CARBEST 81451 LiFePO4 Battery Pack Instruction Manual

CARBEST 81451 LiFePO4 Battery Pack Instruction Manual

SAFETY PRECAUTIONS

• DO NOT reverse the positive and negative of the battery.
• DO NOT touch or store the terminals of the battery with unnecessary wires or other metal materials to avoid short circuit.
• DO NOT puncture, impact, drop or step on the battery.
• DO NOT disassemble the battery or modify the outer casing.
• DO NOT expose the battery under the sun, since this may cause overheat, fire or failure to the battery.
• DO NOT put the battery in a fire or heat the battery. Do not store the battery in a high temperature environment.
• DO NOT put the battery into the water or in the rain for a long time. Battery should be stored in a cool and dry environment.
• If you detect any abnormal smell or noise while charging or discharging, remove the battery immediately and contact the dealer.
• DO NOT install batteries in a zero-clearance compartment, overheating may result. Always leave at least 4″ of space around all sides and top of battery.
• When the battery is operated beyond the temperature range of 0°C~50°C, the capacity may decrease, this does not mean that the battery is damaged.

PRODUCT FEATURES

• Lithium iron phosphate (LiFePO4) for more safety Absolutely maintenance-free, no gassing, no risk of explosion, no risk of fire.
• Integrated battery management Built-in protection against short circuit, overcharge and deep discharge.
• Low weight Enormous weight saving compared to lead-acid/AGM batteries.
• High usable capacity Nearly 100% usable capacity, unlike lead-acid batteries.
• High charge currents and discharge currents with a high cycle stability. Can deliver higher currents, can be charged considerably faster.
• Very low self-discharge Approx. 1-3% per month when not in use

PRODUCT SPECIFICATIONS

DIMENSIONS

TECHNICAL DATA

CARBESTS smartphone App
12V installation| Connection in series up to 4 batteries / in parallel up to 2 batteries| Connection in series up to 4 batteries / in parallel up to 2 batteries| Connection in series up to 4 batteries / in parallel up to 4 batteries
Operating temperature (charge)| 0°C .. +45°C| 0°C .. +45°C| 0°C .. +45°C
Operating temperature (discharge)| -20°C .. +55°C| -20°C .. +55°C| -20°C .. +55°C
Terminal| M8| Standard car battery terminals| M8
Terminal arrangement| Positive terminal left| Positive terminal right| Positive terminal left
Warranty| 5 years| 5 years| 5 years
Weight (ca.)| 12,5 kg| 12,5 kg| 25 kg
Dimensions (L x W x H) in mm| 307 x 172 x 218| 278 x 175 x 190| 378 x 280 x 187
Certification and standards| CE, UN 38.3, MSDS| CE, UN 38.3, MSDS| CE, UN 38.3, MSDS

PRODUCT INTRODUCTION

LITHIUM IRON PHOSPHATE BATTERY

The lithium iron phosphate battery (LiFeP04) is the safest of the mainstream lithium battery types. The nominal voltage of a LiFePO4 cell is 3,2V. A 12,8V LiFePO4 battery therefore consists of 4 cells connected in series. Compared to the traditional lead-acid battery, the LiFeP04 battery has higher densities of energy and power. Lithium batteries are light on weight and smaller in size. The lithium iron phosphate battery has a higher depth of discharge than lead- acid batteries: 100% vs. 50%. This results in a higher usable capacity. And it has a very low self-discharge rate. Compared to lead-acid this is 10 times lower.

BATTERY MANAGEMENT SYSTEM (BMS)

A BMS (Battery Management System) ensures safe discharging/charging of the battery and monitors the individual cells of a battery pack. By balancing unequally charged cells during  charging, cell drift is reduced. Regular balancing ensures optimal capacity utilization while preventing excessive aging of individual cells. In addition, the BMS monitors the individual cell voltage and interrupts the charging or discharging process in the event of overvoltage or undervoltage of an individual cell. By maintaining the operating parameters, the cycle stability, i.e. the service life of the battery, is increased.

The BMS performs the following tasks:

• Monitoring the battery
• Providing battery protection
• Estimating the battery‘s operational state
• Continually optimizing battery performance
• Reporting operational status to external devices

Carbest LiFePO4 batteries always 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 the electrical system from potential damage. The integrated BMS protects against the following conditions:

• Over-Voltage Protection
  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.

