Dragonfly Energy Battle born BB5024H Installation and operating instructions

Battle Born Batteries BB5024 Manual | BB5024H Manual | Edition.PIM_BB5024Rev018_09062022 1

Battle Born Batteries BB5024 Manual | BB5024H Manual | Edition.PIM_BB5024Rev019_082820232
Please read this manual prior to installation and use.
Thank you for investing in a Battle Born Batteries system and welcome to the Battle Born Batteries family. This manual
provides important information on how to install, operate, and care for your Battle Born Batteries. If you have
purchased with us before, you will find this manual useful as a reference tool. If this is your first purchase with Battle
Born Batteries, this manual can serve as an educational tool on how to properly use and care for your investment.
If you have a heat-enabled model, please refer to the additional Heat-Enable Instruction manual prior to use and
installation.
Table of Contents
What is in the Box? ................................................................................................................................................................3
What Do I Need for Installation?............................................................................................................................................3
Connecting Load Specified Cables to the Batteries ................................................................................................................3
Safety .....................................................................................................................................................................................4
How to Properly Charge the Batteries ...................................................................................................................................4
Connecting the Batteries in Parallel.......................................................................................................................................5
Connecting the Batteries in Series. ........................................................................................................................................6
How does the BMS Protect the Batteries...............................................................................................................................7
Voltage vs. Capacity ...............................................................................................................................................................8
How to Properly Size Cables for System Install ......................................................................................................................8
How to Incorporate Fuses Into System Install........................................................................................................................9
How to Properly Store Batteries .............................................................................................................................................9
How to Maintain the Batteries ..............................................................................................................................................9
How to Properly Recycle and Dispose of the Batteries ..........................................................................................................9
Limited Warranty...................................................................................................................................................................9
Return Policy........................................................................................................................................................................11
Refund Policy .......................................................................................................................................................................11
Shipping ...............................................................................................................................................................................11
Lithium-ion vs. Lead Acid .....................................................................................................................................................11
Recommended Accessories .................................................................................................................................................12
QR Codes will appear throughout the manual linking to FAQ videos that may be useful.
To use the QR code, open a QR reader or the camera on your smartphone. Hold your device over the QR code so that
the code is clearly visible within the device’s screen. Your phone will automatically scan the code and pull in the
corresponding weblink.
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Battle Born Batteries BB5024 Manual | BB5024H Manual | Edition.PIM_BB5024Rev019_08282023 3
What is in the Box?
Included with your purchase is:
•(1) BB5024 | BB5024H Battle Born Batteries Battery
oDimensions (L x W x H): 12.76” x 6.86” x 8.95”
oWeight: 31 lbs.
oOperating Temp Range: -4°F (-20°C) to 140°F (60°C)
oAbsorption Time: 15 Minutes per 50Ah Battery Bank
oWater Resistant and Sealed (Batteries should not be submerged) BB5024 | BB5024H Assembly Drawing
oBuilt-in BMS (Battery Management System)
oMade with Cylindrical Cells
oComes with standard flag style terminal posts with a 3/8” hole to accommodate either a
3/8” or a 5/16” bolt
•(1) Finishing Hardware Kit
o(2) ‘18-8 Stainless Steel’ 5/16-18 x 1” Bolts
o(2) ‘18-8 Stainless Steel’ 5/16-18 x 1 1/4” Bolts
o(4) Washers
o(2) Nylok Nuts
What Do I Need for Installation?
If you already have your system set up and are ready to drop in your batteries, you will need a torque wrench that is able
to fit to and properly torque your 5/16” finishing hardware. This is REQUIRED to make sure that you torque to the
specification of 9 to 11 ft-lbs., otherwise you may cause system failures and damage.
Connecting Load Specified Cables to the Batteries
1. Identify the positive and negative terminals. These are labeled and color-coded red
for positive (+), black for negative (–).
2. Determine which finishing hardware set you will use. Verify that your bolt can fully
seat into the nylok insert of the nut. If multiple lugs are used, longer bolts may be required for the bolt to fully seat
into the nylok insert of the nut.
3. Connect your cable lugs to your battery terminal with the previously identified finishing hardware set. Make sure to
connect your positive load specified cable lug to the positive terminal and the negative load specified cable lug to
the negative terminal. The proper order to connect to your terminal with a finishing kit is shown in Fig. 1.
Figure 1: Proper order of hardware to connect cables. When going from left to right in the diagram the correct order is:
bolt, washer, lug, terminal, washer, and nut. If multiple lugs are used, they should be on the same side of the terminal.
4. When connecting to your battery terminals, DO NOT finger tighten. Use a torque wrench to torque your
hardware to the specification of 9 to 11 ft-lbs. Failure to adequately secure connections can result in severe
damage and will void your warranty. Fig. 2 below demonstrates proper and improper connections.

