Vertiv NetSure 5100 Series User manual

NetSure™
5100 SERIES -48 VDC Power System
User Manual (UM582137100), Revision L
Specification Number: 582137100
Model Number: 5100

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The information contained in this document is subject to change without
notice and may not be suitable for all applications. While every precaution
has been taken to ensure the accuracy and completeness of this
document, Vertiv Group Corporation assumes no responsibility and
disclaims all liability for damages resulting from use of this information or
for any errors or omissions. Refer to other local practices or building codes
as applicable for the correct methods, tools, and materials to be used in
performing procedures not specifically described in this document.
This document may contain confidential and/or proprietary information of
Vertiv Group Corporation, 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 Corporation is strictly prohibited.
Vertiv and the Vertiv logo are trademarks or registered trademarks of
Vertiv Co. All other names and logos referred to are trade names,
trademarks or registered trademarks of their respective owners.
© 2018 Vertiv Co. All rights reserved.

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TABLE OF CONTENTS
Admonishments Used in this Document............................................................5
Important Safety Instructions ..............................................................................6
Safety Admonishments Definitions..................................................................................................... 6
General Safety .......................................................................................................................................................... 6
Voltages..........................................................................................................................................................................6
AC Input Voltages........................................................................................................................................................6
DC Input Voltages........................................................................................................................................................6
DC Output and Battery Voltages .................................................................................................................. 7
Battery ...............................................................................................................................................................................7
Personal Protective Equipment (PPE)............................................................................................. 8
Hazardous Voltage.............................................................................................................................................. 8
Handling Equipment Containing Static Sensitive Components.............................9
Maintenance and Replacement Procedures..............................................................................9
Static Warning.........................................................................................................10
Customer Documentation Package....................................................................11
System Description................................................................................................ 12
Operating Procedures...........................................................................................14
Rectifiers, Solar Converters, -48 VDC to +24 VDC Converters, and
Controller.....................................................................................................................................................................14
Solar Mode .................................................................................................................................................................14
ESTOP Function...................................................................................................................................................14
Controller Battery Charge Current Limit Feature ...............................................................15
Local Controls and Indicators.................................................................................................................15
List 60 Hybrid Connection Cabinet.................................................................................................. 17
Maintenance ............................................................................................................19
System Maintenance Procedures.......................................................................................................19
Adding a Module to an Existing Module Mounting Assembly...............................19
Installing a Field Expansion Module Mounting Assembly ......................................... 25
Installing Field Expansion Module Mounting Assembly Spacer Kit,
P/N 560075..............................................................................................................................................................29
Reconfiguring a Dual Voltage Distribution Panel (List DA, DB, DC,
DD, DE) ..........................................................................................................................................................................31
Reconfiguring the Distribution Voltage on Positions 23 to 26 of a
List DF Distribution Panel installed in a List 27 Distribution Cabinet............39
Troubleshooting and Repair............................................................................... 44
Contact Information.........................................................................................................................................44
Controller, Rectifiers, Solar Converters, and -48 VDC to +24 VDC
Converters.................................................................................................................................................................44
Controller Configuration..............................................................................................................................44
System Troubleshooting Information ............................................................................................44
Replacement Information...........................................................................................................................46
Replacement Procedures...........................................................................................................................46

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Replacing a Rectifier, Solar Converter, or -48 VDC to +24 VDC
Converter Module .................................................................................................................................................... 46
Replacing the NCU Controller...................................................................................................................... 46
Replacing a Distribution Device................................................................................................................. 46
Circuit Card Replacement Procedures................................................................................................ 50
Replacing a Distribution Panel in a List 20, 25 Distribution Cabinet...................... 65
Replacing a Distribution Panel in a List 21, 26 Distribution Cabinet....................... 68
Replacing a Battery or Load Disconnect Contactor in a List 20, 25
Distribution Cabinet.................................................................................................................................................71
Replacing a Battery or Load Disconnect Contactor in a List 21, 26
Distribution Cabinet................................................................................................................................................74

