Emerson NetSure DCS 48375 Application Guide
SYSTEM OVERVIEW
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Description: +24VDC to -48VDC @ up to 375A
converter system.
The NetSure™ DCS48375 Converter
System is comprised of a main shelf
and up to two (2) expansion shelves.
Each shelf provides mounting positions
for up to four (4) converter modules.
Each shelf also provides a 15-position
distribution row (19” version) or
20-position distribution row (23”
version) which accepts bullet nose
circuit breakers and TPS/TLS
fuseholders. A GMT fuse block option
is also available.
Note: Refer to UM1C24481500
SAG584622100, SAG584622200
SAG584622300, SAG584622400
System Application Guide
Spec. Nos. 584622100, 584622200,
584622300, 584622400 (Model DCS48375)
Issue AC, July 3, 2012
(Converter Module User
Instructions) for converter
module information.
Family: NetSure™
Spec. Nos.: 584622100 (Main Shelf – 19” version)
584622200 (Expansion Shelf – 19” version)
584622300 (Main Shelf – 23” version)
584622400 (Expansion Shelf – 23” version)
Model: DCS48375
Shelves per System: (1) Main Shelf, up to (2) Expansion Shelves
Input Voltage Nominal +24VDC
Output Voltage: -48VDC, -50VDC, -52VDC, or -54VDC
(User Selectable)
Output Capacity:
per Converter Module: 31A (1500W)
per Shelf: 125A, maximum (Converter Output)
per Distribution Row: 250A, maximum (Distribution Load)
System: 375A, maximum (Converter Output + Distribution Load)
Agency Approval: UL 60950 Recognized (“c UR”), NEBS
(see “1.4 System Compliance Information” under SPECIFICATIONS)
Mounting Type: Nominal 19” or 23” Relay Rack or Equipment Rack Mounting
Mounting Depth: 18.750” (w/out Expansion Wiring Cover)
20.375 (with Expansion Wiring Cover)
6” Front Projection
Mounting Height: 6.968” (4U) (w/out optional 1U Wiring Space Access Cover)
7.718” (5U) (with optional 1U Wiring Space Access Cover)
Page 1 of 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.
SAG584622100, SAG584622200 System Application Guide
Home
SAG584622300, SAG584622400 Spec. Nos. 584622100, 584622200
Issue AC, July 3, 2012 584622300, 584622400 (Model DCS48375)
Access: Front and Rear for Installation, Expansion, and
Maintenance. Front for Operation.
Color: Distribution Door and Converter Module Faceplates: Textured Gray
Shelf: Galvannel
Environment: -40°C to +40°C (-40°F to +104°F).
-40°C to +65°C (-40°F to +149°F), with derating.
(see “1.3.1 Operating Ambient Temperature Range:” under
SPECIFICATIONS)
Page 2 of 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.
System Application Guide SAG584622100, SAG584622200
584622100 / 584622200 shown.
584622300 / 584622400 similar.
Front View
(door removed in illustration for clarity only)
Mounting
Angles
P/N 1C24481500
Converter Modules.
Four (4) per Shelf.
Home
15-Position (19” version)
20-Position (23” version)
Distribution Panel
Optional 1U Wiring
Space Access Cover (if
space permits). Allows
greater access to load
distribution return
connection points.
One (1) Main Shelf
Up to Two (2) Expansion
Shelves
Expansion Wiring
Access Cover
(extra cover supplied with Expansion
Shelf, to be installed on Main Shelf)
Dual Input Feed
Adapter Busbars
Spec. Nos. 584622100, 584622200, SAG584622300, SAG584622400
584622300, 584622400 (Model DCS48375) Issue AC, July 3, 2012
584622100 (19” Main Shelf) 584622300 (23” Main Shelf)
584622200 (19” Expansion Shelf) 584622400 (23” Expansion Shelf)
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 of 34
SAG584622100, SAG584622200 System Application Guide
System
Overview
Picture
Ordering
Information
Specifications
Physical Size
Information
Related
Documentation
SAG584622300, SAG584622400 Spec. Nos. 584622100, 584622200
Issue AC, July 3, 2012 584622300, 584622400 (Model DCS48375)
TABLE OF CONTENTS
SYSTEM OVERVIEW................................................................................................................................................. 1
TABLE OF CONTENTS ............................................................................................................................................. 4
ORDERING INFORMATION ...................................................................................................................................... 5
584622100 Main Shelf and 584622200 Expansion Shelves – 19” Version ..................................................... 5
584622300 Main Shelf and 584622400 Expansion Shelves – 23” Version ..................................................... 5
DC-DC Converter Module (P/N 1C24481500) .................................................................................................... 6
Distribution Devices ............................................................................................................................................ 6
Bullet Nose Circuit Breakers and Bullet Nose Fuseholders e/w TPS/TLS Fuses ........................................... 6
Optional Bullet Nose 6-Position GMT Distribution Fuse Block (P/N 545333) ................................................ 11
Bullet Nose Bypass Busbar (P/N 535015) ..................................................................................................... 12
Replacement Alarm, Reference, and Control Fuses ..................................................................................... 12
Special Application Crimp Lugs, Busbar Adapter Kits, and Hardware Kits ............................................... 12
Special Application Crimp Lugs ..................................................................................................................... 12
