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EVolve Battery Systems
Document: User Manual
Product: Lithium Block™ GEN2
Revision: J
Date: January 2025
Part Number: LB-GEN2-MAN-REVJ
Lithium Block™ GEN2
User Manual
Wire-Bonded Lithium-Ion Battery Module — 18650 Cell Format
🔋
Lithium Block™ GEN2 Module
Document Information
Manual Revision: J
Product Version: GEN2
Effective Date: January 2025
Classification: Customer Use
Language: English
Pages: Multi-page
Table of Contents
- 1. Introduction & Safety
- 2. Product Overview
- 3. Technical Specifications
- 4. Mechanical Design
- 5. Electrical Interface
- 6. Wire-Bond Technology
- 7. Installation Guidelines
- 8. Operating Procedures
- 9. Maintenance & Service
- 10. Troubleshooting
- 11. Safety & Compliance
- 12. Warranty & Support
- Appendix A: Connector Pinouts
- Appendix B: Revision History
1. Introduction & Safety
1.1 Welcome
Thank you for choosing the Lithium Block™ GEN2 module from EVolve Battery Systems. This manual provides comprehensive information for safe installation, operation, and maintenance of your battery module.
⚠️ Critical Safety Information
READ ALL SAFETY INFORMATION BEFORE HANDLING OR INSTALLING
- DANGER: System integrations can produce lethal voltages. Keep tools, fingers, and foreign objects away from conductive surfaces.
- WARNING: Do not operate without an appropriately configured BMS. Doing so risks catastrophic failure and voids warranty.
- Only qualified personnel should handle, install, or service these modules.
- Always use appropriate PPE including safety glasses, insulated gloves, and protective clothing.
- Never short circuit the terminals or allow conductive materials to bridge connections.
- Ensure adequate ventilation and fire suppression systems are in place.
Failure to follow safety procedures can result in serious injury, death, or property damage.
1.2 Intended Use
The Lithium Block™ GEN2 is designed for integration into battery packs for:
- Electric vehicle applications
- Energy storage systems
- Aerospace and defense platforms
- Industrial automation and robotics
- Research and development projects
- Marine and off-grid applications
1.3 Qualifications Required
- Training in lithium-ion battery safety
- Understanding of electrical systems and high-voltage safety
- Familiarity with applicable codes and standards
- Access to appropriate tools and safety equipment
2. Product Overview
2.1 Product Description
The Lithium Block™ GEN2 is a wire-bonded lithium-ion battery module engineered for reliability, scalability, and safety. Each module contains high-performance 18650 lithium-ion cells connected via ultrasonic wire-bonding technology, providing superior electrical and thermal behavior compared to traditional welded connections.
Design Philosophy
- Modular architecture for flexible scaling
- Wire-bond redundancy for enhanced safety
- Integrated monitoring and sensing
- Manufacturing-ready design
Key Advantages
- Lower thermal stress during assembly
- Graceful failure modes
- Simplified rework and service
- Consistent quality and performance
2.2 Available Configurations
The Lithium Block™ GEN2 is available in two optimized variants:
Energy Modules
Optimized for: Maximum energy density and cycle life
Applications: Long-duration discharge, energy storage, range-focused EVs
Configurations: 5P, 6P, 7P, 8P, 9P, 10P
Power Modules
Optimized for: High power output and fast charging
Applications: High-performance EVs, power tools, aerospace
Configurations: 5P, 6P, 7P, 8P, 9P, 10P
2.3 Wire-Bond Technology Overview
⚡
