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Lucent Technologies Lineage

®

2000 50A Ferroresonant Rectifier J85502B-1

Issue 6 May 1999

Spare Parts and Replacement Procedures 8 - 1

8

Spare Parts and Replacement
Procedures

Introduction

This section gives information on spare parts for the Lineage

®

2000, J85502B-1 rectifier, including circuit modules, fuses, how
to modify spare CM1 option boards, and handling precautions.
This section also provides complete disassembly procedures for
replacing components.

Ordering
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 L17 contains these replaceable
boards for the J85502B-1 rectifier. Table 8-A shows the contents
of this kit along with the part numbers.

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79
80
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Summary of Contents for Lineage 2000 J85502B-1

Page 1: ...Lineage 2000 50 Ampere 60 Hertz Ferroresonant Rectifier J85502B 1 Product Manual Select Code 169 790 123 Comcode 107131609 Issue 6 May 1999 1999 Lucent Technologies ...

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Page 3: ...hnologies Lineage 2000 50 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 1999 Lucent Technologies All Rights Reserved Printed in U S A ...

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Page 5: ...iption Overview 2 1 Ferroresonant Technology 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 5...

Page 6: ...ulator Test Set 6 2 Test Load Connection 6 3 Preparation for Testing Off Line 6 4 Testing Off Line 6 8 Startup 6 8 Regulation NL FL Test Off Line 6 9 Rectifier Failure Alarm Fuse Alarm Test Off Line 6 9 Current Limit Test Off Line 6 10 Backup High Voltage Shutdown HVSD Test Off Line 6 11 Control TR Test 6 12 Selective High Voltage Shutdown SHVSD and Restart 6 12 Meter Calibration Test Off Line 6 1...

Page 7: ...1 8 Spare Parts and Replacement Procedures Introduction 8 1 Ordering Circuit Modules 8 1 Handling Circuit Modules 8 2 Electrostatic Discharge 8 2 Modifying the CM1 Option Board 8 5 Spare Fuses 8 5 Replacing Circuit Modules 8 5 Replacing CM1 Option Board 8 5 Replacing CM2 Control Board 8 7 Replacing CM3 Digital Meter Board 8 8 General Information on Replacing Components 8 9 Replacing Components 8 1...

Page 8: ...Lucent Technologies Lineage 2000 50A Ferroresonant Rectifier J85502B 1 4 Table of Contents Issue 6 May 1999 Disconnecting a Rectifier 8 21 9 Product Warranty ...

Page 9: ...re Rectifier 5 3 Figure 5 2 J85502B 1 Rectifier with Door Open 5 3 Figure 6 1 Battery Plant Simulator Test Set 6 3 Figure 6 2 CM1 Option Board ED83158 30 Grp 2 A Showing Test Clip Connections and Movable Straps Q and T 6 7 Figure 6 3 CM2 Control Board Showing Test Clip Connections and Other Component Detail 6 8 Figure 7 1 Component Side of CM3 Digital Meter Boards 7 4 Figure 8 1 Rear Compartment o...

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Page 11: ...nt References 3 2 Table 5 A AC Input Requirements 5 4 Table 5 B DC Output Requirements 5 5 Table 5 C Rectifier Settings for Initial Battery Charge 5 11 Table 6 A Rectifier Control Settings for Testing Off Line 6 5 Table 6 B Test Set Connections 6 6 Table 6 C Rectifier Control Settings Prior to Testing On Line 6 14 Table 6 D Controls for Meter Calibration Test On Line 6 20 Table 7 A Troubleshooting...

Page 12: ...50A Ferroresonant Rectifier J85502B 1 2 List of Tables Issue 6 May 1999 Table 8 D Torque and Minimum Yield Strength for Mechanical Connections Using Hex Head Cap Screws 8 12 Table 8 E Minimum Torque for all Electrical Connections 8 13 ...

Page 13: ...rate correctly the J85502B 1 rectifier is an excellent choice for any telecommunications battery plant The J85502B 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 Training Lucent Technologies offers customer training on many Power Systems products...

Page 14: ...822 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 Canada Pue...

Page 15: ...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 16: ...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 17: ...e 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 provides a const...

Page 18: ...ture 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 CM1 option board are set for List WA TR This sig...

