DISCOVER LITHIUM PRO PROFESSIONAL Series User manual

1
INSTALLATION AND
OPERATION MANUAL
805-0027 REV A
PROFESSIONAL SERIES
BATTERY MODELS
DLP-GC2-12V
DLP-GC2-24V
DLP-GC2-36V
DLP-GC2-48V

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1. Audience, Messages, Warnings, General Safety, Personal Protective Equipment 3
1.1 Audience 3
1.2 Message 3
1.3 Warnings and General Safety 4
1.4 Personal Protective Equipment 5
2. Specifications 5
2.1 Electrical Specifications 5
2.2 Mechanical Specifications 6
2.3 Environmental Specifications 6
2.4 Protection Specifications 6
2.5 Internal Heating Specifications 8
2.6 Specifications for Parallel System Sizing 8
2.7 Regulatory 8
3.Transportation 9
4. Handling 9
5. Features 9
5.1 Battery Fuse 9
5.2 PTFE Membrane Vent 10
5.3 Battery ON/OFF Key 10
5.4 At-A-Glance LED 10
5.5 LYNK Port 10
5.6 Lifting Points 11
6.Theory of Operation 11
6.1 Ingress Protection IP67 11
6.2 Internal Heating 11
6.3 Battery Management System 11
6.4 LYNK Network Communication 13
7. Optional Accessories 14
8. Installation 15
8.1Tools 15
8.2 Location 15
8.3 DC Cables 16
8.4 DC Protection 16
8.5Terminal Connections and Hardware 17
8.6 Single Battery Installation Procedure 17
8.7 Parallel Battery Installation Procedure 18
8.8 LYNK Network 21
9. Operation 22
9.1 Low Voltage Cut-Off 22
9.2 State of Charge 23
9.3 Charging 23
9.4 Charging Profile 25
10. Routine Inspection 26
11. Replacing the Fuse 27
12. Storage 28
13. Related Information 28
14. Glossary ofTerms, Abbreviations, and Acronyms 28

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1. AUDIENCE, MESSAGES, WARNINGS, GENERAL SAFETY,
PERSONAL PROTECTIVE EQUIPMENT
1.1 Audience
Certain configuration, installations, 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
1.2 Messages
Messages on the battery and in this manual are formated according to this
structure.
Additional information concerning important procedures and
features of the battery. Read all the instructions before installation,
operation, and maintenance.
Do not crush, disassemble or dispose of the battery in fire or the
garbage.
This product must be recycled and is made of recyclable materials.
READ AND SAVE THESE INSTRUCTIONS
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 result in damage to the equipment
but not personal injury.
NOTE
Ad hoc information concerning important procedures and features of the battery not
related to personal injury or equipment damage.

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1.3 Warning and General Safety
WARNING
ELECTRIC SHOCK AND FIRE HAZARD. This equipment must only be installed as spec-
ified. Do not disassemble or modify the battery. If the battery case has been damaged,
do not touch exposed contents. 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: 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 and use safe handling procedures when handling
the battery. Failure to follow these instructions may result in injury.
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 fire.
• Promptly dispose or recycle used batteries following local regulations.
• Do not disassemble, open, crush, bend, deform, puncture or shred.
• Do not modify, re-manufacture, attempt to insert foreign objects into
the battery, immerse or expose to water or other liquids, expose to
fire, explosion, or other hazards.
• Only use the battery for the system for which it is specified.
• Do not lift or carry the battery while in operation.
• When lifting a heavy battery, follow the 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 has been qualified for
the system.The use of an unqualified battery or charger may present a
risk of fire, explosion, leakage, or other hazards.

