SKU: DCS-DBS-180Ah
ULTIMATE DCS 12V 180AH DUAL BATTERY SYSTEM (LITHIUM)

FREE DELIVERY AUSTRALIA WIDE

– 2 x DCS 90Ah LFP batteries (optimised for engine bay installs)
– Victron Battery Protect SBP-65A
– Max alternator output 160Amps
– Backed by a 3 year under bonnet replacement warranty
– Fully programmable via bluetooth
– Tiny power consumption 1.2mA when engaged
– Suitable for Hilux, Prado, Nissan’s, Mitsubishi’s, Land Rover Defenders etc…
– Integrated 80V/20A MPPT solar regulator
– Not suitable for the Nissan Y62’s

Availability: In Stock

$2,699.00 AUD

From $134.99 a fortnight withInfo

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Our latest hybrid 180Ah under bonnet dual battery systems now feature our powerful integrated 80V/20A MPPT solar regulators. You can now see the extra solar supply input via a dedicated shunt via our Bluetooth app.

The 180Ah DBS is supplied with 2 x DCS 90Ah Hybrid Batteries, one battery is configured as a Right Hand Positive and the second battery is configured as a Left Hand Positive that also has the solar MPPT input socket. Part of the system you also get a IP67 aviation to Anderson Plug cable, to plug and play your solar supply.

All DCS dual battery systems (DBS) are supplied with the fully programmed Victron Smart Battery Protect’s which are a load disconnect. This device is what governs the reserve for engine starting. Very efficient only drawing 1.2mA when engaged. We recommend to use the top 80% for deep cycling for accessories and the remaining 20% is reserved for engine cranking. The SBP’s should be installed inside the cabin and you should be protecting as many of your light loads as possible, USB sockets, fridges, lighting, dash cams, UHFs, Cel-Fi’s etc.. Inverters over 300W must be wired directly to the batteries bypassing the SBP’s.

With two of the DCS 90Ah Hybrid batteries connected in parallel you can charge up to a maximum of 80A x 2, so 160A. So ideally keep alternators under 150A. All DCS batteries feature high performance cylindrical cells, and this mechanical design is very efficient so it’s very easy to recharge these batteries, there is no need to install larger alternators, OEM alternators are the best for our batteries and will charge them back up very fast. If your running a vehicle with a lazy smart alternator focus on installing a quality commercial solar panel something at least 360W+ as our powerful 20A MPPT is able to yield in excess of 100Ah per day. Which will easily keep the batteries topped up when running a standard sized fridge.

This system is suitable for just about every make/model of 4WD on the market that can accommodate these sized batteries under the bonnet or of course in the cabin if one so wishes.

What 240V charger do we recommend for the DBS?
We recommend the Victron IP-65/15A Charger.

Specifications:
Nominal Voltage 12.8V
Nominal Capacity (1Hr) 90Ah
Case Dimensions (L x W x H) 260mm x 169mm x 210mm
Weight | RHP 10.30KGs (without MPPT)
Weight | LHP 11.90KGs (with MPPT)
Cycling voltage 12.8~ 14.6V
Charge voltage 13.8 ~ 14.6V
Float Voltage 13.5 ~ 13.7V
Max Charge Current 80A
Recommended Charge Current ≤70A
Max Discharge Current ≤200A
BMS (built in) Automatic cell balancing, over discharge/charge
Cell Chemistry DCS 3.2V 5.0 – 7.2Ah Cylindrical (LifePO4)
Cycle Performance 2500 Cycles @ 100% DOD
LCA (Lithium Cranking Amps) 900A
Ingress Protection IP54
Case PP (flame retardant)
Operating temp Range -30 to +110 degrees C
Terminals Top Mount M8 Stainless steel / Copper
Parallel Connections Only Yes
Warranty 3 years

DCS Engineering high efficiency 80V/20A MPPT solar regulator especially developed for in battery applications

Programming the Victron Smart Battery Protect for DCS Hybrid Dual Battery Systems

DCS High Performance 2C Charge & Discharge Curves

DOWNLOAD APP (DCS LFP)

DCS Bluetooth Technology powered by DCS LFP, this APP is only for DCS LFP batteries which is based on BLE 4.0 technology. Every DCS battery pack comes standard with our detailed battery monitoring via Bluetooth.

