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Lucent Technologies Lineage

®

2000 125A Ferroresonant Rectifier J85502C-1

Issue 8 July 1999

Installation 5 - 1

5

Installation

Introduction

This section provides information to consider before installing
the J85502C-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
J85502C-1 rectifier, and carefully read and follow the
admonishments as they are presented throughout this
documentation.

Preparing for
Installation

Location of the J85502C-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 J85502C-1 rectifier weighs at least 240 pounds. Therefore,
the customer must make prior arrangements for appropriate
material handling facilities and equipment to unload, uncrate,
and set up the rectifier. Proper handling is necessary to assure
personnel safety and protect the equipment. Each rectifier, that
is not 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 J85502C-1

Page 1: ...Lineage 2000 125 Ampere 60 Hertz Ferroresonant Rectifier J85502C 1 Product Manual Select Code 169 790 121 Comcode 107044992 Issue 8 July 1999 1999 Lucent Technologies ...

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Page 3: ...00 125 Ampere 60 Hertz Ferroresonant Rectifier J85502C 1 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: ...uals 1 2 2 Product Description Overview 2 1 Ferroresonant Technology 2 2 Standard Features 2 2 Additional Features 2 5 Circuit Modules 2 5 Front Panel Controls and Indicators 2 7 Alarm and Control Flow 2 10 Physical Thermal and Electrical Specifications 2 11 3 Ordering Information Equipment Lists 3 1 Documentation 3 2 4 Safety Admonishments 4 1 Safety Statements 4 1 Precautions 4 2 Warning Stateme...

Page 6: ...ent 6 2 Battery Plant Simulator Test Set 6 2 Test Load Connection 6 2 Preparation for Testing Off Line 6 4 Testing Off Line 6 9 Startup 6 9 Regulation NL FL Test Off Line 6 10 Rectifier Failure Alarm Fuse Alarm Test Off Line 6 10 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 Ca...

Page 7: ...lated Current Measuring Circuit VI 7 10 Adjust Internal Selective HVSD Battery Plant Without Controller 7 11 Adjust Current Limit 7 11 Restoring a Rectifier to Service 7 12 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 4 Spare Fuses 8 5 Replacing Circuit Modules 8 5 Re...

Page 8: ...8 July 1999 AC Inductor L1 8 17 AC Capacitors C10 or C11 8 18 Thyristor Q1 8 19 Relay K2 8 19 Contactor Relay K1 8 19 Transformer T2 8 20 Main Transformer T1 8 20 Rectifier Diode Test and or Replacement 8 22 Heat Shrink Removal 8 23 Disconnecting a Rectifier 8 24 9 Product Warranty ...

Page 9: ...mpere Rectifier With Door Open and Diode Heat Sink Removed 5 7 Figure 5 4 Output Polarity Conversion and Bus Bar Assembly of J85502C 1 Rectifier 5 15 Figure 6 1 Battery Plant Simulator Test Set 6 4 Figure 6 2 CM1 Option Board Showing Test Clip Connections and Movable Straps 6 7 Figure 6 3 CM2 Control Board Showing Test Clip Connections and Other Component Detail 6 8 Figure 7 1 Bus Bar Assembly wit...

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Page 11: ...es 3 2 Table 5 A AC Input Requirements 5 3 Table 5 B DC Output Requirements 5 4 Table 5 C Rectifier Control Settings for Initial Battery Charge 5 16 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 15 Table 6 D Controls for Meter Calibration Test On Line 6 21 Table 7 A Troubleshooting 7 ...

Page 12: ...e 2000 125A Ferroresonant Rectifier J85502C 1 2 Issue 8 July 1999 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 13: ...rrectly the J85502C 1 rectifier is an excellent choice for any telecommunications battery plant The J85502C 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 For in...

Page 14: ...urn service is provided for Lucent Technologies customers around the world For customers in the United States Canada Puerto Rico and the US Virgin Islands call 1 800 255 1402 for information on returning of products for repair For other customers worldwide contact your sales representative to discuss your particular circumstances Warranty Service For warranty service worldwide contact your Warrant...

Page 15: ...Lucent Technologies Lineage 2000 125A Ferroresonant Rectifier J85502C 1 Issue 8 July 1999 Introduction 1 3 When prompted for an order number enter or say 167 790 010 ...

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Page 17: ... rectifier 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 ...

Page 18: ...le service easy 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 lightnin...

