TWS FlexiBlock Battery 12V 100Ah Pro User Manual
Introduction
The TWS FlexiBlock Battery 12V 100Ah Pro is equipped with multiple advanced technologies for motive and stationary applications.
UltraSeal Tech
Rated IP67 water and dust proof, UltraSeal Tech is constructed for harsh environments.
Ultra Safety with Intelligent BMS
Multiple advanced technologies ensure up to 20+ protections for consistent and stable battery performance, anytime and anywhere.
Extremely Versatile in Series and in Parallel
- Easy integration: can be placed both horizontally and vertically.
- Stackable blocks in multiple configurations expand systems up to 10.24 kWh.
- Suitable for the entire portfolio of machines and market applications.
Better Performance at Extreme Temperatures
LiFePO4 ensures excellent discharge performance from -4°F (-20°C) to 131°F (55°C).
Self-Heating Function (Optional)
The battery has a built-in self-heating function to warm up the battery at a low temperature for charging and discharging.
Monitor with Bluetooth & APP (Optional)
The battery's real-time battery SOC, safe charging, and diagnostic information can be monitored anytime and anywhere via Bluetooth and App.
What's In the Box
The package includes:
- 1 x TWS FlexiBlock Battery 12V 100Ah Pro
- 2 x Power Cables
- 2 x M8 Bolts
- Communication Cables
Ensure all accessories are complete and free of any signs of damage.
Read Before Installation
Warnings
- Do not install or service this battery unless you are properly trained.
- Use only with components that have the same voltage and current rating as the battery.
- Do not touch or connect to the terminals unless the battery is manually turned off.
- Do not open or attempt to service the battery; there are no user-serviceable parts inside.
Use & Care
- Do not overcharge or over-discharge the battery.
- Only charge the battery with a battery charger or charge controller compatible with lithium iron phosphate batteries.
- Do not pressure wash, submerge, or use chemical agents to clean your battery.
- Clean the battery using a damp cloth that does not include chemical agents.
Battery Appearance
Prior to installing and configuring the battery, prepare the recommended tools, components, and accessories.
Diagram: An illustration of the TWS FlexiBlock 12V 100Ah Pro battery from multiple angles. Key features are labeled:
- Dimensions: Approximately 393.8mm x 178.85mm x 188.7mm.
- Terminals: M8 Positive Terminal (+) and M8 Negative Terminal (-).
- Handles: Located on the top for carrying.
- LCD Battery Capacity Indicator: Displays battery level (e.g., 100%), current capacity (e.g., 888Ah), voltage (e.g., 88.8V), current (e.g., 88.8A), and remaining time.
- Status Indicators: A set of LEDs or icons indicating:
- Bluetooth Connection Indicator
- Heating Status Indicator
- Low Battery Level Indicator
- High Temperature Indicator
- Low Temperature Indicator
- Discharge Overload Indicator
- Communication Connectors: Two connectors are present. One is used for communication between batteries in series or parallel, and the other is used to connect to a host device.
Battery Operation
Check the Battery
- After opening the battery package, check the battery and accessories. If the battery is damaged or parts are missing, contact the vendor.
- Ensure the electrical specifications of the battery are compatible with the relevant devices and systems.
- Keep the battery away from flame and liquid.
Battery Installation
- Avoid short-circuiting the battery terminals to prevent irreversible damage to the system and battery caused by current bursts.
- Verify polarity before wiring to avoid irreversible battery damage due to polarity reversal. Do not touch the positive and negative terminals of the battery with your hands.
- To ensure safe and reliable operation of the system, a torque of 9 N.m is recommended when securing cable connections. Over-tightening can result in terminal breakage, while loose connections can lead to terminal meltdown or fire.
Batteries in Single Assembly Guidelines
Step 1: Install the CAN impedance matching resistor and series identify terminal to the terminal of the battery as shown in the diagram.
Diagram: Shows a single battery terminal with an M8 bolt and communication connector. An arrow indicates where to install the resistor and terminal.
Step 2: Connect the communication harness and positive/negative series harness as shown in the diagram.
Diagram: Shows a battery with P+ (positive) and P- (negative) terminals, with cables connected to the communication harness and the main power terminals.
Batteries in Parallel Assembly Guidelines
Step 1: Place all batteries as per placement requirement (Max 8 EA).
