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NetSure™
-48V DC Bulk Output Power System
Installation and User Instructions (UM582127100), Revision E
Specification Number: 582127100
Model Number: 722NBBB
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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 accuracy and completeness herein, Vertiv Group
Corp. assumes no responsibility, and disclaims all liability, for damages
resulting from use of this information or for any errors or omissions. Refer
to other local practices or building codes as applicable for the correct
methods, tools, and materials to be used in performing procedures not
specifically described in this document.
This document may contain confidential and/or proprietary information of
Vertiv Group Corp., and its receipt or possession does not convey any right
to reproduce, disclose its contents, or to manufacture or sell anything that
it may describe. Reproduction, disclosure, or use without specific
authorization from Vertiv Group Corp. is strictly prohibited.
Vertiv and the Vertiv logo are trademarks or registered trademarks of
Vertiv Group Corp. All other names and logos referred to are trade names,
trademarks or registered trademarks of their respective owners.
© 2019 Vertiv Group Corp. All rights reserved.
Vertiv | NetSure -48V DC Bulk Output Power System Installation and User Instructions (UM582127100) | Rev. E
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TABLE OF CONTENTS
Admonishments Used in this Document ............................................................ 5
Important Safety Instructions .............................................................................. 6
General Safety .......................................................................................................................................................... 6
Voltages .......................................................................................................................................................................... 6
AC Input Voltages ........................................................................................................................................................ 6
DC Output and Battery Voltages .................................................................................................................. 6
Battery ............................................................................................................................................................................... 7
Personal Protective Equipment (PPE) ............................................................................................. 8
Hazardous Voltage .............................................................................................................................................. 8
Handling Equipment Containing Static Sensitive Components............................. 8
Maintenance and Replacement Procedures .............................................................................. 8
Static Warning ........................................................................................................... 9
System Overview ..................................................................................................... 11
Customer Documentation Package................................................................................................... 11
System Description ............................................................................................................................................ 11
Installation Acceptance Checklist ..................................................................... 12
Installing the System ............................................................................................. 13
General Requirements .................................................................................................................................... 13
Securing the Relay Rack to the Floor .............................................................................................. 14
Mounting System Components in a Relay Rack .................................................................. 14
Setting Switch Options ........................................................................................ 22
Switch Settings on IB2 Interface Board ........................................................................................ 22
Making Electrical Connections ...........................................................................23
Important Safety Instructions ................................................................................................................ 23
Wiring Considerations .................................................................................................................................... 23
Relay Rack Grounding Connection (Frame Ground) ..................................................... 23
AC Input and AC Input Equipment Grounding Connections to
Rectifier Module Mounting Shelves ................................................................................................. 24
Connections to 588705000 List 51 and 61 (Single-Phase, Terminal
Blocks) ..................................................................................................................................................................................24
Connections to 588705000 List 52 and 62 (Three-Phase, Terminal
Blocks) .................................................................................................................................................................................. 27
Connections to 588705000 List 53 and 63 (Single-Phase, Line Cords)............. 29
External Alarm, Reference, Monitoring, and Control Connections ................... 30
External Alarm, Reference, Monitoring, and Control Connection Points
Locations .......................................................................................................................................................................... 30
System Interface Circuit Cards Connections (if required) ................................................. 31
IB2 Controller Interface Board) Connections (if required) ............................................... 34
Controller CAN Bus ..................................................................................................................................................39
Controller Ethernet Connection (if required) ........................................................................ 40
-48V DC Output Connections ................................................................................................................ 41
Installing the Rectifier Modules and Initially Starting the System .......... 44
Vertiv | NetSure -48V DC Bulk Output Power System Installation and User Instructions (UM582127100) | Rev. E
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Installing the Rectifier Modules into Spec. No. 588705000 Rectifier
Module Mounting Shelves ......................................................................................................................... 44
Procedure ......................................................................................................................................................................... 44
Initially Starting, Configuring, and Checking System Operation ......................... 45
Checking System Status .............................................................................................................................. 51
Final Steps ................................................................................................................................................................. 52
Operating Procedures .......................................................................................... 53
Controller and Rectifiers .............................................................................................................................. 53
ESTOP Function .................................................................................................................................................. 53
NCU Battery Charge Current Limit Feature ............................................................................ 53
Local Controls and Indicators ................................................................................................................ 53
Maintenance ........................................................................................................... 54
System Maintenance Procedures ...................................................................................................... 54
Adding a Rectifier Module to an Existing Rectifier Module Mounting
Shelf Spec. No. 588705000...................................................................................................................... 54
Installing a Field Expansion Rectifier Module Mounting Shelf Spec.
No. 588705000 ..................................................................................................................................................... 54
Troubleshooting and Repair ............................................................................... 55
Contact Information ......................................................................................................................................... 55
Controller and Rectifiers .............................................................................................................................. 55
NCU Controller Configuration................................................................................................................ 55
System Troubleshooting Information ............................................................................................ 55
Replacement Information ........................................................................................................................... 56
Replacement Procedures ........................................................................................................................... 56
Vertiv | NetSure -48V DC Bulk Output Power System Installation and User Instructions (UM582127100) | Rev. E
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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
ADMONISHMENTS USED IN THIS DOCUMENT
! Warns of a hazard the reader
! Warns of a potential 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
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 -48V DC Bulk Output Power System Installation and User Instructions (UM582127100) | Rev. E
related to a particular source of hazard or to fire safety. (ISO, ANSI, OSHA)
-fighting and fire-safety equipment. (ISO)
must be performed
in order to prevent
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IMPORTANT SAFETY INSTRUCTIONS
General Safety
DANGER! YOU MUST FOLLOW APPROVED SAFETY PROCEDURES.
Performing the following procedures may expose you to hazards. These procedures should be
performed by qualified technicians familiar with the hazards associated with this type of equipment.
These hazards may include shock, energy, and/or burns. To avoid these hazards:
a) The tasks should be performed in the order indicated.
b) Remove watches, rings, and other metal objects.
c) Prior to contacting any uninsulated surface or termination, use a voltmeter to verify that no voltage
or the expected voltage is present. Check for voltage with both AC and DC voltmeters prior to
making contact.
d) Wear eye protection.
e) Use certified and well maintained insulated tools. Use double insulated tools appropriately rated for
the work to be performed.
Voltages
AC Input Voltages
DANGER! This system operates from AC input voltage capable of producing fatal electrical shock. AC
input power must be completely disconnected from the branch circuits wiring used to provide power to
the system before any AC electrical connections are made. Follow local lockout/tagout procedures to
ensure upstream branch circuit breakers remain de-energized during installation. DO NOT apply AC
input power to the system until all electrical connections have been completed and checked.
DC Output and Battery Voltages
DANGER! This system produces DC power and may have a battery source connected to it. Although
the DC voltage is not hazardously high, the rectifiers and/or battery can deliver large amounts of current.
Exercise extreme caution not to inadvertently contact or have any tool inadvertently contact an output
terminal or battery terminal or exposed wire connected to an output terminal or battery terminal.
NEVER allow a metal object, such as a tool, to contact more than one termination or battery terminal at a
time, or to simultaneously contact a termination or battery terminal and a grounded object. Even a
momentary short circuit can cause sparking, explosion, and injury.
DANGER! Follow local lockout/tagout procedures to ensure DC branch circuit protection devices
remain de-energized during installation at loads, as required.
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Battery
Refer to the battery manufacturer documentation for specific battery safety instructions. The following are
general guidelines.
WARNING! Correct polarity must be observed when connecting battery leads.
WARNING! Special safety precautions are required for procedures involving handling, installing, and
servicing batteries. Observe all battery safety precautions in this manual and in the battery instruction
manual. These precautions should be followed implicitly at all times.
WARNING! A battery can present a risk of electrical shock and high short circuit current. Servicing of
batteries should be performed or supervised only by properly trained and qualified personnel
knowledgeable about batteries and the required precautions.
The following precautions should be observed when working on batteries:
• Remove watches, rings, and other metal objects.
• Eye protection should be worn to prevent injury from accidental electrical arcs.
• Use certified and well maintained insulated tools. Use double insulated tools appropriately rated for
the work to be performed. Ensure that wrenches with more than one working end have only one
end exposed.
• Do not lay tools or metal parts on top of batteries.
• 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.
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.
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FOR THESE REASONS, IT IS OF CRITICAL IMPORTANCE THAT YOU READ THESE INSTRUCTIONS
AND FOLLOW THEM EXACTLY.
WHEN WORKING WITH LEAD-ACID BATTERIES:
• Follow the recommended PPE requirements per the SDS for the battery to be used.
• If battery acid enters your eye, immediately flush your eye with running cold water for at least 15
minutes. Get medical attention immediately.
• If battery acid contacts skin or clothing, wash immediately with soap and water.
ALERT! Performing maintenance and/or troubleshooting procedures may interrupt power to the loads,
if battery reserve is not sufficient.
Personal Protective Equipment (PPE)
DANGER! ARC FLASH AND SHOCK HAZARD.
Appropriate PPE and tools required when working on this equipment. An appropriate flash protection
boundary analysis should be done determine the “hazard/risk” category, and to select proper PPE.
This product is intended only for installation in a Restricted Access Location.
Only authorized and properly trained personnel should be allowed to install, inspect, operate, or maintain
the equipment.
Do not work on LIVE parts. If required to work or operate live parts, obtain appropriate Energized Work
Permits as required by the local authority, per NFPA 70E “Standard for Electrical Safety in the
Workplace”.
Hazardous Voltage
DANGER! HAZARD OF ELECTRICAL SHOCK.
More than one disconnect may be required to de-energize the system before servicing.
Handling Equipment Containing Static Sensitive Components
ALERT! Installation or removal of equipment containing static sensitive components requires careful
handling. Before handling any equipment containing static sensitive components, read and follow the
instructions contained on the Static Warning Page.
Maintenance and Replacement Procedures
CAUTION! When performing any step in procedures that requires removal or installation of hardware,
use caution to ensure no hardware is dropped and left inside the unit; otherwise service interruption or
equipment damage may occur.
