long life lithium batteries - safiery grid free camping ver2-web.pdf2. lithium battery range 3....

UPDATED 20190119

Getting Maximum Life from Lithium BatteriesGuide for Sizing Your Lithium Batteries Caravans & Camper Trailers

UPDATED 20190610

LONG LIFELITHIUM BATTERIES

TRAVEL THE WORLD WITHOUT CONSUMING THE EARTH ™

UPDATED with NEW 48V Lithium storage calculations of 40% Total

Savings over 12V

2 Long Life Lithium Batteries for Comfortable Grid Free Camping

Table of Contents

It is illegal to copy or reproduce any part of this document without the

express approval of Safiery Pty Ltd

1. Why Lithium?

2. Lithium Battery Range

3. Lithium Battery - No of Cycles

4. Storage Mode is critical

5. Advantages of Multiple Batteries in Parallel

6. Assessing Size of Lithium Needed

7. 48V Lithium Batteries -40% lower Total Cost

8. 48V to 12V DC Systems

9. Running an Air-conditioner from Lithium Batteries

10. Replenishing Lithium Batteries with on-engine generator

11. Lithium Battery Range Spec Sheets

12. Lithium Battery Configurations and Dimensions

13. AGM Batteries and their high Maintenance


Copyright Safiery Pty Ltd

TRAVEL THE WORLD WITHOUT CONSUMING THE EARTH

Lithium-iron-phosphate (LiFePO4) is the safest of the li-ion battery types.

Higher Energy Capacity per cell• The nominal voltage of a LFP cell is 3,2V (lead-acid: 2V/cell) producing 12.8V

or 25,6V Batteries.

RuggedA lead-acid or AGM battery will fail prematurely due to sulfation:

• If it operates in deficit mode during long periods of time (i.e. if the battery is rarely, or never at all, fully charged).

• If it is left partially charged or worse, fully discharged (yacht or mobile home during wintertime).

LiFePO4 does not need to be fully charged. • Service life even improves in case of partial charge instead of a full charge.

This is a major advantage of LFP compared to lead-acid.

Wide operating temperature range

Excellent cycling performance

Low internal resistance and high efficiency.• In several applications (especially RV), energy efficiency can be of crucial

importance. The round trip energy efficiency (discharge from 100% to 0% and back to 100% charged) of the average lead- acid battery is 78%.

• The round trip energy efficiency of a LIFEPO4 battery is 92%.

Solar• The charge process of lead-acid batteries becomes particularly inefficient

when the 80% state of charge has been reached, resulting in efficiencies of 50% or even less in solar systems where several days of reserve ener-gy is required.

• In contrast, a LIFEPO4 battery will still achieve 90% efficiency squeezing every once of energy from the solar panels.

Size and weight• Saves up to 70% in space Saves up to 70% in weight

Expensive?• LIFEPO4 batteries are expensive when compared to lead-acid. But in de-

manding applications, the high initial cost will be more than compensated by longer service life, superior reliability and excellent efficiency.

WHY LITHIUM IRON PHOSPHATE BATTERIES?




LITHIUM BATTERIES are MORE THAN JUST LITHIUM

Lithium Batteries we sell are a combination of 3 devices:

1. Lithium energy cells with a Lithium Iron Phosphate Anode. There are 4 cells running longitudinally in the photo below under the board. You can see the bolts that secure each cell to their upper plate in horizontal rows.

2. On top of these Lithium cells is a computer board (photo below). 3. Digital control of charge and discharge current with devices called MOSFETs

and are shown in the picture below.

Because there is a computer with each and every battery:• It controls the charge and discharge currents and turns the battery on and off

for protection with high or low voltage.• It does this “turning on and off for protection” digitally. That’s the main reason

why they are more expensive.

This is why Lithium Batteries are safe and require little maintenance• With Safiery Lithium batteries, do not worry about explosions or fires that you

read about with airlines. In most of these cases the accident occurred because of a fault in the device itself, not the battery.

• We ship Lithium Batteries by Australia Post, thats how safe they are...

Because there are high currents flowing “big and fast” in a Lithium battery, one of the most important factors in specifying a battery is it’s internal re-sistance: • Our battery specification is for ultra-low internal resistance of less than

20mOhms. Our 125Ahr is only 12-15mOhms. This is essential to run Lithium in parallel.




100 Ah Slimline Powerhub

100Ahr Slimline Waterproof

Battery outlets are on the side of battery.Weight 11kgs 10.6kg

Size in depth 88mm deep 88mm deepLength and Height 440mm L and 300mm H 485mm L and 250mm H

Application 4WD, camper Trailers, as all in one powerhub4WD, caravans, camper trailers, boats, trolling

motors, inverter power

Whats special?All in one with multiple direct plug-in outlets for fridge, andersen and

USB. Plug-n-play.

IP67Boating, 4WD Ute backs and any open space.

Also perfect for difficult to access areas. Cables “plug” onto patented battery posts, be-

come water proof to IP67.

Multiple battery BMS in parallel? Yes up to 2 Yes up to 2

Bluetooth ? Connects directly to Victron Bluetooth mesh network, for easy linking of solar, battery charger and inverter and on Smartphone.

SLIMLINE LITHIUM BATTERIES




VERSATILE 125 and 200 Ah LITHIUM BATTERIES:

125Ahr Super Versatile

Go be placed any way except upside down.

