Product Manual
Lithium Ferro Phosphate (LFP) Battery
48V 30Ah N70 Plastic Cased Battery
Part Number GC48V-030AH-C
LFP Battery GC48V-30AH-C – Product Manual
Contents
1 INTRODUCTION .................................................................................................................................................... 3
2 GENERAL INFORMATION ...................................................................................................................................... 3
2.1 LIFE SUPPORT POLICY .................................................................................................................................................... 3
2.2 GENZ ENERGY PTY LTD .................................................................................................................................................. 3
3 SAFETY GUIDELINES .............................................................................................................................................. 4
3.1 WEIGHT ..................................................................................................................................................................... 4
3.2 RISK OF ELECTRIC SHOCK ............................................................................................................................................... 4
3.3 STORED ENERGY........................................................................................................................................................... 4
3.4 COMPETENT SERVICE PERSONNEL ONLY ........................................................................................................................... 4
3.5 MATERIAL SAFETY DATA SHEET (MSDS) .......................................................................................................................... 4
4 SPECIFICATIONS.................................................................................................................................................... 5
5 BATTERY OVERVIEW ............................................................................................................................................. 6
5.1 BATTERY MANAGEMENT SYSTEM (BMS) .......................................................................................................................... 6
5.2 TERMINALS, POSITIVE AND NEGATIVE............................................................................................................................... 6
6 INSTALLATION ...................................................................................................................................................... 6
6.1 RECEIVING INFORMATION .............................................................................................................................................. 6
6.2 INSTALLATION PLACEMENT ............................................................................................................................................. 7
6.3 CHARGER .................................................................................................................................................................... 7
6.4 USE OF A SINGLE BATTERY ............................................................................................................................................. 7
6.5 PARALLEL CONNECTION OF BATTERIES .............................................................................................................................. 7
6.6 SERIES CONNECTION ..................................................................................................................................................... 8
6.7 INSTALLATION OF THE BATTERY ....................................................................................................................................... 8
6.8 CONNECTING TO THE TERMINALS..................................................................................................................................... 9
6.9 TERMINAL PROTECTION ................................................................................................................................................. 9
6.10 VENTILATION .......................................................................................................................................................... 9
6.11 BATTERY MAINTENANCE ........................................................................................................................................... 9
6.12 CHARGING THE BATTERY ......................................................................................................................................... 10
6.13 DISCHARGING THE BATTERY ..................................................................................................................................... 10
6.14 STORAGE ............................................................................................................................................................. 11
7 TROUBLE SHOOTING .......................................................................................................................................... 12
8 WARRANTY & SERVICE INFORMATION ............................................................................................................... 13
8.1 RECORD OF PURCHASE ................................................................................................................................................ 13
8.2 BEFORE CALLING FOR SERVICE ...................................................................................................................................... 13
8.3 WARRANTY OR SERVICE ............................................................................................................................................... 13
9 APPENDIX C – DIMENSIONS ................................................................................................................................ 14
Issued for Use Revision Page
All rights reserved genZ 2020
30/01/2020 1.0 2 of 16
LFP Battery GC48V-30AH-C – Product Manual
1 Introduction
Thank you for purchasing this Lithium Ferro Phosphate (LFP) Battery. It has been designed and
manufactured to provide many years of trouble free service.
Please read this manual prior to installing the Lithium Ferro Phosphate (LFP) Battery. This product
manual covers the following Battery model:
GC48V-030AH-C
This manual provides important information that must be followed during installation, commissioning
and maintenance of the Battery. Failure to follow these instructions may lead to you damaging the
system it is being installed into and/or voiding your warranty. There are important safety and handling
procedures that must be followed for your own safety and the safety of those around you.
This manual also contains information for customer support and factory service if it is required.
2 General Information
2.1 Life Support Policy
We do not recommend the use of this battery in ‘life support’ applications where failure or
malfunction of the battery can be reasonably expected to cause failure of the life support device or
to significantly affect its safety or effectiveness.
2.2 genZ Energy Pty Ltd
All Rights Reserved.
