DICOVER DLB-G24-12V AES BLUE LiFePO4 Lithium Battery Instruction Manual

DISCOVER DLB-G24-12V AES BLUE LiFePO4 Lithium Battery

AUDIENCE, SAFETY, MESSAGES AND WARNINGS

Audience
Certain configuration, installations, service, and operating tasks should only be performed by qualified personnel in consultation with local utilities and/ or authorized dealers. Qualified personnel should have training, knowledge, and experience in:

• Installing electrical equipment
• Applying applicable installation codes
• Analyzing and reducing hazards involved in performing electrical work
• Installing and configuring batteries

Safety, Messages and Warnings

• Do not disassemble, open, crush, bend, deform, puncture or shred.
• Do not modify, re-manufacture attempt to insert foreign objects into the battery, immerse or expose to water or other liquids, expose to fire, explosion or other hazards.
• Only use the battery for the system for which it is specified.
• Do not lift or carry the battery while in operation.
• Only lift, move, or mount in accordance with local regulations.
• Take care when handling battery terminals and cabling.
• Only use the battery with a charging system that has been qualified for the system. The use of an unqualified battery or charger 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 only with another battery that has been qualified for the system. The use of an unqualified battery may present a risk of fire, explosion, leakage, or other hazards.
• Promptly dispose or recycle used batteries in accordance with local regulations.
• Avoid dropping 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.

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 result in damage to the equipment, but not personal injury.

NOTE

• Ad hoc information concerning important procedures and features of the battery not related to personal injury or equipment damage.
• Before using the battery, read all instructions and cautionary markings on the unit and all appropriate sections of this manual.
• 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. No user-serviceable parts inside. Failure to follow these instructions may result in injury.
• CHEMICAL HAZARD: Do not touch the exposed contents of a Lithium cell. Failure to follow these instructions may result in death or serious injury

CAUTION

• FIRE AND BURN HAZARD: Do not cover or obstruct the heat sink or install the battery in a zero-clearance compartment. Compartment ventilation is required.
• Failure to follow these instructions can result in minor to moderate injury.
• ELECTRIC SHOCK: Do not touch the energized surfaces of any electrical component in the battery system.
• Before servicing the battery, follow all procedures to fully de-ener-gize the battery system and use safe handling procedures when handling the battery.
• Failure to follow these instructions may result in injury.
• CAUTION: Hot Surfaces. Do not touch when hot.
• CAUTION: Heavy Object. When lifting, follow appropriate standards.
• Do not dispose of the battery in the garbage. Do not dispose of the battery in the fire.
• Use personal protective equipment when working with batteries.
• Additional information concerning important procedures and features of the battery.
• Read all the instructions before installation, operation, and maintenance.
• This product must be recycled and is made of recyclable materials.

SPECIFICATIONS

• Specifications are published at 25oC / 77oF

Electrical Specifications

Table 2-1. DLB Electrical Specifications

Electrical Spec| DLB-G24-12V| DLB-G24-24V| DLB-G24-36V| DLB-GC12-12V| DLB-GC12-24V
---|---|---|---|---|---
Nominal Voltage| 12.8 V| 25.6 V| 38.4 V| 12.8 V| 25.6 V
Energy| 1280 Wh| 1167 Wh| 1167 Wh| 2560 Wh| 2560 Wh
Capacity 1Hr| 100 Ah| 45.6 Ah| 30.4 Ah| 200 Ah| 100 Ah
Reserve Capacity 25A| 240 minutes| 120 minutes| 76 minutes| 480 minutes| 240 minutes
Charge Bulk Voltage – Bulk VDC| 13.8 – 14.2 V| 27.6 – 28.4 V| 41.4 – 42.6 V| 13.8 – 14.2 V| 27.6 – 28.4 V
Charge Absorption Voltage – U1 MAX| 13.8 V| 27.6 V| 41.4 V| 13.8 V| 27.6 V
Charge Float Voltage – U2| 13.6 V| 27.2 V| 40.8 V| 13.6 V| 27.2 V
ChargeTermination Current a| 2.5 A| 1.15 A| 0.75 A| 5 A| 2.5 A
Low Voltage Disconnect Voltage| 12 V| 24 V| 36 V| 12 V| 24 V
Max. Continuous Discharge Current| 100 A| 45 A| 30 A| 150 A| 100 A
Nominal Charge Current| 50 A| 22.5 A| 15 A| 100 A| 50 A
Max. Continuous Charge Current| 100 A| 45 A| 30 A| 150 A| 100 A
Peak Discharge Current (2 seconds)| 250 A| 120A| 120 A| 250 A| 250 A
Fuse| 200 A| 75 A| 75 A| 200 A| 200 A
a Charge current termination is permitted to be less than specified. When the charger termination current is lowered the internal balancing function has more time to operate.

