Advanced Energy Discover 42-48-6650 User manual

1
AES LiFePO4INSTALLATION AND
OPERATION MANUAL - AUSTRALIA
805-0049 REV A
BATTERY MODEL
42-48-6650

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1. AUDIENCE, SAFETY, MESSAGES, AND WARNINGS ......................................3
1.1 Audience.................................................................3
1.2 Warning, Caution, Notice, and Note Messages ..................................3
1.3 General Warnings .........................................................4
1.4 Safe Handling Procedures...................................................5
1.5 Personal Protective Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2. ITEMS SHIPPED IN THE BOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3. SPECIFICATIONS ....................................................................6
3.1 Electrical Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.2 Mechanical Specifications...................................................7
3.3 Environmental Specifications ................................................7
3.4 Protection Specifications....................................................7
3.5 Regulatory ...............................................................9
4. TRANSPORTATION ..................................................................9
5. HANDLING .........................................................................9
6. FEATURES ..........................................................................9
6.1 Internal Battery Fuse ......................................................10
6.2 ON/OFF Key .............................................................10
6.3 AEbus Port (LYNK Port) ....................................................10
6.4 Equipment Ground .......................................................11
7. THEORY OF OPERATION............................................................. 11
7.1 Ingress Protection IP55 ....................................................11
7.2 Battery Management System ...............................................12
7.3 AEbus (LYNK) Network Communication ......................................13
8. OPTIONAL ACCESSORIES ........................................................... 13
9. INSTALLATION ..................................................................... 14
9.1 Tools ...................................................................14
9.2 Location ................................................................14
9.3 DC Cables ...............................................................15
9.4 Protection ...............................................................15
9.5 Securing the Battery ......................................................16
9.6 Installing the Battery ......................................................17
9.7 Installing Batteries in Parallel Battery Wiring...................................18
9.8 AEbus (LYNK) Network ....................................................20
10. OPERATION ....................................................................... 22
10.1 Low Voltage Cut-Off .......................................................22
10.2 State of Charge ..........................................................22
10.3 Charging ................................................................22
10.4 Charging Profile ..........................................................23
11. ROUTINE INSPECTION .............................................................. 25
12. STORAGE ......................................................................... 25
13. BATTERY MODULE FIRMWARE AND DATA LOGS ....................................... 26
14. TROUBLESHOOTING ................................................................ 26
15. RELATED INFORMATION ............................................................ 26
16. GLOSSARY OF TERMS, ABBREVIATIONS, AND ACRONYMS ............................. 26

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Introduction
The AES LiFePO4is a battery that can operate on its own or in a battery bank
configuration where multiple batteries are connected in parallel.
This Manual covers serial numbers for part number 42-48-6650 greater than
DET424820275xxxx.
1. AUDIENCE, SAFETY, MESSAGES, AND WARNINGS
1.1 Audience
Configuration, installation, service, and operating tasks should only be performed
by qualified personnel in consultation with local authorities having jurisdiction
and authorized dealers. Qualified personnel should have training, knowledge, and
experience in:
• Installing electrical equipment
• Applying applicable installation codes
• Analyzing and reducing hazards involved in performing electrical work
• Installing and configuring batteries
• Installing and configuring systems activated by relays
1.2 Warning, Caution, Notice, and Note Messages
Messages in this manual are formatted according to this structure.
Additional information concerning important procedures and features of
the product. Read all the instructions before installation, operation, and
maintenance.
Important information regarding hazardous conditions.
WARNING
Important information regarding hazardous conditions that may result in personal
injury or death.
CAUTION
Important information regarding hazardous conditions that may result in personal
injury.
NOTICE
Important information regarding conditions that may damage the equipment but
not result in personal injury.
NOTE
Ad hoc information concerning important procedures and features unrelated to
personal injury or equipment damage.

