Expion360 EX-AURA002 User manual

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Expion360 AURA Manual
Rev A
03/13/2023
USER MANUAL
EX-AURA001
EX-AURA002

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Expion360 AURA Manual
Rev A
03/13/2023
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 functionalities
may change without notice.
IMPORTANT
Please be sure to read the entire manual before using the products. Misuse may result in damaging the
products, causing harm, or incurring serious injury. Read this manual in its entirety before using the products.
Instead of saving this manual, check this manual on the Expion360 website for any updates and future
reference.
https://expion360.com/pages/customer-support
ABOUT US
•Safety
Expion360 lithium batteries use lithium iron phosphate (LiFePO4/LFP) chemistry, which is the best choice for
RV, marine, and off-grid power storage applications, because of its high degree of safety and long cycle life.
•Quality
With all the Li-ion players in the market, Expion360 strives to ensure that our products meet the highest quality
standards to maintain our advantage over the competition. Expion360 battery uses cylindrical 26650,
stainless steel encased LiFePO4 cells. The cells are UL 1642 recognized (File No. MH64383). They are
certified to the highest standard in safety and performance. Instead of soldering, all internal cables are
mechanically connected to reduce resistance and ensure robust connections.
The Expion360 proprietary case contains internal structural support to protect the battery pack and BMS
inside from the effects of vibration and movement. The innovative oversized terminals and bus bars provide
substantial electrical connections to accommodate high ampacity cables.
•Service
The Expion360 technical support department has industry experts on standby to assist every valuable
customer, in every way we can. For assistance with our products, contact us by phone or email any weekday
during business hours and receive help from the best technical support in the industry.
[e-mail]
[phone]
Monday-Friday except for holidays
8 am - 4 pm PST

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Expion360 AURA Manual
Rev A
03/13/2023
Please Read Each Warning Carefully to Prevent Damage to the Unit and Injury to Operators.
Ignoring Warnings Voids Warranty.
WARNINGS:
•DO NOT connect non-compatible batteries to the unit.
•DO NOT drop the unit.
•DO NOT open the unit.
•DO NOT short-circuit the unit.
•DO NOT block vents of the unit.
•DO NOT attempt to repair by non-certified parties.
•DO NOT insert any foreign objects into any openings.
•DO NOT use any third-party electrical parts with the unit.
•DO NOT expose the unit to dirt, fire, liquid, extremely hot, or extremely cold.
•DO NOT operate/store the unit outside the stated specifications of the manual.

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Expion360 AURA Manual
Rev A
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Contents
DISCLAIMER ................................................................................................................................................... 2
IMPORTANT ................................................................................................................................................... 2
ABOUT US ...................................................................................................................................................... 2
WARNINGS: .................................................................................................................................................... 3
1. Overview ................................................................................................................................................. 5
1.1 Parts and Accessories ............................................................................................................................ 5
1.2 Unit Diagram .......................................................................................................................................... 6
1.3 Display................................................................................................................................................... 7
1.4 Installation............................................................................................................................................. 8
2. Specifications - AURA Powercap 600 ........................................................................................................ 10
3. Operation .............................................................................................................................................. 11
3.1 Initialization ......................................................................................................................................... 11
3.2 Charging .............................................................................................................................................. 11
3.3 Discharging.......................................................................................................................................... 12
3.4 Storage................................................................................................................................................ 12
3.5 Warning ............................................................................................................................................... 13
3.6 Trouble Shooting .................................................................................................................................. 13
4. Bluetooth and App .................................................................................................................................. 13
5. Warranty................................................................................................................................................ 14
WARRANTY DISCLAIMER .............................................................................................................................. 14
LEGAL RIGHTS.............................................................................................................................................. 14
CLAIM .......................................................................................................................................................... 14

