electroVolt LiONCore Series User manual

RECHARGEABLE LITHIUM BATTERIES
MANUAL
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Manual covers LiONCore models, 55111 - 551117

Thank you for purchasing a LiONCore battery from electroVolt. The LiONCore Series of lithium-ion
batteries offers the kind of power solution you’ve been looking for. Available in several popular power
ranges this robust series of off-the-shelf batteryies can meet all your power needs and is an excellent
replacement option for everyday SLA / AGM batteries. LiONCore batteries are built to last using Lithium
Iron Phosphate (LiFePo4) technology and an onboard BMS. Enjoy your nee power solution.
Read this manual in its entirety before attempting to use this product. Failure to observe any of
the following precautions can result in fire, explosion and cause personal injury.
SAFETY WARNINGS:
1. Before and after every use of a LiFePO4 battery, carefully inspect the pack to ensure no physical
damage, moisture or corrosion of terminals is evident.
2. Always handle LiFePO4 batteries with extreme care and take all necessary care to avoid battery packs
being dinged, dented, punctured, or otherwise damaged.
3. Keep battery packs out of the reach of children and pets.
4. Do not disassemble, modify, or attempt any form of repair of a LiFePO4 battery.
5. Do not short circuit battery terminals.
6. Store your batteries in a cool, dry place between 40-80 F° / 4-26 C°. All battery packs should be
stored away from any flammable materials with the terminals covered.
7. Batteries should be stored at nominal voltage which is the voltage displayed on the battery label.
8. LiFePO4 batteries must be fully charged and returned to nominal voltage (displayed on the battery
label) at least once every three months when not in use.
9. Always take precautions to cover the battery terminals to avoid accidental short circuit.
Using LiFePO4 batteries can be hazardous!
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Using LiFePO4 batteries can be hazardous!

10. Always transport LiFePO4 batteries with the terminals covered using a non-conductive material
such as electrical tape.
11. Keep LiFePO4 batteries out of direct sunlight and environments that might exceed 55°C (131°C).
12. Always keep a class D chemical fire extinguisher nearby, in case of fire when storing, handling,
charging or using LiFePO4 battery packs.
13. Never charge a LiFePO4 battery near any flammable materials.
14. For best performance and cycle life allow a battery to cool to an ambient temperature of 10°C to
35°C (50°F to 95°F) before recharging.
15. Use only a properly specified LiFePO4 charger that matches the requirements for your battery.
Refer to the battery data sheet for the proper voltage and charging amperage values.
16. Make sure the battery connections are securely connected in the proper polarity and free of
corrosion.
17. Battery packs should be properly secured in the application to prevent movement and damage to
the battery while in use.
18. To prevent irreversible damage to your LiFePO4 batteries, proper selection should be made based
on the amp draw requirements of the application. Refer to the data sheet of your specific battery to
determine the rated continuous discharge current.
19. Damaged or ruptured battery packs or cells may leak electrolytes which can cause moderate to
severe irritation including burning and dryness of the skin and eyes. For contact with the skin thoroughly
wash the affected area with soap and warm water. For contact with the eyes, rinse thoroughly with cool
water. Seek immediate medical attention for any burns.
20. Always use insulated tools when making contact, connecting or disconnecting batteries.
21. Keep sparks, flames and sources of static electricity away from batteries.
22. Never place objects on top of batteries.
23. Always disconnect any load prior to connecting or disconnecting battery terminals.
24. Never immerse in water or use high pressure water to clean a battery.
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Failure to observe any of the following precautions can result in fire, explosion and cause personal injury.
CHARGING INSTRUCTIONS & SAFETY WARNINGS
1. Do to international shipping regulations, LiFePO4 batteries are not shipped fully charged. All
ElectroVolt LiFePO4 battery packs should be fully charged prior to the first use. Do not charge in series
or parallel during initial charge.
2. Make sure the battery connections are resurely connected in the proper polarity and free of corrosion.
3. Only use a properly specified LiFePO4 charger that matches the requirements for your battery.
Refer to the battery data sheet for the proper voltage and charging amperage values.
4. For the maximum lifecycle and thorough charging of your LiFePO4 battery, do not exceed the max
charge rate listed on the battery data sheet. Always confirm and follow your specific battery’s recom-
mended charge rate and maximum voltage as shown on the battery *data sheet.
IMPORTANT INFORMATION REGARDING OVER-DISCHARGE & SAFETY WARNINGS
1. Batteries should be stored at nominal voltage which is the voltage dispayed on the battery label.
2. LiFePO4 batteries must be fully charged and returned to nominal voltage (displayed on the battery
label) at least once every three months when not in use.
3. To prevent irreversible damage to your LiFePO4 batteries, proper selection should be made based on
the amp draw requirements of the application. Refer to the *data sheet of your specific battery to
determine the rated continuous discharge current.
*Data sheets available for download at www.vpwllc.com
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Using LiFePO4 batteries can be hazardous!

