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Summary of Contents for EnerSys PowerSafe DDm Series
- Page 1 Battery Installation Manual PowerSafe ® Modular Battery Systems IMPORTANT! Read safety information first See Safety, Storage, Operating and Maintenance Manual RESERVE Visit us at www.enersys.com Publication No: US-DDM-IM-AA June 2016 POWER...
- Page 2 EnerSys. Please check our website for literature updates.
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Page 3: General Safety Instructions
IF ON CLOTHING OR SKIN (or hair): Remove/Take off immediately all contaminated clothing and wash using this product. Avoid contact EnerSys, 2366 Bernville Road, Reading, PA 19605, USA - Tel: +1 610-208-1991 it before reuse. Rinse skin with water/shower. IF INHALED: Remove person to fresh air and keep comfortable ye protection/face protection. - Page 4 10. Use proper lifting means when moving batteries and wear all appropriate safety clothing and equipment. 11. Do not dispose of lead acid batteries except through channels in accordance with local, state and federal regulations. www.enersys.com...
- Page 5 Caution Misuse of this equipment could result in human injury and equipment damage. In no event will EnerSys be responsible or liable for either indirect or consequential damage or injury that may result from the use of this equipment. Caution Do not dispose of the batteries in a fire.
- Page 6 IMPORTANT Read safety information first See Safety, Storage, Operating and Maintenance Manual www.enersys.com...
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Page 7: Table Of Contents
Battery Installation Manual TABLE OF CONTENTS GENERAL SAFETY INSTRUCTIONS GENERAL INFORMATION RECOMMENDED INSTALLATION EQUIPMENT AND SUPPLIES SYSTEM LAYOUT Anchor Spacing FRAME ASSEMBLY AND INSTALLATION Base Beams Vertical Channels Horizontal Channels Cell Support Shelves BATTERY CELL INSTALLATION Module Retainers Electrical Bonding Instructions CONNECTIONS Terminal Plates Inter-Cell Connectors... -
Page 8: General Information
Systems are available in 24, 48 and other voltage configurations. These systems allow for assembly at remote locations. See the ASSEMBLY DRAWING to determine the configuration for your installation. Before installation: Verify items received versus Bill of Lading. Verify parts against system Bill of Materials. SINGLE STACK FIGURE 1 www.enersys.com... - Page 9 Battery Installation Manual MULTI-STACK MULTI-STACK ZERO SEPARATION FIGURE 2 FIGURE 3A MULTI-STACK ZERO SEPARATION FIGURE 3B Pubication No: US-DDM-IM-AA - June 2016...
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Page 10: Recommended Installation Equipment And Supplies
Tape Measure (Nonmetallic) Safety Equipment and Clothing Small Paintbrush Standard Allen Wrench Set Be sure you have all the proper protective clothing, safety tools and equipment on hand before starting the installation. DANGER www.enersys.com Contains: Lead, Sulfuric Acid (Electrolyte), Lead Compounds. -
Page 11: System Layout
Battery Installation Manual D= Distance between bases (variable) SYSTEM LAYOUT Before installing the battery system, lay out available floor space including aisles for installation, maintenance and possible cell replacement. Consult the local installation considerations as determined in Section 5 of the Safety, Storage, Operating and Maintenance Manual for the VRLA Modular Battery Systems. -
Page 12: Anchor Spacing
67.83 L-4.24 125-33 28.09 40.88 53.98 81.32 L-4.24 EXAMPLE: If you are installing a DDm85 MULTI-STACK WITH ZERO SEPARATION and you have 21 plates/cell, 4 cells wide. M (inches) = L (in) - 2.95” 35.26” - 2.95” = 32.31” www.enersys.com... -
Page 13: Frame Assembly And Installation
Battery Installation Manual FRAME ASSEMBLY AND INSTALLATION To assemble and install the frame for the PowerSafe ® battery system, follow the procedure below using the system layout determined in the “System Layout” section. Base Beams 1. LEVEL with customer-supplied floor shims, and anchor in place. -
Page 14: Horizontal Channels
• Lock Washer • Hex Nut INSTALL REAR HORIZONTAL CHANNELS FIGURE 11B All other horizontals: • Serrated Hex Bolt (M10x1.5 – 25mm) 3. Finger-tighten connections. 4. Install all rear horizontal channels before continuing. REAR HORIZONTAL CHANNEL HARDWARE DETAIL FIGURE 12 www.enersys.com... - Page 15 Battery Installation Manual Starting at the bottom of the front verticals: 1. Insert horizontal channels into the vertical channels. Center the horizontals between the verticals. See Figures 13A and 13B. 2. Bolt horizontal channels to vertical channels. Refer to below list for hardware order and Figure 14. NOTE: The bottom two horizontal channels require full thread longer bolts at the vertical channel.
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Page 16: Cell Support Shelves
6. Torque all anchor bolts according to system design and manufacturer’s recommendations. INSTALL CELL SUPPORT SHELVES FIGURE 17 INSTALL BOTTOM CELL SUPPORT SHELF FIGURE 15 www.enersys.com... -
Page 17: Battery Cell Installation
2. Inspect each terminal for visual signs of mechanical defects. NOTE: Report any defects to your nearest EnerSys sales/service representative for resolution, or call the corporate office number listed on the back of this manual and ask for INSTALL SECOND MODULE EnerSys Service. -
Page 18: Module Retainers
Screw through front lip of the battery module into the shelf/horizontal channel. See Figure 23. 2. For each retainer spacer, install one M6 Self-Tapping Screw through the spacer into the horizontal channel. See Figure 23. INSTALL BONDING SCREW FIGURE 23 www.enersys.com... -
Page 19: Connections
Battery Installation Manual CONNECTIONS The cells are now positioned and ready to be connected. The cells must be connected according to the polarities on the ASSEMBLY DRAWING and the following instructions. Before preparing and making connections, heat NO-OX-ID grease in hot water as necessary to soften for application with a paintbrush. -
Page 20: Inter-Cell Connectors
4. Secure all connections finger-tight to allow for some adjustment of position. 5. After all connections are completed, torque all to 85 in-lbs. 6. Apply a light coat of heated NO-OX-ID grease to the bolted connection with a small paintbrush. www.enersys.com... -
Page 21: Terminal Bars
Battery Installation Manual Terminal Bars Terminal bars are supplied with the battery system to provide a cell terminal-to-terminal plate connection. 1. Inspect the system to be assured that all cells are connected correctly – POSITIVE to NEGATIVE and according to the ASSEMBLY DRAWING. 2. -
Page 22: Initial System Readings
EnerSys sales/service representative, or call the corporate office number listed on the back of this manual and ask for EnerSys Service. Make a copy of the Battery maintenance Report found in the Safety, Storage, Operating and Maintenance Manual. -
Page 23: Safety Shields And Covers
Battery Installation Manual SAFETY SHIELDS AND COVERS Safety shields and covers are provided to help prevent accidental contact with connections after installation and during operations. Safety shields and covers should remain in place at all times during normal operation of the system. Terminal plate covers are provided as necessary to prevent accidental contact with the “live”... - Page 24 EnerSys World Headquarters 2366 Bernville Road, Reading, PA 19605, USA Tel: +1-610-208-1991 / +1-800-538-3627 EnerSys EMEA EH Europe GmbH, Baarerstrasse 18, 6300 Zug, Switzerland EnerSys Asia 152 Beach Road, Gateway East Building #11-03, Singapore 189721 Tel: +65 6508 1780 © 2016 EnerSys. All rights reserved.
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