EV Powerpak12V prefabricated battery packs are suitable for any application where portable power is required. They have an integral battery management system (BMS) to balance and monitor the cells. A Battery Control Unit (BCU) is also recommended in most applications to protect the battery from overcharge/discharge.
Most Lithium battery vendors purchase the cells, hide them in a box and double the price. We work on a "less is more" concept. Our cells are not hidden and we are up front about the cell brands we use.
- Plug and Play (well bolt and play)
- Stainless Steel strapping.
- Cell interconnects and battery management cell modules pre-installed
- Protective strong polycarbonate cover
- Brass terminal posts
- Suitable for series connection to make higher voltages, 24V, 36V, 48V etc
- Suitable for parallel connection to increase capacity (using BCU-PPAK)
- Charged, balanced and tested prior to delivery
- Easy installation and trouble free operation
- Proudly designed and assembled in Australia
- Marine House power systems
- Recreational Vehicles and Caravans
- Golf carts and ATVs
- Remote Area power systems
- Portable Lighting towers
- Industrial process control systems
- Electric vehicles
For 12V battery packs connected in parallel or for 24V and higher a Battery Control Unit IS ESSENTIAL FOR SAFE OPERATION, reliability and long life.
FOR WA ONLY, RV AND CARAVAN APPLICATIONS PLEASE CONTACT
INSTALL A GADGET
FOR ALL OTHER APPLICATIONS PLEASE CONTACT US
|GBS||VOLTS||capacity||kWhr||len x wid x ht mm||weight|
|EVG12V040A||12.8V||40Ah||0.5||197 x 127 x 190||6.8kg|
|EVG12V060A||12.8V||60Ah||0.8||273 x 128 x 192||9.2kg|
|EVG12V100A||12.8V||100Ah||1.2||273 x 128 x 245||12.6kg|
|EVG12V160A||12.8V||160Ah||2.0||280 x 290 x 190||21.0kg|
|EVG12V200A||12.8V||200Ah||2.5||285 x 290 x 250||27.0kg|
|EVG12V300A||12.8V||300Ah||3.8||360 x 275 x 330||46kg|
|EVG12V400A||12.8V||400Ah||5.1||365 x 292 x 320||55kg|
|CALB||VOLTS||capacity||kWhr||len x wid x ht mm||weight|
|EVP12V100A||12.8V||100Ah||1.2||287 x 150 x 240||13.5kg|
|EVP12V180A||12.8V||180Ah||2.3||285 x 185 x 300||22.5kg|
NOTE: A Battery Control Unit BCU-PPAK-4C (12V) or 8C (24V) is highly recommended for battery protection. It can control up to three of these battery packs in parallel for up to 240A continuous draw
Note: For deep cycle battery sizing use about 60-70% of the capacity of Lead Acid SLA batteries.
EV Power Paks cost more than SLA batteries. Please inquire if you are prepared to pay more for a better, lighter, longer lasting battery.
BMS-BCU-EVPPAK-4C - 4 cells / 12VDC
BMS-BCU-EVPPAK-8C - 8 cells / 24VDC
A smart device in a small package this control unit is designed to work with the EV Power Paks to deliver trouble free power for portable power applications.
- Low power consumption (<15mA) even when discharge contactor is on.
- Monitors battery voltage 12V minimum, 15.1V maximum.
- Monitors the battery management system (BMS).
- 240A (3 x 80A) contactor isolates the batteries if there is a problem.
- 12V and 24V versions available.
- Can control up to three EV Powerpaks in parallel
12.8V Nominal, 400Ah, 5.1 kWhr capacity. 56 kg, 450 x 285 x 305mm
LFP Battery pack 12.8V, 100Ah. 287 x 150 x 240mm 13.5kg
EVP12V180A, 12.8V, 180Ah, 2.30kWhr, 285 x 185 x 300mm 22.5kg
"I just love your batteries. I am a great supporter of your batteries and have given your number to quite a few fellow travellers after talking to them about the batteries. I just love them as they make energy management so much easier.
"We went away for a two day week end & after coming home allowed the 130 litre fridge/freezer to run for another two days. At that point the battery was
reading 12.4 volts.
This battery is just amazing. I thought you would like this feedback & yes you may quote me if you wish.
"Just a short note to let you know your batteries are performing very well - the 180AH house battery charges at 80A+ with the charge voltage set to 14.5V (there is a 0.4V drop at full charge)and once full the charge current rapidly tapers off over a few mins, goes to <1A and then stops altogether. The only thing is to advise boaties to make sure they have good programmable voltage regulators (mine is a Balmar) and have voltage sensing at the battery not the alternator. The voltage holds up beautifully even down to 25% capacity, which is as low as we have run them. The little 240v charger has performed fine so far (it is probably not quite marine grade but I have protected it as well as I can and we will see how it goes). It is quite powerful enough for our purposes.
