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Page 2 - Battery Rack Assembly and Installation Manual

Page 3 - Contents

Contents Battery Rack Assembly and Installation Manual i Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Safety warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . ....

Page 7 - Safety; Safety warnings

Battery Rack Assembly and Installation Manual 1 Safety Safety warnings Safety precautions Warn in g • Only QUALIFIED ELECTRICIANS may perform this installation! Battery installation must be performed in accordance with all applicable codes! • Observe all WARNING and CAUTION notices! Failure to do so...

Page 8 - Additional considerations; • Remove watches, rings, and other metal objects from your body.

Safety 2 Battery Rack Assembly and Installation Manual Additional considerations C au tion • Observe all requirements and limitations pertaining to floor loading! • Remove watches, rings, and other metal objects from your body. • DO NOT lay tools or metal parts on top of batteries! • To avoid static...

Page 9 - Specifications; either Power or Fiamm battery types.; Weights and dimensions; Rack SKU

Battery Rack Assembly and Installation Manual 3 Specifications Rack/battery options The racks are deployed in multiples of two, with each rack housing one battery string. A maximum of eight racks (battery strings) can be used to support a single Symmetra MW UPS. The total number of strings deployed ...

Page 10 - Shipping and Receiving; Shipping; are shrink-wrapped to the pallet for added stability.; Receiving; Keep boxes on pallet for transportation to installation site; Check for discrepancies.; Make certain the shipment has arrived in its entirety. Compare

4 Battery Rack Assembly and Installation Manual Shipping and Receiving Shipping Rack assemblies are shipped in corrugated boxes. Battery cables, battery boots, terminal blocks, and labels are also included in the shipment. Each pallet can support a maximum of two (2) units. Boxes are shrink-wrapped ...

Page 11 - Placement; Positioning; battery racks fit into the overall system.; Handling; installation position.; “Appendix C: Employing Sidecars” on page 44.

Battery Rack Assembly and Installation Manual 5 Placement Positioning The racks should ideally be positioned so that the batteries can easily be connected to the appropriate breaker in the battery breaker box(es). The graphic below shows a typical UPS system, and how the battery racks fit into the o...

Page 12 - Installation Site; Installation considerations; mm

6 Battery Rack Assembly and Installation Manual Installation Site Installation considerations The installation site should adhere to the following requirements: • There should be ample room for performing rack assembly, battery installation, maintenance, and possible battery replacement. • Aisle spa...

Page 13 - Parts List; installation until all parts are in your possession.; Description

Battery Rack Assembly and Installation Manual 7 Parts List This section provides a listing of parts needed to assemble each battery rack. Do not proceed with this installation until all parts are in your possession. Description APC P/N Qty Top Side Subassembly 870-1657A 2 Bottom Side Subassembly 870...

Page 14 - Battery Cabling; style are detailed in “Appendix A: Battery Wiring Style E” on page 35.

8 Battery Rack Assembly and Installation Manual Battery Cabling Batteries are arranged in the rack in accordance with Wiring Style E. The wiring diagrams for this style are detailed in “Appendix A: Battery Wiring Style E” on page 35. The (included) battery cabling kit was designed to suit the specif...

Page 15 - Rack Assembly; Assembling the bottom section; The bottom section of the rack will contain shelves #3 and #4.

Battery Rack Assembly and Installation Manual 9 Rack Assembly Assembling the bottom section The bottom section of the rack will contain shelves #3 and #4. 1. Bolt Cross Bar #1 to Bottom Side Subassembly #1 at hole position #2 (from front) on the LOWER horizontal support of the Subassembly. Use (1) 3...

Page 16 - Refer to graphic in step 4 below.

Rack Assembly 10 Battery Rack Assembly and Installation Manual 3. Bolt Cross Bar #1 to Bottom Side Subassembly #2 at its opposite hole position #2 (from front). Use (1) 3/8-16 x 1” bolt and related hardware: (2) 3/8 washers and (1) 3/8 KEPS nut. Refer to graphic in step 4 below. 4. Bolt Cross Bar #2...

Page 17 - Assembling the top section

Rack Assembly Battery Rack Assembly and Installation Manual 11 9. Bolt Cross Bar #4 to Bottom Side Subassembly #2 at its opposite hole position #6 (from front). Use (1) 3/8-16 x 1” bolt and related hardware: (2) 3/8 washers and (1) 3/8 KEPS nut. Assembling the top section The top section of the rack...

Page 19 - Refer to graphic in step 6 below.

Rack Assembly Battery Rack Assembly and Installation Manual 13 5. Bolt Cross Bar #6 to Top Side Subassembly #1 at hole position #6 (from front) on the LOWER horizontal support of the Subassembly. Use (1) 3/8-16 x 1” bolt and related hardware: (2) 3/8 washers and (1) 3/8 KEPS nut. Refer to graphic in...

