OzCharge OCBL12-44 User manual

User Manual
OzCharge®Lithium Batteries
© 2022 BY ZYLUX ENERGY. ALL RIGHTS RESERVED.
This document is proprietary to and the copyright of Zylux Energy Pty Ltd. This document cannot be copied or
reproduced in whole or in part, without the express written permission of Zylux Energy Pty Ltd.
08/22 v1.0
IMPORTANT! PLEASE READ THIS MANUAL IN CONJUCTION WITH THE PRODUCT DATA
SHEET AND MATERIAL SAFETY DATA SHEET (AVAILABLE FROM OUR WEBSITE). THIS
MANUAL CONTAINS IMPORTANT INSTRUCTIONS THAT SHOULD BE FOLLOWED DURING
STORAGE, INSTALLATION, OPERATION AND MAINTENACE OF OZCHARGE®LITHIUM
BATTERIES. IT WILL HELP TO ACHIEVE THE HIGHEST PERFORMANCE FROM YOUR
BATTERY AND EXTEND THE LIFESPAN OF YOUR PRODUCT.

Contents
1. Safety First .......................................................................................................................................................3
2. Precautions & Safety Warnings .....................................................................................................................4
3. Support When You Need It ............................................................................................................................4
4. Introduction......................................................................................................................................................5
5. The Power of ONE ..........................................................................................................................................5
6. Applications .....................................................................................................................................................5
7. Care & Maintenance.......................................................................................................................................6
8. Installation & Connecting Your Batteries ......................................................................................................6
9. Storage.............................................................................................................................................................8
10. Shipping ...........................................................................................................................................................9
11. Recycling..........................................................................................................................................................9
12. Battery Management System (BMS) ..........................................................................................................10
13. General Specifications..................................................................................................................................10
14. Charging Your OzCharge® Lithium Battery...............................................................................................11
15. Warranty.........................................................................................................................................................12
PLEASE ENSURE YOU CHARGE THIS BATTERY BEFORE FIRST USE USING A COMPATIBLE LITHIUM
LIFEPO4 BATTERY CHARGER.
DO NOT ATTEMPT TO CHARGE OR DISCHARGE THIS BATTERY OUTSIDE OF THE RATED
CHARGING AND DISCHARGING VOLTAGE, CURRENT AND TEMPERATURE SPECIFICATIONS.

1. Safety First
The OzCharge®Lithium battery range is designed with an integrated Battery Management System (BMS)
to prevent internal damage to the battery under varying conditions. When the BMS activates, power can be
abruptly cut off to connected equipment or accessories and this interruption of power may cause damage
to these connected items or systems.
The installer must understand the automatic safety functions of the BMS and shall assume all
responsibility and liability for any damages to the battery OR connected items and systems if these
functions are not properly applied.
Only a competent person or a suitably qualified person should install this battery.
Safety When Handling
Wear personal protective equipment such as eye protection, gloves, and protective footwear
before handling.
Use insulated tools when working on or with the battery. If you don’t have insulated tools, we
suggest you at least wrap the shafts of spanners or ratches with insulation tape to prevent
shorting.
Keep sparks and open flames away from the battery.
Do not dispose of battery in household waste or incinerator.
Keep an appropriate and updated first aid kit within reach.
Avoid contact with any fluids that leak from the battery.
In Case of Fire
Do not douse or extinguish with water, use dry powder only. Only if it is safe to do so, place the battery in
a safe, well vented location, away from anything combustible and allow it to consume itself and burn out.
Disclaimer
UNLESS SPECIFICALLY AGREED TO IN WRITING, ZYLUX ENERGY:
(a) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY
TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION.
(b) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE, WHETHER DIRECT,
INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH
INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER’S RISK.
There is a real risk of fire, explosion, gases or burning as a result of handling
this product incorrectly. Failure to install or use the product according to the
instructions in this manual may result in premature battery failure or cause
electrical shock or fire damage to the battery, the surrounds
, connected
equipment or accessories and may cause personal injuries.

