Rolls R Series User manual
ROLLS R-SERIES &
S-SERIES DROP-IN LFP
BATTERY OPERATING
MANUAL
Recommended safety, installation, operation
and troubleshooting procedures for Rolls
R-Series and S-Series 12V, 24V, 36V, and
48V LFP (Lithium Iron Phosphate) batteries.
MARINE
MOTIVE
POWER
RENEWABLE
ENERGY
1
TABLE OF CONTENTS
02 Rolls R-Series and S-Series LFP Batteries
05 Storage, Installation, Terminal Torque
06 Cable Connections
07 BMS Protection Summary
08 Connection Limits, Connecting in Series, Example Series Configurations
09 Connecting in Parallel
10 Battery Voltage - Connecting In Series/Parallel
11 Bluetooth/App Connectivity
12 Dashboard & Support Screens, Additional S-Series Features
13 Charging Source: Lead-Acid Battery Charger
13 Status Button, Fuse Access, Fuse Replacement Procedure
14 Upgraded Construction, Case Access, Battery Charging
15 Charging Guidelines
19 Recycling
20 LFP Glossary
22 Appendix
24 Contacts
23
ROLLS R-SERIES AND S-SERIES LFP BATTERIES
Rolls R-Series and S-Series drop-in Lithium Iron Phosphate (LFP/LiFePO4) batteries are an
ideal replacement for traditional lead-acid batteries of equivalent size & capacity and offer
the same quality, reliability and performance found in other Rolls Battery products.
This manual provides detailed instructions for safe and proper installation, operation,
and care of Rolls R-Series and S-Series drop-in LFP battery models. Please read carefully
to clearly understand the operating instructions and any potential safety risks prior to
installation.
Failure to install or use this battery as instructed may result in damage to the product that
may not be covered under the manufacturer warranty. See warranty terms and conditions for
full details.
This manual offers installation, charging, and troubleshooting guidance specific to
Rolls R-Series and S-Series Drop-in LFP lithium batteries.
See Rolls S24-2800LFP & S48-6650LFP ESS Battery Operating Manual for usage instructions
specific to Rolls S24-2800LFP ESS and S48-6650LFP ESS (Energy Storage System) models.
See Rolls 24V & 48V LFP ESS Battery Operating Manual for usage instructions specific to 19”
rack, floor and wall mount ESS models.
Para ver la versión en español, haga clic aquí.
O consulte nuestro sitio web.
23
This document is NOT APPLICABLE to the following models
48V ESS LFP Models
(S48-100LFP ESS)
24V & 48V ESS LFP Models
(S24-2800LFP ESS and S48-6650LFP ESS)
LFP Battery
(Cell Voltage = 3.2V)
Lead-Acid Battery
(Cell Voltage = 2.0V)
Battery Nominal Voltage
12.8V (4 cells)
Battery Nominal Voltage
12.0V (6 cells)
Battery Nominal Voltage
25.6V (8 cells)
Battery Nominal Voltage
24.0V (12 cells)
Battery Nominal Voltage
38.4V (12 cells)
Battery Nominal Voltage
36.0V (18 cells)
Battery Nominal Voltage
51.2V (16 cells)
Battery Nominal Voltage
48.0V (24 cells)
Nominal voltage of an LFP battery differs from equivalent lead-acid batteries.
Rev. Changelog Author/Editor Date
1.0 Release Version - R-Series
Revision Jordan Torrealba 2021/12/14
2.0 Release Version – R-Series
and S-Series Revision Jordan Torrealba 2023/07/25
VERSION HISTORY/CHANGELOG
45
WARNING: Explosion, Electrocution, Or Fire Hazard
• A battery can present a risk of electric shock, burns, fire, or explosion.
• Ensure cables are properly sized for the system current and cable runs are as short as
possible.
• Ensure cables between batteries are of equal length, reducing line inductance and voltage
spikes, which can damage the BMS.
• Ensure adequate airflow around batteries and that they are clear of debris, 2cm/1” spacing
is recommended.
• Never smoke or allow a spark or flame near the batteries.
• Always use insulated tools.
• Avoid dropping tools onto batteries or other exposed electrical parts.
• Prolonged exposure to cold temperatures can cause significant damage to batteries,
proportional to charge and discharge current:
• Never charge an R-Series drop-in LFP battery or bypass the heating controls on
an S-Series drop-in LFP battery below 0°C (32°F).
