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NetSure™ 802 Series
NCU Retrofit Kit
Installation Manual (IM566157), Revision B
Kit Specification Number: 566157
For use in an “Older Style” 582140000 List 16 distribution only bay.
For use in a 582140000 List 17, 18, 22 distribution only bay.
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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.
© 2020 Vertiv Group Corp. All rights reserved. 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. 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.
Specifications are subject to change without notice.
Vertiv | NetSure™ 802 Series NCU Retrofit Kit Installation Manual (IM566157) | Rev. B
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TABLE OF CONTENTS
Admonishments Used in this Document ............................................................ 4
Important Safety Instructions .............................................................................. 5
Safety Admonishments Definitions ......................................................................................................5
General Safety ...........................................................................................................................................................5
Voltages ...........................................................................................................................................................................5
AC Input Voltages ........................................................................................................................................................ 5
DC Output and Battery Voltages .................................................................................................................. 5
Personal Protective Equipment (PPE) ............................................................................................. 6
Hazardous Voltage .............................................................................................................................................. 6
Handling Equipment Containing Static Sensitive Components............................. 6
Static Warning ........................................................................................................... 6
NetSure™ 802 Series NCU Retrofit Kit Installation Instructions ................. 7
Kit Description ........................................................................................................................................................... 7
Kit Contents ................................................................................................................................................................. 7
Tools and Material Required ....................................................................................................................... 7
Installation Procedure ..................................................................................................................................... 10
Vertiv | NetSure™ 802 Series NCU Retrofit Kit Installation Manual (IM566157) | Rev. B
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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 be permitted in some of the applicable standards. (OSHA)
ALERT
equipment, software, data, or service. (ISO)
ALERT
equipment damage, software corruption, data loss, o
FIRE SAFETY
or policies, or of the locations of fire
SAFETY
policies not related to a particular source of hazard or to fire safety. (ISO, ANSI, OSHA)
ADMONISHMENTS USED IN THIS DOCUMENT
! Warns of a hazard the reader
! Warns of a potential hazard the reader
! Warns of a potential hazard the reader
! Alerts the reader to an action that
will
be exposed to that will
may
be exposed to that
may
be exposed to that
must be avoided
likely
result
could
could
in order to protect
! Alerts the reader to an action that
! Informs the reader of fire safety information, reminders, precautions,
! Informs the reader of general safety information, reminders, precautions, or
Vertiv | NetSure™ 802 Series NCU Retrofit Kit Installation Manual (IM566157) | Rev. B
-fighting and fire-safety equipment. (ISO)
must be performed
r service interruption. (ISO)
in order to prevent
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IMPORTANT SAFETY INSTRUCTIONS
Safety Admonishments Definitions
Definitions of the safety admonishments used in this document are listed under “Admonishments Used in this
Document” on page 4.
General Safety
DANGER! Installation of this kit should only be performed by a qualified technician following approved
safety procedures. If a qualified technician is not available, arrangements can be made with Vertiv to
have the kit installed.
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.
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.
Vertiv | NetSure™ 802 Series NCU Retrofit Kit Installation Manual (IM566157) | Rev. B
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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.
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 in the “Static Warning” section on page 6.
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
static dissipative surfaces such as conductive foam or ESD bag. 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.
Vertiv | NetSure™ 802 Series NCU Retrofit Kit Installation Manual (IM566157) | Rev. B
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Preassembled Distribution Only Bay Control Shelf including Ship Loose CAN
Nut Driver Set
NETSURE™ 802 SERIES NCU RETROFIT KIT
INSTALLATION INSTRUCTIONS
Kit Description
These instructions provide a step-by-step procedure to field install this kit into an “Older Style” 582140000 List
16 Distribution Only Bay. See Figure 1 for an illustration of the “Older Style” Bay. Also for use in a 582140000
List 17, 18, 22 distribution only bay. Installation of this kit in other equipment should not be attempted. For a
“Newer Style” 582140000 List 16 Distribution Only Bay (Figure 2), use kit P/N 566156.
