C&D Technologies RDC Series User manual

STANDBY BATTERY RACK
ASSEMBLY INSTRUCTIONS
APPLIES TO ALL RDC SERIES RACKS
(READ ALL INSTRUCTIONS PRIOR TO INSTALLATION)
Standard and Earthquake-Protected (EP) Racks:
Earthquake-protected racks are similar to standard racks,
with the exception of additional frame bracing, battery restraints,
and cell spacer elements. The battery rack frames are common for
Standard, EP1 and EP2 series for the one-tier, two-tier, three-tier
and two-step racks with the exception of the three-tier EP2 rack.
The frame for the three-tier EP2 rack is unique. RDC-EP racks are
certied to the International Building Code, 2009 edition.
Conguration:
Racks are available in single or multiple tier/step congurations as
shown in Figure 2. Rack components are supplied loose and must
be assembled and secured on-site in accordance with these C&D
assembly instructions, the drawings included with the rack shipment,
and applicable codes.
Rack Location:
Locate racks in a clean, cool, dry place so the batteries are not affected
by sources of radiant heat, such as sunshine, heating units, radiators,
steam pipes, etc. Variations of more than 5 degrees Fahrenheit (3º C)
between cells may cause the battery to become electrically unbalanced.
Top rows of batteries in multiple-tier congurations tend to operate at
slightly higher temperature than those on lower tiers. Always provide
adequate ceiling clearance for ventilation and maintenance.
Anchoring:
To provide stability and safety, racks must be securely anchored
to the oor. Anchor bolts are to be installed per contractor
specications and in accordance with applicable codes. Do not
attach rack to walls without consulting the appropriate structural
engineer. Mounting holes are provided in the base of each frame.
All frames must be secured to oor using all anchor bolt hole
locations.
• Do not install batteries until the rack has been properly
installed, with all bolts tightened to specied torque and
frames anchored to the oor.
• Do not use oil or grease as a lubricant for cell installation.
Lubrication is usually not required due to the low friction
interface of the insulating covers. If necessary, a small
amount of water, unscented talcum or Dow Corning III can
be applied to the rail covers to reduce friction.
CAUTION:
Grounding:
Rack grounding provisions are integrated into the base of each
frame. Two through holes are located at the center of the frame’s
bottom cross member and may be used to secure a standard NEMA
lug. These holes are 0.44” in diameter and 1.0” between centers.
The surfaces surrounding the holes have been masked and are free
of powder coat to allow electrical contact. Frame to frame grounding
integrity is accomplished via the lower support rail, attached to each
frame with internal/external “star” washers.
Two Tier Standard Rack Two Tier EP Rack
Figure 1. Standard Vs. EP Rack
Figure 2. Typical Rack Congurations
RS02098
These instructions detail the proper procedure for installing
C&D Standard and EP (Earthquake Protected) battery racks.
The following describes how to locate, assemble, and load
open-frame battery racks for C&D battery mounting applications.
Proper attention to these instructions will help ensure safe,
trouble-free performance.
Standard vs. EP2 Rack
Two Tier Standard Rack Two Tier EP2 Rack
TYPICAL RACK GROUNDING
PROVISION
2-Step 1 Tier 2-Tier 3-Tier
Std & EP1
3-Tier
EP2
RS02098/0114/CD www.cdtechno.com

