Vertiv NetSure 5100 Series User manual

NetSure™ 5100 Series
-48 VDC Power System
User Manual
Specification Number: 582137100
Model Number: 5100

Vertiv™ NetSure™ 5100 Series -48 VDC Power System User Manual
Vertiv™ NetSure™ 5100 Series -48 VDC Power System 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
Safety Admonishments Definitions.........................................................................................................................................................................................................................vi
Safety and Regulatory Statements..........................................................................................................................................................................................................................vi
Déclarations de Sécurité et de Réglementation..........................................................................................................................................................................................vi
1Customer Documentation Package.............................................................................................................................. 1
2System Description .......................................................................................................................................................... 2
3Operating Procedures ..................................................................................................................................................... 4
3.1 Rectifiers, Solar Converters, -48 VDC to +24 VDC Converters, -48 VDC to -58 VDC Converters, Inverters and
Controller..............................................................................................................................................................................................................................................................................4
3.2 Solar Mode ..........................................................................................................................................................................................................................................................................4
3.3 ESTOP Function.............................................................................................................................................................................................................................................................5
3.4 EPO (Emergency Power Off) Function (If Equipped with Optional Inverter System)..................................................................................5
3.5 Controller Battery Charge Current Limit Feature...........................................................................................................................................................................6
3.6 Local Controls and Indicators ...........................................................................................................................................................................................................................6
3.7 List 60 Hybrid Connection Cabinet..........................................................................................................................................................................................................10
4Maintenance ......................................................................................................................................................................12
4.1 System Maintenance Procedures................................................................................................................................................................................................................12
4.2 Adding a Module to an Existing Module Mounting Assembly..........................................................................................................................................12
4.3 Installing a Field Expansion Module Mounting Assembly.....................................................................................................................................................17
4.4 Installing Field Expansion Module Mounting Assembly Spacer Kit, P/N 560075 .........................................................................................22
4.5 Adding an Inverter Module to an Existing Inverter Module Mounting Assembly ........................................................................................ 24
4.6 Reconfiguring a Dual Voltage Distribution Panel (List DA, DB, DC, DD, DE, FA, FB, FC, FD, FE)....................................................26
4.7 Reconfiguring the Distribution Voltage on Positions 23 to 26 of a List DF Distribution Panel installed in a List
27 Distribution Cabinet.........................................................................................................................................................................................................................................32
4.8 Installing a Front Door Kit ..................................................................................................................................................................................................................................37
5Troubleshooting and Repair ........................................................................................................................................ 39
5.1 Contact Information................................................................................................................................................................................................................................................39
5.2 Controller, Rectifiers, Solar Converters, Optional -48 VDC to +24 VDC Converters, Optional -48 VDC to -58
VDC Converters and Optional Inverters..............................................................................................................................................................................................39
5.3 Controller Configuration.....................................................................................................................................................................................................................................39
5.4 System Troubleshooting Information....................................................................................................................................................................................................39
5.5 Replacement Information...................................................................................................................................................................................................................................41
5.6 Replacement Procedures...................................................................................................................................................................................................................................41
5.6.1 Replacing a Rectifier, Solar Converter, Optional -48 VDC to +24 VDC Converter, or Optional -48 VDC
to -58 VDC Converter and Inverter....................................................................................................................................................................................41
5.6.2 Replacing the NCU Controller.................................................................................................................................................................................................41
5.6.3 Replacing a Distribution Device.............................................................................................................................................................................................41
5.6.4 Circuit Card Replacement Procedures...........................................................................................................................................................................45
5.6.5 Replacing a Distribution Panel in a List 20, 25 Distribution Cabinet.................................................................................................. 58
5.6.6 Replacing a Distribution Panel in a List 21, 26 Distribution Cabinet....................................................................................................61
5.6.7 Replacing a Battery or Load Disconnect Contactor in a List 20, 25 Distribution Cabinet.............................................64
5.6.8 Replacing a Battery or Load Disconnect Contactor in a List 21, 26 Distribution Cabinet...............................................67

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5.6.9 Replacing an SPD (Surge Protection Device) (if furnished)......................................................................................................................69

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v
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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vi
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.

