Page 1
NetSure™ 5100 Series
-48 VDC Power System
Installation Manual (IM582137200), Revision J
Specification Number: 582137200
Model Number: 5100
Page 2
2
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 accuracy and completeness herein, Vertiv Group
Corp. 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 may contain confidential and/or proprietary information of
Vertiv Group Corp., and its receipt or possession does not convey any right
to reproduce, disclose its contents, or to manufacture or sell anything that
it may describe. Reproduction, disclosure, or use without specific
authorization from Vertiv Group Corp. is strictly prohibited.
Vertiv and the Vertiv logo are trademarks or registered trademarks of
Vertiv Group Corp. All other names and logos referred to are trade names,
trademarks or registered trademarks of their respective owners.
© 2019 Vertiv Group Corp. All rights reserved.
Vertiv | NetSure™ 5100 Series -48 VDC Power System Installation Manual (IM582137200) | Rev. J
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TABLE OF CONTENTS
Admonishments Used in this Document ............................................................ 5
Important Safety Instructions .............................................................................. 6
General Safety .......................................................................................................................................................... 6
Voltages .......................................................................................................................................................................... 6
AC Input Voltages ........................................................................................................................................................ 6
DC Output and Battery Voltages .................................................................................................................. 6
Battery ............................................................................................................................................................................... 7
Personal Protective Equipment (PPE) ............................................................................................. 8
Hazardous Voltage .............................................................................................................................................. 8
Handling Equipment Containing Static Sensitive Components............................. 8
Maintenance and Replacement Procedures .............................................................................. 8
Static Warning ........................................................................................................... 9
Customer Documentation Package .................................................................... 11
Installation Acceptance Checklist ...................................................................... 11
Installing the System ............................................................................................. 13
General Requirements .................................................................................................................................... 13
Securing the Relay Rack to the Floor (if furnished) ......................................................... 13
Securing the System to a Relay Rack or a Cabinet Equipment Rack
(if required) ................................................................................................................................................................ 15
Securing the System Vertically to a Wall with P/N 553203Kit (if
furnished) .................................................................................................................................................................... 17
Securing the System Horizontally to a Wall with P/N 552537 or P/N
552535 Kit (if furnished) ............................................................................................................................... 19
Installing a List 93, 94 Battery Tray ................................................................................................. 22
Installing Circuit Breakers and Fuses ............................................................................................. 25
Installing an Optional Battery Cabinet............................................................................................ 27
Installing an Optional External IB4 Kit P/N 561929 .......................................................... 28
Attaching the USB Drive Pouch to the System ................................................................... 29
Setting Jumper and Switch Options ................................................................ 30
Circuit Card Locations ................................................................................................................................... 30
Jumper Settings on the System Interface Circuit Card ................................................ 31
Switch Settings on the IB2 (Controller Interface Board) (if furnished) ........ 33
Making Electrical Connections .......................................................................... 35
Important Safety Instructions ................................................................................................................ 35
Wiring Considerations .................................................................................................................................... 35
Relay Rack / Cabinet Frame Grounding Connection...................................................... 35
System Shelves Frame Grounding Connection ................................................................... 36
Central Office Ground Connection ................................................................................................... 38
Rectifier Nominal 120 VAC / 208 VAC / 240 VAC Input and AC Input
Equipment Grounding Connections ................................................................................................ 38
External Alarm, Reference, Monitoring, and Control Connections .................... 41
Circuit Card Locations .......................................................................................................................................... 41
Vertiv | NetSure™ 5100 Series -48 VDC Power System Installation Manual (IM582137200) | Rev. J
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RS-485 Connection (used for Communication with SM Modules) ...........................42
Temperature Probes ..............................................................................................................................................42
System Interface Circuit Card Connections (if required) ...................................................42
IB2 (Controller Interface Board) Connections (if furnished) .......................................... 44
Connecting a Device or System to the NCU CAN Bus (if required) ....................... 54
NCU Controller Ethernet Connection (if required) .......................................................... 55
Control Bus Connections between Controller and System Shelves ............... 57
Load Distribution Wiring, Input Battery Wiring, and CO Ground
Wiring.............................................................................................................................................................................. 59
Load Distribution Wiring, Input Battery Wiring, and CO Ground Wiring
To List BF and NF .................................................................................................................................................... 59
Load Distribution Wiring, Input Battery Wiring, and CO Ground Wiring
to List BC, LC, And NC ......................................................................................................................................... 60
Load Distribution Wiring, Input Battery Wiring, and CO Ground Wiring
to List BA And NA .................................................................................................................................................... 60
Connecting to an Optional Battery Cabinet ............................................................................ 64
Installing and Connecting Batteries in an Optional List 93 or 94
Battery Tray (if furnished) ......................................................................................................................... 64
Installing Rectifier Modules ................................................................................ 67
Initially Starting, Configuring, and Checking System Operation ............. 67
Initial Startup Preparation .......................................................................................................................... 67
Initially Starting the System ..................................................................................................................... 67
NCU Controller Initialization .................................................................................................................... 67
Verifying and Setting the NCU Controller as Required for Your
Application ................................................................................................................................................................ 70
Checking System Status ............................................................................................................................. 79
Final Steps ................................................................................................................................................................. 79
Vertiv | NetSure™ 5100 Series -48 VDC Power System Installation Manual (IM582137200) | Rev. J
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DANGER
in death or serious injury if not avoided. (ANSI, OSHA)
WARNING
result in
death or serious injury if not avoided. This admonition is not used for situations that pose a
risk o
CAUTION
result in minor or moderate injury if not avoided. (ANSI, OSHA) This admonition is not
used for situations that pose a risk only to equipment, data, or service, even if such use
appears to be permitted in some of the applicable standards. (OSHA)
ALERT
equipment, software, data, or service. (ISO)
ALERT
equipment damage, software corruption, data lo
FIRE SAFETY
or policies, or of the locations of fire
SAFETY
policies not related to a particular source of hazard or to fire safety. (ISO, ANSI, OSHA)
ADMONISHMENTS USED IN THIS DOCUMENT
! Warns of a hazard the reader
! Warns of a potential hazard the reader
nly to equipment, software, data, or service. (ANSI)
! Warns of a potential hazard the reader
! Alerts the reader to an action that
will
be exposed to that will
may
be exposed to that
may
be exposed to that
must be avoided
likely
result
could
could
in order to protect
! Alerts the reader to an action that
! Informs the reader of fire safety information, reminders, precautions,
! Informs the reader of general safety information, reminders, precautions, or
Vertiv | NetSure™ 5100 Series -48 VDC Power System Installation Manual (IM582137200) | Rev. J
-fighting and fire-safety equipment. (ISO)
must be performed
ss, or service interruption. (ISO)
in order to prevent
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IMPORTANT SAFETY INSTRUCTIONS
General Safety
DANGER! YOU MUST FOLLOW APPROVED SAFETY PROCEDURES.
Performing the following procedures may expose you to hazards. These procedures should be
performed by qualified technicians familiar with the hazards associated with this type of equipment.
These hazards may include shock, energy, and/or burns. To avoid these hazards:
a) The tasks should be performed in the order indicated.
b) Remove watches, rings, and other metal objects.
c) Prior to contacting any uninsulated surface or termination, use a voltmeter to verify that no voltage
or the expected voltage is present. Check for voltage with both AC and DC voltmeters prior to
making contact.
d) Wear eye protection.
e) Use certified and well maintained insulated tools. Use double insulated tools appropriately rated for
the work to be performed.
Voltages
AC Input Voltages
DANGER! This system operates from AC input voltage capable of producing fatal electrical shock. AC
input power must be completely disconnected from the branch circuits wiring used to provide power to
the system before any AC electrical connections are made. Follow local lockout/tagout procedures to
ensure upstream branch circuit breakers remain de-energized during installation. DO NOT apply AC
input power to the system until all electrical connections have been completed and checked.
DC Output and Battery Voltages
DANGER! This system produces DC power and may have a battery source connected to it. Although
the DC voltage is not hazardously high, the rectifiers and/or battery can deliver large amounts of current.
Exercise extreme caution not to inadvertently contact or have any tool inadvertently contact an output
terminal or battery terminal or exposed wire connected to an output terminal or battery terminal.
NEVER allow a metal object, such as a tool, to contact more than one termination or battery terminal at a
time, or to simultaneously contact a termination or battery terminal and a grounded object. Even a
momentary short circuit can cause sparking, explosion, and injury.
DANGER! Follow local lockout/tagout procedures to ensure DC branch circuit protection devices
remain de-energized during installation at loads, as required.
Vertiv | NetSure™ 5100 Series -48 VDC Power System Installation Manual (IM582137200) | Rev. J
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Battery
Refer to the battery manufacturer documentation for specific battery safety instructions. The following are
general guidelines.
WARNING! Correct polarity must be observed when connecting battery leads.
WARNING! Special safety precautions are required for procedures involving handling, installing, and
servicing batteries. Observe all battery safety precautions in this manual and in the battery instruction
manual. These precautions should be followed implicitly at all times.
WARNING! A battery can present a risk of electrical shock and high short circuit current. Servicing of
batteries should be performed or supervised only by properly trained and qualified personnel
knowledgeable about batteries and the required precautions.
The following precautions should be observed when working on batteries:
• Remove watches, rings, and other metal objects.
• Eye protection should be worn to prevent injury from accidental electrical arcs.
• Use certified and well maintained insulated tools. Use double insulated tools appropriately rated for
the work to be performed. Ensure that wrenches with more than one working end have only one
end exposed.
• Do not lay tools or metal parts on top of batteries.
• Verify that no current will flow when the battery is connected or disconnected by opening battery
disconnects (if available) or adjusting the system to match battery voltage.
• Risk of explosion if battery is replaced with an incorrect type or if polarity is reversed.
Recommended to replace batteries with the same manufacturer and type, or equivalent.
• Dispose of used batteries according to the instructions provided with the batteries. Do not dispose
of batteries in a fire. They may explode.
• ALWAYS FOLLOW THE BATTERY MANUFACTURER’S RECOMMENDATIONS AND SAFETY
INSTRUCTIONS.
DANGER! This equipment may be used in conjunction with lead-acid batteries. Working near lead-acid
batteries is dangerous!
In addition to the hazard of electric shock, gas produced by batteries can be explosive and sulfuric acid
can cause severe burns.
• Do not open or mutilate batteries. Released electrolyte is harmful to the skin and eyes, and is toxic.
• Batteries contain sulfuric acid.
• Batteries generate explosive gases during normal operation. Systems containing batteries should
never be installed in an airtight room or space. Only install in a ventilated environment.
• Batteries are an energy source that can produce high amounts of electrical current.
Vertiv | NetSure™ 5100 Series -48 VDC Power System Installation Manual (IM582137200) | Rev. J
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FOR THESE REASONS, IT IS OF CRITICAL IMPORTANCE THAT YOU READ THESE INSTRUCTIONS
AND FOLLOW THEM EXACTLY.
WHEN WORKING WITH LEAD-ACID BATTERIES:
• Follow the recommended PPE requirements per the SDS for the battery to be used.
• If battery acid enters your eye, immediately flush your eye with running cold water for at least 15
minutes. Get medical attention immediately.
• If battery acid contacts skin or clothing, wash immediately with soap and water.
ALERT! Performing maintenance and/or troubleshooting procedures may interrupt power to the loads,
if battery reserve is not sufficient.
Personal Protective Equipment (PPE)
DANGER! ARC FLASH AND SHOCK HAZARD.
Appropriate PPE and tools required when working on this equipment. An appropriate flash protection
boundary analysis should be done determine the “hazard/risk” category, and to select proper PPE.
This product is intended only for installation in a Restricted Access Location.
Only authorized and properly trained personnel should be allowed to install, inspect, operate, or maintain
the equipment.
Do not work on LIVE parts. If required to work or operate live parts, obtain appropriate Energized Work
Permits as required by the local authority, per NFPA 70E “Standard for Electrical Safety in the
Workplace”.
Hazardous Voltage
DANGER! HAZARD OF ELECTRICAL SHOCK.
More than one disconnect may be required to de-energize the system before servicing.
Handling Equipment Containing Static Sensitive Components
ALERT! Installation or removal of equipment containing static sensitive components requires careful
handling. Before handling any equipment containing static sensitive components, read and follow the
instructions contained on the Static Warning Page.
Maintenance and Replacement Procedures
CAUTION! When performing any step in procedures that requires removal or installation of hardware,
use caution to ensure no hardware is dropped and left inside the unit; otherwise service interruption or
equipment damage may occur.
Vertiv | NetSure™ 5100 Series -48 VDC Power System Installation Manual (IM582137200) | Rev. J
NOTE!
hardware for use in subsequent steps, unless otherwise directed.
When performing any step in procedures that requires removal of existing hardware, retain all
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STATIC WARNING
This equipment contains static sensitive components. The warnings listed below must be observed to
prevent damage to these components. Disregarding any of these warnings may result in personal injury
or damage to the equipment.
1. Strictly adhere to the procedures provided in this document.
2. Before touching any equipment containing static sensitive components, discharge all static
electricity from yourself by wearing a wrist strap grounded through a one megohm resistor. Some
wrist straps have a built-in one megohm resistor; no external resistor is necessary. Read and follow
wrist strap manufacturer’s instructions outlining use of a specific wrist strap.
3. Do not touch traces or components on equipment containing static sensitive components. Handle
equipment containing static sensitive components only by the edges that do not have connector
pads.
4. After removing equipment containing static sensitive components, place the equipment only on
conductive or anti-static material such as conductive foam, conductive plastic, or aluminum foil. Do
not use ordinary Styrofoam™ or ordinary plastic.
5. Store and ship equipment containing static sensitive components only in static shielding containers.
6. If necessary to repair equipment containing static sensitive components, wear an appropriately
grounded wrist strap, work on a conductive surface, use a grounded soldering iron, and use
grounded test equipment.
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Vertiv | NetSure™ 5100 Series -48 VDC Power System Installation Manual (IM582137200) | Rev. J
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CUSTOMER DOCUMENTATION PACKAGE
This document (IM582137200) provides Installation Instructions for the NetSure™ 5100 Series -48 VDC Power
System: Model 5100, Spec. No. 582137200.
