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Lucent Technologies Lineage

®

2000 25A Ferroresonant Rectifier J85502A-1

Issue 4 May 1998

Installation 5 - 1

5

Installation

Introduction

This section provides information to consider before installing
the J85502A-1 rectifier in a Lineage

®

2000 Battery Plant. This

section also describes the input and output wiring required and
the recommended procedure for installing the rectifier from
uncrating through startup. Lucent Technologies offers
“turn-key” engineering and installation services for the products
described in this product manual. Consult your Lucent
Technologies representative for details.

Safety

Please read Section 4, Safety, thoroughly before installing the
J85502A-1 rectifier, and carefully read and follow the
admonishments as they are presented throughout this
documentation.

Preparing for
Installation

Location of the J85502A-1 rectifier and associated equipment
must conform to the specific plans of each Lineage

®

2000 plant

installation. Physical, thermal, and electrical specifications are
given in Section 2. These specifications must be considered in
the plans for any installation that includes this rectifier.

Handling

Equipment

Each J85502A-1 rectifier weighs at least 85 pounds. The
customer should make prior arrangements for appropriate
material handling facilities and equipment to unload, uncrate,
and install the rectifier. Proper handling is necessary to assure
personnel safety and protect the equipment. Each rectifier
(unless it is part of a battery plant when it leaves the factory) is
shipped in a tri-walled corrugated cardboard container secured
to a wooden shipping skid. The container should be moved by a
forklift.

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Summary of Contents for Lineage 2000 J85502A-1

Page 1: ...hnologies Lineage 2000 25 Ampere 60 Hertz Ferroresonant Rectifier Notice Every effort was made to ensure that the information in this document was complete and accurate at the time of printing However information is subject to change 1998 Lucent Technologies All Rights Reserved Printed in U S A ...

Page 2: ...logy 2 2 Standard Features 2 2 Additional Features 2 4 Circuit Modules 2 5 Front Panel Controls and Indicators 2 6 Alarm and Control Flow 2 8 Physical Thermal and Electrical Specifications 2 9 3 Ordering Information Equipment Lists 3 1 Documentation 3 2 4 Safety Admonishments 4 1 Safety Statements 4 1 Precautions 4 2 Warning Statements and Safety Symbols 4 4 5 Installation Introduction 5 1 Safety ...

Page 3: ...ne 6 7 Startup 6 7 Regulation NL FL Test Off Line 6 8 Rectifier Failure Alarm Fuse Alarm Test Off Line 6 8 Current Limit Test Off Line 6 9 Backup High Voltage Shutdown HVSD Test Off Line 6 10 Control TR Test 6 11 Selective High Voltage Shutdown SHVSD and Restart 6 11 Meter Calibration Test Off Line 6 11 Test for 434A or 434B Circuit Module 6 12 Off Line Test Completion 6 12 Bringing the Rectifier ...

Page 4: ...duction 8 1 Ordering Circuit Modules 8 1 Handling Circuit Modules 8 2 Electrostatic Discharge 8 2 Modifying the CM1 Option Board 8 3 Spare Fuses 8 4 Replacing Circuit Modules 8 4 Replacing CM1 Option Board 8 5 Replacing CM2 Control Board 8 6 Replacing CM3 Digital Meter Board 8 7 General Information on Replacing Components 8 8 Replacing Components 8 13 Output Volts Adjust Potentiometer R4 8 13 DC O...

Page 5: ...2 J85502A 1 Rectifier with Door Open 5 3 Figure 6 1 Battery Plant Simulator Test Set 6 2 Figure 6 2 CM1 Option Board ED83158 30 Grp 2 A Showing Test Clip Connections and Movable Straps Q and T 6 6 Figure 6 3 CM2 Control Board Showing Test Clip Connections and Other Component Detail 6 7 Figure 7 1 Component Sides of CM3 Digital Meter Boards 7 4 Figure 8 1 Rear Compartment of the J85502A 1 Rectifier...

Page 6: ... the J85502A 1 Rectifier 3 1 Table 3 B Document References 3 2 Table 5 A AC Input Requirements 5 4 Table 5 B DC Output Requirements 5 4 Table 5 C Rectifier Settings for Initial Battery Charge 5 11 Table 6 A Rectifier Control Settings for Testing Off Line 6 4 Table 6 B Test Set Connections 6 6 Table 6 C Rectifier Control Settings Prior to Testing On Line 6 13 Table 6 D Controls for Meter Calibratio...

Page 7: ...of Tables Issue 4 May 1998 Table 8 B Modifications for the CM1 Option Board 8 4 Table 8 C Spare Fuse Information 8 4 Table 8 D Torque and Minimum Yield Strength for Mechanical Connections Using Hex Head Cap Screws 8 11 Table 8 E Minimum Torque for All Electrical Connections 8 12 ...

Page 8: ...uired in order for the equipment to operate correctly the J85502A 1 rectifier is an excellent choice for any telecommunications battery plant The J85502A 1 rectifier can be used with a Lineage 2000 battery plant older vintage Lucent Technologies battery plants or any commercial battery plant With certain options it can also operate off battery Customer Service For customers in the United States Ca...

