APC AP9924 User's Manual
Contents
1. 5 Attach the female Faston connectors to the battery wire ends and crimp them securely in place Install the battery and Attach a 5 A fuse 0W2015 to the following wire connectors power fuses e Strings A 33A Strings 1B 33B if applicable String 35A negative power wire Attach a 3 4 A fuse 0W2237 to String 34A positive power wire mph0261a 8 Wire Harness Installation Install the Wire Harnesses Slide the receptor end of each fuse over the tab portion on the washers Connect the battery that you installed on the positive terminals of each battery wires Each wire is labeled with a number indicating its correct battery connection For example the battery labeled 1A Note would connect to Battery of String A and so on mph0111a For additional guidance on battery wire connections see the battery connector pinout on page 13 and the battery diagram on page 14 Wire Harness Installation Additional Silcon Connection Procedures Attach harness to the fuse bus and midpoint bus Silcon only Install the 3 4 Aand 5A fuses Silcon only Install the ring terminals onto the appropriate bolts on the fuse bus and midpoint bus 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 To install the fuses onto the fuse bu2. Battery 22 and Battery 23 23 Battery 54 and Battery 55 24 Battery 23 and Battery 24 24 Battery 55 and Battery 56 25 Battery 24 and Battery 25 25 Battery 56 and Battery 57 26 Battery 25 and Battery 26 26 Battery 57 and Battery 58 27 Battery 26 and Battery 27 27 Battery 58 and Battery 59 28 Battery 27 and Battery 28 28 Battery 59 and Battery 60 29 Battery 28 and Battery 29 29 Battery 60 and Battery 61 30 Battery 29 and Battery 30 30 Battery 61 and Battery 62 31 Battery 30 and Battery 31 31 Battery 62 and Battery 63 32 Battery 31 and Battery 32 32 Battery 63 and Battery 64 33 Battery 32 33 Battery 64 34 105 560 VDC power from 34 INC Do not use of first battery in first string 35 105 560 VDC power from 35 INC Do not use of last battery in first string 36 INC 36 NC Wire Harness Installation 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 oe Dail OF 1 33 Qf 2 7 2 34 Oa O 3 35 Ott O 4 36 OHE G 37 Omai O F 6 38 Ort 7 O 7 39 OE 8 40 Ot 9 OF 41 mtt 10 10 42 FF 11 D 43 QF 12 DAF 1 2 44 B F 13 BH 13 45 OF 14 14
3. www apc com Wire Harness for the Battery Management System AP9924 AP9926 AP9927 Installation Contents Preliminary Information 0 0 0 00 cee ee Overview oaei ninda h Ei oe Oia koe Bd Se 1 Silcon versus non Silcon installation 0 0 ce eee 1 INVENTORY eis Se tak ee eed ae eee etd ee ee ee Gh 2 Safety Information hi eee ee eee ESSA OR HES RES Pre installation Procedures 0 0 0c eee ee Lockout Tagout the UPS 0000 0 eee eee 4 Determine battery numbers 1 0 cee ee 4 Determine fuse bus and midpoint bus connections Silcon only 4 Install the Wire Harnesses 0 000 ee ee ee ee es How to install the tab washers on non embedded terminals 6 How to install tab washers on embedded battery terminals 7 Prepare the harness wires 2 0 0 0c ee 8 Install the battery and power fuses 00002 e eae 8 Connect the battery wires 2 0 0 eee ee 9 Additional Silcon Connection Procedures 0005 Attach harness to the fuse bus and midpoint bus Silcon only 10 Install the 3 4 A and 5 A fuses Silcon only 10 Secure the Wire Harness oie so sok soe ee he es wn te Secure the battery Wires 1 ee ee 11 Connect to the Battery Management System Install the Battery Management System 5 5 12 String connection ss aos weca a 0c ee ee 12 Battery Connector Pinouts 0 000 ee eee eee Battery Diagrams ots ace ee e
4. 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 7 7 Battery 38 and Battery 39 8 Battery 7 and Battery 8 8 Battery 39 and Battery 40 9 Battery 8 and Battery 9 9 Battery 40 and Battery 41 10 Battery 9 and Battery 10 10 Battery 41 and Battery 42 11 Battery 10 and Battery 11 11 Battery 42 and Battery 43 12 Battery 11 and Battery 12 12 Battery 43 and Battery 44 13 Battery 12 and Battery 13 13 Battery 44 and Battery 45 14 Battery 13 and Battery 14 14 Battery 45 and Battery 46 15 Battery 14 and Battery 15 15 Battery 46 and Battery 47 16 Battery 15 and Battery 16 16 Battery 47 and Battery 48 17 Battery 16 and Battery 17 17 Battery 48 and Battery 49 18 Battery 17 and Battery 18 18 Battery 49 and Battery 50 19 Battery 18 and Battery 19 19 Battery 50 and Battery 51 20 Battery 19 and Battery 20 20 Battery 51 and Battery 52 21 Battery 20 and Battery 21 21 Battery 52 and Battery 53 22 Battery 21 and Battery 22 22 Battery 53 and Battery 54 23
