Emerson NetSure 802, NetSure 802 DC Installation Guide

SPEC. NO.

MODEL

582140000

802NLDB

802NLEB
802NL-B

NetSure™ -48V DC Power System

Installation Guide

Section 5957 (Issue AM, March 26, 2014)

Business-Critical Continuity™, Emerson Network Power, and the Emerson Network

Power logo are trademarks and service marks of Emerson Electric Co.

Lorain® and Vortex® are registered trademarks of Emerson

Network Power, Energy Systems, North America, Inc.

NetSure™, NetSpan™, NetReach™, NetXtend™, and NetPerform™

are trademarks of Emerson Network Power, Energy Systems, North America, Inc.

All other trademarks are the property of their respective owners.

The products covered by this instruction manual are manufactured and/or

sold by Emerson Network Power, Energy Systems, North America, Inc.

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, Emerson Network Power, Energy Systems, North America, Inc.

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.

This document is the property of Emerson Network Power, Energy Systems, North America, Inc.

and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission

of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Copyright © 2014, Emerson Network Power, Energy Systems, North America, Inc.

All rights reserved throughout the world.

Installation Guide Section 5957
Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Preface

This document (Section 5957) provides an Installation Guide for Power System Models

802NLDB (208V Input Power/Distribution and Power Only Bays), 802NLEB (480V Input
Power/Distribution and Power Only Bays, and 802NL-B (Distribution Only Bay); Spec. No.

582140000. This is a condense version of the Installation Instructions (Section 5876).

Section 5876 can be accessed via the CD (Electronic Documentation Package) furnished
with your system.

For User Instructions, refer to Section 5877 provided on the CD (Electronic
Documentation Package) furnished with your system.

Refer to SAG582140000 (System Application Guide) for additional information. The SAG
can be accessed via the CD (Electronic Documentation Package) furnished with your
system.

For a color MCA Menu Tree, refer to Section 5886. Section 5886 is provided in the
separate INSTALLATION MANUAL and the CD CARRIER MANUAL (it is also provided
on the CD).

Your Power System may contain an optional LMS Monitoring System, refer to Section
5879 (LMS1000 Installation Instructions) and Section 5847 (LMS1000 User Instructions)
provided on the CD (Electronic Documentation Package) furnished with your system.

Danger: INSTALLERS MUST FOLLOW APPROVED SAFETY PROCEDURES.

This system operates from AC 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
electrical connections are made. DO NOT apply AC power to the system
until all electrical connections have been completed and checked.

This system may also require battery to be connected. Although battery
voltage is not hazardously high, the battery can deliver large amounts of
current. Exercise extreme caution not to inadvertently contact or have
any tool inadvertently contact a battery terminal or exposed wire
connected to a battery terminal. NEVER allow a metal object, such as a
tool, to contact more than one termination at a time, or to simultaneously
contact a termination and a grounded object. Even a momentary short
circuit can cause explosion and injury. Remove watches, rings, or other
jewelry before connecting battery leads. Make the DC (battery)
connections last. Make all other electrical connections without DC input
power applied to the system.

Warning: Before handling any circuit card, read and follow the instructions

contained on the Static Warning Page located at the beginning of this
document. A static wrist strap grounded through a one megohm
resistor should always be worn when handling the circuit cards.

Note: Apply electrical anti-oxidation compound to mating surfaces of busbars before

connecting together.

Wiring Considerations

For recommended wire sizes, crimp lugs, branch circuit protection, alarm relay contact
ratings, and general wiring information and restrictions; refer to System Application Guide
SAG582140000. The SAG can be accessed via the CD (Electronic Documentation
Package) furnished with your system.

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 1

Section 5957 Installation Guide
Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Refer to drawing 031110100 for lug crimping information. Refer to drawings 031110200
and 031110300 for additional lug information. These are located in the Installation
Manual.

All wiring and branch circuit protection should follow the current edition of the American
National Standards Institute (ANSI) approved National Fire Protection Association's
(NFPA) National Electrical Code (NEC), and applicable local codes. For operation in
countries where the NEC is not recognized, follow applicable codes. For field wiring, use
wires suitable for at least 75°C.

Installation Acceptance Checklist

Placing the Bays and Installing Internal/External Busbars

 Bays (and PDSC if furnished) Bolted Together (if required) and Mounted to Floor
 Bay-to-Bay Busbar Links Installed (if required)
 PDSC (if furnished) AC Input Connectors Connected to Power/Distribution Bay
 External Top-Mount Busbar Assemblies Installed (if furnished)

Installing Distribution Devices, MCA Relay
Circuit Cards, and MCA I/O Circuit Cards

 Distribution Fuses and Circuit Breakers Installed
 Distribution Lug Adapter Plates Installed
 MCA Customer Alarm Relay Circuit Card(s) Installed (if required)
 MCA I/O Circuit Card(s) Installed (if required)

Making Electrical Connections

 MCA Network Bay Interconnections Made
 MCA Battery Charge Digital Temperature Compensation Probe Mounted and

Connected (if furnished)

 MCA External Alarm, Reference, and Control Connections Made
 Connections Made to all MCA I/O Circuit Cards Installed
 LMS Local Port Connection Made (If Required)
 Bay(s) Frame Grounding Connections Made
 Bay(s) Load Connections Made
 Bay(s) AC Input and AC Input Ground Connections Made
 Battery Connections Made
 All Shields and Cover Panels in Place

Installing the Rectifiers and Setting Switch Options

 Rectifiers Installed
 MCA and Router Circuit Cards Switches Set
 Distribution Bus Monitoring Circuit Cards Jumper Set

Page 2

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

3/8-16 Floor

Leveling Bolts

FRONT

19.62

24.00

2.19

2.19

24.12

30.00

2.44

3.44

0.750 X 2.000 SLOT
(4 PLACES)

Floor Hole Drilling Pattern

Power/Distribution Bay

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Floor Mounting Hole Dimensions ­Primary and Secondary Power/Distribution Bays without PDSC
(Power Only Bays Have the Same Hole Pattern)
(all dimensions in inches)

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 3

Section 5957 Installation Guide

3/8-16 Floor

Leveling Bolts

FRONT

19.62

24.00

2.19

24.12

30.00

2.44

3.44

0.750 X 2.000 SLOT
(4 PLACES)

2.19

9.85

5.63

2.11

2.11

POWER/

DISTRIBUTION BAY

AC POWER
DISTRIBUTION
SERVICE CABINET

0.750 X 2.000 SLOT
(4 PLACES)

3/8-16

Floor

Leveling

Bolts

Floor Hole Drilling Pattern

Power/Distribution Bay

and PDSC

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Floor Mounting Hole Dimensions ­Primary and Secondary Power/Distribution Bays with PDSC
(all dimensions in inches)

Page 4

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

Front

3/8-16

Welded Nut (4)

0.812 Dia.
(8 PLACES)

25.875

23.250

27.625

25.375

19.500

26.625

24.000

3.063

1.750

1.875

2.750

4.063

30.000

31.375

19.500

5.937

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Floor Mounting Hole Dimensions ­Distribution Only Bay (all dimensions in inches)

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 5

Section 5957 Installation Guide

Hardware Build-Up: (use ground washers
in center tie points each side)
Bolt, Ground Washer,Bay/Cabinet Sides,
Ground Washer, Nut

Hardware Build-Up: (use in remaining connection points)
Bolt, Lock Washer, Flat Washer, Bay/Cabinet Sides,
Flat Washer, Lock Washer, Nut

Bay/Cabinet Sides Bay/Cabinet Sides

Holes for Bolting

Power/Distribution

Bays and PDSCs

Togethrer

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Bolting Power/Distribution Bay to PDSC Cabinet

Page 6

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

Hardware Build-Up: (use ground washers
in center tie points each side)
Bolt, Ground Washer, Bay/Cabinet Sides,
Ground Washer, Nut

Hardware Build-Up: (use in remaining connection points)
Bolt, Lock Washer,Flat Washer, Bay/Cabinet Sides,
Flat Washer,Lock Washer, Nut

Bay/Bay Sides Bay/Bay Sides

Holes for Bolting

Power/Distribution

Bays Togethrer

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Bolting Power/Distribution Bay to Power/Distribution Bay

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 7

Section 5957 Installation Guide

3/8-16 x 1-1/2" Bolt
3/8" Belleville Lock Washer
3/8" Belleville Lock Washer
(concave side of Belleville
Lock Washers face each other)
3/8” Hardened Flat Washer
(10 Places per Busbar)

POSITIVE
BUSBAR LINK

NEGATIVE
BUSBAR LINK

Slide Busbar Links Under
Bays' Upright Channels.
Use Bolt Holes as Shown
in Illustration.

Torque to 180 in-lbs.

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Installing Power/Distribution Bay to Power/Distribution Bay
Negative and Positive Busbar Links (WITHOUT PDSC)

Page 8

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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

Busbar Link

Cover Shield

(installed after

all mounting

and electrical

connection

procedures

are completed)

Slide Busbar Links Under
Bays' Upright Channels.
Use Bolt Holes as Shown
in Illustration.

Torque to 180 in-lbs.

3/8-16 x 1-1/2" Bolt
3/8" Belleville Lock Washer
3/8" Belleville Lock Washer
(concave side of Belleville
Lock Washers face each other)
3/8” Hardened Flat Washer
(10 Places per Busbar)

POSITIVE
BUSBAR LINK

NEGATIVE
BUSBAR LINK

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Installing Power/Distribution Bay to Power/Distribution Bay
Negative and Positive Busbar Links (WITH PDSC)

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 9

Section 5957 Installation Guide

3/8-16 x 1-1/2" Bolt
3/8" Belleville Lock Washer
3/8" Belleville Lock Washer
(concave side of Belleville
Lock Washers face each other)
3/8” Hardened Flat Washer

POSITIVE
BUSBAR LINK

NEGATIVE
BUSBAR LINK

Existing Older Style Bay
side, use ALL bolt holes.

Slide Busbar Links Under
Bays' Upright Channels.
Torque to 180 in-lbs.

Newer Style Bay side,

use bolt holes as

shown in illustration.

Existing Older
Style Bay

Existing Older
Style Bay

Newer
Style Bay

Newer
Style Bay

List 1 and 11 shown.
List 2 and 12 w/ List 30 or 31 similar.

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Installing Power/Distribution Bay to Power/Distribution Bay
Negative and Positive Busbar Links – New Style Bay Connected to an Existing Older Style Bay

Page 10

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

Power/Distribution

Bay

Power/Distribution

Bay

PDSC

PDSC

Row of PDSC PCU

AC Input Connectors

Connectors

in PDSC

to

PCU Mtg.

Pos. #1

to

PCU Mtg.

Pos. #2

to

PCU Mtg.

Pos. #3

to

PCU Mtg.

