INSTALLATION AND OPERATION MANUAL BATTERY MODELS DLP-GC2-12V DLP-GC2-24V DLP-GC2-36V DLP-GC2-48V 1 805-0027 REV C
1. Audience, Messages, Warnings, General Safety, Personal Protective Equipment 1.1 Audience 1.2 Message 1.3 Warnings and General Safety 1.4 Personal Protective Equipment 2. Specifications 2.1 Electrical Specifications 2.2 Mechanical Specifications 2.3 Environmental Specifications 2.4 Protection Specifications 2.5 Internal Heating Specifications 2.6 Minimum Size Specifications for Battery System 2.7 Regulatory 3. Transportation 4. Handling 5. Features 5.1 Battery Fuse 5.2 PTFE Membrane Vent 5.
READ AND SAVE THESE INSTRUCTIONS 1. AUDIENCE, MESSAGES, WARNINGS, GENERAL SAFETY, PERSONAL PROTECTIVE EQUIPMENT 1.1 Audience Certain configuration, installations, service, and operating tasks should only be performed by qualified personnel in consultation with local authorities having jurisdiction and authorized dealers.
1.3 Warning and General Safety 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. Failure to follow these instructions may result in death or serious injury. WARNING CHEMICAL HAZARD: Do not touch the exposed contents of a Lithium cell. Failure to follow these instructions may result in death or serious injury.
• Do not short circuit a battery or allow metallic conductive objects to contact battery terminals. • Replace the battery only with another battery that has been qualified for the system. The use of an unqualified battery may present a risk of fire, explosion, leakage, or other hazards. • Avoid dropping the device or battery. If the device or battery is dropped, especially on a hard surface, and the user suspects damage, take it to a service center for inspection. 1.
2.2 Mechanical Specifications Table 2-2. DLP-GC2 Mechanical Specifications Mechanical Spec. DLP-GC2-12V DLP-GC2-24V Chemistry DLP-GC2-36V DLP-GC2-48V LiFePO4 Length 260 mm (10.2 in) Width 180 mm (7.1 in) Total Height 275 mm (10.8 in) 5/16 in Stud (Height 22 mm) 5/16 in Button Insert (Depth 18 mm) Terminal Terminal Torque 8 to 10 Nm (5.9 to 7.4 ft-lb). DO NOT EXCEED 10 Nm (7.4 ft-lb). Weight 14.0 kg (30.7 lb) 14.0 kg (30.7 lb) IP Rating 11.2 kg (24.7 lb) 14.0 kg (30.
Protection Spec.
2.5 Internal Heating Specifications Table 2-5. DLP-GC2 Internal Heating Specifications Internal Heating Spec. Heating Power DLP-GC2-12V DLP-GC2-24V DLP-GC2-36V DLP-GC2-48V 50 W 50 W 50 W 50 W Heating On Charge detected and < 0°C (32°F) Heating Off Temperature > 2°C (36°F) 2.6 Minimum Size Specifications for Battery Systems DLP batteries installed in parallel in a battery bank configuration will increase system capacity.
Table 2-6. DLP-GC2-12V - DC Capacity Values for Sample Battery Systems. Parallel System Peak Current Constant Discharge Constant Charge Energy/Usable Capacity Reserve Capacity at 25A 2 Batteries 720 A 400 A 240 A 3072 Wh 576 minutes 3 Batteries 1080 A 600 A 360 A 4608 Wh 864 minutes 4 Batteries 1440 A 800 A 480 A 6144 Wh 1152 minutes Table 2-7. DLP-GC2-24V - DC Capacity Values for Sample Battery Systems.