Mechanical Specifications Table 2-2. DLB Mechanical Specifications

Mechanical Spec.| DLB-G24-12V| DLB-G24-24V| DLB-G24-36V| DLB-GC12-12V| DLB-GC12-24V
---|---|---|---|---|---
Chemistry| LiFePO4
Length| 262 mm (10.3 in)| 312 mm (12.2 in)
Width| 175 mm (6.9 in)| 177 mm (7.0 in)
Height| 210 mm (8.3 in)| 276 mm (10.8 in)
Terminal| SAE 5/16” stud terminal
Terminal Torque| 8 to 10 Nm (5.9 to 7.4 ft-lb). DO NOT EXCEED 10 Nm (7.4 ft- lb).
Weight| 11.5kg (25.3lb)| 20kg (44.1lb)
IP Rating| IP 67
Case Material| UL94-VO PBT/PC

Environmental Specifications

Table 2-3. DLB Environmental Specifications

• This is the specified temperature of the cells, and not ambient. Ambient temperature and cell temperature may not be the same.
• borage outside of specified temperatures will result in permanent capacity loss and invalidate the warranty.

Protection Specifications

Table 2-4. DLB Protection Specifications

Protection Spec.| DLB-G24-12V| DLB-G24-24V| DLB-G24-36V| DLB-GC12-12V| DLB-GC12-24V
---|---|---|---|---|---
Overvoltage
Protection a| > 14.6 V for 1 second| > 29.2 V for 1 second| > 43.8 V for 1 second| > 14.6 V for 1 second| > 29.2 V for 1 second
Recovery a| < 13.8 V for 5 seconds| < 27.6 V for 5 seconds| < 41.4 V for 5 seconds| < 13.8 V for 5 seconds| < 27.6 V for 5 seconds
Overvoltage Hibernation| 3 Consecutive overvoltage protections. Discharge the battery to recover.
Undervoltage
Protection b| < 10 V for 3 seconds| < 20 V for 3 seconds| < 30 V for 3 seconds| < 10 V for 3 seconds| < 20 V for 3 seconds
Recovery b| > 10.8 V for 1 second| > 21.6 V for 1 second| > 32.4 V for 1 second| > 10.8 V for 1 second| > 21.6 V for 1 second
Undervoltage Hibernation| 3 Consecutive undervoltage protections. Charge the battery to recover.
Protection Spec.| DLB-G24-12V| DLB-G24-24V| DLB-G24-36V| DLB-GC12-12V| DLB-GC12-24V
---|---|---|---|---|---
Overcurrent
Protection| > 110 A for 2 seconds| > 49.5 A for 2 seconds| > 33 A for 2 seconds| > 160 A for 2 seconds| > 110 A for 2 seconds
Recovery| 20 seconds after the load or charge is removed.
Over-temperature in Discharge
Protection c| Cell temperature above 60°C (140°F).
Recovery c| Cell temperature below 55°C (131°F) for 4 seconds.
Under-temperature Discharge
Protection c| Cell temperature below -20°C (-4°F).
Recovery c| Cell temperature above -15°C (5°F) for 4 seconds.
Over-temperature in Charge
Protection c| Cell temperature above 55°C (131°F) and a charge is detected.
Recovery c| Cell temperature below 50°C (122°F) for 4 seconds.
Under-temperature in Charge
Protection c| Cell temperature below 0°C (32°F) and a charge is detected.
Recovery c| Cell temperature above 5°C (41°F) for 4 seconds.

