Lucent Technologies SR Series User manual

Product Manual
J85702E-1
169-790-126
Comcode 107187411
Issue 5
October 1998
Lucent Technologies
Lineage®2000
150-Ampere, -48-Volt
SR Series 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 150A -48V SR Series Rectifier
Issue 5 October 1998 Table of Contents - 1
Table of Contents
1 Introduction
General Information 1 - 1
Customer Service 1 - 2
Technical Support 1 - 2
Product Repair and Return 1 - 2
Documentation References 1 - 2
2 Product Description
Electrical Specifications 2 - 1
Physical Specifications 2 - 2
SR Series Rectifier Technology 2 - 3
Benefits 2 - 3
Features 2 - 4
Typical Battery Plant 2 - 9
Battery Plant Subsystems 2 - 9
3 Engineering and Ordering
Engineering Installation Preparations 3 - 1
AC Power Service 3 - 1
DC Power Output Connection 3 - 2
Rectifier and Controller Interface Cables 3 - 2
Site Preparation 3 - 2
Shipping and Receiving Rectifiers 3 - 3
Additions to Existing Plants 3 - 3
Heat Dissipated to the Environment 3 - 3
Rectifier Control Signals 3 - 3
Ordering Information 3 - 8
Spare Parts 3 - 9
4Safety
Safety Statements 4 - 1
Warning Statements and Safety Symbols 4 - 2
Precautions 4 - 3

Lucent Technologies Lineage®2000 150A -48V SR Series Rectifier
2 - Table of Contents Issue 5 October 1998
5 Installation
Introduction 5 - 1
Safety 5 - 1
Installation Tools and Test Equipment 5 - 1
Unpacking and Handling 5 - 2
Wiring AC Service into an RHA in a New or Operating
Plant 5 - 2
Wiring the Terminal Block for 4 Wire with Ground 5 - 4
Wiring the Terminal Block for 3 Wire with Ground 5 - 4
Adding a PMA to an RHA in a New or Operating Plant 5 - 4
Disconnecting a PMA from an Operating Plant 5 - 5
Initial Start-Up and Check 5 - 5
Introduction 5 - 5
Electrical Testing for Rectifiers 5 - 5
Selection of Internal Selective High Voltage Shutdown
Level 5 - 6
Enabling/Disabling of Load Sharing 5 - 7
Selection of Back-Up High Voltage Shutdown Level 5 - 7
Selection of Shutdown Mode 5 - 7
Initial Power Up and Adjustment 5 - 7
6 Operating Controls
and Displays
General 6 - 1
Specifics 6 - 1
VOLTS ADJ - BST (1) 6 - 1
V-PLANT Test Jacks (2, 3) 6 - 1
V-RECT Test Jacks (4, 5) 6 - 1
VOLTS ADJ - FLT (6) 6 - 1
AMP/VOLT Switch (7) 6 - 2
OUTPUT CURRENT/VOLTAGE Meter (8) 6 - 2
RECT TEST Switch (9) 6 - 2
POWER ON (10) 6 - 2
POWER ON/STBY Switch (11) 6 - 2
STBY (12) 6 - 2
EQUALIZE CURRENT ADJ (13) 6 - 2
CB OFF (14) 6 - 3
TA (15) 6 - 3
EQL (16) 6 - 3
BST (17) 6 - 3
RFA (18) 6 - 3
Connectors and Controls 6 - 4

Lucent Technologies Lineage®2000 150A -48V SR Series Rectifier
Issue 5 October 1998 Table of Contents - 3
7 Maintenance
Introduction 7 - 1
Fan Maintenance 7 - 1
Performance Testing 7 - 2
No Load Testing (NL) 7 - 2
Full Load Testing (FL) 7 - 2
Lamp Test 7 - 3
Diagnostics 7 - 3
Introduction 7 - 3
Required Test Equipment 7 - 3
Repair 7 - 9
Replacement of Fan 7 - 9
Replacement of PMA 7 - 9
Replacing the BGB1 Display and Control Board 7 - 9
8 Product Warranty

