Kon-TEC KT-LFP1250 User manual

Kon-TEC sp. z o.o.
Boya-Żeleńskiego 12, 35-105 Rzeszów
T: [phone] E: [e-mail] W: www.kon-tec.eu
https://www.kon-tec.eu/
1/13
LITHIUM IRON PHOSPHATE LiFePO4 BATTERY
OPERATION AND MAINTENANCE MANUAL
12,8 V
KT-LFP1250 - 50Ah / KT-LFP1275 - 75 Ah / KT-LFP12100 - 100Ah
KT-LFP12150 - 150Ah / KT-LFP12200 - 200Ah
Very durable LiFePO4batteries with A+ category cells.
Equipped with an intelligent BMS system,
wireless communication and the ability to check battery parameters
using the application for mobile devices (iOS and Android)
LEGAL PROVISIONS
LEGAL TERMS
This manual describes in detail the requirements and procedures for safe installation and operation of Kon-TEC lithium battery pack. Please read this manual carefully,
only qualied persons are allowed to install, operate and maintain the system, otherwise it may cause product damage or personal safety risks.
Any actions against safety operation, or do not follow rules of this manual and limited warranty letter, will void warranty and qualication of this product. Meanwhile, the
manufacturer will be not responsible for the product damage, property damage, personal injury or even death.
The information contained in this manual is accurate when it’s issued. Kon-TEC reserve right to change specication (such as optimization, upgrade or other operations)
without prior notice, please always view the latest document via QR code. In addition, please noted that the diagrams/schematics in this document are used to help
understand system conguration and installation instructions, which may be different from the actual items at the installation.
CONTENT
1. Safety precautions.........................................................................................................................................................2
1.1. Safety instructions.......................................................................................................................2
1.2. Transport..............................................................................................................................................2
1.3. Disposal of battery......................................................................................................................2
2. Information.........................................................................................................................................................................3
2.1. General information.....................................................................................................................3
2.2. Efciency.............................................................................................................................................3
2.3. Dimensions and weight...........................................................................................................3
2.4. Application........................................................................................................................................3
3. Installation..........................................................................................................................................................................4
3.1. Single battery installation.....................................................................................................4
3.2. Series and parallel conection of batteries..............................................................4
3.2.1. Battery balancing instruction..........................................................5
3.2.2. Series connection of batteries........................................................5
3.2.3. Parallel conection of batteries....................................................6
3.2.4. Series-parallel conection of batteries...................................6
4. Operation.............................................................................................................................................................................7
4.1. Charge...................................................................................................................................................7
4.2. First charge......................................................................................................................................7
4.3. Charging process - general information..................................................................7
4.4. Battery management system (BMS).............................................................................8
4.5. Wireless communication - parameters control in mobile app....9
4.5.1 Instalation and use instruction....................................................9
5. Battery damage or re procedure..................................................................................................................12
6. General precautions..................................................................................................................................................12
7. Storage..................................................................................................................................................................................12
8. Warranty information...............................................................................................................................................13
Kon-TEC will retain the copyright of this document, do not extract, copy or translate in any ways without the written permission.
Kon-TEC batteries are equipped with wireless communication. Special application allows to monitor state of charge and efciency of the batteries
Download the APP "Kon-TEC" from Apple Store or Google Play or scan the QR code below to download it.
QR-CODE TO DOWNLOAD Android AND iOS APLICATION
50Ah 75Ah 100Ah
200Ah
150Ah

