RELiON InSight User Manual
48V030-GC2 MANUAL
TABLE OF CONTENTS
1. Introduction 3
2. Scope 3
3. Abbreviations 3
4. Product Specifications 3
4.1. General Specifications 3
4.2. Electrical Specifications 4
4.2.1.Charging Specifications 4
4.2.2. Discharging Specifications 4
4.2.3. Parallel Specifications 4
4.3.Mechanical Specifications 4
4.4. Drawing 5
5. Battery Installation 5
5.1. Parallel Connections 5
5.2. Battery Orientation 6
6. Battery Interface 6
6.1. Power Button 6
6.2. LEDs 6
7. Battery Mode Descriptions 6
8. Power Button Functions 7
9. LED Function 1 – Battery Status 7
10. LED Function 2 – SOC Status 7
11. LED Function 3 – Protection/Error Indicators 7
12. Battery Mode Operation Details 8
12.1. OFF Mode 8
12.2. ON Mode 8
12.3. SLEEP Mode 8
12.3.1.Pulse Recovery Operation (PRO)
During SLEEP Mode 8
12.4.UNDER VOLTAGE PROTECTION (UVP)Mode 8
12.4.1. Pulse Recovery Operation (PRO) During
UVP Mode 8
12.5. Turn Battery ON During PRO 9
13. BMS Protection Details 9
13.1. Under Voltage Protection (UVP) 9
13.2. Over Voltage Protection (OVP) 9
13.3. Under Temperature Protection (UTP) 9
13.4. Over Temperature Protection (OTP) 9
13.5. Over Current Protection (OCP) 9
13.6. Short Circuit Protection (SCP) 10
14. CANbus Communication 10
14.1. CAN Connectors 10
14.2. Communication Hardware 10
14.3. CANbus Details 10
14.4. Broadcast Data 10
14.5. Broadcast Data Frame 11
15. Charging Guidelines 11
15.1. Charger Inspection 11
15.2. Charge Temperature 11
15.3. Prior to Charge 11
15.4. During Charge 11
15.5. Charge Completion 12
15.6. Charge Parameters 12
15.6.1. CC Charge Profile – 1 Stage 12
15.6.2. CC-CV Charge Profile – 2 Stage 12
16. Battery Indicator 12
17. Battery Storage 13
18. Energy Consumption During Storage 13
19. Recycling 13
20. Precautions 14
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. INTRODUCTION
RELiON’s InSight Series batteries are the first scalable
LiFePO4 drop-in replacement battery, that comes in an
industry standard, GC2 size.
. SCOPE
This document applies to model 48V030-GC2.
. ABBREVIATIONS
• State of Charge (SOC)
• State of Health (SOH)
• Over Voltage Protection (OVP)
• Under Voltage Protection (UVP)
• Over Temperature Protection (OTP)
• Under Temperature Protection (UTP)
• Over Current Protection (OCP)
• Short Circuit Protection (SCP)
• Light Emitting Diode (LED)
• Pulse Recovery Operation (PRO)
• Controller Area Network bus (CANbus)
• Battery Display Indicator (BDI)
. PRODUCT SPECIFICATIONS
4.1. General Specifications
GENERAL SPECIFICATIONS
Nominal Voltage 51.2V
Cell Chemistry LiFePO4
Cell Type Prismatic
Ampere-hour Capacity 30Ah
Watt-hour Capacity 1.536kWh
Specific Energy 128Wh/kg
Charge Eiciency 99%
Impedance (50% SOC, 1kHz) <150mΩ
Cycles @ 80% DOD >6000
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4.2. Electrical Specifications
4.2.1. Charging Specifications
CHARGE SPECIFICATIONS
Recommended Continuous Charge Current (single battery) ≤60A
Maximum Charge Current (BMS will disconnect if exceeded) 65A - 5 sec
Recommended Charge Voltage 57.6 - 58.4V
Maximum Charge Voltage 58.4V
Float Voltage 55.2V
High Voltage Disconnect 59.2V (3.7vpc) (4s)
Over Voltage Reconnect Automatic
Minimum Charger Output Voltage (for charge initiation) 56V
Temperature Compensation Required None
4.2.2. Discharging Specifications
DISCHARGE SPECIFICATIONS
Continuous Discharge Current 100A
Peak Discharge Current 200A (15 sec)
Short Circuit Protection
560A (366 μsec)
Low Voltage Disconnect 40V (2.5vpc) (5 sec)
Low Voltage Reconnect See section 12.5
4.2.3. Parallel Specifications
All the currents are additive in Parallel operation. See table below.
CHARACTERISTIC V X V X V X V X
Voltage 51.2V 51.2V 51.2V 51.2V
Capacity 30Ah 60Ah 90Ah 120Ah
Cont. Discharge Current 100A 200A 300A 400A
Peak Discharge (15 sec) 200A 400A 600A 800A
4.3. Mechanical Specifications
MECHANICAL SPECIFICATIONS
BCI Size GC2
Dimensions (L x W x H)
Weight
Case Material ABS
Stud Terminal M8 X 1.25 - 20
Insert Terminal M8 X 1.25 - 20
Torque
Handles Molded
Ingress Protection Marking IP67
Case Flame Rating UL94 V-0
10.2 x 7.1 x 10.9 in
260 x 180 x 276 mm
34.4 lb.
15.6 kg
79.7-88.5 in-lbs.
9-10 N-m
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4.4. Drawing
180.00 mm
260 mm
276 mm
271.5 mm
180 mm
250.00 mm
Dimensions shown in mm
. BATTERY INSTALLATION
To ensure proper operation of the battery (for single-battery or multiple-battery installations), follow the steps below:
• InSight batteries can only be used in parallel (not series). Up to 10 batteries may be connected.
• Select proper wire gauge for your applications electrical current (A) demands (Suggested reference: NEC 2014: Table
310.15(B)(16) Allowable Ampacities of Insulated Conductors).
• On new installations it is recommended that new battery cables (free from corrosion) be used.
• Ensure that all battery cables are equal in length to avoid battery imbalances. CAUTION : Any existing 12V
accessories (lights, radio, etc) must be connected to an auxiliary DC/DC converter (48V to 12V)
• All cables should terminate at bus bars with respect to their polarity.
• Torque the battery terminals appropriately as listed in Section 4.3.
• Connect the provided Controller Area Network bus (CANbus) cables as shown in Section 5.1.
• Turn batteries ON. See the table in Section 8 or Section 12.2 for written instructions.
• Charge the batteries to 100% State of Charge (SOC) prior to use.
5.1. Parallel Connections – Options 1 and 2
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