EG4-LL 48V 100AH Rack-Mounted Battery User Manual

Brief Introduction

Product Description

The EG4® 48V-LL rack-mounted lithium batteries are ideal for low-voltage energy storage system applications. These batteries use lithium iron phosphate cells with the highest safety performance and a battery management system (BMS) that can monitor and collect voltage, current, and temperature of each cell within the module in real time. The BMS also contains a passive balance function and an advanced battery control method, both of which can help improve the performance of the battery pack. For enhanced security, the battery has two onboard fire-extinguishing modules.

Battery Overview

System Connections

Below is an example system connection diagram with an EG4 charge controller and EG4 inverter:

Overview of System Components

The battery module is made up of sixteen "AAA" grade cells, a BMS, a housing, a breaker, and wire. It can be installed in a standard 19-inch cabinet and communicates with external devices via CAN/RS485 as well as with other EG4® batteries via RS485. The modules can be connected in parallel to meet expansion requirements. Inter-battery communications support a maximum of 64 modules for the 6 DIP switch model or 16 modules for the 4 DIP switch model.

Battery Diagram

Emergency Stop (RSD, ESS Disconnect)

The optional ESS disconnect can be used to shut down all batteries and inverters (if equipped) with the push of a button.

This integrated safety feature ties directly into the battery communication system via an open Battery-Com port using a standard Cat-5/6 ethernet cable.

Pins 3 & 6 are used to communicate the emergency stop information to the batteries once the stop button is pressed.

If the inverter is equipped with rapid shut down (RSD) capabilities, the emergency stop feature can be used to initiate this function. Check with your AHJ and NEC code for compliance.

Installation

Packaging List and Placement

Packaging List

When the product is unpacked, the contents should match those listed below:

• (1) EG4-LL battery module
• (1) Inter-battery communication cable
• (1) ea. 6 AWG Positive and Negative color-coded connection cables
• (4) M6-1.0 Terminal Bolts
• Battery to PC - USB Communication Cable

Location Selection and Installation

Storage

There are a few steps you can take to ensure that batteries are stored safely and in a state that will ensure they are not damaged during storage. These are detailed below.

Battery State

The state of the battery when placed into storage will affect how long it can be stored as well as the battery's condition when it is brought out of storage. EG4® recommends that each battery is brought to a 100% SOC (state of charge) before placing it in storage. Lithium iron phosphate batteries will lose a certain percentage of their total charge while in storage, depending on how long they are stored and the conditions they are stored in. We recommend recharging the batteries after 8 – 9 months in prolonged storage.

Environmental Factors

The environment you store your EG4® battery in can greatly affect the health of the battery. For best results, the temperature should remain moderate, between 41°F and 68°F (5°C and 20°C). Keep the battery away from locations where it may get wet or locations with high humidity (>55%). Store the batteries away from combustible materials.

Requirements for Installation

• Do not put EG4® 48V-LL batteries in series. The BMS and internal components are not designed to handle this setup, which could cause the modules to fail.
• Avoid exposing batteries to conductive materials, such as water, strong oxidizers, and strong acids.
• Avoid putting batteries in direct sunlight or on extremely hot surfaces.
• Keep all flammable materials out of the working area.
• Use caution when handling batteries and/or battery-powered devices to avoid damaging the battery casing or connections.
• Before using batteries, inspect them for signs of damage. Never use damaged or puffy batteries. Please contact the distributor if a battery is received in this state or experiences this issue.

Never position the battery upside down or face down!

General Installation

This chart applies for a 100A continuous output (one battery). Where ambient temperature is above 86°F (30°C), cable size must be increased according to NEC 310. The 6 AWG cable included in the package is intended only for the connection from the module to an EG4® battery rack busbar.

When adding or removing a battery from any rack, cabinet, or busbar, turn off ALL batteries, and use a voltmeter to confirm there is no voltage present. This will prevent users from encountering live (powered) busbars by accident. Failure to do so can result in severe injury and/or death.

Tools needed for installation

The tools required may vary depending on how you choose to mount your battery. Typically, the following items are needed to install the battery into an EG4® battery rack solution or general racking.

