INSTRUCTIONS for ASSEMBLING and MAINTAINING STANDARD and SEISMIC BATTERY RACKS

Transcription

1 SECTION INSTRUCTIONS for ASSEMBLING and MAINTAINING STANDARD and SEISMIC BATTERY RACKS Read all instructions carefully and observe all warnings before installation. See Safety, Storage, Installation, Operation, and Maintenance Manual, EnerSys Section GENERAL INFORMATION EnerSys stationary battery racks are available for use with both standard (ZONE 0) and seismic (ZONE 1, 2, and 4) applications, as mentioned in the Uniform Building Code (UBC) or Network Equipment Building Systems (NEBS). Racks are supplied unassembled. The basic components consist of: frames, cross braces, support rails, hardware, double-sided tape, and plastic channels. Seismic racks also include: side rails, end rails, corner brackets, foam spacers, shims, and cell clamp assemblies. The types of standard racks supplied by EnerSys are shown in Figure 1. 1 TIER 2 STEP 3 STEP 2 TIER 2 TIER/2 ROW 3 TIER 2 STEP/2 TIER This document provides instructions for the following: Standard rack assembly Back-to-back rack assembly (for standard racks only) End-to-end rack assembly (for standard racks only) Shock-protection equipment assembly (for standard racks only) Seismic rack assembly TYPES OF STANDARD RACKS Figure 1 Rev. Date: - 10//01 1

2 2. PRECAUTIONS BEFORE UNPACKING, STORING, HANDLING, INSTALLING, OPERATING OR PERFORMING MAINTENANCE ON THE BATTERIES OR BATTERY RACKS READ THE FOLLOWING INFORMATION THOROUGHLY! It is important to read, understand and strictly follow the instructions in this manual. If the following precautions are not fully understood, or local conditions are not covered, contact your EnerSys representative for clarification. Or, call the corporate number on the back of this manual and ask for EnerSys Integrated Systems and Services. Also, refer to all applicable federal, state and local regulations and industry standards. YOU SHOULD BE TRAINED IN HANDLING, INSTALLING, OPERATING AND MAINTAINING BATTERIES BEFORE YOU WORK ON ANY BATTERY SYSTEM. 3. SERVICE INFORMATION EnerSys has a nationwide service organization to assist with installation supervision, service, parts, accessories or maintenance of your new rack purchase. Contact your EnerSys representative or the corporate number on the back of this manual and ask for EnerSys Integrated Systems and Services. 4. SAFETY 1. Assemble racks according to the instructions in this document WITHOUT DEVIATIONS. 2. Refer to UBC, OSHA, and EPA regulations and local ordinances pertaining to battery installation and storage. 3. Refer to the SAFETY PRECAUTIONS in the Safety, Storage, Operation and Maintenance Manual for Flooded Lead-Acid Batteries (EnerSys Section 58.00). 4. Do NOT remove braces on a rack with cells already installed. For racks with front and rear cross braces, the front braces must be removed to install cells. DO NOT REMOVE FRONT AND REAR BRACES AT THE SAME TIME. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN CELLS FALLING OFF THE RACK AND CAUSING PERSONAL INJURY. 5. For installations where grounding is required for NEC and/or local codes, see instructions for RACK GROUNDING in Section 15. IMPORTANT! Should you have ANY question concerning safety when working with the battery system, contact your EnerSys representative to clarify any of the noted safety precautions. Or, call the corporate number listed on the back of this manual and ask for EnerSys Integrated Systems and Services. 5. INSPECTION OF BATTERY RACK SHIPMENT 5.1 GENERAL Precautions were taken to pack the battery rack for shipment to ensure its safe arrival. However, upon receipt, inspect for evidence of damage that may have occurred during transit. If any part is damaged or missing from the package, DO NOT proceed with installation until all parts are available. 2 Rev. Date: - 10/01

