Schrack Technik USBB96A5D User manual

BATTERY INSTALLATION MANUAL
Battery Box
Models: USBB96A5D USBB96M1D
USBB96M4D USBB180A3D USBB240A3D
Series GENIO Dual Power (USSD..)

2
Inhalt
BATTERIES INSTALLATION 3
TYPE OF BATTERIES REQUIRED 3
BATTERY BOX OPENING 4
BATTERY INSERTION 6
BATTERY BOX 96A5D (8 BATTERIES) 6
BATTERY BOX 96M1D/96M4D (8+8 BATTERIES CONNECTED IN PARALLEL) 8
BATTERY BOX 180A3 (15 BATTERIES) 10
BATTERY BOX 240A3D/240A5H (20 BATTERIES) 12
LABELING 14
BATTERY BOX 14
WIRING DIAGRAM 15
BATTERY BOX 96A5D (8 BATTERIES) 15
BATTERY BOX 96M1D/96M4D (8+8 BATTERIES) 16
BATTERY BOX 180A3D 17
BATTERY BOX 240A3D/A3H 18
TESTING 19
SAFETY TEST 19

3
BATTERIES INSTALLATION
This charter describes the procedure to be followed to install the batteries in the BATTERY BOX.
WARNING: in order to guarantee your safety and your product, please follow the instructions given below very
carefully.
MAKE SURE THAT THE BATTERY BOX IS DISCONNECTED FROM
THE UPS BEFORE PERFORMING THE FOLLOWING SEQUENCE OF
OPERATIONS
The Manufacturer shall not be held responsible for any damage caused by incorrect connections or by operations that are
not described in this manual
The electrical specifications of the BATTERY BOX are shown on the data plate attached to the rear of the apparatus.
TYPE OF BATTERIES REQUIRED
The BATTERY BOX has been designed to operate with the following types of batteries:
Models USBB96…-
•A5D / 9Ah Version: n° 8 batteries 12Vdc 9Ah
•M1D / 14Ah Version: n° 8+8 batteries 12Vdc 7Ah (connected in parallel)
•M4D / 18Ah Version: n° 8+8 batteries 12Vdc 9Ah (connected in parallel)
Models USBB180…-
•A3D / 7Ah Version: n° 15 batteries 12Vdc 7Ah
Models USBB240…-
•A3D / 7Ah Version: n° 20 batteries 12Vdc 7Ah
•A5H / 9Ah Version: n° 20 batteries 12Vdc 9Ah (only if the Battery Box is coupled with UPS)*
*in this case the UPS and the Battery Box have the same S/N

4
BATTERY BOX OPENING
1. Open the package and place the BATTERY BOX on a horizontal plane.
2. Unhook the plastic front panel and remove the screw of the top cover.
3. Remove the 4 fixing screws of the top cover in the rear panel of the Battery Box.
4. Remove the 11 fixing screws of the top cover in the sides of the Battery Box.
5. Push the cover toward the back of the Battery Box and remove it.

5
6. Remove the two plastic shells marked with the code.

6
BATTERY INSERTION
BATTERY BOX 96A5D (8 BATTERIES)
1. Apply the adhesive foam on each side (left and right) of the 5 batteries that will installed in the central raws.
2. Place the batteries on the plastic housings as shown in the picture below.
3. Place the separating sheets as shown in the picture below.
4. Using the supplied wirings, connect the batteries following the wiring diagram in this manual.
5. Taking care to place the wiring in an orderly way, place the plastic shells to complete the battery packs.
ADHESIVE
FOAM
ADHESIVE
FOAM
ADHESIVE
FOAM
PLASTIC
SEPARATOR
DUMMY
BATTERY

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6. Replace the cover of the Battery Box and secure it with the screws.
7. Polarize the battery expansion sockets placed on the rear part of the battery box. Remove the indicated pin
from the socket following the instruction in the diagram below.
➔
8. Polarize the plugs of the battery expansion cable provided with the battery box. Insert no. 1 plastic pin
(accessory of the battery box) in the indicated hole following the instruction in the diagram below.
➔

8
BATTERY BOX 96M1D/96M4D (8+8 BATTERIES CONNECTED IN PARALLEL)
1. Apply the adhesive foam on each side (left and right) of the 5 batteries that will installed in the central raws.
2. Place the batteries on the plastic housings as shown in the picture below.
3. Place the separating sheets as shown in the picture below.
4. Using the supplied wirings, connect the batteries following the wiring diagram in this manual.
5. Taking care to place the wiring in an orderly way, place the plastic shells to complete the battery packs.
6. Replace the cover of the Battery Box and secure it with the screws.
ADHESIVE
FOAM
ADHESIVE
FOAM
ADHESIVE
FOAM
PLASTIC
SEPARATOR
DUMMY
BATTERY
ADHESIVE
FOAM
DUMMY
BATTERY

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7. Polarize the battery expansion sockets placed on the rear part of the battery box. Remove the indicated pin
from the socket following the instruction in the diagram below.
➔
8. Polarize the plugs of the battery expansion cable provided with the battery box. Insert no. 1 plastic pin
(accessory of the battery box) in the indicated hole following the instruction in the diagram below.
➔

