Hulk HU6490 User manual

Lithium Battery
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lithium Battery
USER MANUAL
Model:
HU6490, HU6491,
HU6494

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1. Introduction
1.1 Product Description ........................................................................................................... 2
1.2 Glossary of Terminology .................................................................................................... 2
2. Product Specifications
2.1 Product Features & Benefits ............................................................................................. 2
2.2 General Product Specifications ......................................................................................... 3
2.2.1 Dimensions ........................................................................................................................ 3
2.3 Environmental Conditions.................................................................................................. 4
2.4 Product Lay-out and Connections ..................................................................................... 4
2.5 Operation Modes ................................................................................................................ 4
3. Safety Guidelines & Measures
3.1 General............................................................................................................................... 5
3.2 Disposal.............................................................................................................................. 5
4. Installation
4.1 General Information........................................................................................................... 6
4.2 Unpacking .......................................................................................................................... 6
4.3 Preparing the Battery for Use............................................................................................ 6
4.3.1 Location of the LiFeP04 Battery ........................................................................................ 6
4.4 Connection Cables (+ and -)............................................................................................... 6
4.5 Connecting a charger to the LiFeP04 Battery ................................................................... 7
4.6 Connecting Batteries in Parallel to a Charger Device....................................................... 7
4.7 DC Load Connected - Discharge Protection...................................................................... 8
4.8 Parallel Battery Use........................................................................................................... 8
5. Battery Use
5.1 General Information........................................................................................................... 8
5.2 Charging............................................................................................................................. 8
5.3 Charging Rate..................................................................................................................... 9
5.3.1 Charging Method................................................................................................................ 9
5.3.2 Battery Balancing ............................................................................................................ 10
6. Inspection, Cleaning & Maintenance
6.1 General Information......................................................................................................... 11
6.2 Inspection......................................................................................................................... 11
6.3 Cleaning ........................................................................................................................... 11
7. Storage ...................................................................................................................................... 12
8. Disposal & Recycling
8.1 General Information......................................................................................................... 12
9. Warranty & Liability .................................................................................................................. 13
CONTENTS

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Dear customer,
This manual contains all relevant information necessary to install, use and maintain
HULK Professional Lithium Iron Phosphate 12.8V Batteries. Read this manual
carefully before installing and using the product.
This manual is meant for the installer and the user of the LiFePO4 batteries.
Only qualified, certified personnel may install and perform maintenance on
HULK Professional Lithium Batteries.
Please consult the index at the start of this manual to read information relevant
to you.
This is the original manual, keep it in a safe location!
USER MANUAL

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1. INTRODUCTION
1.1 Product Description
HULK Professional Lithium Batteries are Lithium Iron Phosphate rechargeable batteries. Lithium
Iron Phosphate (LiFePO4) technology is considered as the latest and safest lithium technology
available in the market.
Potential applications of this LiFePO4 battery include: recreational vehicles, caravans, boats,
mobile homes, camping & industrial energy storage solutions.
1.2 Glossary of Terminology
2. PRODUCT SPECIFICATION
2.1 Product Features & Benefits
•Replacement for sealed lead acid batteries
•Traction battery behavior
•Lithium Iron Phosphate (LiFePO4): Safe lithium technology
•High performance, even under extreme conditions
•Integrated BMS (Battery Management System)
•Fast charging and discharging
•Very efficient, no charge factor
•Maintenance free
•Adaptive cell balancing
•Low self-discharge
•6,000 cycles  50% DOD
•4,000 cycles  80% DOD
•2,000 cycles  100% DOD
BMS: Battery Management System
Charge cycle: A period of use from fully charged, to fully discharged and fully
recharged again
Endurance Life-cycle: The products maximum lifespan, achieved by following the guidelines
presented in this manual
LiFePO4: Lithium Iron Phosphate
SoC: State of Charge
CC-CV: Constant Current - Constant Voltage
DOD: Depth of Discharge

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2.2 General product Specifications
2.2.1 Dimensions
TECHNICAL SPECIFICATIONS 12.8V
Nominal Voltage (V) 12.8V
Charge Cut-off Voltage 15.6V
End Charge Voltage 14.6V +- 0.2V
Cycle Life @ 1C 100% DOD >2,000 cycles
Monthly Self Discharge <3%
Temperature Range (Charging) 0°C to 45°C
Temperature Range (Discharging) -20°C to +60°C
Temperature Range (Storage) 0°C to +40°C
Water Dust Resistance IP56
Cell Configuration 4S
Cell Size 18,650/26,650
Cell Chemistry LiFePO4, Lithium Iron Phosphate Battery
Battery Housing ABS Plastic, UL V0-94
HU6490 HU6494
HU6491
305mm
168mm
210mm
240mm
551mm
110mm
240mm
224mm
522mm

