VERTIV 7100 Series NetSure -48 VDC Power System User Manual
- June 6, 2024
- VERTIV
Table of Contents
7100 Series NetSure -48 VDC Power System
NetSureTM 7100 Series -48 VDC Power System
User Manual
Specification Number: 582127000100, 582127000101, 582127000102, 582127000103,
582127000203, 582127000500, 582127000501, 582127000502, 582127000503 Model
Number: 7100
VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
The information contained in this document is subject to change without notice
and may not be suitable for all applications. While every precaution has been
taken to ensure the accuracy and completeness of this document, Vertiv assumes
no responsibility and disclaims all liability for damages resulting from use
of this information or for any errors or omissions. Refer to other local
practices or building codes as applicable for the correct methods, tools, and
materials to be used in performing procedures not specifically described in
this document. The products covered by this instruction manual are
manufactured and/or sold by Vertiv. This document is the property of Vertiv
and contains confidential and proprietary information owned by Vertiv. Any
copying, use or disclosure of it without the written permission of Vertiv is
strictly prohibited. Names of companies and products are trademarks or
registered trademarks of the respective companies. Any questions regarding
usage of trademark names should be directed to the original manufacturer.
Technical Support Site
If you encounter any installation or operational issues with your product,
check the pertinent section of this manual to see if the issue can be resolved
by following outlined procedures. Visit https://www.vertiv.com/en-us/support/
for additional assistance.
VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
TABLE OF CONTENTS
Admonishments Used in this Document ………………………………………………………………………………………………………….
iv Important Safety Instructions
…………………………………………………………………………………………………………………………… v Static Warning
………………………………………………………………………………………………………………………………………………….. viii 1 Customer
Documentation Package……………………………………………………………………………………………………………… 1 2 System
Description ………………………………………………………………………………………………………………………………………. 2 2.1 Lists
100, 101, 102, 103, and 203
…………………………………………………………………………………………………………………………………………………………………………………………….2 2.2
Lists 500, 501, 502, and
503…………………………………………………………………………………………………………………………………………………………………………………………………….3
3 Operating Procedures ………………………………………………………………………………………………………………………………….. 4
3.1 Controller, Rectifiers, and
Converters………………………………………………………………………………………………………………………………………………………………………………..4
3.2 ESTOP
Function……………………………………………………………………………………………………………………………………………………………………………………………………………………………….4
3.3 Controller Battery Charge Current Limit
Feature………………………………………………………………………………………………………………………………………………………4 3.4 Local
Controls and Indicators
…………………………………………………………………………………………………………………………………………………………………………………………………5
3.4.1 Controller, Rectifiers, and
Converters…………………………………………………………………………………………………………………………………………………………….5 3.4.2
Distribution
Cabinet…………………………………………………………………………………………………………………………………………………………………………………………………..5
4 Maintenance ………………………………………………………………………………………………………………………………………………….. 8 4.1
System Maintenance
Procedures…………………………………………………………………………………………………………………………………………………………………………………………8
4.2 Adding a Rectifier or Converter Module to an Existing Module Mounting
Assembly Spec. No. 588705300……………………8 4.3 Reconfiguring a Dual Voltage
Distribution Panel (List DJ and FJ)
…………………………………………………………………………………………………………….. 11 4.3.1 Removing the Distribution
Panel…………………………………………………………………………………………………………………………………………………………………….11 4.3.2
Reworking the Distribution
Panel……………………………………………………………………………………………………………………………………………………………………13 4.3.3
Replacing the Distribution Panel
……………………………………………………………………………………………………………………………………………………………………19 5
Troubleshooting and Repair ……………………………………………………………………………………………………………………….20
5.1 Contact
Information……………………………………………………………………………………………………………………………………………………………………………………………………………………20
5.2 Controller, Rectifiers, and
Converters…………………………………………………………………………………………………………………………………………………………………………….20
5.3 Controller
Configuration………………………………………………………………………………………………………………………………………………………………………………………………………….20
5.4 System Troubleshooting Information
…………………………………………………………………………………………………………………………………………………………………………….20 5.5
Replacement
Information…………………………………………………………………………………………………………………………………………………………………………………………………………21
5.6 Replacement
Procedures…………………………………………………………………………………………………………………………………………………………………………………………………………21
5.6.1 Replacing a Rectifier or Converter
Module………………………………………………………………………………………………………………………………………………21 5.6.2 Replacing
the NCU
Controller…………………………………………………………………………………………………………………………………………………………………………..21
5.6.3 Replacing a Distribution
Device………………………………………………………………………………………………………………………………………………………………………22 5.6.4
Replacing a Distribution Panel (List AL, DJ,
FJ)…………………………………………………………………………………………………………………………………24 5.6.5 Circuit Card
Replacement
Procedures……………………………………………………………………………………………………………………………………………………….26 5.6.6
Replacing a Battery Disconnect
Contactor…………………………………………………………………………………………………………………………………………….30
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
Admonishments Used in this Document
DANGER! Warns of a hazard the reader will be exposed to that will likely
result in death or serious injury if not avoided. (ANSI, OSHA)
WARNING! Warns of a potential hazard the reader may be exposed to that could
result in death or serious injury if not avoided. This admonition is not used
for situations that pose a risk only to equipment, software, data, or service.
(ANSI) CAUTION! Warns of a potential hazard the reader may be exposed to that
could result in minor or moderate injury if not avoided. (ANSI, OSHA) This
admonition is not used for situations that pose a risk only to equipment,
data, or service, even if such use appears to be permitted in some of the
applicable standards. (OSHA) ALERT! Alerts the reader to an action that must
be avoided in order to protect equipment, software, data, or service. (ISO)
ALERT! Alerts the reader to an action that must be performed in order to
prevent equipment damage, software corruption, data loss, or service
interruption. (ISO)
FIRE SAFETY! Informs the reader of fire safety information, reminders,
precautions, or policies, or of the locations of fire-fighting and fire-safety
equipment. (ISO)
SAFETY! Informs the reader of general safety information, reminders,
precautions, or policies not related to a particular source of hazard or to
fire safety. (ISO, ANSI, OSHA)
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
Important Safety Instructions
Safety Admonishments Definitions
Definitions of the safety admonishments used in this document are listed under
“Admonishments Used in this Document” on page iv.
General Safety
DANGER! YOU MUST FOLLOW APPROVED SAFETY PROCEDURES. Performing the following
procedures may expose you to hazards. These procedures should be performed by
qualified technicians familiar with the hazards associated with this type of
equipment. These hazards may include shock, energy, and/or burns. To avoid
these hazards: a) The tasks should be performed in the order indicated. b)
Remove watches, rings, and other metal objects. c) Prior to contacting any
uninsulated surface or termination, use a voltmeter to verify that no voltage
or the expected
voltage is present. Check for voltage with both AC and DC voltmeters prior to
making contact. d) Wear eye protection. e) Use certified and well maintained
insulated tools. Use double insulated tools appropriately rated for the work
to be
performed.
Voltages
AC Input Voltages
DANGER! This system operates from AC input voltage capable of producing fatal
electrical shock. AC input power must be completely disconnected from the
branch circuits wiring used to provide power to the system before any AC
electrical connections are made. Follow local lockout/tagout procedures to
ensure upstream branch circuit breakers remain deenergized during
installation. DO NOT apply AC input power to the system until all electrical
connections have been completed and checked.
DC Output and Battery Voltages
DANGER! This system produces DC power and may have a battery source connected
to it. Although the DC voltage is not hazardously high, the rectifiers and/or
battery can deliver large amounts of current. Exercise extreme caution not to
inadvertently contact or have any tool inadvertently contact an output
terminal or battery terminal or exposed wire connected to an output terminal
or battery terminal. NEVER allow a metal object, such as a tool, to contact
more than one termination or battery terminal at a time, or to simultaneously
contact a termination or battery terminal and a grounded object. Even a
momentary short circuit can cause sparking, explosion, and injury. DANGER!
Follow local lockout/tagout procedures to ensure DC branch circuit protection
devices remain de-energized during installation at loads, as required.
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
Battery
Refer to the battery manufacturer documentation for specific battery safety
instructions. The following are general guidelines. WARNING! Correct polarity
must be observed when connecting battery leads.
