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ASNZ3001.2.2022
Lithium Battery-school Blog
LiFePO4 Australia , , , , ,
AS/NZS3001.2:2022 Electrical system safety in RVs (Caravans, Motor Homes, and Camper trailers)
What is the new standard?

AS/NZS3001.2:2022 outlines requirements and guidelines for various aspects of the electrical system in Caravans, RVs, and Camper trailers. The standard considers wiring, inverters, solar panels, and batteries. The standard also requires batteries to comply with AS IEC 62619.

What is AS IEC 62619 Certification?

AS IEC 62619 Certification is a globally recognized standard for lithium batteries, developed by the International Electrotechnical Commission (IEC).  IEC 62619 specifies requirements and tests for the safe operation of secondary lithium cells and batteries used in industrial applications, including stationary applications. 

This certification assures consumers that the battery they are purchasing has undergone rigorous testing and meets all the necessary requirements for safe operation. 

What is driving the change in standards?

The change in standards is driven by the need to improve safety and consistency in the storage of batteries in RVs. The new standards, AS/NZS3001.2:2022, have been developed in consultation with electrical experts and industry professionals to address safety concerns and ensure standardization in the industry.

When are they enforced from?

The new standards are enforceable from 18 November 2023.

Who does it apply to?

The standards apply to everyone buying or using a new recreational vehicle build but are of particular importance to manufacturers and importers of recreational vehicles.

Do I need to comply to the new standard?

The standard applies for any new installations from the 18th of November 2023 (the effective date). The new standard applies to any new electrical installations (vehicle builds) conducted after the effective date, but not to existing installations. Installations prior to the effective date will be assessed against the standards at the time of installation so long as they meet basic safety standards.

Typically, repairs may be conducted using methods, fittings and fixtures that were acceptable at the time of the original installation.   Alternatively, currently available methods fittings and fixtures available as direct replacements may be used, providing that basic safety requirements are met. 

Alterations, e.g. replacing lead acid batteries with lithium batteries, are to be completed in line with the current (new) standards and shall not compromise the remainder of the installation.  

We recommend consulting a professional and ensuring the installation complies with the new standard.

Will it affect my existing installation?

The new standards are enforceable on new RVs, so they are unlikely to affect your existing installation. However, if you plan to make any alterations or updates to your RV’s electrical system, including battery system, it is advisable to consult with a qualified professional to ensure compliance with safety standards.

In a nutshell, what are the key changes?

The key changes include requirements for the installation, mounting and wiring of electrical systems into RVs including inverters, solar, wiring and batteries. With respect to batteries the changes focus on minimising the potential for adverse events by considering protection against harmful gasses and fumes and to prevent their build up, fire, damage from water ingress, damage from physical impact and to make sure they are installed and operating withing the batteries specifications.

Do all LiFePo4 Australia lithium batteries comply with the new standard?

The Lifepo4 Australia range of batteries, either comply or are under application with IEC62619, a requirement of the new standard. If these batteries are installed in accordance with the regulations, they are considered to be meeting the standard. You must check the website and or ask us if you require your battery purchase to be used in accordance with this standard.

From the standards

(a) be installed externally, i.e. behind a wall, compartment or barrier that prevents the egress of gases into the habitable area; and
(b) not enter the habitable area of the structure; and
(c) be installed to operate within the manufacturer’s defined operating temperatures, including IP rating; and
(d) be installed in a suitable battery container where the battery manufacturer has not provided encapsulated cells.

What do the standards say about lithium batteries in caravan/camper trailers?

The new regulations stipulate that a lithium battery cannot be installed in a habitable living area, such as inside a caravan or camper trailer, unless it is placed in a sealed enclosure, or the installation location is sealed off from the habitable area and the sealed off area is vented to the exterior environment. 

Solar panels

AS/NZS 3001.2:2022 Electrical Installations Standard also covers the use of solar panels. One significant change to the standard is the requirement for individual fusing and isolation points prior to the panels being connected in parallel. This is to prevent one faulty panel from taking out the entire string, which could lead to a fire. With individual fusing, any faulty panel will blow the singular fuse, and the rest of the system will continue to operate as it should.

How do I get a copy of these regulations / can you send me a copy of them?

You can obtain a copy of AS/NZS3001.2:2022 by purchasing it from Standards Australia. Or alternatively, you can ensure you installer is qualified and is following the new standards by asking them if they comply.

Where do I get more information about these regulations?

Can the batteries be mounted on the outside of the caravan (i.e. Chassis)?

Yes, as this is not classed as a habitable environment, lithium batteries can be mounted on the exterior of the caravan. When installing outside the vehicle it is important to ensure that the installation ensures the batteries are operated within their specifications. The installation must be protected from physical damage, operating within its temperature range, adequately IP rated to protect against water and dust etc. 

How do I install batteries within the standard if the batteries are to be mounted inside the caravan?

When installing batteries inside the caravan while adhering to the standard, it is essential to place the batteries within a sealed enclosure, with venting directing gases outside of any habitable areas whilst also ensuring that the enclosure (venting port) is environmentally protected. The enclosure must provide access for installation and maintenance and must have effective seals. A screwdriver or special tool must be required to access the enclosure. Whilst the standards do not provide specific guidance on the material that should be used to construct this enclosure it should be suitable to provide a sturdy home for the batteries and survive the roads conditions that the Caravan/RV is designed for.

What’s the difference between Lead Acid and Lithium battery installations?

Lead acid (LA) batteries are also required to be sealed off from the habitable area and to be vented externally. Because LA batteries release gasses that are lighter than air they need two vents, one at the top and one at the bottom of the enclosure. An enclosure that is design specially for Lithium batteries, i.e., one has one vent must be clearly labelled as only being suitable for lithium batteries and to not install LA batteries in the enclosure.  

Are lithium batteries safe to use?

Lithium batteries with an in-built BMS that monitors and balances individual cell voltages, monitors charge voltage and current and ensures the battery does not drop below an acceptable charge level are safe to use when installed and maintained correctly. We always recommend the use of LFP Lifepo4 chemistry as it is much safer than NCM, NCA and similar chemistries which include Nickel and Cobalt.

What are the repercussions of installing non-approved lithium after Nov 18?