Pos. #4

to

PCU Mtg.

Pos. #5

to

PCU Mtg.

Pos. #6

to

PCU Mtg.

Pos. #7

to

PCU Mtg.

Pos. #8

to

PCU Mtg.

Pos. #9

to

PCU Mtg.

Pos. #10

Torque to
23 in-lbs.

A
B
C

A
B
C

A
B
C

A
B
C

A
B
C

A
B
C

A
B
C

A
B
C

A
B
C

A
B
C

Row of PCU Mtg. Pos.

AC Input Connectors

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Connecting Rectifier Mounting Position AC Input Connectors to PDSC
(Lists 2 and 12 Only)

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 11

Section 5957 Installation Guide

STEP 1

Install “Main Positive Busbar” onto Bay’s
Positive Busbar.Hand-tighten hardware.

(1) Main Positive Busbar, P/N 554877
Note:Apply Electrical Anti-Oxidation Compound

to Busbar Mating Surfaces.

(12) 3/8” Flat Washer, P/N 214204100
(12) 3/8” Belleville Washer, P/N 214825000
(12) 3/8-16 Hex Nut, P/N 228567100
Hand-tighten.

Note: Concave Side of Belleville Washer Faces

Busbar, Convex Side Faces Hex Nut.
Belleville Washer install between Hex Nut

and Flat Washer.

Rear Top
of Bay

Assembled
View

Do the following first before assembly:

1. Remove 552402 (1) and 116638 (4) from Bay.

2. Mount 554880 to the 554877 with 116638 (3).

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Power/Distribution Bay
External Top-Mount Horizontal Battery Input Busbar Assembly (P/N 554873)
Assembly Procedure Step 1

Page 12

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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

Assembled
View

STEP 2

Install “Support Bar” and “Related
Hardware” onto Top of Bay.

(2) Threaded Insulator, P/N 245857200 Torque to 715 In-lbs.

(2) Support Bar Clip, P/N 351322300
(2) Support Bar, P/N 237790100

(2) 5/8” Lock Washer, P/N 215111800

(2) 5/8” Hex Nut, P/N 228580900 Leave 1/4” Space Between

Bottom of Nut and Top of Bay.

(2) 5/8-11 x 7” Threaded Rod, P/N 334317000

(2) Support Bar Clip, P/N 351322300

Rear Top

of Bay

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Power/Distribution Bay
External Top-Mount Horizontal Battery Input Busbar Assembly (P/N 554873)
Assembly Procedure Step 2

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 13

Section 5957 Installation Guide

Assembled
View

STEP 3

Install “Main Negative Busbar” onto Bay’s
Negative Busbar. Hand-tighten hardware.

(1) Main Negative Busbar, P/N 554875

Rear Top

of Bay

Note: Apply Electrical Anti-Oxidation Compound

to Busbar Mating Surfaces.

(8) 3/8” Flat Washer, P/N 214204100
(8) 3/8” Belleville Washer, P/N 214825000

(8) 3/8-16 Hex Nut, P/N 228567100 Hand-Tighten

Note: Concave Side of Belleville Washer Faces

Busbar,Convex Side Faces Hex Nut.

Belleville Washer Install between Hext Nut
and Flat Washer.

Mount 554876 to the 554875.
Hardware:
214204100 (4)
214825000 (4)
228567100 (4)

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Power/Distribution Bay
External Top-Mount Horizontal Battery Input Busbar Assembly (P/N 554873)
Assembly Procedure Step 3

Page 14

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

Note: Concave Side of Belleville Washer Faces

Busbar, Convex Side Faces Bolt Head.

Belleville Washer install between Bolt Head
and Flat Washer.

(1) Horizontal Landing Negative Busbar, P/N 514434
Note: Apply Electrical Anti-Oxidation Compound

to Busbar Mating Surfaces.

(6) 3/8” Belleville Washer, P/N 214825000

(6) 3/8-16 x 1-1/4” Bolt, P/N 227646800

(6) 3/8" Flat Washer, P/N 214204100

Assembled
View

Rear Top

of Bay

STEP 4

Install “Horizontal Landing Negative Busbar”
onto “Main Negative Busbar”.

Torque to 180 in-lbs.

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Power/Distribution Bay
External Top-Mount Horizontal Battery Input Busbar Assembly (P/N 554873)
Assembly Procedure Step 4

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 15

Section 5957 Installation Guide

STEP 5

Install "Threaded Insulators" onto
"Horizontal Landing Negative Busbar".

(2) Threaded Insulator,P/N 245857200
(2) 5/8-11 x 1-1/4" Threaded Rod, P/N 334315700
(2) Threaded Insulator,P/N 245857200

(2) 5/8-11 x 1-1/2" Threaded Rod, P/N 334315900

Hand-Tighten

Hand-Tighten

Assembled
View

Rear Top

of Bay

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Power/Distribution Bay
External Top-Mount Horizontal Battery Input Busbar Assembly (P/N 554873)
Assembly Procedure Step 5

Page 16

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

STEP 6

Install "Horizontal Landing Positive Busbar"
onto "Main Positive Busbar".

(2) 5/8-11 x 1" Bolt, P/N 227655100
(2) 5/8" Lock Washer, P/N 215111800
(2) 5/8" Flat Washer, P/N 214201300

Torque to 715 in-lbs.

(1) Horizontal Landing Positive Busbar, P/N 514436
Note: Apply Electrical Anti-Oxidation Compound

to Busbar Mating Surfaces.

(6) 3/8" Flat Washer, P/N 214204100
(6) 3/8" Belleville Washer, P/N 214825000

(6) 3/8-16 x 1-1/4" Bolt, P/N 227646800

Torque to 180 in-lbs.

Note: Concave Side of Belleville Washer Faces

Busbar, Convex Side Faces Bolt Head.

Belleville Washer install between Bolt Head
and Flat Washer.

Assembled
View

Rear Top

of Bay

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Power/Distribution Bay
External Top-Mount Horizontal Battery Input Busbar Assembly (P/N 554873)
Assembly Procedure Step 6

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 17

Section 5957 Installation Guide

Torque these connections
to 180 in-lbs (20 places).

Rear Top

of Bay

STEP 7

Final Torque

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Power/Distribution Bay
External Top-Mount Horizontal Battery Input Busbar Assembly (P/N 554873)
Assembly Procedure Step 7

Page 18

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957
Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Power/Distribution Bay
Busbar Shield Kit (P/N 528482)
Assembly Procedure

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 19

Section 5957 Installation Guide

STEP 1

Install "Threaded Insulators".

(1) Threaded Insulator, P/N 245857200

(1) 5/8-11 x 1-1/4" Threaded Rod, P/N 334315700

(1) Threaded Insulator, P/N 245857200

PreviouslyAssembled
Kit P/N 554873

(1) 5/8" Flat Washer, P/N 214201300
(1) 5/8" Lock Washer, P/N 215111800

(1) 5/8-11 x 1" Bolt, P/N 227655100

Hand-Tighten

Torque to 715 in-lbs.

Assembled
View

Rear

Top

of Bay

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Power/Distribution Bay
External Top-Mount Ground (Load Return) Busbar Assembly (P/N 514688 or 514689)
Assembly Procedure Step 1

Page 20

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

P/N214204100

(6)3/8" FlatWasher

STEP 2A

Install "Busbars".

(see Step 2B for Bolt Hole Identification)

(see Step 2C for Assembled View)

Note: Apply ElectricalAnti-Oxidation

Compound to all Busbar
Mating Surfaces.

* Use "Spacer Busbars" or "Spacer Insulators"

Busbar Assy P/N 514688

Busbar Assy P/N 514689

(1)5/8-11x 1-3/4" Bolt,P/N 227653800

or Torque to 715 in-lbs.

5/8-11 x 2-3/4" Bolt,P/N 227653900
and

(1)5/8" LockWasher, P/N215111800

and

(1)5/8" Flat Washer, P/N214201300

Spacer Insulator,P/N514473,
orBusbarfromNext Bay*

P/N 514689 Only

Busbar,P/N514467

Spacer Insulator,P/N514473,
orBusbarfromNext Bay*

Busbar, P/N514467

P/N 514689 Only

Spacer Insulator,P/N514473,
orBusbarfromNext Bay*

P/N 514689 Only

Busbar, P/N514467
SpacerInsulator, P/N514473,

orBusbarfromNext Bay*
Busbar, P/N514467

Note: ConcaveSideofBelleville Washer Faces

Busbar,Convex SideFacesNut.

PreviouslyAssembled
KitP/N554873

Note: ConcaveSideofBelleville

Washer Faces Busbar,
ConvexSideFacesBolt Head.
Belleville Washer install between
Bolt HeadandFlat Washer.

Torque to 180 in-lbs.

P/N227646800

(6)3/8-16x1-1/4"Bolt

P/N214825000

(6)3/8" BellevilleWasher

P/N228567100

(4)3/8-16Hex Nut

P/N214825000

(4)3/8" BellevilleWasher

or BusbarfromNext Bay*

SpacerBusbar,P/N514472,

Busbar, P/N514541

orBusbarfrom Next Bay*

Spacer Busbar, P/N 514472,

P/N 514689 Only

Busbar, P/N514467

P/N 514689 Only

orBusbarfrom Next Bay*

Spacer Busbar, P/N 514472,

orBusbarfrom Next Bay*

Spacer Busbar, P/N 514472,

Busbar, P/N514522

P/N 514689 Only

Busbar, P/N514467

(4)3/8" FlatWasher, P/N214204100

and

3/8-16x 2-3/4" Bolt,P/N 227647700

or

(4)3/8-16x 2" Bolt,P/N 227647400

Torque to 180 in-lbs.

on end bays or stand-alone bays. For multiple

bays, 'sandwich' busbars of adjacent "Busbar

Assemblies" together.

Rear Top

of Bay

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Power/Distribution Bay
External Top-Mount Ground (Load Return) Busbar Assembly (P/N 514688 or 514689)
Assembly Procedure Step 2A

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 21

Section 5957 Installation Guide

STEP 2B

Install "Busbars".

(Bolt Hole Identification)

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Power/Distribution Bay
External Top-Mount Ground (Load Return) Busbar Assembly (P/N 514688 or 514689)
Assembly Procedure Step 2B

Page 22

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

STEP 2C

Install "Busbars".

(Assembled Views)

Spacer Busbars

or Spacer Insulators

Installed

Previously Assembled
Kit P/N 554873

Assembled
Views

No Spacer Busbars or Spacer Insulators.
Busbars ofAdjacent Assemblies 'Sandwich'
and Bolted Together.

Previously Assembled
Kit P/N 554873

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Power/Distribution Bay
External Top-Mount Ground (Load Return) Busbar Assembly (P/N 514688 or 514689)
Assembly Procedure Step 2C

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 23

Section 5957 Installation Guide

STEP 3

Install "Cover" Mounting Standoffs.