Page 9: ...00 225 7822 to contact a product specialist to answer your technical questions and assist in troubleshooting problems For other customers worldwide contact your local field support center or your sales representative to discuss your specific needs Product Repair and Return Repair and return service is provided for Lucent Technologies customers around the world For customers in the United States Ca...

Page 10: ...ectifier uses controlled ferroresonant technology which reduces noise and transients from commercial lines All components in the rectifier meet Lucent Technologies strict specifications and reliability standards The rectifier uses an extremely efficient free convection cooling system that keeps components operating at temperatures well below the recommended maximum resulting in high reliability Al...

Page 11: ...y maintenance and greater cost effectiveness on a dollars per output ampere basis Ferroresonant technology also Eliminates internal switching transients typically associated with other technologies Reduces noise and transients from commercial lines As the interface between commercial power and telephone equipment the ferroresonant rectifier significantly attenuates noise and lightning surges from ...

Page 12: ...p high voltage shutdown This circuit prevents damage to the rectifier in the event of high battery voltage Each rectifier senses its own output voltage and shuts down when this voltage exceeds a preset value This circuit operates if the external selective HVSD fails to operate This backup HVSD operates from an independent voltage source per Bellcore standards Output current limit The rectifier pro...

Page 13: ...ircuit The rectifier has an automatic restart feature that is compatible with the Lineage 2000 controllers and most other controllers If a rectifier shuts down due to the external selective HVSD most controllers try at least once to restart it automatically Remote sense leads These leads permit remote regulation of the rectifier if it is installed with a compatible controller and the straps on the...

Page 14: ... modules or packs Circuit modules are plug in boards that can be ordered separately Table 8 A lists recommended spare parts for the rectifier All circuit modules are accessible by opening the rectifier door Figure 5 2 shows the location of the circuit modules and other features of the rectifier Figures 6 2 6 3 and 7 1 show the CM1 CM2 and CM3 board layouts respectively A description of each module...

Page 15: ...r B has ac and dc voltage monitor circuits When activated these circuits shut down the rectifier The dc circuit issues an RFA alarm The rectifier must be restarted when the problem has been cleared When the ac circuit is activated the rectifier shuts down but automatically restarts when the corrected ac voltage is restored Front Panel Controls and Indicators Figure 2 1 shows the control panel of t...

Page 16: ...f this meter in the various positions The accuracy of the reading depends on the vintage of the digital meter board CM3 in the rectifier The POWER control Figure 2 1 Control Panel of J85502A 1 Rectifier Table 2 A Digital Meter Accuracy Meter Position Accuracy RECT V 0 5 volt for Series 1 or 2 CM3 digital meter boards 0 02 volt for Series 3 CM3 digital meter boards BATT V 0 02 volt for any CM3 digi...

Page 17: ...the normal operating state The OUTPUT VOLTS ADJ potentiometer provides for manual adjustment of the output float voltage The REG test jacks allow for measuring the plant output voltage at the points where the remote sense leads are connected This measurement is accurate only when the remote sense leads are connected The 1 2 AMP V and V alarm fuses protect the internal voltage sense leads to the re...

Page 18: ...ons Tables 2 B 2 C and 2 D give the physical thermal and electrical specifications for the Lineage 2000 J85502A 1 25 ampere rectifier Regulation on battery is 0 5 for the line load frequency and temperature specifications Regulation off battery is 2 for these specifications Figure 2 2 Signal Flow between Rectifier and Lucent Technologies Controller DC Output Circuit Breaker Status CB Rectifier Con...

Page 19: ...tifiers and 54 Vdc 48 volt rectifiers Table 2 C Input Specifications for the J85502A 1 Rectifier Input AC Volts Nominal Line Current Amps Frequency Hz Nominal Range 24V 48V 208 184 220 4 2 8 60 3 240 212 254 4 0 7 Data recorded at full load 28 Vdc for 24 volt rectifiers and 54 Vdc for 48 volt rectifiers Table 2 D Output Specifications for the J85502A 1 Rectifier Nominal Rectifier amps volts Output...

Page 20: ...uipment Lists for the J85502A 1 Rectifier List Number Input Voltage AC Output Voltage DC 1 208 or 240 24 2 208 or 240 48 E 434A voltage monitor board without ac voltage alarm F 434B voltage monitor board with ac voltage alarm Optional List Number Provides 10 Digital meter WA External sensing required when rectifier is installed with a controller equipped with battery regulation fuses WB External h...

Page 21: ...Documentation This document is part of a set of documents developed to assist equipment engineering and installation Table 3 B Document References Document No Document Description J85502A 1 Assembly Ordering and Installation Drawing T 82604 30 Wiring Drawing SD 82604 01 Schematic Drawing 169 790 122 Product Manual ...

Page 22: ...use only in restricted access areas dedicated equipment rooms equipment closets or the like in accordance with articles 110 16 110 17 and 110 18 of the U S National Electric Code NEC ANSI NFPA No 70 and pursuant to applicable local codes This equipment must not be installed over combustible surfaces This equipment is to be used in controlled environments an area where the humidity is maintained at...

