genz III Series User manual

Installation Guide
Lithium Ferro Phosphate (LFP) Battery Module
48V 2kWh and 3kWh 2RU Scalable Energy Solutions
Model Numbers GC48V-040LFP-2RU and GC48V-060LFP-2RU Series III
with or without rack tray kit

LFP Battery Module –Installation Guide
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Contents
1INTRODUCTION.................................................................................................................................................................................3
2GENERAL INFORMATION...................................................................................................................................................................3
2.1 LIFE SUPPORT POLICY ................................................................................................................................................................................. 3
2.2 GENZENERGY PTY LTD ............................................................................................................................................................................... 3
3SAFETY GUIDELINES ..........................................................................................................................................................................4
3.1 WEIGHT ...................................................................................................................................................................................................4
3.2 RISK OF ELECTRIC SHOCK .............................................................................................................................................................................4
3.3 STORED ENERGY ........................................................................................................................................................................................ 4
3.4 QUALIFIED SERVICE PERSONNEL ONLY ...........................................................................................................................................................4
3.5 MATERIAL SAFETY DATA SHEET (MSDS) .......................................................................................................................................................4
4ABBREVIATION DEFINITION...............................................................................................................................................................5
5SPECIFICATIONS ................................................................................................................................................................................6
6MODULE OVERVIEW .........................................................................................................................................................................7
6.1 BATTERY MANAGEMENT SYSTEM (BMS).......................................................................................................................................................7
6.2 POWER IN/OUT J1..................................................................................................................................................................................... 7
6.3 EARTH POINT ............................................................................................................................................................................................ 7
6.4 DUAL POLE 60AMP CIRCUIT BREAKER ...........................................................................................................................................................7
6.5 FRONT PANEL KNURLED KNOBS....................................................................................................................................................................7
7SYSTEM DESIGN ................................................................................................................................................................................8
7.1 OVERVIEW................................................................................................................................................................................................8
7.2 NEW ENERGY STORAGE DESIGNS.................................................................................................................................................................. 8
7.3 CONNECTORS AND CABLES .......................................................................................................................................................................... 9
7.4 EXISTING SYSTEMS ................................................................................................................................................................................... 11
8TRANSPORTATION, DANGEROUS GOODS AND STORAGE.................................................................................................................13
9INSTALLATION OF BATTERY MODULE(S)..........................................................................................................................................13
9.1 CLEARANCES,ALL MODELS WITH OR WITHOUT A SHELF KIT ..............................................................................................................................14
9.2 INSTALLATION OF A SINGLE BATTERY MODULE ..............................................................................................................................................14
9.3 PARALLEL CONNECTION ............................................................................................................................................................................14
9.4 RACKMOUNT CONFIGURATION...................................................................................................................................................................15
9.5 CONNECTING THE BATTERY MODULE .......................................................................................................................................................... 15
10 OPERATION.....................................................................................................................................................................................16
10.1 TO TURN THE BATTERY MODULE ON AND OFF .......................................................................................................................................16
10.2 POWER IN/OUT J1.............................................................................................................................................................................. 16
10.3 CHARGING THE BATTERY MODULE ........................................................................................................................................................ 16
10.4 DISCHARGING THE BATTERY MODULE .................................................................................................................................................... 17
10.5 STORAGE .......................................................................................................................................................................................... 17
11 DISPOSAL OF DAMAGED, FAILED OR END OF LIFE BATTERY MODULES.............................................................................................17
12 TROUBLE SHOOTING .......................................................................................................................................................................18
13 WARRANTY & SERVICE INFORMATION............................................................................................................................................20
13.1 REGISTRATION ...................................................................................................................................................................................20
13.2 BEFORE CALLING FOR SERVICE ..............................................................................................................................................................20
13.3 WARRANTY OR SERVICE....................................................................................................................................................................... 20
14 APPENDIX A –DISCHARGE AND CAPACITY CURVES (25°C) ...............................................................................................................21
15 APPENDIX B –CIRCUIT BREAKER TRIP CURVE (BS) ...........................................................................................................................22
16 APPENDIX C –DIMENSIONS.............................................................................................................................................................23
16.1 2KWH MODULE AND TRAY ..................................................................................................................................................................23
16.2 3KWH MODULE AND TRAY ..................................................................................................................................................................25

