PECO II, Inc.

4380078PD

Issue 8. NW 2000

6875009BLK-62
6875010BLK-62
6875010BLK-62A
MbDULAR -48 MC, 100 AMP
SWITCHMODE RECTIFIER SYSTEM(S)
WITH DISTRIBUTION, LVD,
LO/HI VOLT ALARMS, BATIXRY DISCONNECT

PECO II, Inc.

1376 State Route 598
Galion, OH 44833-0910

11-08-M) RFS

r~

4380078PD.da

1Appr 1P. Woemer

ISSUE
kwe s. NO 2cal

PECO II, Inc.

4380078PD
Issue 8 Nov 2000
DOCUMENT LIST
(INCLUDED AS ATTACHMENTS AT THE BACK OF THE MANUAL)

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DESCRIPTION

PART NUMBER

Power Data for Rectifier Module, SM50F48PM

4380084PD

Wiring Diagram for Rectifier System

4390933P

Manual for PEC 1015. PEC 1015 A Rectifier System

6421015P

PECO II. Inc.

4380078PD
Issue 8. NW 2ooO

TABLE OF CONTENTS
DescriDtion
TOC
List of Figures, Referenced Information
Foreword
Warnings and Cautions

section I
1.1
1.2
1.3
1.3.1
I .3.2
1.3.3
1.3.4
1.3.5
1.3.6
1.3.7
1.3.8
1.3.8.1
1.3.8.2
1.3.8.3
1.3.9
1.3.9.1
1.3.9.2
1.3.9.3
1.3.9.4
1.3.9.5
1.3.9.6
1.3.9.7
1.3.9.8
1.3.9.9
1.3.9.10
1.3.10
1.3.11
1.3.12
1.3.13
1.4
1.4.1
1.4.2
I .4.3
1.5
1.6
1.7

General Information
General
System Description
Standard Features
Front Access
Simple Configuration
Hot Insertion
Input Protection
output Protection
LVD and LVPU
Low Voltage and High Voltage Setpoints
Rectifier Module Indicators
AC ON Indicator
Rectifier Fail
Equalize ON
Distribution and Alarm Panel Indicators
Distribution Fuse Alarm
AC Fail
RFA MIN
RFAMAJ
Test
LVD
Hv
LV
Power On
BATT DISC.
Alaml.s
Battery Disconnect
VOLT/AMPS
High Temperature Shutdown
Primary System Components
Distribution and Alarm Panel
Rectifier Shelf
Rectifier Module
Monitored Faults
Configuration Arrangement

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II
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section II
2.1
2.2
2.2. I
2.3
2.3.1
2.3.2
2.3.3

Power Information
General
Input Power Requirements
Input Electrical Connections
Output Ratings
Float Regulation
Equalize Setting
Output Current

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SectiodT%ra
Front Matter

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5
6
7

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PECO II. Inc.

4380078PD
Issue 8. Nov 2000
TABLE OF CONTENTS - ~onttnucd

Section/Pars
section III

&
1.5
15
1.5
16

3.4
3.4.1
3.4.2
3.5

DWXiDtiOIl
System Installation
G.%W.d
Specifications
Recommended Terminal, Wire, and
Fuse Sizes
system Installation
Pre-Installation Checks
Installation
Operational Checkout

Section Iv
4.1
4.2
4.2.1
4.3

Module and Parts Removal

Gelled
Removing a Module
Rectifier Module Removal
Output Circuit Breaker Removal

22
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22
22
22

Section v
5.1
5.2
5.2.1
5.3

Module and Parts InstaBation

GellCll
Installing a Module
Rectifier Module Installation
Output Circuit Breaker Installation

23
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Section VI
6.1
6.2
6.2.1
6.2.1.1

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6.2.1.2
6.2.1.3
6.2.1.4
6.2.2
6.2.3
6.2.4
6.3

Operational Checkout and Troubleshooting

Gl2lCll
Operational Checkout
Complete Operational Checkout
Initial Turn-011 and System Output
Voltage Adjustment
AC Fail Test
Distribution Fuse Alarm Test
Fuse Alarm Test
HV and LV Adjust Procedure
Dropout and Pickup Adjust Procedure
Completion of Tests
Troubleshooting

Section VII
7.1
7.2

Theory of Operation
GeWX3l
System Theory of Operation

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Section VIII

System ConfigurationSmarts
List
GOXd
Contigurations

31

3.1
3.2
3.3

8.1
8.2

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PECO II, Inc.

4380078PD
Issue 8. Nov 2000

LIST OF FIGURES
Name

Figure Number
I-1

System
system Connections

3-1
REFERENCED

INFORMATION

EQUIPMENT
Eauioment Nomenclature
Digital Multimeter

Part Number
Fluke 87

Manufacturer
John Fluke
Mfg. Co. Inc.,
Everett, WA

TECHNICAL DOCUMENTATION OR SPECIFICATIONS

NOllltXlCl~hlI.Z

Power Data for Rectifier Module SMSOF48PM

ID Number
SM50F48PMPD

CONSUMABLES

Nomenclature
N/A

Part Number

Manufacturer

Manufacturer
PECO II
Galion, OH

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PECO II. Inc.

4380078PD

FOREWORD
This manual is intended to help the user of the 100 Amp Modular Rectifier Systems (system) install, test,
troubleshoot, and remove the system. For information on the modules that comprise the system, refer to the manuals
on those components. If you should have any questions or problems with the installation or maintenance of the
system you should contact one of the following sources:
Service
If you should need any assistance on any of the equipment produced by PECO II, Inc. we have complete
Engineering and Field Service Groups available in our Galion, OH facility. For any engineering or field service
support, please contact:
(419) 468-7700 (direct line to the Field Service Group)
(419) 468-7600 (Operator, ask to speak to the Field Service Group)

For pans replacement or ordering information please contact the Field Service Group at one of the above listed
numbers. If you have all pertinent information, you may simply forward a purchase order to one of the following:
PECO II, Inc.
P.O. Box 910
Galion. OH 44833-0910
iix to (419) 468-1587

Be sure to include the following information:

1.
2.
3.

Give the PECO II part number and engineering level of the equipment.
If the pan is electrical, please include the circuit reference numbers and the PECO U part numbers.
If the part is mechanical in nature, please give a description as to where the equipment is used.

Return and Repair

Equipment may be returned to the factory for repair. To send any equipment for repair. please do the following:
1.
2.
3.

Contact the Field Service Group at one of the above numbers.

Request a Returned Material Authorization (RMA) number for the equipment
Return the material postage paid (prepaid) to the following address:
PECO II. Inc.
1376 State Route 598
Galion, OH 44833-0910

PECO II, Inc.

4380078PD
WARNINGS

1.

ELECTRICAL SHOCK HAZARD. W NOT AlTEMPTTO REMOVE. MAINTAIN. OR INSTALLTHIS EQUIPMENT WilH
POWER APPLLED. PERSONNEL THAT ATTEMFT TO WORK ON THIS EQUrPMENT WH THE POWER APPLIED MAY
SUBJECT THEMSELVES OR OTHERS TO ELFCTRlcAL SHOCK THAT MAY CAUSE SERIOUS INJURY OR DEATH.

2. t

THE AlTEMPTED USE OFTHIS EQUIPMENT BY UNAUTHORaED OR UNTRAINED PERSONNU IS STRICTLY FORBIDDEN.
PERSONNEL THAT AlTEMPT TO WORK ON THIS EQUIPMENT WVOUT THE PROPER TRAINING MAY SUB,ECT
THEMSELVES OR OTHERS TO ELECTRICAL SHOCK THAT MAY CAUSE SERIOUS INJURY OR DEATH,

3. .

4.

Do NOT AlTEMPT TO WORK ON THIS EQUIPMENT IF ,T IS OR HAS BEEN EXPOSED TO A HIGH MOlSTURB COND,TION.
iT IS RECOMMENDED THE EQUIPMENT BE R!ZTURNED TO PECO II TO BE PROPERLY TESTED. WORKING ON THls
EQUIFMENT DURING A HIGH MOlSTURE CONDTON SUBJECTS THE USER TO ELECTRICAL SHOCK THAT MAY CAUSE
SERIOUS EVJURY OR DEATH.
USE OF AN AITACHMENT OTHER THAN ONE THAT HAS BEEN APPROVED BY PECO Is FORBIDDEN. THE Al-,?ZMPTED
USE OF UNAUTHORIZEDATTACHMENTS
W,LL OLD ANY AND ALL WARR-. ,MPL,ED OR OTHER, AND WILL,

Do NOT OPERATE THIS EQUIPMENT IF rr HAS BEEN DROPPED 0~ OTHERME HAS PosstBLY BEEN DAMAGED.
TRYING TO OPERATE THIS EQUIPMENT IF m HAS BEEN DAMAGED SUBJECTS YOURSELF OR OTHERS TO ELEC,RICAL
SHOCK THAT MAY CAUSE SEPJOUS INJURY OR DEATH.
BEFORE YOU PROCEED. ENSURE THE AC INPUT SOURCE Is NOT LhB AND THE INPUT C,RCU,T BREAKER(S,VVSE(S)
HAS BEEN UPPED OR REMOVU). IFTHESE PROCEDUP.ES HAVE NOT BEBN mLLOWZD AND THE EPUT,OUTPUT
POWER Is LlvE SERIOUS PERSONNELINJURY OR DEATH MAY OCCUR.
A RACWSHELF MAY CONTm SEVERAL OPERATING SYSTEMS. IF THERE IS ANOTHER SYSTEM IN THE GENERAL
AREA YOU WANT TO INSTALL THIS SYSTEM. BE CAUTIOUS OF ANY EXPOSED CONNECTORS OR WIRE.5 AND. WITH
PERMISSION. REMOVE POWER TO THE OTHER SYSTEMS. FAILURE TO TAKE THE NECESSARY S-PRECAUTIONS
SUBJECTS THE INSTALLER OR MAINTENANCE PERSONNEL TO SEVERE ELECTRICAL SHOCK THAT MAY CAUSE
SERIOUS INlURY OR DEATH.
8.
ENSURE AU AC INPUT Ls DISCONNECTED (BOTH LEGS).
9. I

I
THIS EQUIPMENT MAY CONNECT TO LEAD-ACID BATTERIES. BATIERY POSTS. TERMINALS. AND RELATED
ACCESSORIES CONTAIN LFAD AND LEAD COMPOUNDS. CHEMICALS KNOWN TO THE STATE OF CALIFORNLA TO
CAUSE CANCER AND BIRTH DEFECTS OR OTHER R!ZPRODUCIIE HARM. WASH HANDS AFl??R HANDLING.

CAUTIONS
1.

FOLLOW PROPER GROUNDING INSTRUCTIONS.

2.

IF CONNECITNG BATTERIES. REMOVE THE BAITERY BOX FUSE OR TRIP THE CIRCU,T BREAKER AND REMEMBER
THAT THE POLARITY Is CR7CAL TO AVOID DAMAGE TO THE SYSTEM. CHECK BATlERIES AND CONN!ZCONS FOR
PROPER PoLxwu AND mwR BEmRE CONNECTING THE BATTERIES TO THE SYSTEM.

3.

TO REMOVE THE CIRCUIT BREAKERS OR FUSES. BOTH THE DC AND AC INPUT TO THE SYSTEM W,LL NEED TO BE
DISCONNECTED. THEREBY DISABLING THE SYSTEM OUTPUT TO THE LOAD(S). TAKE THE NECESSARY
PRECAUTIONS AND IMORM THE PLANT ENGINEER THAT THE SYSTEM OUTPUT POWER TO THE LOADS WILL BE
DISABLED.

4.

ENSURE THE AC AND DC

5.

FUSE HOLDERS AND FUSES ARE TO BE LOADED TO 80 PERCENT OF THEIR AMPERE RATING.

POWER IS NOT APPUED TO THE SYSTEM BEFORE

PERFORM,NG

ANY MAINTENANCE.

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PECO II. Inc.