Page 23: ...obtain appropriate connectors and follow manufacturer s and all local requirements for proper connections All national and local rules and regulations are to be followed when making field connections Torque electrical connections to the values specified on labels or in the product documentation Precautions When working on or using this type of equipment follow these precautions This unit must be i...

Page 24: ...ry and charge ground connectors cables must be taped adequately to prevent them from contacting each other or any other metal surface Alternatively the dc battery cables from the rectifier can be disconnected at the plant charge battery and charge ground buses DC capacitors may be charged even with power disconnected from the rectifier If filter capacitor fuses have blown capacitors will be charge...

Page 25: ...ent Identify exposed hazardous electrical potentials on connectors wiring etc note the condition of these circuits especially any wiring Use care when removing or replacing any covers avoid contacting any circuits Use gloves when handling thermally hot components inside the rectifier Transformers are very hot after sustained operation Warning Statements and Safety Symbols The symbols may sometimes...

Page 26: ...be accompanied by some type of statement for example Battery voltage present Risk of injury due to high current Avoid contacting conductors with uninsulated metal objects Follow safety precautions This symbol is used to identify the need for safety glasses and may sometimes be accompanied by some type of statement for example Fuses can cause arcing and sparks Risk of eye injury Always wear safety ...

Page 27: ...Lucent Technologies Lineage 2000 25A Ferroresonant Rectifier J85502A 1 4 6 Safety Issue 4 May 1998 These symbols are used to identify the safety earth ground or bonding point for the equipment ...

Page 28: ... admonishments as they are presented throughout this documentation Preparing for Installation Location of the J85502A 1 rectifier and associated equipment must conform to the specific plans of each Lineage 2000 plant installation Physical thermal and electrical specifications are given in Section 2 These specifications must be considered in the plans for any installation that includes this rectifi...

Page 29: ...hr 24 volt rectifier or 810 BTU hr 48 volt rectifier The rectifiers use free convective cooling where air enters the cabinet through perforations in the bottom of the rectifier and escapes through perforations in the top cover A minimum of 7 inches in front of the rectifier must be free of obstruction to allow the door to open horizontally and provide for adequate ventilation AC Input Power The cu...

Page 30: ...C Output Hole Figure 5 2 J85502A 1 Rectifier with Door Open VAC 208 240 VAC 208 240 TB1 TB1 208 208 L1 L1 L2 L2 Input Terminal Block Diode Heat Sink Assembly TB3 Output Terminal Block 1 2 Switch S3 for AC Input Conversion Output Volts Adjustment Potentiometer CBA1 Circuit Breaker CA1 Snubber Board ED 83156 30 on Right Wall Thyristor Q1 CM1 Option Board ED 83158 30 CM3 Digital Meter Board 207A Door...

Page 31: ...t Circuit Breaker Size amps Number of Input Wires Gauge Armored Cable Trade Size inches for Wire Size Shown Max Input Wire Gauge Conduit Knockout and Conduit Trade Size inches Terminal Supplied on Rectifier L1 208 or 240 4 2 or 4 0 FN 10 10 3 14 AWG 1 2 12 AWG 7 8 1 2 Screw type L2 208 or 240 8 0 or 7 0 FN 15 15 Input wire count includes one green wire ground Use KS24194 L3 or 75 C commercial wire...

Page 32: ... tools are required for installing rectifiers Material handling equipment to unload rectifiers at site uncrate them and place them in final positions Common electrician s hand tools including jeweler s screwdriver electrical tape wire cutters and strippers 14 AWG to 8 AWG wire Proper crimping tools and dies for connectors used Common mechanic s hand tools including flat blade screwdriver 30 inch b...

Page 33: ... J85502A 1 Installing or Adding a Rectifier Before beginning this procedure read the Preparing for Installation section in its entirety This procedure is appropriate for installing a rectifier in a new plant or adding a rectifier to an existing plant to increase capacity The assumption is made however that the rectifier is being added to an operating plant Observe the safety precautions in Section...

Page 34: ... or insert ac fuses If the branch circuit two input conductors and frame ground is protected by fuses physically remove the fuses from the area of the ac service panel Installing DC Power Cables Plant bus bars may carry 52 volts dc Observe DANGER warnings in Section 4 Use Figures 5 1 and 5 2 as references for this section 1 Turn DC OUTPUT circuit breaker on rectifier Off down 2 Measure the lengths...

Page 35: ...mbly has a 24 pin or 16 pin connector on one end and a 40 pin connector on the other end The 24 pin or 16 pin end terminates on the battery plant controller and the 40 pin end terminates on connector P2A of the CM2 control board located in the rectifier Use Figures 5 1 and 5 2 as references for this section 1 Route the plant control cable from the controller via the cable racks to the rectifier an...

Page 36: ...trolled System CCS plants remove the plastic cover on the back of the bay housing the controller The back of the controller has sixteen 24 pin connectors labeled Rect 1 through Rect 16 For Expandable Controlled System XCS plants open the front panel and thread the control cable through the hole in the wall of the controller There are six 16 pin connectors labeled Rect 1 through Rect 6 For Evolutio...

Page 37: ...e other input wire to the L2 208 terminal on TB1 Connect the green ground wire to the FR GRD termination point next to TB1 Place switch S3 mounted on the inside rear wall of the rectifier in the 208 volt position For 240 Vac Input to Rectifier Connect one ac input wire to the L1 208 240 terminal on TB1 the ac input terminal block Connect the other input wire to the L2 240 terminal on TB1 Connect t...

Page 38: ...wn in Table 5 C 2 Move the straps provided for options Q and T P15 and P16 on the CM1 option board from normal position to charge position as shown in Figure 6 2 3 At the ac service panel supplying power to the rectifier insert the input fuses assigned to the rectifier or turn the circuit breaker On 4 Close the rectifier door and turn the POWER switch On The green POWER ON LED must light If not do...

Page 39: ...down option leave straps Q and T on CM1 in the charge position pins 1 and 2 If the rectifier is not equipped with List WB place Q and T in the normal position pins 2 and 3 10 Turn the OUTPUT VOLTS ADJ potentiometer fully counterclockwise 11 To restore the rectifier to service follow the procedure described in Restoring a Rectifier to Service in Section 7 Note If the rectifier continues to operate ...

Page 40: ... these items For troubleshooting and diagnostic procedures refer to Preparation for Testing Off Line below If you are unfamiliar with the function of rectifier controls and indicators read Section 2 of this manual Precautions When working on power systems observe safety precautions in Section 4 and those within each procedure Voltages required for the control relays the Rectifier Failure Alarm RFA...

Page 41: ...o P2A 6 of CM2 To P2A 39 of CM2 To P2A 38 of CM2 To P2A 34 of CM2 To P2A 37 of CM2 To P2A 31 of CM2 To P2A 27 of CM2 To P2A 2 of CM2 Blue Test Clip See Note White Test Clip Black Test Clip To P2A 12 of CM2 BAT R2 R1 2150 2150 1 WATT 2150 1 WATT 2150 1 WATT 2150 1 WATT R3 R4 R5 MAN 1 1 1 1 1 2 2 2 2 2 3 3 3 1 1 1 2 2 2 F1 F2 1 1 3 1 1 3 TR PWR HV RS RFA TRH PH MAN RFA TRH PH or LOA DPG TR48 HV48 RS...

Page 42: ...er control panel in Figure 2 1 Test load connections are made on the output terminal block of the rectifier after the DC OUTPUT circuit breaker Therefore the rectifier must be disconnected from the plant charge and charge ground bus bars in order to isolate the unit from the batteries 1 Turn the rectifier POWER switch Off 2 Turn Off down the rectifier DC OUTPUT circuit breaker 3 At the ac service ...

Page 43: ...owing steps check the plant control cable and prepare the equipment for testing 1 Verify that the ac supply and rectifier controls are as shown in Table 6 A 2 Use the documentation for the particular battery plant to perform all the preliminary checks on the plant prior to the rectifier tests If the rectifier is in a microprocessor controlled plant with an efficiency algorithm feature disable this...

Page 44: ...troller The problem must be found and repaired before proceeding with testing d With the BAT fuse installed in the plant controller check for battery voltage between pin 5 of J2A and ground e If the plant is equipped with an MCS controller again on J2A check for 15 20 volts dc between pins 35 and 31 Pin 35 should be positive with respect to pin 31 4 Place the Battery Plant Simulator Test Set Figur...

Page 45: ...on CM1 ED83158 30 board 6 2 V Figure 6 2 CM1 Option Board ED83158 30 Grp 2 A Showing Test Clip Connections and Movable Straps Q and T VSK VSK VAC VAC E7 E6 E5 E4 E3 E1 E2 E8 V VSH VSH LG P12 P7 P8 R25 R8 CR1 CR3 CR2 P11 P14 R24 P4 P3 P2 P1 R7 R6 R4 R5 CHARGE CHARGE T Q CHARGE W V W W W W W ZJ V V N V V V V V F K ZA ZA Q T M W W P16 P15 R13 R11 R9 P5 P10 R10 R14 R12 R17 R16 R15 R18 ST9 ST8 ST7 ST6 ...

Page 46: ...ed These leads provide the operating voltages in the test set and the red lead should be approximately 27 volts dc with respect to the black lead 2 The PWR lamp should remain lit during the remaining tests as long as the ac supply is turned On Figure 6 3 CM2 Control Board Showing Test Clip Connections and Other Component Detail E14 E13 C1 C2 C21 C22 C24 C20 R52 P1A P2A R31 IC3 CR25 R70 C16 C14 E5 ...

Page 47: ...ine 1 Hold the meter selector switch in the RECT V position Watch the test meter and move the RECT TEST switch to NL In the NL position the voltage should drop between 0 3 and 0 6 volt 2 Repeat Step 1 with the RECT TEST switch in the FL position The voltage should increase between 0 1 and 0 4 volt Rectifier Failure Alarm Fuse Alarm Test Off Line 1 Insert a piece of bare wire or the end of a paper ...