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1.3 General Warnings
Do not crush, disassemble or dispose of the battery module in fire or the
garbage.
This product is made of recyclable materials and must be recycled.
WARNING
ELECTRIC SHOCK AND FIRE HAZARD
• This equipment must only be installed as specified.
• Do not disassemble or modify the battery.
• If there is damage to the battery case, do not touch exposed contents.
• There are 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.
WARNING
ELECTRIC SHOCK AND FIRE HAZARD
• Do not lay tools or other metal parts on top of the battery or across the terminals.
Failure to follow these instructions may result in death or serious injury.
CAUTION
ELECTRIC SHOCK HAZARD
• 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.
• Follow the “Safe Handling Procedures” below when working with the battery.
Failure to follow these instructions may result in injury.

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1.4 Safe Handling Procedures
Before using the battery, read all instructions and cautionary markings on the unit
and all appropriate sections of this manual.
• Use personal protective equipment when working with batteries.
• Do not dispose of the battery in a fire.
• Promptly dispose of or recycle used batteries following local regulations.
• Do not disassemble, open, crush, bend, deform, puncture or shred.
• Do not modify, re-manufacture, or attempt to insert foreign objects into the
battery, immerse or expose the battery to water or other liquids, fire, explosion,
or other hazards. If the user suspects damage to the battery module due to water,
heat, or other reason, take it to a service center for inspection.
• Only use the battery for the system for which it is specified.
• Do not lift or carry the battery while in operation.
• The battery is heavy. When lifting the battery, follow appropriate standards.
• Only lift, move, or mount following local regulations.
• Take care when handling battery terminals and cabling.
• Only use the battery with a charging system that meets specifications. Using a
battery or charger that does not meet specifications may present a risk of fire,
explosion, leakage, or other hazards.
• Do not short-circuit a battery or allow metallic conductive objects to contact
battery terminals.
• Replace the battery with only another battery that meets the specifications for
the system. Using a battery that does not meet specifications may present a risk
of fire, explosion, leakage, or other hazards.
• Do not drop 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.
1.5 Personal Protective Equipment
When handling or working near a battery:
• Use Personal Protective Equipment, including clothing, glasses, insulated gloves,
and boots.
• Do not wear rings, watches, bracelets, or necklaces.

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2. ITEMS SHIPPED IN THE BOX
Table 2-1, AES LiFePO4box contents
Items Description
1Battery
1Terminator
1Splitter
1 Terminal cover (black)
1Terminal cover (red)
2M8 bolt
1 set Safety warning decals
3. SPECIFICATIONS
All specifications in this document are published @25ºC / 77ºF.
3.1 Electrical Specifications
Table 3-1, AES LiFePO4Electrical Specifications
Electrical Specifications 42-48-6650
Nominal Voltage 51.2 V
Nominal Energy 7.39 kWh
Usable DOD 90%
Rated Wh Capacity (1C) 6.65 kWh
Rated Ah Capacity (1C) 130 Ah
Charge Bulk Voltage - Bulk VDC 54.4 Vdc
Charge Absorption Voltage - U1 MAX 54.4 Vdc
Charge Float Voltage - U2 53.6 Vdc
ChargeTermination Current (a) 2 A
Low Voltage Disconnect Recommended 48.0 V
Low Voltage Disconnect (b) 40.0 V
Max. Continuous Discharge Current 130 Adc
Max. Continuous Charge Current 130 Adc
Peak Discharge Current (3 seconds) 300 Adc
Fuse (Provides backup overcurrent protection) 200 A
Maximum short circuit fault current 6.0 kA / 5.5 ms
Arc Flash Incident Energy IEm 0.1 cal/cm2
Arc Flash Incident Energy AFB 9.4 cm
(a) Charge termination current is permitted to be less than specified.
(b) Under load, low Voltage Disconnect is based on 2.5 VPC. In no load conditions, do not allow the battery to self-
discharge below 3.0 VPC.