ASSEMBLY INSTRUCTIONS FOR RDC STANDARD AND EP RACKS
1. Material Verication: Battery racks are shipped
unassembled with a complete set of related drawings and
documentation. Check received parts and quantities against
the rack’s bill of materials on provided drawings and/or
packing list. Do not assemble rack if parts are missing or
quantities are incomplete.
2. Required Tools: Torque wrench (0 to 65 ft.-lb.) with 9/16”
and 3/4” hex socket. Adjustable wrench or 9/16” and 3/4” box
wrenches, tape measure, square and leveling device. Note:
Consult manufacturer’s instructions for tools required to install
oor mounting hardware.
3. Location of Rack Assembly: When determining rack
location and oor anchoring pattern, use applicable drawings
provided with rack shipment. The optional arrangement
drawing, if ordered, should also be reviewed for rack and
battery cell placement. Consider boundaries and aisle
clearances when locating the general position of the rack.
Locate oor mounting locations using provided drawings. See
Figure 3. Note: Floor mounting hardware must be determined
in accordance with applicable building codes. C&D does
not provide oor mounting hardware. SEE PAGE 7 & 8 FOR
LOCATION OF MULTI-RACK ARRANGEMENTS.
4. Initial Assembly: Anchor bolt washers (P/N RD05084 or
RD05100 for three tier racks) are supplied with the EP racks.
Each washer should be placed against the rack frame (see
Detail A). Place frames over the installed oor mounting
hardware, place the anchor bolt washers, and nger tighten
oor mounting hardware. All frames must face the same
direction. Install rear cross braces nger tight. See Figure 4
and Detail B. Do not install front cross braces at this time (if
required). Note: Cross bracing is used in all rear bays for EP1
racks (except for 2 step racks) and in all front and rear bays for
EP2 racks. Reference the rack assembly drawings included
in shipment for further details of the cross bracing pattern and
location for your specic rack model.
A
nchor Bolt
Washer
Anchor Bolt Washer Installation
Initial Assembly
Rear Cross Brace(s)
Frame
Frame and Cross
Brace Connection
See Detail B
Floor Mounting
Hardware
See Detail A
Note Frame
Orientation
Frame Upright
Cross Brace
1/2-13 Bolt, Lock
Washer and Nut
Brace to Frame
connection (Reverse View)
DETAIL A DETAIL B
FIGURE 3 FIGURE 4
RS02098/0114/CD 2 www.cdtechno.com
Rack Assembly Location
and Anchoring Hole Pattern
2.00" Typical Clearance Around
Existing Boundary
As Required Aisle
Clearance

5. Installing Support Rail(s): See Figure 5. Place support rail(s)
in location using supplied 3/8” bolt, washer, serrated strut nut
and nger tighten (see Detail C). Align support rails with “A”
dimension from rack assembly drawing (See Detail D) and
install rail covers. Note: An internal/external “star” washer is
used in place of the lock washer on the bottom tier or step for
grounding connection. Optional third rail should be installed at
this time.
For rack lengths greater than 20 ft, the rails come in two
sections and are to be joined with a rail splice kit (P/N
RE05149 (See Figure 6). The rail lengths have been sized
to ensure that the joint occurs near the middle of the span
between two frames.
ASSEMBLY INSTRUCTIONS FOR RDC STANDARD AND EP RACKS
6. Leveling: Check that the rack is level and square. Torque down
all bolts. First torque the cross brace bolts to 55-65 ft.-lb. [75-88
N-m], then torque the rail to frame bolts to 15-20 ft.-lbs [20-27
N-m]. Torque anchor bolts to manufacturer’s recommended
value.
This concludes the steps required to install a C&D Standard
Rack, please proceed to step 8 for cell installation or if you are
installing an EP Rack, continue on to step 7.
Rack Label Placement
"A"
"A"
See rack
assembly drawing
for "A" values
Support Rail Location
Support Rail
and Cover
3/8-16 Hex Bolt
Channel
Serrated Nut
Support Rail
and Cover
Rail Splice Kit
Assembled
(P/N RE05149)
Rail Splice Kit
FIGURE 5
DETAIL C
DETAIL D FIGURE 6
Rail covers are supplied in 3’ and 4’ lengths. Rail covers are to be placed end to end over the entire rail length.
RS02098/0114/CD 3 www.cdtechno.com
Support Rail Installation