Wire-Bonding Process
Ultrasonic bonding creates reliable, low-resistance connections
3. Technical Specifications
3.1 Energy Module Specifications
| Parameter | 5P Energy | 6P Energy | 7P Energy | 8P Energy | 9P Energy | 10P Energy | Units |
|---|---|---|---|---|---|---|---|
| Part Number | LBG2-05E | LBG2-06E | LBG2-07E | LBG2-08E | LBG2-09E | LBG2-10E | — |
| Energy Capacity | 63 | 75 | 88 | 100 | 113 | 125 | Wh |
| Charge Capacity | 17.5 | 21 | 24.5 | 28 | 31.5 | 35 | Ah |
| Nominal Voltage | 3.6 | 3.6 | 3.6 | 3.6 | 3.6 | 3.6 | V |
| Maximum Voltage | 4.2 | 4.2 | 4.2 | 4.2 | 4.2 | 4.2 | V |
| Minimum Voltage | 2.5 | 2.5 | 2.5 | 2.5 | 2.5 | 2.5 | V |
| Standard Charge Current | 8.5 | 10.2 | 11.9 | 13.6 | 15.3 | 17 | A |
| Maximum Charge Current | 8.5 | 10.2 | 11.9 | 13.6 | 15.3 | 17 | A |
| Maximum Discharge Current | 50 | 60 | 70 | 80 | 90 | 100 | A |
| Length (approx.) | 119 | 138 | 157 | 177 | 196 | 215 | mm |
| Mass (approx.) | 317 | 374 | 431 | 487 | 544 | 601 | g |
3.2 Power Module Specifications
| Parameter | 5P Power | 6P Power | 7P Power | 8P Power | 9P Power | 10P Power | Units |
|---|---|---|---|---|---|---|---|
| Part Number | LBG2-05P | LBG2-06P | LBG2-07P | LBG2-08P | LBG2-09P | LBG2-10P | — |
| Energy Capacity | 52 | 62 | 72 | 82 | 93 | 103 | Wh |
| Charge Capacity | 14 | 16.8 | 19.6 | 22.4 | 25.2 | 28 | Ah |
| Nominal Voltage | 3.6 | 3.6 | 3.6 | 3.6 | 3.6 | 3.6 | V |
| Maximum Voltage | 4.2 | 4.2 | 4.2 | 4.2 | 4.2 | 4.2 | V |
| Minimum Voltage | 2.5 | 2.5 | 2.5 | 2.5 | 2.5 | 2.5 | V |
| Standard Charge Current | 14 | 16.8 | 19.6 | 22.4 | 25.2 | 28 | A |
| Maximum Charge Current | 30 | 36 | 42 | 48 | 54 | 60 | A |
| Maximum Discharge Current | 175 | 210 | 210 | 210 | 210 | 210 | A |
| Length (approx.) | 119 | 138 | 157 | 177 | 196 | 215 | mm |
| Mass (approx.) | 317 | 374 | 431 | 487 | 544 | 601 | g |
3.21 Subcomponent Identification
3.22 General Module Information
| Item | Detail | Notes / Standard |
|---|---|---|
| Included Accessories | Mating LV connector + contacts | Bus bars & fasteners sold separately |
| Electrical Conductor Spacing | Designed to IEC requirements | IEC 60664 |
| PCB Standards (where applicable) | IPC Class II | Manufacturing & inspection |
| Cell Jacket Material | PET | — |
| Cell Insulator Ring | PC | — |
| Max System Voltage | 500 V DC | Module intended for segmented packs |
| Approx. Wire-Bond Fuse Rating | ~58 A (Power), ~30 A (Energy) | Per-bond median values |
4. Mechanical Design
4.1 Understanding Your Part Number
There are 36 different Lithium Block™ part numbers. The part number convention is as follows:
LBG(n)-(xx)(y)
- LB = Lithium Block (present in all modules)
- G(n) = Product generation (G1 legacy without PCBs, G2 with PCBs)
- (xx) = Parallel configuration (05–10). Example: “06” for a 6P module
- (y) = Cell type designator: E for Energy, P for Power
4.2 Physical Dimensions
Standard Envelope
Height: 65 mm (fixed) | Width: 65 mm (fixed)
Length: Variable by parallel count (see specifications)
Mounting Features
- M4 threaded inserts on both endplates
- Mounting span: 55 mm center-to-center
- Torque specification: 3–4 Nm
- Recommended fasteners: M4 × 12 mm SHCS
4.3 Enclosure Materials
| Component | Material | Properties | Standards |
|---|---|---|---|
| Main Housing | Glass-filled Nylon | High strength, chemical resistant | UL V-0 option available |
| Endplates | Aluminum 6061-T6 | Structural support, heat dissipation | Anodized finish |
| Threaded Inserts | Stainless Steel 316 | Corrosion resistant | M4 × 0.7 thread |
| Gaskets/Seals | EPDM Rubber | Environmental sealing | IP54 rating |
