NetSure 502 Integrated System IM582136700

7/24/2019 NetSure 502 Integrated System IM582136700

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NetSure

-48 VDC Power SystemInstallation Instructions, Section 6009 (Issue U, January 12, 2015)

Specification Number: 582136700Model Number: 502 NGFB


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NetSure -48 VDC Power SystemInstallation Instructions, Section 6009 (Issue U, January 12, 2015)

Spec. No: 582136700 Section 6009Model No: 502 NGFB Issue AT, August 27, 2013

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Spec. No: 582136700 Section 6009Model No: 502 NGFB Issue U, January 12, 2015[i]

Table of ContentsAdmonishments Used In This Document............................................................................................................... iii Important Safety Instructions .............................................................................................................................. iv

General Safety ........................................................................................................................................................iv Voltages .................................................................................................................................................................iv Battery ...................................................................................................................................................................iv Handling Equipment Containing Static Sensitive Components .................................................................................iv

Static Warning ...................................................................................................................................................... v Customer Documentation Package ....................................................................................................................... 1 Installation Acceptance Checklist .......................................................................................................................... 1 Installing the System ............................................................................................................................................. 1

General Requirements ............................................................................................................................................ 1 Securing the Relay Rack(s) to the Floor (if furnished) ................................................................................................ 2 Securing the Power/Distribution Shelf to a Relay Rack or Cabinet ............................................................................. 5 Securing the Power/Distribution Shelf to a Wall with a Part No. 553203 Kit .............................................................. 5 Installing Circuit Breakers and Fuses ........................................................................................................................ 7 Installing Load Distribution Fuses (List KG GMT Load Distribution Fuse Panel) ......................................................... 11 Installing an Optional Battery Cabinet ................................................................................................................... 11

Making Electrical Connections ............................................................................................................................ 12 Important Safety Instructions................................................................................................................................ 12 Wiring Considerations .......................................................................................................................................... 12

Relay Rack Frame Grounding Connection .............................................................................................................. 12

Power/Distribution Shelf Frame Grounding Connection ......................................................................................... 12 AC Input and AC Input Equipment Grounding Connections .................................................................................... 12 External Interface Connections .............................................................................................................................. 15

IB2 (Controller Interface Board) Connections .................................................................................................. 15 Ethernet Connection ............................................................................................................................................. 20 Load Connections ................................................................................................................................................. 22

To GMT Fuse Positions (List BF, LF and NF) ...................................................................................................... 22 To GMT Fuse Positions (List BA, LA, NA, BC, LC and NC) ................................................................................... 24 To Bullet Nose-Type Load Distribution Circuit Breaker Positions (List BC, LC, and NC) ...................................... 25 To Bullet Nose-Type Load Distribution Circuit Breaker Positions (List BA, LA and NA) ....................................... 26 List KG GMT Load Distribution Fuse Panel ....................................................................................................... 27

CO Ground Connection ......................................................................................................................................... 28 Battery Connections ............................................................................................................................................. 28

To Battery Busbars ......................................................................................................................................... 28 To Bullet Nose-Type Circuit Breaker Positions (Lists BA, LA, and NA) ................................................................ 28 Installing and Connecting Batteries in an Optional Battery Tray (if furnished) .................................................. 30

Optional External Battery Disconnect Unit ............................................................................................................. 33 Connecting to an Optional Battery Cabinet ........................................................................................................... 37

Installing the Rectifier Modules ........................................................................................................................... 38


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Spec. No: 582136700 Section 6009Model No: 502 NGFB Issue U, January 12, 2015[ii]

Initially Starting the System ................................................................................................................................ 39

Initially Starting, Configuring, and Checking System Operation when E/W NCU ...................................................... 39

Initial Startup Preparation .............................................................................................................................. 39 Initially Starting the System ............................................................................................................................ 39 NCU Controller Initialization ........................................................................................................................... 39 NCU Start Wizard ........................................................................................................................................... 40 Verifying the Configuration File ...................................................................................................................... 40 Checking Basic System Settings ...................................................................................................................... 41 Checking System Status ................................................................................................................................. 41 Configuring the NCU Identification of Rectifiers and Assigning which Input Feed is Connected to theRectifiers ....................................................................................................................................................... 41 NCU Alarm Relay Check .................................................................................................................................. 41

Final Steps ..................................................................................................................................................... 45 Initially Starting, Configuring, and Checking System Operation when E/W ACU+ .................................................... 46

Initial Startup Preparation .............................................................................................................................. 46 Initially Starting the System ............................................................................................................................ 46 ACU+ Initialization ......................................................................................................................................... 46 Verifying the Configuration File ...................................................................................................................... 47 Checking Basic System Settings ...................................................................................................................... 47 Checking System Status ................................................................................................................................. 47 Configuring the ACU+ Identification of Rectifiers and Assigning which Input Phase is Connected toEach Rectifier ................................................................................................................................................. 48

ACU+ Alarm Relay Check ................................................................................................................................ 48

Final Steps ..................................................................................................................................................... 52 Initially Starting, Configuring, and Checking System Operation when E/W SCU+ ..................................................... 53

Initial Startup Preparation .............................................................................................................................. 53 Initially Starting the System ............................................................................................................................ 53 SCU+ Initialization .......................................................................................................................................... 53 Verifying the Configuration File ...................................................................................................................... 54 Checking System Status ................................................................................................................................. 54 Configuring the SCU+ Identification of Rectifier Modules ................................................................................ 54 SCU+ Alarm Relay Check ................................................................................................................................ 55 Final Steps ..................................................................................................................................................... 58

NetPerform Optimization Services ................................................................................................................... 59


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Spec. No: 582136700 Section 6009Model No: 502 NGFB Issue U, January 12, 2015[iii]

Admonishments Used In This Document

DANGER!Warns of a hazard the reader will be exposed to that will likely result in death or serious injuryif not avoided. (ANSI, OSHA)

WARNING!Warns of a potential hazard the reader may be exposed to that could result in death orserious injury if not avoided. This admonition is not used for situations that pose a risk only toequipment, software, data, or service. (ANSI)

CAUTION!Warns of a potential hazard the reader may be exposed to that could result in minor ormoderate injury if not avoided. (ANSI, OSHA) This admonition is not used for situations that pose a riskonly to equipment, data, or service, even if such use appears to be permitted in some of the applicablestandards. (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 thelocations of fire-fighting and fire-safety equipment. (ISO)

SAFETY!Informs the reader of general safety information, reminders, precautions, or policies not relatedto a particular source of hazard or to fire safety. (ISO, ANSI, OSHA)

Danger

Warning

Caution

Alert

Alert

Fire Safety

Safety


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Spec. No: 582136700 Section 6009Model No: 502 NGFB Issue U, January 12, 2015[iv]

Important Safety InstructionsGeneral Safety

DANGER!YOU MUST FOLLOW APPROVED SAFETY PROCEDURES.

Performing the following procedures may expose you tohazards. These procedures should be performed byqualified technicians familiar with the hazardsassociated with this type of equipment. These hazardsmay include shock, energy, and/or burns. To avoidthese hazards:

a) The tasks should be performed in the orderindicated.

b) Remove watches, rings, and other metal objects.

c) Prior to contacting any uninsulated surface ortermination, use a voltmeter to verify that novoltage or the expected voltage is present.

d) Wear eye protection.

e) Use double insulated tools appropriately rated forthe work to be performed.

