VERTIV um10062803 VDC Bullet Nose 6 Position GMT Fuse Board Kit User Manual

+27 VDC Bullet Nose 6-Position

GMT Fuse Board Kit

Installation and User Manual

Specification Number: 10062803

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.

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)

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.

Safety and Regulatory Statements

Refer to Section 4154 (provided with your customer documentation) for Safety and Regulatory Statements.

1 Description

Spec. No. 10062803 is a +27 VDC Bullet Nose 6-Position GMT Fuse Board Kit, which accepts up to six (6) GMT Fuses (0.18 to 15A). See Figure 1.1 for contents. The kit is designed for mounting in a bullet breaker distribution panel next to a 1C4827375B, +27 VDC Vertiv™ eSure™ Bullet Converter. It should not be used by itself without the +27 VDC VertivTM eSureTM Bullet Converter. Refer to UM60147273 for information on installing and using the 1C4827375B. This +27 VDC Bullet Nose 6Position GMT Fuse Board Kit is designed for use in ­48 VDC systems providing +27 VDC distribution. It takes the place of two (2) bullet breaker positions in a bullet breaker distribution panel. See Table 1.2 for a list of power systems into which this kit can be installed.

Figure 1.1 +27 VDC Bullet Nose 6-Position GMT Fuse Board Kit Contents (Part No. 10062803)

PARTS/MATERIAL LIST

INDEX| PART NO.| DESCRIPTION| QTY
1| 10076456| ASSY, +27VDC, 6 POS GMT BOARDS| 1
2| 549018| JUMPER, 8 AWG, 11″ LONG, GMT FUSE BRD RTN| 1
3| RPM2300023/1| JUMPER, GMT FUSE BRD RTN, 8 AWG, 7.5″ LONG| 1
4| 10062807| BUSBAR, RETURN, +27VDC GMT| 1
5| 214110100| FW, 1/4, .500 OD, .063 THK| 2
6| 215111100| LW, 1/4, .489 OD, .062 THK,| 2
7| 228557100| NUT, – HEX – , 1/4-20| 2
8| 10076780| LABEL, +27VDC, GMT RESTRICTIONS*| 1

*Not shown above

Features

• Single voltage distribution (+27 VDC)
• Mounts in (2) distribution positions of the distribution cabinet.
• Provides (6) Load Distribution Fuse Positions (0.18 A to 15A GMT Alarm-Type Fuses)
• Screw-clamp type terminals
• Includes (6) dummy fuses equipped with safety fuse covers.
• Unless otherwise specified, kit is field-installed when ordered separately.

Restrictions

Only to be connected and used with the +27 VDC Vertiv™ eSure™ Bullet Converter.

Terminal block wire size capacity is 26 AWG to 14 AWG.

It is recommended to mount GMT fuses with the highest ampacity starting in the farthest position from the +27 VDC Vertiv™ eSure™ Bullet Converter(s), starting with that highest ampacity and working towards the lowest ampacity.

At 40 °C Ambient:

• Maximum total current is 27.8 A.
• Maximum fuse size is 15 A.
• When used for power distribution, load should not exceed 80% of device rating, except 10 A and 15 A fuses for which load should not exceed 70% of device rating.
• GMT fuses greater than 10 A SHALL have an empty mounting position between it and any other fuse.

At 65 °C Ambient:

• Maximum total current is 22 A.
• Maximum fuse size is 15 A.
• When used for power distribution, load should not exceed 80% of device rating, except 10 A fuses for which load should not exceed 70% of device rating and 15 A fuses for which load should not exceed 50% of device rating.
• GMT fuses greater than 5 A SHALL have an empty mounting position between it and any other fuse.

The +27 VDC Bullet Nose 6-Position GMT Fuse Board Kit is compatible with any “Bullet-Style” distribution panel installed in any system listed in Table 1.2.

Cannot be installed on the 548066, 548067, 10009822, and 10012729 stand- alone distribution panels in the following positions (counting from left-hand side):

• 19″ Cabinet: Positions 3, 4, 5, 9 or 10
• 23″ Cabinet: Positions 3, 4, 5, 12 or 13

Ordering Notes

1. Order optional +27 VDC GMT Bullet Nose 6-Position GMT Fuse Board Kit (P/N 10062803) as required (see restrictions above). Provides one alarm fuse distribution board, return links, and hardware.
2. Order a Lug Adapter Plate to parallel with the +27 VDC Vertiv™ eSure™ Bullet Converter, depending on the number of converters ordered (See Section 3.1 in Accessories for options). The input bullet terminal on the +27 VDC GMT Bullet Nose 6-Position GMT Fuse Board is located on the top-right of board adjacent to the converter module pole when mounted to the left of the converter/s. When mounting the +27 VDC GMT Bullet Nose 6-Position Fuse Board on the right-hand side of the converter/s, order a lug adapter plate with one additional position. For example, for two bullet converters and a GMT Assembly, a three-position lug adapter plate would be used for mounting the GMT Assembly to the left of the converters and a four-position lug adapter plate for right-side mounting.
3. Order fuses, as required, per Table 1.1.