Vertiv™ NetSure™ 5100 Series -48 VDC Power System User Manual
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1Customer Documentation Package
This document (UM582137100) provides User Instructions for -48 VDC Power System Model Vertiv™ NetSure™ 5100,
Spec. No. 582137100.
The complete Customer Documentation Package consists of…
-48 VDC Power System Installation Manual
•Power System Installation Instructions: IM582137100
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
•-48 VDC to -58 VDC Converter Instructions: UM1C48582000P3
•Inverter Instructions: UM1I1201000
•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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2System 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 or -58 VDC (max.); 340 A (max.) at 40 °C.
-48 VDC; 400 A (300 A maximum per row) and +24 VDC; 300 A or -58 VDC (max.); 270 A (max.) at 65°C.
The Vertiv™ 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), optional converters (-58 VDC output), optional inverter system
(120 VAC 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.
DC 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 and -48 VDC to -58 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, -48 VDC to -58 VDC converter control, -48 VDC to 120 VAC inverter
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 contains a color TFT display and keypad for local access. The controller
provides an Ethernet port and comes with comprehensive webpages for remote access.

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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, optional -48 VDC to
-58 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.
Optional -48 VDC to -58 VDC Converter Modules
Where -58 VDC load power is also required, converter modules are available. These converters operate from the main -48 VDC
system bus to provide -58 VDC load power. Refer to the Converter Instructions (UM1C48582000P3) for more information.
Optional Inverter Module Mounting Assembly
120 VAC @ up to 12kVA Inverter System
The system contains one or more inverter module mounting shelves and AC distribution.
The inverter system can be set to operate in one of the three input power modes, AC Input Power Mode, DC Input Power Mode, and
DC Only Input Power Mode.
•In the AC Input Power Mode, each inverter module operates with the commercial AC input to supply 120 VAC power to the
loads. In the event commercial AC power fails or becomes abnormal, the inverter modules immediately transfer operation
with the 48 VDC input to power to the inverters.
•In the DC Input Power Mode, each inverter module operates with the 48 VDC input to supply 120 VAC power to the loads. In
the event DC power fails or becomes abnormal or an inverter module fails, the inverter module immediately transfers
operation with the commercial 120 VAC input to power to the inverters.
•In the DC Only Input Power Mode, each inverter module operates with the 48 VDC input to supply 120 VAC power to the
loads. In the event DC power fails or becomes abnormal or an inverter module fails, the inverter module shuts off.
This inverter system consists of the following components. Note that the inverter systems are pre-configured and do not have
expansion shelves. The ratings are not only determined by the maximum number of inverters the system can be provided with, but
also the rating of the AC distribution panel. The overall system rating cannot exceed the AC distribution panel rating.
•Inverter Module Mounting Shelf(s)
The inverter system consists of one or more inverter module mounting shelves, depending on power rating. The inverter
module mounting shelves house the inverter modules.

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•Inverter Modules
The inverter system contains inverter modules, supplying 120 VAC power from a commercial AC power source or from a 48
VDC input. Refer to the Inverter Instructions (UM1I1201000) for more information.
•AC Load Distribution Shelf
The inverter system consists of one or more AC load distribution shelves, depending on power rating. A choice of a bulk
output AC load distribution shelf or a NEMA receptacle output AC load distribution shelf is provided.
3Operating Procedures
3.1 Rectifiers, Solar Converters, -48 VDC to +24 VDC Converters, -48 VDC to
-58 VDC Converters, Inverters 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)
•-48 VDC to -58 VDC Converter Instructions (UM1C48582000P3)
•Inverter Instructions (UM1I1201000)
•NCU Controller Instructions (UM1M830BNA)
NOTE! The controller’s default “User Name” is "admin" and the default “Password” is “640275”.
3.2 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.