• Never discharge an R-Series or S-Series drop-in LFP battery below -20°C (-4°F).
• Never charge a battery with a deformed or bulging case.
• Do not expose a Rolls drop-in LFP battery to heat more than 60°C (140°F) during operation,
and do not store for extended periods of time above 45°C (113°F). Do not incinerate or
expose to open flame.
• If a battery must be decommissioned, always remove the grounded terminal from the
battery first. Make sure all connected devices are shut down.
• When installing, leave adequate clearance between batteries 2cm/1” is recommended.
• When replacing batteries, use the same make, model, and quantity of batteries.
• Do not mix old and new batteries, or batteries with different nominal voltages.
• Avoid dropping batteries during the installation process.
• Do not dismantle or remove the battery components.
• Battery maintenance should be carried out by qualified personnel under the guidance of
Rolls Battery.
45
STORAGE
Rolls R-Series & S-Series drop-in LFP batteries should be stored in an environment with
temperatures between -5°C (23°F) and 45°C (113°F). 20°C (68°F) is recommended.
If seasonally stored in a space which will fall below -5°C (23°F), it is recommended to
discharge the battery to between 60-80%, disconnect the battery from any external system
and store the battery in an alternative location above -5°C (23°F).
Rolls drop-in LFP batteries self-discharge and should be charged, at minimum, once per
year, even when in distributor stock or storage. For temperatures above 40°C (104°F) the
battery should be charged every 3 months. Do not store Rolls R-Series & S-Series drop-in LFP
batteries at temperatures above 45°C (113°F).
INSTALLATION
Rolls R-Series & S-Series drop-in LFP batteries may be installed in any orientation*
(except upside down) as required by the application. Rolls drop-in LFP batteries must
be installed in an indoor space and out of direct sunlight.
*Front Terminal (FT) models are installed on one side only. Refer to the label for which.
All installations should consider the ambient temperature. If installed in a region with
freezing temperatures or extreme heat, special care should be given. Rolls R-Series
drop-in LFP batteries cannot be charged below 0°C (32°F), nor discharged below
-20°C (-4°F) and doing so will severely degrade the internal cells. Similarly, operation
above 55°C (131°F) will negatively impact longevity, performance, and safety. Rolls
S-Series drop-in LFP batteries feature internal heating to compensate for reduced
temperatures but are still limited in the external temperatures they can tolerate. Refer to
the datasheet or label of your specific model for accurate information.
Waking up the Battery
If you have just received your battery, it may have entered a low power sleep mode during
transit. In this state, the Bluetooth receiver will be off, and the voltage will be between 2V-10V,
waiting to sense an external device. For R-Series drop-in LFP models, connect a charger or
load to “wake up” that unit and enable charging, discharging, and a Bluetooth connection. To
wake up an S-Series drop-in LFP battery, do this, or press and hold the reset button located
below the onboard screen.
TERMINAL TORQUE
Terminal connections must be properly torqued. Rolls R-Series & S-Series drop-in LFP
batteries using M8 fasteners should be torqued to 10-12Nm.
DO NOT OVERTORQUE: In the event of a damaged terminal, do not attempt to repair
the terminal. Do not use the battery if the recommended torque cannot be met.
67
CABLE CONNECTIONS
All cable connections should be adequately sized, insulated, and undamaged.
Connectors should be clean and properly mated with the battery terminals to ensure a
secure and low resistance connection. Terminal connections should be torqued to the
recommended specification in TERMINAL TORQUE. Although Rolls R-Series and
S-Series drop-in LFP batteries do not require maintenance such as cell inspection &
watering, routine inspection of cabling and terminal connections should be performed
semi-annually. Double check torque specification and that lugs cannot be rotated after
installation. If the batteries are installed in a high vibration environment, this should be
done more frequently.
Amperage 25 30 40 55 75 95 130 150 170 195 260
Wire Gage 14 12 10 8 6 4 2 1 1/0 2/0 4/0
Undersized or improperly insulated cables may lead to cable and/or battery
damage, charging issues, terminal heating, or fire. The gauge table above is provided
for reference only. Always refer to the connector and wire manufacturers’ specifications
prior to purchase and installation.
