Union Battery Service ZLI012051 User manual
1
02/2022
User manual
Zenith Lithium batteries
These instruction concern the following models:
ZLI012051, ZLI024036
INDEX
Introduction........................................................................................................................................................................................................ 1
Warnings ............................................................................................................................................................................................................. 1
Pre-installation.................................................................................................................................................................................................. 2
Installation / use ............................................................................................................................................................................................... 2
Indicator Instruction ....................................................................................................................................................................................... 3
Standard procedure for the management of the alarm status........................................................................................................ 4
Anomalies............................................................................................................................................................................................................ 4
Stand-by .............................................................................................................................................................................................................. 4
Display .................................................................................................................................................................................................................. 4
INTRODUCTION
Lithium batteries are complex devices consisting of
lithium cells and control electronics called BMS (Battery
Management System).
The lithium cells used in these batteries are LiFePO4
(LFP).
The BMS carries out all and only the control functions to
keep the battery safe.
When the BMS detects internal parameters outside the
allowed limits, it blocks the operation of the battery.
It works again only when the alarm stops.
Attention:
• Keep the battery turned o during transport,
assembly and maintenance service.
• Transportation rules stipulate that the maximum
charge capacity during transportation must not
exceed 50%.
• It is strictily forbidden to connect batteries in series
and in parallel.
WARNINGS
•Before use, please carefully read the handling instructions
and the marks on the battery.Check the load is compatible
with the battery.
•During use, please far away from heat source, electrostatic place,
high voltage and avoid children to use. Don’t beat battery.
•Please use the special charger to charge the battery, and
don’t put the battery in the charger more than 24 hours.
•Do not make the positive (+) and negative (-) terminals short
circuit. Do not immerse in any liquid or damage it.
•Please store the battery well if don’t use in a long time.
Please keep the battery in half charge , that is to say don’t
charge fully and don’t discharge completely. Please avoid
to touch with metal to damage the battery. Please store the
battery in shade, cool and dry place.
•Do not put the battery into a re or water, and please safely
deal with the disuse battery.
•Don’t charge the battery in environments where the
temperature is over 50°C or lower than 5°.
•Don’t reverse the two electrodes when use the battery.
•Don’t penetrate the battery with sharp things.
•Do not disassemble the battery.
•Battery has usage cycle life, if its using time is quite little than
usual, please change your battery.
•Don’t weld the battery directly.
•Don’t use the battery with seriously scratch and distortion.
•Never connect the battery in series.
•Never connect in parallel with other batteries dierent from
the ZLI series battery and always check compatibility (always
contact the manufacturer rst).
•Please stop using if you nd the battery heat, smell odor,
change color, distort or other abnormal states.
•Please far away from the battery if you nd leakage. Touch
the battery only if properly protected.
•Please wash with clean water if the electrolyte leak on your
skin or clothes.
•If the battery leaks, and the electrolyte get into the eyes. Do
not wipe eyes, instead, rinse the eyes with clean water, and
immediately see a doctor.
•Store the battery with a maximum of 50% charge.
•When not in use, leave the battery with a maximum of 50% charge.
•Check the vehicle manual for lithium battery compatibility.
•Check if the absorptions involved are compatible with the
currents allowed by the battery (see data sheet).
•Do not cut the cables.
•ZENITH LITHIUM batteries fall under category UN3480,
lithium ion, 9, (E) and are certied according to the relevant
standards (see CE declaration of conformity). The customer
(user) is aware of the product he is using and is therefore
obliged to carefully read the technical characteristics given
on the data sheets as well as the user manual (instructions).
The customer is also obliged to take ALL the necessary
precautions for correct/compatible installation and use,
and to check that the environments in which they are used
are equipped with all the safety devices required by law, with
particular attention to re prevention solutions.
2
PRE-INSTALLATION
Before proceeding with the battery installation, it
is necessary to check the compatibility between the
battery and the application it will be used.
What to check before installation:
•Read the battery data sheet again.
•Check the maximum absorption of your load and
compare with the electrical characteristics of the battery
(see technical data sheet).
•Verify that the size, weight and length of the battery
cables are compatible with your application.
•Check that the temperatures of the environment in
where the battery will be installed is within the limits
indicated in the technical data sheet.