Battle Born Batteries BB5024 Manual | BB5024H Manual | Edition.PIM_BB5024Rev019_08282023 4
Figure 2: Proper and Improper Terminal Connections
Safety
While LiFePO4 batteries are inherently safe, as with all batteries, energy storage devices, and electrical equipment,
safety and electrical hazards do exist. Failure to follow these safety instructions may result in electrical shock, injury, or
death, or may damage the battery or other equipment or property.
Installation
•The battery should be installed as per national and local codes.
•The battery should only be installed in locations approved by local building codes.
•Electrical and shock hazards can be minimized by covering the solar array and using insulated tools.
•Do not short the battery terminals.
•Do not install the battery if there are any signs of physical damage.
•Do not install the battery in a location that may be flooded.
Operation
•Use only approved battery chargers for charging the battery.
•Do not disassemble the battery.
•A CSL is required for use with inverters 3500W or higher.
Emergency
•Disconnect the battery from the system.
•Wear a respirator, eye protection, and rubber gloves where
appropriate.
•Use an ABC type dry chemical fire extinguisher.
•Dispose of as per local regulations.
How to Properly Charge the Batteries
To properly charge your Battle Born Batteries, you will want to verify that any charging component in your system
is capable of being programmed for the following specifications. Charging components can include, but are not
limited to converters, inverter chargers, solar charge controllers, DC to DC chargers, etc.
•Bulk/Absorption: 28.4V –29.2V
•Absorption Time: Two batteries in parallel connections require 30 minutes 100Ah
•Float: 26.8V –27.6V
•Equalization: 28.8V/ Disabled
•Temperature Compensation: 0/Disabled
•Charge Rate: 50% of the battery or battery bank capacity
•Battery Charge Temperature Range: 32°F (0°C) to 131°F (55°C)
•Battery Discharge Temperature Range: -4°F (-20°C) to 140°F (60°C)
•Cell Charge Temperature: 32°F (0°C) to 131°F (55°C)
•Cell Discharge Temperature: -4°F (-20°C) to 140°F (60°C)
NOTE: Not all chargers are capable of multistage charging. If yours is not, you will want to verify it can be programmed for the Bulk/Absorption voltage and have the
other items mentioned disabled if applicable. Consult your charger’s manual or the manufacturer.

