Vertiv NetSure 7100 Series, NetSure 7100 Installation Manual

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NetSure™

7100 SERIES -48V DC Power System

Installation Manual (IM582127000), Revision BB

Specification Number: 582127000 Model Number: 7100

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The information contained in this document is subject to change without notice and may not be suitable for all applications. While every precaution has been taken to ensure the accuracy and completeness of this document, Vertiv Group Corporation 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 Corporation, 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 Corporation is strictly prohibited.

Vertiv and the Vertiv logo are trademarks or registered trademarks of Vertiv Co. All other names and logos referred to are trade names, trademarks or registered trademarks of their respective owners.

Vertiv | NetSure 7100 Series -48V DC Power System Installation Manual (IM582127000) | Rev. BB

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TABLE OF CONTENTS

Admonishments Used in this Document ............................................................ 6

Important Safety Instructions .............................................................................. 7

Safety Admonishments Definitions ...................................................................................................... 7

General Safety ........................................................................................................................................................... 7

Voltages ........................................................................................................................................................................... 7

AC Input Voltages ........................................................................................................................................................ 7

DC Input Voltages ........................................................................................................................................................ 7

DC Output and Battery Voltages .................................................................................................................. 8

Battery .............................................................................................................................................................................. 8

Personal Protective Equipment (PPE) ............................................................................................. 9

Hazardous Voltage .............................................................................................................................................. 9

Handling Equipment Containing Static Sensitive Components........................... 10

Maintenance and Replacement Procedures ............................................................................ 10

Static Warning .......................................................................................................... 11

Customer Documentation Package ................................................................... 13

Installation Acceptance Checklist ..................................................................... 14

Installing the System ............................................................................................. 16

General Requirements .................................................................................................................................... 16

Procedures when the System is Installed in an Enclosure ........................................ 17

Removing the Enclosure Rear Panels ..................................................................................................... 17

Removing the Enclosure Side Panels ..................................................................................................... 17

AC Input Conduit Options .................................................................................................................................. 17

Reversing the Enclosure Front Door .......................................................................................................18

Placing and Securing the Relay Rack(s) to the Floor (if applicable) .............. 20

Placing the Enclosures, Bolting Enclosures Together, and Securing

the Enclosure(s) to the Floor (if applicable) ........................................................................... 24

Mounting the Distribution Cabinet with Module Mounting

Assembly(s) ............................................................................................................................................................. 30

Installing a 582127000 List 93 Battery Tray (Relay Rack Installation

Only) ................................................................................................................................................................................ 34

Installing a Battery Tray ..................................................................................................................................... 34

Installing Optional Battery Disconnect Circuit Breakers ..................................................... 35

Installing Optional Anderson Battery Connector Kit ...............................................................36

Installing Optional Front Battery Cover ................................................................................................ 37

Installing Optional Circuit Breaker Guard ........................................................................................... 38

Installing a Battery Tray Mounting Kit, P/N 565004 (Enclosure

Installation Only) ................................................................................................................................................. 39

Removing the Enclosure Rear and Side Panels ...........................................................................39

Installing a Battery Tray Mounting Kit P/N 565004 ................................................................39

Installing the List 93 Battery Tray ............................................................................................................ 43

Installing the Enclosure Rear and Side Panels ............................................................................. 43

Installing Optional Battery Busbar Extension Kit, Part No. 562364 .................. 44

Vertiv | NetSure 7100 Series -48V DC Power System Installation Manual (IM582127000) | Rev. BB

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Installing Optional Battery Busbar Extension Kit, Part No. 554541 ................... 46

Installing Optional Lug Adapter Busbar Kits, Part Nos. 534449 and

514714 ............................................................................................................................................................................. 48

Installing Optional Lug Adapter Busbar Kit, Part No. 562888 ............................... 50

Installing Circuit Breakers and Fuses ............................................................................................. 52

Setting Jumpers and Switch Options .............................................................. 66

Circuit Card Locations ................................................................................................................................... 66

Jumpers on System Interface Circuit Card (Main Bay Only) ................................. 68

Switch Settings on IB2 Interface Board (Main Bay Only) ........................................... 69

Switch Setting on Optional EIB Interface Board (Main Bay Only) ..................... 70

Switch Setting on SM-DU (Supplemental Bays Only) ....................................................73

Switch Setting on SM-DU+ ........................................................................................................................ 77

Making Electrical Connections .......................................................................... 79

Important Safety Instructions ................................................................................................................ 79

Wiring Considerations .................................................................................................................................... 79

Relay Rack or Enclosure Grounding Connection (Frame Ground) ..................80

Central Office Ground Connection ...................................................................................................80

Nominal 208 VAC, 240 VAC, 277 VAC, or 277 VAC / 480 VAC Input

and Equipment Grounding Connections (if equipped) ................................................ 82

400 Volts DC Input and Equipment Grounding Connections (if

equipped) ..................................................................................................................................................................114

External Alarm, Reference, Monitoring, and Control Connections ................. 123

Circuit Card Locations ........................................................................................................................................123

System Interface Circuit Card .....................................................................................................................125

IB2 (Controller Interface Board) Connections (if required) (Main Bay

Only) ..................................................................................................................................................................................... 127

Optional EIB (Controller Extended Interface Board) Connections (if

required) (Main Bay Only) ...............................................................................................................................132

Optional SM-DU+ and Shunt Interface Board ............................................................................ 138

Connecting a Device or System to the Controller’s CAN Bus ..................................... 140

Controller Ethernet Connection (if required) ........................................................................141

Bay-to-Bay Communications Cable Connections ........................................................... 145

Installing Bay-to-Bay Busbars (582127000 List 1 with List 2 / List 3)

(for system mounted in a relay rack) .......................................................................................... 148

Installing Bay-to-Bay Busbars (582127000 List 1 with List 7 / List 8)

(for system mounted in an enclosure) ....................................................................................... 150

Control Bus Connections between Controller and Module Mounting

Assemblies Spec. No. 588705000 and 588705500 ...................................................... 153

Control Bus Connections between Controller and Module Mounting

Assemblies Spec. No. 588705300 ................................................................................................... 155

Control Bus Connections between Controller and Module Mounting

Assemblies Spec. No. 588705400 ................................................................................................... 157

Connecting Converter Output Cables 582127000 List 60 ..................................... 159

Load Connections ............................................................................................................................................ 162

Recommended Torques .................................................................................................................................. 162

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Load Connections to Single Voltage Distribution Panels ............................................... 163

Load Connections to Dual Voltage Distribution Panels ................................................... 168

Load Connections to Return Bar .............................................................................................................. 173

Load Connections to Bulk Output Panel .......................................................................................... 173

Load Connections to GMT Distribution Fuse Block ............................................................. 174

Battery Connections ...................................................................................................................................... 175

Important Safety Instructions ...................................................................................................................... 175

Recommended Torques ................................................................................................................................... 175

Battery Connections to Optional Battery Disconnect Distribution

Panels .................................................................................................................................................................................. 175

Battery Connections to Distribution Cabinet Battery Busbars (for

system mounted in a relay rack or enclosure) ........................................................................... 179

Battery Connections to Bay-to-Bay Rectifier Busbars (582127000 List 1

with List 2 / List 3) (for system mounted in a relay rack) ............................................... 182

Battery Connections to Optional Battery Busbar Extension Kit P/N

562364 (for system mounted in a relay rack or enclosure) .......................................... 183

Battery Connections to Optional Battery Busbar Extension Kit P/N

554541 (for system mounted in an enclosure) .......................................................................... 185

Battery Connections to Optional Battery Landing Busbar Kit P/N

553584 (for system mounted in a relay rack) ............................................................................. 186

Battery Connections to Optional Battery Landing Busbar Kit P/N

555478 (for system mounted in a relay rack) ............................................................................. 187

Installing and Connecting Batteries in List 93 Battery Tray (if

furnished) (for system mounted in a relay rack) .............................................................. 188

Installing the Modules ......................................................................................... 197

Installing Rectifier or Converter Modules into Spec. No. 588705000

Module Mounting Assemblies ............................................................................................................. 197

Installing Rectifier Modules into Spec. No. 588705500 Module

Mounting Assemblies .................................................................................................................................. 199

Installing the Rectifier and Converter Modules into Spec. No.

588705300 Module Mounting Assemblies ........................................................................... 201

Installing Rectifier Modules into Spec. No. 588705400 Module

Mounting Assemblies ..................................................................................................................................203

Initially Starting, Configuring, and Checking System Operation ........... 205

Initial Startup Preparation .......................................................................................................................205

Initially Starting the System ..................................................................................................................205

ACU+ Controller Procedure ..................................................................................................................205

NCU Controller Procedure ...................................................................................................................... 213

Checking System Status ........................................................................................................................... 219

Final Steps .............................................................................................................................................................. 220

Vertiv | NetSure 7100 Series -48V DC Power System Installation Manual (IM582127000) | Rev. BB

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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 only to equipment, software, data, or service. (ANSI)

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

ALERT

equipment, software, data, or service. (ISO)

ALERT

equipment damage, software corruption, data loss, or service interruption. (ISO)

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

be permitted in some of the applicable standards. (OSHA)

! 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

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 7100 Series -48V DC Power System Installation Manual (IM582127000) | Rev. BB

-fighting and fire-safety equipment. (ISO)

must be performed

in order to prevent

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IMPORTANT SAFETY INSTRUCTIONS

Safety Admonishments Definitions

Definitions of the safety admonishments used in this document are listed under “Admonishments Used in this Document” on page 6.

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.

f) For 400V DC input systems, do not work on an energized system without full arc flash and PPE

protection.

Voltages

AC Input Voltages

DANGER! This system may operate 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 Input Voltages

DANGER! This system may operate from 400V DC input voltage capable of producing fatal electrical

shock. DC input power must be completely disconnected from the branch circuits wiring used to provide power to the system before any DC electrical connections are made. Follow local lockout/tagout procedures to ensure upstream branch circuit breakers remain de-energized during installation. DO NOT apply DC input power to the system until all electrical connections have been completed and checked.

Vertiv | NetSure 7100 Series -48V DC Power System Installation Manual (IM582127000) | Rev. BB

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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.

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.

• Disconnect charging source prior to connecting or disconnecting battery terminals.

• Risk of explosion if battery is replaced with an incorrect type or if polarity is reversed.

Recommended to replace batteries with the same manufacturer and type, or equivalent.

• Dispose of used batteries according to the instructions provided with the batteries. Do not dispose

of batteries in a fire. They may explode.

• ALWAYS FOLLOW THE BATTERY MANUFACTURER’S RECOMMENDATIONS AND SAFETY

INSTRUCTIONS.

Vertiv | NetSure 7100 Series -48V DC Power System Installation Manual (IM582127000) | Rev. BB

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DANGER! This equipment may be used in conjunction with lead-acid batteries. Working near lead-acid

batteries is dangerous!

In addition to the hazard of electric shock, gas produced by batteries can be explosive and sulfuric acid

can cause severe burns.

• Do not open or mutilate batteries. Released electrolyte is harmful to the skin and eyes, and is toxic.

• Batteries contain sulfuric acid.

• Batteries generate explosive gases during normal operation. Systems containing batteries should

never be installed in an airtight room or space. Only install in a ventilated environment.

• Batteries are an energy source that can produce high amounts of electrical current.

FOR THESE REASONS, IT IS OF CRITICAL IMPORTANCE THAT YOU READ THESE INSTRUCTIONS

AND FOLLOW THEM EXACTLY.

WHEN WORKING WITH LEAD-ACID BATTERIES:

• Follow the recommended PPE requirements per the SDS for the battery to be used.

• If battery acid enters your eye, immediately flush your eye with running cold water for at least 15

minutes. Get medical attention immediately.

• If battery acid contacts skin or clothing, wash immediately with soap and water.

ALERT! Performing maintenance and/or troubleshooting procedures may interrupt power to the loads,

if battery reserve is not sufficient.

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.

Vertiv | NetSure 7100 Series -48V DC Power System Installation Manual (IM582127000) | Rev. BB

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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.

NOTE!

When performing any step in procedures that requires removal of existing hardware, retain all

hardware for use in subsequent steps, unless otherwise directed.

Vertiv | NetSure 7100 Series -48V DC Power System Installation Manual (IM582127000) | Rev. BB

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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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This page is intentionally blank.

Vertiv | NetSure 7100 Series -48V DC Power System Installation Manual (IM582127000) | Rev. BB

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CUSTOMER DOCUMENTATION PACKAGE

This document (IM582127000) provides Installation Instructions for NetSure™ -48 VDC Power System Model 7100, Spec. No. 582127000.

NOTE!

Instructions and Installation Instructions are provided with these power systems. For 582127000 List 100, 101, 102, and 103; do not use these instructions. Refer to IM582127000100 and UM582127000 for instructions.

The complete Customer Documentation Package consists of…

NetSure™ -48 VDC Power System Installation Manual

• Power System Installation Instructions: IM582127000

NetSure™ ACU+ Controller User Manual

• ACU+ Controller User Instructions: UM1M820BNA (AC Input Voltage Systems) or UM1M820DNA400

(DC Input Voltage Systems)

NetSure™ NCU Controller User Manual

• NCU Controller User Instructions: UM1M830BNA (AC Input Voltage Systems)

USB Drive with All Customer Documentation

• Power System Quick Start Guide: QS582127000

• Power System Installation Instructions: IM582127000

• Power System Installation Instructions: IM582127000100 (instructions for List 100, 101, 102, and 103)

582127000 List 100, 101, 102, and 103 are specific configurations of 582127000. Separate User

• Power System User Instructions: UM582127000

• Power System User Instructions: UM582127000100 (instructions for List 100, 101, 102, and 103)

• ACU+ Controller User Instructions: UM1M820BNA

• ACU+ Controller User Instructions: UM1M820DNA400

• NCU Controller User Instructions: UM1M830BNA

• Rectifier Instructions: UM1R483500e

• Rectifier Instructions: UM1R483500e3

• Rectifier Instructions: UM1R482000e3

• Converter Instructions: UM1C48241500

• Converter Instructions: UM1C400483500e

• Power System “System Application Guide”: SAG582127000

• NCU Controller 2nd Ethernet Port Add-On Kit Instructions: IM559252

• NCU Controller 2nd Ethernet Port Retrofit Kit Instructions: IM559251

Vertiv | NetSure 7100 Series -48V DC Power System Installation Manual (IM582127000) | Rev. BB

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• Engineering Drawings

• Also provided on the USB drive is a controller configuration drawing and the controller configuration

files loaded into the controller as shipped.

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!

Installing the System

 Relay Rack Secured to Floor (if applicable)

 Enclosures Placed, Bolted Together, and Secured to Floor (if applicable)

 System Components Mounted in Relay Rack (if required)

 Optional Lug Adapter Busbar Kits Installed

 Circuit Breakers Installed

 Fuses Installed

Setting Jumper and Switch Options

 Jumpers on System Interface Circuit Card Set

 Factory Switch Setting on IB2 Interface Board Verified

 Factory Switch Setting on Optional EIB Interface Board Verified

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.

