Essential US 48V GC2 Manuel utilisateur

CONTENTS

1 BEFORE YOU START 4

1.1 SAFETY 4

1.2 EQUIPMENT NEEDED 4

1.3 SAFETY DATA SHEETS (MSDS) 5

2 BATTERY SPECIFICATIONS

OVERVIEW 6

3 BATTERY OPERATION 8

3.1 TURNING ON 8

3.2 TURNING OFF 8

3.3

ACTIVE MODE AND SOC DISPLAY 8

3.4 DISPLAY WHILE CHARGING 9

3.5 FAULT DISPLAY 9

3.5

FAULT TROUBLESHOOTING

4 INSTALLATION

4.1 CABLE SIZE AND BOLT/NUT

SPECIFICATION 11

4.2 TERMINAL PROTECTION AND

INSTALLATION 12

4.3 BATTERY ORIENTATION 12

4.4 PARALLEL BATTERY

CONNECTIONS 12

4.5 ACCESSORIES 13

4.6 BATTERY ENVIRONMENT 13

5 ELECTRICAL

SPECIFICATIONS 15

5.1

DISCHARGE SPECIFICATION 15

5.2

BMS PROTECTION CRITERIA 16

6 CHARGING 17

6.1 BEFORE CHARGING 17

6.2 CHARGING PROFILES 17

6.3 CELL BALANCING 19

6.4 CHARGING FAQS 19

7 CANBus 20

8 RECOMMENDED

BATTERY PACK SIZES

9 STORAGE 22

10 SHIPPING 22

10.1

REGULATORY INFORMATION

10.2 PACKAGING 23

ADDITIONAL INFORMATION

11.1 TERMINOLOGY 24

11.2 CHARGER

OPTIMIZATION/DIAGNOSIS 24

11.3 DISCHARGE TESTING 25

11.4 C-RATES 25

11.5 PRODUCT SPECIFICATION

SHEETS 26

11.6 DATE CODES 26

11.7 WARRANTY 26

11.8 BATTERY DEALERS NEAR YOU 26

12 BATTERY RECYCLING 27

13 NOTES 28

4U.S.Battery Mfg. Co.

1 BEFORE YOU START

The following Safety and Equipment sections are provided to ensure

safe and successful battery installation and maintenance.

1.1 SAFETY

Batteries can deliver an enormous amount of power that can result in injury and/or

death, observing the following precautions is the difference between successful battery

maintenance/installation and a night in the emergency room:

●Wear safety glasses and rubber gloves when working with batteries.

●Use insulated tools with rubber or plastic handles.

●Keep ignition sources and combustible material away from batteries.

●Remove all metal jewelry or other objects when working with batteries.

●Never place objects on top of batteries. A short circuit can occur.

●Make sure all electrical connections are tight (see 4.1) and free of damage

●Only use the built-in handles to move/install batteries.

●Review the Safety Data Sheet prior to handling/storage of batteries

WARNING! Do not disassemble, heat above 140˚F, or incinerate batteries!

Risk of re, explosion, and/or burns. ABC type re extinguishers should be

kept near batteries in case of re. Refer to SDS for more information.

WARNING! Replacing lead-acid batteries with lithium-ion batteries results

in a reduction in weight that can impact vehicle/machine dynamics.

Counterweights may be required to reduce rollover risk. Consult the

machine manufacturer or an installation professional.

1.2 EQUIPMENT NEEDED

The following equipment is recommended to safely maintain/install your batteries:

●Personal Protective Equipment

●Insulated Wrench

●Voltmeter

●Torque Wrench

●CAN bus Communication Cables

●Lithium-Ion Battery Compatible Charger

GC2 Lithium-ion User Manual

1.3 SAFETY DATA SHEETS (MSDS)

U.S. Battery has safety data sheets available for all product lines:

Lithium-Ion Safety Data Sheet

6U.S.Battery Mfg. Co.

2 BATTERY SPECIFICATIONS

OVERVIEW

US 48V GC2 US 24V GC2

Description Specications

Cell Conguration 16S1P 8S1P

Cell Type LFP Prismatic LFP Prismatic

Nominal Capacity* 30Ah 67Ah

Nominal Voltage of Pack 51.2V 25.6V

Rated Energy of Pack 1.5kWh 1.7kWh

Maximum Charge Voltage of Pack 58.4V 29.2V

Discharge Cutt-off Voltage of Pack 40V or 2.5V/cell 20V or 2.5V/cell

Recommended Charging Current 15A (C/2) 30A

Recommended Discharge Current 15A (C/2) 30A

Maximum Continuous Charging Current 30A* (1C) 67A* (1C)