Page 48: ...ut to 52 08 volts 48 volt rectifier 26 04 volts 24 volt rectifier 4 Remove strap from capacitor C24 on CM2 Observe that Vout is 51 98 52 03 volts 48 volt rectifier 25 99 26 01 volts 24 volt rectifier If not see Adjust Current Limit in Section 7 5 Increase the load to 27 28A 110 1 percent Vout should be below 51 58 volts 48 volt rectifier 25 79 volts 24 volt rectifier If not see Adjust Current Limi...

Page 49: ...er when it is being used for applying the initial charge to connected batteries 3 Slowly turn the OUTPUT VOLTS ADJ potentiometer clockwise until the rectifier shuts down This should occur between 32 25 and 33 50 volts 24 volt rectifier or between 63 and 66 volts 48 volt rectifier The RFA LED on the rectifier and the RFA lamp on the test set should light When this step is completed restore R21 or R...

Page 50: ...ective High Voltage Shutdown SHVSD and Restart 1 Adjust the test load so that the rectifier delivers 2 5 4A 10 to 15 percent of its rated amperage 2 Momentarily press the HV switch on the test set The rectifier should shut down and the RFA lamps on the rectifier and the test set should light 3 Momentarily press the RS switch on the test set The rectifier should restart and both RFA lamps should go...

Page 51: ...meter to between 52 02 and 52 13 or 26 01 and 26 06 volts read on the OUTPUT meter or to float voltage as determined in Adjusting Rectifiers to Float Voltage in this section 3 Turn the POWER switch Off 4 Reduce the load to zero 5 Turn Off the ac power at the ac service panel 6 Disconnect and remove the Battery Plant Simulator Test Set the DMM Digital Multimeter and the test load 7 If the reason fo...

Page 52: ...rectifier s ground output lead to the plant charge ground bus bar 5 Remove the tape and reconnect the rectifier s hot output lead to the plant charge bus bar 6 At the ac service panel supplying power to the rectifier insert the input fuses assigned to the rectifier or turn the circuit breaker On 7 To bring the rectifier into service a Turn the rectifier POWER switch On The green POWER LED must lig...

Page 53: ...tted from this section because these signals originate in the plant controller or a remote location and the test procedure depends on that device See your plant controller product manual Also straps on the CM1 option board must be set for List WB to enable the external selective HVSD Straps must be set for List WA to enable external sensing Check CM1 and Table 8 B in this manual or Tables A and R ...

Page 54: ...h in the NL position The output amperes should decrease 3 Repeat from Step 1 and in Step 2 hold the RECT TEST switch in the FL position The output current should increase Rectifier Failure Alarm Fuse Alarm Test On Line I 1 Insert a piece of bare wire or the end of a paper clip into a pencil eraser Holding the pencil insert the wire next to the Note At least two rectifiers must be operating when th...

Page 55: ... and E3 and E14 and E4 Current Limit Test On Line 1 Connect a DMM to the REG test jacks to verify the battery voltage 2 Hold the RECT TEST switch in the full load FL position to raise the rectifier output current to current limit Notes Adjust the current limit only after verifying that a current limit circuit problem exists There must be two or more rectifiers with a plant load of at least 25 perc...

Page 56: ...performed while connected to an MCS or Galaxy controller and a battery Refer to Figure 6 3 for components on the CM2 control board Plant control cable connector J2A MUST be connected to P2A on CM2 for this procedure 1 Connect a DMM between E1 and E2 on CM1 see Figure 6 2 2 Increase the load so the rectifier delivers approximately 12 5A 50 percent of its rated current capacity 3 Observe the DMM and...

Page 57: ...T P16 movable straps on CM1 to the Charge position see Figure 6 2 Verify that moveable strap P14 remains in the 2 3 NOT the Charge position for this test and after the rectifier is placed into service The P14 Charge position is only used to raise the Backup HVSD level of the rectifier when it is being used for applying the initial charge to connected batteries To increase the upper range of the vo...

Page 58: ...e BATT V position Observe and record the voltage readings on the DMM and the rectifier OUTPUT meter 3 If the rectifier OUTPUT meter is not within 0 02 volts of the reading on the DMM refer to Calibrate CM3 Digital Meter in Section 7 to calibrate the OUTPUT meter 4 Connect the DMM to the rectifier output terminal and ground See Figure 5 2 5 Hold the meter selector switch in the RECT V position Obse...

Page 59: ...tring gives maximum life and full capacity This voltage depends on the type and number of batteries in a plant Float voltage per cell number of cells battery string float voltage Traditionally 2 17 volts per cell is the float voltage for flooded lead acid batteries such as the Round Cell For a 24 cell configuration of Round Cells string voltage is 2 17 24 52 08 volts Traditionally 2 27 volts per c...

Page 60: ...urn the OUTPUT VOLTS ADJ potentiometer clockwise c Check the battery voltage and repeat Steps a and b above until the battery voltage is within the required tolerance of the desired float voltage 3 Turn the rectifier Off and repeat this procedure for each rectifier in the group 4 Turn all rectifiers On after the last rectifier is adjusted Adjusting Rectifiers as a Group If the load requirement is ...

Page 61: ...J potentiometer on rectifiers carrying less than 5 percent rated load till they carry more than 5 percent rated load and Turn down counterclockwise the OUTPUT VOLTS ADJ potentiometer on rectifiers carrying more than 95 percent rated load until they carry less than 95 percent rated load c Repeat from Step 2 battery voltage check and adjustment until all rectifiers are carrying between 5 and 95 perc...

Page 62: ...technical assistance refer to Section 1 Technical Support Removing a Rectifier from Service In general adjustments should be made to a rectifier while it is removed from service If a problem is suspected with a rectifier find the problem in Table 7 A Then follow this procedure for removing the rectifier from service before making the adjustments 1 Observe and record the rectifier output voltage 2 ...

Page 63: ...the rectifier POWER switch On and wait approximately 30 seconds for the voltage to stabilize The rectifier is now off line To connect a test load for off line testing see Section 6 Diagnostics and Troubleshooting Table 7 A lists possible problems causes and solutions that may occur with the rectifier subsystems Schematic Drawing SD 82604 01 referred to in the table is shipped with the J85502A 1 re...

Page 64: ...tting down due to high output voltage See Probable Causes associated with Problem 3 3 Rectifier goes to high voltage at turn on 1 Output Volts Adj potentiometer is set too high 2 CM2 board is defective 3 Open thyristor 1 Turn potentiometer counterclockwise 2 Replace CM2 see Section 8 3 Replace thyristor see Section 8 4 Control panel digital meter does not light 1 Defective wiring to CM3 digital me...

Page 65: ...d the door and R15 nearest you Figure 7 1 Component Sides of CM3 Digital Meter Boards C17 C17 R15 R15 PS1 PS1 IC3 IC3 S1 S1 DS1 DS1 IC4 IC4 Digital Meter Potentiometer Digital Meter Potentiometer Connection for J1B from CM2 Control Board Connection for J1B from CM2 Control Board Series 3 Digital Meter Board Series 1 or 2 Digital Meter Board IC7 IC7 IC5 IC5 C11 C11 C10 C10 C2 C2 P1B P1B R14 R14 R16...

Page 66: ...d the rectifier RFA LED extinguished then the RFA problem has been cleared Otherwise continue with the following procedures 6 Observe and record the rectifier output voltage 7 If the rectifier output voltage is greater than the plant float voltage then use the following procedure a Turn the OUTPUT VOLTS ADJ potentiometer counterclockwise to lower the output voltage to the correct value b If the re...

Page 67: ... 1 Loosen the locking screws and open the door of the rectifier 2 Locate the CM3 digital meter board on the inside of the door Note Calibration is not feasible unless the DMM test meter has an accuracy of 0 02 percent or better Caution For Series 1 or 2 CM3 boards use extreme care when removing the board from the support standoffs Notes A Series 3 CM3 board can be calibrated without removing the b...

Page 68: ...de of the board For Series 1 or 2 CM3 boards R15 is located under the wires of the cable connected to P1B The wires will probably have to be pulled aside carefully or separated a small amount in order to access the screwdriver adjustment on R15 6 Connect a DMM Digital Multimeter to the rectifier REG test jacks 7 While holding the meter selector switch in the BATT V position use a jeweler s screwdr...

Page 69: ...e circuit needs adjustment before following this procedure The procedure must be performed in a working plant with the rectifier connected to an MCS or Galaxy controller and to a battery Table 7 B Digital Meter Tolerance Meter Position Tolerance RECT V 0 5 volt for Series 1 or 2 CM3 boards 0 02 volt for Series 3 CM3 boards AMPS 2 5 percent of rectifier rating Notes To compare measure the shunt vol...

Page 70: ...procedure is completed If not continue with Step 3 3 Reduce the load current to zero by opening the test load Using the DMM measure the voltage between test points E5 and E14 E5 is more positive This voltage must be less than 0 5 volt 4 Connect the DMM between test points E7 and E15 and adjust potentiometer R35 until the DMM indicates the voltage that was calculated in Step 2 5 Recheck the results...

Page 71: ...ove the input fuse assigned to the rectifier or turn the circuit breaker Off 8 Disconnect the test load from the output terminals of the rectifier 9 Reconnect the and output leads to TB3 in the rectifier 10 Remove the tape and reconnect the rectifier s ground output lead to the plant charge ground bus bar 11 Remove the tape and reconnect the rectifier s hot output lead to the plant charge bus bar ...

Page 72: ... potentiometer R52 on CM2 see Figure 6 3 until the rectifier delivers 25 25 25A Restoring a Rectifier to Service 1 Set the ac supply and rectifier controls as shown in Table 7 C 2 If the rectifier voltage was NOT at the desired float voltage before it was turned off rotate the OUTPUT VOLTS ADJ potentiometer fully counterclockwise 3 At the ac service panel install the ac fuses or turn the ac input ...

