11va4529bl G

NetSureTM
7100 and 8100, Multi Cabinet, 48V DC Power System

Installation and User Instructions (11 VA 4529 BL), Revision G
The information contained in this document is subject to change
without notice and may not be suitable for all applications. While every
precaution has been taken to ensure the accuracy and completeness
of this document, Vertiv Co. assumes no responsibility and disclaims all
liability for damages resulting from use of this information or for any
errors or omissions. Refer to other local practices or building codes as
applicable for the correct methods, tools, and materials to be used in
performing procedures not specifically described in this document.
The products covered by this instruction manual are manufactured
and/or sold by Vertiv Co. This document is the property of Vertiv Co.
and contains confidential and proprietary information owned by Vertiv
Co. Any copying, use or disclosure of it without the written permission
of Vertiv Co. is strictly prohibited.
Names of companies and products are trademarks or registered
trademarks of the respective companies. Any questions regarding
usage of trademark names should be directed to the original
manufacturer.
© 2017 Vertiv Co. All rights reserved.
Vertiv | NetSureTM 7100 and 8100, Multi Cabinet 48V DC Power Systems Installation and User Instructions (11 VA 4529 BL) | Rev. G
TABLE OF CONTENTS
Admonishments Used in this Document ............................................................................................... 5
Important Safety Instructions ..................................................................................................................6
General Safety...................................................................................................................................................................................................... 6
Voltages ..................................................................................................................................................................................................................... 6
AC Input Voltages ...............................................................................................................................................................................................................6
DC Output and Battery Voltages..........................................................................................................................................................................6
Battery .......................................................................................................................................................................................................................... 7
Personal Protective Equipment (PPE) ........................................................................................................................................... 7
Hazardous Voltage ........................................................................................................................................................................................... 7
Handling Equipment Containing Static Sensitive Components ............................................................................. 7
Maintenance and Replacement Procedures............................................................................................................................. 7
Static Warning ...............................................................................................................................................8
General Information and Installation Acceptance Checklist ..........................................................9
Customer Documentation Package ................................................................................................................................................. 9
System Description ......................................................................................................................................................................................... 9
Installation Acceptance Checklist ................................................................................................................................................... 14
Physically Installing the Power System ............................................................................................... 15
General Requirements ................................................................................................................................................................................ 15
Unpacking.............................................................................................................................................................................................................. 15
Securing the Cabinet(s) to the Floor or Wall ......................................................................................................................... 15
Securing Cabinets to Each Other (side-by-side or back-to-back Installations) ................................... 15
Installing Circuit Breakers and Fuses ........................................................................................................................................... 15
Installing Rectifiers......................................................................................................................................................................................... 16
Setting Switch Options ............................................................................................................................. 16
Switch Settings on IB2 Interface Board ...................................................................................................................................... 16
Switch Settings on Optional EIB Interface Board .............................................................................................................. 16
Switch Settings on Optional SM DU+ ...........................................................................................................................................17
Switch Settings on Optional SM DU-H ....................................................................................................................................... 19
Making Electrical Connections .............................................................................................................. 20
Important Safety Instructions ............................................................................................................................................................. 20
Wiring Considerations................................................................................................................................................................................ 20
General Cabling Information ................................................................................................................................................................ 20
Bottom Cabling .................................................................................................................................................................................................................. 20
Top Cabling ........................................................................................................................................................................................................................... 20
Earthing....................................................................................................................................................................................................................22
AC Mains Protective Earth ...................................................................................................................................................................................... 22
DC System Earth ............................................................................................................................................................................................................... 22
Bonding to the Main Earth Terminal (Main Cabinet Only)....................................................................................................... 22
Telecom Earth...................................................................................................................................................................................................................... 22
Cabinet-to-Cabinet Bonding Connection (Side-by-Side Installation) ............................................................23
Cabinet-to-Cabinet Bonding Connection (Back-to-Back Installation) ..........................................................23
Cabinet-to-Cabinet Bonding Connection (Remote Installation) .........................................................................23
Cabinet-to-Cabinet DC Bus Interconnections (Side-by-Side Installation) ................................................23
Cabinet-to-Cabinet DC Bus Interconnections (Back-to-Back or Remote Installation) .................. 27
Cabinet-to-Cabinet Communications Cable (CAN-Bus) Interconnections ............................................. 29
Cabinet-to-Cabinet Emergency Power-Off (EPO) Cable Connections (if provided) ...................... 30
AC Mains Connections .............................................................................................................................................................................. 31
Vertiv | NetSureTM 7100 and 8100, Multi Cabinet 48V DC Power Systems Installation and User Instructions (11 VA 4529 BL) | Rev. G 3
External Alarm, Reference, Monitoring and Control Connections ..................................................................... 31
Connection Locations ...................................................................................................................................................................................................31
IB2 (Controller Interface) Board Connections ......................................................................................................................................33
Optional EIB (Controller Extended Interface Board) Connections .................................................................................. 34
Temperature Sensor Connections .................................................................................................................................................................. 34
Emergency Power-Off (EPO) Connection (if provided)..............................................................................................................35
Ethernet Connection to the NCU Controller (if required) .........................................................................................35
Load Connections .......................................................................................................................................................................................... 37
Battery Connections..................................................................................................................................................................................... 37
Connections to an Optional NetSure™ Battery Cabinet ............................................................................................. 38
Initially Starting and Checking the System ....................................................................................... 39
Operating Procedures .............................................................................................................................. 40
Controller and Rectifiers ..........................................................................................................................................................................40
EPO Function .....................................................................................................................................................................................................40
Local Controls and Indicators.............................................................................................................................................................40
SM-DU+ (if provided) .................................................................................................................................................................................................. 40
SM DU-H (if provided) ................................................................................................................................................................................................. 41
Maintenance ................................................................................................................................................ 42
System Maintenance Procedures ................................................................................................................................................... 42
System Expansion Procedures.......................................................................................................................................................... 42
Adding a Rectifier to the Power System ................................................................................................................................................... 42
Adding a Circuit Breaker to a DC Distribution Unit ........................................................................................................................ 42
Adding a Plug-in DC Distribution Unit to a Cabinet ...................................................................................................................... 42
Adding an Extension Cabinet to the Power System...................................................................................................................... 42
Troubleshooting and Repair ................................................................................................................... 43
Contact Information..................................................................................................................................................................................... 43
Controller and Rectifiers .......................................................................................................................................................................... 43
NCU Controller Configuration ............................................................................................................................................................ 44
System Troubleshooting Information.......................................................................................................................................... 44
Troubleshooting Alarm Conditions on the NCU Controller.................................................................................................... 44
Replacement Information ....................................................................................................................................................................... 44
Replacement Assemblies ......................................................................................................................................................................................... 44
Replacement Procedures ....................................................................................................................................................................... 44
Replacing a Rectifier Module................................................................................................................................................................................ 44
Replacing the NCU Controller ............................................................................................................................................................................. 44
Replacing the EXU Controller .............................................................................................................................................................................. 44
Replacing Distribution Devices .......................................................................................................................................................................... 44
Circuit Board Replacement Procedures .................................................................................................................................................... 44
Technical Data ............................................................................................................................................ 53
NetSure™ 7100 ..................................................................................................................................................................................................53
System .........................................................................................................................................................................................................................................53
Cabinet ........................................................................................................................................................................................................................................53
Rectifier ......................................................................................................................................................................................................................................53
NetSure™ 8100 ................................................................................................................................................................................................. 54
System ........................................................................................................................................................................................................................................ 54
Cabinet ....................................................................................................................................................................................................................................... 54
Rectifier ..................................................................................................................................................................................................................................... 54
ADMONISHMENTS USED IN THIS DOCUMENT
DANGER! Warns of a hazard the reader will be exposed to that will likely result
in death or serious injury if not avoided. (ANSI, OSHA)
WARNING! Warns of a potential hazard the reader may be exposed to that could result
in death or serious injury if not avoided. This admonition is not used for situations that
pose a risk only to equipment, software, data, or service. (ANSI)
CAUTION! Warns of a potential hazard the reader may be exposed to that could
result in minor or moderate injury if not avoided. (ANSI, OSHA) This admonition is not
used for situations that pose a risk only to equipment, data, or service, even if such
use appears to be permitted in some of the applicable standards. (OSHA)
ALERT! Alerts the reader to an action that must be avoided in order to protect
equipment, software, data, or service. (ISO)
ALERT! Alerts the reader to an action that must be performed in order to prevent
equipment damage, software corruption, data loss, or service interruption. (ISO)
FIRE SAFETY! Informs the reader of fire safety information, reminders, precautions,
or policies, or of the locations of fire-fighting and fire-safety equipment. (ISO)
SAFETY! Informs the reader of general safety information, reminders, precautions, or

policies not related to a particular source of hazard or to fire safety. (ISO, ANSI, OSHA)
IMPORTANT SAFETY INSTRUCTIONS
General Safety
DANGER! YOU MUST FOLLOW APPROVED SAFETY PROCEDURES.
Performing the following procedures may expose you to hazards. These procedures should be
performed by qualified technicians familiar with the hazards associated with this type of equipment.
These hazards may include shock, energy, and/or burns. To avoid these hazards:
a. The tasks should be performed in the order indicated.
b. Remove watches, rings, and other metal objects.
c. Prior to contacting any uninsulated surface or termination, use a voltmeter to verify that no voltage
or the expected voltage is present. Check for voltage with both AC and DC voltmeters prior to
making contact.
NOTE! Always verify that your volt meter is in good condition by testing it towards a recognized
supply.
d. Wear eye protection.
e. Use certified and well maintained insulated tools. Use double insulated tools appropriately rated for
the work to be performed.
Voltages
AC Input Voltages
DANGER! This system operates from AC input voltage capable of producing fatal electrical shock.
AC input power must be completely disconnected from the branch circuits wiring used to provide
power to the system before any AC electrical connections are made. Follow local lockout/tagout
procedures to ensure upstream branch circuit breakers remain de-energized during installation. DO
NOT apply AC input power to the system until all electrical connections have been completed and
checked.
DC Output and Battery Voltages
DANGER! This system produces DC power and may have a battery source connected to it.
Although the DC voltage is not hazardously high, the rectifiers and/or battery can deliver large
amounts of current. Exercise extreme caution not to inadvertently contact or have any tool
inadvertently contact an output terminal or battery terminal or exposed wire connected to an output
terminal or battery terminal. NEVER allow a metal object, such as a tool, to contact more than one
termination or battery terminal at a time, or to simultaneously contact a termination or battery
terminal and a grounded object. Even a momentary short circuit can cause sparking, explosion, and
injury.
DANGER! Follow local lockout/tagout procedures to ensure DC branch circuit protection devices
remain de-energized during installation at loads, as required.
Battery
WARNING! Correct polarity must be observed when connecting battery leads.
WARNING! Special safety precautions are required for procedures involving handling, installing, and
servicing batteries. Observe all battery safety precautions in this manual and in the battery
instruction manual. These precautions should be followed implicitly at all times.
WARNING! A battery can present a risk of electrical shock and high short circuit current. Servicing
of batteries should be performed or supervised only by properly trained and qualified personnel
knowledgeable about batteries and the required precautions.
Personal Protective Equipment (PPE)

