Lucent Technologies Lineage 2000 J85503B-2 Product Manual
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Lucent Technologies Lineage 2000 J85503B-2 Product Manual

Lucent Technologies Lineage 2000 J85503B-2 Product Manual

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®
Lineage
2000
200-Ampere, 60-Hertz
Ferroresonant Rectifier
J85503B-2
Product Manual
Select Code 169-790-128
Comcode 107666356
Issue 8
January 1999
©1999 Lucent Technologies

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Summary of Contents for Lucent Technologies Lineage 2000 J85503B-2

  • Page 1 ® Lineage 2000 200-Ampere, 60-Hertz Ferroresonant Rectifier J85503B-2 Product Manual Select Code 169-790-128 Comcode 107666356 Issue 8 January 1999 ©1999 Lucent Technologies...
  • Page 3 200-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.

  • Page 5: Table Of Contents

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Table of Contents 1 Introduction General 1 - 1 Applications 1 - 1 Features 1 - 2 Benefits 1 - 2 Customer Service 1 - 3 Technical Support 1 - 3...
  • Page 6 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Alarms 2 - 6 Load Share Fail (LSF) 2 - 6 Fuse Alarms (FA) 2 - 6 Rectifier Failure Alarm (RFA) 2 - 6 Auxiliary RFA Alarm 2 - 7 Charger Fail Alarm (RFA/CFA)
  • Page 7 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Documentation References 3 - 10 4 Safety Safety Precautions 4 - 1 ESD Precautions 4 - 3 5 Installation General 5 - 1 Preparing for Installation 5 - 1 Floor Mounting...
  • Page 8 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Rectifier Failure Alarm Test 6 - 8 Current Limit Test 6 - 9 Phase Failure Alarm (PHA) Test 6 - 9 Backup High Voltage Shutdown (HVSD) Test 6 - 10 Control (TR) Test...
  • Page 9 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Preventive Maintenance 7 - 19 8 Replacing Components and Circuit Modules General Considerations for Replacing Components 8 - 1 Replacing Components 8 - 4 Thyristors (Q1, Q2) 8 - 5 Diode Heat Sink Assemblies...
  • Page 10 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 6 - Table of Contents Issue 8 January 1999...
  • Page 11 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 List of Figures Figure 2-1: Block Diagram of a Typical Battery Plant 2 - 2 Figure 2-2: J85503B-2 Control Panel 2 - 8 Figure 2-3: J85503B-2 Rectifier with Door Open 2 - 13...
  • Page 12 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 2 - List of Figures Issue 8 January 1999...
  • Page 13 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 List of Tables Table 2-A: CM2 Circuits 2 - 11 Table 2-B: J85503B-2 Rectifier Specifications 2 - 14 Table 3-A: J85503B-2 Ordering Information 3 - 5 Table 3-B: Hardware Ordering Information...
  • Page 14 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Table 7-E: Signals on TB3 of CM4 7 - 10 Table 7-F: Additional Conditions/Indications on the J85503B-2 7 - 11 Table 7-G: Digital Meter Tolerance 7 - 14 Table 7-H: Control Settings Prior to Restoring...

  • Page 15: Introduction

    200-ampere, 60-hertz, -48 and ±24 volt, floor-mounted ferroresonant rectifier. The manual covers rectifier technology, features and specifications, installation and testing, and operation and maintenance. The J85503B-2 rectifier is a member of the Lucent Technologies ® ® family of Lineage 2000 rectifiers. Like all Lineage...

  • Page 16: Benefits

    65 volts (for -48-volt plants) or to ±32 volts (for ±24 volt plants), as well as operate without batteries. The rectifier works with Lucent Technologies controllers to provide control and alarm functions. An interface board is available to access these functions with commercial controllers.

  • Page 17: Customer Service

    For other customers world-wide, contact your local field support center or your sales representative to discuss your specific needs. Product Repair Repair and return service for Lucent Technologies equipment is available to customers around the world. For customers in the and Return United States, Puerto Rico, the U.S.
  • Page 18 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 1 - 4 Introduction Issue 8 January 1999...

  • Page 19: Product Description

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Product Description General In most telecommunications applications, the output of the rectifier system is electrically connected in parallel with the batteries. The rectifiers provide both the power to the telephone equipment through the plant distribution and the charging and float current to the batteries.