Diagram: Shows multiple batteries arranged in a configuration, with dotted lines indicating potential connections.
Step 2: Install the CAN impedance matching resistor and parallel identify terminal to the terminal of each battery as shown below.
Diagram: Shows multiple batteries, with arrows pointing to the terminals where resistors and identification terminals are to be installed.
Step 3: Connect the communication harness as shown below.
Diagram: Shows multiple batteries connected via communication harnesses.
Step 4: Determine if the communication between the batteries is normal.
- Description of the button (Key) & display panel: The battery has a button and an LCD display.
- Pressing the button on any of the batteries triggers all batteries to display SOC information.
- Normal state: All batteries show their capacity levels (display value according to SOC).
Diagram: Shows a battery display showing "100%".
Step 5: Initialize the setup of battery parallel communication.
- Trigger the system to assign the communication ID and establish the parallel communication: Select any battery (this battery will be the master) and press the button for a long time (more than 5 seconds), then release the button after the display panel enters blinking mode.
Diagram: Shows two battery displays, with an arrow indicating a transition from one state to another, possibly representing the master/slave setup.
Step 6: Detect if the parallel communication setting is successful.
- Normal State: Only one master battery exists; the others are slave batteries, and the slave batteries are online.
- Judge by the thin dotted circle on the panel blinking status. The following figures show the thin dotted circle blinking status when the master and slave batteries are in normal operation.
- Master: Thin Dotted Circle Slow Flashing (Continue: 1.5 sec, off: 1.5 sec)
- Slave: Thin Dotted Circle Fast Flashing (Continue: 0.5 sec, off: 0.5 sec)
- Use the PC monitoring tool to get the working status information of all the batteries. The normal working status of the battery is listed from #1 in order of all the batteries.
Step 7: Using the positive/negative parallel harness, connect the P+/P- terminals of the batteries together.
Diagram: Shows multiple batteries connected in parallel using power and communication harnesses, with P+ and P- connections clearly indicated.
Batteries in Series Assembly Guidelines
Step 1: Place all batteries as per placement requirement (Max 3 EA). Before connecting batteries in series, ensure each battery is fully charged to 100% State of Charge (SOC).
Diagram: Shows three batteries arranged for series connection.
Step 2: Install the CAN impedance matching resistor and series identify terminal to the terminal of each battery as shown below.
Diagram: Shows three batteries, with arrows pointing to the terminals where resistors and identification terminals are to be installed.
Step 3: Connect the communication harness as shown below.
Diagram: Shows three batteries connected via communication harnesses.
Step 4: Determine if the communication between the batteries is normal.
- Description of the button (Key) & display panel: The battery has a button and an LCD display.
- Pressing the button on any of the batteries triggers all batteries to display SOC information.
- Normal state: All batteries show their capacity levels (display value according to SOC).
Diagram: Shows a battery display showing "100%".
Step 5: Initialize the setup of battery series communication.
- Trigger the system to assign the communication ID and establish the series communication: Select any battery (this battery will be the master) and press the button for a long time (more than 5 seconds), then release the button after the display panel enters blinking mode.
Diagram: Shows two battery displays, with an arrow indicating a transition from one state to another, possibly representing the master/slave setup.
Step 6: Detect if the series communication setting is successful.
- Normal State: Only one master battery exists; the other is a slave battery, and the slave battery is online.
- Judge by the thin dotted circle on the panel blinking status. The following figures show the thin dotted circle blinking status when the master and slave batteries are in normal operation.
- Master: Thin Dotted Circle Slow Flashing (Continue: 1.5 sec, off: 1.5 sec)
- Slave: Thin Dotted Circle Fast Flashing (Continue: 0.5 sec, off: 0.5 sec)
- Use the PC monitoring tool to get the working status information of all the batteries. The normal working status of the battery is listed from #1 in order of all the batteries.
Step 7: Using the positive/negative series harness, connect the P+/P- terminals of the batteries together.
Diagram: Shows multiple batteries connected in series using power and communication harnesses, with P+ and P- connections clearly indicated.
Select Appropriate Connection Cables
The user should select the appropriate connection cables according to the power of the third-party power system and the discharge current of the battery.
