Lithionics Battery GTO Series Battery OEM Model Installation Guide
- June 14, 2024
- Lithionics Battery
Table of Contents
Lithionics Battery GTO Series Battery OEM Model Installation Guide
*Model Numbers
GTO12V660A-E2609-DIN
GTO51V330A-F3020-DIN
GTO24V330A-E2609-DIN
GTO51V330A-E2609-DIN
Important Safety Guidelines
This guide contains important safety instructions for the GTO Series Battery System that must be followed during installation procedures. Completely read this manual and become familiar with all system components before attempting installation. Save this installation manual for future reference.
The following symbols and messages are used to identify potential hazards or to clarify the procedure.
CAUTION
The CAUTION symbol indicates a hazardous situation which, if not avoided, could result in moderate or minor injury.
DANGER
The DANGER symbol indicates a hazardous situation which, if not avoided, will result in death or serious injury.
Safety Information
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Before using the Battery System, read all instructions and cautionary markings on the unit, the BMS, and all appropriate sections of this manual.
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The information in this manual is intended for qualified personnel. Qualified personnel have training, knowledge, and experience in:
• Selecting and using Personal Protective Equipment (PPE).
• Installing electrical equipment.
• Applying all applicable local and national installation codes.
• Analyzing and reducing the hazards involved in performing electrical work. -
Use of accessories not recommended or sold by the manufacturer may result in a risk of fire, electric shock, or injury to persons.
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To avoid the risk of fire and electric shock, make sure that existing wiring is in good condition and that wire is not undersized. Do not operate the battery system with damaged or substandard wiring.
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Do not operate the battery system if it has been damaged in any way.
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This unit does not have any user-serviceable parts. Do not disassemble the battery system except where noted for connecting wiring and cabling. Attempting to service the unit yourself may result in a risk of electrical shock or fire. Internal cells remain charged after all power is disconnected.
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To reduce the chance of short-circuits, always use insulated tools when installing or working with this equipment.
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Remove personal metal items such as rings, bracelets, necklaces, and watches when working with electrical equipment.
CAUTION
HAZARD OF ELECTROLYTE VAPOR
- The battery module may emit a non-toxic pressurized electrolyte vapor if punctured.
- Electrolyte vapor may cause temporary minor breathing congestion.
- Electrolyte vapor can decrease visibility in closed compartments.
CAUTION
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
- Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices.
- Always turn OFF all equipment connected to the system in addition to turning OFF the power switch provided on the system to isolate the batteries from other electrical circuits, before performing any repairs or maintenance on the system.
- Do not operate the system if it has received a sharp blow, been dropped, has cracks or openings in the enclosure.
- Do not disassemble any part of the system. Internal cells remain charged after all power is disconnected.
- Do not operate the system with damaged or substandard wiring.
- Always use proper wire sizes to connect the system to inverters, chargers or other equipment.
- Voltage is present at the connector and output terminals. Always ensure that the BMS output terminals have the insulated protective boots in place.
- Always use crimped connections to connect to the output terminals.
- Always use a properly rated voltage sensing device to confirm all circuits are de-energized.
CAUTION
HAZARD OF HEAVY EQUIPMENT
- Use two people to lift and mount the battery module.
- Always use proper lifting techniques during installation to prevent injury.
- Do not lift the battery module by its power or signal wires as they will become damaged.
If the system is operated outside of its limits and/or used in combination with non-original components without authorization, the warranty is void.
Do not expose this unit to direct sunlight, external heat sources or submersion in any liquid. This product is designed for closed compartment use only. Damage to any part of the battery system caused from direct sunlight, external heat sources or submersion in any liquid will not be covered by the product warranty.
The Battery Module and BMS is tested to comply with UN DOT 38.3, the testing requirement for Lithium Batteries per Part III; of the UN Recommendations on the TRANSPORT OF DANGEROUS GOODS (Manual of Tests and Criteria, Fifth revised edition); [ST/SG/AC.10/11/Rev.5].
This Battery Module contains no mercury and is RoHS Compliant. Please consult your local municipal authority for proper disposal.
1. System Specifications
1.1 Operating Specifications
Table 1 GTO Series
Notes for Table 1:
(N1) Maximum charging and discharging rates apply depending upon the ambient
temperature and duty cycle of the system. UL1973 tests of maximum charge and
discharge current were performed at 25°C/77°F.