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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 o
nly 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, o
r 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 5.
General Safety
DANGER! YOU MUST FOLLOW APPROVED SAFETY PROCEDURES.
Performing the following procedures may expose you to hazards. These procedures should be
performed by qualified technicians familiar with the hazards associated with this type of equipment.
These hazards may include shock, energy, and/or burns. To avoid these hazards:
a) The tasks should be performed in the order indicated.
b) Remove watches, rings, and other metal objects.
c) Prior to contacting any uninsulated surface or termination, use a voltmeter to verify that no voltage
or the expected voltage is present. Check for voltage with both AC and DC voltmeters prior to
making contact.
d) Wear eye protection.
e) Use certified and well maintained insulated tools. Use double insulated tools appropriately rated for
the work to be performed.
f) For systems operating with 400 VDC power, do not work on an energized system without full arc
flash and PPE protection.
Voltages
AC Input Voltages
DANGER! This system operates from AC input voltage capable of producing fatal electrical shock. AC
input power must be completely disconnected from the branch circuits wiring used to provide power to
the system before any AC electrical connections are made. Follow local lockout/tagout procedures to
ensure upstream branch circuit breakers remain de-energized during installation. DO NOT apply AC
input power to the system until all electrical connections have been completed and checked.
DC Input Voltages
DANGER! This system may operate from 400 VDC input voltage capable of producing fatal electrical
shock. DC input power must be completely disconnected from the branch circuits wiring used to
provide power to the system before any DC electrical connections are made. Follow local lockout/tagout
procedures to ensure upstream branch circuit breakers remain de-energized during installation. DO
NOT apply DC input power to the system until all electrical connections have been completed and
checked.

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DC Output and Battery Voltages
DANGER! This system produces DC power and may have a battery source connected to it. Although
the DC voltage is not hazardously high, the rectifiers and/or battery can deliver large amounts of current.
Exercise extreme caution not to inadvertently contact or have any tool inadvertently contact an output
terminal or battery terminal or exposed wire connected to an output terminal or battery terminal.
NEVER allow a metal object, such as a tool, to contact more than one termination or battery terminal at a
time, or to simultaneously contact a termination or battery terminal and a grounded object. Even a
momentary short circuit can cause sparking, explosion, and injury.
DANGER! Follow local lockout/tagout procedures to ensure DC branch circuit protection devices
remain de-energized during installation at loads, as required.
Battery
Refer to the battery manufacturer documentation for specific battery safety instructions. The following are
general guidelines.
WARNING! Correct polarity must be observed when connecting battery leads.
WARNING! Special safety precautions are required for procedures involving handling, installing, and
servicing batteries. Observe all battery safety precautions in this manual and in the battery instruction
manual. These precautions should be followed implicitly at all times.
WARNING! A battery can present a risk of electrical shock and high short circuit current. Servicing of
batteries should be performed or supervised only by properly trained and qualified personnel
knowledgeable about batteries and the required precautions.
The following precautions should be observed when working on batteries:
•Remove watches, rings, and other metal objects.
•Eye protection should be worn to prevent injury from accidental electrical arcs.
•Use certified and well maintained insulated tools. Use double insulated tools appropriately rated
for the work to be performed. Ensure that wrenches with more than one working end have only
one end exposed.
•Do not lay tools or metal parts on top of batteries.
•Disconnect charging source prior to connecting or disconnecting battery terminals.
•Risk of explosion if battery is replaced with an incorrect type or if polarity is reversed.
Recommended to replace batteries with the same manufacturer and type, or equivalent.
•Dispose of used batteries according to the instructions provided with the batteries. Do not
dispose of batteries in a fire. They may explode.
•ALWAYS FOLLOW THE BATTERY MANUFACTURER’S RECOMMENDATIONS AND SAFETY
INSTRUCTIONS.