This kit replaces the control shelf in an older style system with the kit supplied control shelf that is offered in
the latest revision system. The latest revision system replaces the MCA (Meter, Control, Alarm Panel) and
optional LMS monitoring system of the older style system with the NCU controller.
Kit Contents
Table 1 lists the items furnished as a part of this kit. Before installing the kit, check the items furnished against
those listed to ensure that there are no shortages.
Table 1:
Kit Contents
Qty. P/N Description
1 565931
Interface Circuit Card P/N 566014
Tools and Material Required
Table 2 lists the items required to install this kit.
Table 2:
Tools and Material Required
Description
Phillips Head Screwdriver
Vertiv | NetSure™ 802 Series NCU Retrofit Kit Installation Manual (IM566157) | Rev. B
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Rear View
Control Shelf
Distribution Only Bay
(front view)
Older Style 582140000 List 16 Bay
Use Kit P/N 566157
(for a newer style bay, use kit P/N 566156)
Figure 1:
Older Style 582140000 List 16 Distribution Only Bay
Vertiv | NetSure™ 802 Series NCU Retrofit Kit Installation Manual (IM566157) | Rev. B
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Control Shelf
Distribution Only Bay
(front view)
Newer Style 582140000 List 16 Bay
Use Kit P/N 566156
(for an older style bay, use kit P/N 566157)
Figure 2:
Newer Style 582140000 List 16 Distribution Only Bay
Vertiv | NetSure™ 802 Series NCU Retrofit Kit Installation Manual (IM566157) | Rev. B
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Control Shelf
Control Module
Remove Hardware to Remove
Control Module from Control Shelf
Installation Procedure
THESE INSTRUCTIONS SHOULD BE READ THROUGH COMPLETELY BEFORE INSTALLING THE KIT.
The following is a step-by-step procedure to install the kit. The procedure has been written for ease of use and
to minimize the possibility of contact with potentially hazardous energy. This procedure should be performed
in the sequence given, and each step should be completely read and fully understood before performing that
step. Observe all “Important Safety Instructions” starting on page 5 and also those presented in the following
procedure. As each step of the procedure is completed, the box adjacent to the respective step should be
checked. This will minimize the possibility of inadvertently skipping any steps. If the step is not required to be
performed for your site, also check the box to indicate that it was read.
DANGER! This kit can be installed with the system operating. Observe the “Important Safety
Instructions” starting on page 5 and those listed in the power system manual.
CAUTION! When performing any step in procedures that requires removal or installation of hardware,
use caution to ensure no hardware is dropped and left inside the unit; otherwise service interruption or
equipment damage may occur.
NOTE!
When performing any step in this procedure which requires removal of existing hardware, retain
all hardware for use in subsequent steps, unless otherwise stated.
Initial 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.
[ ] 2. Open the front door of the bay.
Removing the Existing Control Shelf (Leaving Control Module in Bay) Procedure
[ ] 1. Remove the existing control module from the control shelf by removing the hardware securing it.
See Figure 3. Save hardware for re-installation. Temporarily secure the control module ensuring it
does not come in contact with any energized portion of the bay.
DANGER! Battery is connected to the control module.
Figure 3:
Temporarily Removing Control Module
Vertiv | NetSure™ 802 Series NCU Retrofit Kit Installation Manual (IM566157) | Rev. B
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Remove
Control Shelf
from Bay
[ ] 2. Remove the control shelf. See Figure 4.
Figure 4:
Removing Control Shelf
Vertiv | NetSure™ 802 Series NCU Retrofit Kit Installation Manual (IM566157) | Rev. B
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DIP Switch S1
Communication Address
Reserved
1 2 3
4
DOWN
DOWN
DOWN
Address 1# (Setting for 1st Bay in System)
UP
DOWN
DOWN
Address 2# (Setting for 2nd Bay in System)
DOWN
UP
DOWN
Address 3# (Setting for 3rd Bay in System)
UP
UP
DOWN
Address 4# (Setting for 4th Bay in System)
DOWN
DOWN
UP
Address 5# (Setting for 5th Bay in System)
UP
DOWN
UP
Address 6# (Setting for 6th Bay in System)
DOWN
UP
UP
Address 7# (Setting for 7th Bay in System)
UP
UP
UP
Address 8# (Setting for 8th Bay in System)
J3
R4
USB
1
565309
000 XXX XX
AXXX XXXX X
1 2 3 4
Switch S1
Location
Up
Down
Set the Bay Address Procedure
[ ] 1. Set the bay address. Each bay needs a unique address to communicate with the NCU.
a) Dip Switch S1 is used to set the communications address for each bay. Refer to Table 3 for S1
settings. Refer to Figure 5 for S1 location.
b) Set the addressing switches on each kit installed in the system to a unique address per Table 3.
