2024 How to Handle Golf Cart Lithium Conversion with High-Speed Modules

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Golf Cart Lithium Conversion with High-Speed Module Issues is a topic that raises concerns for many golf cart owners seeking to upgrade from traditional lead-acid batteries. While lithium batteries offer substantial advantages such as increased performance, longer range, and reduced maintenance, integrating them with high-speed modules can introduce challenges. In this article, we’ll explore the reasons for converting your golf cart to lithium, when to make the switch, how to choose the right battery, and how to address common issues that arise when combining golf cart lithium batteries with high-speed modules. By understanding these potential pitfalls and following best practices, you can ensure a successful conversion that enhances your golf cart’s overall performance and longevity.

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Why Switch to Lithium Batteries for Your Golf Cart?

Converting your golf cart to use lithium battery for golf cart brings numerous benefits. Lithium batteries deliver superior performance and longer life compared to older models, making them a worthwhile investment. Here are some reasons to consider this upgrade:

  • Improved Performance: Lithium batteries provide faster acceleration and better overall power delivery.
  • Increased Range: With higher energy density, these batteries can power your cart for longer distances without needing frequent recharges.
  • Less Maintenance: Unlike lead-acid batteries, lithium batteries require minimal upkeep, saving you time and effort.

When to Switch to Lithium Batteries for Golf Cart

Recognizing the right time to upgrade your golf cart batteries is essential. Here are key indicators that it might be time to make the switch:

  • Damaged Batteries: Look for visible signs of damage, such as corrosion around the terminals or swelling of the battery case. These are clear indicators that your lead-acid batteries may be nearing the end of their life cycle.
  • Diminishing Battery Capacity: If you notice your golf cart struggles to maintain speed or the range decreases significantly after a full charge, it may be time to consider lithium. A decline in performance often suggests that the existing batteries are failing.
  • Excessive Maintenance: Lead-acid batteries require regular maintenance, including checking water levels and cleaning terminals. If you’re spending too much time on upkeep, switching to lithium could simplify your life.
  • Desire for Better Performance: If you’re looking for enhanced performance, lithium batteries can offer improved speed and efficiency, making your golf cart feel like new again.

How to Choose the Right Golf Cart Lithium Battery

Selecting the appropriate golf cart lithium battery is crucial for ensuring compatibility and optimal performance.

  • Matching Voltage Requirements: Make sure the voltage of the new golf cart lithium battery matches your golf cart’s requirements. Most golf carts operate on 36V or 48V systems. Ensure that the lithium battery for golf cart you choose aligns with these specifications.
  • Properly Sized Batteries: Understanding the amp-hour (Ah) rating is essential for determining the right battery size. This rating indicates how much energy the battery can store and how long it will last.
  • “Drop-In” Ready Battery Sizing: Opt for batteries that are designed to fit directly into your existing battery compartment without requiring modifications. This “drop-in” approach simplifies installation and minimizes complications.
  • Preparing Your Golf Cart for Conversion: Before starting the conversion process, take the following steps to ensure a smooth transition:
  • Evaluating Current Batteries: Assess the condition of your existing lead-acid batteries. Identifying issues early can save time and money during the conversion.
  • Checking Compatibility: Verify that the new golf cart lithium batteries are compatible with your golf cart’s existing systems, including wiring and charging systems.

Costs of Switching to Lithium Batteries for Golf Cart

When considering a golf cart lithium conversion, it’s important to factor in the costs involved. While the initial investment may seem high, lithium batteries offer long-term savings in terms of reduced maintenance, longer lifespan, and increased efficiency.

Battery and Component Costs

The primary cost associated with the conversion is the price of the lithium batteries. Depending on the type and capacity of the battery you choose, prices can range from a few hundred dollars to several thousand dollars. For example, a high-quality lithium battery designed for golf carts might cost anywhere between $1,000 to $3,500.

Additional components such as battery management systems (BMS), wiring, and high-speed modules also add to the overall cost. However, it’s crucial to invest in quality components to ensure a reliable and efficient conversion.

Labor Costs

Labor costs can vary depending on whether you hire a professional to perform the conversion or choose to do it yourself. Hiring a technician with experience in how to convert golf cart to lithium could cost anywhere from $100 to $150 per hour. However, if you’re familiar with basic mechanical and electrical systems, you could potentially save on labor by completing the conversion on your own.

For those opting for professional installation, it’s essential to find a technician familiar with lithium systems to avoid complications and ensure proper integration with your golf cart’s existing components.

Long-Term Savings

Though the upfront cost of lithium battery for golf cart conversion may be higher than sticking with traditional lead-acid batteries, the long-term savings can outweigh this initial investment. Lithium batteries have a much longer lifespan—often lasting up to 10 years or more—compared to lead-acid batteries, which may need replacement every 3 to 5 years.

Lithium batteries also charge faster, reducing the downtime of your golf cart. Additionally, they require no maintenance, unlike lead-acid batteries, which require regular water checks and terminal cleaning.

Weight Savings

One of the often-overlooked benefits of switching to lithium batteries is the significant weight reduction. Lithium batteries weigh up to 50% less than their lead-acid counterparts. This weight savings can improve your golf cart’s speed, handling, and energy efficiency, further reducing long-term costs by consuming less power for the same performance.

Best Practices for Maintaining Golf Cart Lithium Battery

Proper care and maintenance are crucial for maximizing the lifespan and performance of your lithium batteries. While they require much less maintenance than lead-acid batteries, there are still important steps to follow.

Regular Charging

To get the best performance from your golf cart lithium batteries, make sure to charge them fully after each use. Lithium batteries are not subject to the memory effect that affects lead-acid batteries, so partial discharges will not negatively impact their lifespan. However, keeping the batteries fully charged helps maintain their capacity over time.

Store in a Cool, Dry Place

When not in use, it’s best to store golf cart lithium batteries in a cool and dry environment. Extreme temperatures—whether too hot or too cold—can impact battery performance and longevity. If you’re storing the golf cart for an extended period, it’s advisable to keep the batteries at about 50% charge and avoid exposing them to extreme conditions.

Monitor Battery Health

Using a battery management system (BMS) to monitor key indicators such as voltage, temperature, and charge levels is an essential practice for maintaining lithium battery health. A BMS can help prevent overcharging, over-discharging, and overheating, which are common issues that could shorten battery life.

