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Expion360 EX-G24-60C User Manual Download Page 16

 

16 

Expion360 Battery Manual, G24 and G27 

Rev 2  

07/18/2022 

 

Multi-string Battery Bank: 

For large battery banks that have more than 4 batteries, or have multiple strings configurations, the circuit protection 

(fuses or circuit breakers) should be installed close to the  battery bank’s positive terminal  of each string before 

connecting to the common bus bar. The fuse rating is based on the maximum continuous discharge rate of each string 

of the battery bank. For instance, if the maximum continuous discharge rate of two strings of parallel-connected batteries 

is 800 A with 400 Ah on each string, the battery bank should be paired with a 400 A DC fuse on each string. The cables 

connecting the two strings to the inverter must be sized properly for the maximum 800 A current.   

 

For more information about correctly sizing circuit protection for the battery power system, please contact an authorized 

installer or Expion360 technical support:  

[email protected] 

+1 (541)797-6714  

 

 

 

Summary of Contents for EX-G24-60C

Page 1: ...USER MANUAL EX G24 60C EX G24 80C EX G24 95XDP EX G27 100C EX G27 120XDP PLEASE KEEP THIS MANUAL FOR FUTURE REFERENCE ...

Page 2: ...file no MH64383 and are certified to the highest standard in safety and performance Internal power distribution cables are mechanically connected bolted rather than soldered to lower contact resistance and provide a robust physical connection point The internal power distribution plates connecting the cells battery management system BMS and internal terminals are solid copper Our proprietary case ...

Page 3: ...CONNECT MORE THAN FOUR BATTERIES IN SERIES DO NOT CONNECT MORE THAN FOUR BATTERIES IN PARALLEL DO NOT ATTEMPT TO REPAIR THE BATTERY IF MALFUNCTIONING DO NOT CHARGE THE BATTERY ABOVE 14 6 VDC DO NOT CHARGE THE BATTERY AT OR BELOW 32 F OR 0 C DO NOT CHARGE THE BATTERY ABOVE ITS MAXIMUM CHARGE RATE DO NOT DISCHARGE THE BATTERY BELOW 10 5 VDC DO NOT DISCHARGE THE BATTERY AT OR BELOW 4 F OR 20 C DO NOT...

Page 4: ...nd G27 Rev 2 07 18 2022 Table of Contents 1 Installation 5 2 Battery Management System BMS 9 3 Battery Monitoring 10 4 Charge 11 5 Discharge 13 6 Battery Life 17 7 Storage 18 8 Accessories 19 9 Battery Specifications 20 10 Warranty 21 ...

Page 5: ...ries with the Expion360 Bus Bars or power cables tighten the M 8 x 1 25 hex bolts to 8 lb ft 96 lb in using an adjustable torque wrench Make sure all connections are bundled and well organized to prevent short circuits Ensure all cables and circuit protection fuses and or circuit breakers are properly sized for the entire system See details about circuit protections in Section 5 2 Circuit Protecti...

Page 6: ...hs of the female battery terminal threads are no more than 12 mm Consider this when determining the proper bolt length to secure bus bars cable lugs and any washers that will be affixed to the terminal connection pad If too much torque is applied to a bolt the female threads of the battery terminal will be stripped and the damage will not be covered under warranty due to misuse of the product Cons...

Page 7: ...7 Expion360 Battery Manual G24 and G27 Rev 2 07 18 2022 Battery Banks ...

Page 8: ...8 Expion360 Battery Manual G24 and G27 Rev 2 07 18 2022 Please call technical support if your planned installation will be wired in a way not found in the provided wiring schematics ...

Page 9: ...f your battery When the battery voltage rises above 10 8 Vdc 0 4 Vdc the BMS will reconnect Some chargers will not charge if an open circuit is detected as the BMS has disconnected We recommend using our DC DC charger or AC DC charger to avoid this open circuit problem and an Expion360 Battery Monitor to display voltage clearly Overcurrent Protection The BMS will monitor charge and discharge curre...

Page 10: ... battery chemistries It shows the remaining capacity Ah SoC battery bank voltage V charge discharge current A and charge discharge power W The battery monitor also shows the remaining discharge time until empty and the remaining charge time until full Include this useful accessory for peace of mind and to see your battery metrics at any time without manually probing your batteries Note that the vo...

