® TROJAN GC2 48V LITHIUM-ION BATTERY USER’S GUIDE © 2022, Trojan Battery Company, LLC
CONGRATULATIONS on your purchase from Trojan Battery Company, LLC (“Trojan”), manufacturers of the world’s most trusted batteries. GC2 Lithium-Ion batteries are engineered for safety and performance—delivering faster charge times and longer distances with virtually zero required maintenance. It’s the next innovation in battery power backed by 100 years of expertise. We’re proud to continue our tradition of delivering clean, long-lasting and reliable batteries to power your world.
THIS USER’S GUIDE was created by Trojan’s application engineers and contains vital information regarding proper care and maintenance of your new battery. Please read through this User’s Guide carefully and completely before using your battery. It will help you achieve optimum performance and long life from your new investment.
CONTENTS 4 PAGE NUMBER 1 YOUR TROJAN LITHIUM-ION BATTERY 5 2 SAFETY 6 3 EQUIPMENT NEEDED 7 4 BATTERY INSTALLATION 7 5 PREVENTIVE MAINTENANCE 12 6 CHARGING 13 7 STORAGE AND SHIPPING 15 8 MAXIMIZING THE PERFORMANCE OF YOUR BATTERY 15 9 WHAT TO EXPECT FROM YOUR TROJAN LITHIUM-ION BATTERY 15 10 ELECTRICAL SPECIFICATIONS 16 11 BATTERY RECYCLING 17 12 BATTERY ABBREVIATIONS 17 T R O J A N B A T T E R Y
1 YOUR TROJAN LITHIUM-ION BATTERY The TR GC2-48-G battery is a deep-cycle lithium-ion battery specifically designed for use in golf carts and similar personal transportation vehicles with 48V battery packs. Key attributes of the battery include: î Case size: BCI Group GC2 î Nominal Voltage: 51.2V î Capacity*: 30Ah î Terminal configuration: M8-1.25 threaded studs î Communication Port: CAN Bus SAE J1939 B C D A E F F A. Status Button B. Negative Terminal (M8 size) C. Battery Status Indicators (SOC) D.
2 SAFETY ALWAYS NEVER Always wear proper personal protective equipment (PPE) (eye protection and gloves). Never wear jewelry or other metal objects when working on or around batteries. Always use insulated tools when working on batteries. Never place objects on top of batteries. Always check connections for proper torque. Never attempt to charge a battery when the temperature is below 32°F (0°C) or above 113°F (45°C). Always keep sparks and flames away from batteries.
DANGER! LITHIUM-ION BATTERIES, INCLUDING THE TROJAN® GC2 48V LITHIUM-ION BATTERY, WEIGH SUBSTANTIALLY LESS THAN LEAD-ACID BATTERIES OF COMPARABLE CAPACITY. MANY TYPES OF EQUIPMENT ARE DESIGNED TO UTILIZE THE WEIGHT OF LEAD-ACID BATTERIES TO ACHIEVE THE MANUFACTURER’S INTENDED WEIGHT DISTRIBUTION. IF GC2 BATTERIES ARE INSTALLED AS REPLACEMENT BATTERIES IN EQUIPMENT DESIGNED TO USE LEAD-ACID BATTERIES AS BALLAST, THE WEIGHT DISTRIBUTION OF THE EQUIPMENT COULD BE IMPACTED.
4.1 INSPECTION AND 12V ACCESSORIES (CONTINUED) To prevent damage to 12V accessories in the cart, first verify the voltage requirement of accessories like lights or others items in the vehicle. Then, if needed, the installer can use a voltage reducer to reduce the 48V battery voltage to 12V or as required. To ensure you install your batteries properly and safely, please use the following guidelines. 4.2 TERMINALS AND TORQUE VALUES Both the positive and negative terminals of the battery are M8-1.
4.5 CONNECTING BATTERIES IN BANKS You can increase the cart driving range and battery power capability by connecting multiple batteries together in parallel electrically as shown in Table 2. WARNING! SHOCK HAZARD; RISK OF FIRE – THE TR GC2-48-G IS INTENDED FOR USE IN 48VDC APPLICATIONS ONLY. ATTEMPTING TO USE THIS BATTERY IN HIGHER VOLTAGE SYSTEMS OR CONNECTING IN SERIES MAY BYPASS INTERNAL BATTERY SAFETY FEATURES AND CREATE A HAZARDOUS SITUATION.