Page 73: ...ted with the rectifier that is being restored to service 7 Turn the rectifier POWER switch On 8 Close the rectifier front door and secure the locking screws 9 Adjust the rectifier to float voltage See Section 6 Adjusting Rectifiers to Float Voltage 10 If the rectifier is installed in a microprocessor controlled plant that has an efficiency algorithm feature enable this feature See the controller p...

Page 74: ...Circuit Modules Lucent Technologies combines into spare parts kits CM1 CM2 and CM3 circuit boards described in Section 2 Circuit Modules Kit number H569 358 L7 contains these replaceable boards for the J85502A 1 rectifier Table 8 A shows the contents of this kit along with the part numbers Table 8 A Spare Circuit Modules Order Lucent Technologies Comcode Part Number Description Kit Number H569 358...

Page 75: ...e floormat A grounded person must never hand an unprotected circuit pack to an ungrounded person A static discharge from the ungrounded person through the circuit pack to the grounded person could cause an electrostatic discharge failure All persons and equipment at a work location must be at the same common ground potential to be static safe Handle all circuit packs by the faceplate or latch and ...

Page 76: ...ers The insulation on small hand tools does not represent a static hazard Keep adhesive tape Scotch masking etc away from static sensitive devices When soldering static sensitive semiconductor devices the soldering iron must be grounded to the work table which must also be earth grounded Do not wax the equipment aisles in central offices Whenever possible maintain relative humidity above the 20 pe...

Page 77: ...dded On ED83158 30 1 N V Q ZA K F W T M Mod AA 1 and WA N V Q K F W T M ZA Mod AB 1 and WB N V M ZA K F W T Q Mod AC 1 WA and WB N V M K F W T Q ZA Mod AD 2 N W T ZA K F V M Q Mod AE 2 and WA N W T K V M Q ZA Mod AF 2 and WB N W M ZA K F V T Q Mod AG 2 WA and WB N W M K F V T Q ZA Mod AH Table 8 C Spare Fuse Information List Fuse Designation in SD Drawing Lucent Technologies Part Code Rating amper...

Page 78: ...ng of the option board like that in Figure 6 2 record where each cable connects to the board 8 Remove all cables from CM1 by unlatching first then pulling the cable connector 9 Remove the four quick disconnect connectors from the CM1 option board 10 Remove header connectors from CM1 11 Remove the two mounting nuts and associated lockwashers securing CM1 12 Verify that the new option board has the ...

Page 79: ...hen handling circuit modules 1 Turn the rectifier POWER switch Off 2 Turn the rectifier CBA1 DC OUTPUT circuit breaker Off down 3 At the ac service panel supplying power to the rectifier remove the input fuses assigned to the rectifier or turn the circuit breaker Off 4 At the plant controller remove the REG fuse associated with the rectifier 5 At the rectifier loosen the locking screws and open th...

Page 80: ...ce refer to Restoring a Rectifier to Service in Section 7 Replacing CM3 Digital Meter Board Follow instructions in Handling Circuit Modules to minimize electrostatic discharge when handling circuit modules 1 Turn the rectifier POWER switch Off 2 Turn the rectifier CBA1 DC OUTPUT circuit breaker Off down 3 At the ac service panel supplying power to the rectifier remove the input fuses assigned to t...

Page 81: ... refer to Restoring a Rectifier to Service in Section 7 General Information on Replacing Components Only disassembly procedures are given in this section Reinstallation procedures are usually the exact reverse of removal procedures i e follow the removal procedures in reverse to reinstall the component Specific instructions are given when this does not apply exactly or where special considerations...

Page 82: ...lways disconnect quick disconnect connections by pulling straight apart with pliers to avoid bending or breaking the tabs Do not pull on wire Always remember to save hardware thermal pads and other items necessary for reassembly Heat generating semiconductor components such as diodes and thyristors triacs employ heat conductive devices for heat sinking such as thermal grease or thermal pads The th...

Page 83: ...ng apart bolted and insulated connections such as those used on large transformer leads All removal and replacement procedures are easier to perform on bay mounted rectifiers that have been removed from the bay Most component removals are straightforward and obvious Therefore these procedures can be used as a guide by qualified service personnel rather than as step by step procedures For example y...

Page 84: ... Minimum Yield Strength for Mechanical Connections Using Hex Head Cap Screws Cap Screw Diameter inch Min Yield Strength PSI Torque ft lb UNC 1 4 57 000 6 5 16 57 000 12 3 8 57 000 22 7 16 57 000 35 1 2 57 000 54 9 16 57 000 77 5 8 57 000 107 3 4 57 000 190 7 8 36 000 193 1 36 000 290 1 1 8 36 000 410 1 1 4 36 000 580 1 3 8 36 000 760 1 1 2 36 000 1010 ...

Page 85: ...rews should be the pan head type 2 Slotted machine and hex cap screws should be SAE Grade 2 steel or equivalent 3 Socket cap screws should have 100 000 psi minimum tensile strength 4 Steel flat washers should be furnished under heads of socket cap screws 5 Ferrous flat washers should have a corrosion protective finish 6 Locking means is only required for connections subject to vibration Belleville...

