MYERS Illuminator System CM Series User manual
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This unit contains LETHAL VOLTAGES. All repairs and service should be performed by
AUTHORIZED SERVICE PERSONNEL ONLY! There are NO USER SERVICEABLE
PARTS inside this unit.
IMPORTANT SAFEGUARDS
When using electrical equipment, you should always follow basic safety
precautions, including the following:
1. READ AND FOLLOW ALL SAFETY
INSTRUCTIONS.
2. Do not install the system outdoors.
3. Do not install near gas or electric heaters or in other high-temperature
locations.
4. Use caution when servicing batteries. Depending on battery type, batteries
contain either acid or alkali and can cause burns to skin and eyes. If
battery fluid is spilled on skin or in the eyes, flush with fresh water and
contact a physician immediately.
5. Equipment should be mounted in locations where unauthorized personnel
will not readily subject it to tampering.
6. The use of accessory equipment not recommended by Manufacturer may
cause an unsafe condition and void the warranty.
7. Do not use this equipment for other than its intended use.
8. Qualified service personnel must perform all servicing of this equipment.
SAVE THESE INSTRUCTIONS
The installation and use of this product must comply with all national, federal,
state, municipal, or local codes that apply. If you need help, please call
Service at 1-610-868-5400.
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C A U T I O N
READ ENTIRE MANUAL AND REVIEW ALL DOCUMENTATION BEFORE ATTEMPTING SYSTEM
INSTALLATION!
FOR SERVICE OR INSTALLATION INFORMATION:
TELEPHONE: (610) 868-5400 (24 HR. HOTLINE)
FAX: (610) 954-8227
FOR YOUR PROTECTION....
PLEASE COMPLETE AND RETURN WARRANTY REGISTRATION CARD IMMEDIATELY.
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C H A P T E R 1
SAFETY WARNINGS
Read the following precautions before you install the Illuminator Series C-M.
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS. This manual contains important instructions that you should
follow during installation and maintenance of the system and batteries. Please read all instructions
before operating the equipment and save this manual for future reference.
DANGER
This system contains LETHAL VOLTAGES. AUTHORIZED SERVICE PERSONNEL should
perform all repairs and service ONLY. There is NO USER SERVICEABLE PARTS inside.
WARNING
•Do not install the system outdoors.
•Do not install near gas or electric heaters or in other high-temperature locations.
•Use caution when servicing batteries. Battery acid can cause burns to skin and eyes. If acid is
spilled on skin or in the eyes, flush with fresh water and contact a physician immediately.
•Equipment should be mounted in locations where it is not readily subjected to tampering by
unauthorized personnel.
•The use of accessory equipment not recommended by the manufacturer may cause an unsafe
condition.
•Do not use this equipment for other than intended use.
•Only qualified service personnel (such as a licensed electrician) should perform the system and
battery installation and initial startup. Risk of electrical shock.
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C H A P T E R 2
INTRODUCTION
Please read this manual thoroughly before operating your safety system. Keep this manual and
the system User’s Guide.
WARNING
Only qualified service personnel (such as a licensed electrician) should perform the system
and battery installation and initial startup. Risk of electrical shock.
Please record your unit’s model number, serial number, and part number below. You can find
these numbers on the label on the inside of the system’s circuit breaker door.
Model Number __________________________
Serial Number __________________________
Part Number __________________________
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C H A P T E R 3
BEFORE INSTALLING THE UNIT
Installation Dimensions
INVERTER MODULE DIMENSIONS – 10” X 10” X 26”
INVERTER MODULE WITH BATTERY MODULE DIMENSIONS
UNIT SIZE WIDTH HEIGHT DEPTH
500 26” 20” 10”
1000 26” 30” 10”
1500 26” 40” 10”
2000 26” 50” 10”
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Location Guidelines
Keep the following guidelines in mind when choosing the location for your system and batteries:
•Verify that the environment meets the requirements in “Storage and Operating Environment” on
page 7. The environment can affect the reliability and performance of both the unit and the
batteries.
•Install any separate battery cabinets as close as possible to the unit to reduce the cost of DC
wiring and to improve battery performance. We recommend no clearance between the unit and
the battery cabinet; in other words, the battery cabinet(s) should be directly under or to the left
side of the unit (when you face the front of the unit). If you must place the battery cabinet away
from the unit, you must supply the proper length, gauge, and type of battery cables, and you must
make sure the installation meets the applicable NEC (CEC) requirements.
•Choose a permanent location for the unit and any battery cabinets. Attempting to move them after
you have installed the batteries can damage the batteries and the cabinet.
CAUTION
Do not move the unit or the battery cabinet after you install the batteries. If you do, the unit or
battery cabinet and batteries may be damaged.
CEC (Canadian Electric Code) requires the unit to be located in a service room. If the room is
equipped with a sprinkler system, the unit must be provided with sprinkler proof covers.
The system should be connected to the emergency generator, if available.
This equipment is heavy. Refer to Table 3.4 when you choose a site to make sure that
the floor can support the weight of the system, the batteries, any separate battery
cabinets, and any other necessary equipment.
Table 3.4 System weight [in lbs. (kg)]
500W
1000W
1500W
2000W
Battery
Cabinet 22 (10) 44 (20) 66 (30) 88 (40)
Inverter
Cabinet 72 (33) 72 (33) 72 (33) 72 (33)
Batteries 108 (49) 216 (98) 324 (147) 432 (196)
System
Total 202 (92) 332 (151) 462 (210) 592 (269)
Receiving and Handling the Unit and the Batteries
This system can weigh several hundred pounds (see Table 3.4; ask your sales representative for
additional information). Make sure you are prepared for these weights before you unload or move the
unit or the batteries. Do not install any batteries until you have permanently installed the unit with
battery cabinets and connected all conduit and wiring.
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Storage and Operating Environment
Make sure you store and install the system in a clean, cool, dry place with normal ventilation for
human habitation and level floors.
Storage Temperature
Store the batteries at -18 to 40°C (0 to 104°F). Batteries have a longer shelf life if they are stored
below 25°C (77°F). Keep stored batteries fully charged. Recharge the batteries every 90–120 days.
The system or battery cabinet without batteries may be stored at -20 to 70°C (-4 to 158°F).
Ventilation
The air around the unit must be clean, dust-free, and free of corrosive chemicals or other
contaminants. Do not place the system or batteries in a sealed room or container.
Operating Temperature
System can operate from 20° to 30°C (68° to 86°F) and up to 95% relative humidity. The batteries’
service life is longer if the operating temperature stays below 25°C (77°F).
Batteries
The temperature should be near 25°C (77°F) for optimum battery performance. Batteries are less
efficient at temperatures below 18°C (65°F), and high temperatures reduce battery life. Typically, at
about 35°C (95°F), battery life is half of what it would be at a normal temperature of 25°C (77°F). At
about 45°C (113°F), battery life is one-fourth of normal.
Make sure that heaters, sunlight, air conditioners, or outside air vents are not directed toward the
batteries. These conditions can make the temperature within battery strings vary, which can cause
differences in the batteries’ voltages. Eventually, these conditions affect battery performance.
Remember that the batteries should be installed as close as possible to the unit to reduce DC wiring
costs and improve battery performance.
Do not allow tobacco smoking, sparks, or flames in the system location because hydrogen is
concentrated under the vent cap of each cell of the battery. Hydrogen is highly explosive, and it is
hard to detect because it is colorless, odorless, and lighter than air.
Every type of battery can produce hydrogen gas, even sealed maintenance-free batteries. The gas is
vented through the vent caps and into the air, mainly when the unit is charging the batteries. The
batteries produce the most hydrogen when maximum voltage is present in fully charged batteries; the
batteries do not produce hydrogen during float charging. The amount of current that the charger
supplies to the batteries (not the battery ampere-hour) determines how much hydrogen is produced.
High Altitude Operation
The maximum operating ambient temperature drops 1°C per 300m (2°F per 1000 ft) above sea level.
Maximum elevation is 3000m (10,000 ft).
