Page 1: Table Of Contents
CONTENTS BEFORE YOU START SHIPPING SAFETY 10.1 REGULATORY INFORMATION EQUIPMENT NEEDED 10.2 PACKAGING ADDITIONAL INFORMATION SAFETY DATA SHEETS (MSDS) 5 11.1 TERMINOLOGY BATTERY SPECIFICATIONS 11.2 CHARGER OVERVIEW OPTIMIZATION/DIAGNOSIS BATTERY OPERATION 11.3 DISCHARGE TESTING TURNING ON 11.4 C-RATES TURNING OFF 11.5 PRODUCT SPECIFICATION ACTIVE MODE AND SOC DISPLAY 8 SHEETS DISPLAY WHILE CHARGING...
Page 2: Before You Start
BEFORE YOU START The following Safety and Equipment sections are provided to ensure safe and successful battery installation and maintenance. 1.1 SAFETY Batteries can deliver an enormous amount of power that can result in injury and/or death, observing the following precautions is the difference between successful battery maintenance/installation and a night in the emergency room: ●...
Page 3: Safety Data Sheets (Msds)
1.3 SAFETY DATA SHEETS (MSDS) U.S. Battery has safety data sheets available for all product lines: Lithium-Ion Safety Data Sheet GC2 Lithium-ion User Manual...
Page 4: Battery Specifications Overview
BATTERY SPECIFICATIONS OVERVIEW TABLE 1 US 48V GC2 US 24V GC2 Specifications Description 16S1P 8S1P Cell Configuration LFP Prismatic LFP Prismatic Cell Type 30Ah 67Ah Nominal Capacity* 51.2V 25.6V Nominal Voltage of Pack 1.5kWh 1.7kWh Rated Energy of Pack 58.4V 29.2V...
Page 5 DIAGRAM 1 A. Negative Terminal (M8 insert) G. Positive Terminal (M8 insert) B. Aluminum Heat Sink H. In/Out CANbus Ports C. Battery Status Indicator LEDs I. Lift Handle (SOC) J. Pressure relief valve D. Lift Handle E. Button LED F. Wake/Status Button GC2 Lithium-ion User Manual...
Page 6: Battery Operation
BATTERY OPERATION DIAGRAM 2 The Essential Lithium-Ion GC2 batteries are equiped with an integrated button and LEDs to assist with turning battery on/off, SOC deter- mination, fault/error handling, and status ref- erence. Below is a description of the various button and LED functions.
Page 7: Display While Charging
TABLE 2 LED1 LED2 LED3 LED4 LED5 1%~9% Flash 10%~20% 21%~45% 46%~70% 71%~95% 96%~100% 3.4 DISPLAY WHILE CHARGING TABLE 3 LED1 LED2 LED3 LED4 LED5 1%~20% Pulse 21%~40% Pulse 41%~60% Pulse 61%~80% Pulse 81%~99% Pulse 100% All off, button LED is solid green 3.5 FAULT DISPLAY When faults are active, the Button LED will flash red every 5 seconds.
Page 8: Fault Troubleshooting
TABLE 4 Fault LED1 LED2 LED3 LED4 LED5 Under Voltage Charge Over Current Discharge Over Current Short Circuit Charge Over Temp. Charge Under Temp. Discharge Over Temp. Discharge Under Temp. 3.5 FAULT TROUBLESHOOTING UNDER VOLTAGE Battery has been overdischarged. The batteries need to be charged immediately. If the batteries are in a motive application, wait approximately 15 minutes to allow the voltage to increase.
Page 9: Installation
CHARGE OVER TEMP Battery internal temperature has surpassed the maximum. The battery must be al- lowed to cool. The wait time is dependent on the ambient temperature and battery box design. Battery cables can come loose and cause a significant rise in tempera- ture.
Page 10: Terminal Protection And
TABLE 5 Table values are from NEC table 321.15(B)16 Cable/Wire Gauge Size Ampacity for copper cables rated at 167˚F (75˚C), op- (AWG) (Amps) erating at an ambient temperature of no more than 86˚F (30˚C). Lengths in excess of 6 feet (1829mm) may require heavier gauge wire to avoid unacceptable voltage drop.
Page 11: Accessories
DIAGRAM 3 PARALLEL CONNECTION To increase capacity without increasing voltage Two US 48VGC2, rated at 30AH each connected in parallel Nominal System Voltage: 51.2V System Capacity: 60AH When using multiple batteries in parallel, it is extremely important that batteries are at the same state of charge (SOC) when installed.