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1.1. SAFETY INSTRUCTIONS
1.2. TRANSPORT
1.3. DISPOSAL OF BATTERY
1. SAFETY PRECAUTIONS
Before use, read this manual carefully.
NON-COMPLIANCE WITH THE INSTRUCTIONS, ANY REPAIRS MADE USING NON-ORIGINAL PARTS OR UNAUTHORIZED REPAIRS
RENDER THE WARRANTY VOID.
Any exposed battery material such as electrolyte or dust that contacts with the skin should be rinsed off immediately with clean water,
then consult a doctor. Contaminated clothes should be also rinsed off with clean water.
Explosion or re risk. The battery terminals are always live, so it is forbidden to place any objects or tools directly on the battery.
In case of overdischarge, overcharge or damage, the lithium-ion battery may emit dangerous and harmful gas mixtures.
Never short-circuit positive and negative terminal of the battery!
The battery is heavy. In case of damage or drop from a height, the battery can become explosive! While transport or installation be
especially careful and provide necessary equipment.
It is forbidden to try to open or disassemble the battery.
The electrolyte contained inside is very corrosive. Under normal operating conditions, contact with the electrolyte is impossible. If the
battery case is damaged, do not touch visible electrolyte or dust as these substances are corrosive.
Overdischarge is very dangerous situation and can damage the battery. It is necessary to use internal battery protection (standard
equipment of each Kon-TEC battery).
Wear safety glasses and protective clothing while using the lithium-ion battery.
DANGER
WARNING
NOTICE
WARNING
Lithium-ion battery must be transported in original case, in vertical position. If the batteries are trasported on pallets, it is required to use soft
transport belts to avoid damage. It is forbidden to stand under the battery when it is lifted.
DANGER
Always lift the battery by the handles, never by the terminals!
Batteries marked with the recycling symbol must be disposed of a recognized recycling agency.
With consent, the battery may be returned to the manufacturer.
Used batteries must not be mixed with domestic or industrial waste.

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2. INFORMATION
2.1.GENERAL INFORMATION
Lithium-ion batteries have no memory effect and provide higher energy density than lead-acid batteries, GEL or AGM.
Self-discharge effect of lithium-ion batteries is negligible and they have very long lifetime. The lithium-ion battery, in which the cathode is made of lithium compounds
(LiFePO₄), has the safest cells available on the market. The nominal voltage of one cell is 3,2V. Therefore the 12,8V LiFePO₄ battery consists of 4 cells connected in series.
The nominal capacity of the battery is:
• 50 Ah - KT-LFP1250
• 75 Ah - KT-LFP1275
• 100 Ah - KT-LFP12100
• 150 Ah - KT-LFP12150
• 200 Ah - KT-LFP12200
2.2. EFFICIENCY
The energy efciency of the entire operating cycle of lithium-ion battery (100% discharge and 100% charge) is 98%. By comparison, in a lead-acid battery, the energy
efciency is only 80%. The LiFePO₄ battery can be charged and discharged at high current levels without loss of capacity and has a very high durability. The number of
cycles (lifetime), after the battery maintains up to 80% of nominal capacity, depends on depth of discharge (DoD). It is no less than 3,000 with 100% DoD (fully charged
and fully discharged battery). The lower DoD cycles, the longer the battery life. Accordingly for 80% DoD cycles (discharge to the level of 20% of nominal capacity), the
battery lifetime is 4,500 cycles. For 60% DoD cycles (discharge to the level of 40% of nominal capacity), the battery lifetime is 6,000.
The energy density of the battery reaches over 120Wh/kg, which is desirable and energy efcient.
2.4. APPLICATION
• Replacement for SLA batteries (lead-acid and gel),
• Caravans and camper vans
• Specialized electric vehicles
• Electric drives
• Yachts, catamarans, houseboats
• Wheelchairs and carriages for disabled
• Hybrid photovoltaic systems
• Wind turbines
• Emergency lighting
• Appliances and toys 12V
• Power source for inverters 12V-/230V~
• and more
2.3. DIMENSIONS AND WEIGHT
Capacity [Ah] Dimensions [mm] Weight [kg]
485x170x240
17,8150
307x168x210
260x167x212
197x166x174
485x170x240
11,2
10
6,6
23,7
100
75
50
200