4380078PD
Issue 8. Nov 2COO
SECTION I GENERAL INFORMATION
I.1

GENERAL

The paragraphs that follow contain information that is intended to help the user with the understanding of the 1Cil
Amp Modular Rectitier Systems (system) operation. The system is configured with two Rectifier Modules to
produce either 100 Amps or 50 Amps redundant. It includes a Distribution and Alarm Panel with Battery
Disconnect. Included are paragraphs that explain the system description, standard features, modules. configuration
arrangement, and shelf dimensions.
1.2 SYSTEM DE%XIPTION
The 100 Amp Modular Rectifier Systems (system) is a modular design rectifier system capable of providing either
100 amps or 50 amps redundant utilizing a single DC bus output via the four distribution circuit breakers on the
front of the system. The system operates from 184-264 VAC, 45-60 Hz individual AC input from the AC Power
Service Cabinet to the individual Rectifier Modules via a connection on the rear of each Rectifier Shelf.
Each modular rectifier can be hot inserted. meaning the rectifiers can be removed or installed without shutting down
the entire system provided proper start-up procedures are used. In addition, the system can be operated with or
without batteries and comes supplied with single DC Distribution, an output voltage adjustment (float and equalize)
on the Rectifier Modules, Low Voltage Disconnect (L.VD) and Pick Up (LVFU). HV and LV adjust, Battery
Disconnect, and alarm capability via the DC Distribution and Alann Panel.
13 STANDARD FEATURES
The system comes with many standard features. These features are detailed in the following paragraphs.
1.3.1 FRONT ACCESS
The system has been designed to allow the user total front access to all controls and indicators.
1.32 SIMPLE CONFIGURATION
The system is configured for up to 100 amps or 50 amps redundant.
1.3.3 HOT INSERTION
Rectifiers can be removed/installed without shutting down the entire system provided proper start-up procedures
are followed.
1.3.4 INPUT PROTECTION
Primary input protection is provided by the customer. All input lines need to have protection.
13.5 OUTPUT PROTECTION
Over voltage protection is provided in each rectifier. Should the DC output go above the preset limit the faulty
rectifier is automatically shut down.

PECO II, Inc.

4380078PD
Issue 8. NW Zoo0

1.3.6 LOW VOLTAGE DISCONNECT (LVD) AND LOW VOLTAGE PICK-UP (LVPU)
The system comes equipped with Low Voltage Disconnect (LVD) and Low Voltage Pick-up (LVPU) circuitry. If
the load power is being supplied by the batteries but the battery output is no longer sufficient to power the load(s)
and reaches the LVD setpoint. the system will shut down the output to the load(s) to protect the batteries. This
LVD shutdown is factory set to -42 VDC, however there is an adjustment potentiometer on the front of the
Distribution and Alarm Panel to adjust this setpoint.
The Low Voltage Pick-up (LVPIJ) feature senses when the batteries have recovered and are. capable of providing
the load power. This LVPU is factory set to -49 VDC, however there is an adjustment potentiometer on the front
of the Distribution and Alarm Panel to adjust this setpoint.
In addition, there are test points and aTEST switch that allows these setpoints to be adjusted without taking the
plant off-line as the potentiometers for LVD and LVPU are set. It is recommended that whenever LVD and
LVPU are adjusted, the TEST switch located directly above the LVD and LVPU potentiometers is moved to the
TEST position (Amber TEST lamp illuminated). It is just as important to remember to move this switch away
from the test position back the system on-line position after the potentiometers are adjusted. Refer to the
adjustment procedures in Section VI.
13.7 LOW VOLTAGE AND HIGH VOLTAGE SETPOINTS
The system comes equipped with Low Voltage and High Voltage circuitry. If the system output were to go
above(factory
set at 57.0 VDC) or below (factory set at 49.0 VDC) the setpoints, the system would shutdown and
the loads would be transferred to the batteries (if available).
In addition, there are test points and a TEST switch that allows these setpoints to be adjusted without taking the
plant off-line as the potentiometers for I-IV and LV are set. It is recommended that whenever HV and LV are
adjusted, the TEST switch, located above the HV and LV indicators and potentiometers, is moved to the TEST
position. After the HV and LV potentiometers are adjusted, moving the TEST switch ot of TEST will enable the
HV and LV circuits at the adjusted value. Refer to the adjustment procedures in Section VI.
1.3.8 RECTIFIER MODULE INDICATORS
The types of indicators located on the Rectifier Module are as described in the following paragraphs:
1.3.8.1 AC ON INDICATOR
A green AC ON LED, located on the front of each Rectifier Module, will illuminate when AC input voltage is
present.
1.3.8.2 RECTIFIER FAIL
A red Rectifier Fail Alarm (RFA) indicator, located on the front of each Rectifier Module, will illuminate if any
condition occurs which disables the output of any Rectifier Module in the shelf. Conditions which result in a
RFA are as follows:
A. Complete loss of the AC input voltage.
B. Rectifier output voltage exceeds the high voltage shutdown point.
C. Any failure condition that disables the rectifier output.

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PECO II. Inc.

4380078PD
Issue 8. NW 2OCil
1.3 STANDARDFEATURES-~~~~~~U~~
1.3.8.3 EQUALIZE ON
An amber Equalize ON, located on the front of each Rectifier Module, will illuminate whenever the
FLOAT/EQUALIZE toggle switch is in the EQUALIZE position and the AC Input voltage to the Rectifier is
within tolerance.
1.3.9 DISTRIBUTION AND ALARM PANEL INDICATORS
The visual indications for the Distribution and Alarm Panel are described in the following paragraphs.
1.3.9.1 DISTRIBUTION FUSE ALARM
A red Distribution Fuse Alarm (DFA) indicator, located on the front of the Distribution and Alarm Panel, will
illuminate if a output breaker or an ABS fuse would open.
1.3.9.2 AC FAIL
A red AC Fail indicator, located on the front of the Distribution and Alarm Panel, will illuminate if the AC to
the system were to become disabled.
1.333 RFA MA.l
A red RFA MAJ indicator will illuminate if either Rectifier in a shelf becomes disabled, the output falls out of
tolerance, or if either Rectifier were to lose the AC Input.
1.3.9.4 TEST
An amber TEST indicator will illuminate whenever the TEST switch is placed in the TEST mode (used during
setting the system setpoints).
1.3.9.5 LVD
A red Low Voltage Disconnect (LVD) indicator will illuminate whenever the system has a LVD condition
(factory set at 42.0 VDC) and is used to disconnect the batt&ies from the system (protects the batteries from
being over discharged)
1.3.9.6 I-IV
A red High Voltage (HV) indicator. located on the front of the Distribution and Alarm Module, will illuminate
whenever the system output has exceeded the HV adjust setting (factory set at 57 VDC).
1.3.9.7 LV
A red Low Voltage (LV) indicator, located on the front of the Distribution and Alarm Module, will illuminate
whenever the system output does not achieve the LV adjust setting (factory set at 49 VDC).
L3.9.8

POWER ON

A green Power On (PWR ON) indicator will illuminate whenever there is DC power available.

PECO II. Inc.

4380078PD
Issue 8, NW 2000

1.3.9.9 BAIT DISC

A red Battery Disconnected (BATT DISC) indicator will illuminate whenever the Batteries are off line and will
go out if the batteries are returned to the charging circuits.
1.3.10 ALARMS
Several alarms are available as standard and optional features. For a complete review of the alarm notices, refer to
paragraph 1.5 of this section.
1.3.11 BATIERY DISCONNECT
There is a Battery Disconnect switch, located on the front of the Distribution and Alarm Panel, that removes the
charging circuits to the batteries to permit battery maintenance. The red BAIT DISC LED will illuminate
whenever the batteries are disconnected from the system and will go out when the batteries are connected to the
charging circuits.
1.3.12 VOLT/AMPS
There is a sliding toggle switch, located on the front of the Distribution and Alarm Panel, that aIIows the digital
meter to be toggled between reading either system output voltage or amperage.
1.3.13 HIGH TEMPERATURE SHUTDOWN

PRIMARY

There is a normally closed loop located on the rear of the system on the alarm terminal block that is provided to
connect an external temperature sensor. The sensor connects between tbe NC and common terminals. If the
external sensor senses a high temperature condition, the loop opens and the system will shut down. Typical
applications would be ambient air temperature sensing in a hut environment or remote plant control. These
contacts are jumpered at the factory between the NC and common terminals and the jumpers should be left in
place if they are. not be used.
1.4

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S YS TEM COMPONENTS

The system is comprised of.two primary components consisting of the DC Distribution and Alarm Panel and the
Rectifier Shelf and Modules. A brief descriptiori of each follows. For a more detailed description and theory of
operation of the components, refer to Section VII, Theory of Operation.
1.4.1 DISTRIBUTION AND ALARM PANEL
The Distribution and Alarm Panel provides the DC distribution via circuit breakers wired to individual bus bars
and plant alarm interfaces via a connection on the backplane. DC output connections are dual DC crimp type lugs
and the plant alarm interface is provided via .a pressure type terminal block. Table I-l includes the alarms. The
panel also includes the system adjustment pots and test points to be used during system adjustment or test.
Additionally, the panel also includes the battery disconnect switch and ABS fuses.
1.4.2 RECTIFIER SHELF
The Rectifier Shelf is designed to house up to two 50 amp Rectifiers each. The system has been designed to
provide a total of 100 amps output or 50 amps redundant. dependant on power requirements.

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PECO II. Inc.

4380078PD
Issue 8. Nov 2000
1.4 PRIMARY SYSTEM COMPONENTS-continued

1.4.3 RECTIFIER MODULE

The Rectifier Module is used to convert the AC input to the DC o+put. A complete description of the Rectifier
Module is contained in manual SM50F48PMPD.
1.5 MONITORED FAULTS
The faults monitored by the DC Distribution and Alarm Module are contained in Table I-l.
1.6 CONFIGURATION ARRANGEMENT
The 100 Ann Modular Rectifier &stem kvsteml can be contiaured to the users rewiremeats. Maximum power
output available is 100 amps or 50 amps redundant.
.I

1.7 DIMENSIONS (See Figure 1-l)

The system is housed in a shelf 19.0 in. wide x 8.00 in. high x 17.75 in. deep.

Table l-l. Monitored Faults

&&
Low Voltage
Disconnect

Abbrev.
LVD

Cause
Output Voltage
<42 VDC

Generated BY
Distribution/
Alarm Panel

StandardlOmional
Standard

Output Breaker/
Fuse Open

BKR
OPEN

Any Output
BreakWElec.
Trip Only

Distribution/
Alarm Panel

Standard

AC Fail

AC FAIL

AC Failure

Rectifier Module

Standard

Low Voltage

LV

Output Voltage
~49 VDC

Distribution/
Alarm Panel

Standard

High Voltage

I-IV

Output Voltage
257 VDC

Distribution/
Alarm Panel

Standard

RF Major

RF MAJOR

Rectifier
FailWZS

Rectifier Module

Standard

12

PECO II, Inc.

4380078PD
Issue 8. NW Zoo0

Figure 1-1. System

13

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PECO II, Inc.

438007SPD
Issue 8. Nov 2OCil
SECTION II POWER INFORMATION
2.1 GENERAL

This section is provided to detail the specific input and output power required or provided by the system. Included
are input requirements, output ratings and various other signals that are required and/or provided by the system.
2.2 INPUT POWER REQUIREMENTS

The input voltage required is single phase 184-264 VAC, 45-60 Hz, individual feed to the Rectifier Modules.
2.2.1 INPUT ELECTRICAL CONNECTIONS

The rectifiers are configured for individual AC~input to the rectifiers via the terminals on the back of the system.
2.3 OUTPUTRATINGS
The output rating of the system is dependant on the configuration. The system has a maximum power output of
either 100 Amps or SO Amps redundant.
2.3.1 FLOAT REGULATION

Float Regulation voltage is factory set at 54.00 VDC for all conditions of AC input and loads from 0 to 100 Amps.
2.3.2 EQUALIZE SETlTNG

Equalize voltage is factory set to 56.40 VDC.

2.3.3 OUTPUT CURRENT

Output current is dependant on the number of Rectifier Modules equipped. Each rectifier is capable of providing
up to 50 Amps, maximum system output is either 100 Amps or 50 Amps redundant.

14

PECO II. Inc.

