Marconi LORAIN RHM800E50 User manual

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LORAIN@ MODEL RHMSOOE50
RECTIFIER
SPEC. NO. 548502500

MARCONI@, LORAIN@, SUB-CYCLE@‘, and Vortex@
are trademarks of Marconi Communications Inc.
02000, Marconi Communications Inc.
. . . . - -- --... -._.
.- ..-.
COMMUNICATIONS AND CONTAINS CONFIDENTIAL AND
PROPRIETARY INFORMATION OWNED BY MARCONI
COMMUNICATIONS. ANY COPYING, USE OR DISCLOSURE
OF IT WITHOUT THE WRlll-EN PERMISSION OF MARCONI
COMMUNICATIONS IS STRICTLY PROHIBITED.
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Section 2992
Issue July 2000

Section 2992
Issue July 2000
Marconi Page 2 of 2 I

R ELTEC
Power Products
Section 5737
Issue Bl, September 9,1998
ADDENDUM
INSTALLER’S CONNECTIONS
INSTALLER’S INFORMATION NOTES
FOR
LORAIN@ RECTIFIERS
Remote voltage sensing lead connections should be made to the rectifier side of any
battery protective or disconnect devices present.
If a temperature compensation module is used to regulate rectifier output voltage, the
temperature compensation module battery connections should also be made to the recti-
fier side of any battery protective or disconnect devices present.
CAUTION
Turn ofl all rectifirs before removing any leads from a previously installed battery charge tem-
perature compensation module.
Power Products / 1122 F Street I Lorain. Ohio 44052-2293 / [phone]
In Canada:
RELTEC Canada
122 Edward St. / St. Thomas, Ontario N5P 122! [phone]
In Mexico:
Productos RELTEC de Mexico S.A. de C.V.
Apartado Postal 77001 I Mexico 10 D.F., MX 11200 I(525) 576.6277
~&RELTEC@

LORAIN PRODUCTS Section 5350
Issue Al, January 30,1992
ADDENDUM
PREPARATION FOR
SHUTDOWN
LORAIN o MODEL RL AND RHM
SERIES RECllFlERS
This instruction manual contains various testing, adjustment, and maintenance procedures in which the rectifier
will be shutdown either before or during the procedure. Before perforn+ng any of these procedures the load sharing
lead if installed must be removed using the following procedure then reinstalled after the test or adjustment is made.
If the load sharing lead is not removed during these procedures there is a potential for service interruption.
CAVTION
Before I-emoving the ?-sctifmrfivm swuicc. pnnkions should be made to insure that power 00 critical
&adsisMtintemtpted+andthataryextemalo&?iCzalwme associated with the recti$ier ewe
disabled, if possible. If the extended alaross cannot be disabled at the remote location, the
appropriate personne I dwaZd be notified to disregard wag @ice alarms e.ztendedfmm the rectifier
while this procedure is in progress. If the load must be mdUained while the r-e&&r is removed
frmn service, the folIowing considemtions should be made:
a) lf the rectifier is operating in parallel with one or more additional rectifiers, can the remaining rectifier(s) power
the load? If not, the load must be shutdown or an alternate DC source must be used.
b) tf a battery is to be used to provide load power during rectifier ;hutdown, is the battery fully charged and
capable of powering the load for the time required to make the adjustment.
1) Place the AC INPUT circuit breaker to the OFF position.
2) Refer to the Power Data sheet for location of the load sharing lead
3) Disconnect the load sharing lead from the terminal block and insulate exposed end.
4) Restart the rectifier by referring to the rectifier instruction manual starting and stopping section.
5) Perform the desired test, adjustment, or maintenance procedure in the rectifier instruction manual.
6) When the test, adjustment, or maintenance procedure is complete place the AC INPUT circuit breaker to the
OFFposition.
7) Reconnect the load sharing lead removed in en earlier step.
8) Restart the rectifier by referring to the rectifier instruction manual starting and stopping section.
9) This completes the procedure.
Page 1

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Section 5350
I
LOrain kdUCt5 I 1122 F Street I Lorain, Ohio 44052-2293 I(216) 288-1122
,n Canada :
RELTECCanada
122 Edward St. /St Thomas, Ontario N5P 122 / [phone]
I” Mexico :
Productos brain de Mexico S.A de C.V.
Apartado Postal 77001 I Mexico 10 D.F., MX 11200 I(9OS) 5768277
P
e
RELTEC”
R
Page 2
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RELTEC
Section 4387
Power Products
Issue Fl , August 4.1997
LORAld
MODEL RHM8OOE50 RECTIFIER
SPEC. NO. 548502500
CONTENTS. _ _ . _ _ . _ _ . . . . . . _ _ . _ . . . . . . . . . .
PAGE
CONTENTS (CONTD)
................ PAGE
1.
2.
3.
4.
5.
6.
DESCRIPTION
.........................
1
General ..............................
1
TESTAPPARATUS
.....................
2
INSTALLATION. .......................
2
Electrical Connections. ..................
Alarm and Control Connections. ...........
Initial Startup and Checkout.
..............
4
OPERATION ..........................
3
StartingandStopping ...................
7
Controls and Indicators .................. 7
Metering.
.............................
8
Float Charging
.........................
8
EqualizeCharging ......................
8
Automatic Rectller Shutdown
.............
8
Ripple Regulator Circuit. .................
9
Batteryless Operation ( M Option). .........