As with any non-conformance to Australian Standards, the vehicle in question can be defected and any manufacturer or importer of non-compliant vehicles may be prosecuted to the extent of the law.

What about in-vehicle situations? Can batteries be installed in-cabin or in the engine bay still due to these standards?

The changes to AS/NZS 3001.2:2022 do not explicitly consider in-vehicle installations unless they are installed in a habitable area, however the recommendations on installation including gas venting, fire, physical and environmental protection are still valid for all installations.

Residual Current Device (RCD)

Inverters must be installed using a Residual Current Device (RCD) which will provide protection in a similar manner to all AC wiring which is installed with an RCD at the input to the RV. This would need to be a separate RCD and labelled appropriately that an inverter or and inverter/charger is installed.  The old way of just buying an off the shelf inverter and connecting it to your battery stored under the bed or seat and then plugging in an extension lead is to be thing of the past.  The unit must be accessible and have a visible light to identify the status. 

Solar Panels

Solar panels must have over current protection devices – fusing must be installed on the positive cable at the actual panels where there is circulating current.  Also to note is that cable suitable for solar panel installations must be used – eg. the cable must be double insulated and also IP rated for the harshness of the Australian sun and the environmental conditions. RVers should give due regard to any portable panels that they decide to connect to their system in that these should also be fused and incorporate appropriate cables. 

Fusing

Fusing must also be provided to protect batteries and this again, should be as close as practicable to the battery itself and on the positive wire.  We would recommend the slow blow blade fuses generally used in automotive applications.  These allow for some momentary or temp over current or inrush and are not designed to protect highly sensitive electrical equipment but will certainly blow when there is sustained over current.  In the case of RV installations it is used not only to prevent damage to appliances and chargers etc but also to prevent the wiring insulation from melting as most manufacturers will only used the minimum wiring gauge require to meet voltage drop.

From the standards

(a) be installed externally, i.e. behind a wall, compartment or barrier that prevents the egress of gases into the habitable area; and
(b) not enter the habitable area of the structure; and
(c) be installed to operate within the manufacturer’s defined operating temperatures, including IP rating; and
(d) be installed in a suitable battery container where the battery manufacturer has not provided encapsulated cells.

Further Reading and more detailed analysis of the Standard
Sourced from Our Blog New Standards for Fitment of Batteries to Caravans – Electrical Installations Standard (AS/NZS 3001.2:2022) (12voltdirect.com.au)

AS/NZS 3001.2:2022 Electrical installations – Connectable electrical installations and supply arrangements; Part 2: Connectable electrical Installations is a key Australian Standard, covering electrical installations in recreational vehicles (as well as other connectable installations used for accommodation, habitation or commercial purposes).  This Standard has recently undergone a major revision and was published on 18 November 2022.

Caravan Industry Association of Australia holds a seat on the AS/NZS 3001 Standards Australia committee (through Jason Arter) and has worked in collaboration with our member state associations and industry throughout this standard revision project.

The following overview provides a summary of some of the key changes in this revision and is provided as general guidance and information based on our understanding of the electrical Standard requirements.  However, it is important to note that this does not provide an exhaustive list of changes to the standard.  It is strongly recommended that industry businesses make their own investigations and explore the changes to AS/NZS 3001.2:2022 with regard to the recreational vehicles they are producing.  It is also important to ensure that the relevant personnel (e.g. contract or staff electricians, vehicle designers etc.) within your business are up to date with these changes.

There is a significant administration change with the separation of AS/NZS 3001 into 2 parts:

  • AS/NZS 3001.1, Electrical installations — Connectable electrical installations and supply arrangements, Part 1: Site supplies for connectable electrical installations
  • AS/NZS 3001.2, Electrical installations — Connectable electrical installations and supply arrangements, Part 2: Connectable electrical installations

This summary only addresses Part 2 of the Standard (AS/NZS 3001.2) relating to installations within vehicles and relocatable units.

Within Part 2, the Standard has been divided into separate sections that address specific types of connectable electrical installations.  This assists readers to locate the information relevant to their particular installation.  It may mean that a section is not applicable to your installation, depending on the product and features incorporated.

  • Section 1 provides the scope, inclusions, and exclusions of this Standard. The definitions and alterations and repairs have been expanded;
  • Section 2 provides for the external supply connection and onboard supply installation requirements applicable to a connectable electrical installation;
  • Section 3 provides the installation requirements for relocatable units;
  • Section 4 provides the installation requirements for recreational vehicles and non-recreational vehicles;
  • Section 5 provides the installation requirements for extra-low voltage wiring systems and equipment in all connectable electrical installations; and
  • Section 6 provides verification requirements in all connectable electrical installations.

If you are using the Standard for installations in recreational vehicles, refer to sections 1, 2, 4, 5 and 6 – for installations in relocatable units, refer to sections 1,2,3,5 and 6.

 

Key Changes Summary
One of the most significant changes to the Standard is the inclusion of a section outlining requirements for extra-low voltage d.c. electrical installations (Section 5).  Within this section are significant new requirements for batteries, solar panels (and other sources of supply), wiring, electrical equipment and accessories.

Batteries
Batteries should be rechargeable and have a minimum battery capacity of 40Ah at a 20h discharge rate.

Securing of batteries – no greater than 25mm movement under a pulling force of twice the battery weight.

Clearance to metallic service lines – 300mm clearance around battery terminals, or appropriate shielding in place.  E.g. to gas, diesel, water lines or similar.

Lead-Acid batteries (all types)

  • External location:
    • Open to environment or in a vented battery compartment;
    • Must include a spill tray that can hold at least 20% of the electrolyte held by the battery; and
    • Battery compartment vents must be outside the habitable area.
  • Internal location:
    • Must be in a battery compartment that is vented to the exterior of the vehicle; and
    • Must include a spill tray that can hold at least 20% of the electrolyte held by the battery.
  • Battery compartment ventilation is required via one of three prescribed methods.

Lithium ion batteries (all types)

  • Location – external to the living area, i.e. behind a wall, compartment or barrier that prevents the ingress of gasses to the habitable area.
  • Must be provided with a battery management safety system:
    • Monitors voltage, current and temperature of the battery; and
    • Automatically disconnects for critical conditions.
  • Must be provided with a visible monitoring device:
    • Must display state of charge, may display voltage; and
    • May use wired or wireless communication direct to the battery management safety system.
  • Installer should consult with the battery manufacturer for compartment design and means of venting that are appropriate for the type of battery.