The complete Customer Documentation Package consists of…
NetSure™ -48 VDC Power System Installation Manual
• Power System Installation Instructions: IM582137200
NetSure™ NCU Controller User Manual
• NCU Controller User Instructions: UM1M830BNA
USB Drive with All Customer Documentation
• Power System Installation Instructions: IM582137200
• Power System User Instructions: UM582137200
• Power System “System Application Guide”: SAG582137200
• NCU Controller User Instructions: UM1M830BNA
• Rectifier Instructions: UM1R482000e3
• Engineering Drawings
- SD582137200
- T582137200
• Also provided on the USB drive is a controller configuration drawing and the controller configuration
files loaded into the controller as shipped.
For factory settings of all configurable controller parameters, refer to the Configuration Drawing (C-drawing)
supplied with your power system.
INSTALLATION ACCEPTANCE CHECKLIST
Provided in this section is an Installation Acceptance Checklist. This checklist helps ensure proper installation
and initial operation of the system. As the procedures presented in 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.
NOTE!
NOTE!
Installing the System
Relay Rack Secured to Floor (if furnished)
System Secured to Relay Rack or Cabinet Equipment Rack (if required)
Vertiv | NetSure™ 5100 Series -48 VDC Power System Installation Manual (IM582137200) | Rev. J
The system is not powered up until the end of this checklist.
Some of these procedures may have been performed at the factory for you.
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System Secured to Suitable Wall (if required)
Optional Battery Tray Installed
Optional Battery Tray Battery Disconnect Circuit Breaker Installed
Circuit Breakers and/or Fuses Installed
Setting Jumper and Switch Options
Jumper on System Interface Circuit Card Set
Factory Switch Setting on IB2 (Controller Interface Board) Verified
Making Electrical Connections
Relay Rack / Cabinet Frame Grounding Connection Made
System Shelves Frame Grounding Connection Made
Central Office Ground Connection Made
Rectifier AC Input and AC Input Equipment Grounding Connections Made
External Alarm, Reference, Monitoring, and Control Connections to System Interface Circuit Card Made
External Alarm, Reference, Monitoring, and Control Connections to IB2 (Controller Interface Board)
Made
External Device (such as SM-Temp Module) Connection to NCU Controller CAN Bus Made (if required)
NCU Controller Ethernet Port Connection Made
NCU Controller Second Ethernet Port Connection Made (if required)
Factory NCU Control Bus Connections between NCU Controller and System Shelves Verified
Load Connections Made
Battery Connections Made
o Batteries Installed and Connected in an Optional Battery Tray
o Batteries Installed and Connected in an Optional Battery Cabinet
o External Batteries Connected
Installing the Modules
Rectifier Modules Installed
Initially Starting the System
System Started, Configured, and Checked
Vertiv | NetSure™ 5100 Series -48 VDC Power System Installation Manual (IM582137200) | Rev. J
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INSTALLING THE SYSTEM
General Requirements
• The installer should be familiar with the installation requirements and techniques to be used in securing
the relay rack (if furnished) to the floor.
• The installer should be familiar with the installation requirements and techniques to be used in securing
the system to a relay rack or equipment rack.
- The top rear cover needs to be removed to access the battery and CO ground connection points. If
other equipment is mounted above the shelf, leave enough clearance to access the screws securing
the cover.
• The installer should be familiar with the installation requirements and techniques to be used in securing
the system to a suitable wall (if required).
• 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 crafts persons only.
• This product is intended for installation in network telecommunication facilities CO, vault, hut or other
electronic equipment enclosure that maintains temperature from -5 °C to +50 °C for Class 1 equipment
or from -40 °C to +65 °C for Class 2 equipment.
• This product is intended for connection to the common bonding network in a network
telecommunication facility (CO, vault, hut, or other environmentally controlled electronic equipment
enclosure).
• The DC return connection to this system can remain isolated from system frame and chassis (DC-I).
• This system is suitable for installation as part of the Common Bonding Network (CBN).
• System ventilating openings must not be blocked and temperature of air entering rectifiers must not
exceed rated operating ambient temperature range found in SAG582137200.
• Clearance requirements are (relay rack):
- Recommended minimum aisle space clearance for the front of each bay is 2' 6".
- Recommended minimum aisle space clearance for the rear of each bay is 2’ 0”.
• Clearance requirements are (cabinet or wall mounting):
- Recommended minimum clearance for the rear of the system is 4”.
Securing the Relay Rack to the Floor (if furnished)
Secure the relay rack to the floor per site requirements. Refer to “General Requirements” on page 13.
Ventilation Requirements
Refer to “General Requirements” on page 13.
Relay Rack Floor Mounting Dimensions
Refer to Figure 1 and Figure 2 for relay rack floor mounting dimensions.
Vertiv | NetSure™ 5100 Series -48 VDC Power System Installation Manual (IM582137200) | Rev. J
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Part No. 559817
Part No. 559819
Part No. 559818, 559820,
559821, 559822
17.50
20.13
24.38
2.13
3.44
9.88
12.53
15.00
1.24
2.56
0.875 Dia.
(8 Places)
Masked for Frame Ground Lug
0.281 Dia. Holes on 0.625 Centers
(Top of Rack, 2 Places)
22.500
24.750
1.125
15.000
17.500
20.125
25.000
2.437
3.750
9.871
12.531
15.031
1.250
2.580
2.00
1.00
1.00
2.00
2.00
2.00
5.00
0.437 Dia.
(12 Places)
Masked for Frame Ground Lug
0.281 Dia. Holes on 0.625 Centers
(Top of Rack, 2 Places)
0.875 Dia.
(8 Places)
Masked for Frame Ground Lug
0.281 Dia. Holes on 0.625 Centers
(Top of Rack, 1 Place)
Notes:
1. All dimensions are in inches.
Figure 1:
Relay Rack Floor Mounting Dimensions - 23”
Vertiv | NetSure™ 5100 Series -48 VDC Power System Installation Manual (IM582137200) | Rev. J
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15
20.38
Notes:
1. All dimensions are in inches.
Figure 2:
Relay Rack Floor Mounting Dimensions - 19”
2.13
3.44
15.00
12.53
9.88
1.24
2.56
2.13
3.44
16.13
13.50
Part No. 559824
21.00
16.75
14.13
0.875 Dia.
(8 Places)
Masked for Frame Ground Lug
0.281 Dia. Holes on 0.625 Centers
(Top of Rack, 2 Places)
0.875 Dia.
(8 Places)
15.00
12.03
Masked for Frame Ground Lug
0.281 Dia. Holes on 0.625 Centers
(Top of Rack, 2 Places)
1.49
2.81
9.38
Part No. 559823
Securing the System to a Relay Rack or a Cabinet Equipment Rack (if required)
DANGER! If the system is mounted in a relay rack, the relay rack must be securely anchored to the floor
before the system is installed.
NOTE!
factory.
NOTE!
requirements.
If the power system was ordered in a relay rack, these procedures have been performed at the
Refer to “General Requirements” on page 13 for mounting restrictions and ventilation
NOTE!
The distribution unit is factory connected to the rectifier/controller shelf. The distribution unit
with rectifier/controller shelf is mounted as a complete system.
Vertiv | NetSure™ 5100 Series -48 VDC Power System Installation Manual (IM582137200) | Rev. J
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g
Torq
ue: 65 in-lbs.
NOTE!
The system is furnished for 19” mounting as standard. This requires rear AC connections for the
controller/rectifier shelf. 23” mounting bracket adapters are available for 23” mounting. If the front
accessed AC connector option was ordered, the AC option is built into the mounting bracket and
requires 23” mounting. The expansion rectifier shelf is always furnished with 19’ mounting brackets and
rear AC connectors. 23” mounting bracket adapters are available for 23” mounting. Wall mounting
options are also available.
NOTE!
Refer to UM582137200 for a procedure for field installing an expansion rectifier shelf to the
system.
This power system is designed to mount in a standard 19” or 23” relay rack or equipment rack having 1” or 1 3/4”
multiple drillings. Refer to System Application Guide SAG582137200 for overall dimensions and a list of
available relay racks.
Procedure
1. Position the system in the relay rack or cabinet equipment rack.
2. Secure the system to the relay rack or cabinet equipment rack using hardware as shown in Figure 3
(see Figure 3 for recommended torque). Use grounding washers as indicated in Figure 3.
NOTE!
Install (orient) the ground washers so the teeth dig into the mounting angles for a secure
ground connection.
NOTE!
equipment rack:
- All paint must be removed from the front surface of each equipment rack rail where it mates with a
shelf-mounting bracket, so that good metal-to-metal contact can be established between the shelf
and rack.
- The shelf-to-rack mating surfaces must be cleaned.
- Electrical anti-oxidizing compound must be applied to the shelf-to-rack mating surfaces.
Figure 3:
Mounting the System in a Relay Rack or a Cabinet Equipment Rack
Compliance with Telcordia GR-1089-CORE requires that prior to mounting the system to the
MOU
Fr
ont
NTING H
12-24 x 3/4
Hex Head Scre
No. 10/
12 Grou
ARDWARE
" Thread Formi
w
nd Washer
n
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Securing the System Vertically to a Wall with P/N 553203Kit (if furnished)
An optional wall mount bracket kit (P/N 553203) is available for vertical wall mounting of the system.
NOTE!
Refer to “General Requirements” on page 13 for mounting restrictions and ventilation
requirements.
NOTE!
Refer to
Figure 4
when performing this procedure.
Procedure
1. The installer must provide fasteners for securing the system to a wall or other vertical surface. Ensure
that the wall and fastening technique are suitable for supporting the weight of the system. Suggested
anchors are listed in the illustrations. Refer to System Application Guide SAG582137200 for system
weight and additional dimensions.
2. Attach the brackets to the system mounting angles using kit-furnished screws. Torque to 60 in-lbs.
3. Use drill guide dimensions in the illustration to prepare the wall for customer-furnished fasteners.
Secure the system to the wall.
Vertiv | NetSure™ 5100 Series -48 VDC Power System Installation Manual (IM582137200) | Rev. J
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N
o
t
e
s
:
1. All dimensions are in inches,
unless otherwise specified.
2. Installer to furnish hardware
for fastening brackets to wall.
Use (2) wall anchors per bracket.
For solid concrete block, hard
natural stone or solid brick, use
Hilti HLC H 5/16 X 1-5/8 or similar.
Wall Mount Drilling Guide (Not to scale)
All dimensions are in inches.
3-1/8
18-15/16 (19” Mounting)
22-29/32 (23” Mounting)
3/8 Dia. Clearance Hole
in Bracket for Wall Fastener
(Front)
3/8 Dia.
Top View
Right Side View
Bottom of Shelf
Front View
(19” Mounting, 23” Similar)
Left Side View
3.125
4.625
18.936 (19” Mounting, shown)
22.906 (23” Mounting)
20.543 (19” Mounting, shown)
24.513 (23” Mounting)
Figure 4:
Vertical Wall Mounting with P/N 553203
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Securing the System Horizontally to a Wall with P/N 552537 or P/N 552535 Kit (if furnished)
An optional wall mount bracket kit (P/N 552537 for 19” mounting and P/N 552535 for 23” mounting) is available
for horizontal wall mounting of the system.
NOTE!
Refer to “General Requirements” on page 13 for mounting restrictions and ventilation
requirements.
NOTE!
Refer to
Figure 5
or
Figure 6
when performing this procedure.
Procedure
1. The installer must provide fasteners for securing the system to a wall or other horizontal surface.
Ensure that the wall and fastening technique are suitable for supporting the weight of the system. Refer
to System Application Guide SAG582137200 for system weight and additional dimensions.
2. Prepare the wall for customer-furnished fasteners. Secure the wall bracket to the wall.
3. Attach the system to the wall bracket using the standard mounting technique. See “Securing the
System to a Relay Rack or a Cabinet Equipment Rack (if required)” on page 15.
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Notes:
1. All dimensions are in inches,
unless otherwise specified.
2. Installer to furnish hardware
for fastening bracket to wall.
552537
Frame Grounding Point
(1/4-20 Studs on 5/8” Centers)
Figure 5:
Horizontal Wall Mounting with P/N 552537
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Notes:
1. All dimensions are in inches,
unless otherwise specified.
2. Installer to furnish hardware
for fastening bracket to wall.
552535
Frame Grounding Point
(1/4-20 Studs on 5/8” Centers)
Figure 6:
Horizontal Wall Mounting with P/N 552535
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Installing a List 93, 94 Battery Tray
Perform the following procedures to install a battery tray.
DANGER! The relay rack must be securely anchored to the floor before a battery tray is installed.
Battery Tray Installation
Procedure
1. To install a battery tray, perform the procedure detailed in Figure 7.
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Page 23
23
Battery
Tray
Rear
Angle
Bracket
Rear Angle Bracket
Cabling
Bracket
Front Rear
1. Slide battery tray into relay rack and
secure to relay rack with 12-24 x 3/4"
thread forming hex head screws and
#10/12 ground washers (1 place per
side) or #12 flat washers (3 places per
side). (Torque to 70 in-lbs).
2. Secure rear angle brackets (both sides)
to battery tray with 1/4-20 x 3/4” bolts,
1/4” flat washers, 1/4” lock washers, and
1/4” nuts. (Torque to 84 in-lbs).
3. Secure rear angle brackets (both sides)
to relay rack with 12-24 x 3/4" thread
forming hex head screws and #10/12
ground washers (1 place per bracket)
or #12 flat washers (1 place per bracket).
(Torque to 70 in-lbs).
4. Secure cabling brackets (both sides) to
relay rack with 12-24 x 1/2" thread forming
hex head screws. (Torque to 70 in-lbs).
P/N 559806, 559807, 559808, 559811.
P/N 559809, 559810, 559812 similar
P/N 559809, 559810, 559812
Figure 7:
Installing a List 93, 94 Battery Tray
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Page 24
24
Battery Disconnect
Circuit Breaker Assembly
(left side kit shown,
right side kit available)
1. Remove the cover from the battery
disconnect circuit breaker assembly.
2. Secure the battery disconnect circuit
breaker assembly to the battery tray
using 6-32 x 1/2” screws and 6-32
KEPS nuts (2-places).
3. Secure the ground lead under a battery
tray relay rack mounting bolt.
4. After wiring to the battery disconnect
circuit breaker, replace the cover.
Installing Optional Battery Disconnect Circuit Breaker onto a List 93, 94 Battery Tray
Procedure
1. To install an optional battery disconnect circuit breaker onto the battery tray, perform the procedure
detailed in Figure 8.