3 SECTION INSPECTION IMMEDIATELY upon delivery (while the carrier representative is still on-site), inventory and inspect all materials against the Bill of Lading for visible external damage. If damage is noted: 1. Make a descriptive notation on the delivery receipt before signing. 2. Request an inspection by the carrier. 3. File a damage report. DELAY IN NOTIFYING THE CARRIER MAY RESULT IN THE LOSS OF YOUR RIGHT TO REIMBURSEMENT FOR DAMAGES. Refer to the Bill of Materials if you are unsure about the appearance of a part when performing the parts inventory. Should you have any questions concerning potential damages, contact your EnerSys representative or call the corporate number on the back of this manual and ask for EnerSys Integrated Systems and Services. 6. INSTALLATION CONSIDERATIONS Space Consider available floor space, including aisles for cell installation, maintenance, and possible cell replacement. Measure the aisle space according to the National Electric Code (NEC) Article or local codes. Clearance from wall/equipment 4 (10 cm) minimum (seismic only) Environment Clean, cool, and dry Temperature Ambient temperature, between F (23-26 C). Elevated temperatures reduce operating life. Lower temperatures reduce battery performance. Locate racks to minimize temperature variations between cells. Do NOT locate the battery near HVAC ducts or exhausts, heat sources (i.e., equipment that generates heat) or direct sunlight. Ventilation Adequate ventilation must be provided. Do NOT install in an airtight enclosure or room with no ventilation. Grounding Floor Anchoring Codes Ground rack according to NEC and/or local codes. Reasonably level. Shimming up to 0.25 (6 mm) maximum to level battery front to rear and side to side. The floor must be capable of supporting the weight of the battery and rack system, as well as any auxiliary equipment. ALL rack frames must be securely anchored to the floor. Anchoring should meet all local, state and federal codes and industry standards. Floor anchoring and its design are the responsibility of the installer. SEISMIC RACK ANCHORING: Minimum clearance between racks and any objects (including walls, equipment and other racks) is to be 4 in. (101.6 mm). NO RACKS ARE TO BE BUTTED TOGETHER, END-TO-END OR BACK-TO-BACK. Inter-rack cable connectors (provided by EnerSys) are based on 4 in. (101.6 mm) spacing; any length over this is the responsibility of the installer. Ensure all applicable codes are followed. Rev. - 10/01 3

4 7. RECOMMENDED INSTALLATION EQUIPMENT AND SUPPLIES Before working with the battery system, ensure that you have the tools and equipment listed below. Chalk line Box wrenches (3/8 to 11/16 ) Concrete drill (for floor anchors) Level Electric drill Ohmmeter (for ground testing) Floor anchors (user-supplied) Square Floor shims (user-supplied) Tape measure 3/8 drive ratchet wrench with minimum 3 Torque wrench ( ft-lb.) extension with 3/8-11/16 sockets TABLE 6 Torque Specifications Bolt Diameter Torque in. mm ft-lb. Nm 3/ / FLOOR AND ANCHORING Battery racks should be properly anchored to the floor for safety purposes. For seismic battery racks, use all frame holes to maintain seismic certification. Contact your EnerSys representative if you have any questions. TO LAYOUT BATTERY RACK: 1. Mark locations for anchor bolts using the holes in the bottom of each frame as a template. 2. Install floor anchors in pre-determined locations. TO ANCHOR THE RACK AFTER ASSEMBLY 1. Align rack with floor anchors and attach to floor. Shimming up to 0.25 in. (6 mm) maximum may be required to level support rails both front-to-back and side-to-side. 2. Recheck all bolted connections for proper torque. 3. Torque anchor bolts as directed in manufacturer s instructions. 4. If necessary, move rack to drill and install anchor bolts. 9. CELL INSTALLATION PRECAUTIONS Know the location and polarity orientation of each cell prior to installation. Diagram connections to avoid repositioning of cells once installed (see CONNECTING CELLS in EnerSys Section 58.00). On multi-tier racks with more cells on one row than another, install larger number of cells on bottom row. Start diagram of the bottom row by deciding where termination will be located. Install rear side rail before installing cells. Locate side rail so overhang is equal on both ends of rack. Install plastic channel. Make sure all bolts are torqued as indicated in Table 6 before installing cells. NOTE: Refer to Safety, Storage, Installation, Operation and Maintenance for Flooded Lead-Acid Batteries (EnerSys Section 58.00) for cell unpacking and handling instructions. 4 Rev. - 10/01

