Vertiv NetSure 7100 Series User Manual
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Vertiv NetSure 7100 Series User Manual

-48 vdc power system
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NetSure™ 7100 Series
-48 VDC Power System
User Manual
Specification Number: 582127000
Model Number: 7100

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  • Page 1 NetSure™ 7100 Series -48 VDC Power System User Manual Specification Number: 582127000 Model Number: 7100...
  • Page 2 The information contained in this document is subject to change without notice and may not be suitable for all applications. While every precaution has been taken to ensure the accuracy and completeness of this document, Vertiv assumes no responsibility and disclaims all liability for damages resulting from use of this information or for any errors or omissions.

  • Page 3: Table Of Contents

    Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual TABLE OF CONTENTS Admonishments Used in this Document ..........................v Important Safety Instructions ..............................vi Static Warning ....................................ix 1 Customer Documentation Package ..........................1 2 System Description ................................2 3 Operating Procedures ................................4 3.1 Controller, Rectifiers, and Converters ........................................4...
  • Page 4 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual 5.6.7 Replacing a Distribution Panel (List AA, AB, AC, AD, AE, AF, AG, AH, AJ, AK, BA, BB, BC, BD, BF, and BH) ....................................................56 5.6.8 Replacing a Distribution Panel (List AL, AN, DE, DF, DG, DH, DJ, DK, FE, FF, FG, FH, FJ, FK) ........59 5.6.9 Replacing a Distribution Panel List AA, AB, AC, AD, AE, AF, AG, AH, AJ, AK, DA, DB, DC, DD, BA, BB,...

  • Page 5: Admonishments Used In This Document

    Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Admonishments Used in this Document will likely DANGER! Warns of a hazard the reader be exposed to that will result in death or serious injury if not avoided. (ANSI, OSHA)

  • Page 6: Important Safety Instructions

    Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual 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 v. General Safety DANGER! YOU MUST FOLLOW APPROVED SAFETY PROCEDURES.
  • Page 7 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual 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.
  • Page 8 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual 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 to determine the “hazard/risk” category, and to select proper PPE.

  • Page 9: Static Warning

    Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual 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.
  • Page 10 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual This page intentionally left blank.

  • Page 11: Customer Documentation Package

    Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual 1 Customer Documentation Package This document (UM582127000) provides User Instructions for Vertiv™ NetSure™ -48 VDC Power System Model 7100, Spec. No. 582127000. NOTE! 582127000 List 100, 101, 102, 203, 500, 501, 502, 503, 600, 601, 900, and 901 are specific configurations of 582127000.

  • Page 12: System Description

    -48 VDC @ up to 12000 Amperes Power System The Vertiv™ NetSure™ 7100 DC Power System is an integrated power system containing -48 VDC rectifiers, optional -48 VDC to +24 VDC converters, optional -48 VDC to -58 VDC converters, intelligent control, metering, monitoring, and distribution.
  • Page 13 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Module Mounting Assembly (Spec. No. 588705000) The system may contain one or more Spec. No. 588705000 module mounting assemblies, each of which houses up to six (6) 3500 watt rectifier modules or six (6) 3500 watt converter modules. Refer to System Application Guide SAG582127000 for more information.

  • Page 14: Operating Procedures

    Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual 3 Operating Procedures 3.1 Controller, Rectifiers, and Converters For operation instructions on these units, refer to the following documents. • NCU Controller Instructions (UM1M830BNA) • Rectifier Instructions (UM1R483500e or UM1R482000e3 or UM1R483500e3) •...