4.4 Thermal Design
| Component/Property | Specification |
|---|---|
| Thermistors | 10 kΩ ±0.5% NTC type |
| Thermal Contact Material Used | Scotch-Weld™ EC 2216 |
| Thermal Contact Material Conductivity | 0.395 W/(m·K) |
| Thermal Contact Material Thickness | ~1.5 mm |
5. Electrical Interface
5.1 Power Connections
High Voltage Terminals
Positive Terminal: M6 threaded stud, copper alloy
Negative Terminal: M6 threaded stud, copper alloy
Torque Specification: 8–10 Nm
Recommended Hardware: M6 ring terminals, copper or tinned copper
5.2 Sense Harness
Monitoring Connections
Sense Harness Family: JST GH series (cell voltage & thermistors)
Temperature Sensing: Integrated NTC thermistors
Wire Gauge: 26–24 AWG
5.3 Thermistor Specifications & Locations
| Parameter | Specification | Tolerance | Notes |
|---|---|---|---|
| Resistance @ 25 °C | 10 kΩ | ±0.5% | NTC type |
| Beta Value | 3380 K | ±1% | 25 °C to 85 °C |
| Maximum Voltage | 5 V | — | Measurement circuit |
| Response Time | 5 s | — | 63% of step change |
| Operating Range | −40 °C to +125 °C | — | Sensor range |
| Quantity per Module | 5P/6P: 3; 7P/8P/9P: 4; 10P: 5 | — | |
| Placement | Adhered to 18650 cell can | — | ~4.77 mm above base; first at ~17.80 mm from PCB edge; ~40.14 mm pitch |
5.4 LV Connector (Board)
Connector Details
Board Connector: Molex 430450812 (8-position)
Mating Connector: Molex 43025-0800
Crimp Terminals: Molex 43030-0007
Wire Gauge: 26–24 AWG
See Appendix A for complete pinout diagrams and wiring instructions.
5.22 GEN2 PCB Specs
| Parameter | Specification | Notes / PN |
|---|---|---|
| Board Class | IPC Class II | Conformance & inspection |
| Creepage/Clearance | Per IEC 60664 | Conductor spacing standard |
| Thermistor Type | 10 kΩ NTC, β=3380 K | ±0.5% @25 °C |
| Max Thermistor Voltage | 5 V | — |
| Voltage Sense Fuse | PTC Resettable 200 mA | 0ZCK0020FF2G |
| LV Connector (Board) | Molex 430450812 | — |
| Mating Connector | Molex 43025-0800 | Crimp 43030-0007 |
| Bus Bar Thread Class | M6 × 1 mm | — |
| Unfused Sense Lead | <10 mm | Keep minimal length |
6. Wire-Bond Technology
6.1 Process Overview
EVolve Battery Systems employs ultrasonic wire-bonding to create electrical connections between lithium-ion cells. This solid-state process offers significant advantages over fusion welding methods.
How Ultrasonic Wire-Bonding Works
- Preparation: Cell terminals are cleaned and prepared for bonding
- Positioning: Aluminum wire or ribbon is positioned on the terminal
- Bonding: Ultrasonic energy creates a solid-state metallurgical bond
- Loop Formation: Wire is formed into a compliant loop
- Second Bond: Wire is bonded to the next terminal, completing the connection
6.2 Technical Advantages
Process Benefits
- No molten metal phase
- Minimal heat input to cells
- No spatter or contamination
- Highly repeatable process
- Excellent automation compatibility
Performance Benefits
- Low electrical resistance
- High mechanical compliance
- Excellent fatigue resistance
- Predictable failure modes
- Individual bond redundancy
6.3 Safety Features
Wire-Bond Fusing Characteristics
Individual wire bonds exhibit fuse-like behavior under overcurrent conditions:
- Power Modules: ~58 A per-bond (median)
- Energy Modules: ~30 A per-bond (median)
- Multiple Bonds: Current sharing provides redundancy
- Graceful Degradation: Individual bond failure doesn’t cause catastrophic failure
Fuse sizing (FSAE): Size the main pack fuse ≤ 120% of cumulative parallel-module rating and typically ≤ ~⅓ of total theoretical bond current.
