ampREVOLT 4.5kWh Modular Battery Box Instruction Manual
- October 30, 2023
- ampREVOLT
Table of Contents
ampREVOLT 4.5kWh Modular Battery Box
Product Information
The battery containment system is designed for 4.5, 5.2 and 5.3kWh Tesla Battery Modules. It is made with 1/8 aluminum plates that are powder-coated with a rugged finish to ensure personal safety and battery protection and longevity. The design offers maximum flexibility for the end user. The recommended tools/supplies for assembly are a 3mm hex wrench (included), Philips head PH2 screwdriver, blue thread-lock for all screw fasteners, inch- pound torque wrench, angle grinder for modules with aluminum flanges or tin snips for those with plastic flanges.
All aluminum plates are not scratch-proof, so care should be taken when handling. Only mild soap and water should be used when cleaning finish, however automotive polish (i.e. Mother’s Mag) can be used via a microfiber cloth to remove fingerprints or other blemishing.
Product Usage Instructions
- Carefully unpack all battery box parts.
- Assemble the box sides starting with the right side using M5 x .8 x 12 fasteners. The battery box sides are assembled from an assortment of six different panel types. Inspect the drawings carefully as some panels do have similarities.
- Assemble the left side using the same instructions as step two.
- Assemble the box bottom panel by locating the ladder frame with fuse plate and laying it with the plate facing downward. Locate the bottom plate (no logo) and fasten it to the ladder frame using M5 x .8 x 16 fasteners. Tighten all screws to 38 inch-lbs.
- Join the bottom and side assemblies using M5 x .8 x 16 fasteners.
- Attach the top ladder frame using M5 x .8 x 16 fasteners.
- Tighten all screws in side assemblies to 38 inch-pounds.
- Remove module flange protrusions (2 per module).
- Slide on the included flange grey end-caps and white nylon covers on each side of each module. Note that the end-caps fit snugly around the flange end closest to the high voltage terminals.
- Slide in modules, starting at the bottom (recommended).
- Insert module stops and fasten with the included side screws (2 per stopper).
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 and battery protection and longevity.
Tools
Recommended tools/supplies:
- 3mm hex wrench (included)
- Philips head PH2 screwdriver
- Blue thread-lock for all screw fasteners
- Inch-pound torque wrench
- Angle grinder for modules with aluminum flanges or tin snips for those with plastic flanges
Assembly Instructions
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.
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.
NOTE: if building 2-Module Box now skip to Step K.
NOTE: if building 3-Module Box now skip to Step K.
- 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.
- Finishing a side assembly requires two final smaller panels.
Assemble box sides – Left side
- Use step two again to create mirror image of previous assembly
Assemble box bottom panel
-
Locate ladder frame with fuse plate and lay with plate facing downward.
-
Locate bottom plate (no logo) and fasten to ladder frame.
-
Use M5 x .8 x 16 fasteners for this step. Tighten all screws to 38 inch lbs.
Join bottom and side assemblies
- Use M5 x .8 x 16 fasteners for this step.
Attach top ladder frame
- Use M5 x .8 x 16 fasteners for this step.
- Tighten all screws in side assemblies to 38 inch-pounds
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 tin-snips. If aluminum, an angle grinder can be used if done super carefully.
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.
- Slide in modules, starting at the bottom (recommended).
- Insert module stops and fasten with the included side screws (2 per stopper)
Attach top, front and b ack panels
- Use M5 x .8 x 16 fasteners for this step.
Note: For 6-module version and larger
For 6-module boxes and larger, you may prefer to install the included HBrackets 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 H-bracket.
- D. Screw in the fasteners the rest of the way.
- E. Attach included lock washers and nuts.