Victron energy Lynx Ion User manual

Manual
EN
Lynx Ion
24V/180Ah Lithium Ion Batteries

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Copyrights 2012 Victron Energy B.V.
All Rights Reserved
This publication or parts thereof, may not be reproduced in any form, by any method, for
any purpose.
For conditions of use and permission to use this manual for publication in other than the
English language, contact Victron Energy B.V.
VICTRON ENERGY B.V. MAKES NO WARRANTY, EITHER EXPESSED OR IMPLIED,
INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, REGARDING
THESE VICTRON ENERGY PRODUCTS AND MAKES SUCH VICTRON ENERGY
PRODUCTS AVAILABLE SOLELY ON AN “AS IS” BASIS.
IN NO EVENT SHALL VICTRON ENERGY B.V. BE LIABLE TO ANYONE FOR SPECIAL,
COLLATERAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES IN CONNECTION WITH
OR ARISING OUT OF PURCHASE OR USE OF THESE VICTRON ENERGY PRODUCTS.
THE SOLE AND EXCLUSIVE LIABILITY TO VICTRON ENERGY B.V., REGARDLESS OF
THE FORM OF ACTION, SHALL NOT EXCEED THE PURCHASE PRICE OF THE
VICTRON ENERGY PRODUCTS DESCRIBED HERE IN.
Victron Energy B.V. reserves the right to revise and improve its products as it sees fit. This
publication describes the state of this product at the time of its publication and may not
reflect the product at all times in the future.

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1 SAFETY INSTRUCTIONS
1.1 In general
Please read the documentation supplied with this product first, so that you are familiar with
the safety signs en directions before using the product.
This product is designed and tested in accordance with international standards. The
equipment should be used for the designated application only.
WARNING: DANGER OF ELECTRICAL SHOCK
The product is used in combination with a permanent energy source (battery).
Even if the equipment is switched off.
The product contains no internal user-serviceable parts. Do not remove the front panel and
do not put the product into operation unless all panels are fitted. All maintenance should be
performed by qualified personnel.
Never use the product at sites where gas or dust explosions could occur. Refer to the
specifications provided by the manufacturer of the battery to ensure that the battery is
suitable for use with this product. The battery manufacturer's safety instructions should
always be observed.
WARNING: do not lift heavy objects unassisted.
1.2 Installation
Read the installation instructions before commencing installation activities.
Ensure that the connection cables are provided with fuses and circuit breakers. Never
replace a protective device by a component of a different type. Refer to the manual for the
correct part.
Check before switching the device on whether the available voltage source conforms to the
configuration settings of the product as described in the manual.
Ensure that the equipment is used under the correct operating conditions. Never operate it
in a wet or dusty environment.
Ensure that there is always sufficient free space around the product for ventilation, and that
ventilation openings are not blocked.
Install the product in a heatproof environment. Ensure therefore that there are no chemicals,
plastic parts, curtains or other textiles, etc.in the immediate vicinity of the equipment.

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1.3 Transport and storage
On storage or transport of the product, ensure that the battery leads are disconnected.
No liability can be accepted for damage in transit if the equipment is not transported in its
original packaging.
Store the product in a dry environment; the storage temperature should range from –20°C to
60°C.
1.3.1 Storage instructions of Lithium batteries
Store the Lithium batteries always fully charged.
Check the voltage of the stored Lithium battery periodically. If the voltage is dropped below
24V, recharge it. Because of the battery management electronics there is always a leakage
current which will eventually empty the battery. The weekly consumption of the BMS inside
a 24V/180Ah battery, when not connected to the Lynx Ion, is approximately 2Wh per week.
1.3.2 Storage instructions of a complete system (Lithium batteries with Lynx)
Lithium batteries will permanently damage when fully drained. The system has a small self-
discharge which needs to be taken into account when storing the system. It is best to
always store the batteries fully charged.
• Standby consumption 24V Systems: 77mW for the Lynx Ion (standby) and 28mW
per installed battery.
• Standby consumption 48V systems: 187mW for the Lynx Ion (standby) and
160mW per installed battery.
Two calculation examples:
• A full single 24Volt battery connected to a Lynx Ion which is in standby will last
approximately 1800 days. The same system, but then automatically switched to
standby mode due to under voltage will last approximately 90 days.
• A full 48Volt system with two batteries in series, connected to a Lynx Ion which is
in standby will last approximately 725 days. The same system which has
automatically disconnected and switched to standby mode due to under voltage
will last approximately 37 days.
Note:
From Lynx Ion firmware v1.17 and onwards there has been a significant improvement. The
standby consumption of a Lynx Ion with firmware version v1.16 or lower is approximately
0,8W @ 26,2V and 1,5W @ 52,4V, instead of 77mW and 187mW. The Lynx Ion firmware
version is displayed at the Diagnostics page on the Ion Control display. It is also printed on
a label, which can be found on the back of the Lynx Ion. To update the firmware, contact
your Victron Energy representative.

