ReliOn LiFePO4 Series User manual

INSTALLATION & OPERATION
MANUAL

relionbattery.com +1.803.547.7288
844.385.9840
9868 Harrisburg Road
Fort Mill, SC 29707, US
© 2018 Relion Battery, LLC. All rights reserved. Relion Battery is not liable for damages that may result from any information provided in or omitted from this publication, under any circumstances. Relion Battery reserves the right to make adjustments to this publication at any time, without notice or obligation.
Installation & Operation Manual 06.13.18
This manual only applies to Relion Lithium Batteries. It does not apply to other lithium batteries or chemistries.
I. Safety
Lithium Iron Phosphate (LiFePO4) batteries are an inherently safe chemistry. Please reference RELiON’s Lithium Iron Phosphate
Safety Document (available on our website at relionbattery.com) for more details. However, as with any electronics, safety
measures should always be taken. Please adhere to the instructions within this manual for safe handling and operation.
• Always wear protective gear when handling batteries
• Use a wrench with a rubber coated handle
• Do not place any objects on top of batteries
• Do not place batteries on a metallic surface
• Check that all cables are in good condition
• Make sure all cable connections are properly tightened
• Install and remove batteries using the lifting handles provided
• Do not smoke near batteries
• Keep sparks, flames and metal objects away from batteries
• Have RELiON’s LiFePO4SDS on the premises
• Have a Class D fire extinguisher on the premises
2. Equipment
The following equipment may be required to install your battery.
• Protective Gear; gloves and eye protection
• Wrench with insulated/rubber coated handle
• Voltmeter
3. LiFePO4Battery Basics (vs. Lead-Acid)
3.1. Basic Construction
RELiON LiFePO4battery packs include two main components:
1. Individual cells assembled inside a plastic or steel case
2. An internal or external BMS (Battery Management System) to protect the battery from abusive operation
3.2. Cell and Battery Pack Voltages
Lithium Iron Phosphate (LiFePO4)
Nominal Voltage
Lead-Acid Equivalent
Nominal Voltage
Cell = 3.2V Cell = 2.0V
12.8V – 4 cells in series 12V
25.6V – 8 cells in series 24V
38.4V – 12 cells in series 36V
51.2V – 16 cells in series 48V
THANK YOU FOR CHOOSING RELiON BATTERY POWER!
We hope you enjoy your high-quality lithium iron phosphate battery.
#challengeyourlimits

relionbattery.com +1.803.547.7288
844.385.9840
9868 Harrisburg Road
Fort Mill, SC 29707, US
© 2018 Relion Battery, LLC. All rights reserved. Relion Battery is not liable for damages that may result from any information provided in or omitted from this publication, under any circumstances. Relion Battery reserves the right to make adjustments to this publication at any time, without notice or obligation.
Installation & Operation Manual 06.13.18
Wire Gauge (AWG) – Copper Conductors Ampacity (Amps)
14 25
12 30
10 40
855
675
495
2130
1150
1/0 170
2/0 195
4/0 260
4. Battery Installation
4.1. Battery Connections
To maximize the performance and to ensure safe operation of your battery, use the appropriate
cable size and tighten connections using the proper torque value. Refer to the data sheet for
your particular battery's torque value. It is recommended to use a washer. Place the washer
between the cable lug and nut, not between the cable lug and battery terminal surface.
4.2. Cable Size
Choose the appropriate cable size based on the expected load of your system. See the table below – ENEC 310.15 (B)(16) –
Allowable Ampacities of Insulated Conductors Rated 0-2000 Volts based on ambient temperature of 30°C (86°F).
4.3. Torque Values
Terminal connections should adhere to the appropriate torque values for the specified terminal type to provide optimum
electrical conductivity. Refer to the data sheet for your particular battery's torque value. Over- or under- tightening the
connections can result in terminal breakage, over-heating and/or terminal melting. Use a rubber handled or insulated
wrench when making terminal connections to avoid an external short circuit.
4.4. Terminal Protection
Battery terminals may be covered with a plastic cap to prevent an
external short circuit. Terminals must be covered with a protective cap
or non-conductive tape prior to battery disposal to a lithium recycler.
4.5. Battery Orientation
Lithium batteries can be placed upright or on their sides.