  • Page 15: Local Controls And Indicators

    Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual 3.4 Local Controls and Indicators Refer to the controller, rectifier, and converter instructions for descriptions of the local controls and indicators located on these units. If the system is installed in an enclosure, an enclosure mounted LED kit is available which provides a factory installed LED located at the top of the enclosure visible from the front with the door closed.
  • Page 16 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 3.1 Circuit Card Locations (Main Bay) Optional Second IB2 or EIB (Main Bay Only) Optional IB4 (Main Bay Only) (underside of cover) (Second Ethernet Port Board) Optional EIB (Main Bay Only)
  • Page 17 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 3.1 Circuit Card Locations (Supplementary Bay) 4-Row Cabinet Shown, Others Similar (Illustration for Clarity) SM-DU Optional LVD Driver Circuit Card CAN Interface Card Optional LVD Driver System Interface Lite Circuit Card...
  • Page 18 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual System Interface Circuit Card The system interface circuit card contains test points to externally monitor bay voltage and bay load. Refer to Figure 3.2. Figure 3.2 System Interface Circuit Card...
  • Page 19 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Optional LVD Driver Circuit Card The optional LVD driver circuit card installed in the main bay contains an LVD inhibit switch and indicator. Refer to Figure 3.3. LVD driver circuit cards are required for 2-, 3-, or 4-row distribution cabinets that contain three or more LVD contactors (LVBD and/or LVLD);...
  • Page 20 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Optional LVD Driver Lite Circuit Card The optional LVD driver lite circuit card installed in the main bay contains an LVD inhibit switch and indicator. Refer to Figure 3.4. LVD driver lite circuit cards are required for distribution cabinets that contain two LVLD contactors or one LVLD contactor and one LVBD contactor.
  • Page 21 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Optional Manual Battery Disconnect Circuit Card (Main Bay Only) The optional manual battery disconnect circuit card contains a manual battery disconnect switch and indicator. Refer to Figure 3.5. NOTE! If this option is to be used as a Maintenance Battery Disconnect only, at least one rectifier requires to be active and providing voltage to the system for proper operation.
  • Page 22 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual SM-DU Circuit Card The SM-DU is used in supplemental bays in place of a controller. The SM-DU monitors the bay and reports to the controller. The controller sends commands to the SM-DU to fulfill battery management and load control functions according to the received data.

  • Page 23: Procedures When The System Is Installed In An Enclosure

    Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual 3.5 Procedures when the System is Installed in an Enclosure 3.5.1 Removing the Enclosure Rear Panels Procedure Loosen the fasteners on the rear panel, then remove the panel. Refer to Figure 3.7.
  • Page 24 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 3.8 AC Input Conduit Plates Trade 1.00” Conduit Openings P/N 563714 (factory installed) Trade 0.75” Conduit Openings P/N 563877 (field installed)

  • Page 25: Maintenance

    Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual 4 Maintenance 4.1 System Maintenance Procedures It is recommended to perform the maintenance procedures listed in Table 4.1 every 6-months to ensure continual system operation. Table 4.1 Maintenance Procedures to be Performed at 6-Month Intervals...

  • Page 26: Adding A Rectifier Or Converter Module To An Existing Spec. No. 588705300 Module Mounting Assembly

    Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual 4.3 Adding a Rectifier or Converter Module to an Existing Spec. No. 588705300 Module Mounting Assembly To increase system current capacity, a rectifier module can easily be added to an existing Spec. No. 588705300 module mounting assembly that contains an empty rectifier module mounting position.
  • Page 27 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Place the module into an unoccupied mounting position without sliding it in completely. Rectifiers modules can be installed in any mounting position of each module mounting assembly. Converters modules can be installed in any of the three far right mounting positions of each module mounting assembly (as viewed from the front).
  • Page 28 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 4.3 Installing Rectifier and Converter Modules in a Spec. No. 588705300 Module Mounting Assembly Module Mounting Shelf(s) Front View Rectifier Rectifier or Converter Mounting Positions Mounting Positions Rectifier or Converter Module...

  • Page 29: Installing A Field Expansion Module Mounting Assembly Spec. No. 588705000 Or 588705500 In A System Installed In A Relay Rack Or An Enclosure

    Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual 4.4 Installing a Field Expansion Module Mounting Assembly Spec. No. 588705000 or 588705500 in a System Installed in a Relay Rack or an Enclosure DANGER! Adhere to the “Important Safety Instructions” presented at the front of this document.
  • Page 30 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual For a system installed in a relay rack, replace the rear covers onto the expansion module mounting assembly and the module mounting assembly installed directly above it. Refer to the Power System Installation Instructions (IM582127000) and connect AC input power to the expansion module mounting assembly.
  • Page 31 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 4.4 Installing a Field Expansion Module Mounting Assembly Spec. No. 588705000 or 588705500 (cont’d from previous page) Rear View Completed View (Install Output Busbars from Kit) Expansion Shelf Expansion...
  • Page 32 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 4.5 Controller CAN Bus, Module Mounting Assembly Spec. No. 588705000 or 588705500 Distribution Cabinet Wire Harness Slate and Slate/White Wires Brown and Brown/White Wires These cables are factory connected.
  • Page 33 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual 4.5 Installing a Field Expansion Module Mounting Assembly Spec. No. 588705300 in a System Installed in a Relay Rack DANGER! Adhere to the “Important Safety Instructions” presented at the front of this document.
  • Page 34 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Refer to the Power System Installation Instructions (IM582127000) and install rectifier and converter modules into the expansion module mounting assembly as required. For List 33, two sets of converter polarity caution labels are provided loose. Based on the converter output voltage, apply the correct label to right three converter slots of the expansion shelf: +24V label 60028788 for use with +24VDC converters;...
  • Page 35 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 4.7 Installing a Field Expansion Module Mounting Assembly Spec. No. 588705300 1. Remove busbar rear shield from existing rectifier/converter shelves. Remove the cut-out panel from the busbar rear shield.
  • Page 36 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 4.8 Controller CAN Bus, Module Mounting Assembly Spec. No. 588705300 Distribution Cabinet Wire Harness Exploded View Shown to Illustrate Wire Connections Only Slate and Slate/White Wires Existing Module Brown and...

  • Page 37: Installing A Field Expansion Module Mounting Assembly Spec. No. 588705400 In A System Installed In A Relay Rack Or An Enclosure

    Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual 4.6 Installing a Field Expansion Module Mounting Assembly Spec. No. 588705400 in a System Installed in a Relay Rack or an Enclosure DANGER! Adhere to the “Important Safety Instructions” presented at the front of this document.
  • Page 38 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Refer to the Power System Installation Instructions (IM582127000) and connect AC input power to the expansion module mounting assembly. For a system mounted in an enclosure, replace the rear covers.
  • Page 39 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 4.9 Installing a Field Expansion Module Mounting Assembly Spec. No. 588705400 (cont’d on next page) 4. Install the expansion module 1. Remove busbar rear shield from mounting assembly into the rack.
  • Page 40 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 4.9 Installing a Field Expansion Module Mounting Assembly Spec. No. 588705400 (cont’d from previous page) 5. Remove hardware from the lowest module mounting assembly’s -48V and return busbars. 6. Install the busbars provided...
  • Page 41 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 4.10 Controller CAN Bus, Module Mounting Assembly Spec. No. 588705400 Distribution Cabinet Wire Harness Factory CAN Bus Wiring (Five 588705400 List 01 Shelves) 562087 BMY200004/1 Exploded View Shown to...

  • Page 42: Reconfiguring A Dual Voltage Distribution Panel (List De, Df, Dg, Dh, Dj, Dk, Fe, Ff, Fg, Fh, Fj, Fk)

    Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual 4.7 Reconfiguring a Dual Voltage Distribution Panel (List DE, DF, DG, DH, DJ, DK, FE, FF, FG, FH, FJ, FK) Perform the following procedure to reconfigure a dual voltage distribution panel (List DE, DF, DG, DH, DJ, DK, FE, FF, FG, FH, FJ, FK) to move distribution positions from one voltage to the other.
  • Page 43 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Reworking the Distribution Panel You can reconfigure the distribution panel to swap -48V distribution positions for +24V or -58V distribution positions, and vice versa, in groups of four. The resulting assembly can have following positions. See Table 4.2.
  • Page 44 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 4.11 Removing/Installing the Distribution Panel Ground Busbar Hardware 1/4-20 x 1” Bolt Distribution Panel 1/4” Belleville Lock Washer Distribution Panel Hardware 1/4” Flat Washer Hardware Torque to 60 in-lbs.
  • Page 45 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 4.12 Reworking the Distribution Panel (cont’d on next page) List DE or FE Dual Voltage Distribution Panel List DF or FF Dual Voltage Distribution Panel Extra Shorting Block Stored Here...
  • Page 46 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 4.12 Reworking the Distribution Panel (cont’d from previous page, cont’d on next page) List DE and FE Only: Move the +24V or -58V Input Power Busbar one (1) position to the left.
  • Page 47 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 4.12 Reworking the Distribution Panel (cont’d from previous page, cont’d on next page) After List DF, DG, DH, DJ, Before FF, FG, FH, FJ Dual Voltage Distribution Panel (DF Shown, Others Similar)
  • Page 48 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 4.12 Reworking the Distribution Panel (cont’d from previous page, cont’d on next page) Distribution Panel Reconfigured for All Subsysytem (List DK or FK) or All System Positions From the front, remove the...
  • Page 49 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 4.12 Reworking the Distribution Panel (cont’d from previous page) Detail A For reassigned distribution positions... 1. Remove polarity label plug buttons. 2. Remove polarity label. Barrier 3. Turn over polarity label so other polarity shows.
  • Page 50 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Replacing the Distribution Panel NOTE! In the following procedure, before making busbar-to-busbar connections, apply a thin coating of electrical anti- oxidizing compound to the mating surfaces of the busbars. Procedure...