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LiFePO4 batteries may only be used in conditions specified in this manual. Exposing
the LifePO4 battery to conditions beyond the specified boundaries may lead to serious
damage to the product and/or the user.
Use the LiFePO4 battery in a dry, clean, dust free, well ventilated space. Do not expose the LiFePO4
battery to fire or water or solvents.
When the batteries are placed in an enclosed environment without air circulation, it is advised to
provide 2 ventilation holes of 100mm x 100mm each, to prevent heat built-up.
2.3 Environmental Conditions
2.4 Product Lay-out and Connections
2.5 Operation Modes
Caution!
Recommended charge temperature range 0°C to +45°C*
Discharging operating temperature range -30°C to +60°C*
Short term (<1 month) storage temperature range -10°C to +35°C
Long term (>1 month) storage temperature range 23 ± 5°C
Relative humidity 10-90%
1. (–) Terminal to connect charger/appliance
2. (+) Terminal to connect charger/appliance
3. Handle for lifting
4. Bottom (we advise to install the bottom in
position as shown on the image)
Discharge mode
When the LiFePO4 battery voltage is below 2.5 V/Cell.
Deep discharge mode
For example, with 12V battery, when the LiFePO4 voltage is below 6V. The LiFePO4 battery is not
usable anymore and cannot be repaired, only recycled. Make sure the batteries are not deeper
discharged than 10V.
2
4
1
3

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Warning! Keep the battery away from water, dust and contamination.
Warning! Do not crush or puncture the battery.
Warning! Never touch the battery contacts or allow (conductive) objects to touch the contacts.
Attention
3. SAFETY GUIDELINES AND MEASURES
3.1 General
• Do not short-circuit LiFePO4 battery.
• Treat LiFePO4 battery as described in this manual.
• Do not dismantle, crush, puncture, open or shred LiFePO4 battery.
• Do not expose LiFePO4 battery to heat or fire. Avoid exposure to direct sunlight.
• Do not remove LiFePO4 battery from its original packaging until required for use.
• In the event of LiFePO4 battery leaking, do not allow the liquid to come in contact with the skin or
eyes. If contact has been made, wash the affected area with copious amounts of water and seek
medical advice.
• Use battery charging devices that are capable of charging a LiFePO4 battery.
• Observe the plus (+) and minus (–) marks on LiFePO4 battery and equipment and ensure
correct use.
• Do not use any battery which is not designed for use with LiFePO4 battery.
• Do not mix batteries of different manufacturer, capacity, size or type within a device.
• Keep LiFePO4 battery clean and dry.
• Secondary batteries need to be charged before use. Always use the correct charger and refer this
manual for proper charging instructions.
• Do not leave LiFePO4 battery on continuous charge when not in use.
• After extended periods of storage, it may be necessary to charge and discharge LiFePO4 battery
several times to obtain maximum performance.
• Retain the original product documentation for future reference.
3.2 Disposal
Dispose of LiFePO4 battery in accordance with local, state and federal laws and
regulations. Batteries may be returned to the seller.
Do not mix with other (industrial) waste.

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4. INSTALLATION
4.1 General Information
Warning! Never install or use a damaged LiFePO4 battery.
Caution! Do not reverse connect the power cables (polarity)
Warning! Always remain within the limits indicated in chapter 2 during the use of the LiFePO4
battery.
Caution! In case of an empty LiFePO4 battery shutdown, charge immediately.
Attention
Attention
When connecting several batteries in parallel, always use batteries of the same brand, type, age,
capacity and state of charge.
4.2 Unpacking
Check HULK Professional LiFePO4 battery for damage after unpacking. If the battery is damaged,
contact your reseller. Do not install or use the battery if it is damaged!
4.4 Connection Cables (+ and -)
Use appropriate wire for the connection wires to ensure no overheating or unnecessary losses occur.
Use appropriate fuses matching the wires and load.
4.3.1 Location of the LiFePO4 battery
Before it is used, the battery must be positioned in such a way that it will not move around in its
compartment during use.
Use appropriate LN5 (DIN88) or alternative metal fastening brackets for mounting. Note: battery
hold-down mounting brackets are not provided with the LiFePO4 battery.
4.3 Preparing the Battery for Use

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4.5 Connecting a Charger to the LiFePO4 Battery
Warning! Ensure you have completed all the previous steps described in chapter 4 before
connecting the battery to the charger.
Attention
4.6 Connecting Batteries in Parallel to a Charger Device
The max. number of batteries in parallel is 20pcs and the max. number of batteries in series is 4pcs.
To divide the current equally amongst batteries, use the schematic bellow:
Figure 1. Connecting a charger to the battery
Figure 2. Connecting batteries in parallel or in series

