Forster FBS Series Manuel utilisateur

WWW.FORSTER-BATTERIES.DE

INNOVATION.

ENGINEERING.

SOLUTION.

LITHIUM FBS-SERIE STANDARD

OPERATING INSTRUCTIONS

F12-020FBS

F12-050FBS

F12-100FBS

F12-100FBS1

F12-150FBS1

F12-200FBS

F12-300FBS

F24-050FBS

F24-100FBS

F36-100FBS

WWW.FORSTER-BATTERIES.DE2

OPERATING INSTRUCTIONS

F12-020FBS

F12-050FBS

F12-100FBS

F12-100FBS1

F12-150FBS1

WWW.FORSTER-BATTERIES.DE 3

F12-200FBS

F12-300FBS

F24-050FBS

F24-100FBS

F36-100FBS

WWW.FORSTER-BATTERIES.DE4

TECHNICAL SPECIFICATIONS

DATA / ORDER NO.:

EAN

Capacity

Replaces lead-gel-AGM battery

Nominal voltage

Energy content

Operating voltage

Application in shunt circuit

Application in serial connection

Cell technology

Cell type

Charging programmes

End-of-charge voltage

Trickle charge

Maximum charging current

Recommended charging current

Max. discharge current / 3 sec.

Continuous discharge current

Battery shutdown

BMS Battery Management System

Remote monitoring with APP

Bluetooth

Protection Class

Cycles / longevity at 50% DoD

Cycles / longevity at 80% DoD

Cycles / longevity at 90% DoD

Charging temperature

THERMO CONTROL (TC)

Discharge temperature

Recommended storage temperature

Storage

Self-discharge

Connection

Arrangement of positive pole

Length

Width

Height

Mounting position

Weight

Warranty

Certification

F12-020FBS F12-050FBS F12-100FBS F12-100FBS1 F12-150FBS1 F12-200FBS F12-300FBS F24-050FBS F24-100FBS F36-100FBS

4251847300778 4251847300785 4251847300792 4251847300679 4251847301478 4251847301485 4251847301409 4251847300808 4251847300815 4251847300822

20Ah 50Ah 100Ah 100Ah 150Ah 200Ah 300Ah 50Ah 100Ah 100Ah

12V/40Ah 12V/100Ah 12V/200Ah 12V/200Ah 12V/300Ah 12V/300Ah 12V/300Ah 24V/100Ah 24V/200Ah 36V/200Ah

12.8V 12.8V 12.8V 12.8V 12.8V 12.8V 12.8V 25.6V 25.6V 38.4V

256Wh 640Wh 1280Wh 1280Wh 1920Wh 2560Wh 3840Wh 1280Wh 2560Wh 3840Wh

11.0V - 14.6V 11.0V - 14.6V 22.0V - 29.2V 33.0V - 43.8V

yes, max. 4 pieces of the same type possible yes, max. 4 pieces of the same type possible

yes, 24V, 36V and a maximum of 48V can be operated serially! yes, 24V, 36V and a maximum of 48V can be operated serially! yes, max. 48V no

Lithium LiFePO4 Lithium LiFePO4

PPC Prismatic-Power cells PPC Prismatic-Power cells

CCCV / IU / IUoU / lead-acid CCCV / IU / IUoU / lead-acid

14.0V - 14.6V 14.0V - 14.6V 28.0 - 29.2V 42.0 - 43.8V

13.3 - 13.8V 13.3 - 13.8V 26.6 - 27.6V 39.9 - 41.4V

20A / 60min 40A / 60min 100A / 60min 80A / 75min 100A / 75min 150A / 80min 200A / 75min 50A / 60min 100A / 60min 100A / 60min

10A 25A 50A 60A 60A 80A 100A 25A 50A 50A

68A 150A 350A 350A 350A 400A 450A 150A 350A 300A

30A 50A 100A 150A 150A 150A 200A 50A 100A 100A

8.5V 10.0V 10.0V 10.0V 10.0V 10.0V 10.0V 20.0V 20.0V 30.0V

integrated integrated

n/a yes yes

yes, built-in yes, built-in

IP54 IP67 IP67 IP54 IP54 IP54 IP54 IP54

>5000 >6000 >5000

>3500 >4000 >3500

>3000 >3000 >3000

0°C to +50°C 0°C to +50°C

n/a n/a

-20°C to +60°C -20°C to +60°C

-5°C to +25°C -5°C to +25°C

80 - 100% charged / when not in use, load battery every 6 months 80 - 100% charged / when not in use, load battery every 6 months