• Low-Voltage Protection
  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.

• Over-Current Protection
  After exceeding the over-current protection value for 3s, BMS will cut off the MOS automatically. After 10s, the protection will be automatically released, and the discharge switch will be turned on again, and the lock will not be automatically released if it occurs consecutively for 3 times. (If there is any normal charging or discharging process, the count will be cleared).

Release conditions:

1. Remove the load (for > 13S);
2. Connect to the charger (continuous > 2S)

• Short Circuit Protection
  The BMS has a built-in short circuit protection function. If the short circuit protection is tripped, the BMS will shut the battery down and will remain disconnected until you:

1. Remove the load (for > 13 s) or
2. Connect to the charger (for > 13 s)

• High Temperature Charging and Discharging Protection
  The BMS will not allow a charging or discharging current if the internal temperature of the battery has reached 50 °C/65 °C.

• Low Temperature Charging and Discharging Protection
  The BMS will not allow a charging below 0°C as it will damage the cell (unless it has the heating function). The recovery temperature is around 5 °C. If the internal temperature of the battery has reached -20°C, the BMS will shut the battery down, recovery temperature is around -15 °C.

• Balancing of Cells
  A passive balancing process is activated by the BMS at the top of each charge cycle when the battery cell voltage reached 3.4V and the max. cell voltage difference exceeds 50mV. This ensures that all the cells remain at the same state of charge, which helps the longevity and performance of the battery pack.

SLEEP MODE

1. When the BMS detects that there is no charge or discharge activity (charge or discharge current < 1A) for 24 hours, it will automatically enter into sleep mode to save energy.
2. When the BMS detects that any single cell voltage is lower than 2.5V or battery voltage is lower than 10V for 3 minutes, it will automatically enter into sleep mode. If the battery enters sleep mode, you can activate the battery by:
   • Charging the battery (Charging current >1A), charge voltage should be 1.2V higher than battery voltage.
   • Connecting the battery to load (Discharging current >1A), load resistance should be lower than 5KΩ.

HEATING FUNCTION FOR LOW TEMPERATURE CHARGING

The batteries 81452 and 81453 have an integrated heating function, which allows charging the battery at low temperatures. The internal battery management system (BMS) continuously monitors the ambient temperature of the battery and controls the integrated heating function fully automatically. If a temperature ≤ 0°C is measured during the charging process, the BMS immediately stops the battery charging and simultaneously activates the heating function of the battery. After reaching +5°C, the charging process is automatically continued. If the temperature rises above 10°C, the heating function is deactivated again.

INSTALLATION

LI-BATTERY CONNECT APP (AVAILABLE FOR BATTERY 81452 AND 81453)

If the battery is equipped with Bluetooth function, you can use this to communicate with the Carbest Li-Battery Connect App. The App is used for reading out battery information for real time monitoring, receiving alarms and to update firmware.

CONNECTING TO BLUETOOTH

Important note: Use only the CARBEST App recommended here. Damage to the battery caused by the use of apps from other suppliers is not covered by our warranty.
Communication system: Bluetooth 4.0
Operation frequency: 2402MHz – 2480MHz
Max. EIRP output power: 2.30 dBm
Usage: worldwide, no limitation
Communication range: 40 m

The App is available for iOS and Android smartphones.
Mobile phone requirements: Android version 5.0 or above / iOS Apple 9.0 or above

1. Install APP and allow notification on your phone screen.

2. Activate Bluetooth mode on your phone before connecting battery and phone.

3. Connect the battery to your phone. You can rename the battery after connecting.
   There are two ways for connecting:
   A) Search the battery from the device list that your phone can discover.
   B) Scan QR code on the battery and the battery name will appear.
   Remark: One smartphone can only connect to one battery at the same time. You need to check the batteries one by one in turns if you configure them in series or parallel.
   
   C) You can rename the battery after being connected.

4. Charge or discharge the battery to activate its Bluetooth function
   

5. After connecting, you can see the SOC (States of Charge) at the Basic Info.
   

6. Click to check the Alarm details.

7. Battery State: Standby/Charging/Discharging

8. Perfect: >90% Capacity Good: 80%~90% Capacity Service: ≤80% Capacity

9. Battery Voltage

10. The left half circle in orange presents discharging current in a negative value. The right half circle in blue presents charging current in a positive value.