• a Overvoltage protection monitors individual cell voltages and will trigger with any cell over 3.65 VPC and recover when all cells are below 3.45 VPC. Nominal voltages are provided for guidance only.
• under voltage protection monitors individual cell voltages and will trigger with any cell under 2.5 VPC and recover when all cells are above 2.7 VPC. Nominal voltages are provided for guidance only.
• c This is the specified temperature of the cells, and not ambient. Ambient temperature and cell temperature may not be the same.

System Size Specifications

Table 2-5. DLB-G24-12V System Size Specifications

System Size Specifications| Peak Current| Constant Current| Energy / Usable Capacity| Reserve Capacity at 25A
---|---|---|---|---
1 Battery| 250 A| 100 A| 1280 Wh| 240 minutes
2 Battery| 500 A| 200 A| 2560 Wh| 480 minutes
3 Battery| 750 A| 300 A| 3840 Wh| 720 minutes
4 Battery| 1000 A| 400 A| 5120 Wh| 960 minutes

Table 2-6. DLB-G24-24V System Size Specifications

System Size Specifications| Peak Current| Constant Current| Energy / Usable Capacity| Reserve Capacity at 25A
---|---|---|---|---
1 Battery| 120 A| 45 A| 1167 Wh| 120 minutes
2 Battery| 240 A| 90 A| 2334 Wh| 240 minutes
3 Battery| 360 A| 135 A| 3501 Wh| 360 minutes
4 Battery| 480 A| 180 A| 4668 Wh| 480 minutes

Table 2-7. DLB-G24-36V System Size Specifications

System Size Specifications| Peak Current| Constant Current| Energy / Usable Capacity| Reserve Capacity at 25A
---|---|---|---|---
1 Battery| 120 A| 30 A| 1167 Wh| 76 minutes
2 Battery| 240 A| 60 A| 2334 Wh| 152 minutes
3 Battery| 360 A| 90 A| 3501 Wh| 228 minutes
4 Battery| 480 A| 120 A| 4668 Wh| 304 minutes

Table 2-8. DLB-GC12-12V System Size Specifications

System Size Specifications| Peak Current| Constant Current| Energy / Usable Capacity| Reserve Capacity at 25A
---|---|---|---|---
1 Battery| 250 A| 150 A| 2560 Wh| 480 minutes
2 Battery| 500 A| 300 A| 5120 Wh| 960 minutes
3 Battery| 750 A| 450 A| 7680 Wh| 1440 minutes
4 Battery| 1000 A| 600 A| 10240 Wh| 1920 minutes

Table 2-9. DLB-GC12-24V System Size Specifications

System Size Specifications| Peak Current| Constant Current| Energy / Usable Capacity| Reserve Capacity at 25A
---|---|---|---|---
1 Battery| 250 A| 100 A| 2560 Wh| 240 minutes
2 Battery| 500 A| 200 A| 5120 Wh| 480 minutes
3 Battery| 750 A| 300 A| 7680 Wh| 720 minutes
4 Battery| 1000 A| 400 A| 10240 Wh| 960 minutes

Regulatory

Table 2-10. DLB Regulatory

TRANSPORTATION

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

HANDLING

Prior to handling:

• Keep the battery away from sparks and flames
• Battery cables must be disconnected
• Battery terminals must be protected from short-circuiting and touch
• A battery handle must be used to lift the battery
• Do not lift or carry the battery while it is in use or operation
• Do not lift the battery by the attached battery cable

DESIGN AND FEATURES

2

| Battery terminal covers, positive cover (+/red), negative cover (-/black)
3| Battery negative ( – ) 5/16″ terminal stud
4| Battery positive ( + )5/16″ terminal stud
5| Handle
6| Fuse
7| Battery hold-down
8| PTFE membrane vent

Figure 1. Battery Features.

Battery Management System Protections

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

1. Overvoltage. Overvoltage protection occurs when charge voltages are too high.
2. Under voltage. Under voltage protection occurs during discharge when the voltage is discharged too low.
3. Over-current. Over-current protection can occur during charge or discharge. This may happen when powering up a load (short and high inrush current) or during sustained currents above specified limits.
4. Over-temperature. Over-temperature protection can occur during charge and discharge.
5. Under-temperature. Under-temperature protection can occur during charge and discharge.

