Lithionics Battery NeverDie 200 Series User manual

NeverDie® Compact Series 200 Internal BMS
MiniBMS
GTX12V320A-E2107-CS200-UL Installation Manual
R2Draft
®
TECHNOLOGY
®

Important Safety Guidelines
This guide contains important safety instructions for the GTX12V320A-E2107-CS200-UL Battery System that must be
followed during installation procedures. Completely read this manual and become familiar with all system components
before attempting installation. Save this installation manual for future reference.
The following symbols and messages are used to identify potential hazards or to clarify the procedure.
The CAUTION symbol indicates a hazardous situation which, if not avoided, could result in moderate or minor injury.
The DANGER symbol indicates a hazardous situation which, if not avoided, will result in death or serious injury.
Safety Information
1. Before using the Battery System, read all instructions and cautionary markings on the unit, the BMS, and all
appropriate sections of this manual.
2. The information in this manual is intended for qualified personnel. Qualified personnel have training,
knowledge, and experience in:
•Selecting and using Personal Protective Equipment (PPE).
•Installing electrical equipment.
•Applying all applicable local and national installation codes.
•Analyzing and reducing the hazards involved in performing electrical work.
3. Use of accessories not recommended or sold by the manufacturer may result in a risk of fire, electric shock, or
injury to persons.
4. To avoid a risk of fire and electric shock, make sure that existing wiring is in good condition and that wire is not
undersized. Do not operate the battery system with damaged or substandard wiring.
5. Do not operate the battery system if it has been damaged in any way.
6. This unit does not have any user-serviceable parts. Do not disassemble the battery system except where noted
for connecting wiring and cabling. Attempting to service the unit yourself may result in a risk of electrical shock
or fire. Internal cells remain charged after all power is disconnected.
7. To reduce the chance of short-circuits, always use insulated tools when installing or working with this
equipment.
8. Remove personal metal items such as rings, bracelets, necklaces, and watches when working with electrical
equipment.

LITHIONICS BATTERY, 1770 CALUMET ST, CLEARWATER, FL 33765 USA
PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.COM
Page 3of 13
If the system is operated outside of its limits and/or used in combination with non-original components without
authorization, the warranty is void.
Do not expose this unit to direct sunlight, external heat sources or submersion in any liquid. This product is
designed for closed compartment use only. Damage to any part of the battery system caused from direct sunlight,
external heat sources or submersion in any liquid will not be covered by the product warranty.
The Battery 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].
This Battery contains no mercury and is RoHS Compliant. Please consult your local municipal authority for proper disposal.
HAZARD OF ELECTROLYTE VAPOR
•The battery may emit a non-toxic pressurized electrolyte vapor if punctured.
•Electrolyte vapor may cause temporary minor breathing congestion.
•Electrolyte vapor can decrease visibility in closed compartments.
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
•Apply appropriate personal protective equipment (PPE) and follow safe electrical work
practices.
•Always turn OFF all 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.
•Do not operate the system if it has received a sharp blow, been dropped, has cracks or
openings in the enclosure.
•Do not disassemble any part of the system. Internal cells remain charged after all power
is disconnected.
•Do not operate the system with damaged or substandard wiring.
•Always use proper wire sizes to connect the system to inverters, chargers or other
equipment.
•Voltage is present at the connector and output terminals. Always ensure that the BMS
output terminals have the insulated protective boots in place.
•Always use crimped connections to connect to the output terminals.
•Always use a properly rated voltage sensing device to confirm all circuits are de-
energized.
HAZARD OF HEAVY EQUIPMENT
•Use two people to lift and mount the battery.
•Always use proper lifting techniques during installation to prevent injury.
•Do not lift the battery by its power or signal wires as they will become damaged.

LITHIONICS BATTERY, 1770 CALUMET ST, CLEARWATER, FL 33765 USA
PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.COM
Page 4of 13
Notice of Copyright
GTX12V320A-E2107-CS200-UL Installation Manual Copyright © 2021 all rights reserved. No part of this document may be
reproduced in any form without the express consent of Lithionics Battery®, Clearwater, FL 33765 USA. Lithionics Battery®
reserves the right to revise this document and make periodic changes to the contents without notice.
Index
Index................................................................................................................................................................................ 4
Safety .............................................................................................................................................................................. 4
Overview......................................................................................................................................................................... 4
1. System Components................................................................................................................................................... 5
2. System Specifications................................................................................................................................................. 7
3. System Installation ..................................................................................................................................................... 9
4. System Operation..................................................................................................................................................... 11
Contact Information ..................................................................................................................................................... 13
Safety
▪All electrical work shall be performed in accordance with local and national electrical codes.
▪Assume that voltage is present at the battery terminals, use insulated tools and gloves while working on the system.
▪Always turn OFF equipment connected to the battery in addition to turning OFF the Power button on the battery to
isolate it from other electrical circuits before performing any repairs, maintenance or diagnosis on the system.
▪Always use proper wire sizes to connect the system to inverters, chargers, or other equipment.
▪Always use crimped connections to connect to the battery terminals.
▪Read and follow the inverter, charger, or other equipment manufacturers safety precautions prior to connecting the
battery to that equipment.
▪Always use charging equipment compatible with Lithium Iron Phosphate battery chemistry. See battery charging
section below.
Overview
This Guide is intended to be used by qualified individuals in the installation of the GTX12V320A-E2107-CS200-UL battery
system.

LITHIONICS BATTERY, 1770 CALUMET ST, CLEARWATER, FL 33765 USA
PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.COM
Page 5of 13
Figure 1
1. System Components
1.1 Components
•GTX12V320A-E2107-CS200-UL Battery
•Accessory Harness (#75-H1FCR-CS2-UL)
•DC Circuit Breaker (Sensata #JLE-1-41340-250)
•Protective DC Terminal Covers (not shown)
•Two Sets of M8x12x1.25mm Bolts and Lock Washers for the Terminals
Reference
Feature
Description
A
Positive Terminal
Brass, Nickel Plated, M8-1.25 Thread, Torque to 60in-lbs/6.8Nm
B
OptoLoop®+ Connector
RV-C CANBus Data, Remote Display Unit
C
Accessory Connector
FCC, Remote Power Button, Auxiliary DC Breaker
D
Negative Terminal
Brass, Nickel Plated, M8-1.25 Thread, Torque to 60in-lbs/6.8Nm
E
Power Button
Power Button with Status Light
F
Vent
Pressure Balancing Vent
G
DC Circuit Breaker
Auxiliary DC Circuit Breaker for UL Compliance
H
Accessory Harness
Enables Integration of the Auxiliary DC Breaker, and optional Remote
Power Button, and FCC
DC Circuit Breaker
Accessory Harness
GTX12V320A-E2107-CS200-UL
Battery

LITHIONICS BATTERY, 1770 CALUMET ST, CLEARWATER, FL 33765 USA
PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.COM
Page 6of 13
1.2 DC Circuit Breaker
The Auxiliary DC Breaker is one of the components required that enables the system to be a UL1973 Listed system.
UL1973 Listing represents a high degree of safety tested by Underwriter Laboratories.
The battery operates by using the Auxiliary DC Breaker as a redundant disconnect device if the battery must be
isolated from its loads. In some installations, the Auxiliary DC Breaker can also replace the need for a fuse and can
serve as a manual disconnect for storage and maintenance via its toggle switch.
The required and included DC breaker model is the Sensata Circuit Breaker #JLE-1-41340-250. The 2 control wires
for this feature are wired via the battery accessory connector.
1.3 Accessory Harness
The Accessory Harness connects to the battery and is used to access the BMS’s ported features. This allows
implementation of the features shown below.
75-H1FCR-CS2-UL Accessory Harness

