DISCOVER ELEMENT User manual

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ELEMENT ESS INSTALLATION
AND OPERATION MANUAL
805-0043 REV B
BATTERY MODELS
48-48-5120
48-48-5120-H

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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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2. ITEMS SHIPPED IN THE BOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3. SPECIFICATIONS ....................................................................6
3.1 Electrical Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.2 Mechanical Specifications...................................................7
3.3 Environmental Specifications ................................................8
3.4 Protections Specifications...................................................8
3.5 Internal Heating Specifications..............................................10
3.6 Minimum Specifications for Discover Battery Module Systems ...................10
3.7 Regulatory ..............................................................11
4. TRANSPORTATION ................................................................. 11
5. HANDLING ........................................................................ 11
6. FEATURES ......................................................................... 12
6.1 Battery Module Breaker....................................................12
6.2 Battery Module ON/OFF Key ................................................13
6.3 At-a-glance LED ..........................................................13
6.4 LYNK Port ...............................................................13
6.5 Equipment Ground .......................................................14
7. THEORY OF OPERATION............................................................. 14
7.1 Ingress Protection IP20 ....................................................14
7.2 Internal Heating (48-48-5120-H) .............................................15
7.3 Battery Management System ..............................................15
7.4 LYNK Network Communication .............................................17
8. OPTIONAL ACCESSORIES ........................................................... 18
9. INSTALLATION ..................................................................... 18
9.1 Tools ...................................................................18
9.2 Location ................................................................19
9.3 DC Cables ...............................................................20
9.4 DC Protection ............................................................20
9.5 Terminal Connections and Hardware .........................................21
9.6 Single Battery Module Installation Procedure..................................21
9.7 Parallel Battery Module Installation Procedure .................................23
9.8 LYNK Network ...........................................................25
10. OPERATION ....................................................................... 26
10.1 Low Voltage Cut-Off .......................................................26
10.2 State of Charge ..........................................................26
10.3 Charging ................................................................27
10.4 Charging Profile ..........................................................28
11. ROUTINE INSPECTION ............................................................. 30
12. STORAGE ......................................................................... 30
13. BATTERY MODULE FIRMWARE AND DATA LOGS ....................................... 31
14. TROUBLESHOOTING ................................................................ 31
15. RELATED INFORMATION ............................................................ 31
16. GLOSSARY OF TERMS, ABBREVIATIONS, AND ACRONYMS ............................. 31

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Introduction
The ELEMENT ESS is a battery module that can operate independently or in a
battery bank configuration where multiple battery modules are connected in
parallel.
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 install the battery module in series.
• Do not disassemble or modify the battery module.
• If there is damage to the battery module 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 across the terminals.
Failure to follow these instructions may result in death or serious injury.
CAUTION
HEAVY OBJECT
Two person lift is recommended for the battery module.
Failure to follow these instructions may result in injury.

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CAUTION
ELECTRIC SHOCK HAZARD
• Do not touch the energized surfaces of any electrical component in the battery
module system.
• Before servicing the battery module, follow all procedures to fully de-energize the
battery module system.
• Follow the “Safe Handling Procedures” below when working with the battery
module.
Failure to follow these instructions may result in injury.
1.4 Safe Handling Procedures
Before using the battery module, read all instructions and cautionary markings on
the unit and all appropriate sections of this manual.
• Use personal protective equipment when working with battery modules.
• Do not dispose of the battery module in a fire.
• Promptly dispose of or recycle used battery modules 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 module, immerse or expose the battery module 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 module for the system for which it is specified.
• Do not lift or carry the battery module while in operation.
• The battery module is heavy. When lifting the battery module, follow appropriate
standards.
• Only lift, move, or mount following local regulations.
• Take care when handling battery module terminals and cabling.
• Do not expose the battery module to high temperatures.
• Do not submerge the battery module.
• Do not install the battery module with the faceplate down.
• Only use the battery module with a charging system that meets specifications.
Using a battery module or charger that does not meet specifications may present
a risk of fire, explosion, leakage, or other hazards.
• Do not short-circuit a battery module or allow metallic conductive objects to
contact battery module terminals.
• Replace the battery module with only another battery module that meets
the specifications of the system. Using a battery module that does not meet
specifications may present a risk of fire, explosion, leakage, or other hazards.
• Do not drop the device or battery module. If the device or battery module is
dropped, especially on a hard surface, and the user suspects damage, take it to a
service center for inspection.

