EnerSys PowerSafe DDm Series User manual

Visit us at www.enersys.com Publication No: US-DDM-IM-AA June 2016
RESERVE
POWER
BatteryInstallationManual
PowerSafe®DDm
Modular Battery Systems
IMPORTANT!
Read safety information first
See Safety, Storage, Operating and
Maintenance Manual

The installation manual is for reference only. To maximize safety and performance, read the
accompanying Safety, Storage, Operating and Maintenance Manual thoroughly. It provides full
instructions regarding safety, storage, operation and maintenance. Failure to observe the
precautions as presented may result in injury or loss of life.
This document is proprietary to EnerSys®. This document cannot be copied or reproduced in
whole or in part, nor can its contents be revealed in any manner or to any person except to meet
the purpose for which it was delivered, without the express written permission of EnerSys.
Please check our website for literature updates.
www.enersys.com
www.enersys.com

BatteryInstallationManual
Pubication No: US-DDM-IM-AA - June 2016
GENERAL SAFETY INSTRUCTIONS
Warnings in this manual appear in any of three ways:
Danger
The danger symbol is a lightning bolt mark, enclosed in a triangle. The danger symbol is
used to indicate imminently hazardous situations, locations and conditions which, if not
avoided, WILL result in death, serious injury and/or severe property damage.
Other warning symbols may appear along with the Danger and Caution symbols and are used to specify
special hazards. These warnings describe particular areas where special care and/or procedures are required
in order to prevent serious injury and possible death:
Electrical warnings
The electrical warning symbol is a lightning bolt mark enclosed in a triangle. The electrical
warning symbol is used to indicate high voltage locations and conditions, which may
cause serious injury or death if the proper precautions are not observed.
Harmfulifswallowed,inhaled,orincontactwithskin.Acidcausessevereskinburnsandeyedamage.May
damagefertilityortheunbornchildifingestedorinhaled.Maycauseharmtobreast-fedchildren.Maycause
cancerifingestedorinhaled.Causesskinirritation,seriouseyedamage.Contactwithinternalcomponents
maycauseirritationorsevereburns.Causesdamagetocentralnervoussystem,bloodandkidneysthrough
prolongedorrepeatedexposureifingestedorinhaled.Irritatingtoeyes,respiratorysystem,andskin.May
formexplosiveair/gasmixtureduringcharging.Extremelyflammablegas(hydrogen).Explosive,fire,blastor
projectionhazard.
Obtainspecialinstructionsbeforeuse.Donothandleuntilallsafetyprecautionshavebeenreadand
understood.Washthoroughlyafterhandling.Donoteatdrinkorsmokewhenusingthisproduct.Avoid contact
duringpregnancy/whilenursing.Wearprotectivegloves/protectiveclothing,eyeprotection/faceprotection.
Useonlyoutdoorsorinawell-ventilatedarea.Avoidcontactwithinternalacid.Donotbreathe
dust/fume/gas/mist/vapors/spray.Keepawayfromheat/sparks/openflames/hotsurfaces.Nosmoking.
IFSWALLOWED OR CONSUMED: rinse mouth. Do NOT induce vomiting. Call a poison center/doctor if you feel
unwell.IFONCLOTHINGORSKIN(orhair):Remove/Take off immediately all contaminated clothing and wash
itbeforereuse.Rinseskinwithwater/shower. IF INHALED: Remove person to fresh air and keep comfortable
forbreathing.ImmediatelycallaPOISONCENTERordoctor/physician.IFINEYES:Rinsecautiouslywithwater
forseveralminutes.Removecontactlenses,ifpresentandeasytodo.Continuerinsing.Ifexposed/concerned,
orifyoufeelunwellseekmedicalattention/advice.
Storelockedup,inawell-ventilatedarea,inaccordancewithlocalandnationalregulation.
Disposeofcontents/containerinaccordancewithlocalandnationalregulation.Keepoutofreachofchildren.
EnerSys, 2366 Bernville Road, Reading, PA 19605, USA - Tel: [phone]
Contains: Lead,SulfuricAcid(Electrolyte),LeadCompounds.
DANGER
2201-8677
Harmfulifswallowed,inhaled,orincontactwithskin.Acidcausessevereskinburnsandeyedamage.May
damagefertilityortheunbornchildifingestedorinhaled.Maycauseharmtobreast-fedchildren.Maycause
cancerifingestedorinhaled.Causesskinirritation,seriouseyedamage.Contactwithinternalcomponents
maycauseirritationorsevereburns.Causesdamagetocentralnervoussystem,bloodandkidneysthrough
prolongedorrepeatedexposureifingestedorinhaled.Irritatingtoeyes,respiratorysystem,andskin.May
formexplosiveair/gasmixtureduringcharging.Extremelyflammablegas(hydrogen).Explosive,fire,blastor
projectionhazard.
Obtainspecialinstructionsbeforeuse.Donothandleuntilallsafetyprecautionshavebeenreadand
understood.Washthoroughlyafterhandling.Donoteatdrinkorsmokewhenusingthisproduct.Avoid contact
duringpregnancy/whilenursing.Wearprotectivegloves/protectiveclothing,eyeprotection/faceprotection.
Useonlyoutdoorsorinawell-ventilatedarea.Avoidcontactwithinternalacid.Donotbreathe
dust/fume/gas/mist/vapors/spray.Keepawayfromheat/sparks/openflames/hotsurfaces.Nosmoking.
IFSWALLOWED OR CONSUMED: rinse mouth. Do NOT induce vomiting. Call a poison center/doctor if you feel
unwell.IFONCLOTHINGORSKIN(orhair):Remove/Take off immediately all contaminated clothing and wash
itbeforereuse.Rinseskinwithwater/shower. IF INHALED: Remove person to fresh air and keep comfortable
forbreathing.ImmediatelycallaPOISONCENTERordoctor/physician.IFINEYES:Rinsecautiouslywithwater
forseveralminutes.Removecontactlenses,ifpresentandeasytodo.Continuerinsing.Ifexposed/concerned,
orifyoufeelunwellseekmedicalattention/advice.
Storelockedup,inawell-ventilatedarea,inaccordancewithlocalandnationalregulation.
Disposeofcontents/containerinaccordancewithlocalandnationalregulation.Keepoutofreachofchildren.
EnerSys, 2366 Bernville Road, Reading, PA 19605, USA - Tel: [phone]
Contains: Lead,SulfuricAcid(Electrolyte),LeadCompounds.
DANGER
2201-8677
Harmfulifswallowed,inhaled,orincontactwithskin.Acidcausessevereskinburnsandeyedamage.May
damagefertilityortheunbornchildifingestedorinhaled.Maycauseharmtobreast-fedchildren.Maycause
cancerifingestedorinhaled.Causesskinirritation,seriouseyedamage.Contactwithinternalcomponents
maycauseirritationorsevereburns.Causesdamagetocentralnervoussystem,bloodandkidneysthrough