  • Page 20: Features

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Controller: provides the local and remote control, monitor and diagnostic functions required to administer the battery plant. Batteries: provide energy storage for an uninterrupted power feed to the using equipment during loss of ac input or rectifier failure.
  • Page 21 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Electronic The rectifier provides a constant output voltage up to its rated Current Limit output current, at which point it provides constant current. This current limit set point is typically adjustable from 30 to 110 percent of the rectifier rating, 60 to 220 amperes.
  • Page 22 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 For operation without batteries, the sense point voltage remains within 10 percent of its setting and returns and remains in the 2 percent band within 500 milliseconds for any step load change of 50 to 90 percent, or 90 to 50 percent, or a step change of 10 percent of the input voltage.
  • Page 23 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 1. Receiving a signal from a Lucent Galaxy Controller or an MCS Controller equipped with Version 4.0 firmware 2. Putting the front panel switch on the digital meter board in the Equalize position 3.

  • Page 24: Alarms

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Output Noise The output noise is limited to 32 dBrnc. When measured with a Psophometric noise meter, the noise is less than two millivolts rms. (All of the above requirements are at full load, on battery, and the noise is measured at the battery).
  • Page 25 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 1. Fuse(s) inside the rectifier has operated. 2. Selective high voltage shutdown has operated. 3. Internal selective high voltage shutdown has operated. 4. Backup high voltage shutdown has operated. 5. Output circuit breaker has tripped.

  • Page 26: Front Panel Controls And Indicators

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Unbalance A severe unbalance developed in the rectifier triggers the Alarm Circuit rectifier fail circuit. The rectifier shuts down and an alarm is generated. This shutdown of the rectifier has a delay to prevent false operation from transient disturbances, such as may occur during initial turn-on.

  • Page 27: Rect V

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 • The rectifier output voltage when the meter switch is in the Rect V position • The battery voltage when the meter switch is in the Plt V position Rect V The user may select whether the default position of the meter switch is rectifier current or battery voltage.

  • Page 28: Flt/Eq

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 rectifier goes to maximum current (FL); when it is operated to NL, the rectifier goes to no current. Rect + and - Test The Rect + and - test jacks allow for measuring the output Jacks voltage of the rectifier.

  • Page 29: Cm1

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 The CM1 circuit module (329A Fuse Board) protects the control circuits from faults in the rectifier power train. It contains alarm fuses, bleeder resistors, access points for the plant shunt voltage, and an isolated RFA transfer contact.

  • Page 30: Alarm And Control Flow

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Warning Circuit modules must not be connected or disconnected with voltages present. Personal injury or equipment damage may occur. See Section 8 for how to replace circuit modules. Alarm and The J85503B-2 200-ampere rectifier is typically installed in a...

  • Page 31: Figure 2-3: J85503B-2 Rectifier With Door Open

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 CM1 Fuse Board 329A CM7 Transformer Board 425C, D, or F CM4 Interface Board 330C CM3 Digital Meter Board CB1 Circuit 323D Breaker 225 Amperes CM2 Control Board 208F1 CM5 and CM6...

  • Page 32: Specifications

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Galaxy Plant Control Cable Assembly Controller H285226 G-60 Rectifier Low Current Alm (LCA) AC Fail (ACF) Load Share Fail (LSF) RFA Test DC Output Circuit Breaker Status (CB) Power Switch Status (MAN)
  • Page 33 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Table 2-B: J85503B-2 Rectifier Specifications Regulation off Battery ± 2% AC Ripple 50 millivolts peak to peak (Note 3) Output Noise < 46 dBrnc (On Battery) < 32 dBrnc (Note 3) Psophometric Noise <...
  • Page 34 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 2 - 16 Product Description Issue 8 January 1999...

  • Page 35: Engineering And Ordering

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Engineering and Ordering Rectifier Sizing This section discusses how to determine the minimum number of rectifiers required in a battery plant. Rectifiers of different output current capacities can be paralleled in a plant; therefore, size mixing is also discussed.

  • Page 36: Figure 3-1: Recharge Time Vs. Recharge Factor

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 5 6 7 8 Hours Reserve 12 16 44 48 Hours to 95% Charge Figure 3-1: Recharge Time vs. Recharge Factor Figure 3-1 illustrates some general bounds on sizing rectifiers for recharging batteries. With other conditions fixed, it illustrates three generalities.