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• Do not short circuit a battery or allow metallic conductive objects to
contact battery terminals.
• Replace the battery only with another battery that has been qualified
for the system.The use of an unqualified battery may present a risk of
fire, explosion, leakage, or other hazards.
• Avoid dropping 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.
1.4 Personal Protective Equipment
• Use Personal Protective Equipment, including clothing, glasses,
insulated gloves, and boots.
• Do not wear rings, watches, bracelets, or necklaces when handling or
working near the battery.
2. SPECIFICATIONS
Specifications are published at 25oC / 77oF
2.1 Electrical Specifications
Table 2-1. DLP-GC2 Electrical Specifications
Electrical Spec DLP-GC2-12V DLP-GC2-24V DLP-GC2-36V DLP-GC2-48V
Nominal Voltage 12.8 V 25.6 V 38.4 V 51.2 V
Energy 1536 Wh 1536 Wh 1152 Wh 1536 Wh
Capacity 1Hr 120 Ah 60 Ah 30 Ah 30 Ah
Reserve Capacity 25A 288 minutes 144 minutes 72 minutes 72 minutes
Charge Bulk Voltage - Bulk VDC 13.8 - 14.2 V 27.6 - 28.4 V 41.4 - 42.6 V 55.2 - 56.8 V
Charge Absorption Voltage - U1 MAX 13.8 V 27.6 V 41.4 V 55.2 V
Charge Float Voltage - U2 13.6 V 27.2 V 40.8 V 53.6 V
ChargeTermination Current
a
3.00 A 1.50 A 0.75 A 0.75 A
Low Voltage Disconnect Recommended 12.0 V 24.0 V 36.0 V 48.0 V
Low Voltage Disconnect 10.0 V 20.0 V 30.0 V 40.0 V
Max. Continuous Discharge Current 200 A 120 A 60 A 60 A
Nominal Charge Current 120 A 60 A 30 A 30 A
Max. Continuous Charge Current 120 A 60 A 30 A 30 A
Peak Discharge Current (3 seconds) 360 A RMS 180 A RMS 90 A RMS 90 A RMS
Fuse 200 A 125 A 60 A 60 A
Maximum Load Input Capacitance 49 mF 106 mF 51 mF 23 mF
a
Charge current termination is permitted to be less than specified. Note: when the charger termination current is
lowered, the internal balancing function will have more time to operate.

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2.2 Mechanical Specifications
Table 2-2. DLP-GC2 Mechanical Specifications
Mechanical Spec. DLP-GC2-12V DLP-GC2-24V DLP-GC2-36V DLP-GC2-48V
Chemistry LiFePO4
Length 260 mm (10.2 in)
Width 180 mm (7.1 in)
Total Height 275 mm (10.8 in)
Terminal 5/16 in Stud (Height 22 mm)
5/16 in Button Insert (Depth 18 mm)
TerminalTorque 13 Nm 9.6 ft-lb
Weight 14.0 kg (30.7 lb) 14.0 kg (30.7 lb) 11.2 kg (24.7 lb) 14.0 kg (30.7 lb)
IP Rating IP 67
Case Material UL94-VO PBT/PC
2.3 Environmental Specifications
Table 2-3. DLP-GC2 Environmental Specifications
Environmental Spec. All Models
ChargeTemperature
a,b
-20°C to 55°C (-4°F to 131°F)
Discharge Temperature
a
-20°C to 60°C (-4°F to 140°F)
StorageTemperature (1 month)
c
-20°C to 45°C (-4°F to 113°F)
StorageTemperature (6 months)
c
-10°C to 30°C (14°F to 86°F)
a
This is the specified temperature of the cells and not ambient. Ambient temperature and cell temperature may not
be the same.
b
The Battery Management System will not allow charging of the cells below 0°C. When charge begins below 0°C, the
energy is diverted to the internal heating until the cells reach 2°C, at which time cells will begin to be charged.
c
Storage outside of specified temperatures will result in permanent capacity loss and invalidate the warranty.
2.4 Protection Specifications
Table 2-4. DLP-GC2 Protection Specifications
Protection Spec. DLP-GC2-12V DLP-GC2-24V DLP-GC2-36V DLP-GC2-48V
Overvoltage
Protection
a
> 14.6 V for 3s > 29.2 V for 3s > 43.8 V for 3s > 58.4 V for 3s
Recovery
a
Recover after
120s and < 13.8V
Recover after
120s and < 27.6 V
Recover after
120s and < 41.4 V
Recover after
120s and < 55.2 V
Undervoltage
Protection
b
< 10 V for 5s < 20 V for 5s < 30 V for 5s < 40 V for 5s
Recovery
b
No automatic recovery.The battery will shut down after 120 seconds
Over-charge Current
Protection > 132 A for 10s > 66 A for 10s > 33 A for 10s > 33 A for 10s
Recovery Recovery after 120 seconds.