prolongedorrepeatedexposureifingestedorinhaled.Irritatingtoeyes,respiratorysystem,andskin.May
formexplosiveair/gasmixtureduringcharging.Extremelyflammablegas(hydrogen).Explosive,fire,blastor
projectionhazard.
Obtainspecialinstructionsbeforeuse.Donothandleuntilallsafetyprecautionshavebeenreadand
understood.Washthoroughlyafterhandling.Donoteatdrinkorsmokewhenusingthisproduct.Avoid contact
duringpregnancy/whilenursing.Wearprotectivegloves/protectiveclothing,eyeprotection/faceprotection.
Useonlyoutdoorsorinawell-ventilatedarea.Avoidcontactwithinternalacid.Donotbreathe
dust/fume/gas/mist/vapors/spray.Keepawayfromheat/sparks/openflames/hotsurfaces.Nosmoking.
IFSWALLOWED OR CONSUMED: rinse mouth. Do NOT induce vomiting. Call a poison center/doctor if you feel
unwell.IFONCLOTHINGORSKIN(orhair):Remove/Take off immediately all contaminated clothing and wash
itbeforereuse.Rinseskinwithwater/shower. IF INHALED: Remove person to fresh air and keep comfortable
forbreathing.ImmediatelycallaPOISONCENTERordoctor/physician.IFINEYES:Rinsecautiouslywithwater
forseveralminutes.Removecontactlenses,ifpresentandeasytodo.Continuerinsing.Ifexposed/concerned,
orifyoufeelunwellseekmedicalattention/advice.
Storelockedup,inawell-ventilatedarea,inaccordancewithlocalandnationalregulation.
Disposeofcontents/containerinaccordancewithlocalandnationalregulation.Keepoutofreachofchildren.
EnerSys, 2366 Bernville Road, Reading, PA 19605, USA - Tel: [phone]
Contains: Lead,SulfuricAcid(Electrolyte),LeadCompounds.
DANGER
2201-8677
Harmfulifswallowed,inhaled,orincontactwithskin.Acidcausessevereskinburnsandeyedamage.May
damagefertilityortheunbornchildifingestedorinhaled.Maycauseharmtobreast-fedchildren.Maycause
cancerifingestedorinhaled.Causesskinirritation,seriouseyedamage.Contactwithinternalcomponents
maycauseirritationorsevereburns.Causesdamagetocentralnervoussystem,bloodandkidneysthrough
prolongedorrepeatedexposureifingestedorinhaled.Irritatingtoeyes,respiratorysystem,andskin.May
formexplosiveair/gasmixtureduringcharging.Extremelyflammablegas(hydrogen).Explosive,fire,blastor
projectionhazard.
Obtainspecialinstructionsbeforeuse.Donothandleuntilallsafetyprecautionshavebeenreadand
understood.Washthoroughlyafterhandling.Donoteatdrinkorsmokewhenusingthisproduct.Avoid contact
duringpregnancy/whilenursing.Wearprotectivegloves/protectiveclothing,eyeprotection/faceprotection.
Useonlyoutdoorsorinawell-ventilatedarea.Avoidcontactwithinternalacid.Donotbreathe
dust/fume/gas/mist/vapors/spray.Keepawayfromheat/sparks/openflames/hotsurfaces.Nosmoking.
IFSWALLOWED OR CONSUMED: rinse mouth. Do NOT induce vomiting. Call a poison center/doctor if you feel
unwell.IFONCLOTHINGORSKIN(orhair):Remove/Take off immediately all contaminated clothing and wash
itbeforereuse.Rinseskinwithwater/shower. IF INHALED: Remove person to fresh air and keep comfortable
forbreathing.ImmediatelycallaPOISONCENTERordoctor/physician.IFINEYES:Rinsecautiouslywithwater
forseveralminutes.Removecontactlenses,ifpresentandeasytodo.Continuerinsing.Ifexposed/concerned,
orifyoufeelunwellseekmedicalattention/advice.
Storelockedup,inawell-ventilatedarea,inaccordancewithlocalandnationalregulation.
Disposeofcontents/containerinaccordancewithlocalandnationalregulation.Keepoutofreachofchildren.
EnerSys, 2366 Bernville Road, Reading, PA 19605, USA - Tel: [phone]
Contains: Lead,SulfuricAcid(Electrolyte),LeadCompounds.
DANGER
2201-8677
Warning
The warning symbol is an exclamation mark enclosed in a triangle. The warning symbol
is used to indicate potentially hazardous situations and conditions, which, if not avoided
COULD result in serious injury or death. Severe property damage COULD also occur.
Caution
The caution symbol is an exclamation mark enclosed in a triangle. The caution symbol is
used to indicate potentially hazardous situations and conditions, which, if not avoided may
result in injury. Equipment damage may also occur.
Explosion warnings
The explosion warning symbol is an explosion mark enclosed in a triangle. The explosion
warning symbol is used to indicate locations and conditions where molten or exploding
parts may cause serious injury or death if the proper precautions are not observed.
1
Harmfulifswallowed,inhaled,orincontactwithskin.Acidcausessevereskinburnsandeyedamage.May
damagefertilityortheunbornchildifingestedorinhaled.Maycauseharmtobreast-fedchildren.Maycause
cancerifingestedorinhaled.Causesskinirritation,seriouseyedamage.Contactwithinternalcomponents
maycauseirritationorsevereburns.Causesdamagetocentralnervoussystem,bloodandkidneysthrough
prolongedorrepeatedexposureifingestedorinhaled.Irritatingtoeyes,respiratorysystem,andskin.May
formexplosiveair/gasmixtureduringcharging.Extremelyflammablegas(hydrogen).Explosive,fire,blastor
projectionhazard.
Obtainspecialinstructionsbeforeuse.Donothandleuntilallsafetyprecautionshavebeenreadand
understood.Washthoroughlyafterhandling.Donoteatdrinkorsmokewhenusingthisproduct.Avoid contact
duringpregnancy/whilenursing.Wearprotectivegloves/protectiveclothing,eyeprotection/faceprotection.
Useonlyoutdoorsorinawell-ventilatedarea.Avoidcontactwithinternalacid.Donotbreathe
dust/fume/gas/mist/vapors/spray.Keepawayfromheat/sparks/openflames/hotsurfaces.Nosmoking.
IFSWALLOWED OR CONSUMED: rinse mouth. Do NOT induce vomiting. Call a poison center/doctor if you feel
unwell.IFONCLOTHINGORSKIN(orhair):Remove/Take off immediately all contaminated clothing and wash
itbeforereuse.Rinseskinwithwater/shower. IF INHALED: Remove person to fresh air and keep comfortable
forbreathing.ImmediatelycallaPOISONCENTERordoctor/physician.IFINEYES:Rinsecautiouslywithwater
forseveralminutes.Removecontactlenses,ifpresentandeasytodo.Continuerinsing.Ifexposed/concerned,
orifyoufeelunwellseekmedicalattention/advice.
Storelockedup,inawell-ventilatedarea,inaccordancewithlocalandnationalregulation.
Disposeofcontents/containerinaccordancewithlocalandnationalregulation.Keepoutofreachofchildren.
EnerSys, 2366 Bernville Road, Reading, PA 19605, USA - Tel: [phone]
Contains: Lead,SulfuricAcid(Electrolyte),LeadCompounds.
DANGER
2201-8677

