INSTRUCTIONS FOR ASSEMBLING NEBS FLOODED RACKS

Transcription

1 INSTRUCTIONS FOR ASSEMBLING NEBS FLOODED RACKS Publication No. US-NEBS-IM-003 September 2013

2 INSTRUCTIONS for ASSEMBLING NEBS FLOODED RACKS Read all instructions carefully and observe all warnings before installation. See Safety, Storage, Installation, Operation and Maintenance Manual (Publication US-FL-IOM) 1. GENERAL INFORMATION EnerSys Reserve Power NEBS racks are available for ZONE 0, 2 and 4 applications, designed in accordance with Network Equipment Building Systems (NEBS). Racks are suitable for installation in Network Telecommunications Facilities. Racks are supplied unassembled. The basic components consist of: frames, cross braces, support rails, plastic channels and assembly hardware. Seismic racks may also include: base plates, side rails, end rails, corner brackets, cell clamp assemblies, foam spacers and side rail shims. 2. SAFETY PRECAUTIONS Assemble racks in accordance with the instructions contained in this document WITHOUT DEVIATIONS. Refer to UBC, OSHA and EPA regulations and local ordinances that pertain to battery installation and storage. Refer to additional SAFETY PRECAUTIONS contained in the EnerSys Safety, Storage, Installation, Operation and Maintenance Manual. Racks have two sets of cross braces, front and rear. One set of cross braces must be removed to install cells. Do not remove front and rear cross braces at the same time. Failure to follow these instructions may result in cells falling off the rack and causing personal injury. On installations where grounding is required for National Electrical Code (NEC) and/or local codes, refer to the section on RACK GROUNDING in this manual. Grounding holes are provided on each rack frame; hardware is not provided. 3. SERVICE INFORMATION Should you require installation supervision, service, parts, accessories or maintenance, EnerSys has a service organization to assist with your new rack purchase. Contact your nearest EnerSys representative or call the world headquarters number listed on the back of this manual and ask for Reserve Power Service. 4. INSPECTION OF BATTERY RACK COMPONENTS Upon receipt, check each package against the packing list to ensure all components and quantities are correct. Inspect for visual damage while the carrier representative is still on-site. Make note of any damage. If any part has not been received or has been damaged, DO NOT proceed with installation until all parts are available. 2 US-NEBS-IM-003

3 NEBS RACK ASSEMBLY 5. INSTALLATION CONSIDERATIONS If you have any questions concerning the following installation considerations, contact your EnerSys sales representative. Consider available floor space, including aisles for cell installation, maintenance and possible cell replacement. Aisle spacing should be in accordance with the NEC Article ALL OTHER APPLICABLE CODE REQUIREMENTS SHOULD ALSO BE CONSIDERED. Minimum clearance between seismic racks and any objects (including walls, equipment and other racks) is recommended to be 4 in. (100 mm). NO SEISMIC 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. (100 mm) rack spacing; any length over this is the responsibility of the installer. The floor/mounting platform must be reasonably level. Shimming up to 0.25 in. (6 mm) maximum may be used to have cell support rails level both front-to-back and side-to-side. Shims and shimming hardware is user supplied. The floor/mounting platform must be capable of supporting the weight of the battery and rack system, as well as any auxiliary equipment. ALL APPLICABLE CODE REQUIREMENTS SHOULD BE CONSIDERED. 6. INSTALLATION EQUIPMENT and SUPPLIES Before working with the battery system, ensure that you have the tools and equipment listed below. Chalk line Floor anchors Concrete drill (for floor anchors) Floor shims (user-supplied) Level Ohmmeter (for ground testing) Open end/box wrenches (SAE dimensions) Ratchet set with sockets (SAE dimensions) Square Tape measure Torque wrench ( ft-lb.) TABLE 1 Torque Specifications Bolt Size NEBS Rack Torque Requirements Initial Torque Hex Head (Socket) Size ft-lb. N-m Inches 3/ /16 1/ /4 5/ /16 NOTE: Floor anchoring and its design are the responsibility of the installer. Anchoring should meet all local, state and federal codes and industry standards. US-NEBS-IM