WARNING! Special safety precautions are required for procedures involving
handling, installing, and servicing batteries. Observe all battery safety
precautions in this manual and in the battery instruction manual. These
precautions should be followed implicitly at all times. WARNING! A battery can
present a risk of electrical shock and high short circuit current. Servicing
of batteries should be performed or supervised only by properly trained and
qualified personnel knowledgeable about batteries and the required
precautions. The following precautions should be observed when working on
batteries: · Follow the recommended PPE requirements per the SDS for the
battery to be used. · Batteries are an energy source that can produce high
amounts of electrical current. · Remove watches, rings, and other metal
objects. · Eye protection should be worn to prevent injury from accidental
electrical arcs. · Use certified and well maintained insulated tools. Use
double insulated tools appropriately rated for the work to be
performed. Ensure that wrenches with more than one working end have only one
end exposed. · Do not lay tools or metal parts on top of batteries. · Verify
that no current will flow when the battery is connected or disconnected by
opening battery disconnects (if
available) or adjusting the system to match battery voltage. · Risk of
explosion if battery is replaced with an incorrect type or if polarity is
reversed. Recommended to replace
batteries with the same manufacturer and type, or equivalent. · Dispose of
used batteries according to the instructions provided with the batteries. Do
not dispose of batteries in a fire.
They may explode. · Batteries may generate explosive gases during normal
operation. Systems containing batteries should never be installed
in an airtight room or space. Only install in a ventilated environment. ·
Batteries may contain sulfuric acid. If battery acid enters your eye,
immediately flush your eye with running cold water
for at least 15 minutes. Get medical attention immediately. If battery acid
contacts skin or clothing, wash immediately with soap and water. · Do not open
or mutilate batteries. · ALWAYS FOLLOW THE BATTERY MANUFACTURER’S
RECOMMENDATIONS AND SAFETY INSTRUCTIONS. ALERT! Performing maintenance and/or
troubleshooting procedures may interrupt power to the loads, if battery
reserve is not sufficient.
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
Personal Protective Equipment (PPE)
DANGER! ARC FLASH AND SHOCK HAZARD. Appropriate PPE and tools required when
working on this equipment. An appropriate flash protection boundary analysis
should be done to determine the “hazard/risk” category, and to select proper
PPE. Only authorized and properly trained personnel should be allowed to
install, inspect, operate, or maintain the equipment. Do not work on LIVE
parts. If required to work or operate live parts, obtain appropriate Energized
Work Permits as required by the local authority, per NFPA 70E “Standard for
Electrical Safety in the Workplace”.
Hazardous Voltage
DANGER! HAZARD OF ELECTRICAL SHOCK. More than one disconnect may be required
to de-energize the system before servicing.
Handling Equipment Containing Static Sensitive Components
ALERT! Installation or removal of equipment containing static sensitive
components requires careful handling. Before handling any equipment containing
static sensitive components, read and follow the instructions contained on the
Static Warning Page.
Maintenance and Replacement Procedures
CAUTION! When performing any step in procedures that requires removal or
installation of hardware, use caution to ensure no hardware is dropped and
left inside the unit; otherwise service interruption or equipment damage may
occur. NOTE! When performing any step in procedures that requires removal of
existing hardware, retain all hardware for use in subsequent steps, unless
otherwise directed.
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
Static Warning
This equipment contains static sensitive components. The warnings listed below
must be observed to prevent damage to these components. Disregarding any of
these warnings may result in personal injury or damage to the equipment. 1.
Strictly adhere to the procedures provided in this document. 2. Before
touching any equipment containing static sensitive components, discharge all
static electricity from yourself by
wearing a wrist strap grounded through a one megohm resistor. Some wrist
straps have a built-in one megohm resistor; no external resistor is necessary.
Read and follow wrist strap manufacturer’s instructions outlining use of a
specific wrist strap. 3. Do not touch traces or components on equipment
containing static sensitive components. Handle equipment containing static
sensitive components only by the edges that do not have connector pads. 4.
After removing equipment containing static sensitive components, place the
equipment only on static dissipative surfaces such as conductive foam or ESD
bag. Do not use ordinary Styrofoam or ordinary plastic. 5. Store and ship
equipment containing static sensitive components only in static shielding
containers. 6. If necessary to repair equipment containing static sensitive
components, wear an appropriately grounded wrist strap, work on a conductive
surface, use a grounded soldering iron, and use grounded test equipment.
viii
VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
1 Customer Documentation Package
This document (UM582127000100) provides User Instructions for VertivTM
NetSureTM -48 VDC Power System Model 7100, Spec. No. 582127000, Lists 100,
101, 102, 103, 203, 500, 501, 502, and 503 only. The complete Customer
Documentation Package for Lists 100, 101, 102, 103, 203, 500, 501, 502, and
503 consists of…
NetSure -48 VDC Power System Installation Manual
· Power System Installation Instructions: IM582127000100
NetSure -48 VDC Power System User Manual
· Power System User Instructions: UM582127000100
NetSure NCU Controller User Manual
· NCU Controller User Instructions: UM1M830BNA
USB Drive with All Customer Documentation for 582127000
Applicable documents for this system are as follows. · Power System
Installation Instructions: IM582127000100 (instructions for Lists 100, 101,
102, 103, 203, 500, 501, 502, and 503) · Power System User Instructions:
UM582127000100 (instructions for Lists 100, 101, 102, 103, 203, 500, 501, 502,
and 503) · NCU Controller User Instructions: UM1M830BNA · Rectifier
Instructions: UM1R482000e3 · -48 VDC to +24 VDC Converter Instructions:
UM1C48241500 · -48 VDC to -58 VDC Converter Instructions: UM1C48582000P3 ·
Power System “System Application Guide”: SAG582127000 · Engineering Drawings ·
Also provided on the USB drive is a controller configuration drawing and the
controller configuration files loaded into the controller as shipped.
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
2 System Description
2.1 Lists 100, 101, 102, 103, and 203
-48 VDC @ 1000 A and +24 VDC @ 500 A Power System
Lists 100, 101, 102, 103, and 203 of NetSure 7100 DC Power System are
integrated power systems containing -48 VDC rectifiers, +24 VDC converters,
intelligent control, metering, monitoring, and distribution.
This power system is designed to power a load while charging a positive
grounded battery. This power system is capable of operating in a batteryless
installation or off battery for maintenance purposes. The power system is
designed for operation with the positive output grounded.
List 100, 103, and 203 of NetSure 7100 DC Power System consist of the
following components mounted in a 7’0″ x 23″ relay rack, List 101 is mounted
in 5’0″ x 23″ relay rack, and List 102 is mounted in a 6’0″ x 23″ relay rack.
Distribution Cabinet
A 3-row distribution cabinet is provided. The distribution cabinet is equipped
with manual battery disconnect. Installed in the distribution cabinet are one
(1) List DJ distribution panel and two (2) List AL distribution panels. See
SAG582127000 for descriptions.
The distribution cabinet also houses one (1) IB2 controller interface board,
one (1) optional EIB controller extended interface board, the IB4 second
Ethernet port board, and the system interface board. See SAG582127000 for
descriptions.
NCU (NetSure Control Unit) Controller
The controller provides power system control, rectifier control (including a
charge control function), converter control, metering functions, monitoring
functions, and local/remote alarm functions. The controller also supports
rectifier temperature compensation if the system is equipped with a
temperature probe(s). Temperature probe(s) may also be designated to monitor
ambient temperature and/or battery temperature. The controller also provides
data acquisition, system alarm management, and advanced battery and energy
management. The controller contains a color LCD display and keypad for local
access. The controller provides an Ethernet port and comes with comprehensive
webpages for remote access. The controller has SNMP v3 capability for remote
system management. The controller supports software upgrade via its USB port.
Refer to the NCU Controller Instructions (UM1M830BNA) for more information.
Rectifier Modules
The system contains rectifier modules, which provide load power, battery float
current, and battery recharge current during normal operating conditions.
Refer to the Rectifier Instructions (UM1R482000e3) for more information.