 Factory Switch Setting on SM-DU Verified

 Factory Switch Setting on Optional SM-DU+ Verified

Making Electrical Connections

 Relay Rack or Enclosure Grounding Connection (Frame Ground) Made

 Central Office Ground Connection Made

 AC Input and AC Input Equipment Grounding Connections Made

or DC Input and Equipment Grounding Connections Made

 External Alarm, Reference, Monitoring, and Control Connections Made

Vertiv | NetSure 7100 Series -48V DC Power System Installation Manual (IM582127000) | Rev. BB

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 Ethernet Connection Made (if required)

 Bay-to-Bay Cable Connections Made (as required)

 Bay-to-Bay Busbars Installed (as required)

 Bay-to-Bay Busbar Covers Installed (as required)

 Converter Output Cables (if furnished) Connections to +24VDC Distribution Made (as required)

 Load Connections Made

 Battery Connections Made

a) Batteries Installed and Connected in an optional Battery Tray (if furnished)

b) Optional Battery Tray Front Battery Covers Installed (if furnished)

c) Optional Battery Tray Circuit Breaker Guards Installed (if furnished)

Installing the Modules and Initially Starting the System

 Rectifier and Converter Modules Installed

 System Started, Configured, and Checked

Vertiv | NetSure 7100 Series -48V DC Power System Installation Manual (IM582127000) | Rev. BB

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INSTALLING THE SYSTEM

General Requirements

• 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

environmentally controlled electronic equipment enclosure).

• 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).

• The installer should be familiar with the installation requirements and techniques to be used in securing

the relay rack to the floor.

• Rectifier, converter, and mounting assembly ventilating openings must not be blocked and temperature

of air entering rectifiers and converters must not exceed rated operating ambient temperature range found in SAG582127000.

• Clearance requirements are:

a) Recommended minimum aisle space clearance for the front of each bay is 2' 6". b) Recommended minimum aisle space clearance for the rear of each bay is 2’ 0” for any of the

following conditions:

1. Multiple bay arrangements that incorporate rear inter-bay busbars (List 2 and List 3 or List 7

and List 8 bays).

2. Addition of a module mounting assembly in the field.

3. Making input connections to a field installed module mounting assembly.

4. Adding battery tray(s) in the field.

For all other conditions, required minimum spacing from the rear of the bay to a wall or other solid surface is that which is specified for proper module mounting assembly ventilation. Refer to System Application Guide SAG582127000 for ventilation spacing requirements.

NOTE!

such as busbars or module mounting assemblies.

Vertiv | NetSure 7100 Series -48V DC Power System Installation Manual (IM582127000) | Rev. BB

Minimum spacing specified for ventilation may not permit replacement of certain components

Page 17

Removing Side Panels Removing Rear Panels

Loosen top screws to remove side panels.

Procedures when the System is Installed in an Enclosure

Removing the Enclosure Rear Panels

Procedure

1. Loosen the fasteners on the rear panel, then remove the panel. Refer to Figure 1.

2. For reassembly, note the location of the large holes in two corners of the panels. Orient the panels as

shown in Figure 1.

Removing the Enclosure Side Panels

Procedure

1. Loosen the fasteners on the side panel including panel frame grounding wire hardware, then remove the

panel. Refer to Figure 1.

AC Input Conduit Options

Two types of conduit plates are available. Select and install the conduit plate appropriate for your application. Refer to Figure 2.

Figure 1:

Removing System Enclosure Side and Rear Panels

Vertiv | NetSure 7100 Series -48V DC Power System Installation Manual (IM582127000) | Rev. BB

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Trade 1.00” Conduit Openings

P/N 563714 (factory installed)

P/N 563877 (field installed)

Trade 0.75” Conduit Openings

Figure 2:

AC Input Conduit Plates

NOTE!

Reversing the Enclosure Front Door

Refer to

Figure 3

as this procedure is performed.

Procedure

1. Open the front door.

2. Remove the ground strap from the front door, saving the hardware.

3. Unbolt the front door hinges from the enclosure.

4. Remove the front door.

5. Reverse the front door.

6. Re-bolt the front door hinges to the other side of the enclosure.

7. Re-attach the ground strap to the front door, using the saved hardware.

8. Carefully remove the clips from inside the door securing the door badging emblems.

9. Remove the door badging emblems and relocate them to the opposite corners at the top of the door.

Secure with the clips removed above.

Vertiv | NetSure 7100 Series -48V DC Power System Installation Manual (IM582127000) | Rev. BB

Page 19

Ins

ide View

Figure 3:

Reversing the Enclosure Front Door

Door Badging

Emblems

H Do

inge

H Door

Vertiv | NetSure 7100 Series -48V DC Power System Installation Manual (IM582127000) | Rev. BB

ing

Door

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Placing and Securing the Relay Rack(s) to the Floor (if applicable)

System components are factory mounted in a relay rack, on shipping rails, or in an enclosure as specified when ordered.

Systems Installed in a Relay Rack

The system consists of one to six bays. For busbar-connected systems (List 1 with List 2/List 3), locate relay racks in a line adjacent to each other, with no space between them. Place the List 1 Main Bay at the right or left side end, then the List 2 Supplemental Bay, then the List 3 Supplemental Bay (if furnished), etc.

Secure the relay rack to the floor per site requirements. Refer to “General Requirements” on page 16.

Ventilation Requirements

Refer to the “General Requirements” on page 16.

Relay Rack Floor Mounting Dimensions

Refer to Figure 4 for relay rack floor mounting dimensions.

Vertiv | NetSure 7100 Series -48V DC Power System Installation Manual (IM582127000) | Rev. BB

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Figure 4:

Relay Rack Floor Mounting Dimensions (cont’d on next page)

Vertiv | NetSure 7100 Series -48V DC Power System Installation Manual (IM582127000) | Rev. BB

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0.000

11.000

12.530

15.030

15.62

1. All dimensions are in inches.

Figure 4:

Relay Rack Floor Mounting Dimensions (cont’d from previous page, cont’d on next page)

1.000

0.437 12 Places

Part No.

562351

22.500

24.50 Ref

3.500

5.030

18.00

3.06

1.74

Notes:

0.875 8 Places

25.80

Part No.

562353

19.685

22.310

15.000

12.340

1.502.83

Vertiv | NetSure 7100 Series -48V DC Power System Installation Manual (IM582127000) | Rev. BB

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17.500

25.00

12.531

1.25

15.03

0.875 8 Places

Part No. 562355

9.871

20.125

3.75

2.44

Notes:

1. All dimensions are in inches.

Figure 4:

Relay Rack Floor Mounting Dimensions (cont’d from previous page)

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Placing the Enclosures, Bolting Enclosures Together, and Securing the Enclosure(s) to the Floor (if applicable)

System components are factory mounted in a relay rack, on shipping rails, or in an enclosure as specified when ordered.

Systems Installed in an Enclosure

The system consists of one to six bays. Locate enclosures in a line adjacent to each other, with no space between them. Place the List 1 Main Bay at the right or left side end, then the List 7 Supplemental Bay, then the List 8 Supplemental Bay (if furnished), etc. Refer to the following procedures.

Ventilation Requirements

Refer to the “General Requirements” on page 16.

Enclosure Floor Mounting Dimensions

Refer to Figure 5 for enclosure floor mounting dimensions.

Figure 5:

Enclosure Floor Mounting Dimensions

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Procedure

NOTE!

Refer to

Figure 5, Figure 6

, and

Figure 7

as this procedure is performed.

1. If present, remove the side panels from the adjacent sides of each enclosure.

2. Locate where the enclosure(s) are to be placed. Refer to “General Requirements” on page 16.

3. Drill mounting holes in the floor for the main enclosure. Refer to Figure 5 for enclosure floor drilling

dimensions.

4. Place the main enclosure in position.

5. Open the enclosure’s front door.

6. For seismic Zone 4 applications, ensure the four (4) loose 1/4" thick seismic, 1-hole washers are installed

in each corner of the enclosure. See Figure 7.

7. Install mounting hardware per site requirements. See Figure 8.

NOTE!

Do not tighten. Leave extremely loose.

8. Locate a bag of parts, labeled 563677, shipped with the expansion enclosure.

9. Install one (1) bolt, (3) flat washers, (1) ground washer, and (1) nut in the front enclosure joining hole at

the top of the main enclosure as shown in Figure 6. Torque to value indicated in Figure 6.

10. Repeat the previous step for the front enclosure joining hole at the bottom of the main enclosure.

11. Repeat the above steps for the rear enclosure joining holes at the top and bottom of the main enclosure.

12. Drill mounting holes in the floor for the 1st expansion enclosure. Refer to Figure 5 for enclosure floor

drilling dimensions.

13. Place the 1st expansion enclosure in position so that the bolts installed on the main enclosure enter

enclosure joining holes on the 1st expansion enclosure.

14. Open the enclosure’s front door.

15. For seismic Zone 4 applications, ensure the four (4) loose 1/4" thick seismic, 1-hole washers are installed

in each corner of the enclosure. See Figure 7.

16. Install mounting hardware per site requirements. See Figure 8.

NOTE!

Do not tighten. Leave extremely loose.

17. Fasten the expansion enclosure to the main enclosure by installing (1) flat washer and (1) nut at the top

front of the enclosure as shown in Figure 6. Torque to value indicated in Figure 6.

18. Repeat the previous step for the bottom front of the enclosures.

19. Repeat the above steps for the rear enclosure joining holes at the top and bottom of the enclosures.

20. Repeat the above steps if a 2nd expansion enclosure is furnished.

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21. Level enclosures as required. Level the enclosures so that all enclosures are even at top. Install shims

between bottom of each enclosure and the floor as required to distribute floor loading and to align outside of enclosures.

22. Tighten the floor mounting hardware per hardware manufacturer specifications.

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Front of Cabinet Already Installed

Side of Cabinet

Already Installed

Torque to 150 in-lbs.

Front of Cabinet Being Added

Side of Cabinet Being Added

5/16-18

Bolt

(3) 5/16” Flat Washers

5/16” Ground Washer

Nut

5/16” Flat Washer

5/16”

Nut

Mounting Hole (one in each corner, top and bottom)

Figure 6:

Bolting Enclosures Together

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Page 28

” T

k S

smic,

1-Hole washer (one in each corner)

Figure 7:

Installing Four (4) ¼” Thick Seismic, 1-Hole Washer for Seismic Zone 4 Applications

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tud Type Anchor

Anchor Nut

Anchor Washer

Enclosure

1-Hole Washer

Setting the Anchors

1. Before setting the anchor, review manufacturer’s instructions.

2. A loose, ¼” [6.4 mm] thick seismic, 1-hole washer is provided at each corner. Since the 1-hole washer’s hole diameter is 0.563” [14.3 mm], a stud type anchor is recommended.

3. The total height of the enclosure metal surrounding each mounting hole, including 1-hole washer, is 0.74” [18.8 mm].

4. Remove the nut and washer from the anchor.

5. For eac

h anchor, drop the anchor into the drilled hole. Insert the anchor setting tool and

hit it with a hammer to expand the anchor.

Placing and Securing the Enclosure to the Floor

1. Place the enclosure into position over the anchoring holes.

2. Install the anchor washer and anchor nut FINGER TIGHT for each anchor.

3. Check the enclosure is level front-to-back and side-to-side. Install shims if necessary.

4. When the enclosure is level, tighten all nuts to the appropriate torque.

Figure 8:

Setting the Anchors and Securing the Enclosure to the Floor

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Mounting the Distribution Cabinet with Module Mounting Assembly(s)

NOTE!

If the power system was ordered in a relay rack, these procedures have been performed at the factory. Note also the power system can be ordered, installed in an enclosure. These procedures are only for field installing the power system in a relay rack.

This power system is designed to mount in a standard 23” relay rack having 1” or 1-3/4” multiple drillings. Refer to System Application Guide SAG582127000 for overall dimensions and a list of available relay racks.

NOTE!

The distribution cabinet is factory connected to the module mounting assembly(s). The distribution cabinet with module mounting assembly(s) is mounted as a complete assembly.

The distribution cabinet with module mounting assembly(s) must be the top-most component in the relay rack. Perform the following steps to mount the distribution cabinet with module mounting assembly(s).

DANGER! The relay rack must be securely anchored to the floor before the distribution cabinet with

module mounting assembly(s) is installed.

DANGER! The distribution cabinet with module mounting assembly(s) is heavy. Use a hoist, battery lift,

or other appropriate lifting device to raise and support the assembly during the installation. Take appropriate precautions to avoid injury.

Procedure

1. Remove the distribution cabinet with module mounting assembly(s) from its shipping brackets. Position

the assembly in the equipment rack. Note that part of the Input Termination Assembly will have to be temporarily removed from the distribution cabinet to access the mounting hardware.

NOTE!

Install the ground washers so the teeth dig into the paint on the mounting angles. Torque all screws to 65 in-lbs.

2. Mount the distribution cabinet to the relay rack using the following hardware. Refer to Figure 9.

a) 1-Row Cabinet: Install (8) 12-24 x 3/4" hex head thread-forming screws (P/N 218710600) and (8)

No. 12 ground washers (P/N 215640600).

b) 2-Row Cabinet: Install (10) 12-24 x 3/4" hex head thread-forming screws (P/N 218710600) and (10)

No. 12 ground washers (P/N 215640600).

c) 3-Row Cabinet: Install (12) 12-24 x 3/4" hex head thread-forming screws (P/N 218710600) and (12)

No. 12 ground washers (P/N 215640600).

d) 4-Row Cabinet: Install (16) 12-24 x 3/4" hex head thread-forming screws (P/N 218710600) and (16)

No. 12 ground washers (P/N 215640600).

3. Mount the module mounting assembly to the relay rack using hardware as shown Figure 10 or Figure 11.

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3-ROW CABINET 4-ROW CABINET

1-ROW CABINET 2-ROW CABINET

Mounting Hardware, 4 Places per Side

Mounting Hardware, 6 Places per Side

Mounting Hardware, 8 Places per Side

Mounting Hardware, 5 Places per Side

MOUNTING HARDWARE 12-24 X 3/4" THREAD FORMING HEX HEAD SCREW NO. 12 GROUND WASHER

Module Mounting Assembly not shown for clarity only.

Figure 9:

Distribution Cabinet Mounting Hardware

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Secure the module mounting assembly(s) to the relay rack.

MOUNTING HARDWARE

12-24 x 3/4" Thread Forming Hex Head Screw

No. 10/12 Ground Washer

Front

Figure 10:

Module Mounting Assembly Spec. No. 588705000 and 588705500 Mounting Hardware

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Front

Figure 11:

Module Mounting Assembly Spec. No. 588705300 and 588705400 Mounting Hardware

Secure the module mounting assembly(s) to the relay rack.

MOUNTING HARDWARE

12-24 x 3/4" Hex Head Screw

No. 10/12 Ground Washer

Thread Forming

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Battery Tray

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).

Installing a 582127000 List 93 Battery Tray (Relay Rack Installation Only)

Perform the following procedure to install a 582127000 List 93 Battery Tray into a relay rack.

DANGER! The relay rack must be securely anchored to the floor before a battery tray is installed.

Installing a Battery Tray

Procedure

1. To install a 582127000 List 93 Battery Tray, perform the procedure in Figure 12.

Figure 12:

Installing a 582127000 List 93 Battery Tray

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Page 35

circuit breaker, replace the cover.