Page 19: ...ts 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 follows The CM1 circuit module ED83158 30 Group 2 A contains circuitry common to several rectifi...

Page 20: ...n 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 on the front of the J85502B 1 50 ampere rectifier ...

Page 21: ... rectifier output current Table 2 A gives the accuracy of this meter in the various positions The Figure 2 1 Control Panel of J85502B 1 Rectifier OUTPUT RECT V BATT V AMPS OUTPUT VOLTS ADJ DC OUTPUT REG POWER ON RFA ALARM RECT TEST FL NL OFF 1 2 AMP 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...

Page 22: ...put voltage setting of the rectifier by 0 25 volt when on battery When the switch is in the center position the rectifier is in 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 o...

Page 23: ...tery plant design Physical Thermal and Electrical Specifications Tables 2 B 2 C and 2 D give the physical thermal and electrical specifications for the Lineage 2000 J85502B 1 50 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...

Page 24: ... rectifiers and 54 Vdc 48 volt rectifiers Table 2 C Input Specifications for the J85502B 1 Rectifier Input AC Volts Nominal Line Current Amps Frequency Hz Nominal Range 24V 48V 208 184 220 8 15 60 3 240 212 254 7 13 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 J85502B 1 Rectifier Nominal Rectifier amps volts Outp...

Page 25: ...502B 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 20 Inrush current controlling unit WA External sensing required when rectifier is installed with a controller equipped with battery regulation fuses WB ...

Page 26: ...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 J85502B 1 Assembly Ordering and Installation Drawing T 82604 31 Wiring Drawing SD 82604 01 Schematic Drawing 169 790 123 Product Manual ...

Page 27: ...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 28: ...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 29: ...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 30: ...t circuits before touching Lock out and tag any circuit breakers fuses when possible to prevent accidental turn on Be aware of potential hazards in the area you are working before entering the equipment 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 ...

Page 31: ...mbol is used to identify the presence of hazardous ac or dc voltages It may also be used to warn of hazardous energy levels One of these two symbols or equivalent may be used to identify the presence of rectifier and battery voltages The symbol may sometimes be accompanied by some type of statement for example Battery voltage present Risk of injury due to high current Avoid contacting conductors w...

Page 32: ...e touched without taking care This symbol is used to identify the protective safety earth ground for the equipment This symbol is used to identify other bonding points within the equipment 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 glasses ...

Page 33: ...admonishments as they are presented throughout this documentation Preparing for Installation Location of the J85502B 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 rectifie...

Page 34: ...he J85502B 1 The maximum heat exhausted by each rectifier is approximately 845 BTU hr 24 volt rectifier or 1025 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 10 inches in front of the rectifier must be free of obstruction to allow the...

Page 35: ...t Control Cable Hole DC Output Hole VAC 208 240 VAC 208 240 TB1 TB1 208 208 L1 L1 L2 L2 TB1 Input Terminal Block Diode Heat Sink Assembly Switch S3 for AC Input Conversion Output Volts Adjustment Potentiometer CBA1 Circuit Breaker CA1 Snubber Board ED 83156 30 on Right Wall TB3 Output Terminal Block with Cable Connectors Attached to Left Side Thyristor Q1 CM1 Option Board ED 83158 30 CM3 Digital M...

Page 36: ...nnection See note 57 on J85502B 1 drawing DC Output Power The majority of dc power plants for telecommunication applications are designed to use single conductor cables in parallel for current capacity or to limit voltage drop supported on ladder racks Experience has shown that the use of flexible cables welding type cables makes installation of this type wiring much simpler The terminals are size...

Page 37: ...tal multimeter DMM Fluke 8060A or equivalent with 0 02 percent accuracy on dc scale Unpacking Move the crated rectifier to a convenient area for uncrating and follow the steps listed below 1 Remove any shipping bands 2 Check tilt or shock indicators If tripped contact shipping company and process claims form Table 5 B DC Output Requirements Amps Output Wire Size Output Conduit Trade Size Inches Co...

Page 38: ... straps present or removed according to the options you expect See Table 8 B in this manual or Tables A and R on J drawing J85502B 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 as...

Page 39: ... is Off or fuses are removed Reenergize ac service panel Tag branch circuit breaker or fuse holders to inform others not to close turn On the ac breaker 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 w...

Page 40: ...ant charge bus bar Installing Plant Control Cable Assembly for a Lucent Technologies Controller The Plant Control Cable Assembly 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 ...

Page 41: ...Controlled System MCS plants or Conventional Controlled System CCS plants remove the plastic covers 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 n 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 co...

Page 42: ... 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 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 240 volt ...

Page 43: ... 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 LED must light If not do not attempt to turn On the circuit breaker Troubleshoot the problem as described in Section 7 Wait 10 seconds Table 5 C Rectifier Settings for Initia...

Page 44: ...he 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 Always move P14 back to its normal pin 1 2 position when the initial charge is completed 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 ...

Page 45: ...or testing off line See Tools and Test Equipment below for a description of 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 procedu...

Page 46: ...ewdriver for adjusting potentiometers Straightened paper clip inserted in eraser of wooden pencil Battery Plant Simulator Test Set The Battery Plant Simulator Test Set is a convenient tool used to isolate communication troubles between the plant controller and the rectifier It simulates the plant controller relative to receiving signals from and sending signals to the rectifier If there is a probl...

Page 47: ...CM2 To P2A 25 of CM2 To P2A 16 of CM2 To P2A 4 of CM2 To 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 ...

Page 48: ...the rectifier 9 Install the regulation REG fuse associated with the rectifier in the plant controller 10 When you are ready to power the test load you must restore ac to the rectifier at the ac service panel turn On the rectifier POWER switch and turn On the DC OUTPUT circuit breaker If this is initial testing check the control cable first see Preparation for Testing Off Line Preparation for Testi...

Page 49: ...fier end of the plant control cable Pin 27 should be positive with respect to pin 2 c As an extra precaution check for battery voltage between ground and pin 2 negative plant or pin 27 positive plant If no voltage exists there is a wiring problem associated with the control cable or controller The problem must be found and repaired before proceeding with testing Table 6 A Rectifier Control Setting...

Page 50: ...ion near the rectifier Connect J2A on the other end of the cable from the test set to connector P2A on the CM2 control board which is mounted on the inside of the rectifier door Connect the red black blue and white test clips from the test set to the CM1 and CM2 boards in the rectifier as detailed in Table 6 B Refer to Figures 6 2 and 6 3 Table 6 B Test Set Connections Test Clip Connection Figure ...

Page 51: ...6 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 ST5 ST10 ST11 ST13 ST12 ST14 R19 P13 P6 Used in Backup HVSD Tests Moveable Straps T and Q White Test Point Blue Test Point Shunt Voltage R21 R20 R22 ST1 S...

Page 52: ...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 53: ...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 54: ...Vout 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 54 56A 110 1 percent Vout should be below 51 58 volts 48 volt rectifier 25 79 volts 24 volt rectifier If not see Adjust Current Li...

Page 55: ...r 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 R2...

Page 56: ...the test set The rectifier should continue to operate Selective High Voltage Shutdown SHVSD and Restart 1 Adjust the test load so that the rectifier delivers 5 8A 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 Th...

Page 57: ...n Off switch Off Line Test Completion 1 Reduce load so the rectifier delivers 10 15A 20 30 of its rated current 2 Adjust the OUTPUT VOLTS ADJ potentiometer 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 powe...

Page 58: ...his feature See the controller manual for instructions 3 Reconnect the and output leads to TB3 in the rectifier 4 Remove the tape and reconnect the 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 ...

Page 59: ...ough most tests can be performed in either situation The Control TR and Selective HVSD Tests are omitted 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 ...

Page 60: ...T meter Hold the RECT TEST switch 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 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 alarm indicator of the V...

Page 61: ...he 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 The output current should indicate 50 51A 100 to 101 percent of the rated output current 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 ...

Page 62: ...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 25A 50 percent of its rated current capacity 3 Observe the DMM and record the rectifier s shunt voltage The shunt is rated 62 5A 50mV 1 25A mV which means that each millivolt of voltage drop ac...

Page 63: ...he 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 voltage adjustment short resistor R22 24 volt version or R21 48 volt version on the CM1 board 3 Set the DMM to measure 27 o...

Page 64: ...g 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 Observe and record the voltage readings on the DMM and the OUTPUT meter 6 The OUTPUT meter reading should agree with the test meter within 0 02 volt for Series 3 CM3 boards o...

Page 65: ...id 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 cell is the float voltage for starved electrolyte batteries such as VR cells For a 12 cell configuration of VR cells string voltage is 2 27 12 27 24 volts To adjust rectifiers to the pre determined float voltage the rectifiers must be on line with plant ...

Page 66: ...he 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 always greater than the capacity of the smallest rectifier adjust the rectifiers to float voltage using the following procedure Rectifiers must be on line with plant cables connected and REG fuses install...

Page 67: ...d 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 percent rated load and the battery voltage is within the required t...

Page 68: ......

Page 69: ... 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 However for many off line tests like those in the first half of Section 6 you will need a test load connected and the ci...

Page 70: ...r turn the circuit breaker On 11 Turn 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 ...

Page 71: ...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 per Section 8 3 Replace thyristor per Section 8 4 Control panel digital meter does not light 1 Defective wiring to CM3 digital me...

Page 72: ...d the door and R15 nearest you Figure 7 1 Component Side 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 73: ...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 74: ...he door 3 If a Series 3 CM3 board is provided skip to Step 5 4 For Series 1 or 2 CM3 boards remove the board from the two support standoffs and the switch bezel by using a small flat bladed screwdriver to unlatch the bezel clips 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 th...

Page 75: ...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 screwdriver to adjust R15 potentiometer so that CM3 meter and the DMM connected to the rectifier test points agree wi...

Page 76: ...he 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 vo...

Page 77: ...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 78: ...emove 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 ba...

Page 79: ... potentiometer R52 on CM2 see Figure 6 3 until the rectifier delivers 50 51A 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 cir...

Page 80: ...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 81: ...luding circuit modules fuses how to modify spare CM1 option boards and handling precautions This section also provides complete disassembly procedures for replacing components Ordering 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 L17 contains these replaceable boards for the J85502B 1 re...

Page 82: ...packs in these classes are handled in the same manner regardless of sensitivity Factory packaging provides shielding in the rare instances when it is necessary Electrostatic Discharge Assume all circuit packs containing electronic solid state components can be damaged by ESD Table 8 A Spare Circuit Modules Order Lucent Technologies Comcode Part Number Description Kit Number H569 358 L17 CM1 ED 831...

Page 83: ...und potential Observe warning labels on bags and cartons Whenever possible do not remove circuit packs from antistatic bags or cartons until ready to insert into the rectifier Otherwise open all circuit packs at a static safe work position with wrist straps and dissipative table mats Upon removal from the rectifier immediately put circuit packs into antistatic packages Always store and transport c...

Page 84: ...evices 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 percent level Table 8 B Modifications for the CM1 Option Board List Option Keep Straps Or Resistors Marked With Remove Straps Or Resistors Marked With Stamping To Be Added on ED 83158 30 1 K V Q Z...

Page 85: ... and are never replaced once they are removed Spare Fuses Table 8 C provides spare fuse information for the J85502B 1 rectifier A commercial equivalent fuse and the appropriate SD sheets are referenced Replacing Circuit Modules This section gives step by step instructions for replacing circuit modules CM1 CM2 and CM3 Replacing CM1 Option Board 1 Turn the rectifier POWER switch Off 2 Turn the recti...

Page 86: ...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 correct straps and resistors in place If not modify the board according to Modifying the CM1 Option Board 13 Position the new CM1 board over the fo...

Page 87: ...fier 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 the rectifier door 6 Locate the CM2 control board 7 Disconnect the cable from P2A on CM2 by unlatching first then pulling the cable connector 8 If CM5 is not in place disconnect the ribbon cable from P1A on CM2 If CM5 is in place rem...

Page 88: ...connect it to CM2 reconnect the Y R and S leads of CM5 onto points E2 E4 and E9 respectively of CM2 The BK and W leads of CM5 if not removed in Step 8 are not to be reconnected 14 If the rectifier is to be restored to service 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 w...

Page 89: ... the rectifier is to be restored to service 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 ap...

Page 90: ... relays inductors transformers and wire bundles Always 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 sink...

Page 91: ...es for testing and replacing individual rectifier diodes are provided in Replacing Components Also provided in the same group of instructions is the procedure for taking 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 removal...

Page 92: ... 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 93: ...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 94: ...moved Main Transformer T1 Relay K2 AC Inductor L1 Transformer T2 AC Contactor K3 AC Capacitor C5 Figure 8 2 Top View of J85502B 1 Rectifier T1 K3 T2 L1 K2 L2 R2 CM3 CM1 AC Inductor L1 AC Capacitor C5 under T2 Transformer T2 Relay K2 AC Contactor K3 under L1 Main Transformer T1 TB1 Input Terminal Block Diode Heat Sink Assembly Shunt DC Filter Capacitors C1 C2 C3 DC Inductor L2 Center Mounting Plate...

Page 95: ...utput 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...

Page 96: ...1 bracket assembly from frame by removing its two mounting screws Move CBA1 bracket out of the way 4 Remove thyristor Q1 mounting bracket by removing two mounting nuts from studs on the wall 5 The wire s from Q1 are tied to the center mounting plate Loosen the wire tie on the plate by removing its nut 6 Remove Q1 mounting nut 7 Noting their connection positions unsolder leads from Q1 Diode Heat Si...

Page 97: ... tie DANGER DC capacitors may be charged even with power disconnected from the rectifier This would be true if the main bus bar fuses are open Always check all of the dc capacitor terminals observe polarity with a voltmeter before performing this procedure Discharge capacitors in a safe manner if necessary Note To successfully perform this procedure it is usually necessary to have access to the re...

Page 98: ... section in order to remove a rectifier from a frame if necessary to remove these covers The following points should be noted To facilitate replacement note the positions of all quick disconnect and other leads or header connectors before removing In the case of the dc inductor L2 one of the leads goes to the front compartment and terminates on a dc capacitor terminal The entire dc capacitor remov...

Page 99: ...nector from the CM1 option board leads 11 and 12 7 Remove the L1 inductor from the rear compartment 8 Remove the nut holding the top angle bracket to the center mounting plate 9 Remove the two nuts and one bolt that hold the top angle bracket to T1 10 Loosen the remaining five nuts that hold the center mounting plate to the frame 11 Slide the center mounting plate forward 12 Remove the top angle b...

Page 100: ...ved thermal pad for reinstallation The diode is now electrically isolated for test purposes 2 If this procedure is being performed to test a diode skip to Step 7 To replace a diode that is known to be defective continue with Step 3 3 Refer to the next section to remove any heat shrink tubing and tape on the pigtail connection 4 With the actual connection exposed remove the nut and bolt that holds ...

Page 101: ...ith a clip lead or probe by pushing the insulating tubing and or tape approximately 1 4 to 1 2 inch away from the point where the pigtail lead enters the diode body 8 If the diode checked bad proceed to Step 3 of this procedure to remove and replace it If the diode checked good proceed to Step 6 of this procedure to reinstall Heat Shrink Removal This information is applicable to both rectifier dio...

Page 102: ...ge the capacitors after the DC OUTPUT circuit breaker is turned Off in Step 1 6 One at a time disconnect the battery plant end of the dc output and output return conductors from the battery plant charge and charge ground bus bars Insulate the connector ends and label the conductors for easy identification when reconnecting 7 One at a time disconnect the dc output conductors from the rectifier hot ...

Page 103: ...may be attached to the lifting device of your choice before the mounting screws on each side of the unit are removed Remember that the unit weighs at least 160 to 180 pounds 13 When the rectifier is supported by the lifting device of your choice remove the mounting screws that attach the unit to the bay 14 The rectifier is now both electrically and physically disconnected and may be safely lifted ...

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Page 105: ... 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 106: ... refund or credit based on the original purchase price and installation charges if installed by Seller Where Seller has elected to repair a Seller s Manufactured Product other than Cable and Wire Products which has been installed by Seller and Seller ascertains that the Product is not readily returnable for repair Seller will repair the Product at Customer s site With respect to Cable and Wire Pro...

Page 107: ... conditions or nonconformities resulting from actions of anyone other 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 pre...

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