This App provides comprehensive monitoring for DCS LFP batteries, including:

  • SOC%
  • Time Remaining
  • Battery pack voltage, Power & Current
  • Battery Management MOSFET temperature
  • Individual Cell Status with balancing indicators.
  • Connectivity distance up to 10 meters.
  • Every DCS battery pack comes standard with our detailed battery monitoring via Bluetooth

Learn More About the DCS LFP APP

Click Here to Watch the App Overview Video

Comprehensive overview of the DCS 4WD Lithium batteries, filmed in the Simpson Desert

Learn more about charging DCS batteries directly off alternators

ULTIMATE DCS 12V 180AH DUAL BATTERY SYSTEM

70 Series Land Cruiser – DCS 180Ah Hybrid DBS

2015 Mitsubishi Pajero

2015 Mitsubishi Pajero

4

Prado 90 series – dual DCS lithium 75Ah batteries

1

Toyota Hilux 8th Gen – DCS Lithium dual battery setup. All latest generation of 4WD vehicles using smart alternators do not require DC-DC chargers when running DCS lithium batteries.

3

Toyota Prado 150 – DCS Lithium dual battery setup

SMALL

Holden Colorado DCS dual 75Ah batteries

batteries

Dual DCS 12V 75Ah batteries installed in a Toyota Land Cruiser Prado 150

150

Dual DCS 12V 75Ah batteries installed in a Nissan Patrol Y62

Lithium Dual Battery System: Ideal for Heavy Load

150ah dual battery

For years solar energy systems relied on the typical lead-acid batteries to power their house and ran the electric lights. Nowadays, lithium batteries are also being used to power home appliances such as microwaves, kettles, and other devices. On the other hand, lithium batteries offer better performance and a longer life lifetime. Lithium battery also has a broader powerband for starting engines. Lead-acid batteries have been around for about 150 years, making them a 19th-century invention. 150ah dual battery, on the other hand, is a 21st-century technology. Deep Cycle Systems produces high-quality lithium batteries. Our batteries are excellent at supplying continuous electricity to your home.

Furthermore, our lithium battery delivers a significant amount of power anytime you need it, such as when starting a boat motor. Deep Cycle Systems’ lithium battery is designed to survive extreme weather. Our batteries can withstand rain, heat, and cold depending on the climate. Deep Cycle Systems produces dependable batteries with long service life. Our batteries have a long service life and deliver excellent performance. Deep Cycle Systems is dedicated to providing our customers with a high-quality lithium battery.

Lithium dual battery systemWhat Factors Go Into Determining the Number of Battery Cycles?

The number of cycles a battery can provide is determined by how low it is charged at any given time. Depth of charge, or DoD, is the term for this phenomenon.

The number of battery cycles is also determined by how quickly the lithium or lead-acid battery is depleted. Compared to a lithium battery, a typical lead-acid battery requires more capacity. This is due to the efficiency of lithium batteries, which deliver a consistent power band regardless of whether they are used for cranking or continuous power. At least 1000 charging cycles and 100 per cent discharge at 100ah are required of a decent lithium battery.

When compared to lead-acid batteries, lead-acid batteries can provide 500 charging cycles at 80 per cent DoD. On the other hand, deep cycle batteries from Deep Cycle Systems have more charging cycles than ordinary lead-acid batteries. As a result of the higher discharge rate, the lithium battery performs effectively while offering maximum power.

Lithium Dual Starter Battery System Can Be Employed In a Variety of Situations

Lithium battery, for starters, is becoming increasingly popular among boat owners due to their appropriate and perfect marine characteristics. Lithium dual battery system does not require active maintenance, making them a dependable power source even when left idle. Lithium battery shows or no discharge capabilities allow them to give reliable power for starting your boat after long periods of inactivity. Furthermore, lithium-ion battery efficient power delivers robust and long-lasting energy, ensuring that you are not stranded amid the ocean. As a result, lithium battery is more dependable since they can safely have greater power.

lithium ion dual battery systemDeep Cycle Systems’ Lithium Ion Dual Battery System

Deep Cycle Systems is a prominent provider of energy solutions. We have the most critical items to meet all of your energy solution demands. Inverters, solar panels, solar batteries, deep cycle batteries, lithium batteries, and lithium starting batteries are among the premium energy solutions offered by Deep Cycle Systems. Solar systems, pure sine wave inverters, lifepo4 batteries, dc inverters, solar battery chargers, lithium battery chargers, and deep cycle battery chargers are also available.