DANGER! ARC FLASH AND SHOCK HAZARD.
Appropriate PPE and tools required when working on this equipment. An appropriate flash
protection boundary analysis should be done determine the “hazard/risk” category, and to select
proper PPE.
This product is intended only for installation in a Restricted Access Location.
Only authorized and properly trained personnel should be allowed to install, inspect, operate, or
maintain the equipment.
Do not work on LIVE parts. If required to work or operate live parts, obtain appropriate Energized
Work Permits as required by the local authority, per NFPA 70E “Standard for Electrical Safety in the
Workplace” or by other national building codes and local regulations.
Hazardous Voltage
DANGER! HAZARD OF ELECTRICAL SHOCK.
More than one disconnect may be required to de-energize the system before servicing.
Handling Equipment Containing Static Sensitive Components

ALERT! Installation or removal of equipment containing static sensitive components requires careful
handling. Before handling any equipment containing static sensitive components, read and follow
the instructions contained on the Static Warning Page.
Maintenance and Replacement Procedures

CAUTION! When performing any step in procedures that requires removal or installation of
hardware, use caution to ensure no hardware is dropped and left inside the unit; otherwise service
interruption or equipment damage may occur.
NOTE: When performing any step in procedures that requires removal of existing hardware, retain all
hardware for use in subsequent steps, unless otherwise directed.
STATIC WARNING
This equipment contains static sensitive components. The warnings listed below must be observed
to prevent damage to these components. Disregarding any of these warnings may result in personal
injury or damage to the equipment.
1. Strictly adhere to the procedures provided in this document.
2. Before touching any equipment containing static sensitive components, discharge all static
electricity from yourself by wearing a wrist strap grounded through a one megohm resistor. Some
wrist straps have a built-in one megohm resistor; no external resistor is necessary. Read and follow
wrist strap manufacturer’s instructions outlining use of a specific wrist strap.
3. Do not touch traces or components on equipment containing static sensitive components. Handle
equipment containing static sensitive components only by the edges that do not have connector
pads.
4. After removing equipment containing static sensitive components, place the equipment only on
conductive or anti-static material such as conductive foam, conductive plastic, or aluminum foil. Do
not use ordinary Styrofoam™ or ordinary plastic.
5. Store and ship equipment containing static sensitive components only in static shielding containers.
6. If necessary to repair equipment containing static sensitive components, wear an appropriately
grounded wrist strap, work on a conductive surface, use a grounded soldering iron, and use
grounded test equipment.
GENERAL INFORMATION AND INSTALLATION
ACCEPTANCE CHECKLIST
Customer Documentation Package
This document (11 VA 4529 BL) provides Installation and User Instructions for the NetSure™ Multi Cabinet
48V DC Power System.
The complete Customer Documentation Package consists of…
• Safety Rules: 11 RG 6161 TN
• NetSure™ Power System Installation and User Instructions: 11 VA 4529 BL
• Cabinet Installation Instructions: 11 NR 4202 SF
• ACCU/ACDU Installation and User Instructions: 11 RK 7416 RI
• DC DU Installation and User Instructions: 11 GH 4024 IL
• BFU Installation and User Instructions: 11 KA 8172 KU
• NCU (NetSure™ Control Unit) User Instructions: 11 KO 7503 JL
• EXU (Extension Control Unit) User Instructions: 11 VE 0162 PB
• SM DU+ (Supervisory Module–Distribution Unit +) User instructions: 11 HP 0110 FS
• Installation Test Instructions: 11 XE 3968 YS
• Table of Set Values, NetSure™ Power System with NCU: 11 QF 2335 LA
• R48-3200 and R48-3500e Rectifier User Instructions: 11 AV 1161 LI
• R48-5800e Rectifier User Instructions: 11 FO 6761 VP
• Engineering Drawings
System Description
The NetSure™ 7100 and NetSure™ 8100 Multi Cabinet 48V DC Power Systems are complete integrated
power systems containing rectifiers, intelligent control, metering, monitoring, and distribution. These power
systems are designed to power a load while charging a positive grounded battery. These power systems
are capable of operating in a battery-less installation or off-battery for maintenance purposes. These power
systems are designed for operation with the positive output grounded. The power systems can be
configured as ordered for either overhead or under-floor cabling.
See Figure 1 through Figure 3 for typical equipment arrangements. A system consists of the following
components.
• Main Cabinet
The system always includes one (1) main cabinet. The main cabinet houses optional AC distribution, DC
load distribution, a battery fuse unit, rectifier mounting shelves and the main system controller. The battery
fuse unit contains battery disconnect fuses or circuit breakers, a shunt and a low voltage disconnect (LVD)
contactor.
• Extension Cabinets
The system may include up to four (4) extension cabinets. The extension cabinets house optional AC
distribution, DC load distribution, a battery fuse unit, rectifier mounting shelves and an extension controller.
The battery fuse unit contains battery disconnect fuses or circuit breakers, a shunt and a low voltage
disconnect (LVD) contactor.
• NCU Controller (Main Controller)
The system contains one main controller. The controller provides power system control (including battery
low voltage disconnect control), rectifier control (including a charge control function), metering functions,
monitoring functions, and local/remote alarm functions. The controller also supports rectifier temperature
compensation if the system is equipped with a temperature sensor. Temperature sensors may also be
designated to monitor ambient temperature and/or battery temperature. The controller also provides data
acquisition, system alarm management, and advanced battery and energy management. The controller
contains an LCD display and keypad for local access. The controller provides Ethernet connection and
supports software upgrade via its USB port. It also comes with a comprehensive web page and SNMP
capability for remote system management. Refer to the NCU Controller Instructions (11 KO 7503 JL) for
more information.
• EXU Controller (Extension Controller)
Each extension cabinet contains an Extension Control Unit (EXU).
The EXU measures DC bus voltage, battery current, load current and battery voltage, and reports the data
to the NCU. The EXU acquires digital values from battery fuses/circuit breakers, load fuses/circuit breakers,
and LVD contactor(s) and reports the acquired data to the NCU.
As long as the EXU communicates normally with NCU, it accepts the parameter setting and control
command from NCU. This includes commands to open or close Low Voltage Disconnect (LVD) contactors.
If communication fails, the EXU can control LVD contactor operation according to its parameter setting or
acquired data. The EXU monitors the system current and voltage and displays them on the LCD.
Refer to the EXU Controller Instructions (11 VE 0162 PB) for more information.
• Rectifier Module Mounting Shelf
The system contains one or more rectifier mounting shelves. In the NetSure™ 7100 power system, each
shelf houses up to six (6) 3500 W rectifiers, and each cabinet is equipped with up to two (2) shelves. In the
NetSure™ 8100 power system, each shelf houses up to two (2) 5800 W rectifiers, and each cabinet is
equipped with up to four (4) shelves.
• Rectifiers
The system contains rectifiers, which provide load power, battery float current, and battery recharge current
during normal operating conditions. For the NetSure™ 7100 power system, refer to the Rectifier Instructions
(11 AV 1161 LI) for more information. For the NetSure™ 8100 power system, refer to the Rectifier Instructions
(11 FO 6761 VP) for more information.
Figure 1. Typical Equipment Arrangements, NetSure™ 7100 Cabinets for Overhead Cabling
Positive (0V) Bar(s) Positive (0V) Bar(s)
Battery Fuse Unit, with

Battery Fuse Unit, with
3 x 500 A to 630 A NH3
5 x 300 A CBs, 1000 A
Fuses, 1000 A Shunt &
Shunt & 1000 A LVD
1000 A LVD Contactor
Contactor
Supervision Unit with Supervision Unit with
NCU Controller & NCU Controller, IB2
IB2 Board Board & Optional EPO
Distribution Unit,
1000 A, LOD, with NH2,
NH00/80V & NH00 Distribution Unit,
Fuses 500 A, LOD, with
38 CB Positions
Distribution Unit,
1000 A, LOD, with NH2, Distribution Unit,
NH00/80V & NH00 500 A, LOD, with
Fuses 38 CB Positions
Distribution Unit, 500 A, Distribution Unit,

LOD, with 14 x 22x58 500 A, LOD, with
Fuseholder Positions 38 CB Positions
AC Distribution Unit AC Distribution Unit
Rectifier Shelf for up to Rectifier Shelf for up to

6 x 3500 W Rectifiers 6 x 3500 W Rectifiers
Rectifier Shelf for up to Rectifier Shelf for up to

6 x 3500 W Rectifiers
Figure 2. Typical Equipment Arrangements, NetSure™ 8100 Cabinets for Overhead Cabling
Battery Fuse Unit, with Battery Fuse Unit, with

3 x 500 A to 630 A NH3 5 x 300 A CBs, 1000 A
Fuses, 1000 A Shunt & Shunt & 1000 A LVD
1000 A LVD Contactor Contactor
Supervision Unit with Supervision Unit with

NCU Controller & IB2 NCU Controller & IB2
Board Board
Distribution Unit, Distribution Unit,

500 A, LOD, with 1000 A, LOD, with NH2,
38 CB Positions NH00/80V & NH00
Fuses
Distribution Unit,
500 A, LOD, with
38 CB Positions Distribution Unit,
1000 A, LOD, with NH2,
NH00/80V & NH00
Distribution Unit, Fuses
500 A, LOD, with
38 CB Positions
AC Distribution Unit AC Distribution Unit
Up to 4 x Rectifier Up to 4 x Rectifier
Shelves for up to 2 x Shelves for up to 2 x
5800 W Rectifiers Each 5800 W Rectifiers Each
Figure 3. Typical Equipment Arrangements, NetSure™ 7100 and NetSure™ 8100 Cabinets for Under-floor Cabling
Rectifier Shelf for up to

Up to 4 x Rectifier
Rectifier Shelf for up to Shelves for up to 2 x
6 x 3500 W Rectifiers 5800 W Rectifiers Each
AC Distribution Unit
AC Distribution Unit
Supervision Unit with
NCU Controller, IB2
Board & Optional IB4 Supervision Unit with
Board NCU Controller &
IB2 Board
Distribution Unit,
Distribution Unit, 500 A, LOD, with
500 A, LOD, with 14 x 22x58 Fuseholder
38 CB Positions Positions
Distribution Unit,
Distribution Unit,
500 A, LOD, with
500 A, LOD, with
14 x 22x58 Fuseholder
38 CB Positions
Positions
Distribution Unit,
Distribution Unit,
500 A, LOD, with
500 A, LOD, with
14 x 22x58 Fuseholder
38 CB Positions
Positions
Battery Fuse Unit, with Battery Fuse Unit, with
5 x 300 A CBs, 1000 A 5 x 300 A CBs, 1000 A
Shunt & 1000 A LVD Shunt & 1000 A LVD
Contactor Contactor
Installation Acceptance Checklist
Provided below is an Installation Acceptance Checklist. This checklist helps ensure proper installation and
initial operation of the system. As the installation procedures presented in this document are completed,
check the appropriate box on this list. If the procedure is not required for your installation site, also check
the box in this list to indicate that the procedure was read. When installation is done, ensure that each
block in this list has been checked.
NOTE: The system is not powered up until the end of this checklist.
NOTE: Some of these procedures may have been performed at the factory for you.
Physically Installing the System