5 SECTION RACK ASSEMBLY 10.1 TO ASSEMBLY 1. Place frames at the desired floor locations. 2. Attach cross braces to frames for strength and rigidity between the frames. NOTE: Follow the specific instructions that pertain to the battery rack you purchased, then continue to step 3. FOR STANDARD 1 TIER, 2 TIER, 3 TIER, 2 STEP, AND 3 STEP RACKS: a. Bolt rear braces together (Figure 10A and Details A, B). DETAIL B HEX NUT DETAIL A INSTALL BETWEEN AND DETAIL E REAR VIEW STANDARD 2 TIER RACK ASSEMBLY Figure 10A TO END ASSEMBLY Detail A HEX NUT INSTALL BETWEEN AND INSTALL BETWEEN S HEX NUT INSTALL BETWEEN S S S DOUBLE TO MID-FRA ME ASSEMBLY Detail B TO ASSEMBLY Detail E Rev. - 10/01 5

6 FOR STANDARD 2 STEP/2 TIER RACKS: a. Attach rear braces as directed above, using longer braces. b. Attach top braces, using shorter braces (Figure 10B and Detail C). DETAIL C S INSTALL BETWEEN S INSTALL BETWEEN AND STANDARD 2 STEP/2TIER RACK ASSEMBLY Figure 10B HEX NUT DOUBLE TO TOP ASSEMBLY Detail C FOR STANDARD 2 TIER/2 ROW RACKS: a. Bolt center cross braces to the center of the frame (Figure 10C and Detail D). DETAIL D HEX NUT S INSTALL BETWEEN S AND STANDARD 2 TIER/2 ROW RACK ASSEMBLY Figure 10C TO CENTER ASSEMBLY Detail D 3. Bolt cross braces together where they cross each other (Detail E). Make sure frames are plumb before tightening bolts to the required torque (Table 6). NOTE: Actual hardware supplied with rack may differ from Details. Flat and lock washers may be substituted with tooth lock washers. Frames are symmetrical and can be oriented facing either direction. 6 Rev. - 10/01

7 SECTION SUPPORT RAIL TO ASSEMBLY 1. Attach the support rail to the assembled frame (Figure 10D). a. Install clamp nuts and bolts (Figure 10E). Engage clamp nut approx in. (6 mm). b. Place rail on frame against clamp nut as shown in Figure 10F. c. Rotate rail 90 over clamp nut as shown in Figure 10G. FIGURE 10G SUPPORT RAIL TO ASSEMBLY Figure 10D FIGURE 10E FIGURE 10F FIGURE 10H d. Push bolt assembly upward. Rotate clamp nut 90 (Figure 10H). Fasten bolt finger-tight. e. Position each rail so the overhang beyond the frame is equal at each end of the rack, or as specified on the RACK ASSEMBLY DRAWING. f. With the frame, braces, and lower rails assembled, check frame alignment. g. Torque all bolts as indicated in Table SUPPORT RAIL TO ASSEMBLY 1. Attach the plastic channel to the support rail. Plastic channels are supplied in 3-ft. and 4-ft. lengths. Make sure the ends of rails are cut squarely and butted together. Trim excess or overhanging plastic. a. Apply double-sided tape to the surface of each support rail (Figure 10J). Apply in a continuous piece and avoid wrinkles. PLASTIC CHANNEL DOUBLE-SIDED TAPE SUPPORT RAIL SUPPORT RAIL SHOWN SIMILAR ASSEMBLY FOR SIDE AND END RAILS Figure 10J b. Remove paper backing from the tape. c. Place plastic channel on support rail and press down to make contact with tape. Rev. - 10/01 7