LITHIONICS BATTERY, 1770 CALUMET ST, CLEARWATER, FL 33765 USA
PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.COM
Page 7of 13
2. System Specifications
2.1 Operating Specifications
Table 1
System Model: GTX12V320A-E2107-CS200-UL
Capacity 320Ah
Nominal Voltage 12.8V
Recommended Charging
Voltage
14.4V
Maximum Charging Voltage 14.6V
Overcharge Voltage
Protection
14.8V
Over-discharge Voltage
Protection
11.6V
Standard Charging Current 150A
Maximum Charging Current 200A
Charge Termination Current 10A
Standard Discharging
Current/Load
150A
Maximum Discharge
Current/Load
200A
System Impedance at
Terminals
≤ 2.20mΩ
Ibf Bolted Fault Current at
Nominal Voltage (N2)
5818A
Maximum Charging
Temperature Range (N1)
32 to 131°F (0 to 55°C)
Maximum Discharging
Temperature Range (N1)
-4 to 131°F (-20 to 55°C)
Battery Dimensions 20.3" x 6.4" x 10.0" (516 x 163 x 254mm)
Battery Weight 68lb (30.8kg)
Notes for Table 1:
(N1) 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.
(N2) "Bolted Fault Current" per NFPA-70E. See section 1.2 for details.
2.2 Arc Flash Energy Specifications
•An arc flash is the light and heat produced from an electric arc supplied with sufficient electrical energy to cause
substantial damage, harm, fire, or injury.
oAn example of an arc flash event could be a direct short circuit caused by a metallic object such as a tool bridging
between the positive and negative of an energized circuit.
oTable 3 below quantifies the hazard level of arc flash energy that each battery system is capable of producing.
Per NFPA 70E D.5.1 "Maximum Power Method"
Iarc = 0.5 x Ibf
IEm = 0.01*Vsys* Iarc*Tarc/D2(Arc Flash Energy)
Table 3

LITHIONICS BATTERY, 1770 CALUMET ST, CLEARWATER, FL 33765 USA
PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.COM
Page 8of 13
GTX12V320A-E2107-CS200-UL 12.8 2.20 5818 2909 0.360 1.079 9 0
Tarc= 80mS
circuit breaker
clearing time
Hazard
level
Distance where
IEm=1.2 (Arc
Boundary), inches.
3x IEm
cal/cm^
2
IEm cal/cm^2
Iarc
Ibf, calc.
Impedance
mΩ
Vsys
Configuration
Hazard/risk classification as per NFPA 70E-2000
2.3 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: 01012020001 = manufactured on January 1, 2020 and it was the first battery produced on that day.

LITHIONICS BATTERY, 1770 CALUMET ST, CLEARWATER, FL 33765 USA
PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.COM
Page 9of 13
3. System Installation
3.1 Circuit Breaker
•The battery system must be operated with the included circuit breaker. The model listed in this document was
evaluated and tested by Underwriter Laboratories. The circuit breaker is to be provided downstream of the battery
on the positive side before the load or supply in all cases. The use of any other circuit breaker voids the UL Listing of
the model.
•The circuit breaker must be installed into an enclosure with a NEMA Type 4 rating or better, see Reference 1 and
Figure 2 below.
•Use 10-32 screws to mount the circuit breaker into the enclosure. The screw depth into the circuit breaker (not
including the enclosure material thickness) must be within .230 to .315 max. Torque the 10/32 screws between 10-
12 Inch Pounds.
Reference 1
Enclosure Rating
Figure 2
Panel Mounting Dimensions
3.2 Battery Environment and Mounting orientation
•The Battery needs to be mounted in an environment that does not receive direct sunlight, pressurized water or road
debris.

LITHIONICS BATTERY, 1770 CALUMET ST, CLEARWATER, FL 33765 USA
PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.COM
Page 10 of 13
•To avoid power interruption, your installation may need to consider controlling the ambient operating temperature.
•Mount the Battery in an upright position, i.e. black lid faces up.
oOther orientations are NOT permitted and will void the warranty.
3.3 Battery Power Terminals
•Connect the Battery Negative Terminal to your DC negative bus.
•Connect the Battery Positive Terminal to either one of the power terminals on the circuit breaker (Figure 3, A).
oUse 4/0 wire and 4/0 3/8” stud ring terminals.
oThe battery positive wire (between battery and circuit breaker) is recommended to be 3ft or less.
oTorque the 3/8” nuts on the circuit breaker to 250-260 inch pounds.
oNever stack ring terminals.
oNever place the stainless-steel washer or lock-washer between the conductive power terminal and ring terminal
lug (see Figure 4 on Page 12).
•Connect the opposite end circuit breaker power terminal to your DC positive bus. breaker (Figure 3, A).
Figure 3
3.4 Accessory Harness
•Connect the 2x #10 stud ring terminals to the Circuit Breaker (Figure 3, B).
oTorque the 2x 5/16” nuts to 30-40 inch pounds.
•Connect the Accessory Harness to the Accessory Connector on the Battery (Figure 1, C).
3.5 Initial Charge Cycle
•Initially the system must be FULLY charged once to calibrate the Battery. Please read and follow the next section to
perform this.