5. 46 Ct 15 Or 15 147 Cot 16 O 16 48 Omt 17 OF 17 49 8 4 18 18 50 OF 19 19 51 CO F 20 KOF 20 52 eD 21 7 21 53 kD 22 QF 22 54 rf 23 SF 23 5 CaF 24 OF 24 56 BSF 25 SF 25 57 komt 26 26 58 QF 27 27 59 kam 2g 28 60 CIF 29 2 7 29 61 GO 30 60 7 30 62 BI f 31 6 31 63 62 Vf 32 62 32 64 63 To next unit 63 Power 4 64 Not used Power 5 Nd 5 Not used Not used G fie 66 Not used 14 Wire Harness Installation Warranty and Service Limited warranty Warranty limitations Obtaining service 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 purchaser Except as provided herein APC makes no warranties express or implied including warranties of merchantability and fitness for a particular purpose Some jurisdictions do not permit limitation or exclusion of implied warranties therefore the aforesaid limitation s or exclusion s may not apply to the purchaser Except as provided above in no event w
6. terminals a short circuit could cause the batteries to explode Do not lay tools or metal parts on top of the batteries or near the cable lugs Remove watches rings and other metal objects Use only cables supplied by APC unless otherwise indicated For the UPS and switch gear use Lockout Tagout safety procedures which remove access to a device and physically label the device as intentionally out of service before working on the batteries Wire Harness Installation 3 Pre installation Procedures Lockout Tagout the UPS Determine battery numbers Determine fuse bus and midpoint bus connections Silcon only Before installing the wire harnesses use lockout and tagout safety 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 Flectrical working with the batteries Hazard Before installing the harness wires designate a battery number to each battery in your system Using a volt meter to check polarity determine the most positive battery in your string Battery 1 and count to the most negative last battery in your string Locate the 1 2 fuse bus connectors and 1 2 midpoint bus connectors on the inside roof of the cabinet Fuse Bus Midpoint Bus e The positive fuse bus connectors and mi
7. attery of String A you must install additional tab washers to connect the Battery Management System unit power wires String A wires 34 Note and 35 For each unit on the system attach one additional tab washer For example a four unit system would require five tab washers stacked on top of each other and offset on the positive terminal of both Battery 1 and the last battery of String A This would include one tab washer to manage the battery and four tab washers to connect each unit s power wire 2 Secure each set of washers in place with a nut 3 Coat the tab washers and nuts with approved antioxidant grease If you experience problems connecting wires to the terminals on the batteries contact APC Customer Support at a number on the back cover of this manual Note Wire Harness Installation Install the Wire Harnesses How to install tab washers on embedded AN Verify that the string is an open circuit before working battery terminals with the batteries Electrical zard 1 Remove the bolt from a battery mph0269a 2 Place the ring terminal on the existing battery connection directly under the hex head of the bolt Sa f E mph0270a 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 grease For Battery 1 and the last battery of String A you must install additional tab washers to
8. connect the Battery Management System unit power wires String A wires 34 and 35 For each unit on the system attach one additional tab washer For example a four unit system would require five tab washers stacked on top of each other and offset on the positive terminal of both Battery 1 and the last battery of String A This would include one tab washer to manage the battery and four tab washers to connect each unit s power wire Note batteries contact APC Customer Support at a number on the Q If you experience problems connecting to the terminals on the back cover of this manual Note Wire Harness Installation 7 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 Determine fuse bus and midpoint bus connections Silcon only on page 4 3 Cut the wires to the lengths measured in step 1 and step 2 and reattach the wire labels to the wire ends 4 For an APC Silcon unit attach the male Faston connectors to the fuse bus and midpoint bus wire ends and crimp them securely in place
9. cut at installation to match your battery configuration The majority of the procedures in this manual are used for both system installations Disregard Silcon specific instructions i e midpoint and fuse bus connections if you are installing a generic harness to fit your battery cabinet or rack that is not for an APC Silcon UPS Wire Harness Installation 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 Wire Harness Installation Safety Information in Risk of electric shock battery cabinets contain potentially lethal voltages Batteries are energized even Electrical i fectrical when AC power has been disconnected and safety may install the harnesses Keep unauthorized A Only qualified personnel trained in battery operation Warning personnel away from the batteries When installing the Battery Management System e e e e e e e e Cover the batteries with an insulating blanket before installing the harnesses Wear safety glasses rubber gloves and rubber boots Use double insulated tools Do not short circuit the battery