www.enersys.com
1. Verify that the Uninterruptible Power Supply (UPS) is off and that the power cord is
disconnected from the power source.
2. Remove watches, rings or other metal objects.
3. Use tools with insulated handles to prevent inadvertent shorts.
4. Wear rubber gloves and boots.
5. Do not lay tools or metal parts on top of batteries.
6. Determine if the battery is inadvertently grounded. If inadvertently grounded, remove source of
ground. Contact with any part of a grounded battery can result in electrical shock. The likelihood
of such shock will be reduced if such grounds are removed during installation and maintenance.
7. Verify circuit polarities before making connections.
8. Disconnect charging source and load before connecting or disconnecting terminals.
9. Valve Regulated Lead Acid (VRLA) batteries contain an explosive mixture of hydrogen gas.
Do not smoke, cause a flame or spark in the immediate area of the batteries. This includes static
electricity from the body.
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.
GENERAL SAFETY INSTRUCTIONS
A battery can present a risk of electrical shock and high short circuit current.
The following precautions should be observed when working with batteries.
2
Harmfulifswallowed,inhaled,orincontactwithskin.Acidcausessevereskinburnsandeyedamage.May
damagefertilityortheunbornchildifingestedorinhaled.Maycauseharmtobreast-fedchildren.Maycause
cancerifingestedorinhaled.Causesskinirritation,seriouseyedamage.Contactwithinternalcomponents
maycauseirritationorsevereburns.Causesdamagetocentralnervoussystem,bloodandkidneysthrough
prolongedorrepeatedexposureifingestedorinhaled.Irritatingtoeyes,respiratorysystem,andskin.May
formexplosiveair/gasmixtureduringcharging.Extremelyflammablegas(hydrogen).Explosive,fire,blastor
projectionhazard.
Obtainspecialinstructionsbeforeuse.Donothandleuntilallsafetyprecautionshavebeenreadand
understood.Washthoroughlyafterhandling.Donoteatdrinkorsmokewhenusingthisproduct.Avoid contact
duringpregnancy/whilenursing.Wearprotectivegloves/protectiveclothing,eyeprotection/faceprotection.
Useonlyoutdoorsorinawell-ventilatedarea.Avoidcontactwithinternalacid.Donotbreathe
dust/fume/gas/mist/vapors/spray.Keepawayfromheat/sparks/openflames/hotsurfaces.Nosmoking.
IFSWALLOWED OR CONSUMED: rinse mouth. Do NOT induce vomiting. Call a poison center/doctor if you feel
unwell.IFONCLOTHINGORSKIN(orhair):Remove/Take off immediately all contaminated clothing and wash
itbeforereuse.Rinseskinwithwater/shower. IF INHALED: Remove person to fresh air and keep comfortable
forbreathing.ImmediatelycallaPOISONCENTERordoctor/physician.IFINEYES:Rinsecautiouslywithwater
forseveralminutes.Removecontactlenses,ifpresentandeasytodo.Continuerinsing.Ifexposed/concerned,
orifyoufeelunwellseekmedicalattention/advice.
Storelockedup,inawell-ventilatedarea,inaccordancewithlocalandnationalregulation.
Disposeofcontents/containerinaccordancewithlocalandnationalregulation.Keepoutofreachofchildren.
EnerSys, 2366 Bernville Road, Reading, PA 19605, USA - Tel: [phone]
Contains: Lead,SulfuricAcid(Electrolyte),LeadCompounds.
DANGER
2201-8677