Page 21 - Stabilizing the rack

Rack Assembly Battery Rack Assembly and Installation Manual 15 Stabilizing the rack Bolt (4) Rear Cross Braces to rack at designated hole positions. Use (8) M12 x 35 bolts and related hardware: (16) 12mm washers, (8) 12mm lockwashers and (8) M12 nuts. Note that lower bolts on Brace #1 and Brace #2 a...

Page 22 - Numbering the batteries; in the wiring scheme.; Accessing your wiring diagrams; connecting batteries.

Rack Assembly 16 Battery Rack Assembly and Installation Manual Anchoring the rack (optional) For added stability, any or all of the racks can optionally be bolted to a concrete floor. To anchor the rack, chalk mark four (4) pre-cut holes (at the base of the assembly) in the facility floor, drill, an...

Page 23 - Positioning rails on shelves; points for placing rails. Make adjustments as necessary.; Addressing the bottom shelf; spacing, and later make adjustments as necessary.

Rack Assembly Battery Rack Assembly and Installation Manual 17 Positioning rails on shelves Apply your Battery Type (Power or Fiamm) to the Rail Spacing Matrix below to determine initial positioning of rails. Take into consideration that this information represents “suggested” starting points for pl...

Page 24 - the proper positioning of its positive and negative terminals.; Wiring the batteries; page 20, and “Covering battery connections” on page 21.; numbered batteries are placed on the lower shelves.; comply could result in serious injury or death!; Reading should approximate number of batteries in row times 12V.

Rack Assembly 18 Battery Rack Assembly and Installation Manual 3. Using a rated lifting device, load batteries onto BOTTOM shelf rails in accordance with your wiring diagram for that shelf. Take note of where each numbered battery should be placed, and the proper positioning of its positive and nega...

Page 25 - battery in the second row using the supplied row-to-row cable.; Applying cable boots.

Rack Assembly Battery Rack Assembly and Installation Manual 19 2. Working left to right (from front of rack), connect the last battery in the first row to the first battery in the second row using the supplied row-to-row cable. – Refer to your wiring diagrams for proper cabling and termination point...

Page 26 - Connecting to batteries.; • Insert Terminal

Rack Assembly 20 Battery Rack Assembly and Installation Manual Connecting to batteries. There are three types of battery terminals for connecting cables: 1) Stud terminal, 2) Insert terminal, and 3) L (or I) terminal. The application of hardware for making the connection varies according to the type...

Page 27 - Covering battery connections.; After each lug has been connected to its battery terminal, snap the; Addressing the third shelf; and later make adjustments as necessary.; Addressing the second shelf

Rack Assembly Battery Rack Assembly and Installation Manual 21 Covering battery connections. After each lug has been connected to its battery terminal, snap the boot down over the lug/terminal. Addressing the third shelf The THIRD shelf is addressed only after bottom shelf batteries have been loaded...

Page 28 - spring nut is applied to each cross bar).; Addressing the top shelf

Rack Assembly 22 Battery Rack Assembly and Installation Manual 2. Screw (1) Terminal Block Assembly to the SECOND shelf Cross Bar at the front of the rack. Secure to cross bar with the (2) supplied M6 socket-head cap screws and flange nuts. Select a location on the bar that does not conflict with ba...

Page 29 - positioning of its positive and negative terminals.

Rack Assembly Battery Rack Assembly and Installation Manual 23 3. Using a rated lifting device, load batteries onto TOP shelf rails in accordance with your wiring diagram. Take note of where each numbered battery should be placed, and the proper positioning of its positive and negative terminals. Re...

Page 30 - Assembling the second rack; The battery racks must be deployed in multiples of two.

Rack Assembly 24 Battery Rack Assembly and Installation Manual 5. Remove protective boot and connect this same cable end to the open positive (+) terminal on the first battery in the lower shelf. Snap cable boot over connected lug/terminal. Assembling the second rack The battery racks must be deploy...

Page 31 - Labelling the terminal blocks; terminal block must be appropriately labelled.; Employing sidecars to support separated racks

Rack Assembly Battery Rack Assembly and Installation Manual 25 Labelling the terminal blocks Each rack is equipped with (1) terminal block assembly. The left (+) and right (-) segments of each terminal block must be appropriately labelled. 1. Remove the snap-off cover from the front face of each ter...

Page 32 - Connecting terminal blocks to battery breakers; connections are made prior to

Rack Assembly 26 Battery Rack Assembly and Installation Manual Connecting terminal blocks to battery breakers To minimize risk, terminal block-to-battery breaker connections are made prior to battery-to- terminal block connections. TOP entry of 120 mm 2 [#4/0] cable (not supplied) is recommended for...

