Waterworld 48-6800 User manual

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Version 2.0 - English Lithium Iron Phosphate batter
48-6800
48-6800

2
Water World Electronics
Weerdijk 14 – 8375 AX Oldemarkt
[email protected]
Phone number: 0561 451 636
www.waterworldelectronics.com
Weerdijk 14 – 8375 AX Oldemarkt
www.waterworldelectronics.com

3
Congratulations and thank you for purchasing the Waterworld
48-6800 Lithium Iron Phosphate battery. At Waterworld it is our
goal to give our customers the best performing, most reliable and
safest battery system possible. To achieve this we need your help
during installation and operation. Please read these instructions
carefully to maintain our high standards during installation and
operation of the battery.
Also, reading the manual will teach you how you can get the
best out of your system and increase its longevity!
If you have any questions or remarks regarding this manual or the
battery itself please feel free to contact us at:
[e-mail]
or visit www.waterworldelectronics.com/downloads
We hope you enjoy your battery!
*Technical changes and errors in the manual are reserved. Always use the
latest version of the manual available at waterworldelectronics.com
3
If you have any questions or remarks regarding this manual or the
battery itself please feel free to contact us at:
www.waterworldelectronics.com/downloads
www.waterworldelectronics.com/downloads
We hope you enjoy your battery!
*Technical changes and errors in the manual are reserved. Always use the
latest version of the manual available at waterworldelectronics.com
Congratulations and thank you for purchasing the Waterworld
48-6800 Lithium Iron Phosphate battery. At Waterworld it is our
goal to give our customers the best performing, most reliable and
safest battery system possible. To achieve this we need your help
during installation and operation. Please read these instructions
carefully to maintain our high standards during installation and
operation of the battery.
Also, reading the manual will teach you how you can get the
best out of your system and increase its longevity!
If you have any questions or remarks regarding this manual or the
battery itself please feel free to contact us at:
[email protected]
or visit
www.waterworldelectronics.com/downloads
www.waterworldelectronics.com/downloads
We hope you enjoy your battery!
*Technical changes and errors in the manual are reserved. Always use the
latest version of the manual available at waterworldelectronics.com

Contents
1. Introduction 5
1.1 General information on the instructions 5
1.2 Safety information 5
2. Product delivery details 6
2.1 Overview of components 6
2.2 Overview and controls of WW 48-6800 6
Please charge the battery! 7
3. Technical specications of 48-6800 8
4. Safety 10
4.1 General safety instructions 10
4.2 Safety introduction 10
4.3 Intended use 10
4.4 Unintended use 10
4.5 Before use 10
5. Installation of the battery 13
5.1 Connecting multiple batteries in parallel 13
5.2 Installation 15
5.3 Wiring 15
5.4 Ventilation 16
5.5 Checking your system 16
5.6 Switching the battery on and off 16
5.7 Connecting the WaterWorld Battery Link 16
5.8 Functions of the WaterWorld Battery Link 17
6. Protection mode 18
7. Charging the battery 19
7.1 Connecting the charger to the battery 19
7.2 Charging the battery 21
7.3 LED status indicator 21
7.4 Error identication 21
8. Storage and maintenance 22
4
8.1 Storage 22
8.2 Maintenance 22
9. Error problem solving 22
10. Transportation guidlines 23
11. End of life and disposal 23
12. Tips to increase battery lifetime 23