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DANGER! This equipment may be used in conjunction with lead-acid batteries. Working near lead-acid
batteries is dangerous!
In addition to the hazard of electric shock, gas produced by batteries can be explosive and sulfuric acid
can cause severe burns.
•Do not open or mutilate batteries. Released electrolyte is harmful to the skin and eyes, and is toxic.
•Batteries contain sulfuric acid.
•Batteries generate explosive gases during normal operation. Systems containing batteries should
never be installed in an airtight room or space. Only install in a ventilated environment.
•Batteries are an energy source that can produce high amounts of electrical current.
FOR THESE REASONS, IT IS OF CRITICAL IMPORTANCE THAT YOU READ THESE INSTRUCTIONS
AND FOLLOW THEM EXACTLY.
WHEN WORKING WITH LEAD-ACID BATTERIES:
•Follow the recommended PPE requirements per the SDS for the battery to be used.
•If battery acid enters your eye, immediately flush your eye with running cold water for at least 15
minutes. Get medical attention immediately.
•If battery acid contacts skin or clothing, wash immediately with soap and water.
ALERT! Performing maintenance and/or troubleshooting procedures may interrupt power to the loads,
if battery reserve is not sufficient.
Personal Protective Equipment (PPE)
DANGER! ARC FLASH AND SHOCK HAZARD.
Appropriate PPE and tools required when working on this equipment. An appropriate flash protection
boundary analysis should be done determine the “hazard/risk” category, and to select proper PPE.
This product is intended only for installation in a Restricted Access Location.
Only authorized and properly trained personnel should be allowed to install, inspect, operate, or maintain
the equipment.
Do not work on LIVE parts. If required to work or operate live parts, obtain appropriate Energized Work
Permits as required by the local authority, per NFPA 70E “Standard for Electrical Safety in the
Workplace”.
Hazardous Voltage
DANGER! HAZARD OF ELECTRICAL SHOCK.
More than one disconnect may be required to de-energize the system before servicing.

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Handling Equipment Containing
Static Sensitive Components
ALERT! Installation or removal of equipment containing static sensitive components requires careful
handling. Before handling any equipment containing static sensitive components, read and follow the
instructions contained on the Static Warning Page.
Maintenance and Replacement Procedures
CAUTION! When performing any step in procedures that requires removal or installation of hardware,
use caution to ensure no hardware is dropped and left inside the unit; otherwise service interruption or
equipment damage may occur.
NOTE! When performing any step in procedures that requires removal of existing hardware, retain all
hardware for use in subsequent steps, unless otherwise directed.

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STATIC WARNING
This equipment contains static sensitive components. The warnings listed below must be observed to
prevent damage to these components. Disregarding any of these warnings may result in personal injury
or damage to the equipment.
1. Strictly adhere to the procedures provided in this document.
2. Before touching any equipment containing static sensitive components, discharge all static
electricity from yourself by wearing a wrist strap grounded through a one megohm resistor. Some
wrist straps, such as Part Number 631810600, have a built-in one megohm resistor; no external
resistor is necessary. Read and follow wrist strap manufacturer’s instructions outlining use of a
specific wrist strap.
3. Do not touch traces or components on equipment containing static sensitive components.
Handle equipment containing static sensitive components only by the edges that do not have
connector pads.
4. After removing equipment containing static sensitive components, place the equipment only on
conductive or anti-static material such as conductive foam, conductive plastic, or aluminum foil. Do
not use ordinary Styrofoam™or ordinary plastic.
5. Store and ship equipment containing static sensitive components only in static shielding containers.
6. If necessary to repair equipment containing static sensitive components, wear an appropriately
grounded wrist strap, work on a conductive surface, use a grounded soldering iron, and use
grounded test equipment.