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3.1. SINGLE BATTERY INSTALLATION
3.2. SERIES AND PARALLEL CONECTION OF BATTERIES
3. INSTALLATION
With each type of connection, the batteries must be protected with a fuse in the circuit.
- When connecting the batteries, remember to use the correct cross-section and the same length of wires, to avoid unnecessary energy losses.
- In case of series connection, the individual batteries in the series must not be loaded unevenly. It is allowed to charge individual batteries
separately if the series connection is disconnected during charging.
- When connecting the batteries, make sure that their state of charge is identical and the type of batteries is the same. Otherwise, very high
equalizing currents may ow while connecting the batteries, which may result in damage of batteries or incorrect operation of the system.
To ensure that the batteries are at the same state of charge:
1. Fully charge each battery separately or as in point 2.
2. Connect the batteries in PARALLEL and charge again untill fully charged.
3. Leave the batteries conected to the charger for 12 to 24 hours.
After this process, you can connect the prepared batteries into the systems described below.
BE CAREFUL
Fig. 1. represents single battery instalation to load.
Fig. 1. Single battery installation
SHIELDED
CABLE
SHUNT
+ TERMINAL /P+ LOAD, C+ CHARGER +/
- TERMINAL /P- LOAD, C- CHARGER -/
FUSE
+
-
+-
CHARGER
COULOMETER TK15
DANGER
Before connecting in series, the batteries MUST have the same state of charge (not to be confused with the same
voltage, as LiFePO₄ batteries may have the same voltages, but their state of charge may differ). Batteries balancing instructions can be found
below. It is forbidden to connect the balancer to the batteries of different capacity or state of charge.
Non-compliance to the above recommendations may cause damage to the balancer, battery or charger or even cause a re.
NOTICE
The batteries are equipped with wireless parameters monitor. The reading of parameters is ensured by the application dedicated to mobile devices
with Android or iOS.
The parameters of the batteries can also be monitored by the TK15 coulometer connected directly to the battery or batteries.
Whenever it is not possible or advisable to use the application, we recommend using the TK15 coulometer.

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3.2.2. SERIES CONNECTION OF BATTERIES
3.2.1. BATTERY BALANCING MANUAL
(THE SAME STATE OF CHARGE OF BATTERIES IN SERIES)
Obtaining identical battery state of charge can be achieved by:
Method 1: Charge each battery separately/individually with a dedicated charger until the charger indicates a fully charged battery.
Method 2: (in order not to charge the batteries separately/individually): Connect the batteries in PARALLEL (Fig.2.), and then connect the LiFePO₄ Kon-TEC 12V charger
(accurate 14.6V) to the batteries as follows:
1. Connect the positive cable of the charger to the positive terminal of the rst battery.
2. Connect the negative cable to the negative terminal of the last battery.
After charging (green LED on the charger), leave the batteries for about 12 hours with the charger still connected. After approx. 12 hours, you can
connect the batteries in series and connect the balancer to them. In this way, several batteries can be charged with one 12V LiFePO₄ charger (only when batteries are
connected PARALLEL!)
Example: Connect 2 Kon-TEC 12V batteries (accurate 12.8V) in series to obtain a 24V system (accurate 25.6V).
Method 1: Fully charge each battery separately with a LiFePO₄ Kon-TEC 12V charger (accurate 14.6V). After charging, you can connect the batteries in series
and connect the balancer to them.
Method 2: Connect the batteries in parallel, and then connect the LiFePO₄ Kon-TEC 12V charger (accurate 14.6V) to them as follows:
1. Connect the positive cable of the charger to the positive (+) terminal of the rst battery.
2. Connect the negative cable to the negative (-) terminal of the last battery.
After charging (signal on the charger), leave the batteries for about 12 hours with the charger still connected. After approx. 12 hours, you can
connect the batteries in series and connect the balancer to them.
The batteries can be connected in series (increase the output voltage) up to a maximum of 4 batteries.
Figure 3 represents the serial connection of batteries.
Fig.2 Parallel balancing of batteries
n
n = number of batteries LiFePO₄ 12V CHARGER
BATTERIES TERMINALS
CONNECTION:
POSITIVE (+)
-> FIRST BATTERY
NEGATIVE (-)
-> LAST BATTERY
+
-
-
+ + --
PARALLEL BALANCING THE BATTERIES
SCHIELDED WIRE
SHUNT
TK15
COULOMETER
KT-03
BALANCER
+ TERMINAL /P+ LOAD, C+ CHARGER +/
CONNECTION OF KT03 24V BALANCER
- TERMINAL /P- LOAD, C- CHARGER -/
FUSE
+
-
+
-
-
+
+-
-
Fig. 3 Series connection of batteries
NOTICE
The parameters can be read using wireless monitoring of parameters via the application or using the TK15 coulometer connected directly
to the battery or batteries. Whenever it is not possible or advisable to use the application, we recommend using the TK15 coulometer.