BatteryInstallationManual
Pubication No: US-DDM-IM-AA - June 2016
GENERAL SAFETY INSTRUCTIONS
Save these instructions
This manual contains important instructions for PowerSafe®DDm Lead Acid Battery Systems that should
be followed during the installation and maintenance of the battery system.
Only a qualified service representative who is knowledgeable in batteries and the required precautions
should perform servicing of the batteries. Keep unauthorized personnel away from batteries.
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. The batteries may explode.
Caution
Do not open or mutilate the batteries. Released electrolyte is harmful to the
eyes and skin and may also be toxic.
Warning
This unit contains sealed lead acid batteries. Lack of preventative maintenance
could result in batteries exploding and emitting gasses and/or flame.
An authorized, trained technician must perform annual preventative maintenance.
Warning
Failure to replace a battery before it becomes exhausted may cause the case
to crack, possibly releasing electrolyte from inside the battery and resulting in
secondary faults such as odor, smoke and fire.
Warning
Proper maintenance to the battery system of this unit must be done by a
qualified service technician. This is essential to the safety and reliability of your
Uninterruptible Power Supply (UPS) system.
3
Harmfulifswallowed,inhaled,orincontactwithskin.Acidcausessevereskinburnsandeyedamage.May
damagefertilityortheunbornchildifingestedorinhaled.Maycauseharmtobreast-fedchildren.Maycause
cancerifingestedorinhaled.Causesskinirritation,seriouseyedamage.Contactwithinternalcomponents
maycauseirritationorsevereburns.Causesdamagetocentralnervoussystem,bloodandkidneysthrough
prolongedorrepeatedexposureifingestedorinhaled.Irritatingtoeyes,respiratorysystem,andskin.May
formexplosiveair/gasmixtureduringcharging.Extremelyflammablegas(hydrogen).Explosive,fire,blastor
projectionhazard.
Obtainspecialinstructionsbeforeuse.Donothandleuntilallsafetyprecautionshavebeenreadand
understood.Washthoroughlyafterhandling.Donoteatdrinkorsmokewhenusingthisproduct.Avoid contact
duringpregnancy/whilenursing.Wearprotectivegloves/protectiveclothing,eyeprotection/faceprotection.
Useonlyoutdoorsorinawell-ventilatedarea.Avoidcontactwithinternalacid.Donotbreathe
dust/fume/gas/mist/vapors/spray.Keepawayfromheat/sparks/openflames/hotsurfaces.Nosmoking.
IFSWALLOWED OR CONSUMED: rinse mouth. Do NOT induce vomiting. Call a poison center/doctor if you feel
unwell.IFONCLOTHINGORSKIN(orhair):Remove/Take off immediately all contaminated clothing and wash
itbeforereuse.Rinseskinwithwater/shower. IF INHALED: Remove person to fresh air and keep comfortable
forbreathing.ImmediatelycallaPOISONCENTERordoctor/physician.IFINEYES:Rinsecautiouslywithwater
forseveralminutes.Removecontactlenses,ifpresentandeasytodo.Continuerinsing.Ifexposed/concerned,
orifyoufeelunwellseekmedicalattention/advice.
Storelockedup,inawell-ventilatedarea,inaccordancewithlocalandnationalregulation.
Disposeofcontents/containerinaccordancewithlocalandnationalregulation.Keepoutofreachofchildren.
EnerSys, 2366 Bernville Road, Reading, PA 19605, USA - Tel: [phone]
Contains: Lead,SulfuricAcid(Electrolyte),LeadCompounds.
DANGER
2201-8677
Harmfulifswallowed,inhaled,orincontactwithskin.Acidcausessevereskinburnsandeyedamage.May
damagefertilityortheunbornchildifingestedorinhaled.Maycauseharmtobreast-fedchildren.Maycause
cancerifingestedorinhaled.Causesskinirritation,seriouseyedamage.Contactwithinternalcomponents
maycauseirritationorsevereburns.Causesdamagetocentralnervoussystem,bloodandkidneysthrough
prolongedorrepeatedexposureifingestedorinhaled.Irritatingtoeyes,respiratorysystem,andskin.May
formexplosiveair/gasmixtureduringcharging.Extremelyflammablegas(hydrogen).Explosive,fire,blastor
projectionhazard.
Obtainspecialinstructionsbeforeuse.Donothandleuntilallsafetyprecautionshavebeenreadand
understood.Washthoroughlyafterhandling.Donoteatdrinkorsmokewhenusingthisproduct.Avoid contact
duringpregnancy/whilenursing.Wearprotectivegloves/protectiveclothing,eyeprotection/faceprotection.
Useonlyoutdoorsorinawell-ventilatedarea.Avoidcontactwithinternalacid.Donotbreathe
dust/fume/gas/mist/vapors/spray.Keepawayfromheat/sparks/openflames/hotsurfaces.Nosmoking.
IFSWALLOWED OR CONSUMED: rinse mouth. Do NOT induce vomiting. Call a poison center/doctor if you feel
unwell.IFONCLOTHINGORSKIN(orhair):Remove/Take off immediately all contaminated clothing and wash
itbeforereuse.Rinseskinwithwater/shower. IF INHALED: Remove person to fresh air and keep comfortable
forbreathing.ImmediatelycallaPOISONCENTERordoctor/physician.IFINEYES:Rinsecautiouslywithwater
forseveralminutes.Removecontactlenses,ifpresentandeasytodo.Continuerinsing.Ifexposed/concerned,
orifyoufeelunwellseekmedicalattention/advice.
Storelockedup,inawell-ventilatedarea,inaccordancewithlocalandnationalregulation.
Disposeofcontents/containerinaccordancewithlocalandnationalregulation.Keepoutofreachofchildren.
EnerSys, 2366 Bernville Road, Reading, PA 19605, USA - Tel: [phone]
Contains: Lead,SulfuricAcid(Electrolyte),LeadCompounds.
DANGER
2201-8677
Harmfulifswallowed,inhaled,orincontactwithskin.Acidcausessevereskinburnsandeyedamage.May
damagefertilityortheunbornchildifingestedorinhaled.Maycauseharmtobreast-fedchildren.Maycause
cancerifingestedorinhaled.Causesskinirritation,seriouseyedamage.Contactwithinternalcomponents
maycauseirritationorsevereburns.Causesdamagetocentralnervoussystem,bloodandkidneysthrough
prolongedorrepeatedexposureifingestedorinhaled.Irritatingtoeyes,respiratorysystem,andskin.May
formexplosiveair/gasmixtureduringcharging.Extremelyflammablegas(hydrogen).Explosive,fire,blastor
projectionhazard.
Obtainspecialinstructionsbeforeuse.Donothandleuntilallsafetyprecautionshavebeenreadand
understood.Washthoroughlyafterhandling.Donoteatdrinkorsmokewhenusingthisproduct.Avoid contact
duringpregnancy/whilenursing.Wearprotectivegloves/protectiveclothing,eyeprotection/faceprotection.
Useonlyoutdoorsorinawell-ventilatedarea.Avoidcontactwithinternalacid.Donotbreathe
dust/fume/gas/mist/vapors/spray.Keepawayfromheat/sparks/openflames/hotsurfaces.Nosmoking.
IFSWALLOWED OR CONSUMED: rinse mouth. Do NOT induce vomiting. Call a poison center/doctor if you feel
unwell.IFONCLOTHINGORSKIN(orhair):Remove/Take off immediately all contaminated clothing and wash