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C H A P T E R 4
INSTALLATION OVERVIEW
Figure 4.1 shows a typical vertical installation of the system. This drawing depicts a 2000W inverter
with battery cabinets. The Illuminator Series C-M is a modular system capable of single-phase power
outputs up to 2,000 Watts depending on the number of battery cabinets. The Inverter and Battery
modules are shipped separate and require attachment for the depicted typical vertical installation
shown in figure 4.1. All instructions included in this literature are for this type of installation.
4 x ¼-20 bolts that the user must install secure each cabinet to each other. There are Electrical
Knock- Outs in the vertical and horizontal axis to allow inter-connectivity in multiple configurations.
The Vertical installation is the most popular however; allowing the batteries to be mounted separately
and horizontally allows the user to fit this system almost anywhere where floor space is tight or not
available at all.
Figure 4.1 Typical Vertical Installation
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Inverter Module and Battery Module Assembly
Refer to Chapter 8 for Optional Wall Mounting directions.
5 x 8-32 screws located on the front and top of the module easily remove the
Inverter Module cover and 5 x 8-32 screws located on the front of the Battery
Module’s easily remove each cover. There are 4 holes located on each corner that
allow the ¼-20 hardware to attach to the different modules.
There are Electrical Knock-Outs that must be removed on the Inverter Module and
the Battery Module to allow passage of the battery cables. After the Electrical Knock-
Outs are removed, the factory provided plastic grommet must be inserted through
the hole to provide abrasion resistance for the wires. After the plastic grommet is
inserted, the bolts, washers and lock washers should be inserted and tightened
down. Use the plastic grommet as the alignment between the two modules. Shown
in figure 4.2 is the exploded view showing the hardware, Electrical Knock-Out and
the plastic Grommet.
Battery Module to Battery Module connections uses a plastic grommet, bolts,
washers, lock washers and nuts.
Figure 4.2
AC/DC
Distribution
Center
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TERMINAL BLOCK/CIRCUIT BREAKER STANDARD CONFIGURATION
Series C-M Inverter Module
Input AC Line, Neutral
and Earth Ground.
Output AC Line,
Neutral and Earth
Ground.
Battery Positive
4 Places
Battery
Negative
4 places
Fuse Block
Input Circuit Breaker CB2
Output Circuit Breaker CB3
Battery Circuit Breaker
CB1
Battery Module (s)
Ground Connector
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C H A P T E R 5
AC INPUT &AC OUTPUT INSTALLATION
WARNING
Only qualified service personnel (such as a licensed electrician) should perform the AC
installation. Risk of electrical shock.
Read the following cautions before you continue.
CAUTION
•Unit contains hazardous AC and DC voltages. Because of these voltages, a qualified
electrician must install the system, AC line service, and batteries. The electrician must
install the AC line service according to local and national codes and must be familiar
with batteries and battery installation.
•Before you install, maintain, or service the unit, always remove or shut off all sources of
AC and DC power and shut off the system. You must disconnect AC line input at the
service panel and turn off the Installation Switch (S1), the Main AC Input Circuit
Breaker (CB2), and the Battery Fuse(s) to make sure the unit does not supply output
voltage.
•Whenever AC and/or DC voltage is applied, there is AC voltage inside the unit; this is
because the unit can supply power from AC line or from its batteries. To avoid
equipment damage or personal injury, always assume that there may be voltage inside
the unit.
•Remove rings, watches, and other jewelry before installing the AC wiring. Always wear
protective clothing and eye protection and use insulated tools when working near
batteries. Whenever you are servicing an energized unit with the inside panel open,
electric shock is possible; follow all local safety codes. TEST BEFORE TOUCHING!
•To reduce the risk of fire or electric shock, install the unit and its batteries in a
temperature- and humidity-controlled indoor area free of conductive contaminants. See
page 7 for operating environment specifications.
1. Remove the Inverter Module’s cover. Make sure the installation switch and all the input
circuit breaker are off (off = left).
2. Look at the ID label inside the Inverter Module’s Circuit Breaker Access Door. Write
down the following information:
Input Voltage: __________
Output Voltage: __________
3. Now, make sure the input and output voltages are what you need. Remember that the
system provides single-phase power only.
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•Does the input voltage available for the system at the AC service panel match the
input voltage shown on the unit’s ID label?
