Reid_Welch's Photobucket ADDING EXTERNAL BATTERY TO Back UPS XS 1300 album media

ALL WIRED UP

Reid_Welch — Mon, 10 Nov 2008 04:23:41 MST

Reid_Welch posted a photo

ALL WIRED UP - P1070542.jpg

Notes: the yellow twist tie is a safety strain relief in case someone (me) should trip on the "cable". That black corrugated stuff is simple, cheap, slitted tubing sold at the auto parts stores for the purpose of bundling loose wires. Enlarge the pictures to see details bettter?

Epoxy Putty for GOOD REASON

Reid_Welch — Mon, 10 Nov 2008 04:18:30 MST

Reid_Welch posted a photo

Epoxy Putty for GOOD REASON - P1070541.jpg

Reason: that when I want to disconnect the Back-UPS from the external line, I loosen the two outermost screws. The rock-hard putty will keep the plus and minus nubbins of external battery wire from touching. We have a fuse inside the UPS, already shown in earlier pictures. But if the external battery is not fused, and a shorting accident occurs! Ka-POW: sparks and maybe worse.

Tight, twisted solder-filled wire under compression

Reid_Welch — Mon, 10 Nov 2008 04:17:33 MST

Reid_Welch posted a photo

Tight, twisted solder-filled wire under compression - P1070548.jpg

Re-snug all such connections periodically until they "mush down" no more.

Connections!

Reid_Welch — Mon, 10 Nov 2008 04:15:32 MST

Reid_Welch posted a photo

Connections! - P1070549.jpg

twisted wire, fully soldered, tightly compression-clamped by the post screw. this is the jumper between the black pole of one battery to the red pole of the other battery. the two remaining posts are to be the 24VDc output, plus and minus polarity, to go to the same colored outputs seen there in the backgroud, coming out of the Back-UPS

the battery pari is glued together

Reid_Welch — Mon, 10 Nov 2008 04:12:45 MST

Reid_Welch posted a photo

the battery pari is glued together - P1070550.jpg

Note the way to make a "series connection" of two 12V batteries?

two 18AH batteries, unitized with Gorilla glue

Reid_Welch — Sun, 9 Nov 2008 09:16:51 MST

Reid_Welch posted a photo

two 18AH batteries, unitized with Gorilla glue - P1070536.jpg

compression joints appreciate occasional snugging-up

Reid_Welch — Sun, 9 Nov 2008 09:16:37 MST

Reid_Welch posted a photo

compression joints appreciate occasional snugging-up - P1070531.jpg

embedded 45A disaster fuse

Reid_Welch — Sun, 9 Nov 2008 09:16:10 MST

Reid_Welch posted a photo

embedded 45A disaster fuse - P1070538.jpg

Not pretty, buried in that mass of epoxy. It will never blow unless there were a direct short circuit. WE WILL LATER COVER AL THESE TERMINALS WITH NON FLAMMABLE FELT WITH "SCHOOL GLUE", just to prevent the possibility of, say, if a kid played with the set, or a screwdriver or other metal object bridged the termainals. TAKE CARE and all will be perfectly safe. No worries here.

Gluing two cells together

Reid_Welch — Sat, 8 Nov 2008 14:14:10 MST

Reid_Welch posted a photo

Gluing two cells together - P1070525.jpg

Atop is a spare cell for weight while the Gorilla Glue sets up. Meanwhile, they get their first charge in three years (uh oh, that's not good to let lead acid set uncharged for that long. Can these batteries offer any more service at age three years, anyway? They are only cheap Chiniese-made batteries.

18Ah instead of the OEM 9AH

Reid_Welch — Sat, 8 Nov 2008 14:13:10 MST

Reid_Welch posted a photo

18Ah instead of the OEM 9AH - P1070528.jpg

1 of the two twins I will add for external battery

Reid_Welch — Sat, 8 Nov 2008 13:18:28 MST

Reid_Welch posted a photo

1 of the two twins I will add for external battery - P1070524.jpg

Reid?

