PowerPlus Energy LiFe4838P Installation and Operation Manual

1. INTRODUCTION

PowerPlus Energy designs and manufactures Lithium Ferro Phosphate (LiFePO4 or LFP) batteries in Melbourne, Australia, to operate in some of the world's harshest operating environments. The LiFe4838P battery is a simple, safe, flexible, and reliable energy storage component designed for easy integration with most inverter and charger combinations. It functions as a UPS battery or a cyclical energy storage reserve for solar, wind, and other renewable energy sources. It connects to most DC and AC charging devices and requires virtually no maintenance in on-grid and off-grid system designs, including single-, dual-, and three-phase BESS (Battery Energy Storage System) applications.

This document outlines the technical capabilities of the PowerPlus Energy LiFe4838P battery and provides installers with useful information and tips for safe integration into BESS systems. Due to the large amount of electrical energy stored and its rapid release capability, this product must be handled with care during installation and operation. When installed as intended, the LiFe4838P will deliver its rated electrical performance over its 10-year warranty life.

2. GLOSSARY

3. SAFETY

IMPORTANT: Installers and users are responsible for familiarising themselves with this manual.

The PowerPlus Energy LiFe4838P battery is part of the LiFe Premium series, with a nominal operating voltage of 48V. It uses high-grade cylindrical Lithium Ferro Phosphate (LiFePO4 or LFP) cells, known for robustness and reliability in higher ambient temperatures, designed for a long service life when installed and operated within specifications. The battery contains no heavy metals and most components are recyclable. High-current Amphenol SurLok DC connections allow for safe and rapid installation. For international safety standards, each battery features a 2-pole, non-polarised K-Curve circuit breaker acting as an isolator, and a blue status indicator light for diagnostics. A volt-free alarm contact is available for external monitoring. An internal Battery Management System (BMS) protects against over-charging, excessive discharging, over/under-temperature, and over-current/short-circuit conditions, managing cell-string balancing during charging. Installation must be performed by a qualified person familiar with battery energy storage systems, electrical safety, and local/international standards.

3.1 TRANSPORTATION

The LiFe4838P battery is classified as Dangerous Goods (DG) Class 9 UN3480 and carries a UN38.3 transport safety certificate. It is shipped with capped terminals to prevent short circuits and in a partially discharged state as per transport regulations. Batteries should be shipped horizontally, secured to a pallet, and not stacked more than 6 high. Vertical orientation is not recommended.

3.2 BASIC SAFETY

WARNING: Serious injury or property damage may result from careless handling.

• Do not expose to temperatures outside specified ratings.
• Do not install in direct sunlight.
• Avoid strong impacts and vibrations.
• Do not crush or puncture the battery.
• Keep connectors from touching conductive surfaces unless intended.
• The battery contains no user-serviceable components; do not disassemble.
• Keep the battery dry; do not expose to water or liquids.
• Keep away from animals and children.
• Do not step on or apply strong force to the battery.
• Lift by two persons during installation and handling.
• Do not dispose of with household waste.

In case of:

• Eye Contact: Rinse with water and seek medical attention if irritation develops.
• Skin Contact: Rinse with water and seek medical attention if irritation develops.
• Ingestion: Do not induce vomiting; contact a poison information centre or doctor.
• Inhalation: Evacuate the area and seek professional medical attention.

3.3 HANDLING

Handle with care due to weight; use proper lifting techniques. Do not use if damaged. Clean only with approved methods, not chemicals. Avoid touching DC terminals or busbars.

3.4 STORAGE OF THE BATTERY

Store horizontally, no more than 6 high without support. Keep in a dry environment away from heat, moisture, and incompatible substances. Ideal storage is 0-35°C, with 25°C preferred for long-term storage. Recharge is needed every 6 months. Consult PowerPlus Energy for charging issues after long-term storage.

3.5 LIFE SUPPORT

Batteries are not intended for critical medical or life support applications where failure could compromise equipment.

3.6 DAMAGED BATTERY*

Do not use damaged batteries. Return to PowerPlus Energy or dispose of via recycling. Avoid contact with leaking electrolyte.

3.7 FIRE*

Use ABC or dry chemical extinguisher for small fires. Evacuate and call emergency services. Toxic gases may be produced; cool the battery rapidly.

3.8 QUALIFIED PERSON (INSTALLER)

Installation must be performed by a qualified person with thorough knowledge of BESS operations, design, installation principles, electrical dangers, and local qualifications. Adherence to all safety and installation requirements in this manual is crucial.

3.9 WET BATTERY

Do not access a wet or submerged battery. Seek technical assistance from PowerPlus Energy or your distributor.

4. PRODUCT INFORMATION

This section provides essential technical information regarding the LiFe4838P battery's physical and electrical characteristics.