Table 1.1 GMT Fuses

Table 1.2 Power Systems Compatible with +27 VDC Bullet Nose 6-Position GMT Fuse Board Kit (Part No. 10062803)

2 Specifications

2.1 Electrical

• Input Voltage: Nominal +27 VDC

• Output Voltage: Nominal +27 VDC.

• Note: Alarm signal provided by input from Nominal -48 VDC or -58 VDC input.

• Current Ratings:
  – 27.8 A at 40 °C ambient temperature.
  – 22 A at 65 °C ambient temperature.

• Circuit Breaker / Fuse Alarm Circuit: Relay contact closure is provided to an alarm lead to signal a fuse alarm if one or more distribution fuses open.

2.2 Environmental

• Operating Temperature Range: -40 °C to +65 °C (-40 °F to +149 °F).
• Storage Temperature Range: -40 °C to +85 °C (-40 °F to +185 °F).
• Humidity: Capable of operating in an ambient relative humidity range of 0 % to 95 %, non-condensing.
• Altitude: Will operate at any elevation between sea level and 10,000 ft.

2.3 Dimensions

• See Figure 2.1 and Figure 2.2.

2.4 Compliance Information

• Safety Compliance: The +27 VDC Bullet Nose 6-Position GMT Fuse Board Kit is constructed of UL Listed or Recognized components. The board is included in the UL File of the compatible parent UL Listed power system ( Table 1.2 ) into which it is installed.

Figure 2.1 Dimensions of +27 VDC Bullet Nose 6-Position GMT Fuse Board

NOTE: All dimensions are in inches.

1. Top View
2. Front View
3. Rear View
4. Left Side View
5. Right Side View
6. Bottom View

Figure 2.2 Dimensions of +27 VDC Bullet Nose 6-Position GMT Fuse Board Kit Returns

Note: All dimensions are in inches.

3 Accessories

3.1 Two-, Three-, Four-, and Five-Pole Lug Adapter Plates

Features

• The busbar lug landing adapter plates provide a connection between the output of a +27 VDC Vertiv™ eSure™ Bullet Converter to the input of the +27 VDC Bullet Nose 6-Position GMT Fuse Board.
• Unless otherwise specified, adapters are field-installed when ordered separately.

Ordering Notes

1. Order adapter 60016097 2-pole lug adapter plate when connecting a single bullet converter to the right side of the +27 VDC Bullet Nose 6-Position GMT Fuse Board.
2. Order adapter 545346 3-pole lug adapter plate when connecting two bullet converters to the right side of the +27 VDC Bullet Nose 6-Position GMT Fuse Board or one bullet converter to the left side of the +27 VDC Bullet Nose 6-Position GMT Fuse Board.
3. Order adapter 10078650 4-pole lug adapter plate when connecting three bullet converters to the right side of the +27 VDC Bullet Nose 6-Position GMT Fuse Board or two bullet converters to the left side of the +27 VDC Bullet Nose 6-Position GMT Fuse Board.
4. Order adapter 10078651 5-pole lug adapter plate when connecting three bullet converters to the left side of the +27 VDC Bullet Nose 6-Position GMT Fuse Board.
5. Order the corresponding lug adapter plate as needed:

• 2-pole: Part No. 60016097
• 3-pole: Part No. 545346
• 4-pole: Part No. 10078650
• 5-pole: Part No. 10078651

3.2 Recommended Wire Sizes and Lugs

DC Input Conductors

Features

• The +27 VDC Bullet Nose 6-Position GMT Fuse Board has bullet terminals for connection to the distribution panel in the power system. In addition, lug adapter plates, ordered separately, are used to tie the +27 VDC Bullet Nose 6Position GMT Fuse Board to the +27 VDC VertivTM eSureTM Bullet Converter. The return connection is provided by one of two cables or a busbar attached to the power system return bar.
• For lug spacing dimensions, refer to the power system’s System Application Guide.