8 10.4 SUPPORT RAIL TO ASSEMBLY Anchor to floor according to Section 8, if necessary. Seismic racks must be anchored. If you are installing: Shock protection equipment see Section 13. Multiple racks: - Back-to-back rack assembly see Section End-to-end rack assembly see Section 12 Seismic racks see Section BACK-TO-BACK RACK ASSEMBLY (STANDARD RACKS ONLY) 1. Attach frames and braces (Section 10 and Figure 11). Each rack is supplied with its own set of braces. When installing two racks back-to-back, use both sets of cross braces (Details F and G). Single tier, 2 step and 3 step racks are NOT bolted together when installed back-to-back. DETAIL F HEX NUT DETAIL G SPACER BACK-TO-BACK ASSEMBLY (STANDARD RACKS ONLY) Figure 11 HEX NUT BACK-TO-BACK END ASSEMBLY (STANDARD RACKS ONLY) Detail F BACK-TO-BACK CENTER ASSEMBLY (STANDARD RACKS ONLY) Detail G 2. Follow instructions in Section 10 to assemble and anchor both racks. 3. Install cells as directed in CONNECTING CELLS, EnerSys Section NOTE: If attaching a new rack back-to-back with an existing rack, do not remove cross braces unless the existing rack is properly secured. 8 Rev. - 10/01

9 SECTION END-TO-END RACK ASSEMBLY (STANDARD RACKS ONLY) 1. Assemble the first rack as directed in Section Assemble the second rack as directed in Section 10, with support rails in alignment at the end of first rack (Figure 12). Anchor second rack to floor as directed in Section 8. DETAIL H SUPPORT RAIL S SUPPORT RAIL RAIL JOINER S END-TO-END RACK ASSEMBLY (STANDARD RACKS ONLY) Figure 12 END-TO-END RACK ASSEMBLY (STANDARD RACKS ONLY) Detail H 3. Install rail joiners as shown in Detail H. Tighten bolts to torque specified in Table Install cells as directed in CONNECTING CELLS, EnerSys Section SHOCK-PROTECTION EQUIPMENT ASSEMBLY (FOR C, E, F, AND SC STANDARD RACKS ONLY) The following instructions assume the standard rack has been assembled and properly anchored as directed in Section 10. For multi-tier racks, begin the installation of shock-protection equipment and cells on the bottom tier. Refer to EnerSys Section for cell installation. The components of the shock-protection equipment are to be added to standard racks to provide cell restraint in ZONE 1 areas. See Figure 13. Shock-protection kits consist of foam spacers, side support brackets, side rails, corner brackets, end rails, plastic channels, and hardware. DETAIL K DETAIL J SIDE RAIL SUPPORT RAIL SUPPORT BRACKET SHOCK PROTECTION EQUIPMENT ASSEMBLY Figure 13 SHOCK-PROTECTION SUPPORT RAIL ASSEMBLY Detail J Rev. - 10/01 9

10 1. Place support brackets for the rear side rail under the cell support rails at each end of the rack, using bolts and clamp nuts as shown in Detail J. Locate the side rail so that the overhang beyond the frame is equal at each end of the rack. Do not fully tighten the assembly at this time. 2. Locate additional support brackets uniformly between the two outer support brackets. The location of support brackets ends of the side rail is important. The support brackets should not be closer than 2.5 in. (63.5 mm) from the end of the side rail to allow space for the corner bracket. 3. Attach plastic channels to side rail as directed in Section Place cells on rack as directed in EnerSys Section (install bottom tier first) and insert foam spacers between cells. Be sure to center each cell on the support rails to allow space for the side rails. Move the rear side rails by sliding the side support brackets towards the cells so the rail is snug against the cells. 5. Tighten bolts for side support brackets to the torque specified in Table Repeat steps 1 through 5 for the front side rails. 7. Assemble end rails and corner brackets for each end of the rack as shown in Detail K. SIDE RAIL END RAIL CORNER BRACKET SHOCK-PROTECTION CORNER BRACKET ASSEMBLY Detail K 8. Attach plastic channels to end rail as directed in Section Ensure end rail is snug against cells. 10. Tighten bolts for end rail and corner brackets to torque specified in Table Repeat steps 1 through 10 for the remaining tier(s), if applicable. 12. Complete battery assembly with proper connectors, terminal plates, and cables as directed in EnerSys Section Rev. - 10/01

