Lithionics Battery NeverDie-PSS-SOC Quick start guide

12V 12V
48V Parallel Battery System NeverDie-PSS-SOC
STEP-BY-STEP WIRING DIAGRAM
12V 12V
12V 12V 12V 12V
ALL POWER CABLES 2/0 AWG UNLESS
MARKED OTHERWISE
48V NeverDie Box
BATTERY
(+48V)
LOAD
(+48V)
48V
Discharge and Charge
Connection Point
5/2/14
DWG – NM
CKD – CH
48V SOC Sender Box
BATTERY
(+48V)
LOAD
(+48V)
SOC
AUX. RESET
SWITCH
HVC OUT HVC IN
GENERATOR
START/STOP
SWITCH
GEN. START SIGNAL
(20AWG)
GEN. RUN SIGNAL
(16AWG)
(INPUT 12-24V)

12V 12V
STEP 1: Connect the cell loop from each 12V battery module in series to the NeverDie box as shown.
Cell loop Cell loopCell loop
12V
Cell loop
12V
Cell loop
12V 12V 12V 12V
ALL POWER CABLES 2/0 AWG UNLESS
MARKED OTHERWISE
48V NeverDie Box
BATTERY
(+48V)
LOAD
(+48V)
48V
Discharge and Charge
Connection Point
5/2/14
DWG – NM
CKD – CH
48V SOC Sender Box
BATTERY
(+48V)
LOAD
(+48V)
SOC
AUX. RESET
SWITCH
HVC OUT HVC IN
GENERATOR
START/STOP
SWITCH
GEN. START SIGNAL
(20AWG)
GEN. RUN SIGNAL
(16AWG)
(INPUT 12-24V)

12V 12V
STEP 2: Connect the 12V Battery modules in series to create two 48V battery systems as shown below.
Cell loop Cell loopCell loop
Series Connection
12V
Cell loop
12V
Cell loop
12V 12V
Series Connection
12V
Series Connection
12V
Series Connection
Series Connection Series Connection
ALL POWER CABLES 2/0 AWG UNLESS
MARKED OTHERWISE
48V NeverDie Box
BATTERY
(+48V)
LOAD
(+48V)
48V
Discharge and Charge
Connection Point
5/2/14
DWG – NM
CKD – CH
48V SOC Sender Box
BATTERY
(+48V)
LOAD
(+48V)
SOC
AUX. RESET
SWITCH
HVC OUT HVC IN
GENERATOR
START/STOP
SWITCH
GEN. START SIGNAL
(20AWG)
GEN. RUN SIGNAL
(16AWG)
(INPUT 12-24V)

12V 12V
STEP 3: Connect the 12V Battery modules shown in parallel. This is to promote a better balanced system which
will increase the performance and life span of the battery system over time.
Cell loop Cell loopCell loop
Series Connection
12V
Cell loop
12V
Cell loop
12V 12V
Series Connection
12V
Series Connection
12V
Series Connection
Series Connection Series Connection
Parallel Connection Parallel Connection Parallel Connection
ALL POWER CABLES 2/0 AWG UNLESS
MARKED OTHERWISE
8AWG
8AWG 8AWG
48V NeverDie Box
BATTERY
(+48V)
LOAD
(+48V)
48V
Discharge and Charge
Connection Point
5/2/14
DWG – NM
CKD – CH
48V SOC Sender Box
BATTERY
(+48V)
LOAD
(+48V)
SOC
AUX. RESET
SWITCH
HVC OUT HVC IN
GENERATOR
START/STOP
SWITCH
GEN. START SIGNAL
(20AWG)
GEN. RUN SIGNAL
(16AWG)
(INPUT 12-24V)

12V 12V
STEP 4: Connect the most positive terminal of each 48V system to the NeverDie box terminal labeled Battery.
Cell loop Cell loopCell loop
Series Connection
12V
Cell loop
12V
Cell loop
12V 12V
Series Connection
12V
Series Connection
12V
Series Connection
Series Connection Series Connection
Parallel Connection Parallel Connection Parallel Connection
ALL POWER CABLES 2/0 AWG UNLESS
MARKED OTHERWISE
8AWG
8AWG 8AWG
48V NeverDie Box
BATTERY
(+48V)
LOAD
(+48V)
48V
Discharge and Charge
Connection Point
BMS +48V
5/2/14
DWG – NM
CKD – CH
48V SOC Sender Box
BATTERY
(+48V)
LOAD
(+48V)
SOC
AUX. RESET
SWITCH
HVC OUT HVC IN
GENERATOR
START/STOP
SWITCH
GEN. START SIGNAL
(20AWG)
GEN. RUN SIGNAL
(16AWG)
(INPUT 12-24V)