Voltages

AC Input Voltages

DANGER!This system operates from AC voltage capableof producing fatal electrical shock. AC input powermust be completely disconnected from the branchcircuits wiring used to provide power to the systembefore any AC electrical connections are made. DO NOTapply AC power to the system until all electricalconnections have been completed and checked.

DC Input/Output Voltages

DANGER!This system produces DC Power and mayrequire battery to be connected to it. Although the DCvoltage is not hazardously high, the rectifiers and/orbattery can deliver large amounts of current. Exerciseextreme caution not to inadvertently contact or haveany tool inadvertently contact a battery or outputterminal or exposed wire connected to a battery oroutput terminal. NEVER allow a metal object, such as atool, to contact more than one termination or batteryterminal at a time, or to simultaneously contact atermination or battery terminal and a grounded object.Even a momentary short circuit can cause sparking,explosion, and injury.

BatteryWARNING!Correct polarity must be observed whenconnecting battery leads.

WARNING!Special safety precautions are required forprocedures involving handling, installing, and servicingbatteries. Observe all battery safety precautions in thismanual and in the battery instruction manual. Theseprecautions should be followed implicitly at all times.

WARNING!A battery can present a risk of electricalshock and high short circuit current. Servicing ofbatteries should be performed or supervised only byproperly trained and qualified personnel knowledgeableabout batteries and the required precautions.

The following precautions should be observed whenworking on batteries:

Remove watches, rings, and other metal objects.

Eye protection should be worn to prevent injuryfrom accidental electrical arcs.

Use certified and well maintained insulated tools.Use double insulated tools appropriately rated forthe work to be performed. Ensure that wrencheswith more than one working end have only one endexposed.

Dispose of used batteries according to theinstructions provided with the batteries. Do notdispose of batteries in a fire. They may explode.

ALWAYS FOLLOW THE BATTERY MANUFACTURERSRECOMMENDATIONS AND SAFETY INSTRUCTIONS.

CAUTION!Performing maintenance and/ortroubleshooting procedures may interrupt power to the

loads, if battery reserve is not sufficient.

Handling Equipment ContainingStatic Sensitive Components

ALERT!Installation or removal of equipment containingstatic sensitive components requires careful handling.Before handling any equipment containing staticsensitive components, read and follow the instructionscontained on the Static Warning Page.

Danger

Danger

Warning

Warning

Warning

Danger

Caution

Alert


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Spec. No: 582136700 Section 6009Model No: 502 NGFB Issue U, January 12, 2015[v]

Static Warning

The printed circuit cards used in this equipment contain static sensitive components. The warnings listed below must be observed toprevent 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 static sensitive component or printed circuit card containing such a component, discharge all static electricityfrom yourself by wearing a wrist strap grounded through a one megohm resistor. Some wrist straps, such as Emerson NetworkPower Part Number 631810600, have a built-in one megohm resistor; no external resistor is necessary. Read and follow wrist strapmanufacturers instructions outlining use of a specific wrist strap.

3. Do not touch the traces or components on a printed circuit card containing static sensitive components.Handle the printed circuit card only by the edges that do not have connector pads.

4. After removing a printed circuit card containing a static sensitive component, place the printed circuit card only on conductive oranti-static material such as conductive foam, conductive plastic, or aluminum foil. Do not use ordinary Styrofoam or ordinaryplastic.

5. Store and ship static sensitive devices or printed circuit cards containing such components only in static shielding containers.

6. If necessary to repair a printed circuit card containing a static sensitive component, 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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Spec. No: 582136700 Section 6009Model No: 502 NGFB Issue U, January 12, 2015[vi]

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Spec. No: 582136700 Section 6009Model No: 502 NGFB Issue U, January 12, 2015[1]

Customer Documentation PackageThis document (Section 6009) provides Installation Instructions forNetSure Power System Model 502 NGFB, Spec. No. 582136700 .

The complete Customer Documentation Package consists of

System Installation Manual

Power System Installation Instructions: Section 6009

System User Manual

Power System User Instructions: Section 6010

Rectifier Instructions: UM1R482000e

Power System System Application Guide:SAG582136700

Engineering Drawings

Controller User Manual

NCU Controller User Instructions: UM1M830BNA

ACU+ Controller User Instructions: UM1M820BNA

SCU+ Controller User Instructions: UM1M521BNA

For factory settings of all configurable Controller parameters, referto the Configuration Drawing (C-drawing) supplied with your

Power System.

Installation Acceptance ChecklistProvided below is an Installation Acceptance Checklist. Thischecklist helps ensure proper installation and initial operation ofthe system. As the procedures presented in this document arecompleted, check the appropriate box on this list. If the procedureis not required to be performed for your installation site, alsocheck the box in this list to indicate that the procedure was read.When installation is done, ensure that each block in this list hasbeen checked. Some of these procedures may have been factoryperformed for you.

ote: The system is not powered up until the end of this checklist.ote: Some of these procedures may have been performed at the

factory for you.

Installing the System

Relay Racks (if required) Secured to Floor

Power/Distribution Shelf Secured to Relay Rack orCabinet

Circuit Breakers Installed

Fuses Installed

Making Electrical Connections

Relay Rack Frame Grounding Connection Made

Power/Distribution Shelf Frame Grounding ConnectionMade

AC Input and AC Input Equipment GroundingConnections Made

External Interface Connections Made

Digital Inputs

Relay Outputs

Temperature Probes

Load Connections Made

CO Ground Connection Made

Battery Connections Made

Batteries Installed and Connected in an optionalBattery Tray (if furnished)

Optional External Battery Disconnect UnitConnections Made

Ethernet Connection Made (if required)

Installing Rectifier Modules

Rectifier Modules Installed

Initially Starting the System

System Started, Configured, and Checked

Installing the SystemGeneral Requirements

This product is intended only for installation in aRestricted 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 NetworkTelecommunication Facilities (CO, vault, hut, or otherenvironmentally controlled electronic equipmentenclosure).

This product is intended to be connected to the commonbonding network in a Network Telecommunication


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Facility (CO, vault, hut, or other environmentallycontrolled electronic equipment enclosure).

The installer should be familiar with the installationrequirements and techniques to be used in securing therelay rack(s) to the floor.

Typical industry standards recommend minimum aislespace clearance of 2'6" for the front of the relay rack(s)and 2' for the rear of the relay rack(s).

The installer should be familiar with the installationrequirements and techniques to be used in securing thePower/Distribution Shelf to a relay rack or cabinet.

Rectifier and mounting shelf ventilating openings must

not be blocked and temperature of air entering rectifiersmust not exceed rated Operating Ambient TemperatureRange found in SAG582136700.

Units with the side mounted Molex AC input connectorsEnd Use Application MUST be within an electronicequipment enclosure.

Securing the Relay Rack(s) to the Floor(if furnished)Secure the relay rack(s) to the floor per site requirements. Refer tothe General Requirements section at the beginning of this section.

Ventilation Requirements

Refer to the General Requirements section at the beginning of thissection.

Relay Rack Floor Mounting Dimensions

Refer to Figure 1 and Figure 2 for relay rack floor mountingdimensions.