5
1. Introduction
1.1 General information on the instructions
The instructions in this document describe all functions and pro-
vides safety information on the WW 48-6800 Lithium Iron Phos-
phate Battery.
It is our goal to make the use of our batteries as easy as possible
by providing all the information needed to understand, install
and operate the battery. This instruction manual ensures you are
able to operate the battery safely in compliance with its intended
use. If by any chance you feel information is not clear or are not
certain how to install or operate the battery, please contact our
customer service for your safety and the safety of the battery.
Always use the most recent version of these instructions which
can be downloaded on our website:
www.waterworldelectronics.com/downloads
By reading and following these instructions you will:
• Avoid dangers to yourself and your surroundings.
• Reduce outage times and repairs.
• Increase the lifetime of your battery and the reliability of your
system.
1.2 Safety information
In this instruction manual safety information will be presented us-
ing symbols and hazard classes. The hazard classes are subdivid-
ed in categories based on severity of the consequences and the
likelihood of occurrence. The hazard classes are depicted below:
Hazard classes
Danger!
Direct hazard with high risk.
Death or severe physical injuries may result if the risk is not
avoided.
Warning!
Potential danger
Severe physical injuries may result if theinstructions are not
followed properly.
Caution!
Danger with low risk
Physical injuries may result when the instructions are not fol-
lowed
Advice
Mandatroy instructions
Use these instructions for safety and correct installation of your
battery.

6
2. Product delivery details
2.1 Overview of components
WW 48-6800 Lithium Iron Phosphate battery
The following components are included in the product package:
• 1x 48 Volt battery
• 1x User manual
• 1x Positive terminal connector*
• 1x Negative terminal connector*
• 1x M12 Data cable (male to female)*
Optional: Battery Link (only in combination with a WaterWorld
drivetrain)
The following are included in the Battery link package:
• 1x Battery Link module
• 1x RJ45 waterproof data cable
2.2 Overview and controls of WW 48-6800
1. Negative terminal
2. Communication port
3. Power on/off
4. Expansion valve
5. Positive terminal
6. Speci cations
7. T-slots
*available separate at your WaterWorld dealer
1. Negative terminal
2. Communication port
3. Power on/off
4. Expansion valve
5. Positive terminal
6. Specifications
7. T-slots
M12 Data Cable
Positive terminal connector
Negative terminal connector
Negative terminal connector
Positive terminal connector

7
Negative terminal
The black negative terminal (-) needs to be connected to the
negative (-) terminal of your system. To do this use the black neg-
ative terminal connector provided to you seperately. IMPORTANT!
the battery terminal is only waterproof when covered by the plas-
tic cover that comes with delivery or when the terminal connec-
tor is plugged in. An open terminal is NOT waterproof.
Communication port
The communication socket is only used in combination with a
WaterWorld drivetrain. To enable the communiaction port a Wa-
terWorld communication gateway (batterylink) is needed. This is
further explained in chapter 5.5 of this user manual.
Power on/off
Use the power button to remove voltage over the battery termi-
nals. When the switch is pressed in the battery is turned on and
it will have 51.2V (nominal) over its terminals. When the switch
is pressed again and the button is level with the enclosure the
battery is turned off and will not have voltage over the output
terminals. When the battery is turned off the battery can still be
charged.
Expansion valve
The expansion valve regulates air pressure between the inside of
the battery and its outside environment. The valve is waterproof
as long as it is not damaged. Make sure that during installation
the expansion valve is safe from damage. And is free from obas-
tacles.
Positive terminal
The red postitive terminal connector (+) needs to be connected
to the positive (+) terminal of your system. To do this use the red
positive terminal connector provided to you seperately. IMPORT-
ANT! the terminal is only waterproof when covered by the plastic
cover that comes with delivery or when the terminal connector is
plugged in. An open terminal is NOT waterproof.
Speci cations
The most important speci cations to consider are engraved on
the enclosure. Make sure these are not damaged and can be
read by the user.
T-Slots
The type 30 T-Slots in the alumuninium battery enclosure enable
attaching accessories to the enclosure. Rubber supports are
pre-installed on the bottom T-slots. (standard m6  ench nuts  t in
the type-30 slots)
Serial number
The serial number can be found on the front of the battery. An
example of the serial number is: WWNL-24014868001
Please charge the battery!
Due to safety regulations the battery is charged between 15%-
30% upon delivery. You are required to charge the battery to
at least 50% SoC within 3 months of the battery delivery date
mentioned on the packaging otherwise permanent damage to
the battery may result.

