American Power Conversion 400kW1MW User Manual

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Battery Racks for 400kW–1MWUPS 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 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

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Additional considerations . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Rack/battery options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Weights and dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Shipping and Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installation Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Installation considerations . . . . . . . . . . . . . . . . . . . . . . . . . 6

Installation equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Torque specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Battery Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Battery Rack Assembly and Installation Manual

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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 wiring diagrams . . . . . . . . . . . . . . . . . . . .

16

Positioning rails on shelves . . . . . . . . . . . . . . . . . . . . . . . .

17

Addressing the bottom shelf . . . . . . . . . . . . . . . . . . . . . . .

17

Wiring the batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

Addressing the third shelf . . . . . . . . . . . . . . . . . . . . . . . .

21

Addressing the second shelf . . . . . . . . . . . . . . . . . . . . . . .

21

Addressing the top shelf . . . . . . . . . . . . . . . . . . . . . . . . .

22

Shelf-to-shelf wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

Assembling the second rack . . . . . . . . . . . . . . . . . . . . . . .

24

Labelling the terminal blocks . . . . . . . . . . . . . . . . . . . . . .

25

Employing sidecars to support separated racks . . . . . . . . . .

25

Connecting terminal blocks to battery breakers . . . . . . . . . .

26

Connecting terminal blocks to batteries . . . . . . . . . . . . . . .

28

Reattaching terminal block covers . . . . . . . . . . . . . . . . . . .

33

Applying warning labels . . . . . . . . . . . . . . . . . . . . . . . . .

33

Grounding the racks . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Appendix A: Battery Wiring Style E . . . . . . . . . . . . . . . . . . . . . 35

Style E, rack #1, shelf #1 (top) . . . . . . . . . . . . . . . . . . . . .

35

Style E, rack #1, shelf #2 . . . . . . . . . . . . . . . . . . . . . . . . .

36

Style E, rack #1, shelf #3 . . . . . . . . . . . . . . . . . . . . . . . . .

37

Style E, rack #1, shelf #4 (bottom) . . . . . . . . . . . . . . . . . . .

38

Style E, rack #2, shelf #1 (top) . . . . . . . . . . . . . . . . . . . . .

39

Style E, rack #2, shelf #2 . . . . . . . . . . . . . . . . . . . . . . . . .

40

Style E, rack #2, shelf #3 . . . . . . . . . . . . . . . . . . . . . . . . .

41

Style E, rack #2, shelf #4 (bottom) . . . . . . . . . . . . . . . . . . .

42

Appendix B: Battery Cabling Kits . . . . . . . . . . . . . . . . . . . . . . . 43

References for Power battery cables: References for Fiamm battery cables:

. . . . . . . . . . . . . . . . . 43

. . . . . . . . . . . . . . . . . 43

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Battery Rack Assembly and Installation Manual

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 . . . . . . . . . . . . . . . . . . . . . 58

Battery Rack Assembly and Installation Manual

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iv

Battery Rack Assembly and Installation Manual

Safety

Safety warnings

Warning

Electrical

Hazard

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 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

• Assemble racks in accordance with the instructions contained in this document WITHOUT DEVIATION.

Caution

• 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-acidbatteries contain hazardous, toxic materials. DO NOT dispose of

 

batteries in a fire—theymay 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 type as

 

previously used.

 

• Batteries must remain in a climate-controlledenvironment 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

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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.

Caution • 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!

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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.

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-12150)

16 rails

2

E

120 mm2 (#4/0)

SYR400k1000HxR-2CF

Fiamm (12SLB130)

16 rails

2

E

120 mm2 (#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-rackcombination, the width doubles to 2094mm [82.4”]. The weight of individual racks, battery types, and a fully loadedTWO-racksystem is presented below.

Rack SKU

Weight Per Rack

Battery Type

Weight Per Batt

Total Wgt

 

 

 

 

 

SYR400k1000HxR-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

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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-wrappedto 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—notifythe carrier instead. Otherwise, APC 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.

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Battery Rack Assembly and Installation Manual