Deep Cycle Systems is dedicated to offering dependable and long-lasting lithium ion dual battery systems. Our extensive product line comes with long service life. For a hassle-free experience, we guarantee the best installation.

lithium dual battery setupBuy Deep Cycle Lithium Dual Battery Setup for Ideal Power Energy

One of the most excellent solutions for renewable energy is deep cycle batteries. In essence, these batteries are chemical storage systems. In these batteries, chemical processes occur. The power generated from these reactions is then stored within the battery cells. Over the last few years, the 12v deep cycle battery has progressed. In terms of the dependability of the charging storage option, deep cycle batteries have significantly improved. Compared to the old plumbic acid batteries, they have shown more helpful in supplying energy. So, buy a lithium dual battery setup if you want ideal energy storage.

Deep Cycle Systems is a trustworthy leader in the supply of deep cycle batteries of the highest quality. We are proud to supply top-quality, deep-cycle batteries to our essential clients. Our batteries are designed for harsh weather conditions and reliable energy storage. For years Deep Cycle Systems has been engaged in producing deep cycle batteries. We can now create one of the best quality batteries with our extensive research in combination with experience in the area and product development. Deep Cycle Systems is a trustworthy, long-lasting deep-cycle battery source. Our batteries are designed to deliver long-term service life and high-quality energy when required.

Why Should a Deep Cycle Battery Always Be Purchased?

Deep cycle batteries provide several benefits over other rivals. The power and charging capabilities of deep cycle batteries are wide-ranging. Therefore, deep cycle batteries are straightforward to utilize, as they offer a reliable energy option.

Lighter and Smarter

Compared with the typical lead-acid batteries, deep-cycle batteries are lighter and smaller in size. They are now more powerful in a smaller size. This makes it perfect for applications where there is restricted space like RVs and off-road vehicles.

No Active Maintenance

There is no need for active maintenance with deep cycle batteries. Compared to typical plum-acid batteries requiring active care, these batteries do not require acid topping or water replenishment. It is easier to maintain deep cycle batteries and automatically offer a greater life span.

Safer to Transport

Deep cycle batteries are suitable for RV’s and off-road camping vehicles. This is because most batteries are sealed or AGM. This facilitates the use of batteries on the road. Deep cycle batteries are now easier to employ in transportation since they are impervious to acid spilling or shaking.

No Bi-Products

Battery for sale 12v deep cycle Clean and renewable energies are produced. Thus, as part of chemical processes, these batteries do not release additional hydrogen gases. Therefore, deep cycle batteries are safer to operate.

Service Life Extended

On average, the batteries with a deep cycle last longer than the battery with lead-acid. When you evaluate it in the longer term, a deep-cycle battery with higher purchases prices is value to cash. This is because the lifetime of the deep cycle battery in comparison with the acid battery is usually higher. The batteries in deep cycles are competitively stiff, together with the ability to retain more charges than the same battery in plumbing.

Deep Cycle Systems is a prominent supplier to provide our important clients with the finest energy solutions. Thanks to our significant research and development experience, we are one of the leading suppliers of energy solutions. At an economical price, Deep Cycle Systems provides top-grade deep cycle batteries.

Lithium dual battery kitLithium Dual Battery Kit for Optimal Battery Support

Lithium dual battery kit is an excellent source of renewable energy. Deep cycle batteries serve as energy storage devices. The batteries are good for the environment as compared to the lead-acid battery. Deep storage battery carries chemical reactions inside them, which produces the voltage inside them. Deep cycle batteries undergo charge and discharge cycles several times. Deep cycle batteries provide clean and green energy. Henceforth, they are safe to use for the environment. A deep cycle battery is designed so that it produces a good amount of power for longer durations of time. Therefore, deep cycle batteries are built to provide power backup and active energy to an engine, device, or load.