11. Time to fully charge

12. Total 4 cells in one battery

13. You can also check the individual cell voltage from the Details Info.
    
    

14. You can disconnect battery from the connecting device list
    
    Note: You can check Manual and other information’s from the menu.
    

Important note:
Please note that the “Event Record” section within the CARBEST App also shows when a protection mechanism (for example overvoltage protection or low temperature charging protection) has been activated by the BMS. This does not represent a problem or a defect of the battery but only serves the exact data analysis.

Example

The message “Cell overvoltage protection” here only means that the battery is 100% fully charged at the time of the message and the protection against overcharging has been activated.

The message “Low-temperature charging protection” only indicates that the ambient temperature is too low (below 0°C) and the BMS has activated the charging protection function. This message will also appear for batteries with heating function, shortly before the heating function is activated.

CHARGE BATTERIES BEFORE USE

Always charge the battery before use! If multiple batteries are going to be connected in series or in parallel, each individual battery needs to be charged before all batteries are interconnected. Please charge the battery according to the parameter required in the data sheet. Remark: batteries are approximately 50%-60% charged when shipped from the factory. This is because of the transportation safety requirements. Due to differences in transportation routes and warehouse, the batteries do not all have the same state of charge by the time they are installed.

MOUNTING

CAUTION: Always handle lithium batteries with care. Ensure proper and secure mounting and suitable transport. In the event of an accident, unsecured batteries could become a projectile!

The battery can be mounted in an upright or side position, but can not be upside-down. The battery is only suitable for indoor use and needs to be located in a dry location. Batteries are heavy. When moving the battery into its destined location, please use suitable handling equipment for transportation. Ensure adequate and secure mounting as the battery can become a projectile if involved in an accident. Batteries produce a certain amount of heat when they are charged or discharged. Keep a 20mm space on each side of the battery for ventilation purposes

BATTERY CONNECTION

Note: Cable cross sectional area and fuse ratings:
Please use battery cables with a cross sectional area that matches the currents that can be expected in the battery system. Batteries can produce very large currents. Therefore, it is necessary that all electrical connections to a battery are fused. The battery fuse rating has to match the current rating of the battery cable that has been use Both the battery cable and the fuse have to also match the expected maximum system currents.

A. Connecting a single battery:

• Fuse the battery on the positive side
• Connect the battery to the DC system
  
  Important information’s for series/parallel connection:
  We urgently recommend that you entrust a specialist with the connection of several batteries. Within this instruction manual it is not possible to explain all the technical requirements for wiring and fusing such a setup.
  NOTE: a mixture of series and parallel connection is not useful and is not recommended

B. Series connection (24V / 36V / 48V)

To increase the total voltage while maintaining the same capacity, you can connect the batteries in series. The following notes should be strictly observed:

Li100 (81451): Connection in series up to 4 batteries
Li100BH6 (81452): Connection in series up to 4 batteries
Li200BHD (81453): Connection in series up to 4 batteries

• All batteries need to be the same model, age and capacity.
• Each battery needs to have been fully charged individually before use.
• Connect a maximum of four 12.8V batteries in series to be a 48V max. power system.
• Connect the negative to the positive of the next battery. Fuse the series string on the positive side.
• Connect the battery bank to the system.
  

C. Parallel connection (12V)

When several batteries are connected in parallel, the total capacity is increased while the voltage remains the same. The following notes should be strictly observed:

Li100 (81451): Connection in parallel up to 2 batteries
Li100BH6 (81452): Connection in parallel up to 2 batteries
Li200BHD (81453): Connection in parallel up to 4 batteries

• All batteries need to be the same model, age and capacity.
• Connect a maximum of 4 batteries.
• Fuse each battery on the positive side.
• Take care that cross-sectional area of the system cable is equal to the cross-sectional area of the string cable times the number of strings.
• Fuse the positive main cable going to the battery bank.
• Connect the battery bank to the system.
  