Table 3:
DIP Switch S1 (Bay Addressing)
Figure 5: DIP Switch S1 (Bay Addressing)
Description of Status
DOWN
Vertiv | NetSure™ 802 Series NCU Retrofit Kit Installation Manual (IM566157) | Rev. B
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Install Control
Shelf into Bay
Torque to 32 in-lbs.
Kit Control
Shelf
Existing Control
Module
Re-Install Hardware to Secure
Existing Control Module
to Kit Control Shelf
Installing the Kit Furnished Control Shelf Procedure
[ ] 1. Install the kit furnished control shelf in the same position as the control shelf just removed. See
Figure 6.
Figure 6:
Installing the Kit Furnished Control Shelf
Re-Installing the Existing Control Module to the Kit Control Shelf Procedure
[ ] 1. Re-install the existing control module to the kit control shelf using the hardware removed in a
previous step. See Figure 7. Torque hardware to 11 in-lbs.
DANGER! Battery is connected to the control module.
Figure 7:
Installing Existing Control Module to Kit Control Shelf
Vertiv | NetSure™ 802 Series NCU Retrofit Kit Installation Manual (IM566157) | Rev. B
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Router Circuit Card
(inserted sideways)
MCA Circuit Card P/N 509478
(Primary Power/Distribution Bay)
RJ-45
Jack
MCA
Network
Connector
(for Left
Expansion)
MCA
Network
Connector
(for Right
Expansion)
Router Circuit Card P/N 509509
(Distribution Only Bays)
RJ-45
Jack
RJ-45
Jack
RJ-45
Jack
RJ-45
Jack
RJ-45
Jack
MCA
Network
Connector
(for Left
Expansion)
MCA
Network
Connector
(for Right
Expansion)
MCA
Network
Connector
(for Left
Expansion)
MCA
Network
Connector
(for Right
Expansion)
Router Circuit Card P/N 509509
(Distribution Only Bays)
MCA Network Cable
(Yellow Cable)
MCA Network Cable
(Yellow Cable)
Rear View
Distribution Only Bay
(front view)
Control
Shelf
Front Door Removed in
Illustration for Clarity
Replacing the Router Circuit Card in the Control Shelf with the Kit Supplied CAN Interface Circuit Card
Procedure
[ ] 1. Disconnect the MCA network cable(s) from the control shelf. See Figure 8. These cables can be
reused, depending on length.
Figure 8:
Disconnect MCA Network Cable(s)
Vertiv | NetSure™ 802 Series NCU Retrofit Kit Installation Manual (IM566157) | Rev. B
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Router Circuit Card
Rear View
Rear View
Front View
Front Door Removed in
Illustration for Clarity
F1: Router / CAN Interface Circuit Card Input Power
F2: Distribution Bus Monitor Circuit Cards Input Power for Bus #1 and #2
F3: Distribution Bus Monitor Circuit Cards Input Power for Bus #3 and #4
F13AF23AF3
3A
[ ] 2. Replace the router circuit card in the bay with the kit supplied CAN interface circuit card P/N
566014 as follows (see Figure 9).
WARNING! Damage to the CAN interface circuit card may result if the next step is not followed.
[ ] 3. Connect an approved grounding strap to your wrist. Attach the other end to a suitable ground.
[ ] 4. Remove the fuse which supplies input power to the router circuit card. Refer to Figure 9 for
location.
[ ] 5. Loosen the circuit card retaining screw.
[ ] 6. Remove the router circuit card.
[ ] 7. Slide the kit supplied CAN interface circuit card into the same mounting location, ensuring the rear
edge connector is firmly seated.