2. Battery tray wiring is shown in “Installing and Connecting Batteries in an Optional List 93 or 94 Battery
Tray (if furnished)” on page 64.
Figure 8:
Installing Optional Battery Disconnect Circuit Breaker onto a List 93, 94 Battery Tray
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Page 25
25
Safety Co
ver
Installing Circuit Breakers and Fuses
Circuit breakers and/or fuses may have been factory installed for you. If so, verify their positions and sizes.
Refer to SAG582137200 for any temperature, sizing, and spacing restrictions.
GMT Load Distribution Fuses (List BA, BC, BF, LC, NA, NC, NF)
Procedure
1. Install correctly sized GMT fuses into the fuseholders located on the front of the distribution unit, as
required. If a dummy fuse is installed, first remove the dummy fuse. Install a safety fuse cover over each
GMT fuse. Install a dummy fuse in all unused fuse positions. See to Figure 9.
Figure 9:
Installing GMT Load Distribution Fuses
Front
G
MT Fuse
List
BA show
List BC,
n,
BF, LC,
NA, NC, NF
simila
r.
Installing Bullet Nose Type Circuit Breakers (List BA, BC, BF, LC, NA, NC, NF)
Procedure
1. Ensure that the circuit breaker is in the OFF position and is of the correct rating. Orient the circuit
breaker as shown in Figure 10 or Figure 11. Insert the terminals on the rear of the circuit breaker into
their corresponding sockets on the distribution unit. Ensure the alarm contact on the back of the circuit
breaker makes contact with the alarm terminal on the distribution unit. Push distribution device in firmly
until fully seated in the distribution unit.
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26
Load Distribution
Circuit Breakers
Front
Load Distribution
Circuit Breakers
Insert these
terminals into
corresponding
sockets on
distribution unit .
Insert these
terminals into
corresponding
sockets on
distribution unit .
Shorter Side
of Breaker
Shorter Side
of Breaker
Longer Side
of Breaker
NOTES
1. Turn circuit breaker off before installing.
2. When installing breakers, orient breaker so that when in off position
the handle is towards the center (as shown in the illustration).
3. List BC shown, List LC, NC similar.
4. Components removed in illustration for clarity only.
See
Notes
Battery Disconnect
Circuit Breakers
Front
Load Distribution
Circuit Breakers
Insert these
terminals into
corresponding
sockets on
distribution unit .
Insert these
terminals into
corresponding
sockets on
distribution unit .
NOTES
1. Turn circuit breaker off before installing.
2. When installing breakers, orient breaker so that when in off position
the handle is towards the center (as shown in the illustration).
3. List BA shown, List NA similar.
4. Components removed in illustration for clarity only.
See
Notes
Shorter Side
of Breaker
Shorter Side
of Breaker
Longer Side
of Breaker
Figure 10:
Installing Bullet-Nose-Type Load Distribution Circuit Breakers (List BC, LC, NC)
Figure 11:
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Installing Bullet-Nose-Type Battery Disconnect and Load Distribution Circuit Breakers (List BA, NA)
Page 27
27
Installing an Optional Battery Cabinet
NetSure™ 211BC Battery Cabinet, P/N 541434
Refer to the battery cabinet instructions (Section 6023).
NetSure™ 211BC Battery Cabinet, P/N 545534
Refer to the battery cabinet instructions (Section 6033).
NetSure™ 211BC Battery Cabinet, P/N 554631
Refer to the battery cabinet instructions (UM554631).
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28
Installing an Optional External IB4 Kit P/N 561929
Procedure
NOTE!
Refer to
Figure 12
as this procedure is performed.
1. Mount the external IB4 module within 6.5 feet of the system interface connector.
2. Plug the cable furnished with the external IB4 module between the module and the system interface
connector as shown in Figure 12.
3. If the system is in operation, reboot the NCU.
Local Menu Navigation:
At the Main Screen, press ENT and ESC at the same time to reboot the NCU Controller.
Web Menu Navigation:
Advance Settings Menu / SW Maintenance Tab / Reboot Controller button.
Figure 12:
Installing an Optional External IB4 Kit P/N 561929
External IB4
P/N 561929
Rear
External IB4
Interface Connector
Location
Cable (6.5 feet)
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Page 29
29
Place USB Drive
Pouch Here
Place USB Drive
Pouch Here
Attaching the USB Drive Pouch to the System
The system is provided with a USB drive that contains the controller configuration files loaded into the
controller as shipped. Also provided on the USB drive is a controller configuration drawing and all customer
documentation. The USB drive is to be stored in the pouch provided. The pouch needs to be attached to the
system or near the system by the customer.
Systems with a 5” Front Projection Mounting
Procedure
1. Attach the pouch to the system in the location shown in Figure 13.
2. Make sure the surface is clean, then peel the backing of the pouch fastener and adhere it to the surface.
3. Attach the pouch to the pouch fastener to secure the pouch to the system.
Figure 13:
Attaching the USB Drive Pouch to a System with a 5” Front Projection Mounting
Systems with 23” Mounting
Procedure
1. Attach the pouch to the system in the location shown in Figure 14.
2. Make sure the surface is clean, then peel the backing of the pouch fastener and adhere it to the surface.
3. Attach the pouch to the pouch fastener to secure the pouch to the system.
Figure 14:
Attaching the USB Drive Pouch to a System with 23” Mounting
Systems with Flush Front Mounting
Procedure
1. Customer must choose a location near the system to attach the USB drive pouch to.
2. Make sure the surface is clean, then peel the backing of the pouch fastener and adhere it to the surface.
3. Attach the pouch to the pouch fastener to secure the pouch to the system.
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Page 30
30
A CA
N
termination plug
(P/N 548398) must be
installed if an external
device or system is not
connected here.
System Interface Board
Rear
Rear
The IB2 Controller Interface Board
OR
The IB4 Second Controller Ethernet Port Board
Can Be Installed in the Distribution Unit
Slide Out Tray with
IB2 Board Installed
Slide Out Tray with
IB4 Board Installed
System
Interface
Board
10M Ethernet
Port (RJ-45)
LAN Connection
10M Ethernet
Port (RJ-45)
LAN Connection
USB-B Port
(Factory connected
to NCU Controller
backplane.)
USB-B Port
(Customer connected
to NCU Controller.)
USB-A Port
(not used)
USB-A Port
(not used)
Internal
IB4 Board
External
IB4 Board
IB2 Board
SETTING JUMPER AND SWITCH OPTIONS
Circuit Card Locations
Refer to Figure 15.
Figure 15:
Circuit Card Location
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31
Jumper Settings on the System Interface Circuit Card
Perform the following procedure to make the required setting per your site requirements.
This procedure can also be used to make adjustment on a replacement circuit card.
Controller Power Option
This option allows the controller to remain powered if a battery LVD is furnished and it opens. The controller is
powered from the internal “system” bus. Rectifiers and battery are connected to this “system” bus, so the
controller is powered both by the rectifiers and by the battery. A jumper option allows the controller to be
powered from the “system side” of a battery LVD contactor (if furnished) or the “battery side” of a battery LVD
contactor (if furnished). Refer to Figure 16 for circuit card location and jumper location.
• Jumper in “No Battery Power” Position: The controller is powered from the “system side” of a battery
LVD contactor (if furnished). Note if a battery LVD contactor is not furnished, the controller is powered
by both rectifiers and battery. If a battery LVD contactor is furnished and opens, the controller is
powered by the rectifiers (if functional).
If you lose AC power and your BLVD opens, the controller will shut down.
• Jumper in “Battery Power” Position: The controller is powered from the “battery side” of a battery LVD
contactor (if furnished). Note if a battery LVD contactor is not furnished, the controller is powered by
both rectifiers and battery. If a battery LVD contactor is furnished and opens, the controller is powered
by the battery and the battery will drain. The controller’s power consumption is 5W.
If you lose AC power and your BLVD opens, the controller will continue to operate.
Procedure
1. Refer to Figure 16 and place the jumper on J4 in the “Battery Power” or “No Battery Power” position.
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32
R
e
a
r
System
Interface
Board
A CAN termination plug
(P/N 548398) must be
installed if an external
device or system is not
connected here.
System Interface Board
1 2 3
J3
Wire Size Capacity: 16 AWG to 30 AWG.
Wire Strip Length: 0.32 inch.
Recommended Torque: 2.3 in-lbs.
No
Battery
Pwr
Battery
Pwr
Shorting
Jumper
J4
Selects to power controller
from “Battery Power” or not
if a battery LVD contactor is furnished.
J4
1 2 3
System Temp 1
System Temp 2
Ext. Load CBA / FA
CAN Port
(RJ-45)
H1
J1
J2
J3
J4
J7
J8
R1
R2
R3
1
1
1
1
BATT
PWR
562209
0 0 0 X X X X X
A X X X XX X X X
System Interface Board P/N 562209
Figure 16:
System Interface Board Jumper Location and Settings
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33
IB2
OFF
OFF
Switch Settings on the IB2 (Controller Interface Board) (if furnished)
Perform the following procedure to verify the factory setting.
This procedure can also be used to make adjustment on a replacement circuit card.
Communications Addressing
Dip Switch SW1 on the IB2 board is used to set the communications address for this board. Refer to Table 1 for
SW1 settings. Refer to Figure 17 for circuit card location and SW1 location.
Procedure
1. Ensure SW1 is set per Table 1. Refer to Figure 17 for location.
Table 1:
IB2 Controller Interface Board Switch Settings
DIP Switch SW1
Setting
1 2
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Page 34
34
Switch SW1 is located in
this corner of the IB2
circuit card.
Rear
The IB2 Controller Interface Board
OR
The IB4 Second Controller Ethernet Port Board
Can Be Installed in the Distribution Unit
Slide Out Tray with
IB2 Board Installed
Setting
DIP Switch SW1
1 2
IB2 OFF OFF
ON
OFF
1 2
SW1
SW1
In this system, switch settings
must be in positions shown.
IB2 (Controller Interface Board)
-
J12
8 7 6 5 4 3
2 1
RELAYRELAY
SW1
7
J2
J11
5 3
1
Relay Output Terminal Blocks Digital Input Terminal Blocks
J9 J8 J7 J6 J5 J4
8 6 4
2
J3
8 6 4 2
8 7 6 5 4 3 2 1
+
NO C NCNO C NC
NO
C
NCNO
C
NC
NO
C NCNO C NC
NO
C
NCNO
C
NC
NO
C NCNO C NC
NO
C
NC
NO
C
NC
NO
C NCNO C NC
NO
C
NCNO
C
NC
5 3 1
46 2
5 3 1
46 2
5 3 1
46 2
5
3
1
46 2
5 3 1
46 2
5 3 1
46 2
5
3
1
46 2
Input
No. (
–
)
Input
No. (+)
8 7 6 5 4 3
2 1
ONOFF
1
2
Figure 17:
IB2 Controller Interface Board Switch Location and Settings
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35
Burndy:
Burndy:
Burndy:
MAKING ELECTRICAL CONNECTIONS
Important Safety Instructions
DANGER! Adhere to the “Important Safety Instructions” presented at the front of this document.
Wiring Considerations
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 wire size, branch circuit protection, crimp lug, and general wiring recommendations; refer to System
Application Guide SAG582137200.
Lugs should be crimped per lug manufacturer’s specifications.
Refer to Table 2 for supplemental lug crimping information when using the special application crimp lug / strap
combination.
Table 2:
1
manufacturer’s instructions furnished with the crimp tool or lug.
Supplemental Lug Crimping Information when Using the Special Application Crimp Lug / Strap
Combination
Crimp Tool Required1,
T&B Model TBM12 or TBM15
Hydraulic Heads
Crimp Lug Part No.
Color
Key
245393500
245393600
245393700
245393800
The lugs should be crimped to the specifications given in the
YA25L-4TCG1
YA26L-4TCG1
Burndy:
YA27L-4TCG1
YA28L-4TCG1
Pink 42H 15508
Black 45 15526
Orange 50 15530
Purple 54H 15511
Die
Index/
Code No.
Die Cat.
Number
Relay Rack / Cabinet Frame Grounding Connection
For relay rack / cabinet frame grounding requirements, refer to the current edition of the American National
Standards Institute (ANSI) approved National Fire Protection Association's (NFPA) National Electrical Code
(NEC), applicable local codes, and your specific site requirements.
Attach a customer grounding network lead to the equipment mounting rack per site requirements. Holes are
provided on the top of each relay rack for installing a lead with a two-hole lug that has 1/4" bolt clearance holes
on 5/8" centers. When using 1/4-inch hardware, recommended torque is 84 in-lbs. when a standard flat washer
and lock washer are used. Refer to Figure 18 for locations.
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Page 36
36
Frame Ground
Connection Point
(1/4” clearance holes on 5/8” centers)
Frame Ground
Connection Point
(1/4” clearance holes on 5/8” centers)
Top View
(Typical Relay Rack)
Top View
(Typical Relay Rack)
NOTE!
NOTE!
(DC-I).
NOTE!
Figure 18:
Relay Rack Frame Grounding Connection Points
REMOVE TAPE FROM HOLE LOCATIONS BEFORE INSTALLING LUG
The DC return connection to this system can remain isolated from system frame and chassis
This system is suitable for installation as part of the Common Bonding Network (CBN).
System Shelves Frame Grounding Connection
For shelf grounding requirements, refer to the current edition of the American National Standards Institute
(ANSI) approved National Fire Protection Association's (NFPA) National Electrical Code (NEC), applicable local
codes, and your specific site requirements.
NOTE!
(DC-I).
NOTE!
Relay or Cabinet Rack Procedure
1. The frame grounding connection to the shelf is made by using grounding washers with the mounting
hardware used to secure the shelf to the relay rack or cabinet. Refer to “Securing the System to a Relay
Rack or a Cabinet Equipment Rack (if required)” on page 15. Ensure that the relay rack or cabinet is
properly grounded.
NOTE!
required. Refer to
The DC return connection to this system can remain isolated from system frame and chassis
This system is suitable for installation as part of the Common Bonding Network (CBN).
M4 frame ground studs are located on the rear of the system shelf. Provide a grounding lead, if
Figure 19
for location.
Wall Mounting Procedure
1. M4 frame ground studs are located on the rear of the system shelf. Refer to Figure 19 for location.
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Page 37
37
Groun
d St
uds
2. Frame ground studs (1/4-20) are located on the horizontal wall mounting bracket. Refer to Figure 5 and
Figure 6 for location.