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3.3 ESTOP Function
If an ESTOP switch is wired to the IB2-1 Controller Interface Board, customer-furnished system ground applied to terminal DI8+
activates the ESTOP function. The ESTOP function shuts down and locks out the rectifiers and solar converters, shuts down and
locks out the optional -48 VDC to +24 VDC converters or optional -48 VDC to -58 VDC converters, shuts down and locks out the
inverters (if equipped with optional inverter system), and opens the optional low voltage disconnect (LVD) contactors (battery and
load type). If the system has battery connected and does not contain a battery LVD or the controller power option is set to Battery
Pwr (jumper J4 on the system interface board is set to Battery Pwr), the controller will remain operational. If the system does not
contain battery or load LVD(s) and has battery connected, the loads will be sustained by the battery voltage.
For Systems NOT Containing a Battery LVD: When the ESTOP signal is removed, LVD contactors (load type) will close after the “LVD
Reconnect Delay” has elapsed (customer configurable via the controller) if battery voltage is present on the bus. Rectifiers, solar
converters, optional -48 VDC to +24 VDC converters or optional -48 VDC to -58 VDC converters, and inverters (if equipped with
optional inverter system) will remain off. The rectifiers, solar converters, and inverters (if equipped with optional inverter system) will
restart when the input power to these is removed and restored after 30 seconds or more (until the LEDs on the modules extinguish).
To restart the -48 VDC to +24 VDC converters or -48 VDC to -58 VDC converters: remove the converter, wait 30 seconds or more
(until the LEDs on the converter extinguish), then re-insert the converter.
For Systems Containing a Battery LVD: When the ESTOP signal is removed, LVD contactors (battery and load type) will remain open.
Rectifiers, solar converters, optional -48 VDC to +24 VDC converters or optional -48 VDC to -58 VDC converters, and inverters (if
equipped with optional inverter system) will remain off. The rectifiers and solar converters will restart when the input power to these
is removed and restored after 30 seconds or more (until the LEDs on the modules extinguish). When the rectifiers restart, LVD
contactors (battery and load type) will close after the “LVD Reconnect Delay” has elapsed (customer configurable via the controller)
and the -48 VDC to +24 VDC converters or -48 VDC to -58 VDC converters, and inverters (if equipped with optional inverter system)
will restart.
NOTE! If a customer-furnished method to disconnect the input power to the system is not provided, the rectifiers will stay
locked OFF until the input power is recycled. If the ESTOP signal is removed without recycling the input power, the rectifiers
will remain off and have a local alarm visible on the module. The ESTOP alarm from the controller will extinguish. The
controller will not issue an alarm for this condition.
3.4 EPO (Emergency Power Off) Function (If Equipped with Optional Inverter
System)
The inverter system contains an EPO (Emergency Power Off) function. Connection points for a normally closed external EPO switch
are provided on the customer interface board. If an external EPO switch is wired to the customer interface board, activating the switch
to open the circuit activates the EPO function. The EPO function shuts down and locks out the inverters. When the EPO switch is
returned to normal (closed loop), the inverters remain off. The inverters will restart when the AC and DC power inputs are removed
and restored after 30 seconds or more (until the LEDs on the modules extinguish) (depending on the synchronizing time with the
system). (Note that there is an EPO shorting link factory installed that can be replaced with a customer provided switch.)
NOTE! If a customer-furnished method to disconnect the AC and DC power inputs to the system is not provided, the
inverters will stay locked OFF until the input power is recycled. If the EPO switch is returned to normal (closed loop) without
recycling the input power, the inverters will remain off and have a local alarm visible on the module. The EPO alarm from the
controller will extinguish. The controller will not issue an alarm for this condition.
NOTE! This inverter system EPO feature is in addition to the ESTOP feature described above. If this EPO is not wired, the
inverter system will still respond to the ESTOP feature.

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3.5 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.
3.6 Local Controls and Indicators
General
Refer to the Controller, Rectifier, Solar Converter, -48 VDC to +24 VDC Converter, or -48 VDC to -58 VDC Converter, Inverter
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 3.1.
List KG GMT Load Distribution Fuse Panel
Refer to Figure 3.2 for 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 3.3.

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Figure 3.1 Optional Critical Alarm Indicator
Figure 3.2 Indicator Locations (List KG)
Figure 3.3 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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AC Load Distribution Disconnect Circuit Breakers (if equipped with Optional Inverter System)
The distribution shelf(s) contains front panel AC load distribution disconnect circuit breakers. For the NEMA output AC load
distribution shelf, there is a circuit breaker for each outlet. For the bulk output AC load distribution shelf, there is a circuit breaker for
each bulk output. See Figure 3.4.
Figure 3.4 AC Load Distribution Disconnect Circuit Breakers (cont’d on next page)
Front
Front
Front
Front
Bulk Output Load Disconnect
70 A Circuit Breaker
Bulk Output Load Disconnect
70 A Circuit Breaker
NEM
A5-15R Output Load Disconnect
15 A Circuit Breaker (each)
NEM
A5-15R Output Load Disconnect
15 A Circuit Breaker (each)
NEM
A5-15R Output Load Disconnect
15 A Circuit Breaker (each)
NEM
A5-15R Output Load Disconnect
15 A Circuit Breaker (each)
582137100 List 50
582137100 List 51
582137100 List 52
582137100 List 53