 Seismic Kit Installed in Cabinet (if provided)
 Cabinet Secured to Floor or Wall
 Cabinets Secured to Each Other (side-by-side or back-to-back installations
 Verify Circuit Breakers and Fuses Installed
 Rectifiers Installed
Setting Switch Options
 Switch Settings on IB2 Interface Board Verified
 Switch Settings on EIB Interface Board Verified (if provided)
 Switch Settings on SMDU+ Verified (if provided)
 Switch Settings on SMDU-H Verified (if provided)
Making Electrical Connections
 Earthing Connections Made
 Cabinet-to-Cabinet Bonding Connection Made (if provided)
 Cabinet-to-Cabinet Busbar Connections Made (if provided)
 Cabinet-to-Cabinet Communications Cable Connection Made s (if provided)
 AC Connections Made
 External Alarm, Reference, Monitoring, and Control Connections Made
 Ethernet Connection Made (if required)
 DC Load Distribution Connections Made
 Battery Connections Made
Installing the Rectifiers and Initially Starting the System
 System Installation Checked, System Started, Configured, and Checked
PHYSICALLY INSTALLING THE POWER SYSTEM
General Requirements
• This product is intended only for installation on or above a non-combustible surface.
• This product must be located in a controlled environment with access to crafts persons only.
• This product is intended for installation in network telecommunication facilities (CO, vault, hut, or
other environmentally controlled electronic equipment enclosure).
• This product is intended for connection to the common bonding network in a network
telecommunication facility (CO, vault, hut, or other environmentally controlled electronic equipment
enclosure).
• The installer should be familiar with the installation requirements and techniques to be used in
mounting the system’s cabinet(s) to the floor.
• Cabinet ventilating openings must not be blocked and temperature of air entering rectifiers must not
exceed their rated operating ambient temperature range.
• Clearance requirements are:
• Recommended minimum aisle space clearance for the front of each cabinet is 600 mm if the
cabinet has an optional door, and 26 mm if the cabinet has no door.
• Required clearance for the rear of each cabinet is 0 mm.
Recommended minimum free space above each cabinet is 300 mm. (NOTE: Use of large-
diameter wire may require greater clearance.)
Unpacking
When the equipment arrives, make sure that all the boxes included in the shipping specification are
delivered and that they have their correct numbers.
Leave the final unpacking of each unit until the installation is to begin, thus avoiding the loss of loose details
such as sets of parts delivered with the units.
When handling printed board assemblies, suitable ESD-protection shall be used.
Securing the Cabinet(s) to the Floor or Wall

Refer to the Cabinet Installation Instructions (11 NR 4202 SF) for procedures.
Securing Cabinets to Each Other (side-by-side or back-to-back Installations)

Refer to the Cabinet Installation Instructions (11 NR 4202 SF) for procedures.
Installing Circuit Breakers and Fuses

NOTE: Fuses and circuit breakers may have already been factory-installed for you.
Refer to the DC Distribution Unit Installation and User Instructions (11 GH 4024 IL) for distribution circuit
breaker and fuse installation procedures.
Refer to the Battery Fuse Unit Installation and User Instructions (11 KA 8172 KU) for battery circuit breaker
and fuse installation instructions.
Installing Rectifiers
The rectifiers are normally delivered in separate boxes. Unpack them and place them in the subrack(s), but
do not connect them.
SETTING SWITCH OPTIONS

Refer to the last page of the system circuit diagram when performing the following procedures.
Figure 4. Option Switch Locations, IB2 and EIB Boards
Location of IB2
Board (in Main
Cabinet)
Location of Optional
EIB Board (in Main
Cabinet)
Screw
Lock
EIB Board
Sliding Plate
Switch Settings on IB2 Interface Board

Dip Switch SW1 on the IB2 board is used to set the communications address for this board. Refer to Figure
4 for board location and Figure 5 for switch locations and settings.
Perform the following procedure to verify the factory settings. This procedure can also be used to make
adjustments on a replacement circuit board.
Procedure
1. Ensure SW1 is set as shown in the table in Figure 5.
2. Push in the sliding plate. Ensure the lock has engaged. Reinstall the screw removed in step 1.
Switch Settings on Optional EIB Interface Board

NOTE: If your system does not include an EIB interface board, skip this procedure.
Dip Switch SW1 on the EIB board is used to set the communications address for this board. Refer to Figure
4 for board location and Figure 5 for switch locations and settings.
Perform the following procedure to verify the factory settings. This procedure can also be used to make
adjustments on a replacement circuit board.
Procedure
1. To access the board, remove the screw and release the lock that secure the sliding plate. Pull out
the sliding plate.
2. Ensure SW1 is set per the table in Figure 5.
Figure 5. IB2 Interface Board Switch Location
J12 J11 J2 J3 J4 J2
Digital Inputs
J3:2 (Di1+)
(Di1-) J3:1 Switch default
J3:4 (Di2+) Board
Switch default
I2 C Board I2 C
(Di2-) J3:3 state Name
state
address
J3:6 (Di3+) Name address BIT1 BIT2
(Di3-) J3:5 BIT1 BIT2
J4:2 (Di4+) EIB OFF OFF 0 x 20
(Di4-) J4:1 IB2 OFF OFF 0 x 18
J4:4 (Di5+)
(Di5-) J4:3
J4:6 (Di6+) EIB Board
(Di6-) J4:5
J5:2 (Di7+) IB2 Board
(Di7-) J5:1 ROA 119 0873/1
J5:4 (Di8+) ROA 119 0872/1
(Di8-) J5:3 J5:2 (Shunt 1+)
J5:6 (Empty) (Shunt 1-) J5:1 Switch
(Empty) J5:5 Switch J5:4 (Shunt 2+) Board
Board (Shunt 2-) J5:3 State
State (Shunt 3-) J5:5
J5:6 (Shunt 3+) No.
No. 1 2
1 2 J6:2 (Volt 2)
J6:2 (DO2_NC) (Volt 1) J6:1 Off Off 1
(DO1_NC) J6:1 Off Off 1 J6:4 (Volt 4)
J6:4 (DO2_COM) (Volt 3) J6:3 On Off 2
(DO1_COM) J6:3 On Off 2 J6:6 (Volt 6)
J6:6 (DO2_NO) (Volt 5) J6:5 Off On 3
(DO1_NO) J6:5 Off On 3 J7:2 (DO5_NC)
J7:2 (DO4_NC) (Volt 7) J7:1 On On NA
(DO3_NC) J7:1 On On NA J7:4 (DO5_COM)
J7:4 (DO4_COM) (Volt 8) J7:3
(DO3_COM) J7:3 J7:6 (DO5_NO)
J7:6 (DO4_NO) (Empty) J7:5
(DO3_NO) J7:5 J8:2 (DO2_NC)
J8:2 (DO6_NC) (DO1_NC) J8:1
(DO5_NC) J8:1 J8:4 (DO2_COM) On
J8:4 (DO6_COM) On (DO1_COM) J8:3
(DO5_COM) J8:3 J8:6 (DO2_NO)
J8:6 (DO6_NO) (DO1_NO) J8:5
(DO5_NO) J8:5 Off J9:2 (DO4_NC) Off
J9:2 (DO8_NC) (DO3_NC) J9:1
(DO7_NC) J9:1 J9:4 (DO4_COM)
J9:4 (DO8_COM) (DO3_COM) J9:3
(DO7_COM) J9:3 SW1 (DO3_NO) J9:5
J9:6 (DO4_NO) SW1
J9:6 (DO8_NO)
(DO7_NO) J9:5
Relay Out puts
Set Switch SW1 as shown in table. Set Switch SW1 as shown in table.
Switch Settings on Optional SM DU+

The SM DU+ is included with any BMG 220 017 configurable distribution unit that contains individual load
shunts.
NOTE: If your system does not include and SM DU+, skip this procedure.
SM-DU+ uses two (2) 8-bit switches for parameter setting (SW1 and SW2). Refer to Figure 7 for SW1 and
SW2 locations and settings. Perform the following procedure to verify the factory settings. This procedure
can also be used to make adjustments on a replacement circuit board.
Figure 6. SM DU+ Location
Location of SM DU+
(when cabinet is
equipped with a
BMG 220 017
Distribution Unit
with individual load
shunts)
Procedure
1. Ensure SW1 and SW2 are set per Figure 7.
Figure 7. SM DU+ Switch Location and Settings
Address 1
Settings for DIP Switch Settings for DIP Switch
SW1 for SW Shunt SW 2 in SMDU + in
Setting Main Cabinet
12345 678 12345 678
On On
Off Off
Address 4 Address 2
SW 2 in SMDU + in SW 2 in SMDU + in
Extension Cabinet 3 Extension Cabinet 1
12345 678 12345 678
On On
Off Off
Address 5 Address 3
SW 2 in SMDU + in SW 2 in SMDU + in
Extension Cabinet 4 Extension Cabinet 2
12345 678 12345 678
On On
Off Off
Switch Settings on Optional SM DU-H
The SM DU-H is included with distribution units that contain Hall current sensors.
NOTE: If your system does not include and SM DU-H, skip this procedure.
SM DU-H uses one (1) 8-bit switch for parameter setting (SW1). Refer to Figure 7 for switch location and
settings. Perform the following procedure to verify the factory settings. This procedure can also be used to
make adjustments on a replacement circuit board.
Figure 8. SM DU-H Location
Location of SM DU-H
(when cabinet is
equipped with
Distribution Unit
with Hall sensors)
Procedure
1. Ensure SW1 is set per Figure 9.
Figure 9. SM DU-H Switch Location and Settings
1 234567 8
Setting for DIP

Switch SW1 in
SM DU-H for
Address.
See Table.
OFF
ON
SM DU-H Address Configuration (binary from 1-64)

Switch SW1 (On=1, Off=0)
DIP Switch SW1 Bit
Address
1 2 3 4 5 6 7 8
1 0 0 0 0 0 0 0 0
2 1 0 0 0 0 0 0 0
3 0 1 0 0 0 0 0 0
4 1 1 0 0 0 0 0 0
5 0 0 1 0 0 0 0 0
6 1 0 1 0 0 0 0 0
7 0 1 1 0 0 0 0 0
8 1 1 1 0 0 0 0 0
MAKING ELECTRICAL CONNECTIONS
Important Safety Instructions
DANGER! Batteries can produce large amounts of electrical current. Read and follow the “Important
Safety Instructions” at the beginning of this document before proceeding.
Wiring Considerations
All wiring and branch circuit protection should follow the current edition of the American National
Standards Institute (ANSI) approved National Fire Protection Association's (NFPA) National Electrical Code
(NEC), International Electrotechnical Commission (IEC60950, IEC62305) and applicable local codes. For
operation in countries where the NEC is not recognized, follow applicable codes.
General Cabling Information

