Vertiv NetSure7100 Series User manual

NetSure™
7100 SERIES -48V DC Power System
Quick Start Guide (QS582127000), Revision T
Specification Number: 582127000
Model Number: 7100

Vertiv |NetSure 7100 Series Quick Start Guide (QS582127000)|Rev. T
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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.

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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 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
Physical Installation............................................................................................... 13
Installing Circuit Breakers and Fuses............................................................... 13
Make Jumper and Switch Settings.................................................................... 21
Electrical Connections ......................................................................................... 22
Important Safety Instructions ................................................................................................................ 22
Make Nominal 208 VAC, 240 VAC, 277 VAC, or 277 VAC / 480 VAC
Input and Equipment Grounding Connections (if equipped) ................................ 22
Make Nominal 400 Volts DC Input and Equipment Grounding
Connections (if equipped).........................................................................................................................50
Make External Alarm, Reference, Monitoring, and Control
Connections.............................................................................................................................................................56
Circuit Card Locations......................................................................................................................................... 56
System Interface Circuit Card.......................................................................................................................57
IB2 (Controller Interface Board) Connections (if required) (Main Bay
Only)...................................................................................................................................................................................... 59
Optional EIB (Controller Extended Interface Board) Connections (if
required) (Main Bay Only)................................................................................................................................ 64
Optional SM-DU+ and Shunt Interface Board.............................................................................. 70
Connecting a Device or System to the Controller’s CAN Bus........................................72
Make Controller Ethernet Connection (if required) .........................................................73
Make Bay-to-Bay Communications Cable Connections............................................. 76
Installing Bay-to-Bay Busbars (582127000 List 1 with List 2 / List 3)
(for system mounted in a relay rack) ............................................................................................. 76
Installing Bay-to-Bay Busbars (582127000 List 1 with List 7 / List 8)
(for system mounted in an enclosure)..........................................................................................76
Connecting Converter Output Cables 582127000 List 60.......................................83
Make Load Connections .............................................................................................................................86
Recommended Torques .................................................................................................................................... 86

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Load Connections to Single Voltage Distribution Panels..................................................87
Load Connections to Dual Voltage Distribution Panels ......................................................92
Load Connections to Return Bar................................................................................................................97
Load Connections to Bulk Output Panel............................................................................................97
Load Connections to GMT Distribution Fuse Block............................................................... 98
Make Battery Connections .......................................................................................................................99
Recommended Torques.................................................................................................................................... 99
Battery Connections to Optional Battery Disconnect Distribution
Panels................................................................................................................................................................................... 99
Battery Connections to Distribution Cabinet Battery Busbars (for
system mounted in a relay rack or enclosure)...........................................................................103
Battery Connections to Bay-to-Bay Rectifier Busbars (582127000 List 1
with List 2 / List 3) (for system mounted in a relay rack)...............................................105
List 93 Battery Tray ......................................................................................................................................106
Installing the Modules........................................................................................ 106
Installing Rectifier or Converter Modules into Spec. No. 588705000
Module Mounting Assemblies............................................................................................................106
Installing Rectifier Modules into Spec. No. 588705500 Module
Mounting Assemblies..................................................................................................................................108
Installing the Rectifier and Converter Modules into Spec. No.
588705300 Module Mounting Assemblies ............................................................................ 110
Installing Rectifier Modules into Spec. No. 588705400 Module
Mounting Assemblies....................................................................................................................................112
Initially Starting, Configuring, and Checking System Operation............ 114
Initial Startup Preparation.........................................................................................................................114
Initially Starting the System....................................................................................................................114
ACU+ Controller Procedure....................................................................................................................114
NCU Controller Procedure......................................................................................................................122
Checking System Status........................................................................................................................... 127
Final Steps ...............................................................................................................................................................128

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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 lo
ss, or service interruption. (ISO)
FIRE SAFETY
! Informs the reader of fire safety information, reminders, precautions,
or policies, or of the locations of fire
-fighting and fire-safety equipment. (ISO)
SAFETY
! Informs the reader of general safety information, reminders, precautions, or
policies not related to a particular source of hazard or to fire safety. (ISO, ANSI, OSHA)

