8 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 T R P N M L K J H G F PREMIUM SERIES E D C INSTALLATION AND OPERATION MANUAL B UNLESS OTHERWISE SPECIFIED: DIMENSIONS ARE IN MILLIMETERS SURFACE FINISH: TOLERANCES: LINEAR: ANGULAR: DEBURR AND BREAK SHARP EDGES FINISH: SIGNATURE NAME DATE DO NOT SCALE DRAWING REVISION TITLE: A DRAWN CHK'D APPV'D MFG MATERIAL: Q.A 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 WEIGHT: DWG NO.
1. Audience, Safety, Messages, and Warnings 1.1 Audience 1.2 Safety, Messages, and Warnings 2. Specifications 2.1 Electrical Specifications 2.2 Mechanical Specifications 2.3 Environmental Specifications 2.4 Protection Specifications 2.5 Specifications for System Sizing 2.6 Regulatory 3. Transportation 4. Handling 5. Design and Features 5.1 Battery Management System Protections 5.2 Battery Fuse 5.3 Battery Management System Low Power Hibernation 5.4 Battery Management System Bluetooth Communications 5.
1. AUDIENCE, SAFETY, MESSAGES AND WARNINGS 1.1 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 1.
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. WARNING 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.
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 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. 2.
2.2 Mechanical Specifications Table 2-2. DLB Mechanical Specifications Mechanical Spec. DLB-G24-12V DLB-G24-24V DLB-G24-36V Chemistry DLB-GC12-12V DLB-GC12-24V LiFePO4 Length 262 mm (10.3 in) Width 175 mm (6.9 in) 177 mm (7.0 in) Height 210 mm (8.3 in) 276 mm (10.8 in) Terminal 312 mm (12.2 in) 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) IP Rating 20kg (44.1lb) IP 67 Case Material UL94-VO PBT/PC 2.
Protection Spec. DLB-G24-12V DLB-G24-24V DLB-G24-36V DLB-GC12-12V DLB-GC12-24V > 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 Overcurrent Protection Recovery 20 seconds after the load or charge is removed. Over-temperature in Discharge Protection c Recovery c Cell temperature above 60°C (140°F). Cell temperature below 55°C (131°F) for 4 seconds. Under-temperature Discharge Protection c Cell temperature below -20°C (-4°F).
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 Constant Current Energy / Usable Capacity Reserve Capacity at 25A Table 2-8.
5. DESIGN AND FEATURES Item Description 8 1 The heat sink of the Battery Management System (BMS) 2 Battery terminal covers, positive cover (+/red), negative cover (-/black) 3 3 Battery negative ( - ) 5/16" terminal stud 5 4 Battery positive ( + )5/16" terminal stud 5 Handle 6 Fuse 7 Battery hold-down 8 PTFE membrane vent 2 1 6 4 7 7 Figure 1. Battery Features. 5.
NOTE Charge and discharge have different operating temperature limits. NOTE If the BMS disconnects responding to temperature or current limits, wait for the temperature or current to reach normal operating limits. 5.2 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.
5.6 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. 6. 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.
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. NOTE Warranty will be void if operated outside of these conditions. 6.3 DC Cables CAUTION FIRE HAZARD: Undersized cables can become hot and may potentially catch fire.
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. NOTE 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. 6.
6.6 Single Battery Installation Procedure 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. 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.
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. 2. Equal cable gauge.The interconnection cables should be the same gauge. Equal cable length.
Figure 5. Negative Parallel Connections. 6. Connect the load positive ( + ) cable and load negative ( - ) cable to the opposing ends of the parallel batteries. LOAD (+) LOAD (-) Figure 6. Load Connections. 7. Connect the charger positive ( + ) cable and charger negative ( - ) cable to the opposing ends of the parallel batteries. LOAD (+) CHARGER (+) LOAD (-) CHARGER (-) Figure 7. Charger Connections. 8. Torque all battery terminals to the recommended terminal torque of 8 to 10 Nm (5.9 to 7.
7. 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 warranty. 7.
measures current, rather than voltage, for lithium batteries. 7.4 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. NOTICE Always confirm that the charging device is incapable of producing transient spikes that exceed the published terminal voltage limits for the battery. NOTICE Never charge a visibly damaged or frozen battery.
For charging parameters refer to Table 2-1. DLB Electrical Specifications and Figure 8 DLB Charge Graph. 7.4.3 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.
Bulk Absorption Float 100% SOC U1 Max Bulk Vdc Absorption & Balancing I Max CURRENT I Min U2 Float Terminate at 2% - 3% of battery rated capacity 200 milliamps required for balancing current Figure 8. Charge Graph. 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. 7.5.1 Bulk Charge Bulk phase.
7.5.3 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 sulphate crystals that form on lead-acid plates over time. 7.5.
Table 10-1. DLB Fuse Specifications Discover Part Number 170-0035 170-0033 Fuse Rating 200A 75A 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).
1. 2. 3. 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. Check SOC every 6 months. Recharge the battery to above 95% SOC at least every 6 months. Proper storage temperature. Ensure storage is within the temperatures specified below.
NOTES 24
