)
Under-temperature in Charge
Protection (d)| Cell temperature below 0°C (32°F) for 5 seconds and charge current detected.
Recovery (d)| Charge recovery temperature above 2°C (36°F) Note: Discharge is available to -20°C (-4°F)
(a) Overvoltage protection monitors individual cell voltages. Protection is triggered when any cell is over 3.65 VPC and recovers after 120 seconds. Charge is permitted when VPC is 3.35 or less. Voltages are provided for guidance only.
(b) Under voltage protection monitors the voltage of individual cells. Protection is triggered for any cell below 2.5 VPC for 5 seconds, and the battery is automatically set OFF after 120 seconds. Manually set the battery ON to recover. Voltages are provided for guidance only.
(c) For time versus current interrupt details, see Figure 2, Over-Discharge Protection Time Current Curve.
(d) Specifies the temperature of the cells and not the ambient temperature. Ambient temperature and cell temperature may not be the same.

Figure 1. Over-Discharge Protection Time Current Curve

Regulatory

Table 3-5, 42-48-6650 Regulatory

Regulatory

UN 38.3 Transportation
IEC 62133
UL 1973
UL 2271
UL 9540 (1)
CE
(1) Applies when the battery is used with Schneider Electric XW PRO inverter- chargers.

TRANSPORTATION

If the battery is not installed in the equipment, transport it in the original package or equivalent. Per the UN Handbook of Tests and Criteria, batteries are tested to part III, subsection 38.3 (ST/SG/AC.10/11/ Rev. 5). For transportation, the battery belongs to category UN3480, Class 9.

HANDLING

Before handling:

• Keep the battery away from sparks and flames
• Disconnect the cables from the battery
• Protect battery terminals from short-circuiting and touch
• Do not lift or carry the battery while it is in use or in operation
• Do not lift the battery by the attached battery cables

FEATURES

Internal Battery Fuse

The internal battery fuse provides backup overcurrent protection and should only be replaced by qualified personnel trained in the installation of electrical equipment.

NOTE Additional external DC fusing is required to protect the battery cables from DC overcurrent and to meet installation codes.

ON/OFF Key

Press the battery’s ON/OFF key for 2 to 3 seconds to switch the battery either ON or OFF. The LED illuminates when the battery is ON and darkens when the battery is OFF.

WARNING

ELECTRIC SHOCK HAZARD

• Always assume the battery’s main relay is ON (Closed), even if the LED for the ON/ OFF key is not illuminated.
• Verify the terminal voltage with a voltmeter before handling and installing the battery.
  Failure to follow these instructions may result in death or serious injury.

operation.
Flashing at 1 second intervals| The main relay is OFF (Open).  The flashing indicates protection  has been triggered as one or more operating parameters (voltage, current, temperature) have exceeded their fault threshold.
Refer to Table 3-4, AES LiFePO4 Protection Specifications, for information on faults that trigger protection.

Battery Communication

The AEbus Port (LYNK port) enables multiple Discover Energy Systems batteries to communicate and interact in a closed-loop network. The AEbus Port also enables AES LiFePO4 batteries to be networked in a closed-loop system with other networked devices, such as external power conversion and motor control devices. A closed-loop system enhances safety and optimizes system performance.

AEbus Port (LYNK Port) Communication RJ45 Pin Assignment

(1) Do not populate. Do not terminate to power. Do not terminate to ground. Do not terminate to CAN_L or CAN_H.
Figure 3. AEbus Port (LYNK Port) Communication RJ45 pin assignment

NOTICE

• Isolate unused pins. Crossing pin functions may cause system damage.
• Do not terminate unused wires to ground, power, or other functions.
• Mixing the AEbus Network with other networks may result in equipment malfunction and damage.

Equipment Ground

Grounding the battery is not required.

THEORY OF OPERATION

Ingress Protection IP55

Ingress protection rates the degree of protection provided by mechanical casings and electrical enclosures against intrusion, dust, accidental contact, and water under specified conditions. The IP55 rating indicates that the product is touch-proof, protected from limited dust ingress, and protected from low-pressure water jets from any direction.
IP codes guide suitability for use under different environmental conditions. IP ratings do not indicate fitness for purpose or confer a performance guarantee.