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IMPORTANT SAFETY INSTRUCTIONS
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 400V DC input systems, do not work on an energized system without full arc flash and PPE
protection.
Voltages
AC Input Voltages
DANGER! This system may operate 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 400V DC 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 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 (QS582127000) provides Quick Start Instructions for NetSure™ -48 VDC Power System Model
7100, Spec. No. 582127000.
NOTE! 582127000 List 100, 101, 102, and 103 are specific configurations of 582127000. Separate User
Instructions and Installation Instructions are provided with these power systems. For 582127000 List
100, 101, 102, and 103; do not use these instructions. Refer to IM582127000100 and UM582127000 for
instructions.
The complete Customer Documentation Package consists of…
NetSure™-48 VDC Power System Installation Manual
•Power System Installation Instructions: IM582127000
NetSure™ACU+ Controller User Manual
•ACU+ Controller User Instructions: UM1M820BNA (AC Input Voltage Systems) or UM1M820DNA400
(DC Input Voltage Systems)
NetSure™NCU Controller User Manual
•NCU Controller User Instructions: UM1M830BNA (AC Input Voltage Systems)
USB Drive with All Customer Documentation
•Power System Quick Start Guide: QS582127000
•Power System Installation Instructions: IM582127000
•Power System Installation Instructions: IM582127000100 (instructions for List 100, 101, 102, and 103)
•Power System User Instructions: UM582127000
•Power System User Instructions: UM582127000100 (instructions for List 100, 101, 102, and 103)
•ACU+ Controller User Instructions: UM1M820BNA
•ACU+ Controller User Instructions: UM1M820DNA400
•NCU Controller User Instructions: UM1M830BNA
•Rectifier Instructions: UM1R483500e
•Rectifier Instructions: UM1R483500e3
•Rectifier Instructions: UM1R482000e3
•Converter Instructions: UM1C48241500
•Converter Instructions: UM1C400483500e
•Power System “System Application Guide”: SAG582127000
•NCU Controller 2nd Ethernet Port Add-On Kit Instructions: IM559252
•NCU Controller 2nd Ethernet Port Retrofit Kit Instructions: IM559251

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•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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PHYSICAL INSTALLATION
To do this… See this in the Installation Instructions (IM582127000)
Choose a mounting location General Requirements in the INSTALLING THE
SYSTEM section.
Secure the relay rack or
enclosure to the floor
Securing the Relay Rack or Enclosure to the Floor
in
the INSTALLING THE SYSTEM section.
Mount the Power System Mounting System Components in an Equipment Rack
in the INSTALLING THE SYSTEM section.
Install optional lug adapter
busbar kits
Installing Optional Lug Adapter Busbar Kits, Part Nos.
534449 and 514714 in the INSTALLING THE
SYSTEM section.
INSTALLING CIRCUIT BREAKERS AND FUSES
Load and battery distribution devices were factory-installed if ordered with the power system. If additional
installation is required, refer to Figure 1through Figure 7. For detailed procedures, refer to Installing Circuit
Breakers and Fuses in the INSTALLING THE SYSTEM section of the Installation Instructions (IM582127000).
Figure 1: Installing a Bullet Nose Type Fuseholder and TPS/TLS Fuse
Fuseholder Assembly
Longer Side
to the Bottom
Shorter Side
to the Top
Fuse Carrier
Fuseholder Body
TPS/TLS Fuse
Polarizing Keyway
Matches Key on
Bottom of Fuse Carrier
Fuseholder Assembly
Exploded View
Fuseholder Assembly (P/N 117201) includes
body & carrier, alarm fuse, and alarm fuse safety cover.
Insert these terminals
into corresponding sockets
on distribution panel.
GMT-X
Safety Fuse Cover
(Replacement
P/N 248898700)
GMT-18/100A
Alarm Fuse
(Replacement
P/N 248610301)

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Figure 2: Installing a Bullet Nose Type Circuit Breaker
Figure 3: Installing a TPH Fuse
Insert these terminals
intocorrespondingsockets
on distributionpanel.
Longer Side
to the Bottom
Shorter Side
to the Top
Lettering on
handle must be
right side up.
T
urn o ff
before installing.
Fuse
Fuse Carrier
Fuseholder Body

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Figure 4: Installing TPL-B Fuses
Fuse Case
Open Fuse Case View
TPLFuse
Fuse Installed in
Open Fuse Case
(rear view)
Fuse Installed in
Closed Fuse Case
(rear view)
Fuseblock
(P/N 516241)
GMT-18/100AAlarm Fuse
(P/N 248610301) and
GMT-X Safety Fuse Cover
(P/N 248898700)
(Both are provided
w/ fuseblock)

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Figure 5: Installing an Optional Bullet Nose Type 6-Position GMT Distribution Fuse Block (P/N 550224)
Press in tabs to release
lug terminal busbars for
positions to be occupied
by GMTFuse Block.
Remove two lug terminal busbars
for positions to be occupied
by GMTFuse Block.
Plug in GM TFuse Block and secure
at two locations on the RTN bar.
Torque to 72 in-lbs.
RTN Bar
GMTFuse Block Installed View
1.
2.
3.