2-3% / month 2-3% / month

M5-bolt M8-bold M8-bold Car cone Car cone M8-bolt M8-bolt M8-bolt M8-bolt M8-bolt

front left front right front right front left front end right front left

180mm 197mm 318mm 355mm 355mm 485mm 520mm 318mm 485mm 520mm

76mm 165mm 165mm 175mm 175mm 170mm 268mm 165mm 170mm 268mm

166mm 174mm 215mm 190mm 190mm 245mm 220mm 215mm 245mm 220mm

any, standing, lying, on the side, upright, headfirst any, standing, lying, on the side, upright, headfirst

2.5kg 7.0kg 12.8kg 11.5kg 20.0kg 25.0kg 35.0kg 12.8kg 25.0kg 39.0kg

5 years 3 years

UN38.3 | MSDS | CE | RoHS UN38.3 | MSDS | CE | RoHS

WWW.FORSTER-BATTERIES.DE 5

F12-020FBS F12-050FBS F12-100FBS F12-100FBS1 F12-150FBS1 F12-200FBS F12-300FBS F24-050FBS F24-100FBS F36-100FBS

4251847300778 4251847300785 4251847300792 4251847300679 4251847301478 4251847301485 4251847301409 4251847300808 4251847300815 4251847300822

20Ah 50Ah 100Ah 100Ah 150Ah 200Ah 300Ah 50Ah 100Ah 100Ah

12V/40Ah 12V/100Ah 12V/200Ah 12V/200Ah 12V/300Ah 12V/300Ah 12V/300Ah 24V/100Ah 24V/200Ah 36V/200Ah

12.8V 12.8V 12.8V 12.8V 12.8V 12.8V 12.8V 25.6V 25.6V 38.4V

256Wh 640Wh 1280Wh 1280Wh 1920Wh 2560Wh 3840Wh 1280Wh 2560Wh 3840Wh

11.0V - 14.6V 11.0V - 14.6V 22.0V - 29.2V 33.0V - 43.8V

yes, max. 4 pieces of the same type possible yes, max. 4 pieces of the same type possible

yes, 24V, 36V and a maximum of 48V can be operated serially! yes, 24V, 36V and a maximum of 48V can be operated serially! yes, max. 48V no

Lithium LiFePO4 Lithium LiFePO4

PPC Prismatic-Power cells PPC Prismatic-Power cells

CCCV / IU / IUoU / lead-acid CCCV / IU / IUoU / lead-acid

14.0V - 14.6V 14.0V - 14.6V 28.0 - 29.2V 42.0 - 43.8V

13.3 - 13.8V 13.3 - 13.8V 26.6 - 27.6V 39.9 - 41.4V

20A / 60min 40A / 60min 100A / 60min 80A / 75min 100A / 75min 150A / 80min 200A / 75min 50A / 60min 100A / 60min 100A / 60min

10A 25A 50A 60A 60A 80A 100A 25A 50A 50A

68A 150A 350A 350A 350A 400A 450A 150A 350A 300A

30A 50A 100A 150A 150A 150A 200A 50A 100A 100A

8.5V 10.0V 10.0V 10.0V 10.0V 10.0V 10.0V 20.0V 20.0V 30.0V

integrated integrated

n/a yes yes

yes, built-in yes, built-in

IP54 IP67 IP67 IP54 IP54 IP54 IP54 IP54

>5000 >6000 >5000

>3500 >4000 >3500

>3000 >3000 >3000

0°C to +50°C 0°C to +50°C

n/a n/a

-20°C to +60°C -20°C to +60°C

-5°C to +25°C -5°C to +25°C

80 - 100% charged / when not in use, load battery every 6 months 80 - 100% charged / when not in use, load battery every 6 months

2-3% / month 2-3% / month

M5-bolt M8-bold M8-bold Car cone Car cone M8-bolt M8-bolt M8-bolt M8-bolt M8-bolt

front left front right front right front left front end right front left

180mm 197mm 318mm 355mm 355mm 485mm 520mm 318mm 485mm 520mm

76mm 165mm 165mm 175mm 175mm 170mm 268mm 165mm 170mm 268mm

166mm 174mm 215mm 190mm 190mm 245mm 220mm 215mm 245mm 220mm

any, standing, lying, on the side, upright, headfirst any, standing, lying, on the side, upright, headfirst

2.5kg 7.0kg 12.8kg 11.5kg 20.0kg 25.0kg 35.0kg 12.8kg 25.0kg 39.0kg

5 years 3 years

UN38.3 | MSDS | CE | RoHS UN38.3 | MSDS | CE | RoHS

WWW.FORSTER-BATTERIES.DE6

GENERAL PRODUCT INFORMATION

The lithium iron phosphate battery (LiFePO4) is the safest battery in the lithium-ion battery family.