Solar
Renewable energy sources:

  • Installed only for charging batteries;
  • Only generate extra-low voltage; and
  • Must have a device which prevents overcharging of the battery(ies).

Photovoltaic (PV) array installations shall be installed as per this standard (AS/NZS 3001.2).  Further guidance may be sought from AS/NZS 5033.

Overcurrent protection devices shall be provided at the PV array.

PV modules must comply with all national design rules for road safety (i.e. ADRs):

  • Height & width limits.
  • External projections.
  • Vehicle lighting – obstruction.
  • Strength of attachment – normal operation, emergency braking, crash scenario.

Recreational vehicle manufacturers who offer solar power systems are strongly encouraged to investigate the full details of the section on solar (and other renewable) energy sources.

Multiple sources of supply
An installation may be supplied from multiple sources – either external or on-board, and at either low voltage or extra-low voltage.

A changeover device that ensures only one source of supply can be connected at any given time must be provided on (or adjacent to) the switchboard:

  • Where the switchboard is mounted externally, provision is made for the changeover switch to be placed in a prominent position internally; and
  • Where a changeover switch is incorporated into a source of supply (e.g. inverter charger) a label shall be placed at the switchboard indicating the location the device.

When multiple sources of supply are present, low voltage socket outlets in the installation must be labelled to indicate the sources of supply.

Onboard Supplies – Inverters
All or part of the electrical installation may be supplied by an on-board source of supply, such as an inverter or inverter charger.

If an inverter (or inverter charger) is fitted:

  • Controls must be readily accessible;
  • Final sub-circuits supplied by an inverter or inverter charger must be protected by an RCD device. (For an isolated/EPB inverter this can be integral to the unit or external); and
  • The main switchboard must contain
    1. A warning label indicating the presence of an inverter; and
    2. A visible indicator showing the status of the inverter or inverter charger – active online or in standby mode.

Note: Where the switchboard is mounted externally, provision is made for these indications to be placed in a prominent position internally.

Extra-Low Voltage (12V d.c.) Wiring
Protection must be provided against mechanical damage, environment and other external influences:

  • Retention of wiring.
  • Enclosure.

Protect must be provided against physical contact with live parts:

  • Insulation or physical separation.

Wiring must be suitable for its intended use:

  • Current-carrying capacity.
  • Voltage drop.
  • Conductor size requirements.

Separation must be provided from low voltage (240V) wiring.

Another significant area of change in the standard relates to exclusion areas for electrical equipment and accessories.  Importantly, these restricted areas are applied to both low voltage (240V) and extra-low voltage (e.g. 12V d.c.) equipment and accessories.

Exclusion around gas cylinders
The requirements for this area have been aligned with the controlled areas of AS/NZS 5601.2 Gas Installations Standard.

In very broad summary, devices such as switches, motors, appliances cannot be located within a prescribed controlled area around gas cylinders or gas cylinder compartments.

Exceptions are made for electrical fittings and electrical wiring mounted on a drawbar of an RV whose primary function relates to propulsion or roadworthiness of a vehicle.  e.g. trailer plugs, stability controllers, road vehicle lighting.

Damp area exclusion zones – showers, external shower (sinks unchanged)
An exclusion zone has been applied around an external shower – similar to internal bathroom requirements.  Again, exceptions are made for equipment whose primary function relates to propulsion or roadworthiness of a vehicle.

Dimensions of the defined zones around an internal shower remain consistent with the previous standards.  Further clarification has been provided to address some of the typical door arrangements seen in current vehicle designs.  e.g. shower doors hinged part way along a door.

Cooker exclusion zone
The exclusion zone around an open cooktop has been updated to limit the exclusion area to a height above the cooker as far as the range hood or overhead cupboard (or ceiling if neither of these are applicable).  This is a variation from the corresponding zone in AS/NZS 3000, reducing the area that previously extended up surrounding walls, in recognition of the limited space for relocation of electrical equipment in a recreational vehicle setting.

AS/NZS 3001.2 acts to modify the requirements of AS/NZS 3000 in some key areas:

Appliance switching requirements – cooker, A/C, HWS
Appliances are required to be controlled by a switch that is readily identifiable and convenient for its intended use.

This requirement modifies the AS/NZS 3000 requirements relating to isolation switches for air conditioners, hot water services, and cooking appliances, such that these appliances are not required to have separate isolating devices.

Switchboard (main circuit breaker) clearances – in a cupboard
The requirements for a switchboard (or main circuit breaker) located in a cupboard have some key clarifications:

  • Maximum clearance in front of the switchboard (circuit breaker) is set at 600mm from the face of the device.  note: this modifies AS/NZS 3000 requirements that measure from the edge of an open door in some circumstances;
  • Maximum distance from the face of the device to a protruding bench (or another surface) is 600mm; and
  • Clearance from the face of a device to the front of the cupboard must be no more than 50mm.

This overview highlights some of the significant changes for consideration within your business.  Further technical bulletins will follow with more detail of some of these changes during the implementation phase of the Standard.

As AS/NZS 3001 is made mandatory by electrical legislation in each State and Territory.  While it is expected that each respective Regulatory Authority will honour the 12-month transitional provision, they may apply the new Standard requirements at an earlier time.  Caravan Industry Association of Australia and your state caravanning associations are working with the respective jurisdictions to confirm the details of transitional arrangements in each State, particularly around the timing for full implementation and enforcement of the new Standard. 

Lead acid SLA AGM vs Lifepo4
Blog Lithium Battery-school
LiFePO4 Australia , , ,
Lifepo4 (Lithium) vs Lead-Acid

If you are looking for a reliable and efficient energy storage solution you might be wondering whether to choose lifepo4 or lead-acid batteries. Both types of batteries have their advantages and disadvantages, depending on your needs and preferences. In this article, we will compare lithium and lead-acid batteries in terms of performance, durability, cost, and environmental impact, to help you make an informed decision.

Performance

One of the most important factors to consider when choosing a battery is its performance, which includes its capacity, power, efficiency, and lifespan.

Capacity

The capacity of a battery is the amount of energy it can store and deliver. It is measured in amp-hours (Ah) or watt-hours (Wh). The higher the capacity, the longer the battery can run your appliances and devices.