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Protection Spec. DLP-GC2-12V DLP-GC2-24V DLP-GC2-36V DLP-GC2-48V
Over-discharge Current
Protection
c
3-second rating
350 A
3-second rating
219 A
3-second rating
105 A
Recovery
c
Recover after 120 seconds
Over-temperature in Discharge
Protection
d
Cell temperature above 60°C (140°F) for 3 seconds
Recovery
d
Cell temperature below 50°C (122°F)
Under-temperature 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 3 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 > 2°C (36°F). Please note that discharge will
continue to be available to -20°C (-4°F)
Load Qualification Protection
Protection Mixed System Voltage, Short Circuit, Reverse Polarity, Input Capacitance
Overload
Recovery Re-Qualify after 120s. After 10 failed attempts to qualify, the battery will
switch OFF
a
Overvoltage protection monitors individual cell voltages. Protection will trigger when any cell is over 3.65 VPC and
recover when all cells are below 3.45 VPC for 120 seconds. Voltages are provided for guidance only.
b
Undervoltage protection monitors individual cell voltages. Protection will trigger with any cell under 2.5 VPC and
switch the battery OFF. Manually switch the battery to ON to recover. Voltages are provided for guidance only.
c
See Figure 1 Over-Discharge ProtectionTime Current Curve for time vs current interrupt detail.
d
This is the specified temperature of the cells and not ambient. Ambient temperature and cell temperature may not
be the same.
0.001
100 200 300
0.001
0.01
1
10
100
1000
10000
100000
Current (A)
Interrupt Time ()s)
400 500 600 700 800 900 1,000 1,100 1,200
Figure 1. Over-Discharge ProtectionTime Current Curve.

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2.5 Internal Heating Specifications
Table 2-5. DLP-GC2 Internal Heating Specifications
Internal Heating Spec. DLP-GC2-12V DLP-GC2-24V DLP-GC2-36V DLP-GC2-48V
Heating Power 50 W 50 W 50 W 50 W
Heating On Charge detected and < 0°C (32°F)
Heating Off Temperature > 2°C (36°F)
2.6 Specifications for Parallel System Sizing
Table 2-6. DLP-GC2-12V System Size Specifications - Examples
Parallel
System Peak Current Constant Discharge
Constant
Charge
Energy/Usable
Capacity
Reserve Capacity
at 25A
2 Batteries 720 A 400 A 240 A 3072 Wh 576 minutes
3 Batteries 1080 A 600 A 360 A 4608 Wh 864 minutes
4 Batteries 1440 A 800 A 480 A 6144 Wh 1152 minutes
Table 2-7. DLP-GC2-24V System Size Specifications - Examples
Parallel
System Peak Current Constant Discharge
Constant
Charge
Energy/Usable
Capacity
Reserve Capacity
at 25A
2 Batteries 360 A 240 A 120 A 3072 Wh 288 minutes
3 Batteries 540 A 360 A 180 A 4608 Wh 432 minutes
4 Batteries 720 A 480 A 240 A 6144 Wh 576 minutes
Table 2-8. DLP-GC2-36V System Size Specifications - Examples
Parallel
System Peak Current Constant Discharge
Constant
Charge
Energy/Usable
Capacity
Reserve Capacity
at 25A
2 Batteries 180 A 120 A 60 A 2304 Wh 144 minutes
3 Batteries 270 A 180 A 90 A 3456 Wh 216 minutes
4 Batteries 360 A 240 A 120 A 4608 Wh 288 minutes
Table 2-9. DLP-GC2-48V System Size Specifications - Examples
Parallel
System Peak Current Constant Discharge
Constant
Charge
Energy/Usable
Capacity
Reserve Capacity
at 25A
2 Batteries 180 A 120 A 60 A 3072 Wh 144 minutes
3 Batteries 270 A 180 A 90 A 4608 Wh 216 minutes
4 Batteries 420 A 240A 120 A 6144 Wh 288 minutes
2.7 Regulatory
Table 2-10. DLP-GC2 Regulatory
Regulatory
UN38.3Transportation UL 2271 (pending)
IEC 62619 (pending) CE
UL 1973 (pending)