Busbar Adapter and Hardware Kits................................................................................................................ 13
Wiring Notes ...................................................................................................................................................... 15
Recommended Frame Ground Wire Size and Lug Selection ........................................................................ 15
Recommended DC Inputs Wire Sizes and Lugs Selection ............................................................................ 15
Recommended Load Distribution Wire Sizes and Lugs Selection ................................................................. 17
Recommended External Alarm, Reference, Monitoring, and Control Wire Sizes ......................................... 19
Wiring Illustrations ............................................................................................................................................ 20
DC Inputs and Frame Ground ........................................................................................................................ 20
Load Distribution (TPS/TLS Fuses and Bullet Nose Circuit Breakers) .......................................................... 21
Load Distribution (Optional Bullet Nose 6-Position GMT Fuse Block) ........................................................... 22
External Alarm, Reference, Monitoring, and Control ..................................................................................... 23
Shelf Interconnections .................................................................................................................................... 24
SPECIFICATIONS .................................................................................................................................................... 26
PHYSICAL SIZE INFORMATION ............................................................................................................................ 29
RELATED DOCUMENTATION ................................................................................................................................ 33
REVISION RECORD ................................................................................................................................................ 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.
1.1 System Output Ratings .............................................................................................................................. 26
1.2 System Input Ratings ................................................................................................................................. 26
1.3 System Environmental Ratings ................................................................................................................. 26
1.4 System Compliance Information ............................................................................................................... 27
1.5 System Standard Features......................................................................................................................... 27
Overall Dimensions – 584622100 Main Shelf .................................................................................................. 29
Overall Dimensions – 584622200 Expansion Shelf........................................................................................ 30
Overall Dimensions – 584622300 Main Shelf .................................................................................................. 31
Overall Dimensions – 584622400 Expansion Shelf........................................................................................ 32
Page 4 of 34
System Application Guide SAG584622100, SAG584622200
Home
Spec. Nos. 584622100, 584622200, SAG584622300, SAG584622400
584622300, 584622400 (Model DCS48375) Issue AC, July 3, 2012
ORDERING INFORMATION
584622100 Main Shelf and 584622200 Expansion Shelves – 19” Version
Features
Includes reversible mounting angles for nominal 19” or 23” rack mounting.
Includes the optional 1U wiring space access cover.
Includes two (2) P/N 552506 optional dual input feed busbars.
Accepts up to four (4) DC-DC converter modules.
Includes a 15-position load distribution fuse / circuit breaker panel which accepts...
3A to 100A TPS/TLS fuses,
1A to 250A bullet nose circuit breakers, and
“Optional Bullet Nose 6-Position GMT Distribution Fuse Block (P/N 545333)”.
Ordering Notes
1) Order one (1) Spec. No. 584622100 Main Shelf and up to two (2) Spec. No. 584622200 Expansion
Shelves per system.
2) Order DC-DC converter modules (P/N 1C24481500) as required.
3) Refer also to “Distribution Devices”, “Special Application Crimp Lugs, Busbar Adapter Kits, and Hardware
Kits”, and “Wiring Notes” under ORDERING INFORMATION.
584622300 Main Shelf and 584622400 Expansion Shelves – 23” Version
Features
Includes the optional 1U wiring space access cover.
Includes two (2) P/N 552506 optional dual input feed busbars.
Accepts up to four (4) DC-DC converter modules.
Includes a 20-position load distribution fuse / circuit breaker panel which accepts...
3A to 100A TPS/TLS fuses,
1A to 250A bullet nose circuit breakers, and
“Optional Bullet Nose 6-Position GMT Distribution Fuse Block (P/N 545333)”.
Ordering Notes
1) Order one (1) Spec. No. 584622300 Main Shelf and up to two (2) Spec. No. 584622400 Expansion
Shelves per system.
2) Order DC-DC converter modules (P/N 1C24481500) as required.
3) Refer also to “Distribution Devices”, “Special Application Crimp Lugs, Busbar Adapter Kits, and Hardware
Kits”, and “Wiring Notes” under ORDERING INFORMATION.
Page 5 of 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.
