PML 2000 Battery Replacement instructions
Minuteman recommends that you be a qualified service technician to do
the following procedure.
Note: Read all cautions and warning before doing the following procedures.
WARNING!
THIS UNINTERRUPTIBLE POWER SOURCE CONTAINS
POTENTIALLY HAZARDOUS VOLTAGES. DO NOT ATTEMPT TO
DISASSEMBLE THE UNIT BEYOND BATTERY REPLACEMENT
PROCEDURES BELOW. EXCEPT FOR THE BATTERY, THIS UPS
CONTAINS NO USER SERVICABLE PARTS. REPAIRS CAN BE
PERFORMED BY MINUTEMAN SERVICE PERSONNEL ONLY
CAUTION:
DO NOT OPEN OR MUTILATE BATTERIES. RELEASED ELECTROLYTE IS
HARMFUL TO THE SKIN AND EYES AND MAY BE TOXIC
CAUTION:
DO NOT DISPOSE OF BATTERIES IN A FIRE. THE BATTERIES MAY EXPLODE.
THE BATTERIES IN THIS UPS ARE RECYCLABLE. DISPOSE OF THE
BATTERIES PROPERLY. THE BATTERIES CONTAIN LEAD AND
POSE A HAZARD TO THE ENVIRONMENT AND HUMAN HEALTH IF
NOT DISPOSED OF PROPERLY. REFER TO LOCAL CODES FOR
PROPER DISPOSAL REQUIREMENTS OR RETURN THE BATTERY TO
MINUTEMAN.
CAUTION:
ALTHOUGH BATTERY SYSTEM VOLTAGES ARE 48 VDC THE
BATTERY SYSTEM CAN STILL PRESENT A RISK. THE CURRENT
CAPABILITY OF A BATTERY IS SUFFICENT TO BURN WIRE OR TOOLS
VERY RAPIDLY, PRODUCING MOLTEN METAL. OBSERVE THESE
PRECAUTIONS WHEN REPLACING THE BATTERIES:
1. REMOVE WATCHES, RINGS, OR OTHER METAL OBJECTS;
2. USE HAND TOOLS WITH INSULATED HANDLES;
3. DO NOT LAY TOOLS OR OTHER METAL PARTS ON TOP OF
BATTERIES
CAUTION:
REPLACE BATTERIES WITH THE SAME NUMBER AND TYPE AS ORIGINALLY
INSTALLED IN THE UPS. THESE BATTERIES HAVE PRESSURE OPERATED
VENTS.
CAUTION:
EXCEPT AS PROVIDED ABOVE, IN NO EVENT WILL PARA SYSTEMS BE
LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL, OR
CONSEQUENTIAL INJURY ARISING OUT OF THE USE OF THIS PML2000
INSTRUCTIONAL PROCEDURE, EVEN IF ADVISED OF THE POSSIBILITY OF
SUCH INJURY. Specifically, Para Systems is not liable for any costs, such as
lost profits or revenue, loss of equipment, loss of use of equipment, loss of
software, loss of data, cost of substitutes, claims by third parties, or otherwise.
The following tools will be needed to exercise the Battery Replacement Procedures
correctly.
#2 Phillips Screwdriver
100Ω(Ohm) 5-watt Resistor (see step 9)
2 Jumper Wires with Clip Leads (see step 10)
9/32 or 7mm Socket
1. Remove all loose jewelry from hands and neck.
2. Turn the PML2000 off and disconnect power from the wall.
3. Remove the cover retaining screws from the unit. This unit has four screws on
each side of the units and 4 screws on the back of the unit.
(See figure 1 for assistance.)
COVER RETAINING SCREWS- SIDE VIEW
FIGURE 1
REAR VIEW
4. At the back of the unit, grasp the cover at the bottom and spread outward
while pulling to remove the cover from the unit.
5. Set the cover and the retaining screws aside to prevent damage. These
will be used after the unit assembly is complete.