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3. TRANSPORTATION
If the battery is not installed in equipment, it must be transported in the
original package or equivalent. According to the UN Handbook ofTests and
Criteria, Batteries are tested to part III, subsection 38.3 (ST/SG/AC.10/11/ Rev. 5).
For transport, the batteries belong to category UN3480, Class 9.
4. HANDLING
Before handling:
• Keep the battery away from sparks and flames
• Disconnect the cables from the battery
• Battery terminals must be protected from short-circuiting and touch
• A battery handle must be used to lift the battery
• Do not lift or carry the battery while it is in use or operation
• Do not lift the battery by the attached battery cable
5. FEATURES
Item Description
1
Battery negative (-) dual
terminal 5/16” stud, 5/16”
insert
2
Battery positive (+) dual
terminal 5/16” stud, 5/16”
insert
3 Fuse with cover
4 PTFE membrane vent
5ON/OFF Key and at-a-glance
LED
6 LYNK Port
7 Lifting Points
5.1 Battery Fuse
The battery fuse is intended to protect the electronic components of the
battery’s internal BMS from a high externally generated current. Fuses are
relatively inexpensive and easy to replace in the field compared with the
BMS, which is a high-cost item and is not serviceable in the field.
NOTE
Additional external DC fusing is required to protect the battery cables from DC over-
current and to meet installation codes.
1
2
3
4
5
6
7
7
Figure 2. Battery Features.

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5.2 PTFE Membrane Vent
Membrane vents enable the free passage of gases and vapours and
equalize the pressure between the internal and ambient conditions.This
helps to protect and preserve the internal components of the battery.
5.3 Battery ON/OFF Key
Briefly press the battery’s ON/OFF key to switch the battery ON.
Press and hold the ON/OFF key while the battery is ON for longer than 5
seconds, and the key will arm the Remote Power-Off (RPO) Mode. When the
battery is in RPO mode, the battery will shut down once the ON/OFF key is
released.
5.4 At-a-glance LED
WARNING
ELECTRIC SHOCK AND FIRE HAZARD: Always assumed the battery main relay to be
ON (Closed). Verify the terminal voltage with a voltmeter before battery handling and
installation. Even if the At-A-Glance LED shows that it may be OFF. Failure to follow
these instructions may result in death or serious injury.
Solid Green LED: The main relay is ON (Closed), the battery is ready for
operation.
Flashing Red LED: The main relay is OFF (Open), the battery is in protection
mode, and a fault has occurred. For a list of faults, refer to Table 2-4. DLP-GC2
Protections Specifications.
No LED: The main relay is OFF (Open).
5.5 LYNK Port
LYNK Port allows multiple batteries in a string to communicate and interact
in a closed-loop network and to enable the battery string to be externally
monitored. LYNK Port also allows DLP batteries to be networked in a closed-
loop system with external power conversion and motor control devices which
can automate the system's configuration and optimize performance. Battery
datalogs can be downloaded with LYNK Gateway devices.
5.5.1 LYNK Port PIN Assignment
PIN Number Function
1 ON/OFF Switch
2 LYNK Bus CAN L
3 LYNK Bus CAN H
4 LYNK Bus 12V +
5 LYNK Bus GND
Figure 3. 5 PIN M12
A-Code Circular
Metric Connectors.

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NOTICE
Crossing PIN functions may cause system damage. Do not terminate unused wires
to ground, power, or other functions. Isolate unused PINs.
5.6 Lifting Points
The battery lifting points are
designed to be used with a
standard golf cart battery
lifting strap.
6. THEORY OF OPERATION
6.1 Ingress Protection IP67
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 IP67 rating includes testing that
indicates no ingress of dust particles and no ingress of a harmful quantity of
water when immersed for up to 30 minutes.
IP codes guide suitability for use under different environmental conditions.
IP ratings do not indicate fitness for purpose or confer a performance
guarantee.
6.2 Internal Heating
The battery is equipped with internal heating. When the battery’s internal
temperature is below 0°C (32°F), the charger’s current will be directed to the
heating element. When the battery's internal temperature has reached 2°C
(36°F), heating will stop, and the battery BMS will then direct the current to
charge the cells.
When internal heating is active, discharging the battery is not possible.
6.3 Battery Management System
6.3.1 Battery Management System Protections
The Battery Management System’s (BMS) primary function is to monitor
cell module voltage and temperature and battery current.The BMS uses this
information to maintain cell operation within specification. If a parameter
falls outside of operating specifications, the BMS will disconnect and
protect the battery from:
1. Overvoltage. Protection occurs when charge voltages are too high.
2. Undervoltage.Protection occurs during discharge when the voltage is
discharged too low.
3. Over-current. Protection can occur during charge or discharge.This
may happen when powering up a load (high inrush current) or from a
Lifting strap.

