Lucent Technologies Lineage 2000 J85503C-3 Product Manual
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Lucent Technologies Lineage 2000 J85503C-3 Product Manual

Lucent Technologies Lineage 2000 J85503C-3 Product Manual

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®
Lineage
2000
400-Ampere, 60-Hertz
Ferroresonant Rectifier
J85503C-3
Product Manual
Select Code 169-790-132
Comcode 107239915
Issue 10
July 2000
© 2000 Lucent Technologies

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Summary of Contents for Lucent Technologies Lineage 2000 J85503C-3

  • Page 1 ® Lineage 2000 400-Ampere, 60-Hertz Ferroresonant Rectifier J85503C-3 Product Manual Select Code 169-790-132 Comcode 107239915 Issue 10 July 2000 © 2000 Lucent Technologies...
  • Page 3 400-Ampere, 60-Hertz Ferroresonant Rectifier J85503C-3 Notice: The information, specifications, and procedures in this manual are subject to change without notice. Lucent Technologies assumes no responsibility for any errors that may appear in this document. © 2000 Lucent Technologies All Rights Reserved...

  • Page 5: Table Of Contents

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Table of Contents 1 Introduction J85503C-3 1 - 1 Customer Service Contacts 1 - 2 Customer Training 1 - 2 Customer Service 1 - 2 Technical Support 1 - 2...
  • Page 6 ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Electromagnetic Compatibility (EMC) 2 - 5 Alarms 2 - 6 Load Share Fail (LSF) 2 - 6 Fuse Alarms (FA) 2 - 6 Rectifier Failure Alarm (RFA) 2 - 6...
  • Page 7 5 - 11 DC Power Cables 5 - 12 Supplemental Central Office (CO) Ground 5 - 13 Plant Control Cable Assembly (Lucent Technologies Controller) 5 - 13 Plant Control Cable Assembly (External Alarm/Control Bay) 5 - 16 DIP Switch Settings...
  • Page 8 ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Phase Failure Alarm (PHA) Test 6 - 10 Backup High Voltage Shutdown (HVSD) Test 6 - 10 Control (TR) Test 6 - 11 Selective High Voltage Shutdown (SHVSD) and Restart...
  • Page 9 ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 8 Spare Parts and Replacement Procedures Introduction 8 - 1 Circuit Modules 8 - 2 Ordering 8 - 2 Handling 8 - 2 Fuses 8 - 4 Electrical Parts 8 - 5...
  • Page 11 ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 List of Figures Figure 2-1: J85503C-3 Control Panel 2 - 8 Figure 2-2: J85503C-3 Rectifier With Door Open 2 - 11 Figure 2-3: Signal Flow Rectifier/Galaxy Controller 2 - 14 Figure 3-1: Recharge Time vs.
  • Page 13 ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 List of Tables Table 2-A: Circuit Packs in the J85503C-3 Rectifier 2 - 12 Table 2-B: J85503C-3 Specifications 2 - 15 Table 3-A: J85503C-3 Ordering Information 3 - 5 Table 3-B: Hardware...
  • Page 14 ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Table 7-H: Control Settings Prior to Restoring a Rectifier to Service 7 - 17 Table 8-A: Circuit Packs in the J85503C-3 Rectifier 8 - 2 Table 8-B: Spare Fuse Information...

  • Page 15: Introduction

    Introduction J85503C-3 This product manual (Select Code 169-790-132) describes the J85503C-3, 3-phase, 400-ampere, 60-Hertz, -48-volt, floor-mounted rectifier. The J85503C-3 rectifier is a member of the Lucent Technologies family ® ® of Lineage 2000 rectifiers. Like all Lineage 2000 rectifiers, it represents a significant advancement in efficiency, space savings, and serviceability.

  • Page 16: Customer Service Contacts

    2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Customer Service Contacts Customer Training Lucent Technologies offers customer training on many Power Systems products. For information call 1-972-284-2163. This number is answered from 8:00 a.m. until 4:30 p.m., Central Time Zone (Zone 6), Monday through Friday. Customer Service For customers in the United States, Canada, Puerto Rico, and the US Virgin Islands, call 1-800-THE-1PWR (1-800-843-1797).