11 SECTION SEISMIC RACK ASSEMBLY The following instructions assume the seismic rack has been assembled and properly anchored as directed in Section 10. For multi-tier racks, begin the installation of side rails and cells on the bottom tier. Refer to EnerSys Section for cell installation. In addition to standard rack components, seismic racks (ZONE 1, 2, and 4) utilize foam spacers, side rails, corner brackets, end rails, and cell clamp assemblies (D, F, and G cell racks only). See Figures 14A, 14B, 14C and 14D. Cell clamp assemblies must be used when provided. Evenly distribute cell clamps on each row/tier. (For example, if 4 cell clamps are provided with a 2-tier rack, evenly space 2 clamps on each tier.) CELL CLAMP ASSEMBLY RODS FOAM SPACERS SEISMIC 2 TIER/2 ROW RACK CELL DETAIL M DETAIL L SEISMIC RACK ASSEMBLY INTERLOCKING CORNER BRACKET Figure 14C SEISMIC RACK ASSEMBLY SIDE RAIL, CELL CLAMP and FOAM SPACER ASSEMBLY Figure 14A SEISMIC RACK ASSEMBLY LONG/SHORT CORNER BRACKET Figure 14B SEISMIC RACK ASSEMBLY UNIVERSAL CORNER BRACKET Figure 14D Rev. - 10/

12 14.1 SIDE RAIL AND CELL CLAMP ASSEMBLY 1. Remove front braces, if applicable, to gain access to rack for cell installation. 2. Attach rear side rail to frames, on the bottom tier first, using bolts and clamp nuts as shown in Figures 14E-H. Locate side rail so the overhang beyond the frame is equal at each end of the rack. Tighten rear side rail bolts to required torque specified in Table 6. FIGURE 14G FIGURE 14E FIGURE 14F FIGURE 14H 3. Attach plastic channels to side rail as directed in Section Place cells on rack as directed in EnerSys Section (install lower tier first) and insert foam spacers between cells. Allow for location of cell clamp assemblies, if applicable. Foam spacers are not required at cell clamp locations. Be sure to snug each cell against the rear side rail. See Figure 14A and also Section 9 for cell installation precautions. 5. Before installing the adjacent cell, loosely install cell clamp bracket at a pre-determined location as shown in Detail L. TUBING THREADING SIDE RAIL BRACKET HEX NUTS CELL CLAMP INSTALLATION Detail L 6. Slip length of tubing over rods, insert rods through hole in cell clamp bracket and install jam nuts to within 0.5 in. (12.7 mm) from end. It is important that the tubing just touch the jar. Tighten cell clamp bracket connection to the required torque specified in Table Install the adjacent cell and repeat steps 4 through 6 until the row is filled with cells. 8. Repeat steps 1 through 3 to attach the front side rail, making sure the rail is between the cell clamp rods. Refer to Detail L Rev. - 10/01

13 SECTION Insert rods through front cell clamp bracket holes and attach front cell clamp bracket to front side rail. Tighten cell clamp bracket connection to torque specified in Table Move front side rails towards cells so that rails are snug against cells. Insert rail, spacers, and shims in front, if necessary, so slot is perpendicular to the rail (Detail M). FRONT SIDE RAIL RAIL SHIMS SPACER(S) WHIZ-LICK SIDE RAIL INSTALLATION Detail M 11. Tighten side rail bolts to the required torque specified in Table Install first nut finger-tight on each rod against cell clamp bracket. Install second nut on each end. Hold inside nut stationary and torque the second nut on each end to 15 ft-lbs (21 Nm). Excessive tightening of the inside nut will result in damage to the jar walls END RAIL ASSEMBLY INTERLOCKING CORNER BRACKET Interlocking corner bracket designs provide both short and long corner brackets. Use short bracket unless there is interference with the frame. 1. Assemble end rails and corner brackets for each end of rack as shown in Figures 14J, 14K, 14L and 14M. Attach plastic channels to end rail as directed in Section END RAIL SIDE RAIL LONG CORNERBRACKET WHIZ-LOCK WHIZ-LOCK SEISMIC RACK ASSEMBLY LONG/SHORT CORNER BRACKET Figure 14J LONG/SHORT CORNER BRACKET ASSEMBLY (LONG CORNER BRACKET SHOWN) Figure 14K Rev. - 10/