200Ah Versatile Workhorse

Weight 15.4kg 26.5kgSize in depth 165mm deep 207mm deep

Length and Height 318mmL x 215mmH 534mmL x 220mmHMaximum Discharge Amps 100A C, 350A, 3s 150A C, 200A 20mins, 350A, 3s

No of Cycles at 80% DOD 3,000 3,000

Application4WD, caravans, camper trailers, boats, trolling motors, inverter

power

4WD, caravans, camper trailers, in-verter power

Whats special? Can be in series and/or parallel as has multi-battery BMS Good value large Lithium

Multiple battery BMS in parallel? Yes up to 6 Yes up to 4

Smartphone Bluetooth ? Yes

Victron Connect Optionally connects directly to Victron Bluetooth mesh network for easy linking of solar, battery charger and inverter




100 Ah 12V VICTRON Smart Battery




Weight 15kgs 20kg 27kg 56kgSize in depth 152mm deep 208mm deep 274mm deep 208mm deep

Length and Height 321 L x 197 H 321 L x 237 H 425 L x 297 H 631 L x 317 HMaximum Discharge Amps 100A, 200A 3s 150A, 300A 3s 200A, 400A 3s 200A, 400A 3sNo of Cycles at 70% DOD 3,000

Application Marine, 4WD, Caravans, Cabins, High Inverter power

Whats special?Matched to Victron’s charging system for long life

with special protection if battery completely discharged.Rugged and well protected for Marine “abuse’ but IP22

Multiple battery BMS? Yes up to 5 parallel, 4 in series

Smartphone Bluetooth ? Yes Yes Yes Yes

VICTRON LITHIUM BATTERIES LONG CYCLE LIFE




2.4kWh 48V high energy




Maximum Output Power in kW 2.4kW 4.8kW 4.8kW 4.8kW

Peak Output Current at 48V in A 100, 1 s 200, 1s 200, 3s 200, 3s

Weight 47kgs 69kgs 91kgs 113kgsSize in depth 210mm deep 210mm deep 210mm deep 210mm deep

Length and Height 555mmL 928mmH

Application Large Boats and RV’s, cabins and homes.

Whats special?

Perfectly matched to 48V Charging systemsSuper high energy density for large energy storage in 48V to drive air-con and

other high power for days10 Year Warranty in home, 5 Year Mobile Marine/RV

Multiple battery BMS Yes up to 80kWh

Warranted Cycles 6,000IP Rating IP65 up to 50 deg C

Approvals Clean Energy Council of Australia Approved.

DYNESS 48V LITHIUM BATTERIES HIGH CAPACITY




LITHIUM BATTERY PRICES ARE AT A LOW LEVEL

60% is the drop in Lithium battery prices over last 10 years. However, a major cost is the electronics board that controls the battery. Demand for silicon with the advent of electric vehicles may create some shortage and push prices up in the next 2-3 years.

SIMILARCost per design cycle over the short term. Over the long term, Lithium is a long way in front.Cost per Design Cycle Ritar 100 Ahr AGM Safiery 125 ahr Li

If operating everyday for 24 hours/day, amount of kWh

produced at warranted DOD at one cycle per day

At 50% DOD and 12.6V, 1,500 cycles

= 22.68kWh

At 80% DOD and 13.0V, 3,000 cycles

= 93.6kWh

Cents cost per kWh based on price per battery $0.18 $0.19

Risk of Maintenance FaultHIGH

Battery Must be kept fully charged!

LOWBattery can be 50% with zero damage.




LITHIUM BATTERY - NO. OF CYCLES

No of Cycle Day 1 Day 2 Day 3 Day 4 Day 5

% used each day 20% 20% 20% 20% 20%

Cents cost per kWh based on price per battery 1 Cycle Only = 100% usage

1 CYCLEis not what you may think in Safiery Lithium Batteries. It is when the cumulative total of Ahrs used reaches 100% over consecutive Days. So using 10% a day for 10 days will mean that you have 1 cycle in 10 days!

% is the drop in Lithium battery prices over last 10 years. However, a major cost is the electronics board that controls the battery. These prices are also down to levels that have flattened out. Demand for silicon with the advent of electric vehicles may create some shortage and push prices up in the next 2-3 years.

Safiery Lithium batteries are designed for 3,000 cycles at 80% depth of discharge.




LITHIUM BATTERY - STORAGE MODE IS CRITICAL

100% State of charge in Storage will significantly reduce the capacity of Lithium batteries.Leaving a Lithium battery on 100% charge while your RV or Boat is in storage will reduce its capacity by as much at 10% capacity loss in a 6 month storage period. That makes for very expensive storage!

Here’s how to avoid this and prolong Lithium battery life.

Lithium batteries suffer from stress when kept at a high charge voltage. Keeping a Lithium battery at 100% state-of-charge for an extended time can be more stressful than cycling.

“The result showed that, when only considering ageing from different types of driving in small Depth of Discharges (DODs), using a reduced charge level of 50% SOC increased the lifetime expectancy of the vehicle battery by 44–130%.”




LITHIUM BATTERY - AUTOMATIC STORAGE MODE

There is an easy solution with the new Victron Smart Battery charger (just released in May 2019). It has automatic “Smart Storage Mode”.

Storage Mode starts AutomaticallyWhenever the battery has not been subjected to discharge during the prior 24 hours, the battery charger switches to storage mode. In Storage Mode float voltage is reduced to a user defined level depending on the battery technology. For Lithium batteries 13V is recommended. This will keep the battery between 40-70% SOC depending on what de-vices are running.

Storage Mode Voltage set on Smartphone appYou can easily adjust the storage mode voltage depending on your particular applica-tion. There is no problem leaving a fridge on while in storage mode.

Other New Features in this New Battery Charger that prolong Lithium battery Life

Recover from a deep discharge at a low trickle current.In the unlikely event that you suffer a deep discharge with your Lithium batteries, this smart charger can be switched on a Smartphone to recovery mode at a low trickle current. A low recovery current is absolutely essential as the internal resis-tance of a Lithium battery goes very low and an in-rush of a high current can cause damage. With this new charger, its easy to control this in the palm of your hand.

Restore to Bulk Mode Quickly if required.Lithium batteries are reknown for holding a flat voltage level. At these consistent voltages, some chargers will go to sleep in float mode and may not full recover the Lithium battery to 100% after it has done some mild work.

