Trojan GC2 48V User manual

Trojan Battery Lithium-Ion FAQ Guide Rev 06/20/2022 1
GENERAL
What is a BMS and its purpose? Lithium-Ion batteries are made up of multiple small cells connected together to
provide the voltage and current needed for the application. The Battery Management
System or "BMS" is responsible for keeping these cells working in unison so that
they are charged and discharged correctly. Lithium-Ion cells are more sensitive to
overcharge and undercharge conditions than many other battery chemistries. The
BMS monitors the charge and discharge of the battery to ensure the battery operates
safely. For the Trojan GC2 48V Lithium-Ion Battery, Trojan developed a BMS that is
able to monitor individual cells, internal battery temperatures, state of charge, state
of health plus charging voltage and current to provide the safest and most reliable
operation possible.
What Lithium chemistry is used? The Trojan GC2 48V Lithium-Ion Battery uses Lithium-Iron-Phosphate cells.
My vehicle came with 8V or 12V
batteries, but the Trojan GC2 48V
Lithium-Ion Battery is 48V, what
is the difference?
Most low-speed electric vehicles operate on 36-48V DC, but traditional lead-acid
batteries are designed and built to be 6, 8, or 12V for portability and to make them
more universal. When they are installed into a 36 or 48V application, these batteries
are connected together in series to increase the available voltage to match the
requirements of the vehicle. The Trojan GC2 48V Lithium-Ion Battery is designed to
work with 48V vehicles without using series connections. This provides increased
reliability over configurations that use series connections because each battery can
power the vehicle independently, where one bad battery in a series connection can
reduce the performance of the entire system.
How do you read the date codes
on the batteries?
There is no date code on the Trojan GC2 48V Lithium-Ion Battery. The manufacturing
date is marked on the sticker with the serial number on the side of the battery.
FREQUENTLY ASKED QUESTIONS

Trojan Battery Lithium-Ion FAQ Guide Rev 06/20/2022 2
GENERAL (CONT.)
How do I select the right number
of batteries for my golf car?
Many factors will go into choosing the correct setup for your unique golf car. Factors
that must be considered are:
• Motor Controller Size
• Drive Motor Size
• Oversized Tires or Aftermarket Gearing
• Accessories Using Battery Power (Lights, Radios, etc)
The Trojan GC2 48V Lithium-Ion Battery configuration should be matched to each
golf car to support the instantaneous load that is dictated by the motor controller
and also the continuous load generated by driving at top speed plus the load of any
accessories that may be running.
Authorized Trojan Lithium-Ion Dealers can assist you in determining the best
configuration for your needs.
PERFORMANCE
How does temperature affect the
performance of my batteries?
Generally, the battery performance is directly related to temperature. Charging
and discharging minimum and maximum temperatures are listed below. There are
additional charging temperature constraints described in the User's Guide.
Is there a maximum temperature
for discharging my batteries?
The Trojan GC2 48V Lithium-Ion Battery will disable both charge and discharge
functions when the internal battery temperature exceeds 140°F (60°C) or falls below
-4°F (-20°C).
If discharge functions are disabled, they will be restored automatically when the
internal battery temperature is between 14°F (-10°C) and 131°F (55°C).
How long will this battery last? The Trojan GC2 48V Lithium-Ion Battery has an expected life of at least eight years or
4,000 cycles to 70% depth of discharge. Expected life is per manufacturer guidelines.
What is the range in miles I can
expect on one or more batteries
connected in my golf car?
For a standard golf car (3.5 HP motor and 250A motor controller), two batteries will
go for 30-45 miles, whereas three batteries are good for up to 60 miles. One battery
(not generally recommended except in lite use cases) will go for less than 30 miles
with one person in the car and no additional load in the car.
Actual driving range will vary depending on factors including, but not limited to, load,
terrain, temperature and equipment.

