Azoteq AZBAT24100A Rechargeable Lithium Iron Phosphate Battery User Manual

Azoteq AZBAT24100A Rechargeable Lithium Iron Phosphate Battery

This product manual provides further detail on the AZBAT24100A LiFePO4 battery. Please familiarise yourself with the operating instructions in this document before operating the battery.

Revision History

Disclaimer

This product manual provides further detail on the AZBAT24100A LiFePO4 battery. Please read the operating instructions in this document before using the battery. Also familiarise yourself with the warranty conditions of this product to ensure it is operated within stipulated requirements.
Please complete the battery registration from the Azoteq website to activate your warranty. (https://www.azoteq.com/warranty/)

Overview

The AZBAT24100A incorporates 8 3.2V (8S1P configuration); 100Ah Lithium-Iron Phosphate (LiFePO4) cells with a recommended 0.3C charge and 0.5C discharge current rating. The battery incorporates a battery management system (BMS) which provides the following functionality:

• Protection
  • Cell overcharge and discharge
  • Short circuit
  • Over and under temperature
  • Total over- and under-voltage
• Control
  Cell balancing

The BMS has been tested with leading inverters, including Synapse, Voltronic and GroWatt and has been UN38.3 and IEC 62619 certified
The battery is mounted in a durable steel casing with spring loaded handles for easy handling. It features a LCD display* with an display on/off button. The battery is fitted with M8 terminal connections for sturdy connection to the battery cables.

*The SoC displayed on the LCD is only an estimation which is based on the battery pack voltage. This will be most accurate when the battery is in steady-state no-load.

Safety Precautions

The AZBAT24100A Lithium Ion battery operates at hazardous low DC voltage, please be aware of potential arc and shock hazards and handle with caution. Please make use of a qualified installer and have them familiarize themselves with this product manual.
Failure to do so or to disregard any of the instructions or warnings in this document can result in electrical shock, serious injury, or death and might damage battery, potentially rendering it inoperable.
Please follow the following safety precautions when dealing with the battery:

1. Do not operate the battery in temperatures outside the range of 0°C to 45°C.

2. Do not open the battery, disassemble, or attempt to repair it as this will void the warranty.

3. Do not remove or tamper with the QC sticker or any other labels on the battery as this will void the warranty.

4. Do not connect the battery terminals directly to PV wiring.

5. Do not connect multiple batteries in series.

6. Do not use different battery make, models, manufacturers or products in parallel or series.
   DO NOT mix Azoteq Battery models (AZBAT A, B or C)

7. In the event of a fire, DO NOT use water to extinguish the fire.

8. Take precaution to prevent the battery terminals shorting due to unforeseen events.

9. The batteries should not be subjected to mechanical shock or vibration.

10. Batteries should be recharged within 12 hours after being fully discharged.

11.  The supplier does not take any responsibility for direct or indirect damages caused by incorrect use or negligence. Please refer to the terms and conditions of sale and the warranty document.

Product Information

Production dimensions

Parameters

Table 1: AZBAT24100A electrical and environmental parameters

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GENERAL

| Model| AZBAT24100A|
---|---|---|---
Battery Type| LiFePO4|
Nominal Voltage| 24V|
Nominal Battery Capacity| 100Ah| ±3%
Nominal Capacity| 2.56kW| @ 100% DoD
Cycle life @ 80% DoD| 3 000| @ 25°C
Cycle life @ 100% DoD| 2000| @ 25°C
Recommended DoD| 80%|
Operating Temperature| 0-45°C|
Dimensions [mm]| 185(W) x 480(L) x 180(H)|
Weight| 25kg| ±1.5 kg
IP Rating| 20|
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Storage conditions

| -25°C to 60°C (less than 6 months)

0°C to 25°C (12 months)

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25-85% relative humidity

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CHARGE AND DISCHARGE

| Charge Voltage| 28.0V|
Float / Sustain Voltage| 27.2V|
Standard Charge| 30A (0.3C)|
Maximum Charge| 50A (0.5C)|
Standard discharge| 50A (0.5C)|
Maximum Discharge| 95A (0.95C)|
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Battery Management System