This new battery charger has a “re-bulk” voltage set point that is user defined. When the battery measurement reaches this voltage, the charger will restore to full bulk charge mode.

Automatic voltage compensationThe charger compensates for voltage drop over the DC ca-bling by slightly increasing output voltage when the DC current increases.




LITHIUM BATTERY - REAL BENEFIT IS WITH SOLAR

Efficiency Energy you get out!

Popular DC to DC

with Solar and AGM Battery

Popular DC to DC

with Solar and LithiumBattery

Safiery Lithium with Victron Smart Solar

Solar Panel Wattage 100W 100W 100W

Solar Controller Efficiency 93% 93% 98%

Battery Efficiency 78% 100% 100%

Inverter Efficiency 88% 88% 92%

Watts available to use after Inverter 63.8W 81.8W 90.2W

Efficiency Advantage 128% 142%

Don’t Waste Money on a highly efficient Lithium Battery and then use a less efficient Solar Charger and Inverter...

DC to DC Vehicle chargers are inefficient solar chargers. Not only do they have a lower electronic efficiency but they also dont charge to the maximum Lithium voltage. Two of the most popular units charge to only 14.5V when most Lithium batteries can be charged at 14.6V. The difference when using solar is significant.




ADVANTAGES OF MULTIPLE PARALLEL LITHIUM

It’s easy to understand that when you charge Lithium batteries, the energy that goes into the battery is the charging power less the energy losses of the battery itself. Lithium batteries have a computer board and digital switching devices that control the current flow. The better quality components use less power.

The way to measure the efficiency of a Lithium battery is it’s internal Resistance.

Internal resistance of the battery increases slightly with every cycle. The size of the increase is greater for constant current cycling than for the dynamic cycling you get with solar and vehicles. Having a low internal resistance when the battery is manufactured is a good start to a long cycle life.

This number in milli-ohms is not always presented in data sheets by manufactur-ers. It is always a number that I want to see as an electrical engineer.

Measured voltage = OCV (Open Circuit Voltage) + (I * Ri)I = Current flowing through battery and Ri= Internal Resistance of the battery The first stage of the charge cycle is the bulk stage, in which the charger is pushing all of the available current to the battery. As you put more charge into the battery, the open circuit battery voltage (OCV) will climb. Once the measured voltage reaches the bulk charge setpoint of 14.5 V, the controller will hold at that voltage. Current will gradually taper off as OCV continues to rise. Taken to the extreme, current would eventually fall to a very low value necessary to match the self-discharge of the battery, and the measured voltage would be the same as the OCV.

The voltage you measure during this charge stage will be OCV + (I * Ri). The internal resistance of a Safiery 125Ahr Battery is less than 0.015 Ohm but let’s use that number with a charge current of 50A and a measured voltage of 13.8V and rising. (still in bulk mode)

For one Safiery 125Ahr battery, The OCV would be = 13.8 - (0.015 * 50) = 13.05 V.

For 2 Safiery 125 Ahr batteries in parallel: The OCV would be = 13.8 - (0.007 *50) = 13.45 V. (great!!!)

For a single 200Ahr Lithium battery: The OCV would be = 13.8 - (0.20 *50) = 12.8 V (Not as good)




MULTIPLE BATTERIES vs ONE LARGE BATTERY

ONE small temperature sensor is located in every Lithium Battery. If it is activated, the Lithium Battery shuts down for safety reasons. My first Lithium installation in an off-road caravan was in 2011. It had 4 lithium batteries tied to a central BMS. After 3 days into the trip, the batteries shutdown and all electrical circuits froze. Worse still, the solar was still running. Because there was no battery present, the solar controller starting hunting for a different voltage to connect to. It was a 12/24V system and this is still a common ar-rangement today. It decided on 24V and destroyed virtually every electrical de-vice in the van. One of the true ”Priceless” Mastercard Expressions on my face.

“All fool me”. I had 15 years experience at Honeywell and a good part of that with Industrial controls in critical processes. Honeywell did the controls on the Space Shuttle and had a mantra for the design of every system: “no single point of failure (that an astronaut can’t fix)”. Absolutely none. Now 100kms west of In-naminka was close to the space shuttle to me. The temperature sensor feeding the BMS had come adrift inside one of the batteries and had signaled a fault. So a 10cent component ruined the trip and cost me a fortune.

After a long discussion with one of the owners of the Lithium Battery company in China (and he is an engineer), we agreed that off-road was not the place for the central BMS Lithium system. In 3 months, I had a BMS in every battery and in 6 months had multiple batteries in parallel. That was 2011 and the first sys-tem sold to a customer is still running perfectly today nearly 8 years later.

We believe in and only sell systems that can be connected in parallel so in the unlikely event a battery temp sensor (or similar) fails, the user can still continue.

Photo on right is inside view of a Safiery Lithium Battery.

Small temp sensor is black wire, bottom right.




ASSESSING SIZE OF LITHIUM REQUIRED

Replenishment Power is a Priority of Energy Storage.

Assuming you are camping in one location...

SIZE YOUR SOLAR REQUIREMENTS FIRST• Have Solar in place to replenish the energy you use first;• Even on a poor solar day, you will receive 20-30% energy from a good solar

system.• Purchase a portable system directed to the sun as a backup.

This adds energy when parked in the shade or on a poor solar day.

ASSESS HOW MUCH ENERGY YOU CONSUME PER DAYFrom 15 years assessing and talking with caravan travelers:

Frugal couples: use 60 Ahrs/ day with a compressor fridgeModerate couples +1: use 80-100Ahrs/ day with compressor fridgeBold users: use 120Ahrs/day with compressor fridge and laptopIf you have a 3 way gas fridge,take 40-50 Ahrs/day off this number.If you have a second fridge,add 40-50 Ahrs/day to this number.