(N2) Does not include the power cable’s weight as its length varies per
application.
(N3) Does not include the power cable, main power connector, or terminals.
Please see www.lithionicsbattery.com for dimensions.
(N4) “Bolted Fault Current” per NFPA-70E. See section 1.2 for details.
1.2 Arc Flash Energy Specifications
• An arc flash is the light and heat produced from an electric arc supplied
with sufficient electrical energy to cause substantial damage, harm, fire, or
injury.
o An example of an arc flash event could be a direct short circuit caused by a
metallic object such as a tool bridging between the positive and negative of
an energized circuit.
o Table 2 below quantifies the hazard level of arc flash energy that each
battery system is capable of producing.
Per NFPA 70E D.5.1 “Maximum Power Method”
Iarc = 0.5 x Ibf
IEm = 0.01Vsys Iarc*Tarc/D2 (Arc Flash Energy)
Table 2
Hazard/risk classification as per NFPA 70E-2000
1.3 Manufacturing Date Code Format
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MMDDYYYY001
o MM: Month of Manufacture
o DD: Day of that Month
o YYYY: Year of Manufacture
o 001: Sequence of Battery Produced on That Day -
Example: 01012023001 = manufactured on January 1, 2023 and it was the first battery produced on that day.
2. System Installation
2.1 Short Circuit Protection
• The battery system must be protected by a DC fuse. The models listed in this
document were evaluated and tested by Underwriter Laboratories with external
fuses as noted. UL Listed Class J or Class T Fuse, rated per the table below.
The fuse is to be provided downstream of the BMS before the load or supply in
all cases. The fuse should be used with a UL Listed fuse holder. The use of
any other fuse or non-fuse voids the UL Listing of the models.
• Examples of approved:
- Fuse placement must be directly after the positive power terminal on the BMS. (Fuse placement may be controlled by other industry standards such as ABYC or RVIA.)
2.2 Battery Module and NeverDie BMS Unit Environment and Mounting Orientation
- The Battery Module and BMS Unit should be mounted in an environment that does not receive direct sunlight, pressurized water, or road debris.
- To avoid power interruption, your installation may need to consider controlling the ambient operating temperature.
- The BMS Unit can be mounted in any orientation as long as all of its features are accessible.
- Ensure that the BMS Unit is located in close proximity to the Battery Module so that all connectors can be mated in the following steps.
- Mount the Battery Module in an upright position, i.e. black lid faces up.
o Other orientations are NOT permitted and will void the warranty.
o In the case of the GTO51V165A-F3020-DIN mounting orientation, it must be mounted as shown:
2.3 IonBus® Data and Power Connections
- The Lithionics Battery IonBus® is a data communication network used as a backbone for the distributed energy storage system (ESS) design, which consists of one or more battery modules and an external NeverDie® BMS unit.
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A. (2x) GTO51V165A-F3020A-DIN-12HK-UL Modules
o Each module has a single circular 8-pin IonBus® port. -
B. (1x) Advanced Series BMS
o The BMS has a single circular 8-pin IonBus® port. -
C. Fuse connected to BMS Positive Output Terminal
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D. (3x) Optoloop+ T-Adapters (#80-244)
o Align the connectors and connect the “M” side to the Module or BMS.
Rotate the 2 nuts of the connector to tighten together until it stops.
o Daisy-chain the “Up” and “Down” sides together. -
E. (2x) Optoloop+ Terminator
o Install one at each end of the daisy-chained T-Adapters
Rotate the 2 nuts of the connector to tighten together until it stops. -
F. (1x) Y Harness, 2x A160 1/0 Din Male to 1x A320 4/0 Din Female, 20″ (#75-625-20)
o Connects the 2 battery modules in parallel to the BMS.
o Align the connectors and connect them together.
o Use 2 zip ties to bind the connectors together so that they may not separate during operation.
2.5 NeverDie BMS Unit Power Terminals
- Connect the BMS Unit Power Terminals to your DC bus, both Positive (Red) and Negative (Black).
o Use correctly sized wire conductors for the application.
o Torque the terminals to 108-132in-lbs (12.2-14.9N-m).
o Do not stack ring terminals together, use a sub-busbar if necessary for multiple ring terminal connections.
o Never place the stainless-steel washer between the Power Terminal and ring terminal lug (see Figure 1 on Page 7).
