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Wire Harness for the
Battery Management
System
AP9924
AP9926
AP9927
Installation
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Contents Preliminary Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Silcon versus non-Silcon installation . . . . . . . . . . . . . . . . . . . 1 Inventory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Pre-installation Procedures. . . . . . . . . . . . . . . . . . .
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Preliminary Information The Battery Management System for high voltage applications connects Overview to one of the following: • A single APC Silcon UPS with pairs of strings. • A single non-APC UPS with single strings. The system provides battery management for nominal 2 V, 6 V, 8 V, or 12 V lead-acid batteries; or 1.2 V nickel-cadmium batteries. A system is comprised of at least one AP9921X master unit and up to five AP9921XS expansion units. Each unit supports up to 64 batteries. For more
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Preliminary Information Inventory Item Quantity Wire harness 1 Ring terminal assemblies 3 3/4 A fuse (0W2237) 2 5 A fuse ( 0W2015) 38 Tab washers 38 ® Male Faston connectors 5 Female Faston connectors 37 4-inch wire tie for 5-foot harness 20 for 50-foot harness 80 for 100-foot harness 80 8-inch wire tie for 5-foot harness 20 for 50-foot harness 40 for 100-foot harness 80 2 Wire Harness: Installation
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Safety Information Risk of electric shock: battery cabinets contain potentially lethal voltages! Batteries are energized even Electrical when AC power has been disconnected. Hazard Only qualified personnel, trained in battery operation and safety, may install the harnesses. Keep unauthorized personnel away from the batteries. Warning When installing the Battery Management System: • Cover the batteries with an insulating blanket before installing the harnesses. • Wear safety glasses, rubber
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Pre-installation Procedures Before installing the wire harnesses, use lockout and tagout safety Lockout/Tagout the UPS procedures for the UPS or any attached equipment, such as high-voltage power supplies. If possible, disconnect the main output lead from the battery string to the load. Voltage is present in the battery cabinet even after disconnecting it from the main load. Use caution when Electrical working with the batteries. Hazard Determine battery Before installing the harness wire
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Pre-installation Procedures Determine what connections you need to make: 1. If you are installing harnesses in one cabinet, connect the following: • one positive 1/2-fuse bus (+ 1/2) connector • two positive 1/2-midpoint (+ 1/2) connectors • one negative 1/2-fuse bus (- 1/2) connector 2. If you are installing harnesses in two cabinets, connect the following: Cabinet A: • one positive 1/2-fuse bus (+ 1/2) connector • two positive 1/2-midpoint (+ 1/2) connectors Cabinet B: • two negative 1/2-fu
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Install the Wire Harnesses Before you attach the wire harnesses to the batteries, install a tab washer on the positive terminal of each battery to be managed. How you install the tab washer depends on whether the terminal bolt is embedded in the battery. How to install the tab Do not disturb existing battery connections. Place the tab washers on non- washers and nuts on top of the bolt thread extensions of the embedded terminals existing battery connections. You must provide your own Note
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Install the Wire Harnesses How to install tab washers on embedded Verify that the string is an open circuit before working battery terminals with the batteries. Electrical Hazard 1. Remove the bolt from a battery. 2. Place the ring terminal on the existing battery connection, directly under the hex-head of the bolt. 3. Replace the bolt in the battery, and adjust its torque according to the battery manufacturer’s specifications. 4. Coat the tab washer and nut with approved antioxidant grea
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Install the Wire Harnesses Prepare the harness To prepare the harness wires: wires 1. Measure the length of each wire so that it will reach from the positive terminal on its battery to the battery connector on the rear of the Battery Management System, adding a ‘service loop’ that will permit one repair of the wire without having to replace it. 2. For an APC Silcon unit, measure wires to connect to the fuse bus and midpoint bus located on the inside roof of the battery cabinet. See “Determin