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3.2 Mechanical Specifications
Table 3-2, AES LiFePO4 Electrical Specifications
Mechanical Specifications 42-48-6650
Chemistry LiFePO4
Length 471.5 mm (18.56 in)
Width 347.5 mm (13.68 in)
Height 375 mm (14.76 in)
Terminal (1) M8
Weight 87.0 kg (191.8 lb)
IP Rating IP55
Case Material Powder Coated Cold Rolled Steel
(1) TERMINALTORQUE: 9 Nm +/- 3 (6.64 ft-lb) to a maximum depth of 14 mm.
3.3 Environmental Specifications
Table 3-3, AES LiFePO4 Environmental Specifications
Environmental Specifications 42-48-6650
Charge Operating Temperature Range (a)(b) 0°C to 45°C (32°F to 113°F)
Discharge Operating Temperature Range (a) -20°C to 50°C (-4°F to 122°F)
StorageTemperature (c) -20°C to 45°C (-4°F to 113°F)
(a) Specifies the temperature of the cells and not the ambient temperature. Ambient temperature and cell
temperature may not be the same.
(b) The Battery Management System (BMS) does not allow charging of cells when it is below 0°C (32°F).
(c) Storage outside of specified temperatures will result in permanent capacity loss and void the warranty.
3.4 Protection Specifications
Table 3-4, AES LiFePO4Protection Specifications
Protection Specification 42-48-6650
Overvoltage
Protection (a) Greater than 58.4 V for 3 seconds
Recovery (a) Recovery after 120 seconds. Charge is permitted
at 53.6 V or less
Undervoltage
Protection (b) Less than 40 V for 5 seconds
Recovery (b) No automatic recovery.The battery shuts down
after 120 seconds.
Over-Charge Current
Protection Greater than 143 A for 10 seconds
Recovery Recovery after 120 seconds

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Over-Discharge Current
Protection (c) 3-second rating
300 A
Recovery (c) Recovery after 120 seconds
Over-temperature in Discharge
Protection (d) Cell temperature above 60°C (140°F) for 5
seconds
Recovery (d) Cell temperature below 50°C (122°F)
Under-temperature in Discharge
Protection (d) Cell temperature below -20°C (-4°F) for 5 seconds.
Recovery (d) Cell temperature above -18°C (0°F)
Over-temperature in Charge
Protection (d) Cell temperature above 60°C (140°F) for 5
seconds
Recovery (d) Cell temperature below 50°C (122°F)
Under-temperature in Charge
Protection (d) Cell temperature below 0°C (32°F) for 5 seconds
and charge current detected.
Recovery (d) Charge recovery temperature above 2°C (36°F)
Note: Discharge is available to -20°C (-4°F)
(a) Overvoltage protection monitors individual cell voltages. Protection is triggered when any cell is over 3.65 VPC
and recovers after 120 seconds. Charge is permitted when VPC is 3.35 or less. Voltages are provided for guidance
only.
(b) Undervoltage protection monitors the voltage of individual cells. Protection is triggered for any cell below 2.5
VPC for 5 seconds, and then the battery is automatically set OFF after 120 seconds. Manually set the battery ON
to recover. Voltages are provided for guidance only.
(c) For time versus current interrupt details, see Figure 2, Over-Discharge ProtectionTime Current Curve.
(d) Specifies the temperature of the cells and not the ambient temperature. Ambient temperature and cell
temperature may not be the same.
Current[A]
100 200 300 400 500 600 700 800 900 1,000 1,100 1,200
10000
1000
100
10
1
0.1
00.1
000.1
-
100000
Interrupt Time [s]
Over -Current Curve
Figure 1. Over-Discharge Protection Time Current Curve

