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American Power Conversion 400kW1MW manual

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Table of contents for the manual

  • Page 1

    Battery Racks for 400 kW–1 MW UPS Systems Assembly and Installation Manual This manual provides informatio n pertaining to the assembly , lo ading, and wiring of those APC battery racks designed to s upport the following Symmetra ® MW UPS systems: The basic components of each rack consist of frames, cross braces, support rails, and assembly hard[...]

  • Page 2

    Battery Rack Assembly and Installation Manual[...]

  • Page 3

    Contents Battery Rac k Assembly an d Installation Manual i Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Safety warnin gs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Additional considerations . [...]

  • Page 4

    ii Battery Rack Assembly and Installation Manual Rack Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Assembling the bottom section . . . . . . . . . . . . . . . . . . . . . . 9 Assembling the top section . . . . . . . . . . . . . . . . . . . . . . . . 11 Stabilizing the rack . . . . . . . . . . . . . . . . . [...]

  • Page 5

    Battery Rack Assembly and Installation Manual iii Appendix C: Employing Sideca rs . . . . . . . . . . . . . . . . . . . . . . . 44 Sidecar overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Positioning and accessing the sidecar . . . . . . . . . . . . . . . . . 45 Connecting terminal blocks to sidecars . . . . . . . . . . . .[...]

  • Page 6

    iv Battery Rack Assembly and Installation Manual[...]

  • Page 7

    Battery Rack Assembly and Installation Manual 1 Safety Safety warnings Safety pr ecautions War n in g • Only QUALIFIED ELECTRICIANS may perform this installation! Battery installation must be performed in ac cordance with all applicable codes! • Observe all W ARNING and CAUTION notices! Failure to do so may r e sult in SERIOUS INJURY or DEA TH![...]

  • Page 8

    Safety 2 Battery Rack Assembly and Installation Manual Additional considerations Caut io n • Observe all r equir ements and limitations pertaining to floor loading! • Remove watches, rings, and othe r metal objects from your body . • DO NOT lay tools or meta l parts on top of batteries! • T o avoid static build-up, service personnel should [...]

  • Page 9

    Battery Rack Assembly and Installation Manual 3 Specifications Rack/battery options The racks are deployed in multiples of two, with e ach rack housing one battery string. A maximum of eight racks (battery strings) can be used to support a single Sy mmetra MW U PS. The total number of strings deployed depe nd s on the customer ’ s requ irements f[...]

  • Page 10

    4 Battery Rack Assembly and Installation Manual Shipping and Receiving Shipping Rack assemblies are shipped in corrugated boxes. Ba ttery cables, batte ry boot s, te rminal blocks, and labels are also included in the shipment. Each pallet can support a maximum of two (2) units. Box es are shrink-wrapped to the pallet for added stability . Batteries[...]

  • Page 11

    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 br eaker box(es). The graphi c below sho ws a typi cal UPS syst em, and how th e battery racks fit into the overall system. MWA Handling The rack assembl[...]

  • Page 12

    6 Battery Rack Assembly and Installation Manual Installation Site Installat ion considerations The installation site should adhere to the following requirements: • There should be ample room fo r performing rack assembly , batte ry installation, maintenance, and possible battery replacement. • Aisle spacing should be in accordance with applicab[...]

  • Page 13

    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 T op Side Subassembly 870-1657A 2 Bottom Side Subassembly 870-1658A 2 Battery Rail 870-1696 16 Cross Bar (rack[...]

  • Page 14

    8 Battery Rack Assembly and Installation Manual Battery Cabling Batteries are arranged in the rack in accordance wi th W iring Style E. The wiring diagrams for this style are detailed in “Appendix A: Battery Wiring S tyle E” on page 35. The (included) battery ca bling kit was designed to suit the specific requirements of your product SKU. The c[...]

  • Page 15

    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 Subassembl y #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 hard ware: (2) 3/8[...]