ASSEMBLY INSTRUCTIONS FOR RDC STANDARD AND EP RACKS
7. EP Rack Assembly: Install all back restraint rail(s) and
cover(s). See Figure 7 and Detail E for hardware details.
Position front restraint rail and cover temporarily next to front
support rail prior to installing cells. See step 10 for information
on corner brackets.
If the battery row is shorter than the rack so that the end rail
falls within a frame, the corner bracket must be placed on the
side rail and slid within the frame (See Figure 10)
8. Cell Installation Procedure: Optional arrangement drawing
if ordered, should be reviewed for cell placement. If not
instructed otherwise, install cells starting at the center of the
bottom row and work out towards each end leaving a half
inch space between cells. For EP racks, use cell spacers
between cells as supplied (see Detail F). Do not use oil or
grease as lubricants. A small amount of water, unscented
talcum or Dow Corning III may be applied to the rail cover
to help reduce friction. For rows having an odd number of
batteries, the center of the rst battery installed will match
the center of the row. For rows having an even number of
batteries, a cell space will coincide with the center of the row.
Pay attention to polarities and terminal placement. Refer to
the battery’s Installation and Operating Instruction manual
(RS-1476) for more details. All cells mounted on seismic racks
should be pushed back against back restraint rail and cover.
Up to an 1/8” gap between the restraint rail and cell jar wall
is acceptable. Repeat this procedure for remaining steps and
tiers, working upward. See Figure 8.
FIGURE 7 FIGURE 8
DETAIL E DETAIL F
Back Restraint
and Cover
Frame
3/8-16 Bolt,
Lock Washer and
Serrated Nut
Frame and Restraint Rail(s)
(Reverse View)
Battery Units
Front Restraint
Rail and Cover
(loose)
RS02098/0114/CD 4 www.cdtechno.com
Support Rail
and Cover
Rail to Frame
Connection
See Detail C
Optional Third
Rail
Support Rail Installation
Cell Spacer

ASSEMBLY INSTRUCTIONS FOR RDC STANDARD AND EP RACKS
9. Front Restraint Rail (EP only): With the batteries in place,
slide the front side support rail and cover up from its resting
location to its mounting location, aligning with rear side
restraint rail. Install hardware and torque to 15-20 ft.-lbs.
[20-27 N-m] See Figure 9.
10. Final Assembly: Install corner brackets, end restraint rails,
and covers. Position end restraint rail against the end battery
unit. See Detail G. Note that the corner bracket may be
reversed by 180° if required. When the corner bracket
Corner Bracket
Location
Corner Bracket placement when
end restraint rails are within the frame
End Restraint
Rail and Cover
3/8-16 Hex Bolt
and Lock Washer
Side Restraint
Rail and Cover
Serrated Nut
Corner Bracket
Assembled
Side Restraint
Rail and Cover
Support Rail
and Cover
End Restraint
Rail and Cover
End Rail Restraint Rail(s)
and Corner Brackets
assembly is reversed, the end restraint rail is attached to the
opposite side of the corner bracket. When reversed the
corner bracket is able to slide inside the frame uprights
(See Detail H).
Install all front cross braces if indicated by rack assembly
drawing. Torque to 55-65 ft.-lbs. [75-80 N-m] See Figure 11
for nal rack assembly.
FIGURE 9 DETAIL G
FIGURE 10 DETAIL H
Front Restraint
Rails & Cover
Installed
End Rail Restraint and
Corner Bracket Reversed
End Restraint
Rail and Cover
3/8-16 Hex Bolt
and Lock Washer
Side Restraint
Rail and Cover
Serrated Nut
Corner Bracket
Assembled
Side Restraint
Rail and Cover
Support Rail
and Cover
End Restraint
Rail and Cover
End Rail Restraint Rail(s)
and Corner Bracket Reversed
RS02098/0114/CD 5 www.cdtechno.com

ASSEMBLY INSTRUCTIONS FOR RDC STANDARD AND EP RACKS
11. Tie Rod Assembly: Longer EP racks require a tie rod
assembly (see rack assembly drawings for details). The tie
rod assemblies (P/N RD02320) are to be placed as evenly
as possible among the batteries per tier (see gure 12 and
gure 13).
12. Battery Arrangement: Install inter-cell and inter-unit
connectors and cable assemblies as determined by the
battery arrangement. Refer to Battery Installation Manual
(RS-1476) for more detail on battery connection and
initialization charge. Follow Battery Installation Manual
RS-1476 for battery installation and operation.
Tie Rod
and Cover
Serrated Nut
3/8-16 Bolt
and Lock Washer
5/16-18 Nut
and Lock Washer
Tie Rod
Bracket
Side Restraint
Rails
Tie Rod Assembly
FIGURE 12
FIGURE 11
FIGURE 13
Assembled EP2 Rack
With Corner Brackets and Front Cross Braces
Tie Rod (P/N RD02320)
Tie Rod Placement
RS02098/1011/CD 6 www.cdtechno.com