4380078PD
Issue 8. NW 2000
SECTION III SYSTEM INSTALLATION
3.1 GENERAL
The syslem is installed with single phase 184-264 VAC. 45-60 Hz input power, individual feed to the Rectifier
Modules. Output power connections consist of four (4) output breakers located on the Distribution and Alarm Panel
for load interface, or bulk DC output via the DC Bus Bar. If the system is also connected to a Battery Box, -48 VM:
(bulk) from the system to the battery box for battery charging is also required.
The different installation possibi1ities.a.s well as the required terminal type, capacity, recommended wire size and
recommended branch circuit protection is contained in this section.
3.2 SPECIFICATIONS
The following information is intended to give the user a quick reference to information that is necessary to install
and operate the system. Included are input requirements, output signal characteristics, size, weight, and generated
system noise.
Input Requirements (Per Rectifier Module)
Voltage

184-264 VAC, 45-60 Hz; if equipped with a Battery Box: 48 VDC

CtX.l

c 20 Amps at 264 VAC @ 50 amps load (Per Rect. Module)

Efficiency

85% minimum, 100% load

Recommended
AC Breaker

40 Amps (264 Feeder VAC), per system (2 Rect. Modules); 20 Amps Individual; 2-P&
Circuit Breaker

Output (Per Rectifier Module)

Output Breaker Rating

O-50 Amp, (up to four, Max. System 100 Amps)

Float Voltage

Minimum Adjust = 50.00 VDC

Maximum Adjust = 59.00 VDC
Factory Set = 54.00 VDC

Equalize Voltage

Factory Set = 56.4 VDC

Hv

Factory Set = 57.0 VDC

LV

Factory Set = 49.0 VDC

LVD

Factory Set = 42.0 VDC

Current

50 Amps per Rectifier Module. The Modules are placed in parallel for a maximum
output current of 100 Amps (DC Nominal)

Regulation

<O.l%line
<O.l%load
At 0 - 100% load

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Issue 8. Nov 2OCil
3 3 SPECIWKATIONS-Continued

N&e

<
<
<
<

32 dBmc (Voice Band).

100 mV mu (Wideband,
IOHz-2OMhz)
2.50 mV Peak to Peak (Wideband, 0 - 100 MHZ)
50 mV Peak to Peak Ripple

Filtering

32 dBm-c when connected to batteries with an AH rating of four (4) times the load
current

Size

System Shelf: 19.0 in. wide x 8.00 high x 17.75 in. deep (System Max. Dimensions
Given)

MOUtltig

The system can be relay rack mounted,

Weight

Rectifier Shelf Without Rect. = Approx. 40 Ibs each

Rectifier Module: Approx. 18.0 Ibs each
Total System Weight = <76 Ibs (2 Rect. Installed)

Temperature

Operating: 0 to +50C (+32F to +122F)

Storage: 40 to +85C (-4OF to +185F)

Altitude

Sea Level to 4800 feet: OC/+50C (+32F/+122F)

4800 feet to 7ooO feet: OC/+45C (+32-F/+1 13F)
7OCG feet to 10000 feet: OC/+4OC (+32F/+104F)

Cooling

Cooling Fans on Rectifiers, Remainder of System is Convection Cooled

Humidity

85% Non-condensing

Shock

This equipment, in its shipping container, withstands shock developed during shipping
without physical damage or degradation of the electrical performance.

Vibration

This equipment, in its shipping container, withstands vibration encountered in shipping

without physical damage or degradation of the electrical performance.

Heat Dissipation: Nominal input with output adjusted for 54.00 VDC.
Modules

Shelf Amps

BTU/HR

100

3280

Ventilation

System Ventilation openings should not be blocked and the ambient temperature of the
air entering the system should not exceed 50C (122F).

3.3 RECOMMENDED TERMINAL, WIRE, AND FUSE SIZES

Tables 3-1 thm 3-5 contain the recommended terminal size. types of fittings, wire size, and fuse/breaker size. as
applicable, required for the proper installation of the system into a plant. Also included are Installer Notes for use
as reference information during the installation.

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3.3 RECOMMENDED TERMINAL, WIRE, AND FUSE srzEs-continued

Table 3-1. System Alarm Terminals

TkYllliIlal
Capacity
26-16 GA

Terminal Type

Recommended Wire Size

PreSSWe

20 GA

Table 3-2. Frame Ground Terminals

System
lOOAmp

T~llIlillZd
Capacity
16-6 GA

Terminal Type

Recommended Wire Sue

#IO Lug

10 GA Minimum

Table 3-3. System -48 VDC Battery Terminals

Terminal Capacity

Terminal Type

4 GA-500 MCM

Two-Hole Lug, 318 x 1.0 Ch-s

Recommended Wire
Size
l/O GA Minimum

Table 3.4. System 48 VLK Output Terminals (Ground and -48 VDC)
Terminal Capacity

Terminal Type

8-2 GA

Two-Hole Lug. l/4 x 0.62 Ctrs

Recommended Wire
SiZ.2
8 GA Minimum @ 50
AllIPS

*Output breaker size is dependant on load(s). Maximum of 50 amps per breaker position. In addition, output
breakers should he max. loaded to 80% of the CB rating.
Table 3-5. Rectifier Commercial AC Input Terminals

INSTALLERS INFORMATION NOTES:

-1: Equipment grounding conductor size (Frame or Chassis) is based on the recommendations of the National
Electric code Table 250-95 for copper wire. If aluminum or copper clad aluminum grounding conductor is used,
refer to Table 250-95 for increased conductor size.
-2: Frame or Chassis Ground wire size is based on recommendations of the National Electric Code Table 25095.
-3: Fuse or circuit breaker protection external to the system for commercial AC is to he provided by the
customer.

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32 RECOMMENDED TERMINAL, WIRE, AND FUSE

stzE%continued

Note: Wire sizes are based on the voltage drop considerations and the National Electric Code Table 310-16 for
copper wire.
&t&5: A terminal block is provided for Battery Load. GRD Return Leads require dual hole lug terminations
connecting to the +BAT BUS BAR.
-6: Installation of the system should be in an area that is accessible to qualified personnel only.
Note: The bay the system is to be installed into must be secured to the building structure before the equipment can
be operated.
Note:. I?stallation of the system should be in an area that is accessible only to qualified personnel.
3.4 SYSTEM INSTALLATION
(See figure 3-l and the installation prints cont&ned

as an attachment to this manual.)

The paragraphs that follow contain the necessary procedures to install the system. The system can be rack or wall
mounted and can be utilized with or without a battery box.
3.4.1

PRE-INSTALLATION

CHECKS

A. Remove the system from the shipping containers as follows:

(1) With a utility knife and starting at the four top comers of the cardboard shipping container and working
down, carefully and slowly cut the comers of the cardboard until the shipping container separates.
(2)

Remove the excess packing material.

(3) Inspect the equipment. Note any shipping damage, if present, aad immediately notify the carrier and
PECO II at the numbers listed at the front of this manual. It is recommended that if there is shipping
damage photographs be taken of the damage.
(4)

Take an inventory.

B. The system list number that was ordered will be internally wired at the factory. The only wiring that will be
connected by the installer is the -48 VDC output to the loads (maximum four breaker locations, or bulk), AC
individual input to the Rectifier Modules, alarm wiring to customer famished external alarms (if required). and the
battery box connection to the positive and negative bus bars.
C. Ensure the system matches the order that was placed.
D. Determine the installation location and input power location to be used by the system.
E. The system has been configured for 184-264 VAC. 45-60 Hz it%48 VDC out.

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Issue 8. NW 2OKI
3.4 SYSTEM INSTALLAITON-continued

3.42 INSTALLATION
A. Install the system as follows:
(1) Install the mounting brackets as required for flush or relay rack mounting.
(2) Ensure there is proper clearance in the rack to install the system.
(3) Put the system into position and secure with the screws located at each mounting bracket (four screws
equally spaced each side recommended). Remove the cover that coven the bonom two screws. Install the
cover after the system is secured to the rack.
(4) Trip the AC plant input circuit breaker(s) or remove the input fuse(s), and, if equipped, the -48 VDC
battery Box interface circuit breaker or remove the input fuse.
(5) Trip the system OUTPUT breakers.
B. Gain access to the back of the system and remove the screws that secure the Rectifier Shelf rear access cover.
C. Connect the -48 VDC load(s) to the bus bar (from the Circuit Breakers CBl tbm CB4, as required) on the rear
of the Distribution and Alarm Panel with dual hole II4 on 0.62 in. style lugs. Up to four loads can be connected,
however the maximum breaker size per position is 50 amps. Secure the output wires to the DC lugs with the
bolts. Recommended wire and terminal sizes are listed in the tables at the front of this section.
D. Use dual hole l/4 on 0.62 in. lugs and connect the DC Load Ground(s) to the +BAT Bus Bar with the two
bolts. The +BAT Bus is clearly identified.
Note: In the following step, NEC requires that all AC wires are not exposed. It is required that all AC wires be
run thru conduit. Dependant on local codes, all power wires may need protection. Before you connect the
system, it is advisable to check with the Plant Engineer or local authorities to review local codes regarding types
of conduit and protection. If acceptable. flexible conduit is recommended. In addition, NEC also requires that all
AC and DC wires must be segregated from one another and the alarm wires must exit from the DC side.
E. Place the commercial AC individual input power through the outer case access port. Place the commercial
power to the LINE l(Ll), LINE 2 (L.2). and Ground (GR) terminals of the Input Tetination Terminal Block,
connect as required. Secure the wires to the terminal block with the screws. Recommended wire, circuit
breaker/fuse, and terminal sizes are listed in the tables at the front of this section.
F. Place the Chassis Ground wire to the CH GROUND location on the right, rear of the chassis, aft looking
forward at the terminal provided. Secure the wire to the post with the nut and washers. Recommended wire and
terminal sizes are listed in the tables at the front of this section.

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3.4

SYSTEM

INSTALLATION-continued

C. Connect the Plant Alarm Interface. Recommended wire size is listed in the tables at the front of this section.
Run the alarm interface wires, as directed by the Plant Engineer, through the outer case access port. Connect the
alamw from the interface on the rear of the Distribution and Alarm Module to the plant interfaces as follows:
: The Alarm Terminal block (TB I) is clearly marked as to the Form C contacts for NC, NO, and C.

(1) Connect the Low Voltage Disconnect alarm to the alarm interface terminal block marked LV DISC on
the rear of the system.
(2) Connect the Breaker Open alarm to the alarm interface terminal block marked BKR OPEN on the rear
of the system.
(3) Connect the AC Fail alarm to the alarm interface terminal block marked AC FAIL on the rear of the
system.
(4) Connect the Low Voltage Alarm to the alarm interface terminal block marked LV ALARM on the rear
of the system.
(5) Connect the High Voltage Alarm to the alarm interface terminal block marked HV ALARM on the r&r
of the system.
(6) Connect the Rectifier Fail Major alarm to the alarm interface terminal block marked RF MAJOR on the
rear of the system.
(7) Connect the external high temperature shutdown from an external senssor to the HI TBMP contacts on
the alarm interface terminal block. There is one available position that is jumpered at the factory to
maintain a closed circuit (system shuts down with an open). If no sensor is to be connected, leave the
jumper installed.
H. If a Battery Box is to be connected to the system, proceed as follows:
(1) Connect the Battery interface to the System 48 VDC Battery Bus Bars. For the purpose of this
installation, it is recommended that the GRD is connected prior to connecting the -48 VDC. After the
ground is connected, connect the -48 VDC to the system with the lug located behind the bus bar. This will
give the rear cover enough clearance to be installed. Use dual hole 318 on I.0 in. style lugs. Secure the
leads to the - BAT and + BAT Bus Bars with the hardware provided. Refer to the tables at the front of this
section for recommended lug and wire size.
I. Ensure all leads are terminated with the correct polarity, there are no loose connections or shorted leads, and
there is unrestricted airflow through the unit.
J. Install the system rear cover and secure. it to the system with the hardware provided.
K. Perform the Operational Checkout Procedure (paragraph 3.5).
3.5 OPERATIONAL CHECKOUT
Perform tbe operational checkout of the system per Section VI. Operational Checkout and Troubleshooting.

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I
RmnN AND @AT GRND

BaTIN,

_-__-_
__-___--A----

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Figure 3-I. System Connections

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SECTION IV MODULE AND PARTS REMOVAL
4.1 GENERAL
The system is modular in design and the Rectifier Modules are easily removed. This section gives the procedures
necessary for the removal of the system components that are repairable by field service technicians. The installation
of these components is covered in Section V. Module and Parts Installation.
Only the Rectifier Modules and output circuit breakers can be removed and installed from/to the system. For any
other system errors. contact PECO II Field Service at the numbers listed in the front matter of this manual for repair.
4.2 REMOVING A MODULE
Remove a Rectifier Modules from a working system as follows:
4.2.1 RECTIFIER MODULE REMOVAL
When removing a Rectifier Module from a working system, proceed as follows:
A. Determine which Rectifier Module needs to be removed.
&&: The following step is a precautionary measure. If all Rectifier Modules are. on the same AC service,
tripping the circuit breaker will disable the system. Disregard the following step if all Rectifier Modules are on
the same service.
B. In the AC Service Cabinet, set the AC circuit breaker to the module that is to be removed in the
OFF position.
C. Set the DC circuit breaker located on the front panel for the Rectifier Module to be removed to the OFF
position.
D. Loosen the module holding screws (three screws total)
E. Using the module handle, remove the module from the cage
F . If returning the module to the shop or PECO II for repair, place the module in an ESD non-conducting
container and a small box to protect the module during shipping and handling.
4.3 OUTPUT CIRCUIT BREAKER REMOVAL
Remove the Output Circuit Breakers on the Distribution and Alarm Panel as follows:
A. Trip the system AC feed circuit breaker or remove the input fuse at the AC Power Service Cabinet.
B. If equipped with a battery box, hip the DC battery box output circuit breaker or remove the fuse that goes from
the battery box to the system.
C. Ensure the system has the power removed.
D. From the front of the system, remove the screws that secure the front access cover and remove the access cover
E Remove the circuit breaker.