-48 VDC to +24 VDC DC-DC Converter Modules
Where +24 VDC load power is also required, -48 VDC to +24 VDC DC-DC converter
modules are available. Refer to the Converter Instructions (UM1C48241500) for
more information.
List 100
List 100 provides zero (0) battery tray.
List 101
List 101 provides one (1) battery tray.
List 102
List 102 provides two (2) battery trays.
List 103
List 103 provides three (3) battery trays.
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
List 203
List 203 provides three (3) battery trays.
2.2 Lists 500, 501, 502, and 503
-48 VDC @ 1000 A and -58 VDC @ 500 A Power System
Lists 500, 501, 502, and 503 of NetSure 7100 DC Power System are integrated
power systems containing -48 VDC rectifiers, -58 VDC converters, intelligent
control, metering, monitoring, and distribution.
This power system is designed to power a load while charging a positive
grounded battery. This power system is capable of operating in a batteryless
installation or off battery for maintenance purposes. The power system is
designed for operation with the positive output grounded.
List 500 and 503 of NetSure 7100 DC Power System consist of the following
components mounted in a 7’0″ x 23″ relay rack, List 501 is mounted in 5’0″ x
23″ relay rack, and List 502 is mounted in a 6’0″ x 23″ relay rack.
Distribution Cabinet
A 3-row distribution cabinet is provided. The distribution cabinet is equipped
with manual battery disconnect. Installed in the distribution cabinet are one
(1) List FJ distribution panel and two (2) List AL distribution panels. See
SAG582127000 for descriptions.
The distribution cabinet also houses one (1) IB2 controller interface board,
one (1) optional EIB controller extended interface board, the IB4 second
Ethernet port board, and the system interface board. See SAG582127000 for
descriptions.
NCU (NetSure Control Unit) Controller
The controller provides power system control, rectifier control (including a
charge control function), converter control, metering functions, monitoring
functions, and local/remote alarm functions. The controller also supports
rectifier temperature compensation if the system is equipped with a
temperature probe(s). Temperature probe(s) may also be designated to monitor
ambient temperature and/or battery temperature. The controller also provides
data acquisition, system alarm management, and advanced battery and energy
management. The controller contains a color LCD display and keypad for local
access. The controller provides an Ethernet port and comes with comprehensive
webpages for remote access. The controller has SNMP v3 capability for remote
system management. The controller supports software upgrade via its USB port.
Refer to the NCU Controller Instructions (UM1M830BNA) for more information.
Rectifier Modules
The system contains rectifier modules, which provide load power, battery float
current, and battery recharge current during normal operating conditions.
Refer to the Rectifier Instructions (UM1R482000e3) for more information.
-48 VDC to -58 VDC DC-DC Converter Modules
Where -58 VDC load power is also required, converter modules are available.
These converters operate from the main -48 VDC system bus to provide -58 VDC
load power. Refer to the Converter Instructions (UM1C48582000P3) for more
information.
List 500
List 500 provides zero (0) battery tray.
List 501
List 501 provides one (1) battery tray.
List 502
List 502 provides two (2) battery trays.
List 503
List 503 provides three (3) battery trays.
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
3 Operating Procedures
3.1 Controller, Rectifiers, and Converters
For operation instructions on these units, refer to the following documents.
· NCU Controller Instructions (UM1M830BNA)
· Rectifier Instructions (UM1R482000e3)
· -48 VDC to +24 VDC Converter Instructions (UM1C48241500)
· -48 VDC to -58 VDC Converter Instructions (UM1C48582000P3)
3.2 ESTOP Function
If an ESTOP switch is wired to the IB2-1 Controller Interface Board, customer-
furnished system ground applied to terminal DI8+ activates the ESTOP function.
The ESTOP function shuts down and locks out the rectifiers, shuts down and
locks out the optional -48 VDC to +24 VDC converters or -48 VDC to -58 VDC
converters, and opens the optional low voltage disconnect (LVD) contactors
(battery and load type). If the system has battery connected and does not
contain a battery LVD or the controller power option is set to Battery Pwr
(jumper J3 on the system interface board is set to Battery Pwr), the
controller will remain operational. If the system does not contain battery or
load LVD(s) and has battery connected, the loads will be sustained by the
battery voltage.
For Systems NOT Containing a Battery LVD: When the ESTOP signal is removed,
LVD contactors (battery and load type) will close after the “LVD Reconnect
Delay” has elapse (customer configurable via the controller) if battery
voltage is present on the bus. Rectifiers and -48 VDC to +24 VDC converters or
-48 VDC to -58 VDC converters will remain off. The rectifiers will restart
when the input power is removed and restored after 30 seconds or more (until
the LEDs on the modules extinguish). To restart the -48 VDC to +24 VDC
converters or -48 VDC to -58 VDC converters: remove the converter, wait 30
seconds or more (until the LEDs on the converter extinguish), then re-insert
the converter.
For Systems Containing a Battery LVD: When the ESTOP signal is removed, LVD
contactors (battery and load type) will remain open. Rectifiers and -48 VDC to
+24 VDC converters or -48 VDC to -58 VDC converters will remain off. The
rectifiers will restart when the input power is removed and restored after 30
seconds or more (until the LEDs on the modules extinguish). When the
rectifiers restart, LVD contactors (battery and load type) will close after
the “LVD Reconnect Delay” has elapse (customer configurable via the
controller) and the -48 VDC to +24 VDC converters or -48 VDC to -58 VDC
converters will restart.
NOTE! If a customer-furnished method to disconnect the input power to the
system is not provided, the rectifiers will stay locked OFF until the input
power is recycled. If the ESTOP signal is removed without recycling the input
power, the rectifiers will remain off and have a local alarm visible on the
module. The ESTOP alarm from the controller will extinguish. The controller
will not issue an alarm for this condition.
3.3 Controller Battery Charge Current Limit Feature
Functionality: After a failure of the input source (commercial AC) or when
some battery cells are permanently damaged, the current to the batteries can
be quite extensive. To avoid overheating or further damages to the battery,
the controller can be programmed to limit the battery current to a preset
level by limiting the charging voltage of the rectifiers. Should the battery
current still exceed a higher preset value, an alarm is issued.
The controller limits the current going to the batteries based on the “Battery
Current Limit” set point which is a percentage of the battery capacity in C10.
For example, 0.1C10 would mean 10% of the battery capacity.
Refer to the NCU Controller Instructions (UM1M830BNA) to program this feature.
Battery charge current is limited to the value set in the controller, as long
as battery voltage is above 47 VDC. The default value for battery recharge
current limit is 0.1xC10.
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
3.4 Local Controls and Indicators
3.4.1 Controller, Rectifiers, and Converters
Refer to the controller, rectifier, and converter instructions for
descriptions of the local controls and indicators located on these units.
3.4.2 Distribution Cabinet
Refer to this section for descriptions of the local controls and indicators
located on the circuit cards installed in the distribution cabinet.
System Interface Board Indicator, Switch, and Test Points
The system interface board contains a manual battery disconnect switch and
indicator. The board also contains test points to externally monitor system
voltage. Refer to Figure 3.1 for circuit card location and Figure 3.2 for
indicator, switch, and test points descriptions.
ALERT! Do not hold MBD switch (S1) in the up or down position for more than 3
seconds to avoid damaging the contactor. ALERT! When using switch, after
either pushing up or down let switch return to the center position for 3
seconds before pushing switch in the opposite direction to avoid damaging the
contactor.
IB2 (Controller Interface Board) and OptionalEIB (Controller Extended
Interface Board) Indicator
The IB2 and optional EIB boards have a green LED indicator which is lit in
normal operation and flashes when the IB2 or EIB board is communicating with
the controller. Refer to Figure 3.1 for IB2 and EIB locations.
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
Figure 3.1 Circuit Card Locations
Distribution Cabinet
NCU Controller 1M830DNA
System Interface Board 562662
Optional EIB-1 (Extended
Interface Board) MA455U41
(Front Door Removed in Illustration for Clarity)
IB2-1 (Interface Board #1) MA4C5U31
IB4 (2nd Ethernet Port Board)
558076
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
Figure 3.2 System Interface Board
F2 F1
562662
K4
CR4 R9
R8
CR1 CR3
J1 J4
R14 R16 R18
R15
TB1
K3
K2
J6
R5
R11
R10
J5
K1
R2 R1 R3 R4 CR2
TP1
R6
J3
S1
AXXXXXXXX
DS1
000XXXXX
R12 R13 C1
TP2 R7
J2 H1
Manual Battery Disconnect Switch
Manual Battery Disconnect Active Indicator
TP1 (-) and TP2 (+) System Voltage
Illuminates if the Battery Disconnect Contactor has been manually disconnected (placed in open position).
