SECTION 58.

15

INSTRUCTIONS for ASSEMBLING and MAINTAINING

STANDARD and SEISMIC BATTERY RACKS
Read all instructions carefully and observe all warnings before installation.
See Safety, Storage, Installation, Operation, and Maintenance Manual, EnerSys Section 58.00.

1. GENERAL INFORMATION
EnerSys stationary battery racks are available for use with both standard (ZONE 0) and seismic
(ZONE 1, 2, and 4) applications, as mentioned in the Uniform Building Code (UBC) or Network
Equipment Building Systems (NEBS). Racks are supplied unassembled. The basic components
consist of: frames, cross braces, support rails, hardware, double-sided tape, and plastic channels.
Seismic racks also include: side rails, end rails, corner brackets, foam spacers, shims, and cell
clamp assemblies.

The types of standard racks supplied by EnerSys are shown in Figure 1.

1 TIER 2 STEP 3 STEP

2 TIER 2 TIER/2 ROW 2 STEP/2 TIER

3 TIER

TYPES OF STANDARD RACKS

Figure 1

This document provides instructions for the following:

• Standard rack assembly

• Back-to-back rack assembly (for standard racks only)
• End-to-end rack assembly (for standard racks only)
• Shock-protection equipment assembly (for standard racks only)
• Seismic rack assembly

Rev. Date: - 10//01 www.enersys.com 1

2. PRECAUTIONS
BEFORE UNPACKING, STORING, HANDLING, INSTALLING, OPERATING OR PERFORMING
MAINTENANCE ON THE BATTERIES OR BATTERY RACKS…
READ THE FOLLOWING INFORMATION THOROUGHLY!
It is important to read, understand and strictly follow the instructions in this manual.
If the following precautions are not fully understood, or local conditions are not covered, contact
your EnerSys representative for clarification. Or, call the corporate number on the back of this
manual and ask for EnerSys Integrated Systems and Services.
Also, refer to all applicable federal, state and local regulations and industry standards.
YOU SHOULD BE TRAINED IN HANDLING, INSTALLING, OPERATING AND MAINTAINING
BATTERIES BEFORE YOU WORK ON ANY BATTERY SYSTEM.

3. SERVICE INFORMATION
EnerSys has a nationwide service organization to assist with installation supervision, service,
parts, accessories or maintenance of your new rack purchase. Contact your EnerSys
representative or the corporate number on the back of this manual and ask for EnerSys Integrated
Systems and Services .

4. SAFETY
1. Assemble racks according to the instructions in this document WITHOUT DEVIATIONS.
2. Refer to UBC, OSHA, and EPA regulations and local ordinances pertaining to battery
installation and storage.
3. Refer to the SAFETY PRECAUTIONS in the Safety, Storage, Operation and Maintenance
Manual for Flooded Lead-Acid Batteries (EnerSys Section 58.00).
4. Do NOT remove braces on a rack with cells already installed. For racks with front and rear
cross braces, the front braces must be removed to install cells.
DO NOT REMOVE FRONT AND REAR BRACES AT THE SAME TIME. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN CELLS FALLING OFF THE RACK AND
CAUSING PERSONAL INJURY.
5. For installations where grounding is required for NEC and/or local codes, see instructions for
RACK GROUNDING in Section 15.

IMPORTANT!
Should you have ANY question concerning safety when working with the battery system, contact
your EnerSys representative to clarify any of the noted safety precautions. Or, call the corporate
number listed on the back of this manual and ask for EnerSys Integrated Systems and Services.

5. INSPECTION OF BATTERY RACK SHIPMENT

5.1 GENERAL
Precautions were taken to pack the battery rack for shipment to ensure its safe arrival. However,
upon receipt, inspect for evidence of damage that may have occurred during transit.

If any part is damaged or missing from the package, DO NOT proceed with installation until all
parts are available.

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 SECTION 58.15

5.2 INSPECTION
IMMEDIATELY upon delivery (while the carrier representative is still on-site), inventory and inspect
all materials against the Bill of Lading for visible external damage.

If damage is noted:
1. Make a descriptive notation on the delivery receipt before signing.
2. Request an inspection by the carrier.
3. File a damage report.

