DISCOVER 15-24-1000 User manual

805-0002 REV C
Operating Manual
4-13511 Crestwood Place,
Richmond, BC, V6V 2E9, Canada
discoverbattery.com
15-24-1000
15-36-1000
1. Safety 2
1.1 Warnings, Cautions and Notes 2
1.2 General Warning 2
1.3 Fire Risk 2
1.4 Electric Shock Risk 2
1.5 Chemical Risk 3
1.6 Do’s 3
1.7 Do Not’s 3
1.8 DC Motor Connection 3
1.9Transportation 3
2. Operating Limits 3
2.1 Battery Operating Limits 3
3. Design Features & Components 4
3.1 Battery Management System (BMS) 4
3.2 Fuse 4
3.3Terminals 4
4. Handling 4
5. Installation - Single Battery 4
5.1Tools 5
5.2 Securing Battery 5
5.3 Installation 5
6. Operation 5
6.1 On-Off 5
6.2 Charging 5
6.3 Charge Curve 6
6.4 Discharging 6
6.5 Storage 6
7. Protection and Faults 7
7.1 Faults 7
8. Service & Maintenance 8
8.1 Inspection 8
9.Troubleshooting 8
9.1 Battery Won’tTurn On 8
10. Recycling and Disposal 8
11. 15-24-1000Technical Specications 9
12. 15-36-1000Technical Specications 10

2
1. SAFETY
1.1 Warnings, Cautions, Notes and Symbols
▲WARNING
Important information regarding possible personal injury.
▲CAUTION
Important information regarding possible equipment damage.
▲NOTE
Additional information concerning important
procedures and features of the battery.
1.2 General Warning
▲CAUTION
Important to operate the device with care
to avoid undesirable consequences.
Do not throw in the garbage. Do not dispose in re.
Use personal protective equipment when working with batteries.
Additional information concerning important procedures and features of the battery. Read all the instructions before
installation, operation and maintenance.
This product must be recycled and is made of recycled products.
▲CAUTION
Do not disassemble or modify the battery. If the battery housing
is damaged, do not touch exposed contents.
1.3 Fire Risk
▲WARNING
Risk of re - No user serviceable parts.
• Battery has a battery management system with integrated solid state relay to reduce re risk.
• Primary suppression for lithium battery res is water. Secondary suppression is CO2, powder and halon.
1.4 Electric Shock Risk
▲WARNING
For wet and electrically uninsulated working conditions, electric
shock risk is high, and can cause injury and death.
Model Nominal System Voltage Maximum System Voltage
15-24-1000 24 V 29.6 V
15-36-1000 36V 38.4V

3
1.5 Chemical Risk
▲WARNING
Lithium batteries are chemical risk if misoperated,
mishandled or abused.
1.6 Do’s
• Do protect terminals from short circuit before, during, and after installation
• Do wear electrically insulated gloves
• Do use electrically insulated tools
• Do wear eye protection
• Do wear safety toe boots / shoes
• Do handle battery carefully
• Do secure battery safely
• Do always assume battery terminals are energized
1.7 Do Not’s
• Do not lift or carry the battery during usage or operation
• Do not operate or store battery outside of operating limits
• Do not short circuit battery
• Do not puncture battery
• Do not expose battery to ames, or incinerate
• Do not open battery case or dissemble battery
• Do not wear rings, watches, bracelets or necklaces when handling or working near battery
• Do not drop or crush battery
• Do not lift battery by the terminal cables
• Do not vibrate battery
• Do not expose battery to water or other uids
• Do not expose battery to direct sunlight
• Do not dispose of battery
• Do not connect with other types of batteries
• Do not expose battery to high temperatures
• Do not install with other battery types or brands
1.8 DC Motor Connection
Direct connection to DC motors without proper safety protection, motor controllers, and external motor voltage clamping
systems (such as high power anti-parallel diodes or braking resistor systems) may result in damage to the internal pack
protection system which may result in unsafe situations. Please consult Discover technical support before directly connecting any
motor loads.
1.9 Transportation
If the battery is not installed in equipment, it must be transported in the original package or equivalent.
Batteries are tested according to UN Handbook of Tests and Criteria, part III, sub section 38.3 (ST/SG/AC. 10/11/Rev.5). For
transport the batteries belong to category UN3480, Class 9, Packaging Group II.
2. OPERATING LIMITS
2.1 Battery Operating Limits
The battery should not be operated outside these operating limits.
Operating Limits 15-24-1000 15-36-1000
Discharge and Charge Current 40 A 25 A
Charge Voltage 27.2 V 40.8
Operating Voltage (Min / Max) 22.4 V / 29.6 V 33.6 V / 44.4 V
ChargeTemperature (Min / Max) 0°C / 45°C (32°F / 113°F)
DischargeTemperature (Min / Max) -20°C / 60°C (-4°F / 140°F)
StorageTemperature (Min / Max) -20°C / 45°C (-4°F / 113°F)