Page 86: ...put Circuit Breaker CBA1 and Bracket 1 Disconnect header connector P5 from the CM1 option board 2 Remove the two screws that hold the CBA1 bracket to the rectifier cabinet 3 Carefully clear wires and cables aside while pulling the CBA1 bracket out to access its back side 4 Disconnect the quick disconnect connectors from the back of CBA1 5 Disconnect two dc cables from studs on the back of CBA1 6 R...

Page 87: ...cket 2 Remove nut and lockwasher from the stud of Q1 and pull thyristor out 3 Note their connection positions and unsolder leads from Q1 Diode Heat Sink Assembly 24 volt version of 25 ampere rectifier 1 Remove nuts from studs holding front facing heat sink 2 Pull the heat sink out 3 The diodes can now be tested or removed The common cable can be removed from the heat sink See Rectifier Diode Test ...

Page 88: ... and move the heat sink out of the way to the left 7 Remove the two quick disconnect connectors from shunt R3 mounted on the center of the bracket holding the dc capacitors The quick disconnect leads go to the small and capacitor bus bars 8 Remove the two nuts that secure the dc capacitor bracket to the center mounting plate 9 Rotate the top of the capacitor bus bar assembly forward until the capa...

Page 89: ...thyristor Q1 mounting bracket with Q1 attached by removing the two mounting nuts on the side wall 6 Remove the two nuts that secure the dc capacitor clamp to the center mounting plate 7 Rotate the top of capacitor bus bar assembly forward until capacitor terminal screws through bus bars can be accessed 8 Noting their connection points remove screws holding desired capacitor s 9 During reinstallati...

Page 90: ...nformation before beginning Figure 8 1 Rear Compartment of the J85502A 1 Rectifier with the Cover Removed L1 C5 S3 T2 Main Transformer T1 Center Mounting Plate Relay K2 AC Inductor L1 AC Capacitor C5 Transformer T2 AC Contactor K3 K2 K3 H1 H3 H2 L1 T1 L2 T2 L3 T3 Figure 8 2 J85502A 1 Rectifier Seen from the Top Front with Door Closed and Top Cover Removed T1 K3 T2 K2 C5 L1 L2 R2 CM3 CM1 AC Inducto...

Page 91: ...re P4 can be passed through to the rear compartment Early production models of the J85502A 1 rectifier without 208 240 Vac switch S3 have an ac contactor designated K1 Newer production rectifiers containing S3 have a contactor designated K3 Main Transformer T1 1 Disconnect T1 primary leads at the terminals of the ac contactor K3 2 Remove leads 1 2 and 3 from contactor K3 3 Refer to Diode Heat Sink...

Page 92: ...12 Remove the four nuts that hold T1 to the chassis 13 Carefully slide the center mounting plate forward so that it lies diagonally across the chassis 14 Slide T1 to the right and then lift straight up and out of the chassis using proper lifting equipment of at least 200 pound capacity Rectifier Diode Test and or Replacement If not already done perform the diode heat sink assembly procedure 1 Remo...

Page 93: ...05229147 that was saved in Step 1 Install the new stud nut and torque to 20 40 in lb This completes the rectifier diode replacement procedure If maintenance is completed reinstall the diode heat sink assembly according to Diode Heat Sink Assembly 8 Testing a Rectifier Diode Use a meter with a diode test function or measure the forward and backward resistances of the diode to determine if the diode...

Page 94: ...breaker Off down 2 At the ac distribution service panel remove the fuses or open the circuit breaker supplying the rectifier with ac power Tag fuse holders or circuit breaker to instruct all personnel to leave the circuit open Off 3 Remove associated REG fuse from plant controller 4 Disconnect the plant control cable from the rectifier CM2 control board at connector P2A Remove the cable from the c...

Page 95: ...onnected conduit to the side and if necessary tie the conduit to an adjacent structure to prevent interference with the rectifier removal 10 Withdraw all disconnected conductors from the rectifier cabinet and place them aside so as not to interfere with the rectifier removal or cause a personnel hazard 11 Baffles between rectifiers in bays may have to be removed 12 The rectifier may be attached to...

Page 96: ... warranties given to Seller by its Vendor of such Vendor Items such assignment to be effective upon Customer s acceptance of such Vendor Items With respect to Vendor items recommended by Seller in its specifications for which the Vendor s warranty cannot be assigned to Customer or if assigned less than Sixty 60 days remain of the Vendor s warranty or warranty period when the Vendor s items are shi...

Page 97: ...ts to repair but which are not readily returnable for repair whether or not installed by Seller Seller at its option may repair the cable and Wire Products at Customer s site D If Seller has elected to repair or replace a defective Product Customer shall have the option of removing and reinstalling or having Seller remove and reinstall the defective or nonconforming Product The cost of the removal...

Page 98: ...ther than Seller or its subcontractors caused by any of the following modifications misuse neglect accident or abuse improper wiring repairing splicing alteration installation storage or maintenance use in a manner not in accordance with Seller s or Vendor s specifications or operating instructions or failure of Customer to apply previously applicable Seller modifications and corrections In additi...

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