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3.5 Regulatory
Table 3-5, 42-48-6650 Regulatory
Regulatory
UN 38.3 Transportation
IEC 62133
UL 1973
UL 2271
UL 9540 (1)
CE
(1) Applies when the battery is used with Schneider
Electric inverter-chargers.
4. TRANSPORTATION
If the battery is not installed in the equipment, transport it in the original package or
equivalent. Per the UN Handbook ofTests and Criteria, batteries are tested to part III,
subsection 38.3 (ST/SG/AC.10/11/ Rev. 5). For transportation, the battery belongs to
category UN3480, Class 9.
5. HANDLING
Before handling:
• Keep the battery away from sparks and flames
• Disconnect the cables from the battery
• Protect battery terminals from short-circuiting and touch
• Do not lift or carry the battery while it is in use or in operation
• Do not lift the battery by attached battery cables
6. FEATURES
1
2
8
3
4
5
6
7
Item Description
1Battery negative (-) black, M8 female
2ON/OFF key
3Battery positive (+) red, M8 female
4Xanbus Port
5AEbus Port (LYNK Port)
6USB Port (Type B)
7Mounting Points
8Handles
Figure 2. AES Battery

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6.1 Internal Battery Fuse
The internal battery fuse provides backup overcurrent protection.
NOTE
Additional external DC fusing is required to protect the battery cables from DC
overcurrent and to meet installation codes.
6.2 ON/OFF Key
Press the battery’s ON/OFF key for 2 to 3 seconds to switch the battery either ON or
OFF. The LED illuminates when the battery is ON and darkens when the battery is
OFF.
2-3s
WARNING
ELECTRIC SHOCK HAZARD
• Always assume the battery’s main relay is ON (Closed), even if the LED for the ON/
OFF key is not illuminated.
• Verify the terminal voltage with a voltmeter before handling and installing the battery.
Failure to follow these instructions may result in death or serious injury.
ON/OFF LED Description
Dark The battery’s main relay is OFF (Open).
Illuminated The main relay is ON (Closed), and the battery is ready for
operation.
Flashing at 1 Hz
interval
The main relay is OFF (Open). The flashing indicates protection
has been triggered as one or more operating parameters (voltage,
current, temperature) have exceeded their fault threshold.
Refer to Table 3-4, Protection Specifications, for information on
faults that trigger protection.
6.3 AEbus Port (LYNK Port)
The AEbus Port (LYNK port) enables multiple Discover batteries to communicate
and interact in a closed-loop network.The AEbus Port also enables AES LiFePO4
batteries to be networked in a closed-loop system with other networked devices
such as external power conversion and motor control devices. A closed-loop system
enhances safety and optimizes system performance.

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6.3.1 AEbus Port (LYNK Port) Communication RJ45 Pin Assignment
1 2 3 4 5 6 7 8
Figure 3. AEbus Port (LYNK Port)
Communication RJ45 pin assignment
Pin Number Function
1 (1) Reserved. Do not use.
2 (1) Reserved. Do not use.
3 (1) Reserved. Do not use.
4 CAN Low
5 CAN High
6 (1) Reserved. Do not use.
7 CAN Ground
8 CAN Ground
(1) Do not populate. Do not terminate to power. Do not terminate to ground. Do not terminate to CAN_L or CAN_H.
NOTICE
• Isolate unused pins. Crossing PIN functions may cause system damage.
• Do not terminate unused wires to ground, power, or other functions.
• Mixing the AEbus Network with other networks may result in equipment malfunction
and damage.
6.4 Equipment Ground
Grounding the battery is not required.
7. THEORY OF OPERATION
7.1 Ingress Protection IP55
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 IP55 rating indicates that the product is touch-proof
and protected from limited dust ingress. And protect from low-pressure water jets
from any direction.
IP codes guide suitability for use under different environmental conditions. IP
ratings do not indicate fitness for purpose or confer a performance guarantee.