Periodic Testing

Even though lithium batteries require less maintenance, it’s still a good idea to periodically test them. You can use a multimeter to check individual battery voltages or install a battery monitoring system that provides real-time data on performance.

Getting Ready for Golf Cart Lithium Battery Conversion

Proper preparation is essential to ensure a smooth and successful golf cart lithium conversion. By evaluating your current battery setup and verifying the compatibility of your golf cart components with lithium technology, you can prevent potential issues during the conversion process.

Evaluating Current Batteries

Before making the switch, it’s important to assess the condition of your current lead-acid batteries. This evaluation helps determine whether it’s the right time for a conversion.

You can start by checking for common signs of battery wear, such as corrosion on the terminals, swelling of the battery case, or acid leakage. If any of these issues are present, it’s a good indication that your batteries are nearing the end of their lifespan, making it the ideal time to replace them with lithium battery for golf cart systems.

Additionally, testing the battery’s performance with a full charge and discharge cycle can give you a better idea of how much capacity remains. If you notice a significant drop in driving range or power output, it’s time to upgrade to lithium batteries.

Checking Compatibility

Compatibility is a critical aspect of the conversion process. You need to ensure that the new lithium batteries will work seamlessly with your golf cart’s motor, wiring, and charging system.

First, verify the voltage requirements of your golf cart. Most carts operate on either 36V or 48V systems, so it’s essential to select a lithium battery that matches your cart’s voltage needs. Lithium batteries with incorrect voltage ratings could lead to inefficient performance or even damage to the cart’s components.

Additionally, ensure the wiring in your golf cart can handle the increased current flow from the lithium battery. You may need to upgrade to thicker wiring to accommodate the higher power output of the lithium battery for golf cart.

Lastly, check if your current charger is compatible with lithium batteries. Standard lead-acid chargers are not designed to properly charge lithium batteries and may damage them. Investing in a lithium-specific charger is crucial to ensure efficient and safe charging.

Step-by-Step Golf Cart Lithium Conversion Process

To ensure a smooth and successful golf cart lithium conversion, follow these steps:

Step 1: Remove the Old Batteries

Start by disconnecting the main cables from the lead-acid batteries. Always disconnect the negative cable first to avoid short circuits, then remove the positive cable. Once the cables are detached, carefully remove the old batteries from the tray. It’s a good idea to inspect the tray for any signs of rust or corrosion. Clean it thoroughly to ensure a stable base for the new lithium battery for golf cart.

Step 2: Install the Lithium Battery

Place the new lithium battery into the battery tray. Many lithium batteries are designed as “drop-in” replacements, meaning they fit directly into the existing battery space without the need for modifications. Ensure the battery is securely positioned in the tray before reconnecting any cables.

Step 3: Reconnect the Cables

Reconnect the cables, starting with the positive cable and then the negative cable. Make sure all connections are secure and free from corrosion to avoid any issues with power delivery or overheating. Double-check the cable connections to ensure they are attached to the correct terminals, preventing any potential damage.

Step 4: Connect the Main Power Cables

With the lithium battery in place, connect the main power cables. It’s helpful to take pictures of the original wiring setup before removing the old batteries, as this can guide you in properly reconnecting the new battery system. Ensure the polarity is correct when reconnecting the main cables.

Step 5: Set Up the Charging System

Lithium batteries require a charger specifically designed for lithium technology. Using a lead-acid charger could damage the battery. Choose a charger that matches the voltage of your lithium system (e.g., a 48V charger for a 48V system). These chargers typically shut off automatically when the battery reaches full charge, protecting the battery from overcharging. Set up the charger in a well-ventilated area, and follow the manufacturer’s installation guidelines.

Step 6: Install High-Speed Modules (Optional)

If you’re integrating a high-speed module, it can significantly improve your cart’s speed and responsiveness. High-speed modules are designed to optimize performance during and after the conversion, enhancing the overall driving experience of your golf cart.

Benefits of Golf Cart Lithium Battery Conversion

Converting your golf cart to lithium batteries offers numerous advantages that improve both performance and longevity. Below are some of the key benefits of making this switch:

Faster Charging Times

Lithium batteries charge significantly faster than lead-acid batteries. This means less downtime waiting for your cart to recharge and more time on the course or around the neighborhood.

Longer Lifespan

One of the most compelling reasons to switch to lithium is their extended lifespan. Lithium batteries can last up to 10 years, whereas lead-acid batteries may need replacing after 3-5 years. This longevity reduces replacement costs and increases the overall value of the golf cart lithium conversion.

Weight Reduction

Lithium batteries are much lighter than lead-acid batteries, which can weigh down your golf cart and negatively impact its speed and handling. The lighter weight of lithium reduces strain on the motor, allowing your golf cart to operate more efficiently and achieve higher speeds.

Consistent Power Output

Unlike lead-acid batteries, which lose power as they discharge, lithium batteries provide consistent power output throughout their charge cycle. This means your golf cart will maintain the same level of performance, whether the battery is fully charged or nearing empty.

The Role of High-Speed Modules in Golf Cart Lithium Conversions

When upgrading your golf cart to lithium battery for golf cart, one of the most exciting possibilities is increasing the cart’s speed with the use of high-speed modules. These modules modify the electronic speed controller (ESC) to allow for faster acceleration and higher top speeds. However, integrating high-speed modules with a lithium conversion can sometimes present challenges, including compatibility issues with the motor controller, voltage irregularities, and potential damage to other components if not properly managed.

What Do High-Speed Modules Do?

High-speed modules adjust the electronic speed controller to increase the speed output of your golf cart. While stock carts are often limited to lower speeds for safety reasons, installing a high-speed module can bypass these limits, allowing you to take full advantage of the improved power output from the lithium battery.

However, with the increased power that lithium batteries provide, it’s important to ensure that the module is properly calibrated to avoid issues such as motor overheating, erratic throttle response, or even failure of electrical components.

Key Problems in Golf Cart Lithium Conversions with High-Speed Modules

Voltage Compatibility Problems

One of the primary issues that arise during a golf cart lithium conversion with high-speed modules is voltage compatibility. Lithium batteries generally operate at a higher and more consistent voltage than lead-acid batteries, which can cause problems with components that were designed for the lower and more variable voltage of lead-acid systems.

Solution:
Before installing the high-speed module, verify that your motor controller and high-speed module are compatible with the higher voltage provided by the lithium battery. Upgrading the motor controller or using a module specifically designed for lithium systems can help avoid voltage mismatches that could lead to performance degradation or equipment damage.