  • Page 51: Changing The Controller's Lvd Control Level For A Contactor

    Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual 4.8 Changing the Controller’s LVD Control Level for a Contactor The controller has two available LVD control levels (LVD1 and LVD2). The level used to control a contactor is determined by which connector on the LVD circuit card its control leads are plugged into.
  • Page 52 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Table 4.4 Sample Supplemental Bay Optional SM-DU+ Programmable Parameter Chart (cont’d on next page) Device Parameter Factory Setting Setting for this Bay Full Scale Current (A) Refer to USB Drive...

  • Page 53: Installing Optional Second Ib2 (Controller Interface Board) Or Optional Second Eib

    Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Table 4.4 Sample Supplemental Bay Optional SM-DU+ Programmable Parameter Chart (cont’d from previous page) Device Parameter Factory Setting Setting for this Bay Full Scale Current (A) Refer to USB Drive...

  • Page 54: Troubleshooting And Repair

    Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual 5 Troubleshooting and Repair 5.1 Contact Information Refer to Section 4154 (provided with your customer documentation) for support contact information. 5.2 Controller, Rectifiers, and Converters For troubleshooting and repair instructions on these units, refer to the following documents.

  • Page 55: Replacement Information

    Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual set point of 30 amps. If one or more rectifiers or converters are removed or fail it will take several seconds for the individual set points to the remaining rectifiers or converters 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.

  • Page 56: Replacement Procedures

    Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual 5.6 Replacement Procedures DANGER! Adhere to the “Important Safety Instructions” presented at the front of this document. 5.6.1 Replacing a Rectifier Module (in a Spec. No. 588705000 Module Mounting Assembly) Refer to the Rectifier Instructions (UM1R483500e) for a rectifier module replacement procedure.
  • Page 57 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Procedure An alarm fuse is removed by pulling it straight out of the fuseholder. If the alarm fuse is located in a modular fuse carrier, hold the fuse carrier in place with your thumb while pulling on the alarm fuse to prevent the entire carrier from inadvertently being pulled out.
  • Page 58 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Replacing a Bullet Nose Fuseholder Procedure NOTE! Refer to Figure 5.2 as this procedure is performed. Open the distribution cabinet’s front door by turning the latch in the counterclockwise position (system’s in a relay rack), or open the system’s enclosure door.
  • Page 59 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Replacing a Bullet Nose Circuit Breaker Procedure NOTE! Refer to Figure 5.3 as this procedure is performed. Open the distribution cabinet’s front door by turning the latch in the counterclockwise position (system’s in a relay rack), or open the system’s enclosure door.
  • Page 60 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Replacing a TPH Fuse Procedure NOTE! Refer to Figure 5.4 as this procedure is performed. Open the distribution cabinet’s front door by turning the latch in the counterclockwise position (system’s in a relay rack), or open the system’s enclosure door.
  • Page 61 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Replacing a TPL-B Fuse Procedure NOTE! Refer to Figure 5.5 as this procedure is performed. Open the distribution cabinet’s front door by turning the latch in the counterclockwise position (system’s in a relay rack), or open the system’s enclosure door.
  • Page 62 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Replacing a GJ/218 Circuit Breaker Procedure NOTE! Refer to Figure 5.6 as this procedure is performed. Open the distribution cabinet’s front door by turning the latch in the counterclockwise position (system’s in a relay rack), or open the system’s enclosure door.
  • Page 63 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 5.6 Replacing a GJ/218 Circuit Breaker (1-Pole) (Lists AC, AD, BC, BD) (cont’d on next page) INSTALLING CIRCUIT BREAKER Alarm jumper connector. Holes to route shunt jumper through (if applicable).
  • Page 64 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 5.6 Replacing a GJ/218 Circuit Breaker (2-Pole, 3-Pole, 4-Pole) (Lists AC, AD, BC, BD) (cont’d from previous page, cont’d on next page) Alarm jumper connectors. INSTALLING CIRCUIT BREAKER Holes to route shunt jumper through (if applicable).
  • Page 65 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 5.6 Replacing a GJ/218 Circuit Breaker (1-Pole, 2-Pole, 3-Pole, 4-Pole) (List AM and List AP) (cont’d from previous page) INSTALLING CIRCUIT BREAKER Return Busbar (not included with List AP) Alarm jumper connector.