itbeforereuse.Rinseskinwithwater/shower. IF INHALED: Remove person to fresh air and keep comfortable
forbreathing.ImmediatelycallaPOISONCENTERordoctor/physician.IFINEYES:Rinsecautiouslywithwater
forseveralminutes.Removecontactlenses,ifpresentandeasytodo.Continuerinsing.Ifexposed/concerned,
orifyoufeelunwellseekmedicalattention/advice.
Storelockedup,inawell-ventilatedarea,inaccordancewithlocalandnationalregulation.
Disposeofcontents/containerinaccordancewithlocalandnationalregulation.Keepoutofreachofchildren.
EnerSys, 2366 Bernville Road, Reading, PA 19605, USA - Tel: [phone]
Contains: Lead,SulfuricAcid(Electrolyte),LeadCompounds.
DANGER
2201-8677
Harmfulifswallowed,inhaled,orincontactwithskin.Acidcausessevereskinburnsandeyedamage.May
damagefertilityortheunbornchildifingestedorinhaled.Maycauseharmtobreast-fedchildren.Maycause
cancerifingestedorinhaled.Causesskinirritation,seriouseyedamage.Contactwithinternalcomponents
maycauseirritationorsevereburns.Causesdamagetocentralnervoussystem,bloodandkidneysthrough
prolongedorrepeatedexposureifingestedorinhaled.Irritatingtoeyes,respiratorysystem,andskin.May
formexplosiveair/gasmixtureduringcharging.Extremelyflammablegas(hydrogen).Explosive,fire,blastor
projectionhazard.
Obtainspecialinstructionsbeforeuse.Donothandleuntilallsafetyprecautionshavebeenreadand
understood.Washthoroughlyafterhandling.Donoteatdrinkorsmokewhenusingthisproduct.Avoid contact
duringpregnancy/whilenursing.Wearprotectivegloves/protectiveclothing,eyeprotection/faceprotection.
Useonlyoutdoorsorinawell-ventilatedarea.Avoidcontactwithinternalacid.Donotbreathe
dust/fume/gas/mist/vapors/spray.Keepawayfromheat/sparks/openflames/hotsurfaces.Nosmoking.
IFSWALLOWED OR CONSUMED: rinse mouth. Do NOT induce vomiting. Call a poison center/doctor if you feel
unwell.IFONCLOTHINGORSKIN(orhair):Remove/Take off immediately all contaminated clothing and wash
itbeforereuse.Rinseskinwithwater/shower. IF INHALED: Remove person to fresh air and keep comfortable
forbreathing.ImmediatelycallaPOISONCENTERordoctor/physician.IFINEYES:Rinsecautiouslywithwater
forseveralminutes.Removecontactlenses,ifpresentandeasytodo.Continuerinsing.Ifexposed/concerned,
orifyoufeelunwellseekmedicalattention/advice.
Storelockedup,inawell-ventilatedarea,inaccordancewithlocalandnationalregulation.
Disposeofcontents/containerinaccordancewithlocalandnationalregulation.Keepoutofreachofchildren.
EnerSys, 2366 Bernville Road, Reading, PA 19605, USA - Tel: [phone]
Contains: Lead,SulfuricAcid(Electrolyte),LeadCompounds.
DANGER
2201-8677
Harmfulifswallowed,inhaled,orincontactwithskin.Acidcausessevereskinburnsandeyedamage.May
damagefertilityortheunbornchildifingestedorinhaled.Maycauseharmtobreast-fedchildren.Maycause
cancerifingestedorinhaled.Causesskinirritation,seriouseyedamage.Contactwithinternalcomponents
maycauseirritationorsevereburns.Causesdamagetocentralnervoussystem,bloodandkidneysthrough
prolongedorrepeatedexposureifingestedorinhaled.Irritatingtoeyes,respiratorysystem,andskin.May
formexplosiveair/gasmixtureduringcharging.Extremelyflammablegas(hydrogen).Explosive,fire,blastor
projectionhazard.
Obtainspecialinstructionsbeforeuse.Donothandleuntilallsafetyprecautionshavebeenreadand
understood.Washthoroughlyafterhandling.Donoteatdrinkorsmokewhenusingthisproduct.Avoid contact
duringpregnancy/whilenursing.Wearprotectivegloves/protectiveclothing,eyeprotection/faceprotection.
Useonlyoutdoorsorinawell-ventilatedarea.Avoidcontactwithinternalacid.Donotbreathe
dust/fume/gas/mist/vapors/spray.Keepawayfromheat/sparks/openflames/hotsurfaces.Nosmoking.
IFSWALLOWED OR CONSUMED: rinse mouth. Do NOT induce vomiting. Call a poison center/doctor if you feel
unwell.IFONCLOTHINGORSKIN(orhair):Remove/Take off immediately all contaminated clothing and wash
itbeforereuse.Rinseskinwithwater/shower. IF INHALED: Remove person to fresh air and keep comfortable
forbreathing.ImmediatelycallaPOISONCENTERordoctor/physician.IFINEYES:Rinsecautiouslywithwater
forseveralminutes.Removecontactlenses,ifpresentandeasytodo.Continuerinsing.Ifexposed/concerned,
orifyoufeelunwellseekmedicalattention/advice.
Storelockedup,inawell-ventilatedarea,inaccordancewithlocalandnationalregulation.
Disposeofcontents/containerinaccordancewithlocalandnationalregulation.Keepoutofreachofchildren.
EnerSys, 2366 Bernville Road, Reading, PA 19605, USA - Tel: [phone]
Contains: Lead,SulfuricAcid(Electrolyte),LeadCompounds.
DANGER
2201-8677
Harmfulifswallowed,inhaled,orincontactwithskin.Acidcausessevereskinburnsandeyedamage.May
damagefertilityortheunbornchildifingestedorinhaled.Maycauseharmtobreast-fedchildren.Maycause
cancerifingestedorinhaled.Causesskinirritation,seriouseyedamage.Contactwithinternalcomponents
maycauseirritationorsevereburns.Causesdamagetocentralnervoussystem,bloodandkidneysthrough
prolongedorrepeatedexposureifingestedorinhaled.Irritatingtoeyes,respiratorysystem,andskin.May
formexplosiveair/gasmixtureduringcharging.Extremelyflammablegas(hydrogen).Explosive,fire,blastor
projectionhazard.
Obtainspecialinstructionsbeforeuse.Donothandleuntilallsafetyprecautionshavebeenreadand
understood.Washthoroughlyafterhandling.Donoteatdrinkorsmokewhenusingthisproduct.Avoid contact
duringpregnancy/whilenursing.Wearprotectivegloves/protectiveclothing,eyeprotection/faceprotection.
Useonlyoutdoorsorinawell-ventilatedarea.Avoidcontactwithinternalacid.Donotbreathe
dust/fume/gas/mist/vapors/spray.Keepawayfromheat/sparks/openflames/hotsurfaces.Nosmoking.
IFSWALLOWED OR CONSUMED: rinse mouth. Do NOT induce vomiting. Call a poison center/doctor if you feel
unwell.IFONCLOTHINGORSKIN(orhair):Remove/Take off immediately all contaminated clothing and wash
itbeforereuse.Rinseskinwithwater/shower. IF INHALED: Remove person to fresh air and keep comfortable
forbreathing.ImmediatelycallaPOISONCENTERordoctor/physician.IFINEYES:Rinsecautiouslywithwater
forseveralminutes.Removecontactlenses,ifpresentandeasytodo.Continuerinsing.Ifexposed/concerned,
orifyoufeelunwellseekmedicalattention/advice.
Storelockedup,inawell-ventilatedarea,inaccordancewithlocalandnationalregulation.
Disposeofcontents/containerinaccordancewithlocalandnationalregulation.Keepoutofreachofchildren.
EnerSys, 2366 Bernville Road, Reading, PA 19605, USA - Tel: [phone]
Contains: Lead,SulfuricAcid(Electrolyte),LeadCompounds.
DANGER
2201-8677

