Evolution EV48-60 User manual

USER`S MANUAL
LITHIUM ION BATTERY
VERSION: 201901029

Table of Contents
Introduction…………………………………….…Page 2
Warning label and Safety Operation……………...Page 2
Battery Specifications & Presentation……….........Page 4
Battery and Accessories Presentation…………….Page 5
Battery Installation………………………..………Page 8
Charging…………………………………………. Page 8
Storage…………………………………………... Page 9
Warranty…………………………………………. Page 9
Recycling………………………………………….Page 10
APPENDIX A
Page 1
Li-ion Battery Manual

Introduction
EVOLUTION lithium-ion battery is a type of Lithium iron phosphate battery (LiFePO4), it
is a reliable power source that doesn’t fade over time. Whether it's a new or
five-year-old vehicle, EVOLUTION lithium ion battery vehicles will give you all the
acceleration and hill-climbing power they could want.
EVOLUTION lithium-ion battery is controlled by an advanced Battery
Management System that monitors efficiency, temperature, state of charge and the
health of the batteries.
EVOLUTION lithium-ion battery pack is completely protected from the elements
in a self-contained, aluminum alloy, water-tight case. These batteries have been
used to safely and reliably power electric golf cars.
EVOLUTION lithium-ion battery is completely maintenance-free. Long gone are
the days of watering and cleaning your batteries. No matter your plans, you can
always expect consistent performance with EVOLUTION lithium-ion battery.
Battery Warning label
Safety and warning labels are on the battery cover for your protection. Read and
comply with the instructions on the labels carefully. Do not tear off the warning
labels from the battery pack.
Located on the battery pack cover
Page 2
Li-ion Battery Manual

Safety Operation
Improper handling of batteries and electrical components can result in serious injury or death.
Do not remove the battery pack cover. Do not attempt to remove batteries or battery cables.
Do not use the battery pack without the control module installed. All battery and electrical
service must be performed by an authorized service facility and personnel.
All tools used in or around the battery pack area should be insulated. Do not intentionally cause
a short to the power terminal (B+, B-) with a metallic object.
Do not cut, tear or remove the seal tape. Do not disassemble or modify the design,
including the electrical circuit, of the battery pack or control module.
To prevent the risk of battery explosion, keep all flammable materials, open flames or sparks
away from the batteries. Do not leave the battery pack near a fire or heat source. Do not
throw Lithium-Ion batteries into a fire. Do not apply heat to any part of the battery
pack or battery management module with a soldering iron. Do not place the battery pack
in a microwave oven, dryer or high-pressure container.
Do not attempt to operate the vehicle or charge the battery pack at temperatures above
140°F (60°C).
Do not immerse or throw the battery pack in water. Do not pressure wash the battery
pack.
Do not puncture the battery pack or control module. Do not strike the battery pack with a
hammer or heavy weight. Do not step or stand on the battery pack. Do not throw or drop
the battery pack on hard surfaces.
If the battery pack terminals are contaminated or dirty, clean them with a dry cloth before
using the battery pack.
Keep the battery pack and control module away from static electricity.
Page 3
Li-ion Battery Manual

Battery Specification
Model
EV48-60
EV48-110
EV48-130
EV48-165
General
Parameters
Dimension
(L x W x H) inch
12＂x 13＂x 9＂
23＂x 13＂x 9＂
23＂x 13＂x 9＂
31＂x 13＂x 9＂
Casing material
Aluminum alloy
Aluminum alloy
Aluminum alloy
Aluminum alloy
IP level
IP56
IP56
IP56
IP56
Technical
Parameters
Nominal voltage
48V
48V
48V
48V
Nominal capacity
65AH
110AH
130AH
165AH
Stored energy
3.12kwh
5.28kwh
6.24kwh
7.92kwh
Life cycles
≥3500 cycle times
≥3500 cycle times
≥3500 cycle times
≥3500 cycle times
Self-discharging
rate
≤5% per month
≤5% per month
≤5% per month
≤5% per month
OEM Charger
Parameters
Rated Power
700W
1200W
1200W
1200W
Standard charge
time
4Hr
4Hr
5Hr
5Hr
Environment
Parameters
Charge
temperature
range
32°F and 110°F (0°C and
45°C)
32°F and 110°F (0°C and
45°C)
32°F and 110°F (0°C
and 45°C)
32°F and 110°F (0°C
and 45°C)
Discharge
temperature
range
-4°F and 140°F (-20°C
and 60°C)
-4°F and 140°F (-20°C
and 60°C)
-4°F and 140°F (-20°C
and 60°C)
-4°F and 140°F (-20°C
and 60°C)
Storage
temperature
range
14°F and 95°F (-10°C
and 35°C)
14°F and 95°F (-10°C
and 35°C)
14°F and 95°F (-10°C
and 35°C)
14°F and 95°F (-10°C
and 35°C)
Page 4
Li-ion Battery Manual