Sizing for Lithium:

• Take daily usage x 2 for 2 days; x 3 for 3 days as you require. This assumes zero solar. Round a little as it wont be zero solar.

• For Lithium, x by 1.2 to allow for 80% depth of discharge.

Amp Hours Use

Matching Solar Capacity

suggested in our Triple Insulation

Solar eBook

Suggested Lithium Battery Sizing for 2-3 days

Little Solar (Won’t be nill solar but

may be very little)

Frugal 60 Ahr 280W 125Ahr

Moderate 90 Ahr 420W 200-250Ahr

Bold 120 Ahr 560W 375 - 400 Ahr

Bold Plus 150 Ahr 720W 500 -600 Ahr




RECOVERING FROM A DEEP DISCHARGE (FLAT)

You may call it a flat battery. Others say “deep discharge”.It will happen to most people at least once with their Lithium Batteries. Recover-ing the battery from a deep discharge is very important to prolong battery life.

The voltage of a flat Lithium battery can’t be measured at the battery terminals.• You will read a low voltage.• Don’t let an auto-electrical do a battery capacity test with an AGM or lead

acid test meter.• The computer control board or BMS has turned off the connection between

the negative terminal and the lithium cells.• You need a Smartphone battery app to read the cell voltage or if you have a

central BMS, it may show the voltage.• In the picture on the following page, the Lithium battery voltage is deter-

mined by adding up the millivolts in each of the cell groups. There are 4 of them. In the picture below, it adds to 13.3 V.

• After a deep discharge this will be the invaluable tool to tell you the battery state of charge and/or voltage (SOC will be zero).

• This is important as if the battery is overcharged for some reason, the BMS will turn the battery terminals “off” and you may think you have a flat battery when you haven’t. I have seen this many times over the years.

After a deep discharge, a Lithium battery needs a slow recovery:• A small current of 1-2Amps at first (the BMS will open up and show the volt-

age to the charger at this current level).• Then a larger current of 5-10A until the voltage gets to 10V.• Then full current. • Jumping to full current straight away can shorten battery life.

SOFT START RECOVERY is a nice stardard feature on the Projec-ta DC to DC 25 Lithium charger. It will allow you to do a full recovery easily in the bush. Just press a button!




VDD(VOLTAGE DISCHARGE)

VSS (VOLTAGE SOURCE/SOURCE)

B+ B-

V+ V-

BATTERY MANAGEMENT UNITBATTERY CASING

ACTUAL LITHIUM CELLS4 SETS OF 3.2V EACH 12.8V

CELL BALANCING UNIT

MOSFET

CSR

ORWiFi

MEASURING LITHIUM BATTERY CAPACITY

The actual lithium battery cells are at the bottom section of the battery casing. Each group of cells are 3.2V each and joined in series to give a total of 12.8V nominal. This can be measured at the inner battery terminals marked V+ and V-.

In normal operation, it is not possible to measure this voltage. The voltage that can be measured is at the battery terminals on top of the battery casing and is marked as B+ and B-. The positive V+ and B+ are directly connected (fused only).

The negative V- and B- are not directly connected. The connection between these two passes through a Dual Mosfet Charge/ Discharge Controller and a Current Sense Ratio (CSR) device. The Dual Mosfet Controller is core to battery protection for over-charging current and high or low voltage cut-out. The protection unit will open and close the connection between B- and V- depending on the command of the Battery manage-ment Unit. There are several other sensor and measurement points involved.

The protection unit opens this V- B- Circuit after it has been closed only on a small cur-rent charge when the voltage is low. This is for safety.




State of Charge

Input/Output Voltage

Rename Battery**Please ask custom service for Password

Input Current FlowOutput Current Flow

Discharging & Power >20%

Power 20%

Battery NameTip: To aviod confusion , please remame your battery before installation,

Battery SignalTip: The biger “db” value shows stronger signal,which means the battery is closer.

Cycles

Temperature

CurrentVoltage

Battery Health

Notification

Normal

Alarm

Battery Health

LITHIUM BATTERY APP




STORING LITHIUM - AVOID HEAT

When we say “storing”, we are talking about placing your caravan or camper in storage for a period of time as most people do.With AGM batteries it was key to keep them charged at full voltage.

Lithium batteries suffer from stress when keeping a cell at a high charge volt-age. Exposing the battery to a full state-of-charge for an extended time can be more stressful than cycling. Exposing to high temperatures during storage will also accelerate a drop in capacity.

40-60% is the perfect State of Charge level when not being used.So DO NOT keep your charger on with your caravan in storage.

Turn off the charger and let the system float down to 40% SOC. Set an alert at this level if you can. Use a 7 day wall timer to turn on the charger for a limited period of time every 7 days. Set this time based on battery capacity and charger rate. For most setups it will be 3-5 minutes. Thats all. Keep the caravan cool. Keep a window or hatch open so there is no build up of heat.

This is relatively new research (2018) with the increase in electric vehicles. It is confirmed by the Lithium expert at the CSIRO: Dr Adam Best: https://blog.csiro.au/power-up-our-battery-advice-free-of-charge/ The

Table below demonstrates capacity loss as a function of temperature and SoC. The original Paper is listed in the Notes on P 26.




48V LITHIUM BATTERIES - 40% LOWER TOTAL COST 48V Energy storage is the future for large energy storage systems.

Why?

Look at the Voltage drop using a 35mm2 Cable. This is a bigger size than a large thumb with 50A of Cur-rent at 12V.

At 12V there is 4.2% of losses.At 48V with much less current there is less than 0.3%.

Every connection point of fuse, shunt, battery terminal has a loss based on the current flow.

It starts to add up to a significant amount... Probably closer to 5% difference than 4%.

