Toshiba 1600XPi SERIES User manual

1600XPi SERIES
8-22kVA BATTERY CABINET
INSTALLATION AND OPERATION MANUAL
SINGLE PHASE –8/10/14/18/22 kVA: 288Vdc
Part# 64024-006
November 2019

1600XPi Series Battery Cabinet Installation and Operation Manual 64024-006
IMPORTANT NOTICE
The instructions contained in this manual are not intended to cover all of the details or variations
in equipment, or to provide for every possible contingency to be met in connection with installation,
operation, or maintenance. Should further information be desired or particular problems arise which
are not covered sufficiently for the purchaser's purposes, the matter should be referred to the local
Toshiba sales office.
The contents of this instruction manual shall not become a part of or modify any prior or existing
agreement, commitment, or relationship. The sales contract contains the entire obligation of Toshiba
International Corporation's UPS Division. The warranty contained in the contract between the parties
is the sole warranty of Toshiba International Corporation's UPS Division and any statements
contained herein do not create new warranties or modify the existing warranty.
Any electrical or mechanical modifications to this equipment, without prior written
consent of Toshiba International Corporation, will void all warranties and may void UL/CUL
listing. Unauthorized modifications also can result in personal injury, death, or destruction of
the equipment.
UNINTERRUPTIBLE POWER SYSTEM -
BATTERY CABINET SYSTEM
If additional information or technical assistance is required call Toshiba’s Customer Support Center toll free at 1-
877-867-8773 or write to: Toshiba International Corporation, 13131 W. Little York Rd., Houston, TX 77041-9990.
Please complete the following information for your records and keep this manual with the equipment:
Model Number:
Serial Number:
Date of Installation:
Inspected By:

1600XPi Series Battery Cabinet Installation and Operation Manual 64024-006 i
Table of Contents
LIST OF FIGURES ............................................................................................................................................................................II
LIST OF TABLES..............................................................................................................................................................................II
GENERAL SAFETY INSTRUCTIONS...................................................................................................................................................1
IMPORTANT SAFETY INSTRUCTIONS ..............................................................................................................................................2
IMPORTANT BATTERY SAFETY INSTRUCTIONS ...............................................................................................................................3
1.0 INSPECTION / STORAGE / DISPOSAL ...................................................................................................................................5
1.1 INSPECTION OF THE NEW BATTERY SYSTEM..........................................................................................................................................5
1.2 STORAGE OF BATTERY EQUIPMENT.....................................................................................................................................................5
1.3 DISPOSAL ......................................................................................................................................................................................5
2.0 PRECAUTIONS ....................................................................................................................................................................6
2.1 INSTALLATION PRECAUTIONS .............................................................................................................................................................6
2.2 PRESTART PRECAUTIONS ..................................................................................................................................................................6
2.3 OPERATING PRECAUTIONS ................................................................................................................................................................7
3.0 UPS POWER CONNECTIONS................................................................................................................................................7
3.1 UPS INPUT VOLTAGE.......................................................................................................................................................................7
3.2 CONNECTING MULTIPLE BATTERY CABINETS.........................................................................................................................................7
3.3 BATTERY CABINET POWER CABLING....................................................................................................................................................8
3.4 BATTERY CABINET COMMUNICATION (RS-232) CABLING.......................................................................................................................8
4.0 CONNECTION INSTRUCTIONS AND DIAGRAMS ...................................................................................................................9
4.1 BATTERY CONNECTIONS ...................................................................................................................................................................9
4.2 CABLE UPS TO BATTERY CABINET(S) ................................................................................................................................................10
4.3 CHARGER CONNECTION NOTE .........................................................................................................................................................11
5ENABLE UPS EXTERNAL BATTERY PARAMETERS....................................................................................................................11
6.0 REMOTE ON/OFF..............................................................................................................................................................11
6.1 REMOTE ON/ OFF (FIGURE 2)........................................................................................................................................................11
6.2 EPO OPERATION ..........................................................................................................................................................................11
7.0 EMERGENCY POWER OFF (EPO)........................................................................................................................................12
7.1 EPO CABLING ..............................................................................................................................................................................12
7.2 EPO OPERATION ..........................................................................................................................................................................12
8.0 PREVENTIVE AND SCHEDULED MAINTENANCE / PART REPLACEMENT............................................................................... 12
8.1 PREVENTIVE MAINTENANCE ............................................................................................................................................................12
8.2 PARTS REPLACEMENT ....................................................................................................................................................................12
8.3 POWER CABLES ............................................................................................................................................................................13
9BATTERY REPLACEMENT ......................................................................................................................................................13
9.1 HOT-SWAPPABLE..........................................................................................................................................................................13
9.0 EXTERNAL LAYOUTS / DIMENSIONS / SHIPPING WEIGHTS ................................................................................................15
9.1 EXTERNAL LAYOUTS.......................................................................................................................................................................15
9.2 DIMENSIONS ................................................................................................................................................................................15
9.3 SHIPPING WEIGHTS .......................................................................................................................................................................15

