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Installation Guide for BATTLE BORN models including: BBGC3, BBGC3H, BBGC3H LiFePO4 Heated Battery Kit, BBGC3H, LiFePO4 Heated Battery Kit, Heated Battery Kit, Battery Kit
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File Info : application/pdf, 11 Pages, 1.59MB
DocumentDocumentPlease read this manual prior to installaon and use. Thank you for invesng in a Batle Born Bateries system and welcome to the Batle Born Bateries family. This manual provides important informaon on how to install, operate, and care for your Batle Born Bateries. If you have purchased with us before, you will find this manual useful as a reference tool. If this is your first purchase with Batle Born Bateries, this manual can serve as an educaonal tool on how to properly use and care for your investment. If you have a heat-enabled model, please refer to the addional Heat-Enable Instrucon manual prior to use and installaon. Table of Contents What is in the Box? ............................................................................................................................................................... 3 What Do I Need for Installation? .......................................................................................................................................... 3 Connecting Load Specified Cables to the Batteries .............................................................................................................. 3 Safety .................................................................................................................................................................................... 4 How to Properly Charge the Batteries ................................................................................................................................. 4 Connecting the Batteries in Parallel ..................................................................................................................................... 5 Connecting the Batteries in Series. ...................................................................................................................................... 6 How does the BMS Protect the Batteries............................................................................................................................. 7 Voltage vs. Capacity.............................................................................................................................................................. 8 How to Properly Size Cables for System Install .................................................................................................................... 8 How to Incorporate Fuses Into System Install...................................................................................................................... 9 How to Properly Store Batteries ........................................................................................................................................... 9 How to Maintain the Batteries ............................................................................................................................................. 9 How to Properly Recycle and Dispose of the Batteries........................................................................................................ 9 Limited Warranty.................................................................................................................................................................. 9 Return Policy ...................................................................................................................................................................... 11 Refund Policy ...................................................................................................................................................................... 11 Shipping .............................................................................................................................................................................. 11 Lithium-ion vs. Lead Acid.................................................................................................................................................... 11 Recommended Accessories................................................................................................................................................ 