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C048-702-30 R02, Rev. B (03/2021)
4.2
4.2 Installation Procedure
Installation Procedure
THIS PRODUCT MUST BE INSTALLED WITHIN A RESTRICTED ACCESS LOCATION WHERE ACCESS IS
THROUGH THE USE OF A TOOL, LOCK AND KEY, OR OTHER MEANS OF SECURITY, AND IS CONTROLLED
BY THE AUTHORITY RESPONSIBLE FOR THE LOCATION� THIS PRODUCT MUST BE INSTALLED AND
MAINTAINED ONLY BY QUALIFIED TECHNICIANS�
NOTICE:
WARNING! ELECTRICAL HAZARD
VRLA BATTERY STACKS CAN PROVIDE THOUSANDS OF AMPERES OF DISCHARGE CURRENT INTO
A SHORT CIRCUIT, IN ADDITION, PARALLELED BATTERY STACKS AND LARGE RECTIFIER SYSTEMS
CAN ALSO DISCHARGE EXTREMELY HIGH CURRENTS INTO A SHORT CIRCUIT FAULT� THERE IS
AN EXTREME SAFETY HAZARD WHEN WORKING ON LARGE SYSTEMS WITH THIS DISCHARGE
AMPACITY POTENTIAL� EYE PROTECTION, SAFETY GLOVES AND PROTECTIVE SHIELDS ARE
REQUIRED ENTIRELY DURING THE TRD INSTALLATION PROCESS�
Step 1.
Unpack and inspect contents of TRD kit. See "3.1 Package Contents" on page 6 for more information. Confirm
all parts are present and no shipping damage has occurred�
Step 2.
Installation into the DCX unit technically can be performed with the battery disconnect circuit breaker on and
connected to the rectifier and load system in extreme cases but is not recommended for safety reasons and due
to the fact that battery bus bar connections must be loosened as part of the temperature sensor installation
process. It is recommended that the battery disconnect circuit breaker be turned off for the installation process.
Step 3.
Locate the DCX unit to be retrofitted with the TRD kit. Turn off the DCX circuit breaker and tape in the off position
as a reminder during the work process and as a notification to co-workers that may be present. Ensure that eye
protection, safety gloves, long sleeve shirts are used as a precaution�
Step 4.
Open the flip-up DCX unit lid/door and confirm that it latches in the secure upright position.
Step 5.
Install the TRD circuit board and control assembly from the left of the DCX unit and move toward the right to plug
into the expansion connector on the existing circuit board assembly inside of the DCX unit� Ensure that there is a
secure connection with full alignment and seating of the connectors� Align the mounting holes of the TRD board
assembly with the existing threaded metal stand-offs inside of the DCX unit. Install the screws provided in the kit
to secure the TRD board module assembly to the DCX metal housing�
Step 6.
Locate the temperature sensor kit which consists of two remote terminal temperature sensors and cable
assemblies� Note that one cable may be shorter than the other� One temperature sensor and cable is intended to
mount on a battery terminal near the top of the battery stack which requires a shorter cable, while the other
sensor is intended to be installed on the lower section of the battery stack, requiring the longer cable to route to
this location�
Step 7.
Installation of the temperature sensor modules requires that the bolt connecting the copper bus strap that will be
used to mount the sensor be removed and replaced with a longer bolt to mount the TRD sensor module� This
requires access to the battery terminals and is a safety hazard area� Ensure that insulated tools, safety gloves,
and eye protection are used�
Step 8.
To install the temperature sensor modules, two mounting locations must be confirmed: one at the top of the
battery stack to monitor the upper section of the stack and one near the lower third of the stack to monitor lower
stack temperature�
These two temperature sensing points are compared to an ambient temperature sensor in the TRD unit to
determine the temperature rise of the battery sensors compared to ambient and compared to each other� The
temperature sensor module has a copper lug with a clearance hole for a 1⁄4-20 bolt which is the typical size bolt
used in the strapping kit from the battery manufacturer. Confirm that the DCX circuit breaker is in the OFF
position, then remove the appropriate clear cover from the battery stack that is covering the bolt location desired
for installation� Ensure that insulated tools, safety gloves, and eye protection are used� Carefully loosen and
remove the bolt while being extremely careful to not contact adjacent battery terminal posts or strap locations�
Remove this bolt and washers and nut and set aside�
