Freedom Won Lite Marine 5/4 User manual

Installation Manual
Freedom Lite Marine
Range of Lithium Iron Phosphate Batteries
Manufactured by Freedom Won (Pty) Ltd
Kimbult Industrial Park, Unit C3 & C4
9 Zeiss Road
Laser Park, Honeydew
2040
South Africa
www.freedomwon.co.za
Technical and Installation Assistance – Contact:
Please contact your Freedom Won Distributor or Reseller Installer for technical and installation
support. A directory of Distributors and Reseller Installers is available at www.freedomwon.co.za.
For advanced support please contact [e-mail].
Revision 1 – 07 March 2020

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1. Introduction
This manual is intended to aid an installer with the installation and commissioning of the
range of Freedom Lite Marine lithium iron phosphate (LiFePO4) energy storage units. This
document is not intended to provide detailed information of the inner workings of Freedom
Lite that is not relevant to a person that is performing the installation and final
commissioning. Supplementary information relating to programming of the built-in battery
management system for specific applications is available to approved integrators directly
from Freedom Won.
This manual does not attempt to cover all the details pertaining to the setup of third-party
equipment in relation to the interface and necessary functionality to work with the Lite.
Freedom Won however is available at the contact details on page 1 to provide direct
support where necessary for supported third party brands.
2. Range Overview
The Freedom Lite technology is available in various standard sizes to meet all residential,
commercial and industrial applications ranging from 5kWh up to 2500kWh. Larger systems
are provided by Freedom Won based on specific project requirements by installing multiple
units in parallel. Models designed for mobile applications including Marine and Mobility are
also included in the range line up.
Freedom Won offers the following ranges in the LiFePO4 technology:
1. Lite 12V
2. Lite Home and Business
3. Lite Home and Business HV
4. Lite Marine
5. Lite Mobility (golf carts, forklifts etc)
6. Lite Commercial (including Lite Commercial HV and HV+)
7. Lite Industrial
This manual covers the models of the Lite Marine range from 5kWh up to 30kWh. Please
refer to the manuals specific to the applicable range required.
The Lite Marine range of lithium batteries offers 13V, 26V and 52V options to suit ‘12V’,
‘24V’ and ‘48V’ systems, respectively. These models are water and corrosion resistant (IP65)
and designed for mounting on the floor in land-based applications or on a horizontal deck
inside lockers and compartments for marine applications. These models have different
dimensions to the Lite Home models but are similar internally.
3. Product Description – Lite Marine
The Lite Marine range of lithium batteries is specifically designed to provide high end energy
storage performance to the boating industry. It is designed for below deck applications

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away from direct saltwater exposure. For applications for open deck operation such as ski
boats please contact Freedom Won for a solution.
The range is available in 13V and 26V options to suit ‘12V’ and ‘24V’ systems used in the
marine industry. 52V is also available to accommodate land-based applications where
moisture and corrosion resistance is desired such as houses located particularly close to the
coast.
The Lite Marine range is water resistant (IP65) and resistant to corrosion associated with sea
moisture exposure. Note that the product is not suitable for repeated direct exposure to sea
water contact.
The range is designed with a low profile to fit into height restricted lockers etc. All models
are supplied standard with plastic feet. It is permissible to stack the Marine models on top
of each other up to three high (this relates to land-based applications).
Table 3.1 provides an overview of the Freedom Lite Marine range. The models are classified
in terms of energy capacity [kW].
An image with numbered labels pertaining to the following paragraphs is provided in Figure
3.1. The model number denotes with the first number [1] the total energy storage capacity
in kWh of each model. The second number [2] denotes the average amount of energy in
kWh that should be withdrawn per cycle (on average) in order to optimise the life of the
lithium cells. This equates to 80% of the total for each model i.e. 80% depth of discharge
(DoD). Older models denoted a 70% DoD as in this picture. Note that all Freedom Lite
batteries offer a maximum of 90% DoD as standard.
The available voltage options are also provided in Table 3.1. For assistance with comparing
the Lite Marine against other batteries the Ah ratings have been provided in Table 3.2. Note
that the Ah rating of a Lite Marine need only be about half of the rating of a typical lead
battery in order to offer equivalent useful capacity performance.
The maximum and continuous current for each model is governed by the rating of the built-
in circuit breaker [3], which has been sized below the maximum current capability of the
lithium cells. Even at maximum current the temperature rise inside the battery is negligible
and no cooling of the cells is required. The time limits for operation at the maximum current
should be observed (see notes to Table 3.1). To ensure that the circuit breaker does not trip
in normal operation it is advised that the design of the system aims to remain at or below
the continuous current value.
For assistance with setting up the inverters and charge controllers please refer to Table 3.3
for the voltage values required for operation of the battery.
The BMS will command a connected inverter with CAN Bus interface to stop discharging the
battery at 10% SoC (90% DoD). Under high load the voltage may drop lower than the
estimated voltage provided in Table 3.3 whilst still above 10% SoC. The standby current
draw on the battery and the inverter can cause the battery to be discharged below 10% SoC.