6.4 Quality Control
- Automated pull and shear testing per MIL-STD-883
- Inline process monitoring and data logging
- Visual inspection under magnification
- Electrical continuity and resistance verification
- Statistical process control and traceability
7. Installation Guidelines
7.1 Pre-Installation Checklist
⚠️ Before You Begin
- Verify all personnel are trained and qualified
- Ensure proper PPE is available and worn
- Confirm adequate ventilation and fire suppression
- Have emergency procedures and contacts ready
- Verify tools are insulated and in good condition
- Check that work area is clean and organized
7.2 Unpacking and Inspection
- Visual Inspection: Check packaging for damage during shipping. Report any damage to carrier and EVolve Battery Systems immediately.
- Module Inspection: Examine module for physical damage, cracks, or deformation. Do not use if any damage is observed.
- Connector Check: Verify all connectors are intact and properly seated. Check for bent pins or damaged housings.
- Documentation Review: Confirm all documentation, test reports, and certificates are included with shipment.
7.3 Mechanical Installation
- Mounting Preparation: Ensure mounting surface is flat, clean, and properly grounded. Verify mounting hole alignment.
- Thermal Interface: Apply thermal interface material if using cold plates or enhanced heat dissipation.
- Module Placement: Carefully position module ensuring proper alignment with mounting holes and clearance for connections.
- Fastening: Install M4 fasteners with specified torque (3–4 Nm). Use thread locker if specified in system requirements.
7.4 Electrical Installation
- Power Connections: Install ring terminals on power cables. Ensure proper crimp and insulation. Torque to 8–10 Nm.
- Sense Harness: Connect monitoring harness ensuring proper pin alignment. Verify secure connection with gentle pull test.
- Insulation Test: Perform insulation resistance test between HV terminals and chassis ground (minimum 1 MΩ at 500 V DC).
- Continuity Check: Verify electrical continuity through power path and proper sensor readings.
7.5 System Integration
BMS Integration Requirements
- Cell Monitoring: Individual cell voltage and temperature monitoring
- Balancing: Active or passive cell balancing capability
- Protection: Overvoltage, undervoltage, overcurrent, overtemperature
- Communication: CAN bus or other protocol for system integration
Pack-level fuse: Required. Max rating < 120% of cumulative parallel-module rating.
8. Operating Procedures
8.1 Initial Commissioning
- Pre-Commissioning Checks: Verify all connections, insulation resistance, and BMS configuration.
- Initial Charge: Perform initial charge cycle at reduced rate (C/10) while monitoring all parameters.
- Capacity Test: Conduct capacity verification test to confirm module performance meets specifications.
- System Validation: Test protection functions and emergency shutdown procedures.
8.2 Normal Operation
Charging Guidelines
- Use CC-CV charging profile
- Respect maximum charge current limits
- Monitor temperature during charging
- Terminate charge at 4.2 V per cell
- Allow thermal equilibration
Discharge Guidelines
- Monitor current and temperature
- Respect continuous current limits
- Implement low-voltage cutoff at 2.5 V
- Avoid deep discharge conditions
- Monitor for fault conditions
8.3 Monitoring Parameters
| Parameter | Normal Range | Warning Level | Alarm Level | Action Required |
|---|---|---|---|---|
| Cell Voltage | 3.0–4.1 V | 2.8 V / 4.15 V | 2.5 V / 4.2 V | Reduce current / Stop |
| Module Temperature | 10–45 °C | 50 °C | 60 °C | Reduce current / Stop |
| Charge Current | 0 – Std Rate | 110% Std | 120% Std | Reduce / Stop charging |
| Discharge Current | 0 – Cont Rate | 110% Cont | 120% Cont | Reduce / Stop discharge |
| Voltage Imbalance | < 50 mV | 100 mV | 200 mV | Balance / Service |
8.4 Emergency Procedures
🚨 Emergency Response
Thermal Runaway Signs
- Rapid temperature rise
- Visible smoke or vapor
- Unusual odors
- Swelling or deformation
- Sparking or arcing
Immediate Actions
- Disconnect power immediately
- Evacuate personnel from area
- Activate fire suppression if available
- Contact emergency services
- Notify EVolve Battery Systems
9. Maintenance & Service
9.1 Routine Maintenance
Recommended Maintenance Schedule
| Interval | Maintenance Task | Personnel Required |
|---|---|---|
| Weekly | Visual inspection, parameter logging | Operator |
| Monthly | Connection torque check, cleaning | Technician |
| Quarterly | Capacity test, insulation test | Qualified Technician |
| Annually | Complete system inspection, documentation update | Engineer |
9.2 Inspection Procedures
- Visual Inspection: Check for physical damage, corrosion, loose connections, or signs of overheating. Document any anomalies.