But the other big reason is the significant lower capital cost:

Price Comparison (Retail)

Cable reduction Cost Including Termination

Lug/FuseTotal Saving

Solar Controller 48V at 20A 12v at 75A

For 1000W 48V is $27312V is $970

Saving to 48V $480

Saving to 48V $1,177

Inverter/ Charger 3000W

For 3000W 48V is $1,86012V is $2,750

Saving to 48V $580


Battery 600 Ahr 12V 150Ahr 48V

48V is $6,76012V is $8,970

Saving to 48V $300


Totals 48V is $8,89312V is $12,690Saving to 48V

$1,360


40% less

There is the additional saving in labour of installing / terminating cables 1/4 of the size.




48V / 12V LITHIUM BATTERY SYSTEM

Because of the efficiency and lower cost of 48V Lithium Energy storage and because the efficiency of 240V Inverters from 48V is very high, it is most economical to run 240V appliances in a boat or large RV.

However, this is not the case with lighting. LED lighting at 12V is very efficient and economical as it is low current even at 12V.

The system design is to store energy at 48V and run a small “buffer” battery at 12V for the 12V devices. Because this is being topped up all the time at 100% state of charge, it could even be an AGM battery.

240V 12V Saving

Air-conditionerSplit System

(no need for expensive and in-efficient RV Air-con)

Significant

CookingInduction Cooktop

MicrowaveAir Fryer

Significant

Fridge/Freezer FridgeFreezer Significant

Lighting NONE LED None

Water Pumps

Extraction from stream

(safety reasons)

Slides/ Lifts Large slide outs Small slide outs

There is the additional saving in labour of installing / terminating cables 1/4 of the size.




Operating Air-conditioners from a solar replenishment system can easily be done (and we have experience in completing several). Here is what you need:

Setup Needed Amps Use in an hour typical at 12V

Convert to Solar Watts required for 8 hours at night

at 13V

Convert to Solar panel Capacity needed

allowing for 16% heat derating, 30% incidence

angle derating and 20% efficiency and dust

derating

Truma Roof Top 2kW 75 Amps 7,800W

14.7kwThis is not going to happen with an RV

The 48V Lithium alternative is to run the generator for 1-2 hours during the day and togther with solar, there should be enough replenishment energy to run the air-conditioner for 8 hours straight!

Using Lithium Batteries,

Solar and a 35A/3000w 48V Inverter Charger

Lithium Batteries required

DC Honda Generator

replenishment for 1.5 hours at 240V 42 Ahr at 48V DC

Solar panel Contribution allowing for 16% heat

derating, 30% incidence angle derating and

20% efficiency and dust derating

Mitsubishi Split Air-con

3kW Thermal Power

10Amps/hour at 48V 80 Ahr at 48V

overnight42Ahr at 48V DC

800W in 5-6 Hours

40Ahr at 48v DCThis is easy with an RV

The Lithium battery size recommended is at least 200Ahr at 48VDc (9.6kwH)

This is a standard 48VDC Lithium module available for less than $9,000.

RUN AN AIR-CONDITIONER FOR 8 Hrs FROM LITHIUM




REPLENISHING 48VDC: ON-ENGINE GENERATOR

Large lithium systems are are compact enough for mobile applications. The difficulty, until now, is replenishing the lithium battery energy. Solar and the vehicle’s alternator are “self contained” options. However, a 2 kW Solar panel array on a mobile installation is massive in area. It also only replenishes for limited hours, has variable power, and is only effective on a good solar day. Yet limited 2kW solar power is not enough to replenish demanding power devices.

When you are moving, the power produced from the vehicle’s alternator is small and in-efficient. So you either have to pull out a portable generator, fill with petrol, and suffer the noise; or use limited power for a limited period of time.

The enabling game changer is rooted in a simple invention. Simplicity that came from a complex problem and ten million dollars plus in research and development. It is not renewable energy but very close. It “steals” in-efficient power from the engine to gen-erate DC power while the engine is running. It can produce a massive 8kW of power. This power transfers directly and efficiently to 48VDC lithium battery sets. Within 3 hours of driving or even idling, you can store 24kWh of energy in Lithium batteries. 24kwh will run a typical 240V air conditioner for a large room for 24-30 hours. With this replenishment technology, large lithium battery sets are now practical to use. Whilst this technology needs the vehicle engine to run, it doesn’t have to run for long.

An 8kW portable genset may weigh 160kgs+ and measure 800 x 800x 700mm. It will need an additional battery charger to transfer energy to stored lithium batteries. The 8kW DC generator weighs 15kgs, measures 245 x 220 x 220mm, runs at 48VDC and transfers power directly to the lithium batteries. Game Changer!

The clever bit: this invention is close to renewable energy. The software in the con-troller carefully maps the efficiency of the vehicles engine so that it loads and unloads the engine to get best efficiency. Although this is rocket science stuff, it requires no user intervention. It is completely automatic. It means the DC generator attached to the engine takes very, very little additional fuel to run. Power and lithium storage sys-tems will be totally redesigned in RV’s, special vehicles and the marine market.

48VDC becomes the baseline for stored energy. This is the same baseline used in home energy storage systems. It provides an efficient energy system and is less than the voltage level requiring a step up in electrical safety. This keeps it affordable. The 48V DC generator combined with lithium batteries is not only a true hybrid power sys-tem, but an incredibly efficient one. It will become the norm in off-road applications.

Photo courtesy of SLRV Expedition vehicles who fit INTEGREL 48VDC on engine generators in their motorhomes.




48VDC: WILL BECOME COMMON IN 4WDs

In parallel with 48VDC energy storage systems is the 48VDC HYBRID power systems used in new 4WD vehicles and trucks.

The new Bentley and Audi SUV’s both use 48VDC for power assist with 48vDC starter/generators and lith-ium systems. Yet these are petrol powered engines. Using the same voltage for both power and energy system provides flexibility with electrical systems in 4WD’s and Special vehicles.