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CUSTOMER DOCUMENTATION PACKAGE
This document (UM582137100) provides User Instructions for -48 VDC Power System Model NetSure™ 5100,
Spec. No. 582137100.
The complete Customer Documentation Package consists of…
NetSure™-48 VDC Power System Installation Manual
•Power System Installation Instructions: IM582137100
NetSure™NCU Controller User Manual
•NCU Controller User Instructions: UM1M830BNA
USB Drive with All Customer Documentation
•Power System Installation Instructions: IM582137100
•Power System User Instructions: UM582137100
•Power System “System Application Guide”: SAG582137100
•Module Mounting Assembly Power Data Sheet: PD588705300
•NCU Controller User Instructions: UM1M830BNA
•Rectifier Instructions: UM1R482000E3
•Solar Converter Instructions: UM1S482000E3
•-48 VDC to +24 VDC Converter Instructions: UM1C48241500
•Engineering Drawings
•Also provided on the USB drive is a controller configuration drawing and the controller configuration
files loaded into the controller as shipped.

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SYSTEM DESCRIPTION
The Power Distribution Center…
•List 20, 25 (One Row Distribution Cabinet) is rated…
-48 VDC; 400 A at 40 °C.
-48 VDC; 300 A at 65 °C.
•List 27 (One Row Distribution Cabinet) is rated…
Charge Ratings:
-48 VDC; 600 A and +24 VDC; 63 A at 40 °C.
-48 VDC; 525 A and +24 VDC; 50 A at 65 °C.
Discharge Ratings:
-48 VDC; 771 A at 40 °C.
-48 VDC; 600 A at 65 °C.
•List 21 (Two Row Distribution Cabinet) is rated…
-48 VDC; 600 A (400 A maximum per row) at 40 °C.
-48 VDC; 400 A (300 A maximum per row) at 65 °C.
•List 26 (Two Row Distribution Cabinet) is rated…
-48 VDC; 600 A (400 A maximum per row) and +24 VDC; 400 A at 40 °C.
-48 VDC; 400 A (300 A maximum per row) and +24 VDC; 300 A at 65°C.
The NetSure™ 5100 DC Power System is an integrated power system containing rectifiers (-48 VDC output),
optional solar converters (-48 VDC output), optional converters (+24 VDC output), intelligent control, metering,
monitoring, and distribution. This power system is available in configurations for 19” and 23” rack mounting.
This power system is designed to power a load while charging a positive grounded battery. This power system
is capable of operating in a batteryless installation or off battery for maintenance purposes. The power system
is designed for operation with the positive output grounded.
This system consists of the following components.
Distribution Cabinet
The system always includes a distribution cabinet, which provides DC distribution through fuses and/or circuit
breakers. The distribution cabinet is factory mounted in the relay rack specified when ordered. Different sizes
of distribution cabinets are available to accept from one (1) to two (2) distribution panels. A variety of
distribution panels are available that provide load distribution, battery distribution, and dual voltage load
distribution for use with -48 VDC to +24 VDC converters. These distribution panels are configured to accept
bullet nose type circuit breakers and TPS/TLS fuseholders. The distribution cabinet may be equipped with low
voltage load disconnect (LVLD) and/or low voltage battery disconnect (LVBD) (depending on available
configuration options).
Controller
NCU (NetSure Control Unit) Controller: The NCU controller provides power system control (including optional
low voltage battery disconnect (LVBD) and low voltage load disconnect (LVLD) control), rectifier control
(including a charge control function), solar converter control, -48 VDC to +24 VDC converter control, metering
functions, monitoring functions, and local/remote alarm functions. The controller also supports rectifier
temperature compensation if the system is equipped with a temperature probe(s). Temperature probe(s) may
also be designated to monitor ambient temperature and/or battery temperature. The controller also provides
data acquisition, system alarm management, and advanced battery and energy management. The controller