Service Panel Voltage = ____________ Input Voltage __Yes /__No
•Does the output voltage on the ID label match the voltage your loads (protected
equipment) need?
Load Voltage = _____________ Output Voltage __Yes/__No
If you answered NO to either of the preceding questions, call SERVICE.
4. Now, use the information you wrote down in Step 2 to find the correct circuit breaker for
the service panel that is for your system.
Table 5.1 Recommended Circuit Breaker for Maximum Input Current
System VA
120VAC
277VAC
500
30A
15A
1000
30A
15A
1500
30A
15A
2000
30A
15A
5. Write down the circuit breaker value that applies to your system from Table 5.1:
__________
6. Now, look at Table 5.2 below, and use the notes below to find the proper gauge wire
for the recommended circuit breaker recorded in step 5.
Table 5.2 Recommended Minimum Wire Sizes
Read These Important Notes! For this Input
Circuit Breaker
Size...
Use this Size 90°C
Copper Wire
This table lists the AWG and mm2 wire size for each circuit breaker size.
The minimum recommended circuit breaker sizes for each model and
voltage application are listed in Table 5.1. The temperature rating of
conductor must not be less than 90° C wire. Based on the ampacities
given in Tables 310-16 of the National Electrical Code, ANSI/NFPA 70-
1993 (Table 2 of the CEC), and NEC article 220 (CEC Section 4). Circuit
conductors, must be the same size (ampacity) wires and equipment-
grounding conductors must meet Table 250-95 of the National Electrical
Code. Code may require a larger wire size than shown in this table
because of temperature, number of conductors in the conduit, or long
service runs. Follow local code requirements.
AWG mm2
10, 15, 20
12
3.31
25, 30
10
5.26
7. The input circuit breaker in the input service panel provides the means for
disconnecting AC to the unit. Only authorized persons shall be able to
disconnect AC to the unit [see NEC 700-20 and 700-21(CEC Section 46)]. If
you are using the input circuit breaker to disconnect AC, you must make sure
that only authorized persons have control of the circuit breaker panel to meet
the requirements of NEC 700-20 (CEC Section 46).
8. Read the following caution; before removing conduit knockouts.
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CAUTION
To prevent electrical shock or damage to your equipment, the Keyed
Installation Switch (S1), the Main AC Input Circuit Breaker (CB2), and the
circuit breaker at the input service panel should all be turned off. The DC
Battery Fuse(s) should be removed and the Battery Circuit Breaker should be
turned off.
9. Remove knockouts for AC Input and AC Output in the top left or left side of
the Inverter Module. AC input conductors and AC output conductors must be
installed in separate conduits, and emergency and non-emergency output
circuits must be installed in separate conduits.
CAUTION
Do not drill the cabinet; drilling cabinet will void factory warranty; drill filings may
damage the unit and keep it from operating. If you need larger knockouts, use a
chassis punch to punch out the appropriate knockout.
10. Install the conduit. You must run the AC input service conductors and AC
output conductors through separate conduits. Emergency output conductors
and non-emergency output conductors must also be run through separate
conduits. Emergency output circuits shall be installed in dedicated conduit
systems and not shared with other electrical circuits as described in NEC
700-9(b) [CEC Section 47-108].
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AC INPUT AND OUTPUT CONNECTION
Series C-M Inverter Module
Connect the AC Input and Output to the AC Terminal Blocks Labeled AC Input and
AC Output. Ensure that the systems ac voltage matches the utility input.
For the AC input, use a minimum 10 AWG wire for Line, Neutral and Ground.
For the AC output, use a minimum 12 AWG wire for Line, Neutral and Ground.
Earth Grounding of the system is achieved through the Ground terminal block. There
is a ground terminal block provided for the input and output connections. The
terminal block connects to the din rail through a clamping system and the din rail
connects to the Chassis through the din rail hardware. No additional Ground lugs are
required.
AC LINE INPUT (Black)
AC NEUTRAL INPUT (White)
EARTH GROUND (Green/Yellow)
AC LINE OUTPUT (Black)
AC NEUTRAL OUTPUT (White)
EARTH GROUND (Green/Yellow)
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C H A P T E R 6
INSTALLING BATTERIES AND DC WIRING
WARNING
Only qualified service personnel (such as a licensed electrician) should perform the
battery and DC wiring installation. Risk of electrical shock.