2. Precautions & Safety Warnings
Failure to follow these safety warnings and instructions contained within this manual and on the battery
may result in personal and/or property injury, as well as reduced battery life or battery failure.
• Do not use this battery for starting or cranking applications.
• Do not install this battery under bonnet.
• Do not short circuit the battery terminals.
• Do not reverse polarity charge or discharge the battery or you will damage the
battery.
• Do not connect this battery in series or parallel to batteries with different
chemistries or older manufacture dates.
• Do not penetrate, puncture, impact or drop the battery.
• Do not use the battery in a location where static electricity and magnetic fields are
high or you may damage the battery management system (BMS).
• Do not expose the battery to fire, sparks, high voltage (DC or AC).
• Do not exceed the operating temperatures in accordance with the technical
specifications in this manual.
• NEVER charge the battery at or below Zero Degrees Celsius (0oC)
• Do not disassemble the battery or remove the case lid. Opening the case may
cause electric shock or fire and will void your warranty.
• Check the datasheet for your battery to determine how many batteries can be
joined in series or parallel.
• Do not submerge the battery in any kind of water.
• Do not store the battery at a voltage lower than 13.0V
• Do not overtighten the battery terminals. See battery label for correct tensions.
• To charge the battery, you must use a charger with a specific charging profile for
lithium batteries. Your warranty may be reduced or voided if you use an unsuitable
charger. Refer to the Data Sheet for your battery for specific charging information.
• Never charge your battery directly from an alternator or VSR (Voltage Sensitive
Relay).
• Always ensure that any solar panels connected to the battery are done so via a
solar regulator with a Lithium setting. Never charge your battery with an
unregulated solar panel.
• If the battery emits any unusual smells, appears to be hot or is hot to touch, shows
any signs of distortion or displays any other abnormality during operation or
storage, discontinue use or charging/discharging immediately and contact
OzCharge®for assistance.
3. Support When You Need It
If you have any questions or difficulties with any OzCharge®product, simply contact our dedicated
technical support team and we will do our utmost to assist you. We would rather take a call before
something goes wrong. This is our OzCharge®service guarantee!
Zylux Energy Pty Ltd
166 Christmas St, Fairfield VIC 3078
Australia
Hours: Monday to Friday 8.00am – 5.00pm
Phone:
[phone]
[email protected]u

4. Introduction
Congratulations on purchasing an OzCharge®Lithium battery. The OzCharge®brand is forged on a
reputation for quality, reliability and affordability and our new premium Lithium range is no exception.
Our R&D team have scoured the globe to find cell manufacturing partners who meet our high
standards for quality, reliability, and durability in the harsh Australian conditions.
We bring you:
A battery that is fully certified to international and local safety standards.
Exceptionally high-quality cell technology. We only work with global cell manufacturers of the
highest standards. In fact, we even chose a manufacturer who sources Australian Lithium.
A massive service life of up to 8 years (based on 3000 cycles to 80% DOD - one cycle per day).
Inbuilt safety & protection via an active cell balancing, battery management system (BMS).
OzCharge®Lithium that has faster charging.
A battery that can handle our harsh environment and temperatures.
A low rate of self-discharge less than 3% per month.
OzCharge®Lithium is 100% Cobalt Free which increases fire safety and is both environmentally
and socially conscious.
Optional Bluetooth models so that you can interact with your battery.
Slimline options for those compact installations.
5. The Power of ONE
ONE brand of state-of-the-art lithium battery and ONE brand of trusted and proven battery charger that
are specifically designed to work as ONE. Through the Power of ONE you get optimised charging,
fantastic performance and durability, all at ONE great price.
6. Applications
OzCharge®Lithium Batteries can be used in a wide range of recreational applications where
traditional lead acid, lead Gel batteries or AGM Batteries are used today, including, but not
limited to:
• Caravan, camper, RV & 4WD
• Power boxes and packs, portable power solutions
• Marine depth sounders, trolling motors & lighting
• Motive and electric vehicles (golf carts, mobility scooters, golf caddy etc)
• Solar, wind, or wave energy storage systems
• Security, surveillance, and remote monitoring
+
=

