Instruction Manual for ampREVOLT models including: BHE_battbox_2.4, T25 Modular Battery Box, T25, Modular Battery Box, Battery Box, Box
Assembly Instructions for Modular Battery Box – ampREVOLT
AmpREVOLT Modular Battery Box for Tesla Battery Modules – Legacy EV
assembly instructions CAUTION *** PLEASE READ! Use of this product is intended for those with experience working with high voltage. Such work must always be done with care and caution. An error in judgement could lead to extreme injury from electrical shock, severe burns or even death. Please be aware that the ampREVOLT Modular Battery Box is wholly constructed out of 6061 billet aluminum, and is thus an excellent conductor of electricity. It is incumbent upon the installer to wear all necessary high voltage electrical safety gear whilst installing battery modules, and electrically insulate all connections as needed. Please carefully read and understand all precautions referred to throughout this document. Thank you for investing in our battery containment system for 4.5, 5.2 and 5.3kWh Tesla Battery Modules. Our unique design focuses on maximum flexibility for the end user, as well as personal safety, battery protection and longevity. Recommended tools/supplies: · T25 Torx Bit (included) · Drill/driver, bit screwdriver, or ¼" socket for T25 bit · Philips head PH2 screwdriver · Blue thread-lock for all screw fasteners · Angle grinder for modules with aluminum flanges or tin snips for those with plastic flanges 1 of 20 1. Carefully unpack all battery box parts All 1/8" aluminum plates have been powder-coated with the most rugged finish available, however they are not scratch-proof, so care should always be taken when handling. Be sure to use only mild soap and water when cleaning finish, however automotive polish (i.e. Mother's Mag) can be used via a microfiber cloth to remove fingerprints or other blemishing. 2. Assemble box sides - Right side Note that the battery box sides are assembled from an assortment of six different panel types. Inspect the following drawings carefully as some panels do have similarities. Use M5 x .8 x 12 fasteners for this step, leaving them a little loose. A. Rounded corner Non-threaded thru-holes along bottom edge Part number 1 & 2 2 of 20 B. C. Note: If building a 1-Module Box, skip now to Step K. 3 of 20 D. Panels touch Part number 3 E. ~1/4" gap Part number 4 4 of 20 F. NOTE: If building 2-Module Box, skip now to Step K. G. Part number 3 5 of 20 H. Part number 4 I. NOTE: If building 3-Module Box skip now to Step K. 6 of 20 J. Repeat steps G, H, & I as needed. Number of modules box can accommodate is designated by the number of wider panels + 1. Thus, a four-module box requires three of these wider panels. K. Finishing a side assembly requires two final smaller panels. ~1/4" gap Panels touch Part number 5 7 of 20 L. Non-threaded thru-holes along top edge Part number 6 M. 8 of 20 3. Assemble box sides - Left side Use step two again to create mirror image of previous assembly. ~1/4" gap Panels touch 4. Assemble box bottom panel A.Locate ladder frame with fuse plate and lay with plate facing downward. Part number 7 9 of 20 B. Locate bottom plate (no logo) and fasten to ladder frame. Use M5 x .8 x 16 fasteners for this step. C. 10 of 20 5. Join bottom and side assemblies A.Use M5 x .8 x 16 fasteners for this step. B. Touching panels on same end as fuse plate 11 of 20 C. 6. Attach top ladder frame Use M5 x .8 x 16 fasteners for this step. Part number 8 12 of 20 7. Insert module stoppers. Tighten all screws in side assemblies. 13 of 20 8. Remove module flange protrusions (2 per module) Each S module has two spots where the mounting flange protrudes that should be removed. If your flanges are plastic they can be easily removed with a pair of tinsnips. If aluminum, an angle grinder can be used if done super carefully. Flange protrusion 9. Slide on flange end-caps and covers Slide on the included flange grey end-caps and white nylon covers on each side of each module. NOTE: the end-caps fit snug around the flange end closest to the high voltage terminals. A. 14 of 20 B. 10. Slide in modules, starting at the bottom (recommended). A. 15 of 20 11. Insert module stops and fasten with the included side screws. (1 x ½" screw and 1 x 5/8" screw per stopper) A. B. 16 of 20 12. Attach top, front and back panels A.Use M5 x .8 x 16 fasteners for this step. B. Note: For 6-module version and larger For 6-module boxes and larger, you may prefer to install the included H-Brackets for added stability. A. Remove four screws from the side plate assemblies, as pictured. B. Partially thread four of the M5 x .8 x 30 screws. C. Position the Hbracket. D. Screw in the fasteners the rest of the way. E. Attach included lock washers and nuts. Part number 9 17 of 20 C. D. 18 of 20 APPENDIX: Battery 19 of 20 20 of 20Microsoft Word for Microsoft 365 Microsoft Word for Microsoft 365