The cabinets are built as ordered, either for overhead cabling or for cabling from under the floor. Changing
the cabling mode on site is not recommended.
Bottom Cabling
A suitable cabling hole should be cut in the floor below each cabinet. The hole must correspond to the
requirements from the floor manufacturer.
Top Cabling
The cables enter the top of the cabinet. There are four flexible cable inlets for DC cables and one knockout
suitable for a cable bushing for AC cables in the top cover. Refer to Figure 10.
NOTE: AC and DC cables must enter different inlets.
A suitable strain relief bushing should be installed in the AC inlet prior to installing cables. The AC cable
should be routed down the left side of the cabinet to avoid interference with the control cables behind the
controller.
The DC cables should enter the flexible cable inlets and be fixed with tie wraps to the holders in the cable
inlets.
To avoid the risk of objects falling into the cabinet, close all the flexible inlets and tighten their screws after
the installation. For large cables, it is necessary to cut the foam (to cable width) for exact adjustment.
Figure 10. Cable Inlets, Top-Feed Cabinet
If bushing will not be used for In this system, use only this
AC cable, cable should enter knockout for AC Inlet. See
cabinet at left side of back slot. AC Bushing Installation below.
Cabinet Top
DC Inlets (See details below)

Use cable ties to anchor cables here.
(sliding bracket/foam strip
assembly not shown)
For larger wire, cut out

foam strip as required
for snug fit.
Loosen screws, adjust sliding

bracket/foam strip assembly for
snug fit around cables, then
tighten screws.
AC Bushing Installation
Remove knockout from this side only,
and install cable bushing. BMY 220 121/1
bushing accepts cable 22-32 mm.
Route cable down left side to avoid interference
with control cables behind the controller
Earthing
AC Mains Protective Earth
The rectifier mounting shelves have internal multipoint earthing. The mains PE and the rectifier enclosures
are interconnected to the mounting shelf mechanical structure.
DC System Earth
A 25 mm2 cable links the mechanical structure of the cabinet to the system 0V bar (main cabinet only, in
multi-cabinet systems). This link is essential if a DC short-circuit occurs between live pole (negative) of the
system and the cabinet mechanical structure as it will protect the mains PE conductors from overload.
Bonding to the Main Earth Terminal (Main Cabinet Only)
1. Check that there is an insulated 25 mm² cable connected between the 0 V (+) terminal of the power
supply system and the earth terminal inside the top of the main cabinet.
2. Connect an insulated cable, minimum 25 mm², between the 0V (+) bar of the power supply system
and the site earth collector bar (MET). Refer to Figure 11.
Telecom Earth
The telecommunication equipment should be connected to the MET according to its specific requirement.
The cabinets can be earthed via the power cabinets or directly to the MET.
Figure 11. Earthing Principle of the NetSure™ 7100 (NetSure™ 8100 Similar)
Power Cabinet Telecom Rack
Subrack 1
Rectifier 0V Bar
Mains PE Load
Load
(Main
Cabinet
Only)
Subrack 2 25 mm²
Rectifier
The mechanical
connection
between subrack
and power cabinet
Alt. 2
Alt. 1 25-70 mm²
25-70 mm² Earth electrode
MET
Cabinet-to-Cabinet Bonding Connection (Side-by-Side Installation)
NOTE: If the power system has only one cabinet, skip this procedure.
Procedure
Joining the extension cabinet to the main cabinet with screws and nuts through the joining holes in the
cabinet sides provides the required bonding connection. Refer to the Cabinet Installation Instructions (11 NR
4202 SF) for a procedure.
Cabinet-to-Cabinet Bonding Connection (Back-to-Back Installation)

Procedure
Joining the extension cabinet to the main cabinet with screws and nuts through the wall fixing holes at the
back of the top covers provides the required bonding connection. Refer to the Cabinet Installation
Instructions (11 NR 4202 SF) for a procedure.
DANGER! If the power system is in service, hazardous voltage and energy are present inside the
cabinet. DO NOT allow components being installed to simultaneously contact any grounded and
energized objects during this procedure. Use only insulated tools. Read “Important Safety
Instructions” near the beginning of this document before performing this procedure.
Cabinet-to-Cabinet Bonding Connection (Remote Installation)

After installation of an extension cabinet that is not adjacent to the existing cabinet, a bonding connection
must be made between cabinets. This connects the cabinets to each other electrically.
This procedure can be performed during initial installation of the power system, or as part of a future live
system expansion.
Procedure
1. Locate a set of parts, BMY 220 164/1. The set of parts includes a length of 70 mm2 cable, lugs and
hardware. The cable should be cut to required length, and furnished lugs attached at each end.
NOTE: Parts of this kit may also be used for DC bus interconnections for remote cabinet installations.
2. Connect one end of the bonding cable to the cabinet frame, using a hole in an upright that has a
masked surface. There are 8 locations one on each upright at top and bottom.
3. Connect the remaining end of the bonding cable to the other cabinet frame.
• For a NetSure™ 7100 or 8100 cabinet, use a hole in an upright that has a masked surface. There
are 8 locations one on each upright at top and bottom.
• For a legacy power system cabinet, connect to an earthing point on the cabinet, such as an
earthing screw at the top rear of the cabinet.
Cabinet-to-Cabinet DC Bus Interconnections (Side-by-Side Installation)

NOTE: For a back-to-back installation, see the next section, Cabinet-to-Cabinet DC Bus
Interconnections (Back-to-Back or Remote Installation).
cabinet. External wiring (especially from battery) may be energized from an external source. DO
NOT allow components being installed to simultaneously contact any grounded and energized
objects during this procedure. Use only insulated tools. Read “Important Safety Instructions” near the
beginning of this document before performing this procedure.
After an extension cabinet has been installed and fastened to an existing cabinet, negative (-48V) and
positive (0V) interconnection bars must be installed between cabinets.
These procedures can be performed during initial installation of the power system, or as part of a live
system expansion.
Procedure for Installing Positive (0V) Interconnection Bar
1. Refer to Figure 12 as this procedure is performed.
2. Locate the set of parts, BMY 220 074/1 or BMY 220 074/2.
3. Locate the M8 threaded studs that extend from the rear of the positive (0V) bar in each cabinet.
4. Attach the U-shaped interconnection bar to these studs, using supplied hardware as shown in the
figure. Correct torque is 24 Nm.
5. Refer to Figure 14 to see completed installation of both interconnection bars.
Procedure for Installing Negative (-48V) Interconnection Bar
2. Locate the set of parts, BMY 220 062/1.
3. Attach (1) bracket to the Parallel Connection Bar of the Battery Fuse Unit (BFU) in the existing
cabinet. Use supplied hardware as shown. Attach to the studs that are closest to the extension
cabinet being installed. Correct torque is 47 Nm.
4. Attach (1) bracket to the Parallel Connection Bar of the Battery Fuse Unit (BFU) in the extension
cabinet with supplied hardware as shown. Attach to the studs that are closest to the existing
cabinet. Correct torque is 47 Nm.
5. Ensure that the shrink tubing is in place on the connecting bar. Position the shrink tubing so that it
completely covers the end NOT being connected. Attach the connecting bar to the bracket in the
existing cabinet. Use supplied hardware as shown. Correct torque is 47 Nm.
WARNING! If this is a live upgrade, make all load and battery connections to the expansion cabinet,
turn off all circuit breakers and remove all fuses before making the final busbar connection described
in the next step. Refer to Adding an Extension Cabinet to the Power System on page 42 for
additional live upgrade information.
6. Slide the shrink tubing back to expose remaining end of connecting bar. Attach the connecting bar
to bracket in extension cabinet being installed. Use supplied hardware as shown. Correct torque is
47 Nm.
7. Refer to Figure 14 to see completed installation of both interconnection bars.
Figure 12. Installing Positive (0V) Interconnection Bar (Bottom-cabled system shown. Top-cabled is similar.)
BMY 220 074/1 or

BMY 220 074/2
Positive (0V) Interconnection Bar

(See Detail A)
Cabinet
Rear View Being
of Cabinets Added
DETAIL A
Interconnection
Bar
Cabinet Positive
(0V) Bar
Conical Spring Washer

(2 places)
Cabinet Positive M8 Hex Nut (2 places)

(0V) Bar Tighten to 24 Nm.
Note: Interconnection
bar is rotated 180°
for top-cabled cabinets.
Cabinets with Bar Installed
Figure 13. Installing Negative (-48V) Interconnection Bar (Bottom-cabled system shown. Top-cabled is similar.)
Front View of Cabinets
Bracket
Connect-
ing Bar
BFU
Parallel Cabinet
Connection M10 Conical Hex Shrink Being
Bar Bolt Spring Nut Tubing Added
Washer
SHRINK TUBING DETAIL
Slide shrink tubing

over end of bar being
connected to extension
cabinet until ready to
make connection.
Shrink tubing position

after installation is complete.
Figure 14. Power System with Both Interconnection Bars Installed.
Front View of Bottom-Cabled Cabinets

Positive (0V)
Interconnect
Bar Installed
Negative (-48V)
Interconnection
Bar Installed
Front View of Top-Cabled Cabinets
Positive (0V)
Interconnect
Bar Installed
Negative (-48V)
Interconnection
Bar Installed
Cabinet-to-Cabinet DC Bus Interconnections (Back-to-Back or Remote Installation)

NOTE: For a side-by-side installation, see the preceding section, Cabinet-to-Cabinet DC Bus
Interconnections (Side-by-Side Installation).
cabinet. External wiring (especially from battery) may be energized from an external source. DO NOT
allow components being installed to simultaneously contact any grounded and energized objects
during this procedure. Use only insulated tools. Read “Important Safety Instructions” near the
After an extension cabinet has been installed, negative (-48V) and positive (0V) interconnection cables
must be installed between cabinets. This procedure can be performed during initial installation of the
power system, or as part of a future live system expansion.
Procedure
2. Locate a set of parts, BMY 220 164/1. The set of parts includes a length of 70 mm2 cable, lugs and
hardware. The cable should be cut to required length, and furnished lugs attached at each end.
Figure 15. Cabinet DC Interconnection Points (Back-to-Back or Remote Installation)
NOTE: Parts of this kit may also be used for cabinet bonding connections for remote cabinet
installations.
3. Interconnect the positive (0V) bars in each cabinet with 2 x 70 mm2 cables. Secure with the
furnished M10 nuts and washers. Tighten nuts to 47 Nm.
WARNING! If this is a live upgrade, make all load and battery connections to the expansion cabinet,
turn off all circuit breakers and remove all fuses before making the negative (-48V) connections
described in the next step. Refer to Adding an Extension Cabinet to the Power System on page 42 for
additional live upgrade information.
4. Interconnect the negative (-48V) bars in each cabinet with 2 x 70 mm2 cables. Secure with the
furnished M10 nuts and washers. Tighten nuts to 47 Nm.
Cabinet-to-Cabinet Communications Cable (CAN-Bus) Interconnections
NOTE: For a single-cabinet installation, check to ensure that terminal resistors (supplied with the
main cabinet) are plugged into each of the two CAN bus connectors on the top of the cabinet.
Communications between the controller and the power system are accomplished via the CAN bus. Cables
are standard Cat5 communications cables (straight through).
Multiple cabinets are interconnected using standard Cat5 communications cables. Two CAN bus
connectors are located on the top of each cabinet. Refer to for connector locations. Refer also to the power
system circuit diagram for additional information.
Procedure
1. On the main cabinet, unplug the terminal resistor from the to- CAN-bus connector that is closest to
the adjacent extension cabinet. Save the terminal resistor.
2. Connect a standard Cat5 communications cable (RPM 628 1046/1, supplied with the extension
cabinet) between the CAN bus connectors of adjacent cabinets, as shown in Figure 16.
Figure 16. CAN Bus Cable Connections

