Vertiv NetSure 48BA1200-19 User manual

NetSure™
Battery Rack System (-48 VDC)
Installation Manual (Section 6045), Revision E
Specification Number: 588820100, 588820200
Model Number: 48BA1200-19, 48BA1200-23

Vertiv |NetSure Battery Rack System (-48 VDC) Installation Manual (Section 6045)|Rev. E
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The information contained in this document is subject to change without
notice and may not be suitable for all applications. While every precaution
has been taken to ensure the accuracy and completeness of this
document, Vertiv Group Corporation assumes no responsibility and
disclaims all liability for damages resulting from use of this information or
for any errors or omissions. Refer to other local practices or building codes
as applicable for the correct methods, tools, and materials to be used in
performing procedures not specifically described in this document.
This document may contain confidential and/or proprietary information of
Vertiv Group Corporation, and its receipt or possession does not convey
any right to reproduce, disclose its contents, or to manufacture or sell
anything that it may describe. Reproduction, disclosure, or use without
specific authorization from Vertiv Group Corporation is strictly prohibited.
Vertiv and the Vertiv logo are trademarks or registered trademarks of
Vertiv Group Corporation. NetPerform™, NetReach™, NetSure™ and
NetXtend™ are trademarks of Vertiv Energy Systems, Inc. All other
trademarks are the property of their respective owners.
© 2017 Vertiv Energy Systems, Inc. All rights reserved.

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TABLE OF CONTENTS
Admonishments Used in this Document............................................................4
Important Safety Instructions ..............................................................................5
General Safety ...........................................................................................................................................................5
Voltages...........................................................................................................................................................................5
Battery Voltage............................................................................................................................................................... 5
Battery ..............................................................................................................................................................................6
Personal Protective Equipment (PPE)..............................................................................................7
Maintenance and Replacement Procedures...............................................................................7
Installation Acceptance Checklist.......................................................................9
Mounting the Relay Rack .......................................................................................9
Making Electrical Connections............................................................................11
Observe the Following Admonishment ..........................................................................................11
Wiring Considerations......................................................................................................................................11
Relay Rack Grounding Connection (Frame Ground) .......................................................11
Battery Disconnect Circuit Breakers (if furnished) External Alarm
Connections.............................................................................................................................................................. 12
Battery Connections to Respective Power System ..........................................................13
Installing Batteries................................................................................................. 15
Observe the Following Admonishment .........................................................................................15
Battery Manufacturer Information...................................................................................................... 15
Installing Batteries into the Battery Shelves ............................................................................15
Installing Optional Front Battery Cover (23” Trays Only) ...........................................19
Installing Optional Circuit Breaker Guard...................................................................................20
Initially Starting the System............................................................................... 20

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ADMONISHMENTS USED IN THIS DOCUMENT
DANGER
! Warns of a hazard the reader will be exposed to that will likely result
in death or serious injury if not avoided. (ANSI, OSHA)
WARNING
! Warns of a potential hazard the reader may be exposed to that could
result in
death or serious injury if not avoided. This admonition is not used for situations that pose a
risk only to equipment, software, data, or service. (ANSI)
CAUTION
! Warns of a potential hazard the reader may be exposed to that could
result in minor or moderate injury if not avoided. (ANSI, OSHA) This admonition is not
used for situations that pose a risk only to equipment, data, or service, even if such use
appears to
be permitted in some of the applicable standards. (OSHA)
ALERT
! Alerts the reader to an action that must be avoided in order to protect
equipment, software, data, or service. (ISO)
ALERT
! Alerts the reader to an action that must be performed in order to prevent
equipment damage, software corruption, data loss, or service interruption. (ISO)
FIRE SAFETY
! Informs the reader of fire safety information, reminders, precautions,
or policies, or of the locations of fire
-fighting and fire-safety equipment. (ISO)
SAFETY
! Informs the reader of general safety information, reminders, precautions, or
policies not related to a particular source of hazard or to fire safety. (ISO, ANSI, OSHA)

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IMPORTANT SAFETY INSTRUCTIONS
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
Battery Voltage
DANGER! This system has 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.

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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”.
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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INSTALLATION ACCEPTANCE CHECKLIST
Provided below is an Installation Acceptance Checklist. This checklist helps ensure proper installation and
initial operation of the system. As the procedures presented in this document are completed, check the
appropriate box in this list. If the procedure is not required 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.
Relay Rack Mounted to Floor
Relay Rack Grounding Connection Made
Battery Disconnect Circuit Breakers (if furnished) External Alarm Connections Made
Battery Connections to Respective Power System Made
Batteries Installed
System Started
MOUNTING THE RELAY RACK
This equipment is intended only for installation in a Restricted Access Location on or above a non-combustible
surface.
The installer should be familiar with the installation requirements and techniques to be used in mounting the
relay rack to the floor.
Refer to Figure 1or Figure 2for floor mounting hole dimensions.

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Figure 1: Relay Rack Floor Mounting Hole Dimensions (588820100)
Figure 2: Relay Rack Floor Mounting Hole Dimensions (588820200)

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MAKING ELECTRICAL CONNECTIONS
Observe the Following Admonishment
DANGER! Batteries can produce explosive gasses and large amounts of electrical current. Read and
follow the Safety Statement at the beginning of this document before proceeding.
Wiring Considerations
All wiring should follow the current edition of the National Electrical Code and applicable local codes.
Relay Rack Grounding Connection (Frame Ground)
For relay rack grounding requirements, refer to the National Electrical Code, applicable local codes, and your
specific site requirements.
Two grounding points are provided on the top of the relay rack. At each location, two 1/4” clearance holes on
5/8” centers are provided for connection into a customer's grounding network. Refer to Figure 3for locations.
NOTE! REMOVE TAPE FROM HOLE LOCATIONS BEFORE INSTALLING LUG.
Figure 3: Relay Rack Frame Grounding Connection Points
Frame Ground
Connection Point
(1/4” clearance holes on 5/8” centers)

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Battery Disconnect Circuit Breakers (if furnished) External Alarm Connections
If ordered, the battery disconnect circuit breakers are factory wired to an alarm card located at the top of the
relay rack. The alarm card provides resistive battery and Form-C relay contacts for connection to external
alarm circuits.
If any battery disconnect circuit breaker is in the OFF position, resistive battery is provided at terminal 1 of J3
on the alarm card. Also, relay contacts open between terminals 2 and 3 of J3 and close between terminals 3
and 4 of J3 located on the alarm card. Refer to Figure 4.
Figure 4: Battery Disconnect Circuit Breaker Alarm Card
Top of Relay Rack
Front
Alarm Card
Resistive Battery
Notes:
Relay shown in deenergized state.
Relay energizes during alarm condition.
N.O. (Normally Open Contact)
Com. (Common)
N.C. (Normally Close Contact)
Terminal Block (J3) accepts a wire size in the
range of 26AWG to 14AWG (solid or stranded).
Recommended Torque (J3): 0.5 to 0.6 Nm.
N.C.N.O.
Com.
J3
1234

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Battery Connections to Respective Power System
Lug-terminated battery conductors must extend from the termination busbars located at the top of the Battery
Rack System to the respective power system’s battery busbar and battery return busbar. Refer to the
documentation provided with the power system for connections to the power system. The termination busbars
in the Battery Rack System are provided with 3/8 16 captive fasteners for installation of customer provided two-
hole lugs with 1-inch centers. Customer must provide lug mounting bolts, washers, and additional hardware.
Refer to Figure 5.
Procedure
1. Remove front and rear protective covers.
ALERT! Observe correct polarity when making connections. Reversing polarity may result in damage to
batteries, power system, and loads.
2. Connect the positive (+) conductors to the GROUND/RETURN termination busbar.
3. Connect the negative (-) conductors to the -48V Battery (Supply) termination busbar.
4. Torque all connections. Recommended torque is 180 in-lbs when using 3/8” bolts with a Belleville lock
washer and 300 in-lbs when using 3/8” bolts with a standard flat washer and lock washer.
5. When connections are complete and verified, reinstall front and rear protective covers.

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Figure 5: Battery Lug Landing Locations and Dimensions
588820100
Top of Relay Rack
(some components removed for clarity)
588820200
Top of Relay Rack
(some components removed for clarity)
Front
Front
-48V Battery
Busbar Customer Battery Cable
Connections to Pwr. Sys.
Customer Battery Cable
Connections to Pwr. Sys.
GND/RTN
Busbar
-48V Battery
Busbar
GND/RTN
Busbar
-48V Battery and GND/RTN Busbars
-48V Battery and GND/RTN Busbars
Factory Battery
Cable Connections
Factory Battery
Cable Connections
Factory Battery
Cable Connections
Factory Battery
Cable Connections
Customer Battery Cable
Connections to Pwr. Sys.
Customer Battery Cable
Connections to Pwr. Sys.

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INSTALLING BATTERIES
Observe the Following Admonishment
DANGER! Batteries can produce explosive gasses and large amounts of electrical current. Read and
follow the Safety Statement at the beginning of this document before proceeding.
Battery Manufacturer Information
Refer to System Application Guide SAG588820100_SAG588820200 for specifications and manufacturers of the
batteries to be installed in this Battery Rack System.
Installing Batteries into the Battery Shelves
Procedure
1. If Battery Trays are equipped with Circuit Breakers: Turn OFF the Battery Disconnect circuit
breakers located on all battery trays. Refer to Figure 6or Figure 7for locations.
2. Remove the Battery Retention Bracket as shown in Figure 6or Figure 7. To do so, remove the four 1/4-
20 x 5/8” bolts and associated washers.
3. Slide batteries into the tray, with the battery terminals toward the front as shown in Figure 6or Figure 7.
Slide batteries into the tray as far as they will go.
NOTE! The Battery Retention Bracket can be oriented two ways to accommodate batteries of different
lengths. A correctly oriented bracket will fit snuggly against the batteries.
Spec No. 588820200 Only: If your batteries require the alternate bracket orientation shown in Detail A
of Figure 7, remove and reinstall the bullet-shaped spacers as shown in Detail A before performing the
next step.
4. Reinstall the Battery Retention Bracket. Secure with the hardware removed in a previous step. Refer to
Figure 6or Figure 7for washer location.
Spec No. 588820200 Only: The spacers on the bracket should separate the batteries from each other.
5. Connect two links supplied by the battery manufacturer between pairs of battery terminals as shown in
Figure 6or Figure 7Use hardware furnished by the battery manufacturer. Torque hardware to battery
manufacturer’s recommendations.
6. Ensure the battery cable ends in all trays are insulated with sleeving before performing the next step.
DANGER! In multiple-tray installations, when batteries in one tray are connected, the battery cables in
all trays will be energized. Remove sleeving from and connect one cable at a time. Do not allow cable
end to contact the battery tray or equipment rack.
ALERT! In the next step, observe correct polarity. Connect only cable labeled “+” to battery terminal
labeled “+”. Likewise, connect only cable labeled “–” to battery terminal labeled “–”.

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7. Connect the cables found in the battery tray to the respective battery terminals, “+” to “+” and ”–“ to “– “.
Observe correct polarity. Refer to Figure 6or Figure 7. Torque battery connections to battery
manufacturer’s recommendations.
8. Repeat steps 1 through 7 for any remaining battery trays.
9. If Battery Trays Are Equipped With Circuit Breakers: To connect the batteries to the Power System,
turn ON the Battery Disconnect circuit breakers located on all battery trays.

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Figure 6: Installing Batteries into Battery Shelves (588820100)
Connect POS (+)
Battery Cable
to this Terminal
(string 1)
Battery Retention Bracket.
See Detail A for alternate orientation.
1/4-20 X 2/8” Bolt
1/4” Ground Washer
(1 place)
1/4-20 X 5/8” Bolt
1/4” Lock Washer
1/4” Flat Washer
(3 places)
Connect Link Furnished
with Battery to these
Two Terminals
Connect Link Furnished
with Battery to these
Two Terminals
Connect Link Furnished
with Battery to these
Two Terminals
If trays are equipped with
circuit breakers, TURN OFF ALL
circuit breakers before installing
and connecting any batteries!
Note:
1. One tray shown as example.
2. Cabling detail omitted.
Connect NEG (-)
Battery Cable
to this Terminal
(string 1)
DETAIL A
Alternate Orientation
of Retention Bracket
1/4" Ground
Washer
(1 Place)
1/4-20 x 5/8" Hex
Head Screw
(4 Places)
1/4-20 Lock Washer
(3 Places)
1/4-20 Flat Washer
(3 Places)

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Figure 7: Installing Batteries into Battery Shelves (588820200)
Connect POS (+)
Battery Cable
to this Terminal
(string 1)
Spacers
Separate
Batteries
(3 places per tray,
front and back)
Battery Retention Bracket.
See Detail A for alternate orientation.
1/4-20 X 2/8” Bolt
1/4” Ground Washer
(1 place)
1/4-20 X 5/8” Bolt
1/4” Lock Washer
1/4” Flat Washer
(3 places)
Connect Link Furnished
with Battery to these
Two Terminals
Connect Link Furnished
with Battery to these
Two Terminals
Connect Link Furnished
with Battery to these
Two Terminals
Note:
1. One tray shown as example.
2. Cabling detail omitted.
Connect NEG (-)
Battery Cable
to this Terminal
(string 1)
If trays are equipped with
circuit breakers, TURN OFF ALL
circuit breakers before installing
and connecting any batteries!
DETAIL A
Alternate Orientation
of Retention Bracket
Spacer (3 Places)
No. 10 Lock Washer (3 Places)
10-32 x 1/2" Pan Head Screw (3 Places)
No. 10 Flat Washer (3 Places)
1/4" Ground
Washer
(1 Place)
1/4-20 x 5/8" Hex
Head Screw
(4 Places)
1/4-20 Lock Washer
(3 Places)
1/4-20 Flat Washer
(3 Places)

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Installing Optional Front Battery Cover (23” Trays Only)
Procedure
1. Follow the procedure in Figure 8.
Figure 8: Installing Optional Front Battery Cover
Assembled View
Kit Battery Cover
Assembled to Existing
Front Battery Bracket
Rear View
Kit Battery Cover
Assembled to Existing
Front Battery Bracket
Front View
Use kit supplied hardware. Procedure
1. Install batteries.
2. Install kit battery cover to
existing front battery bracket.
3. Install kit battery cover with existing
front battery bracket to battery shelf.
Kit supplied cover.
Kit supplied spacer bar.
Existing front battery bracket.
Use existing
battery spacers.

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Installing Optional Circuit Breaker Guard
Procedure
1. Follow the procedure in Figure 9.
Figure 9: Installing Optional Circuit Breaker Guard
INITIALLY STARTING THE SYSTEM
•Ensure all furnished protective covers are installed.
•If provided, ensure all battery circuit breakers are placed in the ON position.
NOTE! Circuit breakers are provided with lockout/tagout capability.
•Refer to any Initial Startup procedure in the documentation supplied with the respective power system.
1. Remove this bracket. 2. Replace this hardware after
removing existing bracket.
3. Install Circuit Breaker
Guard Bracket using
existing hardware.
Installed View