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4380078PD
Issue 8. NW 2OiYl
SECTION V MODULE AND PARTS INSTALLATION
5.1 GENERAL

The system is modular in design and the Rectifier Modules are easily installed. This section gives the procedures
necessary for the installation of the system components that are repairable by field service technicians. The removal
of these components is covered in Section N, Module and Parts Removal.
Only the Rectitier Modules and the output circuit breakers can be removed and installed from/to the system. For
any other system errors, contact PECO II Field Service at the numbers listed in the front matter of this manual fox
repair.
5.2 INSTALLING A MODULE

Install a Rectifier Module into a working system as follows:

5.2.1 RBCTIFIER

MODULE INSTALLATION

When installing a Rectifier Module into a working system, proceed as follows:

A. Determine in which position the Rectifier Module needs to be installed.
I&&: In the followi ng step, tripping the AC breaker was a precautionary measure in Removal, Section N. If all
Rectifier Modules are on the same AC service, tripping the circuit breaker will disable the system. If the system is
on the same AC service do not trip the AC breaker. However, the DC circuit breaker MUST be OFF before

I-

B. Ensure the AC circuit breaker in the AC Power Service Cabinet and the DC circuit breaker for the rectifier
were set to OFF.
C. Install the module into position and apply even pressure across the face of the unit until the connector is fully
engaged to the backplane. The module should slide into position with little resistance.
D. Tighten the module holding screws (three screws total).
E. Perform the operational checkout located in Section VI.
5.3 OUTPUT CIRCUIT BREAKER INSTALLATION

Install the Output Circuit Breakers on the Distribution and Alarm Panel as follows:
A. If not already accomplished, trip the system AC feed circuit breaker or remove the input fuse(s) at the AC Power
Service Cabinet.
B. If not already accomplished and if equipped with a battery box, set the DC Battery Disconnect switch on the
front panel to remove the charging circuits. The indicator lamp should come on
C. Ensure the system has the power removed.

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Issue 8. Nov 2OCHl
5.3 OUTPUTClRCZllT BREAKER INSTALLAl7ON-continued

D. Install the circuit breaker into position and push to secure it to the circuit breaker bus bar.
I

E. Install the front access cover and secure with the screws.
F. The installation is complete. Perform the Operational Checkout in Section VI.

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4380078PD
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SECTION VI OPERATIONAL CHECKOUT AND TROUBLESHOOTING
6.1 GENERAL
This section gives the procedures necessary for the operational checkout and troubleshooting of the system.
The appropriate operational checks should be accomplished after any maintenance has been performed.
6.2

OPERATIONAL

CHECKOUT

The following procedure must be followed after installation OT performing any maintenance to the system.
6.2.1 Complete Operational Checkout
6.2.1.1 Initial Turn-On and System Output Voltage Adjushnent

A. Put the ALARM TEST switch, located on the front of the Distribution and Alano Panel, oat of the test
position 0XST LED not illuminated).
B. Ensure the AC power from the AC Service cabinet is not engaged and if not already accomplished, trip the
DC circuit breaker directly below each Rectifier Module.
c. Remove the Rectifier Modules from all but the fmt position
D. If not already accomplished, insert a Rectifier Module into the lint position on the mounting shelf.
E. Ensure the rectifier module is f&y in place.
F. Turn the AC Power Service Cabinet circuit breaker for the Rectifier Module in the first position to ON.

G. Observe the following:

1. The AC ON LED (Green), located on the front of the Rectifier Module, will light indicating that the
Rectifier is operating.
Note: There is a slight difference between the bus voltage and the actual output of the Rectifier. DO not use the
voltage reading from the Rectifiers digital meter. Set a Fluke digital multimeter on the front panel set to read
~60 VDC. Use the voltage reading from the Testpoints GRD and -BAT on the front of the Distribution and
Ahn Panel.
2. The plant voltage will begin to rise to the factory preset float voltage of 54.00 VDC.
3. If the Plant Operator would like a float or equalize voltage other than the factory preset value, proceed to
step 2. If the factory set float voltage of 54.00 VDC and the Equalize factory setting of 56.40 VDC are
acceptable to the Site Engineer, go to paragraph G.

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6.2 OPERATIONAL CHECKOUT-continued

&&: The following steps are used to adjust the plant float and equalize, set point voltage to a setting different
than the factory settings.
H. Float and Equalize adjustments. Adjust the plant Float and Equalize settings by using the steps that follow.
If tbe Float or Equalize factory settings are acceptable, go to paragraph G.
Note: There is a slight difference between the bus voltage and the actual output of the Rectifier. Do not use tbe
voltage reading from the Rectifiers digital meter. Set a Fluke digital multimeter on the front panel set to read
~60 VDC. Use Ihe voltage reading from the Testpoints GRD and -BAT on the front of the Distribution and
Alarm Panel.
1. Wbile.watching Fluke digital multimeter,,adjust the plant float voltage using the float adjust pot located
on the front panel of the Rectifier Module. Adjust the voltage to the value determined by the Site Engineer
(LocaI Engineer).
&&: When the plant float and equalize voltage is set to a value higher than the factory setting, it is likely
that the HV abum indicator on the front panel of the Distribution and Alarm Panel will illuminate and the
Rectifier output will not be available. If an HV condition does come on, you will need to adjust the HV
circuit of the Rectifter Module per paragraph 6.2.2. before proceeding and reset the AC circuit breaker(s)
located within the Power Service Cabinet to reset the Rectifier Shelf.
2. Identify the new float voltage setting on the front of the plant.
3. Adjust equalize voltage (high charge) to the value as determined by the Plant Operator as follows:
a. Repeat step 2.a and 2. b. above, except set the Float/Equalize switch. located on the front of the
Rectifier Module, to the Equalize position.
4. After changing the equalize voltage on the Rectifier Module, return the Float/F.qualize switch to the
Float position.
I. Remove AC power at the Power Service Cabinet and trip the DC circuit breaker located just below the
Rectifier.
J. Remove the Rectifier Module in position number one and install another Rectifier Module in position
number two (Rectifier Module not previously adjusted).
K. Repeat steps E., F., G.. and H. for the remaining Rectifier Module, excluding do not perform paragraph F.
step 2.a. thm 2.d. if the Rectifier Module Float and Equalize voltage do not require adjustment.
L . Ensure both the AC and DC circuit breakers are in the OFF position and then install all Rectifier Modules
into the shelf.
M. Ensure all rectifiers are firmly in place.
N. Repeat step K. for the Rectifier Modules in position number two.
0. Turn the AC circuit breaker(s), located in dte AC Power Service Cabinet, to the ON position until all the
Rectifiers within the system come on line.

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4380078PD
Issue 8. Nov 2000
6.2 OPEKA-ITONAL CHECKOUT-continued

P. Apply the load(s) to the system by setting the load circuit breakers on the DC Distribution and Alarm Panel.
&&e: There is a slight difference between the bus voltage and the actual output of the Rectifier. Do not use the
voltage reading from the Rectifiers digital meter. Set a Fluke digital multimeter on the front panel set to read
~60 VDC. Use the voltage reading from the Testpoints GRD and -BAT on the front of the Distribution and
Alarm Panel.
Q. With the digital multimeter set to read <60.VDC, measure the system output voltage on the Testpoints GRD
and -BAT on the front of the Distribution and Alarm Panel. Output voltage should read whatever the value the
system has been adjusted to (factory setting is 54.00 VDC).
R. If the Float Adjust pot was adjusted, ensure the AC ON indicator located on the front panel of each Rectifier
Module is illuminated and the Rectifier Fail Alarm (RFA) is not illuminated. Also ensure no fail indicators are
illuminated on the Distribution and Alarm Panel.
S. The system is operational. Continue with the operational checks of the system.
6.2.1.2 AC FAIL TEST
Note: Assumes fully charged batteries and that the loads are connected.
A. Remove the AC input fuse or trip the circuit breaker at the AC service cabinet to the system.
B. All Rectitier Module AC ON L.EDs (green) will go off.
C. The RFA LED (red) on the Rectifier Modules and Dishibution and Alarm Panel will come on and the
Form C contact on tbe alarm terminal block located on the rear of tbe system will change state.
D. There should not be a disruption of the loads.
E. Restore the AC power to the system by inserting the fuse OT setting the circuit breaker at the AC service
cabinet. The system should return to normal operation.
6.2.1.3 DL5TRlBUTION FUSE ALARM TFST
The System is equipped with electrical trip circuit breakers only. Tripping the circuit breaker on the front panel
will not cause tbe Form C contacts to change position or cause the front panel indicator to illuminate. The Form
C contact change (electrical trip) and DFA indicator has been tested at the factory for proper operation.
6.2.1.4 FUSE ALARM TEST
A. Remove the fuse on the front of the Distribution and Alarm Panel. The power lamp will go out and the
DFA on the front panel will illuminate. In addition, tbe RF Major alarm will change state.
B. Insert the fuse. The system should return to normal operation.

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6.2 OPER4nONAL CHEcKOuT-continued

Note: In the following procedure, when the ALARM TEST switch is moved to TEST, all Foorm C contacts will
change state and the AC FAIL, RFA MAJOR and RFA MINOR, and DFA visual &n-n LEDs will illuminate.
This would be a good time to verify all alarms change state. Notify alarm surveillance personnel that alama
will be sent.
6.2.2 I-IV AND LV ADJUST PROCEDURE
A . Put a Fluke digital multimeter set to read ~60 VDC on the GRD and -BAT test jncks located on the front of
the Distribution and Alan-n Panel.
B. On the front of the Distribution and Alarm Panel, put the ALARM TEST switch in the TEST position. The
TEST LED should come on. Keep the ALARh4 TEST switch in the TEST position during the complete
adjustment procedure. This allows the system to be adjusted without affecting the operation (output) of the
system.
C. While watching the voltage meter. adjust the TEST ADJ potentiometer to the desired HV setting.
D. Adjust the HV ADJ potentiometer until the HV lamp illuminates and immediately stop. The HV setting is
adjusted to the value set by the TEST ADJ potentiometer in step C.
E. While watching the voltage meter, adjust the TEST ADJ potentiometer to the desired LV setting.
F. Adjust the LV ADJ potentiometer until the LV lamp illuminates and immediately stop. The LV setting is
adjusted to the value set by the TEST ADJ potentiometer in step C.
G. On the front of the Distribution and Alarm Panel, put the ALARh4 TEST switch back in normal system
operation. The TEST LED should go out. The HV and LV setpoint adjustments are complete and the system
should retttm to normal operation.
&I+: In the following procedure. when the ALARM TEST switch is moved to TEST, all Form C contacts will
change state and the AC FAIL, RFA MAJOR and RFA MINOR, and DFA visual alam LEDs will illuminate.
This would be a good time to verify all alarms change state. Notify alarm surveillance personnel that alarms will
be sent.
6.2.3 DROPOUT AND PICKUP ADJUST PROCEDURE
A . Put a Fluke digital multimeter set to read ~60 VDC on the GRD and - BAT test jacks located on the front of
the Distribution and Alarm Panel.
B. On the front of the Distribution and Alarm Panel, put the ALARM TEST switch in the TEST position. The
TEST LED should cme on. Keep the ALARM TEST switch in the TEST position during the complete
adjustment procedure. This allows the system to be adjusted without affecting the operation (output) of the
system
C. While watching the voltage meter, adjust the TEST ADJ potentiometer to the desired LVD setting,
D. Adjust the DROP ADJ potentiometer until the LVD lamp illuminates and immediately stop. The LVD setting
is adjusted to the value set by the TEST ADJ potentiometer in step C.
: The LVD lamp will continue to illuminate until the LV PICKUP voltage is set t the desired setting.