Dedicated & optimized charging
No doubt of charge quality
One single support team
Safety features built into both
Get the most from your
investment
To learn more about OzCharge Lithium range visit our website www.ozcharge.com.au

• Emergency or remote lighting systems
• Off-Grid living
• Tiny homes and powering sheds
• Home automation and more…
7. Care & Maintenance
To ensure that you get the best performance and life from your OzCharge® Lithium battery, take a
moment to familiarise yourself with the following care and maintenance information.
Whilst your OzCharge®Lithium battery comes with a 5 Year Manufacturer’s Warranty against major
defects and workmanship, the life of your OzCharge®Lithium battery will be very much determined by
the Depth of Discharge (DOD) and the number of cycles. The OzCharge® Lithium range is rated at
3000 cycles to 80% DOD (i.e. you have used 80% of the battery capacity and have just 20% of the
energy remaining). If only discharged to 50% DOD once a day the battery could last for many years
beyond the warranty. You may get a service life of up to 10 years or more years.
It is also important that you keep a Lithium battery charged when not in use. We recommend that you
charge your battery at least every 3-6 months and try not to let the battery get below 13V when in
storage.
To ensure a long battery life:
•Endeavour to keep the battery above 30% State of Charge (SOC) or above 13.0V where
possible.
•Charge the battery correctly with a charger that has a dedicated Lithium setting. Check that
the charger will charge to the correct voltage and current (refer to the Data Sheet for your
battery for specific charge voltages and current requirements)
•Do not overload the battery. The maximum discharge specification can be found in the
technical specifications of the Data Sheet for your specific model of battery.
•Do not clean the case with solvents.
•Do not store or leave exposed to direct sunlight for extended periods of time.
•Keep battery terminals clean and free from corrosion, dust and dirt. Clean regularly to
ensure a good electrical contact.
8. Installation & Connecting Your Batteries
When installing your OzCharge® Lithium battery, always consider the environment in which it is being
installed. Avoid areas of high temperature like under a bonnet, next to a heat source or against a tin
shed wall. Consider if sparks or solvents can reach the battery, consider the location, size, and quality
of any connecting cables, and install the battery in a well-ventilated area. NEVER fully enclose or
encapsulate a battery. Here are some further considerations:
TIP - To meet international freight safety standards your OzCharge® Lithium battery will only be
60% charged when you receive it. We recommend you charge the battery prior to first use to
get the most out of your battery.

•Never lift the battery by the terminals.
•Ensure positive and negative battery cables are of an equal length and type.
•Ensure cables are appropriate for the size of charge or discharge load.
•Do not overload battery terminals with connection lugs. As a general rule of thumb, we don’t
recommend any more that 4 connection lugs per terminal. If you need more, we recommend
using a quality Busbar.
•Do not connect more than 4 batteries in series (maximum 48V for 12Vbatteries) or 4
batteries in parallel.
•When connecting batteries, do not connect batteries of different chemistry i.e., don’t
connect a Lithium to an AGM. And don’t connect old batteries to new batteries. Always try
and connect batteries of a similar age or serial number range for best performance.
Parallel Connection Series Connection
Parallel Connections
You can parallel up to 4 OzCharge® Lithium batteries together. Always ensure you use appropriate size
cable and all cables (linking cables and the cables to & from the battery) must be of the same length,
size, and type. Always connect chargers or loads to the first positive and the last negative…never both
from the one battery. Also note that batteries in parallel can become unbalanced over time and we
highly recommend that you periodically charge each battery independently (to full) to restore balance
in the pack and extend the life of your batteries.
Important: All batteries must be same state of charge (we recommend fully charged) and within 100mV
of each other before connecting them in parallel or series.
Series Connections (For 12.8V batteries only)
The OzCharge Lithium Battery Management System (BMS) will accommodate up to 4 batteries in
series (max 48V). However, there are a few things to be aware of when charging Lithium in series.
1. Each battery has its own independent BMS protection which monitors voltage and will disconnect
the battery to protect over voltage
2. Each individual battery has no way of knowing that it is in series with another battery.
3. It is almost impossible to equally charge, or maintain equal charge, to batteries in series with a
single charger.
To prevent uneven charging and possible charging issues (i.e. chargers cutting in and out as some
batteries hit full but others are not yet full), we HIGHLY RECOMMEND that each battery be charged
independently (e.g. 4 chargers for a 48V pack). Or even better still, simply purchase one of our
dedicated 24V, 36V, or 48V batteries. By buying a dedicated voltage battery, every cell is evenly
balanced by the BMS and you will avoid potential issues.
TIP: We recommend that batteries in series or parallel be given a periodical charge to FULL,
independently of each other, to help balance each battery. This will extend the life of your
batteries and ensure optimal capacity.