(2) Standoff, P/N 117843

(2) 1/4" Flat Washer, P/N 214110100

(2) 1/4" Lock Washer, P/N 215111100
(2) 1/4-20 x 1/2" Bolt, P/N 227640200

Torque to 84 in-lbs.

Previously Assembled
Kit P/N 554873

DO NOT PERFORM THIS STEP if you are going to install

"Load Return Lug Extension Busbar Assembly" P/N 514543

Use These Holes

Assembled
View

Rear

Top

of Bay

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Power/Distribution Bay
External Top-Mount Ground (Load Return) Busbar Assembly (P/N 514688 or 514689)
Assembly Procedure Step 3

Page 24

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

STEP 4

Install "Covers".

(2) 1/4-20 x 1/2" Bolt, P/N 227640200
(2) 1/4" Lock Washer, P/N 215111100

(2) 1/4" Flat Washer, P/N 214110100

Torque to 45 in-lbs.

(2) 10-32 Lock Nut, P/N 104564

(2) 10-32 x 3/4" Tap Screw, P/N 218706500

DO NOT PERFORM THIS STEP if you are going to install

"Load Return Lug Extension Busbar Assembly" P/N 514543

P

/

N

5

1

4

5

2

0

P

/

N

5

1

4

5

2

1

Assembled
View

Rear

Top

of Bay

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Power/Distribution Bay
External Top-Mount Ground (Load Return) Busbar Assembly (P/N 514688 or 514689)
Assembly Procedure Step 4

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 25

Section 5957 Installation Guide

STEP 1

Install "Threaded Insulators".

(1) Threaded Insulator, P/N 245857200

(1) 5/8-11 x 1-1/4" Threaded Rod, P/N 334315700

(1) Threaded Insulator, P/N 245857200

Previously Assembled

Kit P/N 554873

(1) 5/8" Flat Washer, P/N 214201300

(1) 5/8" Lock Washer, P/N 215111800

(1) 5/8-11 x 1" Bolt, P/N 227655100

Torque to 715 in-lbs.

Assembled
View

Rear

Top

of Bay

Hand-Tighten

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Power/Distribution Bay
External Top-Mount Ground (Load Return) Busbar Assembly (P/N 514690 or 514691)
Assembly Procedure Step 1

Page 26

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

Torque to 180in-lbs.

BusbarAssy P/N 514690 (1)5/8-11 x 1-3/4" Bolt, P/N227653800

5/8-11 x 2-3/4"Bolt,P/N227653900

and

(1)5/8" LockWasher, P/N215111800

and

(1)5/8" Flat Washer,P/N 214201300

P/N214825000

P/N214825000

(4)3/8" Belleville Washer

P/N228567100

(4)3/8-16HexNut

Note: ConcaveSide of Belleville

Washer FacesBusbar,
Convex Side Faces Nut.

(6)3/8" Flat Washer
P/N214204100

(6)3/8" BellevilleWasher
P/N214825000

(6)3/8-16 x 1-1/4" Bolt
P/N227646800

Torqueto 180 in-lbs.

Note: ConcaveSide of Belleville

Washer FacesBusbar,
ConvexSide Faces BoltHead.
BellevilleWasherinstall between
BoltHead andFlat Washer.

PreviouslyAssembled
Kit P/N554873

Busbar, P/N514469

Busbar, P/N514541

Busbar, P/N514469

Busbar, P/N514467

P/N514691Only

Busbar, P/N514469

P/N514691Only

Busbar, P/N514522

Busbar, P/N514469

Busbar, P/N514467

P/N514691 Only

STEP 2A

Install "Busbars".

(see Step 2B for Bolt Hole Identification)

(see Step 2C for Assembled View)

Note: ApplyElectricalAnti-Oxidation

CompoundtoallBusbar
Mating Surfaces.

* Use"Spacer Busbars" or "Spacer Insulators"

on endbays or stand-alonebays.For multiple
bays, use "Spacer Busbars" andmoveout
to 'bridge'betweenbusbars of both

Assemblies (seeAssembled View).

(4)3/8-16x 2" Bolt, P/N227647400

or

BusbarAssy P/N 514691

or

Torqueto 715 in-lbs.

Spacer Busbar,P/N514472*

Spacer Insulator, P/N514473*

P/N514691Only

Spacer Busbar,P/N514472*

Spacer Insulator, P/N514473*

Spacer Busbar,P/N514472*

Spacer Insulator, P/N514473*

P/N514691Only

Spacer Busbar,P/N514472*

Spacer Insulator, P/N514473*

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Power/Distribution Bay
External Top-Mount Ground (Load Return) Busbar Assembly (P/N 514690 or 514691)
Assembly Procedure Step 2A

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 27

Section 5957 Installation Guide

* Use "Spacer Busbars" or "Spacer Insulators"

on end bays or stand-alone bays. For multiple
bays, use "Spacer Busbars" and move out to
'bridge' between busbars of both Assemblies
(seeAssembled View).

STEP 2B

Install "Busbars".

(Bolt Hole Identification)

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Power/Distribution Bay
External Top-Mount Ground (Load Return) Busbar Assembly (P/N 514690 or 514691)
Assembly Procedure Step 2B

Page 28

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

STEP 2C

Install "Busbars".

(Assembled Views)

Spacer Busbars
or Spacer Insulators
Installed

Previously Assembled
Kit P/N 554873

Assembled
Views

* Use "Spacer Busbars" or "Spacer Insulators"

on end bays or stand-alone bays. For multiple
bays, use "Spacer Busbars" and move out to
'bridge' between busbars of both Assemblies.

Previously Assembled
Kit P/N 554873

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Power/Distribution Bay
External Top-Mount Ground (Load Return) Busbar Assembly (P/N 514690 or 514691)
Assembly Procedure Step 2C

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 29

Section 5957 Installation Guide

STEP 3

Install "Cover" Mounting Standoffs.

(2) Standoff, P/N 117843

(2) 1/4" Flat Washer, P/N 214110100
(2) 1/4" Lock Washer, P/N 215111100

(2) 1/4-20 x 1/2" Bolt, P/N 227640200

Torque to 45 in-lbs.

Previously Assembled
Kit P/N 554873

DO NOT PERFORM THIS STEP if you are going to install
"Load Return Lug Extension Busbar Assembly" P/N 514543

Use These Holes

Assembled
Views

Rear

Top

of Bay

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Power/Distribution Bay
External Top-Mount Ground (Load Return) Busbar Assembly (P/N 514690 or 514691)
Assembly Procedure Step 3

Page 30

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

(2) 1/4-20 x 1/2" Bolt, P/N 227640200
(2) 1/4" Lock Washer, P/N 215111100

(2) 1/4" Flat Washer, P/N 214110100

(2) 10-32 Lock Nut, P/N 104564

(2) 10-32 x 3/4" Tap Screw, P/N 218706500

Assembled
View

Rear

Top

of Bay

Torque to 45 in-lbs.

STEP 4

Install "Covers".

DO NOT PERFORM THIS STEP if you are going to install
"Load Return Lug Extension Busbar Assembly" P/N 514543

P

/

N

5

1

4

5

2

1

P

/

N

5

1

4

5

1

9

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Power/Distribution Bay
External Top-Mount Ground (Load Return) Busbar Assembly (P/N 514690 or 514691)
Assembly Procedure Step 4

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 31

Section 5957 Installation Guide

STEP 1A

Install "Load Return Lug Extension Busbar"

(List 1 and 11 Bays).

Remove any
previously installed
bolts from these
four locations

Note:Apply Electrical Anti-Oxidation

Compound to all Busbar
Mating Surfaces.

(1*) Busbar,P/N 514542

(8*) 3/8-16 x 3" Bolt, P/N 227647800

(8*) 3/8" Flat Washer, P/N 214204100

(hardened, thicker than other Kit
supplied 3/8" flat washer)

(8*) 3/8" Belleville Washer, P/N 214825000

(8*) 3/8-16 Nut, P/N 228567100

* Quantities are per Kit,

two Kits shown in Illustrations.

Previously Assembled
Kit P/N 514688 or 514689

Previously Assembled
Kit P/N 554873

Note: Concave Side of Belleville

Washer Faces Busbar,
Convex Side Faces Bolt Head.

Front Top
of Bay

Assembled
View

Torque to 180 in-lbs.

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Power/Distribution Bay
Load Return Lug Extension Busbar Assembly (P/N 514543)
Assembly Procedure Step 1A

Page 32

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

STEP 2A

Install "Lug Mounting Bolts"

(List 1 and 11 Bays).

(24*) 3/8-16 x 1-1/4" Bolt, P/N 227646800

(24*) 3/8" Flat Washer, P/N 214112100

(thinner than other Kit
supplied 3/8" flat washer)

(24*) 3/8" Flat Washer, P/N 214112100

(thinner than other Kit
supplied 3/8" flat washer)

(24*) 3/8" Lock Washer, P/N 215111300

(24*) 3/8-16 Nut, P/N 228567100

PreviouslyAssembled
Kit P/N 514688 or 514689

PreviouslyAssembled
Kit P/N 554873

Torque to 300 in-lbs.

* Quantities are per Kit,

two Kits shown in Illustrations.

Front Top
of Bay

Assembled

View

PROCEDURE PROVIDED FOR REFERENCE ONLY,
INSTALL BOLTS AS LUGS ARE INSTALLED TO BUSBAR

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Power/Distribution Bay
Load Return Lug Extension Busbar Assembly (P/N 514543)
Assembly Procedure Step 2A

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 33

Section 5957 Installation Guide

STEP 3A

Install "Covers"

(List 1 and 11 Bays).

(2*) 10-32 Lock Nut, P/N 104564

(2*) 10-32 x 3/4" Tap Screw, P/N 218706500

* Parts are from the P/N 514688 or 514689 Kit.
Quantities are per Kit, two Kits shown in Illustrations.
The following parts are not used: (2) 1/4-20 x 1/2" Bolt
(P/N 227640200), (2) 1/4" Lock Washer (P/N 215111100),
(2) 1/4" Flat Washer (P/N 214110100)

Assembled

View

Rear Top
of Bay

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Power/Distribution Bay
Load Return Lug Extension Busbar Assembly (P/N 514543)
Assembly Procedure Step 3A

Page 34

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

(1*) Busbar, P/N 514542

(8*) 3/8-16 x 3" Bolt, P/N 227647800

(8*) 3/8" Flat Washer, P/N 214204100

(hardened, thicker than other Kit
supplied 3/8" flat washer)

(8*) 3/8" Belleville Washer, P/N 214825000

(8*) 3/8-16 Nut, P/N 228567100

* Quantities are per Kit,

two Kits shown in Illustrations.

