American Power Conversion 400kW1MW Power Supply User Manual
Contents
1. three 3 lugs to their landings with six 6 M12 1 2 bolts washers lock washers and hex nuts Hardware not supplied b If using top cable entry reduce strain by zip tying cables to supports at top of frame refer to below graphic Zips not supplied BAT 1 L a To p BAT 2 TH Il BAT 2 Zip tied cables a p a o St iy Eo Ly Front At Battery Breaker 1 Refer to the battery breaker s wiring diagram for the proper BAT 1 lug landings on the other end of these three 3 cables 1 Continue the rack assembly process starting with Connecting terminal blocks to batteries on page 28 Note Battery Rack Assembly and Installation Manual 53 54 Battery Rack Assembly and Installation Manual Battery Rack Assembly and Installation Manual 55 Battery Rack Assembly and Installation Manual 56 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 warranty that is being offered by the leading battery manufacturers Additional coverage can be procured through purchase of an extended warranty Call your APC representative for information concerning the various types of extended warranties available Battery functionality is typically imp2. The SECOND shelf is addressed only after third shelf batteries have been loaded and wired 1 Position Battery Rails on SECOND shelf Cross Bars according to spacing requirements obtained from the Rail Spacing Matrix on page 17 Measure with ruler or tape to ensure proper spacing and later make adjustments as necessary Refer to step 1 on page 17 for similar procedure Battery Rack Assembly and Installation Manual 21 Rack Assembly 2 DO 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 battery or rail placement The end stops can be loosened to allow the block to move left or right on its assembly M6 Socket head Cap Screws Cross Bar End Stops Terminal Block Screw Battery Rails into SECOND shelf Cross Bars using 1 4 20 x 3 4 flathead screws and 1 4 20 spring nuts Each battery rail requires two screws and two spring nuts one screw and spring nut is applied to each cross bar Refer to step 2 on page 17 for similar procedure Using a rated lifting device load batteries onto SECOND 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 Refer to step 3 on page 18 for similar procedure Make
3. 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 Sidecars offer full front access to all of their internal components The sidecar s front door is secured by a key lock keys are included Open the front door by first releasing and then twisting the latch a quarter turn to the left The door can be removed completely by releasing its two hinge pins While the sidecar offers both top and bottom cable entry TOP is recommended A torx head screwdriver is needed to remove the four 4 corner screws securing the top plate to the enclosure or if using bottom entry the six 6 perimeter screws securing the bottom plate ee Hinge Pin Hinge Assembly Front Door Latch Battery Rack Assembly and Installation Manual 45 Appendix C Employing Sidecars Connecting terminal blocks to sidecars 46 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 4 0 cable not supplied is recommended for all connections specified in this section Each terminal block assembly contains preset hardware for securing cable lugs 1 All external cable must comply with European and local electrical code Note 1 Using one 1 120 mm 4 0 cable connect the BAT 1 terminal in Termina
4. terminal on the first battery in the lower shelf Snap cable boot over connected lug terminal Shelf to shelf Wiring 2nd Shelf Assembling the second rack The battery racks must be deployed in multiples of two Repeat all previous steps to assemble load and wire the second battery rack The first rack Rack 1 contains the BAT I string batteries 1 32 and the second rack Rack 2 contains the BAT 2 string batteries 33 64 24 Battery Rack Assembly and Installation Manual Rack Assembly 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 terminal block 2 Apply two terminal block stickers from supplied labels to the partitions on the sides of each terminal block Apply the BAT 1 on the left and BAT 1 on the right stickers to the Rack 1 terminal block Terminal Block 1 and the BAT 2 on the left and BAT 2 on the right stickers to the Rack 2 terminal block Terminal Block 2 BAT 1 I T LVA Terminal Block 1 BAT 2 y E y 3 I Tt LVA Terminal Block 2 Employing sidecars to support separated racks When battery racks are situated apart from their respective battery breakers sidecars should be employed to enhance connectivity between the batteries and the breakers If racks are NOT separated
5. Insert Lockwasher Washer Cable Lug e L or I Terminal L shape Washer Lockwasher Nut Bolt Washer Cable Lug 20 Battery Rack Assembly and Installation Manual Rack Assembly 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 and wired 1 Position Battery Rails on THIRD shelf Cross Bars according to spacing requirements obtained from the Rail Spacing Matrix on page 17 Measure with ruler or tape to ensure proper spacing and later make adjustments as necessary Refer to step 1 on page 17 for similar procedure 2 Screw Battery Rails into THIRD shelf Cross Bars using 1 4 20 x 3 4 flathead screws and 1 4 20 spring nuts Each battery rail requires two screws and two spring nuts one screw and spring nut is applied to each cross bar Refer to step 2 on page 17 for similar procedure 3 Using a rated lifting device load batteries onto THIRD 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 Refer to step 3 on page 18 for similar procedure 4 Make all specified THIRD shelf battery to battery and row to row connections Refer to Wiring the batteries on page 16 Addressing the second shelf
6. cross braces electrolyte F frame IEC Ampere hour American Power Conversion Adjustable rails that rest on cross bars and hold batteries Bill of Materials Centigrade degrees Bars between subassemblies that support battery rails Rack stabilizing braces between subassemblies A non metallic electrical conductor Fahrenheit degrees Main support structure of battery rack International Electric Code in lbs kg Ib Ohmmeter p n shims subassembly torque UPS Inch pounds Kilogram Pound Millimeter Instrument used to indicate resistance in ohms Part number Metal spacers used to level rack due to uneven flooring A component part comprised of other parts Tightening measure applied to nuts and bolts Uninterruptible Power Supply Battery Rack Assembly and Installation Manual Appendix A Battery Wiring Style E Style E rack 1 shelf 1 top i to BAT 1 Terminal Block 1 Front of Battery Rack The following connections must be made to the TOP shelf in Rack 1 e Battery to battery cables 1 6 e Row to row cable 49 e Shelf to shelf cable 57 e Battery to terminal block cable 63 Battery Rack Assembly and Installation Manual 35 Appendix A Battery Wiring Style E Style E rack 1 shelf 2 H RE 1 BAT 1 BAT 1 de Terminal Block 1 Front of Battery Rack The following connections must be made to the SECOND shelf in R