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Issue 8. Nov 2000
6.2 OPERATIONAL CHKCKOUT-continued

E. While watching the voltage meter, adjust the TEST ADJ potentiometer to the desired LV PICKUP setting.
F. Adjust the LV PICKUP potentiometer until the LVD lamp goes out and immediately stop. The LV PICKUP
setting is adjusted to the value set by the TEST ADJ potentiometer in step E.
G. On the front of the Distribution and Alarm Panel, put the ALARM TEST switch back in normal system
operation. The TEST LED should go out. The pickup and dropout setpoint adjustments are complete and the
system should return to normal operation.
6.2.4 COMPLETION OF TESTS
If the Initial Turn-on and operational checks are complete and the system is operating properly, the tests are
complete. Perform normal clean up, collect all tools. and close all access doors, ect. If there was a problem with
the test and acceptance procedures, it is advisable to call PECO II Field Service at the numbers listed at the front
of this manual.
6.3 TROIJEILESHOOTING
Troubleshooting of the system is limited to performing the start-up and operational checks. If further assistance is
required, contact the PECO II Field Service at the numbers listed in the front matter of this manual.
Whenever a malfunction occurs, tint look for the obvious fault. Try to find out whether is caused by the system or
by its environment (e.g. temperature, humidity or load). In addition, there may be other situations such as:
A. Input Voltage is missing/ not at the correct level.
B. Input and Output connections are not securely fastened.
c. Coectors are not secure.
D. Blown fuses.
E. Tripped circuit breakers.
Always check these external factors before concluding that your inverter system is faulty. If, for instance, the unit
stops due to overheating it may have been overloaded, the ambient temperature may be too high, the ventilation slots
could be blocked or a cooling fan may be out of order.

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PECO II, Inc.

4380078PD
Issue 8. NW 2ooO
SECTION VII THEORY OF OPERATION
7.1 GENERAL
This section gives the simplified theory of operation of the system.
7.2 SYSTEM THEORY OF OPERATION
The Rectifier System theory of operation is limited to the signals that are either input or output to or from the
system.
The system accepts 184-264 VAC, 45-60 Hz in as an input source. This voltage is applied to the individual
Rectifier Modules through the AC input connector on the back of each Rectifier Module. The Distribution and
Alarm Panel is interfaced with the output and alarms of the Rectitier Modules via factory installed wiring.
When the AC is present and is within tolerance, as determined by the preset circuits, the rectifiers will begin to
convert the voltage to the preset voltage output at 50 Amps per Rectifier Module. Each rectifier is placed in parallel
with the other, allowing the power output to increase proportionately with the addition of each rectiiier (100 amps
maximum possible with two Modules). When the system is operational and the input/output voltage and current
falls within the preset parameters (refer to Installation), the green AC ON LED, lofated on the front each Rectifier
Module, will illuminate and the Rectifier(s) will output the voltage to the Distribution and Alarm Panel.
When there is a Rectifier Module failure, a red RFA lamp will illuminate on the front of the Rectifier Module.
Unless redundant, the system will fail to have an output and a Low Voltage Alarm will be sent. The conditions that
would cause an RFA indication on the front of the Rectifier Module include low or high AC input, low or high
rectifier voltage or current output. The system will also send an RF MAJOR or RF MINOR alarm via the alarm
terminal block on the rear of the system and associated visual alarm on the Front of the Distribution and Alarm
Panel, depending if the condition is present in one (RF MINOR) or two (RF MAJOR) Rectifier Modules.
When the system has lost input AC and is operating from batteries, a red RFA lamp will be illuminated on the front
of each Rectifier Module and the AC ON indicator on the front of the Rectifier Module will go out. In addition, an
AC fail indicator located on the front of the Distribution and Alarm Panel will illuminate and the Form C contact
will change. state on the alarm terminal. The batteries will then take over the system DC output. As the batteries
continue to provide the system DC output and the output voltage is no longer sufftcient to maintain the load, the
Low Voltage Disconnect relay will drop and the applicable Form C contacts on the alarm terminal block will change
state.
When the system recovers (AC Input is restored and the system is charging the batteries), the Alamo will clear when
the system voltage has recovered and is >SOVDC.

30

PECO II, Inc.

4380078PD
Issue 8. NW 2000
SECTION

VIII

SYSTEM

CONFIGURATIONS/PARTS

LIST

8.1 GENERAL
This section gives the complete parts listing of the system for the components that are repairable at the field level.
Available systems are identified by a conftguration
model code (CC) alpha assignment. Each component as
identified on the parts list has the configuration model code character assigned. In many cases the parts are used on
all systems produced by PECO II. If the component is used on all systems, the configuration model code will have a
dash.
Indenture Code (IC) on the parts list refers to the level of indenture of a part as compared to the assembly. For
example, an assembly may have several subassemblies. Under the subassemblies there may be parts associated with
that subassembly. In this example tlwassembly would not have an indenture level since that is the main component.
The subassembly would be indenture level I. The pat% that make that subassembly would be indenture level 2.
As Required (A/R) in the Quantity (QTY) column implies that the part may be used more than once and is
dependant on the operator. In addition, if a dash precedes an Item Number (i.e., -10) that item is used by the
assembly but is not referenced in the illustration.
8.2 CONFIGURATIONS
The system is Configuration A
TABLE 8-1. System Parts Listing
Item No.
-I

PECO Part No.

6875009BLK-58

Nomenclature
System

cc
A

-10

SM50F48PM

Rectifier Module,
48V, 50A

on

(2.2)
-20

3050076P-50

Output Circuit
Breaker, 50 Amps

31

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PECO II. Inc.

4380078PD
Issue 8. Nov 2000

Al-l-ACHMENTS

32

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4380084PD
Issue 1, Nov 1996
Page 1 of 15

I f2
i%
Iz
:

POWER DATA
for

RECTIFIER MODULE
SM50F48PM (-48V)
(As Used with 6875009BLK-62)

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1.0

SPECIFICATIONS

438

0084PD

2.0 INSTALLATION

3.0 OPERATING METHODS

<ng

D.D.

PECO II, Inc.

Galion, Ohio
Lppr

File Name: (438) 0084pd.wp.s

D.D.
Printed in U.S.A.

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4380084PD
Issue 1, Nov 1996
Page 02
TABLE OF CONTENTS
DESCRIPTION
1.0 SPECIFICATIONS
1.1 GENERAL
1.2
INPUT RATINGS
OUTPUT
RATINGS
1.3
1.4 MECHANICAL SPECIFICATIONS
~1.5 STANDARD FEATURES
1.6
FACTORY SETTINGS
1.7 ENVIRONMENTALSPECIFICATIONS
1.8 RECTIFIER SHELF
2.0
2.1
2.2
2.3
2.4
2.5
2.6

INSTALLATION
GENERAL
AC INPUT CONNECTIONS
OUTPUT CONNECTIONS
INITIAL TURN ON
ADDING/REPLACING A RECTIFIER.
REMOVING A RECTIFIER

3.0 OPERATING MHTBODS

3.1 GENERAL
3.2 FLOAT/EQUALIZE VOLTAGE ADJUST
3.3
CURRENT LIMIT ADJUST

4380084PD
Issue 1, Nov 1996
Page 03
1.0

SPEB

1.1

GENERAL
Rectifier Module (SMSOF48PM) is a -48 VDC @ 50 Amp self
contained unit. The Rectifier is a fully regulated, DC
isolated output switchmode Rectifier designed to charge
batteries. while supplying power to telecommunication.
equipment.
The Rectifier can also operate as a Battery Eliminator not
requiring-external
batteries.
The Rectifier is of modular
.design for easy upgrading or replacement in a shelf
configuration.
-

9
237.74mn

SM50F48PM
FFIONT VIEW)

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4380084PD
Issue 1, Nov 1996
Page 04
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1.2

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INPUT

RATING8

A. VOLTAGE:

176-265 Volts AC
57-63 Hz (Single Phase).

B. CURRENT.AT

NOMINAL OUTPUT:

13.7 Amps (Typical 230V Nominal Line)

18.5 Amps (Typical 176V Low Line).

C. INPUT POWER FACTOR:

0.90 Lagging 10-1008 Output Load
0.95 to 0.99 Lagging Typical.

D. EFFICIENCY:
88% TO 90% 50-100% Load
54.5 VDC @ 50 ADC.

E. RECOMMENDED FEEDER BREAKER:

20 Amps Minimum 2 pole.

F. INTERNAL PROTECTION:
Fuse (20A) in series with AC Input Line.
field replaceable.

This fuse is not

G. TELEPHONE INFLUENCE FACTOR:

Noise: The TIF of the AC current wave has a typical I.T.
product less than values shown in Table A.
Model

Volts

I.T.

SM50F48PM

230

500

TABLE A

4380084PD
Issue 1, Nov 1996
Page 05
1.3 OUTPUT RATINGS
A. VOLTAGE:

Float Adjust:

Minimum 50 to 55 VDC.

O-6 volts above float,

Equalize Adjust:
not to exceed 60.0 VDC.
B.

PROTECTION:
1. output: Electronic Current Limit limits the,output
current to 51.0 Amps or 102% of rated output.
(Factory setting)
2. Short Circuit: Electronic Current Limited
(Internal fuse if the electronic
current limit fails).

C. REGULATION:
1. Static:

+l% for all AC input, output load, and

temperature conditions.

2. Dynamic: Voltage transient is less than 5% and will

return and stay within the 1.0% band within
300MS when a 50% load step is applied or
removed within the Rectifier load range of 10%
to 100% load.
D. NOISE:
Measured at the Battery with an AH rating of four (4) times
the Rectifier's rated output for all AC input and output
load condition.
1. Voice Band: Maximum of 32 dBrn C-message weighing
(Typical max 28 dBrn).
Maximum of 250
2. Wide Band:
over a bandwidth of (10 HZ - 100 MHz).

millivolts

peak-to-peak

Maximum of 100 millivolts RMS in any 3 KHz

band between 10 KHz and 100 KHz.
E. OVER VOLTAGE:
An individual Rectifier, with an output load of greater
than lo%, will shutdown.
Rectifiers, when operated in parallel, will selectively
shutdown if the output voltage reaches 58.0 VDC (factory
setting).

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4380084PD
Issue 1, Nov 1996
Page 06
1.4

MECHANICAL SPECIFICATIONS
A. HEIGHT:

9.36 Inches

237.74 mm.

B. WIDTH:

5.10 Inches

129.54 mm.

C. LENGTH:

13.00 Inches

330.20 mm.

D.

18.00 Lbs

WEIGHT:

1.5 STANDARD

8.16 kg.

FBATUREB

The standard features forSM50F48PM Rectifier are as follows:

A. VOLTAGE CONTROL
The FLOAT/EQUAL switch, located on the front panel,
selects float or equalize modes of operation.
The FL and
EQ adjust potentiometers are provided to make adjustments
for each voltage requirements.
B. REMOTE SENSING
Negative Sense lead is connected to the batteries for
optimum regulation.
CC!. LOAD SHARING
A circuit is provided so Rectifiers can proportionally
share the load with other like Rectifiers within +28 of
rated Load.
D.

CURRENT WALE-IN
Upon 10turn-on'* of the Rectifier, the output current will
gradually increase to it's required output load in
approximately eight (8) seconds.

E. ME TER (DIGITAL)
Selectable Voltmeter/Ammeter,
a c c u r a c y i s f18.

located on the front panel,

F. OVER TEMPERATURE
Rectifier will shutdown due to an internal over temperature
condition.
This could be the result of a fan failure or
other abnormal condition.
G. AIARM INDICATION
Any condition resulting in Rectifier failure, including AC
'%.u-n-off11 or a "fan failure" will provide a signal to the
Office Alarm terminals and will light the RFA LED (Red),
located on the front panel.

4380084PD
Issue 1, NOV 1996
Page 07
1.6

FACTORY

SETTING8

The following settings are factory set, and should not be

adjusted unless necessary.
If the need does arise for one or
all to be changed, refer to Section 3 for the proper
instructions.
A. FLOAT VOLTAGE:
B. EQUALIZE.VOLTAGE:

1.7

54.48 VDC
(2.27V per cell for 24 cells).
55.40 VDC
(2.3OV per cell for 24 cells).

C. CURRENT.LIMIT:

51.0 Amps 102% of rated current.

D. HIGH VOLTAGE ALARM:

58.00 VDC.

ENVIRONMENTAL

SPECIFICATIONS

A. STORAGE AMBIENT TEMPERATURE RANGE:

-40C to +85'C (-40'F to +185OF)
B. OPERATING AMBIENT TEMPERATURE:
Sea Level to
4800 ft: 0C to +50C (+32OF to +122OF)
4800 ft to
7000 ft: O'C to +45'C (+32"F to +113"F)
7000 ft
to 10,000 ft: 0C to +40C (+32"F to +104"F)
Humidity:

95% Non-condensing (Maximum).

