CR-Series External Battery Cabinet Installation Guide For Use with
CR-Series External Battery Cabinet
Installation Guide
For Use with Avaya UPS Systems
Introduction
This manual is intended to assist with the site preparation and installation of a Power Battery Co.
CR-series battery cabinet with an Avaya UPS. It is important that you read these installation
instructions fully as well as the installation instructions for the UPS before attempting to install the
battery cabinet. Compliance with all applicable codes and regulations for the installation are the
responsibility of the installer.
Table 1 shows the Power Battery system model numbers and how much runtime you will get for
each type of system with each UPS. The runtimes are based upon 100% loading of the UPS.
Also shown are the dimensions and weights of the different battery systems. Be sure to make
provisions for the weight of the cabinets when planning the location for the battery cabinet.
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IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important instructions that should be followed during installation and
maintenance of the external battery cabinet.
CONSERVER CES INSTRUCTIONS
Cette notice contient des instructions importantes concernant la securite.
This specification is designed to be a guide to help install the external battery cabinet safely. The
instructions in this manual are not intended to be used for user installation or replacement of the
batteries.
External battery cabinet installation should only be performed by qualified, experienced
personnel, following these instructions step-by-step, adopting normal safety precautions for
electrical installations, paying particular attention to those highlighted in this specification.
Compliance with all applicable codes and regulations is the ultimate responsibility of the
personnel who is installing the equipment.
WARNING: Lethal voltages may be present within this unit even when it is apparently not
operating. Observe all cautions and warnings in this manual. Failure to do so MAY result in
serious injury or death. Never work alone.
This product is designed for Commercial or Industrial use only. This product is not intended for
use with life support and other U.S. FDA designated “critical” devices.
Observe the following safety precautions when working on the external battery cabinet or the
batteries:
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NOTE:
Servicing of batteries should be performed or supervised by personnel
knowledgeable of batteries and the required precautions. Keep unauthorized personnel
away from batteries.
NOTE: When replacing batteries, use the same number and type originally used in the
system. The batteries should be valve-regulated, lead-acid type.
Pour le replacement, utiliser le meme nombre de batteries du modele suivant.
CAUTION: DO NOT dispose of battery or batteries in a fire. The battery or batteries may
explode.
CAUTION: DO NOT open or mutilate the battery or batteries. Released electrolyte is
harmful to the skin and eyes. It may be toxic.
CAUTION: A battery can present a risk of electrical shock and high short circuit current.
Observe proper precautions.
ATTENTION: Une batterie peut presenter un risqué de choc electrique, de brulure par
transfert d’energie. Suivre les precautions qui s’imposent.
CAUTION: Lead-acid batteries contain hazardous toxic materials. Handle, transport and
properly dispose or recycle the batteries in accordance with your local codes and regulations.
L’eliminaiton des batteries est reglementee. Conculter les codes locaux a cet effet.
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The following safety procedures shall be followed when working on the external battery cabinet:
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Have available the following equipment for safe handling of the batteries and protection of
personnel:
- Goggles and face shields.
- Acid resistant insulated gloves.
- Protective aprons and overshoes.
- Lifting devices of adequate capacity, when required.
- Insulated tools.
- Rubber mats for the floor.
Remove watches, rings or other metal objects.
Use tools with insulated handles.
Wear rubber gloves and boots.
DO NOT lay tools or metal parts on top of batteries.
Disconnect charging source prior to connecting or disconnecting battery terminals.
CAUTION/WARNING: Use extreme caution when making connections. Do not allow cables
to touch anything except the intended connection spot.
Determine if the battery is inadvertently grounded. If inadvertently grounded, remove the
source of ground. Contact with any part of a grounded battery can result in electrical shock.
The likelihood of such shocks will be reduced if such grounds are removed during installation
and maintenance.
Inspect all lifting equipment for functional adequacy and to make sure it is of sufficient
capacity to lift the weight involved (see Table 1).
Prohibit smoking and open flame, and avoid arcing in the immediate vicinity of the battery.
Ensure that adequate illumination requirements for inside the cabinet are met.
Always make sure there is an unobstructed path from the battery area to the exit.
Avoid static buildup by having personnel contact ground prior to working on batteries.
To maximize battery performance and life, operate the external battery cabinet in an indoor
environment only in an ambient temperature range of 15°C to 25°C (59°F to 77°F).
Install the cabinet in a clean environment, free from conductive contaminants, moisture,
flammable liquids, gasses or corrosive substances.
Keep all vents free of dust accumulation that could restrict airflow.
Never block or insert any object into the ventilation holes or other openings.
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Preparation
This installation guide provides information needed for positioning the external battery cabinet
(including environmental requirements) and for connecting the AC input and DC output power
cables.
Inspection
Upon receiving the external battery cabinet, examine the packaging for any signs of mishandling
or damage. If any damage is noted, call Power Battery and/or notify your carrier.