  • Page 37: Sizing Example

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 defining a non-redundant system. A redundant system additionally requires that the loss of any one rectifier does not cause the remaining rectifier capacity to fall below the abh value. This is another way of saying that the loss of any one rectifier in the system does not cause the batteries to discharge.

  • Page 38: Ordering Information

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 mirc = abh x recharge factor mirc = 210A x 1.38 = 290A The number of 100A rectifiers required to supply at least 290A is three (3 x 100 = 300A). Three rectifiers are required in a non-redundant system.

  • Page 39: Table 3-A: J85503B-2 Ordering Information

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Rectifier Table 3-A provides a summary of the J85503B-2 list structure. Read all of the notes carefully before ordering. Table 3-A: J85503B-2 Ordering Information List Description Framework, assembly, wiring, and equipment for one rectifier, 24 volts dc 200 amperes output and 208 volts ac 60Hz input.

  • Page 40: Hardware

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 – ACF LED – Equalize LED – Rectifier volts/Rectifier amperes/Plant voltage display selection switch – NL/FL test switch – Float/Equalize switch – Output adjust potentiometer – Equalize potentiometer – Pin jacks for external meter 2.

  • Page 41: Shims

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Table 3-B: Hardware Ordering Information Equipment Requirement Qty Description Comcode Anchor Bolts (Kit) Zone 3 or 4 H569-407 G-6 847320835 Anchor Bolts (Kit) Zone 0, 1, or 2 H569-407 G-1 847135654...

  • Page 42: Junction Plates

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Table 3-C: Shims Ordering Information Thickness Comcode 0.063 inch 842439861 0.125 inch 842439879 0.250 inch 842439887 Junction Plates 10. Order installation mounting plates (junction plates) for side-to-side or front-to-back support at the top of adjacent rectifiers from Table 3-D.

  • Page 43: Table 3-E: Circuit Modules In The J85503B-2 Rectifier

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Table 3-E: Circuit Modules in the J85503B-2 Rectifier Kit - Circuit Apparatus J-List Comcode Description J85503C-3 Modules Code List K1 1 or 2 425C 107134454 Transformer Board List K2 3 or 4...

  • Page 44: Sample Order

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Sample Order This sample order is for a 200-ampere, 48 volt, 60 Hz rectifier with a 208 vac input. It includes a filter for limiting the output noise to 32 dBrnc, and a cable for connection to a Galaxy controller.
  • Page 45 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 ECS-6U Controller Assembly and Ordering Drawing J85501E-1 Wiring Diagram T83122-30 Schematic Drawing SD83122-01 Product Manual Select Code 167-790-045 ECS-12U Controller Assembly and Ordering Drawing J85501E-2 Wiring Diagram T83181-30 Schematic Drawing SD83181-01...
  • Page 46 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 3 - 12 Engineering and Ordering Issue 8 January 1999...

  • Page 47: Safety

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Safety Safety Please read and follow all safety precautions and warnings before installing, maintaining, or troubleshooting the Precautions 200-ampere rectifier. Always take precautions to protect personal safety as well as the equipment when working on power systems.
  • Page 48 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 7. Be sure that the associated framework and cable rack are properly grounded, per local job instructions, before turning on any rectifier. 8. Battery voltage may still be present on one side of the CB1 circuit breaker when both the ac power and dc circuit breaker are turned off.

  • Page 49: Esd Precautions

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 1. Assume all circuit packs containing electronic (solid-state) components can be damaged by ESD. Precautions 2. When handling circuit packs (storing, inserting, removing, etc.) or when working on the backplane, always use the...
  • Page 50 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 10. When soldering static-sensitive semiconductor devices, the soldering iron must be grounded to the work table which must also be earth grounded. 11. Whenever possible, maintain relative humidity above the 20-percent level.

  • Page 51: Installation

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Installation General This section outlines a sequence for installing and testing the J85503B-2 rectifier in a battery plant. The section describes the input and output wiring required and the recommended procedure for installing the rectifier from uncrating through start-up.

  • Page 52: Heat Dissipation

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 12.94" (32.87cm) 2.65" 9.88" 1.54" (6.73cm) (25.10cm) (3.91cm) Note: Allow clearance for screw heads that protrude from the sides at the rear of the cabinet. Two self-adhesive bumpers are included, that can be placed low on the cabinets to provide proper spacing.

  • Page 53: Ac Input Power

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 BTU/hr. The rectifiers use free convective cooling, where cooler air enters the cabinet through perforations in the front bottom plate and is exhausted through perforations in the top cover. A minimum of 66.04cm (26 inches) in front and 30.48cm...