10. dpoint bus connectors are on the right side of the cabinet e The negative fuse bus connectors and midpoint bus connectors are on the left side of the cabinet Wire Harness Installation 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 e two positive 1 2 midpoint 1 2 connectors Cabinet B two negative 1 2 fuse bus 1 2 connectors one negative 1 2 midpoint 1 2 connector Wire Harness Installation 5 Install the Wire Harnesses How to install the tab washers on non embedded terminals 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 Do not disturb existing battery connections Place the tab washers and nuts on top of the bolt thread extensions of the existing battery connections You must provide your own Note nuts for tab washer installation 1 Install a tab washer onto the positive terminal of each battery to be managed a 8 E For Battery 1 and the last b
11. ee eae amp Srl Soe a Bee ate ee Warranty and Service soared ik abe ea Ee ee CAS Limited warranty 2 2 2c annann 15 Warranty limitations 0 0 6 ee 15 Obtaining service 2 0 nnn nnnn nnna 15 Life Support Policy 2s aasa anaana wt eset tee haaaes General policy ve ste heni ao e e e a ee 16 Examples of life support devices 0 00 ee ene eeee 16 Wire Harness Installation Preliminary Information Overview Silcon versus non Silcon installation The Battery Management System for high voltage applications connects to one of the following A single APC Silcon UPS with pairs of strings e 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 information on the features and capabilities of the ra Battery Management System see the initial sections of the Qe User 5 Guide which is available on the Utility CD supplied See also with the Battery Management System Do not turn on the power to the unit until the wire harnesses are connected and the DIP switches are configured Note This manual covers the installation of two types of systems e An installation for an APC Silcon battery cabinet e An installation using 5 50 or 100 foot wire harnesses to be
12. erefore these units do not meet the requirements for use in direct patient care Wire Harness Installation Radio Frequency Interference USA FCC Canada ICES Japan VCCI Changes or modifications to this unit not expressly approved by the party responsible for compliance could void the user s Warning authority to operate this equipment 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 equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with this user manual may cause harmful interference to radio communications Operation of this equipment in a residential area is likely to cause harmful interference The user will bear sole responsibility for correcting such interference This Class A digital apparatus complies with Canadian ICES 003 Cet appareil num rique de la classe A est conforme a la norme NMB 003 du Canada This is a Class A product based on the standard of the Voluntary Control Council for Interference by Information Technology Equipment VCCI If this equipment is used in a domestic environment radio disturbance may occur in which case the user may be required to take corrective actions COREL FURRE T IEE BER h
13. ese VCCI Ode CEOL FR A TABOR CT ORI ARERR CEH TO BRBBe SHOT CEBSVET TORPANT 1E FAA DDR AR EGET OL DIC RENSCEBHOVET t www apc com APC Worldwide Customer Support Customer support for this or any other APC product is available at no charge in any of the following ways e 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 Wwww apc com support Global support searching APC Knowledge Base and using e support e Contact an APC Customer Support center by telephone or e mail Regional centers Silcon Customer Support 1 877 287 7835 toll free APC headquarters U S Canada 1 800 800 4272 toll free Latin America EDIC D ESE WERE LORIS Europe Middle East Africa 353 91 702000 Ireland Japan OELE DIPA Australia New Zealand South Pacific area 61 2 9955 9366 Australia Local country specific centers go to www apc com support contact for contact information Contact the APC representative or other distributor from whom you purchased your APC product for information on how to obtain local customer support Entire contents 2005 American Power Conversion All rights reserved Reproduction in w
14. hole or in part without permission is prohibited APC the APC logo InfraStruXure and Silcon are trademarks of American Power Conversion Corporation and may be registered in some jurisdictions All other trademarks product names and corporate names are the property of their respective owners and are used for informational purposes only AINE IOI aie
