This document is a manual for LiONCore rechargeable lithium batteries, manufactured by electroVolt (Vertical Partners West LLC). The manual covers models 55111 through 55117.
Function Description
LiONCore batteries are a series of robust, off-the-shelf lithium-ion batteries designed to provide power solutions, serving as an excellent replacement option for everyday SLA (Sealed Lead Acid) / AGM (Absorbent Glass Mat) batteries. These batteries utilize Lithium Iron Phosphate (LiFePO4) technology and incorporate an onboard Battery Management System (BMS) for enhanced safety and prolonged life expectancy. The BMS protects the battery from various conditions including high voltage/overcharge, low voltage/undercharge, high current, high temperature, and short circuits.
Important Technical Specifications
The LiONCore series includes several models with varying capacities and physical dimensions:
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Model 551111:
- Nominal Voltage: 12.8V
- Capacity: 7 Ah
- Standard Charge Current: 1.4A
- Max Continuous Charge Current: 7A
- Max Continuous Discharge Current: 7A
- Peak Discharge Current (<5s): 14A
- Terminal Type: F2
- Dimensions: 150 x 65 x 101mm (5.9 x 2.6 x 4in)
- Weight: 1kg (2.2lbs)
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Model 551112:
- Nominal Voltage: 12.8V
- Capacity: 10 Ah
- Standard Charge Current: 2A
- Max Continuous Charge Current: 10A
- Max Continuous Discharge Current: 10A
- Peak Discharge Current (<5s): 20A
- Terminal Type: F2
- Dimensions: 151 x 100 x 104mm (5.9 x 3.9 x 4.1in)
- Weight: 1.5kg (3.3lbs)
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Model 551113:
- Nominal Voltage: 12.8V
- Capacity: 20 Ah
- Standard Charge Current: 4A
- Max Continuous Charge Current: 20A
- Max Continuous Discharge Current: 20A
- Peak Discharge Current (<5s): 40A
- Terminal Type: M5
- Recommended Terminal Torque: 17.5 in-lb
- Terminal Bolt Specifications: M5
- Dimensions: 181 x 77 x 170mm (7.1 x 3 x 6.7in)
- Weight: 2.6kg (5.7lbs)
-
Model 551114:
- Nominal Voltage: 12.8V
- Capacity: 33 Ah
- Standard Charge Current: 6.6A
- Max Continuous Charge Current: 33A
- Max Continuous Discharge Current: 33A
- Peak Discharge Current (<5s): 66A
- Terminal Type: M6
- Recommended Terminal Torque: 26.25 in-lb
- Terminal Bolt Specifications: M6-1, 13mm
- Dimensions: 196 x 132 x 154mm (7.7 x 5.2 x 6.2in)
- Weight: 4.7kg (10.3lbs)
-
Model 551115:
- Nominal Voltage: 12.8V
- Capacity: 75 Ah
- Standard Charge Current: 15A
- Max Continuous Charge Current: 75A
- Max Continuous Discharge Current: 75A
- Peak Discharge Current (<5s): 150A
- Terminal Type: M6
- Recommended Terminal Torque: 26.25 in-lb / 2.94 Nm
- Terminal Bolt Specifications: M6-1, 13mm
- Dimensions: 260 x 168 x 212mm (10.2 x 6.6 x 8.3in)
- Weight: 11kg (24.2lbs)
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Model 551116:
- Nominal Voltage: 12.8V
- Capacity: 100 Ah
- Standard Charge Current: 20A
- Max Continuous Charge Current: 100A
- Max Continuous Discharge Current: 100A
- Peak Discharge Current (<5s): 200A
- Terminal Type: M8
- Recommended Terminal Torque: 61.25 in-lb / 6.86 Nm
- Terminal Bolt Specifications: M8-1.25, 12mm
- Dimensions: 327 x 172 x 218mm (12.9 x 6.8 x 8.6in)
- Weight: 14kg (30.8lbs)
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Model 551117:
- Nominal Voltage: 12.8V
- Capacity: 200 Ah
- Standard Charge Current: 30A
- Max Continuous Charge Current: 100A
- Max Continuous Discharge Current: 100A
- Peak Discharge Current (<5s): 200A
- Terminal Type: M8
- Recommended Terminal Torque: 61.25 in-lb / 6.86 Nm
- Terminal Bolt Specifications: M8-1.25, 12mm
- Dimensions: 522 x 239 x 221mm (20.5 x 9.4 x 8.7in)
- Weight: 27kg (59.4lbs)
Cable/Wire Gauge Size (AWG/mm²) and Ampacity (Amps):
The manual provides a table based on NEC Table 310.15(B)16 for copper cables rated at 167°F (75°C), operating at an ambient temperature of no more than 86°F (30°C).
- 14 AWG (2.08mm²): 20 Amps
- 12 AWG (3.31mm²): 25 Amps
- 10 AWG (5.26mm²): 35 Amps
- 8 AWG (8.36mm²): 50 Amps
- 6 AWG (13.3mm²): 65 Amps
- 4 AWG (21.1mm²): 85 Amps
- 2 AWG (33.6mm²): 115 Amps
- 1 AWG (42.4mm²): 130 Amps
- 1/0 AWG (53.5mm²): 150 Amps
- 2/0 AWG (67.4mm²): 175 Amps
- 4/0 AWG (107mm²): 230 Amps
Usage Features
Installation:
- Use properly sized cables and cable lugs for the expected load, keeping all cables as short as possible.
- Torque battery terminal connections to specified values using the supplied flat washer, split washer (A), and bolts (B). The split washer (A) should be placed first, followed by the flat washer (B).