All rights of this User Manual (“Manual”), including but not limited to the content, information, and
figures are solely owned and reserved by genZ Energy PTY LTD. (“genZ Energy”). The Manual can only
be applied to the operation or the use of this product. Any disposition, duplication, dissemination,
reproduction, modification, translation, extraction, or usage of this manual in whole or in part is
prohibited without the prior written permission of genZ Energy. Given that genZ Energy will
continuously improve and develop the product, changes may be made to the information in this
Manual at any time without obligation to notify any person of such revision or change. genZ Energy
will make all possible efforts to secure the accuracy and the integrity of this manual. genZ Energy
disclaims any kind or forms of warranty, guarantee, or undertaking, either expressly or implicitly,
including but not limited to the completeness, faultlessness, merchantability or fitness for a particular
purpose of the manual.
Issued for Use Revision Page
All rights reserved genZ 2020
30/01/2020 1.0 3 of 16
LFP Battery GC48V-30AH-C – Product Manual
3 Safety Guidelines
3.1 Weight
The Battery is heavy. Any time the Battery has to be handled be sure to use appropriate manual
handling techniques. This is particularly important where the battery maybe being installed in a
confined space.
3.2 Risk of Electric Shock
While this battery is 48 Volts DC, the charger or inverter connected to this battery may be
operating at mains AC voltages. Connecting any of our LFP batteries to any electrical system should
only be carried out by suitably competent service personnel only.
3.3 Stored Energy
These Batteries can, especially if they are connected in parallel, produce high currents.
Care should be taken to avoid shorting the terminals.
3.4 Competent Service Personnel Only
Battery replacement should be performed by competent service personnel only. This battery
contains no user serviceable parts inside and is sealed.
3.5 Material Safety Data Sheet (MSDS)
Refer to the MSDS that was supplied with this battery in case of an accident.
Issued for Use Revision Page
All rights reserved genZ 2020
30/01/2020 1.0 4 of 16
LFP Battery GC48V-30AH-C – Product Manual
4 Specifications
Product Model GC-48V-030AH-C
≤ Ω
≥ （ ）
≥ （ ）
≥ （ ）
≤ ≤
≤1 ± ≤
UN Type Number (chemistry) UN 3480
± ± ±
±
Product design and specification subject to change or modification without notice - images for illustration only. E&OE.
1The over voltage cut-out may vary from that stated. This is due to the fact that the BMS protects the internal cell string voltages ahead of overall pack
voltage.
Issued for Use Revision Page
All rights reserved genZ 2020
30/01/2020 1.0 5 of 16
LFP Battery GC48V-30AH-C – Product Manual
5 Battery Overview
5.1 Battery Management System (BMS)
This battery is fitted with (contained within the battery case) a sophisticated BMS. The BMS is designed
to provide user safety and protect the battery cells from:
Over voltage charging.
Under voltage discharging.
Operation beyond a safe temperature.
Short circuit protection.
Should the BMS activate to protect the battery, the BMS will automatically reset once a normal
operational condition is detected by the BMS.
5.2 Terminals, Positive and Negative
The battery terminals comprise of two M8 brass inserts. The positive
terminal (+) is red and the negative terminal (-) is black. They are also
marked with the + and the – symbols.
The battery is supplied with two M8 bolts.
6 Installation
Failure to follow these guidelines will void the limited warranty and cause potential
damage to property or serious injury.
6.1 Receiving Information
Once you receive the product it should be visually inspected for damage that may have occurred
during shipping. Immediately notify the carrier and place of purchase if any damage is observed. The
packing materials that the product was shipped has been designed to minimize any shipping damage.
In the unlikely event that the product needs to be returned to the manufacturer, use the original
packing material. Since the manufacturer is not responsible for shipping damage incurred when the
product is returned, the original packing material is inexpensive insurance.
Issued for Use Revision Page
All rights reserved genZ 2020
30/01/2020 1.0 6 of 16
LFP Battery GC48V-30AH-C – Product Manual
6.2 Installation Placement
The Battery must be installed such that it is not exposed to:
Sources of radiant heat.