14 CORNER BRACKET CORNER BRACKET CORNER BRACKET SEISMIC RACK ASSEMBLY INTERLOCKING CORNER BRACKET Figure 14L CORNER BRACKET INTERLOCKING CORNER BRACKET ASSEMBLY Figure 14M NOTE: Plastic channels must be cut to fit over each end rail and cover all surfaces of the rails that will come into contact with the cell. 2. Ensure end rails are snug against cells. Tighten bolts for the end rail and side brackets to the required torque as indicated in Table FINAL ASSEMBLY 1. Repeat steps in Section 14 for the remaining tier(s), if applicable. 2. Reinstall front braces, if applicable. 1. Complete battery assembly with proper connectors, terminal plates, and cables as directed in EnerSys Section RACK GROUNDING (OPTIONAL) On installations where grounding is required (as indicated by NEC and/or local codes), the following steps must be taken. 1. Install lug and cable, as shown in Figure 15, to the system ground. (Lug and cable are not furnished by EnerSys.) Tooth lock washers should be installed between contact surfaces of all cross brace mountings. Refer to Detail P. Torque as specified in Table 6. HEX NUT INSTALL BETWEEN AND GROUND CABLE (CUSTOMER SUPPLIED) GROUND CONNECTION ASSEMBLY Figure 15 TO END ASSEMBLY Detail P 14 Rev. - 10/01

15 SECTION An ohmmeter reading between each component and a common point on a frame must indicate continuity to assure complete grounding. Any component that does not show continuity must have at least one connection loosened and retightened and the ohmmeter test must be repeated. 3. It is not necessary for each bolted connection to show continuity as long as there is at least one on each component. NOTE: Ohmmeter checks are to be made by probing each component surface, not at bolted connections. 16. RACK INSPECTION AND MAINTENANCE 1. The members of the battery racks are finished with acid-resistant epoxy paint. Abnormal battery operating conditions, such as overfilling or charging at excessively high currents, may cause spillage of electrolyte from the cells onto the rack. If the electrolyte is not removed, in time the exposed rack components will corrode. 2. Periodic inspections of the entire rack are to be made to observe any signs of acid corrosion. When corrosion is detected, scrape away the corrosion to bare metal. Neutralize the area with a solution of bicarbonate soda and water (1 pound of soda to 1 gallon of water), dry, and then paint the area with acid-resistant paint. 3. Rack corrosion that goes undetected for extended periods may weaken the load bearing members to the point where they are structurally unsound. When such conditions are observed, it is recommended that the rack be replaced. 4. If the rack has been grounded, periodically check the ohmmeter to determine that all components of the rack are still grounded. If the ground becomes lost on any component, loosen one bolt at a time and tighten to the original torque value. Continue to do so until continuity has been reestablished. 17. GLOSSARY OF TERMS CELL CLAMP ASSEMBLY CORNER BRACKETS END RAILS EPA FOAM SPACERS S Assembly connected to side rails and positioned according to battery weight, to help reduce battery movement during a seismic event. Brackets used to attach end rails to side rails to prevent batteries from falling off end of rack during a seismic event. Bracing used to connect rack frames together. Attached to corner brackets to prevent batteries from falling off end of rack during a seismic event. Environmental Protection Agency Spacers used between batteries to prevent batteries from hitting each other during a seismic event. Main support structure of battery rack. (cont.) Rev. - 10/

16 (cont.) INTER-RACK CABLE CONNECTORS NEBS NEC OSHA SIDE RAILS SHIMS SUPPORT RAILS UBC Electrical conductors used to connect cells on two separate racks. Network Equipment Building Systems National Electric Code Occupational Safety & Health Administration Rails on side of frames used to prevent cells from falling off rack in a seismic event. Metal spacers used to bring side rail close to battery or to level rack due to uneven flooring. Rails connected to base of frame to support batteries. Uniform Building Code Represented by: When ordering new batteries, also remember to properly recycle your old lead batteries. Federal and state regulations require lead-acid batteries be recycled. EnerSys nationwide service organization can arrange pickup, transportation to and recycling at any one of our company affiliated smelters. Call for more information. Global Headquarters: P.O. Box 14145, Reading, PA FAX US Sales Offices: Eastern Region: Western Region: Regional Sales Offices: EnerSys Canada: ESB de Mexico SA DE: EnerSys has locations worldwide to serve your needs; for additional information please visit our website at or contact us a Hour Service or Repair, call: (U.S.) 16 Rev. - 10/01