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Figure 3.4 AC Load Distribution Disconnect Circuit Breakers (cont’d from previous page)
Front
Front
Front
Front
Bulk Output Load Disconnect
70 A Circuit Breaker
Bulk Output Load Disconnect
70 A Circuit Breaker
Bulk Output Load Disconnect
70 A Circuit Breaker
NEMA5-15R Output Load Disconnect
15 A Circuit Breaker (each)
NEMA5-15R Output Load Disconnect
15 A Circuit Breaker (each)
582137100 List 54
582137100 List 55
582137100 List 56
582137100 List 57
Bulk Output Load Disconnect
70 A Circuit Breaker

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3.7 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 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 3.1.
Table 3.1 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 3.2.
Refer to Figure 3.5 for location.
Table 3.2 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 3.5 SM-DU Circuit Card in a List 60 Hybrid Connection Cabinet

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4Maintenance
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
Procedure Referenced In
Check ventilation openings for obstructions
such as dust, papers, manuals, etc. --
Inspect and tighten all installer's
connections. IM582137100
4.2 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. Also, a -48 VDC to -58 VDC DC-DC converter module can be added to a module
mounting shelf that contains an empty -48 VDC to -58 VDC converter module mounting position.
Rectifier, solar converter, optional -48 VDC to +24 VDC converter modules, and optional -48 VDC to -58 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 4.3,
Figure 4.4, or Figure 4.5.
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.
ALERT! The system can either have +24V DC-DC converters installed or -58V DC-DC converters installed. The system
cannot have both types of converters installed at the same time.
ALERT! The -48 VDC to +24 VDC converter modules must only be installed in a system position that accepts a +24V DC-DC
converter. Refer to labeling on the system’s module mounting shelf. A sample of this labeling is provided in Figure 4.1.
Figure 4.1 Sample Module Mounting Shelf Labeling

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ALERT! The -48 VDC to -58 VDC converter modules must only be installed in a system position that accepts a -58V DC-DC
converter. Refer to labeling on the system’s module mounting shelf. A sample of this labeling is provided in Figure 4.2.
Figure 4.2 Sample Module Mounting Shelf Labeling
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, optional
-48 VDC to -58 VDC converter modules, and a controller (depending on configuration).
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 or -48 VDC to -58 VDC converter module mounting positions in the specific module mounting
assembly(s) contained in your system. See Figure 4.6.
NOTE! See PD588705300 for additional acceptable module position details.
NOTE! For systems using an AC feed option where each feed connects to two (2) slots in the shelf (List 46 or Molex
connected cords) and -48 VDC to +24 VDC converters or -48 VDC to -58 VDC converters are being used (List 26 two row
distribution panel or List 27 single row distribution panel) in the plant, the following module restrictions apply for factory
installed shelves 2 through 5:
oRectifiers can be in any or all six (6) positions if three (3) AC inputs provided.
o+24V or -58V converters can be in the right three (3) positions (positions 4, 5 and 6).
oRectifiers can be in any position which has AC power that is not taken up with a converter.
oOne (1) Solar converter can be installed in the shelf, position 1 or 2.
oThree (3) solar converters can be installed in the shelf, positions 1 or 2, positions 3 or 4 and positions 5 or 6 if the -48V
to +24V or -48V to -58V bus bar is not installed to the shelf above.
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 4.3, Figure 4.4, or Figure 4.5.
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.

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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, -48 VDC to +24 VDC converter, or
-48 VDC to -58 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, -48 VDC to +24 VDC Converter Module, or -48 VDC to -58 VDC Converter
Module” on page 39.
NOTE! The rectifier, solar converter, -48 VDC to +24 VDC converter module, or -48 VDC to -58 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 or -48 VDC to -58 VDC Converters” in the separate
Power System Installation Manual (IM582137100).
Figure 4.3 Installing Rectifier and Solar Converter Modules (List 20, 25)
Rectifier or Converter Module
Model Number Label
(R48-2000e3 Rectifier)
(S48-2000e3 Solar Converter)
Captive Screw
Latch
Handle
Up to Four (4) Additional Module Mounting Shelves
588705300 List 41, 44, 45: Rectifier, Solar
Converter Mounting Positions
(See PD588705300)
19-inch, 1-Row
Distribution Cabinet
One (1) Module Mounting Shelf w/ Controller
588705300 List 31, 34, 35: Controller, Rectifier,
Solar Converter Mounting Positions
(See PD588705300)
Up to Four (4) Additional Module Mounting Shelves
588705300 List 21, 24, 25: Rectifier,
Solar Converter Mounting Positions
(See PD588705300)
One (1) Module Mounting Shelf w/ Controller
588705300 List 11, 14, 15: Controller, Rectifier,
Solar Converter Mounting Positions
(See PD588705300)
23-inch, 1-Row
Distribution Cabinet
Front
Front