BATTERY CHARGING

• Fully charge a new battery before using it for the first time.
• Recommended charging voltage is 14.2 – 14.4V
• Please always connect the battery charger to the battery first and then switch on the charger.
• The charging current and voltage must not exceed the maximum charging values which are indicated in the specification sheet in this user manual.
• When selecting the charger, make sure that it is suitable for LiFePO4 batteries and that the charging voltage corresponds to that of your battery. Using an inappropriate charger can damage your lithium battery immediately or permanently.
• Never use a lead-acid battery charger if it has any following mode or function: equalization mode / desulfation mode / pulse function
• Do not leave any lead-acid battery charger connected to maintain or store the battery because it will not maintain the proper voltage charge algorithm for lithium batteries and damage will occur to the battery.
• Please ensure to charge at an ambient temperature of 0°C – 45°C. Below 0°C or above 45°C may cause irreversible damage to the battery or even a safety risk.
• At low temperatures the battery is charged with reduced charging current, resulting in a longer charging process.
• If your battery has the heating function, the heating will be turned on when the BMS detects the temperature is lower than 5°C when the battery is being charged. The heating will be turned off when the BMS detects the temperature reaches 10°C. The heating current is less than 9.3A.

BATTERY DISCHARGING

• Please do not exceed the maximum discharge current which is indicated in the specification sheet in this user manual.
• Do not discharge the battery with maximum discharge current several times in succession, since it may cause battery damage.
• Lithium batteries will become permanently damaged if they are discharged too deeply. Lithium batteries can be discharged with high currents.
• Do not mix a new battery and a used battery in a same configuration.

TROUBLESHOOTING

environment and confirm the load power, to ensure the battery is being charged/discharged within the max. charging/discharging current stated in the specifications
2| Battery working time is too short| The charging voltage is too low and the battery cannot be fully charged| Adjust the charging voltage according to the specifications.
The load voltageis too high and the battery cannot be fully discharged| Reduce the load voltage or replace the battery with a larger capacity one
Over temperature| Lower down ambient temperature
Battery capacity becomes lower| Replace the battery
3| Battery heat up| Over current| Reduce load power
Over temperature| Working within the operating temperature
4| Spark occurs on cable terminals| Initial connect to capacitive load or inductive load| No action required
Power supply short circuit| Check the cause of the short circuit and disconnect it

MAINTENANCE AND STORAGE

• The CARBEST LiFePO4 batteries are basically absolutely maintenance-free.
• Keep the battery clean and use a moistened cloth for cleaning.
• Do not expose the product to solvents or other aggressive liquids.
• Please ensure the battery terminals and screw holes are clean and securely connected.
• If the battery is not used for a longer period of time, it should first be fully charged. Check the state of charge regularly and recharge the battery if necessary. We recommend recharging the battery with a suitable charger after each use or at least every 3-6 months. Do not use a trickle charger.
• If the battery is not used for a longer period of time (several months), disconnect the battery from the load to avoid unnoticed discharge.
• Always store the product in a dry, clean and frost-free place.

• Never open the battery casing. This does not contain any parts that require care or maintenance.

TRANSPORT INSTRUCTIONS

• If you wish to return your battery, always use the original packaging.
• The batteries may only be transported or shipped in the original packaging. If alternative packaging is used, the corresponding regulations must be observed.
• The batteries must be transported in accordance with the UN Manual of Tests and Criteria, Part III, subsection 38.3.
• With regard to transport, the batteries belong to category UN3480, Class 9A.
• The original packaging complies with these requirements.

WARRANTY

The warranty period is 5 years. Reimo reserves the right to rectify eventual defaults. The guarantee is excluded for all damages caused by faulty use or improper handling. Liability limitations: In no case Reimo will be reliable for collateral-, secondary- or indirect damages, costs, expenditure, missed benefits or missed earnings. The indicated sales price of the product is representing the equivalent value of Reimo’s liability limitations.

DISPOSAL

Please dispose of all packaging material properly or recycle it. You are legally obligated to return used batteries. Never dispose of LiFePO4 batteries in household or commercial waste! Instead, you must take the batteries to collection points for professional recycling. Alternatively, you can contact your dealer, repair store or the manufacturer for return. When disposing of the battery, make sure that it is completely discharged and insulate the battery terminals to prevent short circuits.

REIMO REISEMOBIL-CENTER GMBH
63329 EGELSBACH · BOSCHRING 10
GERMANY · WWW.REIMO.COM
MADE IN CHINA · © REIMO 06/2023

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