Failure to observe any of the following precautions can result in fire, explosion and cause personal injury.
BATTERY DISPOSAL INSTRUCTIONS & SAFETY WARNINGS
1. Any battery that has been subjected to conditions outside of normal use, shows signs of damage or
has been retired from use should be disposed of properly. We recommend transporting these battery
packs to an approved disposal facility while observing the applicable safety warnings above.
2. Check with your local waste facility to determine if they can handle disposal of lithium batteries and if
they are permitted. Many stores also offer free recycling of rechargeable batteries. To find a drop-off
location near you please visit: http://www.call2recycle.org/locator
Failure to follow any of the instructions and safety warnings contained within this document may cause
irreversible damage to the battery pack or the application and will void all warranties.
SPECIFICATIONS
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MODEL
#
551111 12.8 7 1.4 7 7 14 F2 N/A F2 150 x 65 x 2.2lbs /
101mm / 5.9 1kg
x 2.6 x 4in
551112 12.8 10 2 10 10 20 F2 N/A F2 151 x 100 x 3.3lbs /
104mm / 5.9 1.5kg
x 3.9 x 4.1in
551113 12.8 20 4 20 20 40 M5 17.5 in-lb M5 181 x 77 x 5.7lbs /
170mm / 7.1 2.6kg
x 3 x 6.7in
551114 12.8 33 6.6 33 33 66 M6 26.25 in-lb M6-1, 13mm 196 x 132 x 10.3lbs /
154mm / 7.7 4.7kg
x 5.2 x 6.2in
551115 12.8 75 15 75 75 150 M6 26.25 in-lb / 2.94 Nm M6-1, 13mm 260 x 168 x 24.2lbs /
212mm / 10.2 11kg
x 6.6 x 8.3in
551116 12.8 100 20 100 100 200 M8 61.25 in-lb / 6.86 Nm M8-1.25, 12mm 327 x 172 x 30.8lbs /
218mm / 12.9 14kg
x 6.8 x 8.6in
551117 12.8 200 30 100 100 200 M8 61.25 in-lb / 6.86 Nm M8-1.25, 12mm 522 x 239 x 59.4lbs /
221mm / 20.5 27kg
x 9.4 x 8.7in
NOMINAL
VOLTAGE
(V)
CAPACITY
(Ah)
STD.
CHARGE
CURRENT
(A)
MAX
CONT.
CHARGE
CURRENT
(A)
MAX
CONT.
DISCHARGE
CURRENT
(A)
PEAK
DISCHARGE
CURRENT <
5s (A)
TERMINAL
TYPE
RECOMMENDED
TERMINAL TORQUE
TERMINAL BOLT
SPECIFICATIONS
DIMENSIONS WEIGHT
Using LiFePO4 batteries can be hazardous!