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2 DESCRIPTION
2.1 System components
•One or more 24V 180Ah Lithium-Ion batteries.
•The Lynx Power In. A modular dc busbar.
•The Lynx Ion is the battery management system (BMS) that controls the
batteries. A 350 Ampère safety relay is inside the Lynx Ion.
•The Lynx Shunt VE.Can, a battery monitor including the main fuse. Note that the
fuse needs to be purchased separately.
•The Lynx Distributor, a DC distribution system with fuses.
•Optionally, the Ion Control, a digital control panel.
2.1.1 Battery Management System
Every individual 24V/180Ah Lithium-Ion battery has an onboard Battery Management
System, which monitors and protects the battery on cell level. The Lynx Ion communicates
with all battery packs via the BMS CAN-Bus and monitors the system as a whole.
2.1.2 Safety
When designing the Victron Lithium-Ion battery system, a lot of thought was put into the
safety aspect of the system. Each battery is equipped with a BMS to monitor the
performance on a cell level. To monitor the global performance we have chosen the Lynx
Ion. This serves as a master unit and controls the individual batteries. This way the system
as a whole can function at its best, ensuring a maximum return. The battery differentiates
itself from other batteries thanks to its safety contactor. This breaks the connection between
the battery and the rest of the system when the Lynx Ion is unable to disconnect the
external equipment due to complications.
2.1.3 User interface: Ion Control
The Ion Control is a digital control panel for the system.

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3 LED INDICATIONS
3.1 Lynx Ion LED indications
LED
state
Description
Blinking fast Initialization / Waiting for start. Press the start button to start
the BMS.
On Running
Blinking Balancing active
Flashing 1 time Standby mode
Flashing 2 times Voltage error
Flashing 3 times Temperature error
Flashing 4 times Initialization / Connection error
3.2 Battery LED indications
Battery
status LED
State
Description
On BMS Running
Toggle slow Balancing / BMS stopped
Toggle fast BMS Error
Battery BMSCAN
-
Bus error
LED
State
Description
Off No error in CAN-Bus
Single flash CAN-Bus passive error
On CAN-Bus bus-off
Battery
BMS
CAN
-
Bus status
LED
State
Description
On CAN-Bus operational
Toggle slow CAN-Bus pre-operational
Single flash CAN-Bus stopped

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4 INSTALLATION
This product may only be installed by a qualified electrical engineer.
4.1 Safety precautions
4.2 Location
The product must be installed in a dry and well-ventilated area, as close as possible to the
batteries.
Excessively high ambient temperature will result in a reduced battery lifetime.
The interior of the Lynx components must remain easily accessible after
installation.
Try and keep the distance between the Lynx components and the battery to a minimum in
order to minimize cable voltage losses.
For safety purposes, this product should be installed in a heat-
resistantenvironment. You should prevent the presence of e.g. chemicals,
syntheticcomponents, curtains or other textiles, etc., in the immediate vicinity.
4.3 Mounting
The Lynx system must be mounted on a wall. Every Lynx is provided with holes for
mounting. See Appendix B.
1. Be careful when using metal tools in vicinity of batteries. Dropping a metal tool
onto a battery might cause a short-circuit and possibly an explosion.
2. Always use isolated tool when working with batteries.
3. Remove personal metal items such as rings, bracelets, necklaces, and
watches when working with a battery. A battery can produce a short-circuit
current high
enough to melt such items, leading to severe burns.