Trojan Battery Lithium-Ion FAQ Guide Rev 06/20/2022
3
SAFETY
Are there hazardous materials
inside the battery?
The Trojan GC2 48V Lithium-Ion Battery is a sealed battery so there is no risk of
contact with the internal components under normal operation. 80% of the cells are
solid and only 2% of the contents are corrosive. Refer to the SDS for a breakdown of
the components within the battery.
What kind of PPE do I need? Standard Personal Protective Equipment for installing a golf car battery should also
be used when installing the Trojan GC2 48V Lithium-Ion Battery. This includes safety
glasses, safety toe shoes and cut-resistant gloves.
Insulated tools should always be used when working around batteries.
Do I need to protect the
batteries from water?
The Trojan GC2 48V Lithium-Ion Battery is IP67 rated for water and dust resistance, so
the batteries can be exposed to water indirectly without harm. It is not recommended
to directly spray batteries with pressurized water or fully submerse them intentionally.
While the battery is protected against water ingress, it is important to remember that
water with impurities can be conductive and lead to a short circuit if a path is created
between terminals.
INSTALLATION
How many batteries can
I connect in parallel?
Up to 10 Trojan GC2 48V Lithium-Ion Batteries can be used in parallel.
When do I need to use
a spacer battery?
In most applications, you will not need a spacer battery to install Trojan GC2 48V
Lithium-Ion Batteries with the existing hold-down brackets. Spacer batteries are
needed when a battery hold-down cannot be properly secured to the desired number
of battery cases installed. As an example, if three GC2 48V Lithium-Ion Batteries are
being installed for a desired application, but the hold-down bracket requires a fourth
battery for support, then one additional battery case (spacer battery) is needed to
complete the installation.
Is this compatible with
all golf cars?
The Trojan GC2 48V Lithium-Ion Battery is compatible with nearly all 48V golf
cars that use GC2-sized batteries. The exact configuration of the GC2 48V needed
may vary depending on modifications made to the vehicle and the user's intended
application.
Golf cars with on-board computers that control charging or voltage may require
programming or a separate battery charger for optimum performance.

Trojan Battery Lithium-Ion FAQ Guide Rev 06/20/2022 4
INSTALLATION (CONT.)
What's different about
installing Lithium-Ion
batteries versus lead acid?
Installing the Trojan GC2 48V Lithium-Ion Battery is very similar to installing a lead-
acid battery with a GC2 case. The most important difference is that the GC2 48V
should only be connected in parallel with other GC2 48V batteries. They should never
be connected in series and they should not be connected to any other battery type.
When replacing flooded lead acid batteries, ballasts may be needed because of
the difference in weight and center of gravity. See the Trojan GC2 48V Lithium-Ion
Battery User's Guide.
One unique feature of the GC2 48V is the ability to put the battery into Sleep or
Storage mode. This is recommended during installation because it will eliminate
voltage to the terminals, making installation safer.
Can I connect 12V accessories
to a Lithium-Ion battery?
The Trojan GC2 48V Lithium-Ion Battery is a 48V unit, so 12V accessories cannot
be connected directly to it. A Voltage Converter (also known as a Voltage Reducer)
should be used to allow the use of 12V accessories on a 48V system. When these
converters are used, it is recommended that the 48V connections are made from the
first and last battery in the parallel configuration for optimum balance.
MAINTENANCE
Do I need to clean the terminals
and/or does Lithium corrode the
terminals on the batteries?
Lithium-Ion batteries are sealed and do not accelerate corrosion. Some environmental
conditions such as water exposure, saltwater mist or other may still cause corrosion
on copper cable lugs, cables or non-stainless steel hardware. It is recommended to
regularly inspect the terminals on the battery and clean them as needed.
How do I read out the battery
information from the BMS?
Authorized Trojan Lithium-Ion Dealers have Trojan specific cables and software that
allow them to interface with the BMS and read alarm and event history as well as
view details regarding the battery's current condition.
What CAN BUS cables do I need
to connect to the battery?
Connecting to the BMS requires a Trojan Service Cable kit which includes a USB to
CAN adapter, (2) CAN Terminators and an M8 to DB9 adapter.
What is the torque setting
for the terminal?
The terminal should be torqued to between 80 and 90 inch-pounds using a calibrated
torque wrench.
How do I check battery
charge status?
When the button on top of the battery is pressed, a number of Blue LEDs indicate
the state of charge from 0-25% (1 LED), 26-50% (2 LEDs), 51-75% (3 LEDs) and
76-100% (4 LEDs).

