Vertiv 584622100 User manual

NetSure™ +24 VDC to -48 VDC
Converter System
Installation and User Manual
Specification Number: 584622100 (19” Main Shelf)
584622200 (19” Expansion Shelf)
584622300 (23” Main Shelf)
584622400 (23” Expansion Shelf)
Model Number: DCS48375

Vertiv™ NetSure™ +24 VDC to -48 VDC Converter System Installation and User Manual
Vertiv™ NetSure™ +24 VDC to -48 VDC Converter System Installation and User Manual
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. 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.
The products covered by this instruction manual are manufactured and/or
sold by Vertiv. This document is the property of Vertiv and contains
confidential and proprietary information owned by Vertiv. Any copying, use or
disclosure of it without the written permission of Vertiv is strictly prohibited.
Names of companies and products are trademarks or registered trademarks of
the respective companies. Any questions regarding usage of trademark
names should be directed to the original manufacturer.
Technical Support Site
If you encounter any installation or operational issues with your product, check the pertinent section of this
manual to see if the issue can be resolved by following outlined procedures.
Visit https://www.vertiv.com/en-us/support/ for additional assistance.

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TABLE OF CONTENTS
Admonishments Used in this Document..............................................................................................................................v
Important Safety Instructions.................................................................................................................................................vi
1Description and Installation Acceptance Checklist...................................................................................................1
1.1 System Description ......................................................................................................................................................................................................................................................1
1.2 Installation Acceptance Checklist.................................................................................................................................................................................................................2
2Installing the System ............................................................................................................................................................3
2.1 General Requirements..............................................................................................................................................................................................................................................3
2.2 Installing Optional Wiring Access Cover on Top of Shelf(s), If Desired.....................................................................................................................4
2.3 Mounting the Shelf(s)...............................................................................................................................................................................................................................................5
2.4 Securing the Expansion Shelf(s) to a Relay Rack and Installing the Expansion Wiring Cover on the Main Shelf.............6
2.5 Installing Optional Lug Adapter Busbar Kits .......................................................................................................................................................................................7
2.6 Installing Bullet Nose Circuit Breakers and/or Fuseholders (with TPS/TPL Fuses)......................................................................................8
2.7 Installing an Optional Bullet Nose GMT Fuse Block..................................................................................................................................................................10
3Setting Jumper and Switch Options.............................................................................................................................12
3.1 Jumper and Switch Settings on the System Interface Circuit Card............................................................................................................................12
4Making Electrical Connections .......................................................................................................................................14
4.1 Admonishments ..........................................................................................................................................................................................................................................................14
4.2 Wiring Considerations............................................................................................................................................................................................................................................14
4.3 Shelf(s) Grounding (Frame Ground) Connection.........................................................................................................................................................................15
4.4 External Alarm, Reference, Monitoring and Control Connections ...............................................................................................................................16
4.5 Load Connections ..................................................................................................................................................................................................................................................... 18
4.6 Expansion Shelf(s) Interconnections .....................................................................................................................................................................................................20
4.7 DC Input Connections ...........................................................................................................................................................................................................................................22
5Installing the Converter Modules and Initially Starting the System................................................................ 24
5.1 Installing Converter Modules.........................................................................................................................................................................................................................24
5.2 Initially Starting and Checking System Operation ......................................................................................................................................................................25
5.2.1 Initial Startup Preparation............................................................................................................................................................................................................25
5.2.2 Initially Starting the System.......................................................................................................................................................................................................25
5.2.3 Checking System Status...............................................................................................................................................................................................................25
6Operating Procedures....................................................................................................................................................... 26
6.1 Converter Modules...................................................................................................................................................................................................................................................26
6.2 Using the Converter System with an ACU+ Controller..........................................................................................................................................................26
6.3 Local Indicators and Test Points.................................................................................................................................................................................................................26
6.3.1 Local Indicators.....................................................................................................................................................................................................................................26
6.3.2 Test Points.................................................................................................................................................................................................................................................27
7Maintenance..........................................................................................................................................................................28
7.1 Admonishments ..........................................................................................................................................................................................................................................................28
7.2 System Maintenance Procedures...............................................................................................................................................................................................................28
8Troubleshooting and Repair ...........................................................................................................................................28
8.1 Contact Information.................................................................................................................................................................................................................................................28
8.2 Admonishments ..........................................................................................................................................................................................................................................................28
8.3 Converter Modules...................................................................................................................................................................................................................................................28