4.1 INTRODUCTION

The PowerPlus Energy LiFe4838P is a 'self-managed' battery, operating independently of external Power Control Electronics (PCE). It features an internal Battery Management System (BMS) for protection against adverse conditions like over-charging, excessive discharging, over/under-temperature, and over-current/short-circuit.

4.2 WEIGHT AND DIMENSIONS

Weight: 43kg

Dimensions (D x W x H): 635 x 439 x 88mm

4.3 LABEL AND SYMBOLS

A product specification label is attached to the battery's left side. Key information includes Model No., Battery Type (LiFePO4 3.8kWh 74.2Ah 2RU), Nominal Voltage (51.2Vdc), Maximum Current (63Adc), IP Rating (IP40), and cautions (e.g., do not short circuit, do not dispose of in fire or water, do not disassemble, observe polarity). Symbols indicate 'Read manual before installation/operation' (ℹ️) and 'Pay attention to potential dangers' (⚠️).

4.4 FRONT PANEL

The front panel includes:

• DC Circuit Breaker (ON/OFF switch)
• Advanced Status LED
• Alarm Port (RJ45 connectors)
• Main DC Terminals (+ and -)
• Case Earth Connection

4.5 INCLUSIONS

Each battery is supplied in a cardboard box for potential returns. Other accessories are sold separately. Included DC connectors: Positive DC connection (1 x SLPPA16BSR), Negative DC Connection (1 x SLPPA16BSB), and 25mm to 16mm Reducer (x2).

4.5 SPECIFICATIONS

4.6 CHARGING AND DISCHARGING

4.6.1 CHARGING/DISCHARGING CURVES

Graphs illustrate Voltage/Current curves for charging and discharging the LiFe4838P battery.

4.6.2 STATE OF CHARGE VS DISCHARGE VOLTAGE

Table provides voltage reference against battery energy at 25°C with a 0.5C load:

4.6.3 OVER DISCHARGED BATTERY

If the battery's low voltage protection circuit activates due to excessive discharge, it must be charged to 100% within 7 days to prevent irreversible damage and capacity loss.

4.7 DC CIRCUIT BREAKER CHARACTERISTICS

The integrated DC Circuit Breaker is dual pole with K curve characteristics. A graph shows tripping times based on current multiples.

4.8 CERTIFICATION / COMPLIANCE

5. INSTALLATION

This section provides guidance for a safe and trouble-free installation process. Careful consideration of all specifications is required for suitable location and mounting.

5.1 LOCATION AND ENVIRONMENT

The battery location must comply with IP rating (Table 4.4) and operating temperature range (Table 4.3). The LiFe4838P is designed for 19-inch data rack assemblies or electrical enclosures. For outdoor installations, use an enclosure with IP54 or greater rating.

Location requirements:

• Avoid salt air environments to prevent short circuits and corrosion; use air filtration if unavoidable. Indoors or IP66+ enclosures are recommended.
• Ensure a level floor free from obstructions.
• No explosive or flammable materials nearby.
• Recommended operating temperature: 15°C to 30°C.
• Maintain constant temperature and humidity.
• Environment should be clean, dust-free, and insect/vermin proof.
• Batteries and enclosures must not be exposed to direct sunlight.

5.1.1 EXTREME HUMIDITY CLIMATES

In high humidity, use a humidity control agent inside the enclosure with controlled airflow. WARNING: Operating outside recommended temperatures may cause the BMS to halt operation, negatively impacting long-term performance and longevity. NOTE: Optimal performance and lifespan are achieved within the ideal temperature range (15-30°C). Consider climate-controlled rooms and maintaining cabinet temperature above dew point.

5.2 BATTERY INSTALLATION

PowerPlus Energy recommends their Rack or Slimline Series cabinets. For custom enclosures, consider the following:

5.2.1 CUSTOM CABINETS

The battery fits standard 800mm deep 19-inch racks. For custom enclosures without rails, ensure batteries are securely seated. Do not stack more than 6 high without support rails. Ensure adequate airflow (25mm clearance on sides). Ensure selected IP rating is correct. Use identical length and size cables for parallel connections. A busbar is recommended for parallel connections. Follow PCE instructions for fuses, cables, and connections.

5.2.2 BATTERY ORIENTATION FOR STATIONARY APPLICATIONS

Batteries can be mounted in any of four orientations, excluding resting on the front face or upside down on the lid.

5.2.3 BATTERY TRANSPORTATION WITHIN A PRE-ASSEMBLED BESS

If pre-installed in a BESS for shipping, secure horizontally to limit movement. Use shock-mount systems for prolonged vibration. If these conditions cannot be met, remove and ship in original packaging.