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Expion360 AURA Manual
Rev A
03/13/2023
1. Overview
1.1 Parts and Accessories
•In the Box
1x
Portable Power Station Module
2x
Portable Mounting Bracket
1x
7A AC Charger
2x
Stationary Mounting Bracket
1x
MPPT Charging Cable Adapter
2x
M8 PH3 Screws
1x
Thank You Card
4x
Hex Screws
•Tools
Required: Torque Wrench, 13mm Socket, 2mm HEX Wrench
Optional: 1/2 Socket, 14mm Wrench, 9/16 Wrench, PH3 Driver, Drill
•Accessories
The accessories below are not included. Can be purchased separately.
1. Mounts
AURA Powercap 600
G24 battery Single Mounting Kit (EX-G24-TDS)
AURA Powercap 800
G27 battery Single Mounting Kit (EX-G24-TDS)
2. Solar Chargers
AURA Powercap 600
120W Solar Charging Kit, including:
120W Portable Solar Panel (EX-PSP-120W)
10A MPPT Solar Charger (EX-10ASC)
AURA Powercap 800
30A MPPT Solar Charger (EX-30ASC)
3. Cables
Solar Panel Extension Cable – 8ft (EX-CA-SAE001)
Solar Panel Extension Cable – 16ft (EX-CA-SAE002)

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1.2 Unit Diagram
•Front View
•Back View
1
PD Port
7
Power Switch
2
USB-C Port
8
Display
3
USB-A Port
9
Mounting Bracket Nut Insert
4
12V DC Port
10
Vent
5
DC/Converter Switch
11
110V AC Output
6
Input Port
12
AC/Inverter Switch

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1.3 Display

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1.4 Installation
AURA Powercap 600 Portable Power Station 600W Module is Only Compatible with Expion360
Group 24 batteries.
AURA Powercap 800 Portable Power Station 800W Module is Only Compatible with Expion360
Group 27 batteries.
•Portable Installation
Before installation, make sure all the switches are in the OFF position (flush and LED off).
Do Not tighten two terminals at the same time.
P1
Make sure Aura and the Expion360 battery are in the same orientation. The POSITIVE terminal of Aura
must align the
POSITIVE
terminal ○ 1on the battery. The anti-
fool feature on Aura and battery
(highlighted in the detail view) helps the correct alignment. If Aura is not resting securely on the battery,
stop installing. Turn Aura 180° and check the alignment before proceeding.
P2
Insert M8 screw ○ 2 into each terminal.
Use a 13mm Socket to tighten screws to 8lb-ft/96lb-in (10.85Nm). Do not overtight.
P3
Insert the Portable Mounting Bracket ○ 3 on each side.
P4
Tight the bracket with HEX screws ○ 4 on each side to 30lb-in (3.5Nm). Do not overtight.
P5
Snap the dust cover ○ 5 back to each terminal.
Follow the same procedure for installing AURA Powercap 800 with Expion360 Group 27 batteries.

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•Stationary Installation
AURA Powercap 600 Portable Power Station 600W Module is Only Compatible with Expion360
Group 24 batteries.
AURA Powercap 800 Portable Power Station 800W Module is Only Compatible with Expion360
Group 27 batteries.
Before installation, make sure all the switches are in the OFF position (flush and LED off).
Do Not tighten two terminals at the same time.
S1
Replace the Portable Mounting Bracket with the Stationary Mounting Bracket. Then follow the same
procedure from P1 to P5.
S2
Slightly lift one side.
Insert the T-bolt through the tab on the Mounting Base Plate, the Stationary Mounting Bracket, and a
flat washer. Loosely tight the nut.
Do the same on another side.
S3
Lay the unit flat and tighten the nuts on both sides using a 14mm or 9/16” wrench. Do not over-tight.
S4
Before securing the fully assembled unit, Leave at least 2in (5cm) from each side to the closest objects.
Make sure the installation location is vented and above 32°F (0°C).
S5
The installation orientation is limited to upward only. Do not install the unit on its side or upside down.
Fasteners for securing the Mounting Base Plate are not included. Depending on the different types of
surfaces, use the proper fasteners. Drill pilot holes if needed and follow the fastener manufacturer's
guide.
Follow the same procedure for installing AURA Powercap 800 with Expion360 Group 27 batteries.