1. 10mm socket and ratchet
2. Phillips head screwdriver
3. Torque wrench
4. M6-1.0 terminal bolts (included in package)

Connecting cables to the battery terminals and busbars

EG4® recommends you only use a properly sized (amp rated) busbar to parallel batteries together. Paralleling via the battery terminals may cause inconsistent charging and discharging issues in the bank.

1. Identify the positive and negative terminals of your battery. These are labeled and color coded (red for positive, black for negative).
2. Verify you have all hardware to attach the cable properly. Check to ensure the bolt threads fully into the terminal and can be tightened to the proper torque.
3. Connect the cables to your battery terminals by removing the M8 terminal bolts, inserting them through the eyelet of the proper cable, and reseating the bolt into the terminal block to the correct torque.
4. Connect the positive battery cables to your positive busbar by removing the bus bolts, inserting them through the eyelets of the proper cable, and reseating the bolt into the busbar to the proper torque value. Repeat with all negative cables.
5. DO NOT finger tighten the battery terminal bolts. They require a specific torque to ensure they do not loosen during operation. Failure to properly tighten the terminal bolts can result in serious damage and will void your warranty.

Installation in EG4® Battery Rack

1. Insert the battery into the rack slot, beginning with the top slot and progressing downward. Slide in until the battery is firmly seated in the rack.
2. Use the included 6 AWG power cable to connect each battery to the busbar.
3. DO NOT finger tighten the battery or busbar terminal bolts. Both require a specific torque [60 in. lbs. (7 Nm)] to ensure they do not loosen during operation. Failure to properly tighten the terminal bolts can result in serious damage and will void the warranty.
4. Clearly identify the location of the system's positive and negative terminals--red to the positive terminal and black to the negative terminal--to ensure no connection errors. Then connect to the equipment or switch terminals.

Grounding

You can attach a grounding wire from the rack/cabinet to an equipment grounding conductor, then terminate the EGC at a grounding electrode.

Do not ground rack/cabinet or door to negative or positive bus bars!

Battery Communications

Each EG4® battery is designed with you in mind, displaying as much information as possible in the simplest manner. EG4® Electronics includes the option of connecting the battery to PC software to monitor the module status. This allows you to see and understand exactly what the battery is doing as well as troubleshoot if problems arise.

When a single battery is used, it will communicate directly with the system via the RS485 or CAN port. The battery will connect via a properly pinned battery communications cable (not included).

The communication cable from battery to battery is a standard Cat5 cable. If you need a longer cable to reach from your system to your master battery and would like to create your own, please refer to the Communication Cable Pinout Table in Section 5.3.2.

Connecting multiple batteries in parallel

1. Ensure all battery breakers and BMS are OFF.
2. Set the address code of each battery according to the DIP Switch ID Table (see Section 5.3.2: DIP Switch ID Table), making sure there are no duplicate addresses.
3. Establish communication between the batteries via the “Battery-Comm" ports starting with the right port on the last battery address and terminating on the left port of the host.
4. The battery with DIP Switch ID 1 (referred to as the host) connects to the system via communication cable using the RS485 or CAN port.
5. Power on each battery breaker and BMS ON/OFF switch one at a time beginning with the host battery.

Communication Cable Pinout and DIP Switch ID Tables

EG4®-LL batteries interface with an inverter by designating a "Host" battery (DIP switch ID No. 1). The ID code range is 1–64 (1–16 for the 4 DIP model), and the communication mode can support up to 64 modules in parallel (16 with the 4 DIP model).

If you have multiple batteries, all DIP switch settings must be different from each other. This allows all equipment to see each battery in the bank separately.

Installing with Different EG4 ® Battery Models

EG4® LL-V2 batteries can communicate with all EG4 ® 48V server rack modules. However, you will need to apply the proper firmware to any LL-V1 and/or Lifepower4 modules before installation. Please visit http://www.eg4electronics.com/downloads for the latest firmware.

Battery Operation

LCD Screen

Each module has a built-in HD LCD touch screen used to display important information about the cells including voltage, current, temperature, SOC, and others.

Button description

There are 4 function buttons below the display with detailed descriptions, as shown in the table below.