Reid_Welch — Sat, 8 Nov 2008 10:38:25 MST

Reid_Welch posted a photo

Reid? - Harold.jpg

I won't be able to re-use this after all

Reid_Welch — Sat, 8 Nov 2008 10:38:23 MST

Reid_Welch posted a photo

I won't be able to re-use this after all - P1070439.jpg

....this many pounds

Reid_Welch — Sat, 8 Nov 2008 10:38:18 MST

Reid_Welch posted a photo

....this many pounds - P1070440.jpg

I would need two NEW ones (24V total, matched capacity)

Reid_Welch — Sat, 8 Nov 2008 10:38:14 MST

Reid_Welch posted a photo

I would need two NEW ones (24V total, matched capacity) - P1070442.jpg

SAFETY: always cover the adjacent terminal when wrenching

Reid_Welch — Sat, 8 Nov 2008 10:38:09 MST

Reid_Welch posted a photo

SAFETY: always cover the adjacent terminal when wrenching - P1070443.jpg

Remove oxides

Reid_Welch — Sat, 8 Nov 2008 10:38:05 MST

Reid_Welch posted a photo

Remove oxides - P1070444.jpg

P1070445.jpg

Reid_Welch — Sat, 8 Nov 2008 10:38:02 MST

Reid_Welch posted a photo

P1070445.jpg

ALL greases are "dielectric" and prevent corrosion

Reid_Welch — Sat, 8 Nov 2008 10:37:58 MST

Reid_Welch posted a photo

ALL greases are "dielectric" and prevent corrosion - P1070447.jpg

Heavier wire would be much better

Reid_Welch — Sat, 8 Nov 2008 10:37:53 MST

Reid_Welch posted a photo

Heavier wire would be much better - P1070450.jpg

Steel brush to remove tin oxide

Reid_Welch — Sat, 8 Nov 2008 10:37:47 MST

Reid_Welch posted a photo

Steel brush to remove tin oxide - P1070455.jpg

Wonderful Radio Shack butane iron

Reid_Welch — Sat, 8 Nov 2008 10:37:44 MST

Reid_Welch posted a photo

Wonderful Radio Shack butane iron - P1070456.jpg

Rosin Paste Flux liberally

Reid_Welch — Sat, 8 Nov 2008 10:37:40 MST

Reid_Welch posted a photo

Rosin Paste Flux liberally - P1070458.jpg

BEVEL the tip for better heating of flat surfaces

Reid_Welch — Sat, 8 Nov 2008 10:37:35 MST

Reid_Welch posted a photo

BEVEL the tip for better heating of flat surfaces - P1070460.jpg

LOTS of heat from this Radio Shack butane iron

Reid_Welch — Sat, 8 Nov 2008 10:37:32 MST

Reid_Welch posted a photo

LOTS of heat from this Radio Shack butane iron - P1070462.jpg

The plastic casing did not survive the soldering heat

Reid_Welch — Sat, 8 Nov 2008 10:37:28 MST

Reid_Welch posted a photo

The plastic casing did not survive the soldering heat - P1070464.jpg

Acetone removes soldering flux

Reid_Welch — Sat, 8 Nov 2008 10:37:24 MST

Reid_Welch posted a photo

Acetone removes soldering flux - P1070465.jpg

The "Z" is the fuseable portion

Reid_Welch — Sat, 8 Nov 2008 10:37:19 MST

Reid_Welch posted a photo

The "Z" is the fuseable portion - P1070466.jpg

Might as well clip off the excess metal

Reid_Welch — Sat, 8 Nov 2008 10:37:15 MST

Reid_Welch posted a photo

Might as well clip off the excess metal - P1070467.jpg

Epoxy putty cures fast. Can be smoothed with water while uncured

Reid_Welch — Sat, 8 Nov 2008 10:37:12 MST

Reid_Welch posted a photo

Epoxy putty cures fast. Can be smoothed with water while uncured - P1070471.jpg

TWIST, flux, solder, HOT

Reid_Welch — Sat, 8 Nov 2008 10:37:09 MST

Reid_Welch posted a photo

TWIST, flux, solder, HOT - P1070472.jpg

P1070474.jpg

Reid_Welch — Sat, 8 Nov 2008 10:37:05 MST

Reid_Welch posted a photo

P1070474.jpg

P1070480.jpg

Reid_Welch — Sat, 8 Nov 2008 10:37:00 MST

Reid_Welch posted a photo

P1070480.jpg

Minimum lead length

Reid_Welch — Sat, 8 Nov 2008 10:36:56 MST

Reid_Welch posted a photo

Minimum lead length - P1070485.jpg

Stock condition weighs...