Battery and Accessories Presentation
1. LiFePO4 Lithium-ion Batteries Pack with Aluminum Alloy Casing.
2. B+ :Battery Positive Terminal
3. B - :Battery Negative Terminal
4. RS485: Connector Port for Lithium Battery Power Indicator
5. SW: Inspection Light & Button for BMS
6. Vent Valve for Lithium-ion Battery Pack
7. Lifting Handles for Lithium-ion Battery
8. Nameplate for Lithium-ion Battery
9. Battery Warning Label
10. Installation Base Bracket
11. Lithium Battery Indicator （Two Options: Round or Diamond Shape）
12. Connecting Cable for Battery Power Indicator.
Page 5
Li-ion Battery Manual

Battery Indicator
Evolution lithium battery provides two different shape optional battery indicators for
customer, round shape and diamond shape. Also provide the connecting cable for the
battery indicator.
Connecting cables
NOTE: While plugging this battery indicator, one should be noted that the grove of male
plug must be fit to the boss of female connecting port, otherwise it cannot be pushed in.
Push the battery indictor male plug into
the port as following direction.
Push in
Clock wise
Rotate clockwise the Lock cap to
tighten the connector.
Battery power indicator wiring diagram
Both two kinds of indicators both have four pins:
Positive +5V—Red Cable
Negative—Black Cable
RS485 HI—Yellow Cable
RS485 LO—Green Cable
Page 6
Li-ion Battery Manual

Wiring diagram for battery indicator as following:
When the indicator reaches 0%, all the LED`s will turn off, the lithium battery pack will
automatically cut off the main power output to the vehicles, and the vehicles will stop
immediately..
We recommend that when the last two red LED`s flashing on the battery indicator,
charge the lithium battery immediately, Do not wait until the battery is discharging
completely.
Battery power indicator display introduction
Battery indicator shows the amount of usable power in the battery pack, it should be installed on
the dash panel where the place is obvious to check for drivers. Below are displaying:
Each of LED lights indicates 10% of
battery power
“0”, “1/2”, “1 “, which are above the
LED`s mean empty of battery power,
half of power, full power.
Voltage display means the present
voltage of lithium battery pack
“F” indicates a full charge of battery
pack. “E” indicates low charge.
Each of LED lights indicates 10% of
battery power
Page 7
Li-ion Battery Manual

Battery Installation
NOTE: It is highly recommended that the vehicle be testing driven before
installation of the EVOLUTION lithium battery product to ensure that the vehicles
existing systems operate as normal.
Step 1: Remove the seat bottom. Remove the vehicles existing lead acid
batteries or other type of batteries.
Note: Recycle the original lead-acid batteries properly.
Step 2: The battery tray should be thoroughly cleaned of any residual battery acid
using a 50/50, mixture of baking soda and water to clean the tray with a soft
bristle brush. The tray should be rinsed with water and dried thoroughly before
proceeding.
Step 3: Install the special customized base frame for lithium-ion battery (based
on the vehicles brand or model) to the vehicle.
Step 4: Two people should team lift the lithium battery into the vehicle. The lithium
battery sits down vertically into the battery base frame which has been installed
priority in step3. Lock the battery pack to the base frame.
Step 5: Connect positive terminal and negative terminal of the lithium-ion battery
to the vehicle original main electric system. Make sure the cables are right
tightened.
Step 6: Install the lithium-ion battery power indicator to the reasonable position
on the dash panel and (we provide two optional indicators: round and diamond
shape and cables).
Connect the battery power indicator to port on the lithium battery pack.
Step 7: Testing drive the vehicle and battery charging.
Battery Charging
Charging should be performed when ambient temperatures are between 32°F and
110°F (0°C and 45°C). The battery pack may be charged or topped off after every
use.
Turn the key to the OFF position and remove it.
Inspect the charger cord for cracks, frayed wires or loose connections, if
damaged replace it.
Inspect the vehicle charger receptacle and charger plug for dirt, debris or damage.
Clean if necessary and replace immediately if damage is found.
Connect the charger to a wall receptacle. Do not use a multi-plug adapter or
power strip. Do not connect anything else to the same receptacle.
When the battery pack is finished charging, disconnect the charger cord from the
vehicle. If disconnecting before the charge cycle is complete, it is recommended
that the charger be disconnected from the wall receptacle first, then unplug the
charger from the vehicle receptacle.
Page 8
Li-ion Battery Manual