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8.4 System Troubleshooting Information .....................................................................................................................................................................................................28
8.5 Replacement Information...................................................................................................................................................................................................................................29
8.6 Replacement Procedures...................................................................................................................................................................................................................................29
8.6.1 Replacing a Converter Module ...............................................................................................................................................................................................29
8.6.2 Replacing a Distribution Device.............................................................................................................................................................................................29
8.6.3 Replacing the System Interface Circuit Card.............................................................................................................................................................31

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Admonishments Used in this Document
DANGER!
Warns of a hazard the reader will be exposed to that will likely result
in death or serious injury if not avoided. (ANSI, OSHA)
WARNING!
Warns of a potential hazard the reader may be exposed to that could
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!
Warns of a potential hazard the reader may be exposed to that could
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!
Alerts the reader to an action that must be avoided in order to protect
equipment, software, data, or service. (ISO)
ALERT!
Alerts the reader to an action that must be performed in order to prevent
equipment damage, software corruption, data loss, or service interruption. (ISO)
FIRE SAFETY!
Informs the reader of fire safety information, reminders, precautions,
or policies,
or of the locations of fire-fighting and fire-safety equipment. (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)

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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 v.
Safety and Regulatory Statements
Refer to Section 4154 (provided with your customer documentation) for Safety and Regulatory Statements.
Déclarations de Sécurité et de Réglementation
Reportez-vous à la Section 4154 (fourni avec les documents de votre client) pour les déclarations de sécurité et de réglementation.

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1Description and Installation Acceptance Checklist
1.1 System Description
+24 VDC to -48 VDC @ up to 375 A Converter System.
The NetSure™ DCS48375 Converter System is comprised of a main shelf and up to two (2) expansion shelves. Each shelf provides
mounting positions for up to four (4) converter modules. Each shelf also provides a 15 position distribution row (19” version) or 20
position distribution row (23” version) which accepts bullet nose circuit breakers and TPS/TLS fuseholders. A GMT fuse block option
is also available.
NOTE! Refer to SAG584622100 (System Application Guide) for additional system information.
NOTE! Refer to UM1C24481500 (Converter Module User Instructions) for converter module information.
Converter Operation
The converter modules, when used in this system, revert to their default overvoltage and overcurrent setpoints since they are
initialized without communications to a controller. Reference to a controller in the Converter Module User Instructions do not pertain
to this system, since this system is a stand-alone system and does not include a controller.
•The selective overvoltage shutdown still functions, only the converter module causing the high voltage condition shuts down.
•The converter modules will share load until each reaches its power limit (1500 watts) or current limit point (31.25 A)

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1.2 Installation Acceptance Checklist
Provided below 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! The system is not powered up until the end of this checklist.
NOTE! Some of these procedures may have been factory performed.
Installing the System
Optional Wiring Access Panel Installed on Top of Shelf(s), if desired
Main Shelf Secured to Relay Rack
Expansion Shelf(s) Secured to Relay Rack (if furnished)
and Expansion Wiring Cover installed on Main Shelf
Optional Lug Adapter Busbar Kits Installed
Bullet Nose Circuit Breakers Installed
Bullet Nose Fuseholders and TPS/TLS Fuses Installed
Optional Bullet Nose GMT Fuse Block Installed (if furnished)
Setting Jumper and Switch Options
Jumper on System Interface Circuit Card Set
Switches on System Interface Circuit Card Set
Making Electrical Connections
Shelf(s) Grounding (Frame Ground) Connection Made
External Alarm, Reference, Monitoring, and Control Connections Made
Load Connections Made
Expansion Shelf(s) Interconnections Made (if furnished)
DC Input Connections Made
Installing the Converter Modules and Initially Starting the System
Converter Modules Installed
System Started and Checked

