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