Lucent Technologies Lineage®2000 150A -48V SR Series Rectifier
Issue 5 October 1998 List of Figures - 1
List of Figures
Figure 1-1: 150A, -48V SR Rectifier 1 - 4
Figure 1-2: PMAs Installed in a Rectifier Housing
Assembly 1 - 5
Figure 1-3: Rear View of the RHA 1 - 6
Figure 2-1: Block Diagram of Typical Battery Plant 2 - 10
Figure 3-1: Typical Signal Flow Between Rectifier and
Controller 3 - 4
Figure 5-1: RHA Wiring Instructions 5 - 3
Figure 6-1: Rectifier Location of Controls, Switches,
Indicators and Display 6 - 4
Figure 6-2: PMA Location of Controls and Connectors 6 - 6
Figure 7-1A: Troubleshooting Flowchart 7 - 4
Figure 7-1B: Troubleshooting Flowchart 7 - 5
Figure 7-1C: Troubleshooting Flowchart 7 - 6
Figure 7-1D: Troubleshooting Flowchart 7 - 7
Figure 7-2: Fan Replacement 7 - 8

Lucent Technologies Lineage®2000 150A -48V SR Series Rectifier
Issue 5 October 1998 List of Tables - 1
List of Tables
Table 2-A: 150A, -48V Rectifier Electrical Specifications 2 - 1
Table 2-B: J85702E-1 Physical Specifications 2 - 3
Table 3-A: AC Input 3 - 2
Table 3-B: Rectifier Control Signals 3 - 5
Table 3-C: RHA Ordering Information 3 - 9
Table 3-D: PMA Ordering Information 3 - 9
Table 3-E: Spare Parts 3 - 10
Table 5-A: Rectifier Dip Switch Settings 5 - 6

Lucent Technologies Lineage®2000 150A -48V SR Series Rectifier
Issue 5 October 1998 Introduction 1 - 1
1 Introduction
General
Information This product manual (Select Code 169-790-126) describes
Lucent Technologies’ 150-ampere, -48-volt SR series rectifier,
J85702E-1, which is shown in Figure 1-1.
The SR series rectifiers are designed specifically for any
installationwheresmallsize,low weight,andease ofinstallation
and maintenance are of overriding importance. The 150-ampere,
-48-volt rectifier comprises three power module assemblies
(PMAs) assembled in arectifier housing assembly (RHA) where
all the interconnections between the controller, rectifier, and
distributionare completed. (See Figure 1-2.)Connections for the
DC output and control cable are made on the rear of the RHA.
(See Figure 1-3.) The plug-in design of the PMAs permits easy
growth and maintenance without interrupting service.
Additionally, a near unity power factor design results in lower
installation and operating costs. These features, coupled with
dramatic size and weightreduction, make the SRseries rectifiers
the ideal choice for power applications in the 600-1800 ampere
range. The SR series rectifiers can be operated with or without
controllers or batteries, providing the user with maximum
applications flexibility.
A complete description of the J85702E-1 rectifier is included in
Section 2 of this product manual. Other sections give detailed
information onengineering and ordering, installation,operation,
and maintenance.

Lucent Technologies Lineage®2000 150A -48V SR Series Rectifier
1 - 2 Introduction Issue 5 October 1998
Customer
Service For customers in the United States, Puerto Rico, the U.S. Virgin
Islands, and Canada, call 1-800-THE-1PWR (1-800-843-1797).
Customer service specialists at thisnumber can initiate the spare
parts procurement process, order Lucent Technologies
documents, and provide other product and service information.
Other customers world-wide may call 001-972-840-0382.
This number is answered from 8:00 am until 4:30 pm,
Central Time (Zone 6), Monday through Friday.
Technical
Support Technical support for Lucent Technologies equipment is
available to customers around the world.
Technical support for Lucent Technology customers is available
around the world during thenormal product warranty period and
also while specific contractual arrngements extend this service.
For customers in the United States, Puerto Rico, the U.S. Virgin
Islands, and Canada, call our Technical Support telephone
number 1-800-CAL RTAC (1-800-225-7822) to contact a
Product Specialist to answer your technical questions and assist
in troubleshooting problems. For out-of-hours emergencies, the
800 number will put you in touch with a Regional Technical
Assistance Center Engineer via our 24 hour a day, 7 day per
week Help Desk.
For other customers world-wide, contact your local field support
center or your sales representative to discuss your specific needs.
Product Repair
and Return Repair and return service for Lucent Technologies equipment is
available to customers around the world. For customers in the
United States, Puerto Rico, the U.S. Virgin Islands, and Canada,
call 1-800-255-1402 for information on returning products for
repair.
For other customers world-wide, contact your local field support
center or your sales representative to discuss your specific needs.
Documentation
References 150-Ampere, -48-Volt Rectifier
Assembly and Ordering Drawing J85702E-1