A terminal resistor (RPM 628 350/2) must be installed
in each CAN bus connector.
Main Cabinet
Note: There must always

be a total of 2 terminal
resistors per entire power
system.
SINGLE-CABINET INSTALLATION
Interconnecting Cable (RPM 628 1046/1) Terminal

Note: For back to back installation, add an Resistor
extra RPM 628 351/1 cable.
Terminal
Resistor
Extension Cabinet
Main Cabinet
MULTIPLE-CABINET INSTALLATION
NOTE: A 1meter long extension cable (RPM 628 351/1) is provided for use where the extension
cabinet is not adjacent to the existing cabinet.
3. Repeat the above step for each remaining extension cabinet (if furnished).
4. Plug the terminal resistor from step 1 into the empty connector on the last extension cabinet.
Cabinet-to-Cabinet Emergency Power-Off (EPO) Cable Connections (if provided)

If the power system is equipped with the Emergency Power OFF (EPO) option, application of an external
signal will cause all LVD contactors in the system to open, thus disconnecting all batteries from the
rectifiers and loads.
In a multi-cabinet installation, inter-cabinet control cable connections must be made for this option to
function in all cabinets.
Refer to Figure 17 as the following procedure is performed.
Figure 17. Cabinet-to-Cabinet EPO Control Cable Connections

Route into Route into
Connect mating adjacent Connect mating adjacent
plugs together. cabinet. plugs together. cabinet.
F M F M F
F M F M F
If cabinets are If cabinets are To EPO

TB2
back-to-back or TB2
back-to-back or TB2 Assembly
not adjacent to not adjacent to in next
each other, insert each other, insert Extension
a furnished a furnished Cabinet
extension cable extension cable if any.
(RPM 628 465/4) (RPM 628 465/4)
here. here.
TB1 TB1 TB1
EPO Assembly EPO Assembly EPO Assembly

BMY 211 0006/2 BMY 211 0006/2 in BMY 211 0006/2 in
in Main Cabinet Extension Cabinet Extension Cabinet
Supervision Unit
in Main Cabinet
(Extension Cabinet
Similar)
NOTE: A 5–meter long extension cable (RPM 628 465/4) is provided for use if needed for remote
(cabinets not adjacent to each other) or back-to-back installations.
Procedure
1. Locate the EPO assembly on the supervision unit in each cabinet. The assembly in the main cabinet
has one (1) control cable attached to it. Each extension cabinet has two (2) cables.
2. Route the longer control cable from the extension cabinet into the main cabinet. Connect it to the
cable in the main cabinet.
3. If there is a second extension cable, route the longer control cable from the next extension cabinet
into the previous extension cabinet. Connect it to the shorter cable in the previous cabinet.
4. Repeat Step 3 for each remaining extension cabinet (if furnished).
AC Mains Connections
AC mains are connected to the AC Connection Unit or AC Distribution Unit located inside each cabinet.
Refer to the ACCU/ACDU Installation and User Instructions (11 RK 7416 RI) for procedures for making AC
Mains connections.
External Alarm, Reference, Monitoring and Control Connections

Connection Locations
Refer to Figure 18 for the locations of components having external connection points.
Figure 18. Locations of Components with External Alarm, Reference, Monitoring and Control Connection.
Main Cabinet
(typical arrangement)
Mounting
Supervision
Location
Unit (See
Details of Optional
Below) IB4 Board
Screw
Lock
Internal/External Optional
Interface Board EIB Board
(behind NCU (on sliding plate)
& sliding plate)
Optional IB2 NCU

EPO Assembly Board Controller
IB2 (Controller Interface) Board Connections
The IB2 (Controller Interface Board) provides connection points for digital inputs, programmable relay
outputs, and temperature sensors. Refer to Figure 19 for connection identification.
Figure 19. IB2 (Interface Board) Connections and EIB (Extended Interface Board) Connection
J12 J11 J2 J3 J4 J2
Temp Sensor 1
(if used)
Temp
Digital Inputs Sensor 2 Temp Temp
(Di1-) J3:1
J3:2 (Di1+) (if used) To Sensor 2 Sensor 1 To
J3:4 (Di2+) (if used) (if used) Controller
(Di2-) J3:3 Controller
J3:6 (Di3+)
(Di3-) J3:5
J4:2 (Di4+)
(Di4-) J4:1
J4:4 (Di5+)
(Di5-) J4:3 IB2 Board
J4:6 (Di6+)
(Di6-) J4:5 ROA 119 0872/1 EIB Board
J5:2 (Di7+)
(Di7-) J5:1
J5:4 (Di8+) ROA 119 0873/1
(Di8-) J5:3 J5:2 (Shunt 1+)
J5:6 (Empty) Switch (Shunt 1-) J5:1
(Empty) J5:5 Board Switch
State (Shunt 2-) J5:3
J5:4 (Shunt 2+) Board
Source ( ) Black No. State
1 2 J5:6 (Shunt 3+) No.
for DI s (+) Red (Shunt 3-) J5:5 1 2
J6:2 (DO2_NC) Off Off 1 J6:2 (Volt 2)
(DO1_NC) J6:1 (Volt 1) J6:1 Off Off 1
J6:4 (DO2_COM) On Off 2 (Volt 3) J6:3
J6:4 (Volt 4)
(DO1_COM) J6:3
Off On 3 On Off 2
J6:6 (DO2_NO) J6:6 (Volt 6)
(DO1_NO) J6:5 On On NA
(Volt 5) J6:5 Off On 3
J7:2 (DO4_NC) J7:2 (DO5_NC)
(DO3_NC) J7:1 (Volt 7) J7:1 On On NA
J7:4 (DO4_COM) J7:4 (DO5_COM)
(DO3_COM) J7:3 (Volt 8) J7:3
J7:6 (DO4_NO) On J7:6 (DO5_NO)
(DO3_NO) J7:5 (Empty) J7:5
J8:2 (DO6_NC) J8:2 (DO2_NC) On
(DO5_NC) J8:1 (DO1_NC) J8:1
J8:4 (DO6_COM) J8:4 (DO2_COM)
(DO5_COM) J8:3 (DO1_COM) J8:3
J8:6 (DO6_NO) J8:6 (DO2_NO)
(DO5_NO) J8:5 Off (DO1_NO) J8:5
J9:2 (DO8_NC) J9:2 (DO4_NC) Off
(DO7_NC) J9:1 (DO3_NC) J9:1
J9:4 (DO8_COM) 1 2 J9:4 (DO4_COM)
(DO7_COM) J9:3 SW1
(DO3_COM) J9:3 1 2
J9:6 (DO8_NO) J9:6 (DO4_NO) SW1
(DO7_NO) J9:5 (DO3_NO) J9:5
Relay Out put s
Procedure
Digital Inputs and Relay Outputs: Digital input and relay output leads are connected to screw-type
terminal blocks located on the IB2 (Controller Interface Board). Recommended torque for these
connections is 0.249 Nm (2.2 in-lbs.).
a. Digital Inputs: Connect up to eight (8) digital inputs to the IB2 Board. Note that you must supply
both paths for the digital input (either a positive or negative signal and the opposite polarity return
path). Observe proper polarity.
The digital inputs can be programmed to provide an alarm when the signal is applied (HIGH) or
removed (LOW). Refer to the NCU User Instructions (11 KO 7503 JL) for programming information.
NOTE: -48VDC is factory connected to terminals J5:5 (+) and J5:6 (-) to provide a convenient
source for customer connection to digital inputs.
NOTE: When the power system is equipped with the EPO option, digital input DI5 is used internally
and is not available for customer connection.
b. Programmable Relay Outputs: The IB2 Board provides eight programmable alarm relays with
Form-C contacts. Each relay is user configurable for alarm conditions.
c. Temperature Sensors: Temperature sensors can be connected to the optional IB2 Board.
These connectors are not normally used in this power system. Refer instead to “Temperature
Sensor Connections” in a following section.
Optional EIB (Controller Extended Interface Board) Connections
NOTE: There are normally no customer connections required to the EIB board in this power system.
The following information is provided for reference.
The optional EIB (Controller Extended Interface Board) provides additional connection points for voltage
and current inputs, programmable relay outputs, and temperature sensors. Refer to Figure 18 for board
location and Figure 19for connector locations. To access the board, remove the screw and release the lock
that secure the sliding plate. Pull out the sliding plate. Make connections as per the following procedure.
a. Current Inputs: Up to three (3) shunt inputs can be connected to the EIB Board. In this power
system these connections have been made at the factory.
b. Programmable Relay Outputs: The EIB Board provides five programmable alarm relays with
Form-C contacts. Each relay is user configurable for alarm conditions. These relays are not normally
used in this power system.
c. Temperature Sensors: Temperature sensors can be connected to the EIB Board. These
connectors are not normally used in this power system. Refer instead to “Temperature Sensor
Connections” in the following section.
Temperature Sensor Connections
Up to two (2) temperature sensors (KET 103 06) can be connected to the Internal/External Interface Board.
The board is located in the behind the NCU controller. To access to the connectors, the NCU controller
must be removed. To do so, unlock it by loosening the screw on the handle and pulling the control unit out
from its mounting position. Refer to Error! Reference source not found. for board location and Figure 20
for connector locations. If supplied, mount and connect temperature sensors as follows:
1. Battery: If supplied, mount the temperature sensor as close as possible to the center of a battery
cell or block at the top shelf of the battery cabinet. Do not mount it where it will be affected by
airflow from fans etc. Clean thoroughly the surface where the sensor is to be placed. Remove the
grey paper laminate from the sensor and stick the sensor on the battery.
2. Room: If supplied, mount the temperature sensor on a wall about 1.5 m above the floor. Do not
mount it where it is affected by airflow from fans or by sunlight. Clean thoroughly the surface where
the sensor is to be placed. Remove the grey paper laminate from the sensor and stick the sensor to
the wall.
3. Wind up the excessive cable and fix it with tie wraps to a suitable place. If the cable is too short, it
can be extended by means of 0.82 mm2 (AWG18) standard copper conductors and connecting
terminals.
4. Connect the temperature sensor plug(s) to the terminal(s) on the Internal/External Interface board.
Figure 20. Connections on Internal/External Interface Board
Temp2 Temp1
OPT2 RS485 BA - Battery Alarm Cable
USB Fuel - Fuel Sensors
I²C - Communication
cable to EIB
LA - Load Alarm Cable
LA I²C STD MB - Controller
OB - Controller
OPT - Option Cable
OPT2- Option Cable 2 (CAN
BA Fuel OPT bus, RS232, RS485)
RS485 - RS485 Port
STD - Standard Cable
Temp1 - Temp. Sensor 1
Temp2 - Temp. Sensor 1
OB
USB - Universal Serial Bus
Emergency Power-Off (EPO) Connection (if provided)