4. HANDLING Before handling: • Keep the battery away from sparks and flames • Disconnect the cables from the battery • Battery terminals must be protected from short-circuiting and touch • A battery handle must be used to lift the battery • Do not lift or carry the battery while it is in use or operation • Do not lift the battery by the attached battery cable 5.
seconds, and the key will arm the Remote Power-Off (RPO) Mode. When the battery is in RPO mode, the battery will shut down once the ON/OFF key is released. 5.4 At-a-glance LED WARNING ELECTRIC SHOCK AND FIRE HAZARD: Always assumed the battery main relay to be ON (Closed). Verify the terminal voltage with a voltmeter before battery handling and installation. Even if the At-A-Glance LED shows that it may be OFF. Failure to follow these instructions may result in death or serious injury.
5.6 Lifting Points The battery lifting points are designed to be used with a standard golf cart battery lifting strap. Lifting strap. 6. THEORY OF OPERATION 6.1 Ingress Protection IP67 Ingress protection rates the degree of protection provided by mechanical casings and electrical enclosures against intrusion, dust, accidental contact, and water under specified conditions.
The BMS will reconnect when recovery thresholds are met. If the BMS disconnects due to low voltage protection, the battery will have to be manually switched ON. If the system has a constant parasitic draw, a physical disconnect switch is recommended to reconnect the battery. There is a 120-second delay for the battery to be turned back on again after a load qualification fault.
Closed-loop communication with a Power Conversion device requires using a LYNK II or LYNK LITE Gateway Communication device available from Discover Battery. For details, please refer to the relevant LYNK Gateway Communication User Manual available at www.discoverbattery.com, or contact your Discover Battery provider for assistance. Refer to the appropriate Application Note available at www.discoverbattery.
A latching relay will engage the Remote Power Off (RPO) battery function (refer to Section 5.3 Battery ON/OFF Key). Setting the key to the ON position for 5 seconds will switch the battery ON engaging RPO Mode. Returning the key to the OFF position will release the battery from RPO Mode and switch the battery OFF. Momentary PIN 1 ON/OFF POS + Battery Terminal Latching for RPO PIN 1 ON/OFF POS + Battery Terminal Figure 4. Remote ON/OFF Operation with Battery Network. 7.
NOTICE For chargers or inverters with temperature compensated charging, disable this feature. NOTICE Do not use or install a battery temperature sensor. NOTE It is the responsibility of the installer to ensure that all applicable installation requirements and standards are met. 8.1 Tools • Insulated tools sized to match nuts, bolts, and cables in use • RMS type Voltmeter • Post cleaner and wire brush • Personal protective equipment 8.
The DC battery cables should meet the following requirements. 1. 2. 3. 4. Copper-stranded cable. DC cables must be stranded, copper, and must be rated 90°C (194°F) minimum. The cables must be terminated with lugs that fit the DC terminals. 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. Appropriate cable gauge.
Stud Connection Insert Connection 5/16-18 5/8'' Flange Bolt (Supplied with battery) 5/16"-18 Thread (Supplied with battery) Figure 5. Correct Terminal Installation. NOTICE Failure to torque up to specification may increase resistance and lower voltage, leading to burnout of the terminals and voiding the warranty. Exceeding 10 Nm (7.4 ft-lb) of torque will damage the terminal or may cause the battery casing to crack, and void the warranty.
6. 7. 8. 9. Torque all battery terminals to the recommended terminal torque of 8 to 10 Nm (5.9 to 7.4 ft-lb) to secure cable lugs. DO NOT EXCEED 10 Nm (7.4 ft-lb). Install T connector and attach Comm cable. Attach the other end of the Comm cable to a LYNK device. Refer to Section 8.8.2 Network Installation for complete instructions. Set the battery to ON.
Equipment must be installed in accordance with the standards set by the local authority having jurisdiction. 1. 2. 3. 4. 5. If the circuit of equipment that the batteries are installed in has a disconnect, open the disconnect to isolate the batteries. Ensure that all batteries are set to OFF. Ensure the cable connections are clean and serviceable. Install and secure new batteries. Be careful not to make contact between the terminals and any metal mounting, fixture, or body part.