Page 11: ...to 14 6 Vdc although 14 4 Vdc is preferred The CC bulk or boost stage charges the battery to 95 SoC at the charger s rated current until the battery reaches the charger s voltage setting The charger then transitions to the CV absorption or saturation stage at the charger s given voltage setting and tapers the charge current down to zero as the battery reaches the charger s target voltage The CV st...

Page 12: ...be programmed for two stage charging or one with a lithium battery setting If using a programmable solar charge controller set the charge voltage from 14 2 Vdc to 14 6 Vdc 14 4 Vdc preferred To prevent the solar charge controller from charging the battery bank below 32 F install a disconnect switch between the solar panels and the solar charge controller Make sure the switch is sized to handle the...

Page 13: ...ischarge the battery bank above its maximum continuous discharge rate See the Battery Specifications page Section 9 for the optimal maximum and pulse discharge rates of each Expion360 battery For example a battery bank has four 100 Ah Expion360 batteries connected in parallel The maximum continuous discharge rate of a single Expion360 battery is 100 A 1C The capacity of the battery bank is 400 Ah ...

Page 14: ... 3 Batteries 1h 53m 2h 31m 3h 0m 3h 9m 3h 47m 7h 53m 4 Batteries 2h 31m 3h 22m 4h 0m 4h 12m 5h 2m 10h 30m 2000 Watt Inverter 1 Battery 1h 19m 2 Batteries 1h 3m 1h 16m 2h 38m 3 Batteries 1h 15m 1h 30m 1h 35m 1h 53m 3h 56m 4 Batteries 1h 15m 1h 40m 2h 2h 6m 2h 31m 5h 15m 3000 Watt Inverter 1 Battery 2 Batteries 1h 45m 3 Batteries 1h 3m 1h 15m 2h 38m 4 Batteries 1h 7m 1h 20m 1h 24m 1h 40m 3h 30m Prop...

Page 15: ...fuses between 60 to 200 A use Blue Sea Systems fuse holder 5005 For ANL fuses between 225 to 750 A use Blue Sea Systems fuse holder 5503 Class T fuses are recommended to protect the power system due to their lower voltage drop and higher efficiency For the budget conscious consumer and lower current applications ANL fuses are sufficient at the cost of reduced system efficiency Use fuse and breaker...

Page 16: ... maximum continuous discharge rate of each string of the battery bank For instance if the maximum continuous discharge rate of two strings of parallel connected batteries is 800 A with 400 Ah on each string the battery bank should be paired with a 400 A DC fuse on each string The cables connecting the two strings to the inverter must be sized properly for the maximum 800 A current For more informa...

Page 17: ...atteries at extremely low or high temperatures will significantly decrease their cycle life Please make sure the battery bank is well ventilated or cooled during high temperatures and kept heated at low temperatures Maximum battery life can be achieved when operating temperatures are as close to 77 F as possible We advise installing our heating blankets Section 8 with your batteries to protect the...

Page 18: ...13 4 Vdc 4 F to 95 F 6 months 13 4 Vdc 4 F to 77 F Completely discharge and charge the battery bank to 13 4 Vdc every 6 months Due to the inherent self discharge of all batteries it is advised to check the voltage displayed on the battery monitor periodically If at any time the voltage is below 12 Vdc check the battery bank and make sure it is completely disconnected from any load Charge the batte...

Page 19: ...ays Model EX 24 3 TDS Triple battery tie down system For six batteries use two triple trays Model EX 27 TDS Single battery tie down system for group 27 battery Model EX 27 2 TDS Dual battery tie down system for group 27 battery Model EX 27 3 TDS Triple battery tie down system for group 27 battery EX G24_27 BUS Aluminum bus bar highly economic and efficient to connect batteries EX G24 TJ KIT EX G27...

Page 20: ...rial Brass Terminal Thread M 8 x 1 25 12 mm Torque Spec 8 lb ft 10 Nm Cell Type Cylindrical LiFePO4 Charge Charge Method CC CV Charge Voltage 14 2 Vdc to 14 6 Vdc Optimal Charging Target Voltage 13 8 Vdc about 80 SoC Optimal Charge Current 0 2C 12 A 16 A 19 A 20 A 24 A Quick Charge Current 32 F to 50 F 0 C to 10 C 0 2C 50 F to 140 F 10 C to 60 C 0 5C 30 A 40 A 48 A 50 A 60 A Overcharge Disconnect ...

Page 21: ...pion360 Battery Manual G24 and G27 Rev 2 07 18 2022 10 Warranty Online product registration is required for warranty coverage For current warranty information please check our website http www expion360 com ...

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