Page 12 • Environment Batteries should always be installed or stored in a clean, cool, and dry place. Keep water, oil, and dirt away from the batteries. If these materials are allowed to accumu- late on the batteries, current leakage can occur resulting in self-discharge and possible short-circuits.
Page 13: Electrical Specifications
ELECTRICAL SPECIFICATIONS 5.1 DISCHARGE SPECIFICATION Lithium-Ion batteries have a relatively “flat” discharge curve when compared to lead-ac- id batteries. In other words, the voltage stays level for most of the discharge until the very end. Therefore, estimating the state of charge (SOC) using voltage is unreliable. Many electric vehicles designed for lead-acid batteries have SOC displays that rely on voltage and as such these displays will no longer be accurate when used with lithi- um-ion batteries.
Page 14: Bms Protection Criteria
5.2 BMS PROTECTION CRITERIA The battery management system is designed to disconnect the battery cells from the terminals to protect the battery from damage in adverse conditions. Note that this may cause vehicles to lose power, resulting in loss of control. Do not operate batteries outside of the specifications listed below.
Page 15: Charging
CHARGING 6.1 BEFORE CHARGING Proper charging is critical to maximize battery performance and life. Both under- and over-charging batteries can significantly reduce the life of the battery and cause a safe- ty hazard. For proper charging, refer to the instructions that came with your equipment. Most chargers are automatic and pre-programmed.
Page 16 Below is a generic lithium iron phosphate cell charging curve: CHART 3 State of Charge (%) Voltage Current U.S. Battery has worked with major charger manufacturers to develop more advanced charging profiles to enhance performance and life of the batteries. When possible, se- lect the U.S.
Page 17: Cell Balancing
6.3 CELL BALANCING Lithium-Ion battery packs contain multiple cells in series and/or parallel arrangements. Due to inherent variations in cell manufacturing processes, no two cells are identical. As a result, during charging and discharging, cells become “unbalanced” meaning they are not at equivalent states of charge. If not properly managed, this can cause prema- ture failure of the battery pack.
Page 18: Canbus
CAN I OPPORTUNITY CHARGE? • Yes, this is a great feature of lithium-ion batteries. They can be charged during a break in usage and can quickly regain capacity. A good example would be plug- ging in for an hour while on lunch to get extra runtime. While this does not harm the batteries, it is important that full charge cycles are completed periodically for cell balancing as mentioned in “6.3 Cell...
Page 19: Recommended Battery Pack Sizes
between parallel batteries to allow for communication. This jumper should connect from the “OUT” CAN port of one battery to the “IN” CAN port of the next battery. The last battery in the string should also use a CAN termination plug in the final “OUT” CAN port for applications not using a remote display.
Page 20: Storage
STORAGE For long term storage (more than a month) batteries should be stored, fully charged, and turned off. You can turn the batteries off by following the directions in “3 Battery operation”. This will ensure low self-discharge rate and allow storage of up to one year. Batteries will automatically enter a “sleep”...
Page 21 • *Damaged lithium ion batteries are forbidden from air transport. Shipments are for- bidden to be transported as cargo on passenger aircraft (column 9 of the HMT - § 172.101). When shipping by air, batteries must be at 30% SOC or below. 10.2 PACKAGING Batteries are provided with packaging that meets UN38.3 requirements.
Page 22 ADDITIONAL INFORMATION 11.1 TERMINOLOGY THE FOLLOWING TERMS AND ABBREVIATIONS ARE USED IN THIS DOCUMENT AS WELL AS THE BATTERY INDUSTRY: AMP – Amperes, measure of current Ah – Ampere-Hours, a measure of battery capacity BMS – Battery Management System, electronics inside of battery designed to monitor, control, and report status of battery pack CCA –...
Page 23 11.3 DISCHARGE TESTING • Start with a fully charged battery • Ensure that all charging sources and loads are disconnected from the battery. • Connect and start the discharger at the desired discharge rate. • Record the runtime when the discharger is finished. •...
Page 24 Each battery contains a barcode label on the side of the plastic enclosure. This infor- mation is needed for warranty and product registration purposes. 11.7 WARRANTY US Battery offers a limited liability, 5 year warranty for Essential Lithium-Ion Batteries. Please visit this link to review the warranty specifics: Links to warranty statement on web 11.8 BATTERY DEALERS NEAR YOU...
Page 25 12 BATTERY RECYCLING Lithium-ion batteries should NOT go in household garbage or recycling bins. Addition- ally, they should NOT be combined with lead-acid batteries destined for recycling. Lith- ium batteries entering a lead-acid recycling facility can be catastrophic causing signifi- cant damage and injuries.

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Us 24v gc