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2. Specifications - AURA Powercap 600
General
Unit Dimensions
(Power Module Only)
10.2 in * 6.9 in * 3.8 in
(258 mm * 177 mm * 97 mm)
Install Dimensions
(With EX-G24 Battery Only)
10.6 in * 6.9 in * 12.1 in
(270 mm * 177 mm * 306 mm)
Unit Weigh
(Power Module Only)
6 lb
(2.8 kg)
Install Weigh
(With EX-G24 Battery)
25 lb (11.5 kg) with EX-G24-60C
30 lb (13.7 kg) with EX-G24-80C
31 lb (14.2 kg) with EX-G24-95XDP
Idle Power Loss
≤ 10 W
Communication
Build-in Display / BT
Operating Temperature
-4 °F to 104 °F (-20 °C to 40 °C)
Cooling
Push-Pull Fans
Charging
Charging Temperature
32 °F to 104 °F (0 °C to 40 °C)
AC Charger
100 W
Solar Charger (not Included)
120 W
DC Input
Nominal Voltage
12.8 V
Rated Current
80 A @ 12 V
Compatible Battery
EX-G24-60C/80C/95XDP
DC Output
12 V DC Port
120 W (12 V 10 A)
USB-A
15 W (5 V 3 A)
USB-C / Type-C
15 W (5 V 3 A)
Power Delivery (PD) 3.0
100 W (5/9/15 V 3 A, 20 V 5 A)
AC Output
Nominal Voltage
110 Vac
Nominal Frequency
60 Hz
Rated Power
600 W @ 77°F (25 °C)
Surge
660 W (3 s) / 900 W (50 ms)
Protection
DC Input Over Current
110 A
DC Input Low Voltage
10.6 V
DC Input Over Voltage
15.0 V
AC Output Over Current
6 Aac
Input Short Circuit
Internal Fused
Output Short Circuit
Programmed
Display
Current Tolerance
± 1 A

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3. Operation
3.1 Initialization
Depending on the application, AURA Powercap 600 and 800 can be installed with different capacities of
Expion360 Group 24 and 27 batteries. The pre-set total capacity on AURA Powercap 600 or 800 may not match
the battery capacity.
Expion360 Group 24 battery has capacities of 60, 80, and 95Ah.
Expion360 Group 27 battery has capacities of 100 and 120Ah.
It is very important to update the total capacity for accurate reading of the Fuel Gauge, Estimated Remaining
Time of Charging or Discharging, and State of Charge (SoC). Please refer to Sec. 4 Bluetooth and App for
details about updating total capacity.
After updating the total capacities of the AURA Power Station, turn on the power and charge the unit until the
voltage is higher than 14.2V so that SoC is initialized correctly.
3.2 Charging
The unit can be charged with AC or solar panels. Make sure the batteries are above 32°F (0°C) before
charging. For accurate SoC calculation, disconnect loads, turn off the AC and DC switches, and turn on the
power switch.
•AC Charging
Plug the Anderson port (the port with red and black) into the AURA Powercap Input port. Plug the AC plug into
the wall outlet. The LED indicator on the charger will turn red when charging. The charger will automatically
stop charging, and the LED indicator will turn green when finished.
The estimated charging time is calculated as
Charging time = Total Capacity/Charging Current.
E.g., 60Ah/7A = 8.6h .
For faster AC charging, please upgrade to 20A AC Charger.
•Car Charging
For vehicles with an onboard inverter, check the power rating of the onboard inverter and AC Charger. If the
onboard inverter power rating is lower than the AC Charger power rating, stop immediately. Otherwise, follow
the instructions of vehicle manufacturers for AC Charging.

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•Solar Charging
1. Solar Charging Kit
The solar charging kit is not included in the package. Please refer to Sec. 1.1 Parts and Accessories for
details. The AURA Powercap 600 is limited to use with one 10A Maximum Power Point Tracking (MPPT) Solar
Charger (EX-10ASC) and one 120W Portable Solar Panel (EX-PSP-120W). For a higher solar charge rate, please
choose AURA Powercap 800 with one 30A MPPT Solar Charger (EX-30ASC). For the details about MPPT Solar
Charger, please refer to the MPPT Solar Charger Manual at
https://expion360.com/pages/customer-support
The Solar Panel Extension Cables have 8ft and 16ft two different lengths. Choose the correct length for the
installation or connect multiple cables for a longer extension. Try to minimize the length and quantity of
extension cable for the best performance.
2. Solar Charging Quick Guidance
Solar charging performance is affected by many factors, such as solar irradiation, cloud overage, shade, solar
panel tilt angle, solar panel temperature, solar panel dust coverage, etc. For any factor changes, the MPPT
charger takes about 30s to find the new maximum power point before starting to charge.
To maximize the solar charging performance, try to set up the solar panel where it is clear of clouds, with no
shading, and wipe off the dust from the surface if needed. When setting up the solar panel at the optimal
location, make sure the solar panel is tilted and normal to the sun. The back side of the panel needs to be
clear of obstacles with good airflow.
As the sun moves throughout the day, the solar panel's normal direction may need to be adjusted for maximum
charging performance.
If the charging process is unattended throughout the day, ensure the unit is secured from wind, rain, and theft.
Position the solar panel to the south and tilt the panel based on the latitude and the day of year.
3.3 Discharging
Turn on the DC/Converter switch to enable the DC output ports. Turn on the AC/Inverter switch to enable the
AC output ports. Turn off the DC/Converter or AC/Inverter switch when DC or AC ports are not in use to reduce
power loss.
DO NOT exceed the power rating on each port. Always check the power rating of the load before connecting.
3.4 Storage
Power off the unit and store at 14°F to 104°F (-10°C to 40°C) and RH 5% to 90%. Always check the voltage
and recharge the unit before the next trip.