Lucent Technologies Lineage®2000 150A -48V SR Series Rectifier
Issue 5 October 1998 Introduction 1 - 3
Wiring Diagram T-83185-30
Schematic Drawing SD-83185-01
Product Manual Select Code 167-790-126
J85500S-1 Battery Plant
Assembly and Ordering Drawing J85500S-1
Wiring Diagram T-83214-30
Schematic Drawing SD-83214-01
Product Manual Select Code 167-790-061
J85500T-1 Battery Plant
Assembly and Ordering Drawing J85500T-1
Wiring Diagram T-83197-30
Schematic Drawing SD-83197-01
Product Manual Select Code 167-790-059

Lucent Technologies Lineage®2000 150A -48V SR Series Rectifier
1 - 4 Introduction Issue 5 October 1998
Figure 1-1: 150A, -48V SR Rectifier
CURRENT
OUTPUT CURRENT/RECTIFIER VOLTAGE
CONTAINS STATIC SENSITIVE DEVICES
USE ESD WRIST STRAP
RECT
TEST
FL
POWER
ON FL ON
STBY
STBY
NL
NL
EQUALIZE
CURRENT
ADJUST
SR150/-48V
LAMP
TEST
EQL
CB OFF
BST
BST
VOLTS ADJ
RECT
PLANT
V
FLT RFA TA
VOLTAGE
Lucent
AC Channels
AC Channels
Mounting Slots

Lucent Technologies Lineage®2000 150A -48V SR Series Rectifier
Issue 5 October 1998 Introduction 1 - 5
Figure 1-2: PMAs Installed in a Rectifier Housing Assembly
Dip Switch
SW100

Lucent Technologies Lineage®2000 150A -48V SR Series Rectifier
1 - 6 Introduction Issue 5 October 1998
Figure 1-3: Rear View of the RHA
INTENDED FOE USE IN A CONTROLLED ENVIRONMENT
UTILISER SEULEMENT DANS UNE ATMSPHERE CONTROLEE
LR54761
Lucent
Negative Output Positive Output
Controller Connector
(P790.4)

Lucent Technologies Lineage®2000 150A -48V SR Series Rectifier
Issue 5 October 1998 Product Description 2 - 1
2 Product Description
Electrical
Specifications Table 2-A: 150A, -48V Rectifier Electrical Specifications
Nominal Output Voltage -48 volts dc
Operating Voltage
Range (float/boost) -48 to -58 volts dc
Operating Voltage
Range (equalize) -48 to -65 volts dc
Output Current 0 to 150 amperes over the operating voltage range (float/
boost)
Nominal Input Voltages 208 - 240 volts ac, three phase
Input Voltage Range 176 - 264 volts ac
Input Frequency Range 47 - 63 Hz (50/60 hertz nominal)
Input Current@ full load
and 54.5 volts out
28 amperes @ 208 volts ac (phase
to phase)
16 amperes @ 220 volts ac (phase
to neutral)
Efficiency 85% typical
Power Factor 0.97 typical
Regulation +0.5% of output voltage
AC Ripple 250 millivolts peak to peak

Lucent Technologies Lineage®2000 150A -48V SR Series Rectifier
2 - 2 Product Description Issue 5 October 1998
Data specified for nominal input voltages, frequencies, and rate outputs
of 55.5 volts dc and 150 amperes.
Physical
Specifications The SR 150A, -48V rectifier is a bolt-in unit that houses three
power module assemblies (PMAs). The dimensions and weight
of the power module assembly and rectifier housing assembly
(RHA) are given in Table 2-B.
Output Noise 22 dBrnc with battery 26 dBrnc without battery
2mV, psophometric
Load Share Accuracy +15 amperes
Heat Dissipation 1353 watts, 4620 Btu/hr
Temperature 32° F to 122° F (0° C to 50° C)
Altitude
-200 to 13,000 feet (-61 to 3962
meters). Derate maximum
temperature by 3.6 degrees
Fahrenheit per 1000 feet above
5000 feet. Derate maximum
temperature by 0.656 degrees
Celsius per 100 meters above 1524
meters.
Humidity 10 - 95% non-condensing
Audible Noise 66.5 dBA, 2 feet (0.6 meters) from
rectifier
Electrostatic Discharge IEC 801-2 Level 5 (15kV)
Radiated and Conducted
Emissions EN55022 Class A, FCC Level A
Electromagnetic
Immunity 10V/m over the range of 20 to 2000 MHz
Table 2-A: 150A, -48V Rectifier Electrical Specifications