Anyway, your end of it is working fine, I wouldn’t ever go back to lead acid batteries now I have these."
" I’d just like to let you know how the batteries are going and to know from yourself that your happy with the way they are being charged and looked after. So far it seems we don’t seem them fall below 74% on our Xantrex lite meter. It seems the regulators bring them up to around 94-98% fully charged each day but then on the second or third day they do a full charge up to 100% as they did today.
We are super happy with them and love the way they take charge so quickly. It would be good to make sure we are doing all we can to make the system work as well as it can. I’d like to get the most out of these batteries so would like to treat them in the best manner possible.
It all seems great I’ve also checked the LED’s on the batteries during the full charge and have never seen a red LED so they all seem well balanced for now and they’re constantly around 13.3-13.4 volts when at rest. During the day they never go above 14.2 when the regs do a full charge and they never get lower than 12.9 even when they’re at 80% and we are pulling heavy loads on the inverter during the night of around 80-90A, this is the lowest I’ve seen them but after we’ve finished with the inverter they go back to 13.3-13.2. Honestly the batteries seem to good to be true and I can’t believe how well they’re working or that no one seems to know about how good the bloody things are!!! "
Some People Claim that Lithium Batteries don’t need a BMS (Battery Management System).
For us it’s a question of safety first. It is important to inform customers of the potential risks.
Most times it is true that Lithium batteries will stay relatively balanced for a period without any external balancing or monitoring. However there are some potential risks. Lets have a look at some "what if?" scenarios in a 12V (4 cell) battery. Remember that the upper safety limit for a LiFePO4 cell is 4.2V.
What if the battery does become unbalanced due to aging or cell IR (internal resistance) differences?
- In the worst case this would mean a pack charged to 14.6V could have three cells at 3.3V and one cell at 4.7V. This high cell would swell, heat up, vent and potentially burst with flames.
What if a car or boat alternator voltage regulator malfunctions or is maladjusted and overcharges the battery?
- An alternator can produce up to 300VDC if unregulated. If any LFP battery with no BMS checking the upper cell voltage limit was subjected to this it could fail catastrophically.
What if the battery is accidentally over-discharged?
- There can be varying degrees of this. Many times the battery can be recovered if treated properly. However if one or more cells goes to zero volts for a period or is reverse polarized by discharge currents for even a few seconds then the battery will be permanently damaged and become unbalanced. A subsequent recharge carries a significant risk of catastrophic failure.
What if one cell fails and falls to zero volts?
- This is a very rare but normal failure mode for Lithium cells. In this case the cell most often forms an internal short circuit. So if there are 4 x 3.2V cells in a 12V pack the peak charge voltage would normally be 14.4-14.6V. So 14.4 / 3 = 4.8V per remaining cell. At this voltage the remaining cells would swell, heat up, vent flammable gas, and potentially burst and catch fire.
Some rules of thumb:
- The larger the cell capacity the larger the risk of damage from a catastrophic failure.
- The more cells connected in series the greater the risk of unbalance and failure.
- Batteries comprised of series strings of cells connected in parallel present a much greater risk of catastrophic failure.
- The larger the charge and discharge currents the larger the possibility of variable internal resistances causing unbalance. Internal resistance creates heat during both charge and discharge so the highest IR cell will lose capacity first.
- If a LFP battery is over-discharged it can become unbalanced and unstable unless correctly recovered, preferably using the correct charger for the purpose.
- Using an intelligent Lithium dedicated charger with a deep discharge recovery charge curve is much safer than using a regular SLA charger.
We have a smashed safety glass window in our workshop from an exploded Winston Thundersky cell that we were testing. It proves that LiFePO4 Lithium batteries can explode and catch fire if overcharged. Or more importantly over-discharged and then recharged without checking for a dead cell. We know of at least one other vendor that has had a similar experience. Also there are many examples of battery fires where no BMS was used or where an improperly designed BMS was inactive or failed.
We do our absolute best to minimize the risk of battery failure for our customers. On larger battery packs we advocate the use of our Australian made BMS. Smaller packs are safer but also benefit from over-discharge protection.
A Battery Management System (BMS) performs two functions. The first function extends the battery life. The second works to prevent catastophic failure. No system is perfect but it is better to be annoyed by a system dropout that be alarmed by a dramatic failure.
All EV Power Pak batteries include a cell level balancing and monitoring BMS. Many other vendors do the same. We will sell you the cells. You don’t have to use BMS but it is our duty to explain the risks involved if you don’t.
