APC AP9927, AP9924, AP9926 User Manual

Wire Harness for the

Battery Management

System

AP9924

AP9926

AP9927

Installation

Contents

Preliminary Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Silcon versus non-Silcon installation . . . . . . . . . . . . . . . . . . . 1

Inventory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Pre-installation Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Lockout/Tagout the UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Determine battery numbers . . . . . . . . . . . . . . . . . . . . . . . . 4

Determine fuse bus and midpoint bus connections (Silcon only) 4

Install the Wire Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

How to install the tab washers on non-embedded terminals . . . 6

How to install tab washers on embedded battery terminals . . . 7

Prepare the harness wires . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Install the battery and power fuses . . . . . . . . . . . . . . . . . . . 8

Connect the battery wires . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Additional Silcon Connection Procedures . . . . . . . . . . . . . . . . . 10

Attach harness to the fuse bus and midpoint bus (Silcon only) 10

Install the 3/4 A and 5 A fuses (Silcon only) . . . . . . . . . . . . . 10

Secure the Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Secure the battery wires . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Connect to the Battery Management System . . . . . . . . . . . . . . 12

Install the Battery Management System . . . . . . . . . . . . . . . . 12

String connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Battery Connector Pinouts. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Battery Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Warranty and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Limited warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Warranty limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Obtaining service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Life-Support Policy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

General policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Examples of life-support devices . . . . . . . . . . . . . . . . . . . . 16

Wire Harness: Installation i

Preliminary Information

Overview

Silcon versus non-Silcon installation

The Battery Management System for high voltage applications connects to one of the following:

• A single APC Silcon UPS with pairs of strings.

• A single non-APC UPS with single strings.

The system provides battery management for nominal 2 V, 6 V, 8 V, or 12 V lead-acid batteries; or 1.2 V nickel-cadmium batteries. A system is comprised of at least one AP9921X master unit and up to five AP9921XS expansion units. Each unit supports up to 64 batteries.

For more information on the features and capabilities of the Battery Management System, see the initial sections of the User’s Guide, which is available on the Utility CD supplied

Inventory

Item Quantity

Wire harness 1

Ring terminal assemblies 3

3/4 A fuse (0W2237) 2

5 A fuse ( 0W2015) 38

Tab w a s he r s 38

Male Faston

connectors 5

Female Faston connectors 37

4-inch wire tie

for 5-foot harness for 50-foot harness for 100-foot harness

20 80 80

8-inch wire tie

for 5-foot harness for 50-foot harness for 100-foot harness

20 40 80

2 Wire Harness: Installation

Safety Information

Electrical

Hazard

Warning

When installing the Battery Management System:

• Cover the batteries with an insulating blanket before installing the harnesses.

• Wear safety glasses, rubber gloves, and rubber boots.

• Use double-insulated tools.

• Do not short-circuit the battery terminals; a short circuit could cause the batteries to explode.

• Do not lay tools or metal parts on top of the batteries or near the cable lugs.

• Remove watches, rings, and other metal objects.

• Use only cables supplied by APC unless otherwise indicated.

• For the UPS and switch gear, use Lockout/Tagout safety procedures (which remove access to a device and physically label the device as intentionally out of service) before working on the batteries.

Risk of electric shock: battery cabinets contain potentially lethal voltages! Batteries are energized even when AC power has been disconnected.

Only qualified personnel, trained in battery operation and safety, may install the harnesses. Keep unauthorized personnel away from the batteries.

Wire Harness: Installation 3

Pre-installation Procedures

Lockout/Tagout the UPS

Determine battery numbers

Determine fuse bus and midpoint bus connections (Silcon only)

Before installing the wire harnesses, use lockout and tagout safety procedures for the UPS or any attached equipment, such as high-voltage power supplies. If possible, disconnect the main output lead from the battery string to the load.

Voltage is present in the battery cabinet even after disconnecting it from the main load. Use caution when

Electrical

Hazard

Before installing the harness wires, designate a battery number to each battery in your system. Using a volt meter to check polarity, determine the most positive battery in your string (Battery 1), and count to the most negative (last) battery in your string.

Locate the 1/2-fuse bus connectors and 1/2-midpoint bus connectors on the inside roof of the cabinet.

working with the batteries.

Fuse Bus

Midpoint Bus

• The positive fuse bus connectors and midpoint bus connectors are on the right side of the cabinet.

• The negative fuse bus connectors and midpoint bus connectors are on the left side of the cabinet.

4 Wire Harness: Installation

+ 14 hidden pages