It is highly current resistant, universally applicable and has a low weight compared to lead, gel or AGM

batteries. In addition, the latest lithium iron technology offers a high degree of intrinsic safety, eliminating

the risk of explosion even under the most extreme conditions.

A 12V (14.6V) LiFePO4 battery consists of 4 single cells connected in series, each with a nominal voltage

of 3.2V. A 24V (29.2V) LiFePO4 battery has 8 cells connected in series, a 36V (43.8V) battery has 12 cells

connected in series and a 48V (58.4V) battery has 16 cells connected in series.

A built-in battery management system (BMS) additionally protects the battery cells from damage.

RESISTANT:

One major weakness of lead-acid batteries is sulfation. Sulfation occurs when a battery is rarely or never

charged, or is left in a half-full or empty state for long periods of time. This is one of the biggest advantages

of the new LiFePO4 technology. The battery's state of charge is not decisive for its performance and

lifespan. Whether full or empty, whether often or rarely in use, the LiFePO4 energy storage is extremely

resistant and robust.

EFFICIENT:

Countless applications in connection with the most modern solar and wind power plants increase the energy

efficiency. Compared to approx. 80% for lead-acid batteries, the efficiency is approx. 92% per charging cycle.

OPTIMISED:

You can save up to 60% in space and weight for the same capacity. Or you can pack more than twice the

capacity in the same space.

FLEXIBLE:

LiFePO4 batteries can be installed in a flexible position, which allows for new options in space utilisation.

Parallel arrangement is also possible to increase capacity. Any number of batteries of the same type can be

connected in parallel. For more voltage, you can connect up to 4 batteries (maximum 48V) in series.

SPECIAL FEATURES OF LIFEPO4

LITHIUM BATTERIES

ADVANTAGES

HIGH CYCLE STABILITY

Over 4,000 cycles at 80% DoD reduces your operating costs.

VERY SHORT CHARGING TIMES

Compared to conventional batteries, the lithium battery absorbs extremely high charging

currents in a very short time, thus making it ready for use again more quickly.

BUILT-IN COMPLETE PROTECTION / SAFETY FIRST

The integrated, intelligent battery management system (BMS) protects the battery and

ensures completely worry-free use.

EASY STORAGE

Thanks to extremely low self-discharge, the lithium batteries can easily be stored for more

than six months without sulfation and degassing.

LONG LIFE

The significantly higher number of cycles and the low maintenance requirements increase the

service life of lithium batteries by a factor of 7 compared to conventional batteries.

HIGH HEAT TOLERANCE

The lithium battery is a reliable power supply even at ambient temperatures above 60°C.

LIGHT WEIGHT

The lithium batteries are up to 75% lighter, resulting in enormous weight savings.

Double capacity = same space = half the weight

BLUETOOTH MEASURING SHUNT

Optionally, all our FORSTER X-series batteries are available with a 500A Bluetooth measuring

shunt which allows to display the exact charge level via app.

COLD RESISTANCE

The extended cold resistance of the FORSTER X-series allows the batteries to operate at

temperatures as low as -20°C.

INSTALLATION

Our FORSTER X-series batteries can be installed and operated in any position.

THERMO CONTROL (TC) F12-100FBSH only

Specially designed for installation in non-heated areas or an external battery compartment.

The Thermo Control battery has a computer-controlled cell preheating system that auto-

matically monitors the battery cells and allows charging down to -30°C.

MULTI-LAYER-HEAT SYSTEM (MLS) F12-100FBSH only

Unique system for even and rapid heating of the prismatic lithium cells. By placing heating

film plates between the cells, heating is

uniform, fast and controlled.

WWW.FORSTER-BATTERIES.DE 7

WWW.FORSTER-BATTERIES.DE8

BATTERY MANAGEMENT SYSTEM (BMS)

A battery management system monitors and controls the individual cells of a battery and protects them from

damage.