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3.2.3. PARALLEL CONNECTION OF BATTERIES
3.2.4. SERIES-PARALLEL BATTERY CONNECTION
Batteries can be connected in parallel (capacity increase) and in this case there is no limit to the number of batteries connected.
When connecting batteries in parallel, remember that the wires coming from the negative and positive terminals should not be led out from the rst or last battery.
Properly it should be: Positive wire from rst battery and negative from last battery OR negative wire from rst battery and positive cable from last battery. This is the
correct battery connection. Leading out the wires in such a way takes into account the compensation of the wire resistance. The batteries then work evenly loaded,
as well as have extended service life.
The batteries can also be connected in series-parallel (the sum of 2 single voltages and the sum of 2 single capacities).
A diagram of such a connection is shown in Fig. 5
NOTICE
The parameters can be read using wireless monitoring of parameters via the application or using the TK15 coulometer connected directly
to the battery or batteries. Whenever it is not possible or advisable to use the application, we recommend using the TK15 coulometer
NOTICE
The parameters can be read using wireless monitoring of parameters via the application or using the TK15 coulometer connected directly
to the battery or batteries. Whenever it is not possible or advisable to use the application, we recommend using the TK15 coulometer.
Fig.4. Parallel connection of batteries
n
n = no limit
SCHIELDED
WIRE
SHUNT
LiFePO₄ CHARGER
+ TERMINAL /P+ LOAD, C+ CHARGER +/
- TERMINAL /P- LOAD, C- CHARGER -/
FUSE
+
-
+
+
-
-
-
+-+-
TK15
COULOMETER
Fig.5. Series-parallel connection of batteries
n = number of batteries connected in parallel
m = number of batteries connected in series
m = max 4
Properly matched LiFePO4 charger
(24V or 48V)
SCHIELDED WIRE
SHUNT
CHARGER
+ TERMINAL /P+ LOAD, C+ CHARGER +/
- TERMINAL /P- LOAD, C- CHARGER -/
FUSE
+
-
+
+
-
-
-
m
n
TK15
COULOMETER

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4.2. FIRST CHARGE
4.3. CHARGING PROCESS - GENERAL INFORMATION
For safety reasons, batteries are shipped in a low state of charge. Charge the battery before using it for the rst time.
The process of charging a lithium-ion battery can be divided into 3 cycles:
NOTICE
The parameters can be read using wireless monitoring of parameters via the application or using the TK15 coulometer connected directly
to the battery or batteries. Whenever it is not possible or advisable to use the application, we recommend using the TK15 coulometer.
4.1. CHARGE
4. OPERATION
WARNING
It is recommended to use a dedicated charger from the manufacturer for the charging process. It is allowed to use chargers from other
manufacturers, however, the user must be sure of the compatibility of the equipment that is about to work with the batteries. Non-compliance
with the instructions may cause damage to the device, as well as danger to health and life.
DANGER
Do not charge the battery in temperatures below 0oC.
The battery has a protection that disconnects the charging process when the battery temperature drops below 0oC.
Fig. 6 Charging cycles of LiFePO₄ batteries
t0 - constant current CC;,
t1 - constant voltage CV;
t2 - battery charged
5~10%CC
Current
Voltage
CC MODE CV MODE
t1t0 t2
BETTERY
CHARGED
The CC mode - cycle charges the battery with a constant current, while the output voltage
of the charger is higher than the nominal battery charging voltage. That condition is necessary, because there is a need for such a difference in
potential to pass the charging current. While the battery reaches its maximum safe voltage, the CC cycle ends and the CV cycle begins.
The CV mode - cycle charges the battery with a constant voltage until the current drops to close to 0 A. Then the balancing of the battery cells takes place.
During balancing, the cells that have reached too high voltage are discharged through a special resistor.
There are two reasons for this:
-rst, not to overcharge the cells;
-second, remaining cells with too low voltage have time to charge.
When the voltage difference of balanced cells is small enough for charger and BMS, the cycle CV ends and passes to the charged battery cycle.
The charged battery cycle begins immediately after balancing and ends the charging process. During this cycle the charger is disconnected from the battery by opening
the charging contactor.

