Emerson NetSure DCS 48375 Installation and User Instructions
SPEC. NOS.
MODEL
584622100 (19” MAIN SHELF), 584622200 (19” EXPANSION SHELF)
584622300 (23” MAIN SHELF), 584622400 (23” EXPANSION SHELF)
DCS48375
NetSure™ +24VDC to -48VDC Converter System
Installation and User Instructions
UM584622100 (Issue AC, July 3, 2012)
Business-Critical Continuity™, Emerson Network Power, and the Emerson Network
Power logo are trademarks and service marks of Emerson Electric Co.
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 © 2012, Emerson Network Power, Energy Systems, North America, Inc.
All rights reserved throughout the world.
Installation and User Instructions UM584622100
Spec. Nos. 584622100, 584622200, 584622300, 584622400 (Model DCS48375) Issue AC, July 3, 2012
TABLE OF CONTENTS
CONTENTS PAGE
STATIC WARNING ................................................................................................................... iii
ADMONISHMENTS .................................................................................................................. iv
General Safety .................................................................................................................................................... iv
Voltages .............................................................................................................................................................. iv
Circuit Card Handling .......................................................................................................................................... iv
CHAPTER 1. DESCRIPTION AND INSTALLATION ACCEPTANCE CHECKLIST .................. 1
System Description .............................................................................................................................................. 1
Installation Acceptance Checklist ........................................................................................................................ 1
CHAPTER 2. INSTALLING THE SYSTEM ................................................................................ 3
General Requirements ......................................................................................................................................... 3
Mounting the Shelf(s) ........................................................................................................................................... 5
Securing the Main Shelf to a Relay Rack ...................................................................................................... 5
Securing the Expansion Shelf(s) to a Relay Rack and Installing the Expansion Wiring Cover on
the Main Shelf ................................................................................................................................................ 6
Installing Optional Lug Adapter Busbar Kits ........................................................................................................ 7
Installing Bullet Nose Circuit Breakers and/or Fuseholders (with TPS/TPL Fuses) ............................................ 8
Installing an Optional Bullet Nose GMT Fuse Block .......................................................................................... 10
CHAPTER 3. SETTING JUMPER AND SWITCH OPTIONS ................................................... 12
Jumper and Switch Settings on the System Interface Circuit Card ................................................................... 12
Switch S1 ..................................................................................................................................................... 12
Jumper P2 ................................................................................................................................................... 13
CHAPTER 4. MAKING ELECTRICAL CONNECTIONS .......................................................... 14
Admonishments ................................................................................................................................................. 14
Wiring Considerations ........................................................................................................................................ 14
Shelf(s) Grounding (Frame Ground) Connection ............................................................................................... 15
External Alarm, Reference, Monitoring, and Control Connections .................................................................... 16
Load Connections .............................................................................................................................................. 18
To Distribution Bus Row .............................................................................................................................. 18
To Optional Bullet Nose 6-Position GMT Fuse Block .................................................................................. 20
Expansion Shelf(s) Interconnections ................................................................................................................. 21
Installing Output Paralleling Leads .............................................................................................................. 21
FA/CBA and CAN Bus Interconnections ..................................................................................................... 22
DC Input Connections ........................................................................................................................................ 23
CHAPTER 5. INSTALLING THE CONVERTER MODULES AND INITIALLY STARTING THE
SYSTEM ................................................................................................................................... 25
Installing Converter Modules.............................................................................................................................. 25
Table of Contents Page i
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.
UM584622100 Installation and User Instructions
Issue AC, July 3, 2012 Spec. Nos. 584622100, 584622200, 584622300, 584622400 (Model DCS48375)
Initially Starting and Checking System Operation .............................................................................................. 26
Initial Startup Preparation ............................................................................................................................ 26
Initially Starting the System ......................................................................................................................... 26
Checking System Status ............................................................................................................................. 26
CHAPTER 6. OPERATING PROCEDURES ............................................................................ 27
Converter Modules ............................................................................................................................................. 27
Using the Converter System with an ACU+ Controller ...................................................................................... 27
Local Indicators and Test Points ........................................................................................................................ 27
Local Indicators............................................................................................................................................ 27
Test Points ................................................................................................................................................... 28
CHAPTER 7. MAINTENANCE ................................................................................................. 29
Admonishments ................................................................................................................................................. 29
System Maintenance Procedures ...................................................................................................................... 29
CHAPTER 8. TROUBLESHOOTING AND REPAIR ................................................................ 30
Contact Information ............................................................................................................................................ 30
Admonishments ................................................................................................................................................. 30
Converter Modules ............................................................................................................................................. 30
System Troubleshooting Information ................................................................................................................. 30
Replacement Information ................................................................................................................................... 30
Replacement Procedures ................................................................................................................................... 31
Replacing a Converter Module .................................................................................................................... 31
Replacing a Distribution Device ................................................................................................................... 31
Replacing the System Interface Circuit Card .............................................................................................. 34
REVISION RECORD ................................................................................................................ 36
Page ii Table of Contents
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 and User Instructions UM584622100
Spec. Nos. 584622100, 584622200, 584622300, 584622400 (Model DCS48375) Issue AC, July 3, 2012
STATIC WARNING
The printed circuit cards used in this equipment contain static sensitive components. The warnings listed below
must be observed to prevent damage to these components. Disregarding any of these warnings may result in
personal injury or damage to the equipment.
