Lithium Battery Smart circuit board replacement instruction

Lithium Battery Smart

circuit board replacement

instruction

Rev 00 - 10/2022

ENGLISH

Table of Contents

1. Introduction and safety ............................................................................................................. 1

2. Lithium Battery Smart spare parts list ........................................................................................... 2

3. Opening the battery case ........................................................................................................... 3

4. Replacing the circuit board ........................................................................................................ 4

5. Closing the battery case ............................................................................................................ 6

Lithium Battery Smart circuit board replacement instruction

1. Introduction and safety

Before following the instructions in this document make sure to first troubleshoot the battery. Follow the troubleshooting

instructions in the Lithium Battery Smart manual, see https://www.victronenergy.com/media/pg/Lithium_Battery_Smart/en/

troubleshooting-support-and-warranty.html.

• In case of a cell fault, the battery is irreparable. We do not supply spare cells.

• In case of a circuit board fault, the battery is repairable. We supply spare circuit boards.

This repair instruction describes how to replace the Lithium Battery Smart circuit board with a spare.

This instruction is also available as a video:

https://www.youtube.com/embed/FNS1U5ofeGE

Note that in this instruction, photos of a 200Ah 12.8V battery are used. The other battery models have slightly different circuit

boards and cell layouts, but the general method of replacing the circuit board is the same. Refer to the Lithium Battery Smart

spare parts list on the next page for the part number and a photo of the circuit board for each battery model.

WARNING - HIGH RISK OF ACCIDENTAL SHORT CIRCUIT!!

Short circuits of lithium batteries can be highly hazardous. If you don't understand the risks of exposing

battery cell terminals and the consequences of short circuits in lithium batteries, you must not carry out this

procedure. This information is presented for competent personnel intending to work from a bench top in an

uncluttered space.

This procedure is made publicly available for the benefit of those who are comfortable with, and able to, carry

out the repair themselves.

In case you are not, this is not a problem. Contact your dealer to arrange for the repair to be carried out by an

authorised person.

When performing repairs on a lithium battery, be aware that you are working on live equipment. Although

the voltages are not that high (12.8 or 25.6V), the battery can supply very high currents in case of a short

circuit. Take special care not to accidentally short circuit the positive and negative battery terminals, battery

cell terminals or busbars. Always use insulated tools.

Lithium Battery Smart circuit board replacement instruction

Page 1 Introduction and safety

2. Lithium Battery Smart spare parts list

The table below lists the battery model, part number and what circuit board part number is used in that particular battery. The list

also shows if the lid is screwed or glued onto the battery.

Battery part

number

Battery description

Circuit board

part number

Lid Image

BAT512050610

LiFePO4 Battery

12.8V/50Ah Smart

SBP210050000

Glued up to HQ2132

Screwed from

HQ2132

BAT512110610

LiFePO4 Battery

12.8V/100Ah Smart

SBP210110020

Glued up to HQ2115

Screwed from

HQ2116

BAT512116610

LiFePO4 Battery

12.8V/160Ah Smart

SBP210116020

Glued up to HQ2119

Screwed from

HQ2120

BAT512120610

LiFePO4 Battery

12.8V/200Ah Smart

SBP210120020

Glued up to HQ2111

Screwed from

HQ2112

BAT512132410

LiFePO4 Battery

12.8V/330Ah Smart

SBP210132120 Screwed

BAT524110610

LiFePO4 Battery

25.6V/100Ah Smart

SBP220110020 Screwed

BAT524120610

LiFePO4 Battery

25.6V/200Ah-a

Smart

SBP220120020 Screwed

BAT512060410

LiFePO4 Battery

12.8V/60Ah Smart

(EOL)

SBP210060000 Glued

BAT512130410

LiFePO4 Battery

12.8V/300Ah Smart

(EOL)

SBP210130000 Glued

BAT524120410

LiFePO4 battery

25.6V/200Ah Smart

(EOL)

SBP210120120 Glued

Lithium Battery Smart circuit board replacement instruction

Page 2 Lithium Battery Smart spare parts list

3. Opening the battery case

There are three different battery case types. The way the battery is opened differs for each different battery case type:

• Situation 1: The battery case has screws that are visible on top of the battery.