DELAY IN NOTIFYING THE CARRIER MAY RESULT IN THE LOSS OF YOUR RIGHT TO
REIMBURSEMENT FOR DAMAGES. Refer to the Bill of Materials if you are unsure about the
appearance of a part when performing the parts inventory.

Should you have any questions concerning potential damages, contact your EnerSys
representative or call the corporate number on the back of this manual and ask for EnerSys
Integrated Systems and Services.

6. INSTALLATION CONSIDERATIONS

Space • Consider available floor space, including aisles for cell installation, maintenance, and
possible cell replacement.
• Measure the aisle space according to the National Electric Code (NEC) Article 110-16
or local codes.
• Clearance from wall/equipment – 4” (10 cm) minimum (seismic only)

Environment Clean, cool, and dry

Temperature • Ambient temperature, between 72°-78°F (23°-26°C).

• Elevated temperatures reduce operating life. Lower temperatures reduce battery
performance.
• Locate racks to minimize temperature variations between cells. Do NOT locate the
battery near HVAC ducts or exhausts, heat sources (i.e., equipment that generates
heat) or direct sunlight.

Ventilation • Adequate ventilation must be provided.

• Do NOT install in an airtight enclosure or room with no ventilation.

Grounding Ground rack according to NEC and/or local codes.

Floor Reasonably level. Shimming up to 0.25” (6 mm) maximum to level battery front to rear and
side to side. The floor must be capable of supporting the weight of the battery and rack
system, as well as any auxiliary equipment.

Anchoring • ALL rack frames must be securely anchored to the floor. Anchoring should meet all
local, state and federal codes and industry standards.
• Floor anchoring and its design are the responsibility of the installer.
• SEISMIC RACK ANCHORING: Minimum clearance between racks and any objects
(including walls, equipment and other racks) is to be 4 in. (101.6 mm). NO RACKS ARE
TO BE BUTTED TOGETHER, END-TO-END OR BACK-TO-BACK. Inter-rack cable
connectors (provided by EnerSys) are based on 4 in. (101.6 mm) spacing; any length
over this is the responsibility of the installer.

Codes Ensure all applicable codes are followed.

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7. RECOMMENDED INSTALLATION EQUIPMENT AND SUPPLIES
Before working with the battery system, ensure that you have the tools and equipment listed
below.
• Chalk line • Box wrenches (3/8” to 11/16”)
• Concrete drill (for floor anchors) • Level
• Electric drill • Ohmmeter (for ground testing)
• Floor anchors (user-supplied) • Square
• Floor shims (user-supplied) • Tape measure
• 3/8” drive ratchet wrench with minimum 3” • Torque wrench (10-100 ft-lb.)
extension with 3/8” - 11/16” sockets

TABLE 6 – Torque Specifications

Bolt Diameter Torque
in. mm ft-lb. Nm
3/8 9.53 20 28
1/2 12.7 50 68

8. FLOOR AND ANCHORING

Battery racks should be properly anchored to the floor for safety purposes. For seismic battery
racks, use all frame holes to maintain seismic certification. Contact your EnerSys representative
if you have any questions.

TO LAYOUT BATTERY RACK:

1. Mark locations for anchor bolts using the holes in the bottom of each frame as a template.
2. Install floor anchors in pre-determined locations.

TO ANCHOR THE RACK AFTER ASSEMBLY

1. Align rack with floor anchors and attach to floor. Shimming up to 0.25 in. (6 mm)
maximum may be required to level support rails both front-to-back and side-to-side.
2. Recheck all bolted connections for proper torque.
3. Torque anchor bolts as directed in manufacturer’s instructions.
4. If necessary, move rack to drill and install anchor bolts.

9. CELL INSTALLATION PRECAUTIONS

Know the location and polarity orientation of each cell prior to installation. Diagram connections to
avoid repositioning of cells once installed (see CONNECTING CELLS in EnerSys Section 58.00).
On multi-tier racks with more cells on one row than another, install larger number of cells on
bottom row. Start diagram of the bottom row by deciding where termination will be located.
• Install rear side rail before installing cells. Locate side rail so overhang is equal on both
ends of rack. Install plastic channel.
• Make sure all bolts are torqued as indicated in Table 6 before installing cells.
NOTE: Refer to Safety, Storage, Installation, Operation and Maintenance for Flooded Lead-Acid
Batteries (EnerSys Section 58.00) for cell unpacking and handling instructions.