8. Connect the charger positive ( + ) cable and charger negative ( - ) cable to the opposing ends of the parallel batteries. CHARGER (+) LOAD (+) LOAD (-) CHARGER (-) Figure 9. Charger Connections. 9. Torque all battery terminals to the recommended terminal torque of 8 to 10 Nm (5.9 to 7.4 ft-lb) to secure cable lugs. DO NOT EXCEED 10 Nm (7.4 ft-lb). 10. Install aT connector on each battery and interconnect each battery in a daisy chain with a Comm cable.
8.8 LYNK Network 8.8.1 Network Layout LYNK-enabled Device 1 LYNK-enabled Device 2 LYNK-enabled Device 3 Figure 10. Network Layout. 8.8.2 Network Installation Networking Guidelines: • Separate data and power cables. Allow for separation between data and power cables. Avoid data interference caused by running network cables bundled with power cables. • Allow for LYNK Network cable slack. Ensure that LYNK Network cables are slack and not in tension. • Isolate the LYNK Network.
3. 4. 5. Insert the male end of the cable into the female end of the 950-0038 DLP T Connector and vice versa. Repeat until all nodes have been attached. Network with other devices and accessories as needed. Figure 12. Network Installation. Figure 13. Complete Network Installation. 8.8.3 Testing and Verification of the LYNK Network Network verification must be completed with one of 950-0044 SOC GAUGE TYPE A, 950-0039 SOC GAUGE TYPE B, 950-0025 LYNK II, or 950-0040 LYNK LITE Communication Gateway.
9.2 State of Charge A voltage-based battery meter designed for lead-acid batteries will not provide an accurate State-of-Charge (SOC) for lithium batteries.The following devices are available from Discover and will provide an accurate state of charge: • SOC GAUGE TYPE A • SOC GAUGE TYPE B The following devices are available from Discover and will communicate an accurate state of charge to other devices: • LYNK II Communication Gateway • LYNK LITE Communication Gateway 9.
9.3.3 When to Charge the Battery • • • • • Opportunity charging is OK. Charging the battery after every use will not reduce its cycle life. Partial state of charge is OK. If the battery SOC is greater than 10% at the end of discharge, it does not require an immediate charge. Charge if below 10% SOC. If the battery has been discharged below 10% SOC it must be charged within 24 hours to avoid permanent damage to the battery.
NOTICE Temperature compensation must be disabled. 9.3.5 Charging with Alternators • • Not recommended. Due to the risk of overheating the alternator and BMS protection disconnecting the battery from the electrical system, using an alternator as a charge source without a DC-DC converter is not recommended. It is possible. Charging is possible with a DC-DC converter using a lithium charge profile that matches DLP charge specifications attached to the alternator.
NOTE Charging at 50% of nominal current or lower will extend battery cycle life. 9.4.1 Bulk Charge Bulk phase. The first phase of the charging process is the Bulk Charge, also referred to as the constant current phase. This is when the charger's maximum current is directed to the battery until the desired voltage is reached. The Bulk phase will recharge the battery to approximately 90-95% SOC.
11. REPLACING THE FUSE CAUTION ELECTRIC SHOCK: Do not touch the energized surfaces of any electrical component in the battery system. Before servicing the battery, follow all procedures to fully de-energize the battery system and use safe handling procedures when handling the battery. Failure to follow these instructions may result in injury. Table 11-1.
12. STORAGE Leaving the battery connected to a trickle load or power electronics will cause the battery to be discharged during storage. Without any load, the battery will self-discharge by approximately 3% per month while in storage. After storage, charge the battery to 100% SOC and perform at least one full discharge and charge cycle before returning the battery to service. 1. 2. 3. 4. Store at 95% SOC or greater.
14. TROUBLESHOOTING Data logs from each battery are required for accurate troubleshooting and any warranty claim. LYNK ACCESS Software for 64-bit Windows 10 will be required to download the data logs from each battery in the system via a USB connection to a LYNK Communication Gateway device networked to all batteries in the system. System owners are encouraged to install a LYNK Communication Gateway in their system and to install LYNK ACCESS software on a laptop to monitor and troubleshoot their system.
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