Vertiv NetSure 7100 Series Installation Manual
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Vertiv NetSure 7100 Series Installation Manual

48v dc power system
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NetSure™
7100 SERIES -48V DC Power System
Installation Manual (IM582127000100), Revision H
Specification Number: 582127000100, 582127000101, 582127000102, 582127000103, 582127000203
Model Number: 7100

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  • Page 1 NetSure™ 7100 SERIES -48V DC Power System Installation Manual (IM582127000100), Revision H Specification Number: 582127000100, 582127000101, 582127000102, 582127000103, 582127000203 Model Number: 7100...
  • Page 2 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.

  • Page 3: Table Of Contents

    IB2 (Controller Interface Board) Connections (if required) ..........40 Optional EIB (Controller Extended Interface Board) Connections (if required) .................................... 45 Connecting a Device or System to the NCU CAN Bus (if required) ....51 Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 4 Initially Starting, Configuring, and Checking System Operation ..... 65 Initial Startup Preparation .......................... 65 Initially Starting the System ........................65 NCU Controller Initialization ........................65 Checking System Status ..........................71 Final Steps .................................. 72 Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 5: Admonishments Used In This Document

    (ISO) SAFETY! Informs the reader of general safety information, reminders, precautions, or policies not related to a particular source of hazard or to fire safety. (ISO, ANSI, OSHA) Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 6: Important Safety Instructions

    DANGER! Follow local lockout/tagout procedures to ensure DC branch circuit protection devices remain de-energized during installation at loads, as required. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 7: Battery

    Only install in a ventilated environment. • Batteries are an energy source that can produce high amounts of electrical current. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 8: Personal Protective Equipment (Ppe)

    NOTE! When performing any step in procedures that requires removal of existing hardware, retain all hardware for use in subsequent steps, unless otherwise directed. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 9: Static Warning

    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 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 10 This page is intentionally blank. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 11: Customer Documentation Package

    • Power System “System Application Guide”: SAG582127000 • Engineering Drawings • Also provided on the USB drive is a controller configuration drawing and the controller configuration files loaded into the controller as shipped. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 12: Installation Acceptance Checklist

     Batteries Installed and Connected in the Battery Trays (if furnished) Installing the Modules  Rectifier and Converter Modules Installed Initially Starting the System  System Started, Configured, and Checked Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 13: Installing The System

    Refer to System Application Guide SAG582127000 for ventilation spacing requirements. NOTE! Minimum spacing specified for ventilation may not permit replacement of certain components such as busbars or module mounting assemblies. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 14: Securing The Relay Rack To The Floor

    Relay Rack Floor Mounting Dimensions 25.80 0.875 8 Places 15.000 Part Nos. 562353, 564127, 564169 18.00 12.340 2.83 1.50 3.06 19.685 1.74 22.310 Notes: 1. All dimensions are in inches. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 15: Installing Battery Trays

    (1 place per bracket). (Torque to 70 in-lbs). 4. Secure cabling brackets (both sides) to relay rack with 12-24 x 1/2" thread forming hex head screws. (Torque to 70 in-lbs). Rear Rear Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 16 (1-place) or #8 ground washer Circuit Breaker Assembly (1-place). (left side kit shown, right side kit available) 3. After wiring to the battery disconnect circuit breaker, replace the cover. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 17 Hardware Buildup: 1/4-20 x 7/8” Bolt 1/4” Lock Washer 1/4” Flat Washer Torque to 75 in-lbs. Positive (+) Battery Tray Cables Rear Components removed in illustration for clarity only. Rear Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 18 Figure 5: Battery Tray Wiring Diagram (582127000103 only) to -48V Battery Return Busbar Busbar NOTE! Same diagram applies to 582127000101 (one battery tray) and 582127000102 (two battery trays). Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 19 Figure 6: Battery Tray Wiring Diagram (582127000203 only) To Return To -48V Battery Busbar Busbar Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 20 In the event there is excess length of the probe wires, coil the wires up and tie in a convenient location along the path of the battery power cable. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 21 To Battery Torque to 60 in.-lbs. using supplied To Power System hardware. 1st Battery Tray Battery Disconnect Circuit Breaker Torque to 60 in.-lbs. using supplied hardware. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 22: Installing Optional Lug Adapter Busbar Kits, Part Nos. 534449 And