LFP Battery Module –Installation Guide
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1Introduction
Thank you for purchasing this LFP Battery Module. It has been designed and manufactured to provide
many years of trouble free service.
Please read this guide prior to installing any of the LFP Battery Module models. This installation guide
covers the following battery module models:
GC48V-040LFP-2RU (48Volt, 2kWh, 40Ah, 2 Rack Unit high) Series III
GC48V-060LFP-2RU (48Volt, 3kWh, 60Ah, 2 Rack Unit high) Series III
This guide provides important information that must be followed during installation of the Battery
Modules.
This guide should be used in conjunction with the Battery Module Product Manual.
Failure to follow this guide may lead to you damaging the system it is being installed into and/or
voiding your warranty for the battery module as well as the system it is installed into. There are
important safety and handling procedures that must be followed for your own safety and the safety
of those around you.
This guide also contains information for customer support and factory service if it is required.
2General Information
2.1 Life Support Policy
We do not recommend the use of any of our products in ‘life support’applications where failure or
malfunction of the product can be reasonably expected to cause failure of the life support device or
to significantly affect its safety or effectiveness.
2.2 genZ Energy Pty Ltd
All Rights Reserved. All rights of this User Guide (“Guide”), including but not limited to the content,
information, and figures are solely owned and reserved by genZ Energy PTY LTD. (“genZ Energy”).
The Guide can only be applied to the operation or the use of this product. Any disposition,
duplication, dissemination, reproduction, modification, translation, extraction, or usage of this guide
in whole or in part is prohibited without the prior written permission of genZ Energy. Given that genZ
Energy will continuously improve and develop the product, changes may be made to the information
in this Guide at any time without obligation to notify any person of such revision or change. genZ
Energy will make all possible efforts to secure the accuracy and the integrity of this guide. genZ Energy
disclaims any kind or forms of warranty, guarantee, or undertaking, either expressly or implicitly,
including but not limited to the completeness, faultlessness, merchantability or fitness for a particular
purpose of the guide.

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3Safety Guidelines
3.1 Weight
These Battery Modules are heavy. Any time the Battery Module has to be handled be sure to use,
enough personnel, strong supports and suitable lifting equipment.
3.2 Risk of Electric Shock
Hazardous voltages maybe present on parts inside this module. Do not attempt to open or
disassemble the module. These Battery Modules contain no user serviceable parts.
3.3 Stored Energy
These Battery Modules can, especially if they are connected in parallel, produce high currents.
3.4 Qualified Service Personnel Only
Repairs and Battery replacement must be performed by qualified service personnel only.
3.5 Safety Data Sheet (SDS)
Refer to the SDS that was supplied with this module in case of an accident.

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4Abbreviation Definition
A = Amperes
AC = Alternating Current
Ah = Ampere hours
BMS = Battery Management System
C = Celsius
CB = Circuit Breaker
CC = Constant Current (phase of charging)
cm = Centimetres
CV = Constant Voltage (phase of charging)
DC = Direct Current
DoD = Depth of Discharge
FAT = Factory Acceptance Test
IP = Ingress Protection rating
Kg = Kilograms
kW = Kilo Watts
kWh = kilo Watt hours
LED = Light Emitting Diode
LFP = Lithium Ferro Phosphate
mm = Millimetres
ms = milli seconds
SDS = Safety Data Sheet
NC = Normally Closed
RU = Rack Units
SAT = Site Acceptance Test
V = Volts

