Expion360 EX-360XDP-C User manual

USER MANUAL
EX-360XDP-C
PLEASE KEEP THIS MANUAL FOR FUTURE REFERENCE

2
Expion360 Battery Manual, G24 and G27
Rev 1
03/10/2022
DISCLAIMER
While every precaution has been taken to ensure the accuracy of the contents of this guide, Expion360 assumes no
responsibility for errors or omissions. Note as well that specifications and product functionality may change without
notice.
IMPORTANT
Please be sure to read and save the entire manual before using your Expion360 battery. Misuse may result in damage
to the product(s) and/or cause harm or serious injury. Read this manual in its entirety before using the product and
save it for future reference.
DESCRIPTION
Expion360 lithium batteries use lithium iron phosphate (LiFePO4/LFP) chemistry and are designed for RV, marine, and
off-grid power storage. LiFePO4is considered the best choice for these applications because of its high degree of
safety, long life, and excellent dependability. Every battery uses cylindrical 26650, stainless steel encased LiFePO4
cells. The cells are UL 1642 recognized (file no. MH64383) and are certified to the highest standard in safety and
performance. Internal power distribution cables are mechanically connected (bolted), rather than soldered, to lower
contact resistance and provide a robust physical connection point. The internal power distribution plates connecting
the cells, battery management system (BMS), and internal terminals are solid copper. Our proprietary case contains
structural elements to protect the battery pack and BMS inside from the effects of vibration and movement. The
battery’s oversized power terminals provide a large electrical and physical connection point to accommodate high
ampacity power cables and our unique and innovative bus bars.
SERVICE CONTACT INFORMATION
Our technical support department has battery industry experts on standby to assist you, our valued customers, in every
way they can. If for any reason you require assistance with your Expion360 battery system, contact us by phone or
email any weekday during business hours and receive help from the best technical support in the industry.
[email protected]
[phone]

3
Expion360 Battery Manual, G24 and G27
Rev 1
03/10/2022
PLEASE READ EACH WARNING CAREFULLY TO PREVENT DAMAGE AND EXTEND BATTERY LIFE
WARNINGS:
DO NOT DROP THE BATTERY
DO NOT OPEN THE BATTERY
DO NOT SHORT CIRCUIT THE BATTERY
DO NOT SUBMERGE THE BATTERY IN WATER
DO NOT USE THE BATTERY AS A STARTER BATTERY
DO NOT USE BATTERIES OF DIFFERENT AGES AND CAPACITIES
DO NOT CONNECT MORE THAN FOUR BATTERIES IN SERIES
DO NOT CONNECT MORE THAN FOUR BATTERIES IN PARALLEL
DO NOT ATTEMPT TO REPAIR THE BATTERY IF MALFUNCTIONING
DO NOT CHARGE THE BATTERY ABOVE 14.6 VDC
DO NOT CHARGE THE BATTERY AT OR BELOW 32 °F OR 0 °C
DO NOT CHARGE THE BATTERY ABOVE ITS MAXIMUM CHARGE RATE
DO NOT DISCHARGE THE BATTERY BELOW 10.5 VDC
DO NOT DISCHARGE THE BATTERY AT OR BELOW -4 °F OR -20 °C
DO NOT DISCHARGE THE BATTERY ABOVE ITS MAXIMUM DISCHARGE RATE
DO NOT LEAVE THE BATTERY CONNECTED WHEN IN STORAGE
DO NOT LEAVE THE BATTERY FULLY DISCHARGED LONGER THAN 1 WEEK

4
Expion360 Battery Manual, G24 and G27
Rev 1
03/10/2022
Table of Contents
1Installation ........................................................................................................................................ 5
2Battery Management System (BMS) ...................................................................................................... 9
3Battery Monitoring............................................................................................................................ 10
4Charge ............................................................................................................................................ 11
5Discharge ........................................................................................................................................ 13
6Battery Life...................................................................................................................................... 17
7Storage ........................................................................................................................................... 18
8Accessories..................................................................................................................................... 19
9Battery Specifications ....................................................................................................................... 20
10 Warranty ......................................................................................................................................... 20

5
Expion360 Battery Manual, G24 and G27
Rev 1
03/10/2022
1Installation
Although our batteries can be installed in an outside battery box, be sure to confirm the battery box has drain holes to
prevent water from filling the box. Unlike lead-acid, our batteries do not exhaust any harmful vapor and may be installed
inside a trailer, motorcoach, truck camper, or boat cabin. Installing the batteries within an insulated or conditioned space
is always recommended, especially if the batteries will ever be used in temperatures below 32 °F.
The custom-molded case of our batteries includes rigid internal support structures to hold cells in place in any
orientation. This allows our batteries to be installed in any position, opening up a range of creative mounting solutions
our competitors are unable to accommodate. We recommend using our unique tie-down system with every installation
to eliminate unwanted movement and reduce vibration. Check our website for more information on tie-down solutions
for your Expion360 batteries.
When connecting multiple batteries with the Expion360 Bus Bars or power cables, tighten the M 8 x 1.25 hex bolts to 8
lb-ft (96 lb-in) torque using an adjustable torque wrench. Make sure all connections are bundled and well organized to
prevent short circuits. Ensure all cables and circuit protection (fuses and/or circuit breakers) are properly sized for the
entire system. See details about circuit protections in Section 5.2: Circuit Protection.
1.1 Battery Bank Configurations
Do not mix batteries of different ages and sizes in one battery bank.
Use the Expion360 Bus Bars or 4/0 AWG cables of the same length when connecting multiple batteries.
Before installing batteries for use in series, all batteries must be parallel connected and charged to 100 %.
Parallel Installation:
Connecting multiple batteries in parallel will increase the available energy (Watt-hour), charge and discharge rates
(current), and add capacity (Amp-hour) to use your battery bank. The voltage is not increased. Up to (4) batteries may
be connected in a single parallel string. To further increase the battery bank’s overall capacity, additional strings may
be connected to a common bus bar with equal length cables.
Important: Any batteries wired in parallel using cables must be connected by cables of equal length and gauge (AWG).