Lucent Technologies Lineage®2000 150A -48V SR Series Rectifier
Issue 5 October 1998 Product Description 2 - 3
SR Series
Rectifier
Technology
The Lucent Technologies family of SR series rectifiers
represents a significant advancement in space utilization, ease of
installation, and weight reduction over previously available
products.
The 150-ampere, -48-volt rectifier uses switchmode technology
to convert commercial 50/60 Hz ac input power into highly
regulated and filtered, low-noise, -48-volt dc output power for
telecommunications equipment loads. Since telecommunication
systems typically obtain their primary power from potentially
noisy commercial ac lines (and emergency alternators during
commercial power failures) and since high-quality dc power is
required in order for the equipment to function correctly, the
150-ampere, -48-volt rectifier is an excellent choice for a
telecommunications power plant. The rectifier provides
excellent output regulation over a wide range of load currents,
input voltages, and input frequencies. Processing the power at
higher frequencies allows for substantial reduction in the size
and weight of the energy storage elements.
Benefits Improved Space Efficiency: A unique Lucent Technologies
Bell Laboratories design, which incorporates 70 kHz switching
frequency,hasresulted inrectifierswhichoccupyapproximately
one-third of the space and weigh one-seventh as much as
comparable ferroresonant rectifiers. This 90-pound switchmode
rectifier design provides excellent output regulation over a wide
range of load currents, input voltages, and input frequencies.
Processing thepower athigherfrequencies allowsfor substantial
Table 2-B: J85702E-1 Physical Specifications
Power Module Assembly
Height 11.5 inches (292 millimeters)
Width 7.00 inches (178 millimeters)
Depth 15.25 inches (387 millimeters)
Weight 18 pounds (8.1 kilograms)
Rectifier Housing Assembly
Height 12.3 inches (312 millimeters)
Width 21.5 inches (546 millimeters)
Depth 16.10 inches (409 millimeters)
Weight 36 pounds (16.2 kilograms)

Lucent Technologies Lineage®2000 150A -48V SR Series Rectifier
2 - 4 Product Description Issue 5 October 1998
reduction in the size and weight of the energy storage elements.
Power Factor Correction Circuit: The SR series rectifiers
contain a power factor correction circuit that ensures power
factor equal to 0.97 for all loads above 75 amperes. This allows
for an input current waveshape with low harmonic distortion,
ensuring compatibility with engine alternators and UPS. The
power factor correction circuit also allows operation over a
much wider input voltage range than ferroresonant or silicon
controlled rectifier (SCR) technologies, eliminating the need for
tap changes in the rectifier.
Forced-Air Cooling: The SR series rectifiers use forced-air
cooling to help achieve high power density and light weight.
Each PMA is equipped with an easily replaceable,
self-contained cooling fan. Thermal alarm circuitry offers
additional protection by shutting the rectifier down and
providing an alarm when the internal temperature exceeds
approximately 60° C.Forced air cooling improves the reliability
of the rectifier by reducing the internal ambient temperatures of
the rectifier to essentially the outside ambient temperature.
Self-Protection:Short circuits and overloads are handled safely
and automatically. Various monitoring and alarm signals are
generated by the rectifiers and sent to the controller (if present)
for processing and further action. The resulting action may be
local or remote alarm indications or control signals fed back to
the rectifier. See Figure 3-1 for typical signal flow between a
rectifier and the ECS controller.
Batteries and Load: In most telecommunications applications,
the output of the rectifiers is electrically connected in parallel
with the batteries and the load. Under normal conditions the
rectifiers power the load and provide the float and charging
current required by the batteries. During a commercial ac power
outage, the batteries supply the dc power to the load. When ac
power is restored, the rectifiers recharge the batteries and supply
dc power to the load. No switching is needed in this transition
because of the parallel connection of the rectifiers and batteries.
Although the rectifiers are typically used ina battery plant, these
rectifiers can operate without batteries, making them suitable for
those applications where battery back-up is not necessary or is
achieved using an uninterruptible power supply (UPS).
Features The following standard features are designed into the