Page 33 - If using top cable entry, connect to top terminal (as shown) of the BAT

Rack Assembly Battery Rack Assembly and Installation Manual 27 2. Using one (1) 120 mm 2 [#4/0] cable, connect the appropriate (top or bottom) BAT 1- terminal in Terminal Block #1 to the BAT 1- terminal in Battery Breaker #1. At Terminal Block #1: If using top cable entry, connect to top terminal (a...

Page 34 - Connecting terminal blocks to batteries; terminal blocks TO the batteries. 120 mm

Rack Assembly 28 Battery Rack Assembly and Installation Manual 4. Using one (1) 120 mm 2 [#4/0] cable, connect the appropriate (top or bottom) BAT 2- terminal in Terminal Block #2 to the BAT 2- terminal in Battery Breaker #2. At Terminal Block #2: If using top cable entry, connect to top terminal (a...

Page 35 - Before making connections, apply ONE cable boot. If lug

Rack Assembly Battery Rack Assembly and Installation Manual 29 1. Using specified cable, connect the open BAT 1+ terminal in Terminal Block #1 to the open positive (+) terminal on Battery #1. Before making connections, apply ONE cable boot. If lug sizes are different, apply boot to the cable end wit...

Page 36 - Before making connections, apply ONE cable boot. If

Rack Assembly 30 Battery Rack Assembly and Installation Manual 2. Using specified cable, connect the open BAT 1- terminal in Terminal Block #1 to the open negative (-) terminal on Battery #32. Before making connections, apply ONE cable boot. If lug sizes are different, apply boot to the cable end wi...

Page 39 - Reattaching terminal block covers; battery installation.; Grounding the racks

Rack Assembly Battery Rack Assembly and Installation Manual 33 Reattaching terminal block covers Reattach the snap-off cover to the front face of each terminal block. Applying warning labels Labels must be applied to the more visible areas of the racks to warn of the dangers associated with live bat...

Page 40 - Glossary

34 Battery Rack Assembly and Installation Manual Glossary AH Ampere-hour in-lbs Inch-pounds APC American Power Conversion kg Kilogram battery rails Adjustable rails that rest on cross bars and hold batteries lb Pound BOM Bill of Materials mm Millimeter C Centigrade (degrees) Ohmmeter Instrument used...

Page 41 - Appendix A: Battery Wiring Style E; The following connections must be made to the TOP shelf in Rack #1:; Front of Battery Rack

Battery Rack Assembly and Installation Manual 35 Appendix A: Battery Wiring Style E Style E, rack #1, shelf #1 (top) The following connections must be made to the TOP shelf in Rack #1: • Battery-to-battery: cables 1-6 • Row-to-row: cable 49 • Shelf-to-shelf: cable 57 • Battery-to-terminal block: cab...

Page 43 - The following connections must be made to the THIRD shelf in Rack #1:

Appendix A: Battery Wiring Style E Battery Rack Assembly and Installation Manual 37 Style E, rack #1, shelf #3 The following connections must be made to the THIRD shelf in Rack #1: • Battery-to-battery: cables 13-18 • Row-to-row: cable 51 • Shelf-to-shelf: cable 59 • Battery-to-terminal block: none ...

Page 45 - The following connections must be made to the TOP shelf in Rack #2:

Appendix A: Battery Wiring Style E Battery Rack Assembly and Installation Manual 39 Style E, rack #2, shelf #1 (top) The following connections must be made to the TOP shelf in Rack #2: • Battery-to-battery: cables 25-30 • Row-to-row: cable 53 • Shelf-to-shelf: cable 60 • Battery-to-terminal block: c...

Page 47 - The following connections must be made to the THIRD shelf in Rack #2:

Appendix A: Battery Wiring Style E Battery Rack Assembly and Installation Manual 41 Style E, rack #2, shelf #3 The following connections must be made to the THIRD shelf in Rack #2: • Battery-to-battery: cables 37-42 • Row-to-row: cable 55 • Shelf-to-shelf: cable 62 • Battery-to-terminal block: none ...

Page 49 - Appendix B: Battery Cabling Kits; References for Power battery cables:

Battery Rack Assembly and Installation Manual 43 Appendix B: Battery Cabling Kits References for Power battery cables: References for Fiamm battery cables: Product SKU: SYR400k1000HxR Ref Des Qty Use Length P/n 1-48 48 Battery-to-Battery 356 mm 0W01883 49-56 8 Row-to-Row 914 mm 0W02422 57-62 6 Shelf...