Vertiv | NetSure -48V DC Bulk Output Power System Installation and User Instructions (UM582127100) | Rev. E
NOTE!
hardware for use in subsequent steps, unless otherwise directed.
When performing any step in procedures that requires removal of existing hardware, retain all
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STATIC WARNING
This equipment contains static sensitive components. The warnings listed below must be observed to
prevent damage to these components. Disregarding any of these warnings may result in personal injury
or damage to the equipment.
1. Strictly adhere to the procedures provided in this document.
2. Before touching any equipment containing static sensitive components, discharge all static
electricity from yourself by wearing a wrist strap grounded through a one megohm resistor. Some
wrist straps have a built-in one megohm resistor; no external resistor is necessary. Read and follow
wrist strap manufacturer’s instructions outlining use of a specific wrist strap.
3. Do not touch traces or components on equipment containing static sensitive components. Handle
equipment containing static sensitive components only by the edges that do not have connector
pads.
4. After removing equipment containing static sensitive components, place the equipment only on
conductive or anti-static material such as conductive foam, conductive plastic, or aluminum foil. Do
not use ordinary Styrofoam™ or ordinary plastic.
5. Store and ship equipment containing static sensitive components only in static shielding containers.
6. If necessary to repair equipment containing static sensitive components, wear an appropriately
grounded wrist strap, work on a conductive surface, use a grounded soldering iron, and use
grounded test equipment.
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SYSTEM OVERVIEW
Customer Documentation Package
This document (UM582127100) provides Installation and User Instructions for NetSure™ -48V DC Bulk Output
Power System Model 722NBBB, Spec. No. 582127100.
The complete Customer Documentation Package consists of…
NetSure™ -48V DC Bulk Output Power System Installation and User Manual
• Power System Installation and User Instructions: UM582127100
NetSure™ NCU Controller User Manual
• NCU Controller User Instructions: UM1M830BNA
USB Drive with All Customer Documentation
• Power System Installation and User Instructions: UM582127100
• Power System “System Application Guide”: SAG582127100
• Rectifier Module Mounting Shelf Power Data Sheet: PD588705000
• Rectifier Instructions: UM1R483500E
• NCU Controller User Instructions: UM1M830BNA
• Engineering Drawings
• Also provided on the USB drive is a controller configuration drawing and the controller configuration
files loaded into the controller as shipped.
System Description
-48V DC @ up to 2000 Amperes Bulk Output Power System
The NetSure™ 722NBBB Bulk Output Power System is intended for use to expand or replace legacy -48V DC
rectifiers while retaining the distribution power board. It can be used with any -48V DC power system,
regardless of vendor or plant type.
The 722NBBB is an integrated power system containing rectifiers, intelligent control, metering, and monitoring.
This power system is designed to power a load while charging a positive grounded battery. This power system
is capable of operating in a batteryless installation or off battery for maintenance purposes. The power system
is designed for operation with the positive output grounded.
This system consists of the following components.
Main Rectifier Module Mounting Shelf
The system contains a main rectifier module mounting shelf. This shelf houses up to five (5) rectifier modules,
the controller, a controller interface board, and a system interface board. Refer to Power Data Sheet
PD588705000 for more information.
NCU (NetSure Control Unit): The controller provides power system control (including optional low voltage
battery disconnect (LVBD) and low voltage load disconnect (LVLD) control), rectifier control (including a
charge control function), metering functions, monitoring functions, and local/remote alarm functions. The
Vertiv | NetSure -48V DC Bulk Output Power System Installation and User Instructions (UM582127100) | Rev. E
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controller also supports rectifier temperature compensation if the system is equipped with a temperature
probe(s). Temperature probe(s) may also be designated to monitor ambient temperature and/or battery
temperature. The controller also provides data acquisition, system alarm management, and advanced battery
and energy management. The controller contains a color LCD display and keypad for local access. The
controller provides an Ethernet port and comes with comprehensive webpages for remote access. The
controller has SNMP v3 capability for remote system management. The controller supports software upgrade
via its USB port. Refer to the NCU Controller Instructions (UM1M830BNA) for more information.
Expansion Rectifier Module Mounting Shelf
The system contains one or more expansion rectifier module mounting shelves, each of which houses up to six
(6) rectifier modules. Refer to Power Data Sheet PD588705000 for more information.
Rectifier Modules
The system contains rectifier modules, which provide load power, battery float current, and battery recharge
current during normal operating conditions. Refer to the Rectifier Instructions (UM1R483500E) for more
information.
INSTALLATION ACCEPTANCE CHECKLIST
Provided in this section is an Installation Acceptance Checklist. This checklist helps ensure proper installation
and initial operation of the system. As the procedures presented in this document are completed, check the
appropriate box on this list. If the procedure is not required to be performed for your installation site, also
check the box in this list to indicate that the procedure was read. When installation is done, ensure that each
block in this list has been checked. Some of these procedures may have been factory performed for you.
NOTE!
NOTE!
Installing the System
Relay Rack Secured to Floor
System Components Mounted in Relay Rack and Interconnected (if required)
Setting Switch Options
Factory Switch Setting on IB2 Interface Board Verified
Making Electrical Connections
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.
Relay Rack Grounding Connection (Frame Ground) Made
AC Input and AC Input Equipment Grounding Connections Made
External Alarm, Reference, Monitoring, and Control Connections Made
Controller Ethernet Connection Made (if required)
-48V DC Output Connections Made
Vertiv | NetSure -48V DC Bulk Output Power System Installation and User Instructions (UM582127100) | Rev. E
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Installing the Rectifier Modules and Initially Starting the System
Rectifier Modules Installed
System Started, Configured, and Checked
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 and rectifier module mounting shelf ventilating openings must not be blocked and temperature
of air entering rectifiers must not exceed rated operating ambient temperature range found in
SAG582127100.
• Clearance requirements are:
a) Recommended minimum aisle space clearance for the front of each bay is 2' 6".
b) Minimum spacing from the rear of the bay to a wall or other solid surface is that which is specified
for proper rectifier module mounting shelf ventilation. Refer to the rectifier module mounting shelf
Power Data Sheet for ventilation spacing requirements.
NOTE!
maintenance of the system.
Minimum rear spacing specified for ventilation may not permit installation and
Recommended minimum aisle space clearance for the rear of each bay is 2’ 0” to allow for
installation and maintenance.
Vertiv | NetSure -48V DC Bulk Output Power System Installation and User Instructions (UM582127100) | Rev. E
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Securing the Relay Rack to the Floor
Secure the relay rack to the floor per site requirements. Refer to “General Requirements” on page 13.
Ventilation Requirements
Refer to “General Requirements” on page 13.
Relay Rack Floor Mounting Dimensions
Refer to Figure 1 for relay rack floor mounting dimensions.
Mounting System Components in a Relay Rack
NOTE!
If the power system was ordered in a relay rack, these procedures have been performed at the
factory.
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 SAG582127100 for overall dimensions and a list of available relay racks.
Mounting the Rectifier Module Mounting Shelf(s) to a Relay Rack
DANGER! The relay rack must be securely anchored to the floor before the rectifier module mounting
shelf(s) is installed.
NOTE!
If the system was shipped on shipping rails, rectifier module mounting shelves are installed in
groups of two or less. Space has been provided for pallet forks to fit between the sets of rectifier module
mounting shelves. Simply rest the pallet forks on the bottom-most rectifier module mounting shelf,
unbolt the shelves from the shipping rails, transfer the shelves to the relay rack, and re-secure the
shelves to the relay rack.
NOTE!
Refer to
Figure 2
as this procedure is performed.
Procedure
1. If multiple shelves are in the system, remove the rear center shield from each. Save hardware for later
re-installation.
2. If multiple shelves are in the system, remove and discard the bottom section of the rear center shield
from all shelves except the bottom shelf.
NOTE!
In multiple shelf systems, apply electrical anti-oxidizing compound to busbar mating surfaces
before performing the next step.
3. Position the rectifier module mounting shelf in the relay rack. In multiple shelf systems, align the holes in
the mating busbars before securing the shelves to the relay rack.
NOTE!
Install the ground washers in the next step so the teeth dig into the paint on the mounting
angles.
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4. Secure the rectifier module mounting shelf to the relay rack. Torque all screws to 65 in-lbs.
Hardware build-up is:
12-24 x 3/4" screw and flat washer,
(1) set per side.
12-24 x 3/4" screw and ground washer,
(1) set per side.
5. Repeat for any additional rectifier module mounting shelf. Rectifier module mounting shelves are install
directly below each other with no space between them. The main shelf (the one with the NCU
Controller) should be the top-most shelf.
Interconnecting the Rectifier Module Mounting Shelves Output Busbars in Multiple Shelf Systems
NOTE!
Refer to
Figure 3
as this procedure is performed.
Procedure
1. The mating busbars are factory installed on the expansion rectifier module mounting shelf. Secure
these busbars to the output busbars on the shelf above it. Hardware is provided with the expansion
rectifier module mounting shelf.
Hardware build-up for these connections is:
1/4-20 x 7/8" Bolt,
1/4" Belleville Lock Washer,
1/4" Flat Washer.
Install the Belleville lock washer so the concave side is towards the busbar. Torque all connections to 60
in-lbs.
NOTE!
Some systems may come with two shelves connected together with a common relay rack
mounting bracket and an output busbar spanning both shelves. Connect these shelves to other shelves
in the same manner as described here.
2. Repeat this procedure for each expansion rectifier module mounting shelf.
Changing the Direction of the DC Output Cables
DC output cables can either enter from the right, from the left, or from the rear. To reconfigure the shelf for
these options, remove the appropriate shield and position the DC output busbars per the following procedure.
The DC output busbars are factory connected for DC output cables entering from the right as viewed from the
front.
Procedure
NOTE!
Refer to
Figure 4
as this procedure is performed.
1. In Figure 4, select the view for your DC output cabling requirements (left, right, or rear).
2. Remove the appropriate shield as required as shown in the selected view.
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3. Reposition the DC output lug landing busbars as shown in the selected view.
Figure 1:
Relay Rack Floor Mounting Dimensions
Vertiv | NetSure -48V DC Bulk Output Power System Installation and User Instructions (UM582127100) | Rev. E
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Front
If multiple shelves are in the system,
remove the rear center shield from each.