Trojan Battery Lithium-Ion FAQ Guide Rev 06/20/2022
5
MAINTENANCE (CONT.)
How do I use the battery
indicators to troubleshoot
the battery?
The battery has six LEDs that help the user determine the battery's condition. When
the button on top of the battery is pressed, a number of Blue LEDs indicate the state
of charge from 0-25% (1 LED) 26-50% (2 LEDs) 51-75% (3 LEDs) and 76-100%
(4 LEDs). In addition, either a red or green LED will also illuminate. A green LED
indicates that the battery is operating normally and no faults are present. A red LED
indicates there is a fault.
If a fault is present, users can gather an indication of the fault by the present state of
the battery. Faults are typically caused by one of four conditions:
High Temperature (While Charging or Driving)
Low Temperature (While Charging or Driving)
High Current (While Driving or Charging)
Low Voltage (While Driving)
Trojan indicates the battery is
maintenance-free. Does that mean
I DO NOT have to check periodically
or what recommended actions
should I take?
Maintenance-free indicates that the battery does not require watering, equalizing or
maintenance charges, or frequent cleaning of the terminals. We still recommend that
you perform a visual inspection of the battery regularly.
Follow storage and maintenance according to the GC2 48V Lithium-Ion User's Guide
and warranty.
What do the LEDs mean? The battery has six LEDs that will help the user determine the battery's condition.
When the button on top of the battery is pressed, a number of Blue LEDs indicate
the state of charge from 0-25% (1 LED), 26-50% (2 LEDs), 51-75% (3 LEDs) and
76-100% (4 LEDs). In addition, either a red or green LED will also illuminate. A green
LED indicates that the battery is operating normally and no faults are present. A red
LED indicates there is a fault.
What is a short circuit fault/
condition? Does the recovery
DIFFER from other faults?
A short circuit fault occurs when the battery is powered on and a direct conductive
path is created between the positive and negative terminals. This fault can also be
activated if more than 600A are passed through the battery from an external source.
When the short circuit fault is active, it will not automatically reset. The user must
verify that the cause of the fault has been corrected and then perform the same
procedure used to bring the battery out of storage mode to clear the short circuit
fault.

Trojan Battery Lithium-Ion FAQ Guide Rev 06/20/2022 6
CHARGING
Is there a maximum temperature
for charging my batteries?
Trojan GC2 48V Lithium-Ion Battery will temporarily disable charging function at
temperatures above 113°F (45°C) or below 32°F (0°C). At temperatures below 68°F
(20°C), charging current is automatically limited. Refer to the user guide for charging
current limits.
If charging functions are disabled due to temperature, they will be restored
automatically when temperature is within range.”
STORAGE & SHIPPING
What are the special packaging
requirements?
The Trojan GC2 48V Lithium-Ion Battery arrives in approved packaging that can be
saved for future use.
To ship the GC2 48V, the battery must be packaged in a UN Rated and marked 4G
Fiberboard Box with Y25 Weight. It must be secured and prevented from moving
freely within the box using anti-static bubble wrap or foam.
The box must be labeled as DOT Class 9 with Lithium Ion Batteries, UN3480
displayed on the outside of the box. For air transport, a Cargo Aircraft Only label
must be present.
Download Lithium-Ion Repacking Instructions here or enter:
www.trojanbattery.com/wp-content/uploads/2022/04/TRO1090_
Repacking_LI_Sheet_NoBleed_020722SM.pdf
Can I ship a battery fully charged? The Trojan GC2 48V Lithium-Ion Battery is classified as UN3480 and as such must
be at or below 50% state of charge when shipped via land or sea and below 30%
state of charge when shipped via air.
Can I ship lead acid with
Lithium-Ion?
Yes, as long as both battery types are properly packaged and labeled, they can be
shipped on the same vehicle.
Wherever possible, putting Lithium-Ion and lead-acid batteries on the same pallet
should be avoided. If it cannot be avoided, the pallet must be clearly labeled as
containing both.
Lithium-Ion batteries must be individually packed and labeled on the pallet as well.
Are there any restrictions
to shipping Lithium-Ion?
A battery subject to UN3480 like the Trojan GC2 48V Lithium-Ion Battery cannot be
transported on a passenger aircraft. As long as it is correctly prepared, packaged and
labeled, no other restrictions apply. Refer to the GC2 48V Lithium-Ion Battery User's
Guide or Packaging Requirements section of this FAQ for details on preparation and
packing.