(BMS)

| Communication interface| None|
Parallel| 4| Max
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Series

| __

2

| Max

*External Battery balancer required

Protection – short circuit| Short circuit protection delay| 300µs
 | Short circuit recovery condition| Remove load or charger
Protection – voltage| Low voltage shutdown| 20V (2.5V per cell)
 | Low voltage release / restart| 24.0V (3.0V per cell)
 | Over-discharge protection delay| 1s
 | High voltage shutdown| 29.6V (3.7V per cell)
 | High voltage release / restart| 27.2V (3.4V per cell)
 | Over charge protection delay| 1s
 |  | Over discharge recovery condition| Manual, see section 6
---|---|---|---
Protection – over current| Over-current protection current| 110A
 | Over discharge cut-off current delay| 5s
 | Over discharge recovery condition| Automatic, after 1 minute or once charger is connected
Protection – temperature| Charging over temperature| 55°C
 | Recovery of overcharge temperature| 50°C
 | Charging under temperature| 0°C
 | Re-charge under temperature recovery| 5°C
 | Discharge over temperature| 65°C
 | Discharge over temperature recovery| 55°C
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Balance

| __

Voltage

| >3.4V and 30mV (while charging)
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CERTIFICATION

|  | IEC 62619|
 | UN38.3|

Battery interface
This section details the front panel interface of the battery.

Table 2 describes the front panel functional interface.

Table 2: AZBAT24100A Interface description

with a terminal cover for external connections.
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2

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LCD Display

| Displays the battery voltage and estimated State of Charge based on the battery voltage with no load. Please refer to the Estimated SoC vs

Voltage sticker on the front of the battery to validate the state of charge.

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3

| __

LCD Display Button

| Switches power to the LCD display ON and OFF.

Note that this does not power down the battery terminals.

4| Positive battery terminals| The battery has a single positive M8 terminal with a terminal cover for external connections.
5| Specification Sticker| Battery specifications and limitations
6| Handle| Spring loaded aluminum handles for improved handling and transport.

Installation

Please read the installation manual of the inverter in conjunction with this installation manual. All wiring, cable sizing and installation requirements must be in regulation with the specified installation requirements as governed by the relevant authority in the country of installation. Please ensure that a qualified installer familiar with the installation requirements is used for the installation.
The installation details must be sent to Azoteq for the warranty to apply along with an electrical Certificate of Compliance (CoC). Please complete the warranty document from the Azoteq website (https://www.azoteq.com/warranty/).

Hardware required
The following items are required to install the battery. Please note these items are not included with the battery.

1. Positive (red) and Negative (black) power cables with M8 lugs on the battery side and as per requirements on the inverter side.
2. Recommended cable thickness:
3. ≥35mm2 for 3-5kW installations
4. ≥50mm2 for 8kW installations
5. DC overcurrent protection (fuse) and isolator for additional protection and compliance.
6.  It is recommended to install the batteries in a cool and dry environment.
7. It is not recommended to place the batteries directly on the ground.
8. Do not operate the batteries in areas with temperatures outside the range of 0°C to 45°C

Installation Location
Please note the requirements for the installation location:

1. The area needs to be dry.

2. Relative humidity < 85%.

3. Minimal dust.

4. Ambient temperature between 0-40°C, ideally ~25°C.
   a. Frequent exposure to high temperatures will shorten the life of the battery.

5. No flammable or explosive materials may be near the batteries.

Installation Procedure

Note that the battery terminals are live by default and care should be taken when handling them. The

1. Install the battery in the desired location, preferably inside a cabinet.
   Please make sure the cabinet can support the weight of the battery / batteries.

2. Connect the power cables between the batteries (when using multiple batteries refer to section 5.4)

3. Red and black cables as depicted in Figure 5.

4. Please ensure the power cables are properly torqued to minimum 10N.m for the M8 terminal.

5. Connect the cables to the inverter via the DC fuse and breaker.
   Please ensure the polarity of the connection between the inverter and the batteries are correct.

6.  Once the above has been done, please verify all the connections to ensure everything is as specified.

7. Follow the instructions as specified in the installer manual before switching the inverter ON.
   The inverter should automatically detect the battery and start-up.

8. Configure the inverter settings as follows:

9. Charge Voltage : 28.0 V

10. Float Voltage : 27.2 V

11. Charge Current : 30 A (per battery connected)

12. Equalization: Disabled

Parallel connection
The AZBAT24100A battery can be used in parallel with batteries of the same model, capacity, and manufacturer.

1. DO NOT connect different batteries in parallel.

2. A maximum of 4 batteries connected in parallel is allowed.

3. When using more than one battery, ensure that all battery voltages are fairly similar or within 0.2V of each other.
   A large voltage difference will cause an over-current event due to the inrush current flowing from one battery to the other.

4. Ensure that the batteries are wired in a diagonal fashion, as shown in Figure 3, with the positive connection from the inverter first connected to the first battery and the negative connection from the inverter connected first to the last battery

Series connection
The AZBAT24100A battery can be used in series with batteries of the same model, capacity and manufacturer.

