Vertiv NetSure7100 Series User manual

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

Vertiv |NetSure 7100 Series Installation Manual (IM582127000100)|Rev. H
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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 accuracy and completeness herein, Vertiv Group
Corp. 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 Corp., and its receipt or possession does not convey any right
to reproduce, disclose its contents, or to manufacture or sell anything that
it may describe. Reproduction, disclosure, or use without specific
authorization from Vertiv Group Corp. is strictly prohibited.
Vertiv and the Vertiv logo are trademarks or registered trademarks of
Vertiv Group Corp. All other names and logos referred to are trade names,
trademarks or registered trademarks of their respective owners.
© 2019 Vertiv Group Corp. All rights reserved.

Vertiv |NetSure 7100 Series Installation Manual (IM582127000100)|Rev. H
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TABLE OF CONTENTS
Admonishments Used in this Document............................................................5
Important Safety Instructions ..............................................................................6
General Safety ..........................................................................................................................................................6
Voltages.......................................................................................................................................................................... 6
AC Input Voltages........................................................................................................................................................6
DC Output and Battery Voltages ..................................................................................................................6
Battery ...............................................................................................................................................................................7
Personal Protective Equipment (PPE)............................................................................................. 8
Hazardous Voltage.............................................................................................................................................. 8
Handling Equipment Containing Static Sensitive Components............................. 8
Maintenance and Replacement Procedures.............................................................................. 8
Static Warning...........................................................................................................9
Customer Documentation Package....................................................................11
Installation Acceptance Checklist..................................................................... 12
Installing the System............................................................................................. 13
General Requirements....................................................................................................................................13
Securing the Relay Rack to the Floor..............................................................................................14
Installing Battery Trays.................................................................................................................................. 15
Installing Optional Lug Adapter Busbar Kits, Part Nos. 534449 and
514714............................................................................................................................................................................. 22
Installing Circuit Breakers and Fuses.............................................................................................24
Setting Jumpers and Switch Options.............................................................. 28
Circuit Card Locations...................................................................................................................................28
Jumper on System Interface Board .................................................................................................29
Switch Setting on IB2 Controller Interface Board ..............................................................30
Switch Setting on Optional EIB Controller Extended Interface Board..........30
Making Electrical Connections...........................................................................32
Important Safety Instructions ................................................................................................................ 32
Wiring Considerations.................................................................................................................................... 32
Relay Rack Grounding Connection (Frame Ground) ..................................................... 33
Central Office Ground Connection ................................................................................................... 33
Nominal 208 VAC / 240 VAC Input and Equipment Grounding
Connections.............................................................................................................................................................34
External Alarm, Reference, Monitoring, and Control Connections ....................37
Circuit Card Locations.......................................................................................................................................... 37
Temperature Probes .............................................................................................................................................. 37
System Interface Board .......................................................................................................................................38
IB2 (Controller Interface Board) Connections (if required).............................................40
Optional EIB (Controller Extended Interface Board) Connections (if
required)............................................................................................................................................................................ 45
Connecting a Device or System to the NCU CAN Bus (if required)................51

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NCU Controller Ethernet Connection (if required) .......................................................... 52
Load Connections.............................................................................................................................................. 53
Recommended Torques.....................................................................................................................................53
Load Connections to Single Voltage Distribution Panels..................................................53
Load Connections to Dual Voltage Distribution Panels ......................................................53
Load Connections to GMT Distribution Fuse Block............................................................... 54
External Battery Connections................................................................................................................55
Important Safety Instructions........................................................................................................................55
Recommended Torques.....................................................................................................................................55
Battery Connections to Distribution Cabinet Battery Busbars .....................................55
Installing and Connecting Batteries in the Battery Trays (if
furnished) ...................................................................................................................................................................58
Special Application Rectifier Bus Landing Point Kit P/N 563686.......................61
Generator Input Breaker Kit (P/N 564219)...............................................................................62
Installing the Rectifier and Converter Modules............................................ 63
Initially Starting, Configuring, and Checking System Operation............. 65
Initial Startup Preparation..........................................................................................................................65
Initially Starting the System.....................................................................................................................65
NCU Controller Initialization....................................................................................................................65
Checking System Status.............................................................................................................................. 71
Final Steps ..................................................................................................................................................................72

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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 permitt
ed 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, OS
HA)

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IMPORTANT SAFETY INSTRUCTIONS
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.
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 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.

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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.
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.