Installing Optional Battery Disconnect Circuit Breakers

Procedure

1. To install an optional battery disconnect circuit breaker onto the List 93 Battery Tray, perform the

procedure in Figure 13.

2. Battery tray wiring is shown in “Installing and Connecting Batteries in List 93 Battery Tray (if furnished)”

on page 188.

Figure 13:

Installing Optional Battery Disconnect Circuit Breakers onto a List 93 Battery Tray

1. Remove the cover from the battery disconnect circuit breaker assembly.

2. Secure the battery disconnect circuit

Battery Disconnect Circuit Breaker Assembly (left side kit shown, right side kit available)

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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

Page 36

Installed View

Installing Optional Anderson Battery Connector Kit

Procedure

1. To install an optional Anderson battery connector kit onto the List 93 Battery Tray, perform the

procedure in Figure 14.

Figure 14:

Installing Optional Anderson Battery Connector Kit onto a List 93 Battery Tray

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Assembled View

Kit Battery Cover

Assembled to Existing

Front Battery Bracket

Rear View

Kit Battery Cover

Assembled to Existing

Front Battery Bracket

Front View

Use kit supplied hardware.

Procedure

1. Install batteries.

2. Install kit battery cover to existing front battery bracket.

3. Install kit battery cover with existing front battery bracket to battery shelf.

Kit supplied cover.

Kit supplied spacer bar.

Existing front battery bracket.

Use existing battery spacers.

Installing Optional Front Battery Cover

Procedure

1. To install an optional front battery cover onto a List 93 Battery Tray, perform the procedure in Figure 15.

Note that batteries must be installed first, as described in “Installing and Connecting Batteries in List 93 Battery Tray (if furnished)” on page 188.

Figure 15:

Installing Optional Front Battery Cover onto a List 93 Battery Tray

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1. Remove this bracket.

existing hardware.

Installing Optional Circuit Breaker Guard

Procedure

1. To install an optional circuit breaker guard onto a battery disconnect circuit breaker, perform the

procedure in Figure 16.

Figure 16:

Installing Optional Circuit Breaker Guard

2. Replace this hardware after removing existing bracket.

Installed

View

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3. Install Circuit Breaker Guard Bracket using

Page 39

Installing a Battery Tray Mounting Kit, P/N 565004 (Enclosure Installation Only)

Perform the following procedure to install a 582127000 List 93 Battery Tray into an enclosure.

DANGER! The enclosure must be securing anchored to the floor before the battery tray is installed.

Removing the Enclosure Rear and Side Panels

Procedure

1. Refer to Removing the Enclosure Rear Panels and Removing the Enclosure Side Panels starting on Page

17.

Installing a Battery Tray Mounting Kit P/N 565004

Procedure

1. To install a Battery Tray Mounting Kit, perform the procedure in Figure 17.

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Page 40

. Remove the twelve (12) 1/4-20 x 3/4” screws, locations shown.

Save washers and nuts for reassembly.

2. Remove the two (2) 1/4-20 x 1.75” screw, locations shown. Save washers, spacers, and nuts for reassembly.

3. Assemble battery tray mounting kit rails in location shown.

Figure 17:

Installing a Battery Tray Mounting Kit P/N 565004 (cont’d on next page)

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Page 41

4. Mount hardware to the left and right side rails.

5. Assemble the twelve (12) 1/4-20 x 1” screws provided with kit and saved washers and nuts, locations shown. Leave nuts loose at this time.

6. Assemble the two (2) 1/4-20 x 2“ screws provided with kit; and saved washers, spacers, and nuts, locations shown. Leave nuts loose.

7. Ensure mounting rails are vertically leveled and the front-to-rear flange spacings are 6.0”.

8. Torque to 75 in-lbs.

Washer

Lock Washer

Nut

Frame Rail

Spacer

Washer

Brace Bar

1/4-20 x 2” Screw

Mount hardware to the left and right side rails.

Figure 17:

Installing a Battery Tray Mounting Kit P/N 565004 (cont’d from previous and on next page)

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9. Mount the AC guard to the cabinet.

10. Remove the existing AC guard if the power system distribution is shorter than 4-row. Save 8-32 x 3/8 screws.

11. Install AC guards provided with kit and saved 8-32 x 3/8 screws.

12. Torque to 20 in-lbs.

Figure 17:

Installing a Battery Tray Mounting Kit P/N 565004 (cont’d from next page)

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Page 43

Tighten top screws to secure the panels.

Installing the List 93 Battery Tray

Refer to Installing a 582127000 List 93 Battery Tray (Relay Rack Installation Only) on page 34.

Procedure

1. To install a Battery Tray Mounting Kit, perform the procedure in Figure 12.

NOTE!

Do not install battery tray circuit breaker covers (if provided).

Installing the Enclosure Rear and Side Panels

Procedure

1. Fix in position the rear and side panels that were removed before installing the battery tray mounting kit

Tighten the fasteners on the side panel including panel frame grounding wire hardware. Refer to

Figure 18:

Installing the Enclosure Rear and Side Panels

Figure

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Qty.

Part No.

Description

562362

Return Side Extension Busbar

562363

Power Side Extension Busbar

562354

Cover Kit

214204100

3/8" Flat Washer

214825000

3/8" Belleville Washer

227646800

3/8-16 x 1-1/4" Bolt

Installing Optional Battery Busbar Extension Kit, Part No. 562364

This kit provides plates that extend the system busbars above the top of a List 23 and List 24 distribution cabinet and increases the number of lug landings available for battery cables. This kit provides back-to-back landings for up to ten lugs for the hot side and eight lugs for the return side.

Installing Part No. 562364 Busbar Extension Kit

This kit consists of the following:

Perform the following steps to install the battery busbar extension plates.

Procedure

NOTE!

Refer to

Figure 19

as the procedure is performed. A system installed in a relay rack is shown in the illustration. The procedure for a system installed in an enclosure is the same except as noted in the following procedure steps.

1. Open the distribution cabinet’s front door by turning the latch in the counterclockwise position

(system’s in a relay rack), or open the system’s enclosure door.

2. Install busbar extension plates as shown in Figure 19. Apply anti-oxidizing compound to busbar mating

surfaces before assembling. Tighten bolts to the recommended torque value shown in Figure 19.

NOTE!

Install the Belleville lock washers so the concave side is towards the busbar.

3. Close the distribution cabinet’s front door and turn the latch clockwise to secure the door (system’s in a

relay rack), or close the system’s enclosure door.

Perform the following steps to mount the Lexan cover.

Procedure

NOTE!

Refer to

Figure 20

1. Loosen the four (4) screws at the back of the busbars.

2. Place the Lexan cover at the back of the busbars and use the four (4) screws to secure it.

3. Remove the four (4) screws at the top of the enclosure and place the cover.

4. Re-use the screws to secure the top cover.

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Page 45

Battery (Return Side) Busbar

Battery (Load Side) Busbar

GND RTN

-48V SUPPLY

List 24 Distribution Cabinet (List 23 similar)

Front View

1. Apply anti-oxidizing compound to busbar mating surfaces.

2. Install hardware, 6 places return busbar, 10 places supply busbar.

Assembly Order: 3/8-16 X 1-1/4” Bolt 3/8” Belleville Washer 3/8” Flat Washer Extension Plate System Busbar

3. Torque to 180 in-lbs.

Figure 19:

Installing Battery Busbar Extension Kit, Part No. 562364

Figure 20:

Mounting the Lexan Cover

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Qty.

Part No.

Description

554540

Busbar extension plates, flat

214204100

Flat washer, 3/8” x 1” O.D.

214825000

Belleville washer, 3/8”

227646800

Hex head bolt, 3/8-16 x 1-1/4”

Installing Optional Battery Busbar Extension Kit, Part No. 554541

This kit provides plates that extend the system busbars above the top of the distribution cabinet and increases the number of lug landings available for battery cables. This kit provides back-to-back landings for up to six lugs per polarity.

This kit consists of the following:

Installing Part No. 554541 Busbar Extension Kit

Perform the following steps to install the battery busbar extension plates.

Procedure

Refer to Figure 21 as the procedure is performed.

1. Open the distribution cabinet front door.

2. Install busbar extension plates as shown in Figure 21. Apply anti-oxidizing compound to busbar mating

surfaces before assembling. Tighten bolts to the recommended torque value shown in Figure 21.

NOTE!

Note that the busbars are notched. Some installations require the busbar to be rotate so the

notch portion clears any protrusion present.

NOTE!

Install the Belleville lock washers so the concave side is towards the busbar.

3. Close the distribution cabinet access door.

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Page 47

1. Apply anti-oxidizing compound

Figure 21:

Installing Battery Busbar Extension Kit, Part No. 554541

2. Install hardware,

3. Torque to 180 in-lbs.

(One Row Cabinet Shown, Others Similar)

to busbar mating surfaces.

6 places per busbar.

Assembly Order: 3/8-16 X 1-1/4” Bolt 3/8” Belleville Washer 3/8” Flat Washer Extension Plate System Busbar

Central

Office

Ground

GND RTN

Battery (Return Side) Busbar

-48V SUPPLY

Battery (Load Side) Busbar

Front View

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Qty.

Part No.

Description

534447

Busbar

534448

Busbar

214110100

Flat Washer, 1/4”

214112100

Flat Washer, 3/8”

215111100

Lock Washer, 1/4”

215111300

Lock Washer, 3/8”

227640400

Hex Head Bolt, 1/4-20 x 3/4” (not used)

227646600

Hex Head Bolt, 3/8-16 x 1”

228557100

Nut, 1/4-20

228567100

Nut, 3/8-16

Qty.

Part No.

Description

514676

Busbar

514678

Busbar

214110100

Flat Washer, 1/4”

214112100

Flat Washer, 3/8”

215111100

Lock Washer, 1/4”

215111300

Lock Washer, 3/8”

227640400

Hex Head Bolt, 1/4-20 x 3/4” (not used)

227646600

Hex Head Bolt, 3/8-16 x 1”

228557100

Nut, 1/4-20

228567100

Nut, 3/8-16

Installing Optional Lug Adapter Busbar Kits, Part Nos. 534449 and 514714

These kits provide lug adapter busbars plus hardware for use with 2-pole and 3-pole bullet circuit breakers.

Contents of Kit P/N 534449 (for 2-pole circuit breakers)

Contents of Kit P/N 514714 (for 3-pole circuit breakers)

Perform the following steps to install the lug adapter busbars.

Procedure

Refer to Figure 22 as the procedure is performed. Note also the restrictions on location in Figure 22.

1. Open the distribution cabinet’s front door by turning the latch in the counterclockwise position

(system’s in a relay rack), or open the system’s enclosure door.

2. Install the lug adapter busbars as shown in Figure 22. Apply anti-oxidizing compound to busbar mating

surfaces before assembling. Recommended torque is 72 in-lbs using the supplied 1/4” bolts and hardware.

3. Orient the load lug hardware as shown in Figure 22. Recommended torque is 300 in-lbs using the

supplied 3/8” bolts and hardware.

4. Close the distribution cabinet’s front door and turn the latch clockwise to secure the door (system’s in a

relay rack), or close the system’s enclosure door.

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Page 49

Circuit breaker locations for reference only.

Busbar Adapter

Figure 22:

Installing Lug Adapter Busbar Kits

Kit P/N 534449

Busbar Adapter Kit P/N 514714

Busbar Adapter Kit P/N 534449

Notes:

Orient busbars as shown.

Shield not shown. Remove breakaway areas from shield as required. Breakaways are only provided for positions 1-8, 9-12, and 23-24. This restricts 2 and 3-pole breaker adapter kits to be located in these positions only.

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Page 50

Qty.

Part No.

Description

562392

Busbar

562393

Busbar

Installing Optional Lug Adapter Busbar Kit, Part No. 562888

For use with List AM and List AP.

This kit provides lug adapter busbars for use with 3-pole GJ/218 circuit breakers.

Contents of Kit P/N 562888 (for 3-pole circuit breakers)

Perform the following steps to install the lug adapter busbars.

Procedure

Refer to Figure 23 as the procedure is performed.

1. Open the distribution cabinet’s front door by turning the latch in the counterclockwise position

(system’s in a relay rack), or open the system’s enclosure door.

2. Install the lug adapter busbars as shown in Figure 23. Apply anti-oxidizing compound to busbar mating

surfaces before assembling. Refer to Figure 23 for recommended torque.

3. Close the distribution cabinet’s front door and turn the latch clockwise to secure the door (system’s in a

relay rack), or close the system’s enclosure door.

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Page 51

Apply anti-oxidizing compound to busbar mating surfaces.

1/4" Hardened Flat Washer 1/4" Belleville Lock Washer 1/4-20 x 3/4” Bolt (6 places) Torque to 60 in-lbs. (supplied with breaker mounting kit)

Busbar Adapter Kit P/N 562888

Torque to 300 in-lbs when using 3/8-inch hardware with standard flat and lock washer.

Apply anti-oxidizing compound to busbar mating surfaces.

LOAD RETURN BUSBAR 3/8-16 Captive Nuts on 1” Centers (Customer must supply or order hardware)

OFF

Shorting Busbar (supplied with breaker mounting kit)

Figure 23:

Installing Lug Adapter Busbar Kits

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Page 52

Installing Circuit Breakers and Fuses

Circuit breakers and/or fuses may have been factory installed for you. If so, verify their positions and sizes.

Installing Bullet Nose Type Fuseholders and TPS/TLS Fuses

CAUTION! 100 A circuit breakers and fuses can be used without a space provided the continuous

operating current in each 100 A device does not exceed 64 A. A 175 A or greater circuit breaker shall have an empty mounting position between it and any other overcurrent protective device.

Refer to SAG582127000 for any other restrictions.

Refer to the following procedure and install bullet nose type fuseholders and appropriately sized TPS/TLS fuses into the proper mounting positions in the distribution cabinet.

Procedure

NOTE!

Refer to

Figure 24

as this procedure is performed.

1. Open the distribution cabinet’s front door by turning the latch in the counterclockwise position

(system’s in a relay rack), or open the system’s enclosure door.

2. Orient the fuseholder as shown in Figure 24. Insert the terminals on the rear of the fuseholder into their

corresponding sockets on the distribution panel. Ensure the alarm contact on the back of the fuseholder makes contact with the alarm terminal on the spring strip. Push fuseholder in firmly until fully seated in the distribution panel.

3. When all fuseholders are installed, install an appropriately sized TPS/TLS fuse in each. To do this,

remove the fuse carrier from the mounted fuseholder body. Hold the fuseholder body while you pull the fuse carrier from the body. Slide the fuse in place between the contacts of the fuse carrier. When done, push the fuse carrier back into the fuseholder body. Note that a polarizing key on the bottom of the carrier prevents the carrier from being inserted upside down.

4. Verify that an 18/100 ampere alarm fuse is present in each fuseholder and that a plastic safety cover is

installed on this fuse.

5. Record all fuse sizes on the label provided on the shield.

6. Close the distribution cabinet’s front door and turn the latch clockwise to secure the door (system’s in a

relay rack), or close the system’s enclosure door.