Lithium batteries have a higher capacity than lead-acid batteries of the same size and weight. For example, a 100Ah lithium battery can provide 100Ah of usable energy, while a 100Ah lead-acid battery can only provide 50Ah of usable energy at best. This is because lithium batteries can be discharged up to 100% depth of discharge (DoD), while lead-acid batteries should not be discharged below 50% DoD to avoid damaging the cells.

Power

The power of a battery is the rate at which it can deliver energy. It is measured in watts (W) or amps (A). The higher the power, the faster the battery can charge and discharge, and the more appliances and devices it can run simultaneously.

Lithium batteries have a higher power than lead-acid batteries of the same capacity. For example, a 100Ah lithium battery can deliver up to 200A of continuous current, while a 100Ah lead-acid battery can only deliver up to 100A of continuous current. This is because lithium batteries have a lower internal resistance than lead-acid batteries, which means they can handle higher currents without overheating or losing efficiency.

Efficiency

The efficiency of a battery is the ratio of the energy output to the energy input. It is expressed as a percentage (%). The higher the efficiency, the less energy is wasted during charging and discharging.

Lithium batteries have a higher efficiency than lead-acid batteries. For example, a lithium battery can have an efficiency of up to 98%, while a lead-acid battery can have an efficiency of around 80%. This means that lithium batteries can store and deliver more energy from the same amount of solar input or generator output than lead-acid batteries.

Lifespan

The lifespan of a battery is the number of charge and discharge cycles it can undergo before its capacity drops below 80% of its original value. The higher the lifespan, the longer the battery can serve you before needing replacement.

Lithium batteries have a longer lifespan than lead-acid batteries. For example, a lithium battery can last up to 2000 cycles at 100% DoD, while a lead-acid battery can last up to 600 cycles at 50% DoD. This means that lithium batteries can endure more frequent and deeper cycling than lead-acid batteries without losing much capacity.

Durability

Another factor to consider when choosing a battery is its durability, which includes its resistance to temperature, vibration, and corrosion.

Temperature

The temperature of the environment where the battery is installed and operated can affect its performance and lifespan. Extreme temperatures can cause thermal stress, expansion, contraction, and chemical reactions that can damage the cells.

Lithium batteries are more resistant to temperature than lead-acid batteries. For example, lithium batteries can operate in a wider temperature range than lead-acid batteries, from -20°C to +60°C. They also have built-in battery management systems (BMS) that monitor and regulate the temperature of each cell to prevent overheating or freezing. Lead-acid batteries are more sensitive to temperature changes and require more ventilation and insulation to maintain optimal performance.

Vibration

The vibration of the vehicle or vessel where the battery is installed and operated can also affect its performance and lifespan. Excessive vibration can cause physical damage, loose connections, and internal short circuits that can reduce the capacity and power of the battery.

Lithium batteries are more resistant to vibration than lead-acid batteries. For example, lithium batteries are made of solid-state cells that are tightly packed and sealed in sturdy cases that prevent movement and leakage. They also have BMS that protect them from short circuits and overloads. Lead-acid batteries are made of liquid electrolyte and plates that are prone to spilling and sulfation under vibration.

Corrosion

The corrosion of the terminals and connectors of the battery can also affect its performance and lifespan. Corrosion can cause increased resistance, reduced conductivity, and poor contact that can reduce the capacity and power of the battery.

Lithium batteries are more resistant to corrosion than lead-acid batteries. For example, lithium batteries have stainless steel or brass terminals and connectors that are less likely to rust or oxidize than lead-acid batteries. They also have BMS that prevent overcharging and undercharging that can cause corrosion.

Cost

The cost of a battery is another factor to consider when choosing a battery. It includes the initial purchase price, the installation cost, the maintenance cost, and the replacement cost. But in 2024, its usually far cheaper per cycle to purchase a Lifepo4 battery. Usually 5-10 times cheaper or more.

Purchase Price

The purchase price of a battery is the amount of money you pay upfront to buy the battery. It is usually based on the capacity, power, and quality of the battery.

Lithium batteries have a higher purchase price than lead-acid batteries of the same capacity and power. For example, a 100Ah lithium battery can cost around $400-$600, while a 100Ah lead-acid battery can cost around $300-$600. This is because lithium batteries use more advanced and expensive materials and technologies than lead-acid batteries, but recently the competition of Lithium Iron Lifepo4 has lead to very similar prices

Installation Cost

The installation cost of a battery is the amount of money you pay to install the battery in your vehicle or vessel. It is usually based on the size, weight, and complexity of the battery.

Lithium batteries have a lower installation cost than lead-acid batteries of the same capacity and power. For example, a 100Ah lithium battery can weigh around 12kg and take up around 20L of space, while a 100Ah lead-acid battery can weigh around 30kg and take up around 40L of space. This means that lithium batteries are easier and cheaper to install than lead-acid batteries, especially in tight and limited spaces.

Maintenance Cost

The maintenance cost of a battery is the amount of money you pay to maintain the performance and lifespan of the battery. It is usually based on the frequency, complexity, and necessity of the maintenance tasks.

Lithium batteries have a lower maintenance cost than lead-acid batteries. For example, lithium batteries are maintenance-free and do not require any watering, equalizing, or cleaning. They also have BMS that monitor and regulate their performance and health. Lead-acid batteries require regular maintenance such as watering, equalizing, cleaning, and checking for corrosion and sulfation. They also need external regulators to prevent overcharging and undercharging.

Replacement Cost

The replacement cost of a battery is the amount of money you pay to replace the battery when it reaches the end of its lifespan. It is usually based on the lifespan, availability, and recyclability of the battery.

Lithium batteries have a lower replacement cost than lead-acid batteries. For example, lithium batteries can last up to four times longer than lead-acid batteries, which means they need to be replaced less often. They are also more widely available and recyclable than lead-acid batteries, which means they are easier and cheaper to dispose of.

Environmental Impact

The environmental impact of a battery is another factor to consider when choosing a battery. It includes the energy consumption, greenhouse gas emissions, waste generation, and resource depletion associated with the production, use, and disposal of the battery.

Energy Consumption

The energy consumption of a battery is the amount of energy required to produce, charge, and discharge the battery. It is usually based on the efficiency, lifespan, and capacity of the battery.

