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SECTION 6 

 

BATTERY REMOVAL, INSTALLATION, AND SERVICE 

 
The batteries must only be serviced by authorized service personnel. Always wear eye 
protection and have eye wash near at hand.  Never work on any connections that have 
not been disconnected from all other sources of voltage.  Parallel connected battery 
cabinets require that all battery strings in all battery cabinets be disconnected before 
working within any particular cabinet.  Also, the UPS is usually equipped with internal 
batteries that must be disconnected before service (refer to the UPS manual). 
 
Before servicing batteries, the UPS should be turned off, power should be removed 
from the UPS input, and all battery breakers and disconnect switches should be open.  
If a Maintenance Bypass Switch (MBS) is present, power to the load can be maintained 
during service.  Refer to the instructions for the MBS to put the system in bypass mode 
before removing power from the UPS. 
  
Before any battery service is attempted, the batteries must be disconnected by 
unplugging the cables to the battery trays. If it is necessary to remove the cables from 
the batteries, the connections should be marked in a way that no confusion will exist 
when it is time to reconnect the cables (see 

Figure  9

). The batteries are mounted in 

slide out trays that permit access to the battery to battery connections when the trays 
are withdrawn from the cabinet. 
 

To service the battery trays, they must be removed from the cabinet by 
a fork lift.    The 2 bus bars at the back of the tray, as shown in Figure 7, 
must be removed before servicing or replacing the batteries. 
 

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REMOVE THESE BUS BARS
BEFORE SERVICING THE
BATTERY TRAYS

 

 

Figure 7 - Battery Bus Bar 

Summary of Contents for FLP-BAT-030-150-2-N-30K

Page 1: ...003 2620 FIRSTLINE PLT Battery Cabinet FLP BAT 080 150 2 B 30K USER MANUAL...

Page 2: ...15 Battery Removal Installation and Service 15 Maintenance 17 Table 1 Symbols 3 Table 2 Model Floor Loadings 6 Table 3 Terminal Tightening Torques and Wires Sizes 13 Table 4 Replacement Batteries and...

Page 3: ...W RIGHT SIDE VIEW REAR VIEW BOTTOM VIEW AS VIEWED FROM BOTTOM UL UPS BATTERY SUPPLY 2DA6 3 56 90 5 37 86 961 6 32 62 828 7 42 12 1070 0 71 58 1818 2 5 20 132 2 10 70 271 9 31 95 811 6 WIRE ACCESS COVE...

Page 4: ...before operating the equipment and save this manual for future reference READ AND FOLLOW ALL SAFETY INSTRUCTIONS a Do not use outdoors b Do not route wiring across or near hot surfaces c Do not insta...

Page 5: ...here are NO USER SERVICEABLE PARTS inside the battery cabinet This battery cabinet contains its own energy source batteries Hazardous voltage may be present even when the battery cabinet is not connec...

Page 6: ...ons must be observed including eye protection and skin protection Contact with electrolyte requires flushing with a generous amount of clean water Seek medical attention immediately following contact...

Page 7: ...y charged the useful life of the batteries will be reduced if they are subjected to high temperatures The operating temperature range of 15o C to 40o C 5o F to 104o F must not be exceeded for even sho...

Page 8: ...a copy of the damage claim within 15 days to your service representative FLOOR LOADING When planning the installation consider the battery cabinet weight for floor loading The strength of the installa...

Page 9: ...ent support for the combined weight of the forklift and the battery cabinet 3 Make sure forks are at maximum separation 4 Use a very strong ratchet strap or similar device of sufficient strength to ti...

Page 10: ...the next battery cabinet in the set TB3 3 pole positive neutral negative terminal block and ground connection for battery power output This goes to the input of the N version battery cabinet from the...

Page 11: ...E IN A CONTROLLED ENVIRONMENT REFER TO HANDBOOK FOR ENVIRONMENTAL CONDITIONS BATTERY CIRCUIT BREAKER BATTERY CIRCUIT BREAKER DO NOT DISCONNECT UNDER LOAD BATTERIES BEHIND THIS PANEL FUSES BEHIND THIS...

Page 12: ...EAKERS BATTERY TRAYS U1 R3 R2 R1 Q1 J3 J2 J1 F1 D2 D1 DANGER RISK OF ELECTRIC SHOCK Do not touch uninsulated battery terminals CAUTION WARNING TO REDUCE RISK OF FIRE REPLACE ONLY WITH SAME TYPE AND RA...

Page 13: ...pole connections blue to blue white to white use a voltmeter to verify that the battery string is above 408 VDC at the TB3 connector If the voltage is low or the voltage varies significantly from stri...

Page 14: ...Staco s UL Listing nor is it covered by this manual TB3 is energized at all times Opening the circuit breakers does not remove power from this terminal block 4 Connect the ground wire to the 20 ground...

Page 15: ...abinet may be closed Terminal blocks on the N version cabinets are disconnected by unplugging the powerpole connectors in all cabinets This requires the removal of the inner panel by authorized person...

Page 16: ...t Breaker Interface Connections To trip the battery circuit breakers via the REPO of the UPS connect the battery cabinet interface connector TB4 to the UPS per Figure 6 If any additional battery cabin...

Page 17: ...tenance Bypass Switch MBS is present power to the load can be maintained during service Refer to the instructions for the MBS to put the system in bypass mode before removing power from the UPS Before...

Page 18: ...When the trays are to be reinstalled use the procedure in the following paragraph The battery trays are very heavy and it will be necessary to use a lifting device to support the trays as they are ins...

Page 19: ...hazard and a burn hazard Batteries should only be services by trained personnel Appropriate safety precautions must be observed including eye protection and skin protection Contact with electrolyte re...

Page 20: ...can lead to thermal runaway a condition that damages the battery Thermal runaway can cause batteries to swell If the battery cases burst the hazardous contents may be exposed Maintaining proper ambien...

Page 21: ...3 TRAY 2 TRAY 1 F1 F2 F3 F4 CONNECTORS CONNECTORS TRAY 6 TRAY 5 TRAY 4 WHITE BLUE CONNECTORS CONNECTORS RED CONNECTORS BLACK CONNECTORS F22 F3 F4 BLACK CONNECTORS CONTROL TERMINAL BLOCK LOCATED ON RE...

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