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Page 53

Fuseholder A

Longer Side to the Bottom

Shorter Side to the Top

Fuse Carrier

Fuseholder Body

TPS/TLS Fuse

Polarizing Keyway Matches Key on Bottom of Fuse Carrier

Fuseholder Assembly Exploded View

Fuseholder Assembly (P/N 117201) includes body & carrier, alarm fuse, and alarm fuse safety cover.

Insert these terminals into corresponding sockets on distribution panel.

GMT-X

Safety Fuse Cover

(Replacement

P/N 248898700)

GMT-18/100A Alarm Fuse (Replacement P/N 248610301)

Figure 24:

Installing a Bullet Nose Type Fuseholder and TPS/TLS Fuse

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Page 54

to t

he Bottom

Shorter Side

Lettering on handle must be right side up.

T before installing.

Installing Bullet Nose Type Circuit Breakers

CAUTION! A circuit breakers and fuses can be used without a space provided the continuous operating

current in each 100 A device does not exceed 64 A. A 175 A or greater circuit breaker shall have an empty mounting position between it and any other overcurrent protective device.

Refer to SAG582127000 for any other restrictions.

Refer to the following procedure and install appropriately sized bullet nose type circuit breakers into the proper mounting positions in the distribution cabinet.

Procedure

NOTE!

Refer to

Figure 25

as this procedure is performed.

1. Open the distribution cabinet’s front door by turning the latch in the counterclockwise position

(system’s in a relay rack), or open the system’s enclosure door.

2. Ensure that the circuit breaker is in the OFF position and is of the correct rating. Orient the circuit

breaker as shown in Figure 25. Insert the terminals on the rear of the circuit breaker into their corresponding sockets on the distribution panel. Ensure the alarm contact on the back of the circuit breaker makes contact with the alarm terminal on the spring strip. Push distribution device in firmly until fully seated in the distribution panel.

3. Record all circuit breaker sizes on the label provided on the shield.

4. Close the distribution cabinet’s front door and turn the latch clockwise to secure the door (system’s in a

relay rack), or close the system’s enclosure door.

Figure 25:

Installing a Bullet Nose Type Circuit Breaker

to the Top

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urn o ff

Longer Si

sert th

ese termi

into

corresponding so

on dis

tribution panel.

nals

ckets

Page 55

Installing an Optional Bullet Nose Type 6-Position GMT Distribution Fuse Block (P/N 550224)

NOTE!

Refer to

Figure 26

as this procedure is performed.

NOTE!

Can be used in a List AA, AB, DA, DB, DC, and DD distribution panel only.

NOTE!

Can only be installed in the 1-2, 3-4, 17-18, 19-20, 21-22, and 23-24 positions of the distribution

panel.

Procedure

1. Open the distribution cabinet’s front door by turning the latch in the counterclockwise position

(system’s in a relay rack), or open the system’s enclosure door.

2. Follow the steps in Figure 26.

3. Install an appropriately sized GMT fuse in each fuse mounting position on the GMT Distribution Fuse

Block as required. If dummy fuses are installed, first remove the dummy fuse.

a) Verify that dummy fuses are installed in all unused fuse positions on the GMT distribution fuse

block.

b) Verify that a plastic safety cover is installed on all GMT fuses on the GMT distribution fuse block.

4. Record all fuse sizes (installed on the GMT distribution fuse block) on the label provided on the shield.

5. Close the distribution cabinet’s front door and turn the latch clockwise to secure the door (system’s in a

relay rack), or close the system’s enclosure door.

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Page 56

Press in tabs to release lug terminal busbars for positions to be occupied by GMT Fuse Block.

Remove two lug terminal busbars for positions to be occupied by GMT Fuse Block.

Plug in GM T Fuse Block and secure at two locations on the RTN bar. Torque to 72 in-lbs.

RTN Bar

GMT Fuse Block Installed View

Figure 26:

Installing an Optional Bullet Nose Type 6-Position GMT Distribution Fuse Block (P/N 550224)

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Page 57

Installing an Optional Bullet Nose Type 6-Position GMT Distribution Fuse Block (P/N 549017)

NOTE!

Refer to

Figure 27

as this procedure is performed.

NOTE!

Can be used in a List AL, AN, DE, DF, DG, DH, DJ, and DK distribution panel only.

Procedure

1. Open the distribution cabinet’s front door by turning the latch in the counterclockwise position

(system’s in a relay rack), or open the system’s enclosure door.

2. Follow the steps in Figure 27.

3. Install an appropriately sized GMT fuse in each fuse mounting position on the GMT Distribution Fuse

Block as required. If dummy fuses are installed, first remove the dummy fuse.

a) Verify that dummy fuses are installed in all unused fuse positions on the GMT distribution fuse

block.

b) Verify that a plastic safety cover is installed on all GMT fuses on the GMT distribution fuse block.

4. Record all fuse sizes (installed on the GMT distribution fuse block) on the label provided on the shield.

5. Close the distribution cabinet’s front door and turn the latch clockwise to secure the door (system’s in a

relay rack), or close the system’s enclosure door.

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Page 58

RTN Bar

1. Remove two lug terminal busbars for positions to be occupied by GMT Fuse Block. Remove plastic busbar plugs first.

Plastic Busbar Plugs

2. Plug in GMT Fuse Block.

3. Connect supplied jumper from GMT Fuse Block to Return Bar. Torque to 75 in-lbs.

Part of P/N 549017

Figure 27:

Installing an Optional Bullet Nose Type 6-Position GMT Distribution Fuse Block (P/N 549017)

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Page 59

Fuse

Fuse Carrier

Fuseholder Body

Installing TPH Fuses

Refer to the following procedure and install appropriately sized TPH fuses into the proper fuseholders in the distribution cabinet.

Refer to SAG582127000 for any restrictions.

Procedure

NOTE!

Refer to

Figure 28

as this procedure is performed.

1. Open the distribution cabinet’s front door by turning the latch in the counterclockwise position

(system’s in a relay rack), or open the system’s enclosure door.

2. Remove the TPH fuse carrier from the mounted fuseholder body by grasping its handle and firmly

pulling it straight out. Install the TPH fuse into the fuse carrier. When done, push the fuse carrier securely back into the mounted fuseholder body.

3. Verify that a 1/4 ampere alarm fuse is installed in the GMT-type fuseholder located adjacent to the TPH

fuseholder and that a plastic safety cover is install on this fuse.

4. Record all fuse sizes on the cards provided within the fuseholders.

5. Close the distribution cabinet’s front door and turn the latch clockwise to secure the door (system’s in a

relay rack), or close the system’s enclosure door.

Figure 28:

Installing a TPH Fuse

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Page 60

Installing TPL-B Fuses

Refer to the following procedure and install appropriately sized TPL-B fuses into the proper fuseholders in the distribution cabinet.

Refer to SAG582127000 for any restrictions.

Procedure

NOTE!

Refer to

Figure 29

as this procedure is performed.

1. Open the distribution cabinet’s front door by turning the latch in the counterclockwise position

(system’s in a relay rack), or open the system’s enclosure door.

2. Remove the fuse case from the mounted fuse block by grasping its handle and pulling it straight out.

3. Verify that an 18/100 ampere alarm fuse is present in the GMT-type fuseholder located on the fuse

block and that a plastic safety cover is installed on this fuse.

4. Open the fuse case.

5. Install the TPL fuse into the fuse case.

6. Close the fuse case.

7. Firmly plug the fuse and fuse case into the fuse block.

8. Record all fuse sizes on the cards provided within the fuseholders.

9. Close the distribution cabinet’s front door and turn the latch clockwise to secure the door (system’s in a

relay rack), or close the system’s enclosure door.

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Page 61

Fuse Case

Open Fuse Case View

TPL Fuse

Fuse Installed in Open Fuse Case (rear view)

Fuse Installed in Closed Fuse Case (rear view)

Fuseblock (P/N 516241)

GMT-18/100A Alarm Fuse

(P/N 248610301) and

GMT-X Safety Fuse Cover

(P/N 248898700)

(Both are provided

w/ fuseblock)

Figure 29:

Installing TPL-B Fuses

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Page 62

Installing GJ/218 Circuit Breakers

Refer to the following procedure and install appropriately sized GJ/218 circuit breakers into the proper mounting positions in the distribution cabinet.

Refer to SAG582127000 for any restrictions.

Procedure

NOTE!

Refer to

Figure 30

as this procedure is performed.

1. Locate the appropriate circuit breaker mounting kit ordered with the circuit breaker. The circuit breaker

mounting kit contains installation hardware, an alarm jumper, a shunt jumper (if applicable), a busbar (for 2-pole, 3-pole, and 4-pole circuit breakers), and a circuit breaker guard. Refer to SAG582127000 for part numbers of the circuit breaker mounting kits.

2. Open the distribution cabinet’s front door by turning the latch in the counterclockwise position

(system’s in a relay rack), or open the system’s enclosure door.

3. Ensure that the circuit breaker is in the OFF position, and is of the correct rating and type (electrical

trip/mechanical trip or electrical trip only). Apply anti-oxidizing compound to busbar mating surfaces on the distribution panel and the circuit breaker. Orient the circuit breaker over its mounting location.

a) Attach the alarm jumper connectors to the back of the circuit breaker, then plug the other end of

the alarm jumper into its corresponding connector. See Figure 30.

b) Shunted Breakers Only: Attach the shunt jumper connectors to the back of the circuit breaker,

then route the jumper through the hole in the distribution panel. See Figure 30.

DANGER! The bolts being installed in the following step may be at system potential. Use insulated

tools.

4. Install the circuit breaker into its mounting position and secure with the provided hardware. Torque to

60 in-lbs.

2-Pole, 3-Pole, and 4- Pole Circuit Breakers Only: Also install the mounting kit supplied shorting busbar as shown in Figure 30.

5. Install the circuit breaker guard and label (refer to Figure 30).

6. Shunted Breakers Only: Route and connect shunt leads to the SM-DU+ and Shunt Interface Assembly.

NOTE!

Refer to “Optional SM-DU+ and Shunt Interface Board” on page 138 for proper wiring procedure.

Leads must be terminated before switching breaker ON to avoid circuit fault.

7. Record all circuit breaker sizes on the label provided on the shield.

8. Close the distribution cabinet’s front door and turn the latch clockwise to secure the door (system’s in a

relay rack), or close the system’s enclosure door.

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Page 63

1/4" Hardened Flat Washer 1/4" Belleville Lock Washer 1/4-20 x 3/4” Bolt (2 places) Torque to 60 in-lbs.

OFF

Apply anti-oxidizing compound to busbar mating surfaces before mounting circuit breakers.

INSTALLING CIRCUIT BREAKER

Alarm jumper connector.

Holes to route shunt jumper through (if applicable).

ALARM WIRING (BREAKERS W/OUT SHUNTS)

ALARM WIRING (BREAKERS WITH SHUNTS)

Standard and

Electrical

Trip Breaker

Shunted Breaker Jumper: Red

Alarm Jumper: Brown

Alarm Jumper: Red

Shunted Breaker Jumper: Black

INSTALLING CIRCUIT BREAKER GUARD

OFF

LONGER SIDE OF GUARD

10-32 X 7/16 PH

10-32 LW

CIRCUIT BREAKER GUARD LABEL

CIRCUIT BREAKER GUARD

TYPICAL DIST ASSY SHOWN FOR EXAMPLE

Figure 30:

Installing a GJ/218 Circuit Breaker (1-Pole) (Lists AC, AD, BC, BD) (cont’d on next page)

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Page 64

ALARM WIRING (BREAKERS W/OUT SHUNTS)

ALARM WIRING (BREAKERS WITH SHUNTS)

Standard and

Electrical

Trip Breaker

Shunted Breaker Jumper: Red

Alarm Jumper: Brown

Alarm Jumper: Red

Shunted Breaker Jumper: Black

INSTALLING CIRCUIT BREAKER GUARD

OFF

LONGER SIDE OF GUARD

10-32 X 7/16 PH

10-32 LW

CIRCUIT BREAKER GUARD LABEL

CIRCUIT BREAKER GUARD

TYPICAL DIST ASSY SHOWN FOR EXAMPLE

1/4" Hardened Flat Washer 1/4" Belleville Lock Washer 1/4-20 x 3/4” Bolt (4 places / 2-pole brk, 6 places / 3-pole brk, 8 places / 4-pole brk) Torque to 60 in-lbs.

Apply anti-oxidizing compound to busbar mating surfaces before mounting circuit breakers.

OFF

INSTALLING CIRCUIT BREAKER

Alarm jumper connectors.

Holes to route shunt jumper through (if applicable).

Busbar

2-pole breaker shown. 3-pole and 4-pole breakers similar.

Figure 30:

Installing a GJ/218 Circuit Breaker (2-Pole, 3-Pole, 4-Pole) (Lists AC, AD, BC, BD) (cont’d from

previous page, cont’d on next page)

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Page 65

INSTALLING CIRCUIT BREAKER

ALARM WIRING (BREAKERS W/OUT SHUNTS)

ALARM WIRING (BREAKERS WITH SHUNTS)

Standard and

Electrical

Trip Breaker

Shunted Breaker Jumper: Red

Alarm Jumper: Brown

Alarm Jumper: Red

Shunted Breaker Jumper: Black

INSTALLING CIRCUIT BREAKER GUARD

OFF

LONGER SIDE OF GUARD

10-32 X 7/16 PH

10-32 LW

CIRCUIT BREAKER GUARD LABEL

CIRCUIT BREAKER GUARD

TYPICAL DIST ASSY SHOWN FOR EXAMPLE

Apply anti-oxidizing compound to busbar mating surfaces before mounting circuit breakers.

1/4" Hardened Flat Washer 1/4" Belleville Lock Washer 1/4-20 x 3/4” Bolt (2 places) Torque to 60 in-lbs.

OFF

Alarm jumper connector.

1/4" Hardened Flat Washer 1/4" Belleville Lock Washer 1/4-20 x 3/4” Bolt (4 places / 2-pole breaker, 6 places / 3-pole breaker, 8 places / 4-pole breaker) Torque to 60 in-lbs.

Shorting Busbar

For a 3-pole and 4-pole breaker, install shorting busbars top and bottom. (4-pole shorting busbars shown, 3-pole similar)

2-pole breaker shown. 3-pole and 4-pole breakers similar.

Return Busbar (not included with List AP)

Figure 30:

Installing a GJ/218 Circuit Breaker (1-Pole, 2-Pole, 3-Pole, 4-Pole) (List AM and List AP) (cont’d from

previous page)

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Page 66

ptional SM-DU+ and

Shunt Interface Board

4-Row Cabinet Shown,

Others Similar

(Front Door Removed in

Illustration for Clarity)

Controller

System Interface

Circuit Card

Optional LVD

Driver Circuit Card

Optional LVD

Inhibit Switch

(factory installed

if option specified)

Optional LVD Driver

Lite Circuit Card

Optional Manual Battery Disconnect Circuit Card (Main Bay Only)

IB2 (Main Bay Only)

(Interface Board)

(located on inside side panel)

Optional EIB (Main Bay Only)

(Extended Interface Board)

(located on inside side panel)

Optional IB4 (Main Bay Only) (Second Ethernet Port Board)

Optional Second IB2 or EIB (Main Bay Only) (underside of cover)

SETTING JUMPERS AND SWITCH OPTIONS

Circuit Card Locations

Refer to Figure 31.