  • Page 16

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

  • Page 17

    Rack Assembly Battery Rac k Assembly an d Installation Manual 11 9. Bolt Cross Bar #4 to Bottom Si de Subassembly #2 at its oppos ite hole position #6 (from front). Use (1) 3/8-16 x 1” bolt and related hard ware: (2) 3/8 washers and (1) 3/8 KEPS nut. Assembling the top section The top section of the rack wi ll contain shelves #1 and #2. 1. Bolt T[...]

  • Page 18

    Rack Assembly 12 Battery Rack Assembly and Installation Manual 2. Bolt T op Side Su bassembly #2 onto Bottom Side Subassembly #2 at same basic hole positions specified in step 1 above. Use (3) M12 x 35 bo lts and related hardware: (6) 12mm washers, (3) 12mm lockwashers and (3) M12 nuts. Again, DO NOT bolt REAR hole! 3. Bolt Cross Bar #5 to T op Si [...]

  • Page 19

    Rack Assembly Battery Rac k Assembly an d Installation Manual 13 5. Bolt Cross Bar #6 to T op Side Subassembly #1 at hole position #6 (from front) on the LOWER horizontal support of the Subassemb ly . Use (1) 3/8-16 x 1” b olt 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 T[...]

  • Page 20

    Rack Assembly 14 Battery Rack Assembly and Installation Manual 10.Bolt Cross Bar #8 to T op 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 an d (1 ) 3/8 KEPS nut. Top Side Subassembly #1 Top Side Subassembly #1 Cross Bar #7 (870-3698) Cross Bar #8 (870-3698) STEP [...]

  • Page 21

    Rack Assembly Battery Rac k Assembly an d Installation Manual 15 Stabilizing the rack Bolt (4) Rear Cross Braces to rack at designated hole positions. Use (8) M1 2 x 35 bolts and related hardware: (16) 12mm wash ers, (8) 12mm lockwashers and (8) M1 2 nuts. Note that lower bolts on Brace #1 and Brace #2 also connect the T op Side Assemblies to the B[...]

  • Page 22

    Rack Assembly 16 Battery Rack Assembly and Installation Manual Anchoring the rack (optional) For added stability , any or all of the racks ca n optionally be bolted to a concrete floor . T o anchor the rack, chalk mark four (4) pre-cut hol es (at the base of the assembly) in the facility floor , drill, and apply anchoring hardware (not supplied). G[...]

  • Page 23

    Rack Assembly Battery Rac k Assembly an d Installation Manual 17 Positioning rails on shelves Apply your Battery T ype (Power or Fiamm) to the Rail Spacing Matrix be low to determine initial positioning of rails. T ake into consideration that this information repres ents “suggested” starting points for placing rails. Make adjustments as necessa[...]

  • Page 24

    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. T ake note of wh ere each numbered battery should be placed, and the proper positioning of its positive and negative terminals. Leave a minimum space of 5 mm (.[...]

  • Page 25

    Rack Assembly Battery Rac k Assembly an d Installation Manual 19 2. W orking left to right (from front of rack), connect the last battery in the first row to the first battery in the second row usi ng the supplied row-to-row cable. – Refer to your wiring diagra ms for pr oper cabling and termination points. – Refer to instructions for “Applyi[...]

  • Page 26

    Rack Assembly 20 Battery Rack Assembly and Installation Manual Connecting to batteries. There are three types of batte ry term inals for connecting cables: 1) S tud terminal, 2) Insert terminal, and 3) L (or I) term inal. The applicatio n of hardware for making the connection varies according to the type of terminal. Refer to “T orque specifica t[...]

  • Page 27

    Rack Assembly Battery Rac k Assembly an d Installation Manual 21 Covering batter y connections. After each lug has been connected to its battery terminal, snap the boot down over the lug /te rmin al. Addr essing the thir d shelf The THIRD shelf is addressed only after bottom shelf batteries have been loaded and wired. 1. Position Battery Rails on T[...]

  • Page 28

    Rack Assembly 22 Battery Rack Assembly and Installation Manual 2. Screw (1) T erminal Block Assembly to the SEC OND shelf Cross Bar at the front of the rack. Secure to cross bar with the (2) supplied M6 socket-head cap scr ews and flange nuts. Select a location on the bar th at does not conflict with battery or rail placement. The end stops can be [...]