    Orient the load lug hardware as shown in Figure 8. Recommended torque is 300 in-lbs using the supplied 3/8” bolts and hardware. Close the distribution cabinet’s front door. Turn the latch clockwise to secure the door. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 23 Figure 8: Installing Lug Adapter Busbar Kits Busbar Adapter Kit P/N 514714 Busbar Adapter Kit P/N 534449 Notes: Orient busbars as shown. Circuit breaker locations for reference only. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 24: Installing Circuit Breakers And Fuses

    Longer Side Bottom of Fuse Carrier to the Bottom GMT-18/100A Alarm Fuse (Replacement Fuseholder Assembly (P/N 117201) includes body & carrier, alarm fuse, and alarm fuse safety cover. P/N 248610301) Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 25 To p Lettering on handle must be Insert these terminals right side up. into corresponding sockets on distribution panel. Turn off before installing. Longer Side to the Bottom Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 26 Record all fuse sizes (installed on the GMT distribution fuse block) on the label provided on the shield. Close the distribution cabinet's front door. Turn the latch clockwise to secure the door. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 27 2. Plug in GMT Fuse Block. 3. Connect supplied jumper from GMT Fuse Block to Return Bar. Torque to 75 in-lbs. Part of P/N 549017 Part of P/N 549017 Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 28: Setting Jumpers And Switch Options

    (Front Door Removed in Illustration for Clarity) NCU Controller 1M830DNA (2nd Ethernet Port Board) System Interface Optional EIB-1 IB2-1 558076 Board 562662 (Extended (Interface Interface Board) Board #1) MA455U41 MA4C5U31 Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 29: Jumper On System Interface Board

    CAN termination plug P/N 548398 must be installed if an external Battery Battery device is not connected Shorting Jumper to the system. 1 2 3 Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 30: Switch Setting On Ib2 Controller Interface Board

    Ensure SW1 is set per Table 2. Refer to Figure 12 for circuit card location. Refer to Figure 15 for switch location. Table 2: Optional EIB Controller Extended Interface Board Switch Setting DIP Switch SW1 Setting EIB-1 Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 31 Optional EIB Controller Extended Interface Board Switch Location and Setting (Extended Interface Board) (Top View) (Extended Interface Board) Switch SW1 is located in this corner of the EIB Board. DIP Switch SW1 Setting EIB-1 Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 32: Making Electrical Connections

    YA29L-4TCG1 T & B: 256-30695-1880 514873 15514 Burndy: YA31L-4TCG1 The lugs should be crimped to the specifications given in the manufacturer’s instructions furnished with the crimp tool or lug. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 33: Relay Rack Grounding Connection (Frame Ground)

    American National Standards Institute (ANSI) approved National Fire Protection Association's (NFPA) National Electrical Code (NEC), applicable local codes, and your specific site requirements. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 34: Nominal 208 Vac / 240 Vac Input And Equipment Grounding

    Torque connections to value shown in Figure 17. Reinstalling Covers After all AC input and equipment grounding connections have been made and checked, reinstall the two AC input connector covers. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 35 (1) ground conductor per conduit (based on NEC recommendations), for six (6) PCUs. For operation in countries where the NEC is not recognized, follow applicable codes. Input current based on R48-2000e3 rectifier module. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 36 Shelf 1 and 3 AC 2 Rectifier 6 AC 1 AC 2 Shelf 1 and 3 Rectifier 5 AC 1 AC 2 Shelf 1 and 3 Rectifier 4 AC 1 Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 37: External Alarm, Reference, Monitoring, And Control Connections