Momentary UP / Middle / Momentary Down Momentary UP Position: Closes (latches in close position) the Battery Disconnect Contactor.
Middle Position:
Normal Operation.
Momentary DOWN Position: Opens (latches in open position) the Battery Disconnect Contactor. Momentarily place switch in the UP position to close the contactor.
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
4 Maintenance
4.1 System Maintenance Procedures
It is recommended to perform the maintenance procedures listed in Table 4.1
every 6-months to ensure continual system operation.
Table 4.1 Maintenance Procedures to be Performed at 6-Month Intervals
Procedure
Referenced In
Check ventilation openings for obstructions such as dust, papers, manuals, etc.
—
Inspect and tighten all installer’s connections.
IM582127000100, “Making Electrical Connections” section.
4.2 Adding a Rectifier or Converter Module to an Existing Module Mounting
Assembly Spec. No. 588705300
To increase system current capacity, a rectifier module can easily be added to
an existing module mounting assembly Spec. No. 588705300 that contains an
empty rectifier module mounting position. Likewise, to increase subsystem
capacity a -48 VDC to +24 VDC DC-DC converter module can be added to a module
mounting assembly Spec. No. 588705300 that contains an empty -48 VDC to +24
VDC converter module mounting position. A -48 VDC to -58 VDC DC-DC converter
module can be added to a module mounting shelf that contains an empty -48 VDC
to -58 VDC converter module mounting position.
Rectifier and converter modules can be inserted or removed with power applied
(hot swappable).
Rectifiers modules can be installed in any mounting position of each module
mounting assembly. Converter modules can be installed in any of the three far
right mounting positions of the three lower module mounting assemblies (as
viewed from the front). See Figure 4.3. See Alerts below for restrictions.
NOTE! Each rectifier and converter module locks into the module mounting
assembly by means of a latch located on the bottom of the module. The latch
and module handle are interactive. Pushing the handle up into the module’s
front panel causes the latch to extend to the locking position; pulling the
handle down out from the module’s front panel causes the latch to retract. See
Figure 4.3.
WARNING! To prevent damage to the latching mechanism, ensure the handle is in
the open position when installing or removing a module. NEVER hold the handle
in the closed position when installing a module into a shelf.
ALERT! The system can either have +24V DC-DC converters installed or -58V DC-
DC converters installed. The system cannot have both types of converters
installed at the same time.
ALERT! The -48 VDC to +24 VDC converter modules must only be installed in a
system position that accepts a +24V DC-DC converter. Refer to labeling on the
system’s module mounting shelf. A sample of this labeling is provided in
Figure 4.1.
Figure 4.1 Sample Module Mounting Shelf Labeling
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
ALERT! The -48 VDC to -58 VDC converter modules must only be installed in a
system position that accepts a -58V DC-DC converter. Refer to labeling on the
system’s module mounting shelf. A sample of this labeling is provided in
Figure 4.2. Figure 4.2 Sample Module Mounting Shelf Labeling
Procedure 1. Unpack the modules. 2. Note the model number located on the front
of each module. Model numbers starting with the letter “R” are rectifier
modules. Model numbers starting with the letter “C” are converter modules. 3.
Place the module into an unoccupied mounting position without sliding it in
completely. Rectifier modules can be installed in any mounting position of
each module mounting assembly. Converter modules can be installed in any of
the three far right mounting positions of the three lower module mounting
assemblies (as viewed from the front). See Figure 4.3. 4. Loosen the captive
screw on the module’s handle. Pull the handle down out from the module’s front
panel (this will also retract the latch mechanism). See Figure 4.3. 5. Push
the module completely into the shelf. 6. Push the handle up into the module’s
front panel. This will lock the module securely to the shelf. Tighten the
captive screw on the handle. 7. Repeat the above steps for each module being
installed in the system. 8. After the modules are physically installed in the
module mounting assembly(s), they are ready for operation immediately after
power is supplied to them. NOTE! It is recommended that the current limit
point be checked whenever a rectifier is added to or removed from the power
system. Refer “Checking the Controller’s Current Limit Point after Adding or
Removing a Rectifier Module” on page 20. NOTE! The rectifier or converter
being added is assigned by the controller the lowest available identification
number. If desired, you can change the identification number. Refer to the NCU
Controller Instructions (UM1M830BNA) for a procedure.
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
Figure 4.3 Installing Rectifier and Converter Modules in a Spec. No. 588705300
Module Mounting Assembly
Front View
Rectifiers Only in Top Shelf Rectifiers in Any Position Rectifiers or
Converters in Far Right Three Positions
Rectifier or Converter Module
Captive Screw
Handle
Model Number Label (R48-2000e3 Rectifier) (C48/24-1500 Converter)
(C48/58-2000P3 Converter)
10
Latch
VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
4.3 Reconfiguring a Dual Voltage Distribution Panel (List DJ, FG, and FK)
Perform the following procedure to reconfigure a dual voltage distribution
panel (List DJ, FG, and FK) to move distribution positions from one voltage to
the other.
DANGER! Performing this procedure exposes service personnel to battery
potential. Exercise extreme caution not to inadvertently contact or have any
tool inadvertently contact any energized electrical termination. NOTE! Save
all removed hardware. Hardware will be re-used.
4.3.1 Removing the Distribution Panel
Procedure 1. Performing this procedure may activate external alarms. Do one of
the following. If possible, disable these alarms. If these alarms cannot be
easily disabled, notify the appropriate personnel to disregard any future
alarms associated with this system while the procedure is being performed. 2.
Open the distribution cabinet’s front door by turning the latch in the
counterclockwise position. 3. Remove the plastic shield covering the circuit
breakers and/or fuseholders on the distribution panel to be removed by
loosening the screws holding the shield and sliding the shield upwards. 4.
Record circuit breaker and/or fuse positions and sizes. 5. Remove circuit
breakers and/or fuseholders. 6. Label the load leads. 7. Disconnect and
insulate all load leads from the circuit breaker and/or fuse positions. 8.
Disconnect and insulate all load return leads from the ground busbar. 9. Refer
to Figure 4.4 and remove the hardware securing the +24V or -58V jumper leads.
Insulate and tie back these leads. 10. Refer to Figure 4.4 and locate the in-
line FA/CBA connector located near the back of the distribution panel.
Separate the connector halves. 11. Refer to Figure 4.4 and remove the hardware
securing the distribution panel’s ground busbar to the distribution cabinet’s
busbar. 12. Refer to Figure 4.4 and remove the hardware securing the
distribution panel’s system load distribution busbar to the distribution
cabinet’s busbar. 13. Refer to Figure 4.4 and remove the hardware securing the
distribution panel to the distribution cabinet. Remove the distribution panel
from the distribution cabinet.
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
Figure 4.4 Removing/Installing the Distribution Panel
Distribution Panel Hardware
10-32 x 5/8″ Screw #10 Flat Washer Torque to 31 in-lbs.
Ground Busbar Hardware
1/4-20 x 1″ Bolt 1/4″ Belleville Lock Washer 1/4″ Flat Washer Torque to 60 in-
lbs.
System Load Distribution Busbar Hardware
1/4-20 x 1″ Bolt 1/4″ Belleville Lock Washer 1/4″ Flat Washer Torque to 60 in-
lbs.
Front
In-Line FA/CBA Connector
Components removed in illustration for clarity only.
Distribution Panel Hardware 10-32 x 5/8″ Screw #10 Flat Washer Torque to 31
in-lbs.
Front
List DG (Lists DE, DF, DH, DJ, DK FG, FE, FF, FH, FJ, and FK similar.)
Rear
Lugs can be landed back-to-back.