Figure 19:
System Shelves Frame Grounding Connection Points
M4
Shel
f Fr
ame
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38
Central Office Ground Connection
Landing points are provided on the battery return bus for a central office ground lead (see Figure 31, Figure 32,
or Figure 33). For central office grounding requirements, refer to the current edition of the American National
Standards Institute (ANSI) approved National Fire Protection Association's (NFPA) National Electrical Code
(NEC), applicable local codes, and your specific site requirements.
Rectifier Nominal 120 VAC / 208 VAC / 240 VAC Input and AC Input Equipment Grounding Connections
DANGER! Adhere to the “Important Safety Instructions” presented at the front of this document.
General
The system is equipped with plug-in AC input connectors located on the front or rear of the system. Mating
connectors and cable assemblies or line cords are available (see SAG582137200).
Each List 01 shelf requires two (2) AC input cable assemblies or line cords. Each feeds two (2) rectifiers.
Each List 02 shelf requires three (3) AC input cable assemblies or line cords. Two feed two (2) rectifiers, the
other one (1) rectifier.
NOTE!
This system may also be hardwired into an AC distribution center of an OSP cabinet. Refer to
the cabinet documentation for rectifier AC wiring.
Wiring Considerations
Refer to SAG582137200 for AC input cable assembly and line cord options and recommended branch circuit
protection.
Front AC Input Connections Option
AC input connections are made using the AC input cable assemblies or line cords ordered with the system.
These are connected to the plug-in Molex connectors located on the side of the shelf. Connect the other end
of the AC input cable assemblies or line cords to a properly wired AC outlet or distribution box. Refer to Figure
20.
NOTE!
Front AC input connectors are not available for a List 02 Expansion Shelf.
Rear AC Input Connections Option
AC input connections are made using the AC input cable assemblies or line cords ordered with the system.
These are connected to the plug-in Molex connectors located on the rear of the shelf. Connect the other end
of the AC input cable assemblies or line cords to a properly wired AC outlet or distribution box. Refer to Figure
21.
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Page 39
39
AC Input
Cable Assembly
AC Input
Line CordList 01 Shelf:
AC input connections are
made using the supplied
AC input cable assemblies
or line cords connected here.
Rectifiers are numbered left to
right as viewed from the front.
Nominal
120 VAC / 208 VAC / 240 VAC
AC Input for Main Shelf
Rectifier Module #1 and #2
Nominal
120 VAC / 208 VAC / 240 VAC
AC Input for Main Shelf
Rectifier Module #3 and #4
* Color of AC input cable
assembly or line cord lead.
Front
Front View AC Connectors for List
01 Shelf
L2-N Blue* White*
Ground Green/Yellow* Green*
L1 Brown* Black*
535232 unterminated
553202 unterminated
545252 L5-30P
540946 L6-30P
545616 L6-30P
547525 L5-30P
559301 L6-30P
559302 L6-30P
559842 L6-30P
548196 IEC320 C20
Part Number Customer End
AC Input Cable Assembly / Line Cords
Rectifier AC Input
Rectifier AC Input
Rectifier AC Input
Terminal G
(Green Wire)
Terminal Y
(Black Wire)
Terminal X
(White Wire)
L6-30P
Plug End
(208 VAC / 240 VAC, 30 A)
Terminal G
(Green Wire)
Terminal Y
(Black Wire)
Terminal X
(White Wire)
L5-30P
Plug End
(120 VAC, 30 A)
Green Wire
Black Wire
White Wire
IEC320 C20
Plug End
(16 A @ 250 VAC [international rating],
20 A @ 250 VAC [US rating])
List 01 Shelf
List 02 Shelf
Figure 20:
Front AC Input Connections
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Page 40
40
AC I
npu
t
Cable
Ass
embly
AC Input
Line Cord
Nom
inal
120 VAC / 208 VAC / 240 VAC
Rectifier AC I
nput
* C
olo
r of
AC i
nput
cable
assemb
ly o
r lin
e co
rd lead.
R
ear
Vie
w
L2-NBl
ue*W
hite*
GroundGreen/Yellow*Green*
L1B
row
n*Bl
ack
*
Re
ctif
ier
s ar
e nu
mbe
red l
eft
to
ri
ght
as v
iew
ed fr
om t
he fr
ont
.
Li
s
t 01 Main Shelf
Module #1 and #2
L
ist
02
Expansion Shelf
Module #1 and #2
List 02
Exp
ans
ion S
hel
f
Mo
dule
#3 a
nd #
4
Lis
t 02
Expan
s
io
n
Sh
el
f
Modul
e #5
L
is
t 0
1
Ma
in
S
helf
Module #3 and #4
Li
s
t 0
1 S
h
el
f:
A
C i
n
pu
t
co
nn
e
ct
io
n
s a
re
made using the supplied
AC
i
np
u
t c
ab
l
e a
ss
e
mb
li
e
s
or
l
in
e
co
rd
s
co
nn
e
ct
ed
h
er
e.
L
ist
02 Sh
elf
:
AC input connec
ti
on
s
ar
e
made using the su
pplie
d
AC input cable ass
embl
ies
o
r line cords con
nect
ed h
ere
.
Rear
List 01 She
l
f
L
ist 02 Shel
f
53
5232 untermi
nate
d
553202 unterminated
545252 L5-30P
54
094
6 L6-30P
545
616 L6
-30P
547525 L5-30P
559301 L6-30P
5
59302 L6-30P
5
598
42 L6-30P
548
196 IEC320 C20
Pa
rt N
umbe
r Cu
stomer
End
AC I
npu
t Ca
ble
Assembly / L
ine
Cor
ds
Rectifier AC Input
Rectifier AC Input
Rectifier AC Input
Ter
mina
l G
(Gre
en Wire)
Term
inal Y
(Black Wir
e)
Termi
nal X
(W
hite Wire
)
L6-30P
Plug End
(208 VAC
/ 240 VAC
, 30 A)
T
ermina
l G
(G
reen Wire)
Terminal Y
(Black Wire)
Terminal X
(White W
ire)
L5-30P
Plug End
(120 VAC, 30 A)
Green Wire
Black Wire
White Wire
IE
C320 C20
Plug End
(16 A @ 250 VAC [international rating],
20 A @ 250 VAC [US rating])
Figure 21:
Rear AC Input Connections
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Page 41
41
A
CAN termination plug
(P/N 548398) must be
installed if an external
device or system is not
connected here.
System Interface Board
Rear
Rear
The IB2 Controller Interface Board
OR
The IB4 Second Controller Ethernet Port Board
Can Be Installed in the Distribution Unit
Slide Out Tray with
IB2 Board Installed
Slide Out Tray with
IB4 Board Installed
System
Interface
Board
10M Ethernet
Port (RJ-45)
LAN Connection
10M Ethernet
Port (RJ-45)
LAN Connection
USB-B Port
(Factory connected
to NCU Controller
backplane.)
USB-B Port
(Customer connected
to NCU Controller.)
USB-A Port
(not used)
USB-A Port
(not used)
Internal
IB4 Board
External
IB4 Board
IB2 Board
External Alarm, Reference, Monitoring, and Control Connections
Circuit Card Locations
Refer to Figure 22.
Figure 22:
External Alarm, Reference, Monitoring, and Control Circuit Card Locations
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42
RS-485 Connection (used for Communication with SM Modules)
The RS-485 connector is located near the IB4 or IB2 board. It is a dangling connector with a red and black wire
harness.
• Red Wire (Pin 1): RS485+
• Black Wire (Pin 2): RS485-
Use cable P/N 547674 to interface with SM-AC, SM-BAT, SM-RC, or SM-IO supervisory modules.
Temperature Probes
NOTE!
Each temperature probe consists of two or three pieces that plug together to make a complete
probe. See SAG582137200 for part numbers and descriptions.
Two temperature probes can be connected to the System Interface Board. See Figure 23.
Two temperature probes can be connected to the IB2 (Controller Interface Board), if furnished. See Figure 27.
Any combination of the temperature probes can be programmed to monitor ambient temperature and/or
battery temperature. A temperature probe set to monitor battery temperature can also be used for the rectifier
battery charge temperature compensation feature, or the battery charge temperature compensation feature
can be programmed to use the average or highest value of all battery temperature probes. The battery charge
temperature compensation feature allows the controller to automatically increase or decrease the output
voltage of the system to maintain battery float current as battery temperature decreases or increases,
respectively. Battery life can be extended when an optimum charge voltage to the battery with respect to
temperature is maintained. A temperature probe set to monitor battery temperature can also be used for the
BTRM (Battery Thermal Runaway Management) feature. The BTRM feature lowers output voltage when a high
temperature condition exists to control against battery thermal runaway.
The temperature sensor end of the probe contains a tab with a 5/16” clearance hole for mounting.
A temperature probe programmed to monitor battery temperature should be mounted on the negative post of
a battery cell to sense battery temperature. A temperature probe used for battery charge temperature
compensation and/or BTRM (Battery Thermal Runaway Management) should also be mounted on the negative
post of a battery cell. A temperature probe programmed to monitor ambient temperature should be mounted
in a convenient location, away from direct sources of heat or cold.
System Interface Circuit Card Connections (if required)
The system interface circuit card provides connections for the following. Refer to Figure 22 for circuit card
location. Refer to Figure 23 for connections details.
• Temperature Probes (see “Temperature Probes” starting on page 42)
• NCU CAN Port (see “Connecting a Device or System to the NCU CAN Bus (if required)” starting on page
54)
• External Load and Battery Circuit Breaker / Fuse Alarm Circuits
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R
ear
System
Interface
Board
A CAN termination plug
(P/N 548398) must be
installed if an external
device or system is not
connected here.
System Interface Board
1 2 3
No
Battery
Pwr
Battery
Pwr
Shorting
Jumper
J4
Selects to power controller
from “Battery Power” or not
if a battery LVD contactor is furnished.
J4
1 2 3
System Temp 1
System Temp 2
CAN Port
(RJ-45)
H1
J1
J2
J3
J4
J7
J8
R1
R2
R3
1
1
1
1
BATT
PWR
562209
0 0 0 X X X X X
AX X X X X X X X
System Interface Board P/N 562209
J3
Wire Size Capacity: 16 AWG to 30 AWG.
Wire Strip Length: 0.32 inch.
Recommended Torque: 2.3 in-lbs.
Ext. Load CBA / FA
Figure 23:
System Interface Circuit Card Connections
External Battery Circuit Breaker Alarm Connections
Circuit Breaker Alarm Connections to External Battery Disconnect Unit
Connect the circuit breaker alarm lead from an optional external battery disconnect unit to terminal 1 of J3
located on the System Interface Board. Refer to Figure 24.
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Circuit Breaker Alarm Connections to Battery Disconnect Circuit Breakers on Battery Trays
Connect the circuit breaker alarm lead from an optional battery tray to terminal 1 of J3 located on the System
Interface Board. Refer to Figure 25.
Circuit Breaker Alarm Connections to Battery Disconnect Circuit Breakers on Battery Cabinets
Connect the circuit breaker alarm lead from an optional battery cabinet to terminal 1 of J3 located on the
System Interface Board. Refer to Figure 26.
IB2 (Controller Interface Board) Connections (if furnished)
NOTE!
The distribution unit can contain either an IB2 board or an internal IB4 board, not both.
The IB2 (Controller Interface Board) provides connection points for digital inputs, programmable relay outputs,
and temperature probes. The IB2 interface board is mounted inside the distribution unit. A slide out tray is
provided on the rear of the distribution unit to access the circuit card. Refer to Figure 22.
Digital Inputs and Programmable Relay Outputs
Digital input and relay output leads are connected to screw-type terminal blocks located on the IB2.
Recommended torque for these connections is 2.2 in-lbs. Refer to Figure 27 for terminal locations. Refer to
Table 3 and Table 5 for pin-out information.
NOTE!
digital inputs and another set for the relay outputs. Refer to
Two sets of alarm cables are available (see SAG582137200 for part numbers). One set for the
Table 3
and
Table 5
for color scheme. If
the relay outputs alarm cable or digital inputs alarm cable is ordered, one half is factory connected in the
distribution unit. The other half has a mating connector on one end and is un-terminated on the other
end.
CAUTION! All conductors in this harness may be connected within the shelf. Shorting or grounding of
unused conductors may result in service interruption or equipment damage. Therefore insulate all
conductor ends not being used in your application.
Digital Inputs
Connect up to eight (8) digital inputs to the IB2. Note that you must supply both paths for the digital input
(either a positive or a negative signal and the opposite polarity return path). Observe proper polarity. Refer to
Figure 27 for terminal locations and Table 3 for pin-out information.
The digital inputs can be programmed to provide an alarm when the signal is applied (HIGH) or removed
(LOW). Refer to the NCU Instructions (UM1M830BNA) for programming information.
Digital Input Ratings: Refer to the following.
a) Maximum Voltage Rating: 60V DC.
b) Active High: > 19V DC.
c) Active Low: < 1V DC.
The digital inputs may be preprogrammed for specific functions. Refer to the configuration drawing (Cdrawing) supplied with your system for your system’s specific configuration.
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ESTOP Function
If an ESTOP switch is wired to the IB2-1 Controller Interface Board, customer-furnished system ground applied
to terminal DI8+ activates the ESTOP function. The ESTOP function shuts down and locks out the rectifiers
and opens the optional low voltage disconnect (LVD) contactors (battery and load type). If the system has
battery connected and does not contain a battery LVD or the controller power option is set to Battery Pwr
(jumper J4 on the system interface board is set to Battery Pwr), the controller will remain operational. If the
system does not contain battery or load LVD(s) and has battery connected, the loads will be sustained by the
battery voltage.
For Systems NOT Containing a Battery LVD: When the ESTOP signal is removed, LVD contactors (battery and
load type) will close after the “LVD Reconnect Delay” has elapse (customer configurable via the controller) if
battery voltage is present on the bus. Rectifiers will remain off. The rectifiers will restart when the input power
is removed and restored after 30 seconds or more (until the LEDs on the modules extinguish).
For Systems Containing a Battery LVD: When the ESTOP signal is removed, LVD contactors (battery and load
type) will remain open. Rectifiers will remain off. The rectifiers will restart when the input power is removed and
restored after 30 seconds or more (until the LEDs on the modules extinguish). When the rectifiers restart, LVD
contactors (battery and load type) will close after the “LVD Reconnect Delay” has elapse (customer
configurable via the controller).
NOTE!