Extreme cold where the ambient temperature is expected to regularly fall below -10°C.
Direct and prolonged sunlight.
Direct and prolonged rain or places where it can become submerged in water.
Corrosive and explosive atmospheres.
6.3 Charger
While there are a number of chargers that should work with this battery, it is recommended that
chargers that comply with the LFP batteries charge profile are used.
It should be noted that should the LFP battery be discharged to the point where the batteries BMS
reaches the low voltage cut off limit, some battery chargers will NOT then charge the battery. To
overcome this, the charger should be placed into ‘power supply’ (48V/51.2V) mode (if available) and
allowed to charge the battery until a terminal voltage greater than 51.2 Volts is observed at the battery
terminal.
6.4 Use of a Single Battery
Ensure that the following is considered prior to installing:
Use only good quality cable lugs that are of the size suitable to accommodate the M8
terminal bolts.
The correct size of cable to the battery connector is used.
That the polarity of the connection is observed. + and – symbols are clearly marked on both
the terminals along with the colour of Red for positive and black for negative.
6.5 Parallel Connection of Batteries
In addition to the guidelines for a single module, when connecting in parallel, the following additional
considerations apply:
As the connection of these modules in parallel can result in high currents and stored energy,
the design of such a system should be made by a competent person or persons only.
All Batteries should be fully charged prior to installation as the batteries may have different
states/levels of charge. Refer to the “Charging the Battery” section of this manual for
charging guidelines.
Issued for Use Revision Page
All rights reserved genZ 2020
30/01/2020 1.0 7 of 16
LFP Battery GC48V-30AH-C – Product Manual
Do NOT install a fully discharged Battery into a fully charged bank of batteries.
Do NOT install a fully charged Battery into a fully discharged bank of batteries.
Do NOT mix these Batteries with other battery chemistry types without prior engineered
testing.
Do NOT mix these Batteries with LFP batteries from other manufacturers.
Consider the use of a suitable fuse(s) to protect from the very high currents that can be
achieved when these batteries are connected in parallel.
Parallel connections involve connecting the POSITIVE (+) connection of one battery to the
POSITIVE (+) connection of the next battery. The same goes for the negative side; NEGATIVE
(-) of the first battery connects to the NEGATIVE (-) of the next battery. Please refer to the
below image for suggested connection. This will help balance the current flow.
6.6 Series Connection
These Batteries are NOT designed for connecting in series. Connecting in series will void your
warranty.
6.7 Installation of the Battery
Be sure to read the installation placement and associated cautions before installing the Battery.
Select a location, which will provide good air circulation for the Battery. Route cables so they cannot
be walked on, pinched or damaged in any way.
Where the battery is to be used in a mobile application, ensure that a suitable hold down clamp is
used to prevent the battery moving or vibrating.
These Batteries can be used in any orientation EXCEPT upside down. Upside down is where the
terminals are facing downwards.
Place the Battery in the final desired location and complete the rest of the installation procedure.
Issued for Use Revision Page
All rights reserved genZ 2020
30/01/2020 1.0 8 of 16
LFP Battery GC48V-30AH-C – Product Manual
6.8 Connecting to the Terminals
NOTE: If this battery is to be used where it may receive occasional splashes of water or located in
extremely humid conditions, the use of a small amount of plumbers liquid thread seal around the
M8 bolts thread prior to them being inserted must be applied.
If using flat washers, it is very important to ensure the battery cable lug connection is contacting
the brass surface of the terminal, and the washer is placed on top of the cable lug connection.
Do not place washer between the battery terminal and the battery wire as this creates high
resistance and can cause the terminal to overheat and fail.
It is important that fasteners be tightened to the appropriate torque of 10 – 11 Nm or 85 – 95 in-lbs
6.9 Terminal Protection
While LFP batteries will not present with the same type of corrosion that is seen when lead acid
batteries are used, corrosion can still occur on terminals if they are not kept clean and dry. To prevent
corrosion, after tightening the M8 bolt, apply a thin coat of terminal protector spray that can be
purchased through your local battery dealer.