4 7. RACK ASSEMBLY 7.1 FLOOR ANCHORING Floor anchoring and its design are the responsibility of the installer. All outermost holes in the mounting pattern should be used where possible to maintain seismic certification. Contact your EnerSys sales representative if you have any questions. Refer to the rack assembly drawing for frame and anchor bolt layout. Zone 4 base plates are universal; Zone 2 base plates are NOT universal. Zone 2 base plates must be oriented with the outermost mounting holes toward the outside of the rack. See Figures 7.2a and 7.2b. Rack is designed for anchoring with ½ in. diameter anchor bolts with a 3-3/16 embedment. [Recommended Anchor: HILTI HSL-R-M12/25 3 3/16 or equivalent. Minimum concrete c = 3000 psi (21 Mpa)] Mark locations for anchor bolts using the holes in the frame or base plate as a template. If necessary, move rack to drill and install anchor bolts. Drill holes, install and torque anchor bolts as indicated in the manufacturer s instructions. Figure BASE PLATE TO FRAME ASSEMBLY Figure 7.2a (Zone 2, 2 Tier Shown) Seismic racks have bases that are separate from the frame uprights. Install frame to baseplate using 5/8-11 bolts and associated hardware. Refer to assembly drawing for bolt length. See Figures 7.2a and 7.2b. Each base plate requires a self-tapping screw for electrical bonding. See Figures 7.2a and 7.2b. Torque per Table 1. Figure 7.2b (Zone 4, 2T and 2T/2R Shown) 4 US-NEBS-IM-003

5 NEBS RACK ASSEMBLY 7.3 CROSS BRACE TO FRAME ASSEMBLY Bolt cross braces to respective frames. Refer to below list for hardware order and assembly drawing for bolt size and lengths. See Figures 7.3a and 7.3b for further detail. Torque per Table 1. NOTE: Install cross braces on one side of rack before cells are installed and the other set of cross braces after cells are installed. DO NOT REMOVE both sets of cross braces at the same time with cells installed on the rack for safety concerns. Single Cross Brace Hex Bolt (3) Flat Washers Star Washer Cross Brace Star Washer Rack Frame Star Washer Flat Washer Lock Washer Hex Nut Double Cross Brace Hex Bolt Flat Washer Star Washer Cross Brace Star Washer Cross Brace Star Washer Rack Frame Star Washer Flat Washer Lock Washer Hex Nut Figure 7.3a SINGLE CROSS BRACE Figure 7.3 Figure 7.3b DOUBLE CROSS BRACE US-NEBS-IM

6 7.4 INSTALL SUPPORT RAILS & SIDE RAILS TO FRAME Side rails are used only with seismic racks. NOTE: It is recommended that the rails of the upper tiers on multi-tier racks not be installed until cells are placed on the rails of the lower tiers for safety concerns. Locate support rails and side* rail so overhang is equal on both ends. DO NOT place cells on the rack at this time. For single side rail configurations, side rails are to be located in the upper hole of the two mounting holes on the frame. Refer to assembly drawing for hardware size and length. Figure 7.4a Step 1 Figure 7.4a Step 2 * For 2T/2R model racks, install the center side rail and its associated brackets. Refer to Section 7.5. Fasten rails to frame as shown in Figure 7.4a, Steps 1-4. Depending on battery type, side rail spacer(s) may need to be installed with side rail. Refer to assembly drawing for spacer application and Figure 7.4b. Figure 7.4a Step 3 SPACER Figure 7.4a Step 4 Torque per Table 1. SHIM Figure 7.4 Figure 7.4b 6 US-NEBS-IM-003