In the vehicle aftermarket, “bolt-on” torque boosters for vehicles are 48VDC with matching after-market lithium batteries.

Electric Superchargers outperform turbo chargers. The innovation here is breath-taking... and it’s all 48VDC. My bold prediction is that within a short space of time, torque power boosters will be an af-ter-market option for 4WDs ... and they will operate on the drive shaft with petrol engines. The Electric motor will give as much if not more torque than the diesel of today. Cruise the highways efficiently on petrol and engage electric boost for off-road or tow-ing torque. This is the future.




Product Name Dyness 9.6kWhrBattery Type Lithium Iron PhosphateNominal Storage 9.6kWhrUsable Storage Capacity 7.68kWh (80% DOD)

Unique Features

Can be used in both off-grid and hybrid setups, compact size, modular expansion. Battery is warranted to 50°C ambient Battery is IP65 Australian Clean Energy Council Approved: 25 January 2019

Weight 113kgPower 4.8kW Continuous, 9.6kW Peak

Dimensions (WHD) 93cm x55cm x 21cm (4 models)Can be separated and stacked flat or as a powerbox.Off-grid Capable? YesDesigned for indoor or outdoor installation? Indoor/Outdoor Water Resistant (IP 65)

Operating temperature range up to 50°C

Warranty

Fixed in Home: 6,000 Cycles at 80% DOD at 0.2C charge/Discharge rate 10 Years Warranty.Mounted in Marine/RV: No Cycle warranty 5 Years (Limited to Product repair/ replacement)

Warranty Document Supplied? Yes

Total warranted kWh (1 cycle per day)

46,080 (6,000 cyc * 9.6kwh * 80%)or28,032 10 years @ 80% DOD

Cost per Total warranted kWh (1 cycle per day) $0.21 + Inverter Cost

DYNESS 48VDC LITHIUM BATTERY SPECIFICATION




RUN AN AIR-CONDITIONER FROM 12V LITHIUM

In 2015, I setup a hybrid energy system with a small Honda EU10i Generator and 400 Ahrs of Lithium for an 80 yo customer who couldn’t lift the EU20i and wanted to run an air-conditioner from the HONDA EU10i

It was a costly learning as I “blew up” two sets of Lithium batteries in the pro-cess. However, we got the system working as it still is today.

It required a change in the burst current response time of the battery to be bet-ter than the surge demanded of the Truma 2kW air-conditioner. Remember, the rating on an air-conditioner is the thermal and not electrical load. On startup the Truma demanded 450Amps from the batteries quickly. After it was running, it used less then 1 kW and the the Honda EU10i kept up. Then every time the Truma started up again, it required another 450A. In fact it went higher than that when the compressor was exceptionally hot.

As a result, I designed the battery systems to cope with this. And one point is essential, the batteries have to be in parallel with a reduced inter-nal resistance for the best performance.

However, in 2016 I setup a 240V air-conditioner using a very efficient Mitsubishi Split system. It used only 45A at 12V.

Step forward to today with 48V Lithium storage and the opportunity to run air-conditioners from Lithium batteries all night is now real.

The table on the following page gives a summary of a 12vDC generator, solar and Lithium. There can be variations on this to get the right mix.

In future this will slowly become a more common “luxury” request with caravans.




IMPORTANCE OF BATTERY MONITORING

Volt meters were the standard way to measure AGM Batteries. However, voltage only is a difficult way to measure the State of Charge of your lithium batteries. It is best to protect your investment and purchase a battery monitor that measures current flow and then calculates State of Charge.

Features helpful with Lithium Batteries are:Time to Go and State of Charge..Alarms on both of these are:• “Pre-condition” giving you time to control things• “Capacity Status” giving you peace of mind.

“State of Charge” (SOC) ALARMThis ALARM sets the LOW State Of Charge (SOC) level that will trigger an ALARM. For Lithium batteries set this at 20%. It also has a HIGH alarm: If you are charging your battery with a generator, it can be very helpful to know when your batteries are full or nearly full. By setting the ALARM HIGH on the State of Charge to say 95% or even 100%, you can get an alert when this is reached.

“Time to Go” DisplayThe “home” screen displays this value in days, hours or minutes.

This ALARM sets the Time to Go (TTG) till you reach the 20% level. For your lifestyle, setting this at say 4 hours will give you time to adjust battery usage before you reach the critical voltage level of 20%.

We recommend the SIMARINE battery monitor sys-tem. It is specifically tailored to Lithium Battery Moni-toring. It comes standard with a wifi connected Smart-phone app. It generates it’s own wifi signal.




USING EXISTING 12V BATTERY/SOLAR CHARGERS

Most existing battery chargers; DC to DC chargers and Solar chargers that have a traditional AGM setting can be used to charge Safiery Lithium batteries without fear of damage or abnormally shortening battery life. However, the devil is in the detail and these are the checks required on the system you plan to use.

Surprisingly, earlier charging systems that were marketed as “lithium designed systems” are not compliant. These were designed for Lithium batteries with central BMS that turned the lithium charging circuit on/off based on an external input. We dont use this type of charger and it may be detrimental.

Providing the charger operates in these parameters and providing it doesn’t have an “automatic desulfate” mode that cant be turned off, it will be compat-ible.

The difference to using a specific Lithium Setting and an AGM setting is:• AGM setting will get the battery to 95-97% of charge quite quickly• AGM setting will take a longer time to get to 100% but it will still get there.• Lithium Charging profile gets to 100% quickly.• For solar charging, a solar controller with Lithium profile will respond faster to a

boost or bulk charge after the drop in battery capacity.• Solar settings shown on previous chapter.

• REDARC BMS 30 and most of their DC to DC chargers are 100% compatible.