BATTERY MANAGEMENT SYSTEM (BMS)
ElectroVolt LiONCore batteries come with a built-in battery management system (BMS) that protects the
battery for increased safety and prolonged life expectancy. The ElectroVolt BMS protects against the
following conditions:
High Voltage / Over Charge Protection
If one or more of the battery cells exceeds the pre-defined upper voltage threshold during charging the
BMS will disconnect to prevent charge current from continuing. With this protection active discharge is
always allowed.
Passive cell balancing is activated by the BMS at the top of each charge cycle which ensures that all cells
remain at the same state of charge increasing battery performance and extending battery longevity.
Low Voltage / Under Charge Protection
If one or more cells falls below the pre-defined lower voltage threshold during discharging the BMS will
disconnect the load to prevent current from continuing. With this protection active charging is always
allowed.
High Current Protection
To prevent damage to the BMS and cells the BMS will not allow current that exceeds the pre-defined
value. After high current disconnection the battery will automatically reset once the load is removed.
High Temperature Protection
To prevent damage to the battery cells the BMS will not allow charge or discharge current when the
pre-defined temperature value is exceeded. Release of this protection occurs once the temperature of
the battery falls below the pre-defined release temperature.
Short Circuit Protection
To prevent damage to the battery cells the BMS isolates the cells in a short circuit condition and will
automatically reset once the short circuit is removed.
For specific protection values please refer to the *data sheet for your battery.
*Data sheets available for download at www.vpwllc.com
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BATTERY INSTALLATION
Use properly sized cable and cable lugs (as applicable) to handle the expected load (figure 1) keeping
all cables as short as possible. Torque battery terminal connections to the specified values using the
supplied flat washer, split washer and bolts (as applicable). (reference specifications chart on previous
page). See figure 2 for proper order of the split washer (A) and flat washer (B).
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figure 2
figure 1
CABLE/WIRE GUAGE SIZE, AWG (mm2) AMPACITY (Amps)
14 (2.08) 20
12 (3.31) 25
10 (5.26) 35
8 (8.36) 50
6 (13.3) 65
4 (21.1) 85
2 (33.6) 115
1 (42.4) 130
1/0 (53.5) 150
2/0 (67.4) 175
4/0 (107) 230
Table values are from NEC Table 310.15(B)16 for copper cables rated at
167ºF (75ºC), operating at an ambient temperature of no more than 86ºF
(30º). Lengths in excess of 6 feet (1829 mm) may require heavier gauge
wire to avoid unnacceptable voltage drop. In series/parallel battery banks,
it is preferable for all series cables to be the same length, and all parallel
cables to be the same length.
For more information refer to the National Electric Code for correct
cable/wire size, which can be located at www.nfpa.org
A
B
A
B
F2 Connector
Standard Bolt
Connector

CHARGING
For best results LiONCore LiFePO4 batteries should only be charged using LiFePO4 approved chargers.
Charging with lead-acid battery chargers may not allow the BMS to properly balance or equalize cell
voltages resulting in reduced performance and life expectancy. Charging LiONCore batteries with
lead-acid chargers which utilize an automatic desulfation or equalization mode is strictly prohibited.
ElectroVolt LiONCore LiFePO4 batteries are not shipped fully charged and must be charged prior
to the first use or initial installation in a series string. Do not charge in series or parallel during
the initial charge.
When using ElectroVolt LiONCore LiFePO4 batteries in series, ElectroVolt recommends charging each
battery individually at least every fourth use to avoid imbalance.
CHARGING TEMPERATURE
For optimal performance and longevity charging LiONCore LiFePO4 batteries below 10°C (50°F) should
be avoided. ElectroVolt LiONCore LiFePO4 batteries can be safely charged between 0°C to 45°C (32°F
to 113°F).
All ElectroVolt LiONCore LiFePO4 batteries have buit-in battery management system (BMS) that
protects the battery from damaging over-temperature conditions. At the pre-defined high temperature
threshold value the BMS will disconnect charge or discharge current. Release of this protection occurs
once the temperature of the battery falls below the pre-defined release temperature. Please refer to the
*data sheet for your battery for the BMS high temperature cut-off and release values.
SERIES OR PARALLEL SYSTEMS
ElectroVolt LiONCore LiFePO4 batteries can be connected in series to increase system voltage OR in
parallel to increase system capacity. Do not connect ElectroVolt LiONCore LiFePO4 batteries in both
series and parallel. Multiple battery systems should be created using only one battery type and
capacity from ElectroVolt.
DO NOT EXCEED FOUR BATTERIES IN SERIES OR TWO BATTERIES IN PARALLEL OR IRREVERISLBE
DAMAGE WILL OCCUR VOIDING ALL WARRANTIES. (See example on next page)
*Data sheets available for download at www.vpwllc.com
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When connected in parallel the continuous and peak discharge current values should be in accordance
with the ratings of a single battery per the battery *data sheet.
Check battery cables and connections frequently. Retorque terminal bolts to proper specifications and
replace damaged cables as needed.
Battery cable lugs and terminals should be clean, dry and free of corrosion. Clean terminals only with a
dry cloth or non-metallic brush as needed.
*Data sheets available for download at www.vpwllc.com
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SERIES CONNECTION PARALLEL CONNECTION
To increase capacity, connect batteries in parallel.
This will not increase the system voltage.
Two 12.8V batteries rated at 100Ah.
Connected in parallel.
System Voltage: 12.8V
System Capacity: 100Ah + 100Ah = 200Ah
To increase voltage, connect batteries in series.
This will not increase the system capacity.
Two 12.8V batteries rated at 100Ah.
Connected in series.
System Voltage: 12.8V + 12.8V = 25.6V
System Capacity: 100Ah
PROPER SERIES AND PARALLEL CONNECTIONS:

ELECTROVOLT WARRANTY POLICY
Warranty Coverage
All products sold by ElectroVolt are inspected before leaving the factory and are guaranteed to be free
of defects in material and workmanship appearing within 1 year from the original date of shipment.
During that period, as its sole responsibility and as the purchaser’s sole remedy under this warranty,
ElectroVolt will repair or replace defective products or, at its sole discretion, issue a credit memo for the
purchase price of such products.
Other Warranties
THE ABOVE WARRANTY IS EXCLUSIVE AND IN LIEU OF ANY OTHER EXPRESS OR IMPLIED
WARRANTIES, INCLUDING BUT NO LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY
OR FITNESS FOR PARTICULAR PURPOSE.
Exclusions
There is no “industry standard” for life expectancy of a rechargeable battery. The cycle life of batteries
varies greatly by chemistry and construction and can be greatly affected by how batteries are used,
charged and stored. These factors are outside our control and thus our warranty only covers defects
in materials or workmanship.
ElectroVolt will not be liable for warranty replacement of batteries that are used outside of normal
operating parameters. If you are unsure about how to use or handle any of our products contact
ElectroVolt for assistance.
Limitation of Liability
ELECTROVOLT WILL NOT BE SUBJECT TO ANY OBLIGATIONS OR LIABILITIES OTHER THAN THOSE
SET FORTH IN THIS DOCUMENT, WHETHER ARISING OUT OF BREACH OF CONTRACT, WARRANTY,
TORT (INCLUDING NEGLIGENCE AND STRICT LIABILITY), OR UNDER OTHER THEORIES OF LAW
OR EQUITY, WITH RESPECT TO ITS PRODUCTS, OR ANY UNDERTAKINGS, ACTS OR OMISSIONS
RELATING THERETO, AND IN NO EVENT WILL ELECTROVOLT BE LIABLE FOR ANY CONSEQUENTIAL,
INCIDENTAL, INDIRECT OR CONTINGENT DAMAGES WHATSOEVER.
Without limiting the generality of the foregoing, ElectroVolt specifically disclaims any liability for
property damages, penalties, special or punitive damages, damages for lost profits or revenues,
down-time, lost good will, cost of capital, cost of substitute good or services, or for any other types
of economic loss.
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The information contained herein is provided solely for the purpose of general explanation and illustration and is subject to modification without notice.
No warranty or guarantee is given in regard to the information contained herein or the referenced products. Please contact Vertical Partners West®for the
most current and relevant product information for your application. © 2020 ElectroVolt. All Rights Reserved.