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4.4 Connecting the Lynx components
The Lynx system must be connected in the following order from left
to right:
1. Lynx Power In (optional)
2. Lynx Ion
3. Lynx Shunt VE.Can
4. Lynx Distributor (optional)
Procedure
1. First remove all fronts from the Lynx components.
2. Connect each Lynx to each other from left to right.
3. Mount the Lynx system to the wall.
4. Connect your cha
rgers and energy consumers at the Lynx Distributor.
5. Install the Victron Lithium-Ion batteries.
For installation of the Victron Lithium
battery we refer to the Lithium-Ion manual.
Make sure that the connections
between the Lynx units are connec
This prevents series resistance at the connections.
Do not use washers between the connections.
to right:
rgers and energy consumers at the Lynx Distributor.
For installation of the Victron Lithium
-Ion
between the Lynx units are connec
tedtightly.

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4.5 Connection of the BMS CAN-Bus network
To connect the BMS CAN-Bus communication network you will need:
• CAT5 cable with RJ45 connectors
• Two termination resistors (supplied with the Lynx Ion)
Procedure
1. Use connection A of the Lynx Ion, top left pair of RJ45 connectors. Connect the
other end of the CAT5 cable to the first battery.
2. Then connect it to the second battery (if there is one) with the next CAT5 cable.
3. Repeat this until all batteries are connected.
4. Place a termination resistor in the last connected battery.
5. Place the other termination resistor in the Lynx Ion, connection A.
Now the BMS CAN-Bus network is connected.
4.6 Connection of the VE.Can network
The Lynx Ion is communicating with the Lynx Shunt through VE.Can. This is mandatory.
The VE.Can network is also used to connect the Ion Control.
To connect the Lynx Ion to the Lynx Shunt VE.Can you will need:
• One CAT5 cable with RJ45 connectors
• Two termination resistors (supplied with the Lynx Shunt VE.Can)
Procedure
1. Use connection D of the Lynx Ion, the pair of RJ-45 sockets at lower left. Connect
the CAT5 cable to the Lynx Ion, connection D (see Appendix A).
2. Connect the other end of the CAT5 cable to the Lynx Shunt VE.Can.
3. Now place the termination resistors. One in the Lynx Ion and one in the Lynx
Shunt.
Now the Lynx Ion and the Lynx Shunt are connected.

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4.7 Connection of the Victron Lithium-Ion batteries
Never short a Lithium-Ion battery. There will flow a very high current and can
lead to damage of the battery and its environment.
Always use isolated tools when installing batteries.
To connect the Victron Lithium-Ion batteries make sure you have followed all the steps
above.
Connection of the Lithium-Ion batteries must be done by the following procedure.
Procedure
1. Connect the ‘-’ connection to cable to the Lynx Power In.
2. Now connect the other end to the first battery.
3. Connect the ‘+’ contact of the battery to the Lynx Power In. Be aware of the little
sparking when connecting the cable to the Lynx Power In. (If two batteries are
placed in series, connect the ‘+’ contact to the ‘-’ of the next battery).
4. The Lynx Ion will now start and is placed in standby state.
Make sure a main switch is connected between the ‘+’ of the battery and the
Lynx Power In.
If parallel connections of batteries are made
• Be sure that the battery state-of-charge is equal for each battery.
• Keep wire lengths exactly the same. Otherwise imbalance occurs.