SAG584622100, SAG584622200 System Application Guide
Home
SAG584622300, SAG584622400 Spec. Nos. 584622100, 584622200
Issue AC, July 3, 2012 584622300, 584622400 (Model DCS48375)
DC-DC Converter Module (P/N 1C24481500)
Features
Provides one (1) Model C24/48-1500, Spec. No. 1C24481500,
1500 watt / 24 to 48 volt DC-DC converter module.
Refer to UM1C24481500 (Converter Module User Instructions) for
converter module information.
Restrictions
Each shelf accepts up to four (4) DC-DC converter modules.
Ordering Notes
1) Order by P/N 1C24481500 as required.
Distribution Devices
Bullet Nose Circuit Breakers and Bullet Nose Fuseholders e/w TPS/TLS Fuses
Features
A single fuseholder provides for installation of a 3A to 100A Bussmann TPS or Littelfuse TLS fuse (as
listed in Table 1). This fuseholder plugs into a single distribution row mounting position. This fuseholder
provides a GMT-A alarm fuse, which operates open to provide an alarm indication if the associated
distribution fuse opens.
Each circuit breaker (as listed in Table 2 and Table 3) plugs into one, two, or three distribution row
mounting position(s).
Restrictions
Load should not exceed 80% of device rating.
Unless otherwise specified, fuses and/or circuit breakers are mounted from left to right, starting with the
highest capacity and working to the lowest capacity.
125A, 150A, 175A, and 200A circuit breakers occupy two mounting positions. 225A and 250A circuit
breakers occupy three mounting positions.
Caution: For ambient temperatures at or below +40°C (+104°F), overcurrent devices rated 100A or
greater MUST HAVE an empty mounting position between it and any other overcurrent
protective device. Maximum size circuit breakers that can be used are 100A single pole,
200A double pole, and 250A triple pole. Maximum size fuse is 100A. The distribution row is
rated for a maximum of 250A.
For ambient temperatures between +40°C (+104°F) and +65°C (+149°F), overcurrent devices
rated 60A or greater MUST HAVE an empty mounting position between it and any other
overcurrent protective device. Maximum size circuit breakers that can be used are 70A
single pole. No double pole or triple pole circuit breakers can be used. Maximum size fuse
70A. The distribution row is rated for a maximum of 250A.
Page 6 of 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.
System Application Guide SAG584622100, SAG584622200
Home
Spec. Nos. 584622100, 584622200, SAG584622300, SAG584622400
584622300, 584622400 (Model DCS48375) Issue AC, July 3, 2012
Ordering Notes
1) Order distribution fuses as required per Table 1. Also order one (1) P/N 117201 bullet nose fuseholder
per fuse ordered. Order replacement alarm fuses (18/100A) per Table 5.
2) Order distribution circuit breakers as required per Table 2 or Table 3.
3) See Table 11 for recommended load distribution wire sizes and to order lugs.
Distribution devices requiring a single distribution position require a two hole lug with 1/4” bolt
clearance holes on 5/8” centers (order per Table 11, order hardware kits per Table 7).
Distribution devices requiring two (2) or three (3) distribution positions require special application lugs
(order per Table 11 and Table 6) or busbar adapter kits (order per Table 7) and two hole lugs with
3/8” bolt clearance holes on 1” centers (order per Table 8).
Page 7 of 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.
SAG584622100, SAG584622200 System Application Guide
Ampere
Rating
Part
Number
Bussmann
P/N
Littelfuse
P/N
3
248230900
TPS-3
TLS003
5
248231000
TPS-5
TLS005
6
248231200
TPS-6
TLS006
10
248231500
TPS-10
TLS010
15
248231800
TPS-15
TLS015
20
248232100
TPS-20
TLS020
25
248232400
TPS-25
TLS025
30
248232700
TPS-30
TLS030
40
248233300
TPS-40
TLS040
50
248233900
TPS-50
TLS050
60
248234200
TPS-60
TLS060
70
248234500
TPS-70
TLS070
80
118413
--
TLS080
90
118414
--
TLS090
100
118415
--
TLS100
Bullet Nose Fuseholder
P/N 117201
(Includes Fuseholder,
18/100A GMT-A Alarm Fuse,
and GMT-X Safety Fuse
Cover)
See Table 11 for recommended load distribution wire sizes
and lugs.
Home
SAG584622300, SAG584622400 Spec. Nos. 584622100, 584622200
Issue AC, July 3, 2012 584622300, 584622400 (Model DCS48375)
Bullet Nose Fuseholders and TPS/TLS Fuses
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.