CAUTION:
ALTHOUGH BATTERY SYSTEM VOLTAGES ARE 48 VDC THE
BATTERY SYSTEM CAN STILL PRESENT A RISK. THE CURRENT
CAPABILITY OF A BATTERY IS SUFFICENT TO BURN WIRE OR TOOLS
VERY RAPIDLY, PRODUCING MOLTEN METAL. OBSERVE THESE
PRECAUTIONS WHEN REPLACING THE BATTERIES:
1. REMOVE WATCHES, RINGS, OR OTHER METAL OBJECTS;
2. USE HAND TOOLS WITH INSULATED HANDLES;
3. DO NOT LAY TOOLS OR OTHER METAL PARTS ON TOP OF
BATTERIES
6. Remove the Battery Positive wire located at P13, P12 (BAT +) on the logic
board and tape off the end off each wire to prevent a short from
happening.
7. Remove the Battery Ground wire located at P9 (BAT −) on the logic board
and tape off the end of the wire to prevent a short from happening.
8. Turn the AC switch to the ON position but do not plug it into the wall outlet.
This will help discharge the board.
9. If you have a 100Ω(Ohm) 5watt resistor and the jumper wires with clip
leads, go to step #9.
10. Take one of the clip leads and connect one end to the battery positive post
(P13) on the logic board and connect the other end to one side of the
100Ω(Ohm) 5watt resistor.
11. Take the other clip lead and connect it to the battery ground post (P9) on
the logic board and connect the other end to the other side of the
100Ω(Ohm)5watt resistor. This will completely discharge the entire logic
board.
12. Leave the clip leads and resistor connected to the logic board.
13. Leave unit in the on position for 30 to allow the logic voltage to discharge
naturally.
14. Remove the “side” battery retaining brackets. This unit has two large
“side” brackets and two small “side” brackets. Set the brackets and the
nuts aside for later use during assembly. (See figure 2 for assistance)
(This will total 16 nuts and 4 brackets)
This symbol indicates the location of all screws or nuts.
BATTERY
HOUSING
BRACKET
1 Battery
2 Battery
3 Battery
Transformer
4
FIGURE 2
SIDE VIEW
BATTERY
RETAINING
BRACKETS
BATTERY
RETAINING
BRACKETS
15. Looking from the front of the unit, look on the right hand side you will see
three batteries laying on top of each other.
16. Using a 5/ 16 wrench, or a 5/16 flex socket remove all battery brackets,
start with battery two and three first. (Once you have removed all battery
brackets you will have 8 screws, 8 silver mounting brackets, 3 copper
brackets and one wire with two red wires soldered together)
17. Slide battery two out of the row first, battery one will drop in its place.
Remove battery one and three, then battery four under the transformer by
sliding it toward the open slot to the left. (To remove the last battery turn
unit on its side so that heat sink is toward you, then to loosen battery by
prying top of the battery with a screwdriver between the metal bracket and
the battery to push the transformer toward the heat sinks slightly then
wiggle the battery out.)
18. The replacement batteries have a different style of terminals.
Caution:
Do not connect battery two and three together. First wait until you have all of
the other brackets connected starting with three and four after step 9. Then
you connect two and three last
19. You will need to make two jumper wires approximately 1 ½ inch long for
battery 3 and 4.
20. Connect your battery brackets back on each side as seen in figure 3.
21. Connect bracket from battery 1 to battery 2 first.
22. Connect bracket from battery 3 to battery 4
23. Connect bracket from battery 2 to battery 3
24. Remove tape from negative P9 and then disconnect the jumpered resistor
onP13 and p9.
25. Connect your black negative wire back toP9 only.
26. Remove tape from the two positive wires and connect red positive wires
back to P13 and P12 you may see a little spark do not be alarmed this will
not harm you.
27. Connect your ac line back to the wall outlet and turn your pml2000 on.
FIGURE 3
Terminal 1
11111
1
+
−
Terminal 2
2
Terminal 8
Terminal 3
Terminal 4
Terminal 5
−
+
+
3
−
Terminal 6
+
Terminal 7
−