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Figure 6: Installing an Optional Bullet Nose Type 6-Position GMT Distribution Fuse Block (P/N 549017)
RTN Bar
1. Remove two lug terminal busbars for positions to be occupied
by GMT Fuse Block. Remove plastic busbar plugs first.
Plastic Busbar Plugs
2. Plug in GMT Fuse Block.
3. Connect supplied jumper from
GMT Fuse Block to Return Bar.
Torque to 75 in-lbs.
Part of P/N 549017
Part of P/N 549017

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Figure 7: Installing a GJ/218 Circuit Breaker (1-Pole) (Lists AC, AD, BC, BD) (cont’d on next page)
1/4" Hardened
Flat Washer
1/4" Belleville
Lock Washer
1/4-20 x 3/4” Bolt
(2 places)
Torque to 60 in-lbs.
OFF
ON
Apply anti-oxidizing compound to busbar mating
surfaces before mounting circuit breakers.
INSTALLING CIRCUIT BREAKER
Alarm jumper connector.
Holes to route shunt jumper through (if applicable).
ALARM WIRING (BREAKERS W/OUT SHUNTS) ALARM WIRING (BREAKERS WITH SHUNTS)
Standard and
Electrical
Trip Breaker
Shunted Breaker Jumper: Red
Alarm Jumper: Brown
Alarm Jumper: Brown
Alarm Jumper: Red
Alarm Jumper: Red
Shunted Breaker Jumper: Black
INSTALLING CIRCUIT BREAKER GUARD
ON OFF
LONGER SIDE OF GUARD
10-32 X 7/16 PH
10-32 LW
CIRCUIT BREAKER GUARD LABEL
CIRCUIT BREAKER GUARD
TYPICAL DIST ASSY
SHOWN FOR EXAMPLE

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Figure 7: Installing a GJ/218 Circuit Breaker (2-Pole, 3-Pole, 4-Pole) (Lists AC, AD, BC, BD) (cont’d from
previous page, cont’d on next page)
ALARM WIRING (BREAKERS W/OUT SHUNTS) ALARM WIRING (BREAKERS WITH SHUNTS)
Standard and
Electrical
Trip Breaker
Shunted Breaker Jumper: Red
Alarm Jumper: Brown
Alarm Jumper: Brown
Alarm Jumper: Red
Alarm Jumper: Red
Shunted Breaker Jumper: Black
INSTALLING CIRCUIT BREAKER GUARD
ON OFF
LONGER SIDE OF GUARD
10-32 X 7/16 PH
10-32 LW
CIRCUIT BREAKER GUARD LABEL
CIRCUIT BREAKER GUARD
TYPICAL DIST ASSY
SHOWN FOR EXAMPLE
1/4" Hardened
Flat Washer
1/4" Belleville
Lock Washer
1/4-20 x 3/4” Bolt
(4 places / 2-pole brk,
6 places / 3-pole brk,
8 places / 4-pole brk)
Torque to 60 in-lbs.
Apply anti-oxidizing compound to busbar mating
surfaces before mounting circuit breakers.
OFF
ON
INSTALLING CIRCUIT BREAKER Alarm jumper connectors.
Holes to route shunt jumper through (if applicable).
Busbar
2-pole breaker shown.
3-pole and 4-pole breakers similar.

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Figure 7: Installing a GJ/218 Circuit Breaker (1-Pole, 2-Pole, 3-Pole, 4-Pole) (List AM and List AP) (cont’d from
previous page)
INSTALLING CIRCUIT BREAKER
ALARM WIRING (BREAKERS W/OUT SHUNTS) ALARM WIRING (BREAKERS WITH SHUNTS)
Standard and
Electrical
Trip Breaker
Shunted Breaker Jumper: Red
Alarm Jumper: Brown
Alarm Jumper: Brown
Alarm Jumper: Red
Alarm Jumper: Red
Shunted Breaker Jumper: Black
INSTALLING CIRCUIT BREAKER GUARD
ON OFF
LONGER SIDE OF GUARD
10-32 X 7/16 PH
10-32 LW
CIRCUIT BREAKER GUARD LABEL
CIRCUIT BREAKER GUARD
TYPICAL DIST ASSY
SHOWN FOR EXAMPLE
Apply anti-oxidizing compound to busbar mating
surfaces before mounting circuit breakers.
1/4" Hardened Flat Washer
1/4" Belleville Lock Washer
1/4-20 x 3/4” Bolt
(2 places) Torque to 60 in-lbs.
OFF
ON
OFF
ON
Alarm jumper connector.
1/4" Hardened Flat Washer
1/4" Belleville Lock Washer
1/4-20 x 3/4” Bolt
(4 places / 2-pole breaker,
6 places / 3-pole breaker,
8 places / 4-pole breaker)
Torque to 60 in-lbs.
Shorting
Busbar
For a 3-pole
and 4-pole
breaker, install
shorting busbars
top and bottom.
(4-pole shorting busbars
shown, 3-pole similar)
2-pole breaker shown.
3-pole and 4-pole breakers similar.
Return Busbar
(not included
with List AP)