  • Page 17: Warranty Service

    For domestic warranty service, contact your Warranty Service Manager (WSM). For international warranty service, contact your sales representative. On-Line Power For Lucent Technologies users logging in from inside the corporate Systems Product firewall, the address of the “Power Systems On-Line Product Manuals” Manuals page is http://www.cic.lucent.com/lineage.html.

  • Page 19: Product Description

    • 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 20: Features

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 • All circuits for power control, alarms, voltage regulation, current limiting, restart, plant interface, and remote monitoring/control are mounted on replaceable circuit modules. Front access to the circuit modules simplifies replacement or adjustment, if required.

  • Page 21: Internal Selective High Voltage Shutdown (Ishvsd)

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Internal Selective The rectifier will sense a high voltage condition at its output terminals. High Voltage If delivering more than 10 percent of its rated output, 40 amperes, the Shutdown rectifier shuts down.

  • Page 22: Output Fuse And Fuse Alarm Switch

    The rectifier can be put into the Equalize mode in one of three ways. Boost • Receiving a signal from a Lucent Technologies Galaxy Controller or an MCS Controller equipped with Version 4.0 firmware • Putting the front panel switch on the digital meter board in the Equalize position •...

  • Page 23: Remote Shutdown

    Remote Shutdown The remote shutdown circuit permits the shutdown of a rectifier when the transfer (TR) signal is received from a Lucent Technologies controller. When the rectifier is used with a Galaxy or an MCS controller, spare rectifiers can be shut down via the TR signal, resulting in a significant energy saving.

  • Page 24: Alarms

    When a rectifier fails, an RFA issues to the controller and the interface Alarm (RFA) board and lights the front panel RFA LED. The rectifier transmits a signal to a Lucent Technologies controller, if present, indicating which one of the following has occurred: •...

  • Page 25: Charger Fail Alarm (Rfa/Cfa)

    An RFA/CFA alarm is transmitted to the interface board when the ac Alarm (RFA/CFA) input fails or the RFA relay operates. Manual Alarm A MAN alarm signals the interface board and a Lucent Technologies (MAN) controller, if present, when either the rectifier has been turned off or lost power.

  • Page 26: Front Panel Controls And Indicators

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Front Panel Figure 2-1 shows the control panel on front of the J85503C-3, 400-ampere rectifier. The following list describes the controls and Controls and indicators on the control panel. Bold letters indicate labels that appear Indicators on the control panel or inside the rectifier.

  • Page 27: Leds

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 LEDs The control panel on the J85503C-3 has the following LEDs: PHA: A red LED lights if the rectifier shuts down due to phase voltages falling below the normal operating range or total loss of a phase...

  • Page 28: Flt/Eq

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 FLT/EQ The Float/Equalize, FLT/EQ, switch allows the user to select either the float or equalize operating mode. This switch is disabled when the rectifier is shipped from the factory and must be enabled via S2.1 of the 330C interface board in order to provide the local equalize feature.

  • Page 29: Figure 2-2: J85503C-3 Rectifier With Door Open

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 CM4 Interface CM7 Transformer Board 330C Board 425C, D, E, or F CM1 Fuse Board 329A CB1 Circuit Breaker 450 Amp F7/SW1 Output Fuse and Alarm Switch 600 Amp CM3 Digital...

  • Page 30: Circuit Modules

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Circuit The rectifier's signal processing and control circuitry are located on replaceable circuit modules or packs. Circuit modules are plug-in boards Modules that are ordered separately. (See Section 3 for ordering information.) All modules are accessible by opening the rectifier door.

  • Page 31: Cm2 (208F Control Board)

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 CM2 (208F The CM2 circuit module (208F Control Board) contains the following Control Board) circuits: • Local power supplies • Restart feature • Feedback regulator • Unbalance shutdown • Walk-in feature •...

  • Page 32: Alarm And Control Flow

    Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Alarm and The J85503C-3 400-ampere rectifier is typically installed in a battery plant that is monitored and controlled by a Lucent Technologies Control Flow ® Lineage 2000 controller. The rectifier generates various monitoring and alarm signals and, in this type of installation, sends them to the controller for processing and subsequent action.

