Exide Technologies Section 92.80 - Manual (Page 14)

8.3.3 Horizontal Stacking
When all base modules are set in place, continue with stacking
of subsequent modules. Procedures for assembly of multiple
horizontal stacks are the same as outlined in section 8.1.3. Also
consult layout/wiring diagram. Each stack should be built up in
sequence to the same level until the top modules in all stacks
are the last to be installed. The use of a line chord attached to
upper module corners of opposite end modules as stacking pro-
gresses aids in alignment.
This completes the mechanical assembly of the battery system.
For installation of intermodular connections and terminal plate
assembly, see Section 9.
For installation of protective module cover, see Section 11 .
SECTION 9: ELECTRICAL CONNECTIONS
9.0 Post Preparation
All cell posts were greased at the factory. Using either a brass
bristle suede shoe brush or 3M Scotch Brite scouring pad,
brighten the flat copper terminal surfaces to ensure lowest resis-
tance connections. Apply a thin film of NO-OX-ID “A” grease
(supplied) to all terminal surfaces, bolts, and washers. This will
preclude oxidation after connections are completed.
9.1 Connections - System Terminals
Each system is supplied with a terminal plate assembly for the
positive and negative terminations. These should always be
used to provide proper connection to the operating equipment
and cell terminals. Any attempt to connect load cables directly to
cell terminal may compromise battery system performance as
well as the integrity of cell post seals.
Refer to layout/wiring diagram for location of terminal plate assem-
bly in your battery configuration. Assemble Terminal Support
Bracket to module channel using hardware indicated, items 3, 4,
5, 6. Hardware will be located in a bag labeled K17-417240P for
top termination or K17417256 for side termination. Assemble
Terminal Plate to Support Bracket and battery posts. Hardware to
attach to Support bracket is also located in the terminal plate kit.
It is recommended that all connections be torqued to 11.3
Newton-meters (100 in-lbs). Retorque value is also 11.3 Newton-
meters (100 in-lbs). After making cable connections, assemble
Terminal Plate Covers, Items 7 & 8, to the Terminal Support Bracket
using hardware indicated. Hardware to assemble Terminal Plate
Covers will be located in the terminal plate kit. Refer to Sections
9.0 and 9.2 for electrical contact surface preparation of terminal
plate components.
Terminal plate assembly varies with termination location. Refer
to layout/wiring diagram termination location on your battery.
Figure 20 shows top termination assembly with instructions.
Do not make connections to operating system at this time.
9.2 Connections - Inter-MODULE
Consult layout/wiring diagram for correct quantity of lead-tin plat-
ed
copper connectors required for each
connection. Follow procedure in Section 9.0 and brighten lead-
tin plated surfaces coming in contact with copper posts. Apply a
thin film of NO-OX-ID “A” grease to these areas.
NOTE: Apply a minimum amount of grease to cover the surface.
As a rule: "If you can see it, it's too much".
Where multiple connectors are required across any single con-
nection, brighten both sides of connectors along the entire
length. Grease these areas as well. It is recommended when
installing connectors on horizontal arrangements that the upper
bolts be installed first to reduce risk of accidental shorting.Refer
to layout/wiring diagram for connector placement and materials
list.
Figure 19 shows typical module connections, intrastack
connections and interstack connections.
9.3 Connections - Inter-STACK
Multiple stacks end to end are interconnected as shown in lay-
out/wiring diagram. Follow the procedures in Sections 9.1 & 9.3.
9.4 Torquing
When all inter-module and inter-stack connections have been
installed, tighten all connections to 11.3 Newton-meters (100 in-
Lbs) Use insulated tools. Recheck connections after the initial
charge due to heating during charge.
STACK CONNECTIONS
Figure 19
9.5 Connection - Check
Again, visually check to see that all module terminals are
conected positive (+) to negative (-) throughout the battery.
Positive terminals have red cap. Negative terminals have
black cap
.
14
WASHERS SHOULD BE INSTALLED WITH THE CURVED
EDGE TOWARD THE CONNECTORS.
BOLT WASHER CONNECTOR POST