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2Installing the System
2.1 General Requirements
•The shelf is designed for mounting in a 19-inch or 23-inch wide relay rack with 1-3/4 inch multiple drilling.
•The installer should be familiar with the installation requirements and techniques to be used in securing the shelf(s) to a relay
rack.
•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 Craftspersons 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 to be connected to the common bonding network in a Network Telecommunication Facility (CO,
vault, hut, or other environmentally controlled electronic equipment enclosure).
•Typical industry standards recommend minimum aisle space clearance of 2'6" for the front of the relay rack and 2' for the rear
of the relay rack.
•Converter module and mounting shelf ventilating openings must not be blocked and temperature of air entering system must
not exceed rated Operating Ambient Temperature Range found in SAG584622100.

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2.2 Installing Optional Wiring Access Cover on Top of Shelf(s), If Desired
The optional wiring access cover is a 1U high panel that is installed on top of the shelf(s) to allow greater access to load distribution
return connection points.
Procedure
1. To install the optional wiring access cover, perform the procedure in Figure 2.1.
Figure 2.1: Installing Optional Wiring Access Cover

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2.3 Mounting the Shelf(s)
The 584622100 and 584622200 shelves are equipped with reversible mounting angles for mounting in a standard 19 inch or 23 inch
wide relay rack having 1-3/4 inch multiple drillings.
The 584622300 and 584622400 shelves mount in a standard 23 inch wide relay rack having 1-3/4 inch multiple drillings.
NOTE! Refer to the “General Requirements” section at the beginning of this section.
Securing the Main Shelf to a Relay Rack
Procedure
1. 584622100 and 584622200: Reverse the mounting angles if required to fit your relay rack. Refer to Figure 2.2.
2. Secure the shelf mounting angles to the relay rack at four (4) locations per side. Use grounding washers at one (1) location
per side. Refer to Figure 2.2. Ensure the grounding washers are oriented properly to enable the teeth to dig into the
mounting angle surface for a secure ground connection.
Figure 2.2: Reversing the Mounting Angles (if required) and Securing the Shelf to a Relay Rack

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2.4 Securing the Expansion Shelf(s) to a Relay Rack and Installing the
Expansion Wiring Cover on the Main Shelf
Securing an Expansion Shelf to a Relay Rack
Secure an expansion shelf to a relay rack, directly below the shelf above it, per the previous procedure. The optional 1U wiring access
panel is recommended for expansion shelves to facilitate load cable connections.
Installing the Expansion Wiring Cover on the Main Shelf
Procedure
1. Remove the cover shown in Figure 2.3 from the main shelf.
2. Remove the expansion wiring cover from the expansion shelf as shown in Figure 2.3.
3. On the expansion wiring cover for both the expansion shelf and the main shelf (provided loose with the expansion shelf),
remove the tabs shown in Figure 2.3 so wiring can pass between the shelves. Apply the provided material along the exposed
edges of the cutouts to provide protection to the wires as they are passed between shelves.
4. Make the paralleling connections as described in the “Making Electrical Connections” section of this document.
5. Refer to Figure 2.3, and install the expansion wiring covers to both the main shelf and the expansion shelf.
Figure 2.3: Installing the Expansion Wiring Cover on the Main Shelf
Expansion Wiring Cover
(supplied loose with Expansion
Shelf, attach to Main Shelf)
Replace this cover with the
Expansion Wiring Cover
Remove these tabs at the bottom of the top shelf and
at the top of the bottom shelf to allow wiring between
shelves.
Apply the provided material along the exposed edges
of the cutouts to provide protection to the wires as they
are passed between shelves.
584622100 / 584622200 shown.
584622300 / 584622400 similar.

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2.5 Installing Optional Lug Adapter Busbar Kits
Procedure
Refer to Figure 2.4 to install the optional lug adapter busbar kits.
Figure 2.4: Installing Optional Lug Adapter Busbar Kits
P/N 545405
P/N 545404
P/N 545571
1. Open the shelf’s front door.
2. Install the lug adapter busbar kits as shown.
Apply anti-oxidizing compound to busbar
mating surfaces before installing.
3. Torque connections to 58 in-lbs using the
supplied 1/4” hardware.
4. Close the front door after wiring is complete.
Top Cover Removed in
Illustration for Clarity Only
584622100 / 584622200 shown.
584622300 / 584622400 similar.

