PowerPlus Energy LiFe4838P User manual

LiFe4838P Installation and Operation Manual V2.1 (19/04/2023) Page  of 
LiFe4838P
Installation and
Operation Manual
V2.1

LiFe4838P Installation and Operation Manual V2.1 (19/04/2023) Page  of 

LiFe4838P Installation and Operation Manual V2.1 (19/04/2023) Page  of 
1 Introduction .................................................................................................................................................... 5
2 Glossary .......................................................................................................................................................... 6
3 Safety .............................................................................................................................................................. 7
3.1 Transportation ...................................................................................................................................... 7
3.2 Basic Safety ........................................................................................................................................... 7
3.3 Handling ................................................................................................................................................ 8
3.4 Storage of the Battery ........................................................................................................................... 8
3.5 Life Support ........................................................................................................................................... 8
3.6 Damaged Battery .................................................................................................................................. 8
3.7 Fire ........................................................................................................................................................ 9
3.8 Qualified Person (Installer) ................................................................................................................... 9
3.9 Wet Battery ........................................................................................................................................... 9
4 Product Information ..................................................................................................................................... 10
4.1 Introduction ........................................................................................................................................ 10
4.2 Weight and Dimensions ...................................................................................................................... 10
4.3 Label and Symbols ............................................................................................................................... 11
4.4 Front Panel .......................................................................................................................................... 11
4.5 Specifications ...................................................................................................................................... 12
4.6 DC Circuit Breaker Characteristics....................................................................................................... 13
4.7 Certification / Compliance .................................................................................................................. 13
5 Installation .................................................................................................................................................... 14
5.1 Packing Items ...................................................................................................................................... 14
5.2 Location and Environment .................................................................................................................. 14
5.3 Battery Installation .............................................................................................................................. 15
5.4 Battery Connections ............................................................................................................................ 17
6 Battery Operation ......................................................................................................................................... 19
6.1 Status LED............................................................................................................................................ 19
6.2 DC Circuit Breaker ............................................................................................................................... 20
6.3 Charging and Discharging .................................................................................................................... 20
7 Troubleshooting............................................................................................................................................ 23
7.1 Over-Discharged Battery Recovery ..................................................................................................... 24
8 Maintenance ................................................................................................................................................. 25
9 Upgrading Battery Capacity .......................................................................................................................... 26
10 Capacity Testing the Battery ......................................................................................................................... 27
11 Compatible Inverters .................................................................................................................................... 28
12 End of Life ..................................................................................................................................................... 29

LiFe4838P Installation and Operation Manual V2.1 (19/04/2023) Page  of 

LiFe4838P Installation and Operation Manual V2.1 (19/04/2023) Page  of 
1 Introduction
PowerPlus Energy designs and manufactures Lithium Ferro Phosphate (LiFePO4 or LFP) batteries in Melbourne,
Australia, to operate in some of the world’s harshest operating environments. The LiFe4838P battery is a
simple, safe, flexible, and reliable energy storage component that is designed to be easily integrated with most
inverter and charger combinations.
It can work well as a UPS battery or as a cyclical energy storage reserve for solar, wind and other renewable
energy sources. It is designed to be connected to most DC and AC charging devices and it performs very well,
with virtually no maintenance, in both on-grid and off-grid system designs in single-, dual- and three-phase
BESS (Battery Energy Storage System) applications.
This document outlines the technical capabilities of the PowerPlus Energy LiFe4838P battery and offers
installers useful information and tips to safely integrate this product into BESS systems.
Because this product stores very large amounts of electrical energy and is capable of releasing that energy in a
very short time, it must be treated with care both during installation and operation.
When the LiFe4838P has been installed as intended, it will deliver its intended and rated electrical
performance over its long 10-year warranty life.

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2 Glossary
BESS Battery Energy Storage System
BMS Battery Management System
BS Battery System
LED Light Emitting Diode
LFP Lithium Ferro Phosphate (LiFePO4)
MSDS Material Safety Data Sheet
PCE Power Control (or Conversion) Electronics
PCS Primary Charging Source
RJ45 An 8-way modular connector specification for connectors and cabling
SCS Secondary Charging Source
SDS Safety Data Sheet

LiFe4838P Installation and Operation Manual V2.1 (19/04/2023) Page  of 
3 Safety
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Installers and users are responsible for familiarising themselves with this manual.
The PowerPlus Energy LiFe4838P battery is a member of the LiFe48xxP series of batteries which has a nominal
operating voltage of approximately 48V.
This battery uses high grade cylindrical Lithium Ferro Phosphate (LiFePO4 or LFP) cells which are robust and
reliable when operated in higher ambient temperatures. The battery is designed to have a long service life
when installed and operated within the specifications contained in this document.
The battery contains no heavy metals, and most components are recyclable (by licensed recycling companies).
A pair of high quality, high current Amphenol SurLok Plus DC connections enables users to install the
LiFe4838P safely and rapidly into a variety of energy storage configurations.
To meet stringent international battery safety standards, each battery is fitted with a 2-pole, non-polarised K-
Curve circuit breaker that also doubles as a circuit isolator. There is a blue status indicator light that assists
installers and users with helpful diagnostic information. There is also a volt-free alarm contact that allows the
battery to be monitored by external devices and control systems.
Each LiFe4838P battery is also fitted with an internal Battery Management System (BMS) that provides
protection against over-charging and excessive discharging. The BMS will shut down the battery when it
exceeds its over-current limit or experiences an external short circuit. The battery will also protect itself when
exposed to over-temperature or under-temperature conditions. For a long and reliable service life, the BMS
also carefully manages cell-string balancing during charging.
Installation must be carried out by a suitably qualified and experienced person who can specify the correct
cables, DC bus arrangement and additional external circuit protection. It is crucial that this battery is installed
in accordance with all necessary local and international standards.
3.1 Transportation
Although PowerPlus Energy’s LiFe4838P battery is classed as a Dangerous Goods (DG) Class 9 UN3480 product,
this battery carries a UN38.3 transport safety certificate and is therefore safe for road transport.
The battery is shipped with the terminals capped to prevent electrical short circuit and contact with metallic
objects during transportation. The batteries also leave our warehouses in a partially discharged state to
comply with international transport regulations.
Batteries where possible, should be shipped in the original manufacturer’s packaging, positioned horizontally,
and secured to a pallet. The batteries are not designed to be shipped in a vertical orientation and there should
not be more than 6 batteries in a stack when being transported.
3.2 Basic Safety
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Serious injury or damage to property may result from careless handling of the LiFe4838P battery.
The following precautions should be observed:
 The battery must not be exposed to temperatures above or below the temperature ratings specified
in Table 4-2 (Operating Conditions).