Battery Management System (BMS) Conflicts

The battery management system (BMS) is a critical component of lithium battery setups, designed to protect the battery by regulating charging, discharging, and preventing overcurrent or short circuits. However, integrating a high-speed module with a BMS can sometimes result in conflicts where the BMS limits the current supply to the high-speed module, reducing performance.

Solution:
Ensure that the BMS is capable of handling the current demands of both the lithium battery and the high-speed module. If necessary, upgrade the BMS or recalibrate the module to ensure smooth power delivery without overloading the system.

Motor Overheating

Lithium batteries deliver a much higher and more consistent current than lead-acid batteries, which can strain a motor not built to handle the increased power, especially when paired with a high-speed module. This can lead to overheating, which not only decreases performance but also risks damaging the motor over time.

Solution:
Consider upgrading the motor to one rated for higher speeds and power output. Additionally, you can install cooling systems like heat sinks or fans to help dissipate excess heat, preventing the motor from overheating during extended periods of high-speed operation.

Wiring and Connection Issues

Higher current from the lithium battery can expose weaknesses in your existing wiring setup, leading to potential problems like overheating, voltage drops, or even electrical fires.

Solution:
Upgrade your wiring to thicker gauge cables capable of handling the increased current flow. This will ensure a more efficient and safer power transfer from the battery to the high-speed module and motor.

Throttle Response Issues

When switching from lead-acid to lithium, you might notice that the throttle response becomes either too sensitive or too sluggish. This difference in power delivery between battery types can make it challenging to control the golf cart, particularly at higher speeds.

Solution:
Recalibrate the throttle controller to match the new power output from the lithium battery. Adjusting the acceleration curve on the controller can help provide smoother and more predictable throttle response, making the cart easier to control even at higher speeds.

Regenerative Braking Conflicts

Regenerative braking is a feature in some golf carts that uses the motor to generate power while slowing down the cart, feeding that power back into the battery. However, when converting to lithium, the regenerative braking system may not work correctly due to differences in how the lithium battery’s BMS handles the incoming power.

Solution:
Consult the manufacturer or an expert to either adjust the regenerative braking system to work with the lithium battery or disable it altogether if it causes issues. In some cases, the braking system can be recalibrated to work with the new battery setup, ensuring smoother and more efficient operation.

Effective Solutions for Golf Cart Lithium Conversion with High-Speed Module Issues

To ensure a successful golf cart lithium conversion, particularly when integrating high-speed modules, follow these best practices:

Choose Compatible Components

Ensure that every component you select, including the lithium battery, high-speed module, and motor controller, is designed to work together. Incompatible components can lead to inefficient power usage or system failures.

Upgrade the Speed Controller

Many stock speed controllers are not designed to handle the increased power output of lithium batteries, especially when combined with high-speed modules. Consider upgrading to a programmable speed controller that can be adjusted to optimize the performance of your new setup.

Monitor Battery Health

A BMS is essential to ensure that your lithium battery stays healthy over time. It monitors key factors such as voltage, temperature, and power output. Regularly checking the status of your battery can help prevent issues such as overcharging or overheating, which could shorten its lifespan.

Test in Phases

After installing the high-speed module and lithium battery, it’s important to test your golf cart in phases. Begin by testing at lower speeds and gradually increase to higher speeds. This methodical approach will help you identify any potential issues early and allow you to make adjustments before pushing the system to its limits.

Conclusion

Converting your golf cart to lithium batteries, especially with the addition of high-speed modules, can greatly improve performance, speed, and efficiency. However, there are several technical challenges you may face, such as voltage compatibility issues, BMS conflicts, motor overheating, and wiring problems. By following the outlined solutions and best practices, you can ensure that your golf cart lithium conversion is smooth, safe, and delivers long-term benefits.

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2023 Lithium Ion vs Lead Acid: A Detailed Comparison

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What Are Lithium Ion Batteries?

Lithium-ion batteries are currently the most widely used type of rechargeable batteries. They are the power source behind everyday devices like smartphones, laptops, electric vehicles, and much more.

1. The Widespread Presence of Lithium-Ion Batteries

These batteries are an integral part of our daily lives. They are found in numerous gadgets and tools, including cell phones, tablets, laptops, smartwatches, portable chargers, emergency power sources, electric shavers, electric bicycles and cars, public transport vehicles, sightseeing carts, drones, and various electric tools.

2. How Do Lithium Ion Batteries Work?

Lithium ion batteries function by utilizing lithium ions to store energy. This process involves creating a voltage difference between the battery’s positive and negative sides. The battery contains a special part called a separator, which keeps the two sides apart. This separator allows lithium ions to move across it but prevents the flow of electrons.

  • Charging and Discharging Process: When you charge a lithium-ion battery, the lithium ions travel from the positive side to the negative side through the separator. Conversely, when the battery is in use (discharging), the ions move back to the positive side. This back and forth movement of ions is what generates the battery’s voltage.
  • Powering Your Devices: The voltage created by the lithium-ion battery is used to power electronic devices. When a device is connected to the battery, it directs the electrons, which were blocked by the separator, to flow through the device, providing it with the necessary power.

What Is Lead Acid Battery?

Lead acid batteries are a type of rechargeable battery that harnesses the chemical interaction between lead and sulfuric acid to generate electricity. They’re commonly used in various applications due to their reliability and rechargeability. The core of these batteries is the lead submerged in sulfuric acid, which facilitates a controlled chemical reaction essential for power generation and storage.

1. How Lead Acid Batteries Function

In a lead acid battery, the electrodes are primarily composed of lead and its oxides, while the electrolyte is a sulfuric acid solution. When discharging, the positive electrode is mainly lead dioxide, and the negative electrode is lead. During charging, both electrodes become primarily lead sulfate. A single cell typically has a nominal voltage of 2.0V, can discharge to 1.5V, and charge up to 2.4V. For practical use, six single cells are often connected in series to create a standard 12V battery, with other configurations like 24V, 36V, and 48V also available.