Environment
Note: Operating in temperatures above 77°F (25°C) will reduce battery life. The external battery
cabinet environment must be free of conductive contaminants and excessive moisture (water
condensation, flammable vapors, chemical fumes, or corrosive gasses and liquids).
Required Setup Equipment
The tools below are required to properly setup your external battery cabinet:
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Pallet jack
Torque wrench (in-lb.)
9/16” socket with ratchet or wrench
7/16” socket with ratchet or wrench
6mm Allen wrench
Flathead screwdriver
#2 Phillips head screwdriver
DC Voltmeter
Site Preparation
When deciding where to locate your external battery cabinet, consider the weight and size of the
unit. Make sure the structural integrity of the floor can withstand the weight of the external battery
cabinet. See Table 1 for the dimensions and weights for the external battery cabinet.
Check to be sure that the external battery cabinet will be in a well-ventilated area with at least 2
inches behind it. It should also have 36 inches in front for maintenance.
Fig. 1
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The external battery cabinet is bolted to the shipping pallet to ensure safety. It is recommended
that a pallet jack be used to transport the unit to its operating location (prior to unbolting the unit).
When the cabinet is in its desired location, tighten the thumb screws on each caster to secure the
cabinet in place. If you are installing the cabinet in a location where you need seismic mounting,
the cabinet will need to be bolted to the floor using the holes provided in the legs of the cabinet.
See Fig. 2 for proper seismic mounting.
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Cable Installation
Wiring Preparation
WARNING: Please read this section thoroughly before attempting to install wiring to this unit.
The external battery cabinet should be installed by a qualified / certified electrician.
Removing the Front Panel
In the top corners of the front panel are two screw latches. Unscrew the latches with a flatheaded screwdriver. The screws should stay attached to the panel. Keep the panel off to the
side.
Conduit Connection to Cabinet
The external battery cabinet is intended to be hardwired to the UPS. There are conduit
knockouts provided on the bottom and sides of the cabinet for either 3/4”, 1 1/2” or 2 1/2” conduit.
It is the responsibility of the installer to supply all necessary conduit fittings and hardware, and to
choose which conduit knockouts are best for the particular installation.
Loose Cable Installation
For better safety during transportation, one or more battery-to-battery cables may have been
removed from the system and shipped loose. These cables will be found in a separate box that
will be inside the cabinet. These cables need to be re-installed in their proper locations prior to
start-up of the system. The proper locations to install these cables are found on the system
drawing included with the system. Mounting hardware for the battery terminals will either be in
the box with the cables or will be found still installed on the battery terminals.
Before installing these cables, measure the voltage between the terminals of the two batteries
you are about to connect together with a DC Voltmeter. When you initially take the reading, a
voltage may be found between the two disconnected batteries because of static charges and/or
capacitance. This voltage will start collapsing once you start taking the reading and should
continue to collapse if you continue monitoring the reading.
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WARNING:
Do not connect the cable if the voltage reading does not fall to less than 1 volt.
Recheck all connections for proper polarity. If voltage still does not fall to less than 1 volt after
rechecking all of the connections, contact Power Battery prior to continuing with the installation.
If the voltage between the batteries does fall to less than 1 volt, connect the cable to the two
batteries as shown on the system drawing. There is a terminal connection detail on the system
drawing which shows the proper way to install the terminal hardware. Torque the connection to
the value shown on the battery label.
Once the loose cables have all been installed, measure the overall voltage of the battery system
using the DC Voltmeter. The overall open circuit system voltage should be within the range
shown on the system drawing. If it is not within the range shown, re-check all connections. If the
system voltage is still not within the proper range, please contact Power Battery. Also verify that
the system voltage is correct for the equipment for which you plan to use the battery system.
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UPS to External Battery Cabinet Connection
On the system drawing included with the battery system, you will see the recommended minimum
size cable for connecting the external battery cabinet with the UPS. The recommended minimum
size is based on Table 310-16 of the NEC based on 75°C cable. Use 75°C copper cable for all
connections. Special compensation will need to be made if the cable installation does not meet
all of the prescribed conditions described in Table 310-16 of the NEC, or for long cable runs when
necessary.
The load cables will be installed directly to the circuit breaker as shown on the system drawing.
Torque the cable lug on the breaker to the recommended torque setting that is also shown on the
system drawing. Care must be taken when connecting these cables to be sure that they are
mechanically and electrically secure. Prevent cables from resting on the batteries. Strain relieve
the cables so that the weight of the cable is not putting stress on the connection.
Note: Make sure that the circuit breaker is in the off or open position prior to installing the load
cables so that there is no voltage present when you remove the protective cover from the load
side of the circuit breaker.
CAUTION: Be certain that the cable is connected to the proper polarity.
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System Startup
Consult the UPS instructions for proper startup of the battery system with the UPS.
After completing the system startup, replace the front door to the cabinet and secure it with the
two screw latches.
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