Maximum Continuous Discharge Current 90A* (3C) 100A* (1.5C)

Operating

Temperature

Charge 0-55ºC / 32-131ºF 0-55ºC / 32-131ºF

Discharge -30-60ºC / -22-140ºF -30-60ºC / -22-140ºF

Operating Humidity <90%RH <90%RH

Storage Temperature 10-35ºC / 50-95ºF 10-35ºC / 50-95ºF

Storage Humidity 25-85%RH 25-85%RH

Enclosure Material ABS + PC ABS + PC

Dimensions LxWxH (mm) 10.24” (260) x 7.09”

(180) x 11.04” (280)

10.24” (260) x 7.09”

(180) x 11.04” (280)

Weight 14.6 kg / 32.2 lbs. 14.6 kg / 32.2 lbs.

Communication System CANBus CANBus

Ingress Protection Rating IP67 IP67

Safety Certications UL2580 (cell),

UL2271 (battery)

UL2580 (cell),

UL2271 (battery)

Shipping Classication UN38.3 Class 9 UN38.3 Class 9

Terminals Threaded Insert

(M8x1.25)

Threaded Insert

(M8x1.25)

TABLE 1

*REPEATED OPERATION AT OR NEAR MAXIMUM CONTINUOUS CHARGE OR DISCHARGE CURRENT WILL RESULT

IN HIGH TEMPERATURES AND REDUCED BATTERY LIFE

GC2 Lithium-ion User Manual

BCD

A. Negative Terminal (M8 insert)

B. Aluminum Heat Sink

C. Battery Status Indicator LEDs

(SOC)

D. Lift Handle

E. Button LED

F. Wake/Status Button

G. Positive Terminal (M8 insert)

H. In/Out CANbus Ports

I. Lift Handle

J. Pressure relief valve

DIAGRAM 1

8U.S.Battery Mfg. Co.

3 BATTERY OPERATION

The Essential Lithium-Ion GC2 batteries are

equiped with an integrated button and LEDs to

assist with turning battery on/off, SOC deter-

mination, fault/error handling, and status ref-

erence. Below is a description of the various

button and LED functions.

3.1 TURNING ON

To turn on battery, press and hold the button for 5 seconds. LEDs should light up indi-

cating the SOC of the battery. Voltage should be present at the terminals and the But-

ton LED should ash green every 5 seconds. Note that if multiple batteries are con-

nected in parallel, turn-ing on one battery will turn on all batteries in a string

3.2 TURNING OFF

To turn off, tap once and then tap and hold the button for at least 6 seconds. LEDs 2

and 4 should light up indicating you can release the button to power off. Voltage should

no longer be present at the terminals and the Button LED should no longer be ashing.

Note that if multiple batteries are connected in parallel, with CAN cables installed, turn-

ing off one battery will turn off all batteries.

3.3 ACTIVE MODE AND SOC DISPLAY

When the battery is on and there are no faults/errors, the battery is in “Active” mode.

This mode is identied by the green Button LED ashing every 5 seconds. In this

mode, the battery is ready to be used and voltage is present at the terminals. While in

this mode, you can tap the button once to reveal state of charge as indicated in

“Table 2”. Note that this will display for 5 seconds:

Button LED

DIAGRAM 2

GC2 Lithium-ion User Manual

SOC LED1 LED2 LED3 LED4 LED5

1%~9% Flash

10%~20% On

21%~45% On On

46%~70% On On On

71%~95% On On On On

96%~100% On On On On On

3.4 DISPLAY WHILE CHARGING

SOC LED1 LED2 LED3 LED4 LED5

1%~20% Pulse

21%~40% On Pulse

41%~60% On On Pulse

61%~80% On On On Pulse

81%~99% On On On On Pulse

100% All off, button LED is solid green

TABLE 2

TABLE 3

3.5 FAULT DISPLAY

When faults are active, the Button LED will ash red every 5 seconds. To determine the

specic fault(s) that is active tap the button once. The Button LED will stay solid red for

5 seconds and the LEDs will indicate the specic fault.

If multiple faults are active, tap the button to cycle through the faults. Once all faults

have been displayed, the SOC will be displayed, which is indicated by the Button LED

changing from red to green.