Figure 31:

Circuit Card Locations (Main Bay)

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Page 67

4-Row Cabinet Shown,

Others Similar

(Illustration for Clarity)

CAN Interface

Card

Optional LVD

Driver Circuit Card

Optional LVD Driver

Lite Circuit Card

System Interface

Circuit Card

SM-DU

Figure 31:

Circuit Card Locations (Supplementary Bay)

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Page 68

Jumpers on System Interface Circuit Card (Main Bay Only)

Perform the following procedures to verify the factory settings and/or make the required settings per your site requirements. These procedures can also be used to make adjustments on a replacement circuit card.

Controller Power Option

The controller is always powered from the internal “system” bus. A jumper option allows the controller to be also powered by battery. Battery power allows the controller to stay running in the event rectifiers are off or battery LVD opens (if installed). Note that if powering the controller from battery, the battery will drain if rectifiers are off or battery LVD opens (if installed). The controller’s power consumption is 5W.

Procedure

1. Refer to Figure 32 and place the jumper on J8 in the “Battery Pwr” or “No Battery Pwr” position.

Internal/External Battery Monitoring

Selects to monitor (and display via the controller) battery voltage from either an “internal” or “external” source.

Procedure

1. Refer to Figure 32 and place the jumper on J10 in the “Internal” or “External” position. If “External” is

selected, connect sense leads to TB1-4 and TB1-5 (see Figure 32).

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Page 69

2A 3A

1B 2B 3B

TB2

TB1

TP1 TP2 TP 3 TP4

J10

TB1-2, TB1-3, TB1-4, TB1-5 Main Bay Only.

TB1-4: External Battery Monitoring (-) TB1-5: External Battery Monitoring (+)

4-Row Cabinet Shown,

Others Similar

(Front Door Removed in

Illustration for Clarity)

System Interface

Circuit Card

System Interface

Circuit Card

External Internal

J10

1 2 3

7 8 9

J10 (Main Bay Only) Battery Monitoring External / Internal (see TB1-4 and TB1-5 for external monitoring points)

Shorting Jumper

J8 (Main Bay Only) Selects to power Controller from “Battery Power” or not.

Battery

Pwr

Battery Pwr

1 2 3

7 8 9

Shorting Jumper

Main Bay Only.

Figure 32:

System Interface Circuit Card Jumper Locations

Switch Settings on IB2 Interface Board (Main Bay Only)

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 33 for SW1 location.

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Page 70

IB2-1 in Main Bay

OFF

Optional EIB-2 in Main Bay

OFF

Perform the following procedure to verify the factory settings. This procedure can also be used to make adjustments on a replacement circuit card.

Procedure

1. Ensure SW1 is set per Table 1. Refer to Figure 33 for location.

Table 1:

IB2 Interface Board Switch Settings

DIP Switch SW1

Setting

1 2

Optional IB2-2 in Main Bay ON OFF

Switch Setting on Optional EIB Interface Board (Main Bay Only)

Dip Switch SW1 on the EIB board is used to set the communications address for this board. Refer to Table 2 for SW1 settings. Refer to Figure 34 for SW1 location.

Perform the following procedure to verify the factory settings. This procedure can also be used to make adjustments on a replacement circuit card.

Procedure

1. Ensure SW1 is set per Table 2. Refer to Figure 34 for location.

Table 2:

Optional EIB Interface Board Switch Settings

EIB-1 in Main Bay OFF OFF

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DIP Switch SW1

Setting

1 2

Page 71

Figure 33:

B2 Interfac

(Top

View)

IB2 Interface Board Switch Location and Settings (installed in Main Bay only)

e Bo

ard

J12

J5 J4 J3

J11

Swi

1 2

ff o

tch SW1 is loca

thi

s co

rner of the IB2 Bo

ttin

IB2

-1

in Main B

Opt

n Main Bay

OFF

SW1

ional IB

2-2

(Refer

Optional IB2

DIP Switch SW

1 2

OFF OFF

ON OF

to table

switch

for setting)

ted

ard.

J9 J8 J7

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Page 72

In this system, switch settings

must be in positions shown.

Optional EIB Interface Board

(Top View)

Switch SW1 is located in

this corner of the EIB Board.

SW1

off

OFF

SW1

Setting

DIP Switch SW1

1 2

OFF OFF

Optional EIB-2

in Main Bay

OFF

EIB-1

in Main Bay

(Refer to table for

Optional EIB switch setting)

Figure 34:

Optional EIB Interface Board Switch Location and Settings (installed in Main Bay only)

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Page 73

Supplemental Bay Addressing

8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1

SM-DU Circuit Card

S 1S2S 3

JP 1

JP 2

JP 3

J4J4A

Power

CANRS48 5

RS48

RS232

OFF

Green Indicator (Operation) Yellow Indicator (Alarm) Red Indicator (Alarm)

Switch Setting on SM-DU (Supplemental Bays Only)

SM-DU uses three (3) 8-bit switches for parameter setting (S1, S2, and S3). Refer to Table 3for switch settings. Refer to Figure 35 for switch locations.

Perform the following procedure to verify the factory settings. This procedure can also be used to make adjustments on a replacement circuit card.

Procedure

1. Ensure S1, S2, and S3 are set per Table 3. Refer to Figure 35 for location.

Figure 35:

SM-DU Switch Location

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Page 74

DIP Switch S1

Communication

Address

Shunt

Voltage

Shunt

Current

Description of Status

1 2 3 4 5 6 7 8 OFF

OFF

Address 8#

OFF

Address 1# (Setting for SM-DU in 1st Supp. Bay)

OFF

Address 2# (Setting for SM-DU in 2nd Supp. Bay)

OFF

Address 3# (Setting for SM-DU in 3rd Supp. Bay)

OFF

Address 4# (Setting for SM-DU in 4th Supp. Bay)

OFF

Address 5# (Setting for SM-DU in 5th Supp. Bay)

OFF

Address 6#

Address 7#

OFF

Shunt Voltage: 75mV

OFF

Shunt Voltage: 25mV (Note 1)

OFF

Shunt Voltage: 50mV

Shunt Voltage: 60mV

OFF

Shunt Current: 500A (Note 1)

OFF

Shunt Current: 100A

OFF

Shunt Current: 200A

OFF

Shunt Current: 300A

OFF

Shunt Current: 400A

OFF

Shunt Current: 1000A

OFF

Shunt Current: 1500A

Shunt Current: 2000A

Table 3:

SM-DU Switch Settings (cont’d on next page)

Note 1: Setting for this system.

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Page 75

DIP Switch S2

Shunt 1 Setting

Shunt 2

Setting

Shunt 3

Setting

Shunt 4

Setting

Description of Status

1 2 3 4 5 6 7 8 OFF

OFF

Shunt 1 is Disabled

OFF

Shunt 1 is Used for Battery

OFF

Shunt 1 is Used for Load (Note 1)

Set via Software

OFF

Shunt 2 is Disabled

OFF

Shunt 2 is Used for Battery (Note 1)

OFF

Shunt 2 is Used for Load

Set via Software

OFF

Shunt 3 is Disabled (Note 1)

OFF

Shunt 3 is Used for Battery

OFF

Shunt 3 is Used for Load

Set via Software

OFF

Shunt 4 is Disabled (Note 1)

OFF

Shunt 4 is Used for Battery

OFF

Shunt 4 is Used for Load

Set via Software

Table 3:

SM-DU Switch Settings (cont’d from previous page, cont’d on next page)

Note 1: Setting for this system.

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Page 76

DIP Switch S3

Set via

Software

Contactor

Type

Safe Mode

Dry Contact

Description of Status

1 2 3

(Note

(Note 1)

DIP Switch S3

Shunt 5 Setting

Reserved

Calibration

Mode

Description

of Status

5 6 7

(Note 1)

Table 3:

Off

SM-DU Switch Settings (cont’d from previous page)

Off

On Mono-Stable Contactor

Off

On LVD2 is a Dry Contact

Off LVD2

Shunt parameter is set through DIP switch.

Shunt parameter is set via software.

Bi-Stable Contactor

LVD / reconnection is disabled upon communication failure.

LVD / reconnection is enabled upon communication failure.

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Off Off

Shunt 5 is Disabled

Off On Shunt 5 is Used for Battery

On Off Shunt 5 is Used for Load

On On Set via Software

Off Operation Mode

On Calibration Mode

Note 1: Setting for this system.

Page 77

SM-DU+ and

Shunt Interface Board

SM-DU+

Switches SW1 and SW2 are located in this corner of the SM-DU+.

SW1 SW2

5 6 7 8

1 2 3 4

off

5 6 7 8

1 2 3 4

off

SW1 and SW 2 In this system, switch settings must be in the positions shown, except adressing switches, which must be set to a uniqe address.

Set each SM-DU+ in the system to a unique address.

Power CAN R S485 RS48 5

RS232

SW1 SW2

Shunt Shunt

J8 J6

Fuse

J4 J4A

OFF

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

Green Indicator

Switch Setting on SM-DU+

SM-DU+ uses two (2) 8-bit switches for parameter setting (SW1 and SW2). Refer to Table 4 for SW1 and SW2 settings. Refer to Figure 36 for SW1 and SW2 locations.

Perform the following procedure to verify the factory settings. This procedure can also be used to make adjustments on a replacement circuit card.

Procedure

Ensure SW1 and SW2 are set per Table 4. Refer to Figure 36 for location.

Figure 36: Optional SM-DU+ Switch Location and Settings

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Page 78

DIP Switch SW1

Reserved

/SW

Shunt

Voltage

Shunt

Current

Description of Status

1 2 3 4 5 6 7

OFF

Shunt parameter is set through DIP switch.

Shunt parameter is set through software (note 1).

OFF

Shunt Voltage: 25mV (note 1)

OFF

Shunt Voltage: 50mV

OFF

Shunt Voltage: 60mV

Shunt Voltage: 75mV

OFF

Shunt Current: 500A (note 1)

OFF

Shunt Current: 100A

OFF

Shunt Current: 200A

OFF

Shunt Current: 300A

OFF

Shunt Current: 400A

OFF

Shunt Current: 1000A

OFF

Shunt Current: 1500A

Shunt Current: 2000A

DIP Switch SW2

Reserved

Communications

Address

Baud

Rate

Description of Status

1 2 3 4 5 6 7

OFF

Address 1# (Setting for SM-DU+ in Main Bay)

OFF

Address 2# (Setting for SM-DU+ in 1st Supp. Bay)

OFF

Address 3# (Setting for SM-DU+ in 2nd Supp. Bay)

OFF

Address 4# (Setting for SM-DU+ in 3rd Supp. Bay)

OFF

Address 5# (Setting for SM-DU+ in 4th Supp. Bay)

OFF

Address 6# (Setting for SM-DU+ in 5th Supp. Bay)

OFF

Address 7#

Address 8#

OFF

19200 (note 1)

9600

Table 4: Optional SM-DU+ Switch Settings

Note 1: Setting for this system.

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Page 79

Heads

Die Index/

Code No.

Die Cat. Number

Burndy: YA25L-4TCG1

Burndy: YA26L-4TCG1

Burndy: YA27L-4TCG1

Burndy: YA28L-4TCG1

T & B:

1879

Burndy: YA29L-4TCG1

T & B:

1880

Burndy: YA31L-4TCG1

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 SAG582127000.

Lugs should be crimped per lug manufacturer’s specifications.

Refer to Table 5 for supplemental lug crimping information when using the special application crimp lug / strap combination.

Table 5:

Supplemental Lug Crimping Information when using the Special Application Crimp Lug / Strap

Combination

Crimp Tool Required1,

T&B Model TBM12 or TBM15 Hydraulic

Crimp Lug Part No.

Color Key

245393500

245393600

245393700

245393800

256-30695-

514872

Pink 42H 15508

Black 45 15526

Orange 50 15530

Purple 54H 15511

Yellow 62 15510

Vertiv | NetSure 7100 Series -48V DC Power System Installation Manual (IM582127000) | Rev. BB

256-30695-

514873

The lugs should be crimped to the specifications given in the manufacturer’s

instructions furnished with the crimp tool or lug.

Red 71 15514

Page 80

Relay Rack or Enclosure Grounding Connection (Frame Ground)

System components are factory mounted in a relay rack, on shipping rails, or in an enclosure as specified when ordered.

For relay rack and enclosure 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.

A customer's grounding network lead can be attached to the top of the relay rack or enclosure. Provision is made for installing a lead with a two-hole lug that has 1/4" bolt clearance holes on 5/8" centers. When using 1/4inch hardware, recommended torque is 84 in-lbs when a standard flat washer and lock washer are used. Refer to Figure 37 for locations.

NOTE!

REMOVE TAPE (IF PRESENT) FROM HOLE LOCATIONS BEFORE INSTALLING LUG.

NOTE!

The DC return connection to this system can remain isolated from system frame and chassis

(DC-I).

NOTE!

This system is suitable for installation as part of the Common Bonding Network (CBN).

Central Office Ground Connection

Landing points are provided on the battery return bus for a central office ground lead (see Figure 104, Figure 105, and Figure 108). 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.

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Page 81

Frame Ground

Connection Point

(1/4” clearance holes on 5/8” centers)

Frame Ground

Connection Point

(1/4” clearance holes on 5/8” centers)

Frame Ground

Connection Point

(1/4-20 Clinch Nuts on 5/8” centers)

Top View

(Typical Relay Rack)

Top View

(Typical Relay Rack)

Top View

(Typical Cabinet)

Figure 37:

Relay Rack and Enclosure Frame Grounding Connection Points

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Page 82

Nominal 208 VAC, 240 VAC, 277 VAC, or 277 VAC / 480 VAC Input and Equipment Grounding Connections (if equipped)

System components are factory mounted in a relay rack, on shipping rails, or in an enclosure as specified when ordered.

DANGER! Adhere to the “Important Safety Instructions” presented at the front of this document.

General

NOTE THAT THIS SYSTEM MAY BE EQUIPPED WITH AC OR DC INPUTS. THESE PROCEDURES APPLY TO SYSTEMS WITH AC INPUTS. SPECIFICALLY, THESE PROCEDURES APPLY TO THE FOLLOWING EQUIPMENT:

• 582127000 List 40, 41, 42, 43

• 588705000 List 21, 22, 31, 32, 33

• 588705300 List 01, 03, 21

• 588705400 List 01, 02, 03, 04

• 588705500 List 01, 02, 03, 04, 05

Wiring Considerations

For wire size, branch circuit protection, crimp lug, and general wiring recommendations; refer to System Application Guide SAG582127000.

AC Input Termination Assemblies

The available AC input options for this system are:

• The system can be equipped with an AC input termination assembly which provides a separate single

phase AC input connection for each rectifier position (582127000 List 40).

• The system can be equipped with an AC input termination assembly which provides a separate single

phase AC input connection for every two (2) rectifier positions (582127000 List 41).

• The system can be equipped with an AC input termination assembly which provides a separate three

phase AC input connection for every three (3) rectifier positions (582127000 List 42 and List 43).