Previously Assembled
Kit P/N 514690 or 514691

PreviouslyAssembled
Kit P/N 554873

Note: Concave Side of Belleville

Washer Faces Busbar,
Convex Side Faces Bolt Head.

Front Top
of Bay

Assembled

View

Torque to 180 in-lbs.

Note:Apply Electrical Anti-Oxidation

Compound to all Busbar
Mating Surfaces.

STEP 1B

Install "Load Return Lug Extension Busbar"

(List 2 and 12 Bays E/W List 30 or 31 PDSC).

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Power/Distribution Bay
Load Return Lug Extension Busbar Assembly (P/N 514543)
Assembly Procedure Step 1B

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 35

Section 5957 Installation Guide

(24*) 3/8-16 x 3" Bolt, P/N 227647800

(24*) 3/8" Flat Washer, P/N 214112100

(thinner than other Kit
supplied 3/8" flat washer)

(24*) 3/8" Flat Washer, P/N 214112100

(thinner than other Kit
supplied 3/8" flat washer)

(24*) 3/8" Lock Washer, P/N 215111300

(24*) 3/8-16 Nut, P/N 228567100

Previously Assembled
Kit P/N 514690 or 514691

Previously Assembled
Kit P/N 554873

Front Top
of Bay

Assembled

View

* Quantities are per Kit,

two Kits shown in Illustrations.

STEP 2B

Install "Lug Mounting Bolts"

(List 2 and 12 Bays E/W List 30 or 31 PDSC).

PROCEDURE PROVIDED FOR REFERENCE ONLY,
INSTALL BOLTS AS LUGS ARE INSTALLED TO BUSBAR

Torque to 300 in-lbs.

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Power/Distribution Bay
Load Return Lug Extension Busbar Assembly (P/N 514543)
Assembly Procedure Step 2B

Page 36

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

STEP 3B

Install "Covers"

(List 2 and 12 Bays E/W List 30 or 31 PDSC).

(2*) 10-32 Lock Nut, P/N 104564

(2*) 10-32 x 3/4" Tap Screw, P/N 218706500

* Parts are from the P/N 514690 or 514691 Kit.

Quantities are per Kit, two Kits shown in Illustrations.
The following parts are not used: (2) 1/4-20 x 1/2" Bolt
(P/N 227640200), (2) 1/4" Lock Washer (P/N 215111100),
(2) 1/4" Flat Washer (P/N 214110100)

Rear Top
of Bay

Assembled
View

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Power/Distribution Bay
Load Return Lug Extension Busbar Assembly (P/N 514543)
Assembly Procedure Step 3B

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 37

Section 5957 Installation Guide

STEP 1

Install “Main Positive Busbar” onto
Bay Positive Busbar.

(1) Main Positive Busbar, P/N 554877

Note:Apply ElectricalAnti-Oxidation Compound

to busbar mating surfaces.

(12) 3/8” Flat Washer, P/N 214204100
(12) 3/8” Belleville Washer,P/N 214825000
(12) 3/8-16 Hex Nut, P/N 228567100

Hand-tighten only.

Note: Concave side of Bellville washer faces

busbar; convex side faces hex nut.

Rear Top
of Bay

Assembled
View

Do the following first before assembly:

1. Remove 552402 (1) and 116638 (4) from Bay.

2. Mount 554880 to the 554877 with 116638 (3).

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Power/Distribution Bay
External Top-Mount Vertical Battery Input Busbar Assembly (P/N 554874)
Assembly Procedure Step 1

Page 38

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

STEP 2

Install “Support Bar” and “Related
Hardware” onto Top of Bay.

(2) Threaded Insulator, P/N 245857200 Torque to 715 in-lbs.

(2) 5/8-11 x 7” Threaded Rod, P/N 334317000

(2) Support Bar Clip, P/N 351322300
(2) Support Bar, P/N 237790100

(2) Support Bar Clip, P/N 351322300
(2) 5/8” Lock Washer, P/N 215111800
(2) 5/8” Hex Nut, P/N 228580900 Leave 1/2” space between

bottom of nut and top of bay.

Rear Top

of Bay

Assembled
View

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Power/Distribution Bay
External Top-Mount Vertical Battery Input Busbar Assembly (P/N 554874)
Assembly Procedure Step 2

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 39

Section 5957 Installation Guide

(1) Main Negative Busbar, P/N 554875
Note: Apply ElectricalAnti-Oxidation Compound

to busbar mating services.

Note: Concave side of Belleville washer faces
busbar; convex side faces hex nut.

(8) 3/8” Flat Washer, P/N 214204100
(8) 3/8” Belleville Washer, P/N 214825000

(8) 3/8-16 Hex Nut, P/N 228567100 Hand-tighten only.

Rear Top

of Bay

Assembled
View

STEP 3

Install “Main Negative Busbar” onto Bay
Negative Busbar.

Mount 554876 to the 554875.
Hardware:
214204100 (4)
214825000 (4)
228567100 (4)

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Power/Distribution Bay
External Top-Mount Vertical Battery Input Busbar Assembly (P/N 554874)
Assembly Procedure Step 3

Page 40

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

Note: Concave side of Belleville washer faces

busbar; convex side faces bolt head.

(6) 3/8-16 x 1-1/4” Bolt, P/N 227646800 Torque to 180 in-lbs.
(6) 3/8” Belleville Washer, P/N 214825000

(6) 3/8” Flat Washer, P/N 214204100

Note: Apply electrical anti-oxidation compound

to busbar mating surfaces.

(1) Vertical Landing Negative Busbar, P/N 548000

Rear Top

of Bay

Assembled
View

STEP 4

Install “Vertical Landing Negative Busbar”
onto “Main Negative Busbar”.

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Power/Distribution Bay
External Top-Mount Vertical Battery Input Busbar Assembly (P/N 554874)
Assembly Procedure Step 4

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 41

Section 5957 Installation Guide

(2) 5/8-11 x 1-1/2” Threaded Rod, P/N 334315900

(2) Threaded Insulator, P/N 245857200 Hand-tighten only.

(2) 5/8-11 x 1-1/4” Threaded Rod, P/N 334315700

(2) Threaded Insulator, P/N 245857200 Hand-tighten only.

Rear Top

of Bay

Assembled
View

STEP 5

Install “Threaded Insulators” onto
“Vertical Landing Negative Busbar”.

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Power/Distribution Bay
External Top-Mount Vertical Battery Input Busbar Assembly (P/N 554874)
Assembly Procedure Step 5

Page 42

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

(6) 3/8-16 x 1-1/4” Bolt, P/N 227646800 Torque to 180 in-lbs.
(6) 3/8” Belleville Washer, P/N 214825000

(6) 3/8” Flat Washer, P/N 214204100

(1) Vertical Landing Positive Busbar, P/N 548003

(2) 5/8-11 x 1” Bolt, P/N 227655100 Torque to 715 in-lbs.
(2) 5/8” Lock Washer, P/N 215111800
(2) 58” Flat Washer, P/N 214201300

STEP 6

Install “Vertical Landing Positive Busbar”
onto “Main Positive Busbar”.

Rear Top

of Bay

Assembled
View

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Power/Distribution Bay
External Top-Mount Vertical Battery Input Busbar Assembly (P/N 554874)
Assembly Procedure Step 6

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Page 43

Section 5957 Installation Guide

Torque these connections

to 180 in-lbs (20 places).

STEP 7

Final Torque

Rear Top

of Bay

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Power/Distribution Bay
External Top-Mount Vertical Battery Input Busbar Assembly (P/N 554874)
Assembly Procedure Step 7

Page 44

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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

(2) Standoff Insulator, P/N 117843

(1) Plastic Shield, P/N 548002
(4) 14-20 x 3/8” Pan Head Tap Screw, P/N 218708200

STEP 8

Install Shield

Assembled
View

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Power/Distribution Bay
External Top-Mount Vertical Battery Input Busbar Assembly (P/N 554874)
Assembly Procedure Step 8

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 45

Section 5957 Installation Guide

3-Pole

1 12 13 24

25 36 37 48

Distribution Device

Top Mounting Studs

Distribution Device

Power System Connectors

Distribution Device

Bottom Mounting Studs

Distr.

Bus

#2

Distr.

Bus

#1

Right Half
Distr. Bus
#1 and #2

Left Half

Distr. Bus

#1 and #2

Belleville Lock Washer

3/8-16 Nut

Torque to
180 in-lbs

Torque to

84 in-lbs

Flat Washer

Lock Washer

1/4-20 Nut

Bullet Nose-Type Device

Mounting Assembly

Note: Each half of each bus MUST be populated

with distribution devices from left-to-right,
without skipping any distribution device mounting
positions within each half.

Front View

TPL Fuseholders

218 Circuit Breakers

1-Pole 2-Pole 3-Pole 4-Pole

2-Pole 3-Pole

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Installing 218 Circuit Breakers, TPL Fuseholders, and Bullet Nose-Type Device Mounting Assemblies
into Power/Distribution Bays

Page 46

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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

* IncludesLoad Lug Adapter Plate,

plus 1/4" and 3/8" Mtg. Hardware.

Bus #1

Distribution Device

Mounting Location

Position 1 (left),

Position 24 (right)

Bus #2

Distribution Device

Mounting Location

Position 25 (left),

Position 48 (right)

Front View

Load Lug Adapter

Plate P/N 513701,

Kit P/N 520892*

Load Lug Adapter

Plate P/N 514765,

Kit P/N 520894*

Load Lug Adapter

Plate P/N 513702,

Kit P/N 520893*

Load Lug Adapter

Plate P/N 513700,

Kit P/N 520891*

to Distribution:

Bus #1

Position #12

to Distribution:

Bus #2

Position #25

to Distribution:

Bus #2

Position #36

to Distribution:

Bus #1

Position #1

to Distribution:
Bus #1
Position #13

to Distribution:
Bus #1
Position #24

to Distribution:
Bus #2
Position #37

to Distribution:
Bus #2
Position #48

1 12 13 24

25 36 37 48

Load Lug and/or

Load Lug Adapter Plate

Mounting Locations

REFER TO DISTRIBUTION DEVICES ILLUSTRATIONS

FOR PROPER LOAD LUG ADAPTER SELECTION

NOTE THATBULLET NOSE-TYPE DEVICE MOUNTING

ASSEMBLIES DO NOT REQUIRE LOAD LUG ADAPTER PLATES

Torque to
84 in-lbs

Hardware Build-Up
Load Lug Adapter Mounting Studs
Load Lug Adapter Plate
Flat Washer
Lock Washer
1/4-20 Nut

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Installing Load Lug Adapter Plates
into Power/Distribution Bays

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 47

Section 5957 Installation Guide
Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Installing 218 Circuit Breakers and TPL Fuseholders
into Distribution Only Bays

Page 48

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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

to Distribution:

Bus #2

Position #24

to Distribution:

Bus #2

Position #19

to Distribution:

Bus #2

Position #18

to Distribution:

Bus #2

Position #13

to Distribution:

Bus #4

Position #48

to Distribution:

Bus #4

Position #43

to Distribution:

Bus #4

Position #42

to Distribution:

Bus #4

Position #37

to Distribution:
Bus #1
Position #1

to Distribution:
Bus #1
Position #6

to Distribution:
Bus #1
Position #7

to Distribution:
Bus #1
Position #12

to Distribution:
Bus #3
Position #25

to Distribution:
Bus #3
Position #30

to Distribution:
Bus #3
Position #31

to Distribution:
Bus #3
Position #36

Rear cover panels removed in illustration for clarity.