Battle Born Batteries BB5024 Manual | BB5024H Manual | Edition.PIM_BB5024Rev019_08282023 5
Connecting the Batteries in Parallel
Why Connect in Parallel?
Multiple BB5024 | BB5024H batteries may be connected in parallel to increase the capacity and current of the
system. When batteries are connected in parallel, the voltage of the system does not change, but the capacity and
current limits are additive. For example, two BB5024 | BB5024H batteries connected in parallel (shown in Fig. 3)
create a 24V 100Ah bank that can deliver 120A continuously and 200A for 30 seconds.
How to Make a Parallel Connection
NOTE: All cables and connections MUST be able to accommodate the high currents that can be delivered by the battery. Appropriate fuses and circuit breakers are
highly recommended to protect downstream components from current spikes and short circuits.
1. Identify the positive and negative terminals. These are labeled and color-coded red for positive (+), black for
negative (–).
2. Determine the appropriate finishing hardware set you will use. Verify that your bolt can fully seat into the nylok
insert of the nut. If multiple lugs are used, longer bolts may be required for the bolt to fully seat into the nylok insert
of the nut.
3. Make the proper cable connections to the positive of the first battery. Please reference Fig. 1 for the proper order of
hardware.
4. When connecting to your battery terminals, DO NOT finger tighten. Use a torque wrench to torque your hardware
to the specification of 9 to 11 ft-lbs. Failure to adequately secure connections can result in severe damage and will
void your warranty.
5. Connect the other end of your positive cable to the positive terminal of the other battery you are connecting to.
Repeat step 4.
6. Repeat steps 3-5 for the negative connections.
7.
8. Repeat steps 3-6 for additional batteries in the system. An example of a finished connection can be found below in
Fig. 3.1 and Fig. 3.2.
Figure 3.1: Two 5024 Batteries connected in Parallel to create a
24V 100Ah Battery Bank
Figure 3.2: Four 5024 Batteries connected in Parallel to create a
24V 200Ah Battery Bank

Battle Born Batteries BB5024 Manual | BB5024H Manual | Edition.PIM_BB5024Rev019_08282023 6
Connecting the Batteries in Series
Why Connect in Series?
When batteries are connected in series, current capacities remain the same, but the system voltage is additive. For
example, two BB5024 | BB5024H batteries connected in series form a 48V 50Ah bank (shown in Fig. 4) and should be
charged using a bulk and absorption voltage of 57.6V, and a float voltage of 54.4V.
How to Make a Series Connection
Note: BB5024 | BB5024H Batteries are capable of being connected in series up to 48V. DO NOT exceed a 48V setup or you will void the batteries' warranty.
1. Before making any connections, make sure to charge each battery up to 29.2V with a proper lithium charger. ALL
BATTERIES SHOULD BE AT THE SAME STATE OF CHARGE PRIOR TO CONNECTING, otherwise you will encounter
balance issues within your system. You can check your battery’s state of charge with a multimeter.
2. Identify the positive and negative terminals. These are labeled and color-coded red for positive (+), black for
negative (–).
3. Determine the appropriate finishing hardware set you will use. Verify that your bolt can fully seat into the nylok
insert of the nut. If multiple lugs are used, longer bolts may be required for the bolt to fully seat into the nylok insert
of the nut.
4. Make the proper cable connections to the negative of the first battery. Please reference Fig. 1 for the proper order
of hardware.
5. When connecting to your battery terminals, DO NOT finger tighten. Use a torque wrench to torque your
hardware to the specification of 9 to 11 ft-lbs. Failure to adequately secure connections can result in severe damage
and will void your warranty.
6. Connect the other end of your cable to the positive terminal of the other battery you are connecting to. Repeat step
4.
7. Repeat steps 3-6 for additional batteries, but DO NOT exceed 48V. An example of a correct series connection can be
found below in Fig. 4.1 and Fig. 4.2.
Figure 4.1: Two 5024 Batteries connected in Series to create a
48V 50Ah Battery Bank
Figure 4.2: Four 5024 Batteries connected in Series to create a
48V 100Ah Battery Bank
*Individually charge each battery to 100% prior to connecting your battery bank in series*