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The battery breaker will eventually trip the battery at or around the minimum cut-out to
protect the cells from undervoltage.
Table 3.1 provides the maximum charge and discharge current and power ratings of the
battery and the associated maximum recommended installed inverter power.
Figure 3.1 Labelled Image of the Freedom Lite Marine 10/8 (Labelling corresponds with the
text)
[2]
[1]
[3]
[7]
[8]
[9]
[10]
[12]
[11]
[14]
[13]
[15]
[4]
[6]
[5]

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1. Gross Capacity
2. 80% Capacity recommended for daily cycling (max available is 90%)
3. Breaker
4. Power Cables
5. Analogue and Relay Control Cable (available on special request) (not shown in this
picture but located near the power cables if fitted)
6. CAN Bus Sockets x 2 (RJ45) (one socket must contain a termination resistor if end of
line)
7. DB9 Programming Port
8. Supplied RS232 Adapter
9. State of Charge Display
10. Reset Button
11. On Button
12. Off Button
13. Handles for Manual Lifting (larger models have eye bolts)
14. Moisture protection breaker cover
15. Feet
The weight of each model is given in Table 3.1. The Freedom Lite Marine 5/4 and 10/8 can
be manually lifted with the fitted handles by two people. The larger units require lifting
equipment of varying degrees for handling and installation as explained later in this
document.
The dimensions given are for the principle outlines of the aluminium housing and exclude
items that protrude such as the DC cable glands and handles.
The DC cables [4 inset] exit the unit through glands located on one end of the casing
(opposite end to the breaker). The cable sizes are provided in Table 3.1 for each model. The
correct cable lugs for connecting these leads to the inverter must be in hand when doing an
installation. If there are several inverters, alternators and charge controllers that need to be
connected to the battery it is advisable to install a DC connector box to use as a junction
point from which to branch out to all the battery connected equipment. In boats these
cables would typically be routed to the DC busbars in the power distribution and control
console.
An analogue and relay control cable [5 inset] is an optional item located near the DC cable
glands for use in installations where an analogue or dry contact (relay) interface compatible
alternator, inverter or charge controller is used (note that from 9 September 2019 this cable
is not standard supply and it is only supplied on special request). Where dry contact control
is required an external relay must be installed, which will be controlled by the control pins
in the optional control lead (more detail later in manual).

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Table 3.1 Freedom Lite Marine Range Overview
Lite
Marine
5/4
10/8
20/16
30/24
Total Energy Capacity [kWh]
5
10
20
30
Nom
inal Voltage [V]
Available in 13V, 26V and 52V options
Max/Cont.
Discharge Current [A] (2)
300/240
300/240
480/400
480/400
Max & Cont. Charge Current [A]
100
200
400
600
Max. Daily DoD Suggested (average)
[%] 80%DoD
80% DoD Energy [kWh]
4
8
16
26
Round Trip Efficiency [%]
96
-
98
Height [mm]
220
340
Width
[mm]
300
400
580
Length (including end handles or eye
bolts) [mm] 978 886 1 462 1 462
Total Weight [kg]
55
110
205
305
Enclosure
Aluminium, powder coated, tamper proof, waterproof IP65, corrosi
on resistant,
handles or eye bolts for lifting, rubber feet
DC Connection
–
Fly Leads, [no. per
electrode] (3) 1x 50mm2 1x 50mm2 2 x 50mm2 2 x 50mm2
External Interface
CAN Bus
On
-
board Management
Full battery management system and internal trip protecti
on
Human Interfaces
Serial RS232 Plug for
Programming
and data access with PC, main breaker,
e
rror
reset button, SoC display, error light
Protection
Shunt Trip Circuit Breaker sized to suit max current, can be tripped by BMS if
critical fault, manual reset. Protection for overcurrent, cell under and over
voltage, temperature, weak cell detection and other critical events
Battery Chemistry
Lithium Iron Phosphate (LiFePO4)
Form Factor
Large Format ultra
-
heavy
-
duty prismatic cells of 200Ah each and 3,2V no
minal
voltage, fully sealed in plastic casing with bolt on electrode connections
Battery Cooling
Natural Convection (heat generation is negligible inside the battery)
Suitable Ambient Temp [°C] (4)
0°C to +40°C
Extreme Operating Temp [°C]
-
20°C to +60°
C
Remote Monitoring
Optional: Real
time data logging and transmission via WiFi to online portal of
key battery information
Warranty (5)
10 years or 4 000 cycles for average 80% DoD, and max 90% DoD
Service Life
>16 years (>
5
5
00 cycles) expected life at
8
0% DoD (1), >20 years (>7 500
cycles)
at 50% DoD
Notes to Specification Sheet:
1. This range is not designed for direct exposure to saltwater such as for us above deck on a small boat.
The intended use is below deck away from actual water spray. The product is also recommended for
use on seaside properties where airborne sea spray is a corrosion concern. For above deck applications
please contact Freedom Won.
2. Max discharge load duration – 5 minutes per 30-minute cycle. 2 x Max overload can be handled for 2
seconds.
3. DC Cables 1,8m long, power cable Red = Positive, Black = Negative, conductors in table refer to one
electrode i.e. per positive and negative connections