7. washer lock washer and hex nut hardware is not supplied 5 To connect additional racks to this same sidecar repeat steps 1 4 while using different landing holes on the sidecar s vertical bars Battery Rack Assembly and Installation Manual 49 Appendix C Employing Sidecars 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 500 MCM cable not supplied is recommended for all connections specified in this section To avoid cable congestion the sidecar connections are made from back to front in the enclosure Be certain battery breakers are in the open or OFF position before making connections to them Electrical Hazard All external cable must comply with European and local electrical code If using conduit BAT 1 and and BAT 2 and cables must be run separately Note 1 Using three 3 253 mm 500 MCM cables connect the BAT 2 horizontal bar in the Sidecar to the specified BAT 2 bus in Battery Breaker 2 At the Sidecar a Make connections to the three 3 two hole landings nearest the RIGHT side of the BAT 2 horizontal bar refer to right graphic If using top cable entry connect with lugs pointing down Otherwise connect with lugs pointing up Secure the three 3 lugs to their landings with six 6 eee M12 1 2 bol
8. Battery installation must be performed in accordance with all applicable codes Observe all WARNING and CAUTION notices Failure to do so may result in SERIOUS INJURY or DEATH Disconnect charging source s BEFORE connecting or disconnecting battery terminals Some battery terminals and other components remain LIVE even when the system is switched off LETHAL VOLTAGES may still be present when the rack is non operational or when breakers are in the OFF position USE EXTREME CAUTION when making terminal connections DO NOT allow cables to touch anything except the intended terminal INSULATED TOOLS and proper INSULATING MATERIALS rubber floor stands rubber mats gloves protective clothing etc should be used when connecting battery cables Safety precautions A Caution Assemble racks in accordance with the instructions contained in this document WITHOUT DEVIATION For installations where grounding is required for IEC and or local codes see instructions for RACK GROUNDING Refer to local ordinances that pertain to battery installation and storage Handle transport and properly dispose of or recycle batteries in accordance with regulations Lead acid batteries contain hazardous toxic materials DO NOT dispose of batteries in a fire they may explode Do not open alter or mutilate batteries Released electrolyte is harmful to the skin and eyes and may be toxic Batteries should always be replaced with the same number and
9. Refer to graphic in step 10 below 8 Bolt Cross Bar 7 to Top 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 10 below 9 Bolt Cross Bar 8 to Top Side Subassembly 1 at hole position 6 from front on the UPPER 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 step 10 below Battery Rack Assembly and Installation Manual 13 Rack Assembly 10 Bolt Cross Bar 8 to Top 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 STEP 9 Connection Cross Bar 8 Top Side Subassembly 1 870 3698 at STEP 10 Connection STEP 7 Connection A Cross Bar 7 hs Top Side Subassembly 1 870 3698 a STEP 8 Connection 14 Battery Rack Assembly and Installation Manual Rack Assembly 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 also connect the Top Side Assemblies to the Bottom Side Assemblies Top Side Assembly 2 Top Side Assembly 1 Rear peers 1 Rear Cross Brace 2 870 3697 Rear Cross Brace 3 Rear Cross Brace 4
10. Support center by telephone or e mail Regional centers Direct InfraStruXure Customer Support 1 877 537 0607 toll free APC headquarters U S Canada 1 800 800 4272 toll free Latin America 1 401 789 5735 USA Europe Middle East Africa 353 91 702055 Ireland Japan 0 35434 2021 Australia New Zealand South Pacific 61 2 9955 9366 Australia Local country specific centers go to www apc com support contact for contact information Contact the APC representative or other distributor from whom you purchased your APC product for information on how to obtain local customer support Entire contents copyright 2004 American Power Conversion All rights reserved Reproduction in whole or in part without permission is prohibited APC the APC logo and Symmetra are trademarks of American Power Conversion Corporation and may be registered in some jurisdictions All other trademarks product names and corporate names are the property of their respective owners and are used for informational purposes only 990 4194A OO 4194 03 2004
11. a a a a a i a i i i i i i i i i i i i i i i i i i i Installation considerations 00000000 lt 00002 1 Installation equipment 0ococooocoo oa Torque specifications 00000 0000 Parts ISE ica oa a Battery CablINd 02 ds a Battery Rack Assembly and Installation Manual Rack ASSOMDIY varada O Assembling the bottom section 000e 0 o oo 9 Assembling the top section 00 ooo o 11 Stabilizing the rack iia diria ova 15 Anchoring the rack optional 0000000000 000 2 0 16 Numbering the batteries 0000ooooooooommnmosas 16 Accessing your wiring diagramS 00 0 ooo ooooooon 16 Positioning rails on ShelveS 00000 0000 17 Addressing the bottom shelf 00000 0000 17 Wiring the batteries 0 000 eee eee eee ees 18 Addressing the third shelf 00o0o0 ooo oooomoomos 21 Addressing the second shelf 000coooo ooo 21 Addressing the top Shelf 000 0c ooo ooooono omo 22 Shelf to shelf wiring 02 00 cee eee eee eee ees 23 Assembling the second rack 000oocoooo ooo 24 Labelling the terminal blocks 000000 00000001010 4 25 Employing sidecars to support separated racks 25 Connecting terminal blocks to battery breakers 26 Connecting terminal blocks to batteries 000 000 0 0 28 Reattaching terminal block covers 000o0o 02222 33 Applying warning labels 00 00 lt 0