Battery Management System

Battery Management System Protections
The Battery Management System’s (BMS) primary function monitors cell module voltage, temperature, and battery current. The BMS uses this information to maintain cell operation within operating specifications. If a parameter falls outside of operating specifications, the BMS will disconnect and protect the battery from:

1. Over voltage: Charge voltage that is too high for the battery or for an individual battery cell.
2. Under voltage: Discharge voltage that is too low for the battery or for an individual battery cell.
3. Over current: Current is too high when powering up a load (high inrush current) or from a sustained charging or discharging current above the specified limit.
4. Over-temperature: Cell temperature that is too high during charge and discharge.
5. Under-temperature: Cell temperature that is too low during charge and discharge.

For trigger and recovery values, refer to Table 3-4, AES LiFePO4 Protection Specifications.

The BMS reconnects when it hits recovery thresholds. Manually switch the battery ON if the BMS disconnects due to low voltage protection. A physical disconnect switch is recommended to reconnect the battery if the system has a constant parasitic draw.

NOTE

• Charge and discharge have different operating temperature limits. For information, refer to 3.4 Protection Specifications.
• If the BMS disconnects in response to temperature or current limits, wait for the temperature or current to reach normal operating limits before switching the battery ON.

BMS Pre-Charge System
Turn on all the batteries in the battery bank before energizing any inverter- chargers to prevent blowing a fuse while trying to pre-charge the system.
The battery has a Pre-Charge System to energize external capacitive loads before switching the main relay ON. The maximum input capacitance for a single battery should not exceed the values in Table 3-1, AES LiFePO4 Electrical Specifications.

NOTICE

When switching ON batteries, the inrush current may cause the batteries to fault as they energize external capacitive loads. To resolve this, switch the batteries ON again.

Battery Charge and Discharge Settings
In an open-loop configuration, use the specifications provided in this manual to set up the charge and discharge settings manually at the time of installation through the controller of the Power Conversion device. This system contrasts with a closed loop configuration where the BMS specifies charging and safety settings through a connection with the Power Conversion device.

Closed-loop communication with a Power Conversion device requires using the LYNK II Communication Gateway device from Discover Energy Systems. Refer to the LYNK II Installation and Operation Manual (805-0033) from the www.discoverlithium.com website, or contact your Discover Energy Systems.

Refer to the appropriate Application Note available from www.discoverlithium.com for the set up of closed-loop parameters and integration with specific brands of solar inverter- chargers, solar charger controllers, mobile inverter-chargers, and industrial chargers.

AEbus (LYNK) Network Communication

Discover Energy System batteries use CAN communication over the AEbus (LYNK) Network to coordinate performance with other batteries and communicate with accessories such as the LYNK Communication Gateway.

NOTICE

Termination resistors are required when deploying the battery in an AEbus (LYNK) Network.

Figure 4. Termination Resistor

AEbus (LYNK) Network Power
The Discover battery provides power for the AEbus (LYNK) Network through the AEbus (LYNK) Port. For information, refer to 5.5 Power Sources for LYNK II, LYNK II Installation and Operation Manual (805-0033).

NOTICE Do not use an external power source to power devices over the AEbus (LYNK) Network.

AEbus (LYNK) Network Size
One AEbus (LYNK) Network can support up to 13 AES LiFePO4 batteries.

AEbus (LYNK) Network Cable
Use CAT5 or higher cables for batteries on the AEbus (LYNK) Network.

OPTIONAL ACCESSORIES

The following optional accessories are available for the AES LiFePO4 battery.

INSTALLATION

WARNING

ELECTRIC SHOCK HAZARD

• This equipment must only be installed as specified.
• Do not disassemble or modify the battery.
• If the battery case has been damaged, do not touch exposed contents.
• There are no user-serviceable parts inside.
  Failure to follow these instructions may result in injury.

CAUTION

HEAVY OBJECT
Two-person lift is recommended for the battery.
Failure to follow these instructions may result in injury.

