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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 Verify that the string is an open circuit before working battery terminals with the batteries. Electrical Hazard 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. 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 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. If you experience problems connecting 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 Prepare the harness wires Install the battery and power fuses To prepare the harness 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. 5. Attach the female Faston connectors to the battery wire ends, and crimp them securely in place. Attach a 5 A fuse (0W2015) to the following wire connectors: • 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 Wire Harness: Installation 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 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 mph0107a mph0107a Additional Silcon Connection Procedures Attach harness to the fuse bus and midpoint bus (Silcon only) Install the 3/4 A and 5 A 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 bus 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 (0W1492). 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. Midpoint Bus Fuse Bus Wire Harness: Installation Secure the Wire Harness Warning Secure the harness to the rack or cabinet to prevent damage to the wires or personal injury by people tripping on them. 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 mph0113a 2. Using the 8-inch wire ties, secure the harness to the enclosure to prevent wire damage. mph 0114a Wire Harness: Installation Connect to the B...

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