Ordering Notes

1. Order a two-, three-, four-, or five-pole lug adapter plates as needed. See “Accessories” for part numbers.

DC Load Conductors

Features

• The +27 VDC Bullet Nose 6-Posistion Fuse Board is designed for connection of load and return conductors to the distribution terminal blocks.

Restrictions

All lugs for customer load side (end opposite of the terminal block) connections must be ordered separately.

Terminal block wire size capacity is 26 AWG to 14 AWG.

Ordering Notes

1. The rating of the distribution device determines the wire size requirements. For wire size and lug selection, refer to Table 3.1.
2. Lugs should be crimped to the specifications given in the manufacturer’s instructions furnished with the crimp tool or lugs.

Table 3.1 Recommended Distribution (Load) Wire Size and Lug Selection for GMT Load and Load Return

Recommended 90 °C Wire Size (1) & Loop Length (feet)(2)

Fuse Amperage| 18 AWG| 16 AWG| 14 AWG
0.18A| 872| 1386| 2206
0.25A| 628| 998| 1588
0.50A| 314| 499| 794
0.75A| 209| 333| 529
1.33A| 118| 187| 298
2.00A| 78| 125| 199
3.00A| 78| 125| 199
5.00A| 31| 50| 79
7.50 A| –| 33| 53
10.00A| –| 25| 40
15.00A| –| –| 26

Notes to Table 3.1:

1. Wire sizes are based on recommendations of the American National Standards Institute (ANSI) approved National Fire Protection Association’s (NFPA) National Electrical Code (NEC). Table 310-16 for wire rated at 90 °C conductor temperature operating in ambient temperatures of 40 °C and 65 °C was used. For other operating ambient temperatures, refer to the NEC. For operation in countries where the NEC is not recognized, follow applicable codes.
2. Recommended wire sizes are sufficient to restrict voltage drop to 1.0 volt or less at listed branch current for the loop lengths shown. Loop length is the sum of the lengths of the positive and negative leads.

4 Installation

4.1 Safety Statements

DANGER! Installation of this equipment should only be performed by a qualified installer following approved safety procedures. If a qualified technician is not available, arrangements can be made with Vertiv to have the equipment installed.

DANGER! Adhere to the “Important Safety Instructions” presented at the front of this document.

4.2 Mounting the +27 VDC Bullet Nose 6-Position GMT Fuse Board

Procedure

Identify the panel in which the +27 VDC Bullet Nose 6-Position GMT Fuse Board will be installed in. If the +27 VDC Vertiv™ eSure™ Bullet Converters that will power the +27 VDC Bullet Nose 6-Position GMT Fuse Board are currently installed, go to “Preparing Panel for Installation” on page 14 to remove the converters.

NOTE! Figures depict installation on a 26-position panel for a 582127000 system as an example unless otherwise noted.

1. Install the applicable lug adapter plate to the identified positions. Secure the plate using washers, lock washers, and nuts for the 1/4-20 stud (not provided in kit). See Figure 4.1 for the proper hardware stack-up with the lug on the system return busbar.

Figure 4.1 Installing Lug Adapter Plate

Torque to 72 in-lbs

1. Lug Adapter
2. Washer
3. Lock Washer
4. Nut

2. If using +27 VDC Bullet Nose 6-Positon GMT Fuse Board’s busbar, skip this step. Install the cable return for the +27 VDC Bullet Nose 6-Positon GMT Fuse Board on the system return side. See Figure 4.2.

Figure 4.2 Installing Cable Return for +27 VDC Bullet Nose 6-Position GMT Fuse Board on System Return Side

Torque to 72 in-lbs

1. Cable Return
2. Washer
3. Lock Washer
4. Nut

3. Install return(s) for the +27 VDC Vertiv™ eSure™ Bullet Converter on the system return side. See UM60147273 for detailed instructions. To install the return(s), install return wire faston tab; secure using the washer, lock washer, and then the nut; lastly, connect return wire jumper to faston tab. See Figure 4.3 for the proper hardware stack-up with the lug on the system return busbar.

ALERT! Ensure that the exposed end of the return cable does not make contact to a live -48V/-58V load or supply busbar.

Figure 4.3 Installing Return(s) for +27 VDC Vertiv™ eSure™ Bullet Converter on the System Side

1. Washer
2. Lock Washer
3. Nut

4. Install the +27 VDC Bullet Nose 6-Positon GMT Fuse Board. Align bullet terminals with intended load positions and push in the +27 VDC Bullet Nose 6-Positon GMT Fuse Board (see Figure 4.4 ). Ensure that the top bullet terminal is inserted into the load bar connected via the lug adapter plate with the output of the +27 VDC Vertiv™ eSure™ Bullet Converter.