Deep Cycle Systems specializes in manufacturing high-quality deep cycle batteries. Our deep cycle batteries are built to stand harsh weather conditions while delivering optimal performance. Deep Cycle Systems manufactures reliable and durable batteries. Our batteries are made according to the latest and outstanding industrial standards. Deep Cycle Systems has been in the business of manufacturing deep cycle batteries for years. Henceforth, our vast experience, combined with research and development of deep cycle batteries, enables us to produce one of the most trustworthy batteries. Deep Cycle Systems batteries come with extended service life while delivering top-notch performance.

lithium battery for dual battery systemWhy Should You Buy a Deep Cycle Lithium Battery For Dual Battery System?

Deep cycle batteries have a lot of advantages over the typical lead-acid battery. For instance, deep cycle batteries weigh more minor as compared to lead-acid batteries. You need a smaller-sized deep cycle battery for the exact size of power required from a battery. This is because deep cycle batteries are compact, and they can pack more energy than the same-sized lead-acid battery.

Deep cycle battery does not require active maintenance compared to the lead-acid battery. They do not need acid topping up or maintenance of acid level. Deep cycle batteries have a minimum resistance. Henceforth, they charge fast without wasting too much power. In addition, deep cycle batteries are compact and sealed. This enables the deep cycle batteries to be put into any place tight or closed, making them ideal for RVs and boats. Deep cycle batteries do not require an open space as they do not emit gasses such as hydrogen when running.

However, with advantages come to some disadvantages as well. For example, the price of a lithium deep cycle battery is much more than that of a typical lead-acid battery. Deep cycle batteries are relatively fragile when it comes to handling the abuse. This means if exposed to unsupervised quick charge, deep cycle battery cells could be damaged due to improper charging. Deep cycle batteries are heavy and weigh more because they have high density.

A deep cycle lithium battery for a dual battery system will cost you at least 30% or more than a lead-acid battery. Deep cycle batteries are difficult to repair when damaged. Regardless of these disadvantages, deep cycle batteries work great for providing energy and power backup and better ROI.

Why Deep Cycle Systems?

Deep Cycle Systems is a leading manufacturer for providing premium energy solutions to our valuable customers. We deliver top-notch energy solutions. Our products at Deep Cycle Systems are reliable and durable come with extended service life. We understand that shopping for energy solutions can be hefty in your pocket. Deep Cycle Systems offers energy solution products at very affordable prices.

dual battery system lithiumDeep Cycle Dual Battery System Lithium for Boats, Cars, and Solar Systems at an Affordable Price

Deep cycle batteries are a reliable renewable energy solution. Deep cycle dual battery system lithium provides a durable and dependable energy solution. Batteries store the energy inside them with the help of chemical reactions. As chemical reactions occur, energy is produced as a bi-product. This energy is stored inside the deep cycle batteries and later utilized when needed. The deep cycle battery technology over years has significantly advanced. Henceforth, the deep cycle batteries are much more reliable while increasing efficiency. Due to their renewable energy factor, deep cycle batteries are a greater good for the environment than lead-acid or lithium batteries.

Deep Cycle Systems manufactures high-quality deep cycle batteries. We are one of the largest and top-rated deep cycle manufacturers. Deep Cycle Systems offers reliable batteries with increased durability. Our batteries are built to provide more extended energy storage efficiently. Deep cycle batteries by Deep Cycle Systems are sturdy batteries as they can withstand harsh weather conditions, including extremely cold or hot weather. Our batteries are built to provide extended service life while offering a constant energy supply during usage. Deep Cycle Systems manufactures top-notch deep cycle batteries constructed right on top of industry standards.

Are Deep Cycle Batteries Any Good?

Absolutely yes! Deep cycle batteries are ideal for usage for solar or hybrid applications. Here is the list of advantages deep cycle batteries provide.

  • For the same capacity, a deep cycle battery comes in a lighter and smaller size than the lead-acid battery. This increases the usability and practicality of deep cycle batteries, especially in marine applications where space is limited.
  • Unlike the lead-acid battery, a deep cycle battery does not require active maintenance. Deep cycle batteries do not need the acid level rechecked every once in a while. Therefore, these batteries can quickly provide a long service life without maintenance.
  • A deep cycle battery installed for marine application does not emit hydrogen or any other gas during charging and discharging.
  • The available backup time for deep cycle batteries is superior to the lead-acid battery.
  • A deep cycle battery ensures a smooth energy supply regardless of its charging percentage. Therefore even if you are past half capacity, it will still pump out the same energy. On the other hand, a lead-acid battery drops the power as the battery gets to lower charging levels.

lithium dual battery systemsCons for Deep Cycle Batteries

Deep cycle batteries come with some cons or downsides

  • These batteries cost an average of around 25-30% more as compared to lead-acid batteries.
  • The lithium dual battery systems are sensitive to overcharging. Therefore, they must not be overcharged, or the cells will get damaged. With Deep Cycle Systems, you do not need to worry about overcharging, as our BMS helps protect overcharging.
  • Deep cycle batteries are difficult to repair. Therefore, deep cycle batteries may need to be replaced rather than repaired once the cells might be damaged.