www.enersys.com
IMPORTANT
Read safety information first
See Safety, Storage, Operating and Maintenance Manual
4

BatteryInstallationManual
Pubication No: US-DDM-IM-AA - June 2016
TABLE OF CONTENTS
GENERAL SAFETY INSTRUCTIONS 1
GENERAL INFORMATION 6
RECOMMENDED INSTALLATION EQUIPMENT AND SUPPLIES 8
SYSTEM LAYOUT 9
Anchor Spacing 10
FRAME ASSEMBLY AND INSTALLATION 11
Base Beams 11
Vertical Channels 11
Horizontal Channels 12
Cell Support Shelves 14
BATTERY CELL INSTALLATION 15
Module Retainers 16
Electrical Bonding Instructions 16
CONNECTIONS 17
Terminal Plates 17
Inter-Cell Connectors 18
Terminal Bars 19
INITIAL SYSTEM READINGS 20
SAFETY SHIELDS AND COVERS 21
Safety Shields 21
Terminal Plate Covers 21
5

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GENERAL INFORMATION
PowerSafe®DDm battery systems are modular units that can be installed in a SINGLE STACK (Figure 1), a MULTI-STACK
(Figure 2), or a MULTI-STACK ZERO SEPARATION (Figures 3A and 3B).
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
6

BatteryInstallationManual
Pubication No: US-DDM-IM-AA - June 2016
MULTI-STACK
FIGURE 2 MULTI-STACK ZERO SEPARATION
FIGURE 3A
MULTI-STACK ZERO SEPARATION
FIGURE 3B
7

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RECOMMENDED INSTALLATION EQUIPMENT AND SUPPLIES
Before working with the battery system, be sure that you have the proper protective clothing, safety equipment and
insulated tools as specified in the Safety, Storage, Operating and Maintenance Manual for the VRLA Modular Battery
Systems.
The following is a recommended list of equipment required for installation of a PowerSafe®DDm Battery System.
TABLE 1
EQUIPMENT REQUIRED CHECK IF ON HAND
Chalk Line
Torpedo Level (Plastic)
Torque Wrench (10-200 in-lbs) (SAE and Metric)
Torque Wrench (50-100 ft-lbs) (SAE and Metric)
Floor Anchors (User-supplied per battery system)
Floor Shims (User-supplied)
Drive Ratchet Wrench with Minimum 3” Extension (SAE and Metric)
Box Wrenches (SAE and Metric)
Screwdrivers
Wipes, Paper or Cloth
Stiff Bristle Nonmetallic Brush/Pad
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.
8
Harmfulifswallowed,inhaled,orincontactwithskin.Acidcausessevereskinburnsandeyedamage.May
damagefertilityortheunbornchildifingestedorinhaled.Maycauseharmtobreast-fedchildren.Maycause
cancerifingestedorinhaled.Causesskinirritation,seriouseyedamage.Contactwithinternalcomponents
maycauseirritationorsevereburns.Causesdamagetocentralnervoussystem,bloodandkidneysthrough
prolongedorrepeatedexposureifingestedorinhaled.Irritatingtoeyes,respiratorysystem,andskin.May
formexplosiveair/gasmixtureduringcharging.Extremelyflammablegas(hydrogen).Explosive,fire,blastor
projectionhazard.
Obtainspecialinstructionsbeforeuse.Donothandleuntilallsafetyprecautionshavebeenreadand
understood.Washthoroughlyafterhandling.Donoteatdrinkorsmokewhenusingthisproduct.Avoid contact
duringpregnancy/whilenursing.Wearprotectivegloves/protectiveclothing,eyeprotection/faceprotection.
Useonlyoutdoorsorinawell-ventilatedarea.Avoidcontactwithinternalacid.Donotbreathe
dust/fume/gas/mist/vapors/spray.Keepawayfromheat/sparks/openflames/hotsurfaces.Nosmoking.
IFSWALLOWED OR CONSUMED: rinse mouth. Do NOT induce vomiting. Call a poison center/doctor if you feel
unwell.IFONCLOTHINGORSKIN(orhair):Remove/Take off immediately all contaminated clothing and wash
itbeforereuse.Rinseskinwithwater/shower. IF INHALED: Remove person to fresh air and keep comfortable
forbreathing.ImmediatelycallaPOISONCENTERordoctor/physician.IFINEYES:Rinsecautiouslywithwater
forseveralminutes.Removecontactlenses,ifpresentandeasytodo.Continuerinsing.Ifexposed/concerned,
orifyoufeelunwellseekmedicalattention/advice.
Storelockedup,inawell-ventilatedarea,inaccordancewithlocalandnationalregulation.
Disposeofcontents/containerinaccordancewithlocalandnationalregulation.Keepoutofreachofchildren.
EnerSys, 2366 Bernville Road, Reading, PA 19605, USA - Tel: [phone]
Contains: Lead,SulfuricAcid(Electrolyte),LeadCompounds.
DANGER
2201-8677

