INSTRUCTIONS
FOR ASSEMBLING
NEBS™ FLOODED
RACKS
Publication No. US-NEBS-IM-003 September 2013
INSTRUCTIONS for ASSEMBLING NEBS™ FLOODED RACKS
Read all instructions carefully and observe all warnings before installation.
See Safety, Storage, Installation, Operation and Maintenance Manual
(Publication US-FL-IOM)
1. GENERAL INFORMATION

EnerSys® Reserve Power NEBS™
racks are available for ZONE 0, 2 and 4
applications, designed in accordance
with Network Equipment Building
Systems (NEBS). Racks are suitable
for installation in Network
Telecommunications Facilities.

Racks are supplied unassembled. The
basic components consist of: frames,
cross braces, support rails, plastic
channels and assembly hardware.
Seismic racks may also include: base
plates, side rails, end rails, corner
brackets, cell clamp assemblies, foam
spacers and side rail shims.

On installations where grounding is
required for National Electrical Code
(NEC) and/or local codes, refer to the
section on RACK GROUNDING in this
manual. Grounding holes are provided
on each rack frame; hardware is not
provided.
3. SERVICE INFORMATION
Should you require installation supervision,
service, parts, accessories or maintenance,
EnerSys has a service organization to assist
with your new rack purchase. Contact your
nearest EnerSys representative or call the
world headquarters number listed on the
back of this manual and ask for Reserve
Power Service.
2. SAFETY PRECAUTIONS

Assemble racks in accordance with the
instructions contained in this document
WITHOUT DEVIATIONS.

Refer to UBC, OSHA and EPA
regulations and local ordinances that
pertain to battery installation and
storage.


4. INSPECTION OF BATTERY RACK
COMPONENTS
Refer to additional SAFETY
PRECAUTIONS contained in the
EnerSys Safety, Storage, Installation,
Operation and Maintenance Manual.
Racks have two sets of cross braces,
front and rear. One set of cross braces
must be removed to install cells. Do not

Upon receipt, check each package
against the packing list to ensure all
components and quantities are correct.

Inspect for visual damage while the
carrier representative is still on-site.
Make note of any damage.

If any part has not been received or
has been damaged, DO NOT proceed
with installation until all parts are
available.
remove front and rear cross
braces at the same time. Failure to
follow these instructions may
result in cells falling off the rack
and causing personal injury.
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NEBS™ RACK ASSEMBLY
5. INSTALLATION CONSIDERATIONS
If you have any questions concerning the
following installation considerations, contact
your EnerSys® sales representative.

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
Consider available floor space, including
aisles for cell installation, maintenance
and possible cell replacement.
Aisle spacing should be in accordance
with the NEC Article 110-16.
ALL OTHER APPLICABLE CODE
REQUIREMENTS SHOULD ALSO BE
CONSIDERED.
Minimum clearance between seismic
racks and any objects (including walls,
equipment and other racks) is
recommended to be 4 in. (100 mm). NO
SEISMIC RACKS ARE TO BE BUTTED
TOGETHER, END-TO-END OR BACKTO-BACK.
Inter-rack cable connectors provided by
EnerSys are based on 4 in. (100 mm)
rack spacing; any length over this is the
responsibility of the installer.
The floor/mounting platform must be
reasonably level. Shimming up to 0.25 in.
(6 mm) maximum may be used to have
cell support rails level both front-to-back
and side-to-side. Shims and shimming
hardware is user supplied.
The floor/mounting platform must be
capable of supporting the weight of the
battery and rack system, as well as any
auxiliary equipment. ALL APPLICABLE
CODE REQUIREMENTS SHOULD BE
CONSIDERED.
6. INSTALLATION EQUIPMENT and
SUPPLIES
Before working with the battery system,
ensure that you have the tools and
equipment listed below.