Battery Orientation
You may think that because Lithium doesn’t contain any fluid, it can be mounted in any orientation. This
is technically true, however in motive applications (or anything that is moving or vibrating) we always
recommend installing the battery in the upright position (terminals to the top). The reason for this lies in
the construction of the internal chassis and mounting systems of the individual Lithium cells. In the upright
position you are afforded the best protection from vibration and minor impacts and bumps. That doesn’t
mean mounted to a chassis rail while you smash your way up the Gunbarrel Highway either.
9. Storage
Whilst your OzCharge® Lithium battery has one of the world’s lowest self-discharge rates of less than
3% per month, the battery will self-discharge over time. Therefore, it is important for the life of your
battery to keep the battery charge maintained. Every 3-6 months we recommend that you connect
your dedicated Lithium battery charger and top up the batteries charge to FULL again.
Due to the low self-discharge (unlike traditional lead acid batteries) Lithium does not require a constant
maintenance pulse. So once fully charged, turn your charger off and help us all do our part to reduce
the power required to run the world.
When storing the battery, ensure you:
•Refit the caps terminal caps that came with the battery OR tape battery terminals on
batteries that are in storage or being taken to recycling.
•Never lift the battery by the terminals.
•Always store in a cool dry place (so don’t stack it against the tin shed wall).
•Try to avoid storing in higher than 85% humidity for extended periods.

10. Shipping
Lithium is classified as Class 9 Dangerous Goods. Please ensure you comply with local, national and
international (if applicable) regulations for the transportation of these goods. In Australia, the following
label must be displayed on the packaging when transporting.
UN38.3 (Cell & Pack) Certified
All OzCharge®Lithium batteries are UN38.3 (Cell & Pack) certified. This is an international test that
demands only the highest quality Lithium products can pass, so that they are safe for air and land
transport. It’s not always easy to see the inside of a Lithium battery but this certification gives you
peace of mind that you have purchased a quality product.
If you must transport the battery via couriers, please try to retain the packaging and re-use. This will
help create less waste and ensure the battery is correctly protected in transit.
11. Recycling
Here at Zylux and OzCharge® we are committed to helping our customers (and the planet) by being
environmentally conscious. We start this process by supplying you a product with a significantly longer
life cycle than traditional lead acid batteries. We consider very carefully who we partner with to
manufacture our products and we look at the complete life cycle. We give you lifetime product support
so that you get the most from your battery.
But here is the thing…we need you to do your part at the end of the product’s life. PLEASE recycle
your lithium battery by returning it to us or dropping it off at any approved Lithium recycling station.
https://recyclingnearyou.com.au/
WARNING Lithium batteries must never be disposed of with ordinary refuse or by incineration, as this
can cause significant fires and significant environmental contamination.
100% Cobalt Free
OzCharge® Lithium batteries contain NO Cobalt at all. Lithium free Cobalt is much safer as it is the
Cobalt in Lithium that assists in the creation of oxygen if the battery catches fire. With the rise of
Lithium globally the poor are being exploited, literally scratching at the ground to extract cobalt to meet
the huge demand. OzCharge® Lithium batteries are not only safer, but they are more socially
responsible.

