Emerson NetSure 5100 User Manual
NetSure™ -48 VDC Power System
User Manual, UM582137200
(Revision A, January 11, 2017)
Specification Number: 582137200
™
Model Number: NetSure
5100
NetSure™ -48 VDC Power System
User Manual, UM582137200
This page is intentionally blank.
Spec. No: 582137200 Document Code: U M582137200
Model No: NetSure™ 5100 Revision A, January 11, 2017
NetSure™ -48 VDC Power System
[i]
User Manual, UM582137200
Table of Contents
Admonishments Used in this Document ................................................................................................................ ii
Important Safety Instructions .............................................................................................................................. iii
General Safety ........................................................................................................................................................iii
Voltages .................................................................................................................................................................iii
Battery ...................................................................................................................................................................iii
Personal Protective Equipment (PPE) ....................................................................................................................... v
Hazardous Voltage ................................................................................................................................................. v
Handling Equipment Containing Static Sensitive Components ................................................................................. v
Maintenance and Replacement Procedures ............................................................................................................. v
Static Warning ..................................................................................................................................................... vi
Customer Documentation Package ....................................................................................................................... 1
System Description ............................................................................................................................................... 1
Operating Procedures ........................................................................................................................................... 1
Controller and Rectifier ........................................................................................................................................... 1
ESTOP Function ...................................................................................................................................................... 2
Controller Battery Charge Current Limit Feature ...................................................................................................... 2
Local Controls and Indicators .................................................................................................................................. 2
Maintenance ......................................................................................................................................................... 2
System Maintenance Procedures ............................................................................................................................ 2
Adding a Rectifier ................................................................................................................................................... 2
Installing a Field Expansion Rectifier Shelf ................................................................................................................ 2
Troubleshooting and Repair .................................................................................................................................. 8
Contact Information ............................................................................................................................................... 8
Controller and Rectifier ........................................................................................................................................... 8
Controller Configuration ......................................................................................................................................... 8
System Troubleshooting Information ...................................................................................................................... 8
Replacement Information ....................................................................................................................................... 9
Replacement Procedures ........................................................................................................................................ 9
Replacing a Rectifier ........................................................................................................................................ 9
Replacing the NCU Controller .......................................................................................................................... 9
Replacing a Distribution Device ........................................................................................................................ 9
Circuit Card Replacement Procedures ............................................................................................................ 12
NetPerform™ Optimization Services ................................................................................................................... 17
Spec. No: 582137200 Document Code: U M582137200
Model No: NetSure™ 5100 Revision A, January 11, 2017
NetSure™ -48 VDC Power System
[ii]
DANGER!
if not avoided. (ANSI, OSHA)
WARNING!
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!
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
standards. (OSHA)
ALERT!
data, or service. (ISO)
ALERT!
software corruption, data loss, or service interruption. (ISO)
FIRE SAFETY!
locations of fire
SAFETY!
to a particular source of hazard or to fire safety. (ISO, ANSI, OSHA)
User Manual, UM582137200
Admonishments Used in this Document
Warns of a hazard the reader will be exposed to that will likely result in death or serious injury
D
an
g
er
Warns of a potential hazard the reader may be exposed to that could result in death or
W
ar
Caution
A
lert
Alert
Fi
re Safet
n
in
g
Warns of a potential hazard the reader may be exposed to that could result in minor or
be permitted in some of the applicable
Alerts the reader to an action that must be avoided in order to protect equipment, software,
Alerts the reader to an action that must be performed in order to prevent equipment damage,
Informs the reader of fire safety information, reminders, precautions, or policies, or of the
-fighting and fire-safety equipment. (ISO)
y
Informs the reader of general safety information, reminders, precautions, or policies not related
S
afety
Spec. No: 582137200 Document Code: U M582137200
Model No: NetSure™ 5100 Revision A, January 11, 2017
NetSure™ -48 VDC Power System
[iii]
Danger
D
an
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er
Warning
War
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D
anger
D
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User Manual, UM582137200
Important Safety Instructions
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
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 deenergized during installation at loads, as required.
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.
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 de-energized
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.
during installation. DO NOT apply AC input power to
the system until all electrical connections have been
completed and checked.
Spec. No: 582137200 Document Code: U M582137200
Model No: NetSure™ 5100 Revision A, January 11, 2017
NetSure™ -48 VDC Power System
[iv]
W
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Alert
User Manual, UM582137200
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:
• 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.
• Disconnect charging source prior to connecting or
disconnecting battery terminals.
• 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.
• ALWAYS FOLLOW THE BATTERY MANUFACTURER’S
RECOMMENDATIONS AND SAFETY INSTRUCTIONS.
DANGER! This equipment may be used in conjunction
with lead-acid batteries. Working near lead-acid
batteries is dangerous!
In addition to the hazard of electric shock, gas produced
by batteries can be explosive and sulfuric acid can cause
severe burns.
• Do not open or mutilate batteries. Released
electrolyte is harmful to the skin and eyes, and is
toxic.
• Batteries contain sulfuric acid.
• Batteries 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 are an energy source that can produce
high amounts of electrical current.
FOR THESE REASONS, IT IS OF CRITICAL IMPORTANCE
THAT YOU READ THESE INSTRUCTIONS AND FOLLOW
THEM EXACTLY.
WHEN WORKING WITH LEAD-ACID BATTERIES:
• Follow the recommended PPE requirements per the
SDS for the battery to be used.
• 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.
ALERT! Performing maintenance and/or
troubleshooting procedures may interrupt power to the
loads, if battery reserve is not sufficient.
Spec. No: 582137200 Document Code: U M582137200
Model No: NetSure™ 5100 Revision A, January 11, 2017
NetSure™ -48 VDC Power System
[v]
CAUTION!
NOTE:
Danger
Alert
Caution
Danger
User Manual, UM582137200
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 determine the
“hazard/risk” category, and to select proper PPE.
This product is intended only for installation in a
Restricted Access Location.
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
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.
requires removal of existing hardware, retain all hardware
for use in subsequent steps, unless otherwise directed.
When performing any step in procedures that
When performing any step in procedures that
Spec. No: 582137200 Document Code: U M582137200
Model No: NetSure™ 5100 Revision A, January 11, 2017
NetSure™ -48 VDC Power System
[vi]
User Manual, UM582137200
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, such as Part Number 631810600, 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 conductive or anti-static
material such as conductive foam, conductive plastic, or aluminum foil. Do not use ordinary Styrofoam
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.
™
or ordinary plastic.
Spec. No: 582137200 Document Code: U M582137200
Model No: NetSure™ 5100 Revision A, January 11, 2017
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