Save hardware for later re-installation.
If multiple shelves are in the system,
remove and discard the bottom section
of rear center shield for all shelves
except the bottom shelf.
Rear
Bottom
Section
Secure each shelf to the relay rack.
Mounting Hardware
12-24 x 3/4" Thread Forming
Hex Head Screw (two per side)
No. 10/12 Ground Washer (one per side)
No. 12 Flat Washer (one per side)
Figure 2:
Rectifier Module Mounting Shelf Mounting
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Rear
Components removed in
illustration for clarity only.
1/4-20 x 7/8” Bolt
1/4” Belleville Lock Washer
1/4” Flat Washer
Busbar
(Torque to 60 in-lbs.)
Figure 3:
Interconnecting the Rectifier Module Mounting Shelves Output Busbars
Vertiv | NetSure -48V DC Bulk Output Power System Installation and User Instructions (UM582127100) | Rev. E
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Rear
Rear
Rear
Rear
Rear
Busbar Hardware Build-Up
1/4-20 x 7/8” Bolt
1/4” Belleville Lock Washer
1/4” Flat Washer
Busbar
(Torque to 60 in-lbs.)
DC Output Cables
Entering from the Right
(as viewed from the front)
DC Output Cables
Entering from the Left
(as viewed from the front)
DC Output Cables
Entering from the Rear
Reference Views
Left side busbar shown
mounted in lower mounting holes.
Right side busbar shown
mounted in upper mounting holes.
Left Side
Busbar
Right Side
Busbar
Right side shield removed.
Rear-bottom shield not shown.
Right side busbar mounted
in lower mounting holes.
Left side busbar mounted
in upper mounting holes.
Left side shield removed.
Rear-bottom shield not shown.
References to left and right
are as viewed from the front.
Right side busbar mounted
in lower mounting holes.
Left side busbar mounted
in lower mounting holes.
Right side busbar mounted
in upper mounting holes.
Left side busbar mounted
in lower mounting holes.
Section of rear-bottom
shield removed.
Figure 4:
Changing the Direction of the DC Output Cables
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Interconnecting the Rectifier Module Mounting Shelves CAN Bus
Each Spec. No. 588705000 rectifier module mounting shelf in the system is daisy-chained to the controller. An
NCU CAN Bus connector is located at the top of each shelf and another at the bottom of each shelf. These
connectors are used to interconnect the shelves to the controller. Refer to Figure 5 for connector locations.
These connections are factory made for shelves factory installed. These connections must be made if a
rectifier module mounting shelf(s) is field installed.
• The top connector of the top most rectifier module mounting shelf (main shelf) is internally connected
to the controller.
• The bottom connector of a shelf plugs into the top connector on the shelf below it.
• The bottom connector on the bottom-most shelf must be terminated with a termination plug.
Procedure
NOTE!
Refer to
Figure 5
as this procedure is performed.
1. Connect the bottom connector on the main shelf to the top connector on the 1st expansion shelf.
2. Connect the bottom connector on the 1st expansion shelf to the top connector on the 2nd expansion
shelf.
3. Connect the bottom connector on the 2nd expansion shelf to the top connector on the 3rd expansion
shelf.
4. Connect the bottom connector on the 3rd expansion shelf to the top connector on the 4th expansion
shelf.
5. Connect the bottom connector on the 4th expansion shelf (or bottom-most shelf for systems with less
than four expansion shelves) to CAN Bus Jumper P/N 556430. Route CAN Bus Jumper P/N 556430
within the interiors of the shelves to the controller area in the main shelf. Terminate CAN Bus Jumper
P/N 556430 with termination plug P/N 556273.
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Exploded View Shown to Illustrate Wire Connections Only
Route CAN Bus Jumper
P/N 556430 into this area.
Secure with cable ties.
Connect termination plug
P/N 556273 to open end.
P/N 556430 CAN Bus Jumper
Coil as required in bottom shelf and
route within shelves interiors to controller
area on main shelf.
Alarm & Control
Connections Between
Shelves and Controller
These two connectors
are plugged together.
Rear View (Main Shelf)
(List 61 shown)
Rear View (expansion shelf)
(List 51 shown)
Rear View (expansion shelf)
(List 51 shown)
Rear View (expansion shelf)
(List 51 shown)
Rear View (expansion shelf)
(List 51 shown)
These two connectors
are plugged together.
These two connectors
are plugged together.
These two connectors
are plugged together.
These two connectors
are plugged together.
NCU CAN Port
A CAN termination plug
(P/N 556273) must be
installed here if an external
device or system is not
connected to this connecto r.
Use cable P/N 556238 to connect
to an external device or system.
Figure 5:
Control Bus Connections between Controller and Rectifier Module Mounting Shelves Spec. No.
588705000
Vertiv | NetSure -48V DC Bulk Output Power System Installation and User Instructions (UM582127100) | Rev. E
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22
IB2
OFF
OFF
-
J12
*
RELAY
SW1
7
J2
J11
5 3
1
Relay Output Terminal B locks
Digital Input Terminal Bloc ks
J9 J8 J7
J6
J5 J4
J3
8 6 4 2
8 7 6 5 4 3
2 1
+
IB2 Board (Top View)
NO
C
NC
NO C NC
NO
C
NC
NO C NC
NO
C
NC
NO C NC
NO
C
NC
NO C NC
5 3 1
46 2
5 3 1
46 2
5 3 1
46 2
5 3 1
46 2
5 3 1
46 2
5 3 1
46 2
5
3
1
46 2
Connector
to controller
IB2 TEMP
PROBE 1
IB2 TEMP
PROBE 2
Main Rectifier
Module Mounting Shelf
Top cover can be removed from
controller section to facilitate circuit
card access.
IB2 Board Sliding Tray
on
off
1 2
SW1
In this system, switch settings
must be in positions shown.
ON
OFF
1 2
SW1
DIP Switch SW 1
1 2
OFF OFF
SETTING SWITCH OPTIONS
Switch Settings on IB2 Interface Board
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 6 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 1. Refer to Figure 6 for location.
Table 1:
Figure 6:
IB2 Interface Board Switch Settings
DIP Switch SW1
Setting
1 2
IB2 Interface Board Switch Location and Settings
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23
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 SAG582127100 and Power Data Sheet PD588705000.
Lugs should be crimped per lug manufacturer’s specifications.
Relay Rack Grounding Connection (Frame Ground)
For relay rack 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. 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 1/4-inch
hardware, recommended torque is 84 in-lbs when a standard flat washer and lock washer are used. Refer to
Figure 7 for locations.
NOTE!
NOTE!
(DC-I).
NOTE!
REMOVE TAPE FROM HOLE LOCATIONS BEFORE INSTALLING LUG.
The DC return connection to this system can remain isolated from system frame and chassis
This system is suitable for installation as part of the Common Bonding Network (CBN).
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Page 24
24
Frame Ground
Connection Point
(1/4” clearance holes on 5/8” centers)
Frame Ground
Connection Point
(1/4” clearance holes on 5/8” centers)
Top View
(Typical Relay Rack)
Top View
(Typical Relay Rack)
Figure 7:
Relay Rack Frame Grounding Connection Points
AC Input and AC Input Equipment Grounding Connections to Rectifier Module Mounting Shelves
DANGER! Adhere to the “Important Safety Instructions” presented at the front of this document.
The rectifier module mounting shelves either provide a separate single phase AC input connection for each
rectifier position (588705000 List 51 and 61), two 3 phase AC input connections (each phase of each input
circuit supplies one rectifier module) (588705000 List 52 and 62), or the rectifier module mounting shelves may
be equipped with AC line cords (588705000 List 53 and 63).
For 588705000 List 51, 52, 61, and 62; circular openings are provided in the side panels (side feed) and rear
covers (rear feed) of the rectifier module mounting shelf for AC input and AC input equipment-grounding
conductors. The openings accept 1-inch conduit fittings. AC input wiring should be provided to all rectifier
module 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 AC input feed.
Connections to 588705000 List 51 and 61 (Single-Phase, Terminal Blocks)
Spec. No. 588705000 List 51 and 61 rectifier module mounting shelf provides a separate AC input connection
for each rectifier module position in the shelf.
Refer to Figure 8 as this procedure is performed.
NOTE!
Repeat the following procedure for each rectifier module mounting shelf in the power system.
Vertiv | NetSure -48V DC Bulk Output Power System Installation and User Instructions (UM582127100) | Rev. E
Page 25
25
Accessing Connections and Wire Routing
1. Remove the two AC input access covers from the rear of the rectifier module mounting shelf by first
removing the screws that secure them.
2. Install conduit fittings in the side or rear openings as required. Plug buttons are provided, and must be
installed in the openings not being used.
3. Route wiring into the shelf through the previously installed conduit fittings.
Making AC Input Connections
NOTE!
In each shelf, rectifier module mounting positions are number 1-6 from left to right as viewed
from the front. Note that in the main shelf, the 6th position is occupied by the NCU Controller.
1. Make AC input connections as shown in Figure 8. Connect each wire by inserting the stripped end into
the wire opening, and then tightening the screw. Torque connections to value shown in Figure 8.
Making AC Equipment Grounding Connections
NOTE!
Make equipment grounding connections to earth ground, not to the branch circuit neutral
conductor.
1. Connect AC input equipment grounding leads to the frame ground studs using installer-provided ring
lugs and factory-supplied mounting hardware. Torque connections to value shown in Figure 8.
Reinstalling Covers
1. After all AC input and equipment grounding connections have been made and checked, reinstall the two
AC input access covers on the back of the shelf. Secure with the previously removed screws.
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Page 26
26
L
ist 51 only
FRAME GROUND CONNECTION
ONE 10-32 X 3/4" STUD
AND HARDWARE, PER SIDE.
Recommended torque: 23 in-lbs.
FRAME GROUND CONNECTION
ONE 10-32 X 3/4" STUD
AND HARDWARE, PER SIDE.
Recommended torque: 23 in-lbs.
AC IN: 208-240VAC, 50/60Hz, SINGLE PHASE
Wire Size Capacity: 6-14 AWG.