12. Battery Management System (BMS)
Thanks to years of research and development your OzCharge® Lithium battery has state of the art
technology monitoring the battery. Internally within your battery, an active Battery Management System
or BMS constantly monitors the individual cells for voltage, temperature, state of charge, cell balance,
discharge loads, charge voltage and charge current.
BMS Protections:
Event
Model
Protection Condition
Reset Condition
Over Discharge
OCBL12-44 & OCBL12-55 <10V / 50—300mS
>10V / Cut Load
,Auto release
OCBL12-80, OCBL12-100,
OCBL12-120, OCBL12-200 &
OCBLS12-160
<10V / 3.7-5.7S >10.6V / Cut Load
,Auto release
OCBL36-100 <30V / 10-300ms
>31.2V / Cut Load
,Auto release
Over Charge
OCBL12-44 & OCBL12-55Ah
>14.8V / 0.5-2S
<14.4V
OCBL12-80, OCBL12-100,
OCBL12-120, OCBL12-200 &
OCBLS12-160
>14.88V / 0.5-1.5S <14.4V
OCBL36-100 >44.4V / 0.8-2S <42V / 5S
Over Discharge
Current
All Models
Please Refer to Product Label and / or
Specific Data Sheet
Short Circuit Current
All Models
Please Refer to Product Label and / or
Specific Data Sheet
High Discharge
Temperature Protect
All Models 65°C± 45°C±
High Charge
Temperature Protection
All Models 65°C± 48°C±
Active Cell Balance
OCBL12-44, OCBL12-55,
OCBL12-80,OCBL12-100,
OCBL12-120, OCBL12-200 &
OCBSL12-160
>14V
Automatic as required
OCBL36-100
>42V
Automatic as required
13. General Specifications
Nominal Voltage
12.8V, 24V, 36V or 48V (model dependant)*
IP Rating
IP65 or IP67 (model dependant)*
Parallel Connection
4 Max**
Series Connection
4 Max** (12.8V Models only)
0 for 24V, 36V and 48V models
Case Material
Flame Retardant ABS Plastic
Battery Terminal Torque Setting
M6 (4-6 Nm Torque)
M8 (7-9 Nm Torque)
Operating Temperature Range
-20oC~+60oC Relative Humidity ≤85%
Charge Temperature Range
0oC – 55oC
Charge Voltage 12.8V (for OCBL12-XXX)
14.4V ± 0.2V @ 0°C to 55°C
Charge Voltage 24V (for OCBL24-XXX)
28.8V ± 0.4V @ 0°C to 55°C

Charge Voltage 36V (for OCBL36-XXX)
43.2V ± 0.6V @ 0°C to 55°C
Charge Voltage 48V (for OCBL48-XXX)
57.6V ± 0.8V @ 0°C to 55°C
Charge Current
0.2C – 0.3C
Fast Charge Current
0.5C
Maximum Charge Current
0.75C – 1C (model dependant)*
Maximum Discharge current
0.75C – 1C (model dependant)*
Discharge Efficiency
98-100% @ 1C
Self Discharge
Less than 3% per month
BMS Discharge cut-off Voltage
(12V) (24V) (36V) (48V)
<10.0V <20.0V <30.0V <40.0V
Certifications
UL1642(Cell)
IEC62133(Cell)
IEC62619 (Cell)
CE(Pack)
UN38.3 (Cell / Pack)
ROHS (Cell)
*Please refer to the individual product label or Data Sheet for details, these are readily available from the OzCharge website.
** Please refer to Section 8 of this User Manual for important information about batteries in Series or Parallel.
14. Charging Your OzCharge® Lithium Battery
Lithium batteries need to be charged slightly differently to other batteries to ensure they live a long life
and provide maximum capacity. There are several charging devices you can utilise, but whichever
device you choose, it must have a lithium charge profile.
We recommended that you use a charger that can deliver a charge current or amperage of 20% to
30% or less of your battery capacity. You can charge at much higher rates (refer to the product label
on the battery) however you will reduce the cycle life of your battery at higher charge currents.
Check the “Maximum Charge Voltage” on your products Data Sheet and ensure the maximum output
voltage of any charging device connected to the battery does not exceed that voltage.
Charge Method
Important Note
A/C Domestic Battery Charger Ensure your charger has a dedicated Lithium setting.
Vehicle Alternator D/C Never directly charge from an alternator without an
appropriate regulator or DCtoDC charger in place
between the alternator and the Lithium battery. Not
recommended for under bonnet installations.
DCtoDC charger
Ensure your DCtoDC charger has a Lithium charge
setting.
Solar D/C
Never directly connect an unregulated solar panel to the
battery or you may exceed the maximum voltage allowed
and damage may occur. Use a solar regulator between
the panel and the battery.
Solar Regulator D/C
Ensure your solar regulator has a dedicated Lithium
charge setting.
A/C Mains Power
NEVER connect your battery directly to A/C Mains power.
Always use a dedicated charger
WARNING Do not use a charge profile with an Equalisation setting. This may damage the battery and
void the warranty.