Chalk line

Floor anchors

Concrete drill (for floor anchors)

Floor shims (user-supplied)

Level

Ohmmeter (for ground testing)

Open end/box wrenches
(SAE dimensions)

Ratchet set with sockets
(SAE dimensions)

Square

Tape measure

Torque wrench (10-100 ft-lb.)
TABLE 1 – Torque Specifications
NEBS Rack Torque Requirements
Bolt Size
3/8- 16
1/2- 13
5/8- 11
Initial
Torque
ft-lb.
20
50
100
N-m
27
68
136
Hex Head
(Socket) Size
Inches
9/16
3/4
15/16
NOTE: Floor anchoring and its design
are the responsibility of the installer.
Anchoring should meet all local, state
and federal codes and industry
standards.
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7. RACK ASSEMBLY
7.1
FLOOR ANCHORING
Floor anchoring and its design are the
responsibility of the installer. All outermost
holes in the mounting pattern should be
used where possible to maintain seismic
certification. Contact your EnerSys®
sales representative if you have any
questions.


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

7.2
Refer to the rack assembly drawing for
frame and anchor bolt layout. Zone 4
base plates are universal; Zone 2 base
plates are NOT universal. Zone 2 base
plates must be oriented with the
outermost mounting holes toward the
outside of the rack. See Figures 7.2a and
7.2b.
Rack is designed for anchoring with ½ in.
diameter anchor bolts with a 3-3/16”
embedment. [Recommended Anchor:
HILTI HSL-R-M12/25 3 3/16 or equivalent.
Minimum concrete c = 3000 psi (21 Mpa)]
Mark locations for anchor bolts using
the holes in the frame or base plate as
a template.
If necessary, move rack to drill and
install anchor bolts.
Drill holes, install and torque anchor
bolts as indicated in the manufacturer’s
instructions.
Figure 7.2
Figure 7.2a (Zone 2, 2 Tier Shown)
BASE PLATE TO FRAME ASSEMBLY
Seismic racks have bases that are
separate from the frame uprights.



Install frame to baseplate using 5/8-11
bolts and associated hardware. Refer
to assembly drawing for bolt length.
See Figures 7.2a and 7.2b.
Each base plate requires a self-tapping
screw for electrical bonding. See
Figures 7.2a and 7.2b.
Torque per Table 1.
Figure 7.2b (Zone 4, 2T and 2T/2R Shown)
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NEBS™ RACK ASSEMBLY
7.3
CROSS BRACE TO FRAME
ASSEMBLY
Bolt cross braces to respective frames.
Refer to below list for hardware order and
assembly drawing for bolt size and
lengths. See Figures 7.3a and 7.3b for
further detail. Torque per Table 1.
NOTE: Install cross braces on one side
of rack before cells are installed and the
other set of cross braces after cells are
installed. DO NOT REMOVE both sets
of cross braces at the same time with
cells installed on the rack for safety
concerns.
Single Cross
Brace
Double Cross
Brace





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











Hex Bolt
(3) Flat
Washers
Star Washer
Cross Brace
Star Washer
Rack Frame
Star Washer
Flat Washer
Lock Washer
Hex Nut
Hex Bolt
Flat Washer
Star Washer
Cross Brace
Star Washer
Cross Brace
Star Washer
Rack Frame
Star Washer
Flat Washer
Lock Washer
Hex Nut
Figure 7.3a
SINGLE CROSS BRACE
Figure 7.3b
DOUBLE CROSS BRACE
Figure 7.3
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7.4 INSTALL SUPPORT RAILS & SIDE
RAILS TO FRAME
Side rails are used only with seismic racks.
NOTE: It is recommended that the rails
of the upper tiers on multi-tier racks not
be installed until cells are placed on the
rails of the lower tiers for safety
concerns.

Figure 7.4a
Step 1
Figure 7.4a
Step 2
Locate support rails and side* rail so
overhang is equal on both ends. DO NOT
place cells on the rack at this time. For
single side rail configurations, side rails
are to be located in the upper hole of the
two mounting holes on the frame. Refer
to assembly drawing for hardware size
and length.
* For 2T/2R model racks, install the
center side rail and its associated
brackets. Refer to Section 7.5.

Fasten rails to frame as shown in
Figure 7.4a, Steps 1-4.

Depending on battery type, side rail
spacer(s) may need to be installed with
side rail. Refer to assembly drawing for
spacer application and Figure 7.4b.