Connect “+24V” or “-58V” jumpers to an available landing here. Assembly order
is: lug, 1/4″ flat washer, 1/4″ lock washer, 1/4-20 x 3/4″ bolt. Torque to 84
in-lbs.
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
4.3.2 Reworking the Distribution Panel
You can reconfigure the distribution panel to swap -48V distribution positions
for +24V or -58V distribution positions, and vice versa, in groups of four.
The resulting assembly can have following positions. See Table 4.2.
Table 4.2 Positions
(0) -48V (6) -48V (10) -48V (14) -48V (18) -48V (22) -48V (26) -48V
Positions
(26) +24V or -58V (20) +24V or -58V (16) +24V or -58V (12) +24V or -58V (8) +24V or -58V (4) +24V or -58V (0) +24V or -58V
You do this by moving the shorting bus and CBA/FA alarm strap. Refer to Figure
4.5 to reconfigure the distribution panel.
Note that for a List DE and FE distribution panel, you must also move the
subsystem input power busbar as shown in Figure 4.5.
Note that if you reconfigure a distribution panel for all subsystem voltage
(List DK or FK) or all system voltage, you must also move the extra CBA/FA
alarm strap stored on the far left (as viewed from the rear) to the far right
position (as shown in Figure 4.5).
Note that if you reconfigure a distribution panel for all subsystem voltage
(List DK or FK), you must disconnect and insulate the system CBA/FA lead (as
shown in Figure 4.5).
Note that if you reconfigure a distribution panel for all system voltage, you
must disconnect and insulate the subsystem CBA/FA lead (as shown in Figure
4.5).
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
Figure 4.5 Reworking the Distribution Panel (cont’d on next page)
List DE or FE Dual Voltage Distribution Panel
List DF or FF Dual Voltage Distribution Panel
List DG or FG Dual Voltage Distribution Panel
List DH or FH Dual Voltage Distribution Panel
List DJ or FJ Dual Voltage Distribution Panel
List DK or FK Dual Voltage Distribution Panel
Reconfigured for all System Positions
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
Figure 4.5 Reworking the Distribution Panel (cont’d from previous page, cont’d
on next page)
List DE and FE Only: Move the +24V or -58V Input Power Busbar one (1) position
to the left.
List DE and FE Dual Voltage Distribution Panel
Before
After
From the front, remove the polarity labels for the positions reassigned and
turn the label over so the other polarity shows. See Detail A.
From the front, remove the voltage barrier shield from the right-most EXISTING
sub-system distribution position and place it in the right-most NEW sub-system
distribution position. See Detail B.
List DE and FE Only: Move the CBA/FA alarm strap at the desired point of the
voltage division to the location above the relocated +24V or -58V Input Power
Busbar.
List DE and FE Only: Move the Shorting Bus at the desired point of the voltage
division to the far right position.
Move Shorting Bus Here
Move CBA/FA Alarm Strap Here
6-19 x 1/2 Screw Torque to 9.6 in-lbs.
Apply a thin coating of electrical anti-oxidizing compound to the mating surfaces of the busbars.
1/4-20 x 5/8 Bolt
Move
1/4″ Lock Washer
+24V or -58V Input 1/4″ Flat Washer
Power Bus Here Torque to 75 in-lbs.
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
Figure 4.5 Reworking the Distribution Panel (cont’d from previous page, cont’d on next page)
List DF, DG, DH, DJ FF, FG, FH, FJ Dual Voltage Distribution Panel (DF Shown, Others Similar)
Before
After
From the front, remove the polarity labels for the positions reassigned and
turn the label over so the other polarity shows. See Detail A.
From the front, remove the voltage barrier shield from the right-most EXISTING
sub-system distribution position and place it in the right-most NEW sub-system
distribution position. See Detail B.
Move the CBA/FA alarm strap at the desired point of the voltage division to
the new location.
Move the Shorting Bus at the desired point of the voltage division to the new
location.
Input Power Busbar Not Shown
Move Shorting Bus Here
Move CBA/FA Move CBA/FA Alarm Strap Alarm Strap Here Here
6-19 x 1/2 Screw Torque to 9.6 in-lbs.
Input Power Busbar Not Shown
Move Shorting Bus Here
1/4-20 x 5/8 Bolt 1/4″ Lock Washer 1/4″ Flat Washer Torque to 75 in-lbs.
Apply a thin coating of electrical anti-oxidizing compound to the mating surfaces of the busbars.
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
Figure 4.5 Reworking the Distribution Panel (cont’d from previous page, cont’d on next page)
Distribution Panel Reconfigured for All Subsysytem (List DK) or All System Positions
Apply a thin coating of electrical anti-oxidizing compound to the mating surfaces of the busbars.
From the front, remove the polarity labels for the positions reassigned and
turn the label over so the other polarity shows. See Detail A.
From the front, remove the voltage barrier shield. See Detail B.
1/4-20 x 5/8 Bolt 1/4″ Lock Washer 1/4″ Flat Washer Torque to 75 in-lbs.
All Except List DE: Move the Shorting Bus Stored Here to the Open Position
Ensure the Subsystem Busbar is Installed in
this Position
Modified Panel View
Move CBA/FA Alarm Strap TO Here
6-19 x 1/2 Screw Torque to 9.6 in-lbs.
Move CBA/FA Alarm Strap FROM Here
Before Modification View: An Alarm Strap is Stored Here
Note that if you reconfigure a distribution panel for all subsystem voltage
(List DK and FK), you must disconnect and insulate the system CBA/FA lead
attached here.
After Modification View: The Alarm Strap is Moved Here
Note that if you reconfigure a distribution panel for all system voltage, you
must disconnect and insulate the subsystem CBA/FA lead attached here.
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
Figure 4.5 Reworking the Distribution Panel (cont’d from previous page)
Detail A
Front
For reassigned distribution positions…
1. Remove polarity label plug buttons.
Barrier (Voltage Divider)
2. Remove polarity label. 3. Turn over polarity label so other polarity shows. 4. Replace polarity label.
For the Barrier (Voltage Divider) position…
5. Replace polarity label plug buttons.
1. Remove the Barrier (Voltage Divider).
2. Install the Barrier (Voltage Divider) on the reconfigured panel
where it separates -48V and +24 or -58V busbars.
Detail B
Sub-System System Voltage Voltage
Old Location Voltage Barrier Shield
New Location Voltage Barrier Shield
Load Lug
Load Lug
Front 18
For right-most reassigned sub-system distribution position… 1. Remove the load
lug from the right-most
EXISTING sub-system distribution position. 2. Replace the load lug from the
right-most EXISTING sub-system
distribution position WITHOUT the voltage barrier shield. 3. Remove the load
lug from the right-most
NEW sub-system distribution position. 4. Replace the load lug from the right-
most NEW sub-system
distribution position WITH the voltage barrier shield.
VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
4.3.3 Replacing the Distribution Panel
NOTE! In the following procedure, before making busbar-to-busbar connections,
apply a thin coating of electrical antioxidizing compound to the mating
surfaces of the busbars. Procedure NOTE! If the panel is re-configured for all
subsystem positions (List DK or FK), the distribution cabinet’s load side
busbar must be removed since it is not to be connected to the distribution
panel and will cause interference. Note that the busbar that is removed should
be retained in the event that the panel is re-configured at a later date to
revert back to a panel with some subsystem positions. 1. If the panel is re-
configured for all subsystem positions, remove the distribution cabinet’s load
side busbar. Save this busbar and hardware for future use. 2. Orient the
distribution panel into the distribution cabinet, checking to ensure no wires
are pinched. Replace the hardware securing the distribution panel to the
distribution cabinet. Refer to Figure 4.4 for hardware build-up. Torque as
indicated in Figure 4.4. 3. Reconnect the +24V or -58V jumper leads. Refer to
Figure 4.4 for hardware build-up. Torque as indicated in Figure 4.4. For a
panel re-configured to all -48V positions, the +24V or -58V jumper leads MUST
not be used. They should be retained at the site for future use if necessary.
