Lithionics Battery GT12V450A-F24 Guide

MiniBMS
OptoLoop
*Model Numbers
GT12V450A-F24
GT12V600A-F24
GT24V300A-F24
GT48V150A-F24
GT51V150A-F24
GT12V600A-F27
GT24V300A-F27
GT48V150A-F27
GT51V150A-F27
*See Table 1 for model number details
TECHNOLOGY
Installation Manual
R5 –4/30/2018
®
TECHNOLOGY
®
®

2
1. Important Safety Guidelines
1.1 General
•Completely read this manual before attempting
installation. Save this installation manual for
future use.
•The information in this manual is intended for
qualified personnel. Qualified personnel have
training, knowledge, and experience in:
oInstalling electrical equipment.
oApplying all applicable local and national
installation codes.
oAnalyzing and reducing the hazards involved
in performing electrical work.
oSelecting and using Personal Protective
Equipment-(PPE).
•The GT Series Lithium Battery System contains
no user-serviceable parts. Do not disassemble
any components.
•CAUTION - Electrolyte vapor hazard
oThe battery module may emit a non-toxic
pressurized electrolyte vapor if punctured.
oElectrolyte vapor may cause temporary minor
breathing congestion.
oElectrolyte vapor can decrease visibility in
closed compartments.
•DANGER - Short circuit hazard
oDo not operate the system if it has received a
sharp blow, been dropped, has cracks or
openings in the enclosure.
oDo not disassemble any part of the system.
Internal cells remain charged after all power
is disconnected.
oAlways turn off equipment connected to the
system in addition to turning OFF the Power
switch provided on the system to isolate the
batteries from other electrical circuits, before
performing any repairs or maintenance on
the system.
oDo not operate the system with damaged or
substandard wiring.
oAlways use proper wire sizes to connect the
system to inverters, chargers or other
equipment.
oVoltage is present at the connector and
output terminals. Always ensure that the
BMS output terminals have the insulated
protective boots in place.
oAlways use crimped connections to connect
to the output terminals.
•If the system is operated outside of its limits or
used in combination with non-original
components without authorization, the
warranty is void.
1.2 Transportation
•The Battery Module and BMS is tested to
comply with UN DOT 38.3, the testing
requirement for Lithium Batteries per Part III;
of the UN Recommendations on the
TRANSPORT
OF DANGEROUS GOODS (Manual of Tests
and Criteria, Fifth revised edition);
[ST/SG/AC.10/11/Rev.5].
•CAUTION –The GT Series Lithium Battery
Module is heavy.
oUse two people to lift and mount the unit.
oAlways use proper lifting techniques during
installation to prevent injury.
oDo not lift the battery module by its power or
signal wires as they will become damaged.
1.3 Disposal
•This Battery Module contains no mercury and
Is RoHS Compliant. Please consult your local
municipal authority for proper disposal.

