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Summary of Contents for DISCOVER AES PROFESSIONAL DLP-GC2-12V
- Page 1 INSTALLATION AND OPERATION MANUAL BATTERY MODELS DLP-GC2-12V | 900-0051 DLP-GC2-24V | 900-0052 DLP-GC2-36V | 900-0053 DLP-GC2-48V | 900-0054 805-0027 REV K...
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Page 2: Table Of Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1 . -
Page 3: Introduction
For information on batteries where the last 9 digits of the serial number is less than 242200000, or the firmware version is before 4.7 .0.0, see the following legacy document on the Discover website: https://discoverlithium.com/s4x_files/resources/des-aes-professional-manual-legacy.pdf 1 . AUDIENCE, MESSAGES, WARNINGS, GENERAL SAFETY, PERSONAL PROTECTIVE EQUIPMENT 1 .1 Audience... -
Page 4: Warning And General Safety
NOTICE Important information regarding conditions that may result in damage to the equipment but not personal injury. NOTE Ad hoc information concerning important procedures and features of the battery not related to personal injury or equipment damage. 1 .3 Warning and General Safety WARNING ELECTRIC SHOCK AND FIRE HAZARD •... -
Page 5: Safe Handling Procedures
1 .4 Safe Handling Procedures Before using the battery, read all instructions and cautionary markings on the unit and all appropriate sections of this manual. • Use personal protective equipment when working with batteries. • Do not dispose of the battery in fire. •... -
Page 6: Items Shipped In The Box
2 . ITEMS SHIPPED IN THE BOX Table 2-1, AES PROFESSIONAL box contents Items Description Battery Manual (this document) 3 . SPECIFICATIONS Specifications are published at 25 C / 77 3 .1 Electrical Specifications Table 3-1. DLP-GC2 Electrical Specifications DLP-GC2-12V DLP-GC2-24V DLP-GC2-36V DLP-GC2-48V... -
Page 7: Mechanical Specifications
3 .2 Mechanical Specifications Table 3-2. DLP-GC2 Mechanical Specifications Mechanical DLP-GC2-12V DLP-GC2-24V DLP-GC2-36V DLP-GC2-48V 900-0051 900-0052 900-0053 900-0054 Specifications Chemistry LiFePO Length 260 mm (10.2 in) Width 180 mm (7.1 in) Total Height 275 mm (10.8 in) 5/16 in Stud (Height 22 mm) Terminal 5/16 in Button Insert (Depth 18 mm) Terminal Torque... -
Page 8: Protection Specifications
3 .4 Protection Specifications Table 3-4. DLP-GC2 Protection Specifications Protection DLP-GC2-12V DLP-GC2-24V DLP-GC2-36V DLP-GC2-48V 900-0051 900-0052 900-0053 900-0054 Specifications Overvoltage Protection > 14.56 V for 3.2 s > 29.12 V for 3.2 s > 43.68 V for 3.2 s > 58.24 V for 3.2 s Recovery after Recovery after Recovery after... -
Page 9: Internal Heating Specifications
100000 10000 1000 0.01 0.001 0.001 900 1,000 1,100 1,200 Current (A) Figure 1. Over-Discharge Protection Time Current Curve 3 .5 Internal Heating Specifications Table 3-5. DLP-GC2 Internal Heating Specifications Internal Heating DLP-GC2-12V DLP-GC2-24V DLP-GC2-36V DLP-GC2-48V Specifications 900-0051 900-0052 900-0053 900-0054 Heating Power 50 W... - Page 10 If charging and discharging for repeated cycles, the total charging capacity of all charging sources in the system should not exceed the Max Continuous Charge Current and Max Continuous Discharge Current operating limits of all the batteries in the system. If the Max Charge Current (1 hour) or Max Discharge Current (1 hour) is exceeded for any battery in the system, the BMS in that battery will trigger the over-current protection and disconnect.