Figure 4.4 Installing the +27 VDC Bullet Nose 6-Positon GMT Fuse Board into the Panel

Ensure top bullet terminal is inserted into load bar connected via lug adapter plate.

5. Install one of the provided cables or the busbar return as needed. Use the provided flat washers, lock washers, and nuts to fasten the return to the +27 VDC Bullet Nose 6-Positon GMT Fuse Board’s return busbar. If using the busbar return, also fasten it to the system return busbar. See Figure 4.5 for proper hardware stack-up and return installation orientation.

Figure 4.5 Installing the Return for the +27 VDC Bullet Nose 6-Position GMT Fuse Board

Example 1                                 Example 2

1. Washer
2. Lock Washer
3. Nut
4. Cable Return
5. Busbar Return

Note: Representations show two example installations in two different distribution panels: Example 1 uses the short return cable, and Example 2 shows a standalone-type system that uses the busbar return.

6. Install the +27 VDC Vertiv™ eSure™ Bullet Converter mounting kit (see Figure 4.6 ; for detailed instructions, refer to the Bullet Converter Mounting Kit instructions for the relevant plant), or re-install the +27 VDC Vertiv™ eSure™ Bullet Converter front mounting bracket.

Figure 4.6 Installing the Bullet Converter Mounting Kit

7. Install the +27 VDC Vertiv™ eSure™ Bullet Converter (see UM60147273 for detailed instructions). Following is an overview of the steps for each +27 VDC Vertiv™ eSure™ Bullet Converter (see Figure 4.7 ).

a. Connect the +27 VDC Vertiv™ eSure™ Bullet Converter return wire to the +27 VDC Vertiv™ eSure™ Bullet Converter’s return tab.
b. Ensure the Enable/Disable switch on the +27 VDC Vertiv™ eSure™ Bullet Converter is in the Disabled (down) position.
c. Plug in the +27 VDC Vertiv™ eSure™ Bullet Converter.
d. Fasten the ground screw to front mounting bracket.
e. Leave the +27 VDC Vertiv™ eSure™ Bullet Converter disabled until +27 VDC GMT Loads are connected and ready for power.

Figure 4.7 Installing the +27 VDC Vertiv™ eSure™ Bullet Converter

1. Converter Return
2. Front Mounting Bracket (shown as phantom lines across panel for
3. Ground Screw
4. Enable/Disable Switch

Preparing Panel for Installation

If the +27 VDC Vertiv™ eSure™ Bullet Converter(s) that will power the +27 VDC Bullet Nose 6-Position GMT Fuse Board are currently installed, perform the following steps to remove the remove the converters.

1. Place the Enable/Disable switch on the +27 VDC Vertiv™ eSure™ Bullet Converter(s) in the Disable (down) position.

2. Unfasten the grounding screw.

3. Unfasten the +27 VDC Vertiv™ eSure™ Bullet Converter’s return wire from the tab on the +27 VDC Vertiv™ eSure™ Bullet Converter.

4. Remove the +27 VDC Vertiv™ eSure™ Bullet Converter.

Figure 4.8 Removing Converters

1. Converter Return Wire
2. Converter Tab
3. Grounding Screw

5. Remove the converter front mounting bracket for better access. See Figure 4.9.

Figure 4.9 Removing Converter Front Mounting Bracket

1. Front Mounting Bracket

4.3 Electrical Connections

Wiring Considerations
All wiring and grounding should follow the current edition of the National Electrical Code and applicable local codes.

+27 VDC Bullet Nose 6-Position GMT Fuse Board

WARNING! This +27 VDC Bullet Nose 6-Position GMT Fuse Board is meant to be plugged into a -48V or -58V distribution panel breaker position. Do not plug into any other distribution panel position. This fuse board is to be used with the +27 VDC Vertiv™ eSure™ Bullet Converter and not used standalone.

+27 VDC GMT Load Connections

WARNING! Check for correct polarity before making connections.

Procedure

1. If not already done, open the front door of the distribution cabinet.
2. Refer to Figure 4.10 when making distribution load and load return connections. Lug mounting location and identification, as well as recommended torque are shown. Maximum size of wire to be connected to a single position is 14 AWG.
3. Load and Load Return: Connect wire leads to terminal blocks on the fuse board. Observe correct polarity as shown in Figure 4.10 when connecting leads. Tighten screws as specified in the figure.