Lucent Technologies Lineage®2000 150A -48V SR Series Rectifier
Issue 5 October 1998 Product Description 2 - 5
150-ampere, -48-volt rectifier.
Load Share: A dip switch selectable option enables the rectifier
to share the plant load automatically with other SR series
rectifiers. (See Figure 1-2 and Table 5-A.) The load share circuit
is fail-safe, using an isolated load share bus between the
rectifiers. Upon failure, the failed rectifier is disconnected from
the load share bus.
NOTE CB OFF must be lit and the DC OUTPUT breaker in the
OFF position on all PMAs to adjust the output of the
rectifiers correctly in load share mode.
Boost: The rectifier, in conjunction with signals from the
controller, can charge batteries at higher voltages than the float
voltage. A separate potentiometer allows the boost voltage to be
set independently of the float voltage. A front-panel LED
indicates when the rectifier is in boost mode.
Equalize: The rectifier, in conjunction with external control
circuitry, can charge batteries at higher voltages than the boost
voltage. The rectifier receives a signal to activate equalize. (See
Section 3, “Engineering Installation Preparations.”) A front
panel LED indicates when the rectifier is in the equalize mode.
Parallel Operation: The rectifiers are capable of parallel
operation.
Safety Interlock: A mechanical interlock between the PMAs
and the RHA prevents the PMAfrom being installed in the RHA
with the circuit breaker closed. On installation, the interlock and
associated circuits limit surges of current into the PMA output
capacitors when the PMA is initially connected to the battery
bus.
Output Current “Walk-in”: This circuit controls the time
required for the rectifier to reach full output current after it is
turned on. The output current is initially zero and is gradually
increased to the required output current in about 10 seconds at
full load. This feature minimizes the starting surge on the
customer's power source, which is especially useful when the
source is finite, such as with an engine alternator set.
External Selective High-voltage Shutdown: It the plant
voltage is too high, the controller will signal all of the operating

Lucent Technologies Lineage®2000 150A -48V SR Series Rectifier
2 - 6 Product Description Issue 5 October 1998
rectifiers that a high voltage is present. The rectifier(s) causing
the over voltage will shut down. The remaining rectifiers will
continue operation.
Internal Selective High Voltage Shutdown: If the rectifier
voltage goes too high (based on a user-selectable level) and the
rectifier is delivering at least 10% of its rated output current, the
rectifier will shut down. When rectifiers are operating in load
share mode and a high-voltage situation occurs, only the
defective rectifier will shut down. If the rectifier is connected to
a controller, the internal high-voltage shutdown will
automatically be disabled and the controller will furnish the
selective high voltage shutdown signal. The internal high-
voltage shutdown level can be set in increments of 1.0 +/- 0.5
volts between 50 and 58 volts by DIP switch SW100 (see Figure
1-2 and Table 5-A) on the back of the front door.
Back-up High Voltage Shutdown: This circuit prevents
damageto the rectifierand its loadsin the eventof ahigh voltage
condition. The rectifier monitors its output voltage and shuts
down when this voltage exceeds a user-selected threshold
programmed by DIP switch SW100 (see Figure 1-2 and
Table 5-A) on the back of the front door.
Output Current Limit: The rectifier provides a constant output
voltage up to its rated output current, at which point it provides
constant current. The output current is limited to less than 110%
of the rated output, and no user adjustment is necessary. An
equalize current adjustment setting is provided via
potentiometer on the front panel interface/display board, and is
only active when the rectifier is in the equalize mode. This
adjustment allows the rectifier's current to be limited from 40%
to 65% of the rectifier's rating to minimize battery stress during
equalizing. When the equalize signal is retired, the rectifier's
current limit returns automatically to full rated output.
Failed PMA Shutdown Mode: A DIP switch selectable option
(see Figure 1-2 and Table 5-A)sets the desired rectifier action to
be taken if two or less PMAs fail due to any of the following
causes: selective high voltage shutdown, backup high voltage
shutdown, internal Prichard fuse alarm, internal bias supply
failure, thermal alarm, or AC input phase failure.
Rectifier Test: A front panel switch is provided for
automatically raising or lowering the output voltage of the
rectifiers a small amount to test full load and no load operation.