- Electrical Testing: Measure insulation resistance, connection resistance, and verify sensor functionality.
- Performance Testing: Conduct capacity and internal resistance measurements to assess module health.
- Documentation: Record all measurements and observations in maintenance log. Compare to baseline values.
9.3 Cleaning Procedures
Approved Cleaning Methods
Exterior Surfaces: Use dry cloth or slightly damp cloth with isopropyl alcohol (70% max)
Terminals: Use contact cleaner and fine abrasive pad if necessary
Connectors: Use compressed air and contact cleaner. Ensure completely dry before reconnection
NEVER use water, solvents, or aggressive chemicals. Always disconnect power before cleaning.
9.4 Storage Guidelines
Short-Term Storage (< 6 months)
- Store at 30–50% state of charge
- Temperature: 15–25 °C preferred
- Humidity: <60% RH
- Check voltage monthly
Long-Term Storage (> 6 months)
- Store at ~40% state of charge
- Temperature: 15–20 °C preferred
- Check and recharge every 6 months
- Maintain detailed storage log
10. Troubleshooting
10.1 Common Issues and Solutions
| Symptom | Possible Cause | Recommended Action | Contact Support |
|---|---|---|---|
| Low capacity | Cell aging, temperature, imbalance | Check temperature, balance cells | If <80% rated capacity |
| High temperature | Overcurrent, poor cooling, fault | Reduce current, check cooling | If >60 °C sustained |
| Voltage imbalance | Cell mismatch, BMS issue | Check BMS balancing function | If >200 mV difference |
| High resistance | Connection issue, aging | Check connections, clean terminals | If >2× initial value |
| Sensor error | Connector issue, wire damage | Check harness connections | If persistent errors |
10.2 Diagnostic Procedures
Basic Diagnostic Tests
- Voltage Measurement: Measure individual cell voltages and module voltage
- Temperature Check: Verify thermistor readings across all sensors
- Insulation Test: Measure insulation resistance to ground (>1 MΩ required)
- Connection Resistance: Measure resistance across power connections
- Capacity Test: Perform controlled discharge to measure actual capacity
10.3 When to Contact Support
⚠️ Contact EVolve Battery Systems Immediately If:
- Any signs of thermal runaway or overheating
- Physical damage to module housing or terminals
- Capacity drops below 80% of rated value
- Persistent voltage imbalances >200 mV
- Unusual odors, smoke, or visible damage
- Any safety-related concerns
Emergency Contact: (720) 414-5502 | Email: support@evolvebattery.us
11. Safety & Compliance
11.1 Safety Standards
The Lithium Block™ GEN2 is designed to support compliance with relevant safety standards:
| Standard | Application | Compliance Level | Notes |
|---|---|---|---|
| UN 38.3 | Transport safety | Module level | Test report available |
| IEC 62133 | Cell safety | Cell level | Cell manufacturer cert |
| UL 1973 | Stationary storage | System level | Pack integration required |
| IEC 62619 | Industrial batteries | System level | Pack integration required |
| ISO 12405 | EV applications | System level | Vehicle integration required |
11.2 Material Compliance
Environmental Compliance
- RoHS: Compliant with EU RoHS directive
- REACH: No substances of very high concern (SVHC)
- Conflict Minerals: Responsible sourcing practices
- Recycling: Materials selected for end-of-life recycling
11.3 Safety Architecture
Multi-Layer Safety Design
Cell Level
- Current Interrupt Device (CID)
- Pressure relief vent
- Thermal shutdown
- Internal safety circuits
Module Level
- Wire-bond fusing behavior
- Temperature monitoring
- Mechanical strain relief
- UL V-0 materials
System Level
- BMS protection
- Pack-level fusing
- Isolation monitoring
- Emergency shutdown
11.4 Hazard Analysis
| Hazard | Risk Level | Mitigation | Detection Method |
|---|---|---|---|
| Thermal runaway | High | Temperature monitoring, current limiting | Temperature sensors, BMS |
| Overcharge | High | Voltage monitoring, charge control | Cell voltage monitoring |
| Overdischarge | Medium | Low voltage cutoff | Cell voltage monitoring |
| Overcurrent | Medium | Current limiting, fusing | Current sensors, wire-bond fusing |
| Short circuit | High | Fusing, isolation | Current sensors, voltage monitoring |
| Mechanical damage | Medium | Proper handling, mounting | Visual inspection |
12. Warranty & Support
12.1 Limited Warranty
Warranty Coverage
EVolve Battery Systems warrants the Lithium Block™ GEN2 modules to be free from defects in materials and workmanship under normal use for a period of 12 months from the date of shipment.