6.10 Ventilation
Unlike deep-cycle flooded/wet lead acid batteries which release small amounts of gas during usage,
particularly during the charging process, LFP batteries do not release these harmful and potentially
explosive gases. However, some form of ventilation is still recommended.
6.11 Battery Maintenance
LFP batteries do not require any checking of the battery internals.
The LFP battery is essentially ‘maintenance free’ and no attempt should be made to open the plastic
case. Doing so will void any warranty and may lead to a potentially dangerous short circuit situation.
Issued for Use Revision Page
All rights reserved genZ 2020
30/01/2020 1.0 9 of 16
LFP Battery GC48V-30AH-C – Product Manual
However, depending on the environment and type of use the LFP battery has, the following is
recommended:
1. Examine the outside appearance of the battery, particularly the top of the battery and terminal
connections. They should be clean and dry, as well as free of dirt and corrosion. Refer to
Cleaning Section if cleaning is required.
2. Check battery cables and connections. Replace any damaged cables and tighten any loose
connections. Refer to Torque Values.
3. Reapply anticorrosion spray if required.
6.12 Charging the Battery
Ideally these batteries should only be charged by a charger that is designed to charge LFP chemistry,
at the correct voltage, current and charge profile.
The charging profile described below is designed to achieve maximum number of cycles/life of the
Battery.
6.12.1 Ambient temperature of 20C
An ambient temperature of 20 Celsius is the ideal temperature for the operation of the battery.
6.12.2 Commence a charge cycle where the current is limited (Constant Current or CC) at 0.2C
0.2C is equal to 6 Amps for model GC48V-30AH-C.
6.12.3 Hold Voltage at 57.6 Volts for 2 hours
Charge the Battery at a Constant Current at a maximum of 6 Amps until the battery voltage reaches
57.6 Volts DC.
Continue charging at a constant voltage of 57.6 Volts for one (1) hour or until the charge current drops
to less than 0.5 Amps. This will then allow the battery internal cells to ‘balance’ their terminal voltage.
6.12.4 Remove charge voltage
After two hours or when the charge current drops to less than 1 Amp, the charging voltage can be
removed (or placed onto a float charge) as the battery should now be fully charged.
6.12.5 Float charge at 54.4 to 55.2 Volts
At the completion of the above charge profile, the battery can either be stored or placed on a float
charge of 54.4 to 55.2 Volts. The lower of these two voltages will increase the life of the battery, but,
provide a slightly reduced capacity. Floating at 55.2V will provide maximum capacity.
6.13 Discharging the Battery
The discharge characteristics described below are to achieve maximum number of cycles/life of the
Battery.
Issued for Use Revision Page
All rights reserved genZ 2020
30/01/2020 1.0 10 of 16
LFP Battery GC48V-30AH-C – Product Manual
6.13.1 Battery discharge current
The ideal discharge current for the battery is 6 Amps, however, it should be noted that the battery can deliver
up to 40 Amps (continuously) if required.
6.13.2 When to charge a discharged battery
While the Battery is protected by the BMS to prevent excessive battery discharge, it is recommended
to recharge the battery as soon as practical (within 24 hours) following a discharge event, particularly
if this has been to 100% DoD. This will ensure long life for your battery as well as providing a fully
charged battery for when it is required.
6.14 Storage
The Battery should be stored, fully charged in an area that is protected from the elements and at an
ideal temperature of 20C and low humidity. It should be stored in its original packing. The battery
discharges at approximately 14% per annum. It is recommended that the battery be recharged every
6 months to maintain maximum life as well as a fully charged battery.
If storing a battery for an extended period of time, reference should be made to the “Self Discharge”
characteristics as indicated in the table of specifications.
It should also be noted that, a battery module that has been stored for an extended period of time
may exhibit a loss of capacity when it is first placed into service. This ‘loss of capacity’ can normally be
corrected by cycling the battery at least three times.