- For series/parallel battery banks, all series cables and all parallel cables should be the same length.
Charging:
- Only use LiFePO4 approved chargers. Lead-acid battery chargers, especially those with automatic desulfation or equalization modes, are strictly prohibited as they can prevent proper BMS balancing and reduce battery life.
- Batteries are not shipped fully charged and must be fully charged prior to first use.
- Do not charge in series or parallel during the initial charge.
- For optimal performance and longevity, avoid charging below 10°C (50°F). Safe charging temperature range is 0°C to 45°C (32°F to 113°F).
- Do not exceed the maximum charge rate listed on the battery data sheet.
- When using batteries in series, electroVolt recommends charging each battery individually at least every fourth use to avoid imbalance.
Series and Parallel Connections:
- LiONCore LiFePO4 batteries can be connected in series to increase system voltage or in parallel to increase system capacity.
- Do not connect batteries in both series and parallel simultaneously.
- Multiple battery systems should only use one battery type and capacity from electroVolt.
- Crucially, do not exceed four batteries in series or two batteries in parallel. Exceeding these limits will cause irreversible damage and void all warranties.
- Series Connection Example: Two 12.8V 100Ah batteries connected in series result in a system voltage of 25.6V and a system capacity of 100Ah.
- Parallel Connection Example: Two 12.8V 100Ah batteries connected in parallel result in a system voltage of 12.8V and a system capacity of 200Ah.
- When connected in parallel, the continuous and peak discharge current values should remain in accordance with the ratings of a single battery as per its data sheet.
Battery Management System (BMS):
The built-in BMS provides several protective features:
- High Voltage / Over Charge Protection: Disconnects charge current if any cell exceeds a pre-defined upper voltage threshold. Discharge is always allowed in this state.
- Passive Cell Balancing: Activated at the top of each charge cycle to ensure all cells remain at the same state of charge, enhancing performance and longevity.
- Low Voltage / Under Charge Protection: Disconnects the load if any cell falls below a pre-defined lower voltage threshold during discharge. Charging is always allowed in this state.
- High Current Protection: Prevents current exceeding a pre-defined value. The battery automatically resets once the load is removed.
- High Temperature Protection: Prevents charge or discharge current if the pre-defined temperature value is exceeded. Protection releases once the temperature falls below the pre-defined release temperature.
- Short Circuit Protection: Isolates cells in a short circuit condition and automatically resets once the short circuit is removed.
Maintenance Features
General Handling and Storage:
- Inspect batteries before and after each use for physical damage, moisture, or corrosion.
- Handle batteries with extreme care to avoid dinging, denting, puncturing, or other damage.
- Keep batteries out of reach of children and pets.
- Do not disassemble, modify, or attempt repairs.
- Do not short circuit battery terminals.
- Store batteries in a cool, dry place between 4°C to 26°C (40°F to 80°F).
- Store batteries away from flammable materials with terminals covered.
- Store batteries at their nominal voltage (displayed on the battery label).
- Fully charge and return batteries to nominal voltage at least once every three months when not in use.
- Always cover battery terminals during transport with non-conductive material like electrical tape to prevent accidental short circuits.
- Keep batteries out of direct sunlight and environments exceeding 55°C (131°F).
- Keep a class D chemical fire extinguisher nearby when storing, handling, charging, or using LiFePO4 battery packs.
- Never charge near flammable materials.
- Allow batteries to cool to an ambient temperature of 10°C to 35°C (50°F to 95°F) before recharging for best performance and cycle life.
- Ensure battery connections are securely connected with proper polarity and free of corrosion.
- Secure battery packs in the application to prevent movement and damage.
- Use insulated tools when making contact, connecting, or disconnecting batteries.
- Keep sparks, flames, and static electricity sources away from batteries.
- Never place objects on top of batteries.
- Always disconnect any load prior to connecting or disconnecting battery terminals.
- Never immerse in water or use high-pressure water to clean a battery.
Discharge Management:
- Select batteries based on the amp draw requirements of the application to prevent irreversible damage from over-discharge. Refer to the battery data sheet for rated continuous discharge current.
Terminal Maintenance:
- Check battery cables and connections frequently.
- Retorque terminal bolts to proper specifications and replace damaged cables as needed.
- Battery cable lugs and terminals should be clean, dry, and free of corrosion. Clean terminals only with a dry cloth or non-metallic brush.
Disposal:
- Dispose of batteries that show signs of damage or are retired from use properly.
- Transport battery packs to an approved disposal facility, observing all safety warnings.
- Check with local waste facilities for lithium battery disposal regulations. Many stores offer free recycling of rechargeable batteries; a locator can be found at http://www.call2recycle.org/locator.
Safety Precautions:
- Read the entire manual before use. Failure to observe precautions can result in fire, explosion, and personal injury.
- Damaged or ruptured battery packs or cells may leak electrolytes, causing irritation, burning, and dryness of skin and eyes. In case of skin contact, wash the affected area with soap and warm water. For eye contact, rinse thoroughly with cool water and seek immediate medical attention for any burns.
Warranty:
- All electroVolt products are guaranteed to be free of defects in material and workmanship for 1 year from the original date of shipment. electroVolt will repair or replace defective products or issue a credit memo at its sole discretion.
- The warranty is exclusive and in lieu of any other express or implied warranties, including merchantability or fitness for purpose.
- The warranty does not cover defects due to usage outside of normal operating parameters, as battery life is greatly affected by how batteries are used, charged, and stored.
- electroVolt is not liable for consequential, incidental, indirect, or contingent damages, or for property damages, penalties, special or punitive damages, lost profits, revenues, downtime, lost goodwill, cost of capital, or cost of substitute goods/services.
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