2. Applications of Lead Acid Batteries

Lead acid batteries are versatile and find use in various sectors:

Standby Power Sources

  • Telecommunications
  • Solar Energy Systems
  • Electronic Switch Systems
  • Communication Equipment: Base Stations, PBX, CATV, WLL, ONU, STB, Cordless Phones
  • Backup Power: UPS, ECR, Computer Backup Systems, Sequence, ETC
  • Emergency Equipment: Emergency Lights, Fire and Burglar Alarms, Fire Doors

Primary Power Sources

  • Communication Devices: Transceivers
  • Power Control Vehicles: Collection Vehicles, Automated Transport Vehicles, Electric Wheelchairs, Cleaning Robots, Electric Cars
  • Mechanical Tool Starters: Lawnmowers, Hedge Trimmers, Cordless Drills, Electric Screwdrivers, Electric Snow Sleds
  • Industrial Equipment/Instruments
  • Photography: Flashlights, VTR/VCR, Movie Lights
  • Other Portable Devices

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Lithium Ion vs Lead Acid Battery: 10 Key Differences

1. Differences in Material Composition

Both lithium ion and lead acid batteries operate on similar principles, but the materials they use differ significantly. Lead acid batteries employ lead as the anode and lead oxide as the cathode, with sulfuric acid serving as the electrolyte. In contrast, lithium ion batteries use carbon for the anode and lithium oxide for the cathode, with lithium salt as the electrolyte. The flow of ions between the anode and cathode through the electrolyte is what generates power in both types, reversing during charging.

2. Cost Considerations

Initially, lead acid batteries are more affordable and easier to install than lithium ion ones. However, the price of a lithium ion battery can be twice that of a lead acid battery for the same energy capacity. Despite this, lithium ion batteries offer a longer lifespan, making them more cost-effective for long term applications compared to lead acid batteries.

3. Comparing Battery Capacities

Battery capacity reflects the amount of energy a battery can store per unit volume. Lithium ion batteries boast a higher capacity than lead acid batteries, indicating a greater amount of active material within.

4. Energy Density and Specific Energy

Energy density is crucial in selecting the right battery for specific needs, showing the relationship between a battery’s capacity and its weight. Lithium-ion batteries exhibit higher specific energy compared to lead-acid batteries, making them the preferred choice in electric vehicle (EV) applications.

5. Weight and Size

Thanks to their higher energy density and capacity, lithium-ion batteries are lighter and more compact than lead-acid batteries of the same capacity.

6. Depth of Discharge (DoD) Comparison

DoD measures how much of a fully charged battery can be used without needing a recharge. Lead-acid batteries typically have a DoD of 50%, meaning only half the battery’s capacity should be used before recharging. On the other hand, lithium-ion batteries offer a higher DoD of 80%, allowing for extended use. Modern lithium-ion batteries even reach 100% DoD, showcasing their efficiency and endurance.

7. Durability and Longevity

Lead-acid batteries typically have a lifespan of up to two years with proper maintenance, including recharging after 50% usage. Over-draining can limit their life to just one year. In contrast, lithium-ion batteries boast a remarkable durability of up to 10 years, enduring up to 10,000 cycles.

8. Cycle Life

The cycle life of a battery indicates the number of complete charge and discharge cycles it can handle. Lithium-ion batteries often sustain around 5,000 cycles without significant performance loss, even when fully discharged. Lead-acid batteries, however, generally last between 300 to 500 cycles, with full discharge adversely impacting their cycle life.

9. Charging Speed

Charging speed is a key differentiator between these two types. Lithium-ion batteries can charge much faster than lead-acid batteries, making them preferable for applications needing quick recharge, like electric vehicles (EVs).

10. Safety Considerations

Both battery types pose safety risks if mishandled, especially when overcharged. Lead-acid batteries contain corrosive sulfuric acid and can produce explosive gases. Lithium-ion batteries are at risk of thermal runaway, which can also lead to explosions. Manufacturers like CATL and Panasonic Corporation are key players in creating safer battery systems. The battery’s application often dictates the choice between lithium-ion and lead-acid batteries.

Lithium Ion vs Lead Acid: Which Lasts Longer?

1. Understanding Battery Lifespan and Efficiency

When it comes to longevity, lithium ion (Li-ion) batteries generally have a longer life than lead acid batteries. This is mainly due to their higher life cycle numbers, meaning they don’t need replacing as often. This not only cuts down on replacement costs but also aligns with eco-friendly recycling practices. Additionally, Li-ion batteries are tougher, performing more effectively in demanding environments.

  • Efficiency Matters: In the lithium ion vs lead acid comparison, efficiency plays a crucial role. Efficiency refers to the percentage of the energy stored in the battery that can be effectively utilized. Li-ion batteries are typically at least 95% efficient, significantly outperforming lead acid batteries, which have efficiencies around 80-85%.
  • Battery Discharge Curve: The discharge curve is crucial as it influences how quickly a battery can charge and its effective capacity – the actual amount of energy a battery can store. Li-ion batteries have a superior discharge curve, maintaining their voltage until almost fully depleted, unlike lead acid batteries, which experience a significant voltage drop during discharge.

2. Usage Patterns: A Key Differentiator

  • Lithium ion Batteries: Li-ion batteries are known for their speedy charging times, making them ideal for extended use across multiple work shifts. They lack a memory effect, allowing for partial charging without reducing their overall lifespan. A typical usage pattern includes 8 hours of operation, a swift 1-hour recharge, followed by another 8 hours of use. This cycle enables continuous usage over a 24-hour period, with only brief pauses for charging.
  • Lead Acid Batteries: In contrast, lead acid batteries generate substantial heat while charging, necessitating a cooldown period. Their typical usage cycle includes 8 hours of operation, followed by 8 hours of charging and an equal period of rest. This pattern limits their use to one shift per day, requiring additional batteries for multi-shift operations. They also need well-ventilated areas for charging to prevent the buildup of hazardous gases.

Lithium Ion vs Lead Acid: Prolonging Your Lithium Ion Battery’s Health

1. Introduction to Lithium Ion Battery Care

Maximizing the lifespan of lithium ion batteries is crucial for ensuring long-term efficiency and performance. Implementing strategies such as partial discharge cycles, avoiding full discharges, and managing charging temperatures can significantly impact their durability. It’s important to note that while lead acid batteries should not be discharged beyond 50%, lithium ion batteries can handle deeper discharge cycles without adverse effects.