ii 1600XPi Series Battery Cabinet Installation and Operation Manual 64024-006
10.0 1600XPI SYSTEM BACKUP RUNTIME .................................................................................................................................16
List of Figures
Figure 1 UPS Power Connections.........................................................................................................................................7
Figure 2 RS232 Plugs on Battery Cabinet.............................................................................................................................8
Figure 3 Cabling 8/10kVA UPS to Battery Cabinet(s) ...........................................................................................................8
Figure 4 Cabling 14/18/22kVA UPS to Battery Cabinet.........................................................................................................9
Figure 5 Cabling 8/10kVA UPS to Battery Cabinet..............................................................................................................10
List of Tables
Table 1 Battery Pack Information...........................................................................................................................................2
Table 2 Battery Type and Quantity ........................................................................................................................................4
Table 3 UPS-Battery Cabinet Compatability Chart................................................................................................................6
Table 4 1600XPi Parameter Settings for H3B-BC-1825......................................................................................................11
Table 5 Field Service Replaceable Parts.............................................................................................................................13
Table 6 Battery Cabinet Dimensions ...................................................................................................................................15
Table 7 Battery Cabinet Shipping Weight............................................................................................................................15

1600XPi Series Battery Cabinet Installation and Operation Manual 64024-006 1
GENERAL SAFETY INSTRUCTIONS
Warnings in this manual appear in any of four ways:
1) Danger- The danger symbol is a lightning bolt mark enclosed in a triangle which precedes the 3/16-inch high
letters spelling the word “DANGER”. The danger symbol is used to indicate imminently hazardous situations,
locations, and conditions which, if not avoided, WILL result in death, serious injury, and/or severe property
damage.
DANGER
2) Warning- The warning symbol is an exclamation mark in a triangle which precedes the 3/16-inch high letters
spelling the word “WARNING”. The warning symbol is used to indicate potentially hazardous situations and
conditions which, if not avoided COULD result in serious injury or death. Severe property damage COULD
also occur.
WARNING
3) Caution- The caution symbol is an exclamation mark enclosed in a triangle which precedes the 3/16-inch high
letters spelling the word “CAUTION”. The caution symbol is used to indicate potentially hazardous situations
and conditions which, if not avoided may result in injury. Equipment damage may also occur.
CAUTION
4) Attention warnings- The attention warning symbol is an exclamation mark enclosed in a triangle which
precedes the 3/16-inch high letters spelling the word “ATTENTION”. The Attention warning symbol is used to
indicate situations and conditions that can cause operator injury and/or equipment damage.
ATTENTION
Other warning symbols may appear along with the Danger and Caution symbol and are used to specify special hazards.
These warnings describe particular areas where special care and/or procedures are required in order to prevent serious
injury and possible death:
1) Electrical warnings- The electrical warning symbol is a lighting bolt mark enclosed in a triangle. The Electrical
warning symbol is used to indicate high voltage locations and conditions that may cause serious injury or
death if the proper precautions are not observed:
2) Explosion warnings- The explosion warning symbol is an explosion mark enclosed in a triangle. The
Explosion warning symbol is used to indicate locations and conditions where molten, exploding parts may
cause serious injury or death if the proper precautions are not observed:

2 1600XPi Series Battery Cabinet Installation and Operation Manual 64024-006
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important instructions that should be followed during installation and maintenance of the Battery
System model H3B-BC-1825.
The maximum ambient temperature in which a Battery System should be operated is 104 °F (40 °C).
The nominal battery voltage for the battery cabinet is as follows:
Model
Voltage
H3B-BC-1825
288 VDC
Table 1 Battery Pack Information
Battery Pack Data
Battery Packs
Designed for battery acid leakage containment with (6) batteries per pack.
Battery Pack Size
HxWxD (max)
5 in. (127 mm) x 7.3 in. (185 mm) x 18.2 in. (462 mm)
Battery Pack Quantity
12
Battery Type
Lead Acid 9A/12V (FR)
Toshiba Part Number for
Battery Pack
51896-FS
Battery Pack
Construction
Battery pack case is ABS plastic No. 7
CAUTION
Misuse of this equipment could result in human injury and equipment damage. In no
event will Toshiba Corporation be responsible or liable for
either indirect or consequential damage or injury that may result from the misuse of this
equipment.
CAUTION
Do not dispose of the batteries in a fire. The batteries may explode.
CAUTION
Do not open or mutilate the batteries. Released electrolyte is harmful to the eyes and
skin and could also be toxic.
WARNING
This unit contains sealed lead acid batteries. Lack of preventative maintenance could
result in batteries exploding and emitting gasses
and/or flame. An authorized, trained technician must perform annual preventative
maintenance.
WARNING
Failure to replace a battery before it becomes exhausted may cause the case to crack,
possibly releasing electrolytes from inside the battery, and
resulting in secondary faults such as odor, smoke, and fire.
WARNING
Installation and servicing of batteries should be performed by personnel knowledgeable
of batteries and the required precautions. Keep unauthorized personnel away from the
batteries.

1600XPi Series Battery Cabinet Installation and Operation Manual 64024-006 3
IMPORTANT BATTERY SAFETY INSTRUCTIONS
WARNING
Proper maintenance to the battery system of this unit must be done by a qualified
service technician. This is essential to the safety and reliability of
of your UPS system. Refer to service manual.
DANGER
A battery can present a risk of electrical shock and high short
circuit current.
The following precautions should be observed
when working with batteries.
1)
Verify that the UPS is off and that the power cord is disconnected from the power source.
2)
Remove watches, rings or other metal objects.
3)
Use tools with insulated handles to prevent inadvertent shorts.
4)
Wear rubber gloves and boots.
5)
Do not lay tools or metal parts on top of batteries.
6)
Determine if the battery is inadvertently grounded. If inadvertently grounded, remove
source of ground.
Contact with any part of a grounded battery can result in
electrical shock.
The likelihood of such shock will be reduced if such grounds are
removed during installation and maintenance.
7)
Verify circuit polarities prior to making connections.
8)
Disconnect charging source and load prior to connecting or disconnecting terminals.
9)
VRLA batteries may emit highly flammable hydrogen gas. During charging and operation. Do not smoke, cause
a flame
or spark in the immediate area of the batteries. This includes static electricity from the body.
10
)
Do not attempt to open the batteries in order to add water or sample the specific gravity of the
electrolyte. The batteries are valve regulated lead acid type and such servicing is not possible
without damaging the battery.
11
)
Use proper lifting means when moving batteries and wear all appropriate safety clothing and
equipment.
12
)
Do not dispose of lead acid batteries except through channels in accordance with local, state
and federal regulations.

4 1600XPi Series Battery Cabinet Installation and Operation Manual 64024-006
INSTRUCTIONS IMPORTANTES CONCERNANT LA
SÉCURITÉ
CONSERVER CES INSTRUCTIONS
Cette notice contient des
instructions importantes
concernant la sécurté
ATTENTION
Un battery puet présenter un risque de choc électrique, de brûlure
par transfert d’ énergie.
ATTENTION
Por le replacement, utiliser le même nombre de batteries du modéle
suivant.
Table 2 Battery Type and Quantity
Model Capacity
Type
Battery Pack
Quantity
Battery Quantity
H3B-BC-1825
Lead Acid 9AH/12V (FR)
12
72
ATTENTION
L’élimination des batteries est règlementèe. Consultar les codes
locaux à cet effet.