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sustained current above the specified limit.
4. Over-temperature. Protection can occur during charge and discharge.
5. Under-temperature. Protection can occur during charge and discharge.
6. Load Qualification. When the battery is switched on, it will qualify the
load attached to the battery to prevent turning on into a reverse polarity,
short circuit, mixed voltage system, or large capacitive load.
For trigger and recovery values, refer to Table 2-4 DLP-GC2 Protection Specifications.
The BMS will reconnect when recovery thresholds are met. If the BMS
disconnects due to low voltage protection, the battery will have to be
manually switched ON. If the system has a constant parasitic draw, a
physical disconnect switch is recommended to reconnect the battery.
There is a 120-second delay for the battery to be turned back on again after
a load qualification fault.This means that if a user attempts to switch the
battery OFF after a load qualification fault, the battery cannot be switched
back ON again until the 120-second delay is over.
NOTE
Charge and discharge have different operating temperature limits.
NOTE
If the BMS disconnects responding to temperature or current limits, wait for the
temperature or current to reach normal operating limits.
6.3.2 Battery Management System Pre-Charge System
The battery is equipped with a Pre-charge System that will energize external
capacitive loads before turning on the main relay.The maximum input
capacitance for a single battery should not exceed the values published in
Table 2-1. DLP-GC2 Electrical Specifications.
6.3.3 Battery Management System Load Qualification
When the battery is switched from the OFF state to the ON state, the battery
BMS will qualify the external load before turning on the main relay. Load
qualification will reject turning on into short circuit, reverse polarity, mixed
voltage systems, or capacitive loads that exceed the batteries limits.
The battery will attempt Load Qualification up to a maximum of 10 times.
After 10 failed attempts at Load Qualification, the battery will switch OFF.
During Load Qualification, or when a load has been disqualified, the at-a-
glance LED will flash red.
6.3.4 Battery Management System Cell Balancing
The battery is equipped with cell balancing circuits that compare all cells
in a battery and balance the cell voltage at the end of the charge. When the
battery is networked with other batteries using the LYNK port, all battery
cells are balanced as an entire system and not as an individual battery.

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6.3.5 Battery Charge and Discharge Settings
The charge and discharge settings in an Open-loop configuration are set up
manually through the controller for the Power Conversion device at the time
of installation using the specifications provided in this manual. An Open-
loop system using lithium batteries is also known as a drop-in lead-acid
replacement system.This compares to a Closed-loop configuration where
the BMS controls charge and discharge settings over a connection with the
Power Conversion device.
Closed-loop communication with a Power Conversion device requires using
a LYNK II or LYNK LITE Gateway Communication device available from
Discover Battery. For details, please refer to the relevant LYNK Gateway
Communication User Manual available at www.discoverbattery.com, or
contact your Discover Battery provider for assistance.
Refer to the appropriate Application Note available at www.discoverbattery.
com for closed-loop parameter setup and integration with specific brands
of solar inverter-chargers, solar charger controllers, mobile inverter-chargers
and industrial chargers.
6.4 LYNK Network Communication
CAN communication is used over the LYNK Network by multiple batteries
to coordinate their performance and communicate with accessories such as
LYNK II and LYNK LITE Communication Gateways.
NOTICE
The battery has an intelligent CAN termination.Terminating resistors are not required
when deploying the battery in a LYNK Network.
6.4.1 LYNK Network Power
The battery provides the LYNK Network with power via the LYNK Port.
Discover accessory documentation will specify how many batteries are
required to provide sufficient power for the LYNK Network and compatible
accessories. Some accessories may require more than one DLP battery to
provide sufficient power.
NOTICE
Do not use an external power source to power devices over the LYNK Network.
6.4.2 LYNK Network Size
One LYNK Network is limited to 20 DLP batteries.The Network is limited
to up to 30 devices including batteries, displays, chargers and LYNK
Communication Gateway devices.
6.4.3 LYNK Network Cables
IP 65 rated LYNK Network cables compatible with the DLP battery PIN
configuration are available from Discover in various lengths.