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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 metal rings, watches, bracelets, or necklaces.
2. ITEMS SHIPPED IN THE BOX
Table 2-1, ELEMENT ESS box contents
Items Description
1Battery Module
1CAT5 Cable
4Screws (M6)
1Ground Wire
1 set Serial Number Labels
3. SPECIFICATIONS
All specifications in this document are published @25ºC / 77ºF.
3.1 Electrical Specifications
Table 3-1, ELEMENT ESS Electrical Specifications
Electrical Specifications 48-48-5120 / 48-48-5120-H
Nominal Voltage 51.2 V
Energy 5120 Wh
Capacity 1 Hr 100 Ah
Charge Bulk Voltage - Bulk VDC 55.2 V
Charge Absorption Voltage - U1 MAX 55.2 V
Charge Float Voltage - U2 53.6 V
ChargeTermination Current (a) 2.5 A
Low Voltage Disconnect Recommended 48.0 V
Low Voltage Disconnect (b) 40.0 V
Max. Continuous Discharge Current 100 A
Nominal Charge Current 50 A
Max. Continuous Charge Current 100 A
Peak Charge Current (10 seconds) 200 A
Peak Discharge Current (3 seconds) 220 A
Breaker (K-Curve) Dual 100 A (2-Pole ganged)
Maximum short circuit fault current (IBF / ½ IBF) 3.8 kA (100 ms) / 1.9 kA (100 ms)
Arc Flash Incident Energy IEm 0.112 Cal/cm2
Arc Flash Incident Energy AFB 9.4 cm
(a) Charge termination current is permitted to be less than specified.
(b) Low Voltage Disconnect is based on 2.5 VPC under load. In no load conditions, do not allow the battery module
to self-discharge below 3.0 VPC.

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NOTE
Reduce the charge termination current to increase the time available for the internal
balancing function.
3.2 Mechanical Specifications
Table 3-2, ELEMENT ESS Mechanical Specifications
Mechanical Specifications 48-48-5120 / 48-48-5120-H
Chemistry LiFePO4
Total Length 497.3 mm (19.6 in)
Body Width 439.2 mm (17.3 in) (19U)
Front Face Width 482.6 mm (19 in)
Height 133.5 mm (5.3 in) (3U)
Terminal
Amphenol RadLok
Positive (+) Red - C10-730186-200
Negative (-) Black - C10-730186-100
Weight 44.0 kg (97.0 lb)
IP Rating IP20
Case Material Galvanized Steel Sheet
133.5 mm (5.26 in)
38.00 mm
(1.50 in)
465.90 mm (18.34 in)
497.30 mm (19.58 in)
459.30 mm (18.08 in)
FRONT SIDE
TOP
90 mm (3.54 in)
440 mm (17.32 in)
482.60 mm (19.00 in)
21.7 mm
(0.85 in)
21.7 mm (0.85 in)
Figure 1. ELEMENT ESS Battery Module Dimensions

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3.3 Environmental Specifications
Table 3-3, ELEMENT ESS Environmental Specifications
Environmental Specifications 48-48-5120 48-48-5120-H
Charge OperatingTemperature Range (a)(b) 0°C to 45°C (32°F to 113°F)
Discharge OperatingTemperature Range (a) -20°C to 55°C (-4°F to 131°F)
Internal Heater OperatingTemperature Range (c) Not applicable -20°C to 5°C (-4°F to 41°F)
StorageTemperature (1 month) (d) -30°C to 55°C (-22°F to 131°F)
StorageTemperature (6 months) (d) -10°C to 30°C (14°F to 86°F)
(a) Specifies the temperature of the cells and not the ambient temperature. Ambient temperature and cell
temperature may not be the same.
(b) Although the Battery Management System (BMS) does not allow charging when cells are below 0°C (32°F), the
48-48-5120-H has a heater that warms the battery to a temperature that enables charging to resume at 2°C (37°F).
(c) When the 48-48-5120-H battery cells are between -20°C (-4°F) and 5°C (41°F) and connected to a charging source,
energy is diverted from the charging source to the internal heater until the battery reaches 8°C (46.4°F).
(d) Storage outside of specified temperatures will result in permanent capacity loss and void the warranty.
3.4 Protections Specifications
Table 3-4, ELEMENT ESS Protections Specifications
Protection Specifications 48-48-5120 / 48-48-5120-H
Overvoltage
Protection (a) Above 58.4 V for 3 seconds
Recovery (a) Recovery after 120 seconds and less than 55.2 V
Undervoltage
Protection (b) Less than 40 V for 5 seconds
Recovery (b) No automatic recovery.The battery module shuts down after
120 seconds.
Over-Charge Current
Protection Greater than 110 A for 10 seconds
Recovery Recovery after 120 seconds
Over-Discharge Current
Protection (c) 3-second rating 220 A
Recovery (c) Recovery after 120 seconds
Over-temperature in Discharge
Protection (d) Cell temperature above 55°C (131°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 45°C (113°F) for 5 seconds
Recovery (d) Cell temperature below 40°C (104°F)