12. all specified SECOND shelf battery to battery and row to row connections Refer to Wiring the batteries on page 18 Addressing the top shelf 22 The TOP shelf is addressed only after second shelf batteries have been loaded and wired L Position Battery Rails on TOP shelf Cross Bars according to spacing requirements obtained from the Rail Spacing Matrix on page 17 Measure with ruler or tape to ensure proper spacing and later make adjustments as necessary Refer to step 1 on page 17 for similar procedure Screw Battery Rails into TOP shelf Cross Bars using 1 4 20 x 3 4 flathead screws and 1 4 20 spring nuts Each battery rail requires two screws and two spring nuts one screw and spring nut is applied to each cross bar Refer to step 2 on page 17 for similar procedure Battery Rack Assembly and Installation Manual Rack Assembly 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 Refer to step 3 on page 18 for similar procedure 4 Make all specified TOP shelf battery to battery and row to row connections Refer to Wiring the batteries on page 16 Shelf to shelf wiring Shelf to shelf wiring takes place after ALL of the shelves in your rack have been fully assembled and their batteries wired together in numerical seque
13. and sidecars are NOT used proceed to the next section below If racks ARE separated and sidecars ARE used disregard the next Note Section and proceed instead to Appendix C Employing Sidecars on page 44 Battery Rack Assembly and Installation Manual 25 Rack Assembly 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 4 0 cable not supplied is recommended for all connections specified in this section Each terminal block assembly contains preset hardware for securing cable lugs Be certain battery breakers are in the open or OFF position before making connections to them Electrical Hazard All external cable must comply with European and local electrical code Note 1 Using one 1 120 mm 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 as shown of the BAT 1 segment on left Otherwise connect to bottom terminal Secure lug to stud with preset washer and nut To relieve strain zip tie cable to the shelf directly above the terminal block To Battery Breaker 1 BAT 1 terminal Terminal Block 1 At Battery Breaker 1 Refer to the battery breaker s wiring diagram for the proper BAT 1 lug landing on the other
14. end of this cable 26 Battery Rack Assembly and Installation Manual Rack Assembly 2 Using one 1 120 mm 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 as shown of the BAT l segment on right Otherwise connect to bottom terminal Secure lug to stud with preset washer and nut To relieve strain zip tie cable to the shelf directly above the terminal block To Battery Breaker 1 BAT 1 terminal Terminal Block 1 At Battery Breaker 1 Refer to the battery breaker s wiring diagram for the proper BAT 1 lug landing on the other end of this cable 3 Using one 1 120 mm 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 as shown of the BAT 2 segment on left Otherwise connect to bottom terminal Secure lug to stud with preset washer and nut To relieve strain zip tie cable to the shelf directly above the terminal block To Battery Breaker 2 BAT 2 terminal Terminal Block 2 At Battery Breaker 2 Refer to the battery breaker s wiring diagram for the proper BAT 2 lug landing on the other end of this cable Battery Rack Assembly and Installation Manual 27 Rack Assembly 4 Using o
15. may be unable to assist in recovering the realized amount of the claim All damage claims should be as specific as possible Information pertaining to the shipment should appear on the shipping label and related paperwork BE SURE to request a copy of the carrier s inspection report Check for discrepancies Make certain the shipment has arrived in its entirety Compare information from the shipping label parts list against what has been received If any part is missing or might have been damaged prior to shipping contact APC immediately 4 Battery Rack Assembly and Installation Manual 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 overall system If any or all of the racks are positioned apart from the battery breakers sidecars should be employed to achieve connectivity Sidecars are discussed in detail in Note Appendix C Employing Sidecars on page 44 Mains Supply Service Battery Breaker a ead ni ata Box es ane TH UPS ad 2 m pe at r a e j Ba e E e M Ni i Z k Battery Rack 1 Battery Rack 2 i i Handling The rack assemblies are relatively heavy weighing 156 kg 344 Ibs each so use a forklift or pallet jack to transport boxes on their pallets to th
16. misuse negligence improper installation or testing unauthorized attempts to repair of modify or any other cause beyond the range of the intended use or by accident fire lightning or other hazard There are no warranties express or implied by operation of law or otherwise of products sold or furnished under this agreement or in connection herewith APC disclaims all implied warranties of merchantability satisfaction and fitness for a particular purpose APC s express warranties will not be enlarged diminished or affected by and no obligation of liability will arise out of APC s rendering of technical or other advice or service in connection with the products The foregoing warranties and remedies are exclusive and in lieu of all other warranties and remedies APC s watranties run only to purchaser and are not extended to any third parties Battery Rack Assembly and Installation Manual 57 Arc www apc com APC Worldwide Customer Support Customer support for this or any other APC product is available at no charge in any of the following ways e Visit the APC Web site to access documents in the APC Knowledge Base and to submit customer support requests Www apc com Corporate Headquarters Connect to localized APC Web sites for specific countries each of which provides customer support information Www apc com support Global support searching APC Knowledge Base and using e support e Contact an APC Customer