12 QR Codes will appear throughout the manual linking to FAQ videos that may be useful. To use the QR code, open a QR reader or the camera on your smartphone. Hold your device over the QR code so that the code is clearly visible within the device's screen. Your phone will automacally scan the code and pull in the corresponding weblink. Cauon: Risk of Fire and Burns. Do Not Open, Crush, Heat Above 150ºF or incinerate. Follow Manufacturer's Instrucons Atenon, Risque d'incendie et de brulures. Veuillez ne pas ouvrir, percer, ou exposez à une chaleur égal ou supérieur à 66º C. Neas metre dans le feu. Veuillez suivre les instrucons du fabric Batle Born Bateries BBGC3 Manual | BBGC3H Manual | Edion.PIM_BBGC3Rev020_04242024 2 What is in the Box? Included with your purchase: · (1) GC3 Batery o Dimensions (L x W x H): 22.83" x 7.09" x 13.15" o Weight: 80.8 Ibs. o Batery Charge Temperature Range: 25°F (-3°C) to 135°F (57.2°C) o Batery Discharge Temperature Range: -4°F (-20°C) to 140°F (60°C) o Water Resistant and Sealed (Bateries should not be submerged) o Built-in BMS (Batery Management System) o Made with Cylindrical Cells o Mounng feet come standard, can be removed with a #3 Allen wrench o Terminal covers come standard, can be removed with a Phillips head screwdriver GC3 Assembly Drawing GC3 Direct Mount o Standard flag style terminal posts with a 3/8" hole to accommodate either a 3/8" or a 5/16" bolt · (1) Finishing Hardware Kit o (2) `18-8 Stainless Steel' 5/16-18 x 1" Bolts o (2) `18-8 Stainless Steel' 5/16-18 x 1 1/4" Bolts o (4) Washers GC3 Metal Bracket Mounting o (2) Nylok Nuts What Do I Need for Installaon? If you already have your system set up and are ready to drop in your bateries, you will need a torque wrench that is able to fit to and properly torque your 5/16" finishing hardware. This is REQUIRED to make sure that you torque to the specificaon of 9 to 11 -lbs., otherwise you may cause system failures and damage. Mounng Opons The BBGC3 has the ability to mount directly to a surface using the feet and #8 screws. See the "GC3 Direct Mount" QR code above. For more mounng opons, you will need to purchase the GC3 Mounng Bracket kit at batlebornbateries.com/shop/. See the "GC3 Metal Bracket Mounng" QR code above. Connecng Load Specified Cables to the Bateries 1. Idenfy the posive and negave terminals. These are labeled and color-coded red for posive (+), black for negave (). 2. Determine which finishing hardware set you will use. Verify that your bolt can fully seat into the nylok insert of the nut. If mulple lugs are used, longer bolts may be required for the bolt to fully seat into the nylok insert of the nut. 3. Connect your cable lugs to your batery terminal with the previously idenfied finishing hardware set. Make sure to connect your posive load specified cable lug to the posive terminal and the negave load specified cable lug to the negave terminal. The proper order to connect to your terminal with a finishing kit is shown in Fig. 1. Figure 1: Proper order of hardware to connect cables. When going from left to right in the diagram the correct order is: bolt, washer, lug, terminal, washer, and nut. If multiple lugs are used, they should be on the same side of the terminal. 4. When connecng to your batery terminals, DO NOT finger ghten. Use a torque wrench to torque your hardware to the specificaon of 9 to 11 -lbs. Failure to adequately secure connecons can result in severe damage and will void your warranty. Fig. 2 below demonstrates proper and improper connecons. Batle Born Bateries BBGC3 Manual | BBGC3H Manual | Edion.PIM_BBGC3Rev020_04242024 3 Figure 2: Proper and Improper Terminal Connections Safety While LiFePO4 bateries are inherently safe, as with all bateries, energy storage devices, and electrical equipment, safety and electrical hazards do exist. Failure to follow these safety instrucons may result in electrical shock, injury, or death, or may damage the batery or other equipment or property. Installaon · The batery should be installed as per naonal and local codes. · The batery should only be installed in locaons approved by local building codes. · Always store in a Type 3R enclosure when used in outdoor environments. · Electrical and shock hazards can be minimized by covering the solar array and using insulated tools. · Do not short the batery terminals. · Do not install the batery if there are any signs of physical damage. · Do not install the batery in a locaon that may be flooded. · All heated bateries are not Class 1, Division 2 listed. Operaon · Use only approved batery chargers for charging the batery. · Do not disassemble the batery. Emergency · Disconnect the batery from the system. · Wear a respirator, eye protecon, and rubber gloves where appropriate. · Use an ABC type dry chemical fire exnguisher. · Dispose of as per local regulaons. How to Properly Charge the Bateries To properly charge your