Why Deep Cycle Systems for Exclusive Energy Solutions?

Deep Cycle Systems is one of the leading manufacturers for affordable energy solutions. Deep Cycle Systems is committed to providing the best quality energy solutions to our respectable customers. Deep Cycle Systems offers reliable and durable energy solution products. Our extended list of products includes solar inverters, solar panels, deep cycle batteries, lithium batteries, pure sine wave inverters, etc. Deep Cycle Systems is one of the best solution providers for all your energy needs.

Call Us Today

Get in touch with Deep Cycle Systems today. You can call us on Tel: 1300 795 327. You can also send your queries via email at info@deepcyclesystems.com.au.

Wiring Diagram

BATTERY SPECIFICATIONS

Specifications:
Nominal Voltage 12.8V
Nominal Capacity (1Hr) 90Ah
Case Dimensions (L x W x H) 260mm x 169mm x 210mm
Weight | RHP 10.30KGs (without MPPT)
Weight | LHP 11.90KGs (with MPPT)
Cycling voltage 12.8~ 14.6V
Charge voltage 13.8 ~ 14.6V
Float Voltage 13.5 ~ 13.7V
Max Charge Current 80A
Recommended Charge Current ≤70A
Max Discharge Current ≤200A
BMS (built in) Automatic cell balancing, over discharge/charge
Cell Chemistry DCS 3.2V 5.0 – 7.2Ah Cylindrical (LifePO4)
Cycle Performance 2500 Cycles @ 100% DOD
LCA (Lithium Cranking Amps) 900A
Ingress Protection IP54
Case PP (flame retardant)
Operating temp Range -30 to 110 degrees C
Terminals Top Mount M8 Stainless steel / Copper
Parallel Connections Only Yes
Warranty 3 years

SMART BP SPECIFICATIONS

FAQ

Lithium Ferrophosphate (LFP) is a flame retardant, stable, safe and proven cell chemistry that has a very good energy density around 325 Wh/L. This cell chemistry can be engineered for various applications by adjusting the ratio of elements to provide high performance characteristics. E.g. the DCS marine battery range runs 2C cells, which means our little 75Ah battery will discharge comfortably at 75Ah x 2C = 150A. The DCS 80Ah Extreme runs 10C cells which means the 80A can comfortably discharge at 80Ah x 10C = 800A but is of course limited to lower currents due the the Battery Management System.

LFP also has very good cycling durability between 2,000 ~ 12,000 cycles can be achieved depending on how well the cells are managed, and the lowest rate of capacity loss (aka greater calendar-life) compared to other lithium cell chemistries.

Battery cells are simply a bunch of resistors with the ability to store energy. A 100Ah battery pack has a different resistance characteristic compared to a 50Ah battery pack, that theoretical difference in resistance is 2:1. So if you connect a 100Ah battery in parallel to a 50Ah battery there is no way for these two batteries to equalise and therefore you can’t charge them correctly. So for example connecting a 60Ah calcium starting battery to a 120Ah AGM via a VSR (Voltage Sensing Relay) you cannot charge both batteries correctly and from that day onwards you are prematurely destroying both battery packs. Same theory applies with lithium’s it’s still a battery pack.

What’s the solution? A DC-DC charger, you now have a permanent point of isolation (meaning that both batteries are never connected to each other in parallel). The DC-DC charger takes the surplus power from battery A (engine) and chargers battery B (aux/house). This device now allows any battery capacity and or chemistry to be used.

Yes you can, but lithium’s have a different voltage curve, so you would still need to use a programmable VSR to dial them in correctly. You would also need to ensure the batteries are programmed to never exceed a 10%SOC variance, any larger and you risk damaging the BMS's. These devices also draw a lot of power when engaged to so it’s best to run the two batteries in permanent parallel and run a load disconnect instead of a VSR.

