Identification Labels, Stack 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 termi- nations. 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 termi- nal may compromise battery system performance as well as the integrity of cell post seals.

Refer to layout/wiring diagram for location of terminal plate assembly in your battery configuration. Assemble Terminal Support Bracket to module channel using hardware indi- cated, 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 recom- mended that all connections be torqued to 11 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 ter- minal 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 operat- ing system at this time.

9.2 Connections - Inter-MODULE

Consult layout/wiring diagram for correct quantity of lead- tin plated 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 connection, brighten both sides of connectors along the entire length. Grease these areas as well. It is recom- mended when installing connectors on horizontal arrangements that the upper bolts be installed first to reduce risk of accidental shorting.

WASHERS SHOULD BE INSTALLED WITH THE CURVED EDGE TOWARD THE CONNECTORS.

BOLT

WASHER CONNECTOR

POST

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 layout/wiring diagram. Follow the procedures in Sections 9.1 and 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 connec- tions 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 connected positive (+) to negative (-) throughout the battery. Positive terminals have red cap. Negative terminals have black cap.

Also measure the total open circuit voltage from terminal plate to terminal plate. This should be approximately equal to 2.14 volts times the number of cells in the system, e.g., a 24 cell system would read: 24 x 2.14v = 51.4 volts. An incorrect voltage reading may mean connectors were installed incorrectly.

SECTION 10: IDENTIFICATION LABELS

10.0 Surfaces

Make sure surfaces are free of dirt and grease by wiping with clean, dry wipers (isopropyl alcohol may be used) to ensure proper label adhesion.

10.1 Cell Numerals

A set of pressure sensitive cell numerals and system polarity labels are supplied and should be applied at this time. Cell numerals should be applied to the cell being identified. Designate the positive terminal cell as #1 with succeeding

15 cells in series in ascending order.