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5Specifications
NOTE: All Specifications shown are for an ambient temperature of 25°C (77F) and charge / discharge rates
of 0.5C unless otherwise stated.
Model
GC48V-040LFP-2RU
Series III
GC48V-060LFP-2RU
Series III
Nominal Voltage
Direct Current (DC) 51.2V (48V)
Nominal Capacity
38.4Ah/2kWh
57.6Ah/3kWh
Nominal Current
19.2 Amps
28.8 Amps
Maximum Current
60 Amps (limited by circuit breaker)
Maximum DC Power
1966 Watts
2949 Watts
Minimum Charge Current
0.38 Amps
0.58 Amps
Maximum Charge Current
19.2 Amps
28.8 Amps
Charge/Discharge cycles to specified
Depth of Discharge (DoD)
Capacity retention >80%
10,000 @ 80% DoD
5000 @ 90% DoD
(2500@100% DoD and 1C)
Operating Temperature Limits
Charge 0° to 55°C
Discharge -20° to 60°C
Operating Humidity (non-condensing)
85%
IP Rating
IP50
Battery Case Dimensions (mm)
450D x 420W x 88H
570D x 420W x 88H
Battery Tray Dimensions (mm)
450D x 483W
570D x 483W
Tray Slide Range (mm)
480 to 760
590 to 880
Terminal Connection
Genuine Anderson SB50 BLUE
Weight Module
23.7kg
35kg
Weight Tray
Approximately 4.2kg
1 BMS Over Volt cut off
Approximately 58.4V
BMS Under Volt cut off
40V
BMS Short Circuit cut off
200 ± 30A (20mS Trip)
BMS Over Temp cut off
65°C
Charge time Approx.
2 hours at 19.2 A
2 hours at 28.8 A
Self-Discharge
14% per annum
Round Trip charge/discharge efficiency
>= 96%
Circuit Breaker Compliance
Double Pole, non-polarised, 60A IEC 60947-2
UN Type Number (Module chemistry)
UN 3480
Lithium Composition
As Lithium Ferro Phosphate, LiFePO4or LFP
Decisive Voltage Classification (DVC)
Class A
Casing /Coating
Steel / Satin white industrial coating
Certifications
See genz.com.au for details
1 The over voltage cut-out may vary from that stated. This is due to the fact that the BMS protects the internal cell string
voltages ahead of overall pack voltage.

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6Module Overview
6.1 Battery Management System (BMS)
This battery module is fitted (contained inside the battery module case) with a sophisticated BMS. The
BMS is designed to provide user safety and protect the battery cells from:
Over voltage charging.
Under voltage discharging.
Operation above a maximum temperature.
Short circuit protection. This is in addition to the protection provided by the circuit breaker.
Should the BMS activate to protect the module, the BMS will automatically reset once a normal
operational condition is detected by the BMS.
6.2 Power In/Out J1
The “POWER IN/OUT J1” connector is a standard Anderson SB50 (Blue) connector. The upper pin is
positive and the lower pin is negative.
6.3 Earth Point
Connects the chassis of the battery module to ground. Another earth stud is located at the rear
of the battery module.
NOTE: Neither the positive or negative terminal of this module is connected to the earth point. DC
from the battery module is floating.
6.4 Dual Pole 60Amp Circuit Breaker
This is the ON/OFF control for the battery module. Turning the “BATTERY CIRCUIT BREAKER” ON (up
is ON) will energise the “POWER IN/OUT J1” connector. It will also activate the power “ON” indicating
Light Emitting Diode (LED).
The “BATTERY CIRCUIT BREAKER” will trip in the event of a DC overcurrent condition.
NOTE: Before installing, ensure that the circuit breaker is in the down “OFF” position.
6.5 Front Panel Knurled Knobs
Knurled knobs are provided to assist in withdrawing the battery module from the battery shelf.

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7System Design
Failure to follow these guidelines may void the limited warranty and cause potential
damage to property or serious injury.
7.1 Overview
Preparing a proper design and professional installation by suitably qualified people is key to the
success of any energy storage system. This installation guide is exactly that, a guide and should be
used in conjunction with various codes, regulations and standards applicable to where the battery
modules are to be installed.
7.2 New Energy Storage Designs
7.2.1 Installation Placement
The battery module(s) must be installed such that they are not exposed to:
Sources of radiant heat or where the ambient temperature is expected to regularly exceed
55°C.
Extreme cold where the ambient temperature is expected to regularly fall below -10°C.
Direct sunlight.
Rain, water, salt laden air or where the humidity is likely to condense.
Corrosive atmosphere.
Select a location, which will:
Meet applicable standards and building codes for such an installation.
Provide security from unauthorised access.
Allows for cables to be routed so they cannot be walked on or damaged.
Provides for the shortest cable runs possible to/from the batteries.
If battery modules are to be mounted in a rack:
oAlways consult the rack manufacturers’ specifications to determine suitability for use
with your design.
oThe rack is suitable for the location and will provide the correct level of protection for
the battery modules.