Rear View Rear View

Load Lug and/or

Load Lug Adapter Kit

Mounting Locations

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Installing Load Lug Adapter Plates
into Distribution Only Bays

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 49

Section 5957 Installation Guide

NOTE THAT 1-POLE 218 CIRCUIT BREAKERS
DO NOT REQUIRE LOAD LUG ADAPTER PLATES

2-Position

Lug Adapter Kit

P/N 529132

3-Position

Lug Adapter Kit

P/N 529131

4-Position

Lug Adapter Kit

P/N 534420

1-Position Devices
(Load Busbars with NO
Lug Adapters Installed)

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Installing Load Lug Adapter Plates
into Distribution Only Bays (continuation)

Page 50

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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

Customer
Supplied
Lug

Busbars
P/O Dist.
Bay

2-Position

Lug Adapter Kit

P/N 529132

Customer
Supplied
Lug

Customer
Supplied
Lugs

Customer
Supplied
Lugs

Busbars
P/O Dist.
Bay

Note: Apply Electrical Anti-Oxidation
Compound to all Busbar
Mating Surfaces.

Note: Concave Side of Belleville Washer Faces Busbar,
Convex Side Faces Bolt or Nut.

(1) Spacer Busbar,
P/N 528806

(1) Adapter Busbar,

P/N 528794

(2) 3/8-16 Hex Nut,
P/N 228567100
(2) 3/8" Flat Washer,
P/N 214204100

(1) 3/8-16 Hex Nut,
P/N 228567100
(1) 3/8" Flat Washer,
P/N 214204100

Torque to 180 in-lbs.

(1) 1/4-20 x 7/8" Bolt,
P/N 227640500
(1) 1/4" Flat Washer,
P/N 214110100

(2) 3/8-16 x 1-1/2" Bolt,
P/N 227647000
(2) 3/8" Belleville Lock Washer,
P/N 214825000

(4) 3/8-16 x 1-1/2" Bolt,
P/N 227647000
(4) 3/8" Flat Washer,
P/N 214112100

(1) 3/8-16 x 1" Bolt,
P/N 227646600
(1) 3/8" Belleville Lock Washer,
P/N 214825000

(1) 1/4-20 x 7/8" Bolt,
P/N 227640500
(1) 1/4" Flat Washer,
P/N 214110100

(1) Adapter Busbar,

P/N 528794

(8) 3/8-16 Hex Nut,
P/N 228567100
(8) 3/8" Lock Washer
P/N 215111300
(8) 3/8" Flat Washer,
P/N 214112100

Torque to 300 in-lbs.

Torque to 84 in-lbs.

Torque to 84 in-lbs.

(1) 1/4-20 Hex Nut,
P/N 228557100
(1) 1/4" Lock Washer
P/N 215111100
(1) 1/4" Flat Washer,
P/N 214110100

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Installing Load Lug Adapter Plates
into Distribution Only Bays (continuation)

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 51

Section 5957 Installation Guide

3-Position

Lug Adapter Kit

P/N 529131

Customer
Supplied
Lugs

Customer
Supplied
Lugs

Customer
Supplied
Lugs

Customer
Supplied
Lugs

Busbars
P/O Dist.
Bay

Busbars
P/O Dist.
Bay

Note: Apply Electrical Anti-Oxidation
Compound to all Busbar
Mating Surfaces.

Note: Concave Side of Belleville Washer Faces Busbar,
Convex Side Faces Bolt or Nut.

(1) Adapter Busbar,

P/N 528795

(1) Spacer Busbar,

P/N 528806

(1) Spacer Busbar,

P/N 528806

(1) Adapter Busbar,

P/N 528795

Torque to 180 in-lbs.

(4) 3/8-16 Hex Nut,
P/N 228567100
(4) 3/8" Flat Washer,
P/N 214204100

(4) 3/8-16 x 1-1/2" Bolt,
P/N 227647000
(4) 3/8" Belleville Lock Washer,
P/N 214825000

(4) 3/8-16 x 1" Bolt,
P/N 227646600
(4) 3/8" Belleville Lock Washer,
P/N 214825000

(4) 3/8-16 Hex Nut,
P/N 228567100
(4) 3/8" Flat Washer,
P/N 214204100

(2) 1/4-20 x 5/8" Bolt,
P/N 227640300
(2) 1/4" Lock Washer,
P/N 215111100
(2) 1/4" Flat Washer,
P/N 214110100

Torque to 180 in-lbs.

(2) 3/8-16 Hex Nut,
P/N 228567100
(2) 3/8" Flat Washer,
P/N 214204100

(4) 3/8-16 Hex Nut,
P/N 228567100
(4) 3/8" Flat Washer,
P/N 214204100

(4) 3/8-16 x 1-1/2" Bolt,
P/N 227647000
(4) 3/8" Belleville Lock Washer,
P/N 214825000

(2) 3/8-16 x 1" Bolt,
P/N 227646600
(2) 3/8" Belleville Lock Washer,
P/N 214825000

(1) 1/4-20 x 5/8" Bolt,
P/N 227640300
(1) 1/4" Lock Washer,
P/N 215111100
(1) 1/4" Flat Washer,
P/N 214110100

Torque to 84 in-lbs.

Torque to 84 in-lbs.

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Installing Load Lug Adapter Plates
into Distribution Only Bays (continuation)

Page 52

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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

4-Position

Lug Adapter Kit

P/N 534420

Busbars
P/O Dist.
Bay

Customer
Supplied
Lugs

Customer
Supplied
Lugs

(4) 3/8-16 x 1-1/2" Bolt,
P/N 227647000
(4) 3/8" Belleville Lock Washer,
P/N 214825000

Torque to 180 in-lbs.

(1) Adapter Busbar,

P/N 534421

(1) Spacer Busbar,

P/N 528806

(1) Adapter Busbar,

P/N 534421

(8) 3/8-16 Hex Nut,
P/N 228567100
(8) 3/8" Flat Washer,
P/N 214204100

(4) 3/8-16 x 2" Bolt,
P/N 227647400
(4) 3/8" Belleville Lock Washer,
P/N 214825000

Note: Apply Electrical Anti-Oxidation
Compound to all Busbar
Mating Surfaces.

Note: Concave Side of Belleville Washer Faces Busbar,
Convex Side Faces Bolt or Nut.

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Installing Load Lug Adapter Plates
into Distribution Only Bays (continuation)

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 53

Section 5957 Installation Guide

1-Pole 218 Circuit
Breakers Assemblies

Load Lug Adapter Plate
for 1-Pole Devices

1.000"

3/8" Clearance Holes
Lug Adapter P/N 513700,

Kit P/N 520891
(see Notes 1, 2, 3)

2-Pole 218 Circuit
Breaker Assemblies

Load Lug Adapter Plate
for 2-Pole Devices

3/8" Clearance Holes
Lug Adapter P/N 513701,

Kit P/N 520892
(see Notes 1, 2, 3)

NO LUG ADAPTER KITS
REQUIRED WHEN USED IN
DISTRIBUTION ONLY BAYS

Lug Adapter Kits

Power/Distribution Bays

Lug Adapter Kits

Distribution Only Bays

2-Position

Lug Adapter Kit

P/N 529132

(see Notes 4, 6, 7, 8)

Lug Adapter Kits

Power/Distribution Bays

Lug Adapter Kits

Distribution Only Bays

Notes:

1. Maximum size of wire to be connected to a single lug position is 750 kcmil.

2. Maximum lug width is 1.937 inches.

3. Kit includes Load Lug Adapter Plate, plus 1/4" and 3/8" mtg. hardware.

4. Lug adapter accepts a maximum of (2) 750 kcmil or (4) 350 kcmil lugs.

5. Lug adapter accepts a maximum of (4) 750 kcmil lugs.

6. Lugs are not part of the kit, shown for illustration only.

7. Bay busbars are not part of the kit, shown for illustration only.

8. Two (2) kits shown for illustration of the kit installed on busbars with tops
even with each other and staggered.

1.000"

3/8" Clearance Hole

1.000"

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

218 Circuit Breakers Lug Adapter Kits

Page 54

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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

4-Pole 218 Circuit
Breaker Assemblies

3-Pole 218 Circuit
Breaker Assemblies

Load Lug Adapter Plate
for 3-Pole Devices

1.000"

2.000"
3/8" Clearance Holes

Lug Adapter P/N 513702,
Kit P/N 520893
(see Notes 1, 2, 3)

Lug Adapter Kits

Power/Distribution Bays

Load Lug Adapter Plate
for 4-Pole Devices

2.000"

1.000"
3/8" Clearance Holes

Lug Adapter P/N 514765,
Kit P/N 520894
(see Notes 1, 2, 3)

Lug Adapter Kits

Power/Distribution Bays

Notes:

1. Maximum size of wire to be connected to a single lug position is 750 kcmil.

2. Maximum lug width is 1.937 inches.

3. Kit includes Load Lug Adapter Plate, plus 1/4" and 3/8" mtg. hardware.

4. Lug adapter accepts a maximum of (2) 750 kcmil or (4) 350 kcmil lugs.

5. Lug adapter accepts a maximum of (4) 750 kcmil lugs.

6. Lugs are not part of the kit, shown for illustration only.

7. Bay busbars are not part of the kit, shown for illustration only.

8. Two (2) kits shown for illustration of the kit installed on busbars with tops
even with each other and staggered.

3-Position

Lug Adapter Kit

P/N 529131

(see Notes 5, 6, 7, 8)

Lug Adapter Kits

Distribution Only Bays

3/8" Clearance Hole

1.000"

4-Position

Lug Adapter Kit

P/N 534420

(see Notes 5, 6, 7)

Lug Adapter Kits

Distribution Only Bays

3/8" Clearance Hole

1.000"

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 55

Section 5957 Installation Guide

Fuseholder Assembly

P/N 514403

TPL Fuse

Load Lug Adapter Plate

1.000"

3/8" Clearance Holes
Lug Adapter P/N 513701,

Kit P/N 520892
(see Notes 1, 2, 3)

