DISCOVER LITHIUM BLUE DLB-G24-12V Installation And Operation Manual Download

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1. Audience, Safety, Messages, and Warnings

1.1 Audience

1.2 Safety, Messages, and Warnings

2. Specifications

2.1 Electrical Specifications

2.2 Mechanical Specifications

2.3 Environmental Specifications

2.4 Protection Specifications

2.5 Specifications for System Sizing

2.6 Regulatory

3. Transportation

4. Handling

5. Design and Features

5.1 Battery Management System Protections

5.2 Battery Fuse

5.3 Battery Management System Low Power Hibernation

5.4 Battery Management System Bluetooth Communications

5.5 Ingress Protection IP67

5.6 Membrane Vent

6. Installation

6.1 Tools

6.2 Location

6.3 DC Cables

6.4 DC Protection

6.5 Terminal Connections and Hardware

6.6 Single Battery Installation Procedure

6.7 Parallel Battery Installation Procedure

7. Operation

7.1 Low Voltage Cut-Off

7.2 BMS Hibernation

7.3 State of Charge

7.4 Charging

7.4.1 When to Charge the Battery

7.4.2 What to Charge the Battery with

7.4.3 Charging with a Lead-Acid Charger

7.4.4 Charging with Alternators

7.5 Charging Profile

7.5.1 Bulk Charge

7.5.2 Absorption Charge

7.5.3 Equalization Charge

7.5.4 Float Charge

8. Bluetooth

9. Routine Inspection

10. Replacing the Fuse

11. Storage

12. Related Information

13. Glossary of Terms, Abbreviations, and Acronyms

Summary of Contents for LITHIUM BLUE DLB-G24-12V

Page 1: ...1 DRAWN CHK D APPV D MFG Q A UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MILLIMETERS SURFACE FINISH TOLERANCES LINEAR ANGULAR FINISH DEBURR AND BREAK SHARP EDGES NAME SIGNATURE DATE MATERIAL DO NOT SCALE DRAWING REVISION TITLE DWG NO SCALE 1 1 SHEET 1 OF 1 A0 WEIGHT DL_L3_Covers PREMIUM SERIES BATTERY MODELS DLB G24 12V DLB G24 24V DLB G24 36V DLB GC12 12V DLB GC12 24V ...

Page 2: ... Membrane Vent 11 6 Installation 11 6 1Tools 11 6 2 Location 11 6 3 DC Cables 12 6 4 DC Protection 12 6 5Terminal Connections and Hardware 13 6 6 Single Battery Installation Procedure 14 6 7 Parallel Battery Installation Procedure 14 7 Operation 17 7 1 Low Voltage Cut Off 17 7 2 BMS Hibernation 17 7 3 State of Charge 17 7 4 Charging 18 7 4 1 When to Charge the Battery 18 7 4 2 What to Charge the B...

Page 3: ... re manufacture attempt to insert foreign objects into the battery immerse or expose to water or other liquids expose to fire explosion or other hazards Only use the battery for the system for which it is specified Do not lift or carry the battery while in operation Only lift move or mount in accordance with local regulations Take care when handling battery terminals and cabling Only use the batte...

Page 4: ...in injury WARNING CHEMICAL HAZARD Do not touch the exposed contents of a Lithium cell Failure to follow these instructions may result in death or serious injury CAUTION FIRE AND BURN HAZARD Do not cover or obstruct the heat sink or install the battery in a zero clearance compartment Compartment ventilation is required Failure to follow these instructions can result in minor to moderate injury CAUT...

Page 5: ...ltage 12 V 24 V 36 V 12 V 24 V Max Continuous Discharge Current 100 A 45 A 30 A 150 A 100 A Nominal Charge Current 50 A 22 5 A 15 A 100 A 50 A Max Continuous Charge Current 100 A 45 A 30 A 150 A 100 A Peak Discharge Current 2 seconds 250 A 120A 120 A 250 A 250 A Fuse 200 A 75 A 75 A 200 A 200 A a Charge current termination is permitted to be less than specified When the charger termination current...

Page 6: ...ot ambient Ambient temperature and cell temperature may not be the same b Storage outside of specified temperatures will result in permanent capacity loss and invalidate the warranty 2 4 Protection Specifications Table 2 4 DLB Protection Specifications Protection Spec DLB G24 12V DLB G24 24V DLB G24 36V DLB GC12 12V DLB GC12 24V Overvoltage Protection a 14 6 V for 1 second 29 2 V for 1 second 43 8...

Page 7: ...with any cell over 3 65 VPC and recover when all cells are below 3 45VPC Nominal voltages are provided for guidance only b Undervoltage protection monitors individual cell voltages and will trigger with any cell under 2 5 VPC and recover when all cells are above 2 7VPC Nominal voltages are provided for guidance only c This is the specified temperature of the cells and not ambient Ambient temperatu...

Page 8: ...le Capacity Reserve Capacity at 25A 1 Battery 250 A 100 A 2560 Wh 240 minutes 2 Battery 500 A 200 A 5120 Wh 480 minutes 3 Battery 750 A 300 A 7680 Wh 720 minutes 4 Battery 1000 A 400 A 10240 Wh 960 minutes 2 6 Regulatory Table 2 10 DLB Regulatory DLB Regulatory All Models Transportation UN38 3 EMC EN 61000 6 1 2007 3 TRANSPORTATION If the battery is not installed in equipment it must be transporte...