9
Cooling Fans and Temperature Sensors
.....
9
Fuses ................................
9
Circuit Cards ..........................
9
ADJUSTMENTS .......................
9
General ..............................
9
FloatVoltageAdjustment .................
10
EqualizeVoltageAdjustment
..............
11
Current Limit Adjustment
................. 12
LowVoltageAlarmAdjustment
............ 12
High Voltage Alarm Adjustment. ...........
13
LowCurrent Ahrm Adjustment
............
13
OvervoltageShutdownAdjustment
.........
14
LoadSharing Adjustment. ................ 15
Ripple Regulator Adjustment.
.............
18
CIRCUIT DESCRIPTION
.................
16
General
..............................
18
AC Input Circuit ........................
16
PowerSupply Assembly PSA-A8.
.......... 17
PowerCircuit ..........................
17
Voltageand Current RegulationCircuitry.
.... 17
Voltage Reference and Error Detection
...... 17
Current Sensing and Current Regulation.
.... 18
Pulse Generation and Phase
Control Circuits. ........................
18
Current Walk-in Circuit.
.................. 21
Negative Load Sharing Circuk
............. 21
Afarm Circuits. .........................
22
Ripple Regulator Circuit Card Al 1.
......... 23
Fuse Alarm Circuit ......................
23
Temperature Sensing Circuit
.............. 23
7.
TROUBLESHOOTING
................... 24
General. ..............................
24
Fauit Isolation Chart Use
................. 24
Testing Precautions .....................
24
Repair and Replacement Information.
....... 24
TestProcedures. .......................
31
8. MODEL DATA
.........................
37
APPENDIX
1. DESCRIPTION
General
1.1 These LorafnG Rectifiers operate from 60 Hz three
phase input. to maintain a battery in a fully charged condi-
tion while powering a load. The ModelRHMEWE50 Rec-
tifier can be operated from 480 VAC input power.
1.2 Float Charokra; This rectifier provides constant
outputvoltage; therefore, outputcurrentremains equal to
load current as long as load current does not exceed a
predetermined. adjustable value. This mode of operation
is known as float charging. Since, in normal operation,
Page 1

Section 4367
the battery is not required to furnish load cunent, it
remains in afulb charged condition.
1.3 Faualffe Charainq If a higher DC voltage is
required to equalize the charge on all battery cells. the
FLOAT/EQUALIZE switch can be operated focally to
obtain higher equalize charge voftage. The equal&
function may also be controlled from a remote location if
desired.
Description
Power supply
Model
Variable Power Supply
(O-60 VDC at 10 amps) or
eauivalent
1.4 Current Limftins; When an AC power failure
causes battery discharge. or if a DC overload occurs, an
output current limiting circuit prevents the increase of
output current above a predetermined vafue.
stable from 15 ohms
)52 ohms; 50 KW
. . I
DCAmmeter
ACAmmeter
I .
O-20 amps DC
1 O-60 amps AC
1.5 Parallelim~
This rectifier is equipped wbh an
automatic currentliittmg circuit which enables patallel-
ing with any other battery charger which can be
adjusted to the same output voltage. In addition. a
forced load sharing circuit is furnished which ensures
pmportllnal sharing of load between paralleled rectffi-
ers with compatible negative bus load sharing circuits
tien interconnected with external load sharing wiring.
Table 2-1
Test Apparatus
1.6 Ovefvoltaoe Shutdown: If rectifier output Voltage
increases beyond a preset value while delivering greater
than 3% of rated output current, a circuit trips open the
AC input contactor to disable rectifier output.
proper component cooling during operation. Tempera-
ture of the air entering the cabinet must not exceed
+wc (+122’F).
2. TEST APPARATUS
2.1
Refer to Table 2-1 for a lff of tools and test equfp-
ment that is suffffient to perform any test or adjustment
procedure detailed in this instructkm manuaf.
3.5 Wiring: All wiring and branch circuit protection
shoufd follow provisions of the current edition of the
National Electtic Code. Referenced to the 1996 edition
for specific requirements am:
3. INSTALLATION
Article 240-6 Branch Circuit Rating
3.1 Equipment placement at the central office loca-
tion should be given consfderation, as discussed in the
following paragraphs.
Table 310-16 (75°C) Ampacity of Power Conduc-
tors
mm
32 Wirtna Considerations: Location of the rectffier
should be chosen to mfniifze required lead lengtfts for
both AC input and DC output. Optiium equipment per-
formance and cost effectiveness of thefktalfatffn can
bo realized by proper location Of the rectifier.
The difiet operateafnrm AC UoltW Capabk
of prodvdng -.
perhaps fatal. electrical
shock. Bejim amlmem2ing installation.
ensum that AC and DC sources an? com@et&~
disconnected or disabled.
3.3 Mountino Reouirementx
Thii mctlfler is
designed for floor mounting onfy. The Cabffet base con-
tains four mounting holes which accept II2 inch dff-
ter bofts for securing therectiier in fts mounted positlln.
Refer to the Power Data sheet for further information.
3.4
m All ventitatffn open-
ings in tfte rectifier cabinet must remain unobstructed for
3.6 General: To gain access to input, output, and
control terminals, loosen the captive fasteners securing
the meter and control panels. These panels pivot open
on separate hinges. lf less restricted access to input
and output terminals is required, remove the Phillips
type screws securing two removable panels immedi-
ately above the meter and control panels.