This section explains how to install system batteries, fuses, and cables. An electrician who is
familiar with battery installations and applicable building and electrical codes should install
the batteries.
WARNING
The batteries that will need to be installed in this system could cause you harm or severely
damage the electronics if proper precautions are not followed. Batteries connected in series
parallel configuration could produce lethal voltages with unlimited current. All batteries
should be inspected for damage prior to installation. Never install a battery that is leaking
electrolyte. Battery terminals should be cleaned with a wire brush to remove any oxidation.
All tools should be insulated. Rubber gloves and safety glasses are recommended. IN THIS
SYSTEM BATTERY NEGATIVE IS TIED TO GROUND INSIDE THE INVERTER. This
means that the battery cabinet and shelves are at ground potential as soon as negative
connections are made to the batteries. It is strongly recommended to make all negative
connections to the batteries the last step to prevent any chance of shorting battery positive to
ground. With the DC fuse removed, make connections to battery positive first, working your
way towards battery negative. Leave individual strings of batteries open at the last battery
negative until all batteries are installed. Then connect each strings negative.
Safety Instructions
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This section contains important instructions that a qualified service person should
follow during installation and maintenance of the system and batteries. ONLY a
qualified service person should work with the batteries.
CAUTION
Full voltage and current are always present at the battery terminals. The batteries used
in this system can produce dangerous voltages, extremely high currents, and a risk of
electric shock. They may cause severe injury if the terminals are shorted together or to
ground (earth). You must be extremely careful to avoid electric shock and burns
caused by contacting battery terminals or shorting terminals during battery installation.
Do not touch uninsulated battery terminals.
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A qualified electrician familiar with battery systems and required precautions must
install and service the batteries. Any battery used with this unit shall comply with the
applicable requirements for batteries in the standard for emergency lighting and power
equipment, UL 924 (Canada’s National Building Code). Cabinets are design to be used
with, and batteries must be replaced with, manufacturer battery number BAT-CG12015
or a manufacturer approved equivalent (see the battery wiring diagram that came with
the battery cables). If you substitute batteries not supplied by manufacturer, the unit’s
UL (cUL) listing is void and the equipment may fail. Installation must conform to
national and local codes as well. Keep unauthorized personnel away from batteries.
The electrician must take these precautions:
Wear protective clothing and eyewear. Batteries contain corrosive acids or caustic
alkalis and toxic materials and can rupture or leak if mistreated. Remove rings and
metal wristwatches or other metal objects and jewelry. Don’t carry metal objects in your
pockets where the objects can fall onto the batteries or into the system or battery
cabinet.
Tools must have insulated handles and must be insulated so that they do not short
battery terminals. Do not allow a tool to short a battery terminal to another battery
terminal or to the cabinet at any time. Do not lay tools or metal parts on top of the
batteries, and do not lay them where they could fall onto the batteries or into the
cabinet.
Install the batteries as shown on the battery-wiring diagram provided with the system.
When connecting cables, never allow a cable to short across a battery’s terminals, the
string of batteries, or to the cabinet.
Align the cables on the battery terminals so that the cable lug does not contact any part
of the cabinet even if the battery is moved. Keep the cable away from any sharp metal
edges.
CAUTION
Install the battery cables so they cannot be pinched by the battery cabinet or the
system covers.
External battery cabinet chassis ground (or earth) must be connected to the system’s
chassis ground (or earth). The ground conductor must be insulated. If you use conduit,
this ground conductor must be routed in the same conduit as the battery conductors.
Where conductors may be exposed to physical damage, protect conductors in
accordance with the National Electrical Code (NEC) [Canadian Electrical Code (CEC)].
If you are replacing batteries or repairing battery connections, follow the procedure in
the system user’s Guide to shut down your system and remove both AC and DC input
power.
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Before Installing the Batteries
Location
Before you start installing the batteries, you must install the Inverter Module
and any Battery Modules in their permanent location. If you have not already
done this, see “Location Guidelines” on page 6 to choose a location.