17. placed and the proper positioning of its positive and negative terminals e Because batteries are loaded from bottom to top in the rack the higher 1 numbered batteries are placed on the lower shelves e Prior to loading batteries use a voltmeter to ensure each battery contains its Note required 12V DO NOT load any battery with an insufficient voltage Leave a minimum space of 5 mm 2 in between batteries in the same row 5 mm 2 Positive Terminal Negative Terminal Wiring the batteries All of the batteries loaded onto a given shelf must be connected wired in numerical sequence before starting assembly of the next shelf These connections consist of battery to battery and row to row wiring Review Safety on page 1 for safety warnings and caution notices Take heed of all safety information before proceeding with battery connections Failure to Warning comply could result in serious injury or death 1 Connect all batteries in the same row those on the same rails using the supplied battery to battery cable Refer to your wiring diagrams for proper cabling and termination points Refer to instructions for Applying cable boots on page 19 Connecting to batteries on page 20 and Covering battery connections on page 21 e Prior to connecting batteries use a voltmeter to check the voltage between those terminals being connected Any reading other than zero is unacceptable e After co
18. type as previously used Batteries must remain in a climate controlled environment having a temperature range of 22 to 25 C 72 to 77 F and a relative humidity of 0 to 95 non condensing Failure to adhere to these guidelines could adversely affect the performance of your batteries as well as your battery warranty Battery Rack Assembly and Installation Manual 1 Safety Additional considerations A Caution 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 build up service personnel should contact ground prior to working on batteries DO NOT operate battery breakers without first referring to this manual Battery Rack Assembly and Installation Manual 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 depends on the customer s requirements for run time The racks can accommodate either Power or Fiamm battery types 1 Refer to APC Warranty on Batteries on page 57 Note The following product SKUs reflect the currently available rack battery options Rack SKU Battery Type Model Assembly Qty Wiring Style Cable Size ref SYR400k1000HxR 2CP Power TC 1
19. 2150 16 rails 2 E 120 mm 4 0 SYR400k1000HxR 2CF Fiamm 12SLB130 16 rails 2 E 120 mm 4 0 Cobra cable rated for 150 C Weights and dimensions Each assembled rack measures 1778mm H x 1047mm W x 797mm D 70 x 41 2 x 31 4 For each two rack combination the width doubles to 2094mm 82 4 The weight of individual racks battery types and a fully loaded TWO rack system is presented below Rack SKU Weight Per Rack Battery Type Weight Per Batt Total Wet SYR400k 1000HxR 2CP 156 kg Power TC 12150 45 kg 3192 kg SYR400k1000HxR 2CF 156 kg Fiamm 12SLB130 42 kg 3000 kg Battery Rack Assembly and Installation Manual 3 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 to the pallet for added stability Batteries are shipped separately and shrink wrapped to their pallet as well Receiving Check for damages 1 Upon receipt inspect the boxes for obvious signs of rough handling 2 Remove shrink wrap open boxes and conduct an internal inspection of the equipment Keep boxes on pallet for transportation to installation site 3 Record any damages and call the carrier immediately to allow their personnel to conduct an equipment inspection DO NOT contact APC first notify the carrier instead Otherwise APC
20. 3 8 KEPS nut Refer to graphic in step 9 below 10 Battery Rack Assembly and Installation Manual Rack Assembly 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 STEP 8 Connection Cross Bar 4 870 3698 Bottom Side Subassembly 1 EF e STEP 9 Connection Ea e 5 F 3 Mon P A LEE STEP 6 Connection i ps Cross Bar 3 870 3698 i Bottom Side Subassembly 2 STEP 7 Connection Assembling the top section The top section of the rack will contain shelves 1 and 2 1 Bolt Top Side Subassembly 1 onto Bottom Side Subassembly 1 at designated hole positions Use 3 M12 x 35 bolts and related hardware 6 12mm washers 3 12mm lockwashers and 3 M12 nuts DO NOT bolt the REAR hole at this time Top Side Subassembly 1 870 1657A M12 x35 Bolt 803 1235 DO NOT BOLT HERE e a W 12mm Washer 812 0039 A 12mm Washer 812 0039 M12 Nut 803 1200 12mm Lockwasher 812 0038 Bottom Side Subassembly 1 Battery Rack Assembly and Installation Manual 11 Rack Assembly 2 Bolt Top Side Subassembly 2 onto Bottom Side Subassembly 2 at same basic hole positions specified in step 1 above Use 3 M12 x 35 bolts and related hardware 6 12mm washers 3 12mm lockwashers and 3 M12 nuts Again DO NOT bolt REAR hole Top Side Subassembly 2
21. 870 1657A Bottom Side Subassembly 2 3 Bolt Cross Bar 5 to Top Side Subassembly 1 at hole position 2 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 step 4 below 4 Bolt Cross Bar 5 to Top 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 Top Side Subassembly 1 Top Side Subassembly 2 STEP 3 Connection Cross Bar 5 870 3698 STEP 4 Connection 12 Battery Rack Assembly and Installation Manual Rack Assembly 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 step 6 below 6 Bolt Cross Bar 6 to Top 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 STEP 5 Connection Cross Bar 6 870 3698 Top Side Subassembly 1 Top Side Subassembly 2 STEP 6 Connection 7 Bolt Cross Bar 7 to Top Side Subassembly 1 at hole position 2 from front on the UPPER 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
22. 870 3697 870 3698 Bottom Side Assembly 2 Bottom Side Assembly 1 12mm Washers 803 1235 EN 12mm Lockwasher Ta J 812 0038 M12 Nut 803 1200 Battery Rack Assembly and Installation Manual 15 Rack Assembly 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 and apply anchoring hardware not supplied Graphic provides accurate dimensional data between hole locations a 996 6 p 39 24 694 8 27 35 795 5 31 36 d s 1047 4 j 41 24 AN Numbering the batteries Each battery is numbered from 1 to 64 because batteries are ultimately wired together in numerical sequence Apply a numerical sticker from supplied Labels to the top of each battery to designate its position in the wiring scheme Place a numbered sticker on all 64 of your batteries at this time Accessing your wiring diagrams Wiring diagrams applicable to your rack SKU should be used as points of reference when loading and connecting batteries Refer to Appendix A Battery Wiring Style E on page 35 throughout the process of loading and wiring your batteries 16 Battery Rack Assembly and Installation Manual Rack Assembly Positioning rails on shelves Apply your Battery Type Power or Fiamm to the Rail Spacing Matrix bel