Storage
Improper storage may damage, destroy or cause permanent loss
of battery capacity. Do not exceed storage time or temperature limits. Batteries
must be charged to the correct level before storage. Storing fully depleted
batteries will make them permanently unusable.
Storage Preparation
The optimum storage temperature range is between 65°F and 82°F (18°C and 28°C)
Charge the battery pack based on climate during storage period:
In cold climates, fully charge the battery pack. Make sure that the charging
operation is complete and there are no faults displayed on the charger. The green
light on the charger should be on, indicating the charge cycle is complete.
In hot climates, store the vehicle with a 80% charge of battery pack capacity.
Turn the key to the OFF position and remove it from the key switch
Turn off all accessories.
The storage time for properly charged Lithium-Ion batteries supplied with this vehicle
varies based on the ambient temperature.
During Storage
Check the state of charge every 30 days. If the SOC is below 30%, charge the battery
pack until the state of charge reaches 80% in hot climates; charger reaches 100% in
cold climates.
Returning Vehicle to Service
At the end of the storage period, charge the battery pack to 100% before operating
the vehicle.
Warranty
EVOLUTION Lithium-ion Battery Pack and Battery Management System are
warrantied for FIVE years or 80,000KM, whichever comes first, starting from date of
delivery to the Purchaser`s location against defective material or workmanship.
We make no warranty other than this limited warranty and expressly exclude any
implied warranty including any warranty for consequential damages. This limited
warranty is not transferable.
THIS LIMITED WARRANTY MAY BE VOIDED OR LIMITED AT THE SOLE
DISCRETION OF COMPANY IF THE BATTERY PACK OR BATTERY CONTROL
MODULE:
shows indications that it has been altered or modified in any way from Company
specifications, including but not limited to alterations to the lithium-ion battery
pack, battery management system and the system electric circuit.
Page 9
Li-ion Battery Manual

shows indication that the battery charger has been modified to charged battery
not approved for the charger;
shows indications that the battery pack was disassembled, opened, or tampered
with in any way;
shows indications that attempts may have been made to intentionally reduce the
battery pack life;
contains lithium battery packs that are not paired with the battery management
system as supplied by the Company;
shows indications that were installed with parts or accessories directly to the
battery pack without the company’s Express written approval.
This warranty is invalidated if any of the following occurs, but not limited to:
Failure to follow instruction in the Owner Manual.
Accidental or unreasonable use, misuse or mishandling, over charging or loading,
or normal wear.
Extended storage without recharging or repairs done by an unauthorized person
or modification.
Damages resulting from an accident or collision, or from the neglect, abuse
battery pack system.
This warranty is in lieu of all other express warranties. EVOLUTION will not be liable
for consequential or incidental damages.
Lithium-Ion Battery Recycling
Lithium-Ion batteries must be collected and recycled separately from
other waste. Do not discard lithium-ion batteries as municipal waste.
Speak with your dealer or distributor on how to correctly recycle lithium-ion batteries.
Page 10
Li-ion Battery Manual

APPENDIX A
LITHIUM BATTERY CHARGER
USER`S GUIDE

This manual contains important safety and
operating instructions for Evolution
charger, please read this information
before using Evolution charger for
lithium-ion battery.
Evolution has two models of lithium-ion
battery charger.
DANGER: TO REDUCE THE RISK OF FIRE OR ELECTRIC SHOCK, CAREFULLY READ
AND FOLLOW THESE IMPORTANT SAFETY AND OPERATING INSTRUCTIONS BEFORE
INSTALLING OR OPERATING THE CHARGER.
DANGER: RISK OF ELECTRIC SHOCK. DISCONNECT CHARGER FROM BATTERY AND
AC POWER BEFORE SERVICING. TURNING OFF THE CHARGER DOES NOT REDUCE
THIS RISK.
DANGER: TO PREVENT ELECTRICAL SHOCK, DO NOT TOUCH EITHER AC OR DC
UNINSULATED PARTS. MAKE SURE ALL ELECTRICAL CONNECTORS ARE IN GOOD
WORKING CONDITION. DO NOT USE CONNECTORS THAT ARE CRACKED,
CORRODED OR DO NOT MAKE ADEQUATE ELECTRICAL CONTACT. USE OF A
DAMAGED OR DEFECTIVE CONNECTOR MAY RESULT IN A RISK OF OVERHEATING
OR ELECTRIC SHOCK.
WARNING: TO REDUCE THE RISK OF FIRE, INSTALL THIS BATTERY CHARGER ON A
SURFACE OF NON-COMBUSTIBLE MATERIAL SUCH AS BRICK, CONCRETE, OR
METAL.
APPENDIX A
Evolution
Battery Charger Manual

Operation Instructions
Charger LED Display
Troubleshooting Instruction
If a fault occurs, count the number of red flashes between pauses and refer to the table below.
--RED --GREEN
APPENDIX A
Evolution
Battery Charger Manual

APPENDIX A
Evolution
Battery Charger Manual

Copyrighted Material
EVOLUTION ELECTRIC VEHICLES INC reserves
the right to change or improve the manual
obeying to products and company policy alterations
at any time without notice.
EVOLUTION ELECTRIC VEHICLES INC
15830 El Prado Road Unit D,
Chino, CA 91708, USA
Tel: [phone]
Email: [e-mail]
Website: http://www.evolutionelectricvehicle.com