Issued for Use Revision Page
All rights reserved genZ 2020
30/01/2020 1.0 11 of 16
LFP Battery GC48V-30AH-C – Product Manual
7 Trouble shooting
SYMPTOM / FAULT POSSIBLE CAUSE POSSIBLE SOLUTION
BMS
RECHARGE THE BATTERY AND RECHECK
UNDER VOLTAGE, IN PROTECTION
FOR CORRECT OUTPUT VOLTAGE
MODE
BMS CHECK FOR SHORT CIRCUITS OR
OVERCURRENT, IN PROTECTION MODE EXCESSIVE CURRENT DRAW
NO OUTPUT VOLTAGE AT
BATTERY TERMINALS BMS CHECK FOR CHARGING CIRCUIT
OVER VOLTAGE, IN PROTECTION SUPPLYING EXCESSIVE CHARGE
MODE VOLTAGE
BMS
CHECK AND INVESTIGATE REASON FOR
OVER TEMPERATURE, IN PROTECTION
HIGH TEMPERATURE
MODE
OTHER RETURN TO GENZ FOR SERVICE
SYMPTOM / FAULT POSSIBLE CAUSE POSSIBLE SOLUTION
INSUFFICENT CHARGE CHECK FOR FAULTY CHARGER, POOR
VOLTAGE/CURRENT CABLING OR LOOSE CONNECTIONS
SOLAR OR OTHER CHARGER NOT REFER TO THE MANUFACTURER OF THE
BATTERY FAILING TO CHARGE
CONFIGURED CORRECTLY SOLAR OR MAINS CHARGER
OR HOLD CHARGE
BATTERY CHARGER MAY WELL BE CHECK WITH CHARGER
FAILING TO START A CHARGE CYCLE. MANUFACTURER OR SUBSTITUTE THE
THIS MAY OCCUR WITH SOME SMART CHARGER FOR A DIFFERENT TYPE OR
CHARGERS THAT REQUIRE SEEING AT USE A DC POWER SUPPLY SET TO THE
LEAST SOME VOLTAGE FROM A CORRECT CHARGE VOLTAGE AND
BATTERY CURRENT
OTHER RETURN TO GENZ FOR SERVICE
Issued for Use Revision Page
All rights reserved genZ 2020
30/01/2020 1.0 12 of 16
LFP Battery GC48V-30AH-C – Product Manual
8 Warranty & Service Information
8.1 Record of Purchase
It is important that you maintain a record of your purchase details, the model number and serial
number of the Battery.
8.2 Before Calling for Service
Verify that the charger and load are operating correctly. Refer to the “Trouble Shooting” section of
this manual.
If you believe that the battery is not delivering it’s rated *capacity (refer to Specifications) the
battery may be considered faulty if it fails to deliver less than 70% of it’s rated capacity during the
warranty period.
*Note: Some chargers/inverters display the capacity of a battery module or the battery system.
These calculated values can be inaccurate for a number of technical reasons and as such should not
be relied on.
Refer to the genZ website at www.genz.com.au for full details of the warranty on this product.
8.3 Warranty or Service
In the unlikely event that you believe the battery is faulty, contact the place of purchase or the
dealer/distributor first. If you cannot reach your dealer, or if they cannot resolve the issue please visit
the genZ web site at www.genz.com.au for contact details for technical support.
Please ensure that you have the following information available:
a) Where and when the battery was purchased.
b) The model number.
c) Serial number of your battery.
d) Information on the nature of the failure.
http://www.genz.com.au
Issued for Use Revision Page
All rights reserved genZ 2020
30/01/2020 1.0 13 of 16
LFP Battery GC48V-30AH-C – Product Manual
9 Appendix C – Dimensions
178mm
210mm 170mm
326mm
Issued for Use Revision Page
All rights reserved genZ 2020
30/01/2020 1.0 14 of 16
LFP Battery GC48V-30AH-C – Product Manual
Notes:
Serial Number:
Model Number:
Place of Purchase:
Date of Purchase:
Owner:
Issued for Use Revision Page
All rights reserved genZ 2020
30/01/2020 1.0 15 of 16
genZ Energy Pty Ltd
Western Australia
Email: [email protected]
Web: www.genz.com.au