1600XPi Series Battery Cabinet Installation and Operation Manual 64024-006 5
1.0 Inspection / Storage / Disposal
1.1 Inspection of the New Battery System
Upon receipt of the Battery System, a careful inspection for shipping damage should be made.
1) Check the unit for loose, broken, bent or otherwise damaged parts. If damage has occurred during
shipment, keep all original crating and packing materials for return to the shipping agent. The
equipment warranty will not apply to units which are damaged during shipment.
2) Check to see that the rated capacity and the model number specified on the nameplate conform to
the order specifications.
1.2 Storage of Battery Equipment
If the Battery System is to be subjected to long or short term storage, the following guidelines should be
used.
Avoid:
1) Storage in sites subject to extreme changes in temperature or high humidity.
2) Storage in sites subject to exposure of high levels of dust or metal particles.
3) Storage on inclined floor surfaces or in sites subject to excessive vibration.
Before storing:
1) Charge the system's batteries.
2) Place the Battery System’s input switch (MCCB-C) in the OFF position.
Storing:
1) Store within a temperature range of -4 to 104 °F (-20 to 40 °C).
2) For best results, store the Battery System in the original shipping container and place on a wood or
metal pallet.
3) The optimum storage temperature is 70 °F (21 °C). Higher ambient temperatures cause UPS
batteries to need recharging more frequently.
4) If stored in an ambient temperature under 68 °F (20 °C); recharge the batteries every 9 months.
5) If stored in an ambient temperature of 68 to 86 °F (20 to 30 °C); recharge the batteries every 6
months.
6) If stored in an ambient temperature of 86 to 104 °F (30 to 40 °C); recharge the batteries every 3
months.
1.3 Disposal
Please contact your state environmental agency for details on disposal of electrical components and
packaging in your particular area.
It is illegal to dump lead-acid batteries in landfills or dispose of improperly. Please help our Earth by
contacting the environmental protection agencies in your area, the battery manufacturer, or call Toshiba
toll-free at [phone] for more information about recycling.

6 1600XPi Series Battery Cabinet Installation and Operation Manual 64024-006
2.0 Precautions
2.1 Installation Precautions
1) Install the unit in a well ventilated location; allow at least 10 cm (4 inches) on
all sides for air ventilation and maintenance.
2) Install the unit in a stable, level, and upright position, which is free of vibration.
3) Install the unit where the ambient temperature is within the correct operating
range.
4) Do not install the Battery System in a location that is subject to high humidity.
5) Do not install the unit at sites that are exposed to direct sunlight.
6) Do not install the Battery System in areas which are subject to high levels of
contamination by airborne dust, metal particles, or flammable gases.
7) Avoid installation near sources of electrical noise. Always make sure that the
unit ground is intact to prevent electrical shock and to help reduce electrical
noise.
8) Do not install where water or any foreign objects/substances may get inside
the Battery System.
2.2 Prestart Precautions
1) Before connecting the Battery System to the UPS verify that the two are compatible by comparing them
to the following chart.
Table 3 UPS-Battery Cabinet Compatability Chart
UPS Model Number
Battery Cabinet Model Number
Battery Voltage
H3BG2L080C61T
H3B-BC-1825
288VDC
H3BG2L100C61T
H3BG2L140C61T
H3BG2L180C61T
H3BG2L220C61T
WARNING
DO NOT attempt to connect if the Model numbers do
not match the above chart. This will result in damage
to the UPS, the Battery System, or both. Call your
Toshiba representative if you should have any
questions.
2) Before connecting the Battery System to the UPS; switch the ON/OFF switch MCCB2, located on the
rear panel of the battery system to the OFF position. (See Sections 4 & 5)