relionbattery.com +1.803.547.7288
844.385.9840
9868 Harrisburg Road
Fort Mill, SC 29707, US
© 2018 Relion Battery, LLC. All rights reserved. Relion Battery is not liable for damages that may result from any information provided in or omitted from this publication, under any circumstances. Relion Battery reserves the right to make adjustments to this publication at any time, without notice or obligation.
Installation & Operation Manual 06.13.18
4.6. Series or Parallel Connections
When connecting batteries in series or parallel, please make sure each battery is within 50mV (0.05V) of each other
before putting them in service. This will minimize the chance of imbalance between batteries. If your batteries get out
of balance, the voltage of any battery is >50mV (0.05V) from another battery in the set, you should charge each battery
individually to rebalance. Please reference RELiON’s LiFePO4Charging Instructions document (available on our website at
relionbattery.com) for series and parallel charging.
5. Battery Storage
5.1. Storage Temperature
LiFePO4batteries can be stored between -20°C to 60°C (-4°F to 140°F).
5.2. Storage Conditions
Store batteries at 50% SOC to minimize irreversible capacity loss.
If batteries are stored for long periods of time, cycle the batteries at least every 6 months.
6. Battery Discharging
6.1. Discharge Temperature
Lithium Iron Phosphate batteries generate a fraction of the heat of other lithium chemistries making them very safe.
LiFePO4batteries can safely operate between -20°C to 60°C (-4°F to 140°F). All RELiON LiFePO4come with a BMS that
protects the battery from over-temperature. If the BMS disconnects due to high temperature, wait until the temperature
reduces and the BMS reconnects the battery circuit before using or charging the battery. Please refer to your battery
data sheet for BMS high temperature cut-o value.
6.2. Discharging your LiFePO4Battery
LiFePO4batteries can be discharged up to 100% of their capacity. However, to optimize the performance of your LiFePO4
battery, and to avoid the BMS disconnecting the battery circuit, we recommend limiting the discharge to 80%. Please
refer to your battery data sheet for the continuous and peak rates of discharge for your specific battery model.
7. Battery Charging
7.1. When to Charge your LiFePO4Battery
If LiFePO4batteries are not fully discharged, they do not need to be charged after each use. LiFePO4batteries do not get
damaged when left in a partial state of charge (PSOC). You can charge your LiFePO4batteries after each use or when they
have been discharged up to 80% (20% SOC). If the BMS disconnects the battery due to low voltage, at 100% depth
of discharge, remove the load to reconnect the battery circuit and charge immediately. Please note that we recommend
storing batteries at 50% state of charge (SOC) to minimize irreversible capacity loss.

relionbattery.com +1.803.547.7288
844.385.9840
9868 Harrisburg Road
Fort Mill, SC 29707, US
© 2018 Relion Battery, LLC. All rights reserved. Relion Battery is not liable for damages that may result from any information provided in or omitted from this publication, under any circumstances. Relion Battery reserves the right to make adjustments to this publication at any time, without notice or obligation.
Installation & Operation Manual 06.13.18
7.2. Charging Temperature
Lithium Iron Phosphate batteries generate a fraction of the heat of other lithium chemistries making them very safe.
LiFePO4batteries can safely charge between -20°C to 55°C (-4°F to 131°F). However, at temperatures below 0°C (32°F)
the charge current must be reduced as follows:
1. 0°C to -10°C (32°F to 14°F) charge at 0.1C (10% of the battery capacity)
2. -10°C to -20°C (14°F to -4°F) charge at 0.05C (5% of the battery capacity)
LiFePO4batteries do not require temperature compensation for voltage when charging at hot or cold temperatures. All
RELiON LiFePO4come with a BMS that protects the battery from over-temperature. If the BMS disconnects due to high
temperature, wait until the temperature reduces and the BMS reconnects the battery circuit before using or charging the
battery. Please refer to your battery data sheet for BMS high temperature cut-o value.
7.3. Charging with Lead-Acid Chargers
Most lead-acid battery chargers can be used with LiFePO4batteries as long as they are within the appropriate voltage
guidelines. AGM and Gel algorithms typically fall within the LiFePO4voltage requirements. The voltage for flooded battery
charging algorithms are often higher than LiFePO4requirements which will result in the BMS disconnecting the battery
at the end of the charge cycle and may result in the charger displaying an error code. If this happens, it is generally a
good practice to replace your charger. Since the BMS protects the battery, using lead-acid chargers will not damage the
battery. Please refer to RELiON’s Lithium Charging Instruction document (available on our website at relionbattery.com)
for complete charging instructions and parameters.
8. BMS Operation
All RELiON LiFePO4batteries come with in internal or external BMS. The BMS protects against:
1. Under-Voltage – during discharge
2. Over-Voltage – during charge or regen conditions
3. Over-Current – during discharge and charge
4. Over-Temperature – during discharge or charge
5. Short-Circuit Protection – protects battery cells from damage
Refer to the data sheet for your battery's specific discharge criteria. If the BMS disconnects the battery due to voltage or current
limits, you must remove the load to reconnect the battery. If the BMS disconnects the battery due to temperature limits, you
must wait for the temperature to reduce to reconnect the battery. If your equipment has parasitic loads, it may require a physical
disconnect of the terminals to reconnect the battery circuit. Please note, that while short-circuit protection protects the battery's
cells, it still may produce a spark and damage your cable or bolt, so it is best to avoid short circuit conditions.
9. Battery Recycling
Terminals must be covered with a protective cap or non-conductive tape prior to battery disposal to lithium recycler.
Dispose of LiFePO4batteries at an authorize lithium recycling facility.
10. Technical Support
If you have technical questions about the Product, please contact the place of purchase or RELiON Battery directly at
803-547-7288 or our toll-free number 844-385-9840.