If a customer-furnished method to disconnect the input power to the system is not provided, the
rectifiers will stay locked OFF until the input power is recycled. If the ESTOP signal is removed without
recycling the input power, the rectifiers will remain off and have a local alarm visible on the module. The
ESTOP alarm from the controller will extinguish. The controller will not issue an alarm for this condition.
Programmable Relay Outputs
The IB2 provides eight (8) programmable alarm relays with dry Form-C contacts. Connect up to eight (8) relay
outputs to the IB2. Refer to Figure 27 for terminal locations and Table 5 for pin-out information.
Refer to the NCU Instructions (UM1M830BNA) for programming information.
Relay Ratings: Refer to the following.
a) Steady State: 0.5 A @ 60V DC; 1.0 A @ 30V DC.
b) Peak: 3 A @ 30V DC.
The relays may be preprogrammed for specific functions. Refer to the configuration drawing (C-drawing)
supplied with your system for your system’s specific configuration.
Temperature Probes
See “Temperature Probes” starting on page 42.
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Yellow Alarm Lead
(P/N 535294)
(factory wired to
circuit breaker
alarm terminal)
Torque to 84 in-lbs
using supplied hardware
To
Power
System
To
Battery
Procedure
1. Connect YELLOW lead exiting top of
Battery Disconnect Unit to terminal
1 of J3 located on the System Interface Board.
Remove quick connect terminal first.
The YELLOW lead is factory connected
to circuit breaker “C (Common)” alarm
terminal in the Battery Disconnect Unit.
2. There is NO connection to the circuit
breaker “NO (Normally Open)”
alarm terminal.
3. Connect loose end of Jumper factory
connected to bottom terminal on
circuit breaker to circuit breaker
“NC (Normally Closed)” alarm
terminal.
EXTERNAL BATTERY
DISCONNECT UNIT
(Side cover removed in illustration
to show wiring details.)
Alarm Wiring to a Single
External Battery Disconnect Unit
Remove quick connect
terminal first, then
connect wire to terminal
1 of J3 located on the
System Interface Board.
Figure 24:
Circuit Breaker Alarm Connections to External Battery Disconnect Unit (cont’d on next page)
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Yellow Jumper/Alarm
1st EXTERNAL BATTERY
Yellow Alarm Lead
alarm terminal.
Figure 24:
Circuit Breaker Alarm Connections to External Battery Disconnect Unit (cont’d from previous page)
Lead (P/N 524384)
(Ordered separately
and supplied loose.
by the customer to
each circuit breaker
alarm terminal)
see
previous
page
Must be wired
“C (Common)”
* No terminal
on 524384
jumper
Remove quick
connect terminal
first, then connect
wire to terminal 1
of J3 located on
the System
Interface Board.
previous
page
see
(P/N 535294)
(factory wired to
circuit breaker
alarm terminal)
REMOVE
COMPLETELY
FROM ALL BATTERY
DISCONNECT UNITS
AND DISCARD.
DISCONNECT UNIT
(Side cover removed in illustration
to show wiring details.)
Alarm Wiring to (2) to (3)
External Battery Disconnect Units
Procedure
1. Completely remove YELLOW lead exiting top of
ALL Battery Disconnect Units and discard.
2. Connect separately ordered YELLOW jumper/alarm
lead (P/N 524384) to circuit breaker “C (Common)”
alarm terminals in ALL Battery Disconnect Units.
Connect remaining end to terminal 1 of J3 located
on the System Interface Board.
see
previous
page
2nd EXTERNAL BATTERY
DISCONNECT UNIT
3rd EXTERNAL BATTERY
DISCONNECT UNIT
3. There is NO connection to the circuit
breaker “NO (Normally Open)”
alarm terminal.
4. In ALL Battery Disconnect Units,
connect loose end of Jumper factory
connected to bottom terminal on
circuit breaker to circuit breaker
“NC (Normally Closed)”
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Yellow Jumper/Alarm
1st EXTERNAL BATTERY
Yellow Alarm Lead
alarm terminal.
Figure 25:
Circuit Breaker Alarm Connections to Battery Disconnect Circuit Breakers on Battery Trays
Lead (P/N 524384)
(Ordered separately
and supplied loose.
by the customer to
each circuit breaker
alarm terminal)
see
previous
page
Must be wired
“C (Common)”
* No terminal
on 524384
jumper
Remove quick
connect terminal
first, then connect
wire to terminal 1
of J3 located on
the System
Interface Board.
previous
page
see
(P/N 535294)
(factory wired to
circuit breaker
alarm terminal)
REMOVE
COMPLETELY
FROM ALL BATTERY
DISCONNECT UNITS
AND DISCARD.
DISCONNECT UNIT
(Side cover removed in illustration
to show wiring details.)
Alarm Wiring to (2) to (3)
External Battery Disconnect Units
Procedure
1. Completely remove YELLOW lead exiting top of
ALL Battery Disconnect Units and discard.
2. Connect separately ordered YELLOW jumper/alarm
lead (P/N 524384) to circuit breaker “C (Common)”
alarm terminals in ALL Battery Disconnect Units.
Connect remaining end to terminal 1 of J3 located
on the System Interface Board.
see
previous
page
2nd EXTERNAL BATTERY
DISCONNECT UNIT
3rd EXTERNAL BATTERY
DISCONNECT UNIT
3. There is NO connection to the circuit
breaker “NO (Normally Open)”
alarm terminal.
4. In ALL Battery Disconnect Units,
connect loose end of Jumper factory
connected to bottom terminal on
circuit breaker to circuit breaker
“NC (Normally Closed)”
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Orange wire not used.
located on the System Interface Board.
Figure 26:
Yellow Jumper/Alarm
Lead (P/O Cabinet)
Circuit Breaker Alarm Connections to Battery Disconnect Circuit Breakers on Battery Cabinets
Remove quick connect
terminal first, then
connect wire to terminal
1 of J3 located on the
System Interface Board.
alarm
wire
1st BATTERY CABINET
BATTERY DISCONNECT
CIRCUIT BREAKER
2nd BATTERY CABINET
BATTERY DISCONNECT
CIRCUIT BREAKER
Alarm Wiring to Battery Cabinets
Procedure
1. Remove quick connect terminal from YELLOW battery
cabinet alarm lead and connect to terminal 1 of J3
alarm
wire
alarm
wire
3rd BATTERY CABINET
BATTERY DISCONNECT
CIRCUIT BREAKER
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* The controller relay assigned to “Critical Summary” alarm (relay 1 by default)
will operate in the “Fail Safe Mode”. “Fail Safe Mode” means Relay 1 is
de-energized during an alarm condition, opening the contacts between the
C and NO terminals, and closing the contacts between the C and NC terminals.
The controller’s remaining seven (7) relays energize during an alarm condition, closing
the contacts between the C and NO terminals, and opening the contacts between
the C and NC terminals.
Not all I/O points are available for customer connection (some are used for factory
system connections).
J3-J9:
Wire Size Capacity: 16 AWG to 26 AWG.
Wire Strip Length: 0.20 inch.
Recommended Torque: 2.2 in-lbs.
M
A4C
5U3
1
IB2
DI1-
DI1+
DI2-
DI2+
DI3-
DI3+
J3
J4
J5
J6
J7
J8
J9
DI4-
DI4+
DI5-
DI5+
DI6-
DI6+
DI7-
DI7+
DI8-
DI8+
DO1_NC
DO2_NC
DO1_COM
DO2_COM
DO1_NO
DO2_NO
DO3_NC
DO4_NC
DO3_COM
DO4_COM
DO3_NO
DO4_NO
DO5_NC
DO6_NC
DO5_COM
DO6_COM
DO5_NO
DO6_NO
DO7_NC
DO8_NC
DO7_COM
DO8_COM
DO7_NO
DO8_NO
J11 1
J11 2
J11 3
J12 1
J12 2
J12 3
2
4
3
1
J2
654321 654321 654321 654321 654321 654321 654321
STUPTUOYALER
STUPNILATIGID
Schematic
Diagram
of IB2
IB2 TEMP
PROBE 1
IB2 TEMP
PROBE 2
IB2 Assembly
IB2
(Controller
Interface
Board)
Connector
to Controller
IB2 Temp
Probe 1
IB2 Temp
Probe 2
-
J12
RELAY
SW1
7
J2
J11
5 3
1
Relay Output Terminal Blocks Digital Input Terminal Blocks
J9 J8 J7 J6 J5 J4
J3
8
6 4
2
8 7 6 5 4 3
2 1
+
NO
C
NC
NO C NC
NO
C
NC
NO C NC
NO
C
NC
NO C NC
NO
C
NC
NO C NC
5 3 1
46 2
5 3 1
46 2
5
3
1
46 2
5
3
1
46 2
5 3 1
46 2
5 3 1
46 2
5
3
1
46 2
Relay
No.
Relay
No.
Input
No. (
–
)
Input
No. (+)
8 7 6 5 4 3
2 1
ONOFF
1
2
Figure 27:
IB2 (Controller Interface Board) Connections
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Table 3:
Programmable Digital Inputs (Factory Default) – IB2
Programmable
Digital Input
1
2
3
4
5
6
7
IB2 Pin No. Digital Input Cable Color Scheme Dedicated to...
J3-2 + R-G
User Defined
J3-1 – G-R
J3-4 + R-O
User Defined
J3-3 – O-R
J3-6 + R-BL
User Defined
J3-5 – BL-R
J4-2 + W-S
User Defined
J4-1 – S-W
J4-4 + W-BR
User Defined
J4-3 – BR-W
J4-6 + W-G
User Defined
J4-5 – G-W
J5-2 + W-O
User Defined
J5-1 – O-W
J5-4 + W-BL
8
J5-3 –
Y
(factory wired)
Emergency Stop
(User Pre-Defined)
(see note below)
-- J5-5
Not Used Not Used
-- J5-6
CAUTION! All conductors in this harness may be connected within the cabinet. Shorting or grounding
of unused conductors may result in service interruption or equipment damage. Therefore, insulate all
conductor ends not being used in your application.
NOTE!
-48V is factory wired to the Digital Input #8 (-) terminal for your convenience and function
predefined for ESTOP. Customer-furnished system ground applied to terminal Digital Input #8 (+)
activates the ESTOP function. See ESTOP Function on page 45.
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Y
Table 4:
Programmable
Programmable Digital Inputs (Factory Default) – IB2, Special Application Cable P/N 545591
Special Application
Digital Input
IB2 Pin No.
Cable P/N 545591
Color Scheme
Dedicated to...
J3-2 + None
1
User Defined
J3-1 – None
J3-4 + None
2
User Defined
J3-3 – None
J3-6 + None
3
User Defined
J3-5 – None
J4-2 + Slate
4
User Defined
J4-1 – -48 VDC Applied Internally
J4-4 + Brown
5
User Defined
J4-3 – -48 VDC Applied Internally
J4-6 + Violet
6
User Defined
J4-5 – -48 VDC Applied Internally
7
User Defined
J5-1 – -48 VDC Applied Internally
J5-4 + None
J5-2 + Orange
8
J5-3 –
(factory wired)
Emergency Stop
(see note below)
J5-5
--
not used --
J5-6
CAUTION! All conductors in this harness may be connected within the cabinet. Shorting or grounding
of unused conductors may result in service interruption or equipment damage. Therefore, insulate all
conductor ends not being used in your application.
NOTE!
-48V is factory wired to the Digital Input #8 (-) terminal for your convenience and function
predefined for ESTOP. Customer-furnished system ground applied to terminal Digital Input #8 (+)
activates the ESTOP function. See ESTOP Function on page 45.
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53
NO
J6-5
W-BL
NC
J6-1
W-O
NO
J6-6
O-W
COM
J6-4
W-G
NO
J7-5
W-BR
NC
J7-1
W-S
NO
J7-6
S-W
COM
J7-4
R-BL
NO
J8-5
R-O
NC
J8-1
R-G
NO
J8-6
G-R
COM
J8-4
R-BR
NO
J9-5
R-S
NC
J9-1
BK-BL
Load Share Alarm
Table 5:
Relay Outputs (Factory Default) – IB2
NOTE!
the configuration drawing (C-drawing) supplied with your system for your system’s specific
configuration.
Programmable
Relay Output
1 *
2
3
4
The output relay configuration may not be set according to the factory default setting. Refer to
IB2
Pin No.
Alarm Cable
Color Scheme
Alarms Assigned to
this Relay (Default)
Alarms Assigned to
this Relay (Custom)
Any Critical Alarm COM J6-3 BL-W
Any Major Alarm
NC J6-2 G-W
DC Volt High #1 COM J7-3 BR-W
Batt Discharge
DC Volt Low #1
NC J7-2 BL-R
5
6
7
8
CAUTION! All conductors in this harness may be connected within the cabinet. Shorting or grounding
of unused conductors may result in service interruption or equipment damage. Therefore insulate all
conductor ends not being used in your application.
NC J8-2 BR-R
NO J9-6 BL-BK
COM J9-4 BK-O
NC J9-2 O-BK
DC Volt Low #2 COM J8-3 O-R
AC Failure
Fuse Alarm COM J9-3 S-R
Rect Not Respond
Rect HVSD
Rect AC Fail
Rect Failure
Rect Protect
Rect Fan Fail
Rect Derated
Rect Temp Alarm
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1
CAN L
TB1-5 (CAN L)
3
--
--
5
--
--
7
--
--
NOTE!
* The controller relay assigned to “Critical Summary” alarm (relay 1 by default) will operate in the
“Fail Safe Mode”. “Fail Safe Mode” means Relay 1 is de-energized during an alarm condition, opening the
contacts between the C and NO terminals, and closing the contacts between the C and NC terminals.
The controller’s seven (7) remaining relays energize during an alarm condition, closing the contacts
between the C and NO terminals, and opening the contacts between the C and NC terminals.
Connecting a Device or System to the NCU CAN Bus (if required)
A supporting device or system may be connected to the NCU CAN Port located on the System Interface Circuit
Card. Refer to Figure 22 for circuit card location. Refer to Figure 23 for connections details. Refer to Table 6
for pinouts. Refer also to the external device’s or system’s instruction manual.
General Procedure
1. Remove the CAN termination plug from the CAN Port connector (see Figure 23 for location). Connect
the device or system to the NCU Controller’s CAN port. Refer to Table 6 for pinouts. Ensure that the
last device on the controller’s CAN bus has a CAN termination plug. Refer also to the external device’s
or system’s instruction manual.