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oThat the rack is capable of carrying the combined weight of the battery modules, their
trays and any other equipment installed in the rack.
oThat the rack is placed on a floor that is capable of supporting the combined weight of
both the battery modules and the rack itself.
oThe rack is deep enough to accommodate the battery module trays. In particular this
must be considered for the 3kWh battery modules.
oThe rack can physically be moved within a building or structure, taking into account
doorways and ceiling dimensions.
Ease of access for installation and maintenance.
Not create any health and safety concerns, such as manual handling of the battery modules
due to their weight.
These battery modules can be used in any orientation provided consideration is given to
protecting the circuit breaker, connector and indicator lamp from damage.
If battery modules are to be mounted in an enclosure, then apply the same consideration as
to if mounting in a rack.
As the battery modules do NOT produce any toxic or flammable gases during normal charge/discharge
cycles, there is no requirement for forced ventilation. However, consideration (as with any device)
should be given to providing some air circulation to maintain operational temperatures as close to
those as indicated in the specifications section of this guide.
7.3 Connectors and Cables
7.3.1 Connectors
1. All genZ rack mount products are fitted as standard with genuine Anderson SB50®
connectors.
2. These connectors genderless and colour keyed.
3. All genZ 48V rack mount battery modules are fitted with BLUE connectors.
4. Only genuine Anderson SB50® BLUE connectors can connect/mate with BLUE connectors.
5. Additional connectors can be purchased from genZ
6. For detailed specifications regarding these connectors, please see:
https://www.andersonpower.com/_global-assets/downloads/pdf/ds-sb50.pdf
7. Terminate wires in the connector wire contacts using a crimp tool and
die appropriate to the contact and size of wire used. Refer to ‘6’ above to
locate Anderson specifications.
8. Always allow for sufficient cable length to permit the insertion and removal of the connector
to/from the battery module.

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9. Always allow for sufficient cable length so as to NOT exceed the minimum bending radius of
the wire/cable being used
10. Take care to note the ‘+’ and ‘-‘ symbols on both the connectors and the battery module front
panel. Connect accordingly.
11. Always ensure that the connector contacts have been firmly inserted and will not easily pull
out from the connector housing.
A –Suitable for a 16mm2 wire
7.3.2 Wires and Cables
Undersized cabling is the most common design/installation error.
Cable used should be of a quality that meets or exceeds the requirements for the environment
that it is being used in.
Typical standards for cable used in Australia are:
AS/NZS1125, AS/NZS3808, AS/NZS5000.1, AS/NZS1660.5.6, IEC 60228, IEC 60332-1
As there is no obvious colour standard to use for 48V DC systems, the use of which colour to
identify either the positive and/or negative is often driven by that which makes the most sense
to those interacting with the system. It may also be driven by local standards.
Electrically, the system may be positive earth, negative earth or floating. Identifying the
earthing requirements may also dictate the colours of the cables to be used.
Earth points for the modules can be located on the front panel of the module. Refer to the
“Product Manual”.
Cables should be kept as short as possible to reduce the affects increased resistance and
hence, loss of both charge and discharge power.
System designers should be aware of the relationship between cable length, current flow, and
cable size. Always refer to the cable manufacturers’ tables to calculate volt drop and maximum
current.
If the battery modules are to be connected in parallel then all cables from the battery modules
should be of equal length. Those cables should then run to a common point, such as a busbar.
If Anderson connectors are supplied by genZ, they are suitable for 16mm2 wire.
All connectors and lugs should be well crimped using the correct type of crimp tool, not
soldered to wires.