23. Arc www apec com Battery Racks for 400kW 1MW UPS Systems Assembly and Installation Manual This manual provides information pertaining to the assembly loading and wiring of those APC battery racks designed to support the following Symmetra MW UPS systems e 400 kW e 800 kW e 600 kW e 1 MW The basic components of each rack consist of frames cross braces support rails and assembly hardware Refer to Parts List on page 7 Read these instructions carefully and observe all safety warnings and other precautions before assembling racks or installing batteries Should you require any assembly supervision service parts accessories or maintenance call the appropriate APC number refer to rear of document Battery Rack Assembly and Installation Manual Contents Sally aster weeny haa eas aad a es Safety WA MINOS iia e Bc ce eh a ce ea ace Se Safety PreCAUtiONS wanu 0 AA Aa A Additional considerations 00000 000000 Specifications E E E E E E E E HE E E E E E E E E E E E E E E E E E E E E E E Rack battery Options sisi saw cea eee ee es Weights and dimensions 000 cee une nee n nee Shipping and Receiving 0 lt lt lt 0 lt 0 lt o o SHU PONG ie ara aia ir RECEIVING a A A a aa a Placement E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E PO SITIO RUNING usa a o le A PLAN GUNG waa seine rari es a ee a er ace Se a etl Installation Site a a a
24. aa Ss Cross Bar 1 o Siig Battery Rack Assembly and Installation Manual 9 Rack Assembly 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 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 Cross Bar 2 Bottom Side Subassembly 1 Bottom Side Subassembly 2 870 1658A STEP 4 Connection Cross Bar 1 5 Use a T square to ensure exact right angles between Cross Bars and horizontal supports at all four corners of the rack before proceeding 6 Bolt Cross Bar 3 to Bottom Side Subassembly 1 at hole position 2 from front on the UPPER 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 step 9 below 7 Bolt Cross Bar 3 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 9 below 8 Bolt Cross Bar 4 to Bottom Side Subassembly 1 at hole position 6 from front on the UPPER horizontal support of the Subassembly Use 1 3 8 16 x 1 bolt and related hardware 2 3 8 washers and 1
25. ack 1 e Battery to battery cables 7 12 e Row to row cable 50 e Shelf to shelf cable 58 e Battery to terminal block none 36 Battery Rack Assembly and Installation Manual Appendix A Battery Wiring Style E Style E rack 1 shelf 3 16 Front of Battery Rack The following connections must be made to the THIRD shelf in Rack 1 e Battery to battery cables 13 18 e Row to row cable 51 e Shelf to shelf cable 59 e Battery to terminal block none Battery Rack Assembly and Installation Manual 37 Appendix A Battery Wiring Style E Style E rack 1 shelf 4 bottom BAT 1 Terminal Block 441 44 Front of Battery Rack The following connections must be made to the BOTTOM shelf in Rack 1 e Battery to battery cables 19 24 e Row to row cable 52 e Shelf to shelf none accepts cable 59 e Battery to terminal block cable 64 38 Battery Rack Assembly and Installation Manual Appendix A Battery Wiring Style E Style E rack 2 shelf 1 top 36 lo Battery 41 35 34 to BAT 2 Terminal Block 42 Front of Battery Rack The following connections must be made to the TOP shelf in Rack 2 e Battery to battery cables 25 30 e Row to row cable 53 e Shelf to shelf cable 60 e Battery to terminal block cable 65 Battery Rack Assembly and Installation Manual 39 Appendix A Battery Wiring Style E Style E rack 2 shelf 2 40 33 BAT 2 BAT 2 64 Termin
26. acted by age and environmental conditions and therefore certain requirements must be met by the end user pursuant to this warranty Failure to adhere to the following conditions may put the warranty at risk APC supplied batteries must always be kept in a climate controlled environment and should be re charged at a minimum of every three 3 months in situations where no automatic charging takes place The battery environment must be free of excessive moisture construction dirt corrosive elements or other contaminants The temperature range must be maintained at 22 to 25 C 72 to 77 F for batteries in an operating environment and 0 to 25 C 32 to 77 F for batteries in a storage environment The relative humidity must be maintained at 0 to 95 non condensing APC must be notified immediately upon suspicion of possible battery defects and be subsequently given authority to inspect any sites containing potentially defective batteries If APC determines its supplied batteries to be defective due to material or workmanship APC will repair or replace those batteries at its option F O B factory without charge Should battery repair or replacement occur as a result of this warranty the warranty period will be pro rated accordingly APC shall not be liable under this warranty if its testing and examination disclose that the alleged defect in the product does not exist or was caused by the purchaser s or any third person s
27. al Block 2 Front of Battery Rack The following connections must be made to the SECOND shelf in Rack 2 e Battery to battery cables 31 36 e Row to row cable 54 e Shelf to shelf cable 61 e Battery to terminal block none 40 Battery Rack Assembly and Installation Manual Appendix A Battery Wiring Style E Style E rack 2 shelf 3 Front of Battery Rack The following connections must be made to the THIRD shelf in Rack 2 e Battery to battery cables 37 42 e Row to row cable 55 e Shelf to shelf cable 62 e Battery to terminal block none Battery Rack Assembly and Installation Manual 41 Appendix A Battery Wiring Style E Style E rack 2 shelf 4 bottom to BAT 2 Terminal Block 2 56 Front of Battery Rack The following connections must be made to the BOTTOM shelf in Rack 2 e Battery to battery cables 43 48 e Row to row cable 56 e Shelf to shelf none accepts cable 62 e Battery to terminal block cable 66 42 Battery Rack Assembly and Installation Manual Appendix B Battery Cabling Kits References for Power battery cables Product SKU SYR400k1000HxR Ref Des Qty Use 1 48 48 Battery to Battery 49 56 8 Row to Row 57 62 6 Shelf to Shelf 63 66 4 Battery to Terminal References for Fiamm battery cables Product SKU SYR400k1000HxR Ref Des Qty Use 1 48 48 Battery to Battery 49 56 8 Row to Row 57 62 6 Shelf to Shelf 63 66 4 Battery to Terminal Battery Rack Ass
