American Power Conversion 400kW1MW User Manual
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
• 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).
®
MW UPS systems:
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 i
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: . . . . . . . . . . . . . . . . . 43
References for Fiamm battery cables: . . . . . . . . . . . . . . . . . 43
ii 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 iii
iv Battery Rack Assembly and Installation Manual
Safety
Safety warnings
Warning
• 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!
Electrical
Hazard
• Some battery terminals and other components remain LIVE even when the
• USE EXTREME CAUTION when making terminal connections! DO NOT
• INSULATED TOOLS and proper INSULATING MATERIALS (rubber floor
Safety precautions
• Assemble racks in accordance with the instructions contained in this document
Caution
• For installations where grounding is required for IEC and/or local codes, see
• Refer to local ordinances that pertain to battery installation and storage.
• Handle, transport, and properly dispose of or recycle batteries in accordance
• Lead-acid batteries contain hazardous, toxic materials. DO NOT dispose of
• Do not open, alter, or mutilate batteries! Released electrolyte is harmful to the
• Batteries should always be replaced with the same number and type as
• Batteries must remain in a climate-controlled environment having a
system is switched off! LETHAL VOLTAGES may still be present when the
rack is non-operational, or when breakers are in the OFF position!
allow cables to touch anything except the intended terminal!
stands, rubber mats, gloves, protective clothing, etc.) should be used when
connecting battery cables!
WITHOUT DEVIATION.
instructions for RACK GROUNDING.
with regulations.
batteries in a fire—they may explode!
skin and eyes, and may be toxic.
previously used.
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
• 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!
2 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
SYR400k1000HxR-2CP Power (TC-12150) 16 rails 2 E 120 mm
SYR400k1000HxR-2CF Fiamm (12SLB130) 16 rails 2 E 120 mm
*Cobra cable rated for 150°C
Qty Wiring Style
Cable Size (ref)*
W e ights 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
SYR400k1000HxR-2CP 156 kg Power (TC-12150) 45 kg 3192 kg
SYR400k1000HxR-2CF 156 kg Fiamm (12SLB130) 42 kg 3000 kg
Weight Per Rack Battery Type Weight Per Batt Total Wgt
2
(#4/0)
2
(#4/0)
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 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
MWA
“Appendix C: Employing Sidecars” on page 44.
Mains Supply
Battery Breaker
Box(es)
UPS
Service
Bypass
Panel
Distribution
Panel
Battery Rack #1
Battery Rack #2
Handling
The rack assemblies are relatively heavy (weighing 156 kg [344 lbs] each), so use a forklift or palletjack to transport boxes (on their pallets!) to the 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.
Load
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-ba ck 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 tools and equipment:
• Open end/box wrenches (SAE dimensions) • Battery lifting device (rated)
• Ratchet set w/sockets (SAE dimension)—3/8” • Step ladder or stepping stool
• Torque wrench • Tape measure
• Standard, Phillips, and torx-head screwdrivers • Chalk line
• Concrete drill (for floor anchoring, if applicable) • T-square
• Voltmeter • 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-lbs Brand Nm in-lbs
6 1/4 7 60 Power 7.9 70
10 3/8 27 240 Fiamm 11.3 100
12 1/2 68 600
6 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
T o p 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 W asher 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 Wash er 811-0604 1
Number Sheet Label 885-1617 1
Warning Label 4
CE Rating Label 885-1618 1
Battery Rack Assembly and Installation Manual 7
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 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) 3/8-1 6 x 1” bolt an d related hardware:
(2) 3/8 washers and (1) 3/8 KEPS nut.
3/8-16 x 1” Bolt
(812-0723)
Hole Position #2
from Front
Bottom Side Subassembly #1
(870-1658A)
3
3
3
3/8
3
3/8 Washers
(812-2030)
3/8 KEPS Nut
(812-3101)
3
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) 3/8-1 6 x 1” bolt an d related hardware:
(2) 3/8 washers and (1) 3/8 KEPS nut.
Bottom Side Subassembly #1
Cross Bar #1
Hole Position #6
from Front
Cross Bar #2
(870-3698)
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.
Bottom Side Subassembly #1
Cross Bar #1
STEP 3 Connection
Cross Bar #2
Bottom Side Subassembly #2
(870-1658A)
STEP 4 Connection
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) 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
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 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
M12 x 35 Bolt
(803-1235)
12mm Washer
(812-0039)
12mm Washer
(812-0039)
M12 Nut
(803-1200)
(870-1657A)
DO NOT
BOLT HERE!
12mm Lockwasher
(812-0038)
Battery Rack Assembly and Installation Manual 11
Bottom Side Subassembly #1
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 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
Top Side Subassembly #1
(870-3698)
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.
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 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 and (1) 3/8 KEPS nut.
Top Side Subassembly #1
STEP 7 Connection
STEP 9 Connection
Cross Bar #8
(870-3698)
STEP 10 Connection
Cross Bar #7
(870-3698)
STEP 8 Connection
Top Side Subassembly #1
14 Battery Rack Assembly and Installation Manual
Loading...