1. Ensure that both batteries are fully charged and all cells are balanced before connecting them in series.
2. DO NOT connect batteries in series without a battery balancer module.
3. This is due to the protection nature of the BMS used in Li-ion batteries.
4. If a single battery reaches full charge it will prevent the other battery that it is connected to, in series, from continuing to charge.
5. If a single battery reaches full discharge it will prevent the other battery that it is connected to, in series, from discharging further.

Troubleshooting

Battery start-up procedure
In some cases the battery will go into a safe mode in the event of a short circuit or over-discharge.
The Short Circuit Protection (SCP) circuit in the battery can potentially be activated when connected to an inverter or parallel battery for the first time. Since some inverters have large input capacitors, there is a significant inrush current from the battery to the capacitors inside the inverter which activates the SCP on the battery.
The BMS inside the battery switches off output voltage resulting in an open- circuit. This is visually evident when the display on the battery does not switch on. This can be confirmed by connecting a multi-meter on the terminals of the battery and measuring the voltage which should always be larger than 24Vdc.
In the case of a shut-down the battery needs to be manually reset by following the procedure below:

1. Connect AC power to the inverter after following the procedures as recommended in the inverter installation manual. With some inverters models the battery will automatically reset once power is applied to the inverter.
2. If the battery did not switch ON, disconnect the AC power to the inverter.
3. Use an isolated power supply or a battery charger with an output voltage of 24-29V and a current output larger 1A but less than 10A.
4. Apply the voltage to the terminals of the battery for a few seconds until the voltage on the battery is >24V after which the external voltage source can be removed.
5. The input capacitors on the inverter will remain charged while the battery is connected to the inverter

Battery pack voltage is low or zero

1. If the battery is fully charged it will open-circuit to prevent overcharging.
   Applying a load will reset the protection feature.

2. If the battery has been in storage for a long period or over-discharged it will open-circuit to prevent further discharging.
   Follow the battery start-up procedure in Section 7.1 to re-energize the battery.

3. Unstable battery voltage or irregular charging.
   Make sure that there is proper connections on the battery terminals.

4. Battery voltage between 0V and 16V.

5. The battery has been over-discharged and may have lost some capacity. Apply a charging voltage with a maximum of 10A charging current to re-energize the battery cells.

6. If the battery voltage reaches 24V, increase the charging current and continue to charge to full capacity.

7. Otherwise, immediately stop charging the battery as it has failed and will no longer hold charge. Continuing to charge such a battery will result in over-heating and eventually cause a fire or cell combustion.

Insufficient Energy Capacity
Cycle the battery 4 – 5 times by discharging to 80% DoD and then charging with a low charging current between 2A to 10A.

Precautions

Storage

• If the battery is stored for more than 3 months, it should be stored under environmentally controlled conditions:
  • Ambient temperature: 25 ±3°C
  • Humidity: 25-85% RH
  • Air pressure: 86kPa-106kPa
• Do not store the battery in direct sunlight.
• The battery should be charged and discharged every 6 months.
• Battery storage SOC should be >50%

Safety

Before use

1. Inspect the battery to ensure that it is not damaged. If damaged, please inform the supplier.
2. Ensure that the installation is done by a qualified installer.
3. The installation needs to be done in compliance with the specified regulatory standards as required by governmental and local authorities.
4. Keep in mind that the battery terminals are live.
5. Ensure that the inverter is not powered from AC mains while connecting the battery.
6. It is advised to use suitable protection between the battery and the inverter.
7. Make sure the polarity (positive and negative) connections between the batteries (parallel use) and between the master/main battery and the inverter is correct.
8. Verify that the inverter parameters match that of the battery.
9. The battery should be kept away from heat, fire and water.
10. Double check all connections before switching the breaker/isolator switch to the ON position.

During use

1. In the event of altering or moving the installation, make sure that the breaker switch is in the OFF position and the inverter is switched OFF.
2. Do not use this battery with that of another supplier or a different type of battery.
3. Do not use the batteries with a faulty or incompatible inverter.
4. Do not exceed the charging current and discharging current parameters of the battery.
5. Overcharging or over-discharging will shorten the life-span of the battery and may cause the battery pack fail or overheat and catch fire.

Other

• Do not open the battery, disassemble, or attempt to repair it as this will void the warranty.
• 3. Do not remove or tamper with the QC sticker or any other labels on the battery as this will void the warranty.
• Take precaution to prevent the battery terminals shorting due to unforeseen events.
• The batteries should not be subjected to mechanical shock or vibration.
• Batteries should be recharged within 12 hours after being fully discharged.
• The supplier does not take any responsibility for direct or indirect damages caused by incorrect use or negligence. Please refer to the terms and conditions of sale and the warranty document.