  • Page 54: Dc Output Power

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 2. Where the trade size of the conduit used is smaller than the trade size for which the conduit knockout is sized, use appropriate knockout reducing washers. Use the wire or cable in Table 5-A where available. Otherwise, use commercial UL listed wire or cable that meets the National Electric Code (NEC) and local requirements.

  • Page 55: Figure 5-3: Ac And Dc Termination Points

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 used. The rectifier will accept one 350KCMIL cables at each of the positive and negative output terminals. The output cables must have a minimum rating of 90° C. KS24194 L2 (flex) or KS24194 L3 (Class B) are recommended for the distribution of dc power in the plant.

  • Page 56: Dc Power Cables

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Holes in 4 Corners for Lifting Eyebolts (Not Supplied) C.O. Grd AC Input Fitting Control Cable Figure 5-4: Top View of the J85503B-2 Rectifier DC Power Cables The term “rectifier charge cables” refers to the dc power cables which connect the dc power output of a rectifier to the power plant batteries.

  • Page 57: Handling Equipment

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Table 5-C provides widths for use with 350CKMIL cable. Table 5-C: Rack Widths for 350KCMIL Cables Rack Width Number of 200 Ampere Rectifiers Do not route other cable rack(s) above or through the area above the rectifiers or any other heat source.

  • Page 58: Installation

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 eyebolts. After the rectifiers are in place and the eyebolts removed, the 5/8-11 holes may be used for the threaded rods used to support cable racks. Installation You will need the following for installing rectifiers.

  • Page 59: Installing Or Adding A Rectifier

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 7. Remove parts package from inside rectifier. 8. Verify that the main ac voltage at your distribution panel agrees with the input specified on the label inside the rectifier door. 9. Using all four lifting eyebolts and appropriate material handling equipment, raise the rectifier from the pallet and set it on the floor in its upright vertical position.

  • Page 60: Ac Power Cables

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 AC Power Cables Use Figures 5-3 and 5-4 as references for this section. Observe all precautions in Section 4. 1. Disconnect ac power from ac distribution service panel that supplies power to the rectifier.

  • Page 61: Supplemental Central Office (Co) Ground

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 4. Tape or otherwise insulate the connectors on the end of each cable that does not terminate in the rectifier. Label each cable. 5. Place the dc output return cable in cable rack.

  • Page 62: Table 5-D: Controller Connectors

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Table 5-D: Controller Connectors Controller Equipment Code Connector Conventional Controlled System (CCS) J85501A-3 24-pin Microprocessor Controlled System (MCS) J85501A-2 24-pin Evolutionary Control System-6U (ECS-6U) J85501E-1 40-pin Evolutionary Control System-12U (ECS-12U) J85501E-2...
  • Page 63 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 have sixteen 24-pin connectors labeled Rect 1 through Rect 16. For ECS controllers, open the front panel and thread the control cable through the slot on the right side of the controller.

  • Page 64: Figure 5-6: Cm4 Interface Board (330C)

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Connector for Plant Control Cable Connections for Special Applications Load Share Voltage Adjustment Potentiometer for Special Applications Load Share (NLS) Figure 5-6: CM4 Interface Board (330C) 8. Dress and tie down the cable to provide stress relief at the connector.

  • Page 65: Plant Control Cable Assembly (External Alarm/Control Bay)

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 TB3. Note that when a Lucent controller is used, no connections are permitted from an external alarm/control bay to R+, R-, BAT and GND located on TB1 and TB2. When a Lucent controller and an external monitoring...

  • Page 66: Dip Switch Settings

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 The BAT signal typically is the battery voltage. 2. Route the control cable from the external monitoring system to the rectifier via the cable rack. See Figures 5-4 and 5-3 for the connection point and Table B of note 311 on SD-83281-01, which describes the function of each signal.

  • Page 67: Figure 5-7: 48V Dip Switch Label

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Figure 5-7: 48V DIP Switch Label Issue 8 January 1999 Installation 5 - 17...

  • Page 68: Figure 5-8: 24V Dip Switch Label

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Figure 5-8: 24V DIP Switch Label S2.9 and S2.10 provide local or remote sense. In the factory setting position, the rectifier senses the output voltages remotely 5 - 18 Installation Issue 8 January 1999...
  • Page 69 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 via the regulation leads. If the settings are changed, the voltage is regulated at the output terminals of the rectifier. S3.1 through S3.4 adjust the level of the backup high voltage shutdown (BUHVSD).