Notes:

1. Maximum size of wire to be connected to a single lug position is 750 kcmil.

2. Maximum lug width is 1.937 inches.

3. Kit includes Load Lug Adapter Plate, plus 1/4" and 3/8" mtg. hardware.

4. Lug adapter accepts a maximum of (2) 750 kcmil or (4) 350 kcmil lugs.

5. Lug adapter accepts a maximum of (4) 750 kcmil lugs.

6. Lugs are not part of the kit, shown for illustration only.

7. Bay busbars are not part of the kit, shown for illustration only.

8. Two (2) kits shown for illustration of the kit installed on busbars with tops
even with each other and staggered.

Lug Adapter Kits

Power/Distribution Bays

2-Position

Lug Adapter Kit

P/N 529132

(see Notes 4, 6, 7, 8)

Lug Adapter Kits

Distribution Only Bays

3/8" Clearance Hole

1.000"

GMT-18/100A

Alarm Fuse
and GMT-X

Safety Fuse Cover

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

TPL Fuses Lug Adapter Kits

Page 56

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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

Fuseholder Assembly

P/N 514404

TPL Fuse

GMT-18/100A

Alarm Fuse

and GMT-X

Safety Fuse Cover

Notes:

1. Maximum size of wire to be connected to a single lug position is 750 kcmil.

2. Maximum lug width is 1.937 inches.

3. Kit includes Load Lug Adapter Plate, plus 1/4" and 3/8" mtg. hardware.

4. Lug adapter accepts a maximum of (2) 750 kcmil or (4) 350 kcmil lugs.

5. Lug adapter accepts a maximum of (4) 750 kcmil lugs.

6. Lugs are not part of the kit, shown for illustration only.

7. Bay busbars are not part of the kit, shown for illustration only.

8. Two (2) kits shown for illustration of the kit installed on busbars with tops
even with each other and staggered.

Load Lug Adapter Plate

1.000"

2.000"
3/8" Clearance Holes

Lug Adapter P/N 513702,
Kit P/N 520893
(see Notes 1, 2, 3)

Lug Adapter Kits

Power/Distribution Bays

3-Position

Lug Adapter Kit

P/N 529131

(see Notes 5, 6, 7, 8)

Lug Adapter Kits

Distribution Only Bays

3/8" Clearance Hole

1.000"

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 57

Section 5957 Installation Guide

TLS/TPS Fuses

Bullet Nose Device

Mounting Assembly,

P/N 513747

Fuseholder Assembly

P/N 514403 P/N 514404

TPL Fuses

Flat Washer

Lock Washer

Nut

Torque to

168 in-lbs

TPL

Fuse

Bullet Nose-Type

Circuit Breakers

Bullet Nose Device

Mounting Assembly,

P/N 513747

Toggle-handle

Breaker

Rocker-handle

Breaker

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Installing TPL Fuses, TLS/TPS Fuses, and Bullet Nose-Type Circuit Breakers

Page 58

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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

TLS/TPS Fuses

Bullet Nose-Type

Circuit Breakers

Toggle
Handle

Breaker

Rocker
Handle
Breaker

Load leads are connected to load busbars.
These busbars provide 1/4-20 threaded holes
on 5/8” centers for installation of customer
provided two-hole lugs. Customer must
provide lug mounting bolts and additional
hardware. Bolt length: 3/4”.

Note:

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Installing TPL Fuses, TLS/TPS Fuses, and Bullet Nose-Type Circuit Breakers

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 59

Section 5957 Installation Guide

MCA Customer Alarm Relay
Circuit Card P/N 514348.
MCA I/O Circuit Card
P/N 524550

Install in any position in seven-slot
card cage in any bay. Component
side faces left as viewed from the front.

Power/Distribution Bay Shown,
Power Only Bay Similar

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Installing the MCA Customer Alarm Relay Circuit Card(s) and MCA I/O Circuit Card(s)
into Power/Distribution and Power Only Bays

Page 60

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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

MCA Circuit Card
(Primary Power/Distribution
or Power Only Bay)
or
Router Circuit Card
(Secondary Power/Distribution Bays
and Distribution Only Bays)

MCA Circuit Card P/N 509478

(Primary Power/Distribution

or Power Only Bay)

RJ-45
Jack

MCA
Network
Connector
(for Left
Expansion)

MCA

Network

Connector

(for Right

Expansion)

1 10

RJ-45

Jack

RJ-45
Jack

RJ-45

Jack

RJ-45
Jack

RJ-45

Jack

MCA
Network
Connector
(for Left
Expansion)

MCA

Network

Connector

(for Right

Expansion)

MCA
Network
Connector
(for Left
Expansion)

MCA

Network

Connector

(for Right

Expansion)

Router Circuit Card P/N 509509

(Secondary Power/Distribution Bays,

Secondary Power Only Bays,

and Distribution Only Bays)

Router Circuit Card P/N 509509

(Secondary Power/Distribution Bays,

Secondary Power Only Bays,

and Distribution Only Bays)

MCA Network Cable

(Yellow Cable)

DO NOT USE BOTH

RJ-45 CONNECTORS

IN THE PRIMARY BAY

Power/Distribution Bay (front view)
(Power Only Bay Similar)

SYSTEM MONITORING

AND CONTROL SECTION

Front View

Distribution Only Bay

Front View

* In a Distribution Only Bay, install the

supplied ferrite cable clamp onto the
cable near the router circuit card.
Emerson P/N 242941100
FairRite P/N 0443164251
Steward P/N 28A20025-0A0

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

MCA Network Bay-Bay Interconnections

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 61

Section 5957 Installation Guide

Front Door Removed in
Illustration for Clarity

Distribution Only Bay

Connect BAT RTN to this Terminal

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Distribution Only Bay RTN Connection to System Monitoring and Control Section

Page 62

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

SYSTEM MONITORING
AND CONTROL SECTION

MCA Battery Charge Digital Temperature
Compensation Probe Connector
(Primary Bay Only)

External

CAN BUS

Port

Battery Charge Digital

Temperature Compensation Probe

Power/Distribution Bay Shown,
Power Only Bay Similar

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

MCA Battery Charge Digital Temperature Compensation Probe Connection
to Primary Power/Distribution and Power Only Bays

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 63

Section 5957 Installation Guide

SYSTEM MONITORING
AND CONTROL SECTION

MCA Circuit Card
(Primary Bay)

(See Detail A)

Seven-Slot Card Cage for MCA Circuit Cards

and/or LMS Input/Output (I/O) Circuit Cards.

(See Detail B)

Power/Distribution Bay Shown,
Power Only Bay Similar

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

MCA External Alarm, Reference, and Control Connections to Primary Power/Distribution and Power Only
Bays and I/O Card Connections to Primary and Secondary Power/Distribution and Power Only Bays

Page 64

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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

Detail A

MCA Circuit Card P/N 509478

(Primary Bay)

Remote

Equalize

Remote

HVS

PCU

Emergency

Stop (ESTOP)

Test

Input**

Dry Relay Contact

Closure to Activate

** Apply Test contact closure, then apply
HVS or ESTOP closure to test these circuits.
See MCA display to verify circuits operational.

External

Voltage Input

(for MCA Alarms

and Meter Reading*)

-VSense +VSense

1 10

* Automatic internal sense when not connected.
Note: If connected and removed, external
A/D Volt Alarm activates. Clear alarm by updating
inventory.

Fuse @

1-1/3 Amps

28-16 AWG
Torque to 2.0 in-lbs

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 65

Section 5957 Installation Guide

MCA I/O Circuit Cards

(Primary and/or Secondary Bays)

(P/N 524550, 1 analog input, 1 analog output, 4 binary inputs)

1

12

TB1

B1***

B2***

B3***

B4***

A1 IN*

A1 OUT**

+

_

+

_

1

9

10

18

K3

K2

K1

K6

K5

K4

NC
COM
NO

NC
COM
NO

NC
COM
NO

NC

COM

NO

NC

COM

NO

NC

COM

NO

TB1

MCA Customer Alarm

Relay Circuit Card P/N 514348

(Primary and/or Secondary Bays)

Notes
NC = Normally Closed
COM = Common
NO = Normally Open

All relay contacts are shown
with the relay deenergized.

* 0-50 mv DC Shunt Input
** 0-50 mv DC Output for Remote Plant Output Current Monitoring
*** Dry Contacts, Circuit Closure to ActivateAlarm

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Page 66

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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

1

9

10

18

K3

K2

K1

K6

K5

K4

NC

COM

NO

NC

COM

NO

NC

COM

NO

NC

COM

NO

NC

COM

NO

NC

COM

NO

TB1

Notes

NC = Normally Close Contact

COM = Common

NO = Normally Open Contact

All relay contacts are shown

with the relay de-energized.

All relays are energized

during normal operation,

and de-energized

during an alarm condition.

#1 #2 #3 #4 #5 #6 #7

1

9

10

18

K3

K2

K1

K6

K5

K4

NC

COM

NO

NC

COM

NO

NC

COM

NO

NC

COM

NO

NC

COM

NO

NC

COM

NO

TB1

1

9

10

18

K3

K2

K1

K6

K5

K4

NC

COM

NO

NC

COM

NO

NC

COM

NO

NC

COM

NO

NC

COM

NO

NC

COM

NO

TB1

1

9

10

18

K3

K2

K1

K6

K5

K4

NC

COM

NO

NC

COM

NO

NC

COM

NO

NC

COM

NO

NC

COM

NO

NC

COM

NO

TB1

1

9

10

18

K3

K2

K1

K6

K5

K4

NC

COM

NO

NC

COM

NO

NC

COM

NO

NC

COM

NO

NC

COM

NO

NC

COM

NO

TB1

1

9

10

18

K3

K2

K1

K6

K5

K4

NC

COM

NO

NC

COM

NO

NC

COM

NO

NC

COM

NO

NC

COM

NO

NC

COM

NO

TB1

1

9

10

18

K3

K2

K1

K6

K5

K4

NC

COM

NO

NC

COM

NO

NC

COM

NO

NC

COM

NO

NC

COM

NO

NC

COM

NO

TB1

#1

#3

#5

#7

#6

#4

#2

AC MAJOR

OVER

CURRENT

RECT. MINOR

UNDEFINED

MCA FAIL

AC

MINOR

AC MAJOR

OVER

CURRENT

RECT. MINOR

UNDEFINED

MCA FAIL

AC

MINOR

AUDIBLE

HIGH

VOLTAGE #2

VERY LOW

VOLTAGE

RECT. MAJOR

RECT. FAIL

TEST/EQ

AUDIBLE

HIGH

VOLTAGE #2

VERY LOW

VOLTAGE

RECT. MAJOR

RECT. FAIL

TEST/EQ

AC FAIL

MINOR

MAJOR

HIGH

VOLTAGE #1

BATTERY ON

DISCHARGE

BREAKER/FUSE

AC FAIL

MINOR

MAJOR

HIGH

VOLTAGE #1

BATTERY ON

DISCHARGE

BREAKER/FUSE

UNDEFINED

UNDEFINED

UNDEFINED

Controller Conditions

that are Logged and

that Light the Bay #1

Alarm LED

UNDEFINED

UNDEFINED

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Default MCA Customer Alarm Relay Assignments

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 67

Section 5957 Installation Guide

LMS LOCAL PORT

(USB)

(active only if

optional LMS installed)

(Provided via a USB to RS-232 PortAdapter Unit)

Primary
Bay

Detail A

15

9 6

Mating Connector

in Power System Wire Harness

(9-Pin Female D-Type Jack)

If required to connect to a serial

port, disconnect the factory plug to

the “USB to RS-232 Port Adapter

Unit” and connect to this plug.