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Under-temperature in Charge
Protection (d) Cell temperature below 0°C (32°F) for 5 seconds and charge
current detected
Recovery (d) Recovery after 120 seconds and cell temperature 2°C (32°F) or
higher. Note: Discharge is available to -20°C (-4°F).
Load Qualification Protection
Protection Mixed System Voltage, Short Circuit, Reverse Polarity, Input
Capacitance Overload
Recovery Re-qualify after 120 seconds. After ten failed attempts to
qualify, the battery module switches OFF.
(a) Overvoltage protection monitors individual cell voltages. Protection is triggered when any cell is over 3.65 VPC
and recovers when all cells are below 3.45 VPC for 120 seconds. Voltages are provided for guidance only.
(b) Undervoltage protection monitors the voltage of individual cells. Protection is triggered, and the battery module
is set to OFF when any cell is at or below 2.5 VPC. Manually set the battery module 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.
0.001
0.01
0.1
1
10
100
1000
10000
100000
- 100 200 300 400 500 600 700
Interrupt Time [s]
Current [A]
Over -Current Curve
Dual 100 A Fuse = 48V
Figure 2. Over-Discharge Protection Time Curve
3.4.1 Breaker Delay Specifications
Table 3-5, Breaker Delay
Rating [%] Current DelayTime [s]
100 10 0 A Breaker should not trip
100-135 100 - 135 A Breaker may trip (1)
135 135 A 2.0 - 60.0
150 150 A 1.2 - 40.0
200 200 A 0.6 - 20.0
400 400 A 0.3 - 3.0
600 600 A 0.15 - 1.3
(1) The breaker may trip due to the tolerance range.

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3.5 Internal Heating Specifications
Internal heating is available on the 48-48-5120-H model only.
Table 3-6, 48-48-5120H Internal Heating Specifications
Internal Heating Specifications 48-48-5120-H
Heating Power 50 W
Heating On (a) Charge detected and below 5°C (41°F)
Heating Off (a) Temperature above 8°C (46.4°F) or discharge current
of 250 mA detected for 10 minutes
(a) Specifies the temperature of the cells and not the ambient temperature. Ambient temperature and cell temperature
may not be the same.
3.6 Minimum Specifications for Discover Battery Module Systems
Install ELEMENT ESS battery modules in parallel in a battery bank configuration to
increase system capacity. Overall battery module system capacity must be correctly
sized to meet the requirements of the load and account for:
• Total Continuous Charge Current
• Total Peak Current
• Total Continuous Discharge Current
The total charging capacity of all charging sources in the system should not exceed
the Continuous Charge Current operating limit of all the battery modules in the
system. Exceeding this limit will cause the BMS in battery modules to trigger over-
current protection and disconnect.The charging system’s maximum Continuous
Charge Current must either be below the operating limit of installed battery
modules or curtailed.
The sum of all the Peak Current values for the attached loads must be less than the
Peak Current value of the battery module system, including inrush current values for
any motors and surge values for any inverters.
The sum of all the Continuous Discharge Current values for the attached loads must
be less than the Continuous Discharge Current value of the battery module system.
For ELEMENT ESS battery modules installed in parallel in a battery bank
configuration, the sum of all battery module capacities provides the overall capacity
value for the battery module system. Table 3-7 provides DC capacity values for
sample Discover battery module systems.
NOTICE
• Exceeding the Peak Current, Continuous Discharge, or Continuous Charge values
of the battery modules in the system will lead to either tripping the battery module
Breaker or triggering the battery module BMS over-current protection, resulting in
disconnection of all battery modules in the system.
• Disconnection will result in a voltage spike (Load Dump), which may damage any
component electrically attached to the battery module system.
NOTE
The maximum number of battery modules installed in a parallel configuration is 24.