12V 12V
STEP 5: Using a 4/0AWG cable connect the Load terminal of the NeverDie Box to the Battery Terminal of the
SOC Sender box.
Cell loop Cell loopCell loop
Series Connection
12V
Cell loop
12V
Cell loop
12V 12V
Series Connection
12V
Series Connection
12V
Series Connection
Series Connection Series Connection
Parallel Connection Parallel Connection Parallel Connection
ALL POWER CABLES 2/0 AWG UNLESS
MARKED OTHERWISE
8AWG
8AWG 8AWG
48V NeverDie Box
BATTERY
(+48V)
LOAD
(+48V)
48V
Discharge and Charge
Connection Point
BMS +48V
5/2/14
DWG – NM
CKD – CH
48V SOC Sender Box
BATTERY
(+48V)
LOAD
(+48V)
SOC
4/0 AWG (OR 2x 2/0AWG)
AUX. RESET
SWITCH
HVC OUT HVC IN
GENERATOR
START/STOP
SWITCH
GEN. START SIGNAL
(20AWG)
GEN. RUN SIGNAL
(16AWG)
(INPUT 12-24V)

12V 12V
STEP #: Connect the HVC OUT cable from the NeverDie box to the HVC IN cable of the SOC Sender box.
Cell loop Cell loopCell loop
Series Connection
12V
Cell loop
12V
Cell loop
12V 12V
Series Connection
12V
Series Connection
12V
Series Connection
Series Connection Series Connection
Parallel Connection Parallel Connection Parallel Connection
ALL POWER CABLES 2/0 AWG UNLESS
MARKED OTHERWISE
8AWG
8AWG 8AWG
48V NeverDie Box
BATTERY
(+48V)
LOAD
(+48V)
48V
Discharge and Charge
Connection Point
BMS +48V
5/2/14
DWG – NM
CKD – CH
48V SOC Sender Box
BATTERY
(+48V)
LOAD
(+48V)
SOC
4/0 AWG (OR 2x 2/0AWG)
AUX. RESET
SWITCH
HVC OUT HVC IN
GENERATOR
START/STOP
SWITCH
GEN. START SIGNAL
(20AWG)
GEN. RUN SIGNAL
(16AWG)
(INPUT 12-24V)

12V 12V
STEP 6: Connect the most negative terminal of the closest proximity 48V system to the NeverDie & SOC boxes
negative reference wire.
Cell loop Cell loopCell loop
Series Connection
12V
Cell loop
12V
Cell loop
12V 12V
Series Connection
12V
Series Connection
12V
Series Connection
Series Connection Series Connection
Parallel Connection Parallel Connection Parallel Connection
ALL POWER CABLES 2/0 AWG UNLESS
MARKED OTHERWISE
8AWG
8AWG 8AWG
48V NeverDie Box
BATTERY
(+48V)
LOAD
(+48V)
48V
Discharge and Charge
Connection Point
BMS REF. -48V 16AWG
BMS +48V
5/2/14
DWG – NM
CKD – CH
48V SOC Sender Box
BATTERY
(+48V)
LOAD
(+48V)
SOC
SOC REF. -48V 16AWG
4/0 AWG (OR 2x 2/0AWG)
AUX. RESET
SWITCH
HVC OUT HVC IN
GENERATOR
START/STOP
SWITCH
GEN. START SIGNAL
(20AWG)
GEN. RUN SIGNAL
(16AWG)
(INPUT 12-24V)

12V 12V
STEP 7: Connect the most negative terminal of each 48V system to the negative discharge & charge bus bar.
Cell loop Cell loopCell loop
Series Connection
12V
Cell loop
12V
Cell loop
12V 12V
Series Connection
12V
Series Connection
12V
Series Connection
Series Connection Series Connection
Parallel Connection Parallel Connection Parallel Connection
ALL POWER CABLES 2/0 AWG UNLESS
MARKED OTHERWISE
8AWG
8AWG 8AWG
48V NeverDie Box
BATTERY
(+48V)
LOAD
(+48V)
48V
Discharge and Charge
Connection Point
BMS REF. -48V 16AWG
BMS +48V
5/2/14
DWG – NM
CKD – CH
48V SOC Sender Box
BATTERY
(+48V)
LOAD
(+48V)
SOC
SOC REF. -48V 16AWG
4/0 AWG (OR 2x 2/0AWG)
AUX. RESET
SWITCH
HVC OUT HVC IN
GENERATOR
START/STOP
SWITCH
GEN. START SIGNAL
(20AWG)
GEN. RUN SIGNAL
(16AWG)
(INPUT 12-24V)

12V 12V
Cell loop Cell loopCell loop
Series Connection
12V
Cell loop
12V
Cell loop
12V 12V
Series Connection
12V
Series Connection
12V
Series Connection
Series Connection Series Connection
Parallel Connection Parallel Connection Parallel Connection 8AWG
8AWG 8AWG
48V NeverDie Box
BATTERY
(+48V)
LOAD
(+48V)
48V
Discharge and Charge
Connection Point
BMS REF. -48V 16AWG
BMS +48V
5/2/14
DWG – NM
CKD – CH
48V SOC Sender Box
BATTERY
(+48V)
LOAD
(+48V)
SOC
SOC REF. -48V 16AWG
4/0 AWG (OR 2x 2/0AWG)
4/0 AWG (OR 2x 2/0AWG)
AUX. RESET
SWITCH
HVC OUT HVC IN
GENERATOR
START/STOP
SWITCH
GEN. START SIGNAL
(20AWG)
GEN. RUN SIGNAL
(16AWG)
(INPUT 12-24V)
STEP 8: Connect the SOC Terminal labeled LOAD to the +48V discharge & charge bus bar.
ALL POWER CABLES 2/0 AWG UNLESS
MARKED OTHERWISE