M
M
W
7.67
M
M
W
7.67
BatteryInstallationManual
Pubication No: US-DDM-IM-AA - June 2016
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. Recommended minimum
clearance between these racks and any objects (including
walls and equipment) is 4 inches (102 mm).
1. Layout the system position for either a SINGLE STACK
(Figure 4), a MULTI-STACK (Figure 5), or MULTI-
STACK WITH ZERO SEPARATION (Figures 6, 7 and 8)
configuration with the dimensions defined in Table 2.
2. Locate the position of the floor anchors using the frame
base beams.
NOTE:
• Floor anchoring is REQUIRED for all installations.
• Allow sufficient clearance between adjacent walls or
equipment for proper installation of anchors. Please
check your local codes for clearances required.
• Floor anchor design (including, but not limited to
size, quantity and capacity) and installation are the
responsibility of the user/installer.
• Follow the user’s design and the manufacturer’s
instructions.
3. Mark floor with the position of the floor anchors.
MULTI-STACK
FIGURE 5
DDm35/50 MULTI-STACK WITH ZERO SEPARATION
FIGURE 6
SINGLE STACK
FIGURE 4
DDm85/100 MULTI-STACK WITH ZERO SEPARATION
FIGURE 7
DDm125 MULTI-STACK WITH ZERO SEPARATION
FIGURE 8
9
D
D=Distance between
bases (variable)
W=DDm85=17.46
DDm100=20.47
FRONT

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TABLE 2
Base Beam Anchor Spacing
Cell
Model
2 Cells
Wide
3 Cells
Wide
4 Cells
Wide
6 Cells
Wide
Multi-Stack
w/zero
separation
L (in) L (in) L (in) L (in) M (in)
35-07 6.04 N/A 10.52 15.01 L+0.89
50-09 9.04 N/A 16.52 24.01 L+0.89
50-13 12.04 N/A 22.52 33.01 L+0.89
50-17 15.49 22.48 29.26 43.17 L+0.89
85-13 12.04 N/A 22.52 33.01 L-2.95
85-15 13.54 N/A 25.52 37.51 L-2.95
85-21 18.48 26.93 35.26 53.71 L-2.95
85-25 21.48 31.43 41.26 42.68 L-2.95
85-27 22.98 33.69 44.27 67.22 L-2.95
85-33 27.48 40.43 53.26 80.71 L-2.95
100-21 18.48 26.93 35.26 53.71 L-2.95
100-25 21.48 31.43 41.26 62.68 L-2.95
100-27 22.98 33.69 44.27 67.22 L-2.95
100-33 27.48 40.43 53.26 80.71 L-2.95
125-25 22.09 31.88 41.98 63.29 L-4.24
125-27 23.59 34.14 44.98 67.83 L-4.24
125-33 28.09 40.88 53.98 81.32 L-4.24
Anchor Spacing
EXAMPLE:
If you are installing a DDm85 MULTI-STACK WITH ZERO SEPARATION and you have 21 plates/cell, 4 cells wide.
10
M (inches) = L (in) - 2.95”
35.26” - 2.95” = 32.31”

BatteryInstallationManual
Pubication No: US-DDM-IM-AA - June 2016
FRAME ASSEMBLY AND INSTALLATION
To assemble and install the frame for the PowerSafe®DDm
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. Do NOT torque anchor bolts until frame assembly is
complete.
2. Install ALL base beams before continuing.
Vertical Channels
1. Insert vertical channels into base beams.
See Figure 9.
2. Bolt vertical channels to base beams. Refer to below list
for hardware order and Figure 10:
• Serrated Hex Bolt (M10x1.5 – 100mm)
• Rack Frame
• External Tooth Washer
• Flat Washer
• Lock Washer
• Hex Nut
3. Torque all connections (except anchor bolts) to 40 ft-lbs.
VERTICAL CHANNEL TO BASE
BEAM HARDWARE DETAIL
FIGURE 10
INSTALL VERTICALS
FIGURE 9
11

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Horizontal Channels
Starting at the bottom of the rear verticals:
1. Insert horizontal channels into the vertical channels.
Center the horizontals between the verticals. See Figures
11A and 11B.
2. Bolt horizontal channels to vertical channels.
Refer to below list for hardware order and Figure 12:
NOTE:
The bottom two horizontal channels require full thread
longer bolts at the vertical channel.
Bottom horizontal channel:
• Serrated Hex Bolt (M10x1.5 – 100mm Full Threads)
• Rack Frame
• External Tooth Washer
• Flat Washer
• Lock Washer
• Hex Nut
Second from bottom horizontal channel:
• Serrated Hex Bolt (M10x1.5 – 75mm Full Threads)
• Rack Frame
• External Tooth Washer
• Flat Washer
• Lock Washer
• Hex Nut
All other horizontals:
• Serrated Hex Bolt (M10x1.5 – 25mm)
3. Finger-tighten connections.
4. Install all rear horizontal channels before continuing.
INSTALL REAR HORIZONTAL CHANNELS
FIGURE 11B
REAR HORIZONTAL CHANNEL HARDWARE DETAIL
FIGURE 12
INSTALL REAR HORIZONTAL CHANNELS
FIGURE 11A
12