Batle Born bateries, you will want to verify that any charging component in your system is capable of being programmed for the following specificaons. Charging components can include, but are not limited to converters, inverter chargers, solar charge controllers, DC to DC chargers, etc. · Bulk/Absorpon: 14.2V 14.6V · Absorpon Time: 60-90 minutes per batery (for parallel string) · Float: 13.4V 13.8V · Equalizaon: 14.4V/ Disabled · Temperature Compensaon: 0/Disabled · Charge Rate: .5c · Batery Charge Temperature Range: 25°F (-3°C) to 135°F (57.2°C) · Batery Discharge Temperature Range: -4°F (-20°C) to 140°F (60°C) · Cell Charge Temperature: 32°F (0°C) to 131°F (55°C) · Cell Discharge Temperature: -4°F (-20°C) to 140°F (60°C) NOTE: Not all chargers are capable of multistage charging. If yours is not, you will want to verify it can be programmed for the Bulk/Absorption voltage and have the other items mentioned disabled if applicable. Consult your charger's manual or the manufacturer. Batle Born Bateries BBGC3 Manual | BBGC3H Manual | Edion.PIM_BBGC3Rev020_04242024 4 Connecng the Bateries in Parallel Why Connect in Parallel? Mulple BBGC3 bateries may be connected in parallel to increase the capacity and current of the system. When bateries are connected in parallel, the voltage of the system does not change, but the capacity and current limits are addive. For example, two BBGC3 bateries connected in parallel (shown in Fig. 3) create a 12V 540Ah bank that can deliver 600A connuously and 1,000A for 30 seconds. How to Make a Parallel Connecon NOTE: All cables and connections MUST be able to accommodate the high currents that can be delivered by the battery. Appropriate fuses and circuit breakers are highly recommended to protect downstream components from current spikes and short circuits. 1. Idenfy the posive and negave terminals. These are labeled and color-coded red for posive (+), black for negave (). 2. Determine the appropriate finishing hardware set you will use. Verify that your bolt can fully seat into the nylok insert of the nut. If mulple lugs are used, longer bolts may be required for the bolt to fully seat into the nylok insert of the nut. 3. Make the proper cable connecons to the posive terminal of the first batery. Please reference Fig. 1 for the proper order of hardware. 4. When connecng to your batery terminals, DO NOT finger ghten. Use a torque wrench to torque your hardware to the specificaon of 9 to 11 -lbs. Failure to adequately secure connecons can result in severe damage and will void your warranty. 5. Connect the other end of your posive cable to the posive terminal of the other batery you are connecng to. Repeat step 4. 6. Repeat steps 3-5 for the negave connecons. 7. Repeat steps 3-6 for addional bateries in the system. An example of a finished connecon can be found below in Fig. 3.1 and Fig. 3.2 Figure 3.1: Two GC3 Batteries connected in Parallel to create a 12V 540Ah Battery Bank Figure 3.2: Four GC3 Batteries connected in Parallel to create a 12V 1,080Ah Battery Bank Batle Born Bateries BBGC3 Manual | BBGC3H Manual | Edion.PIM_BBGC3Rev020_04242024 5 Connecng the Bateries in Series Why Connect in Series? When bateries are connected in series, current capacies remain the same, but the system voltage is addive. For example, two BBGC3 bateries connected in series form a 24V 270Ah bank (shown in Fig. 4) and should be charged using a bulk and absorpon voltage of 28.8V, and a float voltage of 27.2V. How to Make a Series Connecon Note: Battle Born GC3 batteries are capable of being connected in series up to 48V. DO NOT exceed a 48V setup or you will void the battery's warranty. 1. Before making any connecons, make sure to charge each batery up to 14.6V with a proper lithium charger. ALL BATTERIES SHOULD BE AT THE SAME STATE OF CHARGE PRIOR TO CONNECTING, otherwise you will encounter balance issues within your system. You can check your batery's state of charge with a mulmeter. 2. Idenfy the posive and negave terminals. These are labeled and color-coded red for posive (+), black for negave (). 3. Determine the appropriate finishing hardware set you will use. Verify that your bolt can fully seat into the nylok insert of the nut. If mulple lugs are used, longer bolts may be required for the bolt to fully seat into the nylok insert of the nut. 4. Make the proper cable connecons to the negave terminal of the first batery. Please reference Fig. 1 for the proper order of hardware. 5. When connecng to your batery terminals, DO NOT finger ghten. Use a torque wrench to torque your hardware to the specificaon of 9 to 11 -lbs. Failure to adequately secure connecons can result in severe damage and will void your warranty. 