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3.5 Warning
•DC Switch LED off
The whole DC output encounters over current, overload, low voltage, or over temperature protections.
•AC Switch LED off
AC output encounters over current, low voltage, high voltage, over temperature, or output short circuit
protections.
3.6 Trouble Shooting
•Input Low Voltage
Turn off DC and AC switches. Disconnect the load and connect Aura to the charger. Turn on the switches
when the voltage is higher than 11V.
•Input Over Voltage
Turn off the AC switch. Disconnect charger. Turn on the AC switch when the voltage is lower than 14.6V.
•Input Over Current
Turn off the DC or AC switches. Wait for 3 seconds. Turn on the DC or AC switch.
•Output Over Current
Turn off the DC or AC switch. Disconnect load. Wait for 3 seconds. Turn on the DC or AC switch.
•Over Temperature
Turn off the DC or AC switch. Disconnect load. Cool down the unit to 195 °F (90°C). Do not block the vents.
Check the load power rating. Turn on the DC or AC switch. Operate the unit in a cooler location.
•Output Short Circuit
Turn off the AC switch. Disconnect the load. Turn on the AC switch.
•Input Short Circuit
Warranty voided. Contact Expion360 technical support for further assistance.
4. Bluetooth and App
Please refer to the Expion360 App Walkthrough for details. The walkthrough can be found at
expion360.com > Support (drop-down tab) > Customer Support
or
https://expion360.com/pages/customer-support

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5. Warranty
The AURA Powercap 600 and AURA Powercap 800 have a 2-year limited warranty which begins on the date
of purchase for the original owner solely. Product registration and Return Merchandise Authorization (RMA)
are required for warranty claims. Valid warranty claims can only be applied once. Upon receiving the unit,
Expion360 will repair or replace the unit if defects in material or workmanship are determined to be the cause
of the malfunction, or Expion360 will deny or charge a reasonable amount for repair and shipping.
The warranty does not cover normal wear, non-quality issues, and misuse - especially the warnings stated in
this manual. The warranty also does not cover the following conditions, including but limited to:
-Improper installation.
-No valid proof of purchase (stolen/free unit, purchased from unauthorized dealer/seller)
-Damage caused by mother nature (e.g., fire, flood, earthquake, …) or accident (e.g., drop, loss, …).
WARRANTY DISCLAIMER
This limited warranty represents the total liability of Expion360. All other warranties implied by law applicable
to the unit shall be limited to the warranty period stated. Expion360 makes no other warranties, express or
implied, including the implied warranties of merchantability or fitness for a particular purpose. Expion360
shall not be liable for any indirect, special, incidental, or consequential damages.
LEGAL RIGHTS
Some states do not allow limitations on how long an implied warranty lasts or exclusion or limitation of
incidental or consequential damages, so the above limitations may not apply to you. This warranty gives you
specific legal rights, and you may also have other rights that vary from state to state. This warranty shall be
governed by and interpreted by the laws of the State of Oregon. This warranty is understood to be the
exclusive agreement between the parties relating to the subject matter hereof. No employee or representative
of Expion360 is authorized to make any warranty in addition to those made in this agreement.
CLAIM
To submit a warranty claim, please contact Expion360 technical support:
[e-mail]
[phone]