4. In all except panels re-configured for all subsystem positions (List DK or
FK), replace the hardware securing the distribution panel’s system load
distribution busbar to the distribution cabinet’s busbar. Refer to Figure 4.4
for hardware build-up. Torque as indicated in Figure 4.4. 5. Replace the
hardware securing the distribution panel’s ground busbar to the distribution
cabinet’s busbar. Torque as indicated in Figure 4.4. 6. Plug the in-line
FA/CBA connector located near the back of the distribution panel into the
mating connector half in the distribution cabinet. Refer to Figure 4.4.
WARNING! In the next step, observe correct polarity; otherwise equipment
damage will result.
7. Reconnect the load return leads to the ground busbar. 8. Reconnect the
load leads to the circuit breaker and/or fuse positions. 9. Replace the
circuit breakers and/or fuseholders. 10. Replace the plastic shield covering
the circuit breakers and/or fuseholders on the distribution panel. 11. Verify
no circuit breaker/fuse alarms are active. 12. Close the distribution
cabinet’s front door. Turn the latch clockwise to secure the door. 13. Ensure
that there are no local or remote alarms active on the system.
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
5 Troubleshooting and Repair
5.1 Contact Information
Refer to Section 4154 (provided with your customer documentation) for support
contact information.
5.2 Controller, Rectifiers, and Converters
For troubleshooting and repair instructions on these units, refer to the
following documents. · NCU Controller Instructions (UM1M830BNA) · Rectifier
Instructions (UM1R482000e3) · -48 VDC to +24 VDC Converter Instructions
(UM1C48241500) · -48 VDC to -58 VDC Converter Instructions (UM1C48582000P3)
5.3 Controller Configuration
If any controller configuration settings were changed, refer to the NCU
Controller Instructions (UM1M830BNA) and save a copy of the configuration
file. This file can be used to restore the controller settings, if required,
at a later date.
· Note that provided on a USB drive furnished with the system is a controller
configuration drawing (C-drawing) and the controller configuration files
loaded into the controller as shipped.
5.4 System Troubleshooting Information
This system is designed for ease in troubleshooting and repair. The various
indicators as described in “Local Controls and Indicators” on page 5 and in
the controller, rectifier, and converter instructions are designed to isolate
failure to a specific element. Once the faulty element has been identified,
refer to “Replacement Information” on page 21 and “Replacement Procedures” on
page 21.
Troubleshooting Alarm Conditions on the Controller
The controller displays alarm conditions as listed in the “Resolving Alarms”
section of the controller’s User Manual. Programmable external alarm relays
are also available. Refer to the System Installation Instructions
(IM582127000100) and the configuration drawing (C-drawing) supplied with your
power system documentation for your alarm relay configurations.
The controller’s Active Alarm and Alarm History submenus allow the User to
view alarm details. Refer to the NCU Controller Instructions (UM1M830BNA) to
access these menus.
Checking the Controller’s Current Limit Point after Adding or Removing a
Rectifier Module
If a rectifier module is added to the power system, the system current limit
point will automatically increase by the percentage each existing rectifier
was set to provide prior to the addition.
If a rectifier module is removed from the system (and the Rect Comm Fail alarm
is reset), the current limit point will remain unchanged unless the capacity
of the remaining rectifiers is not sufficient to maintain the present current
limit point. If that happens, the current limit point will automatically
increase to the maximum (121% of the remaining rectifiers).
It is recommended that the current limit point be checked whenever a rectifier
module is added to or removed from the power system.
When setting total rectifier current limit, the set point to each rectifier is
the total set point divided by the number of rectifiers. For example, if the
system contains five rectifiers and the current limit is set to 150 amps then
each rectifier has a current limit set point of 30 amps. If one or more
rectifiers are removed or fail it will take several seconds for the individual
set points to the remaining rectifiers to be reset. In the example given, if
one rectifier is removed the current limit set point will drop to 120 amps (30
amps times four remaining rectifiers) until the controller can send updated
set points to the remaining rectifiers.
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
This takes a couple communication cycles (several seconds) after which each
rectifier would have a new set point of 37.5 amps for a total of 150 amps. The
total current limit of the rectifiers should not be set such that the loss of
the redundant rectifiers will cause this temporary set point to drop below the
actual maximum expected load. If batteries are used on the rectifier output,
the batteries should support the load until the current limit set points can
be re-established due to loss of a rectifier. Refer to the NCU Controller
Instructions (UM1M830BNA) for a procedure.
Clearing a Rectifier Communications Fail Alarm after Removing a Rectifier
If a rectifier module is removed from the system, a rectifier communications
failure alarm is generated. If the rectifier module will not be replaced, the
alarm should be cleared. Refer to the NCU Controller Instructions (UM1M830BNA)
for a procedure.
Clearing a Converter Communications Fail Alarm after Removing a Converter
If a converter module is removed from the system, a converter communications
failure alarm is generated. If the converter module will not be replaced, the
alarm should be cleared. Refer to the NCU Controller Instructions (UM1M830BNA)
for a procedure.
Clearing a Rectifier Lost Alarm
If the controller resets while a rectifier communications fail alarm is
active, the rectifier communications fail alarm is replaced with a rectifier
lost alarm. Refer to the NCU Controller Instructions (UM1M830BNA) for a
procedure to clear the alarm.
Clearing a Converter Lost Alarm
If the controller resets while a converter communications fail alarm is
active, the converter communications fail alarm is replaced with a converter
lost alarm. Refer to the NCU Controller Instructions (UM1M830BNA) for a
procedure to clear the alarm.
5.5 Replacement Information
Replacement Assemblies
When a trouble symptom is localized to a faulty rectifier module, converter
module, controller, or system circuit card; that particular device or circuit
card should be replaced in its entirety. No attempt should be made to
troubleshoot or repair individual components on any rectifier module,
converter module, controller, or circuit card. Refer to SAG582127000 (System
Application Guide) for replacement part numbers.
5.6 Replacement Procedures
DANGER! Adhere to the “Important Safety Instructions” presented at the front
of this document.
5.6.1 Replacing a Rectifier or Converter Module
Refer to the Rectifier User Instructions (UM1R482000e3) or Converter User
Instructions (UM1C48241500) for a rectifier and converter module replacement
procedure. Refer also to “System Troubleshooting Information” on page 20. The
rectifier or converter module being replaced is assigned by the controller the
lowest available identification number. If desired, you can change the
identification number. Refer to the NCU Controller Instructions (UM1M830BNA)
for a procedure.
5.6.2 Replacing the NCU Controller
Refer to the NCU Controller Instructions (UM1M830BNA) for a controller
replacement procedure.
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
5.6.3 Replacing a Distribution Device
General
Replace distribution devices with the same type and rating. Refer to System
Application Guide SAG582127000 for part numbers.
Distribution Fuse “Alarm Fuse” Replacement
If a distribution fuse opens, the associated alarm fuse opens. Replace the
distribution fuse before replacing the alarm fuse.
Procedure 1. An alarm fuse is removed by pulling it straight out of the
fuseholder. If the alarm fuse is located in a modular fuse carrier, hold the
fuse carrier in place with your thumb while pulling on the alarm fuse to
prevent the entire carrier from inadvertently being pulled out.
2. Safety fuse covers are provided for all Bussmann GMT type fuses installed
in the system. These covers snap onto the fuses and provide protection from
exposed electrical terminations when a fuse opens. Insure that the safety fuse
cover is installed after replacing a fuse. Refer to Figure 5.1 for
installation details.
Figure 5.1 Installation of Safety Fuse Covers
Safety Cover P/N 248898700
(GMT-X)
Safety Cover P/N 102774
(GMT-Y)
Replacing a TPS/TLS Fuse
Procedure NOTE! Refer to Figure 5.2 as this procedure is performed.
1. Open the distribution cabinet’s front door by turning the latch in the
counterclockwise position. 2. Remove the fuse carrier from the mounted
fuseholder body by pulling it straight out. Hold the fuseholder body while you
pull
the fuse carrier from the body. 3. Remove the open fuse from the fuse carrier
and replace it with the same type and rating. 4. Replace the alarm fuse
located in the front of the fuse carrier with the same type and rating. Ensure
that a plastic safety
cover is installed on the alarm fuse. 5. Push the fuse carrier securely back
into the mounted fuseholder body. Note that a polarizing key on the bottom of
the
carrier prevents the carrier from being inserted upside down. 6. Verify no
Fuse Alarms are active.