5.2.4 BATTERY INSTALLATION IN MOTORHOMES, RV'S, TRAILERS, VEHICLES, TRUCKS, BUSES OR SIMILAR

Install horizontally (lid upwards), secured to limit movement. Position in a non-flammable section, vented to the outside, and easily accessible/removable from outside the vehicle. Use shock-mount systems and do not stack more than four high.

5.3 BATTERY CONNECTIONS

Batteries use Amphenol SurLok connectors for easy connection. For parallel connections, all cables must be identical in length and size. Main DC connections use Amphenol SurLok connectors, suitable for 25mm single or 16mm double insulated cable. A 16mm reducing sleeve is provided. Use a 25mm hex crimp tool. WARNING: Do not connect DC cables with reversed polarity; severe damage will occur.

5.3.1 MAIN DC CONNECTIONS

The battery has positive and negative Amphenol SurLok connectors. Table outlines connector types.

5.3.2 CASE EARTHING

The LiFe4838P case is electrically floating. If grounding is required, use the supplied 5mm M6 bolt.

5.3.3 BATTERY ALARM OUTPUT

The battery has an alarm output via two RJ45 connectors that signals BMS or DC Circuit Breaker trips. Pins 5 and 6 provide volt-free contacts. The output is normally closed when the battery is ON and LED is illuminated. When a trip occurs, contacts open. Alarm outputs can be daisy-chained using COM003A cables. The last battery in the chain requires pins 5 and 6 to be bridged with a COMLBA connector. The first battery's top connector can link to an external alarming circuit.

RJ45 Pinout (EIA/TIA 568 A and B) and Alarm Output table are provided.

RJ45 Alarm Output Pin Assignment:

Available cables for alarm contacts include Battery Bridge connector (COMLBA), Battery daisy chain connector lead (COM003A), and various Battery Comms Cables (COM020A to COM150A).

Diagrams illustrate alarm contact usage with Selectronic SP PRO and Victron CEBRO GX systems.

6. BATTERY OPERATION

Before energising, verify installation: correct polarity, no cable damage, all breakers OFF, and adequate airflow. Local compliance checks are also necessary. Startup should align with PCE manufacturer recommendations and this manual. Power up each battery by turning its DC circuit breaker ON. The Status LED will glow blue, indicating voltage at terminals. Then, turn on main system isolation and PCE.

6.1 STATUS LED

The Status LED indicates battery operation:

• ON: Battery is ON, allowing charge/discharge.
• OFF: Battery circuit breaker is OFF.
• OFF (BMS low voltage protection): Charge/discharge prohibited until recovered by a technician.
• FLASH: Battery in protection mode (details in Section 7).

6.2 DC CIRCUIT BREAKER

The integrated DC circuit breaker serves as an ON/OFF switch, protects against internal faults, and isolates the battery. IMPORTANT: If the power system is shut down or charging source removed, switch the battery breaker OFF within 7 days.

6.2.1 BATTERY SYSTEM STARTUP

Follow system startup procedures. The LiFe4838P requires the breaker to be turned ON to provide output voltage. Steps include: ensuring system isolation is OFF, checking connections, systematically turning ON each battery's DC circuit breaker, verifying Status LED illumination, turning ON main system isolation, and finally turning ON the PCE.

6.2.2 BATTERY SYSTEM SHUTDOWN

To shut down: Turn OFF PCE, turn OFF main system isolation, then turn OFF each battery's DC circuit breaker. Ensure Status LEDs are off.

6.3 CHARGING AND DISCHARGING

Battery temperature should be between 4-51°C during charging and -6-56°C during discharging. Maximum current into/out of each battery must not exceed 63A.

6.3.1 FULL RECHARGE UPON FIRST INSTALLATION

Batteries are shipped partially charged and must be fully charged to float stage before use. This initial charge allows the BMS to perform Battery String Balancing. It may also calibrate external SoC counters.

6.3.2 BATTERY STRING BALANCING

Perform string balancing at least every 7 days for optimal performance and longevity. This equalises cells, limits capacity slip, and ensures correct charging. Balancing involves charging to 56.4V (max 39A) until absorption is below 0.741A, then maintaining this voltage for 60 minutes.

6.3.3 OVER-DISCHARGED BATTERY

If the low voltage protection circuit activates, charge to 100% within 7 days to prevent irreversible damage and capacity loss.

6.3.4 PRIMARY CHARGING SOURCE

A Primary Charging Source (PCS) should be programmed as per Table 6.4 to supply up to 95% of the battery's charge energy.

6.3.5 SECONDARY CHARGING SOURCE

A Secondary Charging Source (SCS) can be used if programmed to Table 6.4 settings. Conditions: SCS output voltage ≤ 56.1V, charge current ≤ 63A per battery, and SCS provides ≤ 25% of total charge energy.