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 The battery must not be installed in direct sunlight.
 The battery must not be exposed to strong impacts and vibrations.
 The battery must not be crushed or punctured.
 The battery’s connectors should not touch conductive surfaces unless intended to do so.
 The battery does not contain maintainable or user-serviceable components and must not be
disassembled or opened for repair.
 The battery must be kept dry at all times and must not be exposed to water or other liquids. Do not
touch the battery if it appears to be damp or wet.
 The battery should be kept away from animals and children.
 The battery must not be stepped on or subjected to any strong force.
 The battery is intended to be lifted by 2 persons during installation and handling.
 The battery should not be disposed of with household waste.
3.3 Handling
 Handle the battery with care when installing or transporting. The battery is heavy and proper lifting
techniques or equipment should be applied.
 Do not use the battery if it appears damaged or broken.
 The surfaces of the battery can be cleaned with a rag instilled with IPA (Isopropyl Alcohol). Do not use
chemicals to clean the battery.
 Do not touch the DC terminals of the battery.
3.4 Storage of the Battery
 The battery must be stored horizontally and there must be no more than 6 batteries stacked on top of
each other without additional mechanical support.
 The battery must be kept in a dry environment away from heat and moisture.
 The battery must be stored away from incompatible substances, like liquid, chemical materials.
 The battery should be stored between 0 to 35°C, however close to 25°C should be considered for long
term storage.
 After 6 months of storage the battery may need cell balancing (See 6.3.2 Battery Cell Balancing for
details).
 Any issues with charging after long term storage should be discussed with PowerPlus Energy.
3.5 Life Support
Our batteries should not be used in critical medical or life support applications where failure of our LiFe4838P
batteries can reasonably be expected to cause failure of the life support equipment or effect operation of such
equipment.
3.6 Damaged Battery
A damaged battery should not be used and should be returned to PowerPlus Energy or disposed of via a
recycling facility. Leaking electrolyte can cause breathing difficulties, skin irritation or chemical burns, so
contact should be avoided. Place the damaged batteries in an area where there is good ventilation, away from
heat sources. Fumes need to be evacuated by fans from enclosed spaces.

LiFe4838P Installation and Operation Manual V2.1 (19/04/2023) Page  of 
In case of:-
Eye Contact: Rinse gently with running water and seek medical attention if irritation develops.
Skin Contact: Rinse gently with running water and seek medical attention if irritation develops.
Ingestion: If ingested, do not induce vomiting. Contact your local poisons information centre or doctor.
Inhalation: Evacuate area and seek professional medical attention immediately.
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3.7 Fire
Should the battery catch on fire or start to emit smoke, (for small fire or small emissions of smoke) use a
standard ABC or dry chemical fire extinguisher.
Evacuate the area and call emergency services.
Some toxic gases may be produced if the battery catches fire.
The battery needs to be rapidly cooled to prevent any heat or fire spreading.
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3.8 Qualified Person (Installer)
This manual and task set within regarding installation should be carried out by a suitable qualified and skilled
person who should:
 Have a thorough understanding of operations, design, and installation principles of battery energy
storage systems.
 Have a thorough understanding of all dangers and risks associated with installing and using electrical
devices.
 Hold all local, state and country base qualifications to carry out such work.
 Adhere to all safety and installations requirements within this manual.
3.9 Wet Battery
Do not attempt to access the battery if it is wet or submerged in water. Seek technical assistance from
PowerPlus Energy or your distributor.

LiFe4838P Installation and Operation Manual V2.1 (19/04/2023) Page  of 
4 Product Information
This section provides relevant and important technical information regarding the LiFe4838P battery's physical
and electrical characteristics.
4.1 Introduction
The PowerPlus Energy LiFe4838P is a 'self-managed' battery in that it doesn’t require communication with
external Power Control Electronics (PCE) to operate. Therefore, the battery can also operate with PCE that
doesn’t require communications to operate.
The battery has an internal Battery Management System (BMS) which is designed to protect it from adverse
and incorrect operating conditions such as:
 Over-charging and excessive discharging.
 Over-temperature and under-temperature.
 Over-current and short-circuit.
4.2 Weight and Dimensions
Weight: 43kg
Dimensions: 635mm D x 434mm W x 88mm H
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