NOTICE

• Some chargers and inverters support temperature-compensated charging. Disable temperature-compensated charging on the charger or inverter.
• Do not use or install a battery temperature sensor. If updating an existing system that uses temperature sensors, remove them.

NOTE

The installer is responsible for meeting all applicable installation requirements and standards.

Tools

• Insulated tools sized to match nuts, bolts, and cables
• RMS type Voltmeter
• Post cleaner and wire brush
• Personal protective equipment

Location

WARNING

FIRE HAZARD
Do not install the battery in living or working areas.
Failure to follow these instructions may result in death or serious injury.

Install the battery in locations that meet the following requirements:

1. Do not install in direct sunlight. Avoid installing the battery in an area with high ambient temperature or an area exposed to UV rays.

2. Moderate temperature. The ambient temperature should be between 0°C and 40°C (32°F and 104°F). Ambient temperatures of 15°C to 25°C (59°F to 77°F) are ideal for extending LiFePO4 battery life. Do not install near a generator or other component that produces significant heat, as this could expose the battery to temperatures greater than 40°C (104°F).

3. Ventilation. Do not install in zero-clearance compartments.
   When installing a single battery, allow spacing of at least 25 mm (1 in) around the perimeter of the battery.
   When installing multiple batteries, allow spacing of at least 10 mm (0.4 in) between batteries.
   When installing multiple batteries vertically in tiers, allow at least 25 mm (1 in) between a battery and the rack above it, except for the top tier of batteries. Allow a clearance of at least 150 mm (5.9 in) between the top battery and the enclosure’s roof.
   In the room housing the batteries, add vents to allow airflow to the outdoors.

4. Away from water. Protect from exposure to water, including water sprayed from nozzles. In a wall-mounted configuration, mount the batteries at least 50 mm (2 in) off the ground.
   If installing near the ocean, keep away from salt spray and use dielectric grease on all connectors.

5. Orientation. Install the battery in any direction other than face down. Do not install face-down.

6. Indoor or outdoor. Suitable for use indoors. Refer to 3.3 Environmental Specifications, for temperature ranges in which the battery can operate.

NOTE

Using this product in a location that does not meet requirements will void the warranty.

DC Cables

CAUTION

FIRE HAZARD
Undersized cables can become hot and may potentially catch fire.
Failure to follow these instructions can result in minor to moderate injury.

The DC battery cables should meet the following requirements:

1. Copper-stranded cable. DC cables must be stranded, copper, and rated 90 °C minimum. Terminate the cables with lugs that fit the DC terminals. If near the ocean, use tinned copper-stranded cables to minimize corrosion.
2. Minimum cable lengths. Select a location that minimizes the length of battery cables to reduce voltage drop from the impedance leading to reduced performance.
3. Appropriate cable gauge. The cables should be capable of carrying the normally expected current, plus a margin of safety.
4. Proper polarity. Positive (+) is connected to positive (+), and negative (-) is connected to negative (-). Verify the polarity of all connections before energizing batteries.
5. Minimum cable lengths. Select a location that minimizes the length of battery cables to reduce voltage drop from the impedance leading to reduced performance. Use the same length cables between all the batteries so they charge and discharge equally, which helps maintain battery bank capacity and performance.

Protection

CAUTION

FIRE HAZARD

• Undersized fuses, disconnects, and buses may become overloaded and potentially cause a fire.
• Fuses and breakers are required to open before the cable reaches its maximum current carrying capability.

Failure to follow these instructions can result in minor to moderate injury.

Additional DC overcurrent protection (rated for 58 volts on 48 V batteries) and a DC disconnect switch are required to protect the system and DC battery cables.

1. Appropriate size. Size the fuses and disconnects following local codes to protect the wiring in the system and are required to open before the cable reaches its maximum current carrying capability.

2. Install disconnect in the positive cable. The disconnect should be located close to the battery’s positive cable.
   Figure 5. Example disconnect
   

3. Install fuse protection in the positive cable. The fuse should be located close to the battery and installed in the positive cable. Local codes may limit how far the protection can be from the battery.

References

• Lithium Battery Manufacturers/Suppliers | Discover Energy Systems

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