    Refer to the controller user manual, UM1M830BNA, provided with the system for instructions. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 38: System Interface Board

    • Temperature Probes (see “Temperature Probes” starting on page 37) • NCU CAN Port (see “Connecting a Device or System to the NCU CAN Bus (if required)” starting on page Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 39 J5 (System Temp 1) NCU CAN Port A X X X X X X X X 0 0 0 X X X X X TP1 (-) and TP2 (+) System Voltage Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 40: Ib2 (Controller Interface Board) Connections (If Required)

    (until the LEDs on the rectifiers extinguish), then turn input power to the rectifiers ON. 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. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 41 Temperature Probes Two temperature probes can be connected to the IB2 (Controller Interface Board) mounted inside the distribution cabinet. Refer to “Temperature Probes” on page 37. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 42 Refer to the configuration drawing (C-drawing) supplied with your system for your system’s specific relay labeling. Not all I/O points are available for customer connection (some are used for factory system connections). Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 43 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. Refer to the configuration drawing (C-drawing) supplied with your system for your system’s specific relay labeling. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 44 To restart the rectifiers; turn input power to the rectifiers OFF, wait 30 seconds or more (until the LEDs on the rectifiers extinguish), then turn input power to the rectifiers ON. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 45: Required)

    The alarm is Issued when the difference between any battery midpoint voltage and a reference voltage is greater than the value of the block voltage difference setting. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 46 Temperature Probes Two temperature probes can be connected to the optional EIB (Controller Extended Interface Board) mounted inside the distribution cabinet. Refer to “Temperature Probes” on page 37. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 47 String 4 String 5 String 6 String 7 String 8 DCV1 DCV2 DCV3 DCV4 DCV5 DCV6 DCV7 DCV8 (J6-1) (J6-2) (J6-3) (J6-4) (J6-5) (J6-6) (J7-1) (J7-3) EIB Board Voltage Inputs Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 48: Optional Eib (Controller Extended Interface Board) Connections

    J5-J9 RLY2_NO Wire Size Capacity: 16-26 AWG. RLY1_NO Recommended Torque: 2.2 in-lbs. RLY2_COM RLY1_COM RLY2_NC RLY1_NC RLY5_NO RLY5_COM RLY5_NC SH3+ SH3- SH2+ SH2- SH1+ SH1- EIB (Extended Interface Board) Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 49 J5-3 – J5-6 none J5-5 – Table 8: Voltage Inputs – EIB Default Voltage Input Pin No. Function J6-1 J6-2 J6-3 J6-4 Battery Block Monitoring J6-5 J6-6 J7-1 J7-3 Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 50 The 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. Refer to the configuration drawing (C-drawing) supplied with your system for your system’s specific relay labeling. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 51: Connecting A Device Or System To The Ncu Can Bus (If Required)

    Instructions (UM547490). Table 10: CAN Port Connections NCU CAN SM-Temp Module Port (RJ-45) CAN Port Pin Number Pin Number Function CAN L TB1-5 (CAN L) CAN H TB1-3 (CAN H) Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 52: Ncu Controller Ethernet Connection (If Required)

    USB-B Port (Factory connected to NCU Controller backplane.) USB-A Port 10/100M Ethernet (not used) Port (RJ-45) (to connect a 10M Ethernet computer directly Port (RJ-45) to the NCU) LAN Connection Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 53: Load Connections

    100 A device does not exceed 64 A. A 175 A or greater circuit breaker SHALL HAVE an empty mounting position between it and any other overcurrent protective device. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 54: Load Connections To Gmt Distribution Fuse Block

    Load Return Leads -48VDC Load Leads Wire Size Capacity: 26-14 AWG. Recommended Torque: 4.5 in-lbs. 35A maximum capacity per block. Maximum GMT fuse size is 15A. Part of P/N 549017 Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 55: External Battery Connections

    DANGER! Adhere to the “Important Safety Instructions” presented at the front of this document. Battery is connected to the battery busbars located in the distribution cabinet, as detailed in Figure 26 and Figure 27. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 56 (use any location on (Customer must supply hardware) (Customer must supply hardware) ground / return busbar) Maximum Lug Width: 1.88 inches Battery (Return Side) Battery Busbar (Load Side) Busbar Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 57 Figure 27: Battery Busbar Dimensions Notes: 1. All dimensions are in inches. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 58: Installing And Connecting Batteries In The Battery Trays

    Connect the cables found in the battery tray to the battery terminals, “+” to “+” and “–” to “–”. Observe correct polarity. Refer to Figure 28. Secure with hardware furnished with the battery. Torque hardware to battery manufacturer’s recommendations. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 59 Repeat steps 1 through 7 for any remaining battery trays. To connect the batteries to the power system, turn ON the battery disconnect circuit breaker located on all battery trays. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 60: Furnished)

    Spacer (3 Places) (1 Place) 1/4-20 x 5/8" Hex Head Screw (4 Places) 1/4-20 Lock Washer (3 Places) 1/4-20 Flat Washer (3 Places) DETAIL A Alternate Orientation of Retention Bracket Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 61: Special Application Rectifier Bus Landing Point Kit P/N 563686

    P/N 563574 P/N 563574 Apply electrical anti-oxidizing compound to busbar mating surfaces. -48V SUPPLY GND RTN Negative (-) Cable Positive (+) Cable Rear Components removed in illustration for clarity only. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 62: Generator Input Breaker Kit (P/N 564219)

    3/8” Flat Washer 3/8-16 Nut (Torque to 180 in-lbs.) 3/8” Lock Washer 3/8” Flat Washer Apply electrical anti-oxidation compound to busbar mating surfaces. Components removed in illustration for clarity only. Front Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 63: Installing The Rectifier And Converter Modules

    Repeat the above steps for each module being installed in the system. After the modules are physically installed in the mounting shelf(s), they are ready for operation immediately after power is supplied to them. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 64 Rectifiers in Any Position Rectifiers or Converters in Far Right Three Positions Front View Rectifier or Converter Module Captive Screw Handle Model Number Label (R48-2000e3 Rectifier) (C48/24-1500 Converter) Latch Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 65: Initially Starting, Configuring, And Checking System Operation

    Place each distribution circuit breaker (if furnished) to the ON position. NCU Controller Initialization Refer to the NCU Instructions (UM1M830BNA) for detailed instructions. Refer to Figure 32 for locations of the NCU local indicators and navigation keys. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 66 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. The Main Menu displays. See Figure 33. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 67 IB2 interface board and the optional EIB extended interface board. Refer also to “NCU Start Wizard” on page 68. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 68 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 Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 69 Main Menu / Settings Icon / Other Settings / Under Voltage 2. NOTE! All above parameters are preset at the factory and should not need to be adjusted with the exception of the date, time, and battery capacity. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 70 (lowest serial number is Conv 1, next lowest is Conv 2, etc.). If you prefer the NCU to identify the converters by position in the system, perform the following procedure. Local Menu Navigation: None. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 71: Checking System Status

    Component Indicator Normal State Status (Green) Minor (Yellow) Critical or Major Alarm (Red) Power (Green) Rectifier Protection Modules (Yellow) Alarm (Red) Power (Green) Converter Protection Modules (Yellow) Alarm (Red) Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...

  • Page 72: Final Steps

    Verify all rectifier and converter modules and the controller are fully seated, latched, and the latch handle screws secured. Verify there are no external alarms and the local indicators are as shown in Table 12. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 73 This page is intentionally blank. Vertiv | NetSure 7100 Series Installation Manual (IM582127000100) | Rev. H...
  • Page 74 Vertiv.com Vertiv Headquarters, 1050 Dearborn Drive, Columbus, OH, 43085, USA IM582127000100 (RH 08/19)

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