4
▲ CAUTION!
Do not install batteries in series. Select the appropriate
AES battery model for the voltage of your system.
▲NOTE!
Intentional bypassing of BMS to operate battery outside
maximum and minimum limits voids warranty.
3. Design Features & Components
3.1 Battery Management System (BMS)
Monitoring
BMS monitors:
• Cell module voltage
• Battery voltage
• Battery current
• Battery temperature
• Battery state of charge (SOC)
Module Balancing
• BMS performs balancing of cell modules.
Protection & Fault Management
• BMS sounds buzzer when fault limits are reached
• BMS generates fault when maximum operating limits are reached
• Fault events cause switch to open and battery to shut down after a 120s delay
Communication Ports
BMS has an isolated RS232 communication port (for service technician use only).
3.2 Fuse
Fuse provides back-up over-current protection.
Fuse Replacement
A blown fuse requires service from a qualied technician. Contact your Discover supplier for more information.
3.3 Terminals
Terminals are post-type, M6 female.
Terminal Torque 7.0-7.7 Nm / 5.1-5.7 Ft-lb
4. Handling
▲ WARNING!
Read Safety Section before installing the battery.
• Battery should be off
• Battery cables should be disconnected
• Battery terminals should be protected
• Battery handle should be used to lift battery
• Do not lift or carry the battery during usage or operation
5. Installation - Single Battery
▲ WARNING!
Read Safety Section before installing the battery.

5.1 Tools
• Insulated tools sized to match nuts, bolts and cables in use
• Voltmeter
• Post cleaner and wire brush
• Personal protective equipment
5.2 Securing Battery
• Battery can be strapped in place with non-conductive nylon straps
5.3 Installation
• Check that battery is switched off
• If battery circuit has disconnect, open disconnect to isolate battery
• Clean cable connections. Broken, frayed, brittle, kinked or cut
cables should be replaced
• Install and secure new battery. Be careful not to ground the
terminals to any metal mounting, xture, or body part
• Connect battery cables. Connect ground cable last to avoid sparks
• Recommended terminal torque is 7.0 – 7.7 Nm (5.1 – 5.7 ft-lb)
• Close circuit disconnect (if open)
• Turn battery switch on
▲ NOTE!
All cables 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, product experiencing terminal burn
out will not be warranted.
6. Operation
▲ NOTE!
Review operating limits.
6.1 On–O
• To turn the battery on press and hold switch for 2-3 seconds
• To turn the battery off press and hold switch for 2-3 seconds
6.2 Charging
Before operating the charger make sure to read and understand the instructions that come with the charger. Never attempt to
charge a battery without rst reviewing and understanding the instructions for the charger being used.
▲ CAUTION!
Always make sure the chargers charging curve meets the
battery’s charging requirement; never charge a visibly
damaged battery; never charge a frozen battery.
1. Connect the charger leads to the battery.
2. Make sure that the charger lead, both at the charger and the battery side, connections are tight.
3. Turn the charger on.
4. Turn the battery on (if required).
M6” bolt (supplied)
Copper compression lug
Shrink-wrap to
color-code the cable
Terminal surface
Lock washer (supplied)
Flat washer (supplied)
Battery cable lug
Ensure nothing is between
the terminal surface and the
battery cable lug
5

▲ CAUTION!
NOT ALL CHARGERS ARE CAPABLE OF CHARGING
LITHIUM BATTERIES!
During system design CONFIRM that your chosen charger
is not capable of transient spikes that exceed the published
MAXIMUMTERMINAL RATINGS of the battery
Spikes are fast, short duration electrical transients in voltage (voltage spikes), current (current spikes), or transferred energy
(energy spikes) in an electrical circuit. Voltage spikes usually happen when the AC/DC adaptor is plugged in, or charge current
is cut off quickly. Multi voltage chargers are made using transformers that may be capable of producing spikes that exceed the
maximum ratings of the Discover AES.You must conrm with the charger supplier that the chargers being supplied:
• meet Discover’s recommended charge curve, and
• are not capable of exceeding Discover’s maximum terminal voltages.
6.3 Charge Curve
Charge sequence
1. Use Qualication phase for auto-on feature (optional).
2. Charge at constant current to 3.4 Vdc per cell module (Bulk).
3. Maintain constant voltage 3.4 Vdc per cell module (Absorption).
4. Terminate when charge current drops below 2A.
▲ CAUTION!
Do not charge battery higher than 3.4 Vdc per cell module.
▲ NOTE!
Recommended charge current is 0.5C.
Model VQIQVBATT
15-24-1000 Min 20V / Max 24V (IQ< 1A) < 1 A ≥ 20 V
15-36-1000 Min 20V / Max 36V (IQ< 1A) ≥ 30 V
Model Cell Modules
in Series VBATT I1 U1 Termination Charge Current
15-24-1000 8S ≥ 20 V 40 A maximum 27.2 V I2 ≤ 2 A
15-36-1000 12S ≥ 30 V 25 A maximum 40.8 V
6.4 Discharging
• Turn on battery
• Turn on load
▲ NOTE!
Do not discharge battery below recommended minimum
operating voltages.
▲ NOTE!
Do not discharge battery at rates greater than
recommended operating currents.
6.5 Storage
Systems should be stored out of direct sunlight under the following temperature conditions:
Absorption
Charge Current % of Bulk Charge C-Rate [%]
Voltage - U Current - I
BulkQualification
Battery Voltage [V]
2.820% VBATT
VQ
IQ
40%
60%
80%
100%
3
3.2
3.4
3.6
U1
I2
I1
VQ=12V IQ=1Amax
6