7 NEBS RACK ASSEMBLY 7.5 CENTER RAIL BRACKET ASSEMBLY (Seismic 2T/2R Model Racks Only) The center rail should be installed before any side rails are installed. Cells will be positioned against this rail for optimum fit on rack. Install center rail brackets and center rail as shown in Figure 7.5. Refer to assembly drawing for hardware size and length. Torque per Table ATTACH PLASTIC CHANNEL TO RAILS Plastic channel is supplied in 3 ft. and 4 ft. lengths. The rack shipment contains enough plastic channel to cover the support, side, center and end rails. Cut plastic channels as necessary to cover all rails. Apply double-sided tape to the surface of each rail. Refer to Figure 7.6 Figure 7.5 PLASTIC CHANNEL DOUBLE- SIDED TAPE RAIL Figure 7.6 US-NEBS-IM

8 7.7 CELL INSTALLATION It is important to know the location and polarity orientation of each cell prior to installation. Refer to EnerSys Safety, Storage, Installation, Operation and Maintenance Manual, provided with batteries, for installation and safety precautions. NOTE: The bottom tier should contain the largest number of cells when applicable. Make sure all bolts are torqued per Table 1 before installing cells. Install cells on bottom tier. The battery covers should be spaced 0.25 in. (6 mm) apart to ensure proper spacing for intercell connector installation. See Figure 7.7a. Foam spacers are to be installed between batteries on seismic racks. The black mark on foam spacer edge should be facing the top of the cell. See Figure 7.7b. Install front cross braces as instructed in Section 7.3. See Figure 7.7c. Figure 7.7a Figure 7.7a Figure 7.7b Figure 7.7c 8 US-NEBS-IM-003

9 NEBS RACK ASSEMBLY Attach plastic channel to front side rail per Section 7.6 and install front side rail as instructed in Section 7.4. See Figure 7.7d. Install shim(s) as necessary between side rails and rack frame to ensure proper side rail fit with battery jars. Side rails are to be installed without exerting pressure on the battery jar. Clearance equal to the typical thickness of a business card is allowable between the side rails and battery jar. Refer to Figure 7.4b. The side rail bolts may need to be loosened to perform this step. Be sure to re-torque per Table 1 when complete. Zone 4 racks only - Install cell clamp assemblies. Verify cell clamp locations as shown on the rack assembly drawing. Attach cell clamps to side support rails. See Figure 7.7e, Steps 1 and 2. Refer to assembly drawing for hardware size and length. Torque per Table 1. WHEN TORQUING HEX NUTS ON THREADED ROD, USE CAUTION TO AVOID BENDING CELL CLAMP PLATES AGAINST BATTERY JARS. HOLD HEX NUT BETWEEN PLATES STATIONARY AND TORQUE THE HEX NUT ON THE OUTSIDE OF THE ASSEMBLY. Foam spacers must be trimmed as needed to fit between cells that require cell clamps. Figure 7.7d Figure 7.7e Figure 7.7e and 7.7h Step 1 Figure 7.7e and 7.7h Step 2 US-NEBS-IM

10 Install cells on next tier following the methods as instructed for the bottom tier. See Figures 7.7f, 7.7g and 7.7h. Cross braces per Section 7.3. Rails per Section 7.4. Center rail bracket, if applicable, Section 7.5. (Seismic 2T/2R Racks only.) Plastic channel per Section 7.6. Cells, foam spacers, rail shims and cell clamp assemblies per Section 7.7. Figure 7.7f Figure 7.7g Figure 7.7h 10 US-NEBS-IM-003