4.8 BATTERY ENVIRONMENT Batteries should be stored and installed in a clean, cool and dry place, keeping water, oil and dirt away from the batteries. If any of these materials are allowed to accumulate on the batteries, tracking and current leakage can occur, resulting in self-discharge and possible short-circuits. Battery chargers should also be installed in well-ventilated, clean areas that are easily accessible. Relative humidity should be <90%. 4.
4.10 BATTERY START-UP (CONTINUED) Perform the following steps to turn the battery off and place it in storage mode: î Press and hold the status button. î All LEDs will turn on, then successively turn off, starting with the green LED. î Once all LEDs are off, wait another 2 seconds, then release the status button. If the battery has been intentionally turned off for shipping or because of a shutoff condition, you can restart it by the above steps.
4.12 CAN BUS The battery includes a Controller Area Network (CAN) bus communications interface. The two circular M8 DIN connectors are on the top of the battery to enable one battery to connect to another battery using CAN bus cables in a simple daisy chain wiring scheme. For normal battery operation, the CAN bus feature is not required.
6. CHARGING 6.1 BACKGROUND Trojan® GC2 48V Lithium-Ion batteries may be used in applications where lead-acid batteries have previously been utilized. Best charging results are obtained by using an appropriate Trojan-recommended charger and charging profile (algorithm). Refer to documentation on your specific charger for more information. 6.2 INITIAL CHARGING Unless your dealer has charged your battery prior to delivery, it will be received at partial state of charge.
CHARGING PROFILES Battery Voltage Recommended Charger Range 24V 27.6 - 28.8 VDC 36V 41.4 - 43.2 VDC 48V 55.2 - 57.6 VDC Chargers which charge outside of the recommended range will result in battery faults and lead to slower charging, reduced performance or cell imbalance. Failure to fully charge the battery using the recommended charging profile may lead to reduced lifespan. See section 6.4 for additional information. 6.
7. STORAGE AND SHIPPING A fully charged TR GC2-48-G can be safely stored in climate controlled conditions for up to one year (12 months) while in sleep mode. It is recommended that the battery state of charge is checked every 4-6 months. Temperatures exceeding 77ºF (25ºC) will cause the battery to self-discharge faster and will require more frequent checks. Never put the battery into prolonged storage if the state of charge is below 30%.
10. ELECTRICAL SPECIFICATIONS 10.1 CHARGING The charging and discharging current limits in the tables below are for one battery. Installing and electrically connecting batteries in parallel increases the current limits. For example, two batteries connected in parallel effectively doubles the current values in the tables below. Adding more batteries increases the driving range, current, and power capability. CHARGING INFORMATION Recommended Charging Voltage 55.2 to 57.6V Recommended Float Voltage 55.
AS NOTED IN SECTION 2: “SAFETY,” THE SYSTEM INSTALLER/USER ASSUMES ALL RESPONSIBILITY AND LIABILITY FOR ANY DAMAGES THAT MAY OCCUR DUE TO SUDDEN LOSS OF POWER. PROTECTIVE SHUTOFF AND RESTART CONDITIONS SHUTOFF RESTART Over Voltage Any cell voltage > 3.74V Battery voltage > 59.9V All cell voltages < 3.64V Battery voltage < 58.2V Load attached and discharging Low Voltage Any cell voltage < 2.53V Battery voltage < 40.5V All cell voltages > 2.63V Battery voltage > 42.
NOTES 18 T R O J A N B A T T E R Y
U S E R ’ S G U I D E 19
TROJAN BATTERY COMPANY would like to thank you for selecting our battery. With close to 100 years of experience, Trojan Battery is the world’s most trusted name in deep-cycle battery technology backed by our outstanding technical support. We look forward to serving your battery needs. TECHNICAL SUPPORT 800-423-6569 Ext. 3045 / +1-562-236-3045 technical@trojanbattery.com Do not mix with lead-acid batteries when recycling This publication is protected by copyright and all rights are reserved.