The following table shows the load capacity of different battery connection cables:
| Cable Gauge Size | Ampacity | Cable Gauge Size | Ampacity |
|---|---|---|---|
| 14 AWG (2.08 mm²) | 35A | 2 AWG (33.6 mm²) | 190A |
| 12 AWG (3.31 mm²) | 40A | 1 AWG (42.4 mm²) | 220A |
| 10 AWG (5.25 mm²) | 55A | 1/0 AWG (53.5 mm²) | 260A |
| 8 AWG (8.36 mm²) | 80A | 2/0 AWG (67.4 mm²) | 300A |
| 6 AWG (13.3 mm²) | 105A | 4/0 AWG (107 mm²) | 405A |
| 4 AWG (21.1 mm²) | 140A | / | / |
Battery SOC Table
The SOC values listed below are estimated based on the open circuit voltage when the battery is at rest for 60 minutes, not in charging or discharging state.
| SOC | Open Circuit Voltage | SOC | Open Circuit Voltage |
|---|---|---|---|
| 100% | 13.35V | 35% | 13.05V |
| 99% | 13.26V | 20% | 12.87V |
| 90% | 13.25V | 10% | 12.70V |
| 70% | 13.22V | 5% | 12.40V |
| 60% | 13.10V | 0% | 10.67V |
Battery Management System
The battery is equipped with a battery management system (BMS) and has the following battery protection features:
| Feature | Protection Description |
|---|---|
| Over-discharge Protection | Prevents Over-discharging of Batteries |
| Over-charge Protection | Prevents Over-charging of Batteries |
| Overheat Charging / Discharging Protection | Prevents High Battery Temperature |
| Over-current Charging / Discharging Protection | Prevents Excessive Battery Current |
| Battery Balance Function | Keeps Each Individual Cell in the Same Condition to Ensure the Battery is in An Optimal Condition for Use |
*If a protection alert is triggered, completely disconnect the battery and leave it for some time before reconnecting and restarting.
Self-Heating Function
The normal operation of the self-heating function requires a stable charge current greater than 3A for each battery. The self-heating function will start operating automatically once the battery temperature drops below 19.4°F (-7°C) and stop operating automatically once the battery temperature rises above to 41°F (5°C).
Troubleshooting
| Description of Error | Error Type | Recovery Methods |
|---|---|---|
| The key button switch does not trigger the LCD display | Over discharge due to self discharge or hanging load | Please charge the battery immediately |
| During use, the battery may turn off the output. If this happens, press the key button, and the LCD will display the current capacity as low | The battery voltage drops below the protection threshold | Remove the load and charge the battery |
| Cannot charge below -10 °C | Triggered low-temperature charging protection | Connect the charger. Wait for at least 5 ~ 10s. The battery will automatically heat up and work, with different waiting times at different temperatures, to reach a temperature of -7 °C or above. |
| No output when using in high or low temperature environments | The battery temperature exceeds the threshold value for high or low temperature | Disconnect the battery from the load. Let battery cool. The battery automatically recovers from high and low temperature protection and continues to operate. |
| Battery short circuit occurs | During usage, the positive and negative poles are at risk of short circuiting | Immediately remove the positive and negative short circuits. Wait for 60 seconds for automatic recovery. |
| Discharging the battery with a current greater than 105A damages the battery and prevents it from discharging | Trigger discharge overcurrent protection | Remove the load for recovery or wait for 60 seconds for recovery. The load current should be less than 105A. |
| Charging the battery with a current greater than 105A damages the battery and prevents it from charging | Trigger charging overcurrent protection | Remove the charger and use a charger with an output current below 105A to charge. |
Specifications
| Item | Spec. |
|---|---|
| Nominal Capacity | 100Ah |
| Rated (Min.) Capacity (Cmin) | 98Ah |
| Nominal Voltage | 12.8V |
| Delivery Voltage or SOC | SOC 20-30% |
| Charge Method | CC/CV |
| Limited Charging Voltage (Ucl) | 14.2V |
| Upper Limited Charging Voltage (Uup) | 14.2V |
| End of Discharge Voltage (Ude) | 11.6V |
| Discharge Cut-off Voltage (Udo) | 11.2V |
| Recommended Charge Current (Icr) | 50A |
| Max. Cont. Charge Current (Icm) | 100A |
| Recommended Discharge Current (Idr) | 50A |
| Max. Cont. Discharge Current (Idm) | 100A (250A for 10s) |
| Operating Temperature | Charge: 0°C ~ 45°C Discharge: -20°C ~ 55°C |
| Operating Humidity | 25%~75% |
| Cycle Life | 6000 Cycles (Retention ≥ 70% Cmin) |
| Internal Impedance (AC 1kHz) | ≤ 50 mΩ |
| Weight | 12.9 ± 0.1KG |
| Ingress Protection Grade | IP67 |
| Storage Humidity | 25%~50% |
| Storage Temperature | Within 1 month: -20°C ~ 55°C Within 3 months: -20°C ~ 30°C Within 6 months: 20°C ± 5°C |
Note: 1 ItA charge to Ucl with end current of 0.05 ItA and discharge at CC of 1 ItA to Udo. Rest interval is 30 min.