Lithium batteries have a lower energy consumption than lead-acid batteries. For example, lithium batteries can store and deliver more energy from the same amount of solar or generator input than lead-acid batteries due to their higher efficiency. They also need less energy to produce due to their longer lifespan and smaller size.

Greenhouse Gas Emissions

The greenhouse gas emissions of a battery are the amount of carbon dioxide (CO2) and other gases released into the atmosphere as a result of the production, use, and disposal of the battery. They are usually based on the energy consumption, energy source, and recycling rate of the battery.

Lithium batteries have lower greenhouse gas emissions than lead-acid batteries. For example, lithium batteries can reduce CO2 emissions by up to 50% compared to lead-acid batteries due to their lower energy consumption and higher recycling rate. They also use renewable energy sources such as solar or wind more efficiently than lead-acid batteries due to their higher efficiency.

The production and carbon costs of Lead Acid vs Lithium, are very hard to know, with some saying Lithium is much worse, and it’s true that mining lithium and Iron and the other metals required may have a higher carbon footprint, but if you are using the battery daily, these will eventually become less.

Cranking Amps compared

When comparing cranking amps between LiFePO4 (Lithium Iron Phosphate) and lead-acid batteries, there are some important distinctions:

  1. LiFePO4 Batteries:
    • LiFePO4 batteries are more effective at delivering a large amount of current over a short period.
    • They are particularly suitable for applications where high cranking power is needed, such as starting engines or powering devices with significant initial current demands.
    • For instance, if you require a battery that can sustain a 40-amp device for two hours straight, LiFePO4 is an excellent choice
  2. Lead-Acid Batteries:
    • Lead-acid batteries have been around for a long time and are commonly used in various applications.
    • While they have their advantages, such as being cost-effective, they are not as efficient as LiFePO4 batteries in terms of cranking amps.
    • Lead-acid batteries may struggle to deliver high current consistently over a short duration compared to LiFePO4 batteries.

In summary, if you prioritize high cranking power and need a battery that can handle substantial current demands, LiFePO4 is the way to go.

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Lithium Battery-school News
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48v Battery Circuit Breaker or T Class Fuse

What are the most common curves for circuit breakers that are DC rated to 250A?

If you are looking for a circuit breaker that can handle direct current (DC) loads up to 500A, you might wonder what kind of tripping curve you should choose. A tripping curve is a graphical representation of how fast a circuit breaker will trip in response to different levels of overcurrent. It shows the relationship between the current and the tripping time of a protection device.

There are different types of tripping curves for circuit breakers, such as B, C, D, K and Z. Each curve has a different instantaneous trip current range, which is the amount of current at which the breaker will trip without causing a time delay. Generally, the higher the current spike, the faster the breaker will trip.

The most common curves for circuit breakers that are DC rated to 500A are C and D curves. These curves are suitable for inductive and motor loads with medium to high starting currents. They can also handle the inrush current of DC loads, which is the high current draw during the switching on of a load.

A C curve circuit breaker will trip instantaneously when the current flowing through it reaches between 5 to 10 times the rated current. For example, a C curve circuit breaker with a rated current of 25A will trip between 125A and 250A without any delay. This type of curve is ideal for domestic and residential applications and electromagnetic starting loads with medium starting currents.

A D curve circuit breaker will trip instantaneously when the current flowing through it reaches between above 10 (excluding 10) to 20 times the rated current. For example, a D curve circuit breaker with a rated current of 25A will trip between above 250A (excluding 250A) and 500A without any delay. This type of curve is ideal for inductive and motor loads with high starting currents.

The other curves, such as B, K and Z, are less common for circuit breakers that are DC rated to 250A. These curves are either too sensitive or too insensitive to short circuits and are used for specific applications.

A B curve circuit breaker will trip instantaneously when the current flowing through it reaches between 3 to 5 times the rated current. This type of curve is too sensitive for DC loads with high inrush currents and is mainly used for cable protection and electronic devices with low surge levels.

A K curve circuit breaker will trip instantaneously when the current flowing through it reaches between 8 to 12 times the rated current. This type of curve is similar to a D curve but has a higher instantaneous trip range. It is used for inductive and motor loads with very high inrush currents.

A Z curve circuit breaker will trip instantaneously when the current flowing through it reaches between 2 to 3 times the rated current. This type of curve is too insensitive for DC loads with high inrush currents and is mainly used for highly sensitive devices such as semiconductor devices.

To summarize, the most common curves for circuit breakers that are DC rated to 250A are C and D curves, depending on the type and size of the load. These curves can provide adequate protection against overcurrents and short circuits without tripping unnecessarily or too slowly.

An Alternative is to use a Circuit Breaker is a T class fuse

If you are using lithium batteries in any application, you might want to consider using a T-class fuse as part of your safety measures. A T-class fuse is a type of fuse that is specifically designed for use with lithium batteries. It has a fast-acting, low-melting-point element that can quickly interrupt the flow of current in the event of an overcurrent or short-circuit condition. This helps prevent damage to the battery and reduces the risk of fire or explosion.

Here are some of the benefits of using a T-class fuse in your lithium battery setup:

  1. Improved Safety: T-class fuses can protect the battery from overcurrent and short-circuit conditions, which can help prevent damage to the battery and reduce the risk of fire or explosion .
  2. Increased Reliability: T-class fuses can help increase the overall reliability of your setup by preventing damage to the battery and other components in case of an overcurrent or short-circuit condition . This is especially important in applications where downtime or failure can be costly or dangerous.
  3. Simplified Design: T-class fuses can simplify the design of your lithium battery setup by eliminating the need to select the right type of fuse for your application. Because they are designed specifically for use with lithium batteries, you don’t have to worry about compatibility issues or errors .
  4. Cost-Effective: T-class fuses are generally affordable, especially when compared to the cost of replacing damaged batteries or dealing with the consequences of a battery-related incident. They are also durable and long-lasting, which can save you money in the long run .