Optional SM-Temp Module Procedure
The analog output of the SM-Temp Module may be connected to an NCU temperature port input. In lieu of
connecting the analog output of the SM-TEMP module to an NCU temperature port input, the SM-TEMP
module can simply be connected at the end of the NCU CAN bus. Refer to the SM-Temp Module Instructions
(UM547490) for details.
Connecting the SM-Temp Module to the Controller’s CAN Bus
1. Remove the CAN termination plug from the CAN Port connector (see Figure 23 for location). Connect
the SM Temp Module CAN bus to the CAN Port connector using separately ordered SM-Temp CAN bus
interface cable (P/N 562868). Refer to Table 6 for pinouts. Ensure the last SM-Temp Module (or if only
one) has a CAN termination strap as shown in the SM-Temp Module Instructions (UM547490).
Table 6:
CAN Port Connections
Pin Number Function
NCU CAN
Port (RJ-45)
SM-Temp Module
CAN Port
Pin Number
2 CAN H TB1-3 (CAN H)
4 -- --
6 -- --
8 -- --
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NCU Controller Ethernet Connection (if required)
The NCU Controller provides a Web Interface via an Ethernet connection to a TCP/IP network. This interface
can be accessed locally on a computer or remotely through a network. An RJ-45 10BaseT jack is provided on
the front of the NCU for connection into a customer's network. This jack has a standard Ethernet pin
configuration scheme, twisted pair. Refer to Figure 28 for location and Table 7 for pin outs. Use shielded
Ethernet cable (grounded at both ends). Note that the NCU RJ-45 jack is connected to chassis ground. Refer
to the NCU Instructions (UM1M830BNA) for operational details.
NOTE!
You can access the Web pages of the power system locally by using a "crossover" or “straight”
cable connected directly between your PC and the NCU.
WARNING! The intra-building port(s) of the equipment or subassembly is suitable for connection to
intra-building or unexposed wiring or cabling only. The intra-building port(s) of the equipment or
subassembly MUST NOT be metallically connected to the interfaces that connect to the OSP or its
wiring. These interfaces are designed for use as intra-building interfaces only (Type 2 or Type 4 ports as
described in GR-1089-CORE, Issue 4) and require isolation from the exposed OSP cabling. The addition
of Primary Protectors is not sufficient protection in order to connect these interfaces metallically to OSP
wiring.
The intra-building port (RJ-45) of the equipment or subassembly must use shielded intra-building
cabling/wiring that is grounded at both ends.
Figure 28:
NCU Ethernet Port
NOTE!
If your system has an IB4 board, DO NOT connect your Local Area Network (LAN) to the NCU
front Ethernet port. See “NCU Controller Second Ethernet Port Connection (if IB4 board furnished)” on
page 56.
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56
1
Tx+
Write Signal +
3
Rx+
Read Signal +
4
--
no connection
6
Rx-
Read Signal -
Table 7:
NCU RJ-45 Ethernet Port Pin Configuration
Port Pin
Number
Name Definition
2 Tx- Write Signal -
5 -- no connection
7 -- no connection
8 -- no connection
NCU Controller Second Ethernet Port Connection (if IB4 board furnished)
NOTE!
The distribution unit can contain either an IB2 board or an internal IB4 board, not both.
Your system may be furnished with an internal IB4 board connected to the NCU backplane via a factory
furnished and connected cable. An external IB4 board kit is available. The IB4 board provides a second
Ethernet port. The Ethernet port located on the NCU Controller’s front panel can ONLY be used to connect a
computer directly to the NCU. The Ethernet port located on the IB4 board can be used to connect the NCU to
your Local Area Network (LAN).
NOTE!
If your system has an IB4 board, DO NOT connect your Local Area Network (LAN) to the NCU
front Ethernet port.
An RJ-45 10BaseT jack is provided on the IB4 board for connection into a customer's network. This jack has a
standard Ethernet pin configuration scheme, twisted pair. Refer to Figure 29 for location and Table 7 for pin
outs. Use shielded Ethernet cable (grounded at both ends). Note that the IB4 board’s RJ-45 jack is connected
to chassis ground. Refer to the NCU Instructions (UM1M830BNA) for operational details.
Default IB4 Ethernet Port Parameters
IPv4
IP Address: 192.168.1.2
Subnet Mask: 255.255.255.0
Default Gateway: 192.168.1.1
IPv6
IPv6 Address: 20fa:fffd:fffc:fffb:fffa:fff9:fff8:fff7
IPv6 Prefix: 0
IPv6 Gateway: 20fa:1:fffe:ffff:fffe:fffd:ffff:fffe
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The IB2 Controller Interface Board
OR
The IB4 Second Controller Ethernet Port Board
Can Be Installed in the Distribution Unit
Rear
Slide Out Tray with
IB4 Board Installed
10M Ethernet
Port (RJ-45)
LAN Connection
USB-B Port
(Factory connected
to NCU Controller
backplane.)
USB-A Port
(not used)
Internal
IB4 Board
10M Ethernet
Port (RJ-45)
LAN Connection
USB-B Port
(Customer connected
to NCU Controller.)
USB-A Port
(not used)
External
IB4 Board
WARNING! The intra-building port(s) of the equipment or subassembly is suitable for connection to
intra-building or unexposed wiring or cabling only. The intra-building port(s) of the equipment or
subassembly MUST NOT be metallically connected to the interfaces that connect to the OSP or its
wiring. These interfaces are designed for use as intra-building interfaces only (Type 2 or Type 4 ports as
described in GR-1089-CORE, Issue 4) and require isolation from the exposed OSP cabling. The addition
of Primary Protectors is not sufficient protection in order to connect these interfaces metallically to OSP
wiring.
The intra-building port (RJ-45) of the equipment or subassembly must use shielded intra-building
cabling/wiring that is grounded at both ends.
Figure 29: IB4 Board NCU Controller Second Ethernet Port
Control Bus Connections between Controller and System Shelves
General
Each system shelf in the system is daisy-chained to the controller. NCU CAN bus connectors are located at the
left and right rear of each rectifier shelf. These connectors are used to interconnect the shelf to the controller
and to other shelves.
Refer to Figure 30 for connector locations and an interconnect diagram. These connections are factory made
for shelves factory installed. For field expansion, the new shelf must be tied into the interconnect scheme as
shown in Power System User Instructions UM582137200.
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Components removed in
illustration for clarity only.
Distribution Unit
List 01 Main Shelf
Distribution Unit
List 01 Main Shelf
List 02 Expansion Shelf
Cable P/N 555716
Provided with
Expansion Shelf
(Field Installed)
Exploded View Shown to
Illustrate W ire Connections Only
Termination Resistor
P/N 548398
Termination
Resistor P/N
RPM628350/2
Distribution Unit
with List 01
Distribution Unit
with List 01 and 02
Termination Resistor
P/N 548398
These Are Factory
Connected Together
These Are Factory
Connected Together
These Are Factory
Connected Together
Connect
These
Together
DISCONNECT
These
Connectors
Termination
Resistor P/N
RPM628350/2
Figure 30:
Control Bus Connections between Controller and System Shelves
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Load Distribution Wiring, Input Battery Wiring, and CO Ground Wiring
WARNING! Check for correct polarity before making connections.
Load Distribution Wiring, Input Battery Wiring, and CO Ground Wiring To List BF and NF
Refer to Figure 31.
CO Ground Wiring
Refer to “Central Office Ground Connection” on page 38.
Load Distribution Wiring to GMT Fuse Blocks
Load and load return leads are connected to screw-type terminal blocks located on the front of the distribution
unit. Refer to Figure 31 for terminal block wire size capacity and recommended torque.
Input Battery Wiring
Input battery and battery return leads terminated in two-hole lugs are connected to threaded studs located on
the rear inside of the distribution unit. Refer to Figure 31 for stud size/spacing and recommended torque.
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Load Distribution Wiring, Input Battery Wiring, and CO Ground Wiring to List BC, LC, And NC
Refer to Figure 32.
CO Ground Wiring
Refer to “Central Office Ground Connection” on page 38.
Load Distribution Wiring to GMT Fuse Blocks
Load and load return leads are connected to screw-type terminal blocks located on the front of the distribution
unit. Refer to Figure 32 for terminal block wire size capacity and recommended torque.
Load Distribution Wiring to Distribution Circuit Breakers
Load distribution and load return leads terminated in two-hole lugs are connected to threaded studs located on
the front sides of the distribution unit. Refer to Figure 32 for stud size/spacing and recommended torque.
NOTE!
An insulated thin wall tool may be required to tighten these connections.
Input Battery Wiring
Input battery and battery return leads terminated in two-hole lugs are connected to threaded studs located on
the rear inside of the distribution unit. Refer to Figure 32 for stud size/spacing and recommended torque.
Load Distribution Wiring, Input Battery Wiring, and CO Ground Wiring to List BA And NA
Refer to Figure 33.
CO Ground Wiring
Refer to “Central Office Ground Connection” on page 38.
Load Distribution Wiring to GMT Fuse Blocks
Load and load return leads are connected to screw-type terminal blocks located on the front of the distribution
unit. Refer to Figure 33 for terminal block wire size capacity and recommended torque.
Load Distribution Wiring to Distribution Circuit Breakers
Load distribution and load return leads terminated in two-hole lugs are connected to threaded studs located on
the left front side (as viewed from the front) of the distribution unit. Refer to Figure 33 for stud size/spacing
and recommended torque.
NOTE!
An insulated thin wall tool may be required to tighten these connections.
Input Battery Wiring to Distribution Circuit Breakers
Input battery and battery return leads terminated in two-hole lugs are connected to threaded studs located on
the right front side (as viewed from the front) of the distribution unit. Refer to Figure 33 for stud size/spacing
and recommended torque.
NOTE!
An insulated thin wall tool may be required to tighten these connections.
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Components removed in
illustration for clarity.
List BF Shown, List NF Similar
-48 VDC SUPPLY GND RTN
Rear
Central Office Ground
Battery Return Bus
Battery Bus
Battery, Battery Return, CO Ground:
1/4-20 studs on 5/8” centers for
installation of customer provided
two-hole lugs.
Maximum Lug Width: 0.84 inches.
Hardware:
1/4-20 Hex Nut
1/4" Lock Washer
1/4" Flat Washer
Torque to 58 in-lbs.
Front
Load Return Leads
-48V Load Leads
-48 VDC Load Terminal Blocks:
Wire Size Capacity:
22 AWG to 12 AWG.
Recommended Torque:
4.4 in-lbs.
Load Return Leads
-48V Load Leads
Load Return Leads
-48V Load Leads
Load Return Leads
-48V Load Leads
Load Return Leads
-48V Load Leads
Load Return Leads
-48V Load Leads
Observe proper polarity
when making battery
and load connections.
WARNING!
Rear Cover
Remove the cutout to access
battery lug landing points.
Figure 31:
Load Distribution Wiring, Input Battery Wiring, and CO Ground Wiring (Lists BF and NF)
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Co
mp o
nent
s removed in
il l ustratio n for clari ty.
Li st BC S ho wn, List LC, NC S i mil a r
Rear
-48 VDC SUPP LY G ND RTN
Central O ffice Groun d
Batte ry Ret urn Bus
Batte ry Bu s
Batt
ery, Ba
ttery Return, CO Gro
und:
1/4-20 st udson 5/ 8” cent ersfor
in stallati o n of custo
me r provi de d
t
wo-ho l e l
ugs.
Ma xi m um Lu g Wid th: 0
.84 i nche s.
Hard
ware:
1/4 -20 Hex Nut
1/4 " Lo ck Washer
1/4 " Flat Washer
Torqu e to 58 in -lbs.
Observe pro pe r pol arity
when m aki n g ba tte ry
a
nd l
oad
con
necti ons.
WARNING!
-48 VDC L oa
d T er
mi n
al B
lo c
ks:
W
ire S
ize Ca pa ci ty:
22 AWG
to 12 A
WG.
Reco mm
ende d
Tor
que
:
4.
4 i n -lb s.
G
ND R
TN
Front Front
-48 VDC LO AD -48 VDC
LOAD
GND RTN
Load Bus
Load Bus
Load Return Bus
Load Return Bus
-48 VDC L oad , L oa d Ret urn:
1
/4
-
20 stu ds on 5/8” centersf or
in
st
a
ll
at
i
on
of
c
us
t
om
er provi ded
two-hol e l ug s.
Ma xi m um Lu g Wid th: 0 .47 in ches.
Hardwa re:
1/4 -20 Hex Nut
1/4 " Lo ck Washer
1/4 " Flat Washer
Torqu e to 58 in -lbs.
Lo
a
d D
is
t
ri
b
ut
io
n
Circu it Breakers
Load Di stribu ti o n
Circu it Breakers
Front
Loa
d R
et
ur
n L
e
ads
-48V L oa d Le ads
Load Return L ea ds
-48V L oa d Le ads
Rear Cover
Remove the cutout to access
battery lug landing points.
Figure 32:
Load Distribution Wiring, Input Battery Wiring, and CO Ground Wiring (Lists BC, LC and NC)
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Components removed in
illustration for clarity.
List BA shown, List NA similar.
Observe proper polarity
when making battery
and load connections.
WARNING!
-48 VDC Load Terminal Blocks:
Wire Size Capacity:
22 AWG to 12 AWG.
Recommended Torque:
4.4 in-lbs.
CO Ground:
1/4-20 studs on 5/8” centers for
installation of customer
provided two-hole lugs.
Maximum Lug Width: 0.84 inches.
Hardware:
1/4-20 Hex Nut
1/4" Lock Washer
1/4" Flat Washer
Torque to 58 in-lbs.
Rear
Central Office Ground
-48 VDC Load, Load Return,
Battery, Battery Return:
1/4-20 studs on 5/8” centers for
installation of customer
provided two-hole lugs.
Maximum Lug Width: 0.47 inches.
Hardware:
1/4-20 Hex Nut
1/4" Lock Washer
1/4" Flat Washer
Torque to 58 in-lbs.
Figure 33:
Load Distribution Wiring, Input Battery Wiring, and CO Ground Wiring (Lists BA and NA)
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Connecting to an Optional Battery Cabinet
NetSure™ 211BC Battery Cabinet, P/N 541434
Refer to the battery cabinet instructions (Section 6023).
NetSure™ 211BC Battery Cabinet, P/N 545534
Refer to the battery cabinet instructions (Section 6033).