  • Page 29

    Rack Assembly Battery Rac k Assembly an d Installation Manual 23 3. Using a rated lifting device, load batteries onto TOP shelf rails in accordance with your wiring diagram. T ake note of where each numbered battery should be place d, an d the proper positioning of its positiv e and negative terminals. Refer to step 3 on page 18 for similar pr oced[...]

  • Page 30

    Rack Assembly 24 Battery Rack Assembly and Installation Manual 5. Remove protective boot and connect this same ca ble end to the open pos itive (+) 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 de ployed in multiples of two. Repeat all previous ste[...]

  • Page 31

    Rack Assembly Battery Rac k Assembly an d Installation Manual 25 Labelling the terminal blocks Each rack is equipped with (1) terminal block assembly . The left (+) and right (-) se gments of each terminal block must be appropriately labelled. 1. Remove the snap-off cover from th e front face of each terminal block. 2. Apply two “terminal block?[...]

  • Page 32

    Rack Assembly 26 Battery Rack Assembly and Installation Manual Connecting terminal blocks to batter y br eakers T o minimize risk, terminal block-to-batte ry br eaker connections are made prior to battery-to- terminal block connections. T OP entry of 120 mm 2 [#4/0] cable (not supplied) is recommended for all connections specified in this section. [...]

  • Page 33

    Rack Assembly Battery Rac k Assembly an d Installation Manual 27 2. Using one (1) 120 mm 2 [#4/0] cable, connect the appr opriate (top or bottom) BA T 1- terminal in T erminal Bloc k #1 to the BA T 1- terminal in Battery Breaker #1. At T erm inal Block #1: If using top cable entry , connect to top terminal (a s shown) of the BA T 1- segment on righ[...]

  • Page 34

    Rack Assembly 28 Battery Rack Assembly and Installation Manual 4. Using one (1) 120 mm 2 [#4/0] cabl e, connect the appr opriate (top or bottom) BA T 2- terminal in T erminal Bloc k #2 to the BA T 2- terminal in Battery Breaker #2. At T erm inal Block #2: If using top cable entry , connect to top terminal (a s shown) of the BA T 2- segment on right[...]

  • Page 35

    Rack Assembly Battery Rac k Assembly an d Installation Manual 29 1. Using specified cable, connect the open BA T 1+ terminal in T erminal Block #1 to the open positive (+) terminal on Battery #1. Before making connections, apply ONE cab le boot. If lug sizes are different, apply boot to the cable end with the SMALLER lug. At T erm inal Block #1: Co[...]

  • Page 36

    Rack Assembly 30 Battery Rack Assembly and Installation Manual 2. Using specified cable, connect the open BA T 1- terminal in T erminal Block #1 to the open negative (-) terminal on Battery #32. Before makin g co nn ectio ns, apply ONE cable boot. If lug sizes are different, apply boot to the cable end with the SMALLER lug. At T erm inal Block #1: [...]

  • Page 37

    Rack Assembly Battery Rac k Assembly an d Installation Manual 31 3. Using specified cable, connect the open BA T 2+ terminal in T erminal Block #2 to the open positive (+) terminal on Battery #33. Before making connectio ns, apply ONE cable bo ot. If lug sizes are different, apply boot to the cable end with the SMALLER lug. At T erm inal Block #2: [...]

  • Page 38

    Rack Assembly 32 Battery Rack Assembly and Installation Manual 4. Using specified cable, connect the open BA T 2- terminal in T erminal Block #2 to the open negative (-) terminal on Battery #64. Before making co nn ectio ns, apply ONE cable boot. If lug sizes are different, apply boot to the cable end with the SMALLER lug. At T erm inal Block #2: C[...]

  • Page 39

    Rack Assembly Battery Rac k Assembly an d 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 batteries. 1. Apply supplied “W arning” Labels [...]