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 SECTION 58.15

10. RACK ASSEMBLY

10.1 CROSS BRACE TO FRAME ASSEMBLY

1. Place frames at the desired floor locations.

2. Attach cross braces to frames for strength and rigidity between the frames.

NOTE: Follow the specific instructions that pertain to the battery rack you purchased,
then continue to step 3.

FOR STANDARD 1 TIER, 2 TIER, 3 TIER, 2 STEP, AND 3 STEP RACKS:

a. Bolt rear braces together (Figure 10A and Details A, B).

DETAIL B

HEX NUT

LOCK WASHER
DETAIL A
FLAT WASHER
TOOTH LOCK WASHER
INSTALL BETWEEN
CROSS BRACE AND FRAME

FLAT WASHER

BOLT

DETAIL E

FRAME

REAR VIEW

CROSS BRACE

STANDARD 2 TIER RACK ASSEMBLY CROSS BRACE TO END FRAME ASSEMBLY

Figure 10A Detail A

HEX NUT

HEX NUT
LOCK WASHER
LOCK WASHER
FLAT WASHER TOOTH LOCK WASHER
FLAT WASHER
INSTALL BETWEEN
CROSS BRACE AND FRAME
TOOTH LOCK WASHER
TOOTH LOCK WASHER INSTALL BETWEEN CROSS BRACES
INSTALL BETWEEN CROSS BRACES

FLAT WASHER

FLAT WASHER

BOLT
BOLT

FRAME

CROSS BRACES CROSS BRACES

DOUBLE CROSS BRACE TO MID-FRA ME ASSEMBLY CROSS BRACE TO CROSS BRACE ASSEMBLY
Detail B Detail E

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 FOR STANDARD 2 STEP/2 TIER RACKS:

a. Attach rear braces as directed above, using longer braces.

b. Attach top braces, using shorter braces (Figure 10B and Detail C).

DETAI L C
BOLT

CROSS BRACES FLAT WASHER

TOOTH LOCK WASHER

INSTALL BETWEEN
CROSS BRACES

TOOTH LOCK WASHER

INSTALL BETWEEN
CROSS BRACE AND FRAME

FRAME

FLAT WASHER LOCK WASHER

HEX NUT

STANDARD 2 STEP/2TIER RACK ASSEMBLY DOUBLE CROSS BRACE TO TOP FRAME ASSEMBLY
Figure 10B Detail C

FOR STANDARD 2 TIER/2 ROW RACKS:

a. Bolt center cross braces to the center of the frame (Figure 10C and Detail D).

DETAIL D

HEX NUT

LOCK WASHER

FLAT WASHER

FRAME

CROSS BRACE
FLAT WASHER

BOLT

TOOTH LOCK WASHERS

INSTALL BETWEEN
CROSS BRACES AND FRAME

CROSS BRACE

STANDARD 2 TIER/2 ROW RACK ASSEMBLY CROSS BRACE TO CENTER FRAME ASSEMBLY
Figure 10C Detail D

3. Bolt cross braces together where they cross each other (Detail E). Make sure frames are
plumb before tightening bolts to the required torque (Table 6).
NOTE: Actual hardware supplied with rack may differ from Details. Flat and lock washers
may be substituted with tooth lock washers. Frames are symmetrical and can be oriented
facing either direction.

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 SECTION 58.15

10.2 SUPPORT RAIL TO FRAME ASSEMBLY

1. Attach the support rail to the assembled frame (Figure 10D).

a. Install clamp nuts and bolts (Figure 10E). Engage clamp nut approx. 0.25 in. (6 mm).
b. Place rail on frame against clamp nut as shown in Figure 10F.
c. Rotate rail 90° over clamp nut as shown in Figure 10G.

FIGURE 10G

FIGURE 10E FIGURE 10F

SUPPORT RAIL TO FRAME ASSEMBLY
Figure 10D FIGURE 10H

d. Push bolt assembly upward. Rotate clamp nut 90° (Figure 10H). Fasten bolt finger-tight.
e. Position each rail so the overhang beyond the frame is equal at each end of the rack,
or as specified on the RACK ASSEMBLY DRAWING.
f. With the frame, braces, and lower rails assembled, check frame alignment.
g. Torque all bolts as indicated in Table 6.