28. e installation site Upon arrival re open the boxes and remove the assembly equipment Organize the parts in an area as close as possible to the rack s final installation position If a rack must be moved or repositioned following assembly and battery loading DO NOT lift with forklift or pallet jack from the front This could cause batteries to slide off and might result in rack damage as well Always lift from the Note side of the rack if possible Battery Rack Assembly and Installation Manual 5 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 spacing should be in accordance with applicable code requirements Racks should be set on a firm and reasonably level surface Shimming up to a maximum of 6 mm 0 25 in may be used to level corner posts both front to back and side to side Consider all requirements and restrictions with respect to floor loading Batteries must remain in a climate controlled environment having a temperature range of 22 to 25 C 72 to 77 F and a relative humidity of 0 to 95 non condensing Batteries should not be exposed to excessive moisture construction dirt corrosive elements and other contaminants Installation equipment Prior to assembling racks ensure availability of the following to
29. embly and Installation Manual Length 356 mm 914 mm 1422 mm 1219 mm Length 914 mm 914 mm 1422 mm 1219 mm P n 0W01883 0W02422 0W01881 0W02394 P n 0W02422 0W02422 0W01881 0W02394 43 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 compromising electrical connectivity Sidecars permit use of larger output cables to alleviate the problem of power degradation Separated sidecars must be grouped in multiples of two 2 4 6 8 etc Note Sidecar enclosures measure approximately 585 mm W x 914 mm D x 2032 mm H 23 x 36 x 80 and weigh approximately 227 kg 500 Ib Each sidecar contains four distinct U shaped busbar sets with landing holes for connecting a inputs FROM the battery racks and b outputs TO the battery breakers Each U shaped set consists of two vertical input bars and one horizontal output bar The horizontal bars are staggered in terms of height and depth to avoid congestion when connecting the larger output cables to them The sets are designated as follows from front to back BAT 1 BAT 1 BAT 2 and BAT 2 BAT 2 BAT 2 BAT 1 BAT 1 44 Battery Rack Assembly and Installation Manual Appendix C Employing Sidecars Positioning and accessing the sidecar
30. l 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 as shown of the BAT 1 segment on left Otherwise connect to bottom terminal Secure lug to stud with preset washer and nut To relieve strain zip tie cable to the shelf directly above the terminal block To BAT 1 Terminal Block 1 At the Sidecar Connect other cable end to To BAT 1 one of the single hole landings atop either of the BAT 1 vertical bars Secure lug to landing with M10 3 8 bolt washer lock washer and hex nut hardware is not supplied BAT 1 Battery Rack Assembly and Installation Manual Appendix C Employing Sidecars 2 Using one 1 120 mm 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 as shown of the BAT l segment on right Otherwise connect to bottom terminal Secure lug to stud with preset washer and nut To relieve strain zip tie cable to the shelf directly above the terminal block To BAT 1 Terminal Block 1 At the Sidecar Connect other cable end to one of the single hole landings atop either of the BAT 1 vertical bars Secure lug to ial landing with M10 3 8 bolt washer lock washer and hex nut hardware is not supplied Battery Rack Assembly and Installation Ma
31. lt lt ooo oooooonos 33 Grounding the Tacks swim ao 33 GIOSSA arcada dara aa a Appendix A Battery Wiring Style E lt lt 35 Style E rack 1 Shelf 1 top 00 000 o ooo 35 Style E rack 1 Shelf 2 2 cee ee es 36 Style E rack 1 Shelf 3 2 eee ee es 37 Style E rack 1 shelf 4 bottom 0000o0o0 o 38 Style E rack 2 Shelf 1 top 0000 00 ooooooonoss 39 Style E rack 2 Shelf 2 cece eee ee es 40 Style E rack 2 Shelf 3 0 0oo eee ee es 41 Style E rack 2 shelf 4 bottom 0000 oo 42 Appendix B Battery Cabling KitS lt lt lt 43 References for Power battery cables 0 000 00 n eae 43 References for Fiamm battery cables 000 000 eae 43 Battery Rack Assembly and Installation Manual Appendix C Employing SidecarS 000 lt lt 0 44 Sidecar OVervieWw jx in use ah aise a A aa a 44 Positioning and accessing the sidecar 0000 0000010104 45 Connecting terminal blocks to sidecars 00000000 lt 0101 46 Connecting sidecars to battery breakers 000000000 104 50 APC Warranty on Batteries 0000 cece eee ees OF APC Worldwide Customer Support 000eeeeeanees 58 Battery Rack Assembly and Installation Manual Battery Rack Assembly and Installation Manual Safety Safety warnings Warning Electrical Hazard Only QUALIFIED ELECTRICIANS may perform this installation
32. nce Start with the top shelf and work down Review Safety on page 1 for safety warnings and caution notices Take heed of all safety information before proceeding with battery connections Failure to Warning comply could result in serious injury or death Using the supplied shelf to shelf cable connect the HIGHEST numbered battery on the TOP shelf to the LOWEST numbered battery on the SECOND shelf Then connect the highest numbered battery on the second shelf to the lowest numbered battery on the third shelf Finally connect the highest numbered battery on the third shelf to the lowest numbered battery on the fourth shelf 1 Prior to connecting batteries use a voltmeter to check the voltage between those terminals being connected Any reading other than zero is unacceptable Note Follow these steps for each shelf to shelf connection 1 Refer to your wiring diagrams for proper cabling and termination points 2 Before making connections apply two 2 cable boots 3 Connect one cable end to the open negative terminal on the last battery in the upper shelf Snap cable boot over the connected lug terminal 4 Apply a protective boot not supplied to the other cable end then snake the cable downward through space in centrally located rails Boot Your Cable Battery Rack Assembly and Installation Manual 23 Rack Assembly 5 Remove protective boot and connect this same cable end to the open positive