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OK: Equally divided battery current. All batteries contribute equally to the current into the load.
NOT OK: Current not equally divided.
Batteries closest to load will have the highest contribution to the current into the load. Whereas
batteries further away from load will have lesser current contribution.
Wear and tear will be higher on batteries closest to the load.
1. Connect the charger to the battery as described in paragraph 4.6.
2. Charge the LiFePO4 battery in case of an empty shutdown or if the state of charge drops below 20%
to preserve the lifespan of LiFePO4 battery.
4.7 DC Load Connected - Discharge Protection
HULK Professional LiFePO4 batteries are as standard equipped with a DC switch-off device which is
integrated inside the battery, which is activated at 80% discharge.
However, we recommend to install a bi-stable latch relay which should be installed between the
battery and the entire DC load (or inverter) as an extra security. Ask your dealer or supplier for the
right device.
4.8 Parallel Battery Use
• 12V batteries can be connected in parallel up to 20 pcs
• 12V batteries can be connected in series up to 4 pcs
5.1 Charging
Caution! Please sort the voltage and internal resistance of the battery blocks before make the
connection. To make sure the battery blocks for a battery pack have the same/similar parameters.
Warning! Never charge the battery with a charging current larger than 1C.
Warning! Stop charging if the LiFePO4 battery switches into warning mode.
Warning! Never charge a battery with a charging current larger than 1C.
Caution! Charge before use.
Caution! Disconnect the charger from the LiFePO4 battery if it is not to be used for an
extended period
Caution! To preserve the lifespan of LiFePO4 battery use a HULK Professional charger
Warning! Follow the safety guidelines and measures of chapter 3.
Attention
Attention
Attention
5. BATTERY USE
5.1 General Information

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5.3 Charging Rate
HULK Professional Lithium Iron Phosphate batteries can be charged in 1 hour. Displayed in the
Table are thecharge times for a LiFePO4 battery at different charge currents. Always use the
indicated charge current and end of charge voltage during charging.
5.3.1 Charging Method
We recommend using the following charging method.
A. Constant voltage, constant current, 14.6V +/- 0.2V for a 12V battery, 29.2V +/- 0.2V for a
24V battery.
B. Multiple or three-stage charging, see graphic at right, is allowed.
We recommend using HULK Professional battery chargers with settings at ‘‘Lithium-mode’’ for
best result.
Bulk phase
In this phase the batteries are charged with a constant current up to the end of charge voltage
(Ubulk), If UBulk is reached the charger will automatically switch to absorption phase. The maximum
charge current.
(Imax) for HULK Professional batteries is 1C, however for endurance cycle life we suggest to limit the
current to C3 (1C = nominal battery capacity, C3 = 1/3 of nominal capacity). On some chargers the
maximum charger active time (t0) can be programmed. We suggest setting t0 to: t0 =
2*(BTcap / Chcur) Example: Battery capacity = 90Ah, Charger = 45A, Set to to a maximum of
2*(90/45) = 2 hours.
CHARGING RATE
Parameter Time Change current
Maximum 1 hour 1C (90A)
Endurance lifecycle 3 hours C3 (30A)
BULK PHASE
Parameter Typical Min Max Remark
Imax - - - 1C (90A)
t0 Depends on the
battery SoC - - 2*(BTcap / Chcur)
Table 1. Charging rates at different charge currents
Table 2. Bulk Phase

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Absorption phase
In this phase the charge voltage must be maintained at UAbsorption to fully charge the battery and
set the SoC counter to 100%, see Table. This phase is finished when the SoC is indicating 100%.
Float phase
In this phase the charge voltage is set to UFloat.
ABSORPTION PHASE
Parameter Typical Min Max
UAbsorption 14,6V 14,2V 14,6V
t1 20 minutes 10 minutes 1 hour
FLOAT PHASE
Parameter Typical Min Max
UFloat 13,8V 13,6V 14V
DISCHARGE PHASE
Parameter Typical Min Max
UFloat 13,5V 13,4V 13.6V
Table 3. Absorption Phase
Table 4. Float Phase
Table 5. Maintenance phase
5.3.2. Battery Balancing
The BMS automatically balances the cells if necessary. Balancing can take place during charging and
idle mode and will not have an effect on the functionality of the battery.

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6. INSPECTION, CLEANING AND MAINTENANCE
6.1 General Information
Warning! Never attempt to open or dismantle a LiFePO4 battery! The inside of a HULK Professional
LiFePO4 battery does not contain serviceable parts.
Attention
1. Disconnect the battery from all loads and charging devices before performing cleaning and
maintenance activities (see paragraph 4.8).
2. Place the enclosed protective caps over the terminals before cleaning and maintenance activities to
avoid the risk of contacting the terminals.
6.2 Inspection
1. Inspect for loose and/or damaged wiring and contacts, cracks, deformations, leakage or damage
of any other kind. If damage to the battery is found, it must be replaced by a professional. Do not
attempt to charge or use a damaged battery. Do not touch the liquid from aruptured battery.
2. Regularly check the battery’s state of charge. The battery will slowly self- discharge when not in
use or whilst in storage. (see paragraph 5.3)
3. Consider replacing the battery with a new one if you note either of the following
conditions: The battery run time drops below 80% of the original run time. The battery charge
time increases significantly.
6.3 Cleaning
If necessary, clean the battery with a soft, dry cloth. Never use liquids, solvents, or abrasives to clean
the battery.