CAUTION
To prevent damage to your equipment, do not move the system or separate
battery cabinets after the batteries are installed.
To make sure a location is acceptable for the system, review the
requirements in Chapter 3.
Tools
CAUTION
Always use insulated tools when you work with batteries. Always torque
connections to the manufacturer’s recommendations.
When you work with system batteries, you need the following tools. The tools
must be insulated so they do not short battery terminals to the cabinet. Wear
the safety equipment required by local code whenever the doors are open
and whenever you are working on batteries. Other tools may be necessary for
optional batteries.
•Digital volt-ohm meter
•Conductive grease or petroleum jelly
•10mm / 7/16” open end wrench
•Brush (to apply grease or petroleum jelly to terminals)
•3” extension socket
•Safety equipment required by local codes
•Ratchet
•Torque wrench calibrated in inch-pounds or Newton-meters
•Wire brush
•10mm / 7/16” socket wrench
•Electrical tape
•Safety glasses with side shields
Battery Cable Sizing
The battery cable or wire used is No. 12 AWG for each string of batteries.
If the batteries must be more than four feet (1.2 meters) from the system, you
may need to install larger battery cables between the battery cabinets and the
system.
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Installing and Connecting the Batteries
Battery Wiring Diagram
You should have received a battery-wiring diagram with your system. This battery-wiring
diagram shows how you should install the batteries, make terminal, and fuse connections. Use
the diagram as you follow the steps below.
All systems are based on 48 VDC. When higher wattage is needed, the number of battery
strings (batteries in parallel) increases. For 500W, one string is required. For 1000W, two
strings are required. For 1500W, three strings are required and for 2000W, four strings are
required.
Connecting the Modules
Wherever conductors may be exposed to physical damage, you must protect the conductors
in accordance with the NEC (CEC). This includes battery cables between the system and a
separate battery cabinet and cables between battery cabinets (if you have more than one).
We recommend routing the battery cable through the Electrical Knock-Out’s.
If the cabinets must be farther apart, we recommend that you use conduit (cables not
included). Install the conduit for the battery cables according to local or national codes. If you
are using conduit, you must substitute your own cables for the cables shipped with the unit as
you follow the battery installation instructions. Remember that the terminal blocks supplied
with the unit and battery cabinets accept up to 10 AWG wire. Use the correct type, length, and
gauge of cable; make sure your installation meets all applicable electrical codes.
NOTE As you carry out the following steps, use these guidelines:
If you are using conductive grease, apply a thin coating of high-temperature conductive grease
on each post and every cable connector before you assemble and torque the connection to
slow corrosion.
If you use nonconductive grease like petroleum jelly, do not apply any grease before you
make the connections and torque them. Instead, make the connection first, then torque it to 40
inch pounds. After you make the connection; apply a coating of the nonconductive grease to
the hardware at the battery terminals.
Each Battery module has 4 batteries wired in series. Connect the Battery Module’s four
batteries first and then connect the battery module(s) to the inverter module.
1. Remove the Battery module fuse to isolate the battery module.
2. Start with the Red (+) wire. Connect this wire to battery one positive.
3. Jumper one (factory provided) is from battery one negative to battery two positive.
4. Jumper two (factory provided) is from battery two negative to battery three positive.
5. Jumper three (factory provided) is from battery three negative to battery 4 positive.
6. The final connection is the Yellow (-) wire. Connect this wire to battery four negative.
*** Torque all battery connections to 40 inch pounds.
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There are now 4 batteries connected in series between the red and yellow wire. The red and
yellow wires are connected into the Battery Module’s terminal blocks.
Measure with a voltmeter between the yellow terminal block (battery -) and the fuse block
where the red wire comes into it. There should measure approximately 48 VDC.
The voltage can vary as much as +/- 2 volts depending on the state of charge on the batteries.
CAUTION
If you do not verify that voltage and current direction are correct, the equipment may
fail.
Repeat this process for each battery module.
After all of the battery modules are complete, the battery module(s) can be connected to the
inverter module.
CAUTION
Hazardous voltage is present! System batteries are high current sources. These batteries can produce
dangerous voltages, extremely high currents, and a risk of electric shock.
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