3
2. System Specifications
2.1 System Operating Specifications
Table 1
2.2 Manufacturing Date Code Format
•MMDDYYYY001
oMM: Month of Manufacture
oDD: Day of that Month
oYYYY: Year of Manufacture
o001: Sequence of Battery Produced on
That Day
•Example: 01012018001 = manufactured
on January 1, 2018 and it was the first
battery produced on that day.
* Maximum charging and discharging rates apply depending upon the ambient temperature and duty cycle of the system.
UL1973 tests of maximum charge and discharge current were performed at 25°C/77°F.
** Does not include 4/0 power cable’s weight as its length varies per application.
*** Does not include 4/0 power cable, main power connector, or terminals. Please see http://www.lithionicsbattery.com for dimensions.
System Model:
GT12V-450A-F24-
CTRL300 External
BMS
GT12V-600A-F24-
CTRL300 External
BMS
GT24V-300A-F24-
CTRL300 External
BMS
GT48V-150A-F24-
CTRL300 External
BMS
GT51V-150A-F24-
CTRL300 External
BMS
GT12V-600A-F27-
CTRL300 Internal
BMS
GT24V-300A-F27-
CTRL300 Internal
BMS
GT48V-150A-F27-
CTRL300 Internal
BMS
GT51V-150A-F27-
CTRL300 Internal
BMS
Capacity 450Ah 600Ah 300Ah 150Ah 150Ah 600Ah 300Ah
Nominal Voltage 25.6V 48.0V 51.2V 12.8V 25.6V 48.0V 51.2V
Standard Full Charging
Voltage
29.2V 54.75V 58.4V 14.6V 29.2V 54.75V 58.4V
Overcharge Voltage
Protection
29.6V 55.5V 59.2V 14.8V 29.6V 55.5V 59.2V
Over-discharge Voltage
Protection:
23.2V 43.5V 46.4V 11.6V 23.2V 43.5V 46.4V
Standard Charging
Current
150A (C/3) 200A (C/3) 100A (C/3) 200A (C/3) 100A (C/3)
End of Charging Current 15A (C/30) 20A (C/30) 10A (C/30) 20A (C/30) 10A (C/30)
Maximum Charging
Current
288A @ 28.4V
Charging Voltage
144A @ 53.25V
Charging Voltage
144A @ 56.8V
Charging Voltage
300A @ 14.2V
Charging Voltage
288A @ 28.4V
Charging Voltage
144A @ 53.25V
Charging Voltage
144A @ 56.8V
Charging Voltage
Maximum Charging
Voltage
29.2V @ Standard
Charging Current
54.75V @ Standard
Charging Current
58.4V @ Standard
Charging Current
14.6V @ Standard
Charging Current
29.2V @ Standard
Charging Current
54.75V @ Standard
Charging Current
58.4V @ Standard
Charging Current
Standard Discharging
Current/Load
288A 300A 288A
Maximum Discharge
Current/Load
Maximum Charging
Temperature Range*
Maximum Discharging
Temperature Range*
Module Dimensions
Module Weight** 128lb (58.0kg) 160lb (72.5kg) 160lb (72.5kg) 152lb (68.9kg) 160lb (72.5kg) 170lb (77.1kg) 178lb (80.7kg)
BMS Case
Dimensions***
BMS Weight**
178lb (80.7kg)
N/A
11.25" x 6.96" x 4.1" (286 x 177 x 104mm)
7.7lb (3.5kg)
N/A
14.6V
50A (C/3)
50A (C/3)
12.8V
150Ah
14.8V
11.6V
300A
144A
144A
14.6V @ Standard Charging Current
300A @ 14.2V Charging Voltage
5A (C/30)
5A (C/30)
32 to 113°F (0 to 45℃)
-4 to 131°F (-20 to 55℃)
24.0" x 13.0" x 11.1" (610 x 330 x 282mm)
27.0" x 16.0" x 11.1" (686 x 406 x 282mm)
300A

4
3. System Installation
3.1 Short Circuit Protection
•The battery system must be protected by a
300A fast acting DC fuse, for example:
oFuse: Eaton DFJ-300
oFuse holder: Eaton JM60400-1CR-1
oFuse placement must be directly after the
positive power terminal on the BMS. (Fuse
placement may be controlled by other
industry standards such as ABYC or RVIA.)
3.2 Battery Module and NeverDIE BMS Unit
Environment and Mounting orientation
•The Battery Module and BMS Unit should be
mounted in an environment that does not
receive direct sunlight, pressurized water or
road debris.
•To avoid power interruption, your installation
may need to consider controlling the ambient
operating temperature.
•Mount the Battery Module in an upright
position, i.e. black lid faces up.
oOther orientations are NOT permitted and
will void the warranty.
•The BMS Unit can be mounted in any
orientation as long as all its features are
accessible.
•Ensure that the BMS Unit is located in close
proximity to the Battery Module so that all
connectors can be mated in the following steps.
3.3 Temperature Sensor Connector
•The temperature sensor cable and connector
exiting the battery module must be connected
to the BMS.
•Connect the two M8 circular connectors
together by first aligning their pins and pressing
them together, then rotate the securing nuts
until they stop snugly.
•Do not use the temperature probe from the
inverter-charger manufacturer.
3.4 Main Power Connector
•The battery module has a large black female
main power connector that must be inserted
into the BMS’ male main power connector. This
is the connector with the large 4/0 red and
black wires and single small gauge gray cable.
•Align the connectors and insert them together.
•Use 2 zip ties to bind the connectors together
so that they may not separate during use.
3.5 NeverDIE BMS Unit Power Terminals
•Connect the BMS Unit Power Terminals to your
DC bus, both Positive (Red) and negative
(Black).
oUse correctly sized wire conductors for the
application.
oTorque to 80 INCH pounds
oNever stack ring terminals.
oNever place the stainless-steel washer
between the Power Terminal and ring
terminal lug (see Figure 1 on Page 7).
3.6 Pressure Vent
•It is recommended to install a ventilation hose
onto the pressure vent barb when the Battery
Module is in a location with poor ventilation.
oThe hose should direct the gases to the
atmosphere.
3.7 BMS Unit I/O Connector
•Some systems have a rectangular I/O
connector to extend BMS Unit features
remotely such as remote Power/Reset switch,
LED indicator, or serial datalogging. Be sure to
connect the I/O connector if so equipped.
3.8 Initial Charge Cycle
•Initially the system must be FULLY charged
once to calibrate the BMS Unit to the Battery
Module. Please read and follow the next
section to perform this.
NOTE –For further system operation please refer to
the Advanced Series User Guide available at:
http://www.lithionicsbattery.com/user-guides/