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7. STORAGE
Follow the storage instructions in this manual to optimize the lifespan of HULK Professional
LiFePO4 battery during storage. If these instructions are not followed and the battery has no charge
remaining when it is checked, consider it to be damaged. Do not attempt to recharge or use it.
Replace it with a new LiFePO4 battery.
See chapter 2.4 for storage temperature conditions.
The self-discharge of HULK Professional LiFePO4 battery is 1-2% per month.
Warning
1. Charge the LiFePO4 battery to > 80% of its capacity before storage.
2. Disconnect the LiFePO4 battery from all loads and, if present, the charging device.
3. Place the terminal covers over battery’s terminals during storage.
4. Charge the LiFePO4 battery to > 80% of its capacity every 100 days. After charging set the
LiFePO4 battery in storage mode again.
Attention
8. DISPOSAL AND RECYCLING
8.1 General Information
Always discharge a LiFePO4 battery before disposal. Use electrical tape or other approved covering
over the battery connection points to prevent short circuits.
Battery recycling is encouraged. Dispose of the battery in accordance with local, state and
federal laws and regulations. Batteries may be returned to the seller.

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9. WARRANTY AND LIABILITY
9.1 Upon delivery, the customer is obliged to immediately verify whether the products have been
damaged during transport. The customer must notify the dealer of such transport damage as soon as
possible, in any event no later than within three (3) days of delivery, by means of an accurate, written
statement, stating the damage and where possible a photograph. Failure to inspect the products and
inform the dealer within the stated time or the use of the products at any time shall be conclusive
evidence that HULK Professional has satisfactorily tendered delivery.
9.2 In the event that the customer demonstrates that any of the delivered products do not conform to the
agreement, HULK Professional (at its option, upon having received those products returned by the
customer) has the option to either repair or replace such products by new products, or to refund the
invoice value, exclusive of any dispatch costs.
9.3 HULK Professional grants a 5 years limited warranty (PRO-RATA) for damages caused by
manufacturing defects starting at the time of delivery. Damages caused by manufacturing defects do
not include damage resulting from (a) general wear and tear, (b) short circuit, (c) overcharging, (d)
deep discharging, (e) overheating of the products (f) installation of the product by persons unskilled to
work with electro-technical devices or components, (g) any other wrongful use contrary to the HULK
Professional user manual or the safety instruction, (h) any use contrary to the product specifications
of that product; (i) any acts of force majeure.
9.4 Except as specified in the clause 9.3 HULK Professional makes no warranty, whether express or
implied, including without limitation any implied warranty of merchantability and fitness for a
particular purpose or any warranty arising from any course of dealing, course of performance or
usage of trade and specifically disclaims any representation or warranty that the product will meet
customer’s requirements, perform any specific function or achieve a desired result other than
expressly stated by HULK Professional in writing.
9.5 Any liability to the customer in any case ceases to apply in the event that the customer fails to notify
HULK Professional of the existence of the defect within ten (10) days of having discovered the defect,
in writing, in order to enable HULK Professional to investigate the damage.
9.6 Any liability of HULK Professional for damage suffered by the customer is in any case limited to the
invoice amount of the relevant products, unless such damage has been caused by gross negligence or
willful misconduct of HULK Professional.
HULK Professional can never be held liable for (a) damage caused by any of the circumstances
mentioned in clause 9.3, leading to damage to the HULK Professional products or to any other device
located near those products, or (b) consequential damage or (c) loss of profits or goodwill.
9.7 To the extent that a court determines that the limitation of liability as meant in clause 9.6 cannot be
invoked against a particular claim for damages by the customer, HULK Professional’s liability for loss
of property, damage to property, and bodily injury (including death) caused by the application of those
particular HULK Professional products shall in any event be limited to the amount actually paid out
by HULK Professional’s insurance company to HULK Professional in accordance with the insurance
cover of that insurance policy for that particular type of damage. HULK Professional has taken out
insurance against certain risks, as described in the respective insurance policies. These policies
contain a usual limitation of insurance payment to be paid out to HULK Professional if, and to the
extent that, the event is a covered event.

Lithium Battery
Automotive Imports Pty Ltd
22 - 28 Lexton Road
Box Hill, Victoria,
Australia
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