Power/Distribution Bay Shown,
Power Only Bay Similar

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

MCA Local Control Panel and Display and LMS Local Port

Page 68

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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957
Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

LMS Local Port

Introduction

The LMS Local Port is provided via a USB to RS-232 Port Adapter Unit. The proper
device driver must be installed on the computer to be connected to the USB port. Use
one of the following procedures to install the device driver.

Installing the USB Device Driver from the Furnished CD

A device driver CD is supplied with the USB to RS-232 Port Adapter Unit. The proper
driver must be installed on the computer to be connected to the USB port. Use the
provided CD to install the driver.

Downloading the USB Driver from the Web

1) Go to this link http://vscom.de/downloadcenter.htm.

2) Select “USB to Serial Drivers” from the Product Category drop-down menu.

3) Select your product model’s “Driver and Documentation” to download the files.

4) Select your computer’s operating system.

5) Run or save the application.

Setting up your Computer to Access the Power System

1) Select Hyper terminal.

2) Connect using one of the unused COM ports. (e.g. COM 5)

3) Set Bit Per Second to 19200.

4) Set Data Bits to 8.

5) Set Parity to None.

6) Set Stop bits to 1.

7) Set Flow control to Hardware.

8) Select OK.

9) In Hyper terminal press ENTER.

10) Enter the password 6.

11) Enter “?” to see commands.

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 69

Section 5957 Installation Guide

Two holes with 1/4-20 captive

nuts provided for installation of

customer provided two-hole lug

with 1/4" bolt clearance holes

on 5/8" centers

Two holes with 1/4-20 captive
nuts provided for installation of
customer provided two-hole lug
with 1/4" bolt clearance holes
on 5/8" centers

Top View

Recm. Torque
1/4" Hardware
using Belleville
Lock Washer
60 in-lbs.

Power/Distribution Bay Shown,
Power Only Bay Similar

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Power/Distribution and Power Only Bays Frame Grounding Connection

Page 70

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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

1/4" clearance holes

on 5/8” centers are

provided for installation

of customer provided

two-hole lug.

1/4" clearance holes
on 5/8” centers are
provided for installation
of customer provided
two-hole lug.

Top View

Distribution Only Bay

Recm. Torque

1/4” Hardware
using Belleville
Lock Washer
60 in-lbs.

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Distribution Only Bay Frame Grounding Connection

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 71

* Includes Load Lug Adapter Plate,

plus 1/4" and 3/8" Mtg. Hardware.

Bus #1

Distribution Device

Mounting Location

Position 1 (left),

Position 24 (right)

Bus #2

Distribution Device

Mounting Location

Position 25 (left),

Position 48 (right)

Front View

Load Lug and/or Load Lug Adapter Plate

Mounting Location Dimensions

0.625"

0.765"

1/4-20 Studs
and Hardware

Load Lug Adapter

Plate P/N 513701,

Kit P/N 520892*

Load Lug Adapter
Plate P/N 514765,

Kit P/N 520894*

Load Lug Adapter

Plate P/N 513702,

Kit P/N 520893*

Load Lug Adapter

Plate P/N 513700,

Kit P/N 520891*

to Distribution:

Bus #1

Position #12

to Distribution:

Bus #2

Position #25

to Distribution:

Bus #2

Position #36

to Distribution:

Bus #1

Position #1

to Distribution:
Bus #1
Position #13

to Distribution:
Bus #1
Position #24

to Distribution:
Bus #2
Position #37

to Distribution:
Bus #2
Position #48

1 12 13 24

25 36 37 48

Connect Load Leads Here

(Load LugAdapter Plates

may be Required. Refer to

Previous Illustrations)

Recm. Torque
1/4" Hardware

using Belleville
Lock Washer,
60 in-lbs.

1/4" Hardware
using flat washer
and lock washer,
84 in-lbs.

3/8" Hardware
using Belleville
Lock Washer,
180 in-lbs.

3/8" Hardware
using flat washer
and lock washer,
300 in-lbs.

Section 5957 Installation Guide
Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Load Connections to Power/Distribution Bays

Page 72

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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

Recm. Torque
3/8" Hardware using Belleville

Lock Washer, 180 in-lbs.
3/8" Hardware using flat washer

and lock washer, 300 in-lbs.

Top Front of Bay

Load Return Connections
to Optional Top-Mount
BusbarAssemblies

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 73

Section 5957 Installation Guide

Internal Ground Busbar

Assembly P/N 554862

Internal Ground Busbar

Assembly P/N 555214

Internal Ground Busbar Assembly P/N 555214

Internal Ground Busbars
Mounting Locations

Internal Ground Busbar Assembly P/N 554862

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Load Connections to Power/Distribution Bays Optional Internal Ground (Load Return) Busbar Assembly

Page 74

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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

to Distribution:

Bus #2

Position #24

to Distribution:

Bus #2

Position #19

to Distribution:

Bus #2

Position #18

to Distribution:

Bus #2

Position #13

to Distribution:

Bus #4

Position #48

to Distribution:

Bus #4

Position #43

to Distribution:

Bus #4

Position #42

to Distribution:

Bus #4

Position #37

to Distribution:
Bus #1
Position #1

to Distribution:
Bus #1
Position #6

to Distribution:
Bus #1
Position #7

to Distribution:
Bus #1
Position #12

to Distribution:
Bus #3
Position #25

to Distribution:
Bus #3
Position #30

to Distribution:
Bus #3
Position #31

to Distribution:
Bus #3
Position #36

Rear cover panels removed in illustration for clarity.

Rear View Rear View

Connect Load Leads Here

(Load Lug Adapter Plates

May Be Required, Refer to

Previous Illustrations)

2-Position

Lug Adapter Kit

P/N 529132

3-Position

Lug Adapter Kit

P/N 529131

4-Position

Lug Adapter Kit

P/N 534420

Recm. Torque
3/8" Hardware

using Belleville
Lock Washer,
180 in-lbs

3/8" Hardware
using flat washer
and lock washer,
300 in-lbs

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Load Connections to Distribution Only Bays

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 75

Section 5957 Installation Guide

Note: Load leads are connected to load busbars.
These busbars provide 1/4-20 threaded holes
on 5/8" centers for installation of customer
provided two-hole lugs. Customer must
provide lug mounting bolts and additional
hardware. Bolt length: 3/4".

Recm. Torque
1/4" Hardware

using Belleville
Lock Washer,
60 in-lbs

1/4" Hardware
using flat washer
and lock washer,
84 in-lbs

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Load Connections to Distribution Only Bay Optional Bullet Device Panel

Page 76

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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

Wire Size
24 to 14 AWG.
Torque 5.0 in-lbs.

Load Return

Connections

-48V Load
Connections

Load Lead Connections (-48V) or

Ground/Return to GMT Module (+Ground)

DANGER

Ensure leads are connected to
proper polarity for the device
installed, either a Distribution
Device (load lead connection)
or ground/return to GMT Module
(ground connection).

List C Fuse/Circuit Breaker Panel

GMT Module

P/N 509128

NOT

USED

Connect Ground for

GMT Module at either

of these two points

F11

F12

F1 thru F10

GMT Module

P/N 509128

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Installing and Wiring Optional Bullet Nose-Type 10-Position GMT Fuse Module (P/N 509128)

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 77

Section 5957 Installation Guide

PCU #1
PCU #2
PCU #3
PCU #4
PCU #5
PCU #6
PCU #7
PCU #9
PCU #10

Front View

PCU #1

A B C

PCU #2
A B C

PCU #3
A B C

PCU #7

A B C

PCU #8
A B C

PCU #9

A B C

PCU #10

A B C

PCU #6

A B C

PCU #5

A B C

PCU #4

A B C

480VAC (List A) or 208VAC (List B), 3 Phase, 60Hz

Separate Feed per PCU

PCUAC INPUT: 1/4-20 Studs on 5/8" Centers for Installation of Customer Provided Two-Hole Lugs

Frame Ground

(1/4-20 Studs

for Installation of

Customer Provided

One-Hole Lugs)

Recm. Torque
Using supplied
1/4" hardware,
84 in-lbs.

Cover Removed
in Illustration

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

AC Input Connections to Lists 1 and 11 Power/Distribution Bays (w/out PDSC)
(Ten AC Feeds)

Page 78

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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

A B C

Rear View
Optional Bolt-On PCU
AC Input Service Cabinet

Ensure that each bay is wired into the PDSC as detailed in
"Chapter 2. Placing the Bays and Installing Internal/External Busbars".

Frame Ground Nuts
to Secure Lugs and Lug
Mounting Hardware
(3/8-16 on 1" Centers)
(Accessed from Inside Cabinet)

3/8-16 x 1.25 Studs (6) on 1" Centers

for Installation of Customer Provided Lugs

Recm. Torque
3/8" Hardware

using Belleville
Lock Washer
180 in-lbs, using
flat washer and
lock washer
300 in-lbs.

480VAC (List A) or 208VAC (List B), 3 Phase, 60Hz

Single Feed

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

AC Input Connections to Lists 2 and 12 Power/Distribution Bays (with PDSC)
(One AC Feed)

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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 79

Section 5957 Installation Guide

Note: Remove factory installed
shorting plates. See previous
page for illustration with
shorting plates installed.

Feed #1

A

Feed #1

B

Feed #1

C

Feed #2

A

Feed #2

B

Feed #2

C

Rear View
Optional Bolt-On PCU
AC Input Service Cabinet

Ensure that each bay is wired into the PDSC as detailed in
"Chapter 2. Placing the Bays and Installing Internal/External Busbars".

Frame Ground Nuts
to Secure Lugs and Lug
Mounting Hardware
(3/8-16 on 1" Centers)
(Accessed from Inside Cabinet)

3/8-16 x 1.25 Studs (12) on 1" Centers

for Installation of Customer Provided Lugs

Recm. Torque
3/8" Hardware

using Belleville
Lock Washer
180 in-lbs, using
flat washer and
lock washer
300 in-lbs.