Waking up the LCD screen

Press any key to wake up the screen when the power is on, and the information will be shown on the display.

Main Page Information

Cell Information

Check individual cell voltage by pressing the "Enter" button on the main page of the LCD screen (shown in mV). There are 2 pages. Pressing "Up" and "Down" changes the page.

Temperature Information

Press "Enter" on the Cell Voltage page to view the temperature information of the PCB and the cells (Shown in °C).

Communication Protocol Selection

Only the host battery (Address 1) needs to be set to the inverter protocol; all other batteries must have unique addresses starting at address 2 and ascending in chronological order. You must connect the CAN/RS485 port of the host battery to your inverter's (or communication device's) BMS communication port.

Protocol Change/Selection Procedure

1. Power off all battery DC breakers and BMS power buttons. Ensure that the voltage between positive and negative busbars is 0V.
2. The inverter protocol can only be changed with the host battery temporarily set to address 64 (all dials right) or address 16 for the 4 DIP switch model (all dials down). After the dial is changed, restart the battery (with only the BMS power button) for the settings to take effect.
3. On the host battery, press and hold the “Return” key for 5 seconds to enter the “Protocol Setting."
4. Select the corresponding RS485 program or CAN program, and press Enter.
5. Press the “Return” key to return to the main interface.
6. Change the host DIP switch address back to address 1.
7. Power cycle the host battery, and the BMS will correspond to the protocol selected.

BMS Tools Installation and Interfacing

The PC software “BMS Tools” provides real-time battery analysis and diagnostics. The battery cannot communicate with BMS Tools and a closed loop inverter at the same time.

Downloading and Installing BMS Tools

1. Visit eg4electronics.com/downloads to get the latest version of the software for free. It can be found in the "Software and Drivers" section.
2. Once downloaded, locate the file (typically in the Downloads folder).
3. Right click on the folder and click “Extract All.” Verify the location the file will be extracted to for future reference. Check the box “Show extracted files when complete” and click on “Extract.”
4. Open the folder to access BMS_TOOLS. Right click and click “Run as administrator." You may see a popup for Microsoft Defender appear. Click “More info,” and then click “Run anyway.”
5. You will be brought to the main page of BMS Tools.

Interfacing with BMS Tools

1. Press the ON/OFF button on the battery to power off the BMS.
2. Set the DIP switch ID address of the battery to Address 64 (6-pin DIP) or Address 16 (4-pin DIP).
3. Connect the included battery-to-PC USB cable to your PC and to the RS485 port on the battery. (If BMS Tools is running on your PC, close the program before continuing.)
4. Press the ON/OFF button to power on the battery.
5. In the search bar at the bottom of the PC screen, type “Device Manager."
6. Open "Device Manager", and double click on "Ports” to look for the COM port the battery is in.
7. Open BMS Tools. Under “Monitor Status,” verify “COM" matches the battery COM from the previous "Ports” list. Verify “Baud Rate” is set to 9600, and “PACK ID” is set to 16, then click “SearchDevice." After about 30 seconds, BMS Tools will begin the monitoring process and pull real-time data from the BMS.
8. To review these steps, please watch our step-by-step guide at https://youtu.be/Axhc8_22Go0.

Interface menu definition

Although there are multiple tabs in the BMS Tools software, the following tabs should not be tampered with as any unauthorized changes will void the warranty of this product and risk damaging and/or rendering the product permanently inoperable.

• BMS Parameter
• BMS Control
• Software Parameter

If you are experiencing any issues with the battery module or the BMS, please contact your distributor for assistance or troubleshooting steps.

Battery Charging

Charge cycle

Ensure the proper settings are set on the charge controller and/or inverter being used to avoid overcharging or damaging the module. (Refer to Section 9.1: Technical Specifications Table for a full list of charging/discharging parameters.)

Troubleshooting, Maintenance & Disposal

Introduction to the BMS

The BMS (Battery Management System) is intended to safeguard the battery and battery cells against a variety of situations that could damage or destroy system components. This protection also aids in keeping the battery and battery cells operational for a greater number of life cycles. Each EG4®-LL battery is specifically configured to ensure peak performance and operation with any system.