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3.7
Input Connections: Connect the three phase AC
60 Hz, power leads at terminals Li . L2 and L3 on con-
tactor Kl at the left side of the rear panel.
3.8 Output Connections: Connect DC output leads to
output terminals +BAT. and -BAT at the right side of the
rearpanel.
3.9
Earth Ground (Green Wire) Connections: A
frame ground lug (GND), located near contactor Ki.
must be connected to an earth ground (green wire). Do
~connect to power system neutral.
Alann and Control Connections
WARNING
Polarity of the uo1tage se&g leads is critl-
cd. when connecting these leads. verifi con-
nectlans can?fully to assure em-rect polarity.
terminal If+) and U-1 on terminal board TB3
OPERATION
3.10 Local or Remote Voltaae Sensing: Terminals 1
(positive) and 2 (negative) on terminal board TB3 are
provided as v&age sensing terminals. These terminals
may be connected at the output of the rectiiier or
extended to sense the voltage at a remote location. To
achieve the most effective regulation of output voltage,
the sense leads should be exiended to the battery or
power board at which regulation is required.
The high w&age shutdown cfrndt is connected
acmss the output Idage leads.
3.11 Load Sharinq: This rectifier is equipped with a
negative bus load sharing circul which enables it to
divide the load in proportion to the output current ratings
wlh any oMer LORAIN RL or RHM Series rectifier of
the same output v&age rating. When both rectifiers
have compatible load sharing circuits, a load sharing
connection shoufd be made between the load sharing
terminals of each rectifier. The load sharfng terminal of
this rectifier is located at terminal board TB3 terminal 3.
Refer.to the Power Data Sheet for recommended size of
the load sharing lead and terminal bkxk capacity. For
proper operation. if is essential that each rectffier be
adjustedfor proper output voltageand load sharingloop
voltage. Refer to the ADJUSTMENT section for detailed
information.
3.12 Remote Eaualize Control: The equalize mode of
operation can be remotely controlled by providing a
Section 4367
closed circuit between terminals 4 and 5 of TB3. or by
providing positive battery voltage at terminal 4 only. An
open circus between these terminals or removal of posi-
tive battery voltage from terminal 4 restores OpemtiOnaf
mode control to the FLOAT/EQUALIZE switch on the
rectifier front panel.
3.13 Phase Loss/Reduced Load Alarm: If for any rea-
son, rectifier experiences a high ripple condition caused
by an AC input phase loss an alarm is activated and the
rectifiers output voltage and current will be at a reduced
level. Extended alarm contacts are acfiitad to provide
closed loop circuits between terminals 26 to 27 and 29
to 30 of terminal block TB3. while open loop circuits are
provided between terminals 25 to 26 and 26 to 29 of ter-
minal blodc TB3. During normal operation closed loop
circuits are provided between terminals 25 to 26 and 26
to 29 of terminal block TB3. while open loop circuits are
provided between terminals 26 to 27 and 29 to 30 Of ter-
minal block TB3.
3.14 Rectaier Fail Alarm: During normal rectiiier oper-
ation, posttiie battery is provided at T83 terminal 12 to
provide an exlemal normal operation indication. If a
rectifier failure condiikn occurs, positiie battery is
removed from TB3 terminal 12 and applied to TB3 ter-
minal 10 to actuate external rectifier fail alarms. A recti-
fier failure condition includes the following operational
modes or alarm conditions:
a)
b)
C)
d)
e)
f)
9)
t-4
High voltage alarm
Lowvoltagealarm
Lowcurrenta!arm
Partial load current limtt operation
Fan fail alarm
Heatsink over-temperature alarm
Fuse alarm
Manual or automatic removal of AC power,
includingcommercialpowerfailure condiiion
rf closed loop actuated almms are desired dfscon-
nect and insulate thejumper lead fmm TB3 termi-
nalll. C&sedlooprecti@erfailalarmisthen
provided at lB3 termfnals IO to 1 I during a recti-
fierfkil condftion.
Page 3

3.15
End Cell Switch Inhibit: A positive battery control
signal fs available at TB3 terminal 13 to inhtti activation
of an automatically controlled end cell switch during nor-
mal rectifier operation. If a low current ahrm occurs in
the rectifier, this control signal is automatically removed
from terminal 13.
3.16
fj& A positfve battery alarm signal is present at
TS3 terminal 14 if rectifier shutdown results from a high
output voltage condition.
3.17
LCA: A poskfve battery alarm signal is present at
IBS terminal 15 during a low current alarm condition.
3.18 m Positlive battery to TB3 terminal 16 is nor-
mally supplied through a factory installed jumper wire
between terminals 16 and 20. Positive battery at termi-
nal 16 of TE3 is required for AC input power contmf. If
rectifier startffg and stopping is required from a remote
location or automatic control device. disconnect and
insufate the jumper wire at TB3 terminal 16. Connect
positffebattery to terminal 16 through the remote switch
or control device.
3.18 Voftmeter lndicatffa O~tiin: Connect terminals
17 and 16 of TD3 with a jumper wire if front panel voft-
meter indfff of battery voftage is desired when rectii
fier fs turned off. lf voftmeter indication of zero volts is
desired with rectifier turned off, do not connect jumper
to teninals 17 and 18.
330 Float and Eaualiza Mode Indiitkms: When mc-
tiier is operating in ffoat mode, positive battery is avafl-
able at TB3 terminal 19. When the equalize mode is
selected, positfive battery is removed from TD3 terminal
19 and supplied at terminal 21.