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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.
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
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 (IM582127000100) provides Installation Instructions for NetSure™ -48 VDC Power System
Model 7100, Spec. No. 582127000, Lists 100, 101, 102, 103 and 203 only.
The complete Customer Documentation Package for Lists 100, 101, 102, 103, and 203 consists of…
NetSure™-48 VDC Power System Installation Manual
•Power System Installation Instructions: IM582127000100
NetSure™-48 VDC Power System User Manual
•Power System User Instructions: UM582127000100
NetSure™NCU Controller User Manual
•NCU Controller User Instructions: UM1M830BNA
USB Drive with All Customer Documentation for 582127000
Applicable documents for this system are as follows.
•Power System Installation Instructions: IM582127000100 (instructions for Lists 100, 101, 102, 103, and
203)
•Power System User Instructions: UM582127000100 (instructions for Lists 100, 101, 102, 103, and 203)
•NCU Controller User Instructions: UM1M830BNA
•Rectifier Instructions: UM1R482000e3
•Converter Instructions: UM1C48241500
•Power System “System Application Guide”: SAG582127000
•Engineering Drawings
•Also provided on the USB drive is a controller configuration drawing and the controller configuration
files loaded into the controller as shipped.

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INSTALLATION ACCEPTANCE CHECKLIST
Provided in this section 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 performed at the factory for you.
Installing the System
Relay Rack Secured to Floor
Optional Battery Tray Installed
Optional Battery Tray Battery Disconnect Circuit Breaker Installed
Optional Lug Adapter Busbar Kits Installed
Circuit Breakers Installed
Fuses Installed
Setting Jumper and Switch Options
Jumper on System Interface Board Set
Factory Switch Setting on IB2 Interface Board Verified
Factory Switch Setting on Optional EIB Interface Board Verified
Making Electrical Connections
Relay Rack Frame Ground Connection Made
Central Office Ground Connection Made
AC Input and AC Input Equipment Grounding Connections Made
External Alarm, Reference, Monitoring, and Control Connections Made
Ethernet Connection Made
Load Connections Made
Battery Connections Made
Batteries Installed and Connected in the Battery Trays (if furnished)
Installing the Modules
Rectifier and Converter Modules Installed
Initially Starting the System
System Started, Configured, and Checked

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INSTALLING THE SYSTEM
General Requirements
•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 Crafts persons 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 for connection to the common bonding network in a network
telecommunication facility (CO, vault, hut, or other environmentally controlled electronic equipment
enclosure).
•The DC return connection to this system can remain isolated from system frame and chassis (DC-I).
•This system is suitable for installation as part of the Common Bonding Network (CBN).
•The installer should be familiar with the installation requirements and techniques to be used in securing
the relay rack to the floor.
•Rectifier, converter, and mounting assembly ventilating openings must not be blocked and temperature
of air entering rectifiers and converters must not exceed rated operating ambient temperature range
found in SAG582127000.
•Clearance requirements are:
a) Recommended minimum aisle space clearance for the front of the bay is 2' 6".
b) Recommended minimum aisle space clearance for the rear of the bay to a wall or other solid surface
is that which is specified for proper module mounting assembly ventilation. Refer to System
Application Guide SAG582127000 for ventilation spacing requirements.
NOTE! Minimum spacing specified for ventilation may not permit replacement of certain components
such as busbars or module mounting assemblies.

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Securing the Relay Rack to the Floor
Secure the relay rack to the floor per site requirements. Refer to “General Requirements” on page 13.
Ventilation Requirements
Refer to the “General Requirements” on page 13.
Relay Rack Floor Mounting Dimensions
Refer to Figure 1for relay rack floor mounting dimensions.
Figure 1: Relay Rack Floor Mounting Dimensions
19.685
25.80
15.000
1.50
2.83
18.00
0.875
8 Places
Part Nos.
562353, 564127, 564169 12.340
22.310
3.06
1.74
Notes:
1. All dimensions are in inches.

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Installing Battery Trays
If battery trays are furnished with the system, battery trays are factory installed and wired. If battery trays are
installed in the field, customer must install and wire to the battery trays per the following procedures.
DANGER! The relay rack must be securely anchored to the floor before a battery tray is installed.
Installing Battery Trays
Procedure
1. To install battery trays, perform the procedure detailed in Figure 2.
Figure 2: Installing Battery Trays
Front
Rear
Rear
Rear
3. Secure rear angle brackets (both sides)
to relay rack with 12-24 x 1/2" thread
forming hex head screws (2 places per
side) and #10/12 ground washers
(1 place per bracket) or #12 flat washers
(1 place per bracket).
(Torque to 70 in-lbs).
4. Secure cabling brackets (both sides) to
relay rack with 12-24 x 1/2" thread forming
hex head screws. (Torque to 70 in-lbs).
2. Secure rear angle brackets (both sides)
to battery tray with 1/4-20 x 3/4” bolts,
1/4” flat washers, 1/4” lock washers, and
1/4” nuts. (4 places per bracket)
(Torque to 84 in-lbs).
1. Slide battery tray into relay rack and
secure to relay rack with 12-24 x 1/2"
thread forming hex head screws (4 places per
side) and #10/12 ground washers (1 place per
side) or #12 flat washers (3 places per
side). (Torque to 70 in-lbs).
P/N 562674
Battery Tray