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contains a color TFT display and keypad for local access. The controller provides an Ethernet port and comes
with comprehensive webpages for remote access. The controller has SNMP V3 capability for remote system
management. The controller supports software upgrade via its USB port. Refer to the NCU Controller
Instructions (UM1M830BNA) for more information.
Module Mounting Assembly
The system contains one (1) to five (5) module mounting assemblies (depending on system configuration, see
SAG582137100), which may house rectifier modules, optional solar converter modules, optional -48 VDC to +24
VDC converter modules, and a controller (depending on configuration, see PD588705300). Refer to
PD588705300 for additional information.
Rectifier Modules
The system contains rectifier modules, which provide load power, battery float current, and battery recharge
current during normal operating conditions. Refer to the Rectifier Instructions (UM1R482000E3) for more
information.
Optional Solar Converter Modules
The system may contain solar converter modules (depending on configuration, see SAG582137100), which
provide load power, battery float current, and battery recharge current during solar conditions. Refer to the
Solar Converter Instructions (UM1S482000E3) for more information.
Optional -48 VDC to +24 VDC Converter Modules
Where +24 VDC load power is also required, converter modules are available (depending on configuration, see
SAG582137100). These converters operate from the main -48 VDC system bus to provide +24 VDC load power.
Refer to the Converter Instructions (UM1C48241500) for more information.

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OPERATING PROCEDURES
Rectifiers, Solar Converters, -48 VDC to +24 VDC Converters, and Controller
For operation instructions on these units, refer to the following documents.
•Rectifier Instructions (UM1R482000E3)
•Solar Converter Instructions (UM1S482000E3)
•-48 VDC to +24 VDC Converter Instructions (UM1C48241500)
•NCU Controller Instructions (UM1M830BNA)
NOTE! The controller’s default “User Name” is "admin" and the default “Password” is “640275”.
Solar Mode
Description
You have the option to set the system for solar mode (RECT-SOLAR or SOLAR) or to disable solar mode.
RECT-SOLAR: If you have both rectifiers and solar converters in the system, set Solar Mode to “RECT-SOLAR”.
Also set the “Float Charge Voltage (Solar)” parameter to the desired float setting. The parameter “Float Charge
Voltage (Rect)” setting
MUST
be set 0.5 V lower than the “Float Charge Voltage (Solar)” parameter setting for
solar converters to operate properly.
SOLAR: If you have only solar converters in the system, set Solar Mode to “SOLAR”. Also set the “Float Charge
Voltage (Solar)” parameter to the desired float setting.
Enabling Solar Mode
Local Menu Navigation:
None.
Web Menu Navigation:
Settings / System Tab / Solar Mode / set to “SOLAR” or “RECT-SOLAR” or “Disabled”.
NOTE! When solar converters are all installed prior to applying power and starting system, the NCU will
NOT communicate with solar converters until SOLAR MODE is enabled.
ESTOP Function
If an ESTOP switch is wired to the IB2 Controller Interface Board, customer-furnished system ground applied to
terminal Digital Input #8 (+) activates the ESTOP function. The ESTOP function shuts down and locks out the
rectifiers and solar converters, opens the LVD’s, and shuts down the -48 VDC to +24 VDC converters. When
the ESTOP signal is removed, LVD’s close (if battery present) and -48 VDC to +24 VDC converters restart. To
restart the rectifiers and solar converters; turn input power to the rectifiers and solar converters OFF, wait 30
seconds or more (until the LEDs on the modules extinguish), then turn input power to the rectifiers and solar
converters ON.