  • Page 33: Specifications

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Specifications Table 2-B provides electrical and physical characteristics for the J85503C-3 rectifier. Table 2-B: J85503C-3 Specifications Nominal Output Voltage 52 volts dc Operating Output Voltage 48 - 65 volts dc...
  • Page 34 ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Table 2-B: J85503C-3 Specifications Audible Noise < 65 dBA (Note 3) Earthquake rating Zone 4 per Bellcore TR-EOP-000063 Width 660.4 mm (26 inches) Height 1817.6 mm (71.56 inches) Depth 412.8 mm (16.25 inches) Weight 603.28 kg (1330 pounds)

  • Page 35: Engineering And Ordering

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Engineering and Ordering Rectifier This section discusses how to determine the minimum number of rectifiers required in a battery plant. Rectifiers of different output Sizing 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 400A, 60Hz Ferroresonant Rectifier J85503C-3 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.

  • Page 37: Sizing Example

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 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

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 abh. Therefore, at least one more 100A rectifier is required for a redundant system (four 100A rectifiers total). If one fails, 300A capacity remains, which is greater than the 210 abh.

  • Page 39: Table 3-A: J85503C-3 Ordering Information

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Table 3-A: J85503C-3 Ordering Information List Description Framework, assembly, wiring, and equipment for one rectifier, -48 volt dc 400 amperes output and 208 60Hz input. See Note 21. Framework, assembly, wiring, and equipment for one rectifier, -48 volt dc 400 amperes output and 240 60Hz input.

  • Page 40: Notes

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Notes 1. The 323D display meter board (CM3) features the following: • Power On/Off switch • Power On LED • PH LED • FA LED • RFA LED • LCA LED •...

  • Page 41: Table 3-B: Hardware

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 4. The following items are shipped with each rectifier: • mounting template • top mounting plates • ac input connectors • frame ground connector 5. The central office ground connector, the mounting anchor bolts (kit), and the dc output connectors are not provided with the rectifier.

  • Page 42: Table 3-C: Shims

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 9. Order a maximum of two List 20 side covers with each main list (1, 2, 3, or 4) for shipment in the container with the rectifier. Quantities greater than two will be shipped separately.

  • Page 43: Table 3-D: Circuit Packs In The J85503C-3 Rectifier

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 19. If local codes permit, you may connect an overhead raceway to the rectifier with flex steel conduit. Flex steel conduit kit (846860682) comes complete with 17 inches of 1-1/4 inch diameter flex steel conduit, two KS20785 L-39 connectors, and two KS20785 L-114 insulating bushings.

  • Page 44: Sample Order

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Sample Order This sample order is for a 400-ampere, 60 Hz rectifier with a 208 Vac input. It includes a filter for limiting the output noise to 32 dBrnc, a side cover, and a cable for connection to a Galaxy controller.

  • Page 45: Safety

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Safety Safety Please read and follow all safety precautions and warnings before installing, maintaining, or troubleshooting the 400-ampere rectifier. Precautions Always take precautions to protect personal safety as well as the equipment when working on power systems.
  • Page 46 ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 • AC voltage may be present even when the Power switch is in the Off position. • Be sure that the associated framework and cable rack are properly grounded, per local job instructions, before turning on any rectifier.

  • Page 47: Esd Precautions

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 • Assume all circuit packs containing electronic (solid-state) components can be damaged by ESD. Precautions • 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.

  • Page 48: Warning Statements And Safety Symbols

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Warning The symbols may sometimes be accompanied by some type of statement; e.g., “Hazardous voltage/energy inside. Risk of injury. This Statements unit must be accessed only by qualified personnel.” and Safety...
  • Page 49 ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 This symbol is used to identify the presence of a hot surface. It may also be accompanied by a statement explaining the hazard. A symbol like this with a lightning bolt through the hand also means that the part is or could be at hazardous voltage levels.

  • Page 51: Installation

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Installation Introduction This section outlines a sequence for installing the J85503C-3 rectifier in a battery plant, including the input and output wiring required. Tools You will need the following for installing rectifiers.