Table 1
Page 8 of 34
System Application Guide SAG584622100, SAG584622200
Ampere
Rating
Number
of Poles
Number of
Mounting
Positions
Part Number
Electrical Trip1
(White Handle)
Electrical/
Mechanical Trip2
(Black Handle)
1 1 1
102272
101596
3 1 1
102273
101597
5 1 1
102274
101598
10 1 1
102275
101599
15 1 1
102276
101600
20 1 1
102277
101601
25 1 1
102278
101602
30 1 1
102279
101603
35 1 1
102280
101604
40 1 1
102281
101605
45 1 1
121998
121997
50 1 1
102282
101606
60 1 1
102283
101607
70 1 1
102284
101608
75 1 1
102285
101609
80 1 1
121996
121995
100 1 1
102286
101610
125 2 2
516991
516838
150 2 2
516993
516839
175 2 2
144883
144884
200 2 2
121831
121832
225 3 3
144885
144886
250 3 3
121835
121836
See Table 11 for recommended load distribution wire sizes and lugs.
For 2-pole devices;
either order lugs from Table 6 or
adapter kit 545404 and lugs from Table 8.
For 3-pole devices;
either order lugs from Table 6 or
adapter kit 545571 and lugs from Table 8.
Home
Spec. Nos. 584622100, 584622200, SAG584622300, SAG584622400
584622300, 584622400 (Model DCS48375) Issue AC, July 3, 2012
Circuit Breaker Alarm Operation:
1
Provides an alarm during an electrical trip condition only.
2
Provides an alarm during an electrical or manual trip condition.
Table 2
Toggle Handle Bullet Nose 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 9 of 34
SAG584622100, SAG584622200 System Application Guide
Ampere
Rating
Number of
Poles (and
Mounting
Positions)
Number of
Mounting
Positions
Part Number
Electrical Trip1
(White Handle)
Electrical/
Mechanical Trip2
(Black Handle)
1 1 1
142856
142878
3 1 1
142857
142879
5 1 1
142858
142880
10 1 1
142859
142881
15 1 1
142861
142882
20 1 1
142862
142883
25 1 1
142863
142884
30 1 1
142864
142885
35 1 1
142865
142886
40 1 1
142866
142887
45 1 1
142867
142888
50 1 1
142868
142889
60 1 1
142869
142890
70 1 1
142870
142891
75 1 1
142871
142892
80 1 1
142872
142901
100 1 1
142873
142902
125 2 2
142874
142903
150 2 2
142875
142904
200 2 2
142876
142905
250 3 3
142877
142906
See Table 11 for recommended load distribution wire sizes and lugs.
For 2-pole devices;
either order lugs from Table 6 or
adapter kit 545404 and lugs from Table 8.
For 3-pole devices;
either order lugs from Table 6 or
adapter kit 545571 and lugs from Table 8.
Home
SAG584622300, SAG584622400 Spec. Nos. 584622100, 584622200
Issue AC, July 3, 2012 584622300, 584622400 (Model DCS48375)
Circuit Breaker Alarm Operation:
1
Provides an alarm during an electrical trip condition only.
2
Provides an alarm during an electrical or manual trip condition.
Table 3
Rocker Handle Bullet Nose 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 10 of 34
System Application Guide SAG584622100, SAG584622200
Ampere Rating
Part Number
Fuse Color
18/100 (GMT-A)
248610301
---
1/4
248610200
VIOLET
1/2
248610300
RED
3/4
248610500
BROWN
1-1/3
248610700
WHITE
2
248610800
ORANGE
3
248610900
BLUE
5
248611000
GREEN
7-1/2
248611300
BLACK-WHITE
10
248611200
RED-WHITE
15
248611500
RED-BLUE
Replacement
Safety Fuse
Cover (GMT-Y)
102774
---
Replacement
Dummy Fuse
248872600
---
Home
Spec. Nos. 584622100, 584622200, SAG584622300, SAG584622400
584622300, 584622400 (Model DCS48375) Issue AC, July 3, 2012
Optional Bullet Nose 6-Position GMT Distribution Fuse Block (P/N 545333)
Features
Provides six (6) load distribution fuse positions
(1/4A to 15A GMT alarm fuses).
Mounts in two (2) distribution positions.
Screw clamp type load and load return terminals provided.
Includes six (6) dummy fuses equipped with safety fuse covers.
Restrictions
When used for power distribution, load should not exceed 80% of device rating,
except 10 and 15 amp fuses, for which load should not exceed 70% of device
rating.
Occupies two (2) bullet device mounting positions.
Terminal block wire size capacity: 24 to 14 AWG.
At 40°C ambient, GMT fuses greater than 10A MUST HAVE an empty mounting
position between it and any other fuse. Maximum total current is 35A. Maximum GMT fuse size is 15A.
At 65°C ambient, GMT fuses greater than 5A MUST HAVE an empty mounting position between it and any
other fuse. Maximum total current is 21A. Maximum GMT fuse size is 10A.
Ordering Notes
1) Order optional Bullet Nose 6-Position GMT Fuse Block (P/N 545333) as required.
2) Order fuses as required per Table 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
Table 4
GMT Fuses
Page 11 of 34
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.
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