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Page 83

Direct AC Input Connections to the Module Mounting Assemblies

• The system can be equipped with module mounting assemblies that contain AC input terminal blocks

which provide a separate single phase AC input connection for each rectifier position (588705000 List 31; 588705500 List 03).

• The system can be equipped with module mounting assemblies that contain AC input terminal blocks

which provide a separate three phase AC input connection for every three (3) rectifier positions (588705000 List 32 and List 33; 588705500 List 04 and List 05).

• The system can be equipped with module mounting assemblies that contain AC input line cords (one

for each rectifier module position) (588705000 List 22; 588705500 List 02).

• The system can be equipped with module mounting assemblies that contain AC input cable assemblies

or AC input line cords which provide a separate single phase AC input connection for every two (2) rectifier positions (588705300 List 03).

• The system can be equipped with module mounting assemblies that contain AC input cable assemblies

or AC input line cords (one for each rectifier module position) (588705400 List 02).

• The system can be equipped with module mounting assemblies that contain AC input line cords which

provide a separate three phase AC input connection for every three (3) rectifier positions (588705400 List 03 and List 04).

AC Input Conduit Options (For System Mounted in an Enclosure)

Two types of conduit plates are available. Select and install the conduit plate appropriate for your application. See “AC Input Conduit Options” on page 17.

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Page 84

Connections to AC Input Termination Assemblies (582127000 List 40, 41, 42, 43) (For System Mounted in a Relay Rack)

The AC input termination assemblies provide circular openings at the top for AC input and grounding conductors. The openings accept 1 inch conduit fittings. It is recommended that AC input wiring be provided to all rectifier mounting positions, including currently unused positions. This wiring will ease future installation of rectifiers to meet increased load requirements.

NOTE!

A grounding conductor must be provided with each conduit.

Procedure

Refer to Figure 38, Figure 39, Figure 40, or Figure 41 as these procedures are performed.

Accessing Connections and Routing Wire

1. Remove the two AC input connector covers and the AC input wireway covers by first loosening the

fasteners that secure each of them.

2. Install conduit fittings as required in the top of the AC Input Termination Assembly. Plug buttons are

provided, and must be installed in the openings not being used.

3. Route wiring into the AC Input Termination Assembly through the previously installed conduit fittings.

Making AC Input Connections

1. Make AC input connections as shown in Figure 38, Figure 39, Figure 40, or Figure 41. Connect each

wire by inserting the stripped end into the wire opening, and then tightening the screw. Torque connections to value shown in the appropriate illustration.

NOTE!

Terminal blocks for a system with maximum possible rectifier shelves shown. Your system may

have fewer terminal blocks than shown.

Making Equipment Grounding Connections

NOTE!

Make equipment grounding connections to earth ground,

not

to the branch circuit neutral

conductor.

1. Connect equipment grounding leads to the frame ground studs using installer-provided ring lugs and

factory-supplied mounting hardware. Torque connections to value shown in the appropriate illustration.

Reinstalling Covers

1. After all AC input and equipment grounding connections have been made and checked, reinstall the two

AC input connector covers and the AC input wireway covers. Secure each by tightening the fasteners.

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Page 85

(4-Row Cabinet Shown,

Others Sim ilar)

Front Door Removed in

Illustration for Clarity

AC INPUT CONNECTIONS, 1 FEED PER 1 RECTIFIER, SINGLE PHASE (582127000 LIST 40)

NOTE: WIRING TO A FIELD INSTALLED SHELF IS DONE AT THE REAR OF THE SHELF.

AC Wireway

Cover

AC Wireway Cover

AC Input

Connector Cover

PCU1

L1 L2/N

PCU2

L1 L2/N

PCU3

L1 L2/N

PCU1

L1 L2/N

PCU2

L1 L2/N

PCU3

L1 L2/N

PCU1

L1 L2/N

PCU2

L1 L2/N

PCU3

L1 L2/N

PCU1

L1 L2/N

PCU2

L1 L2/N

PCU3

L1 L2/N

PCU1

L1 L2/N

PCU2

L1 L2/N

PCU3

L1 L2/N

PCU4

L1 L2/N

PCU5

L1 L2/N

PCU6

L1 L2/N

PCU4

L1 L2/N

PCU5

L1 L2/N

PCU6

L1 L2/N

PCU4

L1 L2/N

PCU5

L1 L2/N

PCU6

L1 L2/N

PCU4

L1 L2/N

PCU5

L1 L2/N

PCU6

L1 L2/N

PCU4

L1 L2/N

PCU5

L1 L2/N

PCU6

L1 L2/N

Inside View

Left Side

Inside View Right Side

GND GND

GND

AC 2AC 1

PCU 1

AC 2AC 1

PCU 2

AC 2AC 1

PCU 3

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 1 RECTIFIE R (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60Hz, SINGLE PHASE

SHELF 1

AC 2AC 1

PCU 1

AC 2AC 1

PCU 2

AC 2AC 1

PCU 3

AC 2AC 1

PCU 1

AC 2AC 1

PCU 2

AC 2AC 1

PCU 3

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 1 RECTIFIE R (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60Hz, SINGLE PHASE

SHELF 3 SHELF 2

AC 2AC 1

PCU 1

AC 2AC 1

PCU 2

AC 2AC 1

PCU 3

AC 2AC 1

PCU 1

AC 2AC 1

PCU 2

AC 2AC 1

PCU 3

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 1 RECTIFIE R (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60Hz, SINGLE PHASE

SHELF 5 SHELF 4

AC 2AC 1

PCU 4

AC 2AC 1

PCU 5

AC 2AC 1

PCU 6

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 1 RECTIFIE R (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60Hz, SINGLE PHASE

SHELF 1

AC 2AC 1

PCU 4

AC 2AC 1

PCU 5

AC 2AC 1

PCU 6

AC 2AC 1

PCU 4

AC 2AC 1

PCU 5

AC 2AC 1

PCU 6

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 1 RECTIFIE R (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60Hz, SINGLE PHASE

SHELF 2 SHELF 3

AC 2AC 1

PCU 4

AC 2AC 1

PCU 5

AC 2AC 1

PCU 6

AC 2AC 1

PCU 4

AC 2AC 1

PCU 5

AC 2AC 1

PCU 6

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 1 RECTIFIE R (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60Hz, SINGLE PHASE

SHELF 4 SHELF 5

Line to Line: Connect Line 1 to Terminal L1. Connect Line 2 to Terminal L2/N.

Line to Neutral Connect Line to Terminal L1. Connect Neutral to Terminal L2/N.

Wire Size Capacity: 10-24 AWG. Recommended Torque: 10 in-lbs.

FRAME GROUND CONNECTION Four 10-32 X 3/4" Studs and Hardware. Recommended torque: 23 in-lbs.

Rectifier Module (PCU) Mounting Slots

Shelf #1

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Shelf #2

Shelf #3

Shelf #4

Shelf #5

Note: For fewer power shelves than shown, only the connections for the installed shelves are present.

Figure 38:

AC Input Connections to AC Input Termination Assembly List 40 when Used with 588705000 (Nominal 208 VAC, 240 VAC, 277 VAC) or 588705300 (Nominal 208 VAC, 240 VAC) or 588705400 (Nominal 208 VAC, 240 VAC, 277 VAC) or 588705500 (Nominal 208 VAC, 240 VAC, 277 VAC) Module Mounting Assemblies with Rectifiers (1 Feed per 1 Rectifier, Single Phase) (Installed in a Relay Rack) (cont’d on next page)

Vertiv | NetSure 7100 Series -48V DC Power System Installation Manual (IM582127000) | Rev. BB

Page 86

(4-Row Cabinet Shown,

Others Sim ilar)

Front Door Removed in

Illustration for Clarity

AC INPUT CONNECTIONS, 1 FEED PER 2 RECTIFIERS, SINGLE PHASE (582127000 LIST 41), with Five (5) Shelves Installed

Inside View

Left Side

Inside View Right Side

NOTE: WIRING TO A FIELD INSTALLED SHELF IS DONE AT THE REAR OF THE SHELF.

GND GND GND GND

L2/NL1 L2/NL1 L2/NL1 L2/NL1 L2/NL1 L2/NL1

L2/NL1 L2/NL1 L2/NL1 L2/NL1 L2/NL1 L2/NL1 L2/NL1 L2/NL1 L2/NL1

PCU 1

PCU 2 PCU 3

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 2 RECTIFIERS (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60Hz, SINGLE PHASE

SHELVES 1 AND 2

PCU 4

PCU 5 PCU 6

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 2 RECTIFIERS (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60Hz, SINGLE PHASE

SHELVES 1 AND 2

AC Wireway

Cover

AC Wireway Cover

AC Input

Connector Cover

FRAME GROUND CONNECTION Four 10-32 X 3/4" Studs and Hardware. Recommended torque: 23 in-lbs.

Line to Line:

Connect Line 1 to Terminal L1.

Connect Line 2 to Terminal L2/N.

Line to Neutral Connect Line to Terminal L1. Connect Neutral to Terminal L2/N.

Wire Size Capacity: 6-14 AWG. Recommended Torque: 18 in-lbs.

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 2 RECTIFIERS (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60Hz, SINGLE PHASE

SHELVES 3 AND 4 SHELF 5

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 2 RECTIFIERS (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60Hz, SINGLE PHASE

SHELF 5SHELVES 3 AND 4

PCU 1 PCU 2 PCU 3

PCU 4 PCU 5

PCU 6

PCU 1/2 PCU 3/4

PCU 5/6

Rectifier Module (PCU) Mounting Slots

Shelf #1

Rect. (PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect. (PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect. (PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect. (PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect. (PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Shelf #2

Shelf #3

Shelf #4

Shelf #5

L2/NL1 L2/NL1 L2/NL1 L2/NL1 L2/NL1 L2/NL1

L2/NL1 L2/NL1 L2/NL1 L2/NL1

L2/NL1 L2/NL1 L2/NL1

L2/NL1 L2/NL1

Figure 39:

AC Input Connections to AC Input Termination Assembly List 41 when used with 588705000 (Nominal 208 VAC, 240 VAC, 277 VAC) or 588705300 (Nominal 208 VAC, 240 VAC) or 588705400 (Nominal 208 VAC, 240 VAC, 277 VAC) or 588705500 (Nominal 208 VAC, 240 VAC, 277 VAC) Module Mounting Assemblies with Rectifiers (1 Feed per 2 Rectifiers, Single Phase) - with Five (5) Shelves Installed (Installed in a Relay Rack) (cont’d on next page)

Vertiv | NetSure 7100 Series -48V DC Power System Installation Manual (IM582127000) | Rev. BB

Page 87

(4-Row Cabinet Shown,

Others Sim ilar)

Front Door Removed in

Illustration for Clarity

AC INPUT CONNECTIONS, 1 FEED PER 2 RECTIFIERS, SINGLE PHASE (582127000 LIST 41), with Four (4) Shelves Installed

Inside View

Left Side

Inside View Right Side

NOTE: WIRING TO A FIELD INSTALLED SHELF IS DONE AT THE REAR OF THE SHELF.

GND GND GND GND

PCU 1 PCU 2 PCU 3

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 2 RECTIFIERS (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60Hz, SINGLE PHASE

SHELVES 1 AND 2

PCU 4

PCU 5 PCU 6

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 2 RECTIFIERS (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60Hz, SINGLE PHASE

SHELVES 1 AND 2

AC Wireway

Cover

AC Wireway Cover

AC Input

Connector Cover

FRAME GROUND CONNECTION Four 10-32 X 3/4" Studs and Hardware. Recommended torque: 23 in-lbs.

Line to Line: Connect Line 1 to Terminal L1. Connect Line 2 to Terminal L2/N.

Line to Neutral Connect Line to Terminal L1. Connect Neutral to Terminal L2/N.

Wire Size Capacity: 6-14 AWG. Recommended Torque: 18 in-lbs.

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 2 RECTIFIERS (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60Hz, SINGLE PHASE

SHELVES 3 AND 4

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 2 RECTIFIERS (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60Hz, SINGLE PHASE

SHELVES 3 AND 4

PCU 1

PCU 2 PCU 3

PCU 4 PCU 5 PCU 6

Rectifier Module (PCU) Mounting Slots

Shelf #1

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Shelf #2

Shelf #3

Shelf #4

L2/NL1 L2/NL1 L2/NL1 L2/NL1 L2/NL1 L2/NL1

Figure 39:

AC Input Connections to AC Input Termination Assembly List 41 when used with 588705000 (Nominal 208 VAC, 240 VAC, 277 VAC) or 588705300 (Nominal 208 VAC, 240 VAC) or 588705400 (Nominal 208 VAC, 240 VAC, 277 VAC) or 588705500 (Nominal 208 VAC, 240 VAC, 277 VAC) Module Mounting Assemblies with Rectifiers (1 Feed per 2 Rectifiers, Single Phase) - with Four (4) Shelves Installed (Installed in a Relay Rack) (cont’d from previous page, cont’d on next page)

Vertiv | NetSure 7100 Series -48V DC Power System Installation Manual (IM582127000) | Rev. BB

Page 88

(4-Row Cabinet Shown,

Others Sim ilar)

Front Door Removed in

Illustration for Clarity

AC INPUT CONNECTIONS, 1 FEED PER 2 RECTIFIERS, SINGLE PHASE (582127000 LIST 41), with Three (3) Shelves Installed

Inside View

Left Side

Inside View Right Side

NOTE: WIRING TO A FIELD INSTALLED SHELF IS DONE AT THE REAR OF THE SHELF.

GND GND

PCU 1

PCU 2 P CU 3

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 2 RECTIFIERS (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60Hz, SINGLE PHASE

SHELVES 1 AND 2

PCU 4

PCU 5

PCU 6

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 2 RECTIFIERS (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60Hz, SINGLE PHASE

SHELVES 1 AND 2

AC Wireway

Cover

AC Wireway Cover

AC Input

Connector Cover

FRAME GROUND CONNECTION Four 10-32 X 3/4" Studs and Hardware. Recommended torque: 23 in-lbs.

Line to Line: Connect Line 1 to Terminal L1. Connect Line 2 to Terminal L2/N.

Line to Neutral Connect Line to Terminal L1. Connect Neutral to Terminal L2/N.

Wire Size Capacity: 6-14 AWG. Recommended Torque: 18 in-lbs.

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 2 RECTIFIERS (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60Hz, SINGLE PHASE

SHELF 3

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 2 RECTIFIERS (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60Hz, SINGLE PHASE

SHELF 3

PCU 1/2 PCU 3/4

PCU 5/6

Rectifier Module (PCU) Mounting Slots

Shelf #1

Rect. (PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect. (PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect. (PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Shelf #2

Shelf #3

L2/NL1

L2/NL1 L2/NL1

L2/NL1 L2/NL1 L2/NL1

L2/NL1 L2/NL1 L2/NL1 L2/NL1

L2/NL1

L2/NL1 L2/NL1 L2/NL1

L2/NL1 L2/NL1 L2/NL1 L2/NL1

Figure 39:

AC Input Connections to AC Input Termination Assembly List 41 when used with 588705000 (Nominal 208 VAC, 240 VAC, 277 VAC) or 588705300 (Nominal 208 VAC, 240 VAC) or 588705400 (Nominal 208 VAC, 240 VAC, 277 VAC) or 588705500 (Nominal 208 VAC, 240 VAC, 277 VAC) Module Mounting Assemblies with Rectifiers (1 Feed per 2 Rectifiers, Single Phase) - with Three (3) Shelves Installed (Installed in a Relay Rack) (cont’d from previous page, cont’d on next page)

Vertiv | NetSure 7100 Series -48V DC Power System Installation Manual (IM582127000) | Rev. BB

Page 89

(4-Row Cabinet Shown,

Others Similar)

Front Door Removed in

Illustration for Clarity

AC INPUT CONNECTIO NS, 1 FEED PER 2 RECTIFIERS, SINGLE PHASE (582127000 LIST 41), with Two (2) Shelves Installed

Inside View

Left Side

Inside View Right Side

NOTE: WIRING TO A FIELD INSTALLED SHELF IS DONE AT THE REAR OF THE SHELF.