8
3. Technical specications of 48-6800
General Features
Capacity 6800 Wh
Nominal Voltage 51.2 V
Final discharging voltage 43.2 V
Maximum discharge rate 150 A
Maximum discharge rate at
nominal voltage
7680 W
Weight 61 kg
Dimensions (LxBxH) 683 mm x 255 mm x 215 mm
Volume 36 L
Battery Chemistry Lithium iron phosphate (LFP)
LiFePO4
Battery management and safety
On-off switch Yes
Cell balancing Yes
High current and short-circuit protection Yes, up to 1500A
Deep discharge protection Yes, cut off at 43.2 V
individual cell string voltage monitoring Yes
Safety vent for each cell Yes
Cell temperature monitoring and pro-
tection
Yes
Temperature monitoring of battery
electronics
Yes
Low temperature shut off Yes
High temperature shut off Yes
Lifetime data
Average annual capacity loss Approximately 2% at 25°C
ambient temperature
Ideal storage temperature 15°C - 25°C

9
Battery composition
Capacity per cell 6 Ah+
Nominal voltage per cell 3.2 V
Cell connection 16S22P
Use information
Ambient temperature, dis-
charging
-15°C up to +45°C
Ambient temperature,
charging
+2°C up to +40°C
Ambient temperature, storage -25°C up to +55°C
Typical storage time at 50%
SOC
40 weeks without any load
(turned off)
Max connections Up to 1 Series 8 Parallel
Max quick charge 80 A
Protection class IP67

10
4. Safety
4.1 General safety instructions
Advice!
Read the instructions in this user manual carefully before oper-
ating the battery system. Always comply with safety warnings
stated in this user manual. Always stay alert while working with
and installing of the battery and other electric components
4.2 Safety introduction
The battery and its components are designed with safety and
user friendliness as a top priority and have been extensively test-
ed. However, dangerous situations may occur when the battery
is not handled properly or misused. This can result in physical harm
to persons or property. Always follow the guidelines stated in this
user manual as well as local safety and accident prevention
regulations.
4.3 Intended use
The WaterWorld 48-6800 lithium battery can be used as a stand-
alone battery or in combination with a WaterWorld electric drive.
The data cable only works in combination with the WaterWorld
Battery Link. The maximum power of the battery is 7680 Watt. The
battery will turn off automatically when greater power is drawn
from the battery to prevent damage to the battery*. Despite this
safety mechanism, it is important to avoid this situation. The sys-
tem in which the battery is installed must always meet the speci -
cations of the battery. If more power is required, the batteries can
be connected in parallel up to 8P.
4.4 Unintended use
The manufacturer accepts no liability when the battery is used
as anything that is not speci cally de ned as its “intended use”
as de ned in this user manual. All other use cases that are not
described in this manual are de ned as “unintended use”. The
operator of the battery is solely responsible for any harm or dan-
ger arising from such unintended use.
Amongst others, the following are deemed unintended use:
• Permanent contact with water
• Use of third party battery chargers (Victron excluded)
• Use of cable sets that do not have a master switch or suf -
cient fuses
4.5 Before use
Before use check the condition and functioning of the battery.
The battery may only be handled and operated by adults.
*in combination with the BatteryLink, the power will be reduced instead of the battery shutting down.

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Danger!
Fire Hazard! Danger to life
Always use appropriate conductive electric cable with the right
cross-section when connecting loads. If you are not sure what
cross section is needed please contact your dealer or another
professional.
Danger!
Fire Hazard! Danger to life
never use  ammable gases, solvent or vapours on the system.
Danger!
Risk of death or severe physical injuries from electromagnetic
radiation
Persons with a cardiac pacemaker must maintain a 50 cm
distance from any WaterWorld battery or charger.
4.6 General safety information
Please read the following carefully
Danger!
Risk of fatal electric shock!
Contact with uninsulated or damaged parts may lead to elec-
tric shock resulting in death or severe physical injuries.
• Never do any repair work to any part of the system your-
self. This leads to dangerous circumstances and voids the
warranty.
• Never touch any uninsulated or broken wiring or any other
damaged/defective parts.
• When you suspect a problem never touch any metal com-
ponents and switch off the main system switch and after
switch off the battery immediately.
• Prevent any electrical components from coming into con-
tact with water.
• Always have the battery switched off during installation or
during any form of handling the battery.
Danger!
Fire Hazard! Danger to life
Never charge the battery when it is damaged.