15. ill APC be liable for direct indirect special incidental or consequential damages arising out of the use of this product even if advised of the possibility of such damage Specifically APC is not liable for any costs such as lost profits or revenue loss of equipment loss of use of equipment loss of software loss of data costs of substitutes claims by third parties or otherwise This warranty gives you specific legal rights and you may also have other rights which vary according to jurisdiction To obtain support for problems with your wire harness 1 Note the serial number and date of purchase You can locate the serial number on the box label 2 Contact Customer Support at a phone number on the back cover of this manual A technician will try to help you solve the problem by phone 3 If you must return the product the technician will give you a return material authorization RMA number If the warranty expired you will be charged for repair or replacement 4 Pack the unit carefully The warranty does not cover damage sustained in transit Enclose a letter with your name address RMA number and daytime phone number a copy of the sales receipt and a check as payment if applicable 5 Mark the RMA number clearly on the outside of the shipping carton 6 Ship by insured prepaid carrier to the address provided by the Customer Support technician Wire Harness Installation 15 Life Support Policy General p
16. nt System in a battery cabinet in a rack or enclosure or on top of the battery cabinet The system must be installed in a location that is safe convenient and accessible for connection procedures For instructions and safety information on installing the S Battery Management System AP9921X and AP9921XS see the Battery Management System Installation and Quick Start manual 990 1649A included with your Battery Management System You can also obtain the manual and other documentation for currently available models of the Battery Management System at www apc com by searching for the product s part number e g AP9921X See also After attaching the wire harnesses to the batteries and securing the harnesses to the cabinets or racks connect the battery strings to the Battery Management System Verify that the ON OFF button is in the OFF position on Q each Battery Management System before plugging in Note connectors 1 Plug the connector for String A into the right rear of the Battery Management System in the port marked Battery Power Input A 2 If applicable plug the connector for String B into the left rear of the Battery Management System in the port marked Battery Input B Wire Harness Installation Battery Connector Pinouts Battery Connector A Battery Connector B Wire Battery number and polarity
17. olicy Examples of life support devices 16 American Power Conversion APC does not recommend the use of any of its products in the following situations e 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 satisfactory to APC that a the risks of injury or damage have been minimized b the customer assumes all such risks and c the liability of American Power Conversion is adequately protected under the circumstances The term ife support device includes but is not limited to neonatal oxygen analyzers nerve stimulators whether used for anesthesia pain relief or other purposes autotransfusion devices blood pumps defibrillators arrhythmia detectors and alarms pacemakers hemodialysis systems peritoneal dialysis systems neonatal ventilator incubators ventilators for adults and infants anesthesia ventilators infusion pumps and any other devices designated as critical by the U S FDA Hospital grade wiring devices and leakage current protection may be ordered as options on many APC UPS systems APC does not claim that units with these modifications are certified or listed as hospital grade by APC or any other organization Th
18. s and midpoint bus wires One cabinet system 1 Install the 3 4 A fuse 0W2237 between the ring terminal assembly and the positive 1 2 string fuse bus wire 2 Install 5 A fuses 0W2015 between the ring terminal assemblies and all other fuse bus and midpoint bus connections Two cabinet system 1 Install a 3 4 A fuse 0W2237 on the positive 1 2 string fuse bus wire on the positive string harness 0W 1492 2 Install a 5 A fuse 0W2015 on the negative 1 2 string midpoint bus wire on the negative string harness 0W1491 3 Install 5 A fuses 0W2015 between the ring terminal assemblies and all other fuse bus and midpoint bus connections Fuse Bus Midpoint Bus mph0107a Wire Harness Installation Secure the Wire Harness A 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 A Attaching the wires too tightly could damage their insulation Caution mph0113a 2 Using the 8 inch wire ties secure the harness to the enclosure to prevent wire damage mph 0114a Wire Harness Installation 11 Connect to the Battery Management System Install the Battery Management System String connection Install the Battery Manageme
Download Pdf Manuals
Related Search