2.6 Pressure Vent
- It is recommended to install a ventilation hose onto the pressure vent barb when the Battery Module is in a location with poor ventilation to atmosphere.
o The hose shall direct the gases to the atmosphere.
2.7 BMS Unit I/O Connector
• Some systems have a rectangular I/O connector to extend the BMS Unit
features remotely such as remote Power/Reset switch, LED indicator, or serial
datalogging. Be sure to connect the I/O connector if so equipped.
2.8 Initial Charge Cycle
• Initially the system must be FULLY charged once to calibrate the BMS Unit to
the Battery Module. Please read and follow the next section to perform this.
3. System Operation
3.1 Powering the System On
• Short-press the Power switch for 1 second.
o The switch will illuminate once power is enabled.
o You may notice an audible “thunk” noise of the internal contactor switching
on.
o Check that there is voltage at the Power Terminals with a voltmeter.
3.2 Powering the System Off
• Long-press the Power switch for 3 seconds.
o The switch will cease to illuminate once power is disabled.
o You may notice an audible “thunk” noise of the internal contactor switching
off.
o Check that there is 0V at the output terminals with a voltmeter.
3.3 Charging
• The charging device(s) connected to the Lithium Battery System must be
programmed as per Table 1.
• Charging may be performed at any time the system is powered On.
o NOTE – The Lithium Battery System will disconnect power if the voltage,
amperage, or temperature limits are exceeded during charging.
o Only use a Lithionics Battery approved charging source. Please contact
Lithionics Battery for charger approval.
3.4 Initial Charging Cycle
• The initial charging cycle is required as it calibrates the NeverDie BMS to
the Battery Module(s) for accurate State of Charge percentage (SoC)
monitoring.
• During the initial charging cycle, the system must reach a voltage level
that is equal to the Standard Full Charging Voltage indicated in Table 1.
• Enable the charging device(s) so that they may complete a charge cycle. It
is recommended to not have any discharge loads active during the initial
charging cycle, especially towards the end of charging.
3.5 Discharging
• Discharging may be performed at any time the system is powered On.
o NOTE – The Lithium Battery System will disconnect power if the voltage,
amperage, or temperature limits are exceeded during discharging.
• The NeverDie feature allows the system to have a “reserve” amount of energy
left in the battery. Once the system is discharged to 12.0V or 10% State of
Charge (SoC), whichever comes first, power will be disabled to leave a
“reserve” amount of energy still left in the battery.
• To enable the remaining reserve energy of the system, short-press the Power
switch for 1 second.
o NOTE – Once the reserve range is enabled the battery should be charged as
soon as possible.
o WARNING – If the reserve energy is used and the battery module is left in a deeply discharged state without immediate charging, the battery module will become permanently damaged.
3.6 System Storage Procedure
- Storing your battery at the correct specifications is important as it keeps the battery in the healthiest state possible for the fastest deployment when needed.
- If the Lithium Battery System will not be in use for greater than 2 weeks, it is recommended to enable system storage.
- Storage mode is simply an appropriately charged system with the BMS in the Powered Off state.
- To enable System Storage:
o Perform a full charge cycle, ensure that the System voltage reaches the Standard Full Charging Voltage indicated in Table 1.
o Power off the System, long-press the Power switch for 3 seconds. Check that the switch is no longer illuminated. Check that there is 0V at the Power Terminals with a voltmeter.
Table 3
Storage conditions < 3 months:
1. Fully charge the battery.
2. Turn the battery OFF by the Power/Reset switch.
3. Store the battery in an environment according to the specifications shown
above.
Storage conditions > 3 months:
1. Reduce the battery SOC to 3.3V/cell which is 50% ±10% SOC. NOTE – See
table 4 below for total voltage calculation.
2. Turn the battery OFF via the Power/Reset switch.
3. Store the battery in an environment according to the specifications shown
in table 3 above.
4. Every 6 months charge the battery to 100% SOC, then discharge the battery
to LVC, then charge it to 50% ±10% SOC.
Table 4
NOTE – For further system installation and operation please refer to the Advanced Series User Guide available at: http://www.lithionicsbattery.com /user-guides/
Figure 1: BMS Power Terminals Hardware
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