Refer to Table 2-4. DLB Protection Specifications for trigger and recovery values.

• The BMS will reconnect when recovery thresholds are met.
• If the BMS disconnects due to low voltage protection, the loads must be removed before the BMS will be able to reconnect.
• If the system has a constant parasitic draw a physical disconnect switch is recommended to aid in reconnecting the battery.

NOTE

• Charge and discharge have different operating temperature limits.
• If the BMS disconnects responding to temperature or current limits, wait for the temperature or current to reach normal operating limits.

Battery Fuse

• The Battery fuse is intended to protect the electronic components of the Battery’s internal BMS from a high externally generated current. Fuses are relatively inexpensive and easy to replace in the field, as compared with the BMS which is a high-cost item to replace.

NOTE

• Additional external DC fusing is required to protect the battery cables from DC over-current and to meet installation codes.

Battery Management System Low Power Hibernation

• After 10 continuous minutes of < 300 mA charge or discharge activity, the battery will enter hibernation mode reducing the consumption of energy from the BMS and Bluetooth communications to minimum levels. The internal relay will open and disconnect terminals.

NOTE

• Residual voltage may still be detected at the terminals when the battery is in Low Power Hibernation mode.

Battery Management System Bluetooth Communications

• The BMS communicates important battery operating information such as the State of Charge, voltage, operating current, temperature, and diagnostic logs via Bluetooth communications to devices such as mobile phones and tablets. Battery data is then viewable using the AES BLUE
• Battery Monitor App, which is either downloaded from the Apple Store or Google Play Store.

Ingress Protection IP67

• 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 IP67 rating includes testing that indicates no ingress of dust particles and no ingress of a harmful quantity of water when immersed for up to 30 minutes.
• IP codes provide guidance on suitability for use under different environmental conditions. IP ratings do not indicate fitness for purpose or confer a performance guarantee.

Membrane Vent

• Membrane vents enable the free passage of gases and vapors and allow for the equalization of the pressure between the internal case and ambient conditions.
• This helps to protect and preserve the internal components of the battery.

INSTALLATION

WARNING

• ELECTRIC SHOCK AND FIRE 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.
• No user-serviceable parts inside. Failure to follow these instructions may result in injury.
• FIRE AND BURN HAZARD : Do not cover or obstruct the heat sink or install the battery in a zero-clearance compartment. Compartment ventilation is required.
• Failure to follow these instructions can result in minor to moderate injury.
• It is the responsibility of the installer to ensure that all applicable installation requirements and standards are met.

Tools

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

Location

The battery should be installed 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.
2. Moderate temperatures. Ambient temperatures of 15°C to 20°C (59°F to 68°F) are ideal for extending LiFePO4 battery life. Do not install in the Engine Bay as this will expose the battery to elevated temperatures greater than 40°C (104°F).
3. Ventilated. Do not install in zero-clearance compartments. Maintain at least 50 mm (2 inches) above the top cover for open airflow.
4. Proper orientation. The battery may be installed in any orientation other than upside down. Do not install upside down.
5. Hold-downs. The battery is designed with standard B1/B3 hold-down ledges for use with standard battery trays. The battery may also be strapped in place with over-the-top holds.
6. Minimum cable lengths. Select a location that minimizes the length of battery cables in order to reduce voltage drop from impedance leading to reduced performance.

NOTICE

• Only a non-conductive material that covers less than 20% of the heat sink for ‘over the top’ hold-downs may be used.
• Warranty will be void if operated outside of these conditions.

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 must be rated 90 °C minimum. The cables must be terminated with lugs that fit the DC terminals snugly.
2. Minimum cable lengths. Select a location that minimizes the length of battery cables in order to reduce voltage drop from 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 ( – ).

DC Protection

CAUTION

• FIRE HAZARD: Undersized fuses and disconnects may become overloaded and potentially cause a fire. Fuses and disconnects 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.
• To protect the system and DC battery cables, additional DC over-current protection and a DC disconnect switch are required.