  • Page 70: Converting Ac Voltage

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Converting AC The main list number of the J85503B-2 rectifier (Lists 1, 2, 3, 4, 5, or 6) determines the ac input voltage of the unit. (See Table Voltage 3-A.) Lists 1 and 2 have 208-volt ac input and use the 425C transformer board.
  • Page 71 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 2. To disable internal selective high voltage shutdown (ISHVSD), open S3.5 on the CM2 board for 48V rectifiers. For 24V applications, open S3.6 to disable ISHVSD. See Figure 6-3. 3. To raise the backup HVSD level, adjust S3.1-S3.4 on CM2 to one of the levels given in Table A on the rectifier door.
  • Page 72 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 5 - 22 Installation Issue 8 January 1999...

  • Page 73: Testing

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Testing General This section gives test procedures for newly installed and/or operating rectifiers. If the plant in which a rectifier is being installed has never been operational, the plant and controller tests must be performed before the rectifier tests.

  • Page 74: Tools And Test Equipment

    Figure 6-1 shows how to construct a test set. (Note: The Battery Plant Simulator Test Set shown in Figure 6-1 is equivalent to a Lucent Technologies ITE6369 test set, which is not available to customers.) Table 6-A shows how to connect the test set to the rectifier.

  • Page 75: Test Load Connection

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Test Load Use the following procedures to connect a test load when called for in a test or other procedure. Test load connections are made Connection on the internal bus of the rectifier. Therefore, to isolate the...

  • Page 76: Figure 6-1: Battery Plant Simulator Test Set

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 +27V Red Test Clip PIN 5 2150 1 WATT PIN 16 2150 1 WATT PIN 4 2150 2150 1 WATT PH or LOA PIN 12 2150 1 WATT PIN 6 To CM4...

  • Page 77: Initial Conditions For Testing Off Line

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Initial The following steps verify that the rectifier responds properly to plant controller commands and outputs proper signals in return. Conditions for Referring to Schematic Drawing SD83281-01 may be helpful Testing Off while performing these procedures.

  • Page 78: Figure 6-2: Cm1 Fuse Board With Clip Connections (Older Version Of Cm1 On The Left)

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 • With the BAT fuse installed in the plant controller, check for battery voltage between pin 5 of J5A and ground. • If the plant is equipped with an MCS Controller or with a Galaxy Controller with Intelligent features, again on J5A, check for 15-20 volts dc between pins 35 and 31.

  • Page 79: Figure 6-3: Cm2 Board With Clip Connections

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Isolated Current Measuring Adjustment Potentiometer Blue Test Clip Black Test Clip Test Clip Current Limit Potentiometer DIP Switch S1 Figure 6-3: CM2 Board with Clip Connections Issue 8 January 1999 Testing 6 - 7...

  • Page 80: Testing Off Line

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Testing Off The following tests involve use of the test load and a Battery Plant Simulator Test Set. Refer to page 6-2 for the procedure to Line connect a test load and pages 6-2 and 6-3 for a Battery Plant Simulator Test Set.

  • Page 81: Current Limit Test

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 the RFA and FA LEDs on the control panel and RFA lamp on the test set light. 2. Turn the Power switch Off, then back On. The rectifier should start, and the LEDs lights should go off.
  • Page 82 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 3. Verify that no ac voltage is present on the input leads of the ac contactor K1. (See Figure 5-3.) 4. Disconnect one input lead, L1, L2, or L3 on K1, or at the ac service panel, whichever is more convenient.

  • Page 83: Control (Tr) Test

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Control (TR) Test 1. Press and hold the transfer rectifier (TR) switch on the test set for 5 seconds. The rectifier should turn off simulating a remote shutdown from the controller. The TRH lamp on the test set should light.

  • Page 84: Meter Test

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Local Equalize 1. Set switch S2.1 on CM4 to on (right). Control Test 2. Move the FLT/EQ switch on the control panel (S2 on CM3) to the equalize position. The equalize LED should light.

  • Page 85: Off Line Test Completion

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 5. Compare the amperes calculated in Step 4 with the digital display of the meter while the switch is in the AMPS position. 6. If the digital display is between ±2% ±2A than the amperes calculated in Step 4, this procedure is completed.