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6.4.4 External ON/OFF Key
Use a momentary button type switch or a latching relay with a key to
switch ON/OFF a battery network from a remote location.To toggle the
battery network ON/OFF, connect the device to PIN 1 of the LYNK Network
communication line and the positive terminal of the batteries. Refer to Figure 4.
Remote ON/OFF Operation with Battery Network.
Momentarily activate the button to switch the battery ON and then
momentarily activate the button again to switch the battery OFF.
A latching relay will engage the Remote Power Off (RPO) battery function (refer
to Section 5.3 Battery ON/OFF Key). Setting the key to the ON position for 5 seconds
will switch the battery ON engaging RPO Mode. Returning the key to the OFF
position will release the battery from RPO Mode and switch the battery OFF.
PIN 1
ON/OFF
PIN 1
ON/OFF
POS + Battery
Terminal
POS + Battery
Terminal
Momentary
Latching for RPO
Figure 4. Remote ON/OFF Operation with Battery Network.
7. OPTIONAL ACCESSORIES
Optional accessories are available for use with the DLP battery:
Accessory Part Number
DLP B2B-400 (COMM Cable 0.4 meters / 15.75 inches) 950-0035
DLPTOL-7600 (COMM Cable 7.6 meters / 299.25 inches) 950-0037
DLPTOL-1800 (COMM Cable 1.8 meter / 70.87 inches) 950-0036
DLPT Connector (COMM T Connector)
with DLP B2B-400 (COMM Cable 0.4 meters / 15.75 inches) 950-0038
DLPT Connector (COMMT Connector) 950-0041
LYNK II Communication Gateway 950-0025
LYNK LITE Communication Gateway 950-0040
SOC GAUGETYPE B
CAN Bus Battery Discharge Indicator with 1.8 meters / 70.87 inches cable 950-0039
SOC GAUGETYPE A
CAN Bus Battery Discharge Indicator with 1.8 meters / 70.87 inches cable 950-0044

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8. INSTALLATION
WARNING
ELECTRIC SHOCK AND FIRE 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. No user-serviceable parts inside.
Failure to follow these instructions may result in injury.
NOTICE
For chargers or inverters with temperature compensated charging, disable this feature.
NOTICE
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.
8.1 Tools
• Insulated tools sized to match nuts, bolts, and cables in use
• RMS type Voltmeter
• Post cleaner and wire brush
• Personal protective equipment
8.2 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.
2. Moderate temperatures. Ambient temperatures should be between 0°C
and 40°C (32°F and 104°F). Ambient temperatures of 15°C to 20°C (59°F
to 68°F) are ideal for extending LiFePO4battery life. Do not install in an
engine compartment, as this will expose the battery to temperatures
greater than 40°C (104°F).
3. Ventilated. Do not install in zero-clearance compartments. Maintain at
least 20 mm (0.8 inches) above the top cover for open airflow.
4. Proper orientation.The battery may be installed in any orientation other
than upside down. Do not install upside down.
5. Minimum cable lengths. Select a location that minimizes the length
of battery cables to reduce voltage drop from impedance leading to
reduced performance.

16
NOTE
Warranty will be void if operated outside of these conditions.
8.3 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 must
be rated 90°C (194°F) minimum.The cables must be terminated with
lugs that fit the DC terminals.
2. Minimum cable lengths. Select a location that minimizes the length of
battery cables in order to reduce voltage drop from 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 ( + ) connected to positive ( + ), and negative ( - )
connected to ( - ).
8.4 DC 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:
1. Appropriate size. Fuses and disconnects must be sized 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 protection in the positive cable.The fuse and disconnect should
be located as close as possible to the battery and must be installed in the
positive cable. Applicable 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.

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NOTE
Local electrical code in your area may require both positive and negative DC
disconnect switches. Always refer to the applicable code and check with authority
having jurisdiction to confirm local requirements.
8.5 Terminal Connections and Hardware
The terminal connections and hardware should meet the following requirements:
1. Connect to the battery terminal. All cable lugs must be in direct contact
with the battery terminal deck. Do not put washers between the terminal
deck and cable lug.
2. Use the proper torque. Use a torque wrench to properly adjust terminal
hardware torque. Periodically check to ensure torque is correct.
Stud Connection
5/16"-18 Thread
(Supplied with battery)
Insert Connection
5/16-18 5/8''
Flange Bolt
(Supplied with battery)
Figure 5. CorrectTerminal Installation.
NOTICE
Failure to torque up to specification may increase resistance and lower voltage,
leading to burnout of the terminals and voiding the warranty.Torquing up over the
specification may cause the battery casing to crack, voiding the warranty.
NOTE
Without exception, a product experiencing terminal burnout will not be warranted.
8.6 Single Battery Installation Procedure
Equipment must be installed following the standards set by the local authority
having jurisdiction.
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.
Battery cables (battery to load and battery to charger) must meet the following
requirements to optimize performance:
1. Minimum cable lengths. Select a location that minimizes the length of
battery cables to reduce voltage drop from the impedance.