Battery Maintenance and Disposal
Maintenance Instructions
- The battery must be stored in a dry and well-ventilated environment away from water sources, heat sources, and metal objects. It is recommended to store the battery at a temperature of 15-25°C (59-77°F). If the storage temperature is too high or too low, this will affect the self-discharge rate of the battery and accelerate the natural aging of the battery.
- If the battery is not going to be used for a long period of time, it is recommended to be stored intact in a semi-charged state (60% SOC). The battery is recommended to be discharged to 30% and then recharged to 60% every three months.
- When the temperature of the battery is equal to or below -20°C (-4°F), the battery cannot be used for charging, discharging, or heating.
- If the battery level is below 1% after use, it should be charged to 60% before storage. If the battery is left idle for a long period of time with critically low SOC, irreversible damage to the battery cell will occur, reducing the service life of the battery.
- If the battery SOC is critically low and left idle for too long, it will enter deep sleep mode and will need to be recharged before it can be used again.
Disposal
- If conditions permit, make sure that the battery is completely discharged before placing the battery in the designated battery recycling bin. The battery cells, which contain hazardous chemicals, are strictly prohibited from being placed in an ordinary garbage bin. For relevant details, please comply with the user's local laws and regulations regarding lithium battery recycling and disposal.
- If the battery cannot be fully discharged due to a fault of the product itself, do not dispose of the battery directly.
- Contact a specialized battery recycling company for further disposal.
- An over-discharged battery cannot be switched on. Please dispose of the battery according to local laws and regulations.
Frequently Asked Questions
- What type of battery chemistry is used in this product?
- This product uses high-quality lithium iron phosphate.
- How do I clean the battery?
- The battery can be wiped with a dry, soft, and clean cloth or tissue.
- Are lithium batteries safe?
- TWS's Flexiblock battery is protected by a high-performance BMS and has undergone rigorous testing to ensure safe usage.
- Can the 5kWh LFP Battery and 2kWh LFP Battery be used in parallel?
- This is not recommended. When using two models in parallel, the consistency of the batteries cannot be guaranteed, which can lead to a shortened lifespan of the batteries or even a safety hazard.
- Can I charge the battery at low temperature?
- Yes, when the battery is being charged at low temperature (-20°C ≤ T ≤ 0°C / -4°F ≤ T ≤ 32°F), the charge heating function is switched on prior to heat the battery before it is charged normally.
- Can the battery be used with third-party power systems?
- Yes, the user will need to perform extra wiring for this.
- How do I store the battery?
- When storing the battery, first power it off and then store it in a dry, ventilated place at room temperature and away from water sources.
Disclaimer
Please read this User Manual and ensure you understand it fully before using the product. Please keep this User Manual properly for future reference. Any incorrect usage of this product may cause severe injury to the user or others, damage to the product, or loss of property.
By using this product, the user will be deemed as having understood, recognized, and accepted all the terms and contents of this User Manual, and will be responsible for any incorrect usage and all consequences arising therefrom.
TWS Technology hereby disclaims any liability for any losses due to the user's failure to use the product according to the User Manual.
In compliance with laws and regulations, TWS shall have the final right to interpret this document and all related documents for this product. Any update, revision, or termination of the contents thereof, if necessary, shall be made without prior notice, and users may visit TWS official website for the latest information of the product.
TWS Group