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
7. Close the distribution cabinet’s front door. Turn the latch clockwise to secure the door.
Replacing a Bullet Nose Fuseholder
Procedure NOTE! Refer to Figure 5.2 as this procedure is performed.
1. Open the distribution cabinet’s front door by turning the latch in the
counterclockwise position.
2. Remove the fuse carrier from the mounted fuseholder body by pulling it
straight out. Hold the fuseholder body while you pull the fuse carrier from
the body.
3. Gently rock the defective fuseholder up and down while pulling firmly
outward until the fuseholder is free from the distribution panel.
4. Orient the replacement fuseholder as shown in Figure 5.2. Insert the
terminals on the rear of the fuseholder into their corresponding sockets on
the distribution panel. Ensure the alarm contact on the back of the fuseholder
makes contact with the alarm terminal on the spring strip. Push fuseholder in
firmly until fully seated in the distribution panel.
5. Push the fuse carrier securely back into the mounted fuseholder body. Note
that a polarizing key on the bottom of the carrier prevents the carrier from
being inserted upside down.
6. Verify no Fuse Alarms are active.
7. Close the distribution cabinet’s front door. Turn the latch clockwise to
secure the door.
Figure 5.2 Replacing a TPS/TLS Fuseholder and/or Fuse
Fuseholder Assembly Exploded View
Fuseholder Body
GMT-X Safety Fuse Cover
(Replacement P/N 248898700)
TPS/TLS Fuse Fuse Carrier
Fuseholder Assembly
Shorter Side to the Top
Insert these terminals into corresponding sockets on distribution panel.
GMT-18/100A Alarm Fuse (Replacement P/N 248610301)
Polarizing Keyway Matches Key on Bottom of Fuse Carrier
Longer Side to the Bottom
Fuseholder Assembly (P/N 117201) includes body & carrier, alarm fuse, and alarm fuse safety cover.
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
Replacing a Bullet Nose Circuit Breaker
Procedure NOTE! Refer to Figure 5.3 as this procedure is performed.
1. Open the distribution cabinet’s front door by turning the latch in the
counterclockwise position. 2. Operate the defective circuit breaker to the OFF
position.
3. Gently rock the defective circuit breaker up and down while pulling firmly
outward until the breaker is free from the distribution panel.
4. Ensure that the circuit breaker is in the OFF position, and is of the
correct rating. 5. Orient the replacement circuit breaker as shown in Figure
5.3. Insert the terminals on the rear of the circuit breaker into their
corresponding sockets on the distribution panel. Ensure the alarm contact on
the back of the circuit breaker makes contact with the alarm terminal on the
spring strip. Push distribution device in firmly until fully seated in the
distribution panel. 6. Operate the replacement circuit breaker to the ON
position. 7. Verify no Circuit Breaker Alarms are active. 8. Close the
distribution cabinet’s front door. Turn the latch clockwise to secure the
door.
Figure 5.3 Replacing a Bullet Nose Circuit Breaker
Lettering on handle must be right side up.
Turn off before installing.
Shorter Side to the Top
Insert these terminals into corresponding sockets on distribution panel.
Longer Side to the Bottom
5.6.4 Replacing a Distribution Panel (List AL, DJ, FG, and FK)
DANGER! Performing the next steps exposes service personnel to battery
potential. Exercise extreme caution not to inadvertently contact or have any
tool inadvertently contact any energized electrical termination.
Procedure
NOTE! Refer to Figure 4.4 as this procedure is performed.
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
Removing the Distribution Panel 1. Open the distribution cabinet’s front door
by turning the latch in the counterclockwise position. 2. Remove the plastic
shield covering the circuit breakers or fuseholders on the panel to be removed
by loosening the screws holding the shield and sliding the shield upwards. 3.
Disconnect and insulate all load wiring from the circuit breaker or fuse
positions. 4. Remove all load return wiring from the ground busbar. 5. Locate
the in-line FA/CBA connector located near the back of the panel, and separate
the connector halves. 6. Refer to Figure 4.4 and remove the hardware securing
the panel’s Ground Busbar to the distribution cabinet’s busbar. 7. Refer to
Figure 4.4 and remove the hardware securing the panel’s System Load
Distribution busbar to the distribution cabinet’s busbar. 8. For dual voltage
load distribution panels, refer to Figure 4.4 and remove the hardware securing
the +24V or -58V jumper leads. 9. Refer to Figure 4.4 and remove the hardware
securing the distribution panel to the distribution cabinet. Remove the panel
from the distribution cabinet.
Installing the Distribution Panel NOTE! In the following procedure, before
making busbar-to-busbar connections, apply a thin coating of electrical
antioxidizing compound to the mating surfaces of the busbars.
1. Orient the replacement distribution panel into distribution cabinet,
checking to ensure no wires are pinched. Replace the hardware securing the
distribution panel to the distribution cabinet. Torque per Figure 4.4.
2. For dual voltage load distribution panels, replace the hardware securing
the +24V or -58V jumper leads. Torque per Figure 4.4.
3. Replace the hardware securing the panel’s System Load Distribution busbar
to the distribution cabinet’s busbar. Torque per Figure 4.4.
4. Replace the hardware securing the panel’s Ground Busbar to the
distribution cabinet’s busbar. Torque per Figure 4.4. 5. Locate the in-line
FA/CBA connector located near the back of the panel, and plug it into the
mating connector half in the
distribution cabinet. WARNING! In the next step, observe correct polarity;
otherwise equipment damage will result.
6. Reconnect the load return wiring to the ground busbar. 7. Reconnect the
load wiring to the circuit breaker or fuse positions. 8. Transfer the plug-in
circuit breakers or fuses from the old panel to the replacement panel. 9.
Replace the plastic shield covering the circuit breakers or fuseholders on the
replacement panel. 10. Verify no Circuit Breaker/Fuse Alarms are active. 11.
Close the distribution cabinet’s front door. Turn the latch clockwise to
secure the door.
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
5.6.5 Circuit Card Replacement Procedures
WARNING! Circuit cards used in this power system contain static-sensitive
devices. Read the Static Warning at the front of this document before
performing any of the following procedures.
General
The following circuit card replacement procedures can be performed with the
system operating. Refer to Figure 3.1 for circuit card locations.
CAUTION! When performing any step in these procedures that requires removal or
installation of hardware, use caution to ensure no hardware is dropped and
left inside the cabinet; otherwise service interruption or equipment damage
may occur.
NOTE! When performing any step in these procedures that requires removal of
existing hardware, retain all hardware for use in subsequent steps. ALERT! Do
not hold MBD switch (S1) in the up or down position for more than 3 seconds to
avoid damaging the contactor.
ALERT! When using switch, after either pushing up or down let switch return to
the center position for 3 seconds before pushing switch in the opposite
direction to avoid damaging the contactor.
System Interface Board Replacement
Refer to Figure 3.1 for circuit card location. Procedure
1. Performing this procedure may activate external alarms. Do one of the
following. If possible, disable these alarms. If these alarms cannot be easily
disabled, notify the appropriate personnel to disregard any future alarms
associated with this system while the procedure is being performed. DANGER!
Performing the next steps exposes service personnel to battery potential.
Exercise extreme caution not to inadvertently contact or have any tool
inadvertently contact any energized electrical termination.
2. Open the distribution cabinet’s front door by turning the latch in the
counterclockwise position. WARNING! Damage to the circuit card may result if
the next step is not followed.
3. Connect an approved grounding strap to your wrist. Attach the other end to
a suitable ground. 4. Remove the shield to access the circuit cards at the
bottom of the distribution cabinet. 5. Carefully label the connectors plugged
into the circuit card. These connectors must be plugged into the same
connectors on
the replacement circuit card. Refer to Figure 5.4. 6. Unplug all connectors
plugged into the circuit card. 7. Remove the screws securing the circuit card
and remove the circuit card from the distribution cabinet. 8. In this step,
ensure you do not intermix the old and replacement circuit cards. Set the
shorting jumper on the replacement
circuit card to match the location on the old circuit card. Jumper settings
are documented in the “Setting Jumpers and Switch Options” section of the
Power System Installation Instructions (IM582127000100). 9. Slide the
replacement circuit card into the mounting position inside the distribution
cabinet, and secure with the screws removed from the old circuit card. 10.