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Equipment must be installed in accordance with the standards set by the local
authority having jurisdiction
1. If the circuit of equipment that the battery is installed in has a
disconnect, open the disconnect to isolate the battery.
2. Ensure the battery is OFF.
3. Ensure the cable connections are clean and serviceable.
4. Install and secure the battery. Be careful not to make contact between
the terminals and any metal mounting, fixture, or body part.
5. Connect battery cables taking care to connect the positive ( + ) cable to
the positive ( + ) terminal. Connect the negative ( - ) cable last to avoid
sparks. Short circuits may damage the battery and this will void the
warranty.
6. Torque all battery terminals to the recommended terminal torque of 13
Nm (9.6 ft-lb) to secure cable lugs.
7. Install T connector and attach Comm cable. Attach the other end
of the Comm cable to a LYNK device. Refer to Section 8.8.2 Network
Installation for complete instructions.
8. Set the battery to ON.
9. Close circuit disconnect (if open)
NOTICE
Failure to torque up to specification may increase resistance and lower voltage,
leading to burnout of the terminals and voiding the warranty.Torquing up over the
specification may cause the battery casing to crack, voiding the warranty.
NOTICE
For chargers or inverters with temperature compensated charging, disable this
feature. Do not use or install a battery temperature sensor.
8.7 Parallel Battery Installation Procedure
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.
Batteries used in a parallel system must meet the following requirements:
1. Same model. Batteries must be the same model.
2. Equal voltage. Always ensure that batteries are within 50 mV (0.05 V) of
each other, at 95% SOC or higher, before installing them in parallel.
Battery cables (battery to load and battery to charger) must meet the following
requirements to optimize performance:

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1. Minimum cable lengths. Select a location that minimizes the length of
battery cables to reduce voltage drop from the impedance.
Interconnection cables (battery to battery) must meet the following requirements
to optimize performance:
1. Equal cable gauge.The interconnection cables should be the same gauge.
2. Equal cable length. The interconnection cables should be of equal length.
Equipment must be installed in accordance with the standards set by the local
authority having jurisdiction.
1. If the circuit of equipment that the batteries are installed in has a
disconnect, open the disconnect to isolate the batteries.
2. Ensure that all batteries are set to OFF.
3. Ensure the cable connections are clean and serviceable.
4. Install and secure new batteries. Be careful not to make contact
between the terminals and any metal mounting, fixture, or body part.
5. Connect battery positive ( + ) cables between the battery positive ( + )
terminals with firmly tightened terminal hardware.
Figure 6. Positive Parallel Connections.
6. Connect battery negative ( - ) cables between the battery negative ( - )
terminals with firmly tightened terminal hardware.
Figure 7. Negative Parallel Connections.
7. Connect the load positive ( + ) cable and load negative ( - ) cable to the
opposing ends of the parallel batteries.

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LOAD (+)
LOAD (-)
Figure 8 Load Connections.
8. Connect the charger positive ( + ) cable and charger negative ( - ) cable
to the opposing ends of the parallel batteries.
LOAD (+)
LOAD (-)
CHARGER (-)
CHARGER (+)
Figure 9. Charger Connections.
9. Torque all battery terminals to the recommended terminal torque of 13
Nm (9.6 ft-lb) to secure cable lugs.
10. Install aT connector on each battery and interconnect each battery in a daisy
chain with a Comm cable. If an LYNK device is being used, attach a Comm
cable from theT Connector of the last battery in the string to the LYNK
device. Refer to Section 8.8.2 Network Installation for complete instructions.
11. Energize the system by setting all the batteries to ON.
12. Close the circuit disconnect (if open).
NOTICE
Failure to torque up to specification may increase resistance and lower voltage, leading to
burnout of the terminals and voiding the warranty.Torquing up over the specification may
cause the battery casing to crack voiding the warranty.
NOTE
Wherever replacing an old battery in a string, use a battery of the same age, model,
capacity, and voltage.
NOTE
Before installing the battery in parallel, ensure that each battery is charged to 100% SOC.