  • Page 52: Guidelines

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Guidelines Location of the J85503C-3 rectifier and associated equipment must conform to the specific plans of each plant installation. Physical, thermal, and electrical characteristics are listed in Section 2. Consider these characteristics when planning any installation that includes this rectifier.

  • Page 53: Heat Dissipation

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Hilti Rectifier Floor Anchor Hold Down Plate Figure 5-2: Floor Anchoring Heat Dissipation Heat dissipated to the environment is another factor in selecting a location for the J85503C-3 rectifier. The maximum heat exhausted by each rectifier is approximately 2200 watts or 7500 BTU/hr.

  • Page 54: Ac Input Power

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 AC Input Power The customer is responsible for providing ac power to the rectifier. Separate branch circuits must be provided to each rectifier to ensure the reliability of the system. A branch circuit consists of all the phase leads to a rectifier plus the ac equipment ground (AC EG).

  • Page 55: Table 5-A: Ac Input Requirements

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Table 5-A: AC Input Requirements Line Fuse # Of Input Input Wire, Conduit and Rating Wires/ Ac Ground, Nuts and Armored Knockout Volts/ or Input Gauge, and List and CO...

  • Page 56: Figure 5-3: Ac And Dc Termination Points

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Plant Control Cable with Tie Wrap and Bushing AC Input DC Output –V +V and –V Output Bus Bars CM7 Transformer Board CM1 Fuse Board Figure 5-3: AC and DC Termination Points...

  • Page 57: Dc Output Power

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 DC Output Power The J85503C-3 rectifier requires two dc output cables connected to each of the positive and negative output terminals. Figure 5-3 shows the output terminals. Figure 5-4 shows the opening in the top of the rectifier for the dc output cables.

  • Page 58: Figure 5-5: Dc Output Cables In Cable Rack

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Table 5-C provides widths for use with 350KCMIL cable. Table 5-C: Rack Widths for 350KCMIL Cables Rack Width Number of 400 Ampere Rectifiers Do not route other cable rack(s) above or through the area above the rectifiers or any other heat source.

  • Page 59: Handling Equipment

    Move the container with a forklift. Lucent Technologies recommends that you use four lifting eyebolts to facilitate placing the rectifier upright in the central office. The four holes accommodate customer supplied lifting eyebolts. The holes are 5/8-11 threaded.

  • Page 60: Installing Or Adding A Rectifier

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Installing or This procedure is appropriate for installing a rectifier in a new plant or adding a rectifier to an existing plant to increase capacity. The Adding a assumption here is that the rectifier is being added to an operating plant.

  • Page 61: Ac Power Cables

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 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 62: Dc Power Cables

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 DC Power Cables Plant bus bars carry 52 volts dc. Observe DANGER warnings in Section 4. Use Figures 5-3 and 5-4 as references for this section. 1. Turn circuit breaker, CB1 on the rectifier, off (down).

  • Page 63: Controller)

    Connect the CO ground to the nearest connection point on top of the rectifier (see Figure 5-4). Torque to 8 Nm (65 in-lb). Plant Control All cables connecting Lucent Technologies controllers to this rectifier, Cable Assembly have a 40-pin connector on the rectifier end, which terminates on (Lucent connector P5A of the CM4 interface board inside the rectifier door.

  • Page 64: Table 5-D: Controller Connectors

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 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)
  • Page 65 MCS controller. Therefore, notify alarm personnel that the unit is being installed. 7. If the rectifier is connected to a Lucent Technologies controller, verify that the rectifier S2.1 switch on the 330C interface board, CM4, is in the disable position. An MCS controller must have version 4 software to enable an equalize feature.
  • Page 66 10. Secure the control cable on the cable rack and disconnect terminal strips TB1, TB2, and TB3 from the CM4 interface board. Plant Control If a non-Lucent Technologies controller is used, the external alarm/ Cable Assembly control bay cable assembly is provided by the user. It connects to...

  • Page 67: Dip Switch Settings

    S1.1 through S1.5 and S1.8 ensure stable rectifier output voltage for Board (CM2) various Lucent Technologies rectifiers. For the J85503C-3, the switches are factory set for operation with a battery. If the rectifier is operated without a battery, change S1.1, S1.3, S1.7 and S1.8 to the settings indicated in the options column of Figure 5-7.

  • Page 68: Figure 5-7: Top Half Of Dip Switch Label

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 DIP Switch Settings Field Factory Option (Switch Settings) Board Switch Function Setting S1.1 Stability Network Batteryless: Set to 0 S1.2 Stability Network Bus Bar Plant: Set ot 1 S1.3 Stability Network Batteryless or Bus Bar Plant: Set to 1 S1.4...

  • Page 69: Figure 5-8: Bottom Half Of Dip Switch Label

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Figure 5-8: Bottom Half of DIP Switch Label Issue 10 July 2000 Installation 5 - 19...

  • Page 70: Digital Meter Board (Cm3)

    T1 and Underwriters Laboratory, Inc. (UL) requires the proper circuit module, wiring configuration, input, and product identifying labels for any unit. Therefore, only Lucent Technologies installation personnel are permitted to implement ac input conversions. 5 - 20 Installation...

  • Page 71: Initial Battery Charging

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Initial Battery Initial battery charging should be planned as part of the plant installation. If initial battery charging is desired, the rectifier should Charging be tested before following this procedure. (See Section 6.) The J85503C-3 rectifier is capable of supplying a new battery string with its initial charge.
  • Page 72 ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 7. Adjust the Float Adj potentiometer to obtain the desired initial charge voltage within the limits specified by the battery manufacturer. After completing the initial charge, 1. Turn the rectifier Power switch Off and the circuit breaker off (down).

  • Page 73: Testing

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Testing Overview This section provides 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

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Tools and Test You will need the following items for testing the rectifier. Equipment • DMM (Digital Multimeter) Fluke 8060A or equivalent meter having 0.02 percent accuracy on dc scale •...

  • Page 75: Test Load Connection

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Table 6-A: Test Set Connections Test Connection Figure Voltage Clip E13 on CM2 (positive side of capacitor C4) +27V Black E14 on CM2 (negative side of capacitor C4) Blue Cathode of diode CR56 on CM2...

  • Page 76: Initial Conditions For Testing Off Line

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Initial The following steps verify that the rectifier responds properly to plant controller commands and outputs proper signals in return. Referring to Conditions for Schematic Drawing SD83102-03 may be helpful while performing Testing Off these procedures.
  • Page 77 ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 c. Check for battery voltage between pins 27 and 2 of control cable connector J5A. The J5A connector is at the rectifier end of the plant control cable. Pin 27 should be positive with respect to pin 2.

  • Page 78: Figure 6-2: Cm1 Fuse Board With Clip Connections

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 White White Test Test Clip Clip Older Version CM1 Figure 6-2: CM1 Fuse Board With Clip Connections 6 - 6 Testing Issue 10 July 2000...

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

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 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 10 July 2000...

  • Page 80: Testing Off Line

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Testing Off The following tests involve use of the test load and a Battery Plant Simulator Test Set. Refer to “Tools and Test Equipment” for the Line procedures to construct a Battery Plant Simulator Test Set and to connect a test load.

  • Page 81: Rectifier Failure Alarm Test

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Rectifier Failure 1. Holding the insulation on a piece of bare wire or the end of a paper Alarm Test clip, insert the wire into the fuse holder of the F1 alarm fuse on CM1.

  • Page 82: Phase Failure Alarm (Pha) Test

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Phase Failure 1. Set the load to 200-240A, 50 to 60 percent of the rectifier's rated Alarm (PHA) Test amperage. 2. With the Power switch still On, turn off the ac service and note that the rectifier shuts down and that both the PWR and MAN lamps on the test set go off.

  • Page 83: Control (Tr) Test

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 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: Local Equalize Control Test

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 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: Meter Test

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Meter Test 1. Adjust the load so that the rectifier delivers approximately 200 amperes, 50% of its rated current capacity. 2. Connect a DMM, set on the dc millivolt scale, across test points E25 and E26 on the CM1 329A Fuse Board.

  • Page 86: Bringing A Rectifier On Line

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Bringing a The following steps bring the rectifier into service in preparation for testing on line. The term “on-line” means a battery string and/or office Rectifier On load is connected to the rectifier.

  • Page 87: Testing On Line

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 b. Hold the meter selector switch in the Rect V position, and use a small screwdriver to turn the Float Adj potentiometer clockwise until the digital meter reads approximately battery voltage, typically 52 volts.

  • Page 88: Rectifier Failure Alarm/Fuse Alarm Test

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Rectifier Failure Note: This procedure causes the rectifier to fail and issue alarms to the Alarm/Fuse Alarm plant controller. When the procedure is performed on line, sufficient Test rectifiers must be operating to assume the load of the rectifier being tested.

  • Page 89: Isolated Current Measuring (Vi) Test

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Isolated Current This procedure checks the isolated current measuring circuit (voltage Measuring (VI) proportional to current adjustment) on the CM2 control board. The ® Test procedure is required for plants using Galaxy controllers or Lineage...

  • Page 90: Phase Failure Test

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Phase Failure Test 1. With the Power switch still On, turn off the ac service and note that the rectifier shuts down. 2. Verify that no ac voltage is present on the input leads of the ac contactor K1.

  • Page 91: Control (Tr) Test

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Control (TR) Test 1. MCS or CCS: Place a ground on lug 29 of TB1 in the MCS or CCS controller to turn off rectifiers 1, 2, (9 and 10 with MCS or 3 and 4 with CCS) via the TR signal.

  • Page 92: Selective High Voltage Shutdown (Shvsd) And Restart

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Selective High Warning: This procedure is only safe if the using equipment can Voltage Shutdown tolerate the higher voltage. (SHVSD) and Restart 1. Using the Float Adj potentiometer, raise the rectifier voltage to the SHVSD level of the controller.

  • Page 93: Meter Test (On Line)

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Meter Test (On 1. Verify the conditions shown in Table 6-D. Line) Table 6-D: Rectifier Controls for Meter Test On Line Controls Position/Status Rectifier Power switch On (up) Rectifier must be connected to the battery.

  • Page 94: Adjust Rectifiers To Float Voltage

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Adjust Float voltage is the optimum voltage level at which a battery string gives maximum life and full capacity. This voltage depends on the type and Rectifiers to number of batteries in a plant.

  • Page 95: As A Group

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 As a Group If the load requirement is always greater than the capacity of the smallest rectifier, adjust the rectifiers to float voltage using the following procedure. Rectifiers must be on line with plant cables connected and REG fuses installed in the plant controller or remote bay.

  • Page 96: Enable And Test Load Share

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Enable and After adjusting the rectifiers to float voltage, enable the load share feature. Test Load Share 1. Make sure that each rectifier is carrying some load current, between 5% and 95% of full load.
  • Page 97 7. Reconnect NLS bus connections. 8. Repeat Steps 1 through 7 on each rectifier in the plant. Adjust non-Lucent Technologies according to their respective manuals. 9. After all adjustments have been made, turn on all rectifiers. Total load current should be shared in proportion to the full load rating of the largest rectifier.

  • Page 99: Troubleshooting And Adjustments

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Troubleshooting and Adjustments Introduction This section provides troubleshooting information and adjustment procedures for the J85503C-3 rectifier. Whenever working on or near electrically live equipment, observe all safety precautions (Section 4) and within each procedure.

  • Page 100: Remove Rectifier From Service

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Remove 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 Rectifier in Tables 7-A through Table 7-F. Then follow this procedure for From Service removing the rectifier from service before making the adjustments.

  • Page 101: Diagnostics

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Diagnostics Table 7-A lists possible problems, causes, and solutions that may occur with the rectifier subsystems. Refer to schematic drawing SD-83102-03 shipped with the J85503C-3 rectifier. Table 7-A: Troubleshooting Problem...
  • Page 102 ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Table 7-A: Troubleshooting Problem Probable Cause Probable Corrective Action 1. One of the phase 1. Check connections and voltage at voltages is too low under contactor. a load condition.‘ 5. Rectifier gives Phase 2.
  • Page 103 ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Table 7-A: Troubleshooting Problem Probable Cause Probable Corrective Action 1. Shorted or open triac. 1. Replace triacs. 8. Rectifier does not shut down at no load but may shut 2. Winding 13 or 14 of T1 2.

  • Page 104: Front Panel Conditions

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 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 CM4 Conditions interface board and the associated alarm status or control function. Table 7-F gives additional information concerning conditions and their causes on the J85503C-3 rectifier.
  • Page 105 ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 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; S2.2 of Power LED off CM4 has been enabled.

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

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Table 7-C: Alarms on TB1/TB2 of CM4 Alarm Status TB1, TB2 Interface Condition No alarm CB, CBR Open Output circuit breaker tripped CB, CBR Closed No alarm CB, CBR Open...

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

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 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...

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

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 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...

  • Page 109: Table 7-F: Additional Conditions/Indications On The J85503C-3

    GRD for HV, TR, or Battery plant regulation voltage, fused at 1-1/3 amperes and regulation ground can be applied when a Lucent Technologies controller is not R+, R- connected to the rectifier. In this situation, R+ and R- are used for external regulation sensing.

  • Page 110: Adjustments

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 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 400A, 60Hz Ferroresonant Rectifier J85503C-3 3. If the rectifier output voltage is less than the plant voltage and/or all rectifiers shut down, then use the following procedures. a. If the CM2 board has not been replaced, then replace it at this time.

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

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Table 7-G: Digital Meter Tolerance Switch Position Tolerance Rect V ± 0.1 volt Amps ± 2.5% of reading ± 2 amperes* *To compare, measure the shunt voltage. 1mV of shunt voltage indicates 10 amperes of output current.

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

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Digital Meter Potentiometer Figure 7-1: Adjustment Potentiometer on CM3 Issue 10 July 2000 Troubleshooting and Adjustments 7 - 15...

  • Page 114: Adjust Current Limit

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Adjust Current Off Line Adjustment: Use the Current Limit Test (Off Line) to verify Limit that the current limit circuit needs adjustment, before continuing with this procedure. In Steps 4 and 5 of the Current Limit Test, Section 6, if V...

  • Page 115: Restore Rectifier To Service

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 not operate properly, go to Section 6, Diagnostics and Troubleshooting. 8. Turn on DIP switch S3.7 on CM2, restart the rectifier, and adjust the load to at least 10 percent, 40A.

  • Page 116: Preventive Maintenance

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 2. If the rectifier voltage was NOT at the desired float voltage before it was turned off, rotate the Float Adj potentiometer fully counterclockwise. 3. At the ac service panel, install the ac fuses or turn the ac input circuit breaker On.

  • Page 117: Spare Parts And Replacement Procedures

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Spare Parts and Replacement Procedures Introduction This section provides information on spare parts for the J85503C-3 rectifier, including circuit modules, fuses, and handling precautions. This section further provides complete disassembly and removal procedures to facilitate replacing components.

  • Page 118: Circuit Modules

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Circuit Modules Ordering The circuit modules described in Section 2 can be ordered as spare parts kits (K1-4). Table 8-A shows the contents of the kits along with the part numbers to order modules individually.
  • Page 119 ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 packs in these classes are handled in the same manner, regardless of sensitivity. Factory packaging provides shielding in the rare instances when it is necessary. • Assume all circuit packs containing electronic (solid-state) components can be damaged by ESD.

  • Page 120: Fuses

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Fuses Table 8-B lists spare fuses for the J85503C-3 ferroresonant rectifier. Table 8-B: Spare Fuse Information Reference Part Number Rating Vendor Comcode Designation F1, F2, F3, F4, F5, F6 FLM-30...

  • Page 121: Electrical Parts

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Electrical Table 8-C lists spare electrical parts for the J85503C-3 ferroresonant rectifier. Parts Table 8-C: Spare Electrical Parts Reference Designation Comcode Part Number CR1 - CR4 Diodes 405934449 WP91147 L-8 BSR...

  • Page 122: Replacing Circuit Packs

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Replacing This section gives step-by-step instructions for replacing circuit modules CM1 through CM4 and CM7. Circuit Packs Warning: Minimize electrostatic discharge when handling circuit modules. Do not connect or disconnect circuit modules with voltages present or equipment damage may occur.

  • Page 123: Cm2 Control Board

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 CM2 Control Minimize electrostatic discharge when handling circuit modules. Board Observe all warnings in Section 4. 1. Turn the rectifier Power switch Off. 2. Turn the rectifier CB1 circuit breaker off (down).

  • Page 124: Cm3 Digital Meter Board

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 CM3 Digital Meter Minimize electrostatic discharge when handling circuit modules. Board Observe all warnings in Section 4. 1. Turn the rectifier Power switch Off. 2. Turn the rectifier CB1 circuit breaker off (down).

  • Page 125: Cm4 Interface Board

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 CM4 Interface Minimize electrostatic discharge when handling circuit modules. Board Observe all warnings in Section 4. 1. Turn the rectifier Power switch Off. 2. Turn the rectifier CB1 circuit breaker off (down).

  • Page 126: Cm7 Transformer Board

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 CM7 Transformer Minimize electrostatic discharge when handling circuit modules. Board Observe all warnings in Section 4. 1. Turn the rectifier Power switch Off. 2. Turn the rectifier CB1 circuit breaker off (down).

  • Page 127: Replacing Components

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Replacing Only disassembly procedures are given in this section. Reinstallation procedures are usually the exact reverse of removal procedures (i.e., Components follow the removal procedures in reverse order to reinstall the component).

  • Page 128: Torquing Requirements

    A dental-type mirror aids in viewing these capacitors' blowholes before disassembly. Lucent Technologies recommends that all dc capacitors in a rectifier be replaced whenever any one of them blows.

  • Page 129: Table 8-D: Minimum Torque For Electrical Connections

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Table 8-D: 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 130 ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 DC Capacitors are Behind Bus Bars DC Inductor L4 is Behind –V Output Bus Bar DC Inductor L3 is Behind CB1 Circuit Breaker F7/SW1 Output Fuse and Alarm Switch 600 Amp...

  • Page 131: Thyristors (Q1, Q2)

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Thyristors (Q1, Q2) 1. Remove the wires attached to the thyristor. Note their position for reinstallation. The T4013NK thyristors, originally in the rectifier, use a beryllium ceramic. If the case is cracked, the manufacturer (Semiconductors Ltd., A Ratheon Company) recommends the...

  • Page 132: Dc Capacitors (C7 Through C12)

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 DC Capacitors (C7 DANGER: DC capacitors may be charged even with power through C12) disconnected from the rectifier. If filter capacitor fuses have blown, capacitors will be charged. Always check all of the dc capacitor terminals (observe polarity) with a voltmeter before performing this procedure, and discharge capacitors safely, if necessary.

  • Page 133: F7 Fuse And Sw1 Switch Assembly

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 F7 Fuse and SW1 1. Open circuit breaker CB1. Switch Assembly 2. Place the rectifier on the OFF position. 3. Wait 5 minutes for dc output capacitors to discharge. 4. Open panel door and check voltage on dc capacitor.

  • Page 134: Contactor Relay (K1)

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 Contactor Relay 1. Remove all six of the heavy gauge (input and output) wires from (K1) 2. Remove the five smaller gauge wires from K1 and identify their position for reinstallation.

  • Page 135: Disconnecting A Rectifier

    3. Remove regulation fuses associated with the rectifier remote sense leads (usually located in the plant controller). 4. When a Lucent Technologies controller is used, disconnect the plant cable assembly from the rectifier CM4 interface board at connector P5A. The cable assembly must be removed from the cable tie anchors to permit its withdrawal through the conductor opening in the cabinet.
  • Page 136 ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 8. One at a time, disconnect the ac input conductors from their terminations, the ac equipment ground (green) conductor from the AC EG/FR GRD in the cabinet, and the central office (CO) ground interconnecting the top of the rectifiers.

  • Page 137: Product Warranty

    ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 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 138 ® Lucent Technologies Lineage 2000 400A, 60Hz Ferroresonant Rectifier J85503C-3 WARRANTY PERIOD Product Type New Product Repaired Product or Part Central Office Power 24 Months 6 Months Equipment *The Warranty Period for a repaired Product or part thereof is as listed...
  • Page 139 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. © 2000 Lucent Technologies All Rights Reserved Printed in U.S.A. Issue 10 July 2000 Product Warranty 9 - 3...

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