Integrated Battery Rack

Integrated Battery Rack
Installation Instructions
Purpose
This document provides instructions for initial
assembly and installation of the OutBack
Integrated Battery Rack.
Scope
This document applies to all models of OutBack
Integrated Battery Rack. Although other
batteries can be used, this document depicts
OutBack EnergyCell RE VRLA batteries. The rack
is designed for their use.
Parts Included
¾
¾
¾
¾
¾
¾
Rack assembly
Front protective shields
Side protective shields
Hardware for protective shields
EnergyCell RE Battery Manual
Integrated Battery Rack Manual (this manual)
Figure 1 Rack and Batteries
Assembly
NOTE: If installed in the United States, all wiring methods shall be in accordance with the National Electrical Code
(NFPA 70), Current Edition. If installed in Canada, all wiring methods shall be in accordance with the Canadian Electrical
Code, C22.1, Current Edition.
To assemble the integrated battery rack:
1.
Install four ½” studs into the mounting surface (concrete or a
similarly reinforced material). From the front to the back, the stud
centers should be spaced 19” (48.3 cm) apart, as shown in Figure
2. Spacing from left to right should be 25” (63.5 cm) apart.
2.
Lower the battery rack over the four studs as shown in Figure 2
and settle the rack in place.
Front
Alternately, ½” bolts can be inserted through the mounting holes
into prepared openings.
Back
19” (48.3 cm)
IMPORTANT: The battery rack must be mounted on a level surface.
Figure 2 Mounting on Floor Studs
900-0130-01-00 Rev B
1
EnergyCell RE Battery Rack Instructions
3.
Secure the studs or bolts with nuts or appropriate hardware. Anchor the rack according to local building codes.
4.
Load the batteries into the rack. Load the bottom shelf first to prevent balancing issues. Proceed to the next shelf.
NOTE: Slots are present under the front edge of each shelf for strapping the batteries down if necessary.
Figure 3 Inserting Batteries
5.
Attach the interconnect bars to place the
batteries in series. Batteries should be
connected in series as appropriate to meet
the voltage requirements of the system.
Follow all instructions in the battery manual
and use the recommended torque values.
Install hardware in the order shown in Figure
4. Do not install hardware in a different order
than shown unless specified by the battery
manual or instructions.
Lock
Washer
Flat
Washer
Hex Bolt
Battery Cable
Lug
Mounting
Surface
Figure 4 Battery Interconnect Bars and Hardware
6.
The rack is equipped with cables for each shelf (positive on the right,
negative on the left). Connect each cable to the appropriate side of
each battery string. The cables lead to separate buses on each side of
the rack that place each string in parallel. (See Figure 6.)
Each positive (red) cable is connected to a 175-amp circuit breaker
which protects the batteries on that shelf.
Negative Cable
Positive Cable
Figure 5 Battery Connections
2
900-0130-01-00 Rev B
EnergyCell RE Battery Rack Instructions
The positive and negative bus bars are marked with
“+” and “-“ symbols respectively. The ground terminal
is marked with the
symbol.
7.
8.
9.
Load Cable
Connect a ground cable to the battery rack.
The ground terminal is located directly below
the negative bus bar (see right). Make sure to
follow all applicable electrical codes when
grounding the rack.
Ground
Terminal
The positive and negative bus bars have multiple
attachment points. The battery cables inside the
rack are already attached (see left). The user
should attach a fourth cable for battery loads (see
right). This load cable should be sized
appropriately. As shown to the right, the load
cable must be routed inside the enclosure using
one of the side openings. To complete the circuit,
the return load cable should connect to the bus
bar on the other side of the rack and also routed
inside the enclosure.
Cable entering
enclosure
Conduit
After load cables have been routed inside the enclosure, they should exit
using one of the conduit openings on the side. Six knockouts sized for 2”
conduit are available on each side of the rack. The conduit openings on
the right side of the rack are shown to the right, with a conduit leading
from one of them.
Figure 6 Bus and Load Cabling
10. Install the protective shields on the left and right sides of the battery
rack. Each shield has an edge which is designed to slide into a metal
tab on the rack. (See below.) Once the edge of the shield is secured,
the other side can be attached using M6 screws. (See the illustration
to the right.)
11. Install the protective shields on the front of each battery shelf. Make
certain to orient the shield correctly. The shield has an opening to
allow access to the circuit breaker for each set of batteries. (See the
illustration to the right.) If the shield is oriented incorrectly, it will
block access to the circuit breaker.
Machine
Screw
Circuit
Breaker
NOTE: The battery rack does not require
additional ventilation.
Shield
Provide adequate ventilation for the
room where the battery rack is installed.
Machine
Screw
Machine
Screw
Figure 7 Protective Shields (sides and front)
900-0130-01-00 Rev B
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Installing Shunts
To Install a Shunt or Shunts:
Up to three shunts may be installed for the use of a battery monitor such as the
FLEXnet DC. Perform the following steps before step 5 on page 2.
1.
Remove the negative bus bar and cables from the left side of the rack (see right).
Unbolt the individual cables from the bus bar.
2.
Three pairs of holes are located in the area where the bus bar is mounted (below,
left). A shunt can be placed over each set of holes. Each shunt has twin screws
(below, center) which can be used for mounting.
3.
Reinstall the negative bus bar so that it mounts across the inner terminal of each
shunt (below, right). Each negative battery cable must not be bolted to the bus
bar, but should connect to the outer terminal of each shunt. However, the load
cable must connect to the negative bus bar.
4.
The battery monitor’s voltage sensing wires must connect to the bus bars (positive
and negative), not the batteries.
Holes
Twin
Screws
Figure 8 Installing Shunts
Contact Information
Telephone:
+1.360.435.6030
+1.360.618.4363 (Technical Support)
+1.360.435.6019 (Fax)
Mailing Address:
(North America)
OutBack Power Technologies
5917 – 195th Street N.E.
Arlington, WA 98223 USA
E-mail:
Support@outbackpower.com
Web Site:
http://www.outbackpower.com
Address:
Sales, Marketing, & Warranty
6115 – 192nd Street NE
Arlington, WA 98223 USA
Notice of Copyright
Integrated Battery Rack Installation Manual © March 2012 by OutBack Power Technologies.
All Rights Reserved.
Date and Revision
March 2012, Revision B
Part Number
900-0130-01-00 Rev B