Compatible settings for Safiery Lithium Batteries

Bulk Charge and Charging Limit Voltage

14.4 to 14.6V

Equalize Duration (min.)

0 (MUST BE

ZERO)

Float Charging Voltage 13.7 to 13.8V De-sulfate Phase NONE

Absorption Charging Time To 2 hours




COMBINATIONS WITH VEHICLE 2ND BATTERY

A lot of towing 4WD’s will already have a second battery in the vehicle for a rear fridge/ compressor. In many cases if this is in the engine bay, it will be an AGM battery.

A common question is “Can we continue to use this battery if we have Lithium in the caravan”.

Firstly, you really need a DC to DC charger with Lithium. If this is set for AGM mode already then connecting up the caravan Lithium batteries will mean a slow charge past that 95% mark. In this case they probably can be on the same circuit with the andersen charging connector in between but you would need to take actual voltages of your rig running (and hot) to be sure.

If the ignition is off and the batteries are still actively connected then current will generally flow from the Lithium to the AGM quite quickly. A break in the Anders-en plug can fix that.

The perfect set-up is to put Lithium in the back of the 4WD connected after the DC to DC . Then connect this Lithium battery to the charging andersen plug cable to the caravan. You will then have a satellite system with the two lithium’s connected while camping (and ignition is off). While driving the vehicle one will soak up most charge with a preference and when the solar is running, the cara-van set will have a preference charge. This preference is simply because of the voltage drop with the cable between the batteries.

Unlike AGM, Lithium batteries won’t suffer damage when partially charged. In fact they love being in a relaxed state.

The only rule here is to not mix different brands of Lithiums in parallel or dif-ferent sizes from the same brand. This is because the lithium internal battery resistance will be different by brand and by size. Keep them all the same size, same brand.




APPLICATION WITH PROJECTA IDC 25L

12V

Pow

er

THE

ITEM

S TH

AT A

RE

CO

VER

ED IN

A P

AC

KA

GE

MAY

VA

RY B

ECA

USE

OF

SEN

SOR

AN

D/O

R M

OD

ULE

CO

NFI

GU

RAT

ION

.

APP

LIC

ATIO

N W

ITH

PR

OJE

CTA

IDC

25L

LITH

IUM

BAT

TERY

DO

CU

MEN

T A

ND

CO

NC

EPTS

AR

E C

OPY

RIG

HT

SAFI

ERY

PTY

LTD

V2.

1

Imax = 25A

Imax = 25A

Imax = 25A

Imax = 25A

IN

IN

IN

IN

01

02

03

04

OU

T O

UT

OU

T O

UT

01

02

03

04

R1

R3

R2

R4

U2

U1

GN

D U

3 C

OM

0 -

65k

OH

M

3 2

1 4

SC

Q25

T 0

- 3

5V D

C

5 9

7

V V

V

6 8

SiC

OM

NO

COM

NC

UP

TO 3

UN

ITS

VOLT

AG

E IN

PUTS

RES

ISTA

NC

E IN

PUTS

UP

TO 4

UN

ITS

U1

U2

U3

R1

R2

R3

R4

+Ve

FRID

GE

LIG

HTS

OTH

ER

DC

OU

TLET

S

HEA

TER

PUM

P

TAN

K

INC

LIN

OM

ETER

PITC

H

INC

LIN

OM

ETER

RO

LL

FRID

GE

CA

BIN

SHO

CK

SHO

CK

TO S

ICO

M S

PLIT

TER

Abo

ve




APPLICATION WITH REDARC 1230 BMS S2

12V

Pow

er

THE

ITEM

S TH

AT A

RE

CO

VER

ED IN

A P

AC

KA

GE

MAY

VA

RY B

ECA

USE

OF

SEN

SOR

AN

D/O

R M

OD

ULE

CO

NFI

GU

RAT

ION

.

APP

LIC

ATIO

N W

ITH

RED

AR

C B

MS

1230

LITH

IUM

BAT

TERY

DO

CU

MEN

T A

ND

CO

NC

EPTS

AR

E C

OPY

RIG

HT

SAFI

ERY

PTY

LTD

V2.