12
Caution!
Damage to the battery from heat
• Make sure the battery is never near external heat sources.
• Never store  ammable objects near the battery.
• Store the battery in a well ventilated area.
• Never place the battery in direct sunlight. Especially during
summer or high ambient temperatures.
Advice!
Increase the lifetime of your battery by reducing its exposure to
extreme temperatures, moisture and direct sunlight.
Warning!
Danger injury by electric shock as result of short circuit
• Remove all metal jewelry before handling or installing the
battery or any other electrical equipment.
• Never leave tools in contact with the battery but store
them away at a safe distance.
• Always be aware of the polarity of the battery terminals.
Make sure you connect the battery at the correct polarity.
• Make sure the battery terminals are clean and free of
corrosion.
Caution!
Never open the battery
Opening the battery will void warranty and will lead to perma-
nent damage to the battery. Maintenance and repairs may
only be done by a certi ed WaterWorld professional.
Caution!
Fluids or gases leaking from a damaged battery can cause
injuries and other harm
• Avoid contact with any  uids spilling from the battery.
• Avoid contact with skin and eyes.
• Never inhale gases from the battery.
• Contact your dealer or a professional in case of leakage
from the battery.

13
5. Installation of the battery
Important!Please charge your batteries before use.
Danger!
Danger to life from electric shock
• Avoid touching the battery terminals.
• Never undertake repair work on the battery yourself.
• Never touch any defective components
• Prevent any external forces from working on the battery
and the cables.
• If you detect any defect, shut down your system and the
battery immediately
Caution!
Damage to the battery and your system can result from incor-
rect installation. Please read the instructions carefully.
• Always make sure to turn the battery off during installation
using the main switch.
• Make sure to always  rst connect the red positive cable to
the red positive terminal then connect the black negative
cable to the black negative terminal.
• When disconnecting the battery make sure to  rst discon-
nect the black negative terminal before disconnecting the
red positive terminal.
• Never transpose the polarities!
5.1 Connecting multiple batteries in parallel
Danger!
Never connect the batteries in series! Fire and damage to the
battery and your system may result.
• Make sure to never connect multiple batteries in series.
• Never series connect the battery with any other third party
batteries.
Advice!
• Up to 8 batteries can be connected in parallel.
• For systems containing a WaterWorld drive train or con-
troller a gateway is required to be able to use the data
communication functions.
Important!it is very important the batteries are all at
the same voltage before connecting them in par-
allel. Please check the voltage difference between
the batteries is below 1.0 Volts. If not please charge
or discharge the batteries to equal voltage.
Important!Check your system for short circuit by
measuring the resistance of the system before con-
necting your batteries.

14
Connecting multiple batteries in parallel can be done in the
following way:
Using a positive and a negative busbar to connect the batteries
makes it easier to handle the currents. IMPORTANT: make sure
each battery has equal cable length between the busbar and
the battery for both the negative and the positive sides.
300 A to motor
Increment parallel connections
- Busbar
+ Busbar
-
300 A to motor
max 150 A
(35mm2)
max 150 A
(35mm2)