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Install the Wire Harnesses Connect the battery Slide the receptor end of each fuse over the tab portion on the washers wires that you installed on the positive terminals of each battery. Each wire is labeled with a number indicating its correct battery connection. For example, the battery labeled 1A would connect to Battery1 of String A, and so on. Note For additional guidance on battery-wire connections, see the battery connector pinout on page 13 and the battery diagram on page 14. Wire H
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Additional Silcon Connection Procedures Install the ring terminals onto the appropriate bolts on the fuse bus and Attach harness to the midpoint bus: fuse bus and midpoint bus (Silcon only) 1. Remove the nut from the bolt. 2. Slide the ring terminal onto the bolt. 3. Replace and tighten the nut. See “Determine fuse bus and midpoint bus connections (Silcon only)” on page 4 for the connections to make. Install the 3/4 A and 5 A To install the fuses onto the fuse bus and midpoint bus wires: fus
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Secure the Wire Harness Secure the harness to the rack or cabinet to prevent damage to the wires or personal injury by people tripping on them. Warning Secure the battery wires After the battery wires are connected, secure the harness wires. 1. Using the 4-inch wire ties, attach the battery wires to the battery straps. Attaching the wires too tightly could damage their insulation. Caution 2. Using the 8-inch wire ties, secure the harness to the enclosure to prevent wire damage. Wire Harnes
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Connect to the Battery Management System Install the Battery Management System in a battery cabinet, in a rack or Install the Battery enclosure, or on top of the battery cabinet. The system must be installed Management System in a location that is safe, convenient, and accessible for connection procedures. For instructions and safety information on installing the Battery Management System (AP9921X and AP9921XS), see the Battery Management System Installation and Quick See also Start manua
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Battery Connector Pinouts Battery Connector A Battery Connector B Wire # Battery number and polarity Wire # Battery number and polarity 1 Battery 1 + 1 Battery 33 + 2 Battery 1 - and Battery 2 + 2 Battery 33 - and Battery 34 + 3 Battery 2 - and Battery 3 + 3 Battery 34 - and Battery 35 + 4 Battery 3 - and Battery 4 + 4 Battery 35 - and Battery 36 + 5 Battery 4 - and Battery 5 + 5 Battery 36 - and Battery 37 + 6 Battery 5 - and Battery 6 + 6 Battery 37 - and Battery 38 + 7 Battery 6 - and Battery
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Battery Diagrams The following is an example battery diagram for two strings of 32 batteries or one string of 64 batteries. An example for one string of 32 batteries would include Connector A only. CONNECTOR A CONNECTOR B + + 1 1 1 1 (33) + + 2 2 2 2 (34) 3 3 3 3 (35) 4 4 4 4 (36) 5 5 5 5 (37) 6 6 6 6 (38) 7 7 7 (39) 7 8 8 8 8 (40) 9 9 9 9 (41) 10 10 10 10 (42) 11 11 11 11 (43) 12 12 12 12 (44) 13 13 13 13 (45) 14 14 14 14 (46) 15 15 15 15 (47) 16 16 16 16 (48) 17 17 17 (49) 17 18 18 18 18 (5
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Warranty and Service Limited warranty APC warrants the wire harness to be free from defects in materials and workmanship for a period of two years from the date of purchase. Its obligation under this warranty is limited to repairing or replacing, at its own sole option, any such defective products. This warranty does not apply to equipment that has been damaged by accident, negligence, or misapplication or has been altered or modified in any way. This warranty applies only to the original
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Life-Support Policy American Power Conversion (APC) does not recommend the use of any General policy of its products in the following situations: • In life-support applications where failure or malfunction of the APC product can be reasonably expected to cause failure of the life- support device or to affect significantly its safety or effectiveness. • In direct patient care. APC will not knowingly sell its products for use in such applications unless it receives in writing assurances satisfa
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aRadio Frequency Interference Changes or modifications to this unit not expressly approved by the party responsible for compliance could void the user’s authority to operate this equipment. Warning USA—FCC This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This e
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APC Worldwide Customer Support Customer support for this or any other APC product is available at no charge in any of the following ways: • Visit the APC Web site to access documents in the APC Knowledge Base and to submit customer support requests. – www.apc.com (Corporate Headquarters) Connect to localized APC Web sites for specific countries, each of which provides customer support information. – www.apc.com/support/ Global support searching APC Knowledge Base and using e-support. • Contact