Figure 4.10 Load Connections to +27 VDC Bullet Nose 6-Position GMT Fuse Board

Torque Connections to 5 in-lb

1. Load Return Terminals
2. +27V Load Terminals
3. GMT Fuses

Install Fuses

Refer to “Restrictions” for GMT fuse installation arrangement. Use insulated pliers for fuse covers and GMT fuse puller tool for GMT fuses. Repeat the steps below as needed per load required. Verify that dummy fuses are installed in all unused fuse positions.

1. Remove fuse cover and dummy fuse.
2. Install an appropriately sized GMT-type fuse in fuse holder slot.
3. Install fuse cover.

Fuse Alarm Connections

When a GMT fuse blows, the alarm spring (at +27V) energizes a 24V relay on the bottom board of the GMT assembly. The relay contacts, in turn, connect the negative plant voltage (-48V or -58V) to the common fuse alarm (FA) strip, sending an FA signal to the NCU controller.

4.4 Initial Startup

Procedure

1. Ensure that all access covers are in place.
2. Ensure that fuse safety covers are installed on each fuse, as shown in Figure 4.10.
3. Place the Enable/Disable switch on the +27 VDC Vertiv™ eSure™ Bullet Converter(s) in the Enabled (up) position.
4. Verify that the circuit breaker / fuse alarm located on the NCU is extinguished. There may also be an LED indicator in the system distribution cabinet. If indicator or external alarm is active, refer to the “Troubleshooting and Repair” section.
5. To verify operation of the circuit breaker / fuse alarm circuit:
   a) Remove a GMT fuse from the +27 VDC Bullet Nose 6-Position GMT Fuse Board and replace with a known open fuse. Verify the circuit breaker / fuse alarm indicator located on the NCU illuminates and the LED indicator in the system distribution cabinet activates (if equipped).
   b) Remove the alarm fuse and install the good fuse. Verify the circuit breaker / fuse alarm indicator located on the front of the NCU extinguishes and the LED indicator in the system distribution cabinet retires (if equipped).

5 Operation

5.1 Indicators

When a GMT fuse blows, there will be a Circuit Breaker / Fuse Alarm on the NCU and there may also be an LED indicator lit in the power system distribution cabinet.

Circuit Breaker / Fuse Alarm: When illuminated (red), a circuit breaker or fuse is open.

6 Troubleshooting and Repair

6.1 Contact Information

Refer to Section 4154 (provided with your customer documentation) for support contact information.

6.2 General

Other than the GMT fuses, the +27 VDC Bullet Nose 6-Position Fuse Board contains no user-replaceable parts. No attempt should be made to repair the GMT Assembly. If repair is required, contact Vertiv.

If the local Circuit Breaker / Fuse Alarm indicator illuminates and NCU circuit breaker / fuse alarm circuits activate, check for an open fuse. An open fuse will provide an indicator that is visible through the front of the fuse safety cover. Refer to “GMT Fuse Replacement” in this section for a replacement procedure.

6.3 GMT Fuse Replacement

A defective GMT fuse is replaced by removing the fuse from the fuseholder and replacing the defective fuse. Use of an insulated nylon GMT fuse puller tool is recommended for GMT fuse replacement. Heat resistant gloves are also recommended if the adjacent +27 VDC Vertiv™ eSure™ Bullet Converter is still active at high load.

Procedure
NOTE! Refer to Figure 6.1 as this procedure is performed.

1. Gain access to the identified distribution panel by opening any doors that may be blocking access.
2. Remove the fuse cover and fuse from the mounted fuseholder body with a GMT fuse puller tool by grasping firmly and pulling it straight out.
3. Replace the open fuse with the same type and rating, or equivalent.
4. Ensure that a plastic safety cover is installed on the alarm fuse.
5. Verify no circuit breaker / fuse alarms are active.
6. Close and secure any doors opened to access the distribution panel.

Figure 6.1 Replacing GMT Fuses

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© 2024 Vertiv Group Corp. All rights reserved. Vertiv™ and the Vertiv logo are trademarks or registered trademarks of Vertiv Group Corp. All other names and logos referred to are trade names, trademarks or registered trademarks of their respective owners. While every precaution has been taken to ensure accuracy and completeness here, Vertiv Group Corp. assumes no responsibility, and disclaims all liability, for damages resulting from use of this information or for any errors or omissions.

UM10062803_REVA

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