Like lead acid batteries, connecting devices (like batteries, inverters, chargers, MPPTs,
etc.) at different voltages can result in large current spikes and arcing. Sparks may fly if
you are connecting a power supply or charger with high output capacitance, or a
discharged inverter with high input capacitance, as the battery rapidly charges the
components in the device. Connecting terminals quickly and decisively is recommended
for the least component wear and tear, or using in-line overcurrent protection devices
such as an open breaker, to eliminate arcing.
67
BMS PROTECTION SUMMARY
Rolls R-Series drop-in LFP batteries include a built-in battery management system (BMS)
which offers protection in conditions where the battery voltage, current or operating/cell
temperature may be unsafe or damaging for the internal cells. The switch architecture of the
BMS allows charge and discharge to be stopped independently. Under these undesirable
operating conditions, the internal BMS can independently interrupt charge or discharge, or
disconnect it fully, as required.
BATTERY LIMIT PROTECTION RESET METHOD COMMENTS
Cell/Pack
Overvoltage
Charge
Interruption
Automatic reset after time
delay or discharge
If occurring more than
3 times in 2 minutes,
discharge is required
Cell/Pack
Undervoltage
Discharge
Interruption
Automatic reset after time
delay or charge
If occurring more than 3
times in 2 minutes, charge
is required
Extended Pack
Undervoltage
(Stored While Empty)
Battery Cannot be
Recovered
Always charge R-Series
Batteries within 72 hours of
full discharge
-
Pack Overcurrent or Short
Circuit
Charge and Discharge
Interruption
Automatically reset
after time delay
If occurring more than 3
times in 2 minutes, charge
is required
High temperature at BMS
or Cell*
Charge and Discharge
Interruption
Automatically reset
after cooling
BMS will display alarm
when approaching
disconnect
Low temperature at BMS
or Cell*
Charge Interruption Automatically reset after
warming
BMS will display alarm
when approaching
disconnect
Extreme low temperature
at BMS or Cell
Charge and Discharge
Interruption
Automatically reset
after warming
BMS will display alarm
when approaching
disconnect
(S-Series only) Secondary
Overcurrent Protection
Charge and Discharge
Interrupted, external fuse
is blown.
Replace fuse Secondary protection is
also recommended for all
R-Series batteries.
*Temperatures outside of the ideal operating range require a reduction in charge/discharge current for
optimal battery life.
The BMS also has cell-balancing functionality to balance each internal cell to the same state-of-charge,
enabling the full pack capacity. However, this is not sufficient to balance severely imbalanced cells with a
substantial state-of-charge (SOC) difference, see BATTERY VOLTAGE - CONNECTING IN SERIES/PARALLEL.
89
CONNECTING IN SERIES
Rolls R-Series and S-Series 12V and 24V LFP batteries may be combined in series
strings to achieve higher operating voltages by connecting the positive terminal of one
battery to the negative terminal of the next battery. Don’t connect different voltages in
series. For example, do not connect a 12V and 24V battery to reach 36V, use 3 12V
batteries instead, or a single 36V battery.
CONNECTION LIMITS
EXAMPLE SERIES CONFIGURATIONS
R-SERIES
MODEL
MAX UNITS
SERIES
CONNECTION
MAX UNITS
PARALLEL
CONNECTION
12 VOLT LFP 4 (48V System) 4 (6 if not series connected)
24 VOLT LFP 2 (48V System) 4 (6 if not series connected)
36 VOLT LFP 1 (36V System) 6 (no series connection)
48 VOLT LFP 1 (48V System) 6 (no series connection)
12V batteries in series - Two (2) 2 x 12.8V = 25.6V
For 24V
Applications 24V battery in series - One (1) 1 x 25.6V = 25.6V
NOTE: Do not connect batteries in strings above 48V nominal.
Example 24V Configuration:
Two 12V batteries in series
Example 48V Configuration:
Four 12V batteries in series
NOTE: Rolls R-Series & S-Series drop-in models cannot be mixed. Batteries should only be combined in
the same capacity, and voltage, from the same product line.
12V batteries in series - Three (3) 3 x 12.8V = 38.4V
For 36V
Applications 36V battery in series - One (1) 1 x 38.4V = 38.4V
12V batteries in series - Four (4) 4 x 12.8V = 51.2V
For 48V
Applications 24V battery in series - Two (2)
48V battery in series - One (1)
2 x 25.6V = 51.2V
1 x 51.2V = 51.2V
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