Recommended Torque: 6 AWG, 45 in-lbs.
8-14 AWG, 35 in-lbs.
Service Type:
a. Line to Line:
Connect Line 1 to Terminal 1.
Connect Line 2 to Terminal 2.
b. Line to Neutral:
Connect Line to Terminal 1.
Connect Neutral to Terminal 2.
TB2 TB1TB4 TB3
1
2
1
2
1
2
2
1
2
1
2
1
Rectifier
Module 1
Rectifier
Module 2
Rectifier
Module 3
Rectifier
Module 4
Rectifier
Module 6
Rectifier
Module 5
Rectifier
Module 5
Rectifier
Module 2
Rear View
(List 51 shown)
Hole for 1"
Conduit Fitting
(AC Input)
Hole for 1"
Conduit Fitting
(AC Input)
Rear View
(List 51 shown)
Rectifier Module
Mounting Slots
(front view)
Rect.
1
Rect.
2
Rect.
3
Rect.4Rect.
5
Rect.
6
Figure 8:
AC Input Connections to a 588705000 List 51 and 61 Rectifier Module Mounting Shelf (Single-Phase,
Terminal Blocks)
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Page 27
27
Connections to 588705000 List 52 and 62 (Three-Phase, Terminal Blocks)
Spec. No. 588705000 List 52 and 62 rectifier module mounting shelf provides two 3-phase AC input
connections. Each phase of each input circuit supplies one rectifier module.
Refer to Figure 9 as this procedure is performed.
NOTE!
Repeat the following procedure for each rectifier module mounting shelf in the power system.
Accessing Connections and Wire Routing
1. Remove the two AC input access covers from the rear of the rectifier module mounting shelf by first
removing the screws that secure them.
2. Install conduit fittings in the side or rear openings as required. Plug buttons are provided, and must be
installed in the openings not being used.
3. Route wiring into the shelf through the previously installed conduit fittings.
Making AC Input Connections
NOTE!
In each shelf, rectifier module mounting positions are numbered 1-6 from left to right as viewed
from the front. Note that in the main shelf, the 6th position is occupied by the NCU Controller.
1. Make AC input connections as shown in Figure 9. Connect each wire by inserting the stripped end into
the wire opening, and then tightening the screw. Torque connections to value shown in Figure 9.
Making AC Equipment Grounding Connections
NOTE!
Make equipment grounding connections to earth ground, not to the branch circuit neutral
conductor
1. Connect AC input equipment grounding leads to the frame ground studs using installer-provided ring
lugs and factory-supplied mounting hardware. Torque connections to value shown in Figure 9.
Reinstalling Covers
1. After all AC input and equipment grounding connections have been made and checked, reinstall the two
AC input access covers on the back of the shelf. Secure with the previously removed screws.
Vertiv | NetSure -48V DC Bulk Output Power System Installation and User Instructions (UM582127100) | Rev. E
Page 28
28
Hole for 1"
Conduit Fitting
(AC Input)
Hole for 1"
Conduit Fitting
(AC Input)
Rear View
(List 52 shown)
Rear View
(List 52 shown)
Rectifier Module
Mounting Slots
(front view)
Rect.1Rect.2Rect.3Rect.4Rect.5Rect.
6
CONNECTIONS WITHIN THE SHELF
TB1, Terminal TB2, Terminal
Mounting
Position
1 (ØA) 2 (ØB) 3 (ØC) 1 (ØA) 2 (ØB) 3 (ØC)
L1 L2
L1 L2
L1 L2
L1 L2
L1 L2
Rect 6
Rect 5
Rect 4
Rect 3
Rect 2
Rect 1
L1 L2
List 52 only
(ØA)
TB2 TB1
(ØB)
(ØC)
(ØA)
(ØB)
(ØC)
AC IN Feed 2
Rectifier Modules
#4-#6 (List 52)
#4-#5 (List 62)
AC IN Feed 1
Rectifier Modules
#1-#3 (List 52, 62)
FRAME GROUND CONNECTION
ONE 10-32 X 3/4" STUD
AND HARDWARE, PER SIDE.
Recommended torque: 23 in-lbs.
FRAME GROUND CONNECTION
ONE 10-32 X 3/4" STUD
AND HARDWARE, PER SIDE.
Recommended torque: 23 in-lbs.
AC IN: 208-240VAC, 50/60Hz, THREE PHASE
Wire Size Capacity: 6-14 AWG.
Recommended Torque: 6 AWG, 45 in-lbs.
8-14 AWG, 35 in-lbs.
Figure 9:
AC Input Connections to a 588705000 List 52 and 62 Rectifier Module Mounting Shelf (Three-
Phase, Terminal Blocks)
Vertiv | NetSure -48V DC Bulk Output Power System Installation and User Instructions (UM582127100) | Rev. E
Page 29
29
List 53
List 63
Rear View
Rear View
Rectifier
Module 1
Rectifier
Module 3
Rectifier
Module 2
Rectifier
Module 6
Rectifier
Module 5
Rectifier
Module 4
Rectifier
Module 5
Rectifier
Module 4
Rectifier
Module 1
Rectifier
Module 3
Rectifier
Module 2
Rectifier Module
Mounting Slots
(front view)
Rect.1Rect.2Rect.
3
Rect.
4
Rect.5Rect.
6
AC IN: 208-240VAC, 50/60Hz, SINGLE PHASE
AC IN: 208-240VAC, 50/60Hz, SINGLE PHASE
Connections to 588705000 List 53 and 63 (Single-Phase, Line Cords)
Spec. No. 588705000 List 53 and 63 rectifier module mounting shelf is provided with five (5) or six (6) factory
installed AC input line cords (one for each rectifier module position). Plug each AC line cord into a properly
wired AC outlet or distribution box. Refer to Figure 10.
Figure 10:
AC Input Connections to a 588705000 List 53 and 63 Rectifier Module Mounting Shelf (Single-
Phase, Line Cords)
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NCU
Controller
NCU Controller
NCU
10/100M Ethernet
Port (RJ-45)
IB2 (Controller
Interface Board)
Sliding Tray
System Interface
Circuit Cards
Customer Connection
Terminal Block
Front
Top cover can be removed from
controller section to facilitate circuit
card access.
Main Rectifier
Module Mounting Shelf
External Alarm, Reference, Monitoring, and Control Connections
External Alarm, Reference, Monitoring, and Control Connection Points Locations
Refer to Figure 11.
Figure 11:
External Alarm, Reference, Monitoring, and Control Connection Points Locations
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Page 31
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System Interface Circuit Cards Connections (if required)
Mounted in the main rectifier module mounting shelf is a system internal interface circuit card and a system
external interface circuit card. Factory cabling is routed from the system interface circuit cards to terminal
block TB5. Terminal block TB5 is located on the right side of the main rectifier module mounting shelf and is
provided for customer connections to the system interface circuit cards. Refer to Figure 12 and Table 2. Refer
also to Figure 12 for recommended torque. Note that terminal block TB5 is a screw-type terminal block and
consists of two pieces that can be pulled apart for easy wiring.
System Internal Interface Circuit Card
The system internal interface circuit card provides connections for the following signals to terminal block TB5.
Refer to Figure 12 and Table 2.
• Two (2) External Battery Fuse Alarm Inputs
• Four (4) External Load Fuse Alarm Inputs
• One (1) Load Shunt Input
• One (1) Battery Shunt Input
• One (1) LVD Driver Output
• One (1) LVD Sense Input
• RS-485 Port
Battery Fuse Alarm Input Rating: Refer to the following.
a) The default is 400mV. Anything greater than 400mV causes alarm to be raised.
Load Fuse Alarm Input Signal: Refer to the following.
a) Anything greater than 19V causes alarm to be raised.
Battery and Load Shunt Input Rating: Refer to the following.
a) 1mV – 150mV.
LVD Driver Output Rating: Refer to the following.
a) Mono-stable, normal state is 60V or less at 1A continuous rating. Normally closed contactors are used
for mono-stable option.
b) Bi-Stable, normal state less than 60V and 2A at 500ms – 1000ms pulse rating.
LVD Sense Input Rating: Refer to the following.
a) Normal state is at 60V or less. A RTN signal indicates the contactor is open.
System External Interface Circuit Card
The system external interface circuit card provides direct connections for the following. Refer to Figure 12 and
Table 2.
• RS-232 (used for communication with a DPU)
• Two (2) Temperature Probe Inputs (See Temperature Probes on page 21.)
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A CAN termination plug
must be installed if an
external device or system
is not connected here.
The end of the Controller CAN Bus is routed
from the bottom-most rectifier shelf into
the top-most rectifier shelf via cable P/N 556430.
Use cable P/N 556238 to connect external devices
to the end of the Controller CAN bus. Access the connector
by removing the top cover from the controller section of
the shelf.
RS-485 Connection
Pin 1: RS485+
Pin 2: RS485-
RS-232 Connection
Pin 1: DCD232
Pin 2: RXD232
Pin 3: TXD232
Pin 4: DTR232
Pin 5: CGND
Pin 7: RTS232
RS-232 RS-485
SYSTEM
TEMP
PROBE 1
SYSTEM
TEMP
PROBE 2
1 5
6 9
21
1
2
1
2
1
2
1
2
1
2
STD
Controller Section of Main
Shelf (components removed
for clarity only)
Factory
Connected
to TB5
Internal System
Interface Circuit Card
TB5
External System
Interface Circuit Card
LA BA
OPT
Factory
Connected to
DC Bus and
CAN Bus
Factory
Connected
to TB5
See table
on next page.
Factory
Connected
to TB5
Factory
Connected
to TB5
Wire Size Capacity:
30-12 AWG.
Recommended Torque:
4.4 to 5.3 in-lbs.