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7.2 Battery Management System
7.2.1 Battery Management System Protections
The Battery Management System’s (BMS) primary function is to monitor cell
module voltage, temperature,and battery current.The BMS uses this information to
maintain cell operation within operating specifications. If a parameter falls outside
of operating specifications, the BMS will disconnect and protect the battery from:
1. Overvoltage: Charge voltages that are too high.
2. Undervoltage: Discharged voltage that is too low.
3. Overcurrent: Current is too high when powering up a load (high inrush current)
or from a sustained charging or discharging current above the specified limit.
4. Over-temperature: Cell temperature that is too high during charge and discharge.
5. Under-temperature: Cell temperature that is too low during charge and
discharge.
For trigger and recovery values, refer to Table 3-4, AES LiFePO4Protection
Specifications.
The BMS reconnects when it hits recovery thresholds. Manually switch the battery
ON if the BMS disconnects due to low voltage protection. A physical disconnect
switch is recommended to reconnect the battery if the system has a constant
parasitic draw.
NOTE
• Charge and discharge have different operating temperature limits.
• If the BMS disconnects in response to temperature or current limits, wait for the
temperature or current to reach normal operating limits before switching the battery
ON.
7.2.2 Battery Management System Pre-Charge System
The battery has a Pre-Charge System to energize external capacitive loads before
switching the main relay ON. The maximum input capacitance for a single battery
should not exceed the values inTable 3-1, AES LiFePO4Electrical Specifications.
NOTICE
• When switching ON batteries, the inrush current may cause the batteries to fault as
they energize external capacitive loads. To resolve this, switch the batteries ON again.
7.2.3 Battery Charge and Discharge Settings
In an open-loop configuration, use the specifications provided in this manual to set
up the charge and discharge settings manually at the time of installation through
the controller of the Power Conversion device. This system contrasts with a closed-
loop configuration where the BMS specifies charging and safety settings through a
connection with the Power Conversion device.

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Closed-loop communication with a Power Conversion device requires using the
LYNK II Communication Gateway device from Discover Battery. Refer to the relevant
LYNK II Installation and Operation Manual available from the
www.discoverbattery.com website, or contact your Discover Battery provider for
assistance.
Refer to the appropriate Application Note available from
www.discoverbattery.com
for the set up of closed-loop parameters and integration with specific brands of
solar inverter-chargers, solar charger controllers, mobile inverter-chargers, and
industrial chargers.
7.3 AEbus (LYNK) Network Communication
Discover batteries use CAN communication over the AEbus (LYNK) Network to
coordinate performance with other batteries and communicate with accessories
such as the LYNK Communication Gateway.
NOTICE
• Terminating resistors are required when deploying the battery in an AEbus (LYNK)
Network.
7.3.1 AEbus (LYNK) Network Power
The Discover battery provides the AEbus (LYNK) Network power through the AEbus
(LYNK) Port.
NOTICE
• Do not use an external power source to power devices over the AEbus (LYNK)
Network.
7.3.2 7.3.2 AEbus (LYNK) Network Size
One AEbus (LYNK) Network can support up to 13 AES LiFePO4batteries.
7.3.3 AEbus (LYNK) Network Cable
Use CAT5 cables for batteries on the AEbus (LYNK) Network.
8. OPTIONAL ACCESSORIES
The following optional accessories are available for the AES LiFePO4battery.
Accessory Part Number
LYNK II Communication Gateway 950-0025
AES LiFePO4Wall-Mount Bracket 950-0018

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9. INSTALLATION
WARNING
ELECTRIC SHOCK 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.
• There are no user-serviceable parts inside.
Failure to follow these instructions may result in injury.
NOTICE
• Some chargers and inverters support temperature-compensated charging. Disable
temperature-compensated charging on the charger or inverter.
• 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.
9.1 Tools
• Insulated tools sized to match nuts, bolts, and cables
• RMS type Voltmeter
• Post cleaner and wire brush
• Personal protective equipment
9.2 Location
Install the battery in locations that meet the following requirements:
1. Do not install in direct sunlight. Avoid installing the battery in an area with high
ambient temperature or an area exposed to UV rays.
2. Moderate temperature. The ambient temperature should be between 0°C and
40°C (32°F and 104°F). Ambient temperatures of 15°C to 25°C (59°F to 77°F)
are ideal for extending LiFePO4battery life. Do not install in close proximity to
a generator or other component that produces significant heat, as this could
expose the battery to temperatures greater than 40°C (104°F).
3. Ventilation. Do not install in zero-clearance compartments.
When installing a single battery, allow spacing of at least 25 mm (1 in) around
the perimeter of the battery.
When installing multiple batteries, allow spacing of at least 10 mm (0.4 in)
between batteries.
When installing multiple batteries vertically in tiers, allow at least 25 mm (1 in)
between a battery and the rack above it, except for the top tier of batteries. Allow
a clearance of at least 150 mm (5.9 in) between the top battery and the roof of
the enclosure.