Page 19: ... be set for List WB See Table 8 B Backup 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 when this voltage exceeds a preset value it shuts down This circuit operates if the external selective HVSD fails to operate This backup HVSD operates from an independent voltage source per Bellcore standa...

Page 20: ... lights on the front panel and an RFA signal is generated The FA LED also lights Man alarm This alarm indicates that either the rectifier has been turned off manually or has lost commercial input power Restart circuit 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...

Page 21: ... with FCC Docket 20780 Part 15 Subpart J as required for Class A applications In addition the rectifier meets all specified operating specifications when subjected to electric fields up to 10 volts per meter over a frequency range of 20 to 1000 MHz Circuit Modules The rectifier s signal processing and control circuitry are located on replaceable circuit modules or packs Circuit modules are plug in...

Page 22: ...panel The meter displays the rectifier s output current voltage or the plant battery voltage depending on the three position selector switch see Front Panel Controls and Indicators in this section The CM4 circuit module ED 83211 30 Group 3 is an option provided with List C rectifiers The module allows access to alarm and control functions of the rectifier The module mounts on the floor of the rect...

Page 23: ... displays 1 the rectifier output current when the selector switch is in the AMPS position 2 the rectifier output voltage when the selector switch is in the RECT V position and 3 the plant battery voltage when the selector switch is in the BATT V position The default display is rectifier output current Table 2 A gives the accuracy of this meter in the various positions The output voltage RECT V acc...

Page 24: ...ctifier fails because of external or internal high voltages a blown fuse an internal unbalance or problems with the rectifier 5 volt dc or 12 volt dc The RECT TEST switch provides a manual test of the rectifier regulation by simulating a full load FL or no load NL condition Operating the switch raises or lowers the output voltage setting of the rectifier by 0 25 volt when on battery When the switc...

Page 25: ...llow 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 voltage sense leads to the rectifier control and regulation circuits These fuses are attached to the control panel inside the rectifier door The DC OUTPUT circuit breaker protects...

Page 26: ...nal processing and resultant action Figure 2 2 shows the typical signal flow between a rectifier and a Lucent Technologies controller The control signals and alarms enter and leave the rectifier via the control circuit module CM2 The Lineage 2000 family of plant controllers also uses replaceable circuit modules which give flexibility to battery plant design Figure 2 2 Signal Flow Between Rectifier...

Page 27: ...s inches 23 25 widex17 tallx15 deep Weight lbs 240 370 Heat Dissipation BTU hr at full load 1630 2560 Humidity rating 10 To 95 non condensing Operating Altitude Sea level to 10 000 feet 3048 meters Operating Temperature 35 122o F 1 5 48 8o C Audible noise at 5 ft above floor and 2 ft in front of rectifier Less than 64 dBA Earthquake rating Meets Zone 4 per Bellcore TR EOP 000063 Issue 3 Measured a...

Page 28: ...es Output Range dc volts Minimum Efficiency at Full Load percent Minimum Power Factor at Full Load AC Ripple mV peak to peak Standard Filter Maximum Noise at Battery 125 24 0 125 21 5 30 0 88 90 100 32 125 48 0 125 43 0 60 0 90 85 100 32 Efficiency measured at nominal line 28 Vdc or 54 Vdc Measured on 500 amp hr battery 4 times rectifier capacity with a 2 volt lead drop for standard and 0 5 volt d...

Page 29: ...onal Table 3 A Equipment Lists for the J85502C 1 Rectifier List Number Input AC volts Output DC volts 1 208 or 240 24 2 208 or 240 48 Provides E 434A voltage monitor board without ac voltage alarm F 434B voltage monitor board with ac voltage alarm Optional List Number WA External sensing required when rectifier is installed with a controller equipped with battery regulation fuses WB External high ...

Page 30: ...y with fused filter capacitors and access to alarm and control functions 48V rectifier only B Circuit breaker in positive output lead negative ground system 24V rectifier only Table 3 A Equipment Lists for the J85502C 1 Rectifier List Number Input AC volts Output DC volts Table 3 B Document References Document No Document Description J85502C 1 Assembly Ordering and Installation Drawing T 82659 30 ...

Page 31: ... 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 a...

Page 32: ... 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 ...

Page 33: ...ery 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 charg...

Page 34: ...ment 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 sometime...