  • Page 66: Replacing A Distribution Panel (List Aa, Ab, Ac, Ad, Ae, Af, Ag, Ah, Aj, Ak, Ba, Bb, Bc, Bd, Bf, And Bh)

    Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual 5.6.7 Replacing a Distribution Panel (List AA, AB, AC, AD, AE, AF, AG, AH, AJ, AK, BA, BB, BC, BD, BF, and BH) DANGER! Performing the next steps exposes service personnel to battery potential. Exercise extreme caution not to inadvertently contact or have any tool inadvertently contact any energized electrical termination.
  • Page 67 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual For load distribution panels, replace the hardware securing the panel’s System Load Distribution busbar to the distribution cabinet’s busbar (1/4-20 x 1” bolt, 1/4” Belleville lock washer, 1/4” Belleville lock washer (concave side of Belleville lock washers face each other), 1/4”...
  • Page 68 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 5.7 Replacing a Distribution Panel (List AA, AB, AC, AD, AE, AF, AG, AH, AJ, AK, BA, BB, BC, BD, BF, and BH) Battery Busbar Ground Busbar Hardware Hardware...

  • Page 69: Replacing A Distribution Panel (List Al, An, De, Df, Dg, Dh, Dj, Dk, Fe, Ff, Fg, Fh, Fj, Fk)

    Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual 5.6.8 Replacing a Distribution Panel (List AL, AN, DE, DF, DG, DH, DJ, DK, FE, FF, FG, FH, FJ, FK) DANGER! Performing the next steps exposes service personnel to battery potential. Exercise extreme caution not to inadvertently contact or have any tool inadvertently contact any energized electrical termination.
  • Page 70 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual WARNING! In the next step, observe correct polarity; otherwise equipment damage will result. Reconnect the load return wiring to the ground busbar (if present). Reconnect the load wiring to the circuit breaker or fuse positions.
  • Page 71 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 5.8 Replacing a Distribution Panel (List AL, AN, DE, DF, DG, DH, DJ, DK, FE, FF, FG, FH, FJ, FK) Ground Busbar Hardware 1/4-20 x 1” Bolt Distribution Panel 1/4”...

  • Page 72: Replacing A Distribution Panel List Aa, Ab, Ac, Ad, Ae, Af, Ag, Ah, Aj, Ak, Da, Db, Dc, Dd, Ba, Bb

    Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual 5.6.9 Replacing a Distribution Panel List AA, AB, AC, AD, AE, AF, AG, AH, AJ, AK, DA, DB, DC, DD, BA, BB, BC, BD, BE, BF, BG, or BH with a List AL, AN, DE, DF, DG, DH, DJ, or DK, FE, FF, FG, FH, FK DANGER! Performing the next steps exposes service personnel to battery potential.
  • Page 73 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual NOTE! In the following procedure, before making busbar-to-busbar connections, apply a thin coating of electrical anti- oxidizing compound to the mating surfaces of the busbars. Remove the plastic shield covering the circuit breakers or fuseholders on the replacement panel by loosening the screws holding the shield and sliding the shield upwards.
  • Page 74 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 5.9 Removing the Existing Distribution Panel Ground Busbar Hardware Distribution Panel Hardware List DB Dual Voltage Distribution Panel (other distribution panels similiar) Distribution Panel Hardware System Load Distribution Busbar...
  • Page 75 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 5.10 Replacing the Busbar 1. Remove this busbar. 4-row distribution cabinet shown. 1, 2, or 3-row cabinet similar. 2. Replace with new busbar. See SAG582127000 for part number. Existing busbar.
  • Page 76 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 5.11 Installing the New Distribution Panel Ground Busbar Hardware 1/4-20 x 1” Bolt Distribution Panel 1/4” Belleville Lock Washer Distribution Panel Hardware 1/4” Flat Washer Hardware Torque to 60 in-lbs.

  • Page 77: Replacing A Distribution Panel

    Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual 5.6.10 Replacing a Distribution Panel (List AA, AB, AC, AD, AE, AF, AG, AH, AJ, AK, DA, DB, DC, DD, BA, BB, BC, BD, BE, BF, BG, or BH with AM or AP) DANGER! Performing the next steps exposes service personnel to battery potential.
  • Page 78 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Replace the hardware securing the panel’s System Load Distribution busbar to the distribution cabinet’s busbar (1/4-20 x 1” bolt, 1/4” Belleville lock washer, 1/4” Belleville lock washer (concave side of Belleville lock washers face each other), 1/4”...
  • Page 79 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 5.12 Replacing the Busbar 1. Remove this busbar. 4-row distribution cabinet shown. 1, 2, or 3-row cabinet similar. Existing busbar New busbar Busbar Busbar /-48V/ jumpers. /-48V/ jumpers. Assembly order is: Assembly order is: lug, 1/4”...

  • Page 80: Replacing A Distribution Panel (List Aa, Ab, Ac, Ad, Ae, Af, Ag, Ah, Aj, Ak, Da, Db, Dc, Dd, Ba, Bb, Bc, Bd, Be, Bf, Bg, Or Bh With Ea)

    Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual 5.6.11 Replacing a Distribution Panel (List AA, AB, AC, AD, AE, AF, AG, AH, AJ, AK, DA, DB, DC, DD, BA, BB, BC, BD, BE, BF, BG, or BH with EA) DANGER! Performing the next steps exposes service personnel to battery potential.
  • Page 81 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Replace the hardware securing the panel’s System Load Distribution busbar to the distribution cabinet’s busbar (1/4-20 x 1” bolt, 1/4” Belleville lock washer, 1/4” Belleville lock washer (concave side of Belleville lock washers face each other), 1/4”...
  • Page 82 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 5.13 Replacing the Busbar 1. Remove this busbar. 4-row distribution cabinet shown. 1, 2, or 3-row cabinet similar. Existing busbar New busbar Busbar Busbar /-48V/ jumpers. /-48V/ jumpers. Assembly order is: Assembly order is: lug, 1/4”...