3.21
O~tiinal Auxifffw Power Surxrlv: If. due to a pro-
longed AC input power failure. the associated battery
discharges to below 36 VDC, the rectifier will be unable
to restart. To permit restartiig the rectifiir in thff went,
a customer-furnished auxiliary 49 voft power supply may
be connected to terminals 1 (+) and 2 (-) of auxiliary
power supply tenfnal bfodc TM. TBI is located on
insfde the rectifier cabinet on the rear wall. The auxil-
lary power supply must be capabfs of supplyiig IO
amperes.
. .
m and CheckoUt
322
This mctffier was completely tested and adjusted
by the manufacturer before sh@ment: however, the
installer should perform the following initial checks to
insure proper equipment operation after installatfon is
completed.
Page 4
a) Initial Preoaration
1)
2)
3)
4)
Place the HVSD and POWER
switches on the front panel to the OFF
position. Place the FLOATIEQUAL-
IZE switch to the FLOAT position.
Open the front access panels by loos-
ening the captive fasteners, then
locate battery disconnect link 52.
Remove this link from its receptacle.
Check to insure mat all fuses are
securely installed in their fuseholders.
Any tape and packing materials used
in the interior of the rectifier for ship-
ping purposes should be removed at
this time.
Connect all input. output, and control
wiring in accordance with the Power
Data sheet. Refer to Paragraph 3.06
forfurther wiring information.
b)
lnltial Startup Procedure
DANGER
Steps 1J through 4) must be pelf-d exactly
aspr-#st?ntedintheseinstluctions. Thelecti-
fuzrmustbsstMedoffbatteqtochorgethe
filter capacitor8 before installing BATrERY
DISCGNNECT Iink s2. Installing the discam-
nsct link b&m? charging the capafitors con
result in permnal ir$wy. equipment damclge.
andb&wn#zsesintherect@z
1)
If reference leads are extended to the
battery, perfom the folfowfng steps:
4
B)
C)
Remove the local sensing
leads from their storage termi-
nals on circuft card A9.
Working with one lead at a
time, disconnect the extended
reference leads from terminals
1 and 2 of TB3 on circuit card
A9. Temporarity insulate these
leads.
Connect the local sensing
leads to TBS. terminal 1 (+)

and tenninal 2 (-). Insure that
polarity is correct.
D)
Install the M option capacitor
assembly. Part No. 4251-014-
00. on the appropriate edge
connector of regulator and
alarm circuit card A7. Refer to
Figure 3-l.
Insure that the external AC protective
device is pmperiy sized for rectffier
input requirements. Close this device
to apply AC input power to the recti-
fier.
Section 4387
3)
Place the HVSD circuit breaker toggle
and the POWER rocker switch to the
ON posltn. The rectifier should
start, although the LOW CURRENT
ALARM and an extended rectifier fail
alarm may be activated.
4) Wan
for the vonmeter on the rectifier
front panel to indicate 52 vofts. At this
time, insert BATTERY DISCONNECT
link S2.
5)
Place the POWER switch to the OFF
position. lf reference leads extended
to the battery or load are required,
p&on-n the following steps. If internal
reference only is required, disregard
I REGULATOR AND ALARM CIRCUIT CARD A,
0
HINGED END
CONTROL AND INDICATOR PANEL
(INTERIOR SURFACE)
Figure 3-I. Capacitor Assembly Connector Location
Page 5

Sectbn 4387
Steps a) through c) which follow, then
proceed with Step 6).
DANGER
If the n?cti~ is connected to a battery, uolt-
age is p-t at the local and extended refer-
ence&?Qds. -clueinthefol&wing
steps that the &ads are not accidentally
shorted together or allowed to touch cabinet
parts of ang other electriCal tenniIIations.
AC u&cl@? copab& Of producing sf2VW-e. per-
haps fiatal electrical shock is present at input
contactor Kz E.cercise caution that acciden-
tal bodiZy contact 1~6th any electrical termina-
tirm do& not occur
A)
B)
C)
Disconnect and temporarily
insulate the local reference
leads from TB3, terminals 1
and 2.
Working with one lead at a
time, connect the remote sens-
ing leads to TB3, terminal 1 (+)
and 2 (-). Insure that polarity fs
COWSCt.
Remove the temporary lnsula-
tion from the local reference
leads. and connect these leads
to the storage terminals on cir-
cuit card A9.
6)
If the rsctfffer is used in charging a
battery, remove the M option caps&
tor assembly from its edge connector
on regufator and afarm circuit card
A?.
7)
Place the POWER switch to the ON
posbii. The rectffff should start
and defier output voltage wfthin the
rengeof48t054VDC.
8)
Page 6
The ftoat output voltage of the rectffffr
shoufd be chedmd and adjusted to
meet bad condfins. Unless other-
wise specified. the rectiiier has been
factory adjusted to pmvfde 52.08 VDC
during float operation. This is based
on a float charge of 2.17 volts per cell
for a 24cell battery. When charging a
23cell battery, or when a higher or
lower voltage per cell is desired. the
float output voltage can be changed
by adjusting the FLOAT ADJUST
potentiometer, accessible through a
hole in the front panel of the rectllier.
Turn the potentiometer adjustment
screw slowly cfocfovise or counter-
clocbwise as necessary.
Voltage
should be monitored at the battery
while adjusting float output. The recti-
fier thereby compensates for distribu-
tion losses. and the battery remains
fully charged.