  • Page 40

    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 ba tteries lb Pound BOM Bill of Materials mm Millimeter C Centigrade (degrees) Ohmmeter Instrument used to indicate resistance (in ohms) cross bars Bars[...]

  • Page 41

    Battery Rack Assembly and Installation Manual 35 Appendix A: Batter y Wiring Style E Style E, rack #1, shelf #1 (top) The following connections m ust be ma de to the T OP shelf in Rack #1: • Battery-to-battery: cables 1-6 • Row-to-row: cable 49 • Shelf-to-shelf: cable 57 • Battery-to-terminal block: ca ble 63 Front of Battery Rack[...]

  • Page 42

    Appendix A: Battery Wiring St yle E 36 Battery Rack Assembly and Installation Manual Style E, rack #1, shelf #2 The following connections m ust be ma de to the SECOND shelf in Rack #1: • Battery-to-battery: cables 7-12 • Row-to-row: cable 50 • Shelf-to-shelf: cable 58 • Battery-to-terminal block: none Front of Battery Rack[...]

  • Page 43

    Appendix A: Battery Wiring Style E Battery Rac k Assembly an d Installation Manual 37 Style E, rack #1, shelf #3 The following connections m ust be ma de to the T HIRD 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 Front of Battery Rack[...]

  • Page 44

    Appendix A: Battery Wiring St yle E 38 Battery Rack Assembly and Installation Manual Style E, rack #1, shelf #4 (bottom) The following conn ections must be made to the BOTT OM sh elf in Rack #1: • Battery-to-battery: cables 19-24 • Row-to-row: cable 52 • Shelf-to-shelf: none (accepts cable 59) • Battery-to-terminal block: ca ble 64 Front of[...]

  • Page 45

    Appendix A: Battery Wiring Style E Battery Rac k Assembly an d Installation Manual 39 Style E, rack #2, shelf #1 (top) The following connections m ust be ma de to the T OP shelf in Rack #2: • Battery-to-battery: cables 25-30 • Row-to-row: cable 53 • Shelf-to-shelf: cable 60 • Battery-to-terminal block: ca ble 65 Front of Battery Rack[...]

  • Page 46

    Appendix A: Battery Wiring St yle E 40 Battery Rack Assembly and Installation Manual Style E, rack #2, shelf #2 The following connections m ust be ma de to the SECOND shelf in Rack #2: • Battery-to-battery: cables 31-36 • Row-to-row: cable 54 • Shelf-to-shelf: cable 61 • Battery-to-terminal block: none Front of Battery Rack[...]

  • Page 47

    Appendix A: Battery Wiring Style E Battery Rac k Assembly an d Installation Manual 41 Style E, rack #2, shelf #3 The following connections m ust be ma de to the T HIRD 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 Front of Battery Rack[...]

  • Page 48

    Appendix A: Battery Wiring St yle E 42 Battery Rack Assembly and Installation Manual Style E, rack #2, shelf #4 (bottom) The following conn ections must be made to the BOTT OM sh elf in Rack #2: • Battery-to-battery: cables 43-48 • Row-to-row: cable 56 • Shelf-to-shelf: none (accepts cable 62) • Battery-to-terminal block: ca ble 66 Front of[...]

  • Page 49

    Battery Rack Assembly and Installation Manual 43 Appendix B: Batter y Cabling Kits Refer ences for Power battery cables: Refer ences for Fiamm battery cables: Product SKU: SYR400 k1 000HxR 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-to-Shelf 1422 mm 0W01881 63-66 4 Battery-to-[...]

  • Page 50

    44 Battery Rack Assembly and Installation Manual Appendix C: Employing Sidecars Sidecar overview Battery racks can be situat ed in one or more locatio ns 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 p[...]

  • Page 51

    Appendix C: Employ ing Si decars Battery Rac k Assembly an d Installation Manual 45 Positioning and accessing the sidecar The sidecar is typically positioned alongside one of the separated rack s 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 thei[...]