  • Page 86: Table 6-C: Rectifier Control Settings For Testing On Line

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Table 6-C: Rectifier Control Settings for Testing On Line Controls Position/Status Associated ac circuit breaker or fuses Off or fuses removed and holders at the ac service distribution panel tagged “Out of service”...

  • Page 87: Testing On Line

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 6. Turn rectifier Power switch On. It may be necessary to readjust the Float Adj potentiometer further clockwise in order for the rectifier output to return to plant float voltage and assume any load now that it has changed to external regulation mode.

  • Page 88: Current Limit Test

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 1. Holding the insulation on a piece of bare wire or the end of a paper clip, insert the wire into the fuse holder F1 on the CM1 fuse board. Note that the rectifier shuts down and the RFA and FA lamps on the control panel light.
  • Page 89 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 ® controllers or Lineage 2000 MCS controllers and when the output current reading on the rectifier does not agree to within ±2.5 percent of the rectifier output current reading on the controller.

  • Page 90: Phase Failure Test

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Phase Failure 1. With the Power switch still On, turn off the ac service and Test note that the rectifier shuts down. 2. Verify that no ac voltage is present on the input leads of the ac contactor K1 (Figure 5-3).

  • Page 91: Control (Tr) Test

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 the regulation fuse assigned to the rectifier being tested. (This is the fuse removed in Step 1.) Now, turn ON the rectifer Power switch once again, and turn the Float Adj...

  • Page 92: Ac Fail Test

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 5. Repeat Steps 1 and 2 on: MCS or CCS: TB1-32 to test rectifiers 7, 8, 15, and 16 (MCS) or 13, 14, 15, and 16 (CCS). ECS-6U and ECS-12U: TB101-12 to test rectifiers 4 (8 and 12, ECS-12U).

  • Page 93: Rfa Circuit Verification Rfa Test

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 RFA Circuit This procedure tests the alarm system. Verification RFA Test 1. Provide a contact closure on TB3-1 and TB3-2 of CM4. 2. The rectifier and controller should indicate an RFA, but the rectifier should not shut down.

  • Page 94: Adjust Rectifiers To Float Voltage

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Adjust Float voltage is the optimum voltage level at which a battery string gives maximum life and full capacity. This voltage Rectifiers to depends on the type and number of batteries in a plant.
  • Page 95 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Adjust Rectifiers If the load requirement is always greater than the capacity of as a Group 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 installed in the plant controller or a remote bay.

  • Page 96: Enable And Test Load Share

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 5. 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 tolerance of the desired float voltage.

  • Page 97: Special Application Load Share (Nls)

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 5. Remove the simulated failure. If the rectifier is providing a load greater than 12 amperes, the LCA LED should go off. 6. With the rectifier load sharing, turn the Float Adj potentiometer fully counterclockwise.
  • Page 98 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 load rating of the largest rectifier. You may fine tune the output of each rectifier to reduce the overall variation in load current. (Raise or lower the voltage in order to raise or lower the output current with respect to other rectifiers in the plant.) If plant voltage is not at the desired level, use...

  • Page 99: Troubleshooting And Adjustments

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Troubleshooting and Adjustments General This section provides troubleshooting information and adjustment procedures for the J85503B-2 rectifier. Whenever working on or near electrically live equipment, observe all safety precautions given in Section 4, Safety, and within each procedure.
  • Page 100 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 the cable tie anchors to permit its withdrawal through the conductor opening in the cabinet. The cable tie anchors, while providing a secure physical support of the cable assembly, protect the cable assembly from undesirable abrasion and bending.

  • Page 101: Diagnostics

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 12. Remove the anchoring fasteners from inside the cabinet base and save for reuse. 13. Four lifting eyebolts, supplied by the customer, must be securely fastened into the threaded holes in the top corners of the cabinet.
  • Page 102 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Table 7-A: Troubleshooting Problem Probable Cause Probable Corrective Action 1. Measure output voltage while rectifier is “walking in.” If the output voltage exceeds 58 (28) volts, the rectifier is shutting 1. CM2 is defective.
  • Page 103 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Table 7-A: Troubleshooting Problem Probable Cause Probable Corrective Action 1. Shorted or open triac. 1. Replace triacs. 8. Rectifier does not shut down 2. Check wiring asso-ciated at no load but may shut down at 2.