Plug all connectors removed from the old circuit card into the same position
on the replacement circuit card. 11. Remove the grounding wrist strap.
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
12. Reinstall the shield that covers the circuit cards at the bottom of the distribution cabinet. 13. Close the distribution cabinet’s front door. Turn the latch clockwise to secure the door. 14. Enable the external alarms, or notify appropriate personnel that this procedure is finished. 15. Ensure that there are no local or remote alarms active on the system.
Figure 5.4 System Interface Board Connector Locations
F2 F1
562662
K4
CR4 R9
R8
CR1 CR3
R14 R16 R18
J1
J4
(System Interconnects) (System Interconnects)
J1 J4
1
R15
TB1
2
K3
K2
J6
TB1 Wire Size Capacity: 14AWG to 30AWG Recommended Torque: 0.28Nm or 2.48 in-
lb FA Signals: System voltage applied to the terminal turns in an alarm.
TB1-1: Bat Tray FA TB1-2: Bat Rack FA
J6 (System Temp 2)
R5
R11
R10
K1
J5
J5 (System Temp 1)
R2 R1 R3 R4 CR2
TP1
R6
R12
J3
R13
S1
123
C1
AXXXXXXXX
DS1
000XXXXX
TP2 R7
J2
NCU CAN Port
H1
TP1 (-) and TP2 (+) System Voltage
J3 Selects to power Controller from “Battery Power” or not if the battery
disconnect contactor opens.
No Battery Battery Shorting Jumper Pwr Pwr
J3
123
CAN termination plug P/N 548398 must be installed if an external device is not connected to the system.
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
IB2 (Controller Interface Board) and Optional EIB (Controller Extended
Interface Board) Replacement
Refer to Figure 3.1 for circuit card location.
Procedure 1. Performing this procedure may activate external alarms. Do one of
the following. If possible, disable these alarms. If these alarms cannot be
easily disabled, notify the appropriate personnel to disregard any future
alarms associated with this system while the procedure is being performed.
DANGER! Performing the next steps exposes service personnel to battery
potential. Exercise extreme caution not to inadvertently contact or have any
tool inadvertently contact any energized electrical termination.
2. Open the distribution cabinet’s front door by turning the latch in the
counterclockwise position. WARNING! Damage to the circuit card may result if
the next step is not followed.
3. Connect an approved grounding strap to your wrist. Attach the other end to
a suitable ground. 4. Remove the shield to access the circuit cards at the
bottom of the distribution cabinet. 5. Carefully label the wires connected to
the customer connection terminal blocks on the circuit card. These wires must
be
connected to the same terminals on the replacement circuit card. Refer to
Figure 5.5 or Figure 5.6. 6. Carefully label the connectors plugged into the
circuit card. These connectors must be plugged into the same connectors on
the replacement circuit card. Refer to Figure 5.5 or Figure 5.6. DANGER! In
the next step, external alarm wiring may be energized from an external source.
DO NOT allow bare wire ends to contact any grounded or energized object.
7. Remove the external wiring from the customer connection terminal blocks.
DO NOT allow the bare wire end to contact any grounded or energized object.
Isolate the wire end with electrical tape. Repeat for each wire to be removed.
8. Unplug all connectors plugged into the circuit card. 9. Remove the screws
securing the circuit card and remove the circuit card from the distribution
cabinet. 10. In this step, ensure you do not intermix the old and replacement
circuit cards. Set the switch on the replacement circuit card
to the same setting as the old circuit card. Switch settings are documented in
the “Setting Jumpers and Switch Options” section of the Power System
Installation Instructions (IM582127000100). 11. Slide the replacement circuit
card into the mounting position inside the distribution cabinet, and secure
with the screws removed from the old circuit card. 12. Plug all connectors
removed from the old circuit card into the same position on the replacement
circuit card. DANGER! In the next step, external alarm wiring may be energized
from an external source. DO NOT allow bare wire ends to contact any grounded
or energized object.
13. Reconnect the external wiring to the correct terminals on the customer
connection terminal block. First remove the electrical tape that was applied
to the bare wire end in a previous step. DO NOT allow the bare wire end to
contact any grounded or energized object. After securing the wire, gently tug
on the wire to ensure that it cannot be pulled out of the terminal block.
Repeat for each wire to be reconnected.
14. Remove the grounding wrist strap. 15. Close the distribution cabinet’s
front door. Turn the latch clockwise to secure the door. 16. Reboot the
Controller
Local Menu Navigation: At the Main Screen, press ENT and ESC at the same time
to reset the NCU Controller. Web Menu Navigation: Go to Advance Settings Menu
/ SW Maintenance Tab / Reboot Controller button. 17. Enable the external
alarms, or notify appropriate personnel that this procedure is finished.
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
18. Ensure that there are no local or remote alarms active on the system.
Figure 5.5 IB2 (Controller Interface Board) Connector Locations
IB2 (Interface Board) (Top View)
to Controller
Connector
IB2 TEMP PROBE 1
PROBE 2
IB2 TEMP
J2
J11
J12
- 642 642 642
87 654 3 21
–
531 531 531
J3
J4
Digital Input Terminal Blocks
J5
2
642 642 642 642
531 531 531 531 NO C NC NO C NC NO C NC NO C NC
NO C NC NO C NC NO C NC NO C NC
Relay Output Terminal Blocks
1
J6
IB2 (Interface Board)
RELAY
4
3
J7
SW1
6
5
J8
8
7
J9
J3-J9: Wire Size Capacity: 16-26 AWG. Recommended Torque: 2.2 in-lbs.
Figure 5.6 Optional EIB (Controller Extended Interface Board) Connector
Locations
EIB (Extended Interface Board) (Top View)
J9
J8
J7
J6
J5
SW1
1 2
OFF ON
J5-J9 Wire Size Capacity: 16-26 AWG. Recommended Torque: 2.2 in-lbs.
J2
J3
J4
EIB Temp Probe 1
EIB Temp Probe 2
Connector to Controller
EIB (Extended Interface Board)
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
5.6.6 Replacing a Battery Disconnect Contactor
DANGER! All sources of AC and DC power must be completely disconnected from
this power system before performing this procedure. Use a voltmeter to verify
no DC voltage is present on the system busbars before proceeding. NOTE! In the
following procedure, before making busbar-to-busbar connections, apply a thin
coating of electrical antioxidizing compound to the mating surfaces of the
busbars.
Procedure
NOTE! Refer to Figure 5.7 as this procedure is performed.
Removing the Contactor 1. Verify all AC and DC power sources are disconnected
from the power system. 2. Remove the distribution cabinet’s rear access panel.
3. Disconnect the wiring to the contactor by unplugging the quick disconnects.
4. Note the orientation of the contactor to ensure the replacement is
installed the same way. Unbolt the contactor (4-places) and remove. Save all
hardware.
Installing the Replacement Contactor 1. Position the replacement contactor
oriented the same way as the old. 2. Secure the contactor with the hardware
removed above. Refer to Figure 5.7 for hardware build-up and recommended
torque. 3. Replace the wiring to the contactor by plugging-in the quick
disconnects. Refer to Figure 5.7. 4. Replace the distribution cabinet’s rear
access panel.
Restarting the Power System 1. Reconnect the AC and DC power sources to the
power system. 2. Start the power system. Refer to the separate Installation
Instructions (IM582127000100) for a startup procedure. 3. Verify no alarms are
active.
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
Figure 5.7 Replacing the Battery Disconnect Contactor in the Distribution
Cabinet
Shown being removed from front for clarity only. Removal is from rear.
Components removed in illustration for clarity only. Apply electrical anti-
oxidizing compound to busbar mating surfaces.
Front
Battery Disconnect Contactor
3/8-16 x 1-1/4″ Bolt 3/8″ Belleville Lock Washer (concave side of Belleville
lock washer faces flat washer) 3/8″ Flat Washer (4 places) Torque to 180 in-
lbs.
Black Wire
Red Wire
Rear
Rear
Violet Wire Black Wire
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VertivTM NetSureTM 7100 Series -48 VDC Power System User Manual
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