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Figure 1. Relay Rack Floor Mounting Dimensions - 23 (dimensions are in inches)

Part No. 525004

Part No. 525111

Part No. 524913

17.5020.13

24.38

2.133.44

9.88

12.53

15.00

1.242.56

0.875 Dia.(8 Places)

Masked for Frame Ground Lug0.281 Dia. Holes on 0.625 Centers(Top of Rack, 2 Places)

22.50024.750

1.125

15.000

17.50020.125

25.000

2.4373.750

9.871

12.531

15.031

1.2502.580

2.00

1.00

1.00

2.00

2.002.00

5.00




Masked for Frame Ground Lug0.281 Dia. Holes on 0.625 Centers(Top of Rack, 1 Place)


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Figure 2. Relay Rack Floor Mounting Dimensions - 19 (dimensions are in inches)

Part No. 525003

Part No. 528183

Part No. 524988

13.5016.13

20.38

2.133.44

9.88

12.53

15.00

1.242.56



18.50020.750

1.125

15.000

14.1316.75

21.00

2.133.44

9.38

12.03

15.00

1.492.81

2.00

1.00

1.00

2.00

2.002.00

5.00






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Securing the Power/Distribution

Shelf to a Relay Rack or CabinetThe shelf is designed to mount in a standard 19 or 23 wide relayrack or cabinet frame having 1 or 1-3/4 multiple drillings. Referto SAG582136700 for overall dimensions and a list of availablerelay racks.

ote: Refer to the General Requirements section at the beginning ofthis section for Ventilation Requirements.

ote: Multiple Power/Distribution Shelves may be stacked one abovethe other with no space between the shelves.

Mounting the Shelf

1. Secure shelf mounting angles to relay rack or cabinet attwo (2) locations per side. Use grounding washers at one(1) location per side. Proper orientation of groundingwashers enables teeth to dig into paint for a secureground connection. Torque connections to 70 in-lbs.

ote: Compliance with Telcordia GR-1089-CORE requiresthat prior to mounting the Power/Distribution Shelfto the equipment rack:

All paint must be removed from the frontsurface of each equipment rack rail where itmates with a shelf-mounting bracket, so that good metal-to-metal contact can be

established between the shelf and rack. The shelf-to-rack mating surfaces must be

cleaned.

Electrical anti-oxidizing compound must beapplied to the shelf-to-rack mating surfaces.

Securing the Power/Distribution

Shelf to a Wall with a Part No. 553203 Kit

An optional Wall Mount Bracket Kit (Part No. 553203) is availablefor vertical wall mounting of any List 2 or 6 Power/DistributionShelf.

ote: Refer to the General Requirements section at the beginning ofthis section for Ventilation Requirements.

Procedure

1. Refer to Figure 3 when performing this procedure.

2. The installer must provide fasteners for securing the shelfto a wall or other vertical surface. Ensure that the walland fastening technique are suitable for supporting theweight of the shelf and rectifiers. Suggested anchors arelisted in the illustrations. Refer to System ApplicationGuide SAG582136700 for shelf weight and additionaldimensions.

3. Attach the brackets to the shelf mounting angles usingkit-furnished screws. Torque to 60 in-lbs.

4. Use drill guide dimensions in the illustration to preparethe wall for customer-furnished fasteners. Secure theshelf assembly to the wall.


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Figure 3. Vertical Wall Mounting, List 2 or 6

Front

Installer to furnish hardwarefor fastening brackets to wall.Use (2) wall anchors per bracket.For solid concrete block, hardnatural stone or solid brick, useHilti HLC H 5/16 X 1-5/8 or similar.

Bottomof Shelf

19 shelf shown.23 shelf similar.

Wall Mount Drilling Guide ( Not to scale) All dimensions are in inches.

3-1/8

18-15/16 (19 Shelf)22-29/32 (23 Shelf)

3/8 Dia.Clearance

Hole inBracketfor Wall

Fastener

(Front)


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Installing Circuit Breakers and Fuses

GMT Load Distribution Fuses (List BF, LF and NF)

Procedure

ote: Refer to Figure 4.

1. Open the Distribution Units front access panel.

2. Install correctly sized GMT fuses into the fuse holders located inside the Distribution Unit, as required. If a dummy fuse isinstalled, first remove the dummy fuse. Install a safety fuse cover over each GMT fuse.

3. When finished, close the Distribution Units front access panel.

Figure 4. Installing GMT Load Distribution Fuses (List BF, LF and NF)

Front

GMT FusePositions(Max. 15A)

GMT FusePositions

(Max. 10A)

Front access panelremoved in illustrationfor clarity.


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GMT Load Distribution Fuses (List BA, LA, NA, BC, LC and NC)

Procedure



2. Install correctly sized GMT fuses into the fuse holders located inside the Distribution Unit, as required. If a dummy fuse isinstalled, first remove the dummy fuse. Install a safety fuse cover over each GMT fuse.


Figure 5. Installing GMT Load Distribution Fuses (List BA, LA, NA, BC, LC and NC)

GMT FusePositionsMax. 10AFront

GMTFuses


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Bullet Nose-Type Load Distribution Circuit Breakers (List BC, LC and NC)

Procedure



2. Install correctly sized bullet nose-type circuit breakers into the mounting positions located inside the Distribution Unit, asrequired. Orient the circuit breaker with the ON position to the right. Ensure the alarm contact on the back of the circuitbreaker makes contact with the alarm terminal on the mounting circuit card.


Figure 6. Installing Bullet-Nose-Type Load Distribution Circuit Breakers (List BC, LC and NC)

Front

Load DistributionCircuit Breakers


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Bullet Nose-Type Battery Disconnect and Load Distribution Circuit Breakers (List BA, LA and NA)

Procedure



2. Install correctly sized bullet nose-type circuit breakers into the mounting positions located inside the Distribution Unit, asrequired. Orient the circuit breaker with the ON position to the right. Ensure the alarm contact on the back of the circuitbreaker makes contact with the alarm terminal on the mounting circuit card.


Figure 7. Installing Bullet-Nose-Type Battery Disconnect and Load Distribution Circuit Breakers (List BA, LA and NA)

Front


Battery DisconnectCircuit Breakers


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Installing Load Distribution Fuses (List KG GMT Load Distribution Fuse Panel)

Procedureote: Refer to Figure 8

1. Install distribution fuses. Use only Bussmann GMT type of the rating required for your application.

CAUTION!At +40C and +65C ambient, a fuse with a rating of greater than 10 amperes SHALL HAVE an empty mountingposition between it and any other fuse.

2. If your installation requires dummy fuses in all unused fuse positions, install the dummy fuses (factory provided).

3. Ensure that fuse safety covers are installed on each fuse.

Figure 8. Installing GMT Load Distribution Fuses (List KG)

Installing an Optional Battery CabinetNetSure 201 BC Battery Cabinet, Part No. 541434

Refer to the instructions (Section 6023) supplied with the Battery Cabinet.

NetSure 211 BC Battery Cabinet, Part No. 545534

Refer to the instructions (Section 6033) supplied with this Battery Cabinet.




Refer to the instructions (UM554631) supplied with this Battery Cabinet.

GMT Fuse

Safety Cover

Caution


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Making Electrical ConnectionsImportant Safety Instructions

DANGER!Adhere to the Important Safety Instructionspresented at the front of this document.

Wiring ConsiderationsFor recommended wire sizes, crimp lugs, branch circuit protection,alarm relay contact ratings, and general wiring information andrestrictions; refer to System Application Guide SAG582136700.The SAG is located in the separate User Manual .

Refer to drawing 031110100 for lug crimping information. Refer

to drawings 031110200 and 031110300 for additional luginformation. These are located in the Installation Manual .

All wiring and branch circuit protection should follow the currentedition of the American National Standards Institute (ANSI)approved National Fire Protection Association's (NPFA) NationalElectrical Code (NEC), and applicable local codes. For operation incountries where the NEC is not recognized, follow applicablecodes.

Relay Rack Frame Grounding ConnectionFor relay rack grounding requirements, refer to the current editionof the American National Standards Institute (ANSI) approved

National Fire Protection Association's (NPFA) National ElectricalCode (NEC), applicable local codes, and your specific siterequirements.

Procedure

1. Attach a customer grounding network lead to theequipment mounting rack(s) per site requirements.Holes are provided on the top of each relay rack forinstalling a lead with a two-hole lug that has 1/4" boltclearance holes on 5/8" centers. When using 1/4-inchhardware, recommended torque is 84 in-lbs when astandard flat washer and lock washer are used.

Power/Distribution Shelf

Frame Grounding ConnectionFor shelf grounding requirements, refer to the current edition ofthe American National Standards Institute (ANSI) approvedNational Fire Protection Association's (NPFA) National ElectricalCode (NEC), applicable local codes, and your specific siterequirements.

Procedure

1. The frame grounding connection to the shelf is made byusing grounding washers with the mounting hardwareused to secure the shelf to the relay rack or cabinet.Refer to the previous procedure Securing thePower/Distribution Shelf to a Relay Rack or Cabinet.Ensure that the relay rack or cabinet is properlygrounded.

ote: The DC return connection to this system can remain isolatedfrom system frame and chassis (DC-I).

AC Input and AC Input EquipmentGrounding ConnectionsFollow the Admonishments listed at the beginning of this sectionwhen making AC input connections.

ote: Refer to SAG582136700 for AC Input Cable Assemblies/LineCords and recommended branch circuit protection.

Each shelf requires two (2) AC input branch circuits. In the 19shelf, each feeds one rectifier. In the 23 shelf, one feeds onerectifier and the other feeds two rectifiers.

AC input connections are made using the AC Input CableAssemblies/Line Cords ordered with the system. These areconnected to the plug-in Molex connectors located on the side ofthe shelf. Connect the other end of the AC Input CableAssemblies/Line Cords to a properly wired AC outlet or distributionbox. Note that List 2 is equipped with P/N 556851 vertical flushmount kit or P/N 558707 mount kit, and List 6 is equipped withP/N 558708 mount kit. AC input connectors are made at the rearof the shelf. Refer to Figure 9 and Figure 10 .

Danger


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Figure 9. AC Input Connections Side Mounted Plug-In Molex AC Input Connectors


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Figure 10. AC Input Connections Rear Mounted Plug-In Molex AC Input Connectors


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External Interface Connections

IB2 (CONTROLLER INTERFACE BOARD) CONNECTIONS

The IB2 (Controller Interface Board) provides connection points fordigital inputs, programmable relay outputs, and temperatureprobes. Refer to Figure 11 for connector locations, and to Table 1 , Table 2 , and Table 3 for pin-out information.

If required to access these connection points, loosen the captivefastener on the front of the IB2 Board, and slide the board partiallyout of the shelf.

ote: Alarm Cables sets are available (see SAG582136700 for partnumbers). Two sets are available for the Digital Inputs andanother set for the Relay Outputs. Refer to Table 1 throughTable 3 for color scheme. If the Relay Outputs Alarm Cable orDigital Inputs Alarm Cable is ordered, one half is factoryconnected in the shelf. The other half has a mating connectoron one end and is un-terminated on the other end.

CAUTION!All conductors in the Alarm Cable may beconnected within the cabinet. Shorting or grounding ofunused conductors may result in service interruption orequipment damage. Therefore insulate all conductorends not being used in your application.

ote: Each Temperature Probe assembly consists of two pieces. If probes are ordered with the Power System, one piece is factory

connected in the shelf.Digital Inputs and Programmable Relay Outputs

Digital input and relay output leads are connected to screw-typeterminal blocks located on the IB2. Recommended torque forthese connections is 2.2 in-lbs. Refer to Figure 11 for connectorlocations, and to Table 1 , Table 2 , and Table 3 for pin-outinformation.

Digital Inputs

Connect up to eight (8) digital inputs to the IB2. Note that youmust supply both paths for the digital input (either a positive ornegative signal and the opposite polarity return path). Observeproper polarity. Refer to Figure 11 for terminal locations and Table1 and Table 2 for pin-out information. Note that some of theseinputs are factory connected, as listed in Table 1 and Table 2 .

The digital inputs can be programmed to provide an alarm whenthe signal is applied (HIGH) or removed (LOW). Refer to theController User Manual for programming information.

Digital Input Ratings: Refer to the following.

a. Maximum Voltage Rating: 60V DC.

b. Active High: > 19V DC.

c. Active Low: < 1V DC.

The digital inputs may be preprogrammed for specific functions.Refer to the configuration drawing (C-drawing) supplied with yoursystem for your systems specific configuration.

External Battery Disconnect Circuit Breaker Alarm Input

Connect the alarm lead from an optional External BatteryDisconnect Unit or the battery disconnect circuit breaker on anoptional Battery Tray to the Negative () side of Digital Input #2(terminal 3 of connector J3). 48VDC is applied to the alarm leadwhen the circuit breaker is in the OFF position. Refer to Figure 11 .

-48VDC is supplied to the alarm lead when the circuit breaker is inthe OFF position. The positive side of Digital Input #2 is factory-

wired to battery return.Programmable Relay Outputs

The IB2 provides eight (8) programmable alarm relays with dryForm-C contacts. Connect up to eight (8) relay outputs to the IB2.Refer to Figure 11 for connector locations, and to Table 3 for pin-out information.

ote: The relay assigned to the Major Summary alarm (SCU+) orCritical Summary alarm (NCU or ACU+) (relay 1 by defaulwill operate in the Fail Safe Mode. Fail Safe Mode meansRelay 1 is de-energized during an alarm condition, opening thecontacts between the C and NO terminals, and closing thecontacts between the C and NC terminals.

The remaining 7 relays energize during an alarm condition,closing the contacts between the C and NO terminals, andopening the contacts between the C and NC terminals.

Refer to Table 3 if you are using the default relay assignments. Ablank column in the table is also provided if you want to documenta custom configuration.

Refer to the Controller User Manual for programming information.

Relay Ratings: Refer to the following.

a. 1A Steady State @ 30V DC.

b. 3A Peak @ 30V DC.The relays may be preprogrammed for specific functions. Refer tothe configuration drawing (C-drawing) supplied with your systemfor your systems specific configuration.

Temperature Probes

Up to two (2) temperature probes can be connected to the IB2Board. Either or both probes can be programmed to monitorambient temperature or battery temperature.

Caution


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A temperature probe set as a battery probe can also be designatedto be used for the battery charge temperature compensationfeature. If the system is equipped with the NCU or ACU+Controller, the battery charge temperature compensation featurecan be programmed to use one probe or the average or highestvalue of all probes programmed to monitor battery temperature.The battery charge temperature compensation feature allows thecontroller to automatically increase or decrease the output voltageof the system to maintain battery float current as batterytemperature decreases or increases, respectively. Battery life canbe extended when an optimum charge voltage to the battery withrespect to temperature is maintained.

If the system is equipped with the NCU or ACU+ Controller, atemperature probe set as a battery probe can also be used for

controlling against battery thermal runaway (BTRM feature).