BMS Protection

PCB temperature protection

The BMS will ensure that the Printed Circuit Board (PCB) does not overheat. This is the part that houses most of the "brains" of the battery. This feature will turn off the battery if it begins to overheat.

Cell balance protection

Cell balance ensures that each cell is within a specific voltage range of each other. Cell balance is crucial for ensuring that the battery is operating properly for its lifespan. This is always done automatically.

Environmental temperature protection

It may be dangerous to attempt using the battery in extreme heat or cold. Continued operation in these conditions may result in permanent damage to the battery module and its components. To prevent this, the BMS is designed to measure the temperature while charging/discharging and will shut down the battery to prevent damage.

Voltage protection

The BMS is designed to continuously monitor the voltage of each individual cell and ensure that they are not over/undercharged.

Troubleshooting

Alarm Description and Troubleshooting

When the ALM light on the battery control panel is on, it means that the battery has given an alarm or has been protected from potential damage. Please check the cause of the failure through the app or BMS Tools and take appropriate measures or go directly to the battery site to troubleshoot.

BMS Tools alarms are shown in the table below:

Other common faults and solutions

Battery End of Life

The EG4®-LL 48V battery is designed to last for more than 15 years when used correctly. We have worked tirelessly to ensure that our batteries will maintain a charge after thousands of cycles. However, when it does come time to retire the battery, there are a few things to consider.

Lithium iron phosphate batteries are considered a hazardous material and should not be disposed of by simply placing them in the trash. There are several websites and organizations that will accept this battery to recycle at little to no cost to the user. At EG4®, we understand that we are working with customers across the United States and the world. Our recommendation is to go online and search the term "Lithium Battery Disposal Near Me." There will likely be an assortment of organizations that can safely dispose of LFP batteries. We recommend calling ahead of time to ensure that the location is still open and accepting material.

If, however, users are unable to locate a disposal location safely, EG4® is here to help. Before dumping the battery or disposing of it incorrectly, please contact our customer service team for assistance.

EG4® 10 Year Limited Warranty

The warranty must be registered within the first year of purchase to remain valid. If users choose not to register the product, the warranty may be invalidated. This limited warranty is to the original purchaser of the product and is not transferable to any other person or entity. All BMS and cell exchanges are covered throughout the warranty period. If a full replacement warranty is needed the warranty is prorated 1/9th per year after the first year at the current retail pricing.

Warranty Exclusions

Under this limited warranty, EG4® Electronics has no obligation to the product if it is subject to the following conditions, including but not limited to:

• Damages incurred during installation or removal
• Damages caused during mishandling of product
• Inappropriate environmental exposure
• Damages caused by improper maintenance
• Unauthorized tampering, altering, and/or disassembly of product
• Using the product for purposes other than those intended by the manufacturer
• Lightning, Fire, Flood, or Acts of God
• Any product whose serial number has been altered, defaced, or removed

The equipment sold by EG4® Electronics is designed to be installed only by licensed, trained, and insured solar electrical installation professionals. We strongly advise customers to seek the assistance of such a professional to implement these products, and we make no warranty of the purchaser's safety, success of equipment implementation, or compliance with local codes and regulations.

EG4® Electronics disclaims all additional warranties, expressed or implied, including but not limited to, any implied warranty with respect to the accuracy or completeness of the information they disseminate and /or fitness of the materials sold for a particular purpose. No warranty may be created or extended by sales or promotional materials on these items. Each party hereby irrevocably waives its rights to trial by jury in any action or proceeding arising out of this agreement or the transactions relating to its subject matter. All installation advice provided by EG4® before, during, or after purchase of solar equipment is purely for the purpose of general concept education and must not replace the expertise of a licensed and trained solar specialist. The Customer agrees to full indemnification for EG4® henceforth from any legal recourse relating to and arising out of losses, direct or consequential, from the installation of the products purchased by the customer more than the value of the equipment purchase price.

Technical Specifications

Technical Specifications Table

Module Operating Parameters

Environmental Parameters

Charging/ Discharging Parameters

General Specifications

Physical Specifications

Standards and Certifications

Battery Performance Curves

Notes