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2.6 Installing Bullet Nose Circuit Breakers and/or Fuseholders (with TPS/TPL
Fuses)
ALERT! For ambient temperatures at or below +40°C (+104°F), overcurrent devices rated 100A or greater MUST HAVE an
empty mounting position between it and any other overcurrent protective device. Maximum size circuit breakers that can be
used are 100A single pole, 200A double pole, and 250A triple pole. Maximum size fuse is 100A. The distribution row is rated
for a maximum of 250A.
For ambient temperatures between +40°C (+104°F) and +65°C (+149°F), overcurrent devices rated 60A or greater MUST
HAVE an empty mounting position between it and any other overcurrent protective device. Maximum size circuit breakers
that can be used are 70A single pole. No double pole or triple pole circuit breakers can be used. Maximum fuse size is 70A.
The distribution row is rated for a maximum of 250A.
NOTE! Circuit breakers and/or fuses may have been factory installed for you. If so, verify their positions and sizes.
Procedure
1. Open the shelf’s front door.
2. Circuit Breakers and Fuses: Ensure that a circuit breaker is in the OFF position. Orient the distribution device as shown in
Figure 2.5. Insert the terminals on the rear of the distribution device into their corresponding sockets on the distribution row.
Ensure the alarm contact on the back of the distribution device makes contact with the alarm terminal on the mounting
circuit card. Push distribution device in firmly until fully seated in the distribution row.
3. Fuses: When all fuseholders are installed, install an appropriately sized TPS/TLS fuse in each. To do this, remove the fuse
carrier from the mounted fuseholder body by pulling it straight out. Slide the fuse in place between the contacts of the fuse
carrier. When done, push the fuse carrier back into the fuseholder body. Note that a polarizing key on the bottom of the
carrier prevents the carrier from being inserted upside down. Verify that an 18/100 ampere alarm fuse is present in each
fuseholder and that a plastic safety cover is installed on this fuse.
4. Record all circuit breaker and/or fuse sizes on the label provided.
5. Close the shelf's front door.

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Figure 2.5: Installing Bullet Nose Circuit Breakers and/or Fuseholders (with TPS/TLS Fuse)
Fuseholder Assembly
Circuit Breaker
Insert these terminals
into corresponding sockets
on distribution row.
Insert these terminals
into corresponding sockets
on distribution row.
Longer Side
to the Bottom
Shorter Side
to the Top
Longer Side
to the Bottom
Shorter Side
to the Top
Fuse Carrier
Fuseholder Body
TPS/TLS Fuse
Alarm Fuse
(Replacement
P/N 248610301)
Safety Cover
(Replacement
P/N 248898700)
Polarizing Keyway
Matches Key on
Bottom of Fuse Carrier
Fuseholder Assembly
Exploded View
Fuseholder Assembly (P/N 117201) includes
body & carrier, alarm fuse, and alarm fuse safety cover.
Lettering on
handle must be
right side up.
Turn off
before installing.
584622100 / 584622200 shown.
584622300 / 584622400 similar.

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2.7 Installing an Optional Bullet Nose GMT Fuse Block
ALERT! At 40°C ambient, GMT fuses greater than 10A MUST HAVE an empty mounting position between it and any other
fuse. Maximum total current is 35A. Maximum GMT fuse size is 15A.
At 65°C ambient, GMT fuses greater than 5A MUST HAVE an empty mounting position between it and any other fuse.
Maximum total current is 21A. Maximum GMT fuse size is 10A.
Refer to Figure 2.6 while performing this procedure.
Procedure
1. Open the shelf’s front door.
2. Follow the steps in Figure 2.6.
3. Install an appropriately sized GMT fuse in each fuse mounting position on the GMT distribution fuse block as required. If
dummy fuses are installed, first remove the dummy fuse.
4. Verify that dummy fuses are installed in all unused fuse positions on the GMT distribution fuse block.
5. Verify that a plastic safety cover is installed on all GMT fuses on the GMT distribution fuse block.
6. Record all fuse sizes (installed on the GMT distribution fuse block) on the label provided.
7. Close the shelf's front door.

