Lithionics Battery GTX12V630A NeverDie Compact Series 200 Internal BMS

Safety

• All electrical work shall be performed in accordance with local and national electrical codes.
• Assume that voltage is present at the battery terminals, use insulated tools and gloves while working on the system.
• Always turn OFF equipment connected to the battery in addition to turning OFF the Power button on the battery to isolate it from other electrical circuits before performing any repairs, maintenance, or diagnosis on the system.
• Always use proper wire sizes to connect the system to inverters, chargers, or other equipment.
• Always use crimped connections to connect to the battery terminals.
•  Read and follow the inverter, charger, or other equipment manufacturers safety precautions prior to connecting the battery to that equipment.
• Always use charging equipment compatible with Lithium Iron Phosphate battery chemistry. See battery charging section below.

Overview

This Guide is intended to be used by qualified individuals in the installation of the GTX12V630A-E2112-CS200-UL battery system.

System Components

Components

• GTX12V630A-E2112-CS200-UL Battery
• Accessory Harness (#75-H1FCR-CS2-UL)
• DC Circuit Breaker (Sensata #JLE-1-41340-250)
• Protective DC Terminal Covers (Red & Black, not shown)
• Two Sets of M8x12x1.25mm Bolts and Lock Washers for the Terminals

108-132in-lbs (12.2 – 14.9N-m)
D| Vent| Pressure Balancing Vent
E| Power Button| Power Button with Status Light
F| Negative Terminal| Brass, Nickel Plated, M8-1.25 Thread, Torque to 108-132in-lbs (12.2 – 14.9N-m)
G| DC Circuit Breaker| Auxiliary DC Circuit Breaker for UL Compliance
H| Accessory Harness| Enables Integration of FCC and Remote Power Button

DC Circuit Breaker

The Auxiliary DC Breaker is one of the components required that enables the system to be a UL1973 Listed system. UL1973 Listing represents a high degree of safety tested by Underwriter Laboratories.
The battery operates by using the Auxiliary DC Breaker as a redundant disconnect device if the battery must be isolated from its loads. The Auxiliary DC Breaker replaces the need for a fuse and serves as a manual disconnect for storage and maintenance via its toggle switch.
The required and included DC breaker model is the Sensata Circuit Breaker

JLE-1-41340-250. The 2 control wires for this feature are wired via the

battery accessory connector.

Accessory Harness

The Accessory Harness connects to the battery and is used to access the BMS’s ported features. This allows
implementation of the features shown below.

System Specifications

Notes for Table 1:

Recommended Charging

Voltage

| 14.4V
Maximum Charging

Voltage

| 14.8V @ 200A
Over-discharge Voltage

Protection

| 10.0V @ 230A
Standard Charging

Current

| 150A
Maximum Charging

Current

| 200A
Charge Termination

Current

| 10A
Standard Discharging

Current/Load

| 150A
Maximum Discharge

Current/Load

| 230A
System Impedance at

Terminals

| ≤ 2.20mΩ
Ibf Bolted Fault Current

at Nominal Voltage (N2)

| 5818A
Maximum Charging

Temperature Range (N1)

| 32 to 131°F (0 to 55°C)
Maximum Discharging

Temperature Range (N1)

| -4 to 131°F (-20 to 55°C)
Battery Dimensions| 20.3″ x 12.3″ x 10.6″ (516 x 312 x 269mm)
Battery Weight| 128lb (58.0kg)

(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) “Bolted Fault Current” per NFPA-70E. See section 1.2 for details.

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.
  • 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.
  • Table 3 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 3

Hazard/risk classification as per NFPA 70E-2000

Tarc= 80mS circuit breaker clearing time|

Configuration

|

Vsys

| Impedance

mΩ

|

Ibf, calc.

|

Iarc

|

IEm cal/cm^2

| 3x IEm

cal/cm^ 2

| Distance where IEm=1.2 (Arc

Boundary), inches.

| Hazard level
---|---|---|---|---|---|---|---|---|---
GTX12V630A-E2112-CS200-UL| 12.8| 2.20| 5818| 2909| 0.360| 1.079| 9| 0

Manufacturing Date Code Format

•  MMDDYYYY001
  •  MM: Month of Manufacture
  •  DD: Day of that Month
  •  YYYY: Year of Manufacture
  •  001: Sequence of Battery Produced on That Day
• Example: 01012020001 = manufactured on January 1, 2020 and it was the first battery produced on that day.