Figure 12:
System Interface Connections
Vertiv | NetSure -48V DC Bulk Output Power System Installation and User Instructions (UM582127100) | Rev. E
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33
RS-485 (+)
1
Load Fuse Alarm 1
13
Battery 2 Shunt (-)
3
Load Fuse Alarm 5
not available
Battery 2 Shunt (+)
4
Load Fuse Alarm 6
not available
Load Shunt (-)
5
Load Fuse Alarm 7
not available
LVD2 Sense (-)
7
Load Fuse Alarm 9
not available
LVD2 Drive (+)
8
Load Fuse Alarm 10
not available
LVD2 Sense (+)
10
Battery Fuse Alarm 1
11
Battery Fuse Alarm 3
not available
Table 2:
System Interface Circuit Cards Signals Available on TB5
RS-485 (System External Interface Circuit Card) LA (System Internal Interface Circuit Card)
Signal TB5 Signal TB5
RS-485 (-) 2 Load Fuse Alarm 2 14
OPT (System Internal Interface Circuit Card)
Signal TB5
Load Fuse Alarm 4 16
Load Fuse Alarm 3
Load Shunt (+) 6 Load Fuse Alarm 8 not available
SPD (-) not available
LVD2 Drive (-) 9
SPD (+) not available
STD (System Internal Interface Circuit Card)
Signal TB5
Battery 1 Shunt (-) not available
LVD1 Drive (+) not available
BA (System Internal Interface Circuit Card)
Signal TB5
LVD1 Drive (-)
Battery 1 Shunt (+) not available
LVD1 Sense (-) not available
Battery Fuse Alarm 2 12
LVD1 Sense (+) not available
Battery Fuse Alarm 4 not available
not available
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IB2 Controller Interface Board) Connections (if required)
The IB2 (Controller Interface Board) provides connection points for digital inputs, programmable relay outputs,
and temperature probes. The IB2 interface board is mounted inside the main rectifier module mounting shelf.
Refer to Figure 11.
Digital Inputs and Programmable Relay Outputs
Digital input and relay output leads are connected to screw-type terminal blocks located on the IB2.
Recommended torque for these connections is 2.2 in-lbs. Refer to Figure 13 for terminal locations. Refer to
Table 3 and Table 4 for pin-out information.
• Digital Inputs
Connect up to eight (8) digital inputs to the IB2. Note that you must supply both paths for the digital input
(either a positive or a negative signal and the opposite polarity return path). Observe proper polarity. Refer to
Figure 13 for terminal locations and Table 3 for pin-out information.
The digital inputs can be programmed to provide an alarm when the signal is applied (HIGH) or removed
(LOW). Refer to the NCU Instructions (UM1M830BNA) for programming information.
Digital Input Ratings: Refer to the following.
a) Maximum Voltage Rating: 60V DC.
b) Active High: > 19V DC.
c) Active Low: < 1V DC.
The digital inputs may be preprogrammed for specific functions. Refer to the configuration drawing (Cdrawing) supplied with your system for your system’s specific configuration.
• Programmable Relay Outputs
The IB2 provides eight (8) programmable alarm relays with dry Form-C contacts. Connect up to eight (8) relay
outputs to the IB2. Refer to Figure 13 for terminal locations and Table 4 for pin-out information.
Refer to the NCU Instructions (UM1M830BNA) for programming information.
Relay Ratings: Refer to the following.
a) Steady State: 0.5 A @ 60V DC; 1.0 A @ 30V DC.
b) Peak: 3 A @ 30V DC.
The relays may be preprogrammed for specific functions. Refer to the configuration drawing (C-drawing)
supplied with your system for your system’s specific configuration.
Temperature Probes
NOTE!
Each temperature probe consists of two pieces that plug together to make a complete probe.
See SAG582127100 for part numbers and descriptions.
Temperature probes are connected to the IB2 (Controller Interface Board) and/or the system external interface
board mounted inside the main rectifier module mounting shelf. See Figure 12 and Figure 13.
Up to two (2) temperature probes can be connected to the IB2. Up to two (2) additional temperature probes
can be connected to the system external interface board. Any combination of the four (4) temperature probes
Vertiv | NetSure -48V DC Bulk Output Power System Installation and User Instructions (UM582127100) | Rev. E
Page 35
35
can be programmed to monitor ambient temperature and/or battery temperature. A temperature probe set to
monitor battery temperature can also be used for the rectifier battery charge temperature compensation
feature, or the battery charge temperature compensation feature can be programmed to use the average or
highest value of all battery temperature probes. The battery charge temperature compensation feature allows
the controller to automatically increase or decrease the output voltage of the system to maintain battery float
current as battery temperature decreases or increases, respectively. Battery life can be extended when an
optimum charge voltage to the battery with respect to temperature is maintained. A temperature probe set to
monitor battery temperature can also be used for the BTRM (Battery Thermal Runaway Management) feature.
The BTRM feature lowers output voltage when a high temperature condition exists to control against battery
thermal runaway.
The temperature sensor end of the probe contains a tab with a 5/16” clearance hole for mounting.
A temperature probe programmed to monitor battery temperature should be mounted on the negative post of
a battery cell to sense battery temperature. A temperature probe used for battery charge temperature
compensation and/or BTRM (Battery Thermal Runaway Management) should also be mounted on the negative
post of a battery cell. A temperature probe programmed to monitor ambient temperature should be mounted
in a convenient location, away from direct sources of heat or cold.
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36
IB2
(Controller Interface Board)
Switch settings must be in this position
to interface with the Controller
-
J12
*
RELAY
SW1
7
J2
J11
5 3
1
Relay Output Terminal Blocks
Digital Input Terminal Blocks
J9 J8 J7
J6
J5 J4
J3
8 6 4
2
8 7 6 5 4 3
2 1
+
IB2 Board (Top View)
NO
C
NC
NO C NC
NO
C
NC
NO C NC
NO
C
NC
NO C NC
NO
C
NC
NO C NC
5
3
1
46 2
5 3 1
46 2
5
3
1
46 2
5 3 1
46 2
5
3
1
46 2
5
3
1
46 2
5 3 1
46 2
Connector
to controller
IB2 TEMP
PROBRE 1
IB2 TEMP
PROBE 2
*
The relay assigned to “Critical Summary” alarm (relay 1 by default)
will operate in the “Fail Safe Mode”. “Fail Safe Mode” means Relay 1 is
de-energized during an alarm condition, opening the contacts between the
C and NO terminals, and closing the contacts between the C and NC terminals.
The remaining seven (7) relays energize during an alarm condition, closing
the contacts between the C and NO terminals, and opening the contacts between
the C and NC terminals.
Not all I/O points are available for customer connection (some are used for factory
system connections).
J3-J9:
Wire Size Capacity: 16-26 AWG.
Recommended Torque: 2.2 in-lbs.
Figure 13:
IB2 (Interface Board) Connections
Vertiv | NetSure -48V DC Bulk Output Power System Installation and User Instructions (UM582127100) | Rev. E
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37
J3-3
– 3 J3-6
+
J4-1
– 5 J4-4
+
J4-5
– 7 J5-2
+
(to customer
J5-3
–
to J5-6 (-48VDC)
Table 3:
Programmable Digital Inputs – IB2
Programmable
Digital Input
1
2
4
6
8
IB2
Pin No.
J3-2 +
J3-1 –
J3-4 +
J3-5 –
J4-2 +
J4-3 –
J4-6 +
J5-1 –
J5-4 +
Factory
Wiring
The digital inputs may
be preprogrammed for
specific functions and
have factory wiring
connected. Refer to the
configuration drawing
(C-drawing) supplied
with your system for
your system’s specific
configuration.
ESTOP switch)
Default Digital
Input Function
The digital inputs may
be preprogrammed for
specific functions.
Refer to the
configuration drawing
(C-drawing) supplied
with your system for
your system’s specific
configuration.
ESTOP
Customer Defined
Digital Input Function
Reference
Voltages
Ground J5-5
-48VDC J5-6
NOTE!
-48VDC is factory supplied to J5-6 which is also factory jumpered to J5-3 (Digital Input #8,
minus). A customer provided ESTOP switch can be connected to J5-4 (Digital Input #8, positive). Note
that ground is furnished on J5-5 for a convenient connection to the other side of a customer provided
ESTOP switch. Digital Input #8 is factory configured for the ESTOP function. Customer-furnished
system ground applied to terminal J5-4 (Digital Input #8, positive) activates the ESTOP function. The
ESTOP function shuts down and locks out the rectifiers and opens the LVD’s. When the ESTOP signal is
removed, LVD’s close (if battery present). To restart the rectifiers; turn AC power to the rectifiers OFF,
wait 30 seconds or more (until the LEDs on the rectifier extinguish), then turn AC power to the rectifiers
ON.
IB2
Pin No.
Factory Wiring
(can be connected to the other side of a customer furnished ESTOP
switch)
-48VDC is factory supplied to J5-6.
J5-6 is also factory jumpered to J5-3 (Digital Input #8, minus)
Vertiv | NetSure -48V DC Bulk Output Power System Installation and User Instructions (UM582127100) | Rev. E
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NC
J6-1
NO
J6-6
NO
J7-5
COM
J7-3
COM
J7-4
NC
J7-2
NC
J8-1
NO
J8-6
NO
J9-5
COM
J9-3
COM
J9-4
NC
J9-2
Table 4:
Programmable Relay Outputs – IB2
Programmable
Relay Output
IB2
Pin No.
NO J6-5
1
2
NC J6-2
3
NC J7-1
NO J7-6
4
NO J8-5
5
Alarms Assigned to this
Relay (Default)
The relays may be
preprogrammed for specific
functions. Refer to the
configuration drawing (Cdrawing) supplied with your
system for your system’s
specific configuration.
Alarms Assigned to this
Relay (Custom)
COM J6-3
COM J6-4
COM J8-3
6
7
8
NOTE!
Mode”. “Fail Safe Mode” means Relay 1 is de-energized during an alarm condition, opening the contacts
between the C and NO terminals, and closing the contacts between the C and NC terminals.
The remaining 7 relays energize during an alarm condition, closing the contacts between the C and NO
terminals, and opening the contacts between the C and NC terminals.