Lithium battery cells have a super low resistance so are very easy to charge and very efficient. This level of efficiency means you can charge them at very high C rates. For example if you look at the charge rate of a 100Ah AGM battery the recommended charging current will be around 25A, which is a 0.25C charge rate. If you consider the DCS 12V 100Ah Lithium battery it can be charged at up to 70A which is a 0.70C charge rate. This means you no longer need to consider DC-DC chargers as you can connect our batteries directly to high power charging devices such as suitable alternators, or large buck boosters. For example our popular dual 90Ah battery system for boats and 4WD vehicles, can be connected to alternators up to 160A.

Because our batteries are internally voltage regulated and because our BMS has such a high sustainable peak discharge current they will do an amazing job of equalising very quickly.

The BMS will open circuit the battery terminals to protect the cells. This means there is no longer any resistance in the system. The BMS needs a 12V signal with at least 1A of current to release and wakeup from a cell protection state. Most mains chargers with a lithium profile will do a slow recovery charge as will most solar regulators. Some chargers on the market today that are advertised as ‘lithium’ compatible still don’t have the firmware to do a slow recovery charge to release BMS’s. If you have a charger that will not wakeup the BMS, easiest way to wake it up is to connect a unregulated solar panel directly to the battery terminals, ensure all loads are disconnected before you do this. Having said that every system should have a suitable low cut off voltage to shutdown loads/accessories so that the batteries are not fully drained.

Use the following settings:

Charged voltage 14.0V
Tail current 4%
Charged detection time 1min
Peukert 1.05
Charge efficiency 98%
Current threshold 0.1A
C rates: refer to the battery pack capacity

Fully charge to 100% isolate everything from the terminals and leave for max 3 months and then cycle (fully discharge and fully charge) and leave again for 3 months etc…. Minimum 4 cycles per year to not effect the cells capacity.

The reason many factory batteries fall over after 9/12 months is because modern/smart alternators typically drop the alternators voltage output to 13.5/13.6V. This voltage is not high enough to charge wet/calcium/lead acid batteries so from the getgo they are destined to fail prematurely. They are typically under charged to around ~80%SOC at these voltages.

So what happens when DCS Hybrid batteries are connected to smart alternators? Exactly the same thing they get charged to around the same 80%SOC. However because LFP has no memory effect that's perfectly fine. By only charging to 80% you are further improving the service life of our batteries. It's no not necessary to charge our batteries over 80%SOC. The only advantage is that you give the BMS a chance to detect full charge voltage and calibrate the SOC readout. So try to plug into mains once a week to fully charge your batteries, especially if your not running any fixed solar supply.

BMS & CMS

Here at DCS, designing lithium batteries is not only our bread and butter, but we love this safe, stable, robust, and high-performance cell chemistry so much that we decided to develop our own range of Battery and Cell Management Systems in 2015.

DCS Battery Management System:

What was the objective? Well, the reason we embarked on this project was that all the basic Chinese designed BMS’s are just protection boards, and it is hard to call them a BMS when they don’t do any cell balancing or provide any means of programmability for various parameters and cell control. A lot of Battery Management Systems that we have tested were using inferior PCB engineering design techniques and poor components. That means continuous performance above 100A was more or less impossible, and reliability was also questionable when pushing above 100A with those Battery Management Systems.

Our key BMS objective was to develop a high-performance 200A BMS that could do;

  • 200A continuous operations using high-quality components
  • To have a minimal increase in temperature at peak output current (as these circuit boards are installed inside battery packs, limiting internal heat build-up that is crucial for the longevity of the battery cells).
  • Designed for engine cranking applications, it has to deliver a minimum of 1200LCA’s for 10 seconds (because of the limited voltage drop with suitable lithium cells, it’s very easy to crank over modern engines. Most engines will start in under 1sec, so 10 seconds is plenty). CCA’s don’t apply to lithium batteries as this standard was developed for lead-acid batteries and needed to deliver 30 secs of cranking amps. When a lithium battery is controlled via a BMS, the correct terminology is LCA = Lithium Cranking Amps based on delivering 10 secs of cranking amps.
  • Suitable for high temperatures applications, e.g. engine compartments. It will be stable up to 180 degrees C.
  • Bluetooth and WiFi connectivity in order to develop a comprehensive app platform
  • Pass MIL vibration testing standards (to open up the development of batteries for just about any application).