6. Connect the other end of your cable to the posive terminal of the other batery you are connecng to. Repeat step 4. 7. Repeat steps 3-6 for addional bateries, but DO NOT exceed 48V. An example of a correct series connecon can be found below in Fig. 4.1 and Fig. 4.2. Figure 4.1: Two GC3 Batteries Connected in Series to create a 24V 270Ah Battery Bank Figure 4.2: Four GC3 Batteries Connected in Series to create a 48V 270Ah Battery Ban Batle Born Bateries BBGC3 Manual | BBGC3H Manual | Edion.PIM_BBGC3Rev020_04242024 6 How Does the BMS Protect the Bateries? All Batle Born Bateries come with a built-in batery management system (BMS) that protects the cells from many strenuous circumstances to protect the life cycles of the cells and your electrical system from potenal damage. The BMS in the BBGC3 allows for 300 Amps connuous, 500 Amp surge for 30 seconds, and 1/2 second surge for loads over 500 Amps. All of our BMS' protect against the following condions: High Voltage Disconnect (> 14.7V) If an individual cell voltage exceeds a prescribed threshold during charging, the BMS will prevent a charge current from connuing. Discharge is always allowed under this condion. If the bateries have not been balanced for a long me, high voltage disconnect could occur at a lower voltage. The bateries will rebalance aer several full charges. Low-Voltage Disconnect (< 10.6V) If an individual cell falls below a prescribed threshold during discharge, the BMS will prevent further discharge. Although the batery is in "low-voltage disconnect" mode, it will sll allow a charging current. NOTE: Many chargers must detect a voltage over 10V to send a charge to the battery. Please be aware that some chargers may not sense a battery in low-voltage disconnect and you may need to jump it with a 12V source to "wake up" the battery. You should jump your battery within 24hrs of entering low-voltage disconnect otherwise you risk damaging your battery and voiding the warranty. High Temperature Charging and Discharging (> 135°F/57.2°C) The BMS will not allow a charging or discharging current if the internal temperature of the batery has reached 135°F (57.2°C). Low Temperature Charging (< 25°F/-3.9°C) The BMS will not allow a charging current under 25°F (-3.9°C) but will connue to discharge down to -4°F (-20°C). NOTE: The BBGC3 has an operating temperature range of -4°F (-20°C) to 135°F (57.2°C). High Current Discharge Surges The BMS will not allow a current that exceeds 500 (+/- 5%) Amps for more than 30s, or anything larger for 0.5s. Aer a high current disconnecon, the batery will automacally reconnect aer 5 seconds. Short Current Discharge Surges Our BMS has built-in short circuit protecon. If the short circuit protecon is tripped, the BMS will shut the batery down and will remain disconnected unl you remove the batery cables. While the batery cables are disconnected, we suggest taking the voltage of the batery with a voltmeter. If it reads above 10V, reconnect the batery cables. If you are unsuccessful at obtaining a voltage reading above 10V, please give our technical support team a call. Balancing of Cells A passive balancing process is acvated by the BMS at the top of each charge cycle when the batery voltage exceeds around 14.2V. This ensures that all the cells remain at the same state of charge, which helps pack longevity and performance. Batle Born Bateries BBGC3 Manual | BBGC3H Manual | Edion.PIM_BBGC3Rev020_04242024 7 Voltage vs. Capacity For a Single Batery How to Properly Size Cables for System Install When considering cable sizing there are a few factors to consider. First, what is the size of the load you are powering with the batery bank? Second, how far away from the batery is the load? You can do voltage drop calculaons to see if you need to step up your cable size. Fig. 5 is a chart to use for reference. Do keep in mind that cables are only capable of carrying a certain amperage and you should verify the specificaons of your cable and the power draws before implemenng them into your system to avoid potenal failures and damage. Cable QR Code Figure 5: As a rule of thumb, you can use these numbers as a guideline. Batle Born Bateries BBGC3 Manual | BBGC3H Manual | Edion.PIM_BBGC3Rev020_04242024 8 How to Incorporate Fuses into System Install ANL fuses are designed to melt and separate into two pieces for the purpose of breaking a circuit in the event of excessive current. These fuses are essenal components for protecng against a catastrophic event and are typically placed between Batle Born Bateries and the inverter/load. How to Properly Store the Bateries We recommend bringing the Batle Born bateries to a 100% state