C. COOLING:
Forced Air - Keep ventilating passage ways to the unit
unobstructed to insure adequate cooling during
operation.
Otherwise over temperature
protection alarm may be activated.

1.8

RECTIFIER

SHELF

The SM50F48PM Rectifier Module mounts in the 6875009P-62

Rectifier Shelf.

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4300084PD
Issue 1, Nov 1996
Page 08
2.0

INSTALLATION

2.1 GENERAL
The Rectifier's Input and Output connections are plugable
connectors for the purpose of paralleling and "HOT" Insertion into a working
system.
2.2

AC

:INPUT'CONNECTIONS

A: INPUT CONNECTIONS"("Aq* Module)

. ..Ll connects. to AC Input Line 1 .

CHAS GRD connects to AC Ground (Earth

GRD).

L2 connects to AC Input Line 2.

Ll MODULE "A"
m

MODULE "8"
m

SM50F48PM
(REARVEW)

4380084PD
Issue 1, Nov 1996
Page 9
2.3 OUTPUT CONNECTIONS
Alarms and Control leads enter the unit along with the power
contacts at the lower rear panel of the unit.
The Power and Alarm & Control
pins and their function are described as follows:
A...OUTPUT'POWER'CONNECTIONS.

(+I

Positive.Power

(ltB@l Module):

Output connection.

.(-)~ Negative Power. Output.connection.

B. ALARM & CONTROL CONNECTIONS (IIB1l

l234567-

Module):

Vacant
Vacant
Vacant
Vacant
Vacant
Vacant
Vacant

It is used by the chop

8- (-S)
NEGATIVE SENSE lead.
secondary control:to:regulate:its
output.to~that Sense' Point.
9- PSI
POWER SUPPLYINBIBIT (Remote Restart and
Shutdown).~. By applying. a groundsignal'to this lead, the Rectifier can be
remotely shutdown and restarted from a remote locationremotely controlled.
lo- SCOM
of the Rectifier.

SECONDARY COMMON is the (-) minus output lead

ll- CLSO
CONTROLLED LOAD SHARE lead. When connected
between other like Rectifiers Modules will Load Share within 22% of rated
load.
12- RFA-NO
RECTIFIER FAILURE ALARM (RFA).
These leads
13- RFA-COM are from a set of relay contacts called
14- RFA-NC
"Form C" contacts.
The RFA relay alarm
contacts are shown in their alarm state
(De-energized).
Relays release on alarm
conditions, alarm circuits are energized in
their "Normal" no alarm condition.

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4380084PD
Issue 1, Nov 1996
Page 10
2.3 OUTPUT CONNECTIONS (Cont)

I-

15- VI
CURRENT MONITOR lead is provided for Remote Monitoring of
the Rectifier's output current.
A 1.0 volt/lO.O Amp current signal
referenced:to.~the NegativetSense lead is provided for use with
a
remote;.Monitor,inq~System;:
16- Vacant

-..17-~.BTC,'. 'BATTERY:TEMPBRATURE COMPENSATOR lead is provided

to vary the. output voltage of .the Rectifier to compensate for battery
temperature in the range of 1O'C to 65C.
18- Vacant

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19- RHV
REMOTE HIGH VOLTAGE lead will accept an external
If the Rectifiers output
high voltage signal (Battery) from a system.
current is more than lo&, this signal will shut down the Rectifier Module.
iO- RM-EQ REMOTE EQUALIZE lead will accept an external
equalize signal (Ground) from a system controller or other external system to
raise the plant battery voltage for the purpose of battery maintenance.

4380084PD
Issue 1, Nov 1996
Page 11
2.4

INITIAL TURN ON

A. Make sure that the AC Input Circuit Breaker, located in the

AC Power Service Cabinet or Shelf, for the new Rectifier is in the "OFF"
position.

_.

-..:B.~;'Makesure:that:the:Output
Circuit Breaker, located on shelf
below the .Rectifier, for.the-new Rectifier is "OFF".
C.- Insert.the new Rectifiersinto

the Rectifier Shelf.

D;~-Press- and ~"hold I1 the Cap Charge switch, located on the

shelf below the Rectifier,..forfive.(5)
seconds, then.turn "ON!' the Output
Circuit Breaker.
E. Turn "ON" the AC Circuit Breaker, located in the AC Power
Service Cabinet or Shelf, for the new Rectifier.
F. Turn the STANDBY/ON switch, located on the front of the
Rectifier, to the "ON" position.

.
,:

The GO LED (Green)

G. The Rectifier will come ."on line".
will light. The digital-meter will indicate the output voltage or current,
depending..,on. the position of.the-V/A switch (Volts/Amps), located to the
right-of-the.meter.
Upon turn-on of the Rectifier, the output current will
gradually.increase to .it's required'load;. approximately eight (8) seconds to
full output.
NOTE: If the Rectifier is connected to batteries that are
discharged or new, the Rectifier may go into a Current Limit mode, during
which the Rectifier gives a constant current, but the voltage will be
As the batteries charge up, the
something less than the adjusted voltage.
voltage will increase up to the ~*norrnal~~ output voltage.
NOTE: The Rectifiers are Factory Set per Section 1.6. If
other than factory settings are required refer to Section 3.2 Float/Equalize
Adjust.

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4380084PD
Issue 1, NOV 1996
Page 12
2.5 ADDING / REPLACING A RECTIFIER
When adding / replacing Rectifiers to a "working" system,
proceed as follows:
A. Decide where the new Rectifier Module will be added.
-.B::..,Remove:the.:blank filler'panel where the new Rectifier
will be.inserted..~

C. .Turn..the STANDBY./ON:switch,..located on the front of the,

i Rectifier.,. Ito;.the:.."STANDBY":
position; :

I_...

:.

,.

:.i

.,

.,

:.

D.-Make sure,that the.AC Input.Circuit Breaker, located in

-.- the AC Power.Service,.Cabinet or Shelf.. .forthenew Rectifier is 'in the "OFF"
position.
E. ~Make sure that the Output Circuit Breaker/switch, located on shelf
below the position, for the new Rectifier is "OFF".

F. Insert the new Rectifier into the Rectifier Shelf.

G. Turn "ON" the AC Circuit Breaker, located on the AC Power
Service Cabinet or Shelf, for the new Rectifier.
H. Turn the STANDBY/ON switch, located on the front of the
Rectifier, to the "ON" position.

I
I. The Rectifier will turn "ON".
The GO LED (Green) will
.~ light..!-Then.-digital:meter
will indicate.the output voltage with the SELECT
I switch.-in.the ?V! (Volts) 'position.
The..FloatVoltage ~is::adjustable.using
the FL (Float- Adj)
I pot,J..located
on.the, front panel of.the Rectifier.
NOTE: Before making adjustment of the FL (Float Adj) pot,
A clockwise (CW)
operate
switch to the **FLOAT@' position.
I directionFLOAT/EQUAL
will increase the Float Voltage and a counterclockwise (CCW)
direction will decrease the Float Voltage setting.
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K. The Equalize Voltage is adjusted after the Float Voltage is
set.
The Equalize Voltage is adjustable using the EQ (Equalize Adj) pot,
located on the front panel.
Before making adjustment on the
EQ (Equalize
I Adjust)
pot, operate FLOAT/EQUAL switch to the "EQUAL1* position. A clockwise
(CW) direction will increase the Equalize Voltage and a
counterclockwise (CCW) direction will decrease the Equalize Voltage setting.
I
L. Return FLOAT/EQUAL switch to the "FLOAT@' position.
the CAP CHARGE switch for five (5) seconds,
I then M.turnPress*'ON"andtheholdOutput
Circuit Breaker/switch.
The Rectifier is now in
"service".
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4380084PD
Issue 1, Nov 1996
Page 13
2.6 REMOVING A RECTIFIER
When removing Rectifiers from a "working" system, proceed as follows:
A. Decide what Rectifier needs to be l'removed'*.
B.~ Turnthe STANDBY/ON switch, located.onthe front of the
:
: . Rectif~ier,::to? the'-"STARDBY1'. position..
for

CL Turn. ?OFF'*the.AC~~Circuit~
Breaker, located. on the Shelf,
the,~,Rectitier~ being "removed!':. "

D.;..:I~Turn:.:.?OFF,!5~:.the.~
Output:.Circuit,.:Breaker,~
below
the.:Rectifier::

located on shelf.

E. Remove the Rectifier from the Rectifier Shelf.

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4380084PD
Issue 1, Nov 1996
Page 14

II
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.._~I
...er..J.

3.1 GENERAL
The Rectifier features,
Rectifier, are as follows:

-monitor the ~Rectifiers Voltage

,I ,A. TEST POINTS.are:availableito
andCurrent,with-.respect.to.the
COM Test Point.

:I;:

II

located on the front panel of each

NOTE:. The.~Current:TestPointOsignal

is a 1.0 Volt/lo.0 Amp

signal.
B. TEST-LED (Amber) will light when the Rectifier has an
~p,e~ (-) Negative Sense lead.

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NOTE: When the Test Lamp is '*ON" the Rectifier will be in

a Local Sense Mode.
C. STANDBY/ON switch puts Rectifier in a

"stand-by"

condition.

D. GO LED (Green) will light when AC input voltage is present.

E. FLOAT ADJUST (FL) pot is used to adjust the float voltage
output of the Rectifier.

.F.. EQUALIZE- ADJUST' pot is. used .to adjust the equalize
r.voltage output.of:.the Rectifier. I'
~ I-

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G. CURRENT LIMIT (CL) pot is sealed and must not be adjusted.

NOTE: This is for factory setting only.
H. HIGH VOLTAGE (IiV) pot is used to adjust the high voltage
setting of the Rectifier.
I. FLOAT/EQUALIZE:
The EQ LED (Amber) will light when the
Float/Equalize switch is in the "equalize" position.
J. FAIL LED (Red) will light when the Rectifier fails to
operate.
SELECT switch turns Rectifier Output meter to either
(Volts) reading.

"A"