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4.8 Using the I/O of the Lynx Ion
The Lynx Ion has several I/O‘s. The most important are the ‘allow-to-charge’ and ‘allow-to-
discharge’ contacts. These are used to control loads and chargers based on the battery
state of charge. See appendix A, connection ‘C’ for the connections.
These contacts are potential free, and normally open. They are closed when the system is
normally working. If the battery is fully charged the ‘allow-to-charge’ contact will be opened.
Now the charger knows that it has to stop charging. If it does not stop charging, the safety
contactor will eventually open. This also applies for the ‘allow-to-discharge’ contact. It is set
open when the battery is fully discharged. All consumers have to stop discharging.
The Lynx Ion has also an ‘external contactor output’ and a ‘bilge pump output’. See
appendix A connection ‘B’. The ‘external safety contactor’ output can be used for switching
an external safety contactor. This contact can switch 10ADC and the output voltage is the
same as the supply voltage of the Lynx Ion. It switches the same way as the internal safety
contactor.
The ‘Bilge pump output’ can also switch 10ADC and also outputs the supply voltage of the
Lynx Ion. This contact is always on. It only switches off if the Lynx Ion detects an under
voltage alarm.
Switching limits
Contact
Closed
/ On
Open
/ Off
Allow-to-charge signal When the highest battery
cell voltage drops below
3,32V for 10 sec.
When one battery cell
voltage reaches 3,52V for
10 sec.
Allow-to-discharge signal When the lowest battery cell
voltage rises above 3,35V
for 10 sec.
When one battery cell
voltage drops below 2,8V
for 10 sec.
Internal Safety contactor When all cell voltages are
between 2,60V and 3,62V.
When one of the cell
voltages is above 3,62V or
below 2,60V for 20 sec.
External Safety contactor Same as internal safety contactor
Bilge pump After a system reset. When one cell voltage
drops below 2,4V.

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4.9 Using the Lynx Ion with currents above 350A
The internal safety contactor
in the Lynx Ion is specified for 350A maximum continuous
current. Up to 600A is possible, by using an external safety contactor
, that bypasses the
internal safety relay. The 600A continuous current
limit is the limit of the Lynx Shunt.
There are two options to install an external safety contactor:
•
Use an external contactor with a 12VDC coil and connect it inside the Lynx Ion
•
Use an external contactor with a coil voltage equal to the battery system voltage
(24/48VDC) and use the external contact (
connector ‘B’ pin 3 and 4)
Gigavac contactors are recommended because of their low coil power use.
Gigavac contactors do not need an extinguishing diode.
For use with other contactors like
Allbright always use an extinguishing diode.
Contactors which are tested:Gigavac GX16, GX46, GX56, GX66 series.
Contactor Type
12VDC
(Recommended)
24VDC
Gigavac GX16 600A* GX16BEB GX16CEB
Gigavac GX46 600A GX46BDB GX46CDB
Gigavac GX56 600A GX56BDB GX56CDB
Gigavac GX66 600A GX66BDB GX66CDB
*With the GX16 series the coil contact must be connected with a Deutsch connector
(Gigavac ordernumber.: 0697).
Below an overview of
how to connect the external contactor to the busbar.
The control wires of the internal contactor must
always
from the Lynx Ion if using an external contactor.
Therefore the wires in the
right blue connector must be removed. After that isolate the end of the wires
so they cannot damage the Lynx Ion. It is not necessar
y to remove the
internal safety contactor itself.
in the Lynx Ion is specified for 350A maximum continuous
, that bypasses the
limit is the limit of the Lynx Shunt.
Use an external contactor with a 12VDC coil and connect it inside the Lynx Ion
Use an external contactor with a coil voltage equal to the battery system voltage
connector ‘B’ pin 3 and 4)
Gigavac contactors are recommended because of their low coil power use.
Also the
For use with other contactors like
48VDC
GX16FEB
GX46FDB
GX56FDB
GX66FDB
*With the GX16 series the coil contact must be connected with a Deutsch connector
how to connect the external contactor to the busbar.
always
be disconnected
Therefore the wires in the
right blue connector must be removed. After that isolate the end of the wires
y to remove the

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To connect the coil of the external connector it is important to check which coil voltage it has.
Coil voltage
Remarks
12VDC Connect to the right blue connector inside the Lynx Ion. Same as
where the internal contactor was connected. check ‘+’ and ‘-‘.
24VDC Can only be used when connecting to a 24V system. Must be
connected to the external contactor connection. (connector ‘B’
pin 3 and 4).
48VDC Can only be used when connecting to a 48V system. Must be
connected to the external contactor connection. (connector ‘B’
pin 3 and 4).
Check appendix A for the references of the connections.
Remove wires