Minimum Storage Temperature -20°C / -4°F
Maximum Storage Temperature 45°C / 113°F
Systems should be put into storage at 80% SOC and checked monthly to ensure the system SOC does not fall below 20%. At 20%
SOC the battery will self discharge in approximately 2 months.
7. Protection & Faults
• BMS generates faults when maximum operating limits are reached.
• BMS sounds a buzzer when fault limits are triggered.
• BMS monitors the following information for faults and warning:
1. Cell module voltage
2. Battery current
3. Battery temperature
7.1 Faults
In the event of a fault the BMS will sound an audible buzzer warning and the system will shut off after a 120 second delay.
When the operating conditions are within acceptable ranges, the battery can be recovered from Fault by pushing the ON-OFF
button.
Low State of Charge
Charge
Over Voltage
Stop charge
Over Current
Reduce current
Over Temperature
Stop using/let cool
Short Circuit
Check external
circuits
FLASHING LED
7
FAULT LEVELS
Parameter Trigger Point
High Temperature in Discharge 60°C / 140°F for 2s
High Temperature in Charge 45°C / 113°F for 2s
High Voltage 3.7 V in any cell module 2s
Low Temperature in Discharge -20°C / -4°F for 2s
Low Temperature in Charge -1°C / 30°F for 2s
Low Voltage 2.8 V in any cell module for 2s
Over Current > 45 A for 5 sec.
In-rush Current 200 to 260 A for 640ms
CORRECTIVE ACTIONS
High Temperature • Stop discharge or charge
• Leave the battery to cool
Low Temperature • Stop discharge or charge
High Voltage • If charging stop the charge
Low Voltage
• Do not discharge the battery. Any
discharge current detected will force
the battery into Low Voltage Fault
• The user can charge the battery in
Low Voltage Recovery
• If no charge current is detected
within 2 minutes the BMS will turn
off the battery
Over Current • Reduce current
Low SOC • Stop discharge
• Charge the battery

8. Service & Maintenance
Batteries should be carefully inspected on a regular basis in order to detect and correct potential problems before they can do
harm.This routine should be started when the batteries are rst received.
8.1 Inspection
• Look for cracks in the case
• Check the battery, terminals and connections to make sure they are clean, free of dirt, uids and corrosion
• All battery cables and their connections should be tight, intact, and NOT broken or frayed
• Replace any damaged batteries
• Replace any damaged cables
• Check torque on terminal bolts
9. Troubleshooting
9.1 Battery Won’t Turn On
Symptom Does the battery turn on for a short time then turns itself off?
Description
The battery is likely in a low voltage or low SOC state. Check to
see if the blue light is blinking.This indicates a low voltage or
low SOC condition.
Action Connect to charger and turn on the battery.
Symptom Was the battery left on or stored for extended periods of time?
Description The battery will turn itself off at 5% SOC. If left sitting at a low
SOC, the battery may have discharged itself completely.
Action Do not use. Replace and recycle.
10. Recycling and Disposal
Batteries must not be mixed with domestic or industrial waste. Discover’s Advanced Energy Systems are recyclable and must be
processed through a recognized recycling agency or dealer. Please contact Discover® or your servicing dealer for details.
8

