Lucent Technologies Lineage 2000 User manual

Lineage®2000
100-Ampere, 60-Hertz
Ferroresonant Rectifier
J85503A-1
Product Manual
Select Code 169-790-119
Comcode 107021818
Issue 6
October 1998
© 1998 Lucent Technologies

Product Manual
J85503A-1
Select Code 169-790-119
Comcode 107021818
Issue 6
October 1998
Lucent Technologies
Lineage®2000
100-Ampere, 60-Hertz
Ferroresonant Rectifier
Notice:
Every effort was made to ensure that the information in this
document was complete and accurate at the time of printing.
However, information is subject to change.
©1998 Lucent Technologies
All Rights Reserved
Printed in U.S.A.

Lucent Technologies Lineage®2000 100A Ferroresonant Rectifier J85503A-1
Issue 6 October 1998 Table of Contents - 1
Table of Contents
1 Introduction
General Information 1-1
Customer Training 1-1
Customer Service 1-1
Technical Support 1-2
Product Repair and Return 1-2
Warranty Service 1-2
2 Product Description
Overview 2-1
Ferroresonant Technology 2-1
Standard Features 2-2
Additional Features 2-4
Circuit Modules 2-5
Front Panel Controls and Indicators 2-10
Alarm and Control Flow 2-12
Physical, Thermal, and Electrical Specifications 2-13
3 Ordering Information
Options 3-1
4Safety
Admonishments 4-1
Safety Statements 4-1
Precautions 4-2
Warning Statements and Safety Symbols 4-4
5 Installation
Introduction 5-1
Safety 5-1
Preparing for Installation 5-1
Handling Equipment 5-1
Bay Mounting 5-2

Lucent Technologies Lineage®2000 100A Ferroresonant Rectifier J85503A-1
2 - Table of Contents Issue 6 October 1998
Heat Dissipation 5-2
AC Input Power 5-2
DC Output Power 5-4
Installation Tools 5-4
Unpacking 5-5
Installing or Adding a Rectifier 5-10
Install AC Power Cables 5-10
Install DC Power Cables 5-11
Install Plant Control Cable Assembly for a
Lucent Technologies Controller 5-12
Converting AC Voltage 5-14
Converting DC Output Polarity 5-15
Negative Output (Positive Ground) to Positive
Output (Negative Ground) 5-16
Positive Output (Negative Ground) to Negative
Output (Positive Ground) 5-16
Initial Battery Charging (Optional) 5-17
6 Testing
Introduction 6-1
Precautions 6-1
Tools and Test Equipment 6-2
Battery Plant Simulator Test Set 6-2
Test Load Connection 6-2
Initial Conditions for Testing Off Line 6-4
Testing Off Line 6-6
Startup 6-6
Regulation (NL/FL) Test (Off Line) 6-7
Rectifier Failure Alarm/Fuse Alarm Test (Off Line) 6-7
Current Limit Test (Off Line) 6-7
Phase Failure Test (Off Line) 6-8
Backup High Voltage Shutdown (HVSD) Test
(Off Line) 6-9
Control (TR) Test 6-9
Selective High Voltage Shutdown (SHVSD) and
Restart 6-10
Meter Calibration Test (Off Line) 6-10
Off-Line Test Completion 6-10
Bringing Rectifier On Line 6-11
Testing On Line 6-13
Regulation (NL/FL) Test (On Line) 6-13
Rectifier Failure Alarm/Fuse Alarm Test (On Line) 6-14
Current Limit Test (On Line) 6-15
Isolated Current Measuring (VI) Test (MCS or
Galaxy Controller) 6-15

Lucent Technologies Lineage®2000 100A Ferroresonant Rectifier J85503A-1
Issue 6 October 1998 Table of Contents - 3
Phase Failure Test (On Line) 6-17
Backup High Voltage Shutdown (HVSD) Test
(On Line) 6-17
Meter Calibration Test (On Line) 6-18
Adjust Rectifiers to Float Voltage 6-19
Adjust Rectifiers Individually 6-19
Adjust Rectifiers as a Group 6-20
7 Troubleshooting and
Adjustments
Introduction 7 - 1
Remove Rectifier from Service 7 - 1
Diagnostics and Troubleshooting 7 - 2
Adjustments 7 - 5
Clear Rectifier Failure Alarm (RFA) 7 - 5
Calibrate CM3 Digital Meter 7 - 6
Adjust Isolated Current Measuring Circuit (VI) 7 - 8
Adjust Current Limit 7 - 10
Restore Rectifier to Service 7 - 10
8 Spare Parts and Replacement Procedures
Ordering Circuit Modules 8 - 1
Handling Circuit Modules 8 - 1
Electrostatic Discharge 8 - 2
Modifying the CM1 Option Board 8 - 3
Spare Fuses 8 - 4
Replacing Circuit Modules 8 - 4
Replace CM1 Option Board 8 - 4
Replace CM2 Control Board 8 - 5
Replace CM3 Digital Meter Board 8 - 7
General Considerations for Replacing Components 8 - 8
Replacing Components 8 - 12
Output Volts Adjustment Potentiometer 8 - 12
DC Output Circuit Breaker, CBA1 and CBA1 Bracket 8-12
Protective Shield 8 - 12
Transformer (T3) 8 - 13
K1 Contactor Relay 8 - 13
K2 or K3 Relay (Contactors) 8 - 13
AC Inductors (L1 or L2) 8 - 13
CA1 Board (Snubber Network) 8 - 14
Thyristors (Q1 or Q2) 8 - 14
AC Capacitors (C5 or C7) 8 - 14
Diode Heat Sink Assembly 8 - 15

Lucent Technologies Lineage®2000 100A Ferroresonant Rectifier J85503A-1
4 - Table of Contents Issue 6 October 1998
DC Inductors (L3 or L4) 8 - 15
DC Capacitors (C1, C2, or C3/C4) 8 - 16
Main Transformers (T1 or T2) 8 - 17
Rectifier Diode Test and/or Replacement 8 - 17
Heat Shrink Removal 8 - 19
Disconnecting a Rectifier 8 - 19
9 Product Warranty

Lucent Technologies Lineage®2000 100A Ferroresonant Rectifier J85503A-1
Issue 6 October 1998 List of Figures - 1
List of Figures
Figure 2-1: Location of Circuit Modules 2-6
Figure 2-2: CM1 Option Board Showing White Test
Clip Connection and Removable Straps K and M 2-7
Figure 2-3: CM2 Control Board Showing Test Clip
Connections and Other Component Details 2-8
Figure 2-4: Partial Sketch of CM3 Digital Meter Board 2-9
Figure 2-5: Control Panel on the J85503A-1 Rectifier 2-10
Figure 2-6: Signal Flow between Rectifier and Lucent
Technologies Controller 2-13
Figure 5-1: Four Views of the J85503A-1 Rectifier 5-6
Figure 5-2: Front View of J85503A-1 Rectifier with Door
Open 5-7
Figure 5-3: AC Input Components Mounted on the
Upper Left Side of the J85503A-1 Rectifier Behind
the Protective Shield 5-8
Figure 5-4: Output Polarity Conversion and
Component Detail on Bus Bar Assembly 5-9
Figure 6-1: Battery Plant Simulator Test Set 6-3

Lucent Technologies Lineage®2000 100A Ferroresonant Rectifier J85503A-1
Issue 6 October 1998 List of Tables - 1
List of Tables
Table 2-A: Digital Meter Accuracy 2-11
Table 2-B: Physical and Thermal Specifications
of the J85503A-1 Rectifier 2-13
Table 2-C: Input Specifications for the J85503A-1
Rectifier 2-14
Table 2-D: Output Specifications for the J85503A-1
Rectifier 2-14
Table 3-A: Equipment Lists for the J85503A-1
Rectifier 3-2
Table 5-A: AC Input Requirements 5-3
Table 5-B: DC Output Requirements 5-4
Table 5-C: AC Voltage Conversion 5-14
Table 5-D: Rectifier Control Settings
for Initial Battery Charge 5-18
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 6-12
Table 7-A: Troubleshooting 7 - 3
Table 7-B: Control Settings Prior to Restoring
Rectifier to Service 7 - 10
Table 8-A: Spare Circuit Module Kit Number
H569-358 L8 8 - 1
Table 8-B: Modifications for the CM1 Board 8 - 3
Table 8-C: Spare Fuse Information 8 - 4

Lucent Technologies Lineage®2000 100A Ferroresonant Rectifier J85503A-1
2 - List of Tables Issue 6 October 1998
Table 8-D: Torque and Minimum Yield Strength for
Mechanical Connections (Using Hex Head Cap
Screws) 8 - 10
Table 8-E: Minimum Torque for all Electrical
Connections 8 - 11

Lucent Technologies Lineage®2000 100A Ferroresonant Rectifier J85503A-1
Issue 6 October 1998 Introduction 1 - 1
1 Introduction
General
Information This product manual (Select Code 169-790-119) describes the
J85503A-1 100-ampere ferroresonant rectifier. This rectifier
converts commercial 208V, 240V, or 480V ac input power at 60
hertz into ±24 or -48-volt dc output for telecommunications
loads.
Since central offices usually obtain their electrical power from
potentially noisy commercial ac lines (and emergency
generators during commercial power failures), and since high
qualitydcpower is requiredinorderfor theequipment to operate
correctly, the J85503A-1 rectifier is an excellent choice for any
telecommunications battery plant.
The J85503A-1 rectifier can be used with a Lineage®2000
battery plant, older vintage Lucent Technologies battery plants,
or any commercialbattery plant. With certainoptions, it canalso
operate off battery.
Customer
Training Lucent Technologies offers customer training on many Power
Systems products. For information call 1-972-284-2163. This
numberis answeredfrom 8:00a.m.until4:30p.m.,CentralTime
Zone (Zone 6), Monday through Friday.
Customer
Service Forcustomers in the United States, Canada, Puerto Rico, andthe
US Virgin Islands, call 1-800-THE-1PWR (1-800-843-1797).
Services provided through this contact include initiating the
spare parts procurement process for out of service emergencies,
ordering Lucent Technologies documents, and providing other
product and service information.

Lucent Technologies Lineage®2000 100A Ferroresonant Rectifier J85503A-1
1 - 2 Introduction Issue 6 October 1998
For other customers worldwide, call 001-972-840-0382. This
numberis answeredfrom 8:00a.m.until4:30p.m.,CentralTime
Zone (Zone 6), Monday through Friday.
Technical
Support Technical support for Lucent Technologies customers is
available around the world during the normal product warranty
period and also while specific contractual agreements extend
this service.
For customers in the United States,Canada, Puerto Rico, and the
US Virgin Islands, call 1-800-CAL-RTAC (1-800-225-7822) to
contact a product specialist to answer your technical questions
and assist in troubleshooting problems.
For other customers worldwide, contact your local field support
center or your sales representative to discuss your specific needs.
Product Repair
and Return Repair and return service is provided for Lucent Technologies
customers around the world. For customers in the United States,
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 Warranty Service
Manager (WSM). The WSM serves specific customer-groups,
who have taken ownership of the product. For product
conformance issues prior to customer ownership, contact your
local customer service.

Lucent Technologies Lineage®2000 100A Ferroresonant Rectifier J85503A-1
Issue 6 October 1998 Product Description 2 - 1
2 Product Description
Overview 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. In the event of commercial power
failure, the batteries supply the required dc power to the
telephone equipment. This transition needs no switching
because of the parallel connection of the rectifiers and batteries.
Ferroresonant
Technology The J85503A-1 rectifier isa member of theLucent Technologies
family of Lineage®2000 rectifiers. Like all the rectifiers in the
family, it represents a significant advancement in efficiency,
space savings, and serviceability. The rectifier uses the
electronically controlled, closed-loop, ferroresonant technology
developed by Lucent Technologies. This technology provides
excellent output regulation in spite of variations in the incoming
commercial line voltageand frequency, and theoutgoing current
or “load.”
Highlights of ferroresonant technology include:
• Eliminates internal switching transients typically associated
with other technologies.
• Reduces noise and transients from commercial lines. As the
interface between commercial power and telephone
equipment, the ferroresonant rectifier significantly
attenuates noise and lightning surges from commercial
lines.

Lucent Technologies Lineage®2000 100A Ferroresonant Rectifier J85503A-1
2 - 2 Product Description Issue 6 October 1998
• Introduces far less noise into closely coupled telephone
lines than other technologies due to lower harmonic
components in the input current waveshape.
• Provides highly efficient power conversion.
• Ferroresonant technology and the rectifier's physical design
features combine to provide reliable service, easy
maintenance, and greater cost-effectiveness on a
dollars-per-output-ampere basis.
• All components in the rectifier meet Lucent Technologies's
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.
• 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. Standardized
modules simplify parts inventory, resulting in lower costs
and better equipment availability.
• The rectifier is contemporary in appearance with a blue
cabinet, white front door, and flat-black control panel.
• The rectifier can be used in a plant with or without batteries
and with or without a controller. One of three input voltages
and two output voltages may be ordered. Optional noise
filtering can be added. Each option requires different
equipment, which Lucent Technologies has organized into
numbered lists to simplify ordering. (See “Options.”)
Standard
Features The J85503A-1, 100-ampere rectifier has the following standard
features.
•Output current “walk-in”: This circuit controls the time
required for the rectifier to reach its rated output voltage
after it is turned on. Initially, the output voltage is about 80
percent of normal, and gradually increases to the required
value in approximately 10 seconds. As the output voltage
“walks in,” so does output current. This feature minimizes

Lucent Technologies Lineage®2000 100A Ferroresonant Rectifier J85503A-1
Issue 6 October 1998 Product Description 2 - 3
the starting surge on the customer's power source and is
especially important with amore limited power source, such
as an emergency generator set.
•External selective high voltage shutdown: If the battery
voltage goes too high, the controller signals all of the
connected rectifiers. This signal causes the rectifier(s) that
are delivering at least 10 percent of rated output current to
shut down. The remaining rectifiers continue to operate.
•Backup high voltage shutdown: This circuit prevents
damage to the rectifier in the event of a high battery voltage
condition. Each rectifier senses its own output voltage and
shuts down when this voltage exceeds a preset value. This
circuit operates if the external selective high voltage
shutdown (SHVSD) fails to operate. This backup high
voltage shutdown (BUHVSD) operates from an
independent voltage source in accordance with Bellcore
standards.
•Output current limit: The rectifier provides a constant
output voltage up to its rated output current, at which point
it provides constant current. When the output current tends
to increase above the rated output, the current limit circuit
overrides the voltage regulating signal and limits the output
current of the rectifier.
•Back-up current limit: In addition to the output current
limit, the ferroresonant transformers self-limit current
output between 125-175 percent of full load, or 125-175
amperes.
•Isolated output current indication: When used with a
Microprocessor Controlled System (MCS) controller, the
rectifier provides an isolated 2- to 10-volt signal,
corresponding to a range of no-load to 125 percent of rated
output load, which is used to indicate the rectifier drain on
the controller.
•Safety interlocks: A series-loop circuit electrically
interconnects the control circuit modules and prevents
rectifier operation if an open circuit is detected.
•Output capacitor fusing: A combination of a main fuse
and alarm fuse protects each output filter capacitor.

Lucent Technologies Lineage®2000 100A Ferroresonant Rectifier J85503A-1
2 - 4 Product Description Issue 6 October 1998
•Fuse alarm circuit: The low-power control functions shut
down the rectifier if a fuse alarm (FA) occurs. One fuse
alarm protects each of the regulation leads. When any fuse
alarm occurs, a Rectifier Failure Alarm (RFA) LED lights
on the front panel and an RFA signal is generated.
•Unbalance alarm: An alarm occurs and the rectifier shuts
down if severe unbalance develops between the
ferroresonant transformers. The rectifier-fail circuit delivers
this alarm after a 3-second delay to allow transient
disturbances to subside, such as those occurring during
initial turn-on.
•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 most controllers. If a rectifier
shuts down due to the external selective high voltage
shutdown, most controllers try at least once to restart it
automatically.
•Remote sense leads: These leads permit remote regulation
of the rectifier.
•TR: This signal (Transfer Rectifier) remotely shuts down
the rectifier.
Additional
Features Dynamic Response
For any step load change of10 to90 percent, or 90 to 10 percent,
or a step change of 10 percent of the input voltage, the sense
point voltage remains within 5 percent of its setting, and returns
and remains inthe 1/2 percent band within 300milliseconds. For
batteryless operation, 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, the sense point voltage remains within 10 percent
of its setting, and returns and remains in the 2 percent band
within 500 milliseconds.
Electromagnetic Compatibility (EMC)
The J85503A-1 rectifier complies with FCC Docket 20780, Part
15, Subpart J, as required for Class A applications. In addition,

Lucent Technologies Lineage®2000 100A Ferroresonant Rectifier J85503A-1
Issue 6 October 1998 Product Description 2 - 5
the rectifier meets all specified operating characteristics 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 boards thatcan beordered. All of the circuit modules are
accessible by opening the rectifier's front panel door. Figure 2-1
shows the location of the circuit modules and other features of
the rectifier. Figures 2-2, 2-3, and 2-4 show the CM1, CM2, and
CM3 board layouts, respectively. A description of each module
follows.
• The CM1 circuit module (ED-83159-30 Group 1, A)
contains circuitry common to several rectifiers in the
Lineage®2000 rectifier family. The factory provides the
options required for each application by removing certain
wire straps and resistors from the CM1 board. The factory
modification of CM1 is complete when the board is
installed in the rectifier. However, ordered spare or
replacement CM1 boards have not been modified. The
customer must make this modification. See Section 8 for
information on parts to be removed and retained.
• The CM2 control circuit module (208A) contains the
following circuits:
Local power supplies
Feedback regulator
Walk-in feature
Backup high voltage shutdown
Rectifier portion of external selective high voltage
shutdown
Remote shutdown
Manual on/off relay
Phase monitor
Restart feature
Unbalance shutdown
Fuse alarm
Electronic current limit
Output current isolation circuit
• The CM3 circuit module (207A) controls the digital
Output meter on the rectifier control panel. The meter
displays the rectifier's output current, voltage, or the plant

Lucent Technologies Lineage®2000 100A Ferroresonant Rectifier J85503A-1
2 - 6 Product Description Issue 6 October 1998
battery voltage depending on the three-position selector
switch (see “Front Panel Controls and Indicators”).
• The CA1 circuit module (ED83162-30 Group 1) contains a
triac/thyristor snubber network. Refer to schematic drawing
SD-82605-01 for further information.
Caution
Circuit modules must not be connected or disconnected
with voltages present or equipment damage may occur. See
“Replacing Circuit Modules” in Section 8, Spare Parts and
Replacement Procedures, for how to replace circuit
modules.
Figure 2-1: Location of Circuit Modules
CM3 Digital Meter Board
(if equipped) CM1 Option Board
CM2 Control Board
CA1 Snubber Board