Key features of a battery management system:

OVERLOAD PROTECTION:

The BMS switches off the battery outputs in case of overload to protect the cells. At this point, the battery

has no voltage; after the consumer has finished, the battery unlocks itself.

DEEP DISCHARGE PROTECTION:

Each cell is individually monitored for deep discharge. If the battery outputs are switched off as a result, they

can only be released again by a charging process.

Attention: The BMS protects the cells against deep discharge when in active use. However, a switched off,

empty battery can damage itself over a longer period of time due to the low but existing self-discharge of

3%/month!

Tip: A battery that has been completely discharged should be recharged as soon as possible!

Note: Small consumers such as alarm systems, relays, standby systems or similar also consume capacity and

discharge your battery. If the battery is not used for a long time, make sure that it is disconnected from the

system by disconnecting the plus pole.

OVERVOLTAGE PROTECTION:

LiFePO4 battery cells must not be charged above 3.65V/cell and 14.6V/battery, otherwise the cells will be

destroyed by overvoltage. Only suitable chargers with a final charging voltage of 14.6V may therefore be

used to charge LiFePO4 batteries. Although the BMS protects the cell from overcharging, it must itself

absorb and burn the current. This is possible for a short time, but not a permanent state. A permanently too

high charging current above 14.6V will destroy the BMS!

ACTIVE CELL BALANCING:

The so-called balancing ensures that each individual cell is charged to the maximum final charging voltage of

3.65V/cell. This is important when the battery capacity is used to the maximum. If the cells are completely

empty, they may drift slightly and become unequal. This condition cannot be equalised by normal charging.

As a result, the battery would have less and less capacity over time. The built-in active balancer helps by

balancing the cells at all times. The active balancer ensures maximum efficiency regardless of the battery's

state of charge.

CHARGE CONTROL:

The BMS monitors and controls all parameters of a reliable and safe charge at all times. If problems occur,

charging is blocked by switching off the battery outputs to protect the battery.

TEMPERATURE PROTECTION OF THE CELLS:

All LiFePO4 cells in the battery are individually monitored by a temperature sensor at all times. If the battery

switches off because the cells have reached temperatures above 70°C, they must first cool down again until

the BMS releases the output again.

TEMPERATURE PROTECTION OF THE BMS:

The BMS itself is also permanently monitored by a temperature sensor. If the BMS reaches a temperature of

95°C, the battery outputs are switched off. The output can only be released again after the BMS has cooled

down.

For this purpose, no current may be drawn and not charged for 30 minutes!

BATTERY MANAGEMENT SYSTEM (BMS)

FORSTER standard lithium batteries have a standard BMS with all key control and charging functions built in.

To protect the battery cells, the BMS developed by FORSTER automatically takes over the following functions:

• Overload protection

• Deep discharge protection

• Overvoltage protection

• Active cell balancing

• Charge control

• Cell frost control, reduction of the charging current below 0°C

• Temperature cell monitoring

• Temperature BMS monitoring

• Compatible with common chargers, multi charge mode (MCM)

• Control electronics of the multi-layer heating elements (MLS) with the Thermo Control battery

The BMS is adapted to the respective battery capacity. By connecting 2 or more standard batteries in parallel,

the output power can be additionally increased.

WWW.FORSTER-BATTERIES.DE 9

DISADVANTAGES OF FORMER ROUND CELLS:

• Loss of space and capacity due to large gaps

• Time-consuming assembly of individual cells due

to screw connections on both sides

• High cell levelling effort

• Higher weight due to assembly material

• More vulnerable with regard to the number of

screw connections

• Time-consuming cell replacement due to

complete disassembly of all cells for fault analysis

• High effort to adjust all cells after a repair

ADVANTAGES OF OUR PRISMATIC POWER CELLS:

• Maximum space utilisation

• Few cell connectors

• Less weight

• Fast assembly

• High safety and long life

• Low susceptibility

• Fast cell replacement

• No fire hazard

• No explosion!

WWW.FORSTER-BATTERIES.DE10

SUSTAINABLE. RESOURCE-SAVING

The superior performance of Forster batteries results from the use of Prismatic Power Cells.

In contrast to conventional batteries consisting of many small interconnected cells, FORSTER relies on a

small number of larger battery cells. The minus in complexity brings a plus in performance, service life and

safety. In addition, the modular structure consisting of Prismatic Cells and the innovative battery manage-

ment system makes it easier to adapt to individual requirements and to replace individual components.

PRISMATIC POWER CELLS

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