15. Warranty
OzCharge®Lithium batteries are designed to provide long lasting power in a range of recreational Deep Cycle
applications.
It is important that you read the product user manual in conjunction with the Data Sheet and Material Safety Data
Sheet for your model of battery. These can be found on our website at www.ozcharge.com.au. These documents
contain important care and handling information that may affect your warranty. You will also find tips and advice to
help maximise the life of your battery and information regarding operation, charging, storing, care, maintenance
and recycling.
WARRANTY INFORMATION
This battery is warranted against defects for 5 years (60 months) from date of purchase for recreational cyclic
use. Warranty is void if the battery is used outside of the operating temperature range, in a starting or cranking
application, if installed under the bonnet, in any industrial application, in a float charge application or is reverse
polarity connected. Assessment of the battery is based upon Zylux Energy Pty Ltd warranty testing procedures. If
Zylux Energy Pty Ltd determine this battery is defective we will replace it, however all costs associated with the
delivery of the battery for warranty are at your cost. This includes, both to and from, or for any replacements.
Claims must be made within the warranty period detailed here within. Proof of purchase and the date the battery
was purchased is also required. This Warranty is to the original purchaser and is not transferable. For any
replacement batteries, the Warranty period for a replacement battery starts on the date of the original battery
purchase.
This warranty is offered my Zylux Energy Pty Ltd (ABN 75 104 986 254): 166 Christmas Street, Fairfield, VIC,
3078, Australia.
To make a claim please call [phone] or email [e-mail] in Australia
Warranty does not cover defects due to normal wear and tear, abuse, damage, neglect, reverse polarity
connections, over or under charging, incorrectly charging, charging using a non lithium-ion compatible charger or
incorrect application, installation, storage or maintenance.
The benefits of this warranty are in addition to other rights and remedies available at law. Our goods come with
guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or
refund for a major failure and compensation for any other reasonably foreseeable loss or damage. You are also
entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does
not amount to a major failure.
HELP US HELP THE EARTH AND PLEASE RECYCLE RESPONSIBLY
Do not dispose of your battery with household waste or by incineration.
We advise you complete the following and keep in a safe place for future reference. It’s also a good idea to
attach a photocopy and the original receipt to this manual.
Battery Model: ___________________________ Voltage: _________________Size/AH: _________________
Date of Purchase: ______________________
Sellers Name (i.e. OzCharge®Website or XYZ Batteries): ______________________________________________
Sellers Address: __________________________________________________________________________
Suburb: _________________________________________ State : ______________ Postcode: _________
Sellers Contact Number: ______________________________________________
Did you know that OzCharge®manufactures a range of Lithium compatible battery chargers.
Visit our website today to find out more. https://www.ozcharge.com.au/
ZYLUX ENERGY PTY LTD RESERVES THE RIGHT TO MAKE UPDATES AND CHANGES TO ANY AND
ALL PRODUCT RELATED DOCUMENTATION WITH OR WITH OUT INFORMING DISTRUBUTORS,
RESELERS AND USERS. PLEASE CHECK OUR WEBSITE REGULARLY FOR LITERATURE UPDATES,
DOCUMENT CHANGES AND PROFILE UPDATES