How to Safely Add New Modules to Your LBSA Battery System

At Lithium Batteries South Africa, safety is always our top priority. Whether you're expanding your existing battery setup or performing routine maintenance, following the correct procedures ensures not only the longevity of your system but also your safety and the safety of those around you.

In this guide, we walk you through the safest way to add new modules to an existing low-voltage battery system.

Step 1: Fully Power Down the System

Before working on any battery components, always begin by disconnecting the battery from the inverter.
This isolates the system and prevents accidental power flow while you’re working.

Once the battery is disconnected:

• Remove each module

• Remove the controller

This ensures the busbars are completely powered down before any changes are made.

Step 2: Load New Modules Into the Rack

With the system safely powered down, you can load your new modules into the rack.
Important: Do not connect them yet. They should remain disconnected while you prepare the system for the configuration change.

Step 3: Remove the Side Panel

Using a T20 Torx bit, remove the side panel to access the busbars.
In our demonstration, we used a drill to speed up this step, but a manual Torx tool will work just as well.

Once the panel is removed, you'll have clear access to reposition the L-busbar.

Step 4: Reposition the L-Busbar

To move the L-busbar to the correct module level, you'll need:

• A size 10 spanner

• An 8mm socket for the right-hand side

• A 10mm socket for the left-hand side

Carefully disconnect the L-busbar, move it to its new position, and secure it.
Be sure to place the nuts and bolts back into their original locations to maintain proper fitting and safety.

Step 5: Adjust the DIP Switches

Each module has DIP switches that help the system manage module recognition and communication.

Follow these rules:

• Switch both DIP switches off at the old busbar position

• Switch both DIP switches on at the new module level

• Only the final module inserted should have its DIP switches turned on

This ensures the controller reads the module stack correctly.

Step 6: Reassemble and Power Up

Once everything is positioned and secured:

1. Reinstall the side panel

2. Slide the modules and controller back into the rack
   

3. Power the system back up

Your expanded system is now safely configured and ready for operation.

Why Safety Matters

Working with energy storage systems requires precision. By following these steps, you protect both the equipment and the installer. At LBSA, we remain committed to offering not only high-quality products but also the guidance and support needed to use them safely and effectively.

If you need assistance or prefer an LBSA-certified installer to handle your system expansion, our team is always here to help.