33. ne 1 120 mm 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 as shown of the BAT 2 segment on right Otherwise connect to bottom terminal Secure lug to stud with preset washer and nut To relieve strain zip tie cable to the shelf directly above the terminal block To Battery Breaker 2 BAT 2 terminal Terminal Block 2 At Battery Breaker 2 Refer to the battery breaker s wiring diagram for the proper BAT 2 lug landing on the other end of this cable Connecting terminal blocks to batteries To minimize risk connections between terminal blocks and batteries should be made FROM the terminal blocks TO the batteries 120 mm 4 0 cable is supplied for all connections specified in this section Each terminal block assembly contains preset hardware for securing cable lugs Review Safety on page 1 for safety warnings and caution notices Take heed of all safety information before proceeding with battery connections Failure to Warning comply could result in serious injury or death Prior to making connections use a voltmeter to measure collective voltage of the BAT 1 1 32 and BAT 2 33 64 strings Readings should approximate the Note umber of batteries in each string times 12V or about 386V per string 28 Battery Rack Assembly and Installation Ma
34. nnecting each row use voltmeter to measure the collective voltage Reading should approximate number of batteries in row times 12V 18 Battery Rack Assembly and Installation Manual Rack Assembly 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 points Refer to instructions for Applying cable boots on this page Connecting to batteries on page 20 and Covering battery connections on page 21 e Prior to connecting batteries use a voltmeter to check the voltage between those terminals being connected Any reading other than zero is unacceptable e After connecting the entire shelf use voltmeter to measure the collective Note voltage Reading should approximate number of batteries on shelf times 12V Applying cable boots Before wiring batteries slide both cable ends through a cable boot Battery Rack Assembly and Installation Manual 19 Rack Assembly 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 of terminal Refer to Torque specifications on page 6 e Stud Terminal Lockwasher Washer Cable Lug e Insert Terminal Bolt
35. nual Rack Assembly 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 with the SMALLER lug At Terminal Block 1 Connect the lug on the cable end WITHOUT the boot to the open BAT 1 terminal Secure lug to stud with preset washer and nut Snake cable end WITH the boot between centrally located rails until it reaches Battery 1 At Battery 1 Connect the lug on the cable end WITH the boot to the open positive terminal on Battery 1 Snap the boot over the connected lug terminal Use zip ties as needed to relieve cable strain shelf to shelf to Battery 9 Terminal Block 1 Battery Rack Assembly and Installation Manual 29 Rack Assembly 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 with the SMALLER lug At Terminal Block 1 Connect the lug on the cable end WITHOUT the boot to the open BAT l terminal Secure lug to stud with preset washer and nut Snake cable end WITH the boot between centrally located rails until it reaches Battery 32 At Battery 32 Connect the lug on the cable end WITH the boot to the open negative terminal on Battery 32 Snap
36. nual 47 Appendix C Employing Sidecars 48 3 Using one 1 120 mm 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 as shown of the BAT 2 segment on left Otherwise connect to bottom terminal Secure lug to stud with preset washer and nut To relieve strain zip tie cable to the shelf directly above the terminal block To BAT 2 Terminal Block 2 At the Sidecar Connect other cable end to one of the single hole landings atop either of the BAT 2 vertical bars Secure lug to landing with M10 3 8 bolt washer lock washer and hex nut hardware is not supplied Battery Rack Assembly and Installation Manual Appendix C Employing Sidecars 4 Using one 1 120 mm 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 as shown of the BAT 2 segment on right Otherwise connect to bottom terminal Secure lug to stud with preset washer and nut To relieve strain zip tie cable to the shelf directly above the terminal block To BAT 2 Terminal Block 2 At the Sidecar Connect other cable end to To BAT 2 one of the single hole landings atop either of the BAT 2 vertical bars Secure lug to landing with M10 3 8 bolt
37. nual 51 Appendix C Employing Sidecars 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 the Sidecar a Make connections to the three 3 two hole landings nearest the RIGHT side of the BAT 1 horizontal bar refer to right graphic If using top cable entry connect with lugs pointing down Otherwise connect with lugs pointing up Secure the three 3 lugs to their landings with six 6 M12 1 2 bolts washers lock washers and hex nuts Hardware not supplied If using top cable entry reduce strain by zip tying cables to supports at top of frame refer to below graphic Zips not supplied Zip tied cables AA if MMe a BAT Hl ae a rs m E BAT 1 At Battery Breaker 1 Refer to the battery breaker s wiring diagram for the proper BAT 1 lug landings on the other end of these three 3 cables 52 Battery Rack Assembly and Installation Manual Appendix C Employing Sidecars 4 Using three 3 253 mm 500 MCM cables connect the BAT 1 horizontal bar in the Sidecar to the specified BAT 1 bus in Battery Breaker 1 At the Sidecar a Make connections to the three 3 two hole landings nearest the LEFT side of the BAT 1 horizontal bar refer to right graphic If using top cable entry connect with lugs pointing down Otherwise connect with lugs pointing up Secure the
38. ols and equipment Open end box wrenches SAE dimensions Battery lifting device rated Ratchet set w sockets SAE dimension 3 8 e Step ladder or stepping stool Torque wrench e Tape measure Standard Phillips and torx head screwdrivers e Chalk line Concrete drill for floor anchoring if applicable e T square Voltmeter e Level Ohmmeter for ground testing Felt tip marker Floor shims user supplied Protective boot to cover cable lugs Torque specifications STANDARD BOLT BATTERY TERMINAL Bolt Diameter Torque Battery Type Torque mm inches Nm in Ibs Nm in Ibs 6 1 4 Power 7 9 70 10 3 8 Fiamm 11 3 100 12 1 2 Battery Rack Assembly and Installation Manual 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 1658A 2 Battery Rail 870 1696 16 Cross Bar rack 870 3698 8 Rear Cross Brace 870 3697 4 M12 x 33 Bolt 803 1235 14 M12 Nut 803 1200 14 12mm Lockwasher 812 0038 14 12mm Washer 812 0039 28 1 4 20 Spring Nut 812 0040 32 1 4 20 x 3 4 Socket Flathead Screw 812 0037 32 3 8 16 x 1 Bolt 812 0723 16 3 8 KEPS Nut 812 3101 16 3 8 Washer 812 2030 32 M6 Flange Nut 803 2406 1 M6 Serrated Washer 811 0604 1 Number Sheet Label 885 1617 1 Warning Label 4 CE Rating Label 885 1618 1 Battery Rack Assembly and Ins