15
5.2 Installation
Caution!
Damage to the battery and your system can result from incor-
rect installation. Please read the instructions carefully.
• Install the battery in a dry location that cannot be  ooded.
• Do not install the battery near any heat emitting compo-
nents.
• Choose a well ventilated location for installation of the
battery.
• Make sure to always tightly fasten the battery to a base to
avoid any damage to the battery and its surroundings from
vibrations or shaking of the battery.
Installation using the T-slots of the battery enclosure
1. Place the battery in your chosen location and make sure the
location complies with the requirements mentioned above.
2. Use the T-slot to secure the battery to a solid base with bolts
of your choosing. It is also possible to strap the battery into
place using lashing straps.
3. Check if the battery is fastened securely.
Advice!
• Make sure the battery terminals and data port are easily
accessible and are not in contact or close near any other
objects that can damage the components.
• Make sure the vent plug on the battery is not obstructed
from functioning properly.
5.3 Wiring
Warning!
Danger injury by electric shock as result of short circuit
• Remove all metal jewelry before handling or installing the
battery or any other electrical equipment.
• Never leave tools in contact with the battery but store
them away at a safe distance.
• Always be aware of the polarity of the battery terminals.
Make sure you connect the battery at the correct polarity.
• Make sure the battery terminals are clean and free of
corrosion.
Always use cables with approriate thickness to handle the cur-
rents associated with your system. Table 5.3.1 provides guidelines
for choosing cable thicknesses at different electrical currents and
different cable lengths.
Important: add a 200 A fuse in line with each battery .
Table 5.3.1
Cable thickness guideline
length 1m length 3m length 10m
100 A 35 mm2 35 mm2 50 mm2
150 A 35 mm2 35 mm2 50 mm2
200 A 50 mm2 50 mm2 70 mm2
300 A 70 mm2 95 mm2
400 A 95 mm2 120 mm2
If you are not sure, please contact your WaterWorld dealer.

16
5.4 Ventilation
Caution!
Make sure the vent plug is free of obstacles and can operate
without obstruction
To prevent the battery from overheating please make sure the
battery is in a ventilated space. Positioning your battery in a well
ventilated and cool space will increase battery health and prod-
uct lifetime. The heat  ns on the enclosure function as a heat sink.
Allowing air ow over the enclosure will cool down the battery and
increase performance and product lifetime.
5.5 Checking your system
Before turning on your batteries please check your system for any
mistakes. Check your system for short circuit using your multimeter.
Make sure your system does not draw any small residual currents
<1A or <50W per battery. Loads under 50 Watt will not be detect-
ed by the BMS and can over longer periods of time affect the
State of Charge (SoC) presentation. By charging the battery to
100% the SoC presentation is recalibraterd. If there are any small
loads in your system make sure to charge your batteries to 100%
more frequently.
5.6 Switching the battery on and off
To turn on the battery push the switch(es) on the battery(s) using
the on/off switch on the front of the battery. The system needs
some time to start up. Note: the battery is turned on when the
switch is clicked inwards. The battery is turned off when the switch
is level with the surface.
5.7 Connecting the WaterWorld Battery Link
When combining Waterworld 48-6800 batteries with a WaterWorld
electric drive, a system can be created in which the battery and
motor communicate with each other. To enable this communica-
tion a communication gateway is added between the Water-
World system and the Waterworld battery. Figure 5.5.1 shows how
the system is connected. Always connect the  rst battery in the
most left communication port 1. When adding batteries use the
 rst port available to the right e.g. port 2, port 3, and port 4.
On the side of the Battery Link 2 CAN ports are located. Connect
the CAN communication cable to the gateway and to the other
side to any CAN port on the WaterWorld system.
 gure 5.5.1