To sum up, using a T-class fuse in your lithium battery setup can provide a range of benefits, from improved safety and reliability to simplified design and cost savings. If you want to learn more about T-class fuses and how to use them, you can read more, to learn about

Class T vs ANL fuse

Choosing between ANL and Class T fuses depends on your specific needs and application. Here’s a breakdown of their key differences to help you decide:

Current Interrupt Capacity:

  • ANL fuse: Up to 2,700 amps, suitable for automotive starting batteries and modest DC current applications.
  • Class T fuse: Up to 200,000 amps, significantly higher, making it ideal for high-power systems with lithium batteries, solar panels, inverters, etc.

Response Time:

  • ANL fuse: Moderately fast, but not as fast as Class T.
  • Class T fuse: Very fast, crucial for protecting sensitive electronics from quick surge currents.

Size and Cost:

  • ANL fuse: Larger and typically cheaper.
  • Class T fuse: Smaller and more expensive due to its superior capabilities.

Applications:

  • ANL fuse: Good for:
    • Starter batteries
    • Audio systems
    • Winches
    • Moderate-power DC circuits
  • Class T fuse: Ideal for:
    • Lithium batteries
    • Solar power systems
    • Inverters
    • High-power industrial applications
    • Sensitive electronics requiring fast protection

Additional Considerations:

  • ANL fuses: Prone to arcing after blowing, potentially causing further damage.
  • Class T fuses: Designed to minimize arcing, enhancing safety.
  • Certification: Class T fuses often have UL 248-15 listing, important for marine applications.

In summary:

  • Choose ANL fuse for moderate-power DC applications like car audio or winches where affordability is a concern.
  • Choose Class T fuse for high-power systems with lithium batteries, solar panels, or sensitive electronics where fast response and high interrupt capacity are critical, despite the higher cost.

Class-T fuses

are a type of high-performance, fast-acting fuse designed for protecting demanding electrical systems from damage caused by overcurrents and short circuits. They are known for their:

  • High interrupt capacity: Up to 200,000 amps, making them suitable for high-power applications like marine, solar, and industrial systems.
  • Fast response time: They blow very quickly in the event of a fault, minimizing damage to equipment.
  • Compact size: They are smaller than other types of fuses with similar current ratings, making them ideal for space-constrained applications.
  • Corrosion resistance: They are constructed with nickel-plated terminals and a sealed ceramic body, making them resistant to corrosion in harsh environments.

Here are some of the common applications of Class-T fuses:

  • Marine electrical systems: Protecting batteries, inverters, chargers, and other sensitive equipment. Class T fuse in marine electrical system
  • Solar power systems: Protecting solar panels, charge controllers, and batteries. Class T fuse in solar power system
  • Industrial control panels: Protecting motors, drives, and other critical equipment.
  • Battery banks: Protecting large battery banks from short circuits and overcurrent’s. Class T fuse in battery bank
  • Variable speed drives: Protecting drives from motor faults and overloads.
  • Rectifiers: Protecting rectifiers from overloads and short circuits.

When choosing a Class-T fuse, it is important to consider the following factors:

  • The amount of current the circuit will carry: Choose a fuse with a current rating that is slightly higher than the maximum expected current in the circuit.
  • The type of fault the fuse is protecting against: Choose a fuse with an interrupt capacity that is high enough to handle the maximum fault current that is likely to occur.
  • The physical size constraints of the application: Choose a fuse that will fit in the available space.

I cannot directly recommend a specific fuse size without more information. Choosing the wrong fuse size can be dangerous, so it’s crucial to follow proper guidelines and consult a qualified electrician for accurate sizing.

However, I can help you gather the necessary information to make an informed decision:

1. Identify your application:

  • What are you protecting with the fuse (e.g., battery bank, inverter, solar panel system)?
  • What is the voltage and amperage rating of the circuit?

2. Consult the device manuals:

  • The manuals for your devices (battery, inverter, etc.) should specify the recommended fuse size or amp rating.
  • Do not exceed the recommended fuse size for any device.

3. Consider continuous and surge currents:

  • Choose a fuse with a continuous current rating slightly higher than the maximum expected current in the circuit under normal operation.
  • Account for potential surge currents (e.g., motor startup) and choose a fuse with an interrupt capacity high enough to handle those surges safely.

4. Follow safety standards and regulations:

  • Ensure the chosen fuse complies with relevant safety standards for your application (e.g., UL 248-15 for marine use).

5. Consult a qualified electrician:

  • If you’re unsure about any aspect of fuse selection or electrical work, always seek guidance from a qualified electrician. They can assess your specific needs and recommend the most suitable fuse size for your application, ensuring safety and optimal performance.

Remember, safety is paramount when working with electrical systems. Never experiment with fuse sizes or attempt electrical work without proper knowledge and qualifications.

Class-T fuses are a reliable and effective way to protect your electrical equipment from damage. If you are unsure about which fuse to choose, consult with a qualified electrician.

Remember, consult qualified personnel when dealing with high-power applications and fuse selection. They can assess your specific needs and recommend the most suitable option for safety and optimal performance.

We hope this blog post was informative and helpful for you. If you have any questions or feedback, please feel free to leave a comment below. Thank you for reading!

Lithium Battery-school
LiFePO4 Australia , , , ,
How to Top Balance Lifepo4
  1. Hook up the LiFePO4 cells in parallel – (that means connecting all the positives together and the same for the negatives.)
  2. Charge to 3.45V with a regulated DC power supply with overvoltage protection. This part takes a long time! And your power supply should be large enough to cater to your needs. Our exclusive 30amp Lab supply is voltage and current limited here.
    IMPORTANT – DO NOT CHANGE THE VOLTAGE AFTER CONNECTION TO THE CELLS
  3. Once it hits 3.45V, then adjust the target voltage to 3.65V, keep an eye on the cells during this stage, the voltage will rise very rapidly and it’s good not to rely solely on the overvoltage protection feature of the power supply. Check with a multimeter very regularly.
  4. Once you hit 3.65V, turn off the power and leave for an hour or more. Check to see if it’s still over 3.5V. If not, charge it up to 3.65V again and leave it for another hour. Repeat until it does.
  5. Once done, reassemble the pack into your desired battery Voltage eg. 12V or 24V, and discharge
  6. Storing at a high level of charge is not good for the LiFePO4 cells. If storing for a long time, discharge down to 30-50%. If possible, keep the battery below 90% SOC and above 10% SOC. It will increase the lifespan of the cells. And definitely help with cell bloat.

    Congratulations you have successfully manually top balanced.