Emergency conditions

Please refer the material safety datasheet (MSDS) for the batteries on the Azoteq website.

Leaking cells

1. In the event of a cell leaking liquid or gas, take caution to prevent any contact with the skin and eyes and inhaling the gas.
2. Inhalation: Evacuate the contaminated area immediately and seek medical attention.
3. Contact skin: Wash the affected area thoroughly with soap and water and seek medical attention.
4. Contact with eyes: Rinse your eyes properly with water and seek medical attention.

Fire

2. In the unlikely event of a fire, a dry chemical type extinguisher such as CO2 extinguisher will work effectively. Do not use water to extinguish the fire.

Other

3. Wet batteries
4. If the batteries are wet, please switch the energy storage system OFF immediately.
5. Please contact the supplier for further technical support.
6. Damaged batteries
7. If the batteries seem to be physically damaged, please do not switch them ON.
8. Damaged batteries can be dangerous and need to be handled with care.
9. Please contact the supplier for further technical support.
    | USA| Asia| South Africa
   ---|---|---|---
   Physical Address| 6507 Jester Blvd Bldg 5, suite 510G Austin

TX 78750 USA

| Rm 1227, Glittery City Shennan Rd

Futian District Shenzhen, 518033 China

| 1 Bergsig Avenue Paarl

7646

South Africa

Postal Address| 6507 Jester Blvd Bldg 5, suite 510G Austin

TX 78750 USA

| Rm 1227, Glittery City Shennan Rd

Futian District Shenzhen, 518033 China

| PO Box 3534

Paarl 7620

South Africa

Tel| +1 512 538 1995| +86 755 8303 5294

ext 808

| +27 21 863 0033
Fax| +1 512 672 8442|  | +27 21 863 1512
Email| info@azoteq.com| info@azoteq.com| info@azoteq.com

Visit www.azoteq.com
for a list of distributors and worldwide representation.

The following patents relate to the device or usage of the device: US 6,249,089; US 6,952,084; US 6,984,900; US 7,084,526; US 7,084,531; US 8,395,395; US 8,531,120; US 8,659,306; US 8,823,273; US 9,209,803; US 9,360,510; US 9,496,793; US 9,709,614; EP 2,351,220; EP 2,559,164; EP 2,748,927; EP 2,846,465; HK 1,157,080; SA 2001/2151; SA 2006/05363; SA 2014/01541; SA 2015/023634; SA 2017/02224;

AirButton®, Azoteq®, Crystal Driver, IQ Switch®, ProxSense®, ProxFusion®, LightSense™, SwipeSwitch™, and the trademarks of Azoteq.

The information in this Datasheet is believed to be accurate at the time of publication. Azoteq uses reasonable effort to maintain the information up-to- date and accurate, but does not warrant the accuracy, completeness or reliability of the information contained herein. All content and information are provided on an “as is” basis only, without any representations or warranties, express or implied, of any kind, including representations about the suitability of these products or information for any purpose. Azoteq disclaims all warranties and conditions with regard to these products and information, including but not limited to all implied warranties and conditions of merchantability, fitness for a particular purpose, title and non-infringement of any third party intellectual property rights. Azoteq assumes no liability for any damages or injury arising from any use of the information or the product or caused by, without limitation, failure of performance, error, omission, interruption, defect, delay in operation or transmission, even if Azoteq has been advised of the possibility of such damages.

The applications mentioned herein are used solely for the purpose of illustration and Azoteq makes no warranty or representation that such applications will be suitable without further modification, nor recommends the use of its products for application that may present a risk to human life due to malfunction or otherwise. Azoteq products are not authorized for use as critical components in life support devices or systems. No licenses to patents are granted, implicitly, express or implied, by estoppel or otherwise, under any intellectual property rights. In the event that any of the abovementioned limitations or exclusions does not apply, it is agreed that Azoteq’s total liability for all losses, damages and causes of action (in contract, tort (including without limitation, negligence) or otherwise) will not exceed the amount already paid by the customer for the products. Azoteq reserves the right to alter its products, to make corrections, deletions, modifications, enhancements, improvements and other changes to the content and information, its products, programs and services at any time or to move or discontinue any contents, products, programs or services without prior notification. For the most up-to-date information and binding Terms and Conditions please refer to www.azoteq.com.

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info@azoteq.com

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