  • Page 52

    Appendix C: Employing Sidecars 46 Battery Rack Assembly and Installation Manual Connecting terminal blocks to sidecars T o minimize risk, terminal block-to-sidecar connections are made prior to sidecar-to-battery br eaker connections and battery-to-terminal block connections. TOP entry of 120 mm 2 [#4/0] cable (not supplied) is recommended for all [...]

  • Page 53

    Appendix C: Employ ing Si decars Battery Rac k Assembly an d Installation Manual 47 2. Using one (1) 120 mm 2 [#4/0] cable, connect the BA T 1- terminal in T erminal Block #1 to either of the two BA T 1- ve rtical bars in the Sidecar . At T erm inal Block #1: If using top cable entry , connect to top terminal (a s shown) of the BA T 1- segment on r[...]

  • Page 54

    Appendix C: Employing Sidecars 48 Battery Rack Assembly and Installation Manual 3. Using one (1) 120 mm 2 [#4/0] cable, connect the BA T 2+ terminal in T erminal Block #2 to either of the two BA T 2+ vertical bars in the Sidecar . At T erm inal Block #2: If using top cable entry , connect to top terminal (a s shown) of the BA T 2+ segment on left. [...]

  • Page 55

    Appendix C: Employ ing Si decars Battery Rac k Assembly an d Installation Manual 49 4. Using one (1) 120 mm 2 [#4/0] cable, connect the BA T 2- terminal in T erminal Block #2 to either of the two BA T 2- ve rtical bars in the Sidecar . At T erm inal Block #2: If using top cable entry , connect to top terminal (a s shown) of the BA T 2- segment on r[...]

  • Page 56

    Appendix C: Employing Sidecars 50 Battery Rack Assembly and Installation Manual Connecting sidecars to battery br eakers T o minimize risk, sidecar -to -battery br eaker connections are made prior to battery-to-terminal block connections. TOP entry of 253 mm 2 [500 MCM] ca ble (not supp lied) is recommended for all connections specified in this sec[...]

  • Page 57

    Appendix C: Employ ing Si decars Battery Rac k Assembly an d Installation Manual 51 2. Using three (3) 253 mm 2 [500 MCM] cables, connect the BA T 2+ horizontal bar in the Sidecar to the specified BA T 2+ bus in Battery Br eaker #2. At Battery Breaker #2: Refer to the battery breaker ’ s wiri ng diagram for the proper BA T 2+ lug landings on the [...]

  • Page 58

    Appendix C: Employing Sidecars 52 Battery Rack Assembly and Installation Manual 3. Using three (3) 253 mm2 [500 MCM] cables, connect the BA T 1- horizontal bar in the Sidecar to the specified BA T 1- bus in Battery Breaker #1. At Battery Breaker #1: Refer to the battery breaker ’ s wiring diagram for the proper BA T 1- lug landings on the other e[...]

  • Page 59

    Appendix C: Employ ing Si decars Battery Rac k Assembly an d Installation Manual 53 4. Using three (3) 253 mm 2 [500 MCM] cables, connect the BA T 1+ horizontal bar in the Sidecar to the specified BA T 1+ bus in Battery Br eaker #1. At Battery Breaker #1: Refer to the battery breaker ’ s wiri ng diagram for the proper BA T 1+ lug landings on the [...]

  • Page 60

    54 Battery Rack Assembly and Installation Manual[...]

  • Page 61

    Battery Rack Assembly and Installation Manual 55[...]

  • Page 62

    Battery Rack Assembly and Installation Manual 56[...]

  • Page 63

    Battery Rack Assembly and Installation Manual 57 APC W arranty on Batteries APC warrants that its supplied High-Rate series of V alve Regulated Lead Ac id batteries will be free of defects in material and workmanship for a peri od of one (1) year from date of sh ipment. This amounts to the same basic warranty that is being of fered by the leading b[...]

  • Page 64

    ® *990-4194A* APC W orldwide Customer Support Customer support for this or any other APC product is available at no charge in any of the following ways: • V isit the APC W eb site to access documents in the APC Knowledge Base and to s ubmit customer support requests. – www .apc.com (Corporate Headqu arters) Connect to localized APC W eb sites [...]