9)
Operate the rectifier FLOATIEQUAL-
IZE switch to the EQUALfZE position
and note the equalize output voltage.
Unless otherwise specffied. the recti-
fier has been factory adjusted to pro-
vide 54 VDC during equalize charge
operation. This is based on an squal-
ize charge of 2.25 vats per cell for a
24cell battery. When charging a 23-
cell battery, or when a higher or lower
voltage per cell is desired, the equaf-
ize output voltage can be changed by
adjusting the EQUALIZE ADJUST
potentiometer, accessible through a
hole in me front panel of the rectifier.
Turn ms potentiometer adjustment
screw slowfy &&vise or counter-
clod&se as necessary.
voltage
should be monitored at the battery
while adjusting equafffe output,
thereby allowing the rectifier to com-
pensate for distribution losses.
Return me FLOAT/EOUALIZE switch
to the FLOAT pktlln.
10) Chsctr the rectifier current limit Cir-
cuitry by loading the rectffer to at
least f20% of the rated output of the
unit. lf the existing load is less than
rated bad. a resistive test bad may
be connected to me DC OutpUt termi-
nals of the rectifier. The rectifier
should limit is output current at 110%
of rated output. If adjustment is
required, refer to Paragraph 5.66 of
this manual. Remove the test load
after chech or adjustment.
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11)
Before placing the rectifier into ser-
vice. refer to Table 3-l and note the
factory settings of the overvoltage
shutdown circuit and the high and low
vobge alarm circuit. If these factory
settings are acceptable, the rectifier
may be placed into service. If read-
justment of these circuits is required
to meet customer requirements, fol-
low tie appropriate adjustment proce-
dure referenced in Table 3-1 before
placing the rectifier into service.
Adjustment Factory
Setting
Adjustment
Procedure
Pam. No.
Overvoltage
Shutdown
55VDC
I
5.10
I
1 Hig;;Kt
1 57.6VDC 1 5.6 )
Low voltage
Alarm
47.15VDC
5.7
Table 3-l. Shutdown and Alarm Levels
4. OPERATfON
4.1 Normal Start and Stoo: The rectifier may be
started or stopped locally by pfacfng the HVSD and
POWER controls to the ON or OFF position, respec-
tively.
4.2 Remote Start and Stoo: If remote starting and
stopping control is .desired. allow the HVSD and
POWER controls on the front panel to remain in fhe ON
position. Applyins or removing positive battery at teimi-
nal 16 of TB3 starts or stops the rectifier. respectively.
4.3 Startina After AC Power Failure: The rectifier
restarts automatically following commercial AC power
failure if the HVSD and POWER conbuls are in the ON
position and positfive battery is applied to TB3 terminal
16 at the time of power restoration.
Section 4367
rf battery voltage dfscluuges below 38 uolts DC dur-
ing on extended commercial AC power failure. the
rech@r wfU be w-table to restart automatically
unless an autihy power supply is connected to
termfnal block TBI (see Pam 3.21). If an cuuciliary
power supply is a connected to TBI. refer to Test
Procedure 9 in Chapter 7. Tl?OUBLESHOOTlNG. for
a starhlp procedure in this event
Controls and Indicators
4.4 The following controls and light emining diode
indicators control the operation and indicate the status
of the rectffier. All controls and indicators are located on
the rectiiier front panel unless otherwise noted.
a)
b)
c)
d)
*I
HVSD Circuit Breaker: This circuit breaker
operates in conjunction with the POWER
switch for starting and stopping the rectifier
and normally remains in the ON position.
The circuit breaker contains a trip coil which
is energized in case of a high output voltage
condition, thereby releasing the AC input
contactor which removes AC input power.
POWER Switch: This rocker switch. located
adjacent to the HVSD circuit breaker, is used
to start or stop the rectifier by pfacfng it to
the ON or OFF position, respectively.
BAlTERY DISCONNECT Link 52: The dis-
connect link inserts into a mating receptacle
located at the upper right portion of the rear
panel inside the rectifier. Access is gained
by opening the meter and control panels.
The link serves as a convenient method for
connecting or disconnecting me battery to or
from the output circuits of the rectifier.
FLOAT/EQUALIZE Switch: When this switch
is fn the FLOAT position, sufficient voltage is
provided to maintain the battery in a fully
charged con&ion while supplying load
demands. When this switch is pfaced in the
EQUALIZE position. the rectifier output volt-
age is increased to equaliie me charge of all
battery cells. Refer to Paa. 4.6.
POWER ON IndicatoC: Illuminates when the
AC input voltage is present and the HVSD
and POWER controls are placed in the ON
position.
Page 7

Section 4367
r)
9)
HIGH VOLTAGE ALARM Indicator: lllumi-
nates when the output voltage increases to a
predetermined adjustable high voltage alarm
value. The high voltage alarm circuit moni-
tors output voltage continuously; therefore,
thisalarmis operational even when the recti-
fier is turned off.
LOW VOLTAGE ALARM Indiitor: Illumi-
nates when the output voltage decreases to
a predetermined adjustable low voitage
alarm value. The low voltage a&m circuit
monitors output voltage continuously; there-
fore, this alarm is operational even when the
rectifier is turned off.