BatteryInstallationManual
Pubication No: US-DDM-IM-AA - June 2016
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.
Bottom horizontal channel:
• Serrated Hex Bolt (M10x1.5 – 100mm Full Threads)
• Rack Frame
• External Tooth Washer
• Flat Washer
• Lock Washer
• Hex Nut
Second from bottom horizontal channel:
• Serrated Hex Bolt (M10x1.5 – 75mm Full Threads)
• Rack Frame
• External Tooth Washer
• Flat Washer
• Lock Washer
• Hex Nut
All other horizontals:
• Serrated Hex Bolt (M10x1.5 – 25mm)
3. Finger-tighten connections.
4. Install all front horizontal channels before continuing.
INSTALL FRONT HORIZONTAL CHANNELS
FIGURE 13A
INSTALL FRONT HORIZONTAL CHANNELS
FIGURE 13B
FRONT HORIZONTAL CHANNEL HARDWARE DETAIL
FIGURE 14
13

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Cell Support Shelves
Starting at the bottom of the rack:
1. Place shelves over horizontals. See Figure 15.
2. Align holes of shelf with holes of horizontal channels.
Bolt the shelf to the REAR horizontal using (two)
M10x1.5 – 25mm Serrated Hex Bolts in the two OUTSIDE
holes of the shelf. See Figure 16.
3. Torque these bolts to 20 ft-lbs.
4. After ALL shelves for the rack are in place, position the
vertical channels so that the front and rear horizontals fit
tightly against the shelves. See Figure 17.
5. Torque ALL bolts connecting the horizontals to the
verticals to 20 ft-lbs.
NOTE:
MULTI-STACK WITH ZERO SEPARATION systems are
fastened together at the top front and top rear with a
steel tie bar/plate.
6. Torque all anchor bolts according to system design and
manufacturer’s recommendations.
INSTALL BOTTOM CELL SUPPORT SHELF
FIGURE 15
CELL SUPPORT SHELF REAR HARDWARE DETAIL
FIGURE 16
INSTALL CELL SUPPORT SHELVES
FIGURE 17
14

BatteryInstallationManual
Pubication No: US-DDM-IM-AA - June 2016
BATTERY CELL INSTALLATION
DDm battery cells are designed for shipment and use in steel
modules.
USE CAUTION WHEN HANDLING THE DDm MODULES
After a cell has been inserted into a module at
the factory, a loose fit could develop because of
recombination. The cell could slip very easily from the
module if the module/cell is turned so that the open
end of the module is lower than the closed end of the
module.
Serious personal injury could result if the cell slides
unintentionally from the module. Keep shipping/
installation retainer in place until modules are safely
positioned on the shelves.
1. BEFORE installing the cells, check the voltages.
The minimum acceptable cell voltage is 2.05 vpc.
If a cell has a voltage below 2.05 vpc, call your nearest
EnerSys®sales/service representative for resolution, or
call the corporate office number listed on the back of this
manual and ask for EnerSys Service.
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
EnerSys Service.
If terminals are acceptable:
3. Place the FIRST DDm module onto the LOWEST EMPTY
shelf, with the terminals toward the front. See Figure 18.
INSTALL SECOND MODULE
FIGURE 19
INSTALL FIRST MODULE
FIGURE 18
INSTALL MODULES
FIGURE 20
15

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NOTE:
The larger modules are too heavy to lift onto the shelves
manually. To avoid personal injury use appropriate
lifting devices when lifting modules onto the shelves.
4. Slide the module back into a safe position.
Remove the shipping retainer.
5. Slide module completely into position so the lip of the
module touches the front of the shelf.
6. Place another cell onto the shelf next to the previously
placed battery sleeve. Refer to the Assembly Drawing for
the cell polarity configuration. See Figure 19.
7. Install remaining cells working from the lower shelves to
the higher shelves. See Figures 20 and 21.
Module Retainers
1. For each battery module, install retainer plates and
spacers as required, using a M10x1.5 – 25mm Serrated
Hex Bolt. See Figure 22.
2. Torque to 20 ft-lbs.
Electrical Bonding Instructions
1. For each battery module, install one M6 Self-Tapping
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
INSTALL RETAINERS
FIGURE 22
INSTALL MODULES
FIGURE 21
16
NOTE:
The top row of the rack requires spacers to be installed
behind the upper lip of the battery modules. This spacer
is fastened into place with the retainer and retainer bolt.

BatteryInstallationManual
Pubication No: US-DDM-IM-AA - June 2016
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.
Terminal Plates
Terminal plates are provided with the battery system to
provide a system connections point. All system connections
must be made to the terminal plate and NEVER to the cell
terminal. Top termination is standard, on most configurations,
side termination is optional.
1. Clean the terminal plate electrical contact areas with a
stiff-bristle nonmetallic brush/pad until the plated surface
is bright. Be careful not to remove the plating with
excessive brushing.
2. Apply a light coat of heated NO-OX-ID grease to the
terminal plate electrical contact area with a small
paintbrush.
3. Assemble and install the terminal plate assembly
finger-tight as shown in Figure 24.
4. Check for alignment with cell terminal.
5. Torque all bolts to 15 ft-lbs.
INSTALL TERMINAL PLATES
FIGURE 24
17

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Inter-Cell Connectors
The connections are made by bolting the supplied plated
copper inter-cell and intermodule connectors to the cell
posts of opposite polarity on adjacent cells. See ASSEMBLY
DRAWING for details.
1. Clean the contact surface of the inter-cell connector using
a stiff-bristle nonmetallic brush/pad. Be careful not to
remove the plating with excessive brushing.
2. Apply a light coat of heated NO-OX-ID grease to the
contact surface of the inter-cell connector and terminal
post with a small paintbrush.
3. Bolt all inter-cell connectors according to the ASSEMBLY
DRAWING. Assemble as the example shown in Figure 25
and below list:
NOTE:
Stamped flat washers may have one sharp edge. Install
the washer with the sharp edge away from the plated
copper inter-cell connector to avoid damaging the
plating
• Hex Bolt
• Flat Washer
• Connector
• Battery Post
• Connector
• Flat Washer
• Lock Washer
• Hex Nut
NOTE:
Inter-cell connections vary in length depending on the
type of connection (cell-to-cell, module-to-module, etc.)
and/or stack configuration.
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.
INSTALL INTER-CELL CONNECTORS
FIGURE 25
18