An alternative (not ideal or recommended) way to top balance a battery pack with a BMS, such as the JBD BMS is to connect the battery cells in series, and slowly, incrementally increase the pack voltage inside the Bluetooth app. (occasionally this will not work if the cells are at different SOC, please be aware, it could take weeks to balance if that were the case, and therefore it’s not usually recommended unless you don’t have any access to an appropriate voltage limited Lab supply)

1. Wire up the Battery in series. Eg, connect the 4 cells (positive to negative) Which will create a battery of about 13.2V for a 4s LiFePo4 Battery.
2. Charge with a charger between 14v and 14.6v. Slower is better
3. Inside the JBD Bluetooth app (XiaoXiang), set the fully charged voltage to 3.45v, and a total pack voltage of 13.8v and charge it until the BMS stops. Inside the app turn off the charge balancing feature and leave until all the cells are balanced.
4. The following day or more inside the BMS Bluetooth app settings increase the pack voltage to 14.4v (3.6v per cell) or 14.6v (3.65v) and ensure the balance on charge is turned off. The battery will then go and top balance itself. Leave here until balanced

Xiamen Haichen New Energy Lithium Battery
Blog Lithium Battery-school Manufacturers
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Hithium 280ah 300ah and 320ah cell Lifepo4 Review

Wondering about Hithium Lifepo4 cells quality?

Hithium 280Ah cells are a type of lithium iron phosphate (LiFePO4) battery cells. They are known for their high energy density, long cycle life, and safety features123.

Information about the cell. The cell is identical to the current reference design of a prismatic Lifepo4 cell with the dimensions of 207mm x 173mm x 71mm. These are identical in every way to the cells made by CATL, EVE, CALB, GOTION, BYD, GREAT POWER, REPT, SUNWODA and the list goes on. All of these currently manufacturer this exact same cell, with the exact same dimensions. They all use the same ingredients, with very minute differences to the cathode and anode and electrolyte mixture.

202303301648005656
290AH
Hithium 280AH
  • Product certifications:
    IEC 62619, UL 1973, UL 9540A, UN 38.3
  • Company certifications:
    ISO 9001, ISO 14001, ISO 45001
  • Environmental Compliance: ROHS, REACH

High safety

  • Hithium-developed prismatic LFP cell with high thermal stability
  • Passes crush and nail penetration test
  • Ultra wide operating temperature range


Overall this cell is modified to last longer. Although the truth is the cycle count can be manipulated such as 6000 cycles at 80% is the same as 9000 cycles at 70% and so on. So the claim of 10000 cycles is probably true. Especially considering they are made with the intention of Energy storage, so with a Hithium cell you know you are getting something that will last a very long time.

3.2V 280Ah LiFePO4 Battery Prismatic Cell With 10000cycles (evlithium.com)

EnvisionAESC
Manufacturers
LiFePO4 Australia ,
Who is Envision AESC?
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Origins and Ownership

Envision AESC (Automotive Energy Supply Corporation) is a global battery manufacturer focused on powering electric vehicles (EVs) and energy storage systems.

  • Founded in 2007 in Japan as a joint venture between Nissan, NEC Corporation, and NEC Tokin.
  • In 2018, China’s Envision Group acquired a majority stake. Nissan retained a minority share.
  • Since then, the company has operated as Envision AESC, expanding into one of the world’s fastest-growing battery producers.

Products and Technology

Envision AESC designs lithium-ion battery cells and packs for both cars and stationary energy storage.

  • Chemistries: The company produces both NCM (nickel-cobalt-manganese) and LFP (lithium iron phosphate) cells, depending on the application.
  • EV Batteries: Its Gen5 platform (based on NCM 811 chemistry) targets higher energy densities, approaching ~300 Wh/kg in development.
  • Energy Storage: In 2025, Envision AESC announced 315 Ah and 530 Ah large-format cells, designed for long cycle life (~12,000 cycles) and high efficiency (>95%). Mass production is targeted for 2025.
  • Safety: The company highlights passing over 200 global safety tests, including a CSA-supervised 49-hour fire safety trial. It also claims a record of “zero major safety incidents” in its ESS products.

AESC: 530Ah Battery Cell

Envision AESC has unveiled a 530Ah energy storage cell delivering over 1.6kWh per unit. With 12,000-cycle longevity and 95% energy efficiency, it’s fully compatible with mainstream ESS solutions. Mass production and deliveries are set to begin in 2025.

Global Footprint and Capacity

Envision AESC is aggressively scaling with gigafactories worldwide:

  • Japan: Original facilities supplying early Nissan Leaf batteries.
  • UK (Sunderland): Expanding capacity to support Nissan’s EV hub.
  • France (Douai): A ~9 GWh plant near Renault’s ElectriCity, backed by EU funding.
  • Spain (Navalmoral de la Mata): €1.1 billion LFP factory, with production targeted for 2026.
  • China (Cangzhou, Hebei): “Zero-Carbon Intelligent Industrial Park,” with 10 GWh in production and another 10 GWh under construction.
  • USA: Plants announced in Tennessee and South Carolina; however, the Florence, SC site was paused in June 2025 due to policy and tariff uncertainty.

Past company roadmaps projected hundreds of GWh of global capacity by 2030, but actual targets depend on market conditions and government policy.

Partnerships and Customers

Envision AESC supplies some of the world’s biggest automakers and energy companies:

  • Nissan: Longstanding partner for Leaf and future EV platforms.
  • Renault: Supply through the Douai factory in France.
  • BMW: Planned supply for Spartanburg, USA production.
  • Energy storage integrators: Recent announcements of over 40 GWh of ESS cell supply contracts in China.

Challenges and Risks

Despite its growth, Envision AESC faces several challenges:

  • Policy Risks: Trade disputes and changing subsidy rules (especially in the U.S.) can stall investments.
  • Intense Competition: Rivals such as CATL, BYD, and LG Energy Solution currently dominate global market share.
  • Technology Race: Sodium-ion and solid-state batteries are emerging as future competitors.

Future Outlook

Looking forward, Envision AESC is focused on:

  • Expanding global capacity to the hundreds of GWh scale by 2030.
  • Delivering EV batteries with longer ranges (targets >1,000 km per charge).
  • Scaling grid-scale storage cells for renewable energy and Virtual Power Plant (VPP) projects.
  • Achieving zero-carbon manufacturing across multiple new gigafactories.