10.3 SUPPORT RAIL TO FRAME ASSEMBLY

1. Attach the plastic channel to the support rail.

Plastic channels are supplied in 3-ft. and 4-ft. lengths. Make sure the ends of rails are cut
squarely and butted together. Trim excess or overhanging plastic.

a. Apply double-sided tape to the surface of each support rail (Figure 10J). Apply in a
continuous piece and avoid wrinkles.

PLASTIC CHANNEL

DOUBLE -SIDED TAPE

SUPPORT RAIL

SUPPORT RAIL SHOWN SIMILAR ASSEMBLY

FOR SIDE AND END RAILS
Figure 10J

b. Remove paper backing from the tape.

c. Place plastic channel on support rail and press down to make contact with tape.

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 10.4 SUPPORT RAIL TO FRAME ASSEMBLY
Anchor to floor according to Section 8, if necessary. Seismic racks must be anchored.

If you are installing:

• Shock protection equipment – see Section 13.
• Multiple racks:
- Back-to-back rack assembly – see Section 11.
- End-to-end rack assembly – see Section 12
• Seismic racks – see Section 14

11. BACK-TO-BACK RACK ASSEMBLY (STANDARD RACKS ONLY)

1. Attach frames and braces (Section 10 and Figure 11).
Each rack is supplied with its own set of braces. When installing two racks back-to-back, use
both sets of cross braces (Details F and G). Single tier, 2 step and 3 step racks are NOT
bolted together when installed back-to-back.
DETAIL F HEX NUT
TOOTH LOCK WASHER

DETAIL G CROSS BRACE

TOOTH LOCK WASHER
CROSS BRACE
SPACER
FRAME

BOLT

FRAME
TOOTH LOCK WASHER

BACK-TO-BACK FRAME ASSEMBLY BACK-TO-BACK END FRAME ASSEMBLY

(STANDARD RACKS ONLY) (STANDARD RACKS ONLY)
Figure 11 Detail F
TOOTH LOCK WASHER
CROSS BRACE
TOOTH LOCK WASHER
CROSS BRACE
TOOTH LOCK WASHER
HEX NUT CROSS BRACE
TOOTH LOCK WASHER
FRAME CROSS BRACE
TOOTH LOCK WASHER

BOLT

FRAME

TOOTH LOCK WASHER

BACK-TO-BACK CENTER FRAME ASSEMBLY

(STANDARD RACKS ONLY)
Detail G
2. Follow instructions in Section 10 to assemble and anchor both racks.
3. Install cells as directed in CONNECTING CELLS, EnerSys Section 58.00.
NOTE: If attaching a new rack back-to-back with an existing rack, do not remove cross
braces unless the existing rack is properly secured.
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 SECTION 58.15

12. END-TO-END RACK ASSEMBLY (STANDARD RACKS ONLY)

1. Assemble the first rack as directed in Section 10.
2. Assemble the second rack as directed in Section 10, with support rails in alignment at the
end of first rack (Figure 12). Anchor second rack to floor as directed in Section 8.

SUPPORT RAIL
DETAIL H

CLAMP NUTS

SUPPORT RAIL

RAIL JOINER

BOLTS

END-TO-END RACK ASSEMBLY END-TO-END RACK ASSEMBLY

(STANDARD RACKS ONLY) (STANDARD RACKS ONLY)
Figure 12 Detail H

3. Install rail joiners as shown in Detail H. Tighten bolts to torque specified in Table 6.
4. Install cells as directed in CONNECTING CELLS, EnerSys Section 58.00.

13. SHOCK-PROTECTION EQUIPMENT ASSEMBLY

(FOR C, E, F, AND SC STANDARD RACKS ONLY)
The following instructions assume the standard rack has been assembled and properly anchored
as directed in Section 10. For multi-tier racks, begin the installation of shock-protection
equipment and cells on the bottom tier. Refer to EnerSys Section 58.00 for cell installation.