Page 35: ... 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 36: ...Lucent Technologies Lineage 2000 125A Ferroresonant Rectifier J85502C 1 4 6 Safety Issue 8 July 1999 These symbols are used to identify the safety earth ground or bonding point for the equipment ...

Page 37: ...monishments as they are presented throughout this documentation Preparing for Installation Location of the J85502C 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 ...

Page 38: ...is another factor in selecting a location for the J85502C 1 The maximum heat exhausted by each 24 and 48 volt rectifier is approximately 1630 BTU hr and 2560 BTU hr respectively The rectifiers use free convective cooling where cooler air enters the cabinet through perforations in the front door and is exhausted through perforations in the top cover A minimum of 23 inches in front and 2 inches abov...

Page 39: ...connection which is also provided Use T B crimp tool WT1300 on the crimp connection See Note 65 on the J85502C 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 Table 5 A AC Input Requirements List Amps V olts Line Fuse Type Rating Input Circuit...

Page 40: ...ble size T B connectors and crimp die Also see note 57 on J drawing J85502C 1 Table 5 B DC Output Requirements Amps Output Wire Size Output Conduit Trade Size inches Connectors Required T B Crimp Die 125 1 0 AWG 1 1 2 1 stud with anti rotation tab Ground 5 16 dia T B 54158 Battery 3 8 dia T B 54110 Black Use KS 24194 L2 wire It is a flexible stranded copper wire rated 600 volts stranding meets Ame...

Page 41: ...n 5 5 Figure 5 1 Four Views of the J85502C 1 125 ampere Rectifier Lifting eyebolts Left side Right side AC input hole Top Front 15 5 25 24 31 23 25 17 Holes for mounting screws that attach rectifier to bay Strain relief bushing for plant control cable Plant control cable hole for conduit DC output hole ...

Page 42: ...r J85502C 1 5 6 Installation Issue 8 July 1999 Figure 5 2 Terminal Block 1 TB1 Where Ac Input Voltage Is Converted on J85502C 1 Rectifier Movable tab Mounting screws AC Input side Moveable tab TB1 in 240V ac position Clear plastic shield TB1 in 208V ac position ...

Page 43: ...e screwdriver 30 inch blade width socket and torque wrench for 3 8 inch bolts channel lock pliers for ac conduit tightening hammer and crowbar for uncrating 5 16 hex Allen wrench for dc output connection at CBA1 Three 3 8 16 lifting eyebolts Digital Multimeter DMM Fluke 8060A or equivalent with 0 02 percent accuracy on dc scale Figure 5 3 Typical J85502C 1 125 ampere Rectifier With Door Open and D...

Page 44: ...e the front door of the rectifier If it does not agree two possible conditions on the rectifier may be corrected by the customer Incorrect ac input voltage see Table 3 A Incorrect system polarity circuit breaker in the wrong dc output bus Positive ground systems have the breaker in the negative output bus and negative ground systems have the breaker in the positive output bus The customer may deci...

Page 45: ... the rectifier 3 Install fuse holders or circuit breaker for the rectifier in the ac distribution service panel Leave circuit breaker in Off position or remove fuses 4 Install two phase leads and frame ground at service panel and route conductors to rectifier 5 Install the connector you prefer onto the frame ground lead see the section entitled AC Input Power Use the proper crimping tool and die f...

Page 46: ... for the connector to prevent damage to equipment See Table 5 B 4 Tape or otherwise insulate the connectors on the end of each cable that does not terminate in the rectifier 5 Place dc return cable in cable rack 6 Thread end of cable through right side of rectifier and terminate connector at the appropriate ground bus bar in the rectifier The ground bus bar is positive for negative output voltage ...

Page 47: ...le from P2A 3 Determine the number to be assigned the rectifier in the rectifier lineup that is 1 2 3 etc 4 If the controller is an MCS cut leads TP3 and TP0 pin numbers 18 and 21 in the controller end of the control cable see your controller manual This signals to an MCS that the rectifier is a 125A 5 The next action depends on the type of plant For connection to a Galaxy controller remove the pl...

Page 48: ... Step 4 above This action will cause a minor alarm in an MCS controller For a Galaxy controller the rectifier position used must be programmed per instructions found in the Galaxy controller product manual 7 Dress and tie down the cable to provide stress relief at the connector The rectifier is now installed The last three sections in this chapter are optional procedures that may be needed at inst...