An Emergency Power-Off (EPO) option is available with this power system. If this option is provided, when
the EPO is activated by opening the contacts of a customer-supplied control switch, all LVD contactors in
the system open immediately, disconnecting batteries from the rectifiers and power system loads.
NOTE: The customer-supplied EPO control must also control the AC supply to the power system.
The EPO assembly in the main cabinet provides a connection point for EPO control wiring. Refer to Figure
18 for assembly location and Figure 21 for a procedure for connecting the customer-supplied EPO control
wiring.
Figure 21. EPO Control Connection
EPO External Connection Factory-Connected

Terminals XEPO Jumper Wire
See Detail A (Blue)
12
Supervision
Unit in Main
Cabinet
For Emergency Power Off (EPO) Control:

DETAIL A
1. External EPO switch must have one set of NC contacts.
2. Remove jumper wire from terminals 1 and 2 of XEPO.
3. Connect Normally Closed (NC) contacts to terminals 1 and 2. (A 4A 10x38
fuse is provided to protect customer s external circuits.)
Note: Customer EPO control must also disconnect AC supply from power system.
Note: Battery must be connected to power system for EPO function.
Ethernet Connection to the NCU Controller (if required)

NOTE: If the Web Interface is not being used with this system, skip this procedure.
The NCU Controller provides a Web Interface via an Ethernet connection to a TCP/IP network. An RJ-45
10BaseT jack is provided on the front of the NCU for connection into a customer's network running TCP/IP.
This jack has a standard Ethernet pin configuration scheme, twisted pair. Refer to Figure 22 for location
and Table 1 for pin outs. Use shielded Ethernet cable (grounded at both ends). Note that the NCU RJ-45
jack is connected to chassis ground. Refer to the NCU User Instructions (11 KO 7503 JL) for operational
details.
NOTE: A second Ethernet connection jack is provided on the optional IB4 board. Refer to Error!
Reference source not found. for IB4 board location. Refer to the NCU Controller User Instructions
(11 KO 7503 JL) for further information.
NOTE: You can access the Web pages of the power system locally by using a "crossover" or “straight”
cable connected directly between your PC and the controller.
WARNING! The intra-building port(s) of the equipment or subassembly is suitable for connection to
intra-building or unexposed wiring or cabling only. The intra-building port(s) of the equipment or
subassembly MUST NOT be metallically connected to the interfaces that connect to the OSP or its
wiring. These interfaces are designed for use as intra-building interfaces only (Type 2 or Type 4
ports as described in GR-1089-CORE, Issue 4) and require isolation from the exposed OSP cabling.
The addition of Primary Protectors is not sufficient protection in order to connect these interfaces
metallically to OSP wiring.
The intra-building port (RJ-45) of the equipment or subassembly must use shielded intra-building
cabling/wiring that is grounded at both ends.
Figure 22. NCU Ethernet Port
10/100M Ethernet
Port (RJ-45) ESC ENT
Table 1. NCU RJ-45 Ethernet Port Pin Configuration
Port Pin
Name Definition
Number
1 Tx+ Send Signal +
2 Tx- Send Signal -
3 Rx+ Receive Signal +
4 -- no connection
5 -- no connection
6 Rx- Receive Signal -
7 -- no connection
8 -- no connection
Load Connections
NOTE: When the system includes one or more extension cabinet, the loads being connected should
be divided as equal as possible between all cabinets.
Distribution cables should be selected according to local regulations concerning voltage drop, operational
temperature and type of installation (open, covered, number of layers, parallel connection etc). What cable
dimension to choose depends on the circuit breaker size, the tolerated cable voltage drop and the distance
between power system and load.
Loads are connected to one or more DC Distribution Units located inside the cabinet(s). Refer to the DC DU
Installation and User Instructions (11 GH 4024 IL) for procedures for making load connections.
Some DC Distribution Units do not include 0V (+) connection points. In this case, make 0V (+) load return
connections to the system positive (0V) bar located at the top (top-cabled) or bottom (bottom-cabled) of
the cabinet. Refer to Figure 23 for system positive (0V) bar details.
Battery Connections
NOTE: When the system includes one or more extension cabinet, the batteries being connected
should be divided as equal as possible between all cabinets.
Battery cables should be selected according to local regulations concerning voltage drop, operational
temperature and type of installation (open, covered, number of layers, parallel connection etc.). What cable
dimension to choose depends on the circuit breaker size, the tolerated cable voltage drop and the distance
between power system and batteries.
Batteries are connected to the Battery Fuse Unit (BFU) located inside each cabinet. Refer to the BFU User
Instructions (11 KA 8172 KU) for procedures for making battery connections.
The Battery Fuse Units do not include 0V (+) connection points. 0V (+) battery connections are made to
the system positive (0V) bar located at the top (top-cabled) or bottom (bottom-cabled) of the cabinet.
Refer to Figure 23 for system positive (0V) bar details.
Connect suitable cables to the battery connection points (-) and (+) and to the corresponding battery
terminals.
ALERT! Ensure correct polarity (+ to + and – to –) when making battery connections.
Figure 23. Cabinet Positive (0V) Bar
Top-Cabled Cabinet Bottom-Cabled Cabinet
Positive (0V) Bar

(See Detail A)
Connect battery
positive (+) and
load return (0V)
cables.
M10 Hardware
(15 places)
Tighten to 47 Nm.
34 34 34 34 34 34 34 34 34 34 34 34 34 34
DETAIL A
(Dimensions in mm.)
Note: An additional bar is provided when required.
Connections to an Optional NetSure™ Battery Cabinet

If a separate NetSure™ battery cabinet is provided, the cabinet must be connected to the power system, and
batteries in the cabinet must be connected. Refer to Figure 24 for connection procedures.
NOTE: Connect the battery circuit breaker alarm terminals to an available digital input (DI) on the IB2
interface board in the main cabinet. The NCU must be programmed for the desired alarm message.
Refer to the NCU Controller User Instructions (11 KO 7503 JL) for programming information.
Figure 24. Connections to an Optional NetSure™ Battery Cabinet
Front View DETAIL A

(1000 Amp Cabinet) Connections to 1000A BFU
Negative (-48V) Positive (0V)
Connections Connections
Connections (up to 8 x 150mm2) (up to 8 x 150mm2)
to Power (M10 hardware. (M10 hardware.
System Tighten to 47 Nm.) Tighten to 47 Nm.)
(See Detail A)
Battery 4
CB Alarm
Terminal
(See Detail B)
Battery 3 DETAIL B DETAIL C

Battery CB Alarm Connection Using Battery String Connection
Battery (Contacts open for alarm.) Accessories, BMY 220 150/1
Connections
(See Single Cabinet
Detail C) M8 Nut
M8 Washer
Battery 2
To a DI on IB2
board in main
cabinet. (User
to program.)
Multiple Cabinets
Optional
Contact Bar
Battery 1
for connection
To a DI on IB2 from side
board in main Protective
cabinet. (User Cap
to program.)
DANGER! Energy Harzard! Read Important Safety Instructions

near the beginning of this document before performing these
procedures.
To Install and Connect Batteries
1. Starting with bottom shelf, place battery blocks on shelf.
2. Install inter-cell connectors. Use torque shown in battery documents.
Note: For safety, leave out one inter-cell connector in each string
until the appropriate stage in the commissioning of the power system.
3. Ensure all battery circuit breakers are OFF.
4. Ensure ALL cable ends are isolated before connecting ANY cable to a
battery. Do not remove shrink tubing from a cable until ready to connect.
5. Connect cables to the batteries. Observe correct polarity.
To Make DC Connections to Power System
1. Connect negative (-48V) terminals to circuit breakers or fuses on
BFU or MFU in power system cabinet.
2. Connect positive (0V) terminals to positive (0V) bar on MFU (if present)
in power system cabinet or to positive 0V bar in power system cabinet.
INITIALLY STARTING AND CHECKING THE SYSTEM

For the start-up of a system, see the document Installation Test Instructions (11 XE 3968 YS).
OPERATING PROCEDURES
Controller and Rectifiers
For operation instructions on these units, refer to the following documents.
• NCU (NetSure™ Control Unit) User Instructions (11 KO 7503 JL)
• EXU (Extension Control Unit) User Instructions (11 VE 0162 PB)
• R48-3500e Rectifier User Instructions (11 AV 1161 LI)
• R48-5800e Rectifier User Instructions (11 FO 6761 VP)
EPO Function
If a customer-furnished Emergency Power Off (EPO) switch is wired to the optional EPO assembly, opening
of normally-closed switch contacts activates the EPO function. The EPO function immediately opens all
LVD contactors to disconnect batteries from the remainder of the power system. When the EPO switch is
closed, LVD contactors close (if battery is present.
NOTE: The customer-furnished EPO switch must include a means of disconnecting AC power from
the rectifiers.)
Local Controls and Indicators

Refer to the Controller and Rectifier User Instructions for descriptions of the local controls and indicators
located on these units.
Refer to this section for descriptions of the local controls and indicators located on the circuit boards
installed inside the power system cabinet.
SM-DU+ (if provided)
Figure 25. SM DU+ Indicators
SM DU+
Alarm (Red)
Alarm (Yellow)
Operation (Green)
The SM DU+ is included with BMG 220 017 distribution units that contain individual load shunts. The SM
DU+ monitors the shunts and fuse alarms, and reports to the controller.
There are three (3) status and alarm indicators located on the SM DU+. Refer to Figure 25 for location. The
functions of these indicators are as shown in Table 2.
Table 2. SM DU+ Indicators
Normal Fault
Indicator Fault Cause
State State
Alarm
Off On A critical or major alarm.
(Red)
Alarm
Off On A minor alarm.
(Yellow)
Off SM-DU+ is non-operational.
Operation A 1/3Hz flashing indicates the SM DU+ is being
On
(Green) Flashing identified by the Controller.
A 1Hz flashing indicates a communication failure.
SM DU-H (if provided)

The SM DU-H is included with distribution units that contain Hall current sensors. The SM DU-H monitors
the sensors and reports to the controller.
There are two (2) status and alarm indicators located on the SM DU-H. Refer to Figure 26 for location. The
functions of these indicators are as shown in Table 3.
Figure 26. SM DU-H Indicators
Distribution Unit
with Hall sensors
SM DU-H
(LEDs on bottom)
Operation (Green)
Failure (Red)
Table 3. SM DU-H Indicators