The components of the shock-protection equipment are to be added to standard racks to provide
cell restraint in ZONE 1 areas. See Figure 13. Shock-protection kits consist of foam spacers,
side support brackets, side rails, corner brackets, end rails, plastic channels, and hardware.

DETAIL J
SIDE RAIL
DETAIL K
CLAMP NUT

SUPPORT RAIL

BOLT

CLAMP NUT

SUPPORT BRACKET

BOLT

SHOCK PROTECTION EQUIPMENT ASSEMBLY SHOCK-PROTECTION SUPPORT RAIL ASSEMBLY

Figure 13 Detail J

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 1. Place support brackets for the rear side rail under the cell support rails at each end of the
rack, using bolts and clamp nuts as shown in Detail J. Locate the side rail so that the
overhang beyond the frame is equal at each end of the rack. Do not fully tighten the
assembly at this time.
2. Locate additional support brackets uniformly between the two outer support brackets. The
location of support brackets’ ends of the side rail is important. The support brackets
should not be closer than 2.5 in. (63.5 mm) from the end of the side rail to allow space for
the corner bracket.
3. Attach plastic channels to side rail as directed in Section 10.3.
4. Place cells on rack as directed in EnerSys Section 58.00 (install bottom tier first) and
insert foam spacers between cells. Be sure to center each cell on the support rails to
allow space for the side rails. Move the rear side rails by sliding the side support brackets
towards the cells so the rail is snug against the cells.
5. Tighten bolts for side support brackets to the torque specified in Table 6.
6. Repeat steps 1 through 5 for the front side rails.
7. Assemble end rails and corner brackets for each end of the rack as shown in Detail K.

SIDE RAIL END RAIL

CLAMP NUT

CORNER BRACKET CLAMP NUT

BOLT
BOLT

SHOCK-PROTECTION CORNER BRACKET ASSEMBLY

Detail K

8. Attach plastic channels to end rail as directed in Section 10.3.

9. Ensure end rail is snug against cells.
10. Tighten bolts for end rail and corner brackets to torque specified in Table 6.
11. Repeat steps 1 through 10 for the remaining tier(s), if applicable.
12. Complete battery assembly with proper connectors, terminal plates, and cables as
directed in EnerSys Section 58.00.

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 SECTION 58.15

14. SEISMIC RACK ASSEMBLY

The following instructions assume the seismic rack has been assembled and properly
anchored as directed in Section 10. For multi-tier racks, begin the installation of side rails
and cells on the bottom tier. Refer to EnerSys Section 58.00 for cell installation.

In addition to standard rack components, seismic racks (ZONE 1, 2, and 4) utilize foam spacers,
side rails, corner brackets, end rails, and cell clamp assemblies (D, F, and G cell racks only).
See Figures 14A, 14B, 14C and 14D. Cell clamp assemblies must be used when provided.
Evenly distribute cell clamps on each row/tier. (For example, if 4 cell clamps are provided with a
2-tier rack, evenly space 2 clamps on each tier.)

CELL CLAMP ASSEMBLY RODS

SEISMIC 2 TIER/2 ROW RACK

FOAM
SPACERS

CELL

SEISMIC RACK ASSEMBLY

INTERLOCKING CORNER BRACKET
DETAIL L Figure 14C
DETAIL M

SEISMIC RACK ASSEMBLY

SIDE RAIL, CELL CLAMP
and
FOAM SPACER ASSEMBLY
Figure 14A

SEISMIC RACK ASSEMBLY SEISMIC RACK ASSEMBLY

LONG/SHORT CORNER BRACKET UNIVERSAL CORNER BRACKET
Figure 14B Figure 14D

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 14.1 SIDE RAIL AND CELL CLAMP ASSEMBLY

1. Remove front braces, if applicable, to gain access to rack for cell installation.
2. Attach rear side rail to frames, on the bottom tier first, using bolts and clamp nuts as
shown in Figures 14E-H. Locate side rail so the overhang beyond the frame is equal at
each end of the rack. Tighten rear side rail bolts to required torque specified in Table 6.