GND GND GND GND

PCU 1 PCU 2 PCU 3

RECTIFIER (PCU) AC INPUT FEE DS

1 FEED PER 2 RECTIFIERS (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60Hz, SINGLE PHASE

SHELVES 1 AND 2

PCU 4

PCU 5 PCU 6

RECTIFIER (PCU) AC INPUT FEE DS

1 FEED PER 2 RECTIFIERS (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60Hz, SINGLE PHASE

SHELVES 1 AND 2

AC Wireway

Cover

AC Wireway Cover

AC Input

Connector Cover

FRAME GROUND CONNECTION Four 10-32 X 3/4" Studs and Hardware. Recommended torque: 23 in-lbs.

Line to Line: Connect Line 1 to Terminal L1. Connect Line 2 to Terminal L2/N.

Line to Neutral Connect Line to Terminal L1. Connect Neutral to Terminal L2/N.

Wire Size Capacity: 6-14 AWG. Recommended Torque: 18 in-lbs.

Rectifier Module (PCU) Mounting Slots

Shelf #1

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Shelf #2

L2/NL1 L2/NL1 L2/NL1 L2/NL1 L2/NL1 L2/NL1

Figure 39:

AC Input Connections to AC Input Termination Assembly List 41 when used with 588705000 (Nominal 208 VAC, 240 VAC, 277 VAC) or 588705300 (Nominal 208 VAC, 240 VAC) or 588705400 (Nominal 208 VAC, 240 VAC, 277 VAC) or 588705500 (Nominal 208 VAC, 240 VAC, 277 VAC) Module Mounting Assemblies with Rectifiers (1 Feed per 2 Rectifiers, Single Phase) - with Two (2) Shelves Installed (Installed in a Relay Rack) (cont’d from previous page, cont’d on next page)

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Page 90

(4-Row Cabinet Shown,

Others Similar)

Front Door Removed in

Illustration for Clarity

AC INPUT CONNECTIO NS, 1 FEED PER 2 RECTIFIERS, SINGLE PHASE (582127000 LIST 41), with One (1) Shelf Installed

Inside View

Left Side

Inside View Right Side

NOTE: WIRING TO A FIELD INSTALLED SHELF IS DONE AT THE REAR OF THE SHELF.

GND GND GND GND

RECTIFIER (PCU) AC INPUT FEE DS

1 FEED PER 2 RECTIFIERS (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60Hz, SINGLE PHASE

SHELF 1

RECTIFIER (PCU) AC INPUT FEE DS

1 FEED PER 2 RECTIFIERS (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60Hz, SINGLE PHASE

SHELF 1

AC Wireway

Cover

AC Wireway Cover

AC Input

Connector Cover

FRAME GROUND CONNECTION Four 10-32 X 3/4" Studs and Hardware. Recommended torque: 23 in-lbs.

Line to Line: Connect Line 1 to Terminal L1. Connect Line 2 to Terminal L2/N.

Line to Neutral Connect Line to Terminal L1. Connect Neutral to Terminal L2/N.

Wire Size Capacity: 6-14 AWG. Recommended Torque: 18 in-lbs.

L2/NL1

PCU 1/2

L2/NL1

PCU 3/4

L2/NL1

PCU 5/6

L2/NL1L2/NL1 L2/NL1

Rectifier Module (PCU) Mounting Slots

Shelf #1

Rect. (PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Figure 39:

AC Input Connections to AC Input Termination Assembly List 41 when used with 588705000 (Nominal 208 VAC, 240 VAC, 277 VAC) or 588705300 (Nominal 208 VAC, 240 VAC) or 588705400 (Nominal 208 VAC, 240 VAC, 277 VAC) or 588705500 (Nominal 208 VAC, 240 VAC, 277 VAC) Module Mounting Assemblies with Rectifiers (1 Feed per 2 Rectifiers, Single Phase) - with One (1) Shelf Installed (Installed in a Relay Rack) (cont’d from previous page)

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Page 91

(4-Row Cabinet Shown,

Others Sim ilar)

Front Door Removed in

Illustration for Clarity

AC INPUT CONNECTIONS, 1 FEED PER 3 RECTIFIERS, THREE PHASE (582127000 LIST 42)

Inside View

Left Side

Inside View Right Side

NOTE: WIRING TO A FIELD INSTALLED SHELF IS DONE AT THE REAR OF THE SHELF.

GND GND

AC Wireway

Cover

AC Wireway Cover

AC Input

Connector Cover

A B C

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 3 RECTIFIERS (PCU)

208 VAC / 240 VAC, 50 Hz / 60Hz, THREE PHASE

SHELF 1 - PCUs #1 - #3

A B C

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 3 RECTIFIERS (PCU)

208 VAC / 240 VAC, 50 Hz / 60Hz, THREE PHASE

SHELF 3 - PCUs #1 - #3

A B C

SHELF 2 - PCUs #1 - #3

A B C

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 3 RECTIFIERS (PCU)

208 VAC / 240 VAC, 50 Hz / 60Hz, THREE PHASE

SHELF 5 - PCUs #1 - #3

A B C

SHELF 4 - PCUs #1 - #3

C B A

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 3 RECTIFIERS (PCU)

208 VAC / 240 VAC, 50 Hz / 60Hz, THREE PHASE

SHELF 1 - PCUs #4 - #6

C B A

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 3 RECTIFIERS (PCU)

208 VAC / 240 VAC, 50 Hz / 60Hz, THREE PHASE

SHELF 2 - PCUs #4 - #6

C B A

SHELF 3 - PCUs #4 - #6

C B A

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 3 RECTIFIERS (PCU)

208 VAC / 240 VAC, 50 Hz / 60Hz, THREE PHASE

SHELF 4 - PCUs #4 - #6

C B A

SHELF 5 - PCUs #4 - #6

FRAME GROUND CONNECTION Four 10-32 X 3/4" Studs and Hardware. Recommended torque: 23 in-lbs.

Wire Size Capacity: 6-14 AWG. Recommended Torque: 18 in-lbs.

Rectifier Module (PCU) Mounting Slots

Shelf #1

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Shelf #2

Shelf #3

Shelf #4

Shelf #5

Note: For fewer power shelves than shown, only the connections for the installed shelves are present.

Note: The three-phase input is internally distributed within the system to provide a single-phase line to neutral connection to each rectifier position, evenly distributed across the three phases.

Figure 40:

AC Input Connections to AC Input Termination Assembly List 42 when used with 588705000 or 588705300 or 588705400 or 588705500 Module Mounting Assemblies with Rectifiers (Nominal 208 VAC, 240 VAC) (1 Feed per 3 Rectifiers, Three Phase) (Installed in a Relay Rack)

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Page 92

(4-Row Cabinet Shown,

Others Sim ilar)

Front Door Removed in

Illustration for Clarity

AC INPUT CONNECTIONS, 1 FEED PER 3 RECTIFIERS, THREE PHASE (582127000 LIST 43)

Inside View

Left Side

Inside View Right Side

NOTE: WIRING TO A FIELD INSTALLED SHELF IS DONE AT THE REAR OF THE SHELF.

GND GND

AC Wireway

Cover

AC Wireway Cover

AC Input

Connector Cover

L1 L2 L3

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 3 RECTIFIERS (PCU)

277 VAC / 480 VAC, 50 Hz / 60Hz, THREE PHASE

SHELF 1 - PCUs #1 - #3

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 3 RECTIFIERS (PCU)

277 VAC / 480 VAC, 50 Hz / 60Hz, THREE PHASE

SHELF 3 - PCUs #1 - #3

SHELF 2 - PCUs #1 - #3

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 3 RECTIFIERS (PCU)

277 VAC / 480 VAC, 50 Hz / 60Hz, THREE PHASE

SHELF 5 - PCUs #1 - #3 SHELF 4 - PCUs #1 - #3

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 3 RECTIFIERS (PCU)

277 VAC / 480 VAC, 50 Hz / 60Hz, THREE PHASE

SHELF 1 - PCUs #4 - #6

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 3 RECTIFIERS (PCU)

277 VAC / 480 VAC, 50 Hz / 60Hz, THREE PHASE

SHELF 2 - PCUs #4 - #6 SHELF 3 - PCUs #4 - #6

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 3 RECTIFIERS (PCU)

277 VAC / 480 VAC, 50 Hz / 60Hz, THREE PHASE

SHELF 4 - PCUs #4 - #6 SHELF 5 - PCUs #4 - #6

FRAME GROUND CONNECTION Four 10-32 X 3/4" Studs and Hardware. Recommended torque: 23 in-lbs.

Wire Size Capacity: 6-14 AWG. Recommended Torque: 18 in-lbs.

Rectifier Module (PCU) Mounting Slots

Shelf #1

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect. (PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect. (PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect. (PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect. (PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect. (PCU)

Rect.

(PCU)

Shelf #2

Shelf #3

Shelf #4

Shelf #5

L1 L2 L3

Note: For fewer power shelves than shown, only the connections for the installed shelves are present. Note: The three-phase input is internally distributed within the system to provide a single-phase line to neutral connection to each rectifier position, evenly distributed across the three phases.

Figure 41:

AC Input Connections to AC Input Termination Assembly List 43 when used with 588705000 or 588705400 or 588705500 Module Mounting Assemblies with Rectifiers (Nominal 277/480 VAC) (1 Feed per 3 Rectifiers, Three Phase) (Installed in a Relay Rack)

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Page 93

Connections to AC Input Termination Assemblies (582127000 List 40, 41, 42, 43) (For System Mounted in an Enclosure)

The enclosure provides conduit plates attached to the top of the enclosure. Two types of conduit plates are available. Select and install the conduit plate appropriate for your application. See “AC Input Conduit Options” on page 17. It is recommended that AC input wiring be provided to all rectifier mounting positions, including currently unused positions. This wiring will ease future installation of rectifiers to meet increased load requirements.

NOTE!

A grounding conductor must be provided with each conduit.

Procedure

Refer to Figure 42, Figure 43, Figure 44, or Figure 45 as these procedures are performed.

Accessing Connections and Routing Wire

1. Ensure the proper conduit plates are attached to the top of the enclosure. See “AC Input Conduit

Options” on page 17.

2. Install conduit fittings as required in the conduit plates attached to the top of the enclosure. Plug

buttons are provided, and must be installed in the openings not being used.

3. Inside the distribution cabinet, remove the two AC input connector covers by first loosening the

fasteners that secure each of them.

4. Route wiring into the enclosure through the previously installed conduit fittings.

Making AC Input Connections

1. Make AC input connections as shown in Figure 42, Figure 43, Figure 44, or Figure 45. Connect each

wire by inserting the stripped end into the wire opening, and then tightening the screw. Torque connections to value shown in the appropriate illustration.

NOTE!

Terminal blocks for a system with maximum possible rectifier shelves shown. Your system may

have fewer terminal blocks than shown.

Making Equipment Grounding Connections

NOTE!

Make equipment grounding connections to earth ground,

not

to the branch circuit neutral

conductor.

1. Connect equipment grounding leads to the frame ground studs using installer-provided ring lugs and

factory-supplied mounting hardware. Torque connections to value shown in the appropriate illustration.

Reinstalling Covers

1. After all AC input and equipment grounding connections have been made and checked, reinstall the two

AC input connector covers inside the distribution cabinet. Secure each by tightening the fasteners.

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Page 94

AC INPUT CONNECTIONS, 1 FEED PER 1 RECTIFIER, SINGLE PHASE (582127000 LIST 40)

Line to Line: Connect Line 1 to Terminal L1. Connect Line 2 to Terminal L2/N.

Line to Neutral Connect Line to Terminal L1. Connect Neutral to Terminal L2/N.

(4-Row Cabinet Shown,

Others Sim ilar)

Inside View

Left Side

Inside View Right Side

NOTE: WIRING TO A FIELD INSTALLED SHELF IS DONE AT THE REAR OF THE SHELF.

AC Input

Connector Cover

Rectifier Module (PCU) Mounting Slots

Shelf #1

Rect.

(PCU)

Rect.

(PCU)

Rect. (PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect. (PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect. (PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect. (PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect. (PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Shelf #2

Shelf #3

Shelf #4

Shelf #5

Rect.

(PCU)

Rect.

(PCU)

Rect. (PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Shelf #6

Note: Customer wiring to top terminals of terminal blocks. For fewer power shelves than shown, only the connections for the installed shelves are present.

SHELF 1

PCU #6 L1 L2/N

PCU #5 L1 L2/N

PCU #4 L1 L2/N

PCU #6 L1 L2/N

PCU #5 L1 L2/N

PCU #4 L1 L2/N

PCU #6 L1 L2/N

PCU #5 L1 L2/N

PCU #4 L1 L2/N

PCU #6 L1 L2/N

PCU #5 L1 L2/N

PCU #4 L1 L2/N

PCU #6 L1 L2/N

PCU #5 L1 L2/N

PCU #4 L1 L2/N

PCU #6 L1 L2/N

PCU #5 L1 L2/N

PCU #4 L1 L2/N

SHELF 2

SHELF 3 SHELF 4

SHELF 5 SHELF 6

SHELF 2

PCU #3 L1 L2/N

PCU #2 L1 L2/N

PCU #1 L1 L2/N

PCU #3 L1 L2/N

PCU #2 L1 L2/N

PCU #1 L1 L2/N

PCU #3 L1 L2/N

PCU #2 L1 L2/N

PCU #1 L1 L2/N

PCU #3 L1 L2/N

PCU #2 L1 L2/N

PCU #1 L1 L2/N

PCU #3 L1 L2/N

PCU #2 L1 L2/N

PCU #1 L1 L2/N

PCU #3 L1 L2/N

PCU #2 L1 L2/N

PCU #1 L1 L2/N

SHELF 1

SHELF 4 SHELF 3

SHELF 6 SHELF 5

FRAME GROUND

CONNECTION

Four 10-32 X 3/4"

Studs and Hardware.

Recommended torque:

23 in-lbs.

FRAME GROUND

CONNECTION

Four 10-32 X 3/4"

Studs and Hardware.

Recommended torque:

23 in-lbs.

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 1 RECTIFIER (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60 Hz, SINGLE P HASE

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 1 RECTIFIER (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60 Hz, SINGLE P HASE

Wire Size Capacity: 4 AWG to 14 AW G. Recommended Torque: 10-14 AWG 20 in-lbs. 8 AWG 25 in-lbs. 4 AWG 35 in-lbs.