In a nutshell, the design needed to be tough and reliable for those who use them in the field with no room for error. The construction materials, coating and surfaces, assembly techniques are critical in designing a reliable system. After submitting our brief to all major leading manufacturers in Europe, Japan, USA and Korea, we assessed their expertise and ended up working with a leading and well known Japanese semiconductor manufacturer.

This is a typical Chinese 100A 4S BMS design

This is the DCS 4S 200A BMS

After three years of development, in early 2018, we were satisfied with the circuit board stress testing and released the first batch of our newly developed BMS’s right across our entire 4S (12V) & 16S (48V) battery range. At the same time, we hired an app development team to start working on the software integration to launch our first app platform. The first GEN1 BLE DCS BMS’s that featured Bluetooth chips were launched in OCT 2019. The app platform required a lot of tweaking both on the hardware and software front, and our GEN2 BMS’s were released in mid-2020 along with a more stable app platform with a new design scheme. Our latest GEN3 BLE BMS’s had been released in JAN 2021. The accuracy and stability of the DCS LFP App monitoring system is now very mature and refined. Some additional features had been added along with the ability to create custom battery names. We can produce our DCS BMS technology in any continuous rating range from 10A to 200A with our comprehensive BLE DCS LFP App platform.

DCS Cell Management System:

Having developed such an industry-leading and reliable BMS, it made no sense to combine the cell balancing system together with the BMS. So with our many years of experience in designing and maintaining lithium batteries, we have developed a stand-alone CMS to compliment our BMS. CMS? What? OK, so there are two ‘theories’ of cell balancing in the lithium world passive and active. Passive balancing is a cheap inferior method of cell management as it can burn resistors in an attempt to bleed cell strings. In contrast, active cell balancing is a more complex and efficient balancing technique that redistributes charge between battery cells during the charge and discharge cycles.

Passive balancing has two fundamental setbacks;

  1. Heat: We don’t want unnecessary heat build-up inside a battery pack. The less internal heat, the lesser the impact on the battery cells over time
  2. Resistors have a limited service life, and once they fail game over, you have no cell management. But more importantly, they can fail in such a way in which they will keep drawing power and eventually destroy the cells.

Active balancing is the only way to manage lithium cells correctly. There are many ways to design an integrated circuit (IC) to actively manage cell strings. At DCS, we have tested well over 10 different methods of active balancing IC’s over the years and, in the end, again decided to develop our own active management circuit boards with the best-combined techniques based on our stress testing. Our in house PCB design engineer Max, designed our circuit boards to again meet the following criteria:

  • High current movement (our latest boards now achieve 3.7A dynamic movement per channel)
  • Thermal management to ensure the boards remain reliable in harsh environments
  • Be able to withstand maximum current and thermal loads to ensure long term reliability
  • Fail-safe design, if any component fails, it won’t compromise the battery pack (not consume power from the battery cells)

This is the DCS 16 channel CMS

There are, of course, some other software features and parameters, which we can’t disclose on this page to the public, as well as some very fancy hardware. But what our latest 04 channel and 16 channel CMS’s do is they can easily manage up to 1000Ah battery banks. So, for example, if you wanted to use our 16 channel CMS’s you could run a 51.2V 1000Ah single battery pack, which would be 51.2kWh in size! The DCS 15kWh batteries are just shy of 300Ah in capacity, so one can only imagine the tight CMS control these batteries are under, and that’s why we back them with a 10 year / 80% capacity warranty.

The DCS 16 channel 59.2A active cell balancing system is so powerful that it will change the battery storage market forever. With this system, the lithium market will continue to dominate for the foreseeable future. Of course, all DCS batteries now feature both our BMS & CMS circuit boards.

We design all our own PCB hardware and the circuit boards are tested to withstand a minimum of 10 years of severe abuse. This video is the MIL-STD 810G Method 514.6 which includes 4 procedures for different modes of vibration.

How to wire batteries correctly

CELL SAFETY INFO - Why LiFePO4 (LFP)?