480VAC (List A) or 208VAC (List B), 3 Phase, 60Hz

Two Feeds:

Feed #1 Powers PCU #1, #3, #5, #7, #9

Feed #2 Powers PCU #2, #4, #6, #8, #10

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

AC Input Connections to Lists 2 and 12 Power/Distribution Bays (with PDSC)
(Two AC Feeds)

Page 80

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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

Rectifier #1
Rectifier #2
Rectifier #3
Rectifier #4
Rectifier #5
Rectifier #6
Rectifier #7
Rectifier #8
Rectifier #9
Rectifier #10

Front View

Feed #1

A B C A B C

Feed #2

480VAC (List A) or 208VAC (List B), 3 Phase, 60Hz

Five AC Feeds

(Feed #1 Powers Rectifiers #1 and#2)
(Feed #2 Powers Rectifiers #3 and#4)
(Feed #3 Powers Rectifiers #5 and#6)
(Feed #4 Powers Rectifiers #7 and#8)

(Feed #5 Powers Rectifiers #9 and#10)

Frame
Ground

Frame

Ground

Front Door Removed
in Illustration for
Clarity Only

Feed #3

C
B
A

Feed #5

Feed #4

A
B
C

A
B
C

(3/8-16 Studs
on 1" Centers)

(3/8-16 Studs
on 1" Centers)

(3/8-16 Studs
on 1" Centers)

(3/8-16 Studs
on 1" Centers)

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

AC Input Connections to Lists 3 and 13 Power Only Bays
(Five AC Feeds)

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 81

Section 5957 Installation Guide

Feed #1

C B A A B C

Feed #2

480VAC (List A) or 208VAC (List B), 3 Phase, 60Hz

Two AC Feeds

(Feed #1 Powers Rectifiers #1, #3, #5, #7, #9)

(Feed #2 Powers Rectifiers #2, #4, #6, #8, #10)

Rectifier #1
Rectifier #2
Rectifier #3
Rectifier #4
Rectifier #5
Rectifier #6
Rectifier #7
Rectifier #8
Rectifier #9
Rectifier #10

Front View

Frame
Ground

Front Door Removed
in Illustration for
Clarity Only

Frame

Ground

(3/8-16 Studs
on 1" Centers)

(3/8-16 Studs
on 1" Centers)

(3/8-16 Studs
on 1" Centers)

(3/8-16 Studs
on 1" Centers)

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

AC Input Connections to Lists 4 and 14 Power Only Bays
(Two AC Feeds)

Page 82

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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

Rectifier #1
Rectifier #2
Rectifier #3
Rectifier #4
Rectifier #5
Rectifier #6
Rectifier #7
Rectifier #8
Rectifier #9
Rectifier #10

Front View

Front Door Removed
in Illustration for
Clarity Only

480VAC (List A) or 208VAC (List B), 3 Phase, 60Hz

Ten AC Feeds

Feed #1
Feed #3
Feed #5
Feed #7

Feed #9

Feed #2
Feed #4
Feed #6
Feed #8

Feed #10

A
B
C

A
B
C

A
B
C

A
B
C
A
B
C

A
B
C

A
B
C

A
B
C

A
B
C
A
B
C

Frame

Ground

(1/4-20 Studs
on 5/8" Centers)

(1/4-20 Studs
on 1" Centers)

(1/4-20 Studs
on 5/8" Centers)

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

AC Input Connections to Lists 5 and 15 Power Only Bays
(Ten AC Feeds)

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 83

Section 5957 Installation Guide

Recm. Torque
3/8" Hardware using Belleville
Lock Washer 180 in-lbs, using
flat washer and lock washer
300 in-lbs.

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Battery Connections to Power/Distribution Bays

Page 84

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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

POSITIVE BATTERY
(GROUND RETURN +48V)

NEGATIVE BATTERY
(SUPPLY -48V)

Top Rear

of Bay

Recm. Torque
3/8" Hardware

using Belleville
Lock Washer
180 in-lbs, using
flat washer and
lock washer
300 in-lbs.

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 85

Section 5957 Installation Guide

Top Rear
of Bay

POSITIVE BATTERY
(GROUND RETURN +48V)

NEGATIVE BATTERY
(SUPPLY–48V)

Recm. Torque
3/8” Hardware:

Using Bellevile Washer
180 in-lbs.

Using Flat Washer & Lock Washer
300 in-lbs

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Page 86

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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

POSITIVE BATTERY
(GROUND RETURN)

NEGATIVE BATTERY
(SUPPLY -48V)

2.000"

1.000"

1.000"

3/8-16 Stud

(40)

Rear View

Power Only Bays

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Battery Connections to Power Only Bays

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 87

Section 5957 Installation Guide

3/8" Clearance Hole (22)

2.031"

1.00"

Rear View

Distribution Bay

1.00"

1.00"

1.00"

1.00"

1.00"

1.00"

1.00"

DC Input

(Supply -48V)

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Battery Connection to Distribution Only Bays

Page 88

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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957
Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Installing Rectifiers into Power/Distribution and Power Only Bays

Install Rectifiers from top to bottom, starting with the top most mounting position. (In the MCA display messages,
the Rectifiers are numbered from 1 to 10, starting with the top most position.) The Rectifier weighs approximately
40 lbs.

Procedure

1) Remove the blank panel from the Rectifier mounting position. Save this panel. The panel must be re­installed if a Rectifier is removed.

Note: In the next step, a safety latch is present on the left-hand (as viewed from the front) side panel of each

Rectifier. The latch is designed to prevent the Rectifier from inadvertently being removed completely
from the Bay once it has been installed. It should not be necessary to depress the safety latch release
when installing the Rectifier.

2) Install the Rectifier into the bay by sliding it evenly into its mounting position. Secure the Rectifier to the
bay by tightening the captive fasteners on the Rectifier.

3) Perform steps 1) and 2) for each Rectifier to be installed.

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Page 89

Section 5957 Installation Guide

SYSTEM MONITORING
AND CONTROL SECTION

MCA Circuit Card
(Primary Bay)
or
Router Circuit Card
(Secondary Bay)

Bus #1
Monitoring
Circuit Card
(behind panel)

Bus #2
Monitoring
Circuit Card
(behind panel)

Power/Distribution Bay Shown,
Power Only Bay Similar

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Switch and Jumper Options

Page 90

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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957

Distribution Only Bay

Distribution

Bus Monitoring

Circuit Card

Front Door Removed in
Illustration for Clarity

Distribution Bays

Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 91

Section 5957 Installation Guide

The individual switches of S1 have the following functions.

Note that the switch ON position is the UP position.

Switch of S1

Designation

Function

1

MCA

When in the ON position,
the MCA section of the
circuit card is disabled.

2

MON

When in the ON position,
changing Power System
settings via LMS is disabled.

3

KEY

When in the ON position,
changing Power System
settings via MCA Keypad is
disabled.

4

PRO

When in the ON position,
the remote uploading of new
firmware into the circuit card
is forced. This switch is used
for diagnostic purposes only.

MCA CIRCUIT CARD

(P/N 509478)

(PRIMARY BAY)

S1

1 2 3 4

ON = UP

J4

MCA DISTRIBUTION BUS MONITORING CIRCUIT CARD (P/N 524982)

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

Setting Switch S1 on the MCA Circuit Card in the Primary Power/Distribution and Power Only Bay

Page 92

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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Installation Guide Section 5957
Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B) Issue AM, March 26, 2014

Setting Jumper J4 on MCA Distribution Bus Monitoring Circuit Cards

Note: If a jumper is changed on a live system, an alarm is generated. Update Inventory to clear the alarm.

If the jumper is installed between the two pins of J4 on ALL MCA Distribution Bus Monitoring Circuit Cards, then
there is NO A or B distribution designation in the MCA display of distribution items. If any MCA Distribution
Bus Monitoring Circuit Card has the jumper removed, that distribution bus is designated as B. Those that have
the jumper remaining (installed) are designated as A.

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 93

Section 5957 Installation Guide

Issue

Change

Number

(ECO)

Description of Change

AA

LLP203036

New

AB

LLP203842

P/N 528482 Busbar Shield Kit added.

AC

LLP203895

Populating distribution device restrictions added.

AD

LLP209720

Distribution Only Bays Added.

AE

LLP211532

Model number changed, 480V Rectifier changed.

AF

LLP215440

Implementation of new spiral bound covers.

AG

LLP216269

Input redesigned. LMS Local Port on front door now USB (was RS-232).
Distribution Only Bay Options deleted.

AH

LLP216553

Added P/N 547999 External Top-Mount Vertical Battery Input Busbar Assembly.

AJ

LLP216965

Added 582140001 distribution only bay and List C; added USB to Serial
Converter Unit instructions, and USB type in illustration label, instructions to
download and install USB drivers to customer computer, instructions on how to
connect new bay to an old system

AK

LLP217313

Replaced 514431 with 554873, 547999 with 554874 and updated all related
drawings accordingly. Reinstated 58214000016.

AL

LLP217720

Added Power Only Bay.

AM

LLP220220

Update Insulator Part Number from 245827100 to 245857000.

Issue AM, March 26, 2014 Spec. No. 582140000 (Models 802NLDB, 802NLEB and 802NL-B)

REVISION RECORD

Page 94

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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Technical Support

Email

[e-mail]
[e-mail]

Answers technical product and system
questions; determines status of warranties and
contractual agreements for repair.

Phone

1.800.800.5260

Services - Design, Deployment & Optimization

Email

[e-mail]

Provides quotes and bid responses, order
placement and scheduling for design, and
deployment and optimization services.
Download service & maintenance reports
online.

Phone

1.800.800.1280, option 7

FreedomCare

Secure.EmersonNetworkPower.com

Spare Parts

Email

[e-mail]
[e-mail]

Pricing and PO processing of spare parts,
including but not limited to breakers, cables,
fuses, rectifier fans, misc. breaker and fuse
panels, enclosure fans, doors & switches, etc.

Phone

1.800.800.1280, option 5

DC Power Depot Repair

Email

[e-mail]

Creates and processes RMAs, determines
lead times and pricing, provides repair
shipping information and status.

Phone

1.800.800.1280, option 6

DC Power Product Training

Email

[e-mail]

Requests for quotes, order placement and
scheduling.

Phone

1.800.800.1280, option 8

NetPerform™ Optimization Services

At Emerson Network Power, we understand the importance of reliable equipment – it’s critical to both
your business and your bottom line. That is why we offer a wide array of services to meet all of your
network infrastructure needs.

For More Information

To learn more about service offerings from Emerson Network Power, please contact your sales
representative, call 1-800-800-1280 option 7, email [e-mail] or visit

www.EmersonNetworkPower.com/EnergySystems.