System Installation

• The battery system must be operated with the included circuit breaker. The model listed in this document was evaluated and tested by Underwriter Laboratories. The circuit breaker is to be provided downstream of the battery on the positive side before the load or supply in all cases. The use of any other circuit breaker voids the UL Listing of the model.
•  The circuit breaker must be installed into an enclosure with a NEMA Type 4 rating or better, see Reference 1 and Figure 2 below.
•  The circuit breaker must NOT be installed with the handle/lever facing up or down, see the Permitted Orientations in Figure 6 below.
• Use 10-32 screws to mount the circuit breaker into the enclosure. The screw depth into the circuit breaker (not including the enclosure material thickness) must be within .230 to .315 max. Torque the 10/32 screws between 10-12 Inch Pounds.

Battery Environment and Mounting orientation

• The Battery needs to 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.
• Mount the Battery in an upright position, i.e. black lid faces up.
  • Other orientations are NOT permitted and will void the warranty.

Battery Power Terminals (see Figure 5 for diagram)

• Connect the Battery Negative Terminal to your DC negative bus.
  •  Use 2/0 wire and 2/0 3/8” stud ring terminals.
  •  The battery negative wire is recommended to be 3ft or less.
  • Torque the battery negative power terminal to 108 – 132in-lbs (12.2 – 14.9N-m).
• Connect the Battery Positive Terminal to either one of the power terminals on the circuit breaker (Figure 3, A).
  •  Use 2/0 wire and 2/0 3/8” stud ring terminals.
  •  The battery positive wire (between battery and circuit breaker) is recommended to be 3ft or less.
  • Torque the battery positive power terminal to 108 – 132in-lbs (12.2 – 14.9N-m).
  • Torque the 3/8” nuts on the circuit breaker to 250-260 inch pounds.
  • Never stack ring terminals.
  • Never place the stainless-steel washer or lock-washer between the conductive power terminal and ring terminal lug (see Figure 4 on Page 12).
• Connect the opposite end circuit breaker power terminal to your DC positive bus.
  •  Use 2/0 wire and 2/0 3/8” stud ring terminals.
  •  The battery positive and negative wires are recommended to be 3ft or less.

Accessory Harness

• Connect the 2x #10 stud ring terminals to the Circuit Breaker (Figure 3, B).
  • Torque the 2x 5/16” nuts to 30-40 inch pounds.
•  Connect the Accessory Harness to the Accessory Connector on the Battery (Figure 1, B).

Initial Charge Cycle

• Initially the system must be FULLY charged once to calibrate the Battery. Please read and follow the next section to perform this.

System Operation

Powering the System On

• Ensure that the circuit breaker lever is in the ON position.
• Short-press the Power switch for 1 second.
  • The switch will illuminate once power is enabled.
  •  Check that there is voltage at the Power Terminals with a voltmeter.

Powering the System Off

• Long-press the Power switch for 3 seconds.
  • The switch will cease to illuminate once power is disabled.
  •  Check that there is 0V at the output terminals with a voltmeter.
  •   NOTE: During normal operation, the circuit breaker can be left in the ON position when powering off the battery. For maintenance/storage turn the circuit breaker OFF.

 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.
  • NOTE – The Battery will disconnect power if the voltage, amperage, or temperature limits are exceeded during charging.
  •  Only use a Lithionics Battery approved charging source. Please contact Lithionics Battery for charger approval.

Initial Charging Cycle

• The initial charging cycle is required as it calibrates the Battery 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.

Discharging

•  Discharging may be performed at any time the system is powered On.
  •   NOTE – The Battery 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.
  • NOTE – Once the reserve range is enabled the battery should be charged as soon as possible.
  •   WARNING – If the reserve energy is used and the battery is left in a deeply discharged state without immediate charging, the battery will become permanently damaged.

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 a fully charged system in the Powered Off state.
• To enable System Storage:
  • Perform a full charge cycle, ensure that the System voltage reaches the Standard Full Charging Voltage indicated in Table 1.
  • 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.

Storage Temperature & Humidity Range| < 1 Month| -4~95°F (-20~35°C), 45~75%RH
---|---|---

< 3 Months

|

14~86°F (-10~30°C), 45~75%RH

Long Term Storage

| If the battery needs to be stored for > 3 months the voltage should be 13.2V (50%SOC), and stored at the recommended storage specifications shown above. Additionally, the battery

needs at least one charge & discharge cycle every six months.

Self-discharge rate|

≤3% per month

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 13.2V which is 50% ±10% SOC.
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.

NOTE – For further system installation and operation please refer to the Advanced Series User Guide available at: http://www.lithionicsbattery.com /user-guides/

Permitted DC Circuit Breaker Orientations:

NON-Permitted DC Circuit Breaker Orientations:

Contact Information
For technical or warranty support please first contact the dealer where the system was purchased.
Additionally, for factory support please send an email with your battery’s serial number to Support@LithionicsBattery.com.

References

• Lithionics Battery
• User Guides | Lithionics Battery

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