1. Appropriate size. Fuses and disconnects must be sized in accordance with 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 protection in the positive cable. The fuse and disconnect should be located as close as possible to the battery and must be installed in the positive cable. Applicable codes may limit how far the protection can be from the battery.

NOTE

• AC circuit breakers and DC circuit breakers are not interchangeable. Check the label on the circuit breaker to ensure it is the correct type and rating. Use only DC circuit breakers.
• Local electrical code in your area may require both positive and negative DC disconnect switches. Always refer to the applicable code and check with the authority having jurisdiction to confirm local requirements.

Terminal Connections and Hardware

The terminal connections and hardware should meet the following requirements:

1. Connect to the battery terminal. Do not connect the cable lug to the fuse post. All cable lugs must be in direct contact with the battery terminal deck. Do not put washers between the terminal deck and the cable lug.
2. Use the proper torque. Use a torque wrench to properly adjust terminal hardware torque. Periodically check to ensure torque is correct.

NOTICE

• Failure to properly secure a terminal nut to the specified torque value may increase resistance and lower voltage which may lead to burnout of the terminals and void the warranty. Exceeding 10 Nm (7.4 ft-lb) of torque will damage the terminal and void the warranty.

Single Battery Installation Procedure

• FIRE HAZARD: Undersized cables can become hot and may potentially catch fire. Failure to follow these instructions can result in minor to moderate injury.
• Battery cables (battery to load and/or battery to charger) must meet the following requirements to optimize performance:

1. Minimum cable lengths. Select a location that minimizes the length of battery cables in order to reduce voltage drop from the impedance.

Equipment must be installed in accordance with the standards set by the local authority having jurisdiction

1. If the circuit of equipment that the battery is installed in has a disconnect, open the disconnect to isolate the battery.
2. Ensure the cable connections are clean and serviceable.
3. Install and secure the battery. Be careful not to make contact between the terminals and any metal mounting, fixture, or body part.
4. Connect battery cables taking care to connect the positive ( + ) cable to the positive ( + ) terminal. Connect the negative ( – ) cable last to avoid sparks. Short circuits may damage the battery and this will void the warranty.
5. Torque all battery terminals to the recommended terminal torque of 8 to 10 Nm (5.9 to 7.4 ft-lb) to secure cable lugs. DO NOT EXCEED 10 Nm (7.4 ft-lb)
6. Close circuit disconnect (if open).

NOTICE

Failure to torque up to specifications may increase resistance and lower voltage and may lead to burnout of the terminals and invalidate the warranty. Exceeding 10 Nm (7.4 ft-lb) of torque will damage the terminal and void the warranty.

Parallel Battery Installation Procedure

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

Batteries used in a parallel system must meet the following requirements:

1. Same model. Batteries must be the same model, age, capacity, and voltage.
2. Equal voltage. Always ensure that batteries are within 50mV (0.05V) of each other before installing them in parallel.

Battery cables (battery to load and/or battery to charger) must meet the following requirements to optimize performance:

1. Minimum cable lengths. Select a location that minimizes the length of battery cables in order to reduce voltage drop from the impedance.

Interconnection cables (battery to battery) must meet the following requirements to optimize performance:

1. Equal cable gauge. The interconnection cables should be the same gauge.
2. Equal cable length. The interconnection cables should be of equal length.

Equipment must be installed in accordance with the standards set by the local authority having jurisdiction.

1. If the circuit of equipment that the batteries are installed in has a disconnect, open the disconnect to isolate the batteries.
2. Ensure the cable connections are clean and serviceable.
3. Install and secure new batteries. Be careful not to make contact between the terminals and any metal mounting, fixture, or body part.
4. Connect battery-positive ( + ) cables between the battery-positive ( + ) terminals with snugly tightened terminal hardware.
5. Connect battery negative ( – ) cables between the battery negative ( – ) terminals with snugly tightened terminal hardware.
6. Connect the load positive ( + ) cable and load negative ( – ) cable to the opposing ends of the parallel batteries.
7. Connect the charger positive ( + ) cable and the charger negative ( – ) cable to the opposing ends of the parallel batteries.
8. Torque all battery terminals to the recommended terminal torque of 8 to 10 Nm (5.9 to 7.4 ft-lb) to secure cable lugs. DO NOT EXCEED 10 Nm (7.4 ft-lb).