Key Takeaways

  • Envision AESC is a Chinese-owned, globally active battery maker with Japanese roots.
  • It is not affiliated with Cornex (a separate Chinese company).
  • The company is rapidly scaling with gigafactories across Europe, Asia, and North America.
  • While facing risks from policy and competition, Envision AESC is positioning itself as a key global player in the EV and ESS battery market.

Official Website – https://www.aesc-group.com/

Lithium Battery-school
LiFePO4 Australia , , , , ,
Are second life Lithium Batteries safe?

Are you considering repurposing battery cells and building your own Powerwall or similar Energy storage system?

We are going to take a look at what you must understand before starting a project of this type.

The Chemistry

NMC or NCA

Both of these chemistries are considered dangerous, and they should be avoided, especially in any second life application. And even more importantly in any residential application. There is a real risk of a short circuit, leading to thermal runaway. Both of these chemistries will be extremely difficult to extinguish. And may explode, and burn anything and everything around it down to ashes, Firefighters will not try to extinguish a Lithium Battery fire, as they know they have no option but to wait for the

The capacity loss of LiBs is generally considered to be linear, with end of life typically around 75% to 80% state of health (SoH) and the final end-of-life stage around 50% to 60% SoH. However, at some point a severe and potentially dangerous deterioration can occur and lead to an increased ageing rate. The time at which this occurs, referred to as the “knee,” is difficult to predict. It can occur at a higher SoH than expected, thereby increasing the risk of thermal runaway, internal short circuits, and joule heating, according to the report.

Lithium Iron Phosphate

Although it is possible for LFP to enter thermal runaway, it is very unlikely, and usually only happens when external heat is present, it can also happen when the cell is at 100% SOC and is supplied with a very high current, such as

What is Thermal Runaway?

EVE factory locations
Lithium Battery-school
LiFePO4 Australia , , ,
Who is EVE Energy?

EVE Energy is a technology-driven company focused on the development of lithium batteries. Their products are widely used in the IoT, EV and ESS. Eve Energy makes prismatic, pouch and cylindrical battery cells. Along with a range of other batteries, including Lithium metal non rechargeable batteries.

Company Website – www.evebattery.com
EVE Energy Co., Ltd. (stock code: 300014)

Household ESS, Utility ESS, and Telecom ESS with products covering cells, modules, battery systems, battery management systems, and other comprehensive solutions

Lithium Battery-school
LiFePO4 Australia , , , ,
How does charging differ between LiFePO4 batteries and lead-acid batteries?

How does the charging process differ between LiFePO4 batteries and lead-acid batteries?

The charging process for LiFePO4 batteries and lead-acid batteries is different in several key ways.

LiFePO4 batteries are typically charged using a constant voltage charging method, where the voltage is held at a constant level until the current drops to a certain level. This helps to prevent overcharging and extend the life of the battery.

In contrast, lead-acid batteries are often charged using a constant current charging method, where the current is held at a constant level until the voltage reaches a certain level. This method is less precise and can result in overcharging and shorter battery life.

Additionally, LiFePO4 batteries have a higher charging voltage and require a special charging profile to avoid damaging the cells. Lead-acid batteries have a lower charging voltage and can be charged using a standard charging profile.

It’s also worth noting that LiFePO4 batteries are more tolerant to overcharging compared to lead-acid batteries, and they have a lower risk of sulfation, which is a common problem with lead-acid batteries.

What is the ideal voltage to charge lifepo4?

The ideal voltage to charge a LiFePO4 battery varies depending on the specific battery and the manufacturer’s specifications, but a typical voltage range is between 3.5V to 3.65V per cell. For a 12V LiFePO4 battery, the charging voltage should be between 14v and 14.4v

It’s important to follow the manufacturer’s recommended charging voltage and to use a charger specifically designed for LiFePO4 batteries, as charging a LiFePO4 battery with the wrong voltage or using an inappropriate charger can result in reduced performance and shorter battery life.

LiFePO4 batteries require a multi-stage charging process that includes a constant voltage charge and a topping charge. The constant voltage charge is applied until the current drops to a certain level, at which point a float charge is applied to bring the voltage to the maximum level. The multi-stage charging process helps to prevent overcharging and extend the life of the battery. The float charge is a stage in the charging process for LiFePO4 batteries that occurs after the main constant voltage charge stage. During the float charge, the voltage is held at a slightly lower level than the maximum voltage to prevent overcharging and to ensure that the battery stays fully charged. The float charge serves several purposes. First, it helps to balance the voltage between the cells in the battery, ensuring that all cells are charged to the same level. Second, it helps to prevent overcharging, which can reduce the overall life of the battery. Finally, it helps to maintain the battery in a fully charged state, ready for use when needed.

The exact voltage and duration of the float charge will depend on the specific battery and the manufacturer’s specifications. It’s important to follow the manufacturer’s recommendations to ensure that the battery is charged correctly and to maximize the performance and lifespan.

Contemporary_Amperex_Technology-Logo
Lithium Battery-school
LiFePO4 Australia , ,
Who is CATL?

CATL is the leading Lithium and as of 2023 Sodium-ion battery manufacturer in China and the World.

CATL (Contemporary Amperex Technology Limited) is a Chinese battery manufacturer that produces lithium-ion and as of 2023 sodium-ion batteries for electric vehicles (EVs) and energy storage systems. The company was founded in 2011 and has quickly become the leading EV battery manufacturer in the world. It supplies batteries to a number of major automakers, including Tesla, Volkswagen, BMW, and Toyota. CATL has also established a number of partnerships and collaborations with other companies in the EV and energy storage industries.

The company provides research and development, production, and sale of electric vehicle and energy storage battery systems. It also provides battery management systems, materials, battery cells, and battery recycling and reuse systems. These batteries are used in electric passenger vehicles, electric buses, electric trucks, and other special vehicles; and spare parts. The products of energy storage systems find their applications in renewable energy, communication base stations, grid frequency modulation, commercial and industrial buildings, and household energy storage. It also operates its business from Ningde, Fujian, China also has production in Germany, and overseas offices in Japan, France, and the USA regions.

LiFePo4 Video from CATL

Official CATL VIDEO

HOW China’s CATL makes its batteries

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