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Page 11: Regulatory
Table 3-8. DLP-GC2-36V - DC Capacity Values for Sample Battery Systems Energy/ Parallel Peak Max Charge Discharge Continuous Continuous Usable System Current (1 hr) (1 hr) Discharge Charge Capacity 2 Batteries 180 A 116 A 30 A 58 A 30 A 2304 Wh 3 Batteries 270 A... -
Page 12: Transportation
4 . TRANSPORTATION If the battery is not installed in equipment, it must be transported in the original package or equivalent. According to the UN Handbook of Tests and Criteria, Batteries are tested to part III, subsection 38.3 (ST/SG/AC.10/11/ Rev. 5). For transport, the batteries belong to category UN3480, Class 9. -
Page 13: Battery On/Off Key
6 .3 Battery ON/OFF Key Briefly press the battery’s ON/OFF key to switch the battery ON. Press and hold the ON/OFF key for longer than 5 seconds while the battery is ON, and the key will arm the Remote Power-Off (RPO) Mode. When the battery is in RPO mode, the battery will shut down once the ON/OFF key is released. -
Page 14: Lifting Points
6.5.1 LYNK Port Pin Assignment Pin Number Function ON/OFF Switch LYNK Bus CAN L LYNK Bus CAN H Figure 3. 5-pin M12 LYNK Bus 12V + A-Code Circular LYNK Bus GND Metric Connector NOTICE Crossing pin functions may cause system damage. Do not terminate unused wires to ground, power, or other functions. -
Page 15: Battery Management System
NOTE Charging and heating can occur simultaneously. However, the BMS will not allow charging to continue when cell temperature is below 4°C (39.2°F) for 5 seconds. 7 .3 Battery Management System 7.3.1 Battery Management System Protections The Battery Management System's (BMS) primary function is to monitor cell voltage and temperature, and battery current. -
Page 16: Lynk Network Communication
Power Conversion device. Closed-loop communication with a Power Conversion device requires using a LYNK II Gateway Communication device available from Discover Energy Systems. For details, please refer to the relevant LYNK Gateway Communication User Manual available at www.discoverlithium.com, or contact your Discover Energy... - Page 17 7.4.1 LYNK Network Power The battery provides the LYNK Network with power via the LYNK Port. Discover accessory documentation will specify how many batteries are required to provide sufficient power for the LYNK Network and compatible accessories. Some accessories may require more than one DLP-GC2 battery to provide sufficient power.
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Page 18: Optional Accessories
8 . OPTIONAL ACCESSORIES Optional accessories are available for use with the DLP-GC2 battery: Accessory Part Number DLP B2B-400 (COMM Cable 0.4 m / 15.75 in, M-F) 950-0035 DLP TOL-7600 (COMM Cable 7.6 m / 299.25 in, M-F) 950-0037 DLP TOL -1800 (COMM Cable 1.8 m / 70.87 in, M-F) 950-0036 DLP T Connector (COMM T Connector) with DLP B2B-400 (COMM Cable 950-0038... -
Page 19: Tools
NOTICE • For chargers or inverters with temperature compensated charging, disable this feature. • Do not use or install a battery temperature sensor. NOTE It is the responsibility of the installer to ensure that all applicable installation requirements and standards are met. 9 .1 Tools •... -
Page 20: Dc Protection
The DC battery cables must meet the following requirements. 1. Copper-stranded cable. DC cables must be stranded, copper, and must be rated 90 °C (194 °C) minimum. The cables must be terminated with lugs that fit the DC terminals. 2. Minimum cable lengths. Select a location that minimizes the length of battery cables to reduce voltage drop from impedance leading to reduced performance. - Page 21 Stud Connection Insert Connection 5/16-18 5/8'' Flange Bolt (Supplied with battery) 5/16"-18 Thread (Supplied with battery) Figure 5. Correct Terminal Installation Figure 6. Incorrect Installation (left: washer between cable lug and battery terminal, right: cable lug angled against battery terminal) NOTICE •...
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Page 22: Single Battery Installation Procedure
CAUTION FIRE HAZARD Use cables sized to handle the specified load. Undersized cables can become hot and may potentially catch fire. Failure to follow these instructions may result in injury. To optimize performance, battery cables (battery to load and battery to charger) must meet the following requirements: 1. -
Page 23: Parallel Battery Installation Procedure
NOTICE • If any adjustments are made after installing the battery in its final destination, re-torque the terminals. • Failure to torque to specifications may increase resistance, lower voltage, and potentially burn out the terminals and void the warranty. • Exceeding 10 Nm (7 .4 ft-lb) of torque on the terminal connections will damage the terminal and void the warranty. - Page 24 4. Install and secure new batteries. Be careful not to make contact between the terminals and any metal mounting, fixture, or body part. The batteries may be strapped in place with over-the-top holds. 5. Connect the batteries in parallel. Preferred Connection Method: Busbar A busbar system is the recommended method of connecting multiple batteries in parallel.
- Page 25 Negative busbar CHARGER LOAD Positive busbar Figure 8. Connect Batteries, Charger, and Load to Busbar 11. Connect the load's positive ( + ) cable to the positive busbar, then the load’s negative ( - ) cable to the negative busbar. 12.