Torque per Table 1.
SPACER
SHIM
Figure 7.4b
Figure 7.4
6
Figure 7.4a
Step 4
Figure 7.4a
Step 3
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NEBS™ RACK ASSEMBLY
7.5
CENTER RAIL BRACKET ASSEMBLY
(Seismic 2T/2R Model Racks Only)
The center rail should be installed before
any side rails are installed. Cells will be
positioned against this rail for optimum fit
on rack.
7.6

Install center rail brackets and center
rail as shown in Figure 7.5.

Refer to assembly drawing for
hardware size and length.

Torque per Table 1.
ATTACH PLASTIC CHANNEL TO
RAILS
Plastic channel is supplied in 3 ft. and 4 ft.
lengths. The rack shipment contains
enough plastic channel to cover the
support, side, center and end rails.

Cut plastic channels as necessary to
cover all rails.

Apply double-sided tape to the surface
of each rail. Refer to Figure 7.6
Figure 7.5
PLASTIC
CHANNEL
DOUBLESIDED TAPE
RAIL
Figure 7.6
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7.7
CELL INSTALLATION
It is important to know the location and
polarity orientation of each cell prior to
installation. Refer to EnerSys® Safety,
Storage, Installation, Operation and
Maintenance Manual, provided with batteries,
for installation and safety precautions.
NOTE: The bottom tier should contain
the largest number of cells when
applicable.
Figure 7.7a
7.7a
Figure

Make sure all bolts are torqued per
Table 1 before installing cells.

Install cells on bottom tier. The battery
covers should be spaced 0.25 in. (6 mm)
apart to ensure proper spacing for
intercell connector installation. See
Figure 7.7a.

Foam spacers are to be installed
between batteries on seismic racks.
The black mark on foam spacer edge
should be facing the top of the cell.
See Figure 7.7b.

Install front cross braces as instructed in
Section 7.3. See Figure 7.7c.
Figure 7.7b
Figure 7.7c
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NEBS™ RACK ASSEMBLY

Attach plastic channel to front side rail
per Section 7.6 and install front side
rail as instructed in Section 7.4. See
Figure 7.7d.

Install shim(s) as necessary between
side rails and rack frame to ensure
proper side rail fit with battery jars. Side
rails are to be installed without exerting
pressure on the battery jar. Clearance
equal to the typical thickness of a
business card is allowable between the
side rails and battery jar. Refer to
Figure 7.4b. The side rail bolts may
need to be loosened to perform this
step. Be sure to re-torque per Table 1
when complete.

Figure 7.7d
Zone 4 racks only - Install cell clamp
assemblies. Verify cell clamp locations
as shown on the rack assembly
drawing. Attach cell clamps to side
support rails. See Figure 7.7e, Steps 1
and 2. Refer to assembly drawing for
hardware size and length. Torque per
Table 1.
WHEN TORQUING HEX NUTS ON
THREADED ROD, USE CAUTION TO
AVOID BENDING CELL CLAMP
PLATES AGAINST BATTERY JARS.
HOLD HEX NUT BETWEEN PLATES
STATIONARY AND TORQUE THE
HEX NUT ON THE OUTSIDE OF THE
ASSEMBLY.

Foam spacers must be trimmed as
needed to fit between cells that require
cell clamps.
Figure 7.7e and 7.7h
Step 1
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Figure 7.7e
Figure 7.7e and 7.7h
Step 2
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Install cells on next tier following the
methods as instructed for the bottom tier.
See Figures 7.7f, 7.7g and 7.7h.

Cross braces per Section 7.3.

Rails per Section 7.4.

Center rail bracket, if applicable,
Section 7.5. (Seismic 2T/2R Racks
only.)

Plastic channel per Section 7.6.

Cells, foam spacers, rail shims and
cell clamp assemblies per Section 7.7.
Figure 7.7f
Figure 7.7g
Figure 7.7h
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NEBS™ RACK ASSEMBLY
7.8
END RAIL AND CORNER BRACKET
ASSEMBLY (Seismic Racks Only)
The location of the corner brackets is
determined when the batteries are evenly
spaced on the rack. See Figure 7.8.

Attach plastic channels to end rails per
section 7.6.

One left and one right corner bracket,
one end rail and hardware is needed
for each end rail assembly. Refer to
assembly drawing for hardware size
and length.

Determine the location of each corner
bracket and loosely fasten in place.
Refer to Figure 7.8, Step 1.