COM J8-4
NC J8-2
NC J9-1
NO J9-6
The relay assigned to “Critical Summary” alarm (relay 1 by default) will operate in the “Fail Safe
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CAN-H
Black
CANx-1
CAN-H
Black
CANx-1
CAN-L
Red
CANx-2
Controller CAN Bus
The end of the Controller CAN Bus is routed into the controller section of the main rectifier module mounting
shelf via cable P/N 556430. Use cable P/N 556238 to connect external devices to the end of the Controller
CAN bus. Access the Controller CAN Bus connector by removing the top cover from the controller section of
the main rectifier module mounting shelf. A CAN termination plug must be installed if an external device or
system is not connected here. Refer to Figure 5, Figure 12, and Table 5.
Table 5:
Controller CAN Bus Cables
P/N 556430 (Int. CAN) Cable
Signal Wire Color Pinouts
CAN-L Red CANx-2
P/N 556238 (Ext. CAN) Cable
Signal Wire Color Pinouts
Connecting a Device or System to the Controller CAN Bus
A supporting device or system may be connected to the Controller CAN Port. Refer to Figure 5 and Figure 12
for location. A 10’ long Controller CAN Bus Cable is available (P/N 556238) to extend the end of the Controller
CAN Bus outside the main rectifier module mounting shelf to other equipment. See Table 5 for cable pinouts
and wire colors. Refer also to the external device’s or system’s instruction manual.
Procedure
1. Remove the CAN termination plug from the Controller CAN Port (see Figure 5 and Figure 12 for
location). Connect the device or system to the Controller CAN Port using cable P/N 556238. Refer to
Table 5 for cable pinouts and wire colors. Note that you may have to cut the end off of the cable if it is
not compatible with the device’s CAN Bus connection points. Refer also to the external device’s or
system’s instruction manual.
Optional SM-Temp Module
The analog output of the SM-Temp Module may be connected to a controller temperature port input. In lieu of
connecting the analog output of the SM-TEMP module to a controller temperature port input, the SM-TEMP
module can simply be connected at the end of the Controller CAN Bus. Refer to the SM-Temp Module
Instructions (UM547490) for details.
Procedure
1. Remove the CAN termination plug from the Controller CAN Port (see Figure 5 and Figure 12 for
location). Connect the SM-Temp Module CAN Bus to the Controller CAN Port using cable P/N 556238.
Refer to Table 2 for cable pinouts and wire colors. Note that you will have to cut the end off of the cable
to connect it to the SM-Temp Module’s CAN Bus connection points. Ensure the last SM-Temp Module
(or if only one) has a CAN termination strap as shown in the SM-Temp Module Instructions
(UM547490).
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1
Tx+
Write Signal +
2
Tx-
Write Signal -
3
Rx+
Read Signal +
4
--
no connection
8
--
no connection
Controller Ethernet Connection (if required)
The controller provides a Web Interface via an Ethernet connection to a TCP/IP network. This interface can be
accessed locally on a computer or remotely through a network. An RJ-45 10BaseT jack is provided on the front
of the controller for connection into a customer's network. This jack has a standard Ethernet pin configuration
scheme, twisted pair. Refer to Figure 11 for location and Table 6 for pin outs. Use shielded Ethernet cable
(grounded at both ends). Note that the RJ-45 jack is connected to chassis ground. Refer to the NCU
Instructions (UM1M830BNA) for operational details.
NOTE!
You can access the Web pages of the power system locally by using a "crossover" or “straight”
cable connected directly between your PC and the NCU Controller.
WARNING! The intra-building port(s) of the equipment or subassembly is suitable for connection to
intra-building or unexposed wiring or cabling only. The intra-building port(s) of the equipment or
subassembly MUST NOT be metallically connected to the interfaces that connect to the OSP or its
wiring. These interfaces are designed for use as intra-building interfaces only (Type 2 or Type 4 ports as
described in GR-1089-CORE, Issue 4) and require isolation from the exposed OSP cabling. The addition
of Primary Protectors is not sufficient protection in order to connect these interfaces metallically to OSP
wiring.
The intra-building port (RJ-45) of the equipment or subassembly must use shielded intra-building
cabling/wiring that is grounded at both ends.
Table 6:
RJ-45 Ethernet Port Pin Configuration
Port Pin
Number
Name Definition
Vertiv | NetSure -48V DC Bulk Output Power System Installation and User Instructions (UM582127100) | Rev. E
5 -- no connection
6 Rx- Read Signal -
7 -- no connection
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-48V DC Output Connections
Important Safety Instructions
DANGER! Adhere to the “Important Safety Instructions” presented at the front of this document.
ALERT! Observe proper polarity when making output connections.
Recommended Torques
• 300 in-lbs for 3/8-inch hardware (when using standard flat and lock washer).
• 180 in-lbs for 3/8-inch hardware (when using a Belleville lock washer).
General
DC output leads are connected to the output busbars located on the back of the rectifier shelves. These
busbars provide 3/8” clearance holes for installation of customer-provided two hole lugs that have 1 inch
centers and 3/8 inch bolt clearance holes. Customer must order or provide lug mounting hardware.
You connect DC output leads per a single rectifier shelf in the system or for pairs of rectifier shelves in the
system (depending on how many shelves are in the system). Refer to Figure 14.
DC output cables can either enter from the right, from the left, or from the rear. The shelf should have been
configured for your installation site per the “Changing the Direction of the DC Output Cables” procedure on
page 15. Refer to Figure 15 for typical lug layout diagrams.
After making DC output connections, re-install any rear shield removed in “Mounting the Rectifier Module
Mounting Shelf(s) to a Relay Rack” on page 14.
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GND RTN
Busbars
-48V DC
Output
Busbars
GND RTN
Busbars
-48V DC
Output
Busbars
GND RTN
Busbars
-48V DC
Output
Busbars
GND RTN
Busbars
-48V DC
Output
Busbars
GND RTN
Busbars
-48V DC
Output
Busbars
Rear
Rear
Rear
Rear
Rear
1-Shelf System
2-Shelf System
3-Shelf System
(1) connection per
two shelves.
(1) connection per
two shelves (top).
(1) connection per
two shelves (bottom).
(1) connection per
two shelves (top).
(1) connection per
single shelf (bottom).
(1) connection per
two shelves (top).
(1) connection per
two shelves (middle).
(1) connection per
single shelf (bottom).
(1) connection per
single shelf.
4-Shelf System
5-Shelf System
ug mounting hardware.)
1.31” for three (3) lugs per polarity.
1.78” for two (2) lugs per polarity.
DC Output Connection Options
1. Route cables left, right, or out the back
by repositioning the lug landing busbars.
2. Make connections to each shelf
(List 10 and 11).
3. Make connections to every
two (2) shelves (List 20 and 21).
Figure 14:
-48V DC Output Connections
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Ma
ximum L
ug Tab Wid
th: 1.7
8”
Figure 15:
Typical Lug Layout Diagrams
Three (3) Lugs Layout Dia
Maximum Lug Tab Width: 1
gr
.3
a
m
1
”
T
wo (2) L
ugs Layo
ut Diagr
am
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INSTALLING THE RECTIFIER MODULES AND INITIALLY STARTING THE SYSTEM
Installing the Rectifier Modules into Spec. No. 588705000 Rectifier Module Mounting Shelves
Rectifier modules can be inserted or removed with power applied (hot swappable).
NOTE!
the underside of the rectifier module. The latch and rectifier module handle are interactive. Push the
handle into the rectifier module’s front panel, and the latch will pop out from the rectifier module bottom.
Click the handle to pop it out from the rectifier module’s front panel, and the latch will retract back into
the rectifier module. The latch mechanism is shown in
ALERT! To prevent damage to the latching mechanism, ensure the handle is in the open position when
installing or removing a rectifier module. NEVER hold the handle in the closed position when installing a
rectifier module into a shelf.
NOTE! 588705000 List 52 and 62 Rectifier Mounting Shelves Only (3 Phase Input):
phase input feeds the three rectifier modules on the left-hand side of the shelf. The second three-phase
input feeds the two (List 62) or three (List 52) rectifier modules on the right-hand side. To maintain
phase balance, install rectifier modules in groups of three (List 52); that is, fill all three mounting
positions on the left and/or all three on the right. To maintain phase balance, install rectifier modules in
groups of two or three (List 62); that is, fill all three mounting positions on the left and/or all two on the
right.
Procedure
1. Unpack the rectifier modules.
2. If present, remove blank cover panels from the rectifier module mounting positions into which rectifier
modules are to be installed.
The rectifier module locks into the rectifier module mounting shelf through a latch located on
Figure 16
.
One three-
3. Place the rectifier module into an unoccupied mounting slot without sliding it in completely.
4. Click the rectifier module handle in order to pop it forwards out of the rectifier module’s front panel (this
will also retract the latch mechanism located on the underside of the rectifier module).
5. Push the rectifier module completely into the shelf.
6. Push the handle into the front panel of the rectifier module. This will make the latch lock the rectifier
module securely to the shelf.
7. Repeat the above steps for each rectifier module being installed in the system.
8. After the rectifier modules are physically installed in the mounting shelf(s), they are ready for operation
immediately after power is supplied to them.
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Figure 16:
Installing Rectifier Modules into Spec. No. 588705000 Rectifier Module Mounting Shelf
Initially Starting, Configuring, and Checking System Operation
Important Safety Instructions
ALERT! Performing various steps in the following procedures may cause a service interruption and/or
result in the extension of alarms. Notify any appropriate personnel before starting these procedures.
Also, notify personnel when these procedures are completed.
Initial Startup Preparation
• Ensure that all blocks, except the last one, in the “Installation Acceptance Checklist” starting on page 1
have been checked.
• Ensure that rectifier module mounting positions are filled by a rectifier module or a blank cover panel as
desired. It is acceptable for positions to be left vacant.
• Refer to the configuration drawing (C-drawing) supplied with your power system documentation for
factory settings of adjustable parameters.
Initially Starting the System
Procedure
1. Apply DC input power to the system by closing the external DC disconnect(s) or protective device(s)
that supplies battery power to the system, if furnished.
2. Apply AC input power to the system by closing ALL external AC disconnects or protective devices that
supply AC power to the rectifier module mounting shelves. Rectifiers automatically start.
NCU Controller Initialization
Refer to the NCU Instructions (UM1M830BNA) for detailed instructions.
Refer to Figure 17 for locations of the NCU local indicators and navigation keys.