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Controller Battery Charge Current Limit Feature
Functionality: After a failure of the input source (commercial AC or DC) or when some battery cells are
permanently damaged, the current to the batteries can be quite extensive. To avoid overheating or further
damages to the battery, the controller can be programmed to limit the battery current to a preset level by
limiting the charging voltage of the rectifiers and solar converters. Should the battery current still exceed a
higher preset value, an alarm is issued.
The controller limits the current going to the batteries based on the “Battery Current Limit” set point which is a
percentage of the battery capacity in C10. For example, 0.1C10 would mean 10% of the battery capacity. If the
C10 capacity of a battery is 100 amp-hr, the battery recharge current limiting setpoint is 0.1C10; therefore, the
recharge current is limited to 10 A.
Refer to the NCU Controller Instructions (UM1M830BNA) to program this feature. Battery charge current is
limited to the value set in the controller, as long as battery voltage is above 47 VDC.
Local Controls and Indicators
General
Refer to the Controller, Rectifier, Solar Converter, and -48 VDC to +24 VDC Converter Instructions for
descriptions of the local controls and indicators located on these units.
Optional Critical Alarm Indicator
The system may be equipped with an optional critical alarm indicator which illuminates if the NCU controller
issues a critical alarm. Refer to Figure 1.
List KG GMT Load Distribution Fuse Panel
Refer to Figure 2for indicator locations.
PWR A and PWR B Indicators: These indicators illuminate (green) to indicate power is supplied to the A and
B sides of the panel, respectively.
NOTE! The split (A/B) input bus option provided on this panel is strapped for a single input in this
power system.
FUSE ALARM Indicator: This indicator illuminates (red) to indicate a load distribution fuse is open. The open
fuse also provides a mechanical indicator visible through the fuse safety cover.
Optional Transient Voltage Surge Suppressor (TVSS) Device
An optional Transient Voltage Surge Suppressor (TVSS) device contains an indicator which illuminates when
the circuit activates to suppress voltages. See Figure 3.

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Figure 1: Optional Critical Alarm Indicator
Figure 2: Indicator Locations (List KG)
Figure 3: Optional Transient Voltage Surge Suppressor (TVSS) Device Indicator
Optional
Critical Alarm
Indicator
Front
(1-row cabinet shown, 2-row cabinet similar)
Front
PWR
A
PWR
B
FUSE
ALARM
TVSS Indicator

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List 60 Hybrid Connection Cabinet
The hybrid connection cabinet provides four (4) circuit breaker positions up to 600 A and one (1) circuit
breaker position up to 400 A for -48 VDC distribution to battery and alternate energy sources.
The hybrid connection cabinet includes an SM-DU for monitoring of the circuit breakers internal
shunts.
Hybrid Connection Cabinet Circuit Breaker Shunt Ratings
See Table 1.
Table 1: Hybrid Connection Cabinet Circuit Breaker Shunt Ratings
Circuit Breaker Size Shunt Current Rating Shunt Voltage Rating
100 A
100 A
25 mV
125 A
125 A
25 mV
150 A
150 A
25 mV
175 A
175 A
25 mV
200 A
200 A
25 mV
225 A
225 A
25 mV
250 A
250 A
25 mV
300 A
300 A
25 mV
350 A
350 A
25 mV
400 A 400 A 25 mV
600 A
600 A
25 mV
SM-DU Parameter Settings
•Shunt # Set As (Not Used, General, Load, Battery)
a) Not Used: Indicates this shunt input is not used.
b) General: Indicates the measurement of the shunt will be displayed and will not be added to Total
DC Load or Total Battery Load.
c) Load: Indicates the measurement of the shunt will be displayed and added to the Total DC Load.
d) Battery: Indicates the measurement of the shunt will be displayed and added to the Total Battery
Load and used with Battery Management.
•Shunt # Current (Rating of Shunt.)
•Shunt # Voltage (Rating of Shunt.)
•Current # Break Value (Device Rating.)
•Current # High Current Limit (% of Current # Breaker Value.)
•Current # Very High Current Limit (% of Current # Breaker Value.)