Slide end rail into place. Refer to
Figure 7.8, Step 2 and Step 3.

For 2T/2R model racks, install the
center rail end bracket on the center
rail as shown in Figure 7.8, Step 4.

Figure 7.8
Step 1
Figure 7.8
Step 2
Torque per Table 1. Side, center and
end rails should not exert any pressure
on the battery jar. Space equal to that
of a typical business card is allowable
between the rails and battery jar.
Figure 7.8
Step 3
Figure 7.8
Step 3
Figure 7.8
Step 2
Figure 7.8
Step 4 (2T/2R Racks Only)
Figure 7.8
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7.9 GROUNDING RACK (If Required)
Holes are provided in each frame for rack
grounding. Racks should be grounded
when it is required for NEC and/or local
codes.

Locate (2) 0.125 in. (3 mm) holes x 1
in. (25.4 mm) spacing in frame. See
Figure 7.9.

Scratch paint as necessary keeping
the exposed metal to a minimum.

Clean exposed surface and apply a
light coating of No-Ox grease (provided
with battery shipment).

Install lug and cable as shown in
Figure 7.9a. (Lug and cable not
furnished by EnerSys®).

Ohmmeter readings between each
component and a common point on
frame must indicate continuity to
ensure proper grounding.
Figure 7.9
Figure 7.9a
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NEBS™ RACK ASSEMBLY
GLOSSARY OF TERMS
2T RACK
Rack with one row of batteries located directly above another row of
batteries.
2T/2R RACK
Rack with two parallel rows of batteries located directly above
another two parallel rows of batteries.
CELL CLAMP ASSEMBLY
Brackets and threaded rod assembly connected to side rails and
positioned between battery jars to help reduce lateral battery
movement during a seismic event. Used with Zone 4 racks only.
CORNER BRACKET ASSEMBLY
Bracket assembly (left and right) used to attach end rail to side rails
to prevent batteries from falling off rack during a seismic event.
CROSS BRACE
Steel brace used to connect rack frames together.
END RAIL
Rail attached to corner brackets to prevent batteries from falling off
rack during a seismic event.
EPA
Environmental Protection Agency
FOAM SPACER
Spacers used to prevent batteries from hitting each other during a
seismic event.
FRAME
Main steel support structure of battery rack.
INTERCELL CONNECTOR
Electrical conductors used to connect adjacent cells on the same tier
of a rack.
INTER-RACK CABLE
Electrical conductors used to connect terminal plates on two separate
racks.
NEBS™
Network Equipment Building Systems
NEC
National Electric Code
OSHA
Occupational Safety & Health Administration
REDUNDANT HOLE PATTERN
Hole pattern that has two holes for each anchor location. If the
preferred hole is not usable due to contact with concrete rebar, the
optional hole would be used for anchoring.
RESERVE POWER SERVICE
EnerSys® service and installation group.
SEISMIC RACK
Zone 2 or Zone 4 racks.
SHIM
Thin metal spacers used to bring side rails close to battery or to level
rack due to uneven flooring.
SIDE RAIL
Rails used to prevent cells from falling off rack during a seismic
event.
SPACER
Steel spacers that may be required for certain battery models on
certain battery racks to move the side rails closer to the battery jar for
optimum seismic protection.
SUPPORT RAIL
Rails connected to the frame that supports the batteries.
TIER-TO-TIER CABLE
Electrical conductor used to connect a terminal plate on one tier to a
terminal plate on another tier on the same rack.
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NOTES
Please check our website for literature updates.
EnerSys World Headquarters
2366 Bernville Road
Reading, PA 19605
USA
Tel: +1-610-208-1991
+1-800-538-3627
www.enersys.com
Publication No. US-NEBS-IM-003 September 2013
Subject to revisions without prior notice. E.&O.E.
EnerSys EMEA
EH Europe GmbH
Lowenstrasse 32
8001 Zurich Switzerland
Tel: +41 44 215 7410
EnerSys Asia
152 Beach Road
Gateway East Building #11-03
Singapore 189721
Tel: +65 6508 1780
Represented by:
Printed in USA
©2013 EnerSys. All rights reserved.
Trademarks and logos are the property of EnerSys
and its affiliates except NEBS, which is a trademark
of Telcordia Technologies.