1. Strictly adhere to the procedures provided in this document.
2. Before touching any static sensitive component or printed circuit card containing such a component,
discharge all static electricity from yourself by wearing a wrist strap grounded through a one megohm
resistor. Some wrist straps, such as Emerson Network Power Part Number 631810600, have a built-in
one megohm resistor; no external resistor is necessary. Read and follow wrist strap manufacturer’s
instructions outlining use of a specific wrist strap.
3. Do not touch the traces or components on a printed circuit card containing static sensitive components.
Handle the printed circuit card only by the edges that do not have connector pads.
4. After removing a printed circuit card containing a static sensitive component, place the printed circuit card
only on conductive or anti-static material such as conductive foam, conductive plastic, or aluminum foil.
Do not use ordinary Styrofoam or ordinary plastic.
5. Store and ship static sensitive devices or printed circuit cards containing such components only in static
shielding containers.
6. If necessary to repair a printed circuit card containing a static sensitive component, wear an appropriately
grounded wrist strap, work on a conductive surface, use a grounded soldering iron, and use grounded
test equipment.
Static Warning Page iii
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.
UM584622100 Installation and User Instructions
Issue AC, July 3, 2012 Spec. Nos. 584622100, 584622200, 584622300, 584622400 (Model DCS48375)
ADMONISHMENTS
GENERAL SAFETY
Danger: YOU MUST FOLLOW APPROVED SAFETY PROCEDURES.
Performing the following procedures may expose you to hazards. These
procedures should be performed by qualified technicians familiar with the
hazards associated with this type of equipment. These hazards may
include shock, energy, and/or burns. To avoid these hazards:
a) The tasks should be performed in the order indicated.
b) Remove watches, rings, and other jewelry.
c) Prior to contacting any uninsulated surface or termination, use a
voltmeter to verify that no voltage or the expected voltage is present.
d) Wear eye protection and use recommended tools.
e) Use double insulated tools appropriately rated for the work to be
performed.
VOLTAGES
Danger: This system operates from DC input power. All DC power sources must
be completely disconnected from the branch circuit wiring used to
provide power to this system before DC input connections are made.
Danger: This system produces DC power.
CIRCUIT CARD HANDLING
Warning: Installation or removal of the circuit cards requires careful handling.
Before handling any circuit card, read and follow the instructions
contained on the Static Warning Page.
Page iv Admonishments
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 and User Instructions UM584622100
Spec. Nos. 584622100, 584622200, 584622300, 584622400 (Model DCS48375) Issue AC, July 3, 2012
CHAPTER 1. DESCRIPTION AND INSTALLATION ACCEPTANCE CHECKLIST
SYSTEM 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 SAG584622100 (System Application Guide) for additional system
information.
Note: Refer to UM1C24481500 (Converter Module User Instructions) for converter
module information.
INSTALLATION ACCEPTANCE CHECKLIST
Provided below is an Installation Acceptance Checklist. This checklist helps ensure
proper installation and initial operation of the system. As the procedures presented in
Chapters 2 through 5 of this document are completed, check the appropriate box on this
list. If the procedure is not required to be performed for your installation site, also check
the box in this list to indicate that the procedure was read. When installation is done,
ensure that each block in this list has been checked. Some of these procedures may
have been factory performed for you.
Chapter 1. Description and Installation Checklist Page 1
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.
UM584622100 Installation and User Instructions
Issue AC, July 3, 2012 Spec. Nos. 584622100, 584622200, 584622300, 584622400 (Model DCS48375)
Note: The system is not powered up until the end of this checklist.
Note: Some of these procedures may have been factory performed.