Dimostrative example of ZLI012051 battery data sheet
Dimostrative example of ZLI012051 battery data sheet
Corrente costante di scarica / Constant discharge current 100A
Corrente impulsiva di scarica / Impulse discharge current Max 200A per 15”
Max 400A per 3”
Corrente max di carica consigliata
Max recommended charging current 50A
Corrente impulsiva di carica / Impulse charge current > 80A per 10''
Tensione di carica consigliata / Recommended charging voltage 13.9V
Tensione di carica massima / Maximum charging voltage 14.6V
Temperatura di scarica massima
Maximum discharge temperature -15°C / +60°C
Temperatura di scarica consigliata
Recommended discharge temperature -10°C / +45°C
Temperatura di carica massima / Maximum charge temperature 0°C / +60°C
Temperatura di carica consigliata
Recommended charge temperature +5°C / +40°C
INSTALLATION / USE
The battery has two cables, one red (positive) and a
black one (negative), with which it will be possible to
load and unload it also.
The battery is supplied without connector, available
only on request.
Use a connector with adequate capacity for the
application.
•During installation, make sure that the battery is o.
•Respect the polarities (red +, black -).
•Use cables with a suitable section for the application,
if necessary, ask the manufacturer.
•The favourite mounting position is the spontaneous
one with handles on top. For any dierent positions
ask for manufacturer's authorization.
•Secure the battery in case of movement or
vibration. Use the appropiate threaded inserts (1)
provided on the container.
During use:
•It is strongly recommended that you turn on the
battery first and then the load.
•Connect/disconnect only when the battery is not
used (no flashing led).
•The battery has an ON/OFF button (2) for
switching the BMS on and off (in OFF there is no
voltage on the poles).
•Five LEDs (3) indicate the level of charge (S.o.C.) and
the battery status.
•One connector (4) to plug: the specic display
to view all the battery parameters (RS485).
2.ON/OFF 4.RS485 6.Display
3.S.o.C. indicators
3
OFF
INDICATOR INSTRUCTION
Four led indicate the level of charge (S.o.C.)
Allarm led
Level of charge
Led ON
Led OFF
Flashing led
Battery ON
Battery on discharge
(example: 75% remaining capacity)
Battery on charge
(last led level of charge ashing)
BMS block the battery
(alarm state) Red led + 1green ashing led
CAUSE OF THE ALLARM STATE
Over discharge
Current pulses beyond the allowed limits
Short circuit
Battery temperature too high
Battery temperature too low
from 100% to 76%
from 75% to 51%
from 50% to 26%
from 25% to 11%
from 10% to 0%
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U.B.S. UNION BATTERY SERVICE s.r.l. unipersonale
Via Alessandro Volta
25015 Desenzano del Garda (Bs) – Italia
Tel +39 030 9904570 - Fax +39 030 9902207
www.unionbatteryservice.it
ANOMALIES
•Over discharge.
Procedure:
Follow the standard procedure
•Current pulses beyond the allowed limits (see technical data sheet).
Procedure:
After 10 times in an hour that the battery goes into allarm due to current pulses, the BMS will go into
permanent block.
To reset it, follow the standard procedure.
•Short circuit.
Procedure:
The red alarm LED will remain active until the BMS is manually reset.
To carry out the manual reset, follow the standard procedure.
•Battery temperature too high (see technical data sheet).
Procedure:
Disconnect the battery from the load and wait for the temperature to drop.
When the red alarm LED go o, check the state of charge of the battery and, if not completely discharged,
reconnect it to the load.
•Battery temperature too low (see technical data sheet).
Procedure:
If the battery temperature is below 0°C it will be possible to discharge the battery (till -15C°) but not
to charge it. Even if the discharge is not allowd: disconnect the battery form the load and wait for the
temperature rising.
When the red alarm LED go o, check the state of charge of the battery and, if not completely discharged,
reconnect it to the load.
STAND-BY DISPLAY
If the battery remains on without being used, it will go
into stand-by mode after 5 hours.
To exit stand-by mode, press the ON/OFF button or press
the red trigger button (located above the output cables)
of the charger.
For any information regarding the DISPLAY, contact the
manufacturer.
STANDARD PROCEDURE FOR THE MANAGEMENT OF THE ALLARM STATUS
When the battery goes into allarm, wait 1 minute for the
red allarm LED turning off automatically.
When switched off, check the state of charge of the
battery and, if not completely discharged, it will be
possibile to use it.
If the automatic shutdown does not occur, disconnect
the battery from the load and connect it to the "ZHF.LH"
series compatible charger.
If the charger does not start automatically, press and hold
the red trigger button (located above the output cables)
until the red LED on the charger lights up constantly.
If even in this case the charger does not start, it
means that the battery has a thermal problem,
so wait for the alarm to automatically switch off.
The wait could be long: minutes or hours.
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1
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