FIGURE 14G

FIGURE 14E FIGURE 14F

FIGURE 14H

3. Attach plastic channels to side rail as directed in Section 10.3.

4. Place cells on rack as directed in EnerSys Section 58.00 (install lower tier first) and insert
foam spacers between cells. Allow for location of cell clamp assemblies, if applicable.
Foam spacers are not required at cell clamp locations. Be sure to snug each cell against
the rear side rail. See Figure 14A and also Section 9 for cell installation precautions.
5. Before installing the adjacent cell, loosely install cell clamp bracket at a pre-determined
location as shown in Detail L.
TUBING

THREADING
SIDE RAIL

CLAMP NUT

BRACKET

HEX NUTS

FLAT WASHER

LOCK WASHER

BOLT

CELL CLAMP INSTALLATION

Detail L
6. Slip length of tubing over rods, insert rods through hole in cell clamp bracket and install
jam nuts to within 0.5 in. (12.7 mm) from end. It is important that the tubing just touch the
jar. Tighten cell clamp bracket connection to the required torque specified in Table 6.
7. Install the adjacent cell and repeat steps 4 through 6 until the row is filled with cells.
8. Repeat steps 1 through 3 to attach the front side rail, making sure the rail is between the
cell clamp rods. Refer to Detail L.
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 SECTION 58.15

9. Insert rods through front cell clamp bracket holes and attach front cell clamp bracket to
front side rail. Tighten cell clamp bracket connection to torque specified in Table 6.
10. Move front side rails towards cells so that rails are snug against cells. Insert rail, spacers,
and shims in front, if necessary, so slot is perpendicular to the rail (Detail M).
FRONT SIDE RAIL

CLAMP NUT
RAIL SHIMS

SPACER(S)

FRAME

WHIZ-LICK BOLT

SIDE RAIL INSTALLATION

Detail M

11. Tighten side rail bolts to the required torque specified in Table 6.
12. Install first nut finger-tight on each rod against cell clamp bracket. Install second nut on
each end. Hold inside nut stationary and torque the second nut on each end to 15 ft-lbs
(21 Nm). Excessive tightening of the inside nut will result in damage to the jar walls.

14.2 END RAIL ASSEMBLY

INTERLOCKING CORNER BRACKET

Interlocking corner bracket designs provide both short and long corner brackets. Use short
bracket unless there is interference with the frame.
1. Assemble end rails and corner brackets for each end of rack as shown in Figures 14J,
14K, 14L and 14M. Attach plastic channels to end rail as directed in Section 10.3.

SIDE RAIL
CLAMP NUT
END RAIL

WHIZ-LOCK BOLT
CLAMP NUT LONG CORNER BRACKET

WHIZ-LOCK BOLT

SEISMIC RACK ASSEMBLY LONG/SHORT CORNER BRACKET ASSEMBLY

LONG/SHORT CORNER BRACKET (LONG CORNER BRACKET SHOWN)
Figure 14J Figure 14K

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 LOCK WASHER
BOLT
FLAT WASHER

CORNER BRACKET

CLAMP NUT

CORNER BRACKET

CLAMP NUT

CORNER BRACKET

CORNER BRACKET
FLAT WASHER
LOCK WASHER
BOLT BOLT
LOCK WASHER CLAMP NUT
FLAT WASHER
SEISMIC RACK ASSEMBLY
INTERLOCKING CORNER BRACKET INTERLOCKING CORNER BRACKET ASSEMBLY
Figure 14L Figure 14M

NOTE: Plastic channels must be cut to fit over each end rail and cover all surfaces of the
rails that will come into contact with the cell.
2. Ensure end rails are snug against cells. Tighten bolts for the end rail and side brackets to
the required torque as indicated in Table 6.
14.3 FINAL ASSEMBLY

1. Repeat steps in Section 14 for the remaining tier(s), if applicable.

2. Reinstall front braces, if applicable.
1. Complete battery assembly with proper connectors, terminal plates, and cables as
directed in EnerSys Section 58.00.

15. RACK GROUNDING (OPTIONAL)

On installations where grounding is required (as indicated by NEC and/or local codes), the
following steps must be taken.

1. Install lug and cable, as shown in Figure 15, to the system ground. (Lug and cable are not
furnished by EnerSys.) Tooth lock washers should be installed between contact surfaces of all
cross brace mountings. Refer to Detail P. Torque as specified in Table 6.