[ ] 8. Secure the circuit card by tightening the circuit card retaining screw.
[ ] 9. Replace the fuse which supplies input power to the CAN interface circuit card. Refer to Figure 9 for
location.
[ ] 10. Remove the grounding wrist strap.
Figure 9:
Distribution Only Bay Router Circuit Card Replacement and Fuse Location
Vertiv | NetSure™ 802 Series NCU Retrofit Kit Installation Manual (IM566157) | Rev. B
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Connecting Bay’s Wire Harness to Kit “Preassembled Distribution Only Bay Control Shelf” Procedure
[ ] 1. Connect the bay’s wire harness to the kit “Preassembled Distribution Only Bay Control Shelf”. See
Figure 10.
a) Unplug the bay’s wire harness from the fuse board and connect it to the kit’s wire harness
mating connector.
b) Connect the kit’s wire harness to the fuse board connector vacated above.
c) Connect the three connectors in the kit’s wire harness to the respective circuit card connector.
d) Disconnect the bay’s wire harness blue wire from the fuse board. Connect the kit’s wire harness
blue wire to the fuse board in the same position. Reconnect the bay’s wire harness blue wire to
the piggy-back connector located on the kit’s wire harness blue wire.
e) Disconnect the bay’s wire harness red wire from the fuse board. Connect the kit’s wire harness
red wire to the fuse board in the same position. Reconnect the bay’s wire harness red wire to
the piggy-back connector located on the kit’s wire harness red wire.
Vertiv | NetSure™ 802 Series NCU Retrofit Kit Installation Manual (IM566157) | Rev. B
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Rear View
Control
Shelf
d. Remove the bay’s blue
wire from this connector.
Connect kit’s blue wire to this
connector. Connect bay’s
blue wire to piggy-back
connector on kit’s blue wire.
e. Remove the bay’s red wire
from this connector. Connect
kit’s red wire to this connector.
Connect bay’s red wire to
piggy-back connector on kit’s
red wire.
b. Plug the kit
wire harness into
this connector.
a. Unplug the bay’s
wire harness from
this connector
and connect bay’s
wire harness to kit
connector here.
c. Connect these
three connectors in
the kit’s wire harness
to the respective
circuit card connector.
Figure 10:
Connect Wire Harness Cables
Vertiv | NetSure™ 802 Series NCU Retrofit Kit Installation Manual (IM566157) | Rev. B
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Front
Front
Detail A
Primary Power/Distribution Bay
Primary Power Only Bay Similar
Detail B
Secondary Power Only Bay
Secondary Power/Distribution Bay Similar
Detail C
Distribution Only Bay
CAN Port Connector
(incoming)
(RJ-45 Jack)
CAN
Port
Connector
CAN Port Connector
(outgoing)
(RJ-45 Jack)
CAN Port Connector
(outgoing)
(RJ-45 Jack)
CAN Port Connector
(incoming)
(RJ-45 Jack)
Bay Interconnect Cable
(Yellow Cable)
Bay Interconnect Cable
(Yellow Cable)
CAN Interface Circuit Card
(installed sideways)
CAN Interface
Circuit Card
Rear View
Distribution Only B ay
(front view)
[ ] 2. Connect the network cable(s) to the kit control shelf. See Figure 11.
Figure 11:
Connect Network Cable(s)
Vertiv | NetSure™ 802 Series NCU Retrofit Kit Installation Manual (IM566157) | Rev. B
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Final Procedure
NOTE!
A controller reboot may be required to update controller distribution inventory.
[ ] 1. Dress and secure the kit’s wire harness to the bay. Ensure the cables cannot be pinched when the
door is closed.
[ ] 2. Close the front door of the bay.
[ ] 3. Ensure that there are no local or remote alarms active on the system.
[ ] 4. Enable the external alarms, or notify appropriate personnel that this procedure is finished.
Vertiv | NetSure™ 802 Series NCU Retrofit Kit Installation Manual (IM566157) | Rev. B
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Vertiv.com | Vertiv Headquarters, 1050 Dearborn Drive, Columbus, OH, 43085, USA
IM566157 (RB 04/2020)
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