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4. Away from water. Protect from exposure to water, including water sprayed from
nozzles. In a wall-mounted configuration, mount the batteries at least 50 mm (2
in) off the ground.
5. Orientation. Install the battery in any direction other than face down. Do not
install face-down.
6. Indoor or outdoor. Suitable for use indoors. Refer to Section 3.3, Environmental
Specifications for temperature ranges in which the battery can operate.
NOTE
• Using this product in a location that does not meet requirements will void the
warranty.
9.3 DC Cables
CAUTION
FIRE HAZARD
• Undersized cables can become hot and may potentially catch fire.
Failure to follow these instructions can result in minor to moderate injury.
The DC battery cables should meet the following requirements:
1. Copper-stranded cable. DC cables must be stranded, copper, and rated 90°C
minimum.Terminate the cables with lugs that fit the DC terminals.
2. Minimum cable lengths. Select a location that minimizes the length of
battery cables to reduce voltage drop from the impedance leading to reduced
performance.
3. Appropriate cable gauge. The cables should be capable of carrying the normally
expected current, plus a margin of safety.
4. Proper polarity. Positive (+) is connected to positive (+), and negative (-) is
connected to negative (-).
5. Minimum cable lengths. Select a location that minimizes the length of
battery cables to reduce voltage drop from the impedance leading to reduced
performance.
9.4 Protection
CAUTION
FIRE HAZARD
• Undersized fuses and disconnects may become overloaded and potentially cause a
fire.
• Fuses and disconnects are required to open before the cable reaches its maximum
current carrying capability.
Failure to follow these instructions can result in minor to moderate injury.
Additional DC overcurrent protection and a DC disconnect switch are required to
protect the system and DC battery cables.

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1. Appropriate size. Size the fuses and disconnects following local codes to protect
the wiring in the system and are required to open before the cable reaches its
maximum current carrying capability.
2. Install disconnects in both the positive and negative cables. The disconnect
should be located close to the battery and installed in both the positive and
negative cables. Local codes may limit how far the protection can be from the
battery.
+–
Battery
2 pole
DC Circuit
Breaker
Figure 4. Example disconnects
3. Install fuse protection in the positive cable. The fuse should be located close to
the battery and installed in the positive cable. Local codes may limit how far the
protection can be from the battery.
NOTE
• AC circuit breakers and DC circuit breakers are not interchangeable. Check the label
on the circuit breaker to ensure it is the correct type and rating. Use only DC circuit
breakers.
9.5 Securing the Battery
Use one of the methods below to secure the battery:
• Strap the battery in place with non-conductive nylon straps.
• Use screws in the hold-down brackets at the base of the 42-48-6650 model (see
figure below).
• Secure with a Discover AES Wall-Mount Bracket (p/n 950-0018), available for use
with the 42-48-6650 model.

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446.5 mm 446.5 mm 12.5 mm
226.7 mm
18 mm
Figure 5. 42-48-6650 screw holes
9.6 Installing the Battery
Battery cables must be sized to the specifications required by the inverter-charger
and installed in accordance with the standards set by the authority having local
jurisdiction. Do not use or install a battery temperature sensor.
Battery terminals are button-type, M8 female.The recommended torque is 9.0 Nm
(6.64 ft-lb) to a maximum depth of 14 mm. For information on connecting battery
cables, see Figure 9-2, Battery CableTerminal Connection.
1. Switch the battery OFF.
2. If the battery circuit has a disconnect, open the disconnect to isolate the battery.
3. Ensure the cable connections are clean and in good working order.
4. Install and secure the new battery.
• Take precautions to avoid bridging the terminals.
• Do not contact the terminals with metal mountings, fixtures, or body parts.
5. Connect battery cables.
• Connect the negative cable last to avoid sparking.
• Short circuits may damage the battery and void the warranty.
6. If using the LYNK II Communication Gateway, attach a CAT5 cable to the AEbus
(LYNK) Port on the battery and attach the other end of the cable to the LYNK II.
• Refer to Section 9.8.2, Network Installation, for instructions.
7. If the battery circuit has a disconnect, close the disconnect to reconnect the
battery.
8. Switch the battery ON.