Normal Fault
Indicator Fault Cause
State State
Alarm
Off On Fault condition.
(Red)
Operation Off SM DU-H is non-operational.
On
(Green) Flashing Indicates a communication failure.
MAINTENANCE
System Maintenance Procedures
It is recommended that the maintenance procedures listed in Table 4 be performed every 6 months to
ensure continual system operation.
Table 4. Maintenance Procedures to Be Performed at 6-Month Intervals
Procedure Referenced In Done (√)
Check ventilation openings for obstructions --

such as dust, papers, manuals, etc.
Inspect and tighten all installer’s connections Making Electrical Connections

section of this document.
NOTE: This table may be reproduced as necessary to record and document system performance.
System Expansion Procedures

Adding a Rectifier to the Power System
To increase system current capacity, a rectifier module can easily be added to an existing rectifier mounting
shelf that contains an empty rectifier mounting position.
For rectifier module installation instructions, refer to rectifier User Instructions (11 AV 1161 LI) for the R48-
3500e rectifiers, or rectifier User Instructions (11FO 6761 VP) for the R48-5800e rectifiers.
Adding a Circuit Breaker to a DC Distribution Unit
Refer to DC Distribution Unit Installation and User Instructions (11 GH 4024 IL) for a procedure.
Adding a Plug-in DC Distribution Unit to a Cabinet
Plug-in DC Distribution Units are available for field installation in a main or extension cabinet that has the
required space available.
Refer to DC Distribution Unit Installation and User Instructions (11 GH 4024 IL) for a procedure.
Adding an Extension Cabinet to the Power System
To increase system current capacity, one or more extension cabinets can be added. The power system can
include up to four (4) extension cabinets. An extension cabinet can be added with the power system in
service.
cabinet(s). External wiring (especially from battery) may be energized from an external source. DO
NOT allow components being installed to simultaneously contact any grounded and energized
objects during this procedure. Use only insulated tools. Read “Important Safety Instructions” near the
Perform the following procedures to add and extension cabinet to the system. Check off each step as it is
completed.
Procedures
 Secure the extension cabinet to floor or wall.
See NetSure™ Cabinet Installation Instructions (11 NR 4202 SF) for a procedure.
 Secure the extension cabinet to the adjacent cabinet.
See NetSure™ Cabinet Installation Instructions (11 NR 4202 SF) for a procedure.
 Make the cabinet-to-cabinet bonding connection.
See Cabinet-to-Cabinet Bonding Connection on page 23 of this document for a procedure.
 Make cabinet-to-cabinet DC bus interconnections.
For a Side-by-Side installation, see Cabinet-to-Cabinet DC Bus Interconnections (Side-by-Side
Installation on page 23 of this document for a procedure. For a back-to-back or remote installation,
see Cabinet-to-Cabinet DC Bus Interconnections (Back-to-Back or Remote Installation) on page 27
of this document for a procedure.
WARNING! DO NOT make the final connection of the -48V interconnection bar or cable until all load
and battery connections to the new cabinet are complete.
 Make cabinet-to-cabinet communication cable connections.
See Cabinet-to-Cabinet Communications Cable (CAN-Bus) Interconnections on page 29 of this
document for a procedure.
 If the power system is equipped with the Emergency Power OFF (EPO) option, make cabinet-to-
cabinet emergency power-off (EPO) cable connections.
See Cabinet-to-Cabinet Emergency Power-Off (EPO) Cable Connections (if provided) on page 30
of this document for a procedure.
 Make AC Connections.
Open all external AC protective or disconnect devices before making connections.
See NetSure™ ACCU/ACDU Installation and User Instructions (11 RK 7416 RI) for a connection procedure.
 Make Load Distribution Connections.
Remove distribution fuses or turn off distribution circuit breakers before making connections.
See NetSure™ DC DU Installation and User Instructions (11 GH 4024 IL) for a connection procedure.
 Make Battery Connections.
Remove battery fuses or turn off battery circuit breakers before making connections.
See NetSure™ BFU Installation and User Instructions (11 KA 8172 KU) for a connection procedure.
 Make final connection of the -48V interconnection bar. See Cabinet-to-Cabinet Bus Connections on
page 23 of this document for a procedure.
 Apply AC power.
 Close all battery circuit breakers or install all battery fuses.
 Close all load distribution circuit breakers or install all load distribution fuses.
 This completes the procedure.
TROUBLESHOOTING AND REPAIR

Contact Information
Support contact information is provided on the inside of the back cover of this document.
Controller and Rectifiers

For troubleshooting and repair instructions on these units, refer to the following documents.
• NCU (NetSure™ Control Unit) User Instructions, 11KO 7503 JL
• EXU (Extension Control Unit) User Instructions (11 VE 0162 PB)
• Rectifier Instructions (R48-3500e), 11 AV 1161 LI
• Rectifier Instructions (R48-5800e), 11 FO6761 VP
NCU Controller Configuration
If any NCU Controller configuration settings were changed, refer to the NCU User Instructions (11 KO 7503
JL) and save a copy of the configuration file. This file can be used to restore the NCU Controller settings, if
required, at a later date.
System Troubleshooting Information

This system is designed for ease in troubleshooting and repair. The various indicators as described in the
section entitled Operating Procedures and in the Controller and Rectifier User Instructions are designed to
isolate failure to a specific element. Once the faulty element has been identified, refer to “Replacement
Information” and "Replacement Procedures" in this chapter.
Troubleshooting Alarm Conditions on the NCU Controller
The NCU Controller displays alarm conditions as listed in the Available Alarms section of the NCU User
Instructions (11 KO 7503 JL). Programmable external alarm relays are also available. Refer to the “Table of
Set Values” supplied with your power system documentation for your alarm relay configurations. The NCU’s
Active Alarm and Alarm History submenus allow the User to view alarm details. Refer to the NCU User
Instructions (11 KO 7503 JL) to access these menus.
Replacement Information
Replacement Assemblies
When a trouble symptom is localized to a faulty rectifier module, controller, or system circuit board; that
particular device or circuit board should be replaced in its entirety. Other than a rectifier module fan
replacement, no attempt should be made to troubleshoot or repair individual components on any rectifier
module, controller, or circuit board.
Replacement Procedures
DANGER! Adhere to the “Important Safety Instructions” presented at the front of this document.
Replacing a Rectifier Module
Refer to the Rectifier User Instructions (11 AV 1161 LI for R48-3500e or 11FO 6761 VP for R48-5800e) for a
rectifier module replacement procedure.
Replacing the NCU Controller
Refer to the NCU User Instructions (11 KO 7503 JL) for a controller replacement procedure.
Replacing the EXU Controller
Refer to the EXU User Instructions (11 VE 0162 PB) for a controller replacement procedure.
Replacing Distribution Devices
To replace circuit breakers or fuses in a DC Distribution Unit refer to the DC DU Installation and User
Instructions (11 GH 4024 IL).
To replace circuit breakers or fuses in a Battery Fuse Unit refer to the BFU Installation and User Instructions
(11 KA 8172 KU).
Circuit Board Replacement Procedures
ALERT! Circuit boards used in this power system contain static-sensitive devices. Read the Static
Warning at the front of this document before performing any of the following procedures.
General
The following circuit board replacement procedures can be performed with the system operating.
Refer to Figure 27 for circuit board locations.
ALERT! When performing any step in these procedures that requires removal or installation of
hardware, use caution to ensure no hardware is dropped and left inside the cabinet; otherwise
service interruption or equipment damage may occur.
NOTE: When performing any step in these procedures that requires removal of existing hardware,
retain all hardware for use in subsequent steps.
Figure 27. Board Locations
Location of IB2
Board (in Main
Cabinet)
Location of Optional
EIB Board (in Main
Cabinet)
Screw
Lock
Mounting
Location
of Optional
IB4 Board Sliding Plate
Location of SM DU+
(when cabinet is
equipped with DU4
Distribution Unit
with individual load
shunts)
Location of SM DU-H
(when cabinet is
equipped with
Distribution Unit
with Hall sensors)
Replacing an IB2 (NCU Interface) Board
Procedure
1. Performing this procedure may activate external alarms. Do one of the following. If possible, disable
these alarms. If these alarms cannot be easily disabled, notify the appropriate personnel to disregard
any future alarms associated with this system while the procedure is being performed.
ALERT! Damage to the circuit board may result if the next step is not followed
2. Connect an approved grounding strap to your wrist. Attach the other end to a suitable ground.
3. Carefully label the wires connected to the customer connection terminal blocks on the circuit board.
These wires must be connected to the same terminals on the replacement circuit board. Refer to
Figure 19.
4. Carefully label the connectors plugged into the circuit board. These connectors must be plugged
into the same connectors on the replacement circuit board. Refer to Figure 19.
DANGER! In the next step, external wiring may be energized from an external source. DO NOT allow
bare wire ends to contact any grounded or energized object.
5. Remove the external wiring from the customer connection terminal blocks. DO NOT allow the bare
wire end to contact any grounded or energized object. Isolate the wire end with electrical tape.
Repeat for each wire to be removed.
6. Unplug all connectors plugged into the circuit board.
7. Remove the circuit board by removing the two (2) screws that secure the protective cover, then
removing the two (2) screws that secure the circuit board.
8. In this step, ensure you do not inter-mix the old and replacement circuit boards. Set the switch on the
replacement circuit board to the same setting as the old circuit board. Switch settings are
documented in the section of this instruction entitled Switch Settings on IB2 Interface Board on page
16.
9. Install the circuit board by installing the two (2) screws that secure the circuit board to its mounting
bracket, then installing the two (2) screws that secure the protective cover.
10. Plug all connectors removed from the old circuit board into the same position on the replacement
circuit board.
11. Reconnect the external wiring to the correct terminals on the customer connection terminal block.
First remove the electrical tape that was applied to the bare wire end in a previous step. DO NOT
allow the bare wire end to contact any grounded or energized object. After securing the wire, gently
tug on the wire to ensure that it cannot be pulled out of the terminal block. Repeat for each wire to
be reconnected.
12. Remove the grounding wrist strap.
13. Enable the external alarms, or notify appropriate personnel that this procedure is finished.
14. Ensure that there are no local or remote alarms active on the system.
Replacing an EIB Extended Interface Board)
Procedure
3. To access the board, remove the screw and release the lock that secure the sliding plate. Pull out
the sliding plate.
4. Carefully label the wires connected to the customer connection terminal blocks on the circuit board.
These wires must be connected to the same terminals on the replacement circuit board. Refer to
Figure 19.
5. Carefully label the connectors plugged into the circuit board. These connectors must be plugged
into the same connectors on the replacement circuit board. Refer to Figure 19.
DANGER! In the next step, wiring may be energized from an external source. Carefully isolate each
wire end as it is removed. DO NOT allow any bare wire ends to contact any grounded or energized
object.
6. Remove the external wiring from the customer connection terminal blocks. DO NOT allow the bare
wire end to contact any grounded or energized object. Isolate the wire end with electrical tape.
Repeat for each wire to be removed.
7. Unplug all connectors plugged into the circuit board.
8. Remove the circuit board by removing the two (2) screws that secure the protective cover, then
removing the two (2) screws that secure the circuit board to the sliding plate. Refer to Figure 28.
9. In this step, ensure you do not inter-mix the old and replacement circuit boards. Set the switch on
the replacement circuit board to the same setting as the old circuit board. Switch settings are
documented in the section of this instruction entitled Switch Settings on Optional EIB Interface
Board on page 16.
10. Install the circuit board by installing the two (2) screws that secure the circuit board to the sliding
plate, then installing the two (2) screws that secure the protective cover.
11. Plug all connectors removed from the old circuit board into the same position on the replacement
circuit board.
Figure 28. Replacing the EIB Board
Protective
Cover
Sliding
Plate
12. Reconnect the external wiring to the correct terminals on the customer connection terminal block.
First remove the electrical tape that was applied to the bare wire end in a previous step. DO NOT
allow the bare wire end to contact any grounded or energized object. After securing the wire, gently
tug on the wire to ensure that it cannot be pulled out of the terminal block. Repeat for each wire to
be reconnected.
Replacing the Optional IB4 Board