• Situation 2: The battery case does not have screws that are visible on top of the battery and has ventilation slots.

• Situation 3: The battery case does not have screws that are visible on top of the battery and does not have ventilation slots.

These are the instructions for each situation:

Opening instructions for situation 1:

• Remove the two large aluminium nuts from the terminals.

• Remove all Philips head screws from the top cover.

• Lift the lid upwards to remove it.

Opening instructions for situation 2:

• Remove the two large aluminium nuts from the terminals.

• Using a piece of wood and a hammer, tilt the piece of wood up into one of the

ventilation holes and give the piece of wood a short and firm tap with the hammer.

• Repeat for each ventilation hole.

• Lift the lid upwards to remove it.

Opening instructions for situation 3:

• Remove the two large aluminium nuts from the terminals.

• Using a large flat head screwdriver and a hammer, lay the battery on its side

and place the screwdriver at an angle in the seam between the top cover and

the battery case, and give a few short and firm taps on the screwdriver with the

hammer.

• Repeat at regular intervals around the battery.

• Place the battery upright and lift the lid upwards to remove it.

Lithium Battery Smart circuit board replacement instruction

Page 3 Opening the battery case

4. Replacing the circuit board

High risk of accidental electrical short circuit. Perform at your own risk.

Replacement instructions:

Step 1:

• Loosen and remove the bolts that hold the circuit board wires.

• CAUTION: for models where the busbar comes loose, do not remove the bolt but

replace them after the circuit board wire is removed.

• Leave the other bolts in place.

Step 2:

• Remove the circuit board.

Step 3:

• The image on the right shows the battery without the circuit board.

Step 4:

• Remove the new circuit board from its anti-static bag.

Step 5

• Bend all circuit board wires upward. This prevents an accidental connection

between a wire and the wrong busbar or battery cell.

Step 6:

• Position the circuit board above the battery.

• Ensure that the "BAT +" text is at the positive terminal and the "BAT –" text is at the

negative terminal.

Step 7:

• Insert the top right-hand circuit board wire, with the text "+ 3V3", to the top right-

hand busbar.

• Hand tighten the bolt using your fingers.

Step 8:

• Repeat this for the other circuit board wires.

Lithium Battery Smart circuit board replacement instruction

Page 4 Replacing the circuit board

Replacement instructions:

Step 9:

• Hand tighten all bolts using a tool.

Step 10:

• Further tighten the bolts to 10Nm, using a torque wrench.

Step 11:

• Use two cable ties as strain relief for the two BMS cables.

• A new pair of cable ties are included with the circuit board.

Step 12:

• Confirm that the circuit board is functioning correctly before closing the cover.

• Connect to the battery with the VictronConnect app and check that everything looks

all right.

Lithium Battery Smart circuit board replacement instruction

Page 5 Replacing the circuit board

5. Closing the battery case

Closing instructions:

Step 1:

• Place the lid back on the battery.

• In case the battery has screws, place and tighten the screws. Use a low torque

setting, and do not over-tighten the screws to avoid damaging the screw holes.

• In case the battery was glued, use super glue to glue the lid back on. Use the glue

sparingly.

Step 2:

• Fasten the two aluminium terminal nuts (hand-tight).

• Take care that the top of the nut is at least 2 to 3 mm under the top of the battery

terminal.

• Do not over-tighten the nut to prevent the cover from being pulled down too much

and possibly damaged.

Step 3:

• The spare circuit board came with a new serial number sticker including puk code

and other details.

• Affix this new sticker over the old one.

Lithium Battery Smart circuit board replacement instruction

Page 6 Closing the battery case