of charge. Then, disconnect the batery from any loads by removing the negave cable from one batery. On average, the bateries lose approximately 2-3% capacity per month. This is subject to increasing if stored in extreme environmental condions. How to Maintain the Bateries Batle Born Bateries require very litle maintenance. If your bateries are in series and not being charged by a mul-bank charger it is recommended that you fully charge the bateries individually once a year if the system is used frequently. This will internally balance your bateries to ensure that they will reach their expected life span and allow you to get the full power out of them with each use. If your bateries are in parallel this is not necessary, just make sure the bateries are charged to 14.2V 14.6V frequently for internal balance. Our BMS has a built-in passive balancing system that will take care of this for you. For more FAQs scan the QR code. To see what else Batle Born Bateries has to offer, scan the QR code to the right or visit htps://batlebornbateries.com/shop/ Fuse QR Code Storage QR Code FAQ QR Code How to Properly Recycle and Dispose of the Bateries Battery Line QR Code Here at Dragonfly Energy our goal is to provide our customers with long lasng green energy that will support them for years on all their adventures. That is why we not only build bateries that can keep up with you for a long me but also provide industry leading customer support to help you get the most out of your bateries. When the me does come, and your bateries have reached the end of their lifeme it is important to recycle them responsibly. Here are a few suggesons: 1. Make sure all loads are removed from your system before removing the bateries. Once the bateries are removed cover the terminals using electrical tape. Now can be a good me to inspect any cable runs or lugs. 2. Visit www.earth911.com or www.call2recycle.org/locator to find a drop off locaon. Be sure to call ahead of me to confirm that the drop off locaon is sll accepng materials. 3. Give us a call if you are having any trouble finding a drop off locaon and we can help you find one. Limited Warranty Please find Limited Warranty informaon online at htps://batlebornbateries.com/limited-warranty/ or via phone at (855) 292-2831. Limited Warranty QR Code Batle Born Bateries BBGC3 Manual | BBGC3H Manual | Edion.PIM_BBGC3Rev020_04242024 9 Return Policy You have 30 calendar days to return an item from the invoice date. To be eligible for a return, your item must be in the same condion that you received it in. You must have the receipt or proof of purchase. If an item is new, unused, and in the original packaging, we are happy to accept a return up to 30 days from the original invoice date with no restocking fee. The item must be returned with its original packaging. Original packaging must be in the same condion as it was received, otherwise you may be responsible for a restocking fee. If the item has been installed, used, or no longer has the original packaging, we will assess a restocking fee that will be shared when the return merchandise authorizaon (RMA) is issued. Items 60 days past the original invoice will be reviewed at Batle Born's discreon. Returns will not be accepted without an RMA number, which can be obtained by filling out the return form at htps://batlebornbateries.com/returns/. To avoid being charged restocking fees, review the full return/refund policy at htps:// batlebornbateries.com/terms- condions/#returns. Refund Policy You have 30 calendar days to return an item from the invoice date. Once we receive your item, we will inspect it and nofy you that we have received your returned item. We will immediately nofy you of the status of your refund aer inspecng the item. If your return is approved, we will iniate a refund to your credit card (or original method of payment). You will receive the credit within a certain amount of days, depending on your card issuer's policies. No refund is guaranteed aer the inial 30 days has passed or if the item has been used. Shipping You will be responsible for paying for your own shipping costs for returning your item. If you are returning prior to 30 days from the original ship date, you may be eligible for a free return. In order to be eligible for free shipping, you MUST have the original packing in which the order was shipped, including boxes, foam, wrapping, and pallets if necessary. Not all items will be eligible for free return shipping. Shipping costs are nonrefundable. If you receive a refund, the cost of return shipping may be deducted from your refund. If you have any quesons, please contact us by calling 855-292-2831 or email us at