4380084PD
Issue 1, Nov 1996
Page 15
3.2 FLOAT/EQUALIZE VOLTAGE ADJUST
Operate the "STANDBY/ON" switch, located on the Rectifier, to the
l'STANDBY1* position. Operate the Rectifier Shelf Breaker/Switch to the **OFF11
position... .Now operate the "STANDBY/ON" switch to the "ON" position.
A. .The Float Voltage-is.adjustable:using.the FLOAT ADJ (FL).
-.:~.pot,.-;located~~on...the~frontl-panel..of~r..the:..Rectifi;er..
-:
.:~z%:I? . ..~.~::-=:NOTE-:~:Before~~.making--adj,ustment:of.'-the FLOAT ADJUST;'(
1~~pat~~~~opeltatep,F~AT~EQUAL~:switch
'.to. the: ."FLOAT" position:::.A clockwise' (CW)
-._
-~direction.~w~~~;increase~~theoat;Voltage,and.a counterclockwise'(CCW)
~~~ectio~~~wi,~l.rdecrease~the~~-;Floa.t-..Voltage.~.setting..
, . . .
B. The-Equalize--Voltage:is-.adjusted afterthe Float Voltage is
set.. The-.Equalize.Voltage is~adjustable..using:the.-EQUALIZE.ADJ.Spot,-.located
onnthe front panel, of the ,-Rectifier.
Before making adjustment on the
Equalize Adjust (EQ)'pot; operateFLOAT/EQUALswitch to the "EQUAL" position.
A clockwise (CW) direction will increase the Equalize Voltage and a
counterclockwise (CCW) direction will decrease the Equalize Voltage setting.

3.3 CURRENT LIMIT ADJUST

The.Current-Limit Adjust is'adjustable using the.Current Limit Adj pot,
located >on the..front:panelLof:,the;Rectifier..The-Current;-Limit is factory
:-set at.51.~0 Amps;
:-=.-***************~~***********************~~~~~~~~~~~*~~~~~~~~~~~
:.. -CAUTION:..Do not.adjust;the output current limit to a value l
*
greater,,than:51.0 Amps or 102% of rated output.
Also;.do
.not:adjust.-:greater.than
lOO%..if t h e
*
l
Rectifier is operating in parallel without'any
*
means for load sharing.
**************************************************************
NOTE: It is not recommended that the Current Limit be
adjusted.
An external load would be required to reset the Current Limit.

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6
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MANUtACTURINb

7
NOttS:

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9
1 T-439093SP

1. A L L WIRES SHALL BE 20GA BLACK, UNLESS OTHERYlSE

SPECIFIED.

CA

2 . 01 DENOTES YlRlW, ROUTED IN THE SmTEST POSSlBLE

IIMUIER. U S I N G 2OcX BLKK MLESS OTCR,SE S P E C I F I E D .
3 . 03 DEMlTES YlRlNG NOT IN A CMLE. AND ROUTED IN T H E
MST CONYENlENT MANNER. S,NG 206A BLACK UNLESS
OTHERYlSE
SPECIFIED.
4 . IRES TO BE RUN BY THE INSTALLER &?E DESIGNATED,&

,
-8

5 . T O P S I D E IRING.
6

BOTTOSIDE

YlR,NG

7. YHEN FIGURE. Z O N E , OR TERHlNALS A R E N O T P R O V I D E D ,

UNUSED LEADS SHALL DE SPLICED, SOLDERED, ,NSLATED
AND TlCD B A C K .

8. WLTIPAL CO.NNECT,ONS. HEN EO,P!4CENT I S N O T PRWlDED

LEADS SHALL BE SPLICED. SOLDERED. ,NSLATEO A N D
TIED BACK.
9 . :$0&M SAKE O F C L A R I T Y . N O T A L L TERlllNALS

HAVE B E E N

D
ENGINEERING

NOTES:

51. SEE TABLE A FOR SHEET INFORMATION.

c
E

Y,R,NG D,M.W FOR

~!$i%:%%a T-439D933P
W.l&
A
SHEET (\I
9
I
8

9
A

D
c
E
F
G
H

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PECO II. Inc.

6421015P
Issue 16. NW 2000

MANUAL
for

PEC 1015
PEC 1015A
RECTIFIER SYSTEM
-48 VDC @ 50-200 AMP

PECO II, Inc

Galion, Ohio
Printed in U.S.A.

PECO II. Inc.

6421015P
Issue 16. Nov 2000
AITACHMENTS
(Included at the back of the manual)

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DESCRIPTION
Manual
PEC 1015. PEC lOl5A
Power Data Sheets
PEC 1015, PEC lOl5A (Shelf)
Power Data Sheets
Rectifier (-48V)
Schematic
Rectifier Shelf

PART NUMBER
6421015P
4381015PD
SM50F48PMPD
4390332P

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PECO II. Inc.

6421015P

SERVICE - If for any reason further assistance is needed on any power equipment, complete engineering and field
service groups are available in Galion. Ohio, to assist you in any way possible.
CALL: 4 19/468-7700 Field Service
419/468-7600 and ask for Field Service.
PARTS ORDERING - Replacement pans for power equipment may be obtained by forwarding B Purchase Order
to:
PECO II, Inc
P. 0. Box 910
Galion; Ohio 44833
kx to: (419) 462-8180
Include the following information:
A. PECO II part number and engineering level of equipment
B. If part is electrical, give circuit reference numbers and PECO II part numbers.
C. If pan is mechanical in nature, give description as to where it is used.
RETURN & REPAIR - Equifiment may be returned to the Factory for repair. In order to do this, the procedure
must be as follows:
A. Call: 419/468-7700 Field Service
Or
419/468-7600 and ask for Field Service.
B. Request a @MA) Returned

Material Authorization number for the defective equipment.

C. Return material prepaid to:

PECO II, Inc
1376 State Route 598
Galion, Ohio 44833
An: Field Service Dept

POWER DATA
for

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PEC 1015
PEC 1015A
RECTIFIER

SYSTEM

-48 VDC @ 50-200 AMP

SECTIONS
1.0

SPECIFICATIONS

1.1
1.2
1.3
1.4
1.5
1.6

General
Output Ratings
Input Ratings SMSOF48P
Input Ratings SM50F48PM
Standard Features
Environmental Ratings

2.0

DIMENSIONS

3.0

INSTALLERS

CONNECTIONS

3.1 PEC 1015 Rectifier Shelf System

3.2 PEC 1015A Rectifier Shelf System
3.3 Installers Connections
4.0 INSTALLERS NOTES
4.1 Installers Information Notes
4.2 Adding a Rectifier (SM50F48P)
and Plant Adjustment
4.3 Removing a Rectifier (SM50F48P)
4.4 Adding/Replacing a Rectifier
(SM50F48PM) and Adjustment
4.5 Removing a Rectifier (SM50F48PM)
PECO II, Inc.
Galion, Ohio
Printed in U.S.A.

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4381015PD
Issue 9, Aug 1997
Page 02
1.0 SPECIFICATIONS
1.1

GENERAL

The PEC 1015 (Individual AC Input) & PEC 1015A (Bulk AC Input)
Rectifier System (48 VDC) is designed to "power" a load while
"charging" a battery. However, this system will operate as a
BATTERY-LESS SYSTEM and does not require batteries to
function.
The Modular Rectifier outputs are paralleled on a
common output bus. Alarms are available per Module or Shelf.
The PEC 1015 & PEC 1015A Rectifier System is housed in the
following rectifier shelf combinations:
A. PEC 1015:

23" shelf x 10.5" high x 18.0" deep & has four

(4) DC Circuit Breakers.

B. PEC 1015A: 23" shelf x 12.25" high x18.0" deep & has four
(4) AC & four (4) DC Circuit Breakers.
NOTE: 23" RECTIFIER SHELF can accommodate up to four (4)

plug-in type modular Switchmode Rectifiers.

are seven (7) different shelf arrangements.
(See Chart 1-l)
UNIT

PEC
1015

PEC
1015A

23

PART
NUMBERS

INCH
SHELF

6571015P48-0
6571015P48D-0
6571015R48-0
6571015P-0
6571015R-0
6571015P48-OPS

X
X
X
X
X
X

6571015PA-0

CHART l-l PEC 1015 br

TERMINATION

(See

There

Note)

INTERFACE
BOARD
YES

NO

x
X

X
X
X

-I-+

X! 1015A ARRAE; IGI ENENTS

NOTE: Interface Board allows Rectifiers to work

with a Monitor, Alarm, and Control System

(Such as PECO II, MACS System).
C. PEC 1015:

19" shelf x 10.5 inches high x 18.0 inches deep

& has three (3) DC Circuit Breakers.

D. PEC 101SA: 19" shelf x 12.25 inches high x 18.0 inches deep
& has three (3) AC & three (3) DC Circuit
Breakers.
NOTE: 19" RECTIFIER SHELF can accommodate up to three (3)

plug-in type modular Switchmode Rectifiers.

4381015PD
Issue 9, Aug 1997
Page 03
1.1 GENERAL (Cant)
E. SWITCHMODE RECTIFIERS (SM50F48P or SM50F48PM):
(1) Rectifier:
(2) Rectifiers:
Three (3) Rectifiers:
Four (4) Rectifiers:

One
TWO

NOTE:

1 . 2 OUTPUT

48V @ 50
48V @ 100
48V @ 150
48V @ 200

Amp
Amp
Amp
Amp

There are two (2) different Rectifier modules

(SM50F48P & SMSOF48PM) used in the PEC 1015 & PEC
1015A Rectifier Systems. Ensure you read and
follow the procedures for the correct Rectifier.

RATING

A. VOLTAGE: Float voltage is adjustable from 50 to 60'VDC for

floating a 24 cell battery. Unless otherwise specified,
the factory float settings are as shown in Table l-l.
TABLE 1-3
LIMITED MAINTENANCE
BATTERY SETTINGS

ADJUSTMENT

FLOAT
VOLATGE

CONVENTIONAL
FLOODED CELL SETTINGS

54.48VDC
I

52.08VDC
I

B. CURRENT: Current is dependant on the number of Switchmode

Rectifier modules equipped: (See Table l-2)

NUMBER OF RECTIFIERS
(oer shelf assembly)

TABLE l-2
CURRENT

200

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4381015PD
Issue 6, May 1996
Page 04
1.3 INPUT RATINGS (SM5OF48P RECTIFIER)
A. VOLTAGE: Nominal 230 VAC RMS, single phase, 47 to 63 Hz,
with input voltage ranges of i/-15%.
B. TYPICAL DATA: When rectifier system is equipped with one
(1) Rectifier module, fully charged batteries, and nominal
input, the following data applies:
1. Rectifier output voltage initially adjusted to 54.48
VDC at 50% load is as follows:
PERCENT
LOAD

INPUT
CURRENT

INPUT
VA

INPUT
WATTS

PERCENT
EFFICIENCY

10

1.8

469

413

66.0

50

6.81

1582

1566

87.0

100

13.93

3167

3135

86.9

2. Maximum input current with 54 VDC output and full load

is as follows:
Nominal Input:
Input Voltage:
Input Current:

230 VAC
196 VAC
16.36 AAC

B. TYPICAL DATA: When rectifier system is equipped with four

(4) Rectifier modules and nominal input, the following data
applies:
1. Rectifier output voltage initially adjusted to 54.48
VDC at 50% load is as follows:
PERCENT
LOAD

INPUT
CURRENT

INPUT
VA

INPUT
WATTS

PERCENT
EFFICIENCY

10

7.2

1876

1651

66.0

50

27.23

6325

6262

87.0

100

55.73

12665

12539

86.9

2. Maximum input current with 54 volts output and 200 amps

load is as follows:
Nominal Input:
Input Voltage:
Input Current:

230 VAC
196 VAC
65.44 AAC

4381015PD
Issue 5, May 1996
Page 05
1.4

INPUT

RATINGS (SM50F48PM

RECTIFIER)

A. VOLTAGE: Nominal 230 VAC RMS, single phase, 47 to 63 Hz,

with input voltage ranges of +15/-23.5%.
B. TYPICAL DATA: When rectifier system is equipped with one
(1) Rectifier module, fully charged batteries, and nominal
input, the following data applies:
1. Rectifier output voltage initially adjusted to 54.48
VDC at 50% load is as follows:

PERCENT
LOAD
10

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INPUT
CURRENT
1.67

INPUT
VA

INPUT
WATTS

384

357

PERCENT
EFFICIENCY
I

76.3

50

6.63

1525

1511

90.1

100

13.16

3026

3003

90.7

2. Maximum input current with 54 VDC output and fu 11 load

is as follows:
Nominal Input:
Input Voltage:
Input Current:

230
VAC
176
VAC
17.35 AAC.

C. TYPICAL DATA: When rectifier system is equipped with four

(4) Rectifier modules and nominal input, the following data
applies:
1. Rectifier output voltage initially adjusted to 54.48
VDC at 50% load is as follows:
INPUT
INPUT
PERCENT
PERCENT
INPUT
VA
WATTS
EFFICIENCY
LOAD
CURRENT
10

6.7

1536

1428

73.3

50

26.52

6100

6044

90.1

100

52.64

12104

12012

90.7

2. Maximum input current with 54 volts output and 200 amps

load is as follows:
Nominal Input:
Input Voltage:
Input Current:

230 VAC
176 VAC
69.4 AAC.

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4381015PD
Issue 5, May 1996
Page 06
1

STANDARDFEATURES

A. FRONT ACCESS: Modular Switchmode Rectifiers (50 Amp )

operate in the high frequency range.
B. INPUT PROTECTION:
External protection to be provided by
the customer. Both sides of the input line should be
protected.
C. OUTPUT PROTECTION
1. Over Voltage Shutdown:
If the Rectifiers output
voltage exceeds a preset value the Rectifier will
shutdown.