6
Expion360 Battery Manual, G24 and G27
Rev 1
03/10/2022
Series Installation:
Connecting multiple batteries in series will increase the battery bank’s energy capacity and voltage while maintaining
the charge, and discharge rates of the battery system. Note that available Watt-hours will increase while the Amp-hour
capacity remains the value of the individual batteries and is not summed together as in the parallel configuration. Up to
(4) batteries may be series connected to achieve 24, 36, and 48 Vdc systems. To further increase the battery bank’s
overall capacity, additional strings may be connected to a common bus bar.
Important: Any batteries wired in series using cables must be connected by cables of equal length and gauge (AWG).
1.2 Installation Diagram
Battery Terminal:
The depths of the female battery terminal threads are no more than 12 mm. Consider this when determining the proper
bolt length to secure bus bars, cable lugs, and any washers that will be affixed to the terminal connection pad. If too
much torque is applied to a bolt, the female threads of the battery terminal will be stripped and the damage will not be
covered under warranty due to misuse of the product. Consider the 12 mm thread depth when selecting your bolts so
that they do not bottom out, and a minimum of 3 threads are fully engaged.
Torque to 8 lb-ft (96 lb-in).
Do not finger-tighten. Do not overtighten. Check thread depth vs. bolt length. The female thread depth of the battery
terminals is 12 mm.
Prior to series installation, connect the batteries in parallel and fully charge to balance the batteries. For series-
connected battery banks, a battery balancing device is recommended as described in 4.2 Charging Options.

7
Expion360 Battery Manual, G24 and G27
Rev 1
03/10/2022
Battery Banks:

8
Expion360 Battery Manual, G24 and G27
Rev 1
03/10/2022
Please call technical support if your planned installation wired in a way not found in the provided wiring schematics.

9
Expion360 Battery Manual, G24 and G27
Rev 1
03/10/2022
2Battery Management System (BMS)
See the Battery Specifications page for complete BMS protection settings.
Short Circuit Protection:
If a short circuit occurs, the BMS will disconnect to protect the battery. When the short circuit condition is corrected, the
BMS will automatically reconnect. If the BMS does not reconnect, a charge is required to reset the BMS.
Overvoltage Protection:
If the charge voltage is higher than 14.6 Vdc ± 0.1 Vdc, the BMS will disconnect to protect the battery. When the
battery voltage falls to 14.2 Vdc ± 0.2 Vdc, the BMS will automatically reconnect. If the BMS does not reconnect, a
charge is required to reset the BMS. In some cases, it may take some time for the battery voltage to drop to 14.2 Vdc.
Undervoltage Protection:
If the battery reaches the minimum voltage of 9.5 Vdc ± 0.5 Vdc, the BMS will disconnect to protect the battery. A charge
is required within one week to prevent permanent damage and voiding the warranty of your battery. When the battery voltage
rises above 10.8 Vdc ± 0.4 Vdc, the BMS will reconnect. Some chargers will not charge if an open circuit is detected as
the BMS has disconnected. We recommend using our DC-DC charger or AC-DC charger to avoid this open circuit problem
and an Expion360 Battery Monitor to display voltage clearly.
Overcurrent Protection:
The BMS will monitor charge and discharge currents to protect the battery. If the charge or discharge current is too high,
the BMS will disconnect to protect the battery. When a high current condition is corrected, the BMS will automatically
reconnect. If the BMS does not reconnect, a charge is required to reset the BMS. See the specifications page for more
details.
Thermal Protection:
If the temperature is too high or low while charging or discharging the battery, the BMS will disconnect to protect the
battery. When the temperature is within the acceptable range, the BMS will automatically reconnect.
Cell Balancing:
The BMS will monitor and prevent each of the four cell bricks from overcharging. If the individual cell brick voltages are
outside the acceptable range, the BMS will automatically balance the cell bricks to bring them within range.

10
Expion360 Battery Manual, G24 and G27
Rev 1
03/10/2022
3Battery Monitoring
The charge/discharge characteristic curve of a LiFePO4battery has a much more gradual slope than lead-acid batteries.
Determining the battery’s state-of-charge (SoC) based on the voltage readings is not the best practice for LiFePO4
batteries. To accurately calculate the SoC of a LiFePO4battery bank, the Expion360 Battery Monitor is recommended.
The battery monitor calculates the SoC based on measuring the current that passes through a finely tuned shunt resistor,
rather than voltage, to give a more accurate reading of the battery bank.
The Expion360 Battery Monitor is easy to program, simple to install, and is compatible with all other brands and battery
chemistries. It shows the remaining capacity (Ah), SoC (%), battery bank voltage (V), charge/discharge current (A), and
charge/discharge power (W). The battery monitor also shows the remaining discharge time until empty and the
remaining charge time until full. Include this useful accessory for peace of mind, and to see your battery metrics at any
time without manually probing your batteries.
Note that the voltage displayed on the Battery Monitor will read higher or lower than the actual value if the battery has
been charged or discharged within an hour of measurement. Precision will increase with time until 12 hours have passed,
after which the measured voltage will not change. This is not a design flaw, but an inherent characteristic of all batteries
as they are charged and discharged. A greater difference in voltage will be measured when the battery is disconnected
from high current sources/loads than low current sources/loads.