2. Key Techniques for Prolonging Battery Life

  • Optimal Discharge Cycles: Utilize only 20-30% of the battery’s capacity before recharging. Avoid keeping the battery fully charged or fully discharged for extended periods, as both extremes can shorten its lifespan.
  • Temperature Management During Charging: Charging lithium ion batteries in extreme temperatures, particularly below freezing, can reduce their longevity. Ensure the charging environment is temperature controlled to extend battery life.
  • Proper Charging Practices: Use the correct charger type for your lithium ion battery to ensure it charges efficiently and safely. Lithium ion batteries require more specific charging regimes compared to lead acid batteries.
  • Benefits of Lithium Ion Over Lead Acid: Lithium ion batteries offer a range of advantages over lead acid batteries, including improved performance in challenging environments and overall cost-effectiveness over their lifespan.

3. Detailed Tips for Optimal Battery Usage

  • Lowering Discharge Rates: Reducing the C rate during discharge helps maintain the battery’s capacity and cycle life. Avoid high discharge rates to prevent increased internal resistance and premature aging.
  • Temperature Considerations: The operating temperature significantly impacts a battery’s power consumption and efficiency. Manage temperatures effectively to enhance lithium ion battery performance.
  • Partial Depth of Discharge (DoD): Favor partial discharges over full cycles. A shallower DoD results in a significantly higher number of battery cycles, thereby extending the battery’s lifespan.
  • Balancing Multiple Cells: If your battery pack has more than one cell, periodic balancing is necessary to ensure even usage and prevent voltage loss. Employ methods like bypassing certain cells during charging to focus on weaker cells.
  • Monitoring the State of Health (SoH): Keeping track of the SoH provides insights into the battery’s condition and remaining lifespan. A drop in SoH indicates the need for maintenance or replacement.

6 Primary Types of Lithium Ion Batteries

Lithium ion batteries, a cornerstone of modern technology, come in several types, each with unique characteristics and applications. The diversity in lithium ion batteries stems from the various active materials used in their construction, influencing their performance, longevity, and suitability for different uses.

 Key Types of Lithium Ion Batteries

  • Lithium Iron Phosphate (LFP): Known for their durability and safety, LFP batteries use phosphate in the cathode and a carbon electrode in the anode. These batteries are known for their long life cycle and good thermal stability. They are ideal for replacing lead-acid deep-cycle batteries due to their nominal voltage and stability.
  • Lithium Cobalt Oxide (LCO): These batteries are notable for their high specific energy but are limited in high-load situations. They were commonly used in portable electronics like phones and laptops but have seen a decline in popularity due to cost and safety concerns.
  • Lithium Manganese Oxide (LMO): LMO batteries, used in tools and some hybrid vehicles, offer quick charging and high specific power. They stand out for their improved thermal stability and versatility in different applications.
  • Lithium Nickel Manganese Cobalt Oxide (NMC): Combining nickel, manganese, and cobalt, NMC batteries balance stability with high energy density. They are frequently used in power tools and electric vehicles.
  • Lithium Nickel Cobalt Aluminium Oxide (NCA): Offering high specific energy and a respectable lifespan, NCA batteries are a popular choice in the electric vehicle industry, particularly for high-performance models like Tesla.
  • Lithium Titanate (LTO): Unique for using lithium titanate instead of graphite in the anode, LTO batteries are exceptionally safe and fast-charging. They are used in various applications, including electric vehicles and energy storage, despite their lower energy density and higher cost.

LiFePO4 Batteries: Leading the Charge in Lithium-Ion Technology

Lithium Iron Phosphate (LiFePO4) batteries are one of many types of lithium-ion batteries, each defined by different cathode materials. Other common types include Lithium Cobalt Oxide (LCO), Lithium Manganese Oxide (LMO), Lithium Nickel Cobalt Aluminum Oxide (NCA), Lithium Nickel Manganese Cobalt Oxide (NMC), and Lithium Titanate (LTO). Each has unique strengths and weaknesses, making them suitable for specific applications. (Learn more about Best LiFePO4 Battery)

Energy Density Comparison

LiFePO4 batteries boast one of the highest specific power ratings among lithium-ion batteries, meaning they can deliver large amounts of current efficiently. However, they have a lower specific energy, indicating less energy storage capacity per unit weight compared to other types. While this may not be a concern for many applications, it can be limiting in scenarios requiring high energy density, such as in battery electric vehicles.

Battery Life Cycles

LiFePO4 batteries excel in longevity, with lifespans starting at 2,000 full discharge cycles and potentially exceeding 5,000 cycles. This extended lifespan, only second to Lithium Titanate, offers significant advantages in terms of cost-effectiveness and environmental impact.

Discharge Rates

LiFePO4 batteries commonly feature a 1C continuous discharge rate, with the potential to exceed this under certain conditions. This capability makes them suitable for high-power applications that require current spikes at startup.

Operating Temperatures

With a high thermal runaway threshold of approximately 270 degrees Celsius, LiFePO4 batteries can operate safely under higher temperatures compared to other lithium-ion types. This characteristic, combined with robust Battery Management Systems (BMS), significantly reduces the risk of thermal runaway events.

Safety Advantages

Among all lithium-ion batteries, LiFePO4 batteries are known for their stability and safety, making them a preferred choice for both consumer and industrial applications. Their safe chemistry, alongside Lithium Titanate, is ideal for applications requiring a high degree of safety and reliability.

LiFePO4 vs. Other Lithium Ion Batteries

While LiFePO4 batteries may not be optimal for small, wearable devices due to lower energy density, they excel in larger applications like solar energy systems, RVs, golf carts, and electric motorcycles. They surpass other lithium-ion batteries in cycle life, safety, and depth of discharge capabilities.

Cycle Life and Safety

LiFePO4 batteries can achieve over 3,000-5,000 cycles, with the ability to reach 100% depth of discharge without over-discharging risks. This longevity, combined with their inherent safety, makes them the safest lithium battery type available, surpassing lithium-ion and other battery types in safety metrics.

Environmental and Efficiency Advantages

Eco-friendly and rechargeable, LiFePO4 batteries outperform lead-acid batteries in terms of efficiency, life span, and environmental impact. They charge faster, have a lower self-discharge rate, and maintain consistent power even below 50% battery life, all with no maintenance requirements.

Size and Weight Benefits

LiFePO4 batteries are significantly lighter than other lithium and lead-acid batteries, enhancing fuel efficiency and maneuverability in vehicles. Their compact size also frees up space for additional applications.

