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This Lithium-Ion Battery Safety Guide is specifically tailored for BSR Electric Karts with a 48V and 96V DC low-voltage system. Lithium-ion (Li-Ion) batteries are at the heart of delivering power and performance for your electric kart, but they also require proper handling and care to ensure safety and longevity. This guide is designed to help drivers, and mechanics understand the essentials of Li-Ion battery safety so you can enjoy a safe racing experience.

This guide provides recommendations for using batteries safely and effectively. While the technology behind these batteries is Low Voltage and offers a high level of safety, there are still various risks that are not covered in this manual. Therefore, we urge every user to exercise caution and use this information to make informed and confident decisions regarding battery usage.

Safety should always be your top priority.

Battery Management System (BMS)

All BSR batteries are equipped with a Battery Safety Management (BMS) system that provides continuous monitoring during charging, discharging, and in response to temperature changes or damage, ensuring the battery operates safely. If the BMS system detects any issues, it automatically shuts down the battery to prevent risks, making the battery cease operation. Additionally, the batteries feature extra safety and monitoring mechanisms like circuit breakers, thermal sensors, and data analysis systems to enhance overall safety.

Charging Instructions and Precautions

Before starting the charging process, ensure the battery is not physically damaged or excessively hot to the touch (around 30-40 degrees Celsius (86°F – 104°F) on the outer casing). If there are any indications of damage or overheating, do not charge the battery until its condition has improved. During charging, the battery must not be kept in a damp area where it could come into contact with water; the charger should be turned off or disconnected from the outlet before connecting it to the battery, and only then turned on to avoid damaging the battery’s charging contacts or preventing the safety mechanism from initiating charging. Charging can be performed using any standard plug (from 90-260 VAC), with the understanding that lower input voltage will slow down the charging process.

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Battery Temperature and Cooling

The ideal operating temperature range for the battery is 20-50 degrees Celsius (68°F – 122°F), with a maximum allowable temperature of 65-70 degrees Celsius (149°F – 158°F). Upon reaching the maximum temperature, the battery will activate safety protocols and shut down, potentially experiencing a power drop during operation beforehand. If a battery reaches such temperatures, it cannot be charged until its temperature falls below 50 degrees Celsius (122°F). Constant overheating significantly shortens the battery’s lifespan. Batteries can also operate in sub-zero conditions; they maintain warmth and discharge capacity while in use, but if allowed to freeze, their performance will degrade, and they won’t function fully. Charging an overheated or frozen battery is strictly prohibited.

Handling and Storage

When not in use, batteries should be stored in an environment with a stable temperature of 15-25 degrees Celsius (59°F – 77°F) and low humidity. Batteries can be stored and transported in any orientation without affecting their processes, and they do not emit any chemicals or hazardous emissions that could impact health or the environment. Before long-term storage (2+ months), including for transportation, charge the battery to at least 50% and check its condition every 2-3 months, performing a recharge if necessary. Failing to monitor and maintain the battery over extended periods (3-6 months) can lead to irreversible discharge, rendering it impossible to charge or revive. Always keep an eye on your batteries during storage

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Moisture and Water Resistance

Each battery has its IP rating (Ingress Protection rating), usually ranging from IP61 to IP64, as detailed in the user manual, indicating its level of protection against moisture and dust ingress. If water penetrates the battery, it may continue to function for a certain period until its safety mechanisms can no longer maintain operation, leading to shutdown; water ingress results in irreversible damage. External moisture on the battery’s connection contacts does not directly harm the battery, but if water causes additional current leakage at any power connection terminal during operation, the system will shut down the kart and battery, resuming function after drying. It is strictly prohibited to use the battery underwater or in applications involving direct exposure to significant amounts of water or pressure, and it must not be cleaned with high-pressure washing equipment.

Maintenance Procedures

It is strictly prohibited to attempt to repair the battery yourself; tampering with the battery will void the warranty, and BSR will not be responsible for any subsequent impact on the battery’s operational quality. Only BSR-certified specialists or technicians trained by BSR for specific tasks, ensuring adherence to all safety protocols, are authorized to perform battery repairs. Any modification to the battery poses a risk to its safety and can have irreversible consequences; in case of any uncertainties, you are encouraged to contact us at support@blueshockrace.com.

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Emergency Response

Battery ignition is a high-risk situation, so BSR has developed a safety kit for racing needs, which includes a 3kg CO2 fire extinguisher and a fireproof blanket for each racing team. In the case of battery ignition, the most effective extinguishing methods are using large amounts of water or CO2 since the burning process is chemical and not influenced by the presence of oxygen. If a battery exceeds temperatures of 70-80 degrees Celsius (158°F – 176°F), indicating a chemical combustion process, and shows signs like excessive heat, rising temperature, or emits smoke, it is advised to place it 2-3 meters away from flammable materials until it cools down or completes its reaction process.

Disposal and Recycling

BSR batteries are designed to serve the karting industry for 2-5 years and then be repurposed for renewable energy storage systems for an additional 10-15 years, potentially reaching a lifecycle of up to 20 years. After their service life, the batteries are handed over to recycling companies, where up to 98% of valuable materials such as copper, nickel, aluminum, lithium, and others are separated, ground down, and then reused to manufacture new batteries. This process not only makes new batteries cheaper but also eliminates the need for new material extraction, creating a sustainable cycle for battery materials.

Conclusions and Recommendations

Li-Ion batteries are very safe, with high safety standards ensuring an extremely low risk of incidents under normal operating conditions. Recognizing the inherent risks in motorsport, BSR develops educational materials for worst-case scenarios, detailing how to respond effectively, from fire safety to other considerations. Given that any system involving significant energy has a high potential for risk, it is crucial to exercise caution and adhere to all safety regulations set by BSR and race or track operators, prioritizing safety above all.

Contact Information

For Further Inquiries

blueshockrace.com, info@blueshockrace.com, +1 (484) 585-0115 (the U.S.A.), (+371) 2046-5432 (the E.U.)