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4.4. BATTERY MANAGEMENT SYSTEM (BMS)
The cells in a lithium-ion battery are not completely identical and may charge and discharge at different rates and discharge differently. Each lithium-ion cell is very
sensitive to overcharging and overdischarge. For this reason, it is essential that each battery pack has protection against these hazards.
The Battery Management System (BMS) performs specic tasks by measuring and controlling battery parameters:
- protects the battery cells from exceeding the minimum safe voltage (for LiFePO₄ cells it is 2.5V),
- protects the battery cells from exceeding the maximum safe voltage (for LiFePO₄ cells it is 3.65V),
- during charging, balances and equalizes voltages of all cells, which extends battery life and reliability.
- In addition, the BMS protects against short-circuits and battery overloads.
Fig.7. General diagram of the BMS system installed in the battery
transistor key
B+
P+
B-
first cell (or series)
second cell (or series)
third cell (or series)
last cell (or series)
3,20V
3,20V
3,20V
3,20V
cell package
P-
WARNING
In the BMS system, despite the protections used, it is possible to damage the battery through incorrect use. Examples may be: leaving
the discharged battery for a period longer than 72 hours (permanent damage to the battery) or leaving the fully charged battery for MORE
than 6 months (partial loss of capacity) without use. It is necessary to discharge and recharge the battery once every 6 months, so that it does not
lose its capacity.
WARNING
In case of a deep discharge of the Kon-TEC LiFePO₄ 12V battery, the BMS system will disconnect the battery from further use.
In this case, the BMS works to avoid excessive discharge of cells, dangerous for the battery. The voltage of the battery terminals can be ~ 0 V.
In order to reactivate such a battery for further operation, it should be connected to the terminals with a voltage close to its
rated voltage (approx. 12.8 V), or higher, close to the charging voltage (max. 14.6 V). For this purpose, use a dedicated charger
Kon-TEC LiFePO₄ 12V or a suitable power supply/charger. The process of "awakening" the battery lasts a few/several seconds.
After the above operation, the battery should have a voltage at the terminals of ≥10 V and will be ready to be charged and to continue the work.
NOTICE
Not all processor chargers are suitable for the process of "awakening" of such a battery, because some of them do not have constant voltage on
terminals. Therefore, use only a dedicated Kon-TEC LiFePO₄ 12V charger or a suitable power supply/charger.
NOTICE
In the event of disconnection (by BMS) of any of the batteries connected in series 24V / 36V / 48V, the entire block will turn off, because deeply
discharged, disconnected battery will create an open circuit. In order to "awake" such battery, it must be disconnected from the series and also be
"awaken" by dedicated Kon-TEC LiFePO₄ 12V charger or appropriate power supply/charger. You cannot "awake" a single battery
connected in series with a charger matched to charge 24 V / 36 V / 48 V batteries in series!

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4.5. WIRELESS COMMUNICATION - PARAMETERS CONTROL IN MOBILE APP
4.5.1 INSTALLATION AND USE MANUAL
The app connects with the battery via wireless communication to monitor the parameters and status of the battery in real time with mobile device.
The connection provides great exibility and ease of use for Kon-TEC batteries. Multiple batteries can be connected to the application simultaneously
and the user is able to monitor the status of each battery.
The app displays:
• Battery State of Charge (%)
• Battery temperature (ºC / F)
• Discharge current (A)
• Load current (A)
• Battery life (number of cycles)
Advantages of using the application:
+ No need to use separate monitoring device
+ No wires - no need to connect the battery monitor with wires to the battery
+ Ability to connect multiple Kon-TEC batteries to one application.
1. Enable wireless communication on your mobile device
2. Download the application "Kon-TEC" from Google Play for Android devices or " Kon-TEC Battery Monitor" from Apple Store for iOS devices.
The qr-code can be scanned do download application - please scan the corresponding qr-code for your device.
3. Run the "Kon-TEC Battery Monitor" and allow the app to access your device's location.
WARNING
The battery is only connected via the "Kon-TEC Battery Monitor" application. Do not connect the battery directly via wireless communication on
your mobile device.

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4. After launching, the application will search for the batteries
within the working range of wireless communication (about 10m).
6. To check the parameters of the battery, select (press) the desired battery.
5. The distance to the battery can be checked by monitoring
"Signal strength" parameter. When approaching the battery
or moving away from the battery, select the "Refresh" button,
"Signal strength" will increase (e.g. -87dB) or decrease
(e.g. -25dB) depending on the distance from the battery
or batteries.