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Guide: Adding Extra Run-Time to Your UPS - The Operation - Changing Connectors
Written by Gizmo   
Monday, 30 January 2006 00:00
Article Index
Guide: Adding Extra Run-Time to Your UPS
The Operation
The Operation - Removing the Face-Plate
The Operation - Removing the Battery
The Operation - Opening It Up
The Operation - Exposed Wiring
The Operation - Changing Connectors
The Operation - Splicing
First Smoke Test
Build the Battery Pack
Build the Battery Pack - The Wiring Harness
Second Smoke Test
Reassembly and Final Configuration
Reassembly and Final Configuration - Calibration
Reassembly and Final Configuration - All Done
All Pages

What we need to do now is run power directly from the battery to the inverter without going through the disconnect plug. We will do this by taking the wire that goes from the inverter to the disconnect plug and routing it to the battery connector instead.

If you look carefully at the end of one of the connectors, you will see something like the following:


In this picture, I have removed one of the pins so that you can see things a bit better. Each pin has a 'lip' on the back side, which slides over a flat spring-steel retainer in the connector housing You can just see the retainer under the left pin, and you can see it on the right side of the housing where I removed the pin. What you need to do is find the black wire going from the inverter board to the disconnect housing and remove it from the disconnect housing. Then remove the black wire from the battery connector housing, and replace it with the black wire from the disconnect housing. When you are finished, both wires from the battery connector should be going to the inverter board. The disconnect housing will have only a single black wire. If you purchased a new pair of gray 'Anderson' connectors, go ahead and remove the black wire from the yellow disconnect housing. Hopefully by now you have observed that the battery connector is gray. Knowing that we are going to be adding an external battery pack, maybe now you are beginning to understand why we are using the gray connector; to keep things consistent so that we can swap battery packs around as we like.

Now, take the black wire and cut it into two equal lengths. Here's where we get to the tricky bit; we need to splice this wire into the wire that is routed to the battery connector. When we get done, we will have a wiring harness that looks something like this:


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