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Lithium Iron Phosphate Battery Vs Lead acid

Lithium iron phosphate battery:

  • Durability: Lithium iron phosphate battery has strong durability, slow consumption, more than 2000 charging and discharging times, and no memory, and the general life span is 5-8 years.
  • Discharge rate: Lithium iron phosphate battery can be discharged with high current, suitable for solar street lights, electric cars, electric bicycles, etc.
  • In terms of volume and quality: Lithium batteries are relatively small in size.
  • Battery capacity:  The capacity of lithium batteries in the same volume is larger. The lead-acid battery has a capacity of about 20 amps; the lithium battery has a capacity of 8-10 amps.
  • No memory effect: Lithium iron phosphate battery can be charged and used at any time, no matter what state it is in. It does not need to be discharged before recharging.
  • Nominal voltage of monomer: The nominal voltage of lithium iron phosphate battery is 3.2V.
  • Environmental protection: Lithium materials do not contain any toxic and harmful substances, and are regarded as green and environmentally friendly batteries in the world. The batteries are pollution-free in production and use, and have become a hot research topic.
  • Safety: Lithium iron phosphate has passed strict safety tests and will not explode even in the worst traffic accidents, showing higher safety performance.

Lead-acid batteries:

  • Lead-acid batteries are generally deep-charged and discharged within 300 times, have memory, and have a lifespan of about two years. And there is liquid in the lead-acid battery, after a period of consumption, if the battery is found to be hot or the charging time becomes shorter, you need to replenish the liquid. To
  • Generally, the weight of lead-acid batteries is 16-30 kg, and the volume is relatively large;
  • There is a large amount of lead in lead-acid batteries. If they are not handled properly after being discarded, they will pollute the environment and cause pollution during the production process. To
  • The nominal voltage of a lead-acid battery is 2V, and the voltage of an ordinary lead-acid battery is usually 12V.

12v lithium battery 02 - manly

Comparison Table: LiFePO4 vs. Lead Acid Battery

Feature LiFePO4 Battery Lead Acid Battery
Energy Density High energy density, more power per unit weight. Lower energy density.
Weight Lighter, making them more suitable for portable applications. Heavier, less suitable for applications where weight is a concern.
Cycle Life Typically 2000 – 5000 cycles or more. Around 300 – 500 cycles.
Efficiency High efficiency, around 85-95%. Lower efficiency, about 80-85%.
Charge Time Fast charging capability. Slower charging compared to LiFePO4.
Operating Temperature Range Wider operating temperature range. More limited temperature range, performance declines in extreme temperatures.
Maintenance Low maintenance, no need for regular watering. Requires regular maintenance like watering and equalization.
Safety Generally safer, more stable chemistry, lower risk of thermal runaway. Risk of acid spills and gas emissions, requires careful handling.
Environmental Impact Environmentally friendlier, contains no heavy metals. Contains lead, a toxic heavy metal, requires careful disposal.
Lifespan Longer lifespan, can last up to 5 years or more. Shorter lifespan, typically 3-5 years.
Cost Over Life Cycle Initially more expensive but cost-effective over its life cycle. Cheaper initially but less cost-effective in the long run due to shorter lifespan and maintenance.

MANLY LiFePO4 Battery vs Other Brands LiFePO4 Battery

MANLY LiFePO4 Batteries stand out in the competitive battery market with their robust combination of innovation, quality, and versatility. Backed by over 13 years of expertise, these batteries, hailing from China’s technological hubs, offer unparalleled customization, catering to diverse applications from solar energy storage to advanced robotics. Unlike standard LiFePO4 batteries, MANLY Batteries boast a remarkable 98% energy efficiency rate, enhanced safety features, and global certifications like UN38.3, IEC62133, UL, and CE. Their commitment to durability and user experience is further exemplified by features like Bluetooth connectivity and intuitive displays. This focus on consumer-centric innovation and superior performance makes MANLY Batteries a leading choice for those seeking reliable, high-quality battery solutions, distinctly setting them apart from other brands in the market.

Feature MANLY LiFePO4 Battery Other Brands LiFePO4 Battery
Key Competitive Advantage
  • 13 years of battery industry experience
  • Stable quality
  • Ample production capacity
  • Competitive pricing
  • Fast delivery
  • Excellent after-sales service
  • Customizable products to meet customer needs
  • Main industries: Solar energy, residential/industrial storage, various robots, base stations, solar street lights, UPS etc.
  • Popular brands: High quality, Expensive, no customizable, Limited industry applications
  • Generic brands: Poor quality, Cheap, no after-sales support, Limited industry applications
Customization Options Offers customization in voltage, capacity, current, dimensions, aesthetics, etc. Customization varies by manufacturer; not all offer extensive options.
Certifications Boasts UN38.3, IEC62133, UL, CE, among others. Certification depends on the manufacturer; common ones include CE, UL.
Warranty 10-year warranty. Warranty periods vary, typically around 1-5 years.
Protection Features Includes short circuit, overcharge/discharge, balancing circuits, overvoltage/overcurrent, and safety against explosion or ignition. Standard protections include overcharge/discharge, short circuit, and temperature control.
Operating Conditions Operates in -20°C to 75°C. (Advised not to charge below 0°C) Operating temperature ranges vary, typically -10°C to 60°C.
Efficiency Rate Energy efficiency rate of 98%. Efficiency rates vary, typically around 85-95%.
Enhanced Features Optional BMS, Bluetooth connectivity and battery level display. Additional features vary by model and manufacturer.
Waterproof Up to IP67 waterproof rating (depends on the customer’s waterproof requirements for the product) Not all productions have waterproof
Lifespan Lifespan of 8000+ cycles , typically 10-20 years (Longevity relies on MANLY’s expert R&D team) Lifespan varies, typically 5-10 years depending on usage and maintenance.

Unlocking the Potential of Lithium Batteries Across Industries

Let’s delve into the various industries where lithium batteries shine as the preferred power source:

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Cold Weather Battery Guide: Top Picks for 2023

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Choosing The Right Battery for Electric Scooter

Marine battery - manly

Best Lithium Marine Battery: Guide to Selecting in 2023

Golf cart battery - manly

The 6 Best Lithium Golf Cart Batteries

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Six Important Parameters of Lithium Batteries

Battery charge level indicators isolated on white. Charging. 3d - manly

1. Battery capacity

Generally the capacity of the battery is determined by the amount of active material in the battery, usually expressed in milliampere-hour mAh or Ah. For example, 1000 mAh can be discharged for 1 h with a current of 1 A.

1.1 Understanding Battery Capacity: Rated vs. Actual vs. Theoretical

Battery capacity can be categorized into actual capacity, theoretical capacity, and rated capacity, based on different conditions.

The capacity that a battery provides when discharged at a particular discharge rate at 25°C down to its terminal voltage is defined as the battery’s capacity during design and production. This is termed the rated capacity for a given discharge rate RH.

Battery capacity is typically measured in AH (Ampere-hours). Another method of measurement is in terms of CELL (per unit plate) in watts (W/CELL).

  1. For Ah (Ampere-hours) calculations, you take the discharge current (constant current) I and multiply it by the discharge time (in hours) T. For instance, a 7AH battery discharged continuously at 0.35A can last for approximately 20 hours.
  2. The standard charging time is 15 hours, and the charging current is 1/10 of the battery’s capacity. Fast charging may reduce the battery’s lifespan.

Battery capacity refers to the size of the stored electrical charge in a battery. The unit for battery capacity is “mAh”, known in Chinese as milliampere-hours. For larger capacity batteries, such as lead-acid batteries, “Ah” (Ampere-hours) is generally used for convenience, where 1Ah = 1000mAh. If a battery has a rated capacity of 1300mAh, and you discharge the battery with a current of 130mA, the battery can operate for about 10 hours (1300mAh/130mA = 10h). If the discharge current is 1300mA, then the operational time drops to around 1 hour. These calculations assume ideal conditions, and actual device operation may vary based on components, like an LCD screen or flash in a digital camera, which can cause large variations in current. Hence, the actual operational time for a device powered by the battery can only be approximated, usually based on real-world experience.

1.2 Unit of Capacity

Typically, battery capacity is measured in ampere-hours (Ah), and this is determined for a specific battery in mind. For instance, the question might be: What’s the capacity of this smartphone battery? Or, what’s the capacity of this electric scooter battery? These queries are unique to each battery. When the battery voltage is already defined and one isn’t considering the real-time voltage, merely stating the ampere-hours can represent the battery’s capacity.

However, when dealing with batteries of different voltages, one can’t simply rely on ampere-hours to denote capacity. Take, for instance, a MANLY 12V 20AH battery and a MANLY 15V 20AH battery. Even though both have 20AH, when powering a device with the same load, the device will work just fine, but the duration of operation will differ. Hence, the standard capacity should be measured in terms of power.

To illustrate further, consider a device that can support both 12V and 24V. If powered by a MANLY 12V 20AH battery, it can last for one hour. However, if two such batteries are connected in series, resulting in 24V 20AH, the ampere-hours remain unchanged, but the operational time doubles. In this context, the capacity should be viewed in terms of the power the battery can hold, not just the ampere-hours.

Power (W) = Power (P) * Time (T) = Current (I) * Voltage (U) * Time (T).

This approach to discussing battery capacity is more meaningful. One must be realistic and factual; otherwise, you might end up with the illogical claim that a smartphone battery has a larger capacity than an electric scooter battery, which is clearly unscientific.

12v 100ah battery - manly

2. Nominal voltage

The potential difference between the positive and negative electrodes of the battery is called the nominal voltage of the battery. The nominal voltage is determined by the electrode potential of the plate material and the concentration of the internal electrolyte. The discharge diagram of lithium battery is parabolic, with 4.3V dropping to 3.7V and 3.7V dropping to 3.0V, both of which change rapidly. Only the discharge time of about 3.7V is the longest, accounting for almost 3/4 of the time, so the nominal voltage of the lithium battery refers to the voltage that maintains the longest discharge time.

  1. Ternary Lithium Battery

The nominal voltage of a ternary lithium cell is 3.6V, with an operating voltage range between 2.5V and 4.2V. For a battery pack, you multiply the voltage by the number of cells in series. For instance, for a 10-series ternary lithium battery pack, the nominal voltage stands at 36V, and the working voltage range spans from 25V to 42V.

  1. Lithium Iron Phosphate Battery

The nominal voltage of a lithium iron phosphate cell is 3.2V, with an operational voltage range of 2.0V to 3.65V. Similarly, for the corresponding battery pack, you multiply by the number of cells in series. For example, a 15-series lithium iron phosphate battery pack has a nominal voltage of 48V, with a working voltage range of 30V to 54.75V.

So, what are the implications of a low voltage for lithium batteries?

It’s recommended that lithium batteries be stored long-term with about 70% of their charge. If not in use for 3 to 6 months, it’s advisable to cycle through one full charge and discharge. This benefits the overall lifespan of the battery pack.

If stored for extended periods without use and at very low voltages, the materials in the lithium battery can be adversely affected. Their chemical reactivity might deteriorate, which in turn impacts the battery pack’s lifespan.

Lithium-ion batteries operate at voltages ranging from 2.5V to 4.2V. When the voltage drops below 2.5V, the battery discharge terminates, and due to the closing of the discharge circuit, the current loss of the internal protection circuit drops to its lowest. However, in real-world applications, due to variations in internal materials, the discharge termination voltage can range from 2.5V to 3.0V. When the voltage exceeds 4.2V, the charging circuit is terminated to ensure the battery’s safety.

3. Charge termination voltage

When the rechargeable battery is fully charged, the active material on the electrode plate has reached a saturated state, and the battery voltage will not rise when the battery continues to be charged. The voltage at this time is called the end-of-charge voltage. The ternary lithium battery is 4.2V, and the lithium iron phosphate battery is 3.65V.

12v lithium battery - manly

4. Discharge termination voltage

The end-of-discharge voltage refers to the lowest voltage allowed when the battery is discharged. The discharge termination voltage is related to the discharge rate.

5. Internal resistance of the battery

The internal resistance of the battery is determined by the resistance of the electrode plate and the resistance of the ion flow. During the charging and discharging process, the resistance of the image engine and the electrode plate is unchanged, but the resistance of the ion flow will increase or decrease with the concentration of the electrolyte and the charged ions. And change. When the OCV voltage of a lithium battery decreases, the impedance will increase. Therefore, when charging at low power (less than 3V), pre-charge (trickle charging) must be carried out first to prevent too much current from causing excessive heat generation of the battery.

Composition of Lithium Battery Internal Resistance

Ohmic resistance mainly arises from the electrode materials, electrolyte, separator resistance, as well as the contact resistance of current collectors and tab connections. It’s related to the battery’s size, structure, and connection methods.