NOTICE

• Failure to properly secure a terminal nut to the specified torque value may increase resistance and lower voltage which may lead to burnout of the terminals and void the warranty.
• Exceeding 10 Nm (7.4 ft-lb) of torque will damage the terminal and void the warranty.
• Wherever replacing an old battery in a string, use a battery of the same age, model, capacity, and voltage.
• Before installing the battery in parallel, ensure that each battery is charged to 100% SOC.

OPERATION

The Battery BMS prevents battery operation outside of specified operating conditions. Make sure to understand each of these protections and how to set up the system accordingly. Refer to Table 2-4. DLB Protection Specifications.

NOTICE

Intentional bypassing of the BMS to operate the battery outside maximum and minimum limits voids the warranty.

Low Voltage Cut-Off

• The low voltage cut-off, as controlled by the application, should be programmed at or above the Low Voltage Disconnect Voltage value given in Table 2-1. DLB Electrical Specifications.
• This ensures that the load will disconnect before the BMS is forced to enter low-voltage protection.

NOTICE

• Storing or leaving the battery at 0% SOC will lead to irreversible damage.

BMS Hibernation

• The BMS will enter hibernation mode if there is no charge or discharge activity detected for 10 minutes, or if the battery triggers low or high voltage protection three consecutive times.
• During this time, the BMS will disconnect the internal SSR. This protection helps safeguard the battery from becoming over-discharged.

The battery will exit hibernation mode by:

• Applying a charge current. If the battery is in low voltage protection and hibernation mode a small charge current will reactivate the BMS.
• Applying charge or discharge current. If the battery is not in low voltage protection but is in hibernation mode a charge or discharge current will activate the BMS.

State of Charge

• A Bluetooth App for mobile devices provides real-time access to the battery state-of-charge, voltage, operating current, temperature, status, and a diagnostic report. Search for the AES BLUE Battery Monitor App on Apple’s App Store or Google Play.
• A voltage-based battery meter that is designed for lead-acid batteries will not provide an accurate state of charge (SOC) for lithium. Use a battery meter that measures current, rather than voltage, for lithium batteries.

Charging

• Each electrical system will have different characteristics and balance-of-system components. Modifications to charger settings may be required to optimize the system performance of each.
• Always confirm that the charging device is incapable of producing transient spikes that exceed the published terminal voltage limits for the battery.
• Never charge a visibly damaged or frozen battery.
• Always confirm the charging curve meets the battery’s charging requirement.

When to Charge the Battery

• Opportunity charging is OK. Charging the battery after every use will not reduce its cycle life.
• The partial state of charge is OK. If the battery SOC is greater than 10% at the end of discharge, it does not require an immediate charge.
• Charge if below 10% SOC. If the battery has been discharged below 10% SOC it must be charged within 24 hours to avoid permanent damage to the battery. Otherwise, irreversible damage to the battery cells will occur in a very short period of time.
• Low currents extend life. Charging at 50% of nominal current or lower helps extend battery cycle life.
• Proper temperature. Ensure charging is within the charge temperatures specified in Table 2-3 DLB Environmental Specifications.
• The battery must be charged within 24 hours if it has been discharged below 10% SOC. Otherwise, irreversible damage to the battery cells will occur in a very short period of time and the warranty will be invalid.
• Charging the battery when it is below 0°C will cause irreversible damage and invalidate the warranty.

What to Charge the Battery with

• Use a Lithium LiFePO4 charger. Use a charger with a dedicated LiFePO4 charging algorithm that matches the DLB charging profile and parameters. For charging parameters refer to Table 2-1. DLB Electrical Specifications and Figure 8 DLB Charge Graph.