The LOW VOLTAGE ALARM
indicator may illumi-
nate duirq a battery recharge condition $the recti-
/ier operates in the current limiting mode. and
n?duces output udtage lzccordfngly. lx& is normal
opemtim.andthe&rmwiUextinguishasthebat-
tery udtage trl-es.
h) LOW CURRENT ALARM Indiitor: Illumi-
nates when the rectffier is operating and
supplying less than 0.5% of tated output cur-
rent or when the rectnier is turned off.
0
FUSE ALARM Indicator: Illuminates if one
or more fuses Fl thmugh F4 should open.
j) FAN FAILURE ALARM Indiftor: fifumf-
nates t cooimg fans El or 82 should fail.
Matwinq
4.5 A DC ammeter and a DC voftmeter indicate reck-
fier output current and voltage. respectively. SimCe the
voltmeter is connected acmss the reference leads, this
hater indicates battery voltage if remote Sensing is
Used.
Float cherpiaa
4.6 This rectifier provides conetant output voltage;
therefore, output current remains equal to load current
as long as load current does not exceed the current liik
setting. This mode of operation is known as float charg-
ing. In normal operation. the battery is not required to
furnish toad current and remains in a fully charged con-
dition.
Page 6
NOTE
IJ the current demand by the load exceeds the cur-
rent limit setting. the battery is required tofurnish
the dtQI&ertce and subsequently begins discharg-
ing.
Equalize CharajQg
4.7 Higher charging voltage is sometimes required to
equalize the charge of all battery cells, or to recharge
the battery as quickly as possble foflowing commercial
AC power failure. To obtain this voltage, operate the
FLOAT/EQUALIZE swkch to EQUALlZE positffn. To
restore usual float operation, operate the switch to the
FLOAT position.
4.6 The equalize function of the rectifier can also be
initiated from a remote location. if desired. (Refer to
Power Data Sheet.) When the equalffe function is con-
trolled remotely, the FLOAT/EQUALIZE switch on the
rectlier is disabled.
W-G
Do not supply eqialize voltage for a longer
period than necesory.
I’mlonged higher
charya udtage wiII oerchaqw the battery
cells and reduce battery life.
4.9 Occurrence of any of the following condiiions
results inautomaticrectifiershutdown:
a) Operation
of any fuse br the rectifier, other
than fan fuses F5 and F6
b)
Overvoltageconditionatrectifier output
If condition a) occurs, indicator FUSE ALARM illumi-
nates but all other operating controls remain in their nor-
mal positions. Correctfon of the failure condiikm and
replacement of the opened fuses allows the rectifier to
restart.
ff condition b) occurs. the rectifier will restart autornati-
tally after twenty seconds. If a second HVSD occurs
within a 5 minute period, the rectifier will shut down and
hip the HVSD circuit breaker located on the fmnt door.
Once the failure has been corrected, placing the circuit
breaker toggle to the ON position shouM restart the rec-
tffier. lf the rectifier can operate for a period of 5 min-
utes wfthout a HVSD the circuit will reset and be ready
for the next HVSD event.
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Section 4387
after removal of the lower panel at the front of the recti-
4.10 This rectifier contains a circuit which permits
fier.
selective overvoltage shutdown when two or more recti-
fiers are operated in parallel. The circuit allows opera-
tion of the overvoltage shutdown circuit only in the
rectffier which causes the overvoftage condiiin.
&~de Reaulator Circuif
4.11 This rectiiier is equipped with a ripple regulator
circuit. located on cinutt card Al 1, which continuously
monitors the ripple current through the rectifier DC out-
put filter capackors. In the event of a high ripple current
condition caused by the loss of an AC input phase, the
ripple regulator circuit senses the high ripple through
the capacitors and provides a signal to the rectifier regu-
Table 4-l. Fuse Types and Sizes
lation circukry whichreducesrectifieroutputvoltageand
current. This permits the rsctiiier to continue operating
at a reduced capacity until such tkne as the phase loss
is corrected. External alarms are also actttated refer to C.
wcuft Cards
Paragraph 3.14 for details.
&~ttervless Operation I M Ontiop
4.15 Any of the circuit cards listed in Table 4-2 can
easily be replaced as individual assemblies if the need
arises.
4.12 If rectifier operation off battery is required, a
capacitor assembly, Part No. 425101400, must be
r
installed on circuit card A7 to stabilbe rectifier output
Circuit Card Description
voltage. See Figure 4-1.
Al-A6 (433401600)
1 SCR Firing Circuit Card
Coolina
sense
A7 (486508700)
Regulator 8 Alarm Card
4.13 The rectifier is equipped with cooling fans and
temperature sensors mounted on heatsink assemblies
at the bottom of the cabinet. The cooling fans circulate
air across the heatsinks to cool power semiconductors
while the temperature sensors monitor heatsink tem-
perature.
lf air flow ceases or il heatsink temperature
reaches +85’C (+18X=). output current of the ractffllr
is reduced to approximately 88% of the full load rating,
and an external rectifier fail alarm is activated, if con-
nected. In addition. if a cooling fan has failed, a red FAN
FAILURE indicator will illuminate. When the tempera-
ture decreases or fans have been repaired, the rectifier
returns to full load capability and the external rsctffiir
fail alarm is canceled.