Polarization resistance, which emerges instantly when current is applied, represents the cumulative tendency of various barriers inside the battery preventing charged ions from reaching their destinations. This resistance can be further categorized into electrochemical polarization and concentration polarization.

Currently, the standout 18650 lithium battery has an internal resistance of around 12 milliohms, while typical ones hover between 13 to 15 milliohms. Given that impedance can affect the battery’s performance, generally speaking, 50 milliohms is deemed normal. Between 50 to 100 milliohms, the battery remains functional, but performance starts to degrade. When exceeding 100 milliohms, parallel use is necessary, and anything above 200 milliohms is virtually unusable.

Impacts of Lithium Battery Internal Resistance

All factors that impede the movement of lithium ions and electrons from one pole to another within the lithium battery contribute to its internal resistance. Ideally, the lower the internal resistance, the better. A higher internal resistance leads to increased thermal losses, preventing high current discharge. Moreover, a high internal resistance means the battery heats up during use. Elevated temperatures can cause the battery’s discharge operating voltage to drop and its discharge duration to shorten, severely affecting battery performance and lifespan. In extreme cases, this can even pose a risk of spontaneous combustion.

6. Self-discharge rate

It refers to the percentage of the total capacity that is automatically lost when the battery is not in use for a period of time. Generally, the self-discharge rate of lithium-ion batteries at room temperature is 5%-8%.

6.1 How Does the Discharge Rate Affect Battery Capacity?

The discharge rate directly impacts a battery’s effective capacity. Specifically, a higher discharge rate can decrease the available capacity, as the battery might not be able to maintain its maximum rated capacity during rapid discharges. Thus, when evaluating a battery’s usable capacity, the discharge rate must be taken into account.

6.2 What is the Discharge Rate of Electric Bicycle Batteries?

The discharge rate of electric bicycle batteries can vary based on the specific battery chemistry and design. Electric bikes typically employ lithium-ion batteries due to their high energy density and performance. These batteries generally demonstrate a discharge rate ranging from 1C to 4C or even higher. To illustrate, a 1Ah battery with a 10C discharge rate can deliver a continuous discharge current of 10 amps, whereas a 4C rate would allow for a continuous discharge current of 40 amps.

6.3 What is Considered a High Discharge Rate for Lithium Batteries?

For lithium batteries, a discharge rate typically considered “high” starts at 1C and above. However, it’s important to note that what’s deemed as a high specific discharge rate may vary based on the battery’s design, chemical composition, and intended application.

6.4 What is a Good Discharge Rate for Batteries?

An optimal C-rate for a battery hinges on the specific demands of its application. Typically, a discharge rate that facilitates efficient power transfer without overly stressing the battery is regarded as favorable. It’s recommended to consult the manufacturer’s specifications and guidelines to ascertain the best discharge rate for a particular battery.

6.5 How Do You Calculate the C-rate?

C-rate (C) = Charging or discharging current in amperes (A) / Battery’s rated capacity (Ah)

Let’s delve into an example involving a 100Ah lithium battery:

1C represents a discharge current of 100 amps, meaning the battery can provide a continuous discharge of 100 amps for one hour. In simpler terms, it can handle a load current of 100 amps for 60 minutes.

If we boost the C-rate to 2C, the discharge current becomes 200 amps. This signifies that the battery can now furnish a discharge current of 200 amps, but for a reduced duration. At a 2C rate, the battery can sustain a load current of 200 amps for 30 minutes or half an hour.

On the other hand, reducing the C-rate to 0.5C results in a discharge current of 50 amps. At a 0.5C rate, the battery can deliver a discharge current of 50 amps, thereby prolonging the discharge period. Under these conditions, the battery can support a load current of 50 amps for 2 hours or 120 minutes.

When assessing the performance and capacity of lithium batteries, the C-rate stands out as a crucial factor since it determines both the available discharge current and the corresponding discharge duration.

Six important parameters of lithium batteries - manly

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Lithium battery PCM principle

Pcm - manly

The reason why lithium batteries need protection is determined by their own characteristics. Since the material of the lithium battery itself determines that it cannot be overcharged, overdischarged, overcurrent, short circuited, and ultra-high temperature charge and discharge, the lithium battery components of the lithium battery will always appear with an exquisite protection board.

Ordinary lithium battery protection boards usually include control ICs, MOS switches, resistors, capacitors and auxiliary devices FUSE, PTC, NTC, ID, memory, etc. Among them, the control IC controls the MOS switch to turn on under all normal conditions to make the cell and the external circuit conduct, and when the cell voltage or loop current exceeds the specified value, it immediately controls the MOS switch to turn off to protect the cell’s Safety.

When the protection board is normal, Vdd is high, Vss and VM are low, DO and CO are high. When any parameter of Vdd, Vss, VM is changed, the level of DO or CO will be Changes.
1. Overcharge detection voltage: Under normal conditions, Vdd gradually rises to the voltage between VDD and VSS when the CO terminal changes from high level to low level.
2. Overcharge release voltage: In the charging state, Vdd gradually decreases to the voltage between VDD and VSS when the CO terminal changes from low level to high level.
3. Overdischarge detection voltage: Under normal conditions, Vdd gradually decreases to the voltage between VDD and VSS when the DO terminal changes from high level to low level.
4. Overdischarge release voltage: In the overdischarge state, Vdd gradually rises to the voltage between VDD and VSS when the DO terminal changes from low level to high level.
5. Overcurrent 1 detection voltage: Under normal conditions, VM gradually rises to the voltage between VM and VSS when DO changes from high level to low level.
6. Overcurrent 2 detection voltage: In the normal state, VM rises from OV to the voltage between VM and VSS when the DO terminal changes from high to low at a speed of 1ms or more and 4ms or less.
7. Load short-circuit detection voltage: Under normal conditions, VM starts from OV and rises to the voltage between VM and VSS when the DO terminal changes from high level to low level at a speed of 1μS or more and 50μS or less.
8. Charger detection voltage: In the over-discharge state, VM gradually decreases with OV to the voltage between VM and VSS when DO changes from low level to high level.
9. Current consumption during normal operation: Under normal conditions, the current (IDD) flowing through the VDD terminal is the current consumption during normal operation.
10. Over-discharge current consumption: In the discharging state, the current (IDD) flowing through the VDD terminal is the over-current discharge current consumption.

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