10
BATTERY BOX 180A3 (15 BATTERIES)
1. Apply the adhesive foam on each side (left and right) of the 5 batteries that will installed in the central raws.
2. Place the batteries on the plastic housings as shown in the picture below.
3. Place the separating sheets as shown in the picture below.
4. Using the supplied wirings, connect the batteries following the wiring diagram in this manual.
5. Taking care to place the wiring in an orderly way, place the plastic shells to complete the battery packs.
6. Replace the cover of the Battery Box and secure it with the screws.
ADHESIVE
FOAM
ADHESIVE
FOAM
PLASTIC
SEPARATOR
ADHESIVE
FOAM
ADHESIVE
FOAM

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7. Polarize the battery expansion sockets placed on the rear part of the battery box. Remove the indicated pins
from the socket following the instruction in the diagram below.
➔
8. Polarize the plugs of the battery expansion cable provided with the battery box. Insert the 4 plastic pins
(accessory of the battery box) in the indicated holes following the instruction in the diagram below.
➔

12
BATTERY BOX 240A3D/240A5H (20 BATTERIES)
1. Apply the adhesive foam on each side (left and right) of the 6 batteries that will installed in the central raws.
2. Place the batteries on the plastic housings as shown in the picture below.
3. Using the supplied wirings, connect the batteries following the wiring diagram in this manual.
4. Taking care to place the wiring in an orderly way, place the plastic shells to complete the battery packs.
5. Replace the cover of the Battery Box and secure it with the screws.
ADHESIVE
FOAM
ADHESIVE
FOAM
ADHESIVE
FOAM
ADHESIVE
FOAM

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6. Polarize the battery expansion sockets placed on the rear part of the battery box. Remove the indicated pins
from the socket following the instruction in the diagram below.
➔
7. Polarize the plugs of the battery expansion cable provided with the battery box. Insert the 4 plastic pins
(accessory of the battery box) in the indicated holes following the instruction in the diagram below.
➔

14
LABELING
BATTERY BOX
1. On the rear panel of the Battery Box apply the labels present inside the accessory kit:
•For Battery Box 96Vdc, use the kit labels marked with 0EAU0908
•For Battery Box 180Vdc, use the kit labels marked with 0EAU0827
•For Battery Box 240Vdc, use the kit labels marked with 0EAU0828
2. On the “technical data label” (silver label), apply the label with the data of the batteries installed in the field
“BATTERY”. Follow the example below:
NEW LABEL TO APPLY ON TECHNICAL DATA LABEL
TECHNICAL DATA LABEL

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WIRING DIAGRAM
BATTERY BOX 96A5D (8 BATTERIES)

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BATTERY BOX 96M1D/96M4D (8+8 BATTERIES)

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BATTERY BOX 180A3D

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BATTERY BOX 240A3D/A3H

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TESTING
Safety standards: The Battery Box carries a high risk of electric shock and a high short-
circuit current, the instructions below should be followed precisely.
Measuring instruments: 1 Multimeter to measure the direct voltage with a scale of 400V
with 0,08% read accuracy + 100mV (E. g. ASITA MD800)
Insert the fuses in the fuseholders SWBATT and close them.
Measure the voltage and check the right polarity on the Battery Extension connectors.
It is suggested to connect the Battery Extension cable to the socket and measure the voltage on the
other side of the cable.
•For Battery Box 96Vdc: the admitted range is from +94Vdc to +104Vdc
•For Battery Box 180Vdc: the admitted range is from +176Vdc to +200Vdc
•For Battery Box 240Vdc: the admitted range is from +235Vdc to +265Vdc
Remove the fuses and the cable.
SAFETY TEST
The tests described below should be carried out after reassembling the covers and closing the
BATTERY BOX. All the operations described must be performed with the BATTERY BOX
electrically disconnected from the mains and from any other equipment.
EQUIPMENT REQUIRED
Measuring instruments: ●a ground resistance measuring instrument with probe electrodes (characteristics:
12Vac no load, 25A AC for short circuit).
For example, the RS28 made by ELEKTROTECHN LABORATORIUM or similar.
●instrument for rigidity tests (characteristics: 1500Vac no load, 100mA for short
circuit).
For example, the UH28M made by ELEKTROTECHN LABORATORIUM or similar.
MEASURING GROUND CONTACT RESISTANCE (ESSENTIAL FOR SAFETY)
Connect an electrode of the “RS 28” generator to one of the ground poles on one of the two expansion sockets of the
BATTERY BOX. Apply the test current through the other probe electrode to all the different parts of themetal casing. Ground
continuity must also be tested on the ground pole present on the battery charger mains plug. The ground resistance reading
must be 0.1 Ohm. Before performing tests on enamelled casings, perforate the enamel coating with the prod and then
proceed with the test.
RIGIDITY TESTS (ESSENTIAL FOR SAFETY)
Close the battery fuse holders. Using the “UH28M” instrument, apply the test potential (1500Vac between the ground pole
and the neutral pole (-) present on one of the BATTERY BOX expansion sockets for ≥ 5 sec.

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Check that the leakage current is < 10mA and that there are no discharges to the metal casing.
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_USBB180A3D_USBB240A3D_EN_2021_08_19_0MNADSDU001ENIC.docx
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