Lucent Technologies Lineage®2000 150A -48V SR Series Rectifier
Issue 5 October 1998 Product Description 2 - 7
Lamp Test: This circuit allows the rectifier front panel meter
and LEDs to be tested. When the unit is in STBY and the NL/FL
switch is pressed in either direction, all of the front panel LEDs
and meter segments will activate. The LEDs on the front panel
of the PMA can be tested by operating the LAMP TEST switch
on the front of the PMA.
Restart Circuit: The rectifiers are compatible with the
automatic restart features of the controller. If a rectifier has been
shut down due to high voltage, the controller will try once to
restart it automatically.
Metering: A 4-digit, LED meter is located on the front panel
interface/display board. A switch next to the display selects
either the rectifier voltage (in the VOLTS position) or the
rectifier current (in the AMPS position) to be indicated.
ActiveInrush CurrentLimiting:Upon initial application ofac
source voltage, an active circuit limits the peak inrush current.
This prevents possible tripping of input breakers or overloading
of engine alternators during ac source voltage transfers.
RFA (Rectifier Failure Alarm) Indicator: An RFA alarm
provides both a local visual indication of failure and a signal to
the plant controller. An RFA is generated by the following:
High voltage shutdown
Thermal alarm
Rectifier precharge fuse alarm
Rectifier internal bias supply failure
AC Fail Alarm: An ac input voltage of less than approximately
170 Vrms causes an ACF alarm to be issued to the controller.
Rectifier Standby: The rectifier may be placed in the standby
modebyanexternallygeneratedsignal.The rectifier willremain
in the standby mode until removal of that signal.
Thermal Alarm (TA): The SR series rectifiers are fan cooled to
increase their reliability. High temperatures caused by fan
failure or other conditions cause a thermal alarm to be issued.
(See Section 7, Maintenance, for details on fan replacement.)
DCOUTPUT CircuitBreaker:Acircuit breaker isprovidedto
protecteachPMA from malfunctionand overcurrent.Itmay also
be used to disconnect the PMA from the rectifier output bus.

Lucent Technologies Lineage®2000 150A -48V SR Series Rectifier
2 - 8 Product Description Issue 5 October 1998
Remote Sense: The rectifier can regulate remotely and can
compensate for a voltage drop of up to 2 volts between the
rectifier's output terminals and the regulation point.
Test Jacks: Two sets of test jacks are provided. One set
measures the plant voltage at the remote regulation sense point.
The other set measures the voltage of the PMAs before their DC
OUTPUT circuit breakers. When the breakers are open and the
rectifier is on, but disconnected from the local bus, the rectifier
output voltage can be adjusted without affecting the plant
voltage.
Wide ac Input Frequency Range: The rectifier's power factor
correction circuit and switchmodetechnology allow itto operate
over 47 to 63 Hz with no degradation in performance.
Batteryless Operation: All performance characteristics remain
the same when the SR series rectifier is running in batteryless
applications.
NOTE Although all other specified characteristics remain within
limits, the presence of a battery does alter both the output
noise and transient response of the rectifier.
Dynamic Response: Using a battery having an ampere-hour
capacity (8-hour rate) four times greater than the output rating of
the rectifier, step changes in load over the range of 10 to 90
percent, or90 to 10 percent, will not cause the voltage measured
at the point of regulation to overshoot or undershoot more than
5 percent. After the step change, the voltage will return to and
stay within the regulation band within 300 milliseconds.
Lightning Protection: The rectifiers are capable of
withstanding, without damage, repeated surges of the following
wave forms (per ANSI C62.1 C62.2 and 587-1980
requirements):
• Rise time of 8 microseconds to 3000 amperes peak
amplitude and decay time to 1500 amperes in 20
microseconds
• 0.5 microsecond -100 KHz ring wave with a peak
voltage of 6000 volts