Emerson NetSure-48 VDC Power System Installation Instructions Manual
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Emerson NetSure-48 VDC Power System Installation Instructions Manual

Emerson NetSure-48 VDC Power System Installation Instructions Manual

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NetSure
-48 VDC Power System
Installation Instructions, IM582127000100 (Revision A, January 9, 2017)
Specification Number: 582127000100, 582127000103
Model Number: 7100
582127000100
582127000103
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  • Page 1 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Specification Number: 582127000100, 582127000103 Model Number: 7100 582127000100 582127000103...
  • Page 2 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) This page is intentionally blank. Spec. No: 582127000100, 582127000103 Document Code: IM582127000100 Model No: 7100 Revision A, January 9, 2017...

  • Page 3: Table Of Contents

    ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Table of Contents Admonishments Used in this Document ....................... iii Important Safety Instructions ..........................iv General Safety ................................iv Voltages .................................iv Battery ...................................iv Personal Protective Equipment (PPE) ........................v Hazardous Voltage ..............................
  • Page 4 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Checking System Status ............................50 Final Steps................................50 NetPerform™ Optimization Services ........................51 Spec. No: 582127000100, 582127000103 Document Code: IM582127000100 [ii] Model No: 7100 Revision A, January 9, 2017...

  • Page 5: Admonishments Used In This Document

    ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) 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) Danger WARNING! Warns of a potential hazard the reader may be exposed to that could result in death or serious injury if not avoided.

  • Page 6: Important Safety Instructions

    ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Important Safety Instructions General Safety DC Output and Battery Voltages DANGER! DANGER! This system produces DC power and may YOU MUST FOLLOW APPROVED SAFETY PROCEDURES. have a battery source connected to it. Although the DC Danger Danger Performing the following procedures may expose you to...

  • Page 7: Personal Protective Equipment (Ppe)

    ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) WARNING! A battery can present a risk of electrical FOR THESE REASONS, IT IS OF CRITICAL IMPORTANCE shock and high short circuit current. Servicing of THAT YOU READ THESE INSTRUCTIONS AND FOLLOW Warning batteries should be performed or supervised only by THEM EXACTLY.

  • Page 8: Static Warning

    ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) 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. Strictly adhere to the procedures provided in this document.

  • Page 9: Customer Documentation Package

    ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Customer Documentation Package NOTE: The system is not powered up until the end of this checklist. This document (IM582127000100) provides Installation NOTE: Some of these procedures may have been Instructions for NetSure™...

  • Page 10: Installing The System

    ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Installing the System • Rectifier, converter, and mounting assembly ventilating openings must not be blocked and temperature of air General Requirements entering rectifiers and converters must not exceed rated operating ambient temperature range found in •...

  • Page 11: Installing Battery Trays

    ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) 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.
  • Page 12 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Installing Battery Disconnect Circuit Breakers onto Battery Trays Procedure To install battery disconnect circuit breakers onto battery trays, perform the procedure detailed in Figure Figure 3. Installing Battery Disconnect Circuit Breakers onto Battery Trays 1.
  • Page 13 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Connecting Battery Tray Cables from the Battery Trays to the System Busbars Procedure 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.
  • Page 14 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Figure 5. Battery Tray Wiring Diagram to -48V Battery Return Busbar Busbar Spec. No: 582127000100, 582127000103 Document Code: IM582127000100 Model No: 7100 Revision A, January 9, 2017...
  • Page 15 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Connecting Battery Tray Cables to the Battery Tray’s Battery Disconnect Circuit Breaker Procedure Connect battery tray cables labeled (-) to the battery disconnect circuit breaker located on each battery tray Refer to Figure Rout the cables into the battery trays.
  • Page 16 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Figure 6. Battery Tray Battery Disconnect Circuit Breaker Alarm Wiring Alarm Wiring to Battery Disconnect Circuit Breakers when (1) to (3) Battery Trays are Used Procedure Connect kit-supplied YELLOW jumper/alarm lead Yellow Alarm Wire (P/N 524384) to circuit breaker “C (Common)”...

  • Page 17: Installing Optional Lug Adapter Busbar Kits, Part Nos. 534449 And 514714

    ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Installing Optional Lug Adapter Busbar Kits, Part Nos. 534449 and 514714 These kits provide lug adapter busbars plus hardware for use with 2-pole and 3-pole circuit breakers. Contents of Kit P/N 534449 (for 2-pole circuit breakers) Qty.
  • Page 18 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Figure 7. Installing Lug Adapter Busbar Kits Busbar Adapter Kit P/N 514714 Busbar Adapter Kit P/N 534449 Notes: Orient busbars as shown. Circuit breaker locations for reference only. Spec.

  • Page 19: Installing Circuit Breakers And Fuses

    ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Installing Circuit Breakers and Fuses Installing Bullet Nose Type Fuseholders and TPS/TLS Fuses CAUTION! A 100 A circuit breaker or fuse SHALL HAVE an empty mounting position between it and any other overcurrent protective device.
  • Page 20 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Installing Bullet Nose Type Circuit Breakers CAUTION! A 100 A circuit breaker or fuse SHALL HAVE an empty mounting position between it and any other overcurrent protective device.
  • Page 21 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Installing an Optional Bullet Nose Type 6-Position GMT Distribution Fuse Block (P/N 549017) NOTE: Refer to Figure 10 as this procedure is performed. Procedure Open the distribution cabinet’s front door by turning the latch in the counterclockwise position. Follow the steps in Figure Install an appropriately sized GMT fuse in each fuse mounting position on the GMT Distribution Fuse Block as required.
  • Page 22 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Figure 10. Installing an Optional Bullet Nose Type 6-Position GMT Distribution Fuse Block (P/N 549017) 1. Remove two lug terminal busbars for positions to be occupied by GMT Fuse Block.

  • Page 23: Setting Jumpers And Switch Options

    ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Setting Jumpers and Switch Options Circuit Card Locations Refer to Figure Figure 11. Circuit Card Locations Distribution Cabinet (Front Door Removed in Illustration for Clarity) NCU Controller 1M830DNA (2nd Ethernet Port Board)

  • Page 24: Jumper On System Interface Board

    ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Jumper on System Interface Board Perform the following procedure to make the required setting per your site requirements. This procedure can also be used to make adjustments on a replacement circuit card.

  • Page 25: Switch Setting On Ib2 Controller Interface Board

    ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Switch Setting on IB2 Controller Interface Board Dip Switch SW1 on the IB2 board is used to set the communications address for this board. Refer to Table 1 for SW1 settings.
  • Page 26 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Figure 13. IB2 Controller Interface Board Switch Location and Setting IB2 (Interface Board) (Top View) IB2 (Interface Board) Switch SW1 is located in this corner of the IB2 Board. DIP Switch SW1 Setting IB2-1...

  • Page 27: Making Electrical Connections

    ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Making Electrical Connections Table 3. Supplemental Lug Crimping Information when using the Special Application Crimp Lug / Strap Combination Important Safety Instructions Crimp Tool Required DANGER! Adhere to the “Important Safety Instructions” T&B Model TBM12 or TBM15 Hydraulic Heads presented at the front of this document.

  • Page 28: Relay Rack Grounding Connection (Frame Ground)

    ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Relay Rack Grounding Connection (Frame Ground) Nominal 208 VAC / 240 VAC Input and Equipment Grounding Connections For relay rack grounding requirements, refer to the current edition of the American National Standards Institute (ANSI) approved DANGER! Adhere to the “Important Safety Instructions”...
  • Page 29 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Reinstalling Covers After all AC input and equipment grounding connections have been made and checked, reinstall the two AC input connector covers. Table 4. Recommended AC Input Branch Circuit Protection and Wire Size (List 100, 103) List 100, 103 AC Input to AC Input Termination Assembly...
  • Page 30 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Figure 16. Nominal 208 VAC / 240 VAC Input and Equipment Grounding Connections (1 Feed per 2 Rectifiers, Single Phase) RECTIFIER AC INPUT FEEDS Shelf #1 Rect.

  • Page 31: External Alarm, Reference, Monitoring, And Control Connections

    ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) External Alarm, Reference, Monitoring, and Control Connections CIRCUIT CARD LOCATIONS Refer to Figure TEMPERATURE PROBES NOTE: Each temperature probe consists of two or three pieces that plug together to make a complete probe. See SAG582127000 for part numbers and descriptions.
  • Page 32 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) SYSTEM INTERFACE BOARD The System Interface Board provides connections for the following. Refer to Figure • Battery Tray or Battery Rack Fuse Alarm • System Voltage Monitoring Test Points •...
  • Page 33 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) IB2 (CONTROLLER INTERFACE BOARD) CONNECTIONS Digital Inputs (IF REQUIRED) Connect up to eight (8) digital inputs to the IB2. Note that you must supply both paths for the digital input (either a positive or The IB2 (Controller Interface Board) provides connection points for negative signal and the opposite polarity return path).
  • Page 34 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Figure 18. IB2 (Controller Interface Board) Connections Schematic Diagram of IB2 Board IB2 TEMP IB2 TEMP PROBE 2 PROBE 1 IB2 (Interface Board) (Top View) DI1- DI1+ DI2- DI2+...
  • Page 35 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Table 5. Programmable Relay Outputs – IB2 Board Programmable Alarms Assigned to this Relay Alarms Assigned to this Relay Relay Output Pin No. (Default) (Custom) J6-5 J6-3 Critical Summary J6-1...
  • Page 36 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Table 6. Programmable Digital Inputs – IB2 Board Programmable Factory Default Digital Customer Defined Digital Input Pin No. Wiring Input Function Digital Input Function J3-2 J3-1 –...
  • Page 37 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) OPTIONAL EIB (CONTROLLER EXTENDED INTERFACE BOARD) battery block monitoring per site requirements. The CONNECTIONS (IF REQUIRED) controller issues an alarm when any block voltage of any battery string has an abnormal value.
  • Page 38 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Figure 19. Sample Battery Block or Battery Midpoint Monitoring Connections Battery Block Monitoring Return Load Rectifiers Load Shunt Battery Battery -48V String 1 String 2 DCV1 DCV2 DCV3 DCV4...
  • Page 39 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Figure 20. Optional EIB (Controller Extended Interface Board) Connections EIB (Extended Interface Board) Schematic Diagram of EIB Board (Top View) RLY4_NO RLY3_NO RLY4_COM RLY3_COM RLY4_NC RLY3_NC J5-J9 RLY2_NO Wire Size Capacity: 16-26 AWG.
  • Page 40 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Table 7. Shunt Inputs – EIB Factory Default Customer Shunt Input Pin No. Wiring Function Defined Function J5-2 none J5-1 – J5-4 none J5-3 – J5-6 none J5-5 –...
  • Page 41 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Table 9. Programmable Relay Outputs – EIB Programmable Relay Alarms Assigned to this Relay Alarms Assigned to this Relay Output Pin No. (Default) (Custom) J8-5 J8-3 J8-1 J8-6 J8-4...

  • Page 42: Connecting A Device Or System To The Ncu Can Bus (If Required)

    ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Connecting a Device or System to the NCU CAN Bus (if required) A supporting device or system may be connected to the NCU CAN Port located on the system interface board. Refer to Figure 11 system interface board location.

  • Page 43: Ncu Controller Ethernet Connection (If Required)

    ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) NCU Controller Ethernet Connection (if required) The controller provides a Web Interface via an Ethernet connection to a TCP/IP network. This interface can be accessed locally on a computer and/or remotely through a network.

  • Page 44: Load Connections

    ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Load Connections Loads are connected to the various distribution panels located inside the distribution cabinet, as detailed in this section. RECOMMENDED TORQUES • 72 in-lbs for 1/4-inch hardware (when using standard flat and lock washer). •...
  • Page 45 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) LOAD CONNECTIONS TO GMT DISTRIBUTION FUSE BLOCK Figure 24. Optional Bullet Nose 6-Position GMT Distribution Fuse Block, P/N 549017 1/4-20 Hardware. Torque to 75 in-lbs. Part of P/N 549017 Load Return Leads -48VDC Load Leads Wire Size Capacity: 26-14 AWG.

  • Page 46: External Battery Connections

    ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) External Battery Connections IMPORTANT SAFETY INSTRUCTIONS DANGER! Adhere to the “Important Safety Instructions” presented at the front of this document. Danger WARNING! Observe proper polarity when making battery connections. Warning RECOMMENDED TORQUES •...
  • Page 47 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Figure 25. Battery Connections to Distribution Cabinet Battery Busbars GND RTN -48V SUPPLY Battery (Return Side) Busbar Battery (Load Side) Busbar Distribution Cabinet BATTERY RETURN CONNECTIONS BATTERY CONNECTIONS (6 landings) (5 landings)
  • Page 48 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Figure 26. Battery Busbar Dimensions Notes: 1. All dimensions are in inches. Spec. No: 582127000100, 582127000103 Document Code: IM582127000100 [40] Model No: 7100 Revision A, January 9, 2017...

  • Page 49: Installing And Connecting Batteries In The Battery Trays (If Furnished)

    ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Installing and Connecting Batteries in the Battery Trays (if furnished) Important Safety Instructions DANGER! Adhere to the “Important Safety Instructions” presented at the front of this document. Danger Battery Manufacturer Information Refer to System Application Guide SAG582127000 for specifications and manufacturers of the batteries to be installed in this power...
  • Page 50 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Figure 27. Battery Tray Battery Installation Details Connect Link Furnished Connect Link Furnished Connect Link Furnished with Battery to these with Battery to these with Battery to these Two Terminals Two Terminals Two Terminals...

  • Page 51: Special Application Rectifier Bus Landing Point Kit P/N 563574

    ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Special Application Rectifier Bus Landing Point Kit P/N 563574 Special application rectifier bus landing point kit P/N 563574 is available for use with List 100 (582127000100) and List 103 (582127000103).

  • Page 52: Installing The Rectifier And Converter Modules

    ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Installing the Rectifier and Converter Procedure Modules Unpack the modules. Note the model number located on the front of each Rectifier and converter modules can be inserted or removed with module.
  • Page 53 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Figure 29. Installing Rectifier and Converter Modules into Spec. No. 588705300 Module Mounting Assembly Rectifiers Only in Top Shelf Rectifiers in Any Position Rectifiers or Converters in Far Right Three Positions Front View Rectifier or Converter Module Captive Screw...

  • Page 54: Initially Starting, Configuring, And Checking System Operation

    Open the distribution cabinet’s front door by turning the After the NCU is powered on, the display shows the latch in the counterclockwise position. “Emerson Network Power” screen. The controller is Place each distribution circuit breaker (if furnished) to the initializing.
  • Page 55 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Figure 31. NCU Local Display Main Menu the first three supplied with the system and external inputs/outputs connected to the IB2 interface board and the optional EIB extended interface board. Refer also to “NCU Start Wizard”...
  • Page 56 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Checking Basic System Settings Users programmed into the NCU are shown. Users are programmed via the Web Interface. The default User is admin. Navigate through the controller menus and submenus to check system settings.
  • Page 57 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Changing Battery Capacity Rating in the NCU Upon power up, the NCU arbitrarily assigns Feed AC1, AC2, or AC3 to each rectifier. This assignment is used to display rectifier AC input feed voltage(s).
  • Page 58 ™ NetSure -48 VDC Power System Installation Instructions, IM582127000100 (Revision A, January 9, 2017) Checking System Status Procedure Observe the status of the indicators located on the controller, rectifiers, and converters (if furnished). If the system is operating normally, the status of these is as shown in Table Table 12.
  • Page 59 NetPerform™ Optimization Services At Emerson Network Power, we understand the importance of reliable equipment – it’s critical to both your business and your bottom line. That is why we offer a wide array of services to meet all of your network infrastructure needs.
  • Page 60 NetSpan™, NetSure™ and NetXtend™ are trademarks of Emerson Network Power, Energy Systems, North America, Inc. Any other product, brand, or company names or logos are the property of the respective owner. While every precaution has been taken to ensure accuracy and completeness herein, Emerson Electric Co. assumes no responsibility, and disclaims all liability, for damages resulting from use of this information or for any errors or omissions.

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