Charging with a Lead-Acid Charger

CAUTION

• FIRE AND BURN HAZARD: Do not perform an equalization charge on lithium batteries. Failure to follow these instructions can result in minor to moderate injury.
• Not recommended. For the reasons stated below, it is not recommended to use a lead-acid charger.
• It is possible. Short-term charging with a lead-acid charger is possible only if the bulk and absorption voltages are equal to or below the bulk voltage. Refer to Table 2-1 DLB Electrical Specifications for charging parameters and Figure 8 DLB Charge Graph.
• Gel profiles. GEL profiles are typically the lead-acid settings closest to the recommended Lithium settings.
• No equalization. Do not perform an equalization charge on lithium batteries.
• No temperature compensation. Temperature compensation must be disabled.
• Some lead-acid charge profiles are within the LiFePO4 charging voltages, however many will exceed the BMS high voltage protection limits.
• This will result in the BMS disconnecting at the end of the charge cycle, likely causing the charger status indicator to display an error.
• Not recommended. For the reasons stated below, it is not recommended to use an alternator as a charge source.
• It is possible. Charging with an alternator is possible. However, use one of the following is REQUIRED:
• Voltage regulator, battery isolator, or DC/DC converter

NOTICE

• If the alternator charge voltage or current is too high, the BMS will protect the battery by disconnecting the battery from the system. In a one-battery system, a large voltage spike may also be created, potentially damaging both the alternator and BMS.
• LiFePO4 batteries are so efficient the alternator may burn itself out over extended periods of output at or close to peak current.

Charging Profile

• DLB LiFePO4 battery charging should include both Bulk and Absorption phases. For charging parameters refer to Table 2-1. DLB Electrical Specifications.

NOTE

• Charging at 50% of nominal current or lower will extend battery cycle life.

Bulk Charge

• Bulk phase. The first phase of the charging process is the Bulk charge, also referred to as the constant current phase. This is when the maximum amount of current from the charger is directed to the battery until the desired voltage is reached.
• The Bulk phase will recharge the battery to approximately 90%-95% SOC.
• If the charging source is a generator or other charge source that is not efficient at low output current a single-stage charge may be appropriate. A single-stage charge will only complete the Bulk phase portion of the charge curve.
• This method should return the battery to between 90-95% SOC.
• Refer to Table 2-1 DLB Electrical Specifications for charging parameters.

Absorption Charge

• Absorption phase. The second phase of the charging process is the Absorption Charge, also referred to as the constant voltage phase. This is when the charger reduces current accordingly to maintain the desired voltage.
• Refer to Table 2-1 DLB Electrical Specifications for charging parameters.

Equalization

CAUTION

• FIRE AND BURN HAZARD : Do not perform an equalization charge on lithium batteries. Failure to follow these instructions can result in minor to moderate injury.
• Do not equalize charge. Do not equalize charge Lithium batteries. Equalization charging is intended only for lead-acid batteries.
• Equalization charge is a purposeful overcharge that targets a voltage above standard charge voltage in order to remove sulfate crystals that form on lead-acid plates over time.

Float Charge

• Float phase. Float charge, the third phase of charging is optional. During this stage, the battery is maintained at 100% SOC for extended periods of time counteracting any self-discharge or parasitic loads.
• Not necessary. Float charging is not necessary.
• If needed refer to Table 2-1 DLB Electrical Specifications for float parameters.

BLUETOOTH

• A Bluetooth App for mobile devices provides real-time access to the battery state-of-charge, voltage, operating current, temperature, status and a diagnostic report. Search for Discover Blue on Apple’s App Store or Google Play.
• One Battery. The App will only communicate with one battery at a time.
• No Bluetooth when the battery is in hibernation mode. Bluetooth is only active when the battery is not in hibernation mode. Ensure that there is a charge or discharge current to activate Bluetooth communications.

ROUTINE INSPECTION

Periodically inspect the battery system:

1. Ensure that the DC cables are secure and fasteners are tight
2. Ensure that the installation location is clean and free from debris
3. Inspect for cracks in the battery casing
4. Replace any damaged batteries
5. Replace any damaged cables

REPLACING THE FUSE

CAUTION

• ELECTRIC SHOCK: 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 and use safe handling procedures when handling the battery.
• Failure to follow these instructions may result in injury.