6.3.6 PCS WITH SCS EXAMPLE

Example: PCS (Solar PV) supplies 75% of charging energy, programmed per Table 6.4. SCS (Solar Charge Controllers) supplies 25%, but must not exceed 56.2V or total system charge current, and voltage cannot be adjusted per Table 6.4.

6.3.7 POWER CONVERSION EQUIPMENT (PCE) SETTINGS

Custom PCE settings from PowerPlus Energy take precedence. If none exist, Table 6.4 provides generic settings.

6.4. CALIBRATION TO 100%

Internal cell balancing occurs during charging. Charge to 100% at least weekly for battery health and capacity maintenance.

6.5. SOC (STATE OF CHARGE) DRIFT

SoC drift is caused by cumulative errors in voltage/current measurement. Most products reset this at 100% SoC or float. Reaching float/100% regularly (every 1-2 days) helps reset drift. Strategies include using sufficient solar for float, a backup source, or a more accurate PCE shunt.

7. TROUBLESHOOTING

This section helps identify and resolve common issues. Contact Customer Support at +61 (3) 8797 5557 or support@powerplus-energy.com.au for assistance.

During normal operation, voltage is present across terminals. If BMS limits are exceeded, the BMS enters an alarm state, and voltage disappears. Fault recovery may require external assistance. Table 7.1 lists LED flash codes and actions.

7.1 OVER-DISCHARGED BATTERY RECOVERY

7.1.1 SOFT SHUTDOWN (2 FLASHES)

Use an approved battery charger. Contact PowerPlus Energy.

7.1.2 BMS THRESHOLD SOFT SHUTDOWN

Occurs at a designated LOW voltage level. The battery will not provide DC voltage until reset. Recovery time varies by model. The battery will not deliver power until a designated recovery voltage is reached.

7.1.3 SOFT SHUTDOWN RECOVERY

This procedure requires a qualified person:

1. Shutdown system per procedure.
2. Ensure all loads are OFF.
3. Turn off battery/s via DC circuit breaker; wait 30 seconds.
4. Turn on battery via DC circuit breaker.
5. Wait for Status LED to illuminate.
6. Connect and turn on site PCE.
7. If PCE starts, initiate a full charge cycle.
8. If battery does not turn on or stay on, follow Hard Shutdown Recovery.

7.1.4 HARD SHUTDOWN (15 OR 16 FLASHES)

Occurs after prolonged disuse without charge (excessive self-discharge) or due to damage. The battery cannot be charged or discharged after Hard Shutdown.

7.1.5 HARD SHUTDOWN RECOVERY

This is not a user-serviceable fault. Contact your installer or PowerPlus Energy. NOTE: Consult your installer or PowerPlus Energy if your battery will not activate.

8. MAINTENANCE

The LiFe4838P requires no regular user maintenance. Yearly checks include:

• Status LED.
• Battery DC Circuit Breaker (turn off and on).
• Connections and cables for secure fitting/damage.
• Obstructions around the battery or enclosure.
• Presence of animals, insects, or creatures.
• Build-up of foreign objects.

9. UPGRADING BATTERY CAPACITY

Additional batteries can be added to existing LiFe4838P installations. Mixing battery types/capacities is not permitted; all batteries in a rack must be identical. Before adding batteries, ensure their voltage is within 0.2VDC of the existing rack voltage. Methods include charging both sets separately before combining, or inserting a new battery into a partially discharged bank and charging for 6 hours. Adjust PCE settings to reflect new capacity.

10. CAPACITY TESTING THE BATTERY

Battery capacity can be tested using calibrated equipment by a qualified person at 25°C. The procedure involves discharging at 0.5C to low voltage cut-off, charging to recommended voltage for 6 hours, then discharging again at 0.5C to cut-off. Record discharge hours. Calculate State of Health (SoH) using the formula: (((Ah*0.5)*Discharge hrs)/Ah)*100. Example: LiFe4838P (74.2Ah) tested for 1.85 hours yields 92.5% SoH.

11. COMPATIBLE GRID-CONNECT HYBRID INVERTERS

Visit the PowerPlus Energy website for the latest list of compatible inverters or access the document directly via the provided URL: https://www.powerplus-energy.com.au/files/LiFe4838P_Inverter_Declaration.pdf

12. END OF LIFE

PowerPlus Energy batteries can be returned for recycling. Due to LFP cell stability, returned batteries may be refurbished for low-power applications (community, education, charity). Unsuitable Lithium cells are sent to a licensed recycling facility for metal separation.

13. WARRANTY

PowerPlus Energy warrants the product when installed and used as per the manual and warranty documents. Improper installation or use voids the warranty. Warranty does not cover damages from incorrect storage/transportation, installation/wiring errors, incorrect operation, inappropriate environmental conditions, failure to follow safety requirements, tampering, unauthorized repairs, external influences (physical damage, overcharging), or use outside warranty terms.