1

Imax = 25A

Imax = 25A

Imax = 25A

Imax = 25A

IN

IN

IN

IN

01

02

03

04

OU

T O

UT

OU

T O

UT

01

02

03

04

R1

R3

R2

R4

U2

U1

GN

D U

3 C

OM

0 -

65k

OH

M

3 2

1 4

SC

Q25

T 0

- 3

5V D

C

5 9

7

V V

V

6 8

SiC

OM

NO

COM

NC

UP

TO 3

UN

ITS

VOLT

AG

E IN

PUTS

RES

ISTA

NC

E IN

PUTS

UP

TO 4

UN

ITS

U1

U2

U3

R1

R2

R3

R4

+Ve

FRID

GE

LIG

HTS

OTH

ER

DC

OU

TLET

S

HEA

TER

PUM

P

TAN

K

INC

LIN

OM

ETER

PITC

H

INC

LIN

OM

ETER

RO

LL

FRID

GE

CA

BIN

SHO

CK

SHO

CK

TO S

ICO

M S

PLIT

TER

Abo

ve




100Ah SLIMLINE SAFIERY LITHIUM BATTERY SPEC




125Ah SAFIERY LITHIUM BATTERY SPEC




200Ah SAFIERY LITHIUM BATTERY SPEC




CONFIGURATIONS

1 PCS

PACKAGE DIMENSIONL: 318MMW: 165MMH: 217MM


12V 125AHR

2 PCS-PARALLEL 12V 250AHR


3 PCS-PARALLEL 12V 375AHRPACKAGE DIMENSION

L: 954MMW: 165MMH: 217MM






4~6 PCS-PARALLEL 12V 500/625/750AHRPACKAGE DIMENSION

L: 1272/1590/1908MMW: 165MMH: 217MM

PACKAGE DIMENSIONL: 318MMW: 660/825/990MMH: 217MM

。。。

。。。




CONFIGURATIONS




CONFIGURATIONS


2 PCS-SERIAL 24V 125AHR



4 PCS-PARALLEL & SERIAL 24V 250AHR







1 PCS

PACKAGE DIMENSIONL: 534 ± 2MMW: 207 ± 2MMH: 220 ± 2MM


12V 200AHR

2 PCS-PARALLEL 12V 400AHR


2 PCS-SERIAL 24V 200AHRPACKAGE DIMENSION

L: 1068MMW: 207MMH: 220MM


PACKAGE WEIGHT26 ±0.5KG

CONFIGURATIONS - 200 Ahr




CONFIGURATIONS - 200 Ahr







GALLERY




VIDEOS

Safiery Lithium Batteries in Kimberley Karavanhttps://youtu.be/qQPaLCvxuNQ

Safiery Lithium Bluetooth App in Actionhttps://youtu.be/BNSeUGQdTdg




VISIT SAFIERY UNIVERSITY




AGM BATTERIES

Users have had a good run with AGM batteries, the technology is a great leap on wet lead-acid batteries. However:

The chemistry of AGM Batteries requires maintenance• The chemistry requires constant awareness of correct charge level.• Vulnerable to “sulfation” - battery equivalent to scale on your teeth, but it’s

scale on the battery plates. It will happen, it’s just a matter of when!• Correct charging levels and maintenance is needed to keep sulfation at bay.

When it isn’t going to plan, what is the problem? • Is the charging voltage high enough ?• Was their a deep discharge in storage that you missed?• Has your Vehicle setup changed?• Is there an issue with the battery charger?

Lithium Batteries are a maintenance free alternative:

• Lithium batteries have a computer built inside of the battery• The computer does a lot of protection for you• Lithium batteries last longest when kept in a mid point of charge

Lithium Batteries are:

• A fraction of the weight• Soak up solar charging at 100% efficiency (AGM is about 70% efficient)• Last a lot longer




Cost of replacing AGM on a trip when required.• AGM Batteries are “cheaper” than Lithium to buy • Consider changing out to Lithium before your AGM’s have died,

If you are out in the bush and a bank of batteries die, the costs mount up:

What are the things to consider with AGM Replacement?• Lithium has a long life.• Lithium has lower maintenance.• Lithium is much lighter

4 x Ritar AGMs: 124kgs vs 2 x 125Ahr Long Life Lithium’s: 31kgs 93 kgs weight saving

However, the really big advantages to get the most from Lithium:• Lithium charges much faster then AGM - hours faster,• Lithium technology is 100% efficient;

AGM is only 78% efficient: AGM needs 1.27 Ahrs of solar power going into the battery to get 1 Ahr out.

In the Bush

Battery Price (Alice

Spings)

Call out, install, dispose of old,

service fee,100kms out of town

Estimated total cost

4 x Ritar 100 Ahr (200 Ahr usable) $459 $450 $2,286

3 x Lifeline 120Ahr (180 Ahr usable) $945 $450 $3,285

Lithium Equiv. Capacity Cost installed before trip

2 x 125 Ahr (200 Ahr usable)

$3,580 Brisbane $120 $3,700

DECISION POINTS FOR AGM REPLACEMENT




ABOUT SAFIERY & THE AUTHOR - BRUCE LOXTON

Safiery develops and enhance ENERGY and WATER conservation products of the highest performance:• Triple Insulated Solar Panels and highest

performance VICTRON Smart Solar.• 8kW DC Power Generation off engine-on

the move and INTEGREL highest perfor-mance controller.

• 12V, 24V and 48V Lithium Batteries with in-built VICTRON Bluetooth mesh for highest performance.

• VICTRON Bluetooth Mesh Networks of Smart Charging devices

• SIMARINE Energy and Tank Monitoring Displays.

• SAFIERY Gas bottle Monitoring both wired and Wifi

• SAFIERY Water Monitoring and Automation using high accuracy performance sensors.

• SAFIERY EASY TOUCH SWITCHES: Patented Dual colour LED Lighting Control and Automation with auto colour change at sunset for insect control.

Voice Control will transform the convenience for users and reduce costs for manufacturers.

This is our vision: architecture of robust wireless devices to specialized sensors that require no user intervention.

Bruce has an Honours degree in Engineering from University of Queensland.

Safiery is his sixth career role.

His early career was with Anglo American on one of the largest Copper mines in Africa. He held a drilling and blasting licence and modelled underground ore bodies. His innovation with engine oil conservation in 100 ton dump trucks saved the mine tens of millions of dollars.

He spent 15 years at Honeywell in engineering and project roles before becoming General Man-ager in the USA.

He then spent 7 years with ABB on heavy elec-trical engineering, drives and ran the robotics business globally from Zurich.

He was appointed Chairman of Qinetiq , a public listed Defence Consultancy company. Under his watch, Qinetiq delivered the technical assess-ment on the submarine proposals to the Aus-tralian Govt in 2016. He held the role for over 6 years in Canberra in parallel to his Kimberley business.

Bruce installed over 2,000 Lithium batteries when he owned Kimberley Kampers from 2003 till 2016. Kimberley was the first RV company to use Lithium as a standard product. The experi-ence gained of seeing multiple chargers, solar controllers and inverters perform is invaluable.

He created the Kimberley Karavan, Kimberley Kruiser and the Automatic Waterless Toilet.

Bruce is an alumni of Harvard University, University of Southern California and is a Member of the Institute of Engineers.

TRAVEL THE WORLD WITHOUT CONSUMING THE EARTH. (TM)

long life lithium batteries - safiery grid free camping ver2-web.pdf2. lithium battery range 3....

Documents