17
The Battery Link feautures a LED light for every communication
port. This LED signals the status of the communication.
• Green: the battery has succesfully connected to the Water-
World system.
• Green blinking: the system is trying to connect. Please wait a
moment.
• Orange: The battery discharge is turned off. There is no volt-
age over the battery terminals.
• Red: there is no connection detected between the battery
and the Battery Link. Please reset the system by turning of all
batteries and turning them back on after 30 seconds. If there
is still no connection please contact our customer support.
• LED off: there is no data cable connected. Please make sure
you properly connected the cable to the data socket on the
battery.
5.8 Functions of the WaterWorld Battery Link
The Battery Link integrates your batteries with the other compo-
nents of your WaterWorld drive. This results in an extremely reliable
system. In addition, the functions of the BatteryLink ensure that
your batteries are managed even better, so that they will last
longer. The functions of the Battery Link are described below.
Accurate battery State of Charge (SoC)
Thanks to the built-in smart shunt of the battery management sys-
tem in the battery, the current battery percentage of the battery
is always accurately communicated to the WaterWorld display.
The self-learning algorithm in the battery management system
corrects for degradation of your battery over time, so that the
battery percentage and sailing time remain accurate over the
entire life of your system.
High temperature power protection
When the battery gets too hot (60C+) it will switch off. To prevent
this, the Battery Link will reduce the power of the motor before this
temperature is reached. When this happens you will receive a no-
ti cation in the WaterWorld display. Limiting the power gives the
battery(s) the opportunity to cool down and ensures a reliable
system that does not stop you unexpectedly.
Low temperature power protection
At low temperatures (below freezing) the Battery Link protects
the battery. The power of the motor is reduced untill the battery is
warmed up after which the maximum power can be deliverd. This
will extend the battery lifetime.
Battery shut-off protection
In the case of a multi-battery system, it can happen unexpect-
edly that a battery fails due to low battery voltage, too high
temperature or some other problem. This can result in a chain
reaction where other batteries have to deliver too much power
beyond the limit as described in the speci cations. This results in
shutting down all battery(s) and thus shutting down the system.
To prevent this, in this event the Battery Link will limit the power so
that the remaining battery(s) always continue to work within their
speci cations. This ensures that your system does not shut down
and you can continue sailing. You will receive a message in the
WaterWorld display with the error message.
Getting home safely
When the battery(s) are almost empty, it is important not to use
too much power from the engine as this can result in the batteries
dropping below cut off voltage. This is the case with all types of
batteries. To minimize this effect, with a low “state of charge” of
the batteries, the maximum power of the motor is reduced some-
what and you will receive an error message. This ensures that you
can always come home safely and that you do not come to a
standstill unexpectedly.

18
Error messages
When the Battery Link limits the system, you will always be pro-
vided with a message in the display. This means you are always
aware of what is happening in the system.
6. Protection mode
The battery will go in protection mode when the battery is
operating outside its specication limits. There are two types of
protection. The rst protection switches off the battery, when the
conditions of the battery are back within its specication limits
the battery turns back on and is functioning again. The second
protection kicks in when the battery is used way beyond its
intended use. This protection is irreversible and a dealer needs to
be contacted for service.

19
7. Charging the battery
Danger!
Fire hazard!
• Never charge a damaged battery.
• Do not use the charger near  ammable or explosive mate-
rials and provide ventilation.
• The output voltage of the battery charger must be the
same as the speci ed charging voltage of the battery.
• Position the charger so that the fan can rotate properly
and blow air freely through the heat  ns.
• Place the charger in a dry location where it will not be in
permanent contact with water.
• Do not open the charger to avoid electric shock
For optimal battery life, we recommend using a WaterWorld lithi-
um iron phosphate battery charger to charge the 48-6800 battery.
When using a third-party battery charger, it should always be a
CC/CV lithium charger with the correct charging voltage.
Warning!
• Always use Waterworld approved LFP battery chargers.
• Make sure the charger is connected with the correct polar-
ity.
• Make sure the battery terminals are clean and free of
corrosion.
• The battery charger needs to be compatible with the bat-
tery and output 56.8 Volt.
7.1 Connecting the charger to the battery
Always be aware of the polarity of the battery. Make sure the
positive terminal of the battery is connected to the positive ter-
minal of the charger and the negative terminal of the battery is
connected to the negative terminal of the charger.
Never exceed the maximum charging current as stated in the
battery speci cations. Charge overcurrent will cause the battery
to go into protection mode and charging will stop. When multiple
batteries are connected in parallel the maxmimum allowed
charging current is the sum of the individual max charging cur-
rents of the batteries. In this case multiple chargers can be con-
nected to the batteries in parallel to achieve higher charge rates.

20
Increment parallel connections
35 A to battery
AC 230 V
AC 230 V
35 A to battery
- Busbar
+ Busbar