  • Page 104: Front Panel Conditions

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Front Panel Table 7-B lists possible front panel conditions and describes their significance. Tables 7-C, 7-D, and 7-E list conditions of the Conditions CM4 interface board and the associated alarm status or control function.
  • Page 105 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Table 7-B: Front Panel Conditions and Indications Condition Indication Power switch off Rectifier turned off manually Power switch off or On Rectifier operating normally; Power LED off S2.2 of CM4 has been enabled.

  • Page 106: Table 7-C: Alarms On Tb1/Tb2 Of Cm4

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Table 7-C: Alarms on TB1/TB2 of CM4 TB1, TB2 Interface Alarm Status Condition No alarm CB, CBR Open Output circuit breaker tripped CB, CBR Closed No alarm CB, CBR Open Output circuit breaker tripped...

  • Page 107: Table 7-D: Controls On Tb1/Tb2 Of Cm4

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Table 7-D: Controls on TB1/TB2 of CM4 Control Status TB1/TB2 Interface Condition No control Open circuit between RS, RSR Rectifier restart initiated Momentary short applied to RS, RSR No control Open circuit between TR, TRR...

  • Page 108: Table 7-E: Signals On Tb3 Of Cm4

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Table 7-E: Signals on TB3 of CM4 Alarm Status TB3 Interface Condition No test RFAT Open RFA alarm generated without RFAT Closed turning the rectifier off No alarm ACF, ACFR Open...

  • Page 109: Table 7-F: Additional Conditions/Indications On The J85503B-2

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Table 7-F: Additional Conditions/Indications on the J85503B-2 Signal/Condition Indication Nominal 52 or 24 volt control battery fused at 1-1/3 amperes and ground should be applied when a Lucent controller is not connected to the rectifier.

  • Page 110: Adjustments

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Adjustments This section includes procedures to check fuses (Clear RFA and FA), calibrate the meter, adjust the current limit, and set the internal selective high voltage shutdown (ISHVSD) for rectifiers without controllers. It may be necessary to remove the rectifier from service before completing these procedures.

  • Page 111: Clear Fuse Alarm (Fa)

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 b. If the rectifier Float Adj potentiometer can be used to adjust the voltage to the correct level, the RFA problem has been cleared. Otherwise, continue with the following procedures. 3. If the rectifier output voltage is less than the plant voltage and/or all rectifiers shut down, then use the following procedures.

  • Page 112: Table 7-G: Digital Meter Tolerance

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Calibrate CM3 Calibration is not feasible unless the test meter has an accuracy Digital Meter of ± 0.02 percent or better. 1. Loosen the locking screws and open the front door of the rectifier.

  • Page 113: Figure 7-1: Adjustment Potentiometer On Cm3

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Table 7-G: Digital Meter Tolerance Switch Position Tolerance Amps ± 2.5% of reading ± 2 amperes* To compare, measure the shunt voltage. 1mV of shunt voltage indicates 5 amperes of output current. For example, the shunt voltage should be 40 mV at full load (200 amperes).

  • Page 114: Ishvsd In Plants Without A Controller

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 In steps (4) and (5) of the Current Limit Test in Section 6, if V is not within the required range, adjust R88 on CM2 (see Figure 6-3) until a correct voltage reading is obtained.
  • Page 115 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 the rectifier does not operate properly, refer to “Diagnostics” section. 8. Turn on dip switch S3.7 on CM2, restart the rectifier, and adjust the load to at least 10 percent, 20A.

  • Page 116: Restore Rectifier To Service

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Restore 1. Set the ac supply and rectifier controls as shown in Table 7-H. Rectifier to Service Table 7-H: Control Settings Prior to Restoring a Rectifier to Service Controls Position/Status Associated ac circuit breaker or...

  • Page 117: Preventive Maintenance

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 9. Adjust the rectifier to float voltage per Section 6. 10. If the rectifier is installed in a microprocessor-controlled plant that has an efficiency algorithm feature, enable this feature. (See the controller manual for instructions).
  • Page 118 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 7 - 20 Troubleshooting and Adjustments Issue 8 January 1999...

  • Page 119: Replacing Components And Circuit Modules

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Replacing Components and Circuit Modules General Only disassembly procedures are given in this section. Some points are common to all rectifier disassembly work. Considerations for Replacing Reinstallation procedures are usually the exact reverse of Components removal procedures (i.e., follow the removal procedures in...
  • Page 120 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 • The ac service and dc battery buses can be safely disconnected from the rectifier by following the steps in Section 7, “Disconnecting a Rectifier.” All work must be done carefully because you are working with live cables at battery bus potentials and current capabilities.