Battle Born Batteries BB5024 Manual | BB5024H Manual | Edition.PIM_BB5024Rev019_08282023 7
How Does the BMS Protect the Batteries?
All Battle Born Batteries come with a built-in battery management system (BMS) that protects the cells from many
strenuous circumstances to protect the life cycles of the cells and your electrical system from potential damage. The BMS
in the BB5024 | BB5024H allows for 60 Amps continuous, 100 Amp surge for 30 seconds, and 1/2 second surge for loads
over 100 Amps. All of our BMS' protect against the following conditions:
High Voltage Disconnect (> 29.4V)
If an individual cell voltage exceeds a prescribed threshold during charging, the BMS will prevent a charge current from
continuing. Discharge is always allowed under this condition. If the batteries have not been balanced for a long time,
high voltage disconnect could occur at a lower voltage. The batteries will rebalance after several full charges.
Low-Voltage Disconnect (< 21.2V)
If an individual cell falls below a prescribed threshold during discharge, the BMS will prevent further discharge. Although
the battery is in “low-voltage disconnect” mode, it will still allow a charging current.
NOTE: Many chargers must detect a voltage over 10V to send a charge to the battery. Please be aware that some chargers may not sense a battery in low-voltage
disconnect and you may need to jump it with a 12V source to “wake up” the battery. You should jump your battery within 24hrs of entering low-voltage disconnect
otherwise you risk damaging your battery and voiding the warranty.
High Temperature Charging and Discharging
The BMS will not allow a charging current if the internal temperature of the battery has reached 131°F (55°C).
If the internal temperature of the battery has reached 140°F (60°C), the BMS will not allow a discharging current.
Low Temperature Charging
The BMS will not allow a charging current under 32°F (0°C) but will continue to discharge down to -4°F (-20°C).
NOTE: The BB5024 | BB5024H has an operating temperature range of -4°F (-20°C) to 131°F (55°C).
High Current Discharge Surges
The BMS will not allow a current that exceeds 100 (+/- 5%) Amps for more than 30s, or anything larger for 0.5s. After a
high current disconnection, the battery will automatically reconnect after 5 seconds.
Short Current Discharge Surges
Our BMS has built-in short circuit protection. If the short circuit protection is tripped, the BMS will shut the battery down
and will remain disconnected until you remove the battery cables. While the battery cables are disconnected, we suggest
taking the voltage of the battery with a voltmeter. If it reads above 20V, reconnect the battery cables. If you are
unsuccessful at obtaining a voltage reading above 20V, please give our technical support team a call.
Balancing of Cells
A passive balancing process is activated by the BMS at the top of each charge cycle when the battery voltage exceeds
around 28.4V. This ensures that all the cells remain at the same state of charge, which helps pack longevity and
performance.

Battle Born Batteries BB5024 Manual | BB5024H Manual | Edition.PIM_BB5024Rev019_08282023 8
Voltage vs. Capacity
For a Single Battery
How to Properly Size Cables for System Install
When considering cable sizing there are a few factors to consider. First, what is the size of the load
you are powering with the battery bank? Second, how far away from the battery is the load? You
can do voltage drop calculations to see if you need to step up your cable size. Fig. 5 is a chart to
use for reference. Do keep in mind that cables are only capable of carrying a certain amperage and
you should verify the specifications of your cable and the power draws before implementing them
into your system to avoid potential failures and damage. Cable QR Code
Figure 5: As a rule of thumb, you can use these numbers as a guideline.