Page 50 - Appendix C: Employing Sidecars; Sidecar overview; problem of power degradation.; input; bars and one horizontal; output; bar. The horizontal bars are “staggered” (in terms of

44 Battery Rack Assembly and Installation Manual Appendix C: Employing Sidecars Sidecar overview Battery racks can be situated in one or more locations separate and apart from the battery breakers. In these instances, a sidecar should be employed at each separated location to prevent distance from c...

Page 51 - Positioning and accessing the sidecar

Appendix C: Employing Sidecars Battery Rack Assembly and Installation Manual 45 Positioning and accessing the sidecar The sidecar is typically positioned alongside one of the separated racks it supports, and ideally should be positioned closest (of all units in the group) to the battery breakers. Si...

Page 52 - Connecting terminal blocks to sidecars; either of the two BAT 1+ vertical bars in the Sidecar.

Appendix C: Employing Sidecars 46 Battery Rack Assembly and Installation Manual Connecting terminal blocks to sidecars To minimize risk, terminal block-to-sidecar connections are made prior to sidecar-to-battery breaker connections and battery-to-terminal block connections. TOP entry of 120 mm 2 [#4...

Page 53 - either of the two BAT 1- vertical bars in the Sidecar.

Appendix C: Employing Sidecars Battery Rack Assembly and Installation Manual 47 2. Using one (1) 120 mm 2 [#4/0] cable, connect the BAT 1- terminal in Terminal Block #1 to either of the two BAT 1- vertical bars in the Sidecar. At Terminal Block #1: If using top cable entry, connect to top terminal (...

Page 54 - either of the two BAT 2+ vertical bars in the Sidecar.

Appendix C: Employing Sidecars 48 Battery Rack Assembly and Installation Manual 3. Using one (1) 120 mm 2 [#4/0] cable, connect the BAT 2+ terminal in Terminal Block #2 to either of the two BAT 2+ vertical bars in the Sidecar. At Terminal Block #2: If using top cable entry, connect to top terminal (...

Page 55 - either of the two BAT 2- vertical bars in the Sidecar.; landing holes on the sidecar’s vertical bars.; Connect other cable end to

Appendix C: Employing Sidecars Battery Rack Assembly and Installation Manual 49 4. Using one (1) 120 mm 2 [#4/0] cable, connect the BAT 2- terminal in Terminal Block #2 to either of the two BAT 2- vertical bars in the Sidecar. At Terminal Block #2: If using top cable entry, connect to top terminal (...

Page 56 - Connecting sidecars to battery breakers; Top

Appendix C: Employing Sidecars 50 Battery Rack Assembly and Installation Manual Connecting sidecars to battery breakers To minimize risk, sidecar-to-battery breaker connections are made prior to battery-to-terminal block connections. TOP entry of 253 mm 2 [500 MCM] cable (not supplied) is recommende...

Page 57 - landings nearest the LEFT side of the; Front

Appendix C: Employing Sidecars Battery Rack Assembly and Installation Manual 51 2. Using three (3) 253 mm 2 [500 MCM] cables, connect the BAT 2+ horizontal bar in the Sidecar to the specified BAT 2+ bus in Battery Breaker #2. At Battery Breaker #2: Refer to the battery breaker’s wiring diagram for t...

Page 58 - landings nearest the RIGHT side of the

Appendix C: Employing Sidecars 52 Battery Rack Assembly and Installation Manual 3. Using three (3) 253 mm2 [500 MCM] cables, connect the BAT 1- horizontal bar in the Sidecar to the specified BAT 1- bus in Battery Breaker #1. At Battery Breaker #1: Refer to the battery breaker’s wiring diagram for th...

Page 59 - batteries” on page 28.

Appendix C: Employing Sidecars Battery Rack Assembly and Installation Manual 53 4. Using three (3) 253 mm 2 [500 MCM] cables, connect the BAT 1+ horizontal bar in the Sidecar to the specified BAT 1+ bus in Battery Breaker #1. At Battery Breaker #1: Refer to the battery breaker’s wiring diagram for t...

Page 63 - APC Warranty on Batteries; following conditions may put the warranty at risk.

Battery Rack Assembly and Installation Manual 57 APC Warranty on Batteries APC warrants that its supplied High-Rate series of Valve Regulated Lead Acid batteries will be free of defects in material and workmanship for a period of one (1) year from date of shipment. This amounts to the same basic war...

Page 64 - APC Worldwide Customer Support

® *990-4194A* APC Worldwide Customer Support Customer support for this or any other APC product is available at no charge in any of the following ways: • Visit the APC Web site to access documents in the APC Knowledge Base and to submit customer support requests. – www.apc.com (Corporate Headquarter...