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4. Charging below 0°C not permitted. Extended time above 45°C not recommended for optimal battery
life.
5. Warranty is 10 years or 4 000 cycles at an average of 80% DoD per cycle, 70% capacity guaranteed by
end of warranty.
Two RJ45 sockets [6 inset] are provided, one for connecting the CAN interface from the
battery to the system controller (or directly to the inverter depending on the inverter
brand), and another for connecting the battery to another battery or for a termination
resistor (more detail later in manual).
A DB9 Serial Connector [7] is fitted adjacent to the breaker for use by technicians for
programming the required profile onto the BMS. The required profile is typically loaded by
Freedom Won prior to delivery but installers are advised to obtain the correct adapter (a
DB9 RS232 to USB adapter cable [8](Figure 3.2) is required) to allow Freedom Won or
authorised distributors to program batteries remotely on behalf of the installer or user via a
Windows laptop. The DB9 RS232 adapter must have male pins. One is supplied by Freedom
Won with each battery (note that only the unit supplied by Freedom Won is guaranteed to
work, inferior brands do not always work properly).
Freedom Lite is also fitted with a State of Charge (SoC) display [9], which includes a red LED
error indicator and below it a “low power” indicator.
An error reset button [10] is positioned near the SoC display.
Figure 3.2 RS232 DB9 (male) to USB Adapter for Programming Freedom Lite Marine models
(appearance may vary)
The ON button [11] and OFF button [12] is located beside the SoC display.
The Marine 5/4 and 10/8 models are fitted with handles for lifting the battery manually
[13]. The larger models are fitted with eye bolts to enable slinging the batteries. A metal bar
can also be placed through the eye bolts for carrying manually by four or more people.

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A clear cover is provided to prevent moisture entering the battery through the breaker [14].
This cover must be removed using an Allen key to switch the battery on for commissioning
and then replaced immediately after commissioning to maintain the IP65 rating.
All Lite Marine models have feet (one on each corner) as standard [15].
A warranty seal is fixed to the lid of the battery to prevent unauthorised removal of the lid.
Damage to this seal will void the battery warranty.
Table 3.2 Ah Ratings of the Marine Range
Model 13V 26V 52V
Lite 5/4 Marine 400Ah 200Ah 100Ah
Lite 10/8 Marine 800Ah 400Ah 200Ah
Lite 20/16 Marine 1600Ah 800Ah 400Ah
Lite 30/24 Marine 2400Ah 1200Ah 600Ah
Table 3.3 Suggested Voltage Values Required for Setting Up Inverters and Charge Controllers
Model 13V 26V 52V
Absolute Max Voltage [V] 14,4 28,1 56,2
Ideal Charge Voltage [V] 13,9 to 14.2 27,8 to 27,9 55,8
Approx. 80% DoD Voltage [V] 12,6 25,5 51,0
Approx. 90% DoD Voltage [V] 12,2 25,0 50,0
Min Cut-out Voltage [V] 11,5 23,0 47,0
4. Transport, Handling and Mounting
The Freedom Lite units are packaged in protective layering and fastened into a wooden
crate with feet, which allows lifting with a forklift or a pallet jack. The Freedom Lite Marine
5/4 and 10/8 models are easily handled by two people. The 20/16 model may be manually
handled by sufficient people but is best handled by a pallet jack or forklift. The 30/24 and
model must be handled with care by a forklift or pallet jack. A light crane will be required for
lowering this model below deck through a hatch.
For small boats with restricted access the 10/8 would typically be the largest option.
Multiple of this model can be connected in parallel to provide the required storage capacity.
Larger boats with facilities for handling heavy items or with deck hatches above the battery
room will favour the larger models such as the 20/16 and 30/24. It is acceptable to sling the
20/16 and 30/24 models by one end in order to fit them through deck hatches.
The Marine batteries are usually strapped down into place using ratchet straps secured to
tie down points in the boat deck. The strap is placed over the casing. The units with eye
bolts on each end can be fastened down to the deck using turnbuckles secured to the eyed