Etmss
A8 (486562200)
A9 (433852700)
Power Supply Card
Alarm Interface Assy
1 All (486569800) I Riiple Reaulator Card I
1 A12. Al3 (433837100) I Fan Failure Ahrm
1 A14.15 (425702200)
1~ ~~~~
LED Alarm Card
I
Al6 (433800209)
HVSD Resart Circuit
1
Table 4-2. Replaceable Circuit Cards
5. ADJUSTMENTS
4.14 Table 4-l lists the rating and types for all the
5.1 Various
adjustment potentiometers are
fuses used in the rectkier. Fuses should be replaced
accessible on the control and indicator panel at Regula-
with the type and size listed, or equivalent. To gain tor and Alarm Circuk A7 and Ripple Regulator Circuit
access to all fuses except F5 and F6, open the meter
All. These potentiometers are factory adjusted and
and control panels. Fuses F5 and F6 are accessible readjustment is not normally required.
Page 9

Section 4387
HINGED END
r OFPANEL
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MOUNTING LOCATION OFMOUNTING LOCATION OF
zi =I
CAFAClTORASSEMBLYCAI’ACITORASSEMBLY
425101400425101400
3 zl
0
00
0
CONTROL AND INDICATOR PANELCONTROL AND INDICATOR PANEL
(INTERIOR SURFACE)(INTERIOR SURFACE)
> REGULATOR AND ALARM CIRCUIT CARD A7 C
0,
Figure 4-1. Capacitor Assembly Connector Location
small fncremsnts. Before adjustments are made, verify
that lhe battery is fully charged.
I
Adjustment of this recti@r should only be
attempted bg trained semice pelwmnel.
a)
A&smentmu.5i&offangesmbeyondlimits
statedint&eFmuerDataSheetisnotmcom-
mended.
To obtain float output voftage. place the
FLOATEQUALIZEswitchintheFLOAT posf-
tion. I
b)
52 Potentiometer FLOAT ADJUST is accessible
thmugh a hole on the front panel of the rectifier. Thtt
potentiometer sets the value of the float output voitage.
Unless othetwise specified, the float voltage ts fadory
adjusted to 52.08 VDC (24 cells at 2.17Vkell). The
potentfomstsr settfng. if changed, shoufd be dons in
C)
To increase float voftags, adjust potentiome-
ter FLOAT ADJUST slowly clodwise. To
decrease float voftage. adjust potentiometer
I
slowly countemlockwiss.
When the ssttiig of potentiometer FLOAT
I
ADJUST has been changed. allow battery
voltage to stabilize at its new value. then
note whether this value is as desired.
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HINGED END
0
REGULATORANDALARM CIRCUITCARDA7
0
FACTORY ADJUST ONLY
-:
LOAD SHARING ADJ (R28)
-z
OVERVOLTAGE SWTDOWN ADJ (W32--j
ADJUSTMENT POTENllOMETERS
HIGHVOLTAGEALARMADJ (R39)-c
z
(ON OTHER SIDE OF CIRCUIT CARD)
LOW CVRRENT ALARM ADJ (RY)) -+
_ LOW VOLTAGE ALARM ADJ (R39) -r”
Y
1
=I
00
CONTROLANDINDICATORPANEL
(INTERIOR SURFACE)
0
Figure 5-l Regulator and Alarm Circuit Card Adjustment Potentiometer Locations
d) Repeat Steps b) and c) as necessaly to
age. Unless otherwise specified. the equalize voltage
obtain the required float voltage.
has been factory adjusted to 54 VDC (24 cells at 2.25W
cell). The potentiometer setting. if changed, should be
m.m
done in small increments.
whentht?Jldatvdtageisadfusted.theequrdize
voltage wilt be a&ad. It is recommended that the
equalize voltage be checked and $ necessary.
a) To obtain equalize output voltage, place the
FLOAT/EQUALIZE switch in the EQUALIZE
posttion.
b) Allow DC output voltage to stabilize at its
new value.
5.3 Potentiometer EQUALlZE ADJUST is accessible
through a hole on the front panel of the rectifier. This
potentiometer sets the value of the equalize output volt-
c) To increase equalize voltage, adjust potenti-
ometer EQUALIZE ADJUST clockwise. To
decrease, adjust potentiometer counter-
clodwise.
Page 11

sdiin 4387
d) Repeat steps b) and c) as necessary to
obtain desired equalize voltage.
5.4 The value at which the current limif circuit pm-
vents turtfter increase of output current is set by potenti.
ometer CURRENT LIMIT ADJUST accessible through a
hole on the front panel of the rectifier. Unless otherwise
spaclied, the rectifier is factory adjusted to limit current
at 110% of rated load. To change the current limit set-
ting, observe the following procedure:
WARNING
Thisrecti@erisnot ratedfotcontinuouedu@
abowellO% of rated current. Loads ofup to
125% may bs tolerated for short periods of
tim~lt?.&~hen mcharginga di.%hQrpedbQt-
[email protected]~~Longedope~t[onwerllO%badloaday
overheat the recti@8r and cause permanent
dQQIQgetQSQ~CQQtpQQeQts.
4
b)
a
If the load on the rectifier is not greater than
the desired current limit setting, a resistive
test load should be used to insure the
amount of load exceeds the desired oufpuf
current limit s8ttt”g.
To decrease the current limit setting, adjust
potentiometer CURRENT LIMIT ADJUST
counterckxkwise until the output cutrant
decreases to the desired lknft.
To increase the cUf~aht liml setting, adjust
potentiometer CURRENT LIMlT ADJUST
clockwfsa until the output current increases
to the desired liift.