FRAME HEX NUT

TOOTH LOCK WASHER LOCK WASHER

FLAT WASHER
CROSS BRACE TOOTH LOCK WASHER
INSTALL BETWEEN
CROSS BRACE AND FRAME

TOOTH LOCK WASHER FLAT WASHER

FLAT WASHER BOLT

BOLT
FRAME

CROSS BRACE

GROUND CABLE
(CUSTOMER SUPPLIED) CROSS BRACE TO END FRAME ASSEMBLY
GROUND CONNECTION ASSEMBLY Detail P
Figure 15
14 Rev. - 10/01
 SECTION 58.15

2. An ohmmeter reading between each component and a common point on a frame must
indicate continuity to assure complete grounding. Any component that does not show
continuity must have at least one connection loosened and retightened and the ohmmeter test
must be repeated.
3. It is not necessary for each bolted connection to show continuity as long as there is at least
one on each component.
NOTE: Ohmmeter checks are to be made by probing each component surface, not at bolted
connections.
16. RACK INSPECTION AND MAINTENANCE

1. The members of the battery racks are finished with acid-resistant epoxy paint. Abnormal
battery operating conditions, such as overfilling or charging at excessively high currents, may
cause spillage of electrolyte from the cells onto the rack. If the electrolyte is not removed, in
time the exposed rack components will corrode.
2. Periodic inspections of the entire rack are to be made to observe any signs of acid corrosion.
When corrosion is detected, scrape away the corrosion to bare metal. Neutralize the area with
a solution of bicarbonate soda and water (1 pound of soda to 1 gallon of water), dry, and then
paint the area with acid-resistant paint.
3. Rack corrosion that goes undetected for extended periods may weaken the load bearing
members to the point where they are structurally unsound. When such conditions are
observed, it is recommended that the rack be replaced.
4. If the rack has been grounded, periodically check the ohmmeter to determine that all
components of the rack are still grounded. If the ground becomes lost on any component,
loosen one bolt at a time and tighten to the original torque value. Continue to do so until
continuity has been reestablished.

17. GLOSSARY OF TERMS

CELL CLAMP ASSEMBLY Assembly connected to side rails and positioned according to
battery weight, to help reduce battery movement during a
seismic event.

CORNER BRACKETS Brackets used to attach end rails to side rails to prevent
batteries from falling off end of rack during a seismic event.

CROSS BRACE Bracing used to connect rack frames together.

END RAILS Attached to corner brackets to prevent batteries from falling off
end of rack during a seismic event.

EPA Environmental Protection Agency

FOAM SPACERS Spacers used between batteries to prevent batteries from

hitting each other during a seismic event.

FRAMES Main support structure of battery rack.

(cont.)

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 (cont.)

INTER-RACK CABLE
CONNECTORS Electrical conductors used to connect cells on two separate racks.

NEBS Network Equipment Building Systems

NEC National Electric Code

OSHA Occupational Safety & Health Administration

SIDE RAILS Rails on side of frames used to prevent cells from falling off
rack in a seismic event.

SHIMS Metal spacers used to bring side rail close to battery or to level
rack due to uneven flooring.

SUPPORT RAILS Rails connected to base of frame to support batteries.

UBC Uniform Building Code

Represented by:

Global Headquarters: P.O. Box 14145,

Reading, PA 19612-4145
1-610-208-1991 • 1-800-538 -3627
FAX 1-610-372- 8613
When ordering new batteries, also remember to
properly recycle your old lead batteries. Federal and US Sales Offices:
state regulations require lead-acid batteries be Eastern Region: 1-800-346-4402 • 1-215-491 -3700
recycled. EnerSys’ nationwide service organization Western Region: 1-800-423-4667 • 1-562-949 -4266
can arrange pickup, transportation to and recycling
Regional Sales Offices:
at any one of our company affiliated smelters. Call EnerSys Canada: 1-905-790-1212
1-800-972-7372 for more information. ESB de Mexico SA DE: 52-8-329- 6405

EnerSys has locations worldwide to serve your needs;

for additional information please visit our website at
www.enersys.com or contact us a 1-800-538-3627.

24 Hour Service or Repair, call:

1-800-423-9602 (U.S.)

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