Each Temperature Probe consists of two pieces. One piece isfactory installed to the shelf and the other is shipped loose. Locateand install the shipped loose piece to the piece factory installed inthe shelf. A temperature probe programmed to monitor batterytemperature should be mounted on the top or side of a battery cellto sense battery temperature. A temperature probe used forbattery charge temperature compensation or BTRM (BatteryThermal Runaway Management) should also be mounted on thetop or side of a battery cell. A temperature probe programmed tomonitor ambient temperature should be mounted in a convenientlocation, away from direct sources of heat or cold. To mount, peelthe backing from the self-adhesive surface, and affix the probe to aclean, dry surface. Note that temperature probes with a mountingtab are also available (see SAG582136700).

Table 1. Programmable Digital Inputs (Factory Default)

ProgrammableDigital Input IB2 Pin No. Digital Input Cable Color Scheme Dedicated to...

1 J3-2 + Internal Wiring Internal Load

Circuit Breaker /Fuse Alarm J3-1 Internal Wiring

2 J3-4 + Jumpered to J3-2(Battery Return) External Battery

Circuit Breaker Alarm J3-3 O-R

3 J3-6 + R-BL

User Defined J3-5 BL-R

4 J4-2 + W-S

User Defined J4-1 S-W

5 J4-4 + W-BR

User Defined J4-3 BR-W

6 J4-6 + W-G

User Defined J4-5 G-W

7 J5-2 + W-O

User Defined J5-1 O-W

8 J5-4 + W-BL Emergency Stop(User Pre-Defined) J5-3 BL-W-- J5-5

Not Used Not Used-- J5-6

CAUTION!All conductors in this harness may be connected within the cabinet. Shorting orgrounding of unused conductors may result in service interruption or equipment damage.Therefore insulate all conductor ends not being used in your application.

Caution


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Table 2. Programmable Digital Inputs (Factory Default)SPECIAL APPLICATIO CABLE P/ 54559 1

ProgrammableDigital Input IB2 Pin No.

Special ApplicationCable P/N 545591

Color SchemeDedicated to...

1 J3-2 +

Internal WiringInternal Load

Circuit Breaker /Fuse Alarm J3-1

2 J3-4 + Jumpered to J3-2(Battery Return) External Battery

Circuit Breaker Alarm J3-3 None

3 J3-6 + None

User Defined J3-5 None

4 J4-2 + Slate

User Defined J4-1 -48VDC Applied Internally

5 J4-4 + Brown


6 J4-6 + Violet


7 J5-2 + Orange


8 J5-4 + None

Emergency Stop J5-3 None

-- J5-5 not used -- J5-6

CAUTION!All conductors in this harness may be connected within the cabinet. Shorting orgrounding of unused conductors may result in service interruption or equipment damage.Therefore insulate all conductor ends not being used in your application.

Caution


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Table 3. Programmable Relay Assignments (Factory Default)

ProgrammableRelay Output IB2 Pin No.

Alarm CableColor Scheme

Alarms Assigned to thisRelay (Default)

Alarms Assigned to thisRelay (Custom)

1 *NO J6-5 W-BL SCU+: Any Major Alarm

NCU or ACU+: Any CriticalAlarm

COM J6-3 BL-WNC J6-1 W-O

2NO J6-6 O-W SCU+: Any Minor Alarm

NCU or ACU+: Any MajorAlarm

COM J6-4 W-GNC J6-2 G-W

3NO J7-5 W-BR

DC Volt High #1COM J7-3 BR-WNC J7-1 W-S

4NO J7-6 S-W

Batt DischargeDC Volt Low #1

COM J7-4 R-BLNC J7-2 BL-R

5NO J8-5 R-O

DC Volt Low #2COM J8-3 O-RNC J8-1 R-G

6NO J8-6 G-R

AC FailureCOM J8-4 R-BRNC J8-2 BR-R

7

NO J9-5 R-S

Fuse AlarmCOM J9-3 S-RNC J9-1 BK-BL

8

NO J9-6 BL-BKLoad Share AlarmRect No Response

Rect HVSDRect AC FailRect FailureRect ProtectRect Fan FailRect Derated

Rect Temp Alarm

COM J9-4 BK-O

NC J9-2 O-BK

ote: * The controller relay assigned to Critical Summary (NCU or ACU+) alarm or Major Summary (SCU+) alarm (relay 1 by default)will operate in the Fail Safe Mode. Fail Safe Mode means Relay 1 is de-energized during an alarm condition, opening the contacts

between the C and NO terminals, and closing the contacts between the C and NC terminals.The remaining 7 relays energize during an alarm condition, closing the contacts between the C and NO terminals, and opening thecontacts between the C and NC terminals.

CAUTION!All conductors in this harness may be connected within the cabinet. Shorting orgrounding of unused conductors may result in service interruption or equipment damage. Thereforeinsulate all conductor ends not being used in your application.

Caution


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Figure 11. IB2 Controller Interface Board Assembly External Interface Connections


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Ethernet Connection

ote: If the Web Interface is not being used with this system, skip this procedure.The controller provides a Web Interface via an Ethernet connection to a TCP/IP network. An RJ-45 10BaseT jack is provided on the front ofthe controller for connection into a customer's network running TCP/IP. This jack has a standard Ethernet pin configuration scheme,twisted pair. Refer to Figure 12 for location and Table 4 for pin outs. Use shielded Ethernet cable (grounded at both ends). Note that thecontroller RJ-45 jack is connected to chassis ground.

WARNING!The intra-building port(s) of the equipment or subassembly is suitable for connection to intra-building orunexposed wiring or cabling only. The intra-building port(s) of the equipment or subassembly MUST NOT be metallicallyconnected to the interfaces that connect to the OSP or its wiring. These interfaces are designed for use as intra-buildinginterfaces only (Type 2 or Type 4 ports as described in GR-1089-CORE, Issue 4) and require isolation from the exposed OSPcabling. The addition of Primary Protectors is not sufficient protection in order to connect these interfaces metallically to OSPwiring.

Table 4. Controller RJ-45 Ethernet Port Pin Configuration

Port Pin Number Name Definition

1 Tx+ Write Signal +2 Tx- Write Signal -3 Rx+ Read Signal +4 -- no connection5 -- no connection6 Rx- Read Signal -7 -- no connection8 -- no connection

ote: You can access the Web pages of the Power System locally byusing a "crossover" cable connected directly between your PC andthe controller.

Warning


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Figure 12. Controller RJ-45 Ethernet Port


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Load Connections

TO GMT FUSE POSITIONS (LIST BF, LF AND NF)

Load distribution (GMT fuses) and load return leads are connected to receptacles located inside the Distribution Unit. Load leads arebrought into the right side (as viewed from the front) of the shelf and are accessible from the front of the shelf. Note that the GMTdistribution fuse block accepts two ranges of fuse amperage sizes, and that two different types of receptacles are provided.

O serve correct polarity as shown in Figure 13 when connecting leads.

a. Lists 61 provides 12 long, 16 AWG, load and load return leads that are terminated on one end with the appropriate matingconnector to plug into the systems lower amperage rating GMT fuse connector, and are left un-terminated at the remainingend for connection into customer loads. Refer to SAG582136700 for P/Ns of the mating connector if you decide to make yourown cable.

b. Lists 62 provides 12 long, 14 AWG, load and load return leads that are terminated on one end with the appropriate mating

connector to plug into the systems higher amperage rating GMT fuse connector, and are left un-terminated at the remainingend for connection into customer loads. Refer to SAG582136700 for P/Ns of the mating connector if you decide to make yourown cable.