10 U.S.Battery Mfg. Co.

Fault LED1 LED2 LED3 LED4 LED5

Under Voltage On

Charge Over Current On

Discharge Over Current On On

Short Circuit On

Charge Over Temp. On On

Charge Under Temp. On On On

Discharge Over Temp. On

Discharge Under Temp. On On

TABLE 4

3.5 FAULT TROUBLESHOOTING

UNDER VOLTAGE

Battery has been overdischarged. The batteries need to be charged immediately. If

the batteries are in a motive application, wait approximately 15 minutes to allow the

voltage to increase. If the fault is no longer active, turn on the vehicle and drive imme-

diately to the charging station. Fully recharge the battery pack.

OVER CHARGE CURRENT

Charge current is greater than the maximum allowed. Verify charger is designed for

Lithium Ion and that the algorithm is also set for Lithium Ion.

OVER DISCHARGE CURRENT OVER DISCHARGE CURRENT

Discharge load is greater than the maximum allowed. Verify that the battery pack is

sufciently sized for the application. Installing an additional battery in parallel may be

required in order to decrease the discharge load across each battery below the maxi-

mum allowed.

SHORT CIRCUIT

Stop operation immediately. Short circuit protection is activated when when the dis-

charge current exceeds the short circuit limit in Table 6. This is a dangerous scenario

and should be handled with extreme caution. Verify that all connections are secure

and free of obstructions. Verify that batteries are clean of all debris. If fault occurs

again, have a professional evaluate the electrical system.

GC2 Lithium-ion User Manual

4.1 CABLE SIZE AND BOLT/NUT SPECIFICATION

Cable Size with Max Ampacity Table

Cable size has a direct inuence on the voltage drop across the system. The following

are guidelines. A trained professional should verify that your system is correctly sized

and installed. Cables must be sized according to the expected load using “Table 5”.

CHARGE OVER TEMP

Battery internal temperature has surpassed the maximum. The battery must be al-

lowed to cool. The wait time is dependent on the ambient temperature and battery

box design. Battery cables can come loose and cause a signicant rise in tempera-

ture. Check that all battery cables are secure. If multiple batteries are in parallel,

make sure that there is at least a 1 inch gap surrounding the battery.

CHARGE UNDER TEMP

Battery Internal temperature has surpassed the minimum. Battery temperature must

be allowed to increase before usage. Do not heat the battery using external devices

such as heat guns, ovens, etc. To prevent future “under Temp” errors store the

batteries or vehicle inside a temperature controlled environment.

DISCHARGE OVER TEMP

Battery internal temperature has surpassed the maximum. The battery must be al-

lowed to cool. The wait time is dependent on the ambient temperature and battery

box design. Battery cables can come loose and cause a signicant rise in tempera-

ture. Check that all battery cables are secure. If multiple batteries are in parallel,

make sure that there is at least a 1 inch gap surrounding the battery.

DISCHARGE UNDER TEMP

Battery Internal temperature has surpassed the minimum. Battery temperature must

be allowed to increase before usage. Do not heat the battery using external devices

such as heat guns, ovens, etc. To prevent future “under Temp” errors store the batter-

ies or vehicle inside a temperature controlled environment.

4 INSTALLATION

12 U.S.Battery Mfg. Co.

Table values are from NEC table 321.15(B)16

for copper cables rated at 167˚F (75˚C), op-

erating at an ambient temperature of no more

than 86˚F (30˚C). Lengths in excess of 6 feet

(1829mm) may require heavier gauge wire to

avoid unacceptable voltage drop. In series/

parallel banks, it is preferable for all series

cables to be the same length, and all parallel

cables to be the same length. Refer to the

national Electrical Code for correct wire sizing

which can be located at http://www.nfpa.org/.

4.2 TERMINAL PROTECTION AND INSTALLATION

During installation and handling, ensure that terminals are covered with supplied ter-

minal protectors and only remove when ready to attach cables. It is recommended that

cables be installed while the battery is turned off. See “3 Battery Operation” for instruc-

tions on turning batteries on/off.

4.3 BATTERY ORIENTATION

Lithium-Ion batteries can be oriented in any direction except upside down.

4.4 PARALLEL BATTERY CONNECTIONS

Lithium-Ion batteries should never be installed in series connection. Only parallel

connections are recommended. You can increase the capacity by creating a parallel

connection as shown in “Diagram 3”.

Never install multiple batteries in parallel without rst checking the SOC. The best way

to ensure batteries are matched is by fully charging each battery prior to installation in

parallel. Another way would be to ensure voltages are within 0.5V of one another prior

to installation. Always install the batteries in the “Off” state by following

“3 Battery Operation”.

Cable/Wire Gauge Size

(AWG)

Ampacity

(Amps)

14 20

12 25

10 40

8 65

6 95

4 125

2 170

1 195

1/0 230

2/0 265

4/0 360

TABLE 5

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