Reid_Welch — Sat, 8 Nov 2008 10:36:53 MST

Reid_Welch posted a photo

Stock condition weighs... - P1070486.jpg

OEM battery access cover

Reid_Welch — Sat, 8 Nov 2008 10:36:45 MST

Reid_Welch posted a photo

OEM battery access cover - P1070489.jpg

The OEM battery weighs....

Reid_Welch — Sat, 8 Nov 2008 10:36:41 MST

Reid_Welch posted a photo

The OEM battery weighs.... - P1070490.jpg

How the OEM battery tucks in

Reid_Welch — Sat, 8 Nov 2008 10:36:37 MST

Reid_Welch posted a photo

How the OEM battery tucks in - P1070491.jpg

Pliers save fingers

Reid_Welch — Sat, 8 Nov 2008 10:36:34 MST

Reid_Welch posted a photo

Pliers save fingers - P1070493.jpg

OEM: two 9Ah 12V batteries in series

Reid_Welch — Sat, 8 Nov 2008 10:36:30 MST

Reid_Welch posted a photo

OEM: two 9Ah 12V batteries in series - P1070494.jpg

Uh oh, now what?

Reid_Welch — Sat, 8 Nov 2008 10:36:25 MST

Reid_Welch posted a photo

Uh oh, now what? - P1070496.jpg

Pass-through holes

Reid_Welch — Sat, 8 Nov 2008 10:36:20 MST

Reid_Welch posted a photo

Pass-through holes - P1070498.jpg

...this many pounds

Reid_Welch — Sat, 8 Nov 2008 10:36:16 MST

Reid_Welch posted a photo

...this many pounds - P1070499.jpg

Naked 45A fuse

Reid_Welch — Sat, 8 Nov 2008 10:36:12 MST

Reid_Welch posted a photo

Naked 45A fuse - P1070500.jpg

Solder it with lots of flux and lots of heat

Reid_Welch — Sat, 8 Nov 2008 10:36:08 MST

Reid_Welch posted a photo

Solder it with lots of flux and lots of heat - P1070503.jpg

Epoxy putties, even the "steel fillled" kind, are perfect INSULATORS

Reid_Welch — Sat, 8 Nov 2008 10:36:04 MST

Reid_Welch posted a photo

Epoxy putties, even the "steel fillled" kind, are perfect INSULATORS - P1070504.jpg

A hot air gun will turn epoxy soft as cheese, and so then it can be picked off the joint easily.

Rosin flux removes oxides, eases soldering

Reid_Welch — Sat, 8 Nov 2008 10:36:01 MST

Reid_Welch posted a photo

Rosin flux removes oxides, eases soldering - P1070505.jpg

Splicing into the black wire, no fuse needed

Reid_Welch — Sat, 8 Nov 2008 10:35:57 MST

Reid_Welch posted a photo

Splicing into the black wire, no fuse needed - P1070506.jpg

P1070507.jpg

Reid_Welch — Sat, 8 Nov 2008 10:35:52 MST

Reid_Welch posted a photo

P1070507.jpg

Wally Grommett

Reid_Welch — Sat, 8 Nov 2008 10:35:48 MST

Reid_Welch posted a photo

Wally Grommett - P1070508.jpg

P1070509.jpg

Reid_Welch — Sat, 8 Nov 2008 10:35:42 MST

Reid_Welch posted a photo

P1070509.jpg

Plenty of room for the new lead-out wires

Reid_Welch — Sat, 8 Nov 2008 10:35:37 MST

Reid_Welch posted a photo

Plenty of room for the new lead-out wires - P1070510.jpg

P1070511.jpg

Reid_Welch — Sat, 8 Nov 2008 10:35:32 MST

Reid_Welch posted a photo

P1070511.jpg

TWIST, flux, solder

Reid_Welch — Sat, 8 Nov 2008 10:35:28 MST

Reid_Welch posted a photo

TWIST, flux, solder - P1070514.jpg

Excellent compression screw connectors

Reid_Welch — Sat, 8 Nov 2008 10:35:13 MST

Reid_Welch posted a photo

Excellent compression screw connectors - P1070518.jpg

Ready for adding 24V of fused, external battery

Reid_Welch — Sat, 8 Nov 2008 10:35:08 MST

Reid_Welch posted a photo

Ready for adding 24V of fused, external battery - P1070522.jpg