5
4. System Operation
4.1 Powering the System On
•Press the momentary Power/Reset switch for 1
second.
oThe switch will illuminate once power is
enabled.
oYou may notice an audible “thunk” noise of
the internal contactor switching on.
oCheck that there is voltage at the Power
Terminals with a voltmeter.
4.2 Powering the System Off
•Press and hold the momentary Power/Reset
switch for 3 seconds.
oThe switch will cease to illuminate once
power is disabled.
oYou may notice an audible “thunk” noise of
the internal contactor switching off.
oCheck that there is 0V at the output terminals
with a voltmeter.
4.2 Charging
•The charging device(s) connected to the GT
Series Lithium Battery System must be
programmed as per Table 1.
•Charging may be performed at any time the
system is powered On.
oNOTE - The GT Series Lithium Battery System
will disconnect power if the voltage,
amperage, or temperature limits are
exceeded during charging.
oOnly use a Lithionics Battery approved
charging source. Please contact Lithionics
Battery for charger approval.
4.3 Initial Charging Cycle
•The initial charging cycle is required as it
calibrates the NeverDIE BMS to the Battery
Module for accurate State of Charge
percentage (SoC) monitoring.
•During the initial charging cycle the system
must reach a voltage level that is equal to the
Standard Full Charging Voltage indicated in
Table 1.
•Enable the charging device(s) so that they may
complete a charge cycle. It is recommended to
not have any discharge loads active during the
initial charging cycle, especially towards the
end of charging.
4.4 Discharging
•Discharging may be performed at any time the
system is powered On.
oNOTE - The GT Series Lithium Battery System
will disconnect power if the voltage,
amperage, or temperature limits are
exceeded during discharging.
•The NeverDIE feature allows the system to
have a “reserve” amount of energy left in the
battery. Once the system is discharged to 12.0V
or 10% State of Charge (SoC), whichever comes
first, power will be disabled to leave a “reserve”
amount of energy still left in the battery.
•To enable the remaining reserve energy of the
system, press the momentary Power/Reset
switch for 1 second.
oNOTE - Once the reserve range is enabled the
battery should be charged as soon as
possible.
oWARNING - If the reserve energy is used and
the battery module is left in a deeply
discharged state without immediate
charging, the battery module will become
permanently damaged.
4.4 System Storage Procedure
•Storing your battery at the correct
specifications is important as it keeps the
battery in the healthiest state possible for the
fastest deployment when needed.
•If the GT Series Lithium Battery System will not
be in use for greater than 2 weeks, it is
recommended to enable system storage.
•Storage mode is simply a fully charged system
in the Powered Off state.
•To enable System Storage:
oPerform a full charge cycle, ensure that the
System voltage reaches the Standard Full
Charging Voltage indicated in Table 1.
oPower off the System, press and hold the
Power/Reset switch for 3 seconds. Check that
the switch is no longer illuminated. Check

6
that there is 0V at the Power Terminals with
a voltmeter.
•4.4 System Storage Procedure (continued)
Table 2
Storage
Temperature &
Humidity Range
< 1 Month
-4~95°F (-20~35°C), 45~75%RH
< 3 Months
14~86°F (-10~30°C), 45~75%RH
Long Term Storage
If the battery needs to be stored for > 3 months the voltage should be 13.2V for
a 12V battery (or 3.3V x number of cells in series) (~50%SOC) and stored at the
recommended storage specifications shown above. Additionally, the battery
needs at least one charge-discharge-recharge to 50% SOC cycle every six
months.
Self-discharge rate
≤3% per month
Typical storage scenario < 3 months:
1. Fully charge the battery.
2. Turn the battery OFF by the Power/Reset switch.
3. Store the battery in an environment according to the specifications shown above.
Typical storage scenario > 3 months:
1. Reduce the battery SOC to 3.3V/cell which is 50% ±10% SOC.
NOTE - See table 3 below for voltage calculation.
2. Turn the battery OFF via the Power/Reset switch.
3. Store the battery in an environment according to the specifications shown above.
4. Every 6 months charge the battery to 100% SOC, then discharge the battery to LVC, then charge
it back to 50% ±10% SOC.
Table 3
Battery
Voltage
Number of
Cells
~50% SOC
Voltage
12V
4
13.2
24V
8
26.4
48V
15
49.5
51V
16
52.8

7
Figure 1: System Example
NeverDIE
BMS
Main Power
Connectors
Temperature
Sensor
Connectors
Battery
Module
Pressure
Vent
300A Fast
Acting Fuse