Chapter 2. Installing the System
Optional Wiring Access Panel Installed on Top of Shelf(s), if desired
Main Shelf Secured to Relay Rack
Expansion Shelf(s) Secured to Relay Rack (if furnished)
and Expansion Wiring Cover installed on Main Shelf
Optional Lug Adapter Busbar Kits Installed
Bullet Nose Circuit Breakers Installed
Bullet Nose Fuseholders and TPS/TLS Fuses Installed
Optional Bullet Nose GMT Fuse Block Installed (if furnished)
Chapter 3. Setting Jumper and Switch Options
Jumper on System Interface Circuit Card Set
Switches on System Interface Circuit Card Set
Chapter 4. Making Electrical Connections
Shelf(s) Grounding (Frame Ground) Connection Made
External Alarm, Reference, Monitoring, and Control Connections Made
Load Connections Made
Expansion Shelf(s) Interconnections Made (if furnished)
DC Input Connections Made
Chapter 5. Installing the Converter Modules and Initially Starting the System
Converter Modules Installed
System Started and Checked
Page 2 Chapter 1. Description and Installation Checklist
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 and User Instructions UM584622100
Spec. Nos. 584622100, 584622200, 584622300, 584622400 (Model DCS48375) Issue AC, July 3, 2012
CHAPTER 2. INSTALLING THE SYSTEM
GENERAL REQUIREMENTS
The shelf is designed for mounting in a 19-inch or 23-inch wide relay rack with 1-3/4
inch multiple drilling.
The installer should be familiar with the installation requirements and techniques to
be used in securing the shelf(s) to a relay rack.
This product is intended only for installation in a Restricted Access Location on or
above a non-combustible surface.
This product must be located in a Controlled Environment with access to
Craftspersons only.
This product is intended for installation in Network Telecommunication Facilities (CO,
vault, hut, or other environmentally controlled electronic equipment enclosure).
This product is intended to be connected to the common bonding network in a
Network Telecommunication Facility (CO, vault, hut, or other environmentally
controlled electronic equipment enclosure).
Typical industry standards recommend minimum aisle space clearance of 2'6" for the
front of the relay rack and 2' for the rear of the relay rack.
Converter module and mounting shelf ventilating openings must not be blocked and
temperature of air entering system must not exceed rated Operating Ambient
Temperature Range found in SAG584622100.
Chapter 2. Installing the System Page 3
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.
UM584622100 Installation and User Instructions
1. Open front door.
2. Remove top panel.
3. Install Wiring Access Cover
(use same hardware removed from top panel).
4. Close front door.
WiringAccess Cover
Top Panel
584622100 / 584622200 shown.
584622300 / 584622400 similar.
Issue AC, July 3, 2012 Spec. Nos. 584622100, 584622200, 584622300, 584622400 (Model DCS48375)
INSTALLING OPTIONAL WIRING ACCESS COVER ON TOP OF SHELF(S), IF DESIRED
The optional wiring access cover is a 1U high panel that is installed on top of the shelf(s)
to allow greater access to load distribution return connection points.
Procedure
1) To install the optional wiring access cover, perform the procedure in Figure 2-1.
Figure 2-1
Installing Optional Wiring Access Cover
Page 4 Chapter 2. Installing the 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.
Installation and User Instructions UM584622100
584622100 and 584622200
Reversible MountingAngle
Torque mounting angle to
shelf connections to 20 in-lbs.
Torque mounting angle to
relay rack connections to 70 in-lbs.
584622100 / 584622200 shown.
584622300 / 584622400 similar.
Spec. Nos. 584622100, 584622200, 584622300, 584622400 (Model DCS48375) Issue AC, July 3, 2012
MOUNTING THE SHELF(S)
The 584622100 and 584622200 shelves are equipped with reversible mounting angles
for mounting in a standard 19-inch or 23-inch wide relay rack having 1-3/4 inch multiple
drillings.
The 584622300 and 584622400 shelves mount in a standard 23-inch wide relay rack
having 1-3/4 inch multiple drillings.
Note: Refer to the “General Requirements” section at the beginning of this chapter.
Securing the Main Shelf to a Relay Rack
Procedure
1) 584622100 and 584622200: Reverse the mounting angles if required to fit your
relay rack. Refer to Figure 2-2.
2) Secure the shelf mounting angles to the relay rack at four (4) locations per side.
Use grounding washers at one (1) location per side. Refer to Figure 2-2. Ensure
the grounding washers are oriented properly to enable the teeth to dig into the
mounting angle surface for a secure ground connection.
Figure 2-2
Reversing the Mounting Angles (if required) and Securing the Shelf to a Relay Rack
Chapter 2. Installing the System Page 5
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.