Page 9: ...s are too high 2 Under voltage Under voltage protection occurs during discharge when the voltage is discharged too low 3 Over current Over current protection can occur during charge or discharge This may happen when powering up a load short and high inrush current or during sustained currents above specified limits 4 Over temperature Over temperature protection can occur during charge and discharg...

Page 10: ...l voltage may be still be detected at the terminals when the battery is in Low Power Hibernation mode 5 4 Battery Management System Bluetooth Communications The BMS communicates important battery operating information such as the State of Charge voltage operating current temperature and diagnostic logs via Bluetooth communications to devices such as mobile phones and tablets Battery data is then v...

Page 11: ...icable installation requirements and standards are met 6 1 Tools Insulated tools sized to match nuts bolts and cables in use RMS type Voltmeter Post cleaner and wire brush Personal protective equipment 6 2 Location The battery should be installed in locations that meet the following requirements 1 Do not install in direct sunlight Avoid installing the battery in an area with high ambient temperatu...

Page 12: ...reduce voltage drop from impedance leading to reduced performance 3 Appropriate cable gauge The cables should be capable of carrying the normally expected current plus a margin of safety 4 Proper polarity Positive connected to positive and negative connected to 6 4 DC Protection CAUTION FIRE HAZARD Undersized fuses and disconnects may become overloaded and potentially cause a fire Fuses and discon...

Page 13: ...Terminal Connections and Hardware The terminal connections and hardware should meet the following requirements 1 Connect to the battery terminal Do not connect the cable lug to the fuse post All cable lugs must be in direct contact with the battery terminal deck Do not put washers between the terminal deck and cable lug 2 Use the proper torque Use a torque wrench to properly adjust terminal hardwa...

Page 14: ...e terminals and any metal mounting fixture or body part 4 Connect battery cables taking care to connect the positive cable to the positive terminal Connect negative cable last to avoid sparks Short circuits may damage the battery and this will void the warranty 5 Torque all battery terminals to the recommended terminal torque of 13 Nm 9 6 ft lb to secure cable lugs 6 Close circuit disconnect if op...

Page 15: ...must be installed in accordance with the standards set by the local authority having jurisdiction 1 If the circuit of equipment that the batteries are installed in has a disconnect open the disconnect to isolate the batteries 2 Ensure the cable connections are clean and serviceable 3 Install and secure new batteries Be careful not to make contact between the terminals and any metal mounting fixtur...

Page 16: ... Charger Connections 8 Torque all battery terminals to the recommended terminal torque of 13 Nm 9 6 ft lb to secure cable lugs NOTICE Failure to properly torque battery terminal nuts may increase resistance and lower voltage which may lead to burnout of the terminals and void the warranty NOTE Wherever replacing an old battery in a string use a battery of the same age model capacity and voltage NO...

Page 17: ...he battery triggers low or high voltage protection three consecutive times During this time the BMS will disconnect the internal SSR and Bluetooth functions will be disabled This protection helps safeguard the battery from becoming over discharged The battery will exit hibernation mode by Applying a charge current If the battery is in low voltage protection and hibernation mode a small charge curr...

Page 18: ... below 10 SOC it must be charged within 24 hours to avoid permanent damage to the battery Otherwise irreversible damage to the battery cells will occur in a very short period of time Low currents extend life Charging at 50 of nominal current or lower helps extend battery cycle life Proper temperature Ensure charging is within the charge temperatures specified in Table 2 3 DLB Environmental Specifi...

Page 19: ...arging voltages however many will exceed the BMS high voltage protection limits This will result in the BMS disconnecting at the end of the charge cycle likely causing the charger status indicator to display an error 7 4 4 Charging with Alternators Not recommended For the reasons stated below it is not recommended to use an alternator as a charge source It is possible Charging with an alternator i...

Page 20: ...e appropriate A single stage charge will only complete the Bulk phase portion of the charge curve This method should return the battery to between 90 95 SOC Refer to Table 2 1 DLB Electrical Specifications for charging parameters 7 5 2 Absorption Charge Absorption phase The second phase of the charging process is Absorption Charge also referred to as the constant voltage phase This is when the cha...

Page 21: ...real time access to the battery state of charge voltage operating current temperature status and a diagnostic report Search for Discover Blue on Apple s App Store or Google Play One Battery The App will only communicate with one battery at a time No Bluetooth when the battery is in hibernation mode Bluetooth is only active when the battery is not in hibernation mode Ensure that there is a charge o...

Page 22: ...touch by covering them with terminal covers or electrically rated tape 4 Install the fuse on the battery fuse post The battery will not operate if the battery fuse is installed on the battery terminal post 5 Remove the nut holding the fuse and replace it with a new fuse paying strict attention to orientation and the fuse ratings in Table 10 1 DLB Fuse Specifications 6 Torque the nut holding the ne...

Page 23: ...y subject the battery to a trickle drain which could result in irreversible damage and void the warranty NOTICE Storage outside of specified temperatures will result in irreversible damage and void the warranty NOTICE Storing or leaving the battery at 0 SOC will cause irreversible damage and void the warranty NOTICE Allowing the battery to self discharge below an open circuit voltage of 3 0VPC wil...

Page 24: ...24 NOTES ...

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DISCOVER LITHIUM BLUE DLB-G24-12V, Installation And Operation Manual

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