Table 10-1. DLB Fuse Specifications

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Applicable

| DLB-G24-12V DLB-GC12-12V DLB-GC12-24V| DLB-G24-24V DLB-G24-36V
Fuse Terminal Torque| 8 to 10 Nm (5.9 to 7.4 ft-lb). DO NOT EXCEED 10 Nm (7.4 ft-lb).

This task should be performed by qualified personnel:

• Use only Insulated tools
• Wear Personal protective equipment
• The battery system must be de-energized
• Battery cables must be disconnected
• Battery terminals must be protected from short-circuiting and touch
• Refer to Section 6.5 Terminal Connections and Hardware, Section 6.6 Single Battery Installation Procedure and Section 6.7 Parallel Battery Installation Procedure.

1. Ensure that the DC system is de-energized and, the battery charger and all loads are disconnected. If the battery is in a DC circuit of equipment that has a disconnect, open the disconnect to isolate the battery.
2. If connected to others, remove the battery and isolate it.
3. Protect the battery terminals from short-circuiting and touch by covering them with terminal covers or electrically rated tape.
4. Install the fuse on the battery fuse post. The battery will not operate if the battery fuse is installed on the battery terminal post.
5. Remove the nut holding the fuse and replace it with a new fuse paying strict attention to orientation and the fuse ratings in Table 10-1 DLB Fuse Specifications.
6. Torque the nut holding the new fuse to 8 to 10 Nm (5.9 to 7.4 ft-lb). DO NOT EXCEED 10 Nm (7.4 ft-lb).
7. After removing the terminal protection, reinstall the battery into the system.
8. If installed, close the disconnect to complete the circuit of equipment and energize the battery system.

NOTICE

Failure to properly secure a terminal nut to the specified torque value may increase resistance and lower voltage which may lead to burnout of the terminals and void the warranty. Exceeding 10 Nm (7.4 ft-lb) of torque will damage the terminal and void the warranty.

STORAGE

• Leaving the battery connected to a trickle load, or to power electronics will cause the battery to be discharged during storage.
• Without any load, the battery will self-discharge by approximately 3% per month while in storage.
• After storage, charge the battery to 100% SOC and then perform at least 1 full discharge and charge cycle before returning the battery to service.

1. Store at 95% SOC or greater. To store the battery for a period of up to 6 months, the battery must be initially put into storage at 95% SOC or greater. It must remain disconnected from all loads and power electronics during the storage period.
2. Check SOC every 6 months. Recharge the battery to above 95% SOC at least every 6 months.
3. Proper storage temperature. Ensure storage is within the temperatures specified below.

• 1 Month storage temperature -20°C to 45°C (-4°F to 113°F)
• 6 Month storage temperature -10°C to 30°C (14°F to 86°F)

NOTICE

• Leaving the battery connected to a load or power electronics during storage may subject the battery to a trickle drain which could result in irreversible damage and void the warranty.
• Storage outside of specified temperatures will result in irreversible damage and void the warranty.
• Storing or leaving the battery at 0% SOC will cause irreversible damage and void the warranty.
• Allowing the battery to self-discharge below an open-circuit voltage of 3.0 VPC will cause irreversible damage and void the warranty.

RELATED INFORMATION

Find information about Discover Energy Systems at discoverlithium.com For warranty information, see 885-0021 Discover AES BLUE Warranty Policy.

GLOSSARY OF TERMS, ABBREVIATIONS, AND ACRONYMS

DLB

Discover AES BLUE

| LFP

LiFePO 4 Lithium Iron Phosphate

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BMS

Battery Management System

| SOC

State of Charge

DOD

Depth of Discharge

| VPC

Volts Per Cell

NOTES

Documents / Resources

| DICOVER DLB-G24-12V AES BLUE LiFePO4 Lithium Battery [pdf] Instruction Manual
DLB-G24-12V AES BLUE LiFePO4 Lithium Battery, DLB-G24-12V, AES BLUE LiFePO4 Lithium Battery, BLUE LiFePO4 Lithium Battery, LiFePO4 Lithium Battery, Lithium Battery
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References

• Lithium LiFePO4 Battery Manufacturers/Suppliers | Discover Energy Systems

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