Covered Items
- Manufacturing defects
- Material failures
- Wire-bond integrity
- Connector defects
- Enclosure issues
Exclusions
- Misuse or abuse
- Operation outside specifications
- Unauthorized modifications
- Normal wear and aging
- Damage during shipping
12.2 Technical Support
Support Services Available
- Technical Consultation: Application engineering support
- Integration Assistance: BMS selection and configuration guidance
- Troubleshooting Support: Remote and on-site diagnostic assistance
- Training Services: Safety and operation training programs
- Documentation: Additional technical documentation and updates
12.3 Return Material Authorization (RMA)
- Contact Support: Call (720) 414-5502 or email support@evolvebattery.us with issue details and module serial number.
- RMA Number: Obtain RMA number and return instructions. Do not return any product without prior authorization.
- Packaging: Use original packaging if available, or equivalent protection. Follow all hazmat shipping requirements.
- Documentation: Include RMA number, description of issue, and any relevant test data or logs.
Appendix A: Connector Pinouts
A.1 LV Connector (Board)
Molex MicroBlade / Micro JST Footprint
Board Connector: Molex 430450812 (8-position)
Mating Connector: Molex 43025-0800
Crimp Terminals: Molex 43030-0007
Wire Gauge: 26–24 AWG
| Pin | Signal Name | Description | Wire Color | Voltage Range |
|---|---|---|---|---|
| 1 | V_CELL_1 | Cell 1 voltage sense | Red | 2.5–4.2 V |
| 2 | TEMP_1 | Temperature sensor 1 | Yellow | 0–5 V |
| 3 | V_MODULE_POS | Module positive voltage | Orange | 2.5–4.2 V |
| 4 | TEMP_2 | Temperature sensor 2 | Green | 0–5 V |
| 5 | V_MODULE_NEG | Module negative (reference) | Black | 0 V (ref) |
| 6 | TEMP_3 | Temperature sensor 3 | Blue | 0–5 V |
| 7 | RESERVED | Reserved for future use | White | — |
| 8 | SHIELD | Cable shield/drain | Bare | Ground |
A.2 Temperature Sensor Characteristics
NTC Thermistor Specifications
Type: 10 kΩ NTC, β = 3380 K
Accuracy: ±0.5% at 25 °C
Temperature Calculation:
T(K) = 1 / (1/T₀ + (1/β) × ln(R/R₀))
where T₀ = 298.15 K, R₀ = 10 kΩ, β = 3380 K
Appendix B: Revision History
| Revision | Date | Changes | Approved By |
|---|---|---|---|
| A | March 2020 | Initial release for GEN2 modules | Engineering |
| B | August 2020 | Updated specifications, added power modules | Engineering |
| C | January 2021 | Revised safety procedures, updated connector info | Engineering |
| D | June 2021 | Added troubleshooting section, updated warranty | Engineering |
| E | November 2021 | Updated wire-bond specifications, added maintenance schedule | Engineering |
| F | April 2022 | Revised environmental specifications, updated pinouts | Engineering |
| G | September 2022 | Added diagnostic procedures, updated safety warnings | Engineering |
| H | March 2023 | Updated compliance information, revised installation procedures | Engineering |
| I | August 2023 | Added storage guidelines, updated support contact information | Engineering |
| J | January 2025 | Complete manual restructure, updated branding, enhanced safety sections | Engineering |
Document Control
Document Owner: EVolve Battery Systems Engineering Department
Review Cycle: Annual or as needed for product changes
Distribution: Customer-facing document, available on request
Language: English (primary); translations available upon request