NetSure™ 211BC Battery Cabinet, P/N 554631
Refer to the battery cabinet instructions (UM554631).
Installing and Connecting Batteries in an Optional List 93 or 94 Battery Tray (if furnished)
Important Safety Instructions
DANGER! Adhere to the “Important Safety Instructions” presented at the front of this document.
Battery Manufacturer Information
Refer to System Application Guide SAG582137200 for specifications and manufacturers of batteries that can be
installed in this power system. These are only suggested batteries. Other batteries may be used as approved
by your company.
Installing and Connecting Batteries
Procedure
Tray P/N 559806 is used in the following procedure. The procedure for all other available trays is similar.
NOTE!
Refer to
Figure 34
as this procedure is performed.
1. If Battery Trays are Equipped with a Circuit Breaker: Turn OFF the battery Disconnect circuit
breaker located on all battery trays. Refer to Figure 34 for locations. Follow local lockout/tagout
procedures to ensure circuit breakers remain in the off position during installation.
2. Remove the battery retention bracket as shown in Figure 34. To do so, remove the four 1/4-20 x 5/8”
bolts and associated washers.
3. Slide batteries into the tray, with the battery terminals toward the front as shown in Figure 34. Slide
batteries into the tray as far as they will go.
NOTE!
The battery retention bracket can be oriented two ways to accommodate batteries of different
lengths. A correctly oriented bracket will fit snuggly against the batteries. If your batteries require the
alternate bracket orientation shown in Detail A of
Figure 34
, remove and reinstall the bullet-shaped
spacers (trays P/N 559806 and 559807 only) as shown in Detail A before performing the next step.
4. Reinstall the battery retention bracket. The spacers on the bracket should separate the batteries from
each other. Secure with the hardware removed in a previous step. Refer to Figure 34 for washer
location.
NOTE!
The spacers on the bracket are used to accommodate the various sizes of batteries available.
Install or remove the spacers as required so that the batteries are tight in the battery tray.
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5. Connect three links supplied by the battery manufacturer between pairs of battery terminals as shown in
Figure 34. Use hardware furnished by the battery manufacturer. Torque hardware to battery
manufacturer’s recommendations.
6. Ensure the battery cable ends in all trays are insulated with sleeving before performing the next step.
DANGER! In multiple-tray installations, when batteries in one tray are connected, the battery cables in
all trays will be energized. Remove sleeving from and connect one cable at a time. Do not allow a cable
end to contact the battery tray or equipment rack.
WARNING! In the next step, observe correct polarity. Connect only cables labeled “+” to battery
terminals labeled “+”. Likewise, connect only cables labeled “–” to battery terminals labeled “–”.
7. Connect the cables found in the battery tray to the battery terminals, “+” to “+” and “–” to “–”. Observe
correct polarity. Refer to Figure 34. Secure with hardware furnished with the battery. Torque hardware
to battery manufacturer’s recommendations.
8. Repeat steps 1 through 7 for any remaining battery trays.
9. If Battery Trays Are Equipped With a Circuit Breaker: To connect the batteries to the power system,
turn ON the battery disconnect circuit breaker located on all battery trays.
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Note:
1. Two trays shown as example.
2. Cabling detail omitted.
Connect POS (+)
Battery Cable
to this Terminal
Spacers Separate
Batteries (3 places
per tray, front and
back)
Battery Retention
Bracket. See Detail A
for alternate orientation.
1/4-20 X 5/8” Bolt
1/4” Ground Washer
(1 place)
1/4-20 X 5/8” Bolt
1/4” Lock Washer
1/4” Flat Washer
(3 places)
Connect Link Furnished
with Battery to these
Two Terminals
If trays are
equipped with
circuit breakers,
TURN OFF ALL
circuit breakers
before installing
and connecting
any batteries!
Connect NEG (-)
Battery Cable
to this Terminal
Connect Link Furnished
with Battery to these
Two Terminals
Connect Link Furnished
with Battery to these
Two Terminals
DETAIL A
Alternate Orientation
of Retention Bracket
Spacer (3 Places)
No. 10 Lock Washer (3 Places)
10-32 x 1/2" Pan Head Screw (3 Places)
No. 10 Flat Washer (3 Places)
1/4" Ground
Washer
(1 Place)
1/4-20 x 5/8" Hex
Head Screw
(4 Places)
1/4-20 Lock Washer
(3 Places)
1/4-20 Flat Washer
(3 Places)
Figure 34:
List 93 and 94 Battery Tray Battery Installation Details
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INSTALLING RECTIFIER MODULES
Refer to the rectifier instruction manual 1R482000E3 for a rectifier installation procedure.
INITIALLY STARTING, CONFIGURING, AND CHECKING SYSTEM OPERATION
CAUTION! Performing various steps in the following procedures may cause a service interruption
and/or result in the extension of alarms. Notify any appropriate personnel before starting these
procedures. Also, notify personnel when these procedures are completed.
Initial Startup Preparation
• Ensure that all blocks (except the last one) in the “Installation Acceptance Checklist” on page 11 have
been checked.
• Ensure that rectifier mounting positions are filled by a rectifier module or a blank panel as required.
• Refer to the separate NCU User Manual supplied with your power system for complete controller
operating information.
• Refer to the configuration drawing (C-drawing) supplied with your power system documentation for
factory settings of adjustable parameters.
Initially Starting the System
Procedure
1. Apply battery power to the system by closing the external battery disconnect(s) or protective device(s)
that supplies battery power to the system, if furnished. Close the system’s internal battery disconnect
circuit breakers, if furnished.
2. Apply rectifier AC input power to the system by closing ALL external AC disconnects or protective
devices that supply rectifier AC power to the rectifier mounting shelves. Rectifiers automatically start.
3. Place each distribution circuit breaker (if furnished) to the ON position.
NCU Controller Initialization
Refer to the NCU Instructions (UM1M830BNA) for detailed instructions.
Refer to Figure 35 for locations of the NCU local indicators and navigation keys.
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M830B
Critical or Major
Alarm Indicator
(Red)
Minor Alarm
Indicator (Yellow)
USB
Port
10/100M Ethernet
Port (RJ-45)
Menu
Navigation
Keys
Status
Indicator
(Green)
ENT
ESC
ATIS
label
Figure 35:
NCU Local Indicators and Navigation Keys
Procedure
NOTE!
illuminate on the NCU front panel and an audible alarm may sound. Disregard all alarms. An audible
alarm can be silenced at any time by momentarily depressing the ENT key on the NCU Controller.
The initialization routine takes several minutes. During that time various alarm indicators may
1. After the NCU is powered on, the display shows the logo screen. The controller is initializing.
2. When initialization is complete, the language screen appears. Press the UP or DOWN arrow key to
select the desired language. Press the ENT key to confirm the selection.
3. The Main Menu displays. See Figure 36.
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Graphics
Menu Name
Description
Alarm
(Green - No Alarm)
(Red - Alarm)
View active alarms and
alarm history.
Settings
Gain access to the NCU
Controller’s settings menus.
Input Power
View AC, Solar, DG, and
Wind related information.
Module
View rectifier, solar converter,
and converter module
related information.
DC
View DC equipments
related information.
Battery
View battery related
information.
To reboot the Controller, from the Main Menu press the ENT and ESC
keys at the same time. Release both keys. Press ENT to confirm.
Date and time are
alternately displayed.
Green - No Alarm
Red - Alarm
Main Menu
Sys Cap Used: 22.3 %
The number in ( ) indicates
the total number of alarms.
Press the UP and DOWN keys to highlight
the desired Menu graphic in the Main Menu.
Press the ENT key to enter the selected menu.
Figure 36:
NCU Local Display Main Menu
NOTE!
“Sys Cap Used” is based on the number of installed rectifiers and solar converters (if furnished).
4. System information is displayed in multiple screens. Press the ESC key to view other system
information. Press the down arrow key to view the next screen. Press the ESC key to return to the Main
Menu.
5. From the Main Menu, press the UP and DOWN keys to highlight the desired Menu graphic in the Main
Menu. Press the ENT key to enter the selected menu.
NOTE!
the Main Menu appears.
6. Refer to the following procedures to verify and set the NCU controller as required for your application.
Repeatedly press the “ESC” key to return in reverse order level by level from any submenu until
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Verifying and Setting the NCU Controller as Required for Your Application
Refer to the NCU Instructions (UM1M830BNA) for additional information.
Temperature Probes: Depending on if NCU temperature probe inputs are enabled or disabled in the NCU
configuration, you may have to program the NCU for any temperature probes being used. Note that some
temperature probe inputs may not be enabled by default. Refer to the C-drawing supplied with your system to
determine if temperature probe inputs are enabled and pre-programmed. Refer to “Setting Temperature
Sensors” in the “Common Tasks Performed via the Local Keypad and/or Web Interface” section of the NCU
controller manual (UM1M830BNA) if temperature probe inputs require programming.
NOTE!
Verify the NCU temperature probe configuration if temperature probes are installed from the
factory. Refer to the C-drawing supplied with your system.
Refer also to “NCU Start Wizard” on page 70.
NOTE!
When setting total rectifier current limit, the set point to each unit is the total set point divided
by the number of units. For example, if the system contains five rectifiers and the current limit is set to
150 amps then each rectifier has a current limit set point of 30 amps. If one or more rectifiers are
removed or fails it will take several seconds for the individual set points to the remaining rectifiers to be
reset. In the example given, if one rectifier is removed the current limit set point will drop to 120 amps
(30 amps times four remaining rectifiers) until the controller can send updated set points to the
remaining rectifiers. This takes a couple communication cycles (several seconds) after which each
rectifier would have a new set point of 37.5 amps for a total of 150 amps. The total current limit of the
rectifiers should not be set such that the loss of the redundant rectifiers will cause this temporary set
point to drop below the actual maximum expected load. If batteries are used on the rectifier output, the
batteries should support the load until the current limit set points can be re-established due to loss of a
rectifier.
NCU Start Wizard
For initial startup, you can perform the Start Wizard from the local keypad and display to enter basic
programmable parameters in one session. Refer to the “Start Wizard” section in the NCU Instructions
(UM1M830BNA).
Verifying the Configuration File
Your NCU was programmed with a configuration file that sets all adjustable parameters. The version number of
the configuration file can be found on the configuration drawing (C-drawing) that is supplied with your power
system documentation, and on a label located on the NCU. You can verify that the correct configuration file
has been loaded into your NCU by performing the following procedure.
Procedure
1. With the Main Menu displayed, press ESC. A screen displays the NCU name, serial number, IP number,
software version, hardware version, and configuration version number.
2. Press ESC to return to the Main Menu.
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Checking Basic System Settings
Navigate through the controller menus and submenus to check system settings. You can adjust any parameter
as required. Note that these settings can also be checked (and changed if required) via the WEB Interface.
Refer also to “NCU Start Wizard” on page 70.
NOTE!
Repeatedly press the “ESC” key to return in reverse order level by level from any submenu until
the Main Menu appears.
Procedure
1. To Select a Sub-Menu:
Press the UP and DOWN keys to highlight the desired sub-menu. Press the ENT key to enter the
selected sub-menu.
2. To Select a User:
To select a User, use the UP and DOWN keys to move the cursor to the Select User field. Press ENT.
Use the UP and DOWN keys to select a User previously programmed into the NCU. Press ENT to select
the User. Note that only Users programmed into the NCU are shown. Users are programmed via the
Web Interface. The default User is admin.
3. To Enter a Password:
If a password screen opens, a password must be entered to allow the User to make adjustments. To
enter a password, use the UP and DOWN keys to move the cursor to the Enter Password field. Press
ENT. Use the UP and DOWN keys to choose a character. Press ENT to accept and move to the next
character. Continue this process until all characters are entered. Press ENT again to accept the
password. The default password is 640275.
4. To Change a Parameter:
Press the UP and DOWN keys to move up and down the list of parameters. Press ENT to select the
parameter. Press the UP and DOWN keys to change the parameter. Press ENT to make the change.
Press ESC to cancel the change.
5. Table 8 shows the menu navigation for some basic settings. Refer to the separate NCU Manual
(UM1M830BNA) supplied with your power system for complete Local Display menus.
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Time
Main Menu / Settings Icon / Sys Settings / Time.
IP Communications
Equalize Voltage
Main Menu / Settings Icon / Batt Settings / Charge / EQ Voltage.
Main Menu / Settings Icon / Batt Settings / Charge / Curr Limit Mode
Main Menu / Settings Icon / Batt Settings / Basic Settings / Reset Batt
BTRM Feature
Web Menu Navigation Only: Settings Menu / Battery Tab.
Web Menu Navigation Only: Settings Menu / Rectifiers Tab / HVSD
Main Menu / Settings Icon / Rect Settings / Current Limit (set to
Over Voltage Alarm 2
Main Menu / Settings Icon / Other Settings / Over Voltage 2.
Under Voltage Alarm 1
Main Menu / Settings Icon / Other Settings / Under Voltage 1.
Table 8:
NCU Basic Settings Menu Navigation
Parameter Menu Navigation
Date Main Menu / Settings Icon / Sys Settings / Date.
Parameters
(IP address, subnet mask
Main Menu / Settings Icon / Comm Settings / enter parameters.
address, gateway address)
Float Voltage Main Menu / Settings Icon / Batt Settings / Charge / Float Voltage.
Battery Current Limit
Battery Capacity
Reset Battery Capacity
Battery Charge Temperature
Compensation
and Batt Curr Limit.
Main Menu / Settings Icon / Batt Settings / Batt1 Settings or Batt2
Settings / Rated Capacity.
Cap
Main Menu / Settings Icon / Batt Settings / Temp Comp (enter
parameters).
HVSD Limit
Rectifier Current Limit
(set to enabled) then set HVSD Limit.
enabled) then set Curr Limit Pt.
Over Voltage Alarm 1 Main Menu / Settings Icon / Other Settings / Over Voltage 1.
Under Voltage Alarm 2 Main Menu / Settings Icon / Other Settings / Under Voltage 2.
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Changing Battery Capacity Rating in the NCU
NOTE!
After setting the battery capacity, the User should also reset the battery capacity (battery must
be fully charged).
1. Change the battery capacity setting of the NCU to match the battery connected to the power system.
Local Menu Navigation:
Main Menu / Settings Icon / Batt Settings / Batt1 Settings or Batt2 Settings / Rated Capacity.
Web Menu Navigation:
Settings Menu / Battery Tab / Batt1 Rated Capacity and Batt2 Rated Capacity.