  • Page 121: Table 8-A: Minimum Torque For Electrical Connections

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Table 8-A: Minimum Torque for Electrical Connections Torque Values in In-Lb (or Ft-Lb)/Nm Wire Connections Head Tightened Nut Tightened Slotted Screw Size Slotted Hex /Socket Slotted Hex /Socket Machine/ Socket Cap...

  • Page 122: Replacing Components

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Table 8-B: Torque and Minimum Yield Strength Values for Mechanical Connections (Using Hex Head Cap Screws) Torque Cap Screw Diameter Min. Yield Ft-Lb (Inch) Strength UNRC 57,000 3/16 57,000 57,000 7/16...

  • Page 123: Figure 8-1: Component Locations

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 DC Capacitors (Optional) DC Inductor L4 Behind Circuit Breaker (Optional) Diodes CR1 to CR4 on Heat Sink AC Inductors DC Capacitors L1 and L2 and AC Capacitors Behind Heat Sink Thyristors...

  • Page 124: Diode Heat Sink Assemblies

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 2. Remove the two nuts that secure the thyristor to the heat sink. Save the nuts and the thermal pad from under the thyristor. 3. When reinstalling a new thyristor, use the hardware and thermal pad (DP102 comcode 403208242) saved in Step (2).

  • Page 125: Cb1 Circuit Breaker

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 1. DC Capacitors C5 through C9 are located behind the capacitor bus bars. The bus bars are mounted directly to the capacitors by the capacitor terminal screws. In order to remove a capacitor, remove fuse board CM1, the capacitor terminal screws, mounting screws, and the screw supporting the fuse assembly.

  • Page 126: Contactor Relay (K1)

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 2. While supporting the weight of the inductor, remove all four of the mounting nuts that secure it to the frame. Reinstall in reverse order. Contactor Relay 1. Remove all six of the heavy gauge (input and output) wires (K1) from K1.

  • Page 127: Handling Circuit Modules

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 4. Remove the four transformer mounting nuts, from under the T1/T2 mounting bracket, that secure the transformer. 5. While supporting the transformer with adequate lifting equipment (at least 1000 lb), lift the transformer outward.

  • Page 128: Replacing Circuit Modules

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 • Handle all circuit packs by the faceplate or latch and by the top and bottom outermost edges. Never touch the components, conductors, or connector pins. • Do not rub or wipe circuit packs to clean them unless you and the circuit pack are at the same ground potential.

  • Page 129: Cm2 Control Board

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 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.
  • Page 130 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 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 fuse REG fuse associated with the rectifier.

  • Page 131: Cm4 Interface Board

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 4. At the plant controller, remove the fuse REG fuse associated with the rectifier. 5. At the rectifier, loosen the locking screws and open the door. Caution Support the CM3 control board with your hands when connecting and disconnecting the cables, or damage to the board may result.
  • Page 132 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 5. At the rectifier, loosen the locking screws and open the door. Caution Support the CM4 control board with your hands when connecting and disconnecting the cables, or damage to the board may result.
  • Page 133 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 4. At the plant controller, remove the fuse REG fuse associated with the rectifier. 5. At the rectifier, loosen the locking screws and open the door. Caution Support the CM7 control board with your hands when connecting and disconnecting the cables, or damage to the board may result.
  • Page 134 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 8 - 16 Replacing Components and Circuit Modules Issue 8 January 1999...

  • Page 135: Product Warranty

    ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Product Warranty A. Seller warrants to Customer only, that: 1. As of the date title to Products passes, Seller will have the right to sell, transfer, and assign such Products and the title conveyed by Seller shall be good;...
  • Page 136 ® Lucent Technologies Lineage 2000 200A Ferroresonant Rectifier J85503B-2 Warranty Period Product Type New Product Repaired Product or Part* Central Office Power Equipment 24 Months 6 Months The Warranty Period for a repaired Product or part thereof is as listed...
  • Page 137 FOR A PARTICULAR PURPOSE. CUSTOMER’S SOLE AND EXCLUSIVE REMEDY SHALL BE SELLER’S OBLIGATION TO REPAIR, REPLACE, CREDIT, OR REFUND AS SET FORTH ABOVE IN THIS WARRANTY. Copyright 1999 Lucent Technologies All Rights Reserved Printed in U.S.A. Issue 8 January 1999...

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