Q- HOW TO CALCULATE 12V CARAVAN USAGE - CUSTOMER EXAMPLE (Rods calcs in Bold)
We watch some DVD/ TV@ 60 w, x 4 hours
60W x 4 hrs = 240 Watt Hours (WHr)
all lights are LED 4 amp x 4 hours
4A x 12V x 4hrs = 192 WHr
7 amp shower pump for approx 15 min day
7A x 12V x 0.25hrs = 24WHr
, Using a 600 w pure sinewave inverter for 2 x phone charging 4 amps & computers 8 amp = 12 amp day, plus extractor fan while cooking.= 1 amp. total amps @ 12 v = 38 amps
Lets assume 1 hour average usage per day for all: 38A x 12V x 1hr x 1.2 (inverter efficiency loss) = 547 WHr
TOTAL Consumed Watt Hours per day = 240 + 192 + 24 + 547 = 1003 WHr
Charging by 180 w solar, + 120 w foldout when needed.
180W + 120W = 300W max x 4hrs average insolation = 1200 WHr. This is cutting it fine I would say.
Battery Storage required for 2 days of no sun: 2 x 1003 = 2006 Whr
Battery Amp Hours @ 12V = ( 2006 Whr / 12V ) + 20% spare = 12V 200Ah Voila !
Q- Does Temperature effect the total discharge rate? Hot weather vs freezing.
A- The battery voltage will sag more under load in cold conditions but it will still deliver most of its Ah capacity.
Q- Is the charging pack and bms water resistant?
A- Yes, we make the 12V battery modules with covers and seal the edge to prevent water/dust ingress. It won’t handle getting rained on directly though so must be inside the cart.
Q- A lead acid battery gases while charging, does lithium emit anything?
A- Nothing under normal charging/discharging.
Q- What safety concerns do we need to be aware of in the event of a short circuit or heavy impact to the battery pack in the event of a crash or failure?
A- LFP batteries contain an organic electrolyte which is mildly flammable. In the event of a catastrophic short circuit or accident where the batteries are ruptured there is the potential of a fire. A small dry powder fire extinguisher is recommended near the pack.
LFP batteries are much safer in this respect than Lithium Cobalt and Lithium Manganese.
Q- Does the BMS control over discharging?
A- The BCU-PPAK has two protection modes. The first is that it monitors the overall pack voltage and if it goes below the limit (about 90% discharged) for more than 15 seconds the battery will be disconnected. The second is that each cell is monitored so if any cell becomes over-discharged the battery will be disconnected.
Q- If 70% discharge = 2000 cycles we would not want to discharge any lower than 70%.
What lets us know when the batts reach 70% discharge?
A- For this a SOC amphour counting type meter is required such as the Xantrex Battery monitor. It can generate an alarm at 70% discharge to warn the operator to limp home. We are also working on our own battery monitor but it is not in production yet.
Q- Is lithium recyclable?
A- Yes, all the battery components are valuable and recyclable. In future this will be a big industry.
Q- Lead acid batteries sometimes have cells fail. Do Lithium have any failures?
A- Occasionally yes. In my experience about 1 in 5000 cells will fail. In most cases it will be DOA so is easy to pick. Subsequent to installation failures in my experience are due to over-discharge because of installer or operator negligence. That is why we are now supplying the prefabricated 12V EV Power Paks with BMS installed and insist on a BMS master unit being correctly installed. We are moving towards a plug-and-play system which is very robust.
Q- What’s the maximum amperage @ 48volts that the Lithium pack can handle?
A- For a 180Ah system it would be 1800A in short bursts or 360A continuous. 145A continuous is recommended for long life. Your carts would not draw anything near this except when accelerating/pulling heavy loads.
Q- When the Lithium pack is exhausted can we just replace the battery or do you need to replace the bms and charger as well?
A- Just batteries. I think you will find that once they are installed and run in, if they are not abused by running flat continuously they will last a very long time (5-10 years) without any maintenance.
Q- Are lifepo and lifepo4 one and the same battery type?
A- Yes, Lithium Iron Phosphate, or LFP. Not to be confused with LiPoly which are Lithium Cobalt Polymer cells.
Q- Does battery height dimensions include the terminals?
A- Yes, but you should confirm if space is tight.
Q- Is the BCU the BMS master unit you refer to in the "FAQ,s" or are these different?
A- Yes, Battery control unit = Master Unit
Q- what is the warranty period on the batteries and BCU?
A- 12 months from the invoice date on battery and BCU assembly. 36 months on the cells themselves if we can show the cell had a manufacturing fault.