Installation manual

Do not install any fuses in a small battery enclosure as this is a potential source of ignition.

Take care that the wrench/spanner handle does not bridge between terminals when

connecting batteries as this can cause arcs, burns and explosions. Insulate all tools with

insulating tape prior to any work on your battery bank.

A well ventilated enclosure to outside air will help to reduce battery temperature on hot days

and in the very rare event of an internal battery short allow the explosive mix of hydrogen

and oxygen to quickly leave the enclosure.

Due to the small risk of explosion and fire, batteries should be installed in a locked and

ventilated enclosures, not within dwellings.

The author of this section was once on a site where a client accidental dropped a large

spanner on the battery terminals which then became wedged. Almost immediately the

sparks from the shorted spanner ignited gases at the battery vents. After 2-3 seconds the

first battery in the string exploded showering the owner in acid, as the owner turned to run

out of the battery shed the 2

battery exploded. This second explosion sheared off the

battery terminals and the short circuit was broken.

Fortunately help was quickly on hand to wash the client of battery acid as the client was in a

state of severe shock and unable to help himself or comprehend what had just happened.

The fire extinguisher in the battery room was quickly used to extinguish the fire that was

being fuelled on hydrogen and melting plastic of the battery cases. Helpers on site quickly

cut through the battery links to make the site safe, as at this stage is was not known to them

what had caused the explosion.

The battery bank consisted of 2 x 48V DC strings of 500 amps hours each. The bank was in

an adequate enclosure, but once the lid was opened there was no fall protection on the

battery terminals.

This is how you can avoid such an event:

 Cover all exposed battery terminals with petro-tape. This will give protection in the

event that a metal object accidently falls on the battery terminals while the battery lid

is open.

 Insulate all tools handles prior to use.

 Have a large drum of water close by.

 Never work alone, make sure help is close to hand.

 Wear an overall, apron and eye protection.

7.2.3. Battery installation example 1

Here each battery is in a separate battery case. Each case

provides ventilation and prevents accidental contact with the

terminals.

Note the very clear safety warnings making it obvious what is

inside the boxes.

Access for servicing is straight forward.