- Page 26 6. Connect battery positive ( + ) cables between the battery positive ( + ) terminals with firmly tightened terminal hardware. Figure 9. Positive Parallel Connections 7 . Connect battery negative ( - ) cables between the battery negative ( - ) terminals with firmly tightened terminal hardware.
- Page 27 9. Connect the charger positive (+) cable and charger negative (-) cable to the opposing ends of the parallel batteries. CHARGER (+) LOAD (+) LOAD (-) CHARGER (-) Figure 12. Charger Connections 10. Torque all battery terminals to the recommended terminal torque of 8 to 10 Nm (5.9 to 7 .4 ft-lb) to secure cable lugs.
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Page 28: Lynk Network
9 .8 LYNK Network 9.8.1 Network Layout LYNK-enabled LYNK-enabled Device 1 Device 2 LYNK-enabled Device 3 Figure 13. Network Layout 9.8.2 Network Installation Networking Guidelines: • Separate data and power cables. Allow for separation between data and power cables. Avoid data interference caused by running network cables bundled with power cables. -
Page 29: Operation
Figure 15. Network Installation Figure 16. Complete Network Installation 9.8.3 Testing and Verification of the LYNK Network Network verification must be completed with one of SOC GAUGE TYPE A (950-0044), SOC GAUGE TYPE B (950-0039), LYNK II (950-0025), or LYNK LITE Communication Gateway (950-0040). -
Page 30: State Of Charge
A voltage-based battery meter designed for lead-acid batteries will not provide an accurate state-of-charge (SOC) for lithium batteries. The following devices are available from Discover and will provide an accurate state of charge: • SOC GAUGE - TYPE A (950-0006, 950-0044) •... - Page 31 10.3.3 When to Charge the Battery • Opportunity charging is OK: Charging the battery after every use will not reduce its cycle life. • Fully charge every 4 cycles: Every 4 cycles, fully charge the battery so the inverter- charger reaches the charge termination criteria. This ensures the battery cells are balanced and that each battery cell is fully charged.
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Page 32: Charging Profile
WARNING ELECTRICAL FIRE HAZARD Do not install this lithium product stand-alone with an alternator, as it could damage the BMS. • In a one-battery system, a large voltage spike may be created, potentially damaging the alternator and BMS and other electronics in the system. •... - Page 33 10.4.1 Bulk Charge Bulk phase. The first phase of the charging process is the Bulk Charge, also referred to as the constant current phase. This is when the charger's maximum current is directed to the battery until the desired voltage is reached. The Bulk phase will recharge the battery to approximately 90-95% SOC.
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Page 34: Routine Inspection
10.4.3 Equalization Charge CAUTION FIRE AND BURN HAZARD Do not perform an equalization charge on lithium batteries. Failure to follow these instructions may result in injury. Do not equalize charge. Do not equalize charge Lithium batteries. Equalization charging is intended only for lead-acid batteries. Equalization charge is a purposeful overcharge that targets a voltage above standard charge voltage to remove sulphate crystals that form on lead-acid plates over time. - Page 35 Table 12-1. DLP-GC2 Fuse Specifications Discover Service Part Number 960-0018 960-0019 960-0020 Applicable DLP-GC2-12V DLP-GC2-24V DLP-GC2-36V 900-0051 900-0052 900-0053 DLP-GC2-48V 900-0054 Fuse Rating 58 V, 200 A 58 V, 125 A 58 V, 60 A Fuse Mounting bolt Fuse Terminal Torque 8 to 10 Nm (5.9 to 7.4 ft-lb).
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Page 36: Storage
10 / 11 are required to update the battery firmware and to download data logs from the battery. LYNK Communication Gateway devices are available from Discover Energy Systems dealers and distributors. LYNK ACCESS Software and the latest battery operating firmware can be obtained from the Discover Energy Systems website at discoverlithium.com. 15 . TROUBLESHOOTING Data logs from each battery are required for accurate troubleshooting and any warranty claim. -
Page 37: Related Information
16 . RELATED INFORMATION Find information about Discover Energy Systems at www.discoverlithium.com. For warranty information, see 885-0031 Discover AES PROFESSIONAL Warranty Policy. 17 . GLOSSARY OF TERMS, ABBREVIATIONS, AND ACRONYMS DLP - AES PROFESSIONAL Battery LFP - LiFePO Lithium Iron Phosphate... - Page 38 NOTES...
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