High Voltage Shutdown is factory set at 57.0
VDC.
2. Current Limiting: A circuit that limits the output
current to a.safe value is incorporated in each unit
and is factory set.
D.

EM1 SUPPRESSION: This unit meets requirements for

VDE 0871 Class A and FCC 20780 Class A.

4381015PD
Issue 6, May 1996
Page 07
1.6 ENVIRONMENTAL RATINGS
A. OPERATING AMBIENT TEMPERATURE RANGE:
0C to + 50C (+32"F to + 122F)
B. STORAGE TEMPERATURE RANGE:
-40C to +85"C (-40'F to + 185F)
C. ALTITUDE:
Sea Level to 4800 ft: 0C to +SO"C (+32"F to +122"F)
4800 ft: to
7000 ft: 0C to +45"C (+32"F to +113"F)
,700O ft: to 10,000 ft: 0C to +4O"C (+32"F to +104"F)
D. HUMIDITY: This system is capable of operating in an
ambient relative humidity range of 0 to 95%, noncondensing.
E. SHOCK: This equipment, in its shipping container,
withstands shock developed when one edge of the container
is dropped 6 inches while the opposite edge is resting on
the ground, or is dropped 2 inches on any surface without
physical damage or degradation of the electrical
performance.
F. VIBRATION: This equipment, in its shipping container,
withstands vibration encountered is shipping without
physical damage or degradation of the electrical
performance.
G. HEAT DISSIPATION:
54.47 VDC.

Nominal input with output adjusted for

NO. OF
MODULES

SHELF OUTPUT CURRNT

AMPERES

1
2
3

50
100
150
200

BTU/HR
SM50F48P
1400.0
2800.0
4200.0
5fifio.o

SMSOF48PM

953.0
1906.0
2859.0
3812.0

H. AUDIBLE NOISE: The audible noise at any point 5 feet from

and vertical surface of the system does not exceed 55 dB
"A" weighted when measured with a General Radio 1551-C or
Western Electric 3C Sound Level Meter (or equivalent)
conforming to ANSI S1.4.
I. SURGE PROTECTION: The system is capable of withstanding
surges per ANSI C 62.41 1980, Category B across the input
terminals.
J.

VENTILATION REQUIREMENTS: For continuous operation, the

system ventilating openings should not be blocked and the
ambient temperature of the air entering the units does not
exceed 50C.

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4381015PD
Issue 5, May 1996
Page 08
2.0 DIMENSIONS (Rectifier Shelf)

RECTIFIER SHELF ASSEMBLY

PEC 1015
(TYPICAL)
_-____ - -_--- -__-------__----__-_---_-__--_-

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RECTIFIER SHELF ASSEMBLY

PEC 1015A
(TYPICAL)

__-__

4381015PD
Issue 9, Aug 1997
Page 09
3.0

INSTALLERS

3.1

PEC

CONNECTIONS

1015 RECTIFIER SHELF SYSTEM

The PEC 1015 Rectifier Shelf System shou Id be insta lled as

fo llows:
A.

PEC 1015 RECTIFIER SYSTEM (Individual AC Input)

1. AC Input (230 VAC):
a.
b.
c.
d.

Connect
Connect
Connect
Connect

Ll,
Ll,
Ll,
Ll,

L2,
L2,
L2,
L2,

&
&
&
&

GR
GR
GR
GR

to
to
to
to

TBl
TB2
TB3
TB4.

2. Battery Bus (Single Output):

a. Connect (+) Battery Lead to GND Bus Bar.
b. Connect (-1 Battery Lead to -48V Bat Bus Bar.
3. Battery Bus (: Dual Output):
a. Connect (+ ) Battery Lead to GND Bus Bar.
b. Connect (-) "A" Battery Lead to -48V Bat "A" Bus Bar.
c. Connect (-) "B" Battery Lead to -48V Bat "B" Bus Bar.
4. Alarms Out (RFA):
a. Connect TB5,

Pin RFA to Office Alarm System.

5. Load Sharing (LSO):

a. Connect TB5,

Pin LSO to Load Sharing as required.

NOTE: See Charts in Section 4.0 for recommended wire sizes

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4381015PD
Issue 9, Aug 1997
Page 10
3.2 PEC 1015A RECTIFIER SHELF SYSTEM
The PEC 1015A Rectifier Shelf System should be installed as
follows:
A. PEC 1015A RECTIFIER SYSTEM (Bulk AC Input)
1. AC Input (230 VAC):
a. Connect Ll, L2, & GR to TBl.
2. Battery Bus (Single Output):
a. Connect (+) Battery Lead to GND Bus Bar.
b. Connect (-1 Battery Lead to -48V Bat Bus Bar.
3. Alarms Out (RFA):
a. Connect TB5,

Pin RFA to Office Alarm System.

4. Load Sharing (LSO):

a. Connect TB5,

Pin LSO to Load Sharing as required.

NOTE: See Charts in Section 4.0 for recommended wire sizes.

4381015PD
Issue 9, Aug 1997
Page 11
3.3 INSTALLERS CONNECTIONS

(GND)

BUS

(-48V BAT) BUS

&NO)

BUS

fI

(-48V BAT) "B" BUS

IIon

PEC 1015 SHELF ASSEMBLY

INDIVIDUAL AC INPUT (SINGLE OWJT)
(REAR

AC INPUT
(TB4)

VI E W )

AC INPUT
(W

AC INPUT
@32)

(TBl)

AC INPUT

PEC 1015 SHELF ASSEMBLY

INDIVIDUAL AC INPUT(DUAL OUTPUT)
(REAR

VIEW)

OUT
085)

L ALARMS OUT
(TB5)

(-4BV BAT) -Au BU

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4381015PD
Issue 9, Aug 1997
Page 12
3.3

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ALARMS
OUT
(TBS)

INSTALLERS

CONNECTIONS

(Cant)

4381015PD
Issue 9, Aug 1997
Page 13
4.0 INSTALLERS NOTES
4.1 INSTALLERS INFORMATION NOTES

PEC 1015

AC INPUT (TBl, 2,

TERMINALS
CAPACITY

TYPE

10 Ga

Screw
Term

Maximum

INPUT
VOLTAGE

RECOMMENDED
WIRE
SIZE

BRANCH CIRCUIT
PROTECTION
(2 POLE CIR BKR)

230

12 Ga

20 Amps

AC INPUT (TBl, Ll, L2) [Bulk1

(See Note 4.1.5)

PEC 1015
TERMINALS
CAPACITY

TYPE

2 Ga
Maximum

Screw
Term

ALARM

INPUT
VOLTAGE

RECOMMENDED
WIRE
SIZE

BRANCH CIRCUIT
PROTECTION
(2 POLE CIR BKR)

230

4 Ga

80 Amps

TERMINALS

TERMINALS
CAPACITY

TYPE

12 Ga
Maximum

Pressure
Terminal

3, & 4) [Individual]
(See Note 4.1.5)

RECOMMENDED
WIRE
SIZE
22 Ga

C.O. Ground (Note 4.1.6)

CAPACITY

TYPE

RECOMMENDED
WIRE
SIZE

6 Ga
Maximum

Crimp Lug
0.25" x 0.625"

As
Req'd

TERMINALS

D. DC OUTPUT: A drilled GND BUS BAR is provided for

installation of customer furnished DC output lugs,
0.25" x 0.625" hole pattern.

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4381015~~
Issue I. Aug 1996
Page 14
4.1 INSTALLERS INFORMATION NOTES (Cant)
E. Wire sizes based on National Electric Code Table 310-16 for
copper wire with rated conductor temperature of 75"~
operating in 30C ambient. For operation in ambient
higher than 30C apply derating factors listed in Table
310-16 of the National Electric Code.
F. Equipment grounding conductor size based on recommendations
of National Electric code Table 250-95 for copper wire. If
aluminum or copper clad aluminum grounding conductor is
used, refer to Table 250-95 for increased conductor size.
G. Connect this wire to C.0 GRD, per local Telephone Company
grounding schematic.

4.2 ADDING A RECTIFIER (SNSOF48P) h PLANT ADJ'USTNEN'T

When adding Rectifiers to a "working" system, proceed as
follows:
A. Decide where the new Rectifier will be added.
B. Remove the blank filler panel where the new Rectifier
will be inserted.
C. Make sure that the AC Input Circuit Breaker, located in
the AC Power Service Cabinet, for the new Rectifier is
in the "OFF" position.
D. Make sure that the Output Circuit Breaker, located below
the Rectifier, for the new Rectifier is "OFF".
E. Insert the new Rectifier into the Rectifier Cage.
F. Press the Cap Charge switch for five (5) seconds, then
turn "ON" the Output Circuit Breaker.
G. Turn "ON" the AC Circuit Breaker for the new Rectifier.
H. The Rectifier will come "on line".
The AC ON LED
(Green) will light. The digital meter will indicate the
output voltage or current, depending on the position of
the V/I switch, located to the left of the meter.
NOTE: If only one Rectifier has been installed and it does not
meet the voltage or current tolerances as stated in the
following steps, adjust the float voltage pot of the Rectifier
that was just
installed until it falls within the tolerances given.

4381015PD
Issue 7, Aug 1996
Page 15
4.2 ADDING A RECTIFIER (SM50F48P) 6 PLANT ADJUSTMENT (Cent)
NOTE: If the Plant Float or Equalize voltage needs to be

adjusted, it is recommended that all the Rectifier

meters within the bay are set to read current (I) and
then the Float or Equalize pot be adjusted to set the
current of the Rectifier to the reading of the other
Rectifiers within the bay.
NOTE: To properly adjust the Equalize voltage, set all

By not setting all the

Rectifiers to Equalize.
Rectifiers within the bay to Equalize, the Rectifier
that is set to Equalize will control the output
voltage of the remaining Rectifiers.
I. Rectifier voltage will be the same as all other

Rectifiers,

+/- 0.1 VDC.

J. Rectifier current will be the same as all other

Rectifiers, +/- 10%.

K. You have just finished with adding of the "new"
Rectifier.

4.3 REMOVING A RECTIFIER (SM50F48P)

When removing Rectifiers from a "working" system, proceed

as'follows:
A. Decide what Rectifier needs to be "removed".
B. Turn "OFF" the AC Circuit Breaker for the Rectifier
being removed.
C. Turn "OFF" the Output Circuit Breaker, located below the
Rectifier.
D. Remove the Rectifier from the Rectifier Cage.
E. You have just finished with "removal" of a

Rectif ier.

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4381015PD
Issue 7, Aug 1996
Page 16
4.4 ADDING / REPLACING A RECTIFIER (SMSOF48PM) & ADJUSTMENT

When adding / replacing Rectifiers to a "working" system,

proceed as follows:
A. Decide where the new Rectifier Module will be added.
B. Remove the blank filler panel where the new Rectifier
will be inserted.
C. Turn the STANDBY/ON switch, located on the front of the
Rectifier, to the "STANDBY" position.
D. Make sure that the AC Input Circuit Breaker, located in
the AC Power Service Cabinet, for the new Rectifier is
in the "OFF" position.
E. Make sure that the Output Circuit Breaker/switch, located
below the position, for the new Rectifier is "OFF".
F. Insert the new Rectifier into the Rectifier Cage.
G. Turn the AC Circuit Breaker for the new Rectifier to the
"ON" position.
H. Turn the STANDBY/ON switch, located on the front of the
Rectifier, to the "ON" position.
I. The Rectifier will turn "ON". The GO LED (Green) will
light. The digital meter will indicate the output
voltage with the V/A switch in the "V" (Volts) position.
J. The Float Voltage is adjustable using the FL (Float Adj)
pot, located on the front panel.
NOTE:

Before making adjustment of the FL (Float Adj) pot,

operate FLOAT/EQUAL switch to the "FLOAT" position.
A clockwise (CW) direction will increase the Float
Voltage and a counterclockwise (CCW) direction wi 11
decrease the Float Voltage setting.

NOTE: For Plant adjustment, to properly adjust the

Float/Equalize voltage, ensure the DC circuit breaker

directly
._.below the Rectifier is in the OFF position.
-~
Atter the Rectifier has been adjusted, follow the startup procedure.
Rectifiers can be adjusted one at a time.

4381015PD
Issue 7, Aug 1996
Page 11
4.4 ADDING / REPLACINGARECTIFIER

(SMSOF48PM) &ADJUSTMENT (Cant)

K. The Equalize Voltage is adjusted after the Float Voltage

is set.
The Equalize Voltage is adjustable using the EQ
(Equalize Adj) pot, located on the front panel.
Before
making adjustment on the Equalize Adjust pot, operate
A clockwise
FLOAT/EQUAL switch to the "EQUAL" position.
(CW) direction will increase the Equalize Voltage and a
counterclockwise (CCW) direction will decrease the
Equalize Voltage setting.
L. Return FLOAT/EQUAL switch to the "FLOAT" position.
M. Press and hold the CAP CHARGE switch for five (5) seconds,
then turn the Output Circuit Breaker/switch to the "ON"
The Rectifier is now in "service".
position.

4.5 REMOVING A RECTIFIER (SMSOF48PM)

When removing Rectifiers from a "working" system, proceed

as follows:
A. Decide what Rectifier needs to be "removed".
B. Turn the STANDBY/ON switch,