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Figure 2.6: Installing an Optional Bullet Nose GMT Fuse Block
Remove two lug terminal busbars
for positions to be occupied
by GMT Fuse Block.
2.
Press in tabs to release
lug terminal busbars for
positions to be occupied
by GMT Fuse Block.
1.
Plug in GMT Fuse Block and secure
at one location on the RTN bar with
hardware provided. Torque to 58 in-lbs. RTN Bar
3.
Top Cover Removed in
Illustration for Clarity Only
584622100 / 584622200 shown.
584622300 / 584622400 similar.

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3Setting Jumper and Switch Options
3.1 Jumper and Switch Settings on the System Interface Circuit Card
Perform the following procedures to verify the factory settings and/or make the required settings per your site requirements. These
procedures can also be used to make adjustments on a replacement circuit card.
Refer to Figure 3.1 for switch and jumper locations.
Switch S1
Switch Positions 1 and 2 of S1
Selects the converter system’s output voltage as shown in Table 3.1.
Table 3.1: Converter System Output Voltage Selection
When P/N 10017022 System Interface Circuit Card Installed
S1 52V 54V 56V 58V
Switch 1 OFF OFF ON ON
Switch 2 OFF ON OFF ON
When P/N 556434 System Interface Circuit Card Installed
S1 48V 50V 52V 54V
Switch 1 OFF OFF ON ON
Switch 2 OFF ON OFF ON
Switch Position 3 of S1
Selects the current scale for the output current test points as shown in Table 3.2.
Table 3.2: Output Current Test Points “Current Scale” Selection
S1 1A / 1mV 400A / 50mV
Switch 3 OFF ON
Switch Position 4 of S1
Selects whether converter system output voltage is controlled by the system interface circuit card (stand alone mode) or by an ACU+
as shown in Table 3.3.
Table 3.3: Output Voltage Control Selection
S1 Stand Alone Mode ACU+ Controller Mode
Switch 4 OFF ON

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Jumper P2
Jumper P2 is the CAN termination jumper.
a) When in stand-alone mode, the jumper P2 must be in place to ensure reliable communications.
b) When an ACU+ is on the CAN bus, jumper P2 should be removed.
Figure 3.1: System Interface Circuit Card Jumper and Switch Locations
Inside View of Main Shelf’s Front Door
TB1
1 9 1 12
TB2P2P1
Jumper
P2
Switch
S1
S1
OFF
ON
4 3 2 1

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4Making Electrical Connections
4.1 Admonishments
Observe the admonishments located at the beginning of this document.
4.2 Wiring Considerations
All wiring 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 recommended wire sizes, crimp lugs, alarm relay contact ratings, and general wiring information and restrictions; refer to System
Application Guide SAG584622100.
Refer to drawing 031110100 for lug crimping information. Refer to drawings 031110200 and 031110300 for additional lug information.
Refer to Table 4.1 for supplemental lug crimping information when using the special application crimp lug / strap combination.
Table 4.1: Supplemental Lug Crimping Information when using the Special Application Crimp Lug / Strap Combination
Crimp Lug Part No.
Crimp Tool Required1, T&B Model
TBM12 or TBM15 Hydraulic Heads
Color Key Die Index/
Code No.
Die Cat.
Number
245393500 Burndy: YA25L-4TCG1 PINK 42H 15508
245393600 Burndy: YA26L-4TCG1 BLACK 45 15526
245393700 Burndy: YA27L-4TCG1 ORANGE 50 15530
245393800 Burndy: YA28L-4TCG1 PURPLE 54H 15511
514872
T & B: 256-30695-1879
YELLOW 62 15510
Burndy: YA29L-4TCG1
514873
T & B: 256-30695-1880
RED 71 15514
Burndy: YA31L-4TCG1
1The lugs should be crimped to the specifications given in the manufacturer’s instructions furnished with the
crimp tool or lug.