Back to Back Assembly:
Where two rows of racks are required, two rack assemblies may be
installed back to back.
Frame Location:
Locate back to back frames relative to each other as shown in
Figure 14, such that the rear cross brace attachment holes align
for the two adjoining frames (The frames will be facing opposite
directions). All braces must be installed, as described previously,
except that a single bolt may be used to connect the front and
rear frames and respective cross braces. The ½-13 x 1.50” long
bolt supplied with the rack is to be replaced by a ½-13 x 2 ¼” long
(supplied with racks).
When placed back to back, there must be enough distance between
the frames to allow all of the braces (four total) to be installed. The
“X” distance between anchor bolt holes should be as noted in Table
1 (see Figure 15).
Two step standard racks placed back to back do not need to have
the frames bolted together. For 2 step EP1 racks a bolt assembly is
required (C&D part # REO5253 purchased separately). Contact C&D
for more details.
The EP racks have anchor bolt slots with a 1.06” x 0.69” (26.9 mm x
17.5 mm) for One Tier and Two Step rack models and a 1.06” x 0.81”
(26.9 mm x 20.6 mm) for Two Tier and Three Tier rack models.
The distance between the anchor bolt locations when the racks are
placed back to back is shown in Table 1 and Figure 15.
Note: There may be a de-rating of anchor bolt load ratings due to the
proximity of holes. Reference anchor bolt manufacturer’s data for
information.
ADDITIONAL INSTRUCTIONS FOR MULTI-RACK ARRANGEMENTS
Table 1
Front of Rack A
Front of Rack B
Back of
Racks A & B
Back to Back Assembly
Anchor Bolt
Center Distance
"X"
Anchor Bolt distance (center to center)
racks back to back
NOTE:
Anchor selection is determined by the anchor type, the diameter of the anchor, the depth of embedment
and anchor spacing. The selection of the anchor bolt must be reviewed by a structural engineer to ensure
that the racks will meet the seismic rating for the EP racks.
FIGURE 15
FIGURE 14
RDC Rack
Inches mm Inches mm
1 Tier 3.95 1004.32110
2 Tier 3.88 99 4.08 104
2 Step (Std & EP1)3.63925.67144
2 Step (EP2)4.01102 4.26 108
3 Tier (EP1)4.64118 3.88 99
3 Tier (EP2)4.26108 4.24 108
"X" Distance
See Figure 15
Anchor Bolt Distance
RS02098/1011/CD 7 www.cdtechno.com

Any data, descriptions or specications presented herein are subject to revision by C&D
Technologies, Inc. without notice. While such information is believed to be accurate as
indicated herein, C&D Technologies, Inc. makes no warranty and hereby disclaims all
warranties, express or implied, with regard to the accuracy or completeness of such
information. Further, because the product(s) featured herein may be used under conditions
beyond its control, C&D Technologies, Inc. hereby disclaims all warranties, either express or
implied, concerning the tness or suitability of such product(s) for any particular use or in any
specic application or arising from any course of dealing or usage of trade. The user is solely
responsible for determining the suitability of the product(s) featured herein for user’s intended
purpose and in user’s specic application.
Copyright 2014 C&D TECHNOLOGIES, INC. Printed in U.S.A. RS02098 0114/CD
1400 Union Meeting Road
P.O. Box 3053 • Blue Bell, PA 19422-0858
[phone] • Fax [phone] • [phone]
customersv[email protected]
www.cdtechno.com
End to End Rack Installation Instructions:
Where a continuous rack string is required, two racks may be
installed adjacent in length.
Frame Location:
End to end rack assemblies are installed as two individual, stand-
alone rack assemblies as shown. When installing standard racks,
there is no minimum clearance between racks (they can be abutted).
When installing EP racks the two racks must be spaced apart so that
the minimum distance between the ends of the restraint rails is 5”.
If the support rails are fully packed with cells, the end restraint rails
may extend beyond the support rails. In such an instance, the 5”
clearance dimension should be applied to the corner brackets.
See Figure 16.
RACK LABEL:
Place the IBC certication label (one (1) supplied with rack) on a
frame upright. Select a frame upright that is readily viewable. See
Figure 17.
TOUCH UP PAINT:
Touch up paint (C&D part number RH00289) is available through separate purchase. Contact C&D rep for more details.
ADDITIONAL INSTRUCTIONS FOR MULTI-RACK ARRANGEMENTS
FIGURE 16
End to End Installation
FIGURE 17
Rack Label Placement
End Rail within Support Rails End Rail beyond Support Rails