1600XPi Series Battery Cabinet Installation and Operation Manual 64024-006 7
2.3 Operating Precautions
1) The UPS should not be powered up until the entire operation manual has been reviewed.
3.0 UPS Power Connections
The following illustration shows the wiring connections from the power distribution panel (not part of the
UPS) to the UPS, and from the UPS to the battery cabinet. This connection diagram is to be used with the
H3B-BC-1825 Battery Units (Hereafter known as BC-1825).
Figure 1 UPS Power Connections
3.1 UPS Input Voltage
208V In: If the UPS AC input power is 208 V rated, connect a jumper wire between terminals 11 and 12 on
the UPS terminal block. DO NOT jumper terminal 13 to 11 or 12. The UPS ships from the factory with the
jumper in the 208 V position.
240 V In: If the UPS AC input power is 240 V rated, connect a jumper wire between terminals 12 and 13
on the UPS terminal block. DO NOT jumper terminal 11 to 12 or 13.
3.2 Connecting Multiple Battery Cabinets
Up to two (2) BC-1825 battery cabinets may be connected in parallel with the UPS. See Figure 3, and
Sections 4 and 5.

8 1600XPi Series Battery Cabinet Installation and Operation Manual 64024-006
3.3 Battery Cabinet Power Cabling
The battery cabinets ship with six-foot long connection cables. Contact Toshiba Customer Support at 1-
877-867-8773 if longer cables are required for your application, or if additional cables or connectors are
required.
3.4 Battery Cabinet Communication (RS-232) Cabling
The 1600XPi BC-1825 can be remotely monitored by the UPS by connecting the UPS RS-232 port to the
BC-1825(s) as shown below.
There is also a provision for adding an external remote shutdown.
BC-1825 BC-1825 External Control –Detail
Figure 2 RS232 Plugs on Battery Cabinet
Figure 3 Cabling 8/10kVA UPS to Battery Cabinet(s)
CN22
CN23
CN24
CN22
CN23
CN24
RS232C
REMOTE
CONTACTS

1600XPi Series Battery Cabinet Installation and Operation Manual 64024-006 9
4.0 Connection Instructions and Diagrams
4.1 Battery Connections
The following illustration shows the wiring connections between the UPS and the battery cabinet.
DANGER Contacts are not rated with interrupting capacity. Ensure the MCCB
switch on the rear panel of the Battery Unit is set to the OFF position before connecting the
UPS to the battery cabinet.
The following diagrams shows the rear view of the 8/10kVA and 14/18/22 kVA UPS with a BC-1825 battery
cabinet. NOTE: Use only compatible cabinets! See page 6.
1600XPi 14/18/22 kVA UPS BC-1825 BATTERY CABINET
Figure 4 Cabling 14/18/22kVA UPS to Battery Cabinet
CN22
CN23
CN24

10 1600XPi Series Battery Cabinet Installation and Operation Manual 64024-006
1600XPi 8/10 kVA UPS BC-1825 BATTERY CABINET
Figure 5 Cabling 8/10kVA UPS to Battery Cabinet
4.2 Cable UPS to Battery Cabinet(s)
Connect up to two (2) battery cabinets to the UPS as shown in Figure 3 and Figure 4.
1. Ensure all power is locked and tagged out.
2. Remove the battery connector cover mounted on the UPS back panel.
To connect the first battery cabinet to the UPS
3. Connect the RS232 cable from the Battery Cabinet 1 RS232 to UPS/BC port to the UPS RS232C port.
(Figure 3)
4. Connect Battery Cabinet 1 CN12A to UPS CN12,
5. Connect Battery Cabinet 1 CN13A to UPS CN13,
6. Connect Battery Cabinet 1 CN14A to UPS CN14.
If a second battery cabinet is to be installed go to step 7, otherwise go to Section 4.3.
7. Connect the RS232 cable from the Battery Cabinet 2 RS232 to UPS/BC port to the Battery Cabinet 1
RS232 to BC port.(Figure 3)
8. Connect Battery Cabinet 2 CN12A to cabinet 1 CN22,
9. Connect Battery Cabinet 2 CN13A to cabinet 1 CN23,
10. Connect Battery Cabinet 2 CN14A to cabinet 1 CN24.
CN22
CN23
CN24