11 NEBS RACK ASSEMBLY 7.8 END RAIL AND CORNER BRACKET ASSEMBLY (Seismic Racks Only) The location of the corner brackets is determined when the batteries are evenly spaced on the rack. See Figure 7.8. Attach plastic channels to end rails per section 7.6. One left and one right corner bracket, one end rail and hardware is needed for each end rail assembly. Refer to assembly drawing for hardware size and length. Determine the location of each corner bracket and loosely fasten in place. Refer to Figure 7.8, Step 1. Slide end rail into place. Refer to Figure 7.8, Step 2 and Step 3. For 2T/2R model racks, install the center rail end bracket on the center rail as shown in Figure 7.8, Step 4. Torque per Table 1. Side, center and end rails should not exert any pressure on the battery jar. Space equal to that of a typical business card is allowable between the rails and battery jar. Figure 7.8 Step 1 Figure 7.8 Step 2 Figure 7.8 Step 3 Figure 7.8 Step 3 Figure 7.8 Step 2 Figure 7.8 Figure 7.8 Step 4 (2T/2R Racks Only) US-NEBS-IM

12 7.9 GROUNDING RACK (If Required) Holes are provided in each frame for rack grounding. Racks should be grounded when it is required for NEC and/or local codes. Locate (2) in. (3 mm) holes x 1 in. (25.4 mm) spacing in frame. See Figure 7.9. Scratch paint as necessary keeping the exposed metal to a minimum. Clean exposed surface and apply a light coating of No-Ox grease (provided with battery shipment). Install lug and cable as shown in Figure 7.9a. (Lug and cable not furnished by EnerSys ). Ohmmeter readings between each component and a common point on frame must indicate continuity to ensure proper grounding. Figure 7.9 Figure 7.9a 12 US-NEBS-IM-003

13 NEBS RACK ASSEMBLY GLOSSARY OF TERMS 2T RACK 2T/2R RACK CELL CLAMP ASSEMBLY CORNER BRACKET ASSEMBLY CROSS BRACE END RAIL EPA FOAM SPACER FRAME INTERCELL CONNECTOR INTER-RACK CABLE NEBS NEC OSHA REDUNDANT HOLE PATTERN RESERVE POWER SERVICE SEISMIC RACK SHIM SIDE RAIL SPACER SUPPORT RAIL TIER-TO-TIER CABLE Rack with one row of batteries located directly above another row of batteries. Rack with two parallel rows of batteries located directly above another two parallel rows of batteries. Brackets and threaded rod assembly connected to side rails and positioned between battery jars to help reduce lateral battery movement during a seismic event. Used with Zone 4 racks only. Bracket assembly (left and right) used to attach end rail to side rails to prevent batteries from falling off rack during a seismic event. Steel brace used to connect rack frames together. Rail attached to corner brackets to prevent batteries from falling off rack during a seismic event. Environmental Protection Agency Spacers used to prevent batteries from hitting each other during a seismic event. Main steel support structure of battery rack. Electrical conductors used to connect adjacent cells on the same tier of a rack. Electrical conductors used to connect terminal plates on two separate racks. Network Equipment Building Systems National Electric Code Occupational Safety & Health Administration Hole pattern that has two holes for each anchor location. If the preferred hole is not usable due to contact with concrete rebar, the optional hole would be used for anchoring. EnerSys service and installation group. Zone 2 or Zone 4 racks. Thin metal spacers used to bring side rails close to battery or to level rack due to uneven flooring. Rails used to prevent cells from falling off rack during a seismic event. Steel spacers that may be required for certain battery models on certain battery racks to move the side rails closer to the battery jar for optimum seismic protection. Rails connected to the frame that supports the batteries. Electrical conductor used to connect a terminal plate on one tier to a terminal plate on another tier on the same rack. US-NEBS-IM

14 NOTES Please check our website for literature updates. EnerSys World Headquarters 2366 Bernville Road Reading, PA USA Tel: Publication No. US-NEBS-IM-003 September 2013 Subject to revisions without prior notice. E.&O.E. EnerSys EMEA EH Europe GmbH Lowenstrasse Zurich Switzerland Tel: EnerSys Asia 152 Beach Road Gateway East Building #11-03 Singapore Tel: Represented by: Printed in USA 2013 EnerSys. All rights reserved. Trademarks and logos are the property of EnerSys and its affiliates except NEBS, which is a trademark of Telcordia Technologies.