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Installing Battery Disconnect Circuit Breakers onto Battery Trays
Procedure
1. To install battery, disconnect circuit breakers onto battery trays, perform the procedure detailed in
Figure 3.
Figure 3: Installing Battery Disconnect Circuit Breakers onto Battery Trays
Battery Disconnect
Circuit Breaker Assembly
(left side kit shown,
right side kit available)
1. Remove the cover from the battery
disconnect circuit breaker assembly.
2. Secure the battery disconnect circuit
breaker assembly to the battery tray
using 8-32 nuts (2-places) and #8 flat
washer (1-place) or #8 ground washer
(1-place).
3. After wiring to the battery disconnect
circuit breaker, replace the cover.

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Connecting Battery Tray Cables from the Battery Trays to the System Busbars
Procedure
1. Connect battery tray cables to the system’s -48V and return busbars. Battery tray cables are labeled +1,
-1, +2, -2, +3, and -3. Connect the negative cables to the system’s -48V busbar. Connect the positive
cables to the system’s return busbar. Refer to Figure 4. Refer also to the wiring diagram provided in
Figure 5.
2. Rout the cables into the battery trays. Route the cables labeled +1 and -1 into the bottom tray. Route
the cables labeled +2 and -2 into the middle tray. Route the cables labeled +3 and -3 into the top tray.
3. Connect the -1, -2, and -3 cables to the battery disconnect circuit breaker located on the respective
battery tray. Refer to Figure 7. Cables labeled +1, +2, and +3 are connected to the battery strings in a
later procedure.
Figure 4: Cables from Battery Trays to System Power Busbars
Components removed in
illustration for clarity only.
Positive (+)
Battery Tray Cables
Negative (-)
Battery Tray Cables
Rear
Rear
Hardware Buildup:
1/4-20 x 7/8” Bolt
1/4” Lock Washer
1/4” Flat Washer
Torque to 75 in-lbs.

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Figure 5: Battery Tray Wiring Diagram (582127000103 only)
NOTE! Same diagram applies to 582127000101 (one battery tray) and 582127000102 (two battery
trays).
to
Return
Busbar
to -48V
Battery
Busbar

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Figure 6: Battery Tray Wiring Diagram (582127000203 only)
To -48V Battery
Busbar
To Return
Busbar

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Connecting Battery Tray Cables to the Battery Tray’s Battery Disconnect Circuit Breaker
Procedure
1. Connect battery tray cables labeled (-) to the battery disconnect circuit breaker located on each battery
tray. Refer to Figure 7.
2. Rout the cables into the battery trays. The unconnected ends are connected to the battery strings in a
later procedure.
Battery Tray Battery Disconnect Circuit Breaker Alarm Wiring
Procedure
1. Connect alarm jumper P/N 524384 to the battery disconnect circuit breakers located on the battery
trays by performing the procedure detailed in Figure 7.
2. Connect the stripped end of alarm jumper P/N 524384 to TB1 located on the System Interface Board.–
48VDC is applied to the alarm lead when the circuit breaker is in the OFF position. Refer to Figure 7.
Refer also to Figure 18.
Connecting Battery Temperature Probes
Procedure
Three battery temperature probes are provided with Lists 100, 103, and 203, two probes with List 102 and one
probe with List 101.These connections may be provided from the factory.
1. Connect a temperature probe to the System Temp 1 input on the System Interface Board. Route this
probe to the bottom battery tray. Refer to Figure 18.
2. Connect a temperature probe to the System Temp 2 input on the System Interface Board. Route this
probe to the center battery tray. Refer to Figure 18.
3. Connect a temperature probe to the Temp 1 input on the IB2-1 interface board. Route this probe to the
top battery tray. Refer to Figure 19.
4. In the event there is excess length of the probe wires, coil the wires up and tie in a convenient location
along the path of the battery power cable.