1600XPi Series Battery Cabinet Installation and Operation Manual 64024-006 11
4.3 Charger Connection Note
The Battery cabinet model BC-1825 requires a 240 Vac connection between the UPS and battery cabinet
for battery charging. This connection is made from CN14A of the battery cabinet to CN14 of the UPS (and
CN14A of battery cabinet 2 to CN24 of battery cabinet 1 if paralleling cabinets). NOTE: Without this
connection the battery cabinet will not be able to charge its batteries.
5 Enable UPS External Battery Parameters
Set the UPS external battery parameters 222 and 223 to enable battery string monitoring of the external
battery cabinet(s).
1. Power on the UPS and Battery Cabinet(s).
2. Follow the instructions in the 1600XPi manual, 60616, to log in as Administrator.
3. Press the SETTING tab, then press Batt on the touchscreen.
4. Use the <<, <, >, and >> buttons to navigate to the parameters 522, 523, and 525-527. Entering
parameters 528 and 529 is optional (See Table 1 below).
5. Touch the parameter on the touchscreen to select it for editing. See the UPS manual 60616. Set per the
following table.
Table 4 1600XPi Parameter Settings for H3B-BC-1825
Parameter
Description
UPS
Only
UPS +
1 BC1
UPS +
2 BC1
522 Enable BC1
Enable External Batt. Cabinet 1
Disable
Enable
Enable
523 Enable BC2
Enable External Batt. Cabinet 2)
Disable
Disable
Enable
524 External BC Status
External Battery Cabinet Status
0
1
1
525 No Ex Batt(Series)
Number of External Batt. Packs in Series String
0
24
24
526 No Ex Batt(Paral)
Number of External Batt. Strings in Parallel
0
3
6
527 Ex Batt Rated Ahr
External Battery Capacity in A-hr
0
9
9
528Ex Batt C Rate 1
External Battery Cabinet Charge/Discharge
Rate
0
2
2
529 Ex Batt Ins Date 1
External Battery Installation Date
(e.g YYYMMDD)
N/A
YYYYMMDD
YYYYMMDD
1 –Parameter is informational only. Value is not used in calculations
6. Model BC-1825 requires a 240 Vac connection between the UPS and battery cabinet for battery charging.
This connection is made from CN14A of the battery cabinet to CN14 of the UPS (and CN14A of battery
cabinet 2 to CN24 of battery cabinet 1 if paralleling cabinets). NOTE: Without this connection the
battery cabinet will not be able to charge its batteries.
6.0 Remote ON/OFF
6.1 Remote ON/ OFF (Figure 2)
The Battery Cabinet does not have an EPO. The EPO on the UPS connects to the battery cabinet through
the battery cabinet connection cable between CN14 and CN14A. No other battery cabinet connection is
needed.
6.2 EPO Operation
Pressing the EPO will cause the breaker on the battery cabinet and the UPS, to switch to the OFF position
simultaneously, disabling both the battery cabinet and the UPS.

12 1600XPi Series Battery Cabinet Installation and Operation Manual 64024-006
The DC breaker on the battery cabinet is provided with a shunt trip. This device is operated with an applied
voltage of 120 Vac (supplied from the UPS). When the EPO is pressed the UPS applies 120V to the
shunt trip, causing the breaker to switch to the OFF position.
7.0 Emergency Power Off (EPO)
7.1 EPO Cabling
The Battery Cabinet does not have an EPO. The EPO on the UPS connects to the battery cabinet through
the battery cabinet connection cable between CN14 and CN14A. No other battery cabinet connection is
needed.
7.2 EPO Operation
Pressing the EPO will cause the breaker on the battery cabinet and the UPS, to switch to the OFF position
simultaneously, disabling both the battery cabinet and the UPS.
The DC breaker on the battery cabinet is provided with a shunt trip. This device is operated with an applied
voltage of 120 Vac (supplied from the UPS). When the EPO is pressed the UPS applies 120V to the
shunt trip, causing the breaker to switch to the OFF position.
8.0 Preventive and Scheduled Maintenance / Part Replacement
8.1 Preventive Maintenance
Toshiba's 1600XPi Series of UPS battery cabinets have been designed to provide years of trouble-free
operation requiring a minimum of preventive maintenance.
The best preventive measure that the battery cabinet user can take is to keep the area around the unit,
particularly the air inlet vents, clean and free of moisture and dust accumulations. If the atmosphere of the
installation site is very dusty, use a vacuum cleaner to periodically remove dust accumulations from the air
inlet vents. Schedule authorized service centers to perform internal parts inspections annually.
CAUTION
Before performing any maintenance, the technician should become
familiar with and follow the important safety instructions on pages 1–4.
WARNING
Proper maintenance of the battery system of this unit by factory authorized
personnel is essential to the safety and reliability of your battery cabinet
system. Refer to service manual.
8.2 Parts Replacement
The following list shows intervals for periodic maintenance and replacement of certain UPS parts.
Batteries: VRLA batteries are maintenance free with respect to electrolyte only. The charging
voltage, temperature, performance and connection resistance must be checked periodically.
Necessary corrective actions must be made in order to assure safe reliable power is supplied by
the battery cabinet. Charging voltage, storage/operating temperature, charging cycles, and
connection resistance all affect battery life.
The recommended battery replacement interval is 3 to 5 years. All of the batteries must be
replaced at the same time.
Monthly Maintenance
A. Visual Checks:
1. Leakage
2. Corrosion on positive terminal
B. Check battery temperature at the negative terminal.