UM584622100 Installation and User Instructions
Expansion Wiring Cover
(supplied loose with Expansion
Shelf, attach to Main Shelf)
Replace this cover with the
Expansion Wiring Cover
Remove these tabs at the bottom of the top shelf and
at the top of the bottom shelf to allow wiring between
shelves.
Apply the provided material along the exposed edges
of the cutouts to provide protection to the wires as they
are passed between shelves.
584622100 / 584622200 shown.
584622300 / 584622400 similar.
Issue AC, July 3, 2012 Spec. Nos. 584622100, 584622200, 584622300, 584622400 (Model DCS48375)
Securing the Expansion Shelf(s) to a Relay Rack and Installing the Expansion Wiring Cover on the Main Shelf
SECURING AN EXPANSION SHELF TO A RELAY RACK
Secure an expansion shelf to a relay rack, directly below the shelf above it, per the
previous procedure. The optional 1U wiring access panel is recommended for expansion
shelves to facilitate load cable connections.
INSTALLING THE EXPANSION WIRING COVER ON THE MAIN SHELF
PERFORM THIS PROCEDURE AFTER PARALLELING THE OUTPUTS OF BOTH
SHELVES AS DESCRIBED IN THE “MAKING ELECTRICAL CONNECTIONS”
CHAPTER.
Procedure
1) Remove the cover shown in Figure 2-3 from the main shelf.
2) Remove the expansion wiring cover from the expansion shelf as shown in Figure
2-3.
3) On the expansion wiring cover for both the expansion shelf and the main shelf
(provided loose with the expansion shelf), remove the tabs shown in Figure 2-3
so wiring can pass between the shelves. Apply the provided material along the
exposed edges of the cutouts to provide protection to the wires as they are
passed between shelves.
4) Make the paralleling connections as described in the “Making Electrical
Connections” chapter.
5) Refer to Figure 2-3, and install the expansion wiring covers to both the main shelf
and the expansion shelf.
Installing the Expansion Wiring Cover on the Main Shelf
Page 6 Chapter 2. Installing the 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.
Figure 2-3
Installation and User Instructions UM584622100
P/N 545405
P/N 545404
P/N 545571
1. Open the shelf’s front door.
2. Install the lug adapter busbar kits as shown.
Apply anti-oxidizing compound to busbar
mating surfaces before installing.
3. Torque connections to 58 in-lbs using the
supplied 1/4” hardware.
4. Close the front door after wiring is complete.
Top Cover Removed in
Illustration for Clarity Only
584622100 / 584622200 shown.
584622300 / 584622400 similar.
Spec. Nos. 584622100, 584622200, 584622300, 584622400 (Model DCS48375) Issue AC, July 3, 2012
INSTALLING OPTIONAL LUG ADAPTER BUSBAR KITS
Procedure
1) Refer to Figure 2-4 to install the optional lug adapter busbar kits.
Figure 2-4
Installing Optional Lug Adapter Busbar Kits
Chapter 2. Installing the System Page 7
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.
UM584622100 Installation and User Instructions
Issue AC, July 3, 2012 Spec. Nos. 584622100, 584622200, 584622300, 584622400 (Model DCS48375)
INSTALLING BULLET NOSE CIRCUIT BREAKERS AND/OR FUSEHOLDERS (WITH TPS/TPL FUSES)
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.
Note: Circuit breakers and/or fuses may have been factory installed for you. If so, verify
their positions and sizes.
Procedure
1) Open the shelf’s front door.
2) Circuit Breakers and Fuses: Ensure that a circuit breaker is in the OFF
position. Orient the distribution device as shown in Figure 2-5. Insert the
terminals on the rear of the distribution device into their corresponding sockets
on the distribution row. Ensure the alarm contact on the back of the distribution
device makes contact with the alarm terminal on the mounting circuit card. Push
distribution device in firmly until fully seated in the distribution row.
3) Fuses: When all fuseholders are installed, install an appropriately sized
TPS/TLS fuse in each. To do this, remove the fuse carrier from the mounted
fuseholder body by pulling it straight out. Slide the fuse in place between the
contacts of the fuse carrier. When done, push the fuse carrier back into the
fuseholder body. Note that a polarizing key on the bottom of the carrier prevents
the carrier from being inserted upside down. Verify that an 18/100 ampere alarm
fuse is present in each fuseholder and that a plastic safety cover is installed on
this fuse.
4) Record all circuit breaker and/or fuse sizes on the label provided.
5) Close the shelf's front door.
Page 8 Chapter 2. Installing the 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.
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