Trojan Battery Lithium-Ion FAQ Guide Rev 06/20/2022
7
STORAGE & SHIPPING (CONT.)
Do Lithium-Ion batteries
require special storage?
Storage requirements for the Trojan GC2 48V Lithium-Ion Battery are the same as
other battery types. They should be stored in a clean, cool and dry environment and
protected from direct sunlight.
For batteries being stored in a warehouse, it is recommended that they be left in the
original packaging for protection and so they can be shipped easily.
The Trojan GC2 48V Lithium-Ion Battery can be stored alongside lead-acid batteries.
However, it is recommended that they be clearly labeled as Lithium-Ion to prevent
mis-identification.
Follow storage and maintenance according to the GC2 48V Lithium-Ion User's Guide
and warranty."
How long can I store the battery? The Trojan GC2 48V Lithium-Ion Battery is designed to be stored for up to six months
when placed into storage mode at a state of charge above 25%.
Temperatures exceeding 77ºF (25ºC) or below 32ºF (0ºC) can reduce the available
storage time.
I hear that lithium batteries self-
discharge. Is there a concern
when storing the batteries in
my golf car for long period of time?
A BMS integrated into a battery pack does draw a small amount of current from the
batteries to continue running. The Trojan GC2 48V Lithium-Ion Battery features a
sleep/storage mode which reduces this draw by 5x.
This allows the GC2 48V to be stored for up to six months as long as it is placed into
storage mode with more than 25% state of charge.
If the battery is not put into storage mode, it will automatically enter storage mode
after 30 days of inactivity.
How do I turn off the battery? Press and hold the button on the top of the battery. If it is already in storage mode,
the LEDs will illuminate one at a time until they are all illuminated. Continue to hold
the button for 2 more seconds and then release. Wait 10 seconds and confirm the
battery has powered on by pressing the button for one second to show a Red or
Green LED indicating the battery status and a combination blue LEDs indicating the
state of charge.
If the battery is powered on, the LEDs will all illuminate and then turn off one by one.
Continue to hold the button for an additional two seconds and then release. Wait 10
seconds and press the power button briefly, only a blue LED will flash to indicate that
the battery is in storage mode. "

Trojan Battery Lithium-Ion FAQ Guide Rev 06/20/2022 8
©2022 Trojan Battery Company, LLC. All rights reserved. Trojan Battery Company is not liable for damages that may result from any
information provided in or omitted from this publication, under any circumstances.Trojan Battery Company reserves the right to make
adjustments to this publication at any time, without notice or obligation. PN 10000782
Do not mix with lead-acid batteries when recycling.
ACCESSORIES
Does Trojan provide an
external Battery Charge
Indicator or commonly
knows as a “Fuel Gauge”?
Yes, Trojan offers an external Battery Charge Indicator separately from the battery
to provide end users with the remaining State of Charge % of the batteries in the
vehicle. When the display reaches 20%, it will show a low battery notification to let
the user know that the battery is approaching its total usable capacity and should
be recharged soon. The display will also show if any faults or alarms are present on
the batteries.
Authorized Trojan Lithium-Ion Dealers can perform the installation of the external
gauge and all necessary cable connections.
PURCHASING
Where can I purchase the battery? You can find your local Authorized Trojan Lithium-Ion Dealer here or at:
www.trojanbattery.com/Lithium-Ion-battery-dealer-locator/