info@batlebornbateries.com. Noce: Product improvements and enhancements are connuous; therefore, the specificaons and informaon contained in this document may change without noce. Dragonfly Energy Corp. shall not be liable for errors contained herein or for incidental or consequenal damages in connecon with the furnishing, performance, or use of this material. No part of this document may be photocopied, reproduced, or translated to another language without the prior writen consent of Dragonfly Energy Corp. Copyright © 2022, Dragonfly Energy Corp., all rights reserved. Batle Born Bateries® is a registered trademark of Dragonfly Energy Corp. All other trademarks, trade names, service marks, and logos referenced herein belong to their respecve owners. Lithium-ion vs. Lead-Acid Batle Born Bateries BBGC3 Manual | BBGC3H Manual | Edion.PIM_BBGC3Rev020_04242024 10 Recommended Accessories (Available via batlebornbateries.com or call us at 855.292.2831) BMV-712 With Bluetooth built-in, the BMV-712 is the most efficient way to monitor your system. Being a shunt-based device, the unit will monitor power coming in and out of your system all at the palm of your hand. This device is highly recommended to give you the most accurate reading on your bateries. MulPlus Compact 2000 W The Victron MulPlus Compact Inverter Charger, as the name suggests, is a combined inverter and charger in one elegant package. Its many features include a true sine wave inverter, adapve charging, and hybrid Power Assist technology, plus mulple system integraon features. *This unit pairs well with 200Ah or more of batery capacity. MulPlus 3000 W The Victron MulPlus Inverter Charger, as the name suggests, is a combined inverter and charger in one elegant package. Its many features include a true sine wave inverter, adapve charging, and hybrid Power Assist technology, plus mulple system integraon features. * This unit pairs well with 300Ah or more of batery capacity. MulPlus-II With all the funconality of a MulPlus and a MulGrid, the MulPlus-II 2x 120V is a great opon for those with 50A 120/240VAC split-phase applicaons. Whether it is supplied from shore power or a generator, the MulPlus-II 2x 120V can accept and pass through both lines of a 120/240V supply, with the capability to ulize the full 50A for charging and AC loads. * This unit pairs well with 300Ah or more of batery capacity. Solar Charge Controller 100/50 A solar charger gathers energy from your solar panels and stores it in your bateries. Using the latest, fastest technology, SmartSolar maximizes this energy harvest, driving it intelligently to achieve full charge in the shortest possible me. SmartSolar maintains batery health, extending its life. * This device pairs well with up to 700 W of solar with a 12V batery bank. Cerbo GX The Cerbo GX communicaon center maximizes your system's performance and allows you to always have complete control over your system from wherever you are. Simply connect through the Victron Remote Management (VRM) Portal, access directly using the separateGX Touch 50, or use the VictronConnect App with the device's added Bluetooth capability. * RJ45 and VE Direct wires will be required to allow other Victron items to communicate info to the Cerbo. Orion DC-DC Charger The Victron Orion-Tr Smart DC-DC Charger is a DC to DC adapve 3-stage charger with built-in Bluetooth. This device can be used in dual batery systems in vehicles or on boats where the alternator and the start batery are used to charge your house bateries. The unit can be monitored and programmed via Bluetooth and can be remotely controlled via a remote on/off switch. * The Orion-Tr Smart DC-DC Charger can be used in 12V or 24V systems. Models are available up to 400W and mulple units can be connected in parallel to increase output power. IP65 The Blue Smart IP65 Charger is a professional batery charger with built-in Bluetooth. The Blue Smart IP65 Charger is a 12-volt, 15-amp charger that can be used with lithium-ion bateries in RVs, boats, and campervans. * This device is a great addion to offer a handheld charger to top off your bateries before connecng into your system. Rich Solar Panels Coming in a variety of opons, Rich Solar Panels offer Mono PERC Technology, a lightweight, anodized aluminum frame, high transmission, an-reflecve coated tempered glass, a plug-and-play juncon box, and industry-standard quickconnect cables that work in series or in parallel. These panels are cerfied to withstand challenging environmental condions and are excellent with low light performance on cloudy days, mornings, and evenings. Batle Born Bateries BBGC3 Manual | BBGC3H Manual | Edion.PIM_BBGC3Rev020_04242024 11