Page 49: ... Vac input to the rectifier When the tab is set to the desired position connect the ac lead to the unblocked screws 208 or 240 Put on the flat washer lockwasher and nut Torque to 25 in lbs The green ac ground wire goes to the FR GRD AC EG point Retighten the TB1 mounting screws when finished and replace the clear plastic shield Converting DC Output Polarity Optional This section gives conversion p...

Page 50: ...d at point A Replace and tighten the nut 4 Disconnect lead Y from point C and retain the nut for Step 5 5 Place the terminal of lead Y on the stud at point D Install the nut on the connection and tighten 6 Swap the NEG and POS flags on the two dc output cables Also add List B marking on the inside of the door 7 The bus bar cable connections should now appear as in the right drawing in Figure 5 4 I...

Page 51: ...ve the normal plant voltage neither the battery nor the rectifier used to supply its initial charge should be connected to the rest of the plant during this procedure One rectifier should be sufficient to supply the charge However the high voltage shutdown levels must be raised to accomplish the initial charge The following procedure describes how to raise the high voltage shutdown levels Figure 5...

Page 52: ...on 7 Wait 10 seconds Table 5 C Rectifier Control Settings for Initial Battery Charge Controls Position Status Rectifier POWER switch Off down Rectifier DC OUTPUT circuit breaker Off down OUTPUT VOLTS ADJ potentiomneter Fully counterclockwi se Plant control connector J2A on CM2 control board mounted on inside of door Disconnected from P2A on CM2 Warning Do not remove the ZJ option strap on the CM1 ...

Page 53: ...leting the initial charge turn the rectifier POWER switch Off and the DC OUTPUT circuit breaker Off down 9 If the rectifier has List WB external high voltage shutdown 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 Always move P14 back to its normal pin 1 2 position when the initi...

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Page 55: ...is section for a description of these items For troubleshooting and diagnostic procedures see Diagnostics and Troubleshooting in Section 7 Those unfamiliar with the function of rectifier controls and indicators should read Front Panel Controls and Indicators in Section 2 Precautions When working on power systems observe the safety precautions described in Section 4 and those within each procedure ...

Page 56: ...st 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 problem and the rectifier works properly with the test set the problem is either at the controller or in the interface wiring pla...

Page 57: ...A from CM2 by unlatching first then pulling the cable connector 4 Refer to Figure 5 4 and connect the test load between the and output buses marked on the rectifier Caution Support the CM2 control board when disconnecting the cable leads or damage to the control board may result Do NOT disconnect plant control cable connector J2A from control board CM2 by pulling the cable ...

Page 58: ...T 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 RSR APG R R V V 27V Return Note Use 24 AWG multiconducting wire and 40 pin female connector from Amp Inc Harrisburg PA Cable will then plug into connector on board For example the wire coming from PH shown above must be terminated on pin 12 of the new co...

Page 59: ... with the rectifier in the plant controller c Check for battery voltage between pins 27 and 2 of control cable connector J2A The J2A connector is at the rectifier end of the plant control cable Pin 27 should be positive with respect to pin 2 d 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 pro...

Page 60: ...location near the rectifier Connect J2A on the other end of the cable from the test set to connector P2A on the CM2 control board 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 No V...

Page 61: ...125A Ferroresonant Rectifier J85502C 1 Issue 8 July 1999 Testing 6 7 Figure 6 2 CM1 Option Board Showing Test Clip Connections and Movable Straps Blue test point Movable straps Q and T White test point Used in Backup HVSD test off line ...

Page 62: ...wing Test Clip Connections and Other Component Detail Current limit capacitor and potentiometer Red test clip Connection for J1A from CM1 option board Isolated Current Measuring potentiometer Internal selective HVSD potentiometer Black test clip Connection for J2A on plant control cable Connection for J3A from CM3 digital meter board ...

Page 63: ...art Startup 1 Turn On the ac supply to the rectifier The PWR lamp on the test set should light brightly If it does not light properly check the connection of the two small red and black clip leads They may be reversed or otherwise incorrectly connected 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 Th...

Page 64: ...il insert the wire next to the alarm indicator of the V fuse on the control panel Note that the rectifier shuts down and the RFA lamps on the control panel and test set light The FA LED on the control panel should also light 2 Turn the POWER switch Off then back On The RFA light should go off 3 Repeat Steps 1 and 2 at the V fuse Current Limit Test Off Line Read the following notes before proceedin...

Page 65: ... High Voltage Shutdown HVSD Test Off Line 1 If the DC OUTPUT circuit breaker is On turn it Off down 2 Disable the internal selective shutdown by moving the Q P15 or T P16 movable straps on CM1 to the Charge position See Figure 6 2 and refer to Table 8 B for options 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...

Page 66: ...d restart and the TRH lamp should go out 3 Press the HV switch on 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 12 19A 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 s...

Page 67: ...age in order to return the batteries to the correct voltage faster than they would otherwise recover after a power outage To equalize the battery charge in this manner your plant controller must support the float equalize feature and your battery manufacturer must provide an equalize procedure for your plant batteries The Lineage 2000 MCS and other controllers with certain options support the floa...

Page 68: ...hould shut down and the red RFA LED should be on 3 Restart the rectifier by cycling the front On Off switch 4 Using a clip lead momentarily short E3 and E14 12V The rectifier should shut down and the red RFA LED should be on 5 Restart the rectifier by cycling the front On Off switch Off Line Test Completion 1 Reduce load so the rectifier delivers 25 38A 20 30 of its rated current 2 Adjust the OUTP...

Page 69: ...precautions for personal safety and equipment protection should be taken as when testing off line see Precautions in this section 1 Verify the ac supply and rectifier controls are as shown in Table 6 C 2 If the rectifier is in a microprocessor controlled plant with an efficiency algorithm feature disable this feature See the controller product manual for instructions 3 At the ac service panel supp...

Page 70: ...ng require different procedures although 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 controller product manual Also straps on the CM1 option board must be set for List WB to enable the external ...

Page 71: ...ncrease Rectifier Failure Alarm Fuse Alarm Test On Line Read the following notes before proceeding 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 fuse inside the door on the control panel Note that the rectifier shuts down and the RFA lamp on the control panel lights 2 Turn the POWER switch Off t...

Page 72: ...ocedure is required only when CM2 is installed as part of a Lineage 2000 Battery Plant with an MCS Microprocessor Controlled System or Galaxy Intelligent only controller and when the output current reading on the rectifier does not agree to within 2 5 percent of the MCS or Galaxy Controller reading This procedure must be performed Notes Adjust the current limit only after verifying that a current ...

Page 73: ...ample if the DMM reads 40mV then of output current As this calculation indicates the rectifier is operating at full load and the rectifier shunt voltage is 40mV at full load 5 Compare the amperes calculated in Step 4 with the rectifier drain indication on the MCS or Galaxy Controller 6 If the rectifier drain indication is between 0 and 2 higher than the amperes calculated in Step 4 this procedure ...

Page 74: ...citor bus for positive ground plants and the filter capacitor bus for negative ground plants 3 Slowly turn the OUTPUT VOLTS ADJ potentiometer clockwise until the rectifier shuts down This should occur between 29 and 31 25 volts 24 volt rectifier or between 58 and 62 5 volts 48 volt rectifier The RFA lamp on the rectifier should light To increase the upper range of the voltage adjustment short resi...

Page 75: ... 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 or within 0 5 for Series 1 and 2 CM3 boards If the reading is not within these limits refer to Calibrate CM3 Digital Meter in Section 7 to calibrate the CM3 digital meter and repeat this procedure from Step 1 Table 6 D Controls for Meter Calibration...

Page 76: ...If equalize voltage is 2 volts above float voltage raise the ESHVSD level by 2 volts Normally ESHVSD is 5 volt above float for 24 volt rectifiers and 1 volt above float for 48 volt rectifiers 2 Put the plant controller in Equalize mode Consult your controller manual 3 Hold the meter selector switch on the rectifier in the RECT V position and observe whether the meter reading agrees with the equali...

Page 77: ...ty of the smallest rectifier 1 Measure the battery voltage by holding the meter selector switch in the BATT V position 2 If the battery voltage is not the pre determined float voltage or the desired battery float voltage perform the following a If the voltage is too high turn the OUTPUT VOLTS ADJ potentiometer counterclockwise b If the voltage is too low turn the OUTPUT VOLTS ADJ potentiometer clo...

Page 78: ... rectifiers are not carrying some load current between 5 percent and 95 percent of rated load a Turn Off all spare rectifiers but leave enough rectifiers On to handle the load current b Turn up clockwise the OUTPUT VOLTS ADJ potentiometer on rectifiers carrying less than 5 percent rated load till they carry more than 5 percent rated load and c Turn down counterclockwise the OUTPUT VOLTS ADJ potent...

Page 79: ...Lucent Technologies Lineage 2000 125A Ferroresonant Rectifier J85502C 1 Issue 8 July 1999 Testing 6 25 g Repeat for each rectifier that has not been adjusted h Upon completion turn all rectifiers On ...

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Page 81: ...r to Tools and Test Equipment in Section 6 For technical assistance at any time call Lucent Technologies at 1 800 CAL RTAC 1 800 225 7822 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 be...

Page 82: ...d to the rectifier or 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 ready to be tested off line Diagnostics and Troubleshooting Table 7 A lists possible problems causes and solutions that may occur with the rectifier subsystems Schematic Drawing SD 82659 01 referred to in the table is shipped wi...

Page 83: ...2 board per Replacing CM2 Control Board in Section 8 4 Check wiring associated with coil of K1 and contacts 4 7 of K2 2 Rectifier attempts to start but K1 contactor does not operate make clunk sound and RFA lights 1 Fuses F1 1 F1 8 FA1 1 FA1 8 and or V V blown 2 CM2 board is defective 1 Check fuses per Clear Rectifier Failure Alarm RFA in this section 2 Measure output voltage while rectifier is po...

Page 84: ...digital meter board 2 CM3 board is defective 3 CM2 board is defective 1 Check wiring to CM3 board Check connectors J1B on CM3 and J3A on CM2 for proper insertion 2 Replace CM3 per Replacing CM3 Digital Meter Board in Section 8 and then calibrate per Calibrate CM3 Digital Meter Board in this section 3 Replace CM2 per Replacing CM2 Control Board in Section 8 5 POWER LED is on ac is good rectifier ou...

Page 85: ...m 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 rectifier OUTPUT VOLTS ADJ potentiometer can adjust the vo...

Page 86: ...r the problem then windings 11 and 12 of T1 may be open Try the following Check the wiring to the thyristor See Figure 5 3 Check for defective thyristor Replace if defective per Thyristor Q1 in Section 8 Clear Fuse Alarm FA 1 Check to see if the DC OUTPUT circuit breaker CBA1 tripped Off down If so turn the POWER switch Off and then back On Then turn CBA1 back On up 2 If CBA1 did not trip off chec...

Page 87: ...er board see Figure 7 2 For Series 3 CM3 boards R15 is easily accessible on the component side 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 ja...

Page 88: ...02C 1 7 8 Troubleshooting and Adjustments Issue 8 July 1999 Figure 7 2 Partial Sketch of CM3 Digital Meter Boards Series 3 Digital Meter Board Series 1 or 2 Digital Meter Board R15 Connection for JB1 from CM2 Control Board Connection for JB1 from CM2 Control Board R15 ...

Page 89: ...eet the tolerances replace the CM3 meter board per Replacing CM3 Digital Meter Board in Section 8 Repeat this procedure from Step 1 Table 7 B Digital Meter Tolerance Meter Position Tolerance RECT V 0 5 volt for Series 1 or 2 CM3 boards 0 2 volt for Series 3 CM3 boards AMPS percent of rectifier rating Notes To compare measure the shunt voltage 1mV of shunt voltage indicates 3 125A of output current...

Page 90: ...ectifier connected to an MCS or Galaxy Intelligent only controller and to a battery Figure 6 3 shows test points and components on the CM2 control board Other E test points are always positive with respect to either E14 or E15 for all voltage measurements The plant control cable connector J2A MUST be connected to P2A on CM2 for this procedure 1 Connect a DMM across the rectifier shunt and a test l...

Page 91: ... section Connect the test load between the and buses marked on the rectifier Then complete the steps listed 2 Turn the rectifier POWER switch Off 3 Turn the DC OUTPUT circuit breaker Off down 4 Adjust the test load to 138A 10 percent or more above the rectifier s current rating Read the load current on the OUTPUT meter 5 Adjust the OUTPUT VOLTS ADJ potentiometer to obtain a rectifier voltage of 27...

Page 92: ...tion and adjust the current limit potentiometer R52 on CM2 see Figure 6 3 until the rectifier delivers 125 126A 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 th...

Page 93: ...r install the REG fuse associated 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 per Adjusting Rectifiers to Float Voltage in Section 6 10 If the rectifier is installed in a microprocessor controlled plant that has an efficiency algorithm feature enable ...

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Page 95: ...ow 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 Circuit Modules in Section 2 Kit number H569 358 L13 contains these replaceable boards for the J85502C 1 rectifier Table 8 A shows the...

Page 96: ...tate components can be damaged by ESD When handling circuit packs storing inserting removing etc or when working on the backplane always use the appropriate grounding procedure either a wrist strap connected to ground or when standing a heel strap with a grounded dissipative floor mat A grounded person must never hand an unprotected circuit pack to an ungrounded person A static discharge from the ...

Page 97: ...ic packages Always store and transport circuit packs in antistatic packaging Shielding is not required unless specified Keep all static generating materials away from circuit packs These materials include common plastics such as food wrappers clear plastic bags styrofoam containers packing material drinking cups notebooks and nonconductive plastic solder suckers The insulation on small hand tools ...

Page 98: ... and Figure 6 2 show the straps and resistors to keep and to remove from the CM1 board for each option on the J85502C 1 rectifier The plug in type wire straps are removed completely from a 2 hole jack The other wire straps shown are soldered in and are never replaced once they are removed Table 8 B Modifications for the CM1 Option Board Feature List Option Keep Straps or Resistors Marked with Remo...

Page 99: ...ac service panel supplying power to the rectifier remove the input fuse assigned to the rectifier or turn the circuit breaker Off Table 8 C Spare Fuse Information List Fuse Designation in SD Drawing Lucent Technologies Part Code Rating amperes Commercial Equivalent Shown on SD Sheets All FA1 V 70G 1 2 BUSSMAN 70G B1 C1 FA2 V List C F1 1 F1 8 KS 19780 L6 30 SOC Type SKM4 B1 C4 FA1 1 FA1 8 70G 1 2 B...

Page 100: ...screwdriver to push in the latches on each standoff 10 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 in this section 11 Position the new CM1 board over the four support standoffs Verify that each latch snaps and locks in place 12 Reconnect all cables that were disconnected in Step 8 13 If the recti...

Page 101: ...connector on the cable from the CM1 option board If CM6 is in place remove it and the Y R and S leads for it from points E2 E4 and E9 respectively on CM2 The ribbon cable may remain connected to CM6 If BK and W leads of CM6 are connected to E1 and E3 of CM2 remove them also but then cut off and discard 9 Disconnect the J3A connector on the cable from the CM3 digital meter board 10 Remove the CM2 c...

Page 102: ...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 fuse assigned to the rectifier or turn the circuit breaker Off 4 At the plant controller remove the fuse REG fuse associated with the rectifier 5 At the rectifier loosen the locking scr...

Page 103: ...l considerations or precautions must be taken during reinstallation Applicable portions of Section 5 Installation may be helpful Portions of Section 6 Testing can be used after reinstallation to verify proper operation of the rectifier Some points are common to all rectifier disassembly work Please read this section before using the rectifier disassembly procedures Take precautions against acciden...

Page 104: ...ms 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 thermal grease used should be KS 21343 L1 Diode thermal pads used in new rectifiers are comcode 406506907 Triac Q1 uses DP102 comcode 403208242 DC capacitors can be examined to see if they have blown i e...

Page 105: ...to remove a part not called for in order to make more room for access to a component being replaced Tables 8 D and 8 E provide the reassembly torquing requirements for the electrical and mechanical connections in the rectifier Use these values unless otherwise directed in the procedures Table 8 D Torque and Minimum Yield Strength for Mechanical Connections Using Hex Head Cap Screws Cap Screw Diame...

Page 106: ...ew Size Torques for In Lb or Ft Lb Wire Connections Head Tightened Nut Tightened Slotted Machine Hex or Socket Cap Slotted Machine Hex or Socket Cap Slotted Machine or Hex Cap Socket Cap 8 32 15 15 19 19 19 23 10 24 21 21 27 27 27 33 1 4 20 50 50 65 65 65 80 5 16 18 100 135 135 165 3 8 16 180 240 240 290 7 16 14 280 385 385 465 1 2 13 500 585 585 710 5 8 11 71 97 97 118 3 4 10 125 172 172 209 ...

Page 107: ...rrosion protective finish 6 Locking means is only required for connections subject to vibration Belleville type washers or jam nuts are the preferred means 7 For less that 1 4 inch thick tapped copper bars use slotted No 8 No 10 or 1 4 inch machine screws to minimize applicable torque When larger size screws are required provide captive type steel nuts or reduce torques 8 Torque recommendations ar...

Page 108: ...he bus or from the top of shunt R3 that is connected to the top of the circuit breaker 2 Remove the two screws that hold the CBA1 bracket to the rectifier cabinet 3 Rotate the CBA1 bracket to the right and remount to the outside of the cabinet flange This will provide access to Figure 8 1 Typical J85502C 1 125 ampere Rectifier with Door Open and Diode Heat Sink Removed CM2 control board 205A1 CM6 ...

Page 109: ...hold CBA1 to its bracket DC Inductor L2 1 Perform the instructions in CBA1 Bracket Assembly in this section to move the CBA1 bracket out of the way 2 Disconnect the cables from the inner and outer tabs of L2 While doing this small flyback diodes CR3 and CR4 with red and blue leads and their mounting tabs will also come off the inner and outer L2 tabs Note their positions for proper subsequent reas...

Page 110: ... two terminal mounting screws from the bus bar side of the capacitor b On the capacitor side loosen the clamp screw at the capacitor base and remove the capacitor 7 During reinstallation put the capacitor terminal screws in first and tighten Then tighten the clamp screws Verify that the capacitor polarity is correct during installation The capacitor blow vent holes should be visible through the ho...

Page 111: ...the heat sink remove the two insulator bracket mounting screws Then pull the bracket off of the tab and rotate the heat sink 90o clockwise from looking down on the unit 2 Using one of the two mounting screws just removed mount the insulator bracket and heat sink to the T1 metal bracket by passing the screw through the oval shaped tab hole from the right Then turn the screw into the threaded hole i...

Page 112: ...l of the rectifier Then loosen the two lower nuts that secure the plate to the wall Lift up the L1 plate assembly and then pull forward to remove For 48 Volt Rectifier Remove the topmost two nuts of L1 and loosen the bottom two nuts Slide L1 up and then pull forward to remove AC Capacitors C10 or C11 1 Perform the steps in Diode Heat Sink Assembly in this section to move the diode heat sink comple...

Page 113: ... the diode heat sink assembly completely out of the way 2 Noting their positions remove the quick disconnect connectors from the K2 terminal tabs 3 Using a rachet type socket wrench with an extension and a 1 4 inch socket loosen the rear mounting nut behind K2 and remove the front mounting nut Then remove K2 by pulling forward Contactor Relay K1 1 Perform the steps in Diode Heat Sink Assembly in t...

Page 114: ...onnectors coming from ac input leads 1 2 and 3 terminal tabs on the top of the K1 contactor 3 Remove the other three quick disconnect connectors leads 4 5 and 6 from their connection points in the wiring harness 4 Remove the two mounting nuts to free T2 Main Transformer T1 This procedure assumes that the rectifier has been removed from the bay and that the top cover of the rectifier has been remov...

Page 115: ...rmer lifting bracket and the upper left front rear bracket flanges on the transformer Remove the two nuts that attach the lifting bracket to the mounting studs on the left cabinet wall near the upper cabinet flange 5 Remove the two nuts that attach the lower front mounting feet of the transformer brackets to the studs on the bottom surface of the cabinet 6 Remove the following electrical connectio...

Page 116: ...nge at the top of the cabinet Now the transformer can be lifted out of the cabinet Rectifier Diode Test and or Replacement If not already done perform the diode heat sink assembly procedure 1 Remove the nut from the stud that replace secures the diode to the heat sink The stud can be anode or cathode of diode see the rectifier SD to determine Lift the diode body from the heat sink by the pigtail s...

Page 117: ...ment procedure If maintenance is completed reinstall the diode heat sink assembly according to Contactor Relay K1 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 is good A good diode should measure at least 50 ohms in both directions and one direction should measure at least 50 times the other...

Page 118: ...olders or circuit breaker to instruct all personnel to leave the circuit deenergized 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 cable tie anchors to permit its withdrawal through the conductor opening in the cabinet The cable tie anchors while providing a secure physical sup...

Page 119: ... 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 Size 3 8 16 lifting eyebolts may be fastened into the threaded holes in the top of the rectifier for removal by a forklif...

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Page 121: ...e 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 sh...

Page 122: ...air 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 and the reinstallation shall be borne by Customer With r...

Page 123: ...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 addition Seller makes no warranty with respect to Products ...

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