39. ow to determine initial positioning of rails Take into consideration that this information represents suggested starting points for placing rails Make adjustments as necessary Battery Wiring Left Corner Post Space Between Type Style Rails Shelf to Ist Rail Facing Rails Center Space mm in Power E 4 345 13 50 235 9 25 Fiamm E 4 405 16 00 110 4 25 Addressing the bottom shelf To maintain structural integrity batteries are loaded from bottom to top in the rack 1 Position Battery Rails on BOTTOM shelf Cross Bars according to spacing requirements obtained from the Rail Spacing Matrix chart above Measure with ruler or tape to ensure proper spacing and later make adjustments as necessary Each set of two 2 rails should face inward to enable their facing edges to support batteries Refer to graphic in step 2 below 2 Screw Battery Rails into BOTTOM shelf Cross Bars using 1 4 20 x 3 4 flathead screws and 1 4 20 spring nuts Each battery rail requires two screws and two spring nuts one screw and spring nut is applied to each cross bar Battery Rail 870 1696 Tee 1 4 20 x 3 4 Flathead Aer Screw 812 0037 1 4 20 Spring Nut i 812 0040 T iy ite Cross Bar Battery Rack Assembly and Installation Manual 17 Rack Assembly 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
40. tallation 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 specific requirements of your product SKU The cable references for this kit are provided in Appendix B Battery Cabling Kits on page 43 If your kit 1s missing cables contact APC immediately Do not proceed with this installation until all parts are in your possession 8 Battery Rack Assembly and Installation Manual 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 8 16 x 1 bolt and related hardware 2 3 8 washers and 1 3 8 KEPS nut 3 8 16 x 1 Bolt Bottom Side Subassembly 1 812 0723 870 1658A 3 8 Washers 812 2030 3 8 KEPS Nut Hole Position 2 812 3101 from Front Cross Bar 1 870 3698 2 Bolt Cross Bar 2 to Bottom 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 Bottom Side Subassembly 1 Hole Position 6 from Front Cross Bar 2 0 ts 870 3698 ae
41. the boot over the connected lug terminal Use zip ties as needed to relieve cable strain shelf to shelf from Battery 24 Terminal Block 1 30 Battery Rack Assembly and Installation Manual Rack Assembly 3 Using specified cable connect the open BAT 2 terminal in Terminal Block 2 to the open positive terminal on Battery 33 Before making connections apply ONE cable boot If lug sizes are different apply boot to the cable end with the SMALLER lug At Terminal Block 2 Connect the lug on the cable end WITHOUT the boot to the open BAT 2 terminal Secure lug to stud with preset washer and nut Snake cable end WITH the boot between centrally located rails until it reaches Battery 33 At Battery 33 Connect the lug on the cable end WITH the boot to the open positive terminal on Battery 33 Snap the boot over the connected lug terminal Use zip ties as needed to relieve cable strain shelf to shelf to Battery 41 Terminal Block 2 Battery Rack Assembly and Installation Manual 31 Rack Assembly 4 Using specified cable connect the open BAT 2 terminal in Terminal Block 2 to the open negative terminal on Battery 64 Before making connections apply ONE cable boot If lug sizes are different apply boot to the cable end with the SMALLER lug At Terminal Block 2 Connect the lug on the cable end WITHOUT the boot to the open BAT 2 terminal Secure lug to stud with preset washer and n
42. ts washers lock washers BAT 1 and hex nuts Hardware not supplied b Ifusing top cable entry reduce strain by zip N tying cables to supports at top of frame refer to below graphic Zips not supplied BAT 2 Zip tied cables At Battery Breaker 2 Refer to the battery breaker s wiring diagram for the proper BAT 2 lug landings on the other end of these three 3 cables 50 Battery Rack Assembly and Installation Manual Appendix C Employing Sidecars 2 Using three 3 253 mm 500 MCM cables connect the BAT 2 horizontal bar in the Sidecar to the specified BAT 2 bus in Battery Breaker 2 At the Sidecar d Make connections to the three 3 two hole landings nearest the LEFT side of the BAT 2 horizontal bar refer to right graphic If using top cable entry connect with lugs pointing down Otherwise connect with lugs pointing up Secure the three 3 lugs to their landings with six 6 M12 1 2 bolts washers lock washers and hex nuts Hardware not supplied If using top cable entry reduce strain by zip tying cables to supports at top of frame refer to below graphic Zips not supplied Zip tied cables BAT 2 BAT 2 At Battery Breaker 2 Refer to the battery breaker s wiring diagram for the proper BAT 2 lug landings on the other end of these three 3 cables Battery Rack Assembly and Installation Ma
43. ut Snake cable end WITH the boot between centrally located rails until it reaches Battery 64 At Battery 64 Connect the lug on the cable end WITH the boot to the open negative terminal on Battery 64 Snap the boot over the connected lug terminal Use zip ties as needed to relieve cable strain shelf to shelf from Battery 56 Terminal Block 2 J i ae 32 Battery Rack Assembly and Installation Manual Rack Assembly 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 batteries 1 Apply supplied Warning Labels to the front facing Cross Bar on each shelf in the battery racks 2 Apply supplied CE Rating Label p n 885 1618 to a highly visible area in the vicinity of the battery installation Grounding the racks Connect an external grounding cable not supplied to a grounding stud located in one of the rack s Bottom Side Subassemblies Secure the cable to the stud by applying hardware as follows Serrated washer Cable lug Flange nut M6 Flange Nut 803 2406 Cable Lug M6 Welded Grounding Stud 3 AT M6 Serrated Washer 811 0604 ij at Battery Rack Assembly and Installation Manual 33 Glossary 34 AH APC battery rails BOM C cross bars
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