Reducing Potential Difference Across the Battery (Front Cover Removed)

FRT No: 16030103

    Remove


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  1. Use the top RH edge to release and remove the E-connector insulators (x4) from sheets 5, 6, 7 and 8.


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  2. Using a torquing tool, loosen but do not remove screws (x4) securing center E-connector to sheets (torque - 4.5 Nm / 40 in-lbs).

  3. Install the extended E-connector insulators to sheets 5 and 8.

  4. Attach the high voltage resistor to the sheets and secure with thumbwheels.


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  5. Clip resistor leads (x2) to exposed E-connector terminals on sheets 6 and 7, with the contacts going through the holes in the collector plates and hooking around edges of plates.

    6. NOTE: On those sheets without holes in the collector plates, clip the probe to the plate in the same position.


  6. Measure voltage between sheets 5 and 6. Verify the voltage is less than 1V (DC).
    7. WARNING: If voltage is above this value, stop working on battery immediately and contact a field support engineer for instruction
     

    WARNING: Do not touch E-connector contacts.
     


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  7. Remove outer screws (x2) securing E-connector to sheet and replace with guide pins.

  8. Remove inner screws (x2) securing E-connector to sheet.

  9. Slide the E-connector along the pins and remove from sheet.

  10. Remove the guide pins (x2) from the sheets.

  11. Remove the extended E-connector insulators from sheets 5 and 8 and install regular E-connector insulators.


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  12. Install clear covers to sheets 6 and 7 where the E-connector has been removed.

  13. Use the top RH edge to release and remove the E-connector insulator from sheet 11.


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  14. Using the torquing tool, remove screws (x2) securing LH busbar to sheet 11 (torque - 4.5 Nm / 40 in-lbs). Position busbar aside.


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  15. Install an extended E-connector insulator to sheet 11.

  16. Use the top RH edge to release and remove the E-connector insulator from sheet 1.


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  17. Using the torquing tool, remove screws (x2) securing RH busbar to sheet 1 (torque - 4.5 Nm / 40 in-lbs). Position busbar aside.


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  18. Install an extended E-connector insulator to sheet 1.

    Installation


  1. Installation procedure is the reverse of removal except for the following:

  2. Before installing the final E-connector, measure the voltage between the two unconnected sheets. Verify that the voltage is between 240 and 260 VDC.
    3. WARNING: If voltage is above or below this value, stop working on battery immediately and contact a field support engineer for instruction
     


  3. Attach the high voltage resistor to the sheets and secure with thumbwheels.


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  4. Clip resistor leads (x2) to exposed E-connector terminals on sheets 5 and 6, with the contacts going through the holes in the collector plates and hooking around edges of plates.

    5. NOTE: On those sheets without holes in the collector plates, clip the probe to the plate in the same position.


  5. Measure voltage between sheets 5 and 6. Verify the voltage is less than 1V (DC).
    6. WARNING: If voltage is above this value, stop working on battery immediately and contact a field support engineer for instruction
     

    WARNING: Do not touch E-connector contacts.
     


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  6. If any sheets were removed, use pitch plate to ensure proper alignment of E-connectors. Install pitch plate to enclosure using screws (x3). Align sheets with holes in pitch plate and loosely install screws (x11) securing pitch plate to sheets.

    7. NOTE: Only use the screws that are supplied with the pitch plate.


  7. If a sheet front mount has too much side-to-side misalignment, then using the upper handling area, reposition the sheet until it aligns with the pitch plate and then install screw.

  8. If a sheet front mount has too much vertical misalignment, use assistance to reposition the sheet using the upper handling area, until it aligns with the pitch plate and then install screw.

  9. Ensure that the countersunk holes on the E-connector face outwards.

  10. Tighten all E-connector screws lightly until all screws are fitted then perform a final torque tighten using the torquing tool.

  11. Mark fastenings after tightening using torquing pen to identify tightened fastenings.

  12. Ensure E-connector insulators are correctly seated and are flush with other insulators.

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