9
Electrical Specications
Nominal Voltage 25.6 V
Charge Voltage 27.2 V
Maximum Voltage 29.6 V
Minimum Voltage 22.4 V
Nominal Capacity 40 Ah
Nominal Energy 1024 Wh
Max Continuous Current 40 A
Fuse 40 A Internal Fuse -
provides backup over-
current protection
Cell Chemistry LiFePO4
Cell Modules 8S 8P
Self-Discharge 25°C / 77°F < 3% per month
(battery off)
Fault Limits
OverTemperature - Discharge Protection > 60°C/140°F for 2s
OverTemperature - Charge Protection > 45°C/113°F for 2s
LowTemperature - Discharge Protection < -20°C/-4°F for 2s
LowTemperature - Charge Protection < -1°C/30°F for 2s
Over Voltage Protection > 3.7 V in any cell
module for 2s
Under Voltage Protection < 2.8 V in any cell
module for 2s
Over Current Protection 45 to 200 A for 5s
In-Rush Current Protection 200 to 260 A for 640ms
Mechanical Specications
Battery Dimensions (HxWxD) 198 x 167 x 258 mm
Battery Weight 12.4 kg
Shipping Dimensions (HxWxD) 248 x 250 x 340 mm
Shipping Weight 13 kg
Terminal A2 - M6
Terminal Hardware M6 Stainless Steel
Bolt, Flat Washer, Lock
Washer (Supplied)
Terminal Torque 7.0 - 7.7 Nm
Case Material PC-ABS UL 94 V0
Compliant
Enclosure IP Rating IP 55
ChargeTemperature Range 0°C/45°C (32°F/113°F)
DischargeTemperature Range -20°C/50°C (-4°F/122°F)
StorageTemperature Range -20°C/45°C (-4°F/113°F)
5 4 3 2 1
9 8 7 6
10
15 14 13 12 11
54321
9876 10
1514131211
FEMALE
MALE
Pin 3 RS232 GND Isolated RS232 Ground
Pin 4 RS232TX Isolated RS232Transmit
Pin 5 RS232 RX Isolated RS232 Receive
Regulatory Approvals UN 38.3, IEC 62133,
UL2271
Operational Specications
Battery Management System (BMS) Integrated, with Solid
State Relay (SSR)
Cell Balancing Passive balancing
during charge when
Cell Voltage > 3.35 V
Non-Volatile Memory Yes
Lifetime Logged Data Charge Amp-Hours,
Discharge Amp-Hours
(lifetime)
State of Charge Battery Meter 5 LEDs (> 80%, 60%,
40%, 20%, 5%)
Communication Ports Isolated RS232
communication port
Communication Connector DE-15 Female
11. 15-24-1000 TECHNICAL SPECIFICATIONS

10
Electrical Specications
Nominal Voltage 38.4 V
Charge Voltage 40.8 V
Maximum Voltage 44.4 V
Minimum Voltage 33.6 V
Nominal Capacity 25 Ah
Nominal Energy 960 Wh
Max Continuous Current 25 A
Fuse 40 A Internal Fuse -
provides backup over-
current protection
Cell Chemistry LiFePO4
Cell Modules 12S 5P
Self-Discharge 25°C / 77°F < 3% per month
(battery off)
Fault Limits
OverTemperature - Discharge Protection > 60°C/140°F for 2s
OverTemperature - Charge Protection > 45°C/113°F for 2s
LowTemperature - Discharge Protection < -20°C/-4°F for 2s
LowTemperature - Charge Protection < -1°C/30°F for 2s
Over Voltage Protection > 3.7 V in any cell
module for 2s
Under Voltage Protection < 2.8 V in any cell
module for 2s
Over Current Protection 45 to 200 A for 5s
In-Rush Current Protection 200 to 260 A for 640ms
Mechanical Specications
Battery Dimensions (HxWxD) 198 x 167 x 258 mm
Battery Weight 12.4 kg
Shipping Dimensions (HxWxD) 248 x 250 x 340 mm
Shipping Weight 13 kg
Terminal A2 - M6
Terminal Hardware M6 Stainless Steel
Bolt, Flat Washer, Lock
Washer (Supplied)
Terminal Torque 7.0 - 7.7 Nm
Case Material PC-ABS UL 94 V0
Compliant
Enclosure IP Rating IP 55
ChargeTemperature Range 0°C/45°C (32°F/113°F)
DischargeTemperature Range -20°C/50°C (-4°F/122°F)
StorageTemperature Range -20°C/45°C (-4°F/113°F)
5 4 3 2 1
9 8 7 6
10
15 14 13 12 11
54321
9876 10
1514131211
FEMALE
MALE
Pin 3 RS232 GND Isolated RS232 Ground
Pin 4 RS232TX Isolated RS232Transmit
Pin 5 RS232 RX Isolated RS232 Receive
Regulatory Approvals UN 38.3
Operational Specications
Battery Management System (BMS) Integrated, with Solid
State Relay (SSR)
Cell Balancing Passive balancing
during charge when
Cell Voltage > 3.35 V
Non-Volatile Memory Yes
Lifetime Logged Data Charge Amp-Hours,
Discharge Amp-Hours
(lifetime)
State of Charge Battery Meter 5 LEDs (> 80%, 60%,
40%, 20%, 5%)
Communication Ports Isolated RS232
communication port
Communication Connector DE-15 Female
12. 15-36-1000 TECHNICAL SPECIFICATIONS