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Status
Indicator
(Green)
Minor Alarm
Indicator (Yellow)
Critical or
Major Alarm
Indicator
(Red)
Menu
Navigation
Keys
USB
Port
10/100M Ethernet
Port (RJ-45)
M830D
ESC ENT
Figure 17:
NCU Local Indicators and Navigation Keys
Procedure
NOTE!
illuminate on the NCU front panel and an audible alarm may sound. Disregard all alarms. An audible
alarm can be silenced at any time by momentarily depressing the
The initialization routine takes several minutes. During that time various alarm indicators may
ENT
key on the NCU Controller.
1. After the NCU is powered on, the display shows the “logo” screen. The controller is initializing.
2. When initialization is complete, the language screen appears. Press the up or down arrow key to select
the desired language. Press the ENT key to confirm the selection.
3. The Main Menu displays. See Figure 18.
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Figure 18:
NCU Local Display Main Menu
4. System information is displayed in multiple screens. Press the ESC key to view other system
information. Press the down arrow key to view the next screen. Press the ESC key to return to
the Main Menu.
5. From the Main Menu, press the UP and DOWN keys to highlight the desired Menu graphic in
the Main Menu. Press the ENT key to enter the selected menu.
NOTE!
Repeatedly press the “ESC” key to return in reverse order level by level from any submenu until
the Main Menu appears.
6. Verify and set the NCU controller as required for your application. Refer to the NCU
Instructions (UM1M830BNA) for procedures. Note that you will have to program the NCU for
any temperature probes and external inputs/outputs connected to the IB2 Interface Board.
Refer also to “NCU Start Wizard” on page 48.
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48
NOTE!
When setting total rectifier current limit, the set point to each unit is the total set point divided
by the number of units. For example, if the system contains five rectifiers and the current limit is set to
150 amps then each rectifier has a current limit set point of 30 amps. If one or more rectifiers are
removed or fail it will take several seconds for the individual set points to the remaining rectifiers to be
reset. In the example given, if one rectifier is removed the current limit set point will drop to 120 amps
(30 amps times four remaining rectifiers) until the controller can send updated set points to the
remaining rectifiers. This takes a couple communication cycles (several seconds) after which each
rectifier would have a new set point of 37.5 amps for a total of 150 amps. The total current limit of the
rectifiers should not be set such that the loss of the redundant rectifiers will cause this temporary set
point to drop below the actual maximum expected load. If batteries are used on the rectifier output, the
batteries should support the load until the current limit set points can be re-established due to loss of a
rectifier.
NCU Start Wizard
For initial startup, you can perform the Start Wizard from the local keypad and display to enter basic
programmable parameters in one session. Refer to the “Start Wizard” section in the NCU Instructions
(UM1M830BNA).
Verifying the Configuration File
Your NCU was programmed with a configuration file that sets all adjustable parameters. The version number of
the configuration file can be found on the configuration drawing (C-drawing) that is supplied with your power
system documentation, and on a label located on the NCU. You can verify that the correct configuration file
has been loaded into your NCU by performing the following procedure.
Procedure
1. With the Main Menu displayed, press ESC. A screen displays the NCU name, serial number, IP number,
software version, hardware version, and configuration version number.
2. Press the
DOWN
key. A screen displays the NCU file system and MAC address.
3. Press ESC to return to the Main Menu.
Checking Basic System Settings
Navigate through the controller menus and submenus to check system settings. You can adjust any parameter
as required. Note that these settings can also be checked (and changed if required) via the WEB Interface.
Refer also to “NCU Start Wizard” on page 48.
NOTE!
Repeatedly press the “ESC” key to return in reverse order level by level from any submenu until
the Main Menu appears.
Procedure
1. To Select a Sub-Menu:
Press the UP and DOWN keys to highlight the desired sub-menu. Press the ENT key to enter the
selected sub-menu.
2. To Select a User:
To select a User, use the UP and DOWN keys to move the cursor to the Select User field. Press ENT.
Use the UP and DOWN keys to select a User previously programmed into the NCU. Press ENT to select
the User. Note that only Users programmed into the NCU are shown. Users are programmed via the
Web Interface. The default User is admin.
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Date
Main Menu / Settings Icon / Sys Settings / Date.
Time
Main Menu / Settings Icon / Sys Settings / Time.
IP Communications
address, gateway address)
Float Voltage
Main Menu / Settings Icon / Batt Settings / Charge / Float Voltage.
Equalize Voltage
Main Menu / Settings Icon / Batt Settings / Charge / EQ Voltage.
Main Menu / Settings Icon / Batt Settings / Batt1 Settings or Batt2
Settings / Rated Capacity.
Battery Charge Temperature
Compensation
Main Menu / Settings Icon / Batt Settings / Temp Comp (enter
parameters).
Main Menu / Settings Icon / Rect Settings / Current Limit (set to
enabled) then set Curr Limit Pt.
Over Voltage Alarm 1
Main Menu / Settings Icon / Other Settings / Over Voltage 1.
Over Voltage Alarm 2
Main Menu / Settings Icon / Other Settings / Over Voltage 2.
Under Voltage Alarm 1
Main Menu / Settings Icon / Other Settings / Under Voltage 1.
Under Voltage Alarm 2
Main Menu / Settings Icon / Other Settings / Under Voltage 2.
3. To Enter a Password:
To enter a password, use the UP and DOWN keys to move the cursor to the Enter Password field. Press
ENT. Use the UP and DOWN keys to choose a character. Press ENT to accept and move to the next
character. Continue this process until all characters are entered. Press ENT again to accept the
password. The default password is 640275.
4. To Change a Parameter:
Press the UP and DOWN keys to move up and down the list of parameters. Press ENT to select the
parameter. Press the UP and DOWN keys to change the parameter. Press ENT to make the change.
Press ESC to cancel the change.
Table 7 shows the menu navigation for some basic settings. Refer to the separate NCU Manual
(UM1M830BNA) supplied with your power system for complete Local Display menus.
Table 7:
NCU Basic Settings Menu Navigation
Parameter Menu Navigation
Parameters
(IP address, subnet mask
Main Menu / Settings Icon / Comm Settings / enter parameters.
Battery Capacity
Rectifier Current Limit
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Changing Battery Capacity Rating in the NCU
Change the battery capacity setting of the NCU to match the battery connected to the power system.
Local Menu Navigation:
Main Menu / Settings Icon / Batt Settings / Batt1 Settings or Batt2 Settings / Rated Capacity.
Web Menu Navigation:
Settings Menu / Battery Tab / Batt1 Rated Capacity and Batt2 Rated Capacity.
Refer to the NCU Instructions (UM1M830BNA) for detailed instructions.
Configuring the NCU Identification of Rectifiers and Assigning which Input Feed is Connected to the Rectifiers
When rectifiers are all installed prior to applying power and starting the system, the order in which the NCU
identifies the rectifiers is by serial number (lowest serial number is Rect 1, next lowest is Rect 2, etc.). If you
prefer the NCU to identify the rectifiers by position in the system, perform the following procedure.
Upon power up, the NCU arbitrarily assigns Feed AC1, AC2, or AC3 to each rectifier. This assignment is used to
display rectifier AC input feed voltage(s). The User may reassign the feed to each rectifier per your specific
installation by following the procedure below.
Local Menu Navigation:
None.
Web Menu Navigation:
Refer to the NCU Instructions (UM1M830BNA) for detailed instructions.
NCU Alarm Relay Check
To verify operation of the external alarm relays, use the NCU alarm relay test feature. Refer to the NCU
Instructions (UM1M830BNA) for instructions in using this feature.
NOTE!
The relays may be preprogrammed for specific functions. Refer to the configuration drawing (Cdrawing) supplied with your system for your system’s specific configuration.
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Checking System Status
Procedure
1. Observe the status of the indicators located on the controller and rectifiers. If the system is operating
normally, the status of these is as shown in Table 8.
Table 8:
Status and Alarm Indicators
Component Indicator Normal State
Status
(Green)
Minor
NCU
(Yellow)
Critical or
Major Alarm
(Red)
Power
(Green)
Protection
(Yellow)
Rectifier
Modules
or
or
Alarm
or
(Red)
On
Off
Off
On
Off
Off
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Final Steps
Procedure
1. If any controller configuration settings were changed, refer to the NCU Instructions (UM1M830BNA) and
save a copy of the configuration file. This file can be used to restore the controller settings, if required,
at a later date.
NOTE!
Note that provided on a USB drive furnished with the system is a controller configuration
drawing (C-drawing) and the controller configuration files loaded into the controller as shipped.
2. 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.
3. Verify all rectifier modules and the controller are fully seated, latched, and the latch handle screws
secured.
4. Verify there are no external alarms and the local indicators are as shown in Table 8.
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OPERATING PROCEDURES
Controller and Rectifiers
For operation instructions on these units, refer to the following documents.
• NCU Controller Instructions (UM1M830BNA)
• Rectifier Instructions (UM1R483500E)
ESTOP Function
If an ESTOP switch is wired to the IB2 Interface Board, customer-furnished system ground applied to terminal
DI8+ activates the ESTOP function. The ESTOP function shuts down and locks out the rectifiers. To restart
the rectifiers after removing the ESTOP signal; turn AC power to the rectifiers OFF, wait 30 seconds or more
(until the LEDs on the rectifier extinguish), then turn AC power to the rectifiers ON.
NCU Battery Charge Current Limit Feature
Functionality: After a commercial AC failure or when some battery cells are permanently damaged, the current
to the batteries can be quite extensive. To avoid overheating or further damages to the battery, the NCU can
be programmed to limit the battery current to a preset level by limiting the charging voltage of the rectifiers.
Should the battery current still exceed a higher preset value, an alarm is issued.
The controller limits the current going to the batteries based on the “Battery Current Limit” set point which is a
percentage of the battery capacity in C10. For example, 0.1C10 would mean 10% of the battery capacity.
In this system, the NCU Battery Charge Current Limit feature is set to be enabled. If enabled, battery charge
current is limited to the value set in the NCU Controller, as long as battery voltage is above 47VDC. Refer to the
NCU Controller Instructions (UM1M830BNA) for more information.
