590-2172-501A/SL-29241/4200-136
10-1
Sense Lead Harness Connections
10. Sense Lead Harness Connections
Refer to the Wiring Schematic Diagram located at the rear of this manual to determine the routing path
from each Sense Lead harnesse
s’
connection point (J1-J8) on the equipment to the required cell voltage
sense point on the battery. Note that wires terminating on a positive post are solid colors. Wires
terminating on negative posts are white with colored stripe. For ease of future cell maintenance, leave
some slack in the wiring to the cells. A write-on label is provided on each harness to mark the correct
harness assembly number to appropriate equipment connector location of the harness. If the
connections are removed for maintenance, the labels on the harness will be a useful reference to
reconnect the cables to the correct connector. Refer to the following steps to install the proper
termination to each battery connection point.
10.1 Voltage Sense Lead Connection Preparation
In order to prepare the sense lead harness connection, follow these steps:
1. Each voltage sense lead wire from the sense lead harnesses must have a 10K
0.1% flameproof
resistor sense lead assembly installed before connection to the tab washer.
2. After determining the routing path and required wire length from the equipment to the
connection point, begin assembling the 10K resistor sense lead assembly to the sense lead
harnesses by cutting each wire to the required length and strip the wire at approximately ¼
”
of
the insulation from the end of the wire.
3. Place the stripped wire into the butt-splice of the 10K
0.1% resistor sense lead assembly.
4. Place the wire and insulated section of the butt-splice into the first die of the Panduit crimper,
making sure that the intersection is centered within the die.
5. Crimp the connection.
6. Check the crimped connection to make sure it is secure and holds well.
7. Connect the completed voltage sense lead to its appropriate cell sensing point tab washer.