Battle Born Batteries BB5024 Manual | BB5024H Manual | Edition.PIM_BB5024Rev019_08282023 9
Fuse QR Code
FAQ QR Code
How to Incorporate Fuses into System Install
ANL fuses are designed to melt and separate into two pieces for the purpose of breaking a circuit in the
event of excessive current. These fuses are essential components for protecting against a catastrophic
event and are typically placed between Battle Born Batteries and the inverter/load.
How to Properly Store Batteries
We recommend bringing the Battle Born batteries to a 100% state of charge. Then, disconnect the
battery from any loads by removing the negative cable from one battery. On average, the batteries lose
approximately 2-3% capacity per month. This is subject to increasing if stored in extreme environmental
conditions.
How to Maintain the Batteries
Battle Born Batteries require very little maintenance. If your batteries are in series and not being
charged by a multi-bank charger it is recommended that you fully charge the batteries individually once
a year if the system is used frequently. This will internally balance your batteries to ensure that they will
reach their expected life span and allow you to get the full power out of them with each use. If your
batteries are in parallel this is not necessary, just make sure the batteries are charged to 14.2V –14.6V
frequently for internal balance. Our BMS has a built-in passive balancing system that will take care of
this for you.
Please Note: A CSL is required for use with inverters 3500W or higher.
For more FAQs scan the QR code.
To see what else Battle Born Batteries has to offer, scan the QR code to the right or visit
https://battlebornbatteries.com/shop/
How to Properly Recycle and Dispose of the Batteries
Battery Line QR Code
Here at Dragonfly Energy our goal is to provide our customers with long lasting green energy that will support them for
years on all their adventures. That is why we not only build batteries that can keep up with you for a long time but also
provide industry leading customer support to help you get the most out of your batteries. When the time does come,
and your batteries have reached the end of their lifetime it is important to recycle them responsibly.
Here are a few suggestions:
1. Make sure all loads are removed from your system before removing the batteries. Once the batteries are
removed cover the terminals using electrical tape. Now can be a good time to inspect any cable runs or lugs.
2. Visit www.earth911.com or www.call2recycle.org/locator to find a drop off location. Be sure to call ahead of
time to confirm that the drop off location is still accepting materials.
3. Give us a call if you are having any trouble finding a drop off location and we can help you find one.
Limited Warranty
Please find Limited Warranty information online at https://battlebornbatteries.com/limited-warranty/ or via phone at
[phone].
Limited Warranty QR Code
Storage QR Code

Battle Born Batteries BB5024 Manual | BB5024H Manual | Edition.PIM_BB5024Rev019_08282023 10
Return Policy
You have 30 calendar days to return an item from the invoice date. To be eligible for a return, your item must be in the same
condition that you received it in. You must have the receipt or proof of purchase. If an item is new, unused, and in the
original packaging, we are happy to accept a return up to 30 days from the original invoice date with no restocking fee. The
item must be returned with its original packaging. Original packaging must be in the same condition as it was received,
otherwise you may be responsible for a restocking fee. If the item has been installed, used, or no longer has the original
packaging, we will assess a restocking fee that will be shared when the return merchandise authorization (RMA) is issued.
Items 60 days past the original invoice will be reviewed at Battle Born’s discretion.
Returns will not be accepted without an RMA number, which can be obtained by filling out the return form at
https://battlebornbatteries.com/returns/. To avoid being charged restocking fees, review the full return/refund policy at
https:// battlebornbatteries.com/terms- conditions/#returns.
Refund Policy
You have 30 calendar days to return an item from the invoice date. Once we receive your item, we will inspect it and notify you that
we have received your returned item. We will immediately notify you of the status of your refund after inspecting the item. If your
return is approved, we will initiate a refund to your credit card (or original method of payment). You will receive the credit within a
certain amount of days, depending on your card issuer's policies. No refund is guaranteed after the initial 30 days has passed or if
the item has been used.
Shipping
You will be responsible for paying for your own shipping costs for returning your item. If you are returning prior to 30 days from
the original ship date, you may be eligible for a free return. In order to be eligible for free shipping, you MUST have the original
packing in which the order was shipped, including boxes, foam, wrapping, and pallets if necessary. Not all items will be eligible for
free returnshipping. Shipping costs are nonrefundable. If you receive a refund, the cost of return shipping may be deducted from
your refund.
If you have any questions, please contact us by calling 855-292-2831 or email us at [e-mail].
Notice: Product improvements and enhancements are continuous; therefore, the specifications and information contained in this document may change without notice. Dragonfly Energy Corp.
shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing, performance, or use of this material. No part of this document may
be photocopied, reproduced, or translated to another language without the prior written consent of Dragonfly Energy Corp.
Copyright © 2022, Dragonfly Energy Corp., all rights reserved. Battle Born Batteries® is a registered trademark of Dragonfly Energy Corp. All other trademarks, trade names, service marks, and
logos referenced herein belong to their respective owners.
Lithium-ion vs. Lead-Acid