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Copper
compression lug
Shrink-wrap to
color-code the cable
Washers ARE NOT
compressed
Terminal hardware
is bottomed out!
Battery cable lug
Ensure nothing is between
the terminal surface and the
battery cable lug
Terminal
surface
Terminal hardware
IS NOT
bottomed out!
Flat washer (supplied with battery)
M8” bolt (supplied with batter)
Lock washer (supplied with battery)
Figure 6. Battery Cable Terminal Connection
NOTE
• All cable ends must be connected to battery terminals without any washers between
terminal bushings and cable ends.
Terminal burnout is caused by:
• Discharge currents exceeding allowable limits
• Improper cable installation
• Improper cable sizing
• Improper terminal torque
NOTE
• Without exception, a product experiencing terminal burnout will void the warranty.
9.7 Installing Batteries in Parallel Battery Wiring
For proper balancing and load sharing between parallel batteries, refer to Figure
9-3, Batteries in Parallel Installation. Lithium batteries are very sensitive to voltage, and
undersized battery cables impede battery and system performance.The thickness
(cross-section) of cables should exceed the recommended minimum for the
inverter-charger installation.
When installing four or more batteries in parallel, use a busbar configuration.
In a busbar configuration, use the same length cable for all battery cable sets,
regardless of the battery’s proximity to the busbar (or combiner box). Actual wiring
requirements may vary. Consult with the authority having local jurisdiction.

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LOAD/CHARGER LOAD/CHARGER LOAD CHARGER LOADCHARGER
All parallel cables should be the same length
LOAD/CHARGER LOAD/CHARGER
INSTALLATION USING BUS BAR
LOAD CHARGER CHARGER LOAD
Figure 7. Batteries in Parallel Installation
NOTE
• Whenever replacing a battery in a parallel installation, use a battery of the same age,
model, capacity, and voltage.
• Before installing the battery in parallel, ensure that each battery is charged to 100%
SOC.
9.7.1 Commissioning a Parallel Battery System
In a parallel battery system, charge all batteries to 100% State of Charge (SOC)
before switching the batteries ON. Before energizing power electronics, switch all
batteries ON.
NOTICE
• Failure to ensure all batteries are at equal SOC when commissioning a paralleling
system may result in blown battery fuses.

20
9.8 AEbus (LYNK) Network
9.8.1 Network Layout
AES batteries use the AEbus (LYNK) Network to coordinate voltage, temperature,
and current data. Network terminators are required for the AEbus (LYNK) Network
to function properly.
Battery Battery
COM1 COM1 COM1
Battery
Terminate AEBus
Connector
Figure 8. Batteries connected to AEbus (LYNK) Network
9.8.2 Configuration with Power Conversion and Monitoring Devices
Set up AES batteries to work with Power Conversion and Monitoring devices in
either an Open-Loop or Closed-Loop configuration. Set up the charge and discharge
settings in an Open-Loop configuration through the Power Conversion device’s
controller at the time of installation. In a Closed-Loop configuration, the BMS of the
AES Battery dynamically controls charge and discharge settings over a connection
with the Power Conversion device. Closed-Loop communication on a Power
Conversion device network requires using the LYNK II Communication Gateway
(p/n 950-0025) available from Discover Battery.
For information on Closed-Loop and Open-Loop configuration with a Power
Conversion device, refer to the appropriate Application Note for your Power
Conversion device, available from the website www.discoverbattery.com, or contact
your Discover Battery provider for assistance.