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Example schematic of connecting the contactor to connector ‘B’.
If connecting an external contactor to connector ‘B’ always check if the coil
voltage of the contactor is equal to the busbar voltage. Also check if
extinguishing diode is needed.
If connecting an external contactor to connector ‘B’ always check if the coil
voltage of the contactor is equal to the busbar voltage. Also check if
an

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5 CONFIGURING A MULTI OR QUATTRO
The Multi is controlled by the Lynx Ion, via the allow-to-charge and allow-to-discharge
contacts.
State of Charge
A B C D E
0% 100%
A The batteries are discharged too low. The 350A safety contactor in the Lynx
Ion will open.
B
The batteries are discharged. The allow-to-discharge signal contact will open.
The Multi will switch to ‘Charger Only’, to prevent further discharging the
batteries.
C OK. The Multi can both charge and discharge the batteries. The allow-to-
charge and the allow-to-discharge contacts are closed.
D The batteries are full. The allow-to-charge contact will open. The Multi will
switch to float, to prevent further charging the batteries.
E The batteries are almost over charged. The 350A safety contactor in the Lynx
Ion will open.
Condition A and E are error conditions. Proper configuration of the system will prevent these
conditions from occurring. When they occur, correct the situation, and press the start button
again to restart the Lynx Ion.
Connections
To configure the Multi for BMS support, VEConfigure3 is necessary. See the Support &
downloads section at www.victronenergy.com for more information on installing
VEConfigure3 and updating the Multi to firmware version xxxx200 or higher.
1. Connect the allow-to-charge signal to the AUX input on the Multi
2. Connect the allow-to-discharge signal to Temp sense input on the Multi. It is not
necessary to use a temperature sensor with the Multi, since the batteries have
their own internal temperature sensors.

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3. Start VEConfigure3, and configure the Li-ion BMS Support assistant as follows:

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6 FIRST POWER UP
Other than below procedure, no configuration is needed. The battery configuration is
automatically recognized. And the Lynx Shunt parameters will be configured by the Lynx Ion
on power up.
Power up procedure
1. Make sure that all energy consumers are switched off before starting up the
system.
2. The Lynx Ion will pre-charge the system before closing the 350A safety contactor.
The Lynx Ion will not start if there is more than 10A drawn by the system during
pre-charging.
3. Press the START-button on the front of the Lynx Ion.
4. Now the system is being pre-charged. The 350A safety contactor is closed as
soon as the voltage rises above 80% of the battery voltage.
5. If the status LED is continuously on, then the system is running and ready for use.
Power down/reset procedure
1. Press the START-button on the front of the Lynx Ion for 10 sec.
2. The Lynx Ion will reset and the status LED is blinking fast.
3. Now the 350A safety contactor is open and the batteries are disconnected from
the system.

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7 TEMPERATURE PROTECTION
The Lynx Ion constantly monitors the battery temperatures, and protects them according
below rules. In case the temperature is outside the limits, it will first signal the chargers
and/or loads via the allow-to-charge and allow-to-discharge contacts. It will open the safety
contactor if there is no response. In that case you will see the LED blinking in the specified
error code (three flashes, see chapter 3 for details). Press the START-button to restart the
system.
High temperature signals:
•Stop charging and discharging at +60°C (allow-to-charge and allow-to-discharge
contacts open)
•Charge and discharge alarm at +65°C (safety contactor open)
Low temperature signals:
•Stop charging at -5°C (allow-to-charge contact open)
•Stop discharging at -20°C (allow-to-discharge contact open)
Alarm temperatures:
•Charging alarm at -10°C and current > 10A (safety contactor open)
•Discharging alarm at -25°C and current < -10A (safety contactor open)
Please note that these rules have been implemented per firmware version v1.15,
release on 22nd of January 2013.Versions before that had more stringent set of rules,
with a smaller temperature operating range.

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8 MAINTENANCE
The Lynx Ion does not require specific maintenance. It will suffice to check all connections
once a year. Avoid moisture and oil/soot/vapors, and keep the device clean.