Procedure
3. Remove the cabinet front cover plate located immediately above the supervision unit.
4. Remove the screw and release the lock that secure the sliding plate. Pull out the sliding plate.
5. Unplug all connectors plugged into the IB4 circuit board.
NOTE: If you wish to remove the entire assembly from the cabinet, perform the next step. If you wish
to exchange the board without removing the entire assembly, skip the next step, and proceed to
step 7.
Remove the circuit board assembly from the cabinet by pushing in on bracket tongue with a screwdriver
screwdriver while lifting the assembly up until it is free from the guiding flanges in the controller box side
side plate. See Detail A in
6. Figure 29.
7. Remove the three (3) screws that secure the protective cover and circuit board to the mounting
bracket
8. Secure the replacement circuit board and the protective cover to the mounting bracket by installing
the three (3) screws.
9. If the entire assembly was removed in step 0, install the circuit board assembly by sliding it into the
guiding flanges in the controller box side plate until fixed in place.
10. Plug all connectors removed from the old IB4 circuit board into the same position on the
replacement circuit board.
12. Re-install the cabinet front cover plate.
Figure 29.Replacing the Optional IB4 Board
Protective Cover
IB4 Board
Mounting Bracket
Controller Box Sliding
Side Plate Plate
DETAIL A
To Remove Complete Assembly:
(Board not shown)
1. Use screwdriver
to push in on tongue
while...
2. Lifting bracket up.
Replacing an SM DU+
Procedure
these alarms. If these alarms cannot be easily disabled, notify the appropriate personnel to
disregard any future alarms associated with this system while the procedure is being performed.
ALERT! Damage to the circuit board may result if the next step is not followed.
3. Carefully label the connectors plugged into the SM DU+. These connectors must be plugged into
the same locations on the replacement circuit board. Refer to Figure 30.
4. Unplug all connectors plugged into the SM DU+.
NOTE: If you wish to replace the entire assembly, perform the next step. If you wish to exchange the
circuit board without replacing the entire assembly, skip the next step, and proceed to step 10.
5. Remove the SM DU+ by removing the two (2) screws that secure it to its mounting bracket.
NOTE: If you wish to exchange the circuit board only, perform steps 6 through 9. If you wish to
replace the entire assembly, skip these steps, and proceed to step 10.
6. Remove the cover from the assembly. The cover lifts off.
7. Remove the four (4) screws that secure the circuit board to the mounting plate.
8. Secure the replacement circuit board to the mounting plate by installing the four (4) screws.
9. Rein stall the cover. The cover snaps in place.
10. In this step, ensure you do not inter-mix the old and replacement SM DU+. Set the switch on the
replacement SM DU+ to the same setting as the old SM DU+. Switch settings are documented in
the section of this instruction entitled Switch Settings on Optional SM DU+ on page 17.
NOTE: In the next step, make sure that the two (2) screws find their threads. Use only thread-
forming screws.
11. If the entire assembly was removed in step 5, install the replacement SM DU+, and secure it the
mounting bracket with the screws removed in step 5.
12. Plug all connectors removed from the old SM DU+ into the same positions on the replacement
SM DU+.
Figure 30. Replacing an SM DU+
Replacing an SM DU-H
Procedure
ALERT! Damage to the circuit board may result if the next step is not followed.
3. Carefully label the connectors plugged into the SM DU-H. These connectors must be plugged into
the same locations on the replacement.
4. Unplug all connectors plugged into the SM DU-H.
NOTE: If you wish to replace the entire assembly, perform the next step. If you wish to exchange the
board without replacing the entire assembly, skip the next step, and proceed to step 6.
5. Remove the SM DU-H assembly by removing the two (2) screws that secure it to the cabinet.
NOTE: If you wish to exchange the circuit board only, perform steps 6 through 9. If you wish to
replace the entire assembly, skip these steps, and proceed to step10.
6. Remove the cover from the assembly. The cover lifts off.
7. Remove the four (4) screws that secure the circuit board to the mounting plate.
Figure 31. Replacing an SM DU-H
Cover Board Mounting

Plate
Complete Assembly
8. Secure the replacement circuit board to the mounting plate by installing the four (4) screws.
9. Reinstall the cover. The cover snaps in place.
10. In this step, ensure you do not inter-mix the old and replacement SM DU-H. Set the switch on the
replacement SM DU-H to the same setting as the old SM DU-H. Switch settings are documented in
the section of this instruction entitled Switch Settings on Optional SM DU-H on page 19.
NOTE: In the next step, make sure that the two (2) screws find their threads. Use only thread-
forming screws.
11. If the entire assembly was removed in step 5, install the replacement SM DU-H assembly, and
secure it the cabinet with the screws removed in step 5.
12. Plug all connectors removed from the old SM DU-H into the same positions on the replacement
SM DU-H.
TECHNICAL DATA
NetSure™ 7100
System
Nominal AC Input Voltage: 6x230 VAC (1W+N+PE) 50-60Hz,
3x400 VAC (3W+N+PE) 50-60Hz,
3x110 VAC (3W+PE) 50-60Hz
Nominal DC Voltage: –48 V
Maximum Output Current @ 48 V: 5256 A
Maximum Number of Cabinets: 5
Operational Temperature: +5 °C to +40 °C
Storage Temperature: –40 °C to +70 °C
Relative Humidity: 5% to 90%
Installation Category:
• The voltage of supply system is 200-240/346-415VAC.
• The power system is equipment of Overvoltage Category II energy-consuming equipment to be supplied
from the fixed installation.
EMC : ETSI EN 300 386 v1.5.1, Class B according to EN 55022
Product Safety: EN 60950-1
Market Approval:
• CE Marking 93/68/EC
• Low Voltage Directive 2006/95/EC
• EMC Directive 2006/95/EC
• RoHS 2011/65/EU
• REACH 1907/2006
• WEEE 2002/96/EC
Cabinet
Maximum Output Current: 875 A
Building Practice: 23”
Height (excl. top cover and feet): 1800, 2020 mm
Footprint (width x depth): 600 x 600 mm or 600 x 400 mm
Weight (fully equipped, without batteries): Maximum 250 kg
Rectifier
See Rectifier User Instructions (11 AV 1161 LI)
NetSure™ 8100
System
Nominal AC Input Voltage: 3x400 VAC (3W+N+PE) 50-60Hz
Nominal DC Voltage: –48 V
Maximum Output Current @ 48 V: 5760 A
Maximum Number of Cabinets: 5
Operational Temperature: +5 °C to +40 °C
Storage Temperature: –40 °C to +70 °C
Relative Humidity: 5% to 90%
Installation Category:
• The voltage of supply system is 346-415VAC.
• The power system is equipment of Overvoltage Category II energy-consuming equipment to be
supplied from the fixed installation.
EMC : ETSI EN 300 386 v1.5.1, Class B according to EN 55022 (Class A if equipped with optional front
door)
Product Safety: EN 60950-1
Market Approval:
• CE Marking 93/68/EC
• Low Voltage Directive 2006/95/EC
• EMC Directive 2006/95/EC
• RoHS 2011/65/EU
• REACH 1907/2006
• WEEE 2002/96/EC
Cabinet
Maximum Output Current: 960 A
Building Practice: 23”
Height (excl. top cover and feet): 1800, 2020 mm
Footprint (width x depth): 600 x 600 mm
Weight (fully equipped, without batteries): Maximum 250 kg
Rectifier
See Rectifier User Instructions (11 FO 6761 VP)
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NetSureTM

7100 and 8100, Multi Cabinet, 48V DC Power System

SAFETY! Informs the reader of general safety information, reminders, precautions, or

Personal Protective Equipment (PPE)

Handling Equipment Containing Static Sensitive Components

Maintenance and Replacement Procedures

Positive (0V) Bar(s) Positive (0V) Bar(s)

Battery Fuse Unit, with

Distribution Unit, 500 A, Distribution Unit,

AC Distribution Unit AC Distribution Unit

Rectifier Shelf for up to Rectifier Shelf for up to

Rectifier Shelf for up to Rectifier Shelf for up to

Positive (0V) Bar(s) Positive (0V) Bar(s)

Battery Fuse Unit, with Battery Fuse Unit, with

Supervision Unit with Supervision Unit with

Distribution Unit, Distribution Unit,

AC Distribution Unit AC Distribution Unit

Rectifier Shelf for up to

Positive (0V) Bar(s) Positive (0V) Bar(s)

Physically Installing the System

Securing the Cabinet(s) to the Floor or Wall

Securing Cabinets to Each Other (side-by-side or back-to-back Installations)

Installing Circuit Breakers and Fuses

SETTING SWITCH OPTIONS

Figure 4. Option Switch Locations, IB2 and EIB Boards

Switch Settings on IB2 Interface Board

Switch Settings on Optional EIB Interface Board

Figure 5. IB2 Interface Board Switch Location

Switch Settings on Optional SM DU+

Figure 7. SM DU+ Switch Location and Settings

Setting for DIP

SM DU-H Address Configuration (binary from 1-64)

General Cabling Information

DC Inlets (See details below)

For larger wire, cut out

Loosen screws, adjust sliding

Power Cabinet Telecom Rack

Cabinet-to-Cabinet Bonding Connection (Back-to-Back Installation)

Cabinet-to-Cabinet Bonding Connection (Remote Installation)

Cabinet-to-Cabinet DC Bus Interconnections (Side-by-Side Installation)

BMY 220 074/1 or

Positive (0V) Interconnection Bar

Conical Spring Washer

Cabinet Positive M8 Hex Nut (2 places)

Cabinets with Bar Installed

Front View of Cabinets

SHRINK TUBING DETAIL

Slide shrink tubing

Shrink tubing position

Front View of Bottom-Cabled Cabinets

Front View of Top-Cabled Cabinets

Cabinet-to-Cabinet DC Bus Interconnections (Back-to-Back or Remote Installation)

Figure 15. Cabinet DC Interconnection Points (Back-to-Back or Remote Installation)

Figure 16. CAN Bus Cable Connections

Note: There must always

Interconnecting Cable (RPM 628 1046/1) Terminal

Cabinet-to-Cabinet Emergency Power-Off (EPO) Cable Connections (if provided)