1600XPi Series Battery Cabinet Installation and Operation Manual 64024-006 13
C. Measure and record the system float charging voltage.
D. Measure and record the individual unit’s battery tray voltage.
Semi-Annual maintenance
A. Repeat the monthly checks.
B. Perform a 10-second high rate (e.g. 100 amp) load test on the individual batteries.
C. Re-torque all inter-battery connecting hardware (if applicable).
D. Perform inter-battery connector resistance checks.
Table 5 Field Service Replaceable Parts
Component*
Function
Rating
Part No.
FU1, FU2
Control Power Fuses
500 V, 10 A
00649
Battery Tray Fuse
Internal Battery tray Fuse
500 V, 40 A
00637
Battery Pack
Replaceable Battery Pack
-
51896-FS
* Field Service replaceable parts only.
8.3 Power Cables
The three battery cabinet connector cables (battery positive, battery negative, and battery charger) are
each equipped with individually keyed Anderson connectors to prevent cross connecting the battery cabinet
and UPS circuitry.
The battery cabinet connector cables are six (6) foot in length.
9 Battery Replacement
9.1 Hot-Swappable
The battery packs can be replaced while the UPS is in On-Line or Bypass mode without removing power from the critical
loads.
CAUTION
If a power failure occurs as the battery pack is being removed/inserted or
occurs during the period batteries are out of the circuit, the unit will try to go to
Backup (without battery) and would thus drop the load. It would also arc/spark
between the battery and chassis connections if going to Backup as the tray is
pulled.
To perform a hot swap of the battery packs:
1. Open the 1600XPi Battery Cabinet front door.
2. Loosen the battery retaining plate screws and remove the battery pack retaining plate(s).
CAUTION
Each battery pack weighs approximately 40 lb (18 kg).
Dropping or uncontrolled handling of the battery pack may result in personal
injury or damage to the UPS or battery pack.
Use two-handed or two person lift to handle each battery pack. Maintain
horizontal orientation of the battery pack with setting it down.
3. Slowly draw out each battery pack half-way, then support the bottom of the pack as the pack is drawn out of its
receptacle.
4. Place the old battery pack aside.
5. Lift the new battery pack using the same technique described above to slide the battery pack half-way into the battery
pack receptacle.
Ensure the battery pack is oriented right-side up.
6. Slowly slide the battery pack the rest of the way into the receptacle.

14 1600XPi Series Battery Cabinet Installation and Operation Manual 64024-006
6.1. If oriented correctly, the battery pack will slide all the way into the battery pack receptacle, and a faint but audible
click can be heard when the rear connectors mate.
6.2. If the battery pack does not slide smoothly back completely into the receptacle, remove it and verify the battery
pack is not upside down.
6.3. Notify the factory if the battery pack still will not fully seat in the receptacle, and a cause cannot be determined.
7. Repeat steps 3-6 for remaining battery packs.
8. Reinstall battery pack retaining plates.
9. Close the 1600XPi Battery Cabinet front door.