Local Controls and Indicators
Refer to the Controller and Rectifier Instructions for descriptions of the local controls and indicators located on
these units.
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MAINTENANCE
System Maintenance Procedures
It is recommended to perform the maintenance procedures listed in Table 9 every 6 months to ensure
continual system operation.
Table 9:
Check ventilation openings for obstructions such as
dust, papers, manuals, etc.
Inspect and tighten all installer's connections.
NOTE!
Maintenance Procedures to be Performed at 6-Month Intervals
PROCEDURE REFERENCED IN
--
“Making Electrical Connections”
starting on page 23.
This table may be reproduced as necessary to record and document system performance.
COMPLETED
(√)
Adding a Rectifier Module to an Existing Rectifier Module Mounting Shelf Spec. No. 588705000
To increase system current capacity, a rectifier module can easily be added to an existing rectifier module
mounting shelf Spec. No. 588705000 that contains an empty rectifier module mounting position.
It is recommended that the current limit point be checked whenever a rectifier module is added to or removed
from the power system. Refer to “Checking the NCU Current Limit Point after Adding or Removing a Rectifier”
on page 55.
The rectifier module being added is assigned by the NCU the lowest available identification number. If desired,
you can change the identification number. See “Configuring the NCU Identification of Rectifiers and
Assigning which Input Feed is Connected to the Rectifiers” on page 50.
• For rectifier module installation instructions, refer to “Installing the Rectifier Modules into Spec. No.
588705000 Rectifier Module Mounting Shelves” on page 44.
Installing a Field Expansion Rectifier Module Mounting Shelf Spec. No. 588705000
Refer to “Mounting System Components in a Relay Rack” on page 14.
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TROUBLESHOOTING AND REPAIR
Contact Information
Refer to Section 4154 (provided with your customer documentation) for support contact information.
Controller and Rectifiers
For troubleshooting and repair instructions on these units, refer to the following documents.
• NCU Controller Instructions (UM1M830BNA)
• Rectifier Instructions (UM1R483500E)
NCU Controller Configuration
If any NCU Controller configuration settings were changed, refer to the NCU Instructions (UM1M830BNA) and
save a copy of the configuration file. This file can be used to restore the NCU Controller settings, if required, at
a later date.
• Note that provided on a USB drive furnished with the system is an NCU configuration drawing (C
drawing) and the NCU configuration files loaded into the NCU as shipped.
System Troubleshooting Information
This system is designed for ease in troubleshooting and repair. The various indicators as described in “Local
Controls and Indicators” on page 35 and in the Controller and Rectifier Instructions are designed to isolate
failure to a specific element. Once the faulty element has been identified, refer to “Refer to the NCU
Instructions (UM1M830BNA) for a procedure to clear the alarm.
Replacement Information” on page 56 and “Replacement Procedures” on page 56.
Troubleshooting Alarm Conditions on the NCU Controller
The NCU Controller displays alarm conditions as listed in the “Resolving Alarms” section of the NCU
Instructions (UM1M830BNA). Programmable external alarm relays are also available. Refer to “Digital Inputs
and Programmable Relay Outputs” on page 34 and the configuration drawing (C-drawing) supplied with your
power system documentation for your alarm relay configurations.
The NCU’s Active Alarm and Alarm History submenus allow the User to view alarm details. Refer to the NCU
Instructions (UM1M830BNA) to access these menus.
Checking the NCU Current Limit Point after Adding or Removing a Rectifier
If a rectifier is added to the power system, the system current limit point will automatically increase by the
percentage each existing rectifier was set to provide prior to the addition.
If a rectifier is removed from the system (and the Rect Comm Fail alarm is reset), the current limit point will
remain unchanged unless the capacity of the remaining rectifiers is not sufficient to maintain the present
current limit point. If that happens, the current limit point will automatically increase to the maximum (121% of
the remaining rectifiers).
It is recommended that the current limit point be checked whenever a rectifier is added to or removed from the
power system.
Refer to the NCU Instructions (UM1M830BNA) for a procedure.
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Clearing a Rectifier Communications Fail Alarm after Removing a Rectifier
If a rectifier module is removed from the system, a rectifier communications failure alarm is generated. If the
rectifier module will not be replaced, the alarm should be cleared.
Refer to the NCU Instructions (UM1M830BNA) for a procedure.
Clearing a Rectifier Lost Alarm
If the NCU Controller resets while a rectifier communications fail alarm is active, the rectifier communications
fail alarm is replace with a rectifier lost alarm.
Refer to the NCU Instructions (UM1M830BNA) for a procedure to clear the alarm.
Replacement Information
When a trouble symptom is localized to a faulty rectifier module, controller, or system circuit card; that
particular device or circuit card should be replaced in its entirety. No attempt should be made to troubleshoot
or repair individual components on any rectifier module, controller, or circuit card.
Refer to SAG582127100 (System Application Guide) for replacement part numbers.
Replacement Procedures
DANGER! Adhere to the “Important Safety Instructions” presented at the front of this document.
Replacing a Rectifier Module
Refer to the Rectifier Instructions (UM1R483500E) for a rectifier module replacement procedure. Refer also to
“System Troubleshooting Information” on page 55.
The rectifier module being replaced is assigned by the NCU the lowest available identification number. If
desired, you can change the identification number. See “Configuring the NCU Identification of Rectifiers and
Assigning which Input Feed is Connected to the Rectifiers” on page 50.
Replacing the NCU Controller
Refer to the NCU Instructions (UM1M830BNA) for a controller replacement procedure.
Replacing the IB2 (Controller Interface Board)
The following circuit card replacement procedure can be performed with the system operating.
ALERT! Circuit cards used in this power system contain static-sensitive devices. Read the Static
Warning at the front of this document before performing any of the following procedures.
ALERT! When performing any step in these procedures that requires removal or installation of
hardware, use caution to ensure no hardware is dropped and left inside the shelf; otherwise service
interruption or equipment damage may occur.
NOTE!
When performing any step in these procedures that requires removal of existing hardware, retain
all hardware for use in subsequent steps.
Procedure
1. Performing this procedure may activate external alarms. Do one of the following. If possible, disable
these alarms. If these alarms cannot be easily disabled, notify the appropriate personnel to disregard
any future alarms associated with this system while the procedure is being performed.
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ALERT! Damage to the circuit card may result if the next step is not followed.
2. Connect an approved grounding strap to your wrist. Attach the other end to a suitable ground.
3. Loosen the captive fastener that secures the IB2 (Controller Interface Board) sliding tray to the main
rectifier module mounting shelf. Carefully slide the assembly out until the wires are accessible. Refer to
Figure 19. Note that the top cover can be removed from the controller section to facilitate IB2
replacement.
4. Remove the shield covering the IB2 (Controller Interface Board). The shield is secured with two (2) of
the circuit card’s mounting screws.
5. Carefully label the wires connected to the customer connection terminal blocks J3 through J9 on the
circuit card. These wires must be connected to the same terminals on the replacement circuit card.
Refer to Figure 19.
6. Carefully label the connectors plugged into the circuit card. These connectors must be plugged into the
same connectors on the replacement circuit card. Refer to Figure 19.
DANGER! In the next step, external wiring may be energized from an external source. DO NOT allow
bare wire ends to contact any grounded or energized object.
7. Remove the external wiring from the customer connection terminal blocks. DO NOT allow the bare wire
end to contact any grounded or energized object. Isolate the wire end with electrical tape. Repeat for
each wire to be removed.
8. Unplug all connectors plugged into the circuit card.
9. Remove the remaining circuit card mounting screws and remove the circuit card from the mounting
plate.
10. In this step, ensure you do not intermix the old and replacement circuit cards. Set the switch on the
replacement circuit card to the same setting as the old circuit card. Refer to Figure 19.
11. Orient the replacement IB2 circuit card over its mounting position. Replace the shield over the circuit
card and secure the circuit card to the mounting plate.
12. Carefully slide the IB2 (Controller Interface Board) assembly partially into the main rectifier module
mounting shelf.
13. Plug all connectors removed from the old circuit card into the same position on the replacement circuit
card.
DANGER! In the next step, external wiring may be energized from an external source. DO NOT allow
bare wire ends to contact any grounded or energized object.
14. Reconnect the external wiring to the correct terminals on the customer connection terminal blocks.
First remove the electrical tape that was applied to the bare wire end in a previous step. DO NOT allow
the bare wire end to contact any grounded or energized object. After securing the wire, gently tug on
the wire to ensure that it cannot be pulled out of the terminal block. Repeat for each wire to be
reconnected.
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15. Slide the IB2 (Controller Interface Board) assembly completely into the main rectifier module mounting
shelf and secure with the captive fastener.
16. Remove the grounding wrist strap.
17. Enable the external alarms, or notify appropriate personnel that this procedure is finished.
18. Ensure that there are no local or remote alarms active on the system.
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J3-J9:
Wire Size Capacity: 16-26 AWG.
Recommended Torque: 2.2 in-lbs.
-
J12
*
RELAY
SW1
7
J2
J11
5 3
1
Relay Output Terminal Blocks
Digital Input Terminal Blocks
J9 J8 J7
J6
J5 J4
J3
8
6 4
2
8 7 6 5 4 3
2 1
+
IB2 Board (Top View)
NO
C
NC
NO C NC
NO
C
NC
NO C NC
NO
C
NC
NO C NC
NO
C
NC
NO C NC
5 3 1
46 2
5 3 1
46 2
5
3
1
46 2
5
3
1
46 2
5 3 1
46 2
5 3 1
46 2
5
3
1
46 2
Connector
to controller
IB2 TEMP
PROBE 1
IB2 TEMP
PROBE 2
Main Rectifier
Module Mounting Shelf
Top cover can be removed from
controller section to facilitate replacement.
IB2 Board Sliding Tray
on
ON
off
OFF
1 2
1 2
SW1
In this system, switch settings
must be in positions shown.
SW1
DIP Switch SW1
1 2
OFF OFF
Figure 19:
IB2 (Controller Interface Board) Replacement
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Vertiv.com | Vertiv Headquarters, 1050 Dearborn Drive, Columbus, OH, 43085, USA
UM582127100 (RE 08/19)
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