C&D Technologies RS-2098 User Manual

RS02098

STANDBY BATTERY RACK
ASSEMBLY INSTRUCTIONS

APPLIES TO ALL RDC SERIES RACKS

(READ ALL INSTRUCTIONS PRIOR TO INSTALLATION)

These instructions detail the proper procedure for installing
C&D Standard and EP (Earthquake Protected) battery racks.
The following describes how to locate, assemble, and load

open-frame battery racks for C&D battery mounting applications.

Proper attention to these instructions will help ensure safe,
trouble-free performance.

Two Tier Standard Rack Two Tier EP Rack

Figure 1. Standard Vs. EP Rack

Standard and Earthquake-Protected (EP) Racks:

Earthquake-protected racks are similar to standard racks,
with the exception of additional frame bracing, battery restraints,
and cell spacer elements. The battery rack frames are common for

Standard, EP1 and EP2 series for the one-tier, two-tier, three-tier

and two-step racks with the exception of the three-tier EP2 rack.

The frame for the three-tier EP2 rack is unique. RDC-EP racks are
certied to the International Building Code, 2009 edition.

Conguration:

Racks are available in single or multiple tier/step congurations as

shown in Figure 2. Rack components are supplied loose and must

be assembled and secured on-site in accordance with these C&D

assembly instructions, the drawings included with the rack shipment,
and applicable codes.

Rack Location:

Locate racks in a clean, cool, dry place so the batteries are not affected
by sources of radiant heat, such as sunshine, heating units, radiators,

steam pipes, etc. Variations of more than 5 degrees Fahrenheit (3º C)

between cells may cause the battery to become electrically unbalanced.

Top rows of batteries in multiple-tier congurations tend to operate at

slightly higher temperature than those on lower tiers. Always provide
adequate ceiling clearance for ventilation and maintenance.

Anchoring:

To provide stability and safety, racks must be securely anchored

to the oor. Anchor bolts are to be installed per contractor
specications and in accordance with applicable codes. Do not

attach rack to walls without consulting the appropriate structural
engineer. Mounting holes are provided in the base of each frame.

All frames must be secured to oor using all anchor bolt hole

locations.

Grounding:

Rack grounding provisions are integrated into the base of each
frame. Two through holes are located at the center of the frame’s
bottom cross member and may be used to secure a standard NEMA

lug. These holes are 0.44” in diameter and 1.0” between centers.

The surfaces surrounding the holes have been masked and are free
of powder coat to allow electrical contact. Frame to frame grounding
integrity is accomplished via the lower support rail, attached to each

frame with internal/external “star” washers.

TYPICAL RACK GROUNDING
PROVISION

2-Step

Figure 2. Typical Rack Congurations

1 Tier 2-Tier 3-Tier

Std & EP1

3-Tier

EP2

CAUTION:

• Do not install batteries until the rack has been properly
installed, with all bolts tightened to specied torque and
frames anchored to the oor.

• Do not use oil or grease as a lubricant for cell installation.

Lubrication is usually not required due to the low friction
interface of the insulating covers. If necessary, a small

amount of water, unscented talcum or Dow Corning III can

be applied to the rail covers to reduce friction.

RS02098/0114/CD www.cdtechno.com

ASSEMBLY INSTRUCTIONS FOR RDC STANDARD AND EP RACKS

A

1. Material Verication: Battery racks are shipped
unassembled with a complete set of related drawings and

documentation. Check received parts and quantities against

the rack’s bill of materials on provided drawings and/or
packing list. Do not assemble rack if parts are missing or
quantities are incomplete.

2. Required Tools: Torque wrench (0 to 65 ft.-lb.) with 9/16”
and 3/4” hex socket. Adjustable wrench or 9/16” and 3/4” box

wrenches, tape measure, square and leveling device. Note:

Consult manufacturer’s instructions for tools required to install
oor mounting hardware.

3. Location of Rack Assembly: When determining rack

location and oor anchoring pattern, use applicable drawings

provided with rack shipment. The optional arrangement
drawing, if ordered, should also be reviewed for rack and

battery cell placement. Consider boundaries and aisle

clearances when locating the general position of the rack.

nchor Bolt

Washer

Locate oor mounting locations using provided drawings. See

Figure 3. Note: Floor mounting hardware must be determined

in accordance with applicable building codes. C&D does
not provide oor mounting hardware. SEE PAGE 7 & 8 FOR
LOCATION OF MULTI-R ACK ARRANGEMENTS.

4. Initial Assembly: Anchor bolt washers (P/N RD05084 or

RD05100 for three tier racks) are supplied with the EP racks.

Each washer should be placed against the rack frame (see

Detail A). Place frames over the installed oor mounting
hardware, place the anchor bolt washers, and nger tighten
oor mounting hardware. All frames must face the same
direction. Install rear cross braces nger tight. See Figure 4

and Detail B. Do not install front cross braces at this time (if

required). Note: Cross bracing is used in all rear bays for EP1

racks (except for 2 step racks) and in all front and rear bays for
EP2 racks. Reference the rack assembly drawings included
in shipment for further details of the cross bracing pattern and

location for your specic rack model.

Frame Upright

Cross Brace

1/2-13 Bolt, Lock

Washer and Nut

Brace to Frame

Anchor Bolt Washer Installation

connection (Reverse View)

DETAIL A DETAIL B

2.00" Typical Clearance Around
Existing Boundary

Frame

As Required Aisle
Clearance

Frame and Cross

Brace Connection

See Detail B

Rack Assembly Location
and Anchoring Hole Pattern

Rear Cross Brace(s)

Floor Mounting
Hardware
See Detail A

Initial Assembly

Note Frame
Orientation

FIGURE 3 FIGURE 4

RS02098/0114/CD 2 www.cdtechno.com

ASSEMBLY INSTRUCTIONS FOR RDC STANDARD AND EP RACKS

5. Installing Support Rail(s): See Figure 5. Place support rail(s)

in location using supplied 3/8” bolt, washer, serrated strut nut
and nger tighten (see Detail C). Align support rails with “A”

dimension from rack assembly drawing (See Detail D) and

install rail covers. Note: An internal/external “star” washer is

used in place of the lock washer on the bottom tier or step for

grounding connection. Optional third rail should be installed at

this time.

For rack lengths greater than 20 ft, the rails come in two

sections and are to be joined with a rail splice kit (P/N

RE05149 (See Figure 6). The rail lengths have been sized

to ensure that the joint occurs near the middle of the span
between two frames.

6. Leveling: Check that the rack is level and square. Torque down

all bolts. First torque the cross brace bolts to 55-65 ft.-lb. [75-88
N-m], then torque the rail to frame bolts to 15-20 ft.-lbs [20-27

N-m]. Torque anchor bolts to manufacturer’s recommended
value.

This concludes the steps required to install a C&D Standard

Rack, please proceed to step 8 for cell installation or if you are

installing an EP Rack, continue on to step 7.

Support Rail Installation

FIGURE 5

Support Rail

and Cover

Rail Splice Kit

Assembled

(P/N RE05149)

DETAIL C

"A"

See rack

assembly drawing

for "A" values

Support Rail Location

DETAIL D

Rail covers are supplied in 3’ and 4’ lengths. Rail covers are to be placed end to end over the entire rail length.

"A"

3/8-16 Hex Bolt

FIGURE 6

Support Rail

and Cover

Serrated Nut

Channel

Rail Splice Kit

RS02098/0114/CD 3 www.cdtechno.com