2. Reset the battery capacity (resets the battery capacity calculation).
NOTE!
Only reset the battery capacity when the battery is fully charged; otherwise, the battery charge
status may not be accurate.
Local Menu Navigation:
Main Menu / Settings Icon / Batt Settings / Basic Settings / Reset Batt Cap.
Web Menu Navigation:
Settings Menu / Battery Tab / Reset Battery Capacity.
Refer to the NCU Instructions (UM1M830BNA) for detailed instructions.
Configuring the NCU Identification of Rectifiers and Assigning which Input Feed is Connected to the Rectifiers
When rectifiers are all installed prior to applying power and starting the system, the order in which the NCU
identifies the rectifiers is by serial number (lowest serial number is Rect 1, next lowest is Rect 2, etc.). If you
prefer the NCU to identify the rectifiers by position in the system, perform the following procedure.
Upon power up, the NCU arbitrarily assigns Feed AC1, AC2, or AC3 to each rectifier. This assignment is used to
display rectifier AC input feed voltage(s). The User may reassign the feed to each rectifier per your specific
installation by following the procedure below.
Local Menu Navigation:
None.
Web Menu Navigation:
Refer to the NCU Instructions (UM1M830BNA) for detailed instructions.
NCU Alarm Relay Check
The following procedures can be used to verify operation of the external alarm relays in a power system
equipped with an NCU with the factory default configuration. Note that alarm relays on an NCU with a custom
configuration may operate differently.
NOTE!
There are two methods to check alarm relays. The first is by actually causing an alarm. The
second is by using the NCU alarm relay check function. The first method is used in the following
procedures.
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Checking the AC Fail Alarm
Procedure
NOTE!
Battery must be connected during this procedure.
1. Verify system is operating and no alarms are present.
2. Verify the NCU displays the Main Menu. If not, press ESC repeatedly to return to the Main Menu.
3. Open the external AC disconnect(s) or protective device(s) that supply power to all of the rectifier
modules.
a) Requirement: An audible alarm sounds. Alarm will be silenced in Requirement d.
b) Requirement: On subject rectifier module(s), the “Protection” indicator goes from off to yellow.
After approximately 30 seconds, the green “Power” and yellow “Protection” indicators go off.
c) Requirement: NCU “Critical/Major” alarm indicator goes from off to red.
d) Requirement: NCU displays “Rect AC Fail” alarm.
To see the specific alarm(s), navigate to the Alarm Menu and press ENT. The Active Alarm screen
lists two critical alarms. “Power System CAN Comm Fail Critical” is displayed. Scroll down by
pressing the down arrow key. “Rect Mains Failure Critical” is displayed.
e) Requirement: External “AC Fail” (Relay 6) and “Critical” (Relay 1) alarms activate.
4. Return external AC disconnect(s) or protective device(s) to the ON position.
a) Requirement: “Power” indicator on subject rectifier modules goes from off to green.
NOTE!
A “Rect Group All Rect No Response” alarm may activate briefly.
b) Requirement: NCU “Critical/Major” alarm indicator goes from red to off.
c) Requirement: Press ESC repeatedly to return to the Main screen. NCU displays “No Alarm”.
d) Requirement: All external alarms deactivate.
Checking Rectifier Alarm
Procedure
1. Verify system is operating and no alarms are present.
2. Verify the NCU displays the Main Menu. If not, press ESC repeatedly to return to the Main Menu.
3. Pull one rectifier module half way out of the shelf. To do this, first loosen the captive fastener securing
the top of the latch mechanism to the front of the rectifier module. Pull the top of the latch mechanism
away from the rectifier module (this will retract the latch mechanism located on the underside of the
rectifier module).
a) Requirement: An audible alarm sounds. Alarm will be silenced in Requirement c.
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b) Requirement: NCU “Critical/Major” alarm indicator goes from off to red.
c) Requirement: NCU displays “Alarm”.
To see the specific alarm(s), navigate to the Alarm Menu and press ENT. The “Active Alarm” screen
lists one major alarm. “Rect (###) Comm Fail Major” is displayed.
d) Requirement: External “Rectifier” (Relay 8) and “Major” (Relay 2) alarms activate.
NOTE!
If the system is equipped with only one rectifier, skip step 4.
4. Pull a second rectifier module half way out of the shelf, as described in Step 3.
a) Requirement: An audible alarm sounds. The alarm will cancel in Requirement c.
b) Requirement: NCU “Critical/Major” alarm indicator stays red.
c) Requirement: Press ESC repeatedly to return to the Main screen. NCU displays “Alarm”.
To see the specific alarm(s), navigate to the Alarm Menu and press ENT. The Active Alarm screen
lists one critical and two major alarms. “Rect Group Multi-Rect Fail Critical” is displayed. Use
arrow keys to scroll through the list of alarms. “Rect ### Comm Fail Major” is displayed for each
removed rectifier.
d) Requirement: External “Rectifier” (Relay 8) and “Major” (Relay 2) alarms remain in alarm state and
“Critical” (Relay 1) alarm activates.
5. Reinstall the rectifier module(s).
a) Requirement: “Power” indicator on subject rectifier(s) goes from off to green.
b) Requirement: NCU “Critical/Major” alarm indicator goes from red to off.
c) Requirement: Press ESC repeatedly to return to the Main screen. NCU displays “No Alarm”.
d) Requirement: All external alarms deactivate.
Checking System Over Voltage Alarm 1 and Over Voltage Alarm 2
1. Verify system is operating and no alarms are present.
2. Verify the NCU displays the Main Menu. If not, press ESC repeatedly to return to the Main Menu.
3. Record the system voltage displayed on the NCU Main screen.
4. Navigate to the Settings Menu.
5. With the Settings menu screen displayed, navigate to “Over Voltage 1”. Main Menu / Settings Icon /
Other Settings / Over Voltage 1. Record the displayed voltage setpoint.
6. Press the Enter (ENT) key; then use the UP or DOWN keys to adjust the “Over Voltage 1” value to below
the system voltage recorded in step 3. Press ENT.
a) Requirement: An audible alarm sounds. The alarm will be silenced in Requirement c.
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b) Requirement: NCU “Critical/Major” alarm indicator goes from off to red.
c) Requirement: Press ESC repeatedly to return to the Main Menu. NCU displays “Alarm”.
To see the specific alarm(s), navigate to the Alarm Menu and press ENT. The Active Alarm screen
lists one critical alarm. “Power System Over Voltage 1 Critical” is displayed.
d) Requirement: External “DC Over Voltage 1” (Relay 3) and “Critical” (Relay 1) alarms activate.
7. Without readjusting the “Over Voltage 1” setpoint, navigate to “Over Voltage 2”. Main Menu / Settings
Icon / Other Settings / Over Voltage 2. Record the displayed voltage setpoint.
8. Press the Enter (ENT) key; then use the UP or DOWN keys to adjust the “Over Voltage 2” value to below
the system voltage recorded in step 3. Press ENT.
a) Requirement: An audible alarm sounds. Alarm will be silenced in Requirement d.
b) Requirement: NCU “Critical/Major” alarm indicator stays red.
c) Requirement: Press ESC repeatedly to return to the Main Menu. NCU displays “Alarm”.
To see the specific alarm(s), navigate to the Alarm Menu and press ENT. The Active Alarm screen
lists two critical alarms. “Power System Over Voltage 2 Critical” is displayed. Use arrow keys to
scroll through the list of alarms. “Power System Over Voltage 1 Critical” is displayed.
d) Requirement: External “DC Over Voltage 1” (Relay 3) alarm and “Critical” (Relay 1) alarm remain
active.
Navigate to “Over Voltage 2”. Main Menu / Settings Icon / Other Settings / Over Voltage 2.
Press ENT; then use the UP or DOWN keys to adjust the “Over Voltage 2” setting to the value recorded in step
7. Press ENT.
NOTE!
Over Voltage 2 alarm will retire. The audible alarm will be silenced in the next step.
9. Use the UP or DOWN keys to scroll up to “Over Voltage 1”.
10. Press ENT; then use the UP or DOWN keys to adjust the “Over Voltage 1” setting to the value recorded
in step 5. Press ENT.
a) Requirement: NCU “Critical/Major” alarm indicator goes from red to off.
b) Requirement: Press ESC repeatedly to return to the Main screen. NCU displays “No Alarm”.
c) Requirement: All external alarms deactivate.
Checking System Under Voltage Alarm 1 and Under Voltage Alarm 2
1. Verify system is operating and no alarms are present.
2. Verify the NCU displays the Main Menu. If not, press ESC repeatedly to return to the Main Menu.
3. Record the system voltage displayed on the NCU Main screen.
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4. Navigate to the Settings Menu.
5. With the Settings Menu screen displayed, navigate to “Under Voltage 1”. Main Menu / Settings Icon /
Other Settings / Under Voltage 1. Record the displayed voltage setpoint
6. Press the Enter (ENT) key; then use the UP or DOWN keys to adjust the “Under Voltage 1” value to
above the system voltage recorded in step 3. Press ENT.
a) Requirement: An audible alarm sounds. The alarm will be silenced in Requirement c.
b) Requirement: NCU “Critical/Major” alarm indicator goes from off to red.
c) Requirement: Press ESC repeatedly to return to the Main screen. NCU displays “Alarm”.
To see the specific alarm(s), navigate to the Alarm Menu and press ENT. The Active Alarm screen
lists one critical alarm. “Power System Under Voltage 1 Critical” is displayed.
d) Requirement: External “DC Under Voltage 1” (Relay 4) and “Critical” (Relay 1) alarms activate.
7. Without readjusting the “Under Voltage 1” setpoint, navigate to “Under Voltage 2”. Main Menu /
Settings Icon / Other Settings / Under Voltage 2. Record the displayed voltage setpoint.
8. Press the Enter (ENT) key; then use the UP or DOWN keys to adjust the “Under Voltage 2” value to
above the system voltage recorded in step 3. Press ENT.
a) Requirement: An audible alarm sounds. Alarm will be silenced in Requirement c.
b) Requirement: NCU “Critical/Major” alarm indicator stays red.
c) Requirement: Press ESC repeatedly to return to the Main screen. NCU displays “Alarm”.
To see the specific alarm(s), navigate to the Alarm Menu and press ENT. The Active Alarm screen
lists two critical alarms. “Power System Under Voltage 2 Critical” is displayed. Use arrow keys to
scroll through the list of alarms. “Power System Under Voltage 1 Critical” is displayed.
d) Requirement: External “DC Under Voltage 2” (Relay 5) alarm activates, “DC Under Voltage 1” (Relay
4) alarm resets, and “Critical” (Relay 1) alarm remains active.
9. Navigate to “Under Voltage 2”.
10. Press ENT; then use the UP or DOWN keys to adjust the “Under Voltage 2” setting to the value recorded
in step 7. Press ENT.
NOTE!
Low Voltage 2 alarm will retire. The audible alarm will be silenced in the next step.
11. Use the UP or DOWN keys to scroll up to “Under Voltage 1”.
12. Press ENT; then use the UP or DOWN keys to adjust the “Under Voltage 1” setting to the value recorded
in step 5. Press ENT.
a) Requirement: NCU “Critical/Major” alarm indicator goes from red to off.
b) Requirement: Press ESC repeatedly to return to the Main screen. NCU displays “No Alarm”.
c) Requirement: All external alarms deactivate.
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Checking Circuit Breaker/Fuse Alarm
NOTE!
For all shelves equipped with battery disconnect circuit breakers, an open battery disconnect
circuit breaker will not activate the fuse/circuit breaker alarm unless a battery (or a temporary test load)
is connected to the system battery terminals. The battery fuse input is looking for a delta voltage across
a battery circuit breaker to activate the alarm. You will not have a reference if there is no battery (or a
temporary test load) connected.
1. Verify system is operating and no alarms are present.
2. Verify the NCU displays the Main Menu. If not, press ESC repeatedly to return to the Main Menu.
3. Open the front door of the distribution unit at the right-hand side of the shelf.
NOTE!
The following procedure is to be used only with circuit breakers that provide an alarm indication
when manually placed to the OFF (open) position (black handle). Electrical trip alarm circuit breakers
(white handle) cannot be easily tested in the field.
4. Do one of the following: (1) Remove a good fuse or a dummy fuse from a GMT fuse position, and replace
it with a blown fuse, or (2) Place the handle (if black) of a load circuit breaker in the OFF (open) position.
a) Requirement: An audible alarm sounds. The alarm will be silenced in Requirement c.
b) Requirement: NCU “Critical/Major” alarm indicator goes from off to red.
c) Requirement: NCU displays “Alarm”.
To see the specific alarm(s), navigate to the Alarm Menu and press ENT. The Active Alarm screen
lists one critical alarm. “Power System Load Fuse Brkr Critical” is displayed.
d) Requirement: External “Fuse/Circuit Breaker Alarm” (Relay 7) and “Critical” (Relay 1) alarms
activate.
5. Do one of the following: (1) Replace the blown GMT fuse with a known good fuse (or a dummy fuse), or
(2) place the handle of the circuit breaker in the ON (closed) position.
a) Requirement: NCU “Critical/Major” alarm indicator goes from red to off.
b) Requirement: Press ESC repeatedly to return to the Main screen. NCU displays “No Alarm”.
c) Requirement: All external alarms deactivate.
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Checking System Status
Procedure
1. Observe the status of the indicators located on the controller, rectifiers, solar converters, and -48 VDC to
+24 VDC converters (if furnished). If the system is operating normally, the status of these is as shown in
Table 9.
Table 9:
Status and Alarm Indicators
Component Indicator Normal State
Status (Green) On
NCU
Rectifier
Modules
Minor Alarm (Yellow) Off
Critical or Major
Alarm (Red)
Power (Green) On
Protection (Yellow) Off
Alarm (Red) Off
Off
Final Steps
Procedure
1. If any controller configuration settings were changed, refer to the NCU Instructions (UM1M830BNA) and
save a copy of the configuration file. This file can be used to restore the controller settings, if required,
at a later date.
NOTE!
Provided on a USB drive furnished with the system is a controller configuration drawing (Cdrawing) and the controller configuration files loaded into the controller as shipped.
2. Verify all rectifier modules and the controller are fully seated, latched, and the latch handle screws
secured.
3. Verify there are no external alarms and the local indicators are as shown in Table 9.
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IM582137200 (RJ 11/19)
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