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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:
• 400 kW • 800 kW
•600 kW •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 precauti
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Battery Rack Assembly and Installation Manual
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Contents Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Safety warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Additional considerations . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Rack/battery options . . . . . . . . . . . . . . . . .
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Rack Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Assembling the bottom section . . . . . . . . . . . . . . . . . . . . . . 9 Assembling the top section . . . . . . . . . . . . . . . . . . . . . . . . 11 Stabilizing the rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Anchoring the rack (optional) . . . . . . . . . . . . . . . . . . . . . . 16 Numbering the batteries . . . . . . . . . . . . . . . . . . . . . . . . . 16 Accessing your wi
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Appendix C: Employing Sidecars . . . . . . . . . . . . . . . . . . . . . . . 44 Sidecar overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Positioning and accessing the sidecar . . . . . . . . . . . . . . . . . 45 Connecting terminal blocks to sidecars . . . . . . . . . . . . . . . . 46 Connecting sidecars to battery breakers . . . . . . . . . . . . . . . 50 APC Warranty on Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 APC Worldwide Customer Support .
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iv Battery Rack Assembly and Installation Manual
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Safety Safety warnings • Only QUALIFIED ELECTRICIANS may perform this installation! Battery installation must be performed in accordance with all applicable codes! Warning • 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 Electrical Hazard system is switched off! LETHAL VOLT
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Safety Additional considerations • 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! Caution • 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! 2 Battery Rack Assembly and Installation Manual
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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. Refer to “APC Warranty on Batteries” on page 57. Note The following product SKUs reflect the currently available rack/battery opt
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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 box
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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 “Appendix C: Employing Sidecars” on page 44. Note MWA Mains Suppl
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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. • C
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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 35 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
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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 is missing cables, contact APC immediately. Do not proceed with this installation until all parts
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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. Bottom Side Subassembly #1 3/8-16 x 1” Bolt (870-1658A) 3 (812-0723) 3 3 3/8 3 3 3/8 Washers (812-2030) 3/8 KEPS Nut (812-3101) Hole Position #2 from Front Cross Bar
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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
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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 STEP 9 Connection STEP 6 Connection Cross Bar #3 (870-3698) 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 Bo
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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 (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 rela
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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
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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 (870-3698) Top Side Subassembly #1 STEP 10 Connection STEP 7 Connection Cross Bar #7 Top Side Subassembly #1 (870-3698) STEP 8 Connection 14 Battery Rack Assembly and Installation Manual