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SM-DU Circuit Card Indicators
The SM-DU is used in a List 60 Hybrid Connection Cabinet. The SM-DU monitors the internal shunts in the
cabinet.
There are three (3) status and alarm indicators located on the SM-DU. The functions of these indicators are as
shown in Table 2. Refer to Figure 4for location.
Table 2: SM-DU Indicators
Indicator Normal State Fault State Fault Cause
Operation
(Green) On
Off SM-DU is non-operational.
Flashing
A 1/3Hz flashing indicates the
SM-DU is being identified by
the Controller.
A 1Hz flashing indicates a
communication failure.
Alarm
(Yellow) Off On A minor alarm.
Alarm
(Red) Off On A critical or major alarm.
Figure 4: SM-DU Circuit Card in a List 60 Hybrid Connection Cabinet

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MAINTENANCE
System Maintenance Procedures
It is recommended to perform the maintenance procedures listed in Table 3every 6-months to ensure
continual system operation.
Table 3: Maintenance Procedures to be Performed at 6-Month Intervals
Procedure Referenced In
Check ventilation openings
for obstructions such as dust,
papers, manuals, etc.
--
Inspect and tighten all
installer's connections. IM582137100
Adding a Module to an Existing Module Mounting Assembly
To increase system current capacity, a rectifier or solar converter module can easily be added to an existing
module mounting assembly that contains an empty rectifier module or solar converter module mounting
position. Likewise, to increase subsystem capacity, a -48 VDC to +24 VDC converter module can be added to a
module mounting assembly that contains an empty -48 VDC to +24 VDC converter module mounting position.
Rectifier, solar converter, and -48 VDC to +24 VDC converter modules can be inserted or removed with power
applied (hot swappable).
Procedure
NOTE! Each module locks into the module mounting assembly by means of a latch located on the
bottom of the module. The latch and module handle are interactive. Pushing the handle up into the
module’s front panel causes the latch to extend to the locking position; pulling the handle down out from
the module’s front panel causes the latch to retract. See
Figure 5 , Figure 6 , or Figure 7 .
WARNING! To prevent damage to the latching mechanism, ensure the handle is in the open position
when installing or removing a module. NEVER hold the handle in the closed position when installing a
module into a module mounting assembly.
1. Unpack the modules.
2. Note the model number located on the front of each module. Model numbers starting with the letter “R”
are rectifier modules. Model numbers starting with the letter “C” are converter modules. Model numbers
starting with the letter “S” are solar converter modules.
3. Place the module into an unoccupied mounting position without sliding it in completely. Each module
mounting assembly may house rectifier modules, optional solar converter modules, optional -48 VDC to
+24 VDC converter modules, and a controller (depending on configuration).

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NOTE! Refer to the module position identification label located either on the inside of the distribution
cabinet door (rack mounted systems) or inside the OSP cabinet when no door is furnished for
acceptable rectifier, solar converter, and -48 VDC to +24 VDC converter module mounting positions in
the specific module mounting assembly(s) contained in your system. See Figure 8 .
NOTE! See PD588705300 for additional acceptable module position details.
4. Loosen the captive screw on the module’s handle. Pull the handle down out from the module’s front
panel (this will also retract the latch mechanism). See Figure 5, Figure 6, or Figure 7.
5. Push the module completely into the module mounting assembly.
6. Push the handle up into the module’s front panel. This will lock the module securely to the module
mounting assembly. Tighten the captive screw on the handle.
7. Repeat the above steps for each module being installed in the system.
8. After the modules are physically installed in the mounting module mounting assembly(s), they are ready
for operation immediately after power is supplied to them.
NOTE! It is recommended that the current limit point be checked whenever a rectifier or -48 VDC to
+24 VDC converter is added to or removed from the power system. Refer to “Checking the Controller’s
Current Limit Point after Adding or Removing a Rectifier or -48 VDC to +24 VDC Converter Module” on
page 44.
NOTE! The rectifier, solar converter, or -48 VDC to +24 VDC converter module being replaced is
assigned by the NCU the lowest available identification number. If desired, you can change the
identification number, see “Configuring the NCU Identification of Rectifiers”, “Configuring the NCU
Identification of Solar Converters”, or “Configuring the NCU Identification of -48 VDC to +24 VDC
Converters” in the separate Power System Installation Manual (IM582137100).