Manual for LIFEPO4 battey packs    48-96 V 100-200A systems     V 1.7 2013

PREPARATION OF KIT

If you have ordered a kit—not a ready to go battery box, the system is prewired and all the connections are either marked or described hereafter in detail. You just need to connect the system. Please read carefully!

INSTALLATION OF BATTERY CELLS

The battery cells are arranged in blocks of 4 or 8 and need to be fixed with a stable frame which can carry a force of at least 3 G (3 times the battery weight). See next page for possible arrangements.  Make sure you do not touch the  positive or negative terminals with any tools, metall or body

parts!!

CONNECTION OF THE CELLS

Before connecting the cells, please check the alignment and make sure, the cells are fixed and can not move. The terminal connectors are not suitable to hold the cells together!

The cell connectors are connected to the battery cell terminal—use anti oxydant fluid for long lasting connections. Next connect the cell balancer. The main board is connected to the NEGATIVE terminal and the red cable with the lug to the POSITIVE terminal. When connected a green LED lights up. If not, you have either conneted incorrectly or the balancer is defect.

The cells need to be conneted from  a POSITIVE to a NEGATIVE terminal and the balancer controll cables (Red and Black) from the OUT connection on the balancer board from cell 1 to the IN connection on the balancer board from cell 2 etc.

Connect 16 cells in series for 48 volt, 32 cells in series for 96 volt.

 

If all cells are connected there must be a POSITIVE terminal free at one end of

The string and a NEGATIVE terminal at the other end.  You have to measure 48—54 volts for a 16 cell system and 96-108 volt for a 96 volt system.

CONNECTION OF BMS / POWER

The BMS system is mounted on a board fully wired with the DCDC converter (12 volts), the main fuse and the contactor. The safety switch is either mounted on the board or supplied separately with cables. Connect the safety switch to the POSITIVE battery terminal. Switch if off (pull out) and then connect to the contactor terminal. Use anti oxydant for all connections. Connect the positive cable from the main fuse to the main switch. Connect the cable from the main switch to the positive terminal on the engine controller.

Connect the NEGATIVE battery terminal with the supplied cable to the battery side of the shunt. Connect the engine side of the shunt to the negative terminal on the engine controller. SEE ALSO „Problems with LiFePo4 cells“

 

Follow the instructions for the battery box and the operator‘s manual of the engine to check & startup the system.

ALL CELLS HAVE TO BE CHARGED TO THE EXACT SAME VOLTAGE. Check the documentation for the BMS system supplied and the battery instructions before connecting or changing settings.

 

 

 

 

 

 

 

 

ERRORS / CAUTION                  LED on balancers = green ok   red&green = balancing  red = not ok

The battery is safe to operate when THE GREEN LED ON THE BMS IS ON | THE RED LIGHT ON THE BMS IS NOT ON | THE GREEN LED ON EACH BATTERY CELL IS ON | THE BATTERY MONITOR IS ON | THE VOLTAGE IS OVER 48 / 96 VOLTS.

The battery is not to be used when THE GREEN LED ON THE BMS IS NOT ON | THE RED LIGHT ON THE BMS IS ON | THE GREEN LED ON EACH BATTERY CELL IS OFF OR RED | THE BATTERY MONITOR IS OFF | THE VOLTAGE IS UNDER 44 / 88 VOLTS (Recharge allowed, if all other indicators are ok) MEASURE  CELL VOLTAGES FIRST—if inbalanced see separate instructions