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bolts on each corner. For Marine applications it is advisable to secure the battery to the
deck.
Caution:
1. Handle the Freedom Lite with great care when lifting and manoeuvring. The Freedom
Lite Marine can be handled at any angle during installation but must be fitted on its
feet for operation.
2. Take care not to knock any of the protruding items against obstacles during handling
such as the DC cabling and plugs and the circuit breaker handle and circuit breaker
cover.
3. Take care not to scratch the Lite during handling. Packaging foam should be used to
protect the paint when being handled on a trolley or pallet jack.
4. Always ensure that lifting equipment and slings are adequately rated for the lifting
weight.
5. Ensure that the eye bolts fixing point shows no signs of damage before lifting.
6. Wear personal protective equipment such as safety shoes and gloves while handling
and mounting the Freedom Lite
7. Always ensure that you have enough people on hand to perform the operation safely,
i.e. at least one person to guide and stabilise and one person to hoist or handle the
lifting equipment.
8. Do not allow persons or parts of persons to be positioned underneath the load while
lifting
5. Connecting the Freedom Lite Marine
5.1 Power Cables
The Freedom Lite is simple to connect to the DC bus or battery inverter. First of all you will
connect the battery positive and negative cables to the inverter terminals or DC bus bar
using the applicable lugs.
Caution: Prior to connecting the positive and negative cables to the inverter or DC bus bar
be sure to check that the main battery circuit breaker is switched off. This will ensure that
there are no short circuits between the loose ends of the cables.
The cables are supplied with the Freedom Lite Marine, permanently fixed into the unit and
secured onto the casing using compression cable glands. Attach crimp plugs to the ends of
both cables ensuring that the correct terminal size is used. Also be sure to match the size of
the cable to the lug. The positive cable is red and the negative cable is black. See Table 2.1
for the cable size and quantity fitted to each Freedom Lite Marine model. The cable sizes are
based on the inverter or main DC busbar being close to the Freedom Lite battery so that the
cable run is less than 5m (note however that the standard cable length is 1,8m, longer
cables available in request).

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Runs longer than 5m should be assessed, and larger cables considered for extending the
Freedom Lite cables, to minimise voltage drop. Double Insulation welding cable is
recommended.
On Installations where there are too many inverters and/or charge controllers to connect to
the DC bus directly from the battery using the inverter terminals as a junction point a DC
connector box is required.
5.2 Control Cables – Overview
For controlling external devices you will need to connect the control wiring that allows the
Battery Management System inside the Freedom Lite to control and interface with these
devices.
The connection of the cables and the method of control depends on the model of inverter,
alternator, or charge controller. There are three main control options for the connected
equipment, namely:
1. hard wired potential free contacts that are connected to auxiliary inputs or remote
on/off switches on the inverter, alternator regulator or charge controller,
2. analogue 0-5V signal,
3. or CAN Bus.
The primary control option is CAN Bus, which requires an ethernet cable to be plugged into
one of the RJ45 plugs on the battery. The RJ45 connection is standard supply on the
Freedom Lite Marine.
The second control connection method is an optional analogue signal and relay control
cable. The cable is not supplied as standard because most modern applications use CAN Bus
control, but it can be ordered as an option from Freedom Won where CAN Bus interfacing is
not available on all connected equipment. All control methods can be used simultaneously.
The Lite does not contain internal relays for method 1 above, so external relays are
required, which are controlled by the relay coil driver wires from the optional control cable.
The relay used must be rated for the voltage of the battery i.e. 12V, 24V or 48V.
Relays controlled by the battery relay driver signals may also be used to control larger
contactors. Note that it is not feasible to control overcharge by disconnecting the DC
connection from an alternator, as disconnecting the DC power cable from an alternator
while it is running will result in regulator and/or alternator damage. To enable battery
control over the alternator output it is necessary to use a regulator alternator combination
that provides a remote enable/disable ignition input or a CAN Bus controlled regulator.
The optional control cable contains 12 wires, each of a different colour, of which eight are
used. Table 4.1 below provides the colour coding for the Freedom Won supplied cable.
Further explanation of the functions is laid out in Table 4.1