Lithium Ferrophosphate (LFP) is a flame retardant, stable, safe and proven cell chemistry that has a very good energy density around 325 Wh/L. This cell chemistry can be engineered for various applications by adjusting the ratio of elements to provide high performance characteristics. E.g. the DCS marine battery range runs 2C cells, which means our little 75Ah battery will discharge comfortably at 75Ah x 2C = 150A. The DCS 80Ah Extreme runs 10C cells which means the 80A can comfortably discharge at 80Ah x 10C = 800A but is of course limited to lower currents due the the Battery Management System.

LFP also has very good cycling durability between 2,000 ~ 12,000 cycles can be achieved depending on how well the cells are managed, and the lowest rate of capacity loss (aka greater calendar-life) compared to other lithium cell chemistries.

WHY YOU CANNOT USE A VSR BETWEEN TWO DIFFERENT BATTERIES CAPACITIES & CHEMISTRIES?

Battery cells are simply a bunch of resistors with the ability to store energy. A 100Ah battery pack has a different resistance characteristic compared to a 50Ah battery pack, that theoretical difference in resistance is 2:1. So if you connect a 100Ah battery in parallel to a 50Ah battery there is no way for these two batteries to equalise and therefore you can’t charge them correctly. So for example connecting a 60Ah calcium starting battery to a 120Ah AGM via a VSR (Voltage Sensing Relay) you cannot charge both batteries correctly and from that day onwards you are prematurely destroying both battery packs. Same theory applies with lithium’s it’s still a battery pack.

What’s the solution? A DC-DC charger, you now have a permanent point of isolation (meaning that both batteries are never connected to each other in parallel). The DC-DC charger takes the surplus power from battery A (engine) and chargers battery B (aux/house). This device now allows any battery capacity and or chemistry to be used.

What if both batteries are the same, can I run a VSR between exactly the same two batteries?

Yes you can, but lithium’s have a different voltage curve, so you would still need to use a programmable VSR to dial them in correctly. However these devices draw a lot of power when engaged to so it’s best to run the two batteries in parallel and run a load disconnect instead of a VSR.

The advantages of the lithium battery cell chemistry

Lithium battery cells have a super low resistance so are very easy to charge and very efficient. This level of efficiency means you can charge them at very high C rates. For example if you look at the charge rate of a 100Ah AGM battery the recommended charging current will be around 25A, which is a 0.25C charge rate. If you consider the DCS 12V 100Ah Lithium battery it can be charged at up to 70A which is a 0.70C charge rate. This means you no longer need to consider DC-DC chargers as you can connect our batteries directly to high power charging devices such as suitable alternators, or large buck boosters. For example our popular dual 90Ah battery system for boats and 4WD vehicles, can be connected to alternators up to 160A.

WHY CAN DCS BATTERIES BE CONNECTED IN PARALLEL WITHOUT ANY EXTERNAL COMMUNICATION SYSTEM?

Because our batteries are internally voltage regulated and because our BMS has such a high sustainable peak discharge current they will do an amazing job of equalising very quickly.

WHAT HAPPENS IF I FULLY DISCHARGE MY BATTERY TO EMPTY?

The BMS will open circuit the battery terminals to protect the cells. This means there is no longer any resistance in the system. The BMS needs a 12V signal with at least 1A of current to release and wakeup from a cell protection state. Most mains chargers with a lithium profile will do a slow recovery charge as will most solar regulators. Some chargers in the market today that are advertised as ‘lithium’ compatible still don’t have the firmware to do a slow recovery charge to release BMS’s. If you have a charger that will not wakeup the BMS, easiest way to wake it up is to connect a unregulated solar panel directly to the battery terminals, ensure all loads are disconnected before you do this. Having said that every system should have a suitable low cut off voltage to shutdown loads/accessories so that the batteries are not fully drained.

BATTERY MONITOR SETTINGS

Use the following settings:

Charged voltage 14.0V
Tail current 4%
Charged detection time 1min
Peukert 1.05
Charge efficiency 98%
Current threshold 0.1A
C rates: refer to the battery pack capacity

What is the best state/charge to store these batteries ?

Fully charge to 100% isolate everything from the terminals and leave for max 3 months and then cycle (fully discharge and fully charge) and leave again for 3 months etc…. Minimum 4 cycles per year to not effect the cells capacity.