Figure 42:

AC Input Connections to AC Input Termination Assembly List 40 when used with 588705000 or 588705400 or 588705500 Module Mounting Assemblies with Rectifiers (Nominal 208 VAC, 240 VAC, 277 VAC) (1 Feed per 1 Rectifier, Single Phase) (Installed in an Enclosure) (cont’d on next page)

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Page 95

AC INPUT CONNECTIONS, 1 FEED PER 2 RECTIFIERS, SINGLE PHASE (582127000 LIST 41), with Six (6) Shelves Installed

Line to Line: Connect Line 1 to Terminal L1. Connect Line 2 to Terminal L2/N.

Line to Neutral Connect Line to Terminal L1. Connect Neutral to Terminal L2/N.

(4-Row Cabinet Shown,

Others Sim ilar)

Inside View

Left Side

Inside View Right Side

NOTE: WIRING TO A FIELD INSTALLED SHELF IS DONE AT THE REAR OF THE SHELF.

AC Input

Connector Cover

Rectifier Module (PCU) Mounting Slots

Shelf #1

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Shelf #2

Shelf #3

Shelf #4

Shelf #5

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Shelf #6

Note: Customer wiring to top terminals of terminal blocks. For fewer power shelves than shown, only the connections for the installed shelves are present.

PCU #6

L1 L2/N

PCU #5

L1 L2/N

PCU #4

L1 L2/N

SHELVES 1 AND 2SHELVES 3 AND 4 SHELVES 1 AND 2 SHELVES 3 AND 4

SHELVES 5 AND 6 SHELVES 5 AND 6

PCU #3

L1 L2/N

PCU #2

L1 L2/N

PCU #1

L1 L2/N

FRAME GROUND

CONNECTION

Four 10-32 X 3/4"

Studs and Hardware.

Recommended torque:

23 in-lbs.

FRAME GROUND

CONNECTION

Four 10-32 X 3/4"

Studs and Hardware.

Recommended torque:

23 in-lbs.

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 2 RECTIFIERS (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60 Hz, SINGLE PHASE

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 2 RECTIFIERS (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60 Hz, SINGLE PHASE

Wire Size Capacity: 4 AWG to 14 AWG. Recommended Torque: 10-14 AWG 20 in-lbs. 8 AWG 25 in-lbs. 4 AWG 35 in-lbs.

PCU #6 L1 L2/N

PCU #5 L1 L2/N

PCU #4 L1 L2/N

PCU #6 L1 L2/N

PCU #5 L1 L2/N

PCU #4 L1 L2/N

PCU #3 L1 L2/N

PCU #2 L1 L2/N

PCU #1 L1 L2/N

PCU #3 L1 L2/N

PCU #2 L1 L2/N

PCU #1 L1 L2/N

Figure 43:

AC Input Connections to AC Input Termination Assembly List 41 when used with 588705000 or 588705400 or 588705500 Module Mounting Assemblies with Rectifiers (Nominal 208 VAC, 240 VAC, 277 VAC) (1 Feed per 2 Rectifiers, Single Phase) - with Six (6) Shelves Installed (Installed in an Enclosure) (cont’d on next page)

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Page 96

AC INPUT CONNECTIONS, 1 FEED PER 2 RECTIFIERS, SINGLE PHASE (582127000 LIST 41), with Five (5) Shelves Installed

Line to Line: Connect Line 1 to Terminal L1. Connect Line 2 to Terminal L2/N.

Line to Neutral Connect Line to Terminal L1. Connect Neutral to Terminal L2/N.

(4-Row Cabinet Shown,

Others Similar)

Inside View

Left Side

Inside View Right Side

NOTE: WIRING TO A FIELD INSTALLED SHELF IS DONE AT THE REAR OF THE SHELF.

AC Input

Connector Cover

Rectifier Module (PCU) Mounting Slots

Shelf #1

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Shelf #2

Shelf #3

Shelf #4

Shelf #5

Note: Customer wiring to top terminals of terminal blocks. For fewer power shelves than shown, only the connections for the installed shelves are present.

SHELVES 1 AND 2 SHELVES 3 AND 4

SHELF 5

PCU

#5, #6

L1 L2/N

SHELVES 3 AND 4 SHELVES 1 AND 2

PCU

#3, #4

L1 L2/N

PCU

#1, #2

L1 L2/N

SHELF 5

FRAME GROUND

CONNECTION

Four 10-32 X 3/4"

Studs and Hardware.

Recommended torque:

23 in-lbs.

FRAME GROUND

CONNECTION

Four 10-32 X 3/4"

Studs and Hardware.

Recommended torque:

23 in-lbs.

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 2 RECTIFIERS (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60 Hz, SINGLE PHASE

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 2 RECTIFIERS (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60 Hz, SINGLE PHASE

Wire Size Capacity: 4 AWG to 14 AWG. Recommended Torque: 10-14 AWG 20 in-lbs. 8 AWG 25 in-lbs. 4 AWG 35 in-lbs.

PCU #6 L1 L2/N

PCU #5 L1 L2/N

PCU #4 L1 L2/N

PCU #6 L1 L2/N

PCU #5 L1 L2/N

PCU #4 L1 L2/N

PCU #3 L1 L2/N

PCU #2 L1 L2/N

PCU #1 L1 L2/N

PCU #3 L1 L2/N

PCU #2 L1 L2/N

PCU #1 L1 L2/N

Figure 43:

AC Input Connections to AC Input Termination Assembly List 41 when used with 588705000 or 588705400 or 588705500 Module Mounting Assemblies with Rectifiers (Nominal 208 VAC, 240 VAC, 277 VAC) (1 Feed per 2 Rectifiers, Single Phase) - with Five (5) Shelves Installed (Installed in an Enclosure) (cont’d on next page)

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Page 97

C INPUT

TIO

1 F

EED PER 2 RECTIFIERS, SINGLE PHASE (582127000 LIST 41), with Four (4) Shelves Installed

Line to Line: Connect Line 1 to Terminal L1. Connect Line 2 to Terminal L2/N.

Line to Neutral Connect Line to Terminal L1. Connect Neutral to Terminal L2/N.

(4-Row Cabinet Shown,

Others Similar)

Inside View

Left Side

Inside View Right Side

NOTE: WIRING TO A FIELD INSTALLED SHELF IS DONE AT THE REAR OF THE SHELF.

AC Input

Connector Cover

Rectifier Module (PCU) Mounting Slots

Shelf #1

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Shelf #2

Shelf #3

Shelf #4

Note: Customer wiring to top terminals of terminal blocks. For fewer power shelves than shown, only the connections for the installed shelves are present.

SHELVES 1 AND 2 SHELVES 3 AND 4

SHELVES 3 AND 4 SHELVES 1 AND 2

FRAME GROUND

CONNECTION

Four 10-32 X 3/4"

Studs and Hardware.

Recommended torque:

23 in-lbs.

FRAME GROUND

CONNECTION

Four 10-32 X 3/4"

Studs and Hardware.

Recommended torque:

23 in-lbs.

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 2 RECTIFIERS (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60 H

z, SINGLE PHASE

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 2 RECTIFIERS (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60

Hz, SINGLE PH

ASE

Wire Size Capacity: 4 AWG to 14 AWG. Recommended Torque: 10-14 AWG 20 in-lbs. 8 AWG 25 in-lbs. 4 AWG 35 in-lbs.

PCU #6 L1 L2/N

PCU #5 L1 L2/N

PCU #4 L1 L2/N

PCU #6 L1 L2/N

PCU #5 L1 L2/N

PCU #4 L1 L2/N

PCU #3 L1 L2/N

PCU #2 L1 L2/N

PCU #1 L1 L2/N

PCU #3 L1 L2/N

PCU #2 L1 L2/N

PCU #1 L1 L2/N

Figure 43:

AC Input Connections to AC Input Termination Assembly List 41 when used with 588705000 or 588705400 or 588705500 Module Mounting Assemblies with Rectifiers (Nominal 208 VAC, 240 VAC, 277 VAC) (1 Feed per 2 Rectifiers, Single Phase) - with Four (4) Shelves Installed (Installed in an Enclosure) (cont’d from previous page, cont’d on next page)

Vertiv | NetSure 7100 Series -48V DC Power System Installation Manual (IM582127000) | Rev. BB

Page 98

AC INPUT CONNECTIONS, 1 FEED PER 2 RECTIFIERS, SINGLE PHASE (582127000 LIST 41), with Three (3) Shelves Installed

Line to Line: Connect Line 1 to Terminal L1. Connect Line 2 to Terminal L2/N.

Line to Neutral Connect Line to Terminal L1. Connect Neutral to Terminal L2/N.

(4-Row Cabinet Shown,

Others Similar)

Inside View

Left Side

Inside View Right Side

NOTE: WIRING TO A FIELD INSTALLED SHELF IS DONE AT THE REAR OF THE SHELF.

AC Input

Connector Cover

Rectifier Module (PCU) Mounting Slots

Shelf #1

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Shelf #2

Shelf #3

Note: Customer wiring to top terminals of terminal blocks. For fewer power shelves than shown, only the connections for the installed shelves are present.

SHELVES 1 AND 2

PCU

L1 L2/N

PCU

L1 L2/N

PCU

L1 L2/N

PCU

#5, #6

L1 L2/N

SHELF 3

PCU

#3, #4

L1 L2/N

PCU

#1, #2

L1 L2/N

PCU

L1 L2/N

PCU

L1 L2/N

PCU

L1 L2/N

SHELVES 1 AND 2

FRAME GROUND

CONNECTION

Four 10-32 X 3/4"

Studs and Hardware.

Recommended torque:

23 in-lbs.

FRAME GROUND

CONNECTION

Four 10-32 X 3/4"

Studs and Hardware.

Recommended torque:

23 in-lbs.

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 2 RECTIFIERS (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60 Hz, SINGLE PHASE

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 2 RECTIFIERS (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60 Hz, SINGLE PHASE

Wire Size Capacity: 4 AWG to 14 AWG. Recommended Torque: 10-14 AWG 20 in-lbs. 8 AWG 25 in-lbs. 4 AWG 35 in-lbs.

Figure 43:

AC Input Connections to AC Input Termination Assembly List 41 when used with 588705000 or 588705400 or 588705500 Module Mounting Assemblies with Rectifiers (Nominal 208 VAC, 240 VAC, 277 VAC) (1 Feed per 2 Rectifiers, Single Phase) - with Three (3) Shelves Installed (Installed in an Enclosure) (cont’d from previous page, cont’d on next page)

Vertiv | NetSure 7100 Series -48V DC Power System Installation Manual (IM582127000) | Rev. BB

Page 99

AC INPUT CONNECTIONS, 1 FEED PER 2 RECTIFIERS, SINGLE PHASE (582127000 LIST 41), with Two (2) Shelves Installed

Line to Line: Connect Line 1 to Terminal L1. Connect Line 2 to Terminal L2/N.

Line to Neutral Connect Line to Terminal L1. Connect Neutral to Terminal L2/N.

(4-Row Cabinet Shown,

Others Similar)

Inside View

Left Side

Inside View Right Side

NOTE: WIRING TO A FIELD INSTALLED SHELF IS DONE AT THE REAR OF THE SHELF.

AC Input

Connector Cover

Rectifier Module (PCU) Mounting Slots

Shelf #1

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Shelf #2

Note: Customer wiring to top terminals of terminal blocks. For fewer power shelves than shown, only the connections for the installed shelves are present.

SHELVES 1 AND 2SHELVES 1 AND 2

FRAME GROUND

CONNECTION

Four 10-32 X 3/4"

Studs and Hardware.

Recommended torque:

23 in-lbs.

FRAME GROUND

CONNECTION

Four 10-32 X 3/4"

Studs and Hardware.

Recommended torque:

23 in-lbs.

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 2 RECTIFIERS (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60 Hz, SINGLE PHASE

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 2 RECTIFIERS (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60 Hz, SINGLE PHASE

Wire Size Capacity: 4 AWG to 14 AWG. Recommended Torque: 10-14 AWG 20 in-lbs. 8 AWG 25 in-lbs. 4 AWG 35 in-lbs.

PCU #3 L1 L2/N

PCU #2 L1 L2/N

PCU #1 L1 L2/N

PCU #6 L1 L2/N

PCU #5 L1 L2/N

PCU #4 L1 L2/N

Figure 43:

AC Input Connections to AC Input Termination Assembly List 41 when used with 588705000 or 588705400 or 588705500 Module Mounting Assemblies with Rectifiers (Nominal 208 VAC, 240 VAC, 277 VAC) (1 Feed per 2 Rectifiers, Single Phase) - with Two (2) Shelves Installed (Installed in an Enclosure) (cont’d from previous page, cont’d on next page)

Vertiv | NetSure 7100 Series -48V DC Power System Installation Manual (IM582127000) | Rev. BB

Page 100

100

C INPUT

CONNECTIONS, 1 FEED PER 2 RECTIFIERS, SINGLE PHASE (582127000 LIST 41), with One (1) Shelf Installed

Line to Line: Connect Line 1 to Terminal L1. Connect Line 2 to Terminal L2/N.

Line to Neutral Connect Line to Terminal L1. Connect Neutral to Terminal L2/N.

(4-Row Cabinet Shown,

Others Similar)

Inside View

Left Side

Inside View Right Side

NOTE: WIRING TO A FIELD INSTALLED SHELF IS DONE AT THE REAR OF THE SHELF.

AC Input

Connector Cover

Rectifier Module (PCU) Mounting Slots

Shelf #1

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Rect.

(PCU)

Note: Customer wiring to top terminals of terminal blocks. For fewer power shelves than shown, only the connections for the installed shelves are present.

SHELF 1

PCU

#5, #6

L1 L2/N

PCU

#3, #4

L1 L2/N

PCU

#1, #2

L1 L2/N

SHELF 1

FRAME GROUND

CONNECTION

Four 10-32 X 3/4"

Studs and Hardware.

Recommended torque:

23 in-lbs.

FRAME GROUND

CONNECTION

Four 10-32 X 3/4"

Studs and Hardware.

Recommended torque:

23 in-lbs.

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 2 RECTIFIERS (PCU) 208 VAC, 240 VAC, 277 VAC, 50 Hz / 60 Hz, SINGLE PHASE

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 2 RECTIFIERS (PCU)

208 VAC, 240 VAC, 277 VAC, 50 Hz / 60 Hz, SINGLE PHASE

Wire Size Capacity: 4 AWG to 14 AWG. Recommended Torque: 10-14 AWG 20 in-lbs. 8 AWG 25 in-lbs. 4 AWG 35 in-lbs.

Figure 43:

AC Input Connections to AC Input Termination Assembly List 41 when used with 588705000 or 588705400 or 588705500 Module Mounting Assemblies with Rectifiers (Nominal 208 VAC, 240 VAC, 277 VAC) (1 Feed per 2 Rectifiers, Single Phase) - with One (1) Shelf Installed (Installed in an Enclosure) (cont’d from previous page)

Vertiv | NetSure 7100 Series -48V DC Power System Installation Manual (IM582127000) | Rev. BB