  • Page 83: Circuit Card Replacement Procedures

    Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual 5.6.12 Circuit Card Replacement Procedures WARNING! 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.
  • Page 84 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Slide the replacement circuit card into the mounting position inside the distribution cabinet, and secure with the screws removed from the old circuit card. Plug all connectors removed from the old circuit card into the same position on the replacement circuit card.
  • Page 85 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 5.14 System Interface Circuit Card Connector Locations (Main Bay Only) J1, J2, J3, J4 * When an NCU configuration is Distribution Panels FA Inputs furnished that enables NCU capability to receive status...
  • Page 86 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual SM-DU Circuit Card Replacement (Supplemental Bays Only) Procedure 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.
  • Page 87 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 5.15 SM-DU Circuit Card Replacement (Supplemental Bays Only) SM-DU Supplemental Bay Addressing SM-DU Circuit Card 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1...
  • Page 88 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual IB2 (Controller Interface Board) and Optional EIB (Controller Extended Interface Board) Replacement (Main Bay Only) Procedure 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.
  • Page 89 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Reboot the Controller Local Menu Navigation: At the Main Screen, press ENT and ESC at the same time to reset the NCU Controller. Web Menu Navigation: Go to Advance Settings Menu / SW Maintenance Tab / Reboot Controller button.
  • Page 90 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 5.17 EIB (Controller Extended Interface Board) Connector Locations Optional EIB Interface Board Assembly Optional EIB Interface Board (Top View) J5-J9 Wire Size Capacity: 16-26 AWG. Recommended Torque: 2.2 in-lbs.
  • Page 91 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual SM-DU+ and Shunt Interface Assembly Replacement Procedure 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.
  • Page 92 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Reboot the Controller Local Menu Navigation: At the Main Screen, press ENT and ESC at the same time to reset the NCU Controller. Web Menu Navigation: Go to Advance Settings Menu / SW Maintenance Tab / Reboot Controller button.
  • Page 93 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual IB4 (NCU Controller Second Ethernet Port Board) Replacement (Main Bay Only) Procedure 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.
  • Page 94 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 5.19 IB4 (NCU Controller Second Ethernet Port Board) Replacement Screws to secure IB4 IB4 Board USB-A Port boa rd cover to top of (not used) distribution cabine t. 10M Ethernet...
  • Page 95 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Optional LVD Driver and LVD Driver Lite Circuit Card Replacement Procedure 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.
  • Page 96 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 5.20 Optional LVD Driver Circuit Card Connector Locations Main Bay J1, J2, J3 To LVLD contactor, uses Controller DO NOT change a Low Voltage LVD1 control setting (Level 1).
  • Page 97 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 5.21 Optional LVD Driver Lite Circuit Card Connector Locations Main Bay DO NOT change a Low Voltage Load Disconnect contactor to LVD Control Level 2 (LVD2) if the system is furnished with a Low Voltage Battery Disconnect contactor.
  • Page 98 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Optional Manual Battery Disconnect Circuit Card Replacement Procedure 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.
  • Page 99 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 5.22 Optional Manual Battery Disconnect Circuit Card Connector Locations (Main Bay Only)

  • Page 100: Replacing A Battery Or Load Disconnect Contactor

    Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual 5.6.13 Replacing a Battery or Load Disconnect Contactor DANGER! All sources of AC and DC power must be completely disconnected from this power system before performing this procedure. Use a voltmeter to verify no DC voltage is present on the system busbars before proceeding.
  • Page 101 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 5.23 Replacing a Battery Disconnect Contactor in a 1-Row Distribution Cabinet 5/16-18 x 1” Bolt Battery 5/16" Belleville Lock Washer Disconnect 5/16" Belleville Lock Washer Contactor (concave side of Belleville Lock Washers face each other) 5/16"...
  • Page 102 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 5.24 Replacing a Battery Disconnect Contactor in a 2, 3, or 4-Row Distribution Cabinet 1/2-13 x 1-1/4” Bolt 1/2" Belleville Lock Washer 1/2" Belleville Lock Washer (concave side of Belleville Lock Washers face each other) 1/2"...
  • Page 103 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 5.25 Replacing a Load Disconnect Contactor in a 1-Row Distribution Cabinet 5/16-18 x 1” Bolt 5/16" Belleville Lock Washer 5/16" Belleville Lock Washer Load (concave side of Belleville Disconnect...
  • Page 104 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Figure 5.26 Replacing a Load Disconnect Contactor in a 2, 3, or 4-Row Distribution Cabinet Components removed in Load Disconnect illustration for clarity only. Contactor 5/16-18 Nut 5/16" Belleville Lock Washer 5/16"...
  • Page 105 Vertiv™ NetSure™ 7100 Series -48 VDC Power System User Manual Connect with Vertiv on Social Media https://www.facebook.com/vertivI https://www.instagram.com/vertiv/ https://www.linkedin.com/company/vertiv/ https://www.twitter.com/vertiv/...
  • Page 106 Vertiv.com | Vertiv Headquarters, 1050 Dearborn Drive, Columbus, OH, 43085, USA © 2021 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 here, Vertiv Group Corp.

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