Low Wtsae Alarm Adiuetmenl
5.5 The low voltage alarm adjustment potentiometer
R36. located on Regulator and Alarm circuit card A7.
sets the value af which light emttting diode LOW VOLT-
AGE ALARM illuminates and an external alarm is acti-
vated, if connected. Unless otherwise specified. the km
voftage alamt is factory adjusted for 47.15 VDC. To
readjust tftii limit. observe Me following procedure:
8)
b)
Page 12
Turn off the rectifier by operating the
POWER switch to the OFF poskion.
Open the mater and control panels by loos-
ening the captive fasteners. Disconnect the
rectifier from battery by removing the BAT-
TERY DISCONNECT link.
jMNGER
Connect an adjustable DC supply capable of
supplying 60 volts DC to the positive output
terminal (+) and either terminal of fuse Fl (-
), observing proper polarity.
Adjust potentiometer R36 fully counterclock-
wise. Refer to Figure 5-1 for location.
Turn on the external DC supply and adjust
output voftage to the desired low voltage
alarm value.
lh?fluer cQpwftors chwge slowly when the t?Yier-
n~IDC+upplyl~bmedon. AUmqpmximatelg
40 seconds to elqme beJbreflnd supply adjust-
ment to the desired low uoltoge okvm uolue.
f)
9)
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i)
Slowly adjust potentiometer R38 clockwise
until light emitting diode LOW VOLTAGE
ALARM on the front panel illuminates.
As a check. Increase the output voltage of
the external DC supply; light emftting diode
LOW VOLTAGE ALARMshould extinguish.
Slowly decrease the voltage until tight emit-
ting die LOW VOLTAGE ALARM illumi-
nates. Repeat Steps f) and g). if necessary.
until the ahrm is activated at the desired
voltage.
Adjust power supply output voltage to
exactly the same value of battery voltage at
the rectifier output terminals. These voft-
ages should be measured wfth a digital mul-
tiieter.
With power supply output voftage pmperfy
adjusted, insert the BATTERY DISCON-
NECT link.
Turn off the external DC power supply, then
disconnect the test leads.
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k) Close the meter and control panels, then
start the rectifier by placing the POWER
switch to the ON position.
Hiah Voltaae Alarm Adiustment
5.6 The high voltage alan adjustment potentiometer
R39, located on Regulator and Alarm Circuit card A7.
sets the value at which light emitting diode HIGH VOLT-
AGE ALARM illuminates and an external alarm is acti-
vated, if connected. Unless otherwise specified, the
high vottage alam, is factory adfsted for 57.6 VDC. To
readjust this limit, observe the following procedure:
4
b)
Turn off the rectiiier by operating the
POWER switch to the OFF position.
Open the meter and contml panels by loos.
ening the captive fastenets. Disconnect the
rectifier from battery by removing the SAT-
TERY DISCONNECT link.
DANGER
Rxl?rcisl? extreme caution when performing
step cl. Easlwdous DC sortage is present at
the DC output terminals.
d
d)
e)
Connect an adjustable DC supply capable of
supplying 60 volts DC to me poslive output
terminal (+) and either terminal of fuse Fl
(-). obsenring proper polarity.
Adjust potentiometer R39 fuliy clockwise.
Refer to Figure 5-l for location.
Turn on the external DC supply and adjust
output voltage to the desired high voltage
alan value.
NOTE
TheJilter capacitors charge slowly when the exter-
nal DC supply is turned on. Allow qprmdmate4(
40 seconds to el@se before ~01al supply adjust-
ment to the desired high uoltage alarm ualue.
f)
a
Slowly adjust potentiometer R39 counter-
clockwise until light emkting diode HIGH
VOLTAGE ALARM on the front panel illumi-
nates.
As a check, decrease the output voltage of
the external DC supply; light emktttg diode
HIGH VOLTAGE ALARM should extinguish.
h)
0
i)
W
Section 4387
Slowly increase the vottage until light emit-
ting diode HIGH VOLTAGE ALARM illumi-
nates. Repeat Steps f) and g). if necessary,
until the atam, is activated at the proper vok-
age.
Adjust power suppN output voltage to
exactly the same value of battery voltage at
the rectifier output terminals. These volt-
ages should be measured with a digital mul-
timeter.
With power supply output voltage property
adjusted, inset-l the BATTERY DISCON-
NECT link.
Turn off the external DC power supply, then
disconnect the test leads.
Close the meter and control panels, then
start the rectifier by placing the POWER
swftdt to the ON poskion.
J cw Current Alarm Adiustment
5.7 The low current alarm adjustment potentiometer
R50. located on Regutator and Alarm Circuk card A7.
sets the value at which light emtttfmg diode LOW CUR-
RENT ALARM illuminates and an external low current
alarm is activated, if connected. Unless otherwise
specified, the low current alarm adjusbnent is factory
set to provide an atann when rectiiiar output decreases
below 0.5% of rated cunent. To readjust the low current
alarm,observe the followingprocedure:
DANOER
This @ustment procedure is performed with
therec@eroperatiqinatestmo&. ACvolt-
ages ecrpabk of voduchf seuere. perhaps
fatal ehxtrical shock am p-t at cont~~tor
KZ and in other podons of the circuit when
the n?ct!fier is opemting. Exercise caution
that accidentti contact with any electrical
terminations does Iwt occur.
a)
b)
Turn off the recteier by operating the
POWER switch to the OFF position. Open
the meter and control panels.
If remote sensing is used in the rectifier, dis-
connect and temporarily insulate the remote
sensing leads. These leads are connected
at TS3 terminals 1 and 2.
Page 13