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Figure 13. Load Connections to GMT Fuse Positions (List BF, LF, and NF)

Load DistributionLeads Enter Here

GMT Fuse LoadDistribution LeadsConnect Here

GMT FusePositions(Max. 10A)

GMT FusePositions

(Max. 15A)

Mating Connectors and 12 Leads provided with List 62.

GMT Fuse LoadDistribution Leads

Connect Here

Mating Connectors and 12 Leads provided with List 61.

-48V on Left (Black Lead),Return on Right (White Lead)

-48V on Left (Black Lead),Return on Right (White Lead)

Front


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TO GMT FUSE POSITIONS (LIST BA, LA, NA, BC, LC AND NC)

Load distribution (GMT fuses) and load return leads are connected to receptacles located inside the Distribution Unit. Load leads arebrought into the right side (as viewed from the front) of the shelf and are accessible from the front of the shelf.

O serve correct polarity as shown in Figure 14 when connecting leads.

a. List 60 provides 12 long, 16 AWG, load and load return leads that are terminated on one end with the appropriate matingconnector to plug into the systems GMT fuse connector, and are left un-terminated at the remaining end for connection intocustomer loads. Refer to SAG582136700 for P/Ns of the mating connector if you decide to make your own cable.

Figure 14. Load Connections to GMT Fuse Positions (List BA, LA, NA, BC, LC and NC)

Front

GMT Fusesand Safety CoversMax. 10A

GMT Fuse LoadDistribution LeadsConnect Here

Mating Connectors and 12 Leads provided with List 60

-48V on Left (Black Lead),Return on Right (White Lead)as viewed from side with door closed


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TO BULLET NOSE-TYPE LOAD DISTRIBUTION CIRCUIT BREAKER POSITIONS (LIST BC, LC, AND NC)

Load distribution (circuit breakers) and load return leads terminated in two-hole lugs are connected to threaded studs located inside theDistribution Unit. Load leads are brought into the right side (as viewed from the front) of the shelf and are accessible from the front ofthe shelf. Refer to Figure 15.

ote: 10-32 studs (w/hardware) on 5/8" centers are provided for these connections. Note that one stud is used to secure lug, the other is usedfor anti-rotation. Recommended torque is 20 in-lbs when using the supplied hardware.

Figure 15. Load Connections to Bullet Nose-Type Distribution Circuit Breaker Positions and CO Ground Connection (List BC, LC, and NC)

10-32 studs (w/ hardware0on 5/8 centers for installationof customer provided two-hole lugs.Note that one stud is used to securelug, the other is used for anti-rotation.

Portion of shelf removedin illustration for clarity.Leads are brought intoside of shelf, and toolsto secure lugs fromfront of shelf.


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TO BULLET NOSE-TYPE LOAD DISTRIBUTION CIRCUIT BREAKER POSITIONS (LIST BA, LA AND NA)

Load distribution (circuit breakers) and load return leads terminated in two-hole lugs are connected to threaded studs located inside theDistribution Unit. Load leads are brought into the right side (as viewed from the front) of the shelf and are accessible from the front ofthe shelf. Refer to Figure 16.

ote: 10-32 studs (w/hardware) on 5/8" centers are provided for these connections. Note that one stud is used to secure lug, the other is usedfor anti-rotation. Recommended torque is 20 in-lbs when using the supplied hardware.

Figure 16. Load Connections to Bullet Nose-Type Distribution Circuit Breaker Positions Battery Connections to Bullet Nose-Type Circuit BreakerPositions CO Ground Connection (List BA, LA and NA)

Front

CO Ground, Circuit Breaker Load Distribution, and CircuitBreaker Battery LeadsEnter Here

Front

Portion of shelf removedin illustration for clarit y.Leads are brought intoside of shelf, and toolsto secure lugs fromfront of shelf.

OBSERVE PROPERPOLARITY WHENMAKING BATTERYCONNECTIONS

Battery Return LeadsLoad Return LeadsCO Ground Lead

10-32 studs (w/ hardware)on 58 centers for installationof customer provided two hole lugs.

-48V BatteryLeads

-48V LoadDistribution Leads


Battery DisconnectCircuit Breakers


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LIST KG GMT LOAD DISTRIBUTION FUSE PANEL

WARNING!Check for correct polarity before making connections.

Load and Load Return connections are made to the terminal blocks located on the front of the assembly. These terminal blocks providescrew compression type terminals, which accept a wire size in the range of 26 to 14 AWG. Refer to Figure 17 . Recommended torque is5.0 in-lbs.

ote: A Side and B Side inputs are strapped in this power system.

Figure 17. Load Connections (List KG)

A S i d e

L o a

d s

# 1

- # 5

A S i d e

L o a

d s

# 6

- # 1 0

A S i d e

R e t u r n s

B S i d e

L o a d s

# 1

- # 5

B S i d e

L o a

d s

# 6

- # 1 0

B S i d e

R e t u r n s

Warning


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CO Ground Connection

Two 10-32 studs on 5/8 centers with hardware are provided on the Return Bus for CO Ground wiring.A CO ground lead terminated in a two-hole lug can be connected as shown in Figure 18 .

ote: 10-32 studs (w/hardware) on 5/8" centers are provided for this connection. Note that one stud is used to secure lug, the other is used foranti-rotation. Recommended torque is 20 in-lbs when using the supplied hardware.

Battery ConnectionsDANGER!Although battery voltage is not hazardously high, the battery can deliver large amounts of current. Exercise extremecaution not to inadvertently contact or have any tool inadvertently contact a battery terminal or exposed wire connected to abattery terminal. NEVER allow a metal object, such as a tool, to contact more than one termination at a time, or tosimultaneously contact a termination and a grounded object. Even a momentary short circuit can cause explosion and injury.

Remove watches, rings, or other jewelry before connecting battery leads. Make the DC (battery) connections last. Make allother electrical connections without DC input power applied to the system.

DANGER!Ensure correct polarity when connecting battery leads.

TO BATTERY BUSBARS

Battery and battery return leads terminated in two-hole lugs are connected to threaded studs located inside the Distribution Unit.Battery leads are brought into the right side (as viewed from the front) of the shelf and are accessible from the front of the shelf. Refer toFigure 18 . Observe proper polarity when connecting leads.

ote: 1/4-20 studs (w/hardware) on 5/8" centers are provided for these connections. Both studs are used on Lists 2 and 6. Recommendedtorque is 84 in-lbs when using the supplied hardware.

TO BULLET NOSE-TYPE CIRCUIT BREAKER POSITIONS (LISTS BA, LA, AND NA)

Battery and battery return leads terminated in two-hole lugs are connected as shown in Figure 16 . Observe proper polarity whenconnecting leads.

ote: 10-32 studs (w/hardware) on 5/8" centers are provided for these connections. Recommended torque is 20 in-lbs when using the suppliedhardware.

Danger

Danger


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Figure 18. Battery Connections


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INSTALLING AND CONNECTING BATTERIES IN AN OPTIONAL BATTERY TRAY (IF FURNISHED)

Important Safety Instructions

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 befollowed implicitly at all times.

WARNING!A battery can present a risk of electrical shock and high short circuit current. Servicing of batteries should beperformed or supervised only by properly trained and qualified personnel knowledgeable about batteries and the requiredprecautions.

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 beperformed. 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. When replacing batteries, replacewith 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 MANUFACTURERS RECOMMENDATIONS AND SAFETY INSTRUCTIONS.

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. If electrolyte comes intocontact with skin, the affected area should be washed immediately with large amounts of water.

DANGER! This equipment may be used in conjunction with lead-acid batteries.Working near lead-acid batteries is dangerous!

Batteries contain sulfuric acid.

Batteries generate explosive gases during normal operation. Systems containing batteries should never be installed in anairtight 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

WHEN WORKING WITH LEAD-ACID BATTERIES:

Wear complete protection for eyes, face, hands, and clothing. Examples are safety goggles or face shield, a rubber apronand gloves.

If battery acid enters your eye, immediately flush your eye with running cold water for at least 15 minutes. Get medicalattention immediately.

If battery acid contacts skin or clothing, wash immediately with soap and water.

Warning

Warning

Warning

Danger


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Battery Manufacturer Information

Refer to SAG582136700 for specifications and manufacturers of the batteries to be installed in this power system.

Procedure

Tray P/N 528496 is used in the following procedure. The procedure for all other available trays is similar.

ote: Refer to Figure 19 as this procedure is performed.

1. If Battery Trays are Equipped With Circuit Breakers : Turn OFF the Battery Disconnect circuit breakers located on all batterytrays. Refer to Figure 19 for locations.

2. Remove the Battery Retention Bracket as shown in Figure 19 . To do so, remove the four 1/4-20 x 5/8 bolts and associatedwashers.

3. Slide batteries into the tray, with the battery terminals toward the front as shown in Figure 19. Slide batteries into the tray as far

as they will go.ote: The Battery Retention Bracket can be oriented two ways to accommodate batteries of different lengths. A correctly oriented bracke

will fit snuggly against the batteries. If your batteries require the alternate bracket orientation shown in Detail A of Figure 19, remove and reinstall the bullet-shaped spacers (trays P/N 528496 and 540842 only) as shown in Detail A before performing the nexstep.

4. Reinstall the Battery Retention Bracket. Secure with the hardware removed in a previous step. Refer to Figure 19 for washerlocation.

ote: The spacers on the bracket are used to accommodate the various sizes of batteries available. Install or remove the spacers asrequired so that the batteries are tight in the battery tray.

5. Connect three links supplied by the battery manufacturer between pairs of battery terminals as shown in Figure 19 . Usehardware furnished by the battery manufacturer. Torque hardware to battery manufacturers 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 beenergized. Remove sleeving from and connect one cable at a time. Do not allow cable end to contact the battery tray orequipment rack.

WARNING!In the next step, observe correct polarity. Connect only cable labeled + to battery terminal labeled +.Likewise, connect only cable labeled to battery terminal labeled .

7. Connect the cables found in the battery tray to the battery terminals, + to + and to . Observe correct polarity. Referto Figure 19 . Secure with kit-furnished hardware as shown in the figure. Torque hardware to battery manufacturersrecommendations.

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 BatteryDisconnect circuit breakers located on all battery trays.

Danger

Warning


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Figure 19. Battery Installation Details (Optional Battery Tray)

Connect link furnishedwith battery to these

2 terminals.

Connect NEG (-)battery cable to

this terminal.

Connect POS (+)battery cable tothis terminals

SpacersSeparateBatteries(3 placesper tray)*

Battery RetentionBracket.

See Detail A for alternate orientation.

1/4-20 X 5/8" Bolt1/4" Lock Washer 1/4" Flat Washer

3 Places

1/4-20 X 5/8" Bolt

1/4" Ground Washer (1 place)

If trays areequipped withcircuit breakers,TURN OFF ALLcircuit breakersbefore installingand connectingany batteries!

Two trays shownas example.Cabling detailomitted.

Note:1.

2.

Connect link furnishedwith battery to these2 terminals.

Connect link furnishedwith battery to these

2 terminals.

DETAIL AAlternate Orientationof 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" GroundWasher

(1 Place)

1/4-20 x 5/8" HexHead Screw(4 Places)

1/4-20 Lock Washer(3 Places)

1/4-20 Flat Washer(3 Places)

* The spacers on the bracket are used to accommodate the various sizes of batteries available. Install or remove the spacers as required so that the batteries are tight in the battery tray.


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Optional External Battery Disconnect Unit

Refer to Figure 20 for battery and alarm connection details to the optional External Battery Disconnect Unit and torque information. Alsoprovided are alarm connection details to battery disconnect circuit breakers located on the optional battery trays and battery cabinets.

Figure 20. External Interface Connections (contd on next page)

Yellow Alarm Lead(P/N 535294)

(factory wired tocircuit breaker

alarm terminal)

Connect to shelf per table below.Remove quickconnect terminalfirst.

Torque to 84 in-lbsusing supplied hardware

ToPower

SystemTo

BatteryProcedure

1. Connect YEL LOW lead exiting top of Battery Disconnect Unit per table below.Remove quick connect terminal first.The YELLOW lead is factory connectedto circuit breaker C (Common) alarmterminal in the Battery Disconnect Unit.

2. There is NO connection to the circuitbreaker NO (Normally Open)alarm terminal.

3. Connect loose end of Jumper factoryconnected to bottom terminal oncircuit breaker to circuit breaker NC (Normally Closed) alarmterminal.

Alarm Wiring to a SingleExternal Battery Disconnect Unit

541311 Alarm Cableon shelf

NO

YES

BREAKER ALARM CONNECTIONCONNECT YELLOW WIRE TO:

Pin 3 of J3 on Customer Interface board(negative side of Digital Input 2)

O-R Lead of 541311Splice and heat shrink tubing included with 541311


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Figure 20 External Interface Connections (contd from previous page, contd on next page)


NO

YES




In ALL Battery Disconnect Units,connect loose end of Junper factoryconnected to bottom terminal oncircuit breaker to circuit breaker NC (Normally Closed)alarm terminal.

There is NO connection to the circuitbreaker NO (Normally Open)alarm terminal.

Completely remove YELLOW lead exiting top of ALL Battery Disconnect Units and discard.

Connect separately ordered YELLOW jumper/alarmlead (P/N 524384) to circuit breaker C (Common)alarm terminals in ALL Battery Disconnect Units.Connect remaining end per table below.

1st EXTERNAL BATTERYDISCONNECT UNIT

2nd EXTERNAL BATTERYDISCONNECT UNIT

3rd EXTERNAL BATTERYDISCONNECT UNIT

Yellow Jumper/AlarmLead (P/N 524384)

(Ordered separatelyand supplied loosed.

Must be wiredby the cusomer to

each circuit breaker C (Common)alarm terminal


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Figure 20 External Interface Connections (contd from previous page, contd on next page)

Yellow Jumper/AlarmLead (P/N 524384)(Ordered separatelyand supplied loose.

Must be wiredby the customer to

each circuit breaker C (Common)

alarm terminal)

seeprevious

page

Procedure

1. Connect kit-supplied YELLOW jumper/alarm lead(P/N 524384) to circuit breaker C (Common)alarm terminals on ALL Battery Disconnect CircuitBreakers. Connect remaining per table below.

2. There is NO connection to the circuitbreaker NO (Normally Open)alarm terminal.

1st BATTERY TRAYBATTERY DISCONNECT

CIRCUIT BREAKER

Alarm Wiring to Battery Disconnect CircuitBreakers when (1) to (3) Battery Trays are Used

(Side cover removed in illustrationto show wiring details.)

seeprevious

page

seeprevious

page

3. OnALL Battery Disconnect circuitbreakers, there should be a factoryconnected Jumper connected fromthe bottom terminal on the circuitbreaker to the circuit breaker NC(Normally Closed) alarm terminal.

2nd BATTERY TRAYBATTERY DISCONNECT

CIRCUIT BREAKER(if furnished)

3rd BATTERY TRAYBATTERY DISCONNECT

CIRCUIT BREAKER(if furnished)

Connect toshelf per table below.

* No terminalon 524384

jumper


NO

YES

BREAKER ALARM CONNECTIONCONNECTYELLOW WIRE TO:

Pin 3 of J3 on CustomerInterface board(negative side of Digital Input 2)



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Figure 20 External Interface Connections (contd from previous page)

Yellow Jumper/AlarmLead (P/O Cabinet)

Orange wire on541434 not used

Procedure1. Remove quick connect terminal from YELLOW battery

cabinet alarm lead and wire per table below.

1st BATTERY CABINETBATTERY DISCONNECT

CIRCUIT BREAKER

Alarm Wiring to Battery Cabinets

alarmwire

2nd BATTERY CABINETBATTERY DISCONNECT

CIRCUIT BREAKER

3rd BATTERY CABINETBATTERY DISCONNECT

CIRCUIT BREAKER

Connect toshelf per table below.

alarmwire

alarmwire


NO

YES





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Connecting to an Optional Battery Cabinet


Refer to the instructions (Section 6023) supplied with the Battery Cabinet.






Refer to the instructions (UM554631) supplied with this Battery Cabinet.


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Installing the Rectifier ModulesThe Rectifier Module is hot swappable. It can be installed with the system operating.

Refer to Figure 21 as this procedure is performed.

Procedure

1. Place the Rectifier Module into an unoccupied mounting slot without sliding it in completely.

2. Loosen the captive fastener securing the top of the latch mechanism to the front of the Rectifier Module. Pull the top of thelatch mechanism away from the Rectifier Module (this will retract the latch mechanism located on the underside of the RectifierModule).

3. Push the Rectifier Module completely into the shelf. Push the top of the latch mechanism into the front panel of the RectifierModule, and secure by tightening the captive fastener. This locks the Rectifier Module securely to the shelf.

4. Repeat the above steps for each Rectifier Module being installed in the system.

5. After the Rectifier Modules are physically installed in the mounting shelf(s), they are ready for operation immediately afterpower is supplied to them.

Figure 21. Latch Mechanism on the Rectifier Module

Latch Mechanism

Captive Fastener


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Initially Starting the SystemInitially Starting, Configuring, andChecking System Operation when E/W NCUINITIAL STARTUP PREPARATION

Ensure that all blocks except the last one in theInstallation Acceptance Checklist on page 1 have beenchecked.

Refer to the separate NCU User Manual supplied withyour Power System for complete Controller operatinginformation.

Refer to the Configuration Drawing (C-drawing) suppliedwith your Power System for settings of adjustableparameters.

INITIALLY STARTING THE SYSTEM

Procedure

1. Apply DC input power to the system by closing theexternal DC disconnect(s) or protective device(s) thatsupplies battery power to the system, if furnished.

Close the systems internal battery disconnect circuitbreakers, if furnished.

2. Apply AC input power to the system by closing theexternal AC disconnects or protective devices thatsupplies power to the shelf(s).

Note that the shelf requires two (2) AC input branchcircuits.

The rectifiers start and supply power to the loads.

NCU CONTROLLER INITIALIZATION

Refer to Figure 22 for locations of the NCU local indicators andnavigation keys.

Figure 22. NCU Local Indicators and Navigation Keys

Procedure

ote: The initialization routine takes several minutes. During thattime various alarm indicators may illuminate on the NCU fron panel and an audible alarm may sound. Disregard all alarms. An audible alarm can be silenced at any time by momentarilydepressing the E T key on the NCU Controller.

1. After the NCU is powered on, the display shows theEmerson Network Power screen. The controller isinitializing.

2. When initialization is complete, the language screenappears. Press the up or down arrow key to select thedesired language. Press the ENT key to confirm theselection.

3. The Main Menu displays.


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4. System information is displayed in multiple screens.Press the ESC key to view other system information.Press the down arrow key to view the next screen. Pressthe ESC key to return to the Main Menu.

5. From the Main Menu, press the UP and DOWN keys to

highlight the desired Menu graphic in the Main Menu.Press the ENT key to enter the selected menu.

ote: Repeatedly press the ESC key to return in reverseorder level by level from any submenu until the MainMenu appears.

6. Verify and set the NCU controller as required for yourapplication. Refer to the separate NCU User Manual forprocedures. Refer also to NCU Start Wizard on page40.

ote: Any LVD is on LVD1.

ote: When setting total rectifier current limit, the set point to eachunit is the total set point divided by the number of units. Forexample, if the system contains five rectifiers and the currentlimit is set to 150 amps then each rectifier has a current limitset point of 30 amps. If one or more rectifiers are removed orfail it will take several seconds for the individual set points tothe remaining rectifiers to be reset. In the example given, ifone rectifier is removed the current limit set point will drop to120 amps (30 amps times four remaining rectifiers) until thecontroller can send updated set points to the remainingrectifiers. This takes a couple communication cycles (severalseconds) after which each rectifier would have a new set pointof 37.5 amps for a total of 150 amps. The total current limit ofthe rectifiers should not be set such that the loss of the

redundant rectifiers will cause this temporary set point to dropbelow the actual maximum expected load. If batteries areused on the rectifier output, the batteries should support theload until the current limit set points can be re-established dueto loss of a rectifier.

NCU START WIZARD

For initial startup, you can perform the Start Wizard from the localkeypad and display to enter basic programmable parameters inone session. Refer to the Start Wizard section in the NCUInstructions (UM1M830BNA).

VERIFYING THE CONFIGURATION FILE

Your NCU was programmed with a configuration file that sets alladjustable parameters. The version number of the configurationfile can be found on the configuration drawing (C-drawing) that issupplied with your power system documentation, and on a labellocated on the NCU. You can verify that the correct configurationfile has been loaded into your NCU by performing the followingprocedure.

ote: The quantity of LVDs and shunt values for your specific systemmay be different from the values shown on the C-drawing.

Procedure

1. With the Main Menu displayed, press ESC. A screendisplays the NCU name, serial number, IP number,software version, hardware version, and configurationversion number.

2. Press the DOW key. A screen displays the NCU filesystem and MAC address.

3. Press ESC to return to the Main Menu.


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CHECKING BASIC SYSTEM SETTINGS

Navigate through the controller menus and submenus to checksystem settings. You can adjust any parameter as required. Notethat these settings can also be checked (and changed if required)via the WEB Interface. Refer also to NCU Start Wizard on page40.

ote: Repeatedly press the ESC key to return in reverse order levelby level from any submenu until the Main Menu appears.

Procedure

1. To Select a Su -Menu:Press the UP and DOWN keys to highlight the desiredsub-menu. Press the ENT key to enter the selected sub-menu.

2. To Select a User: To select a User, use the UP and DOWN keys to move thecursor to the Select User field. Press ENT. Use the UP andDOWN keys to select a User previously programmed intothe NCU. Press ENT to select the User. Note that onlyUsers programmed into the NCU are shown. Users areprogrammed via the Web Interface. The default User isadmin.

3. To Enter a Password: If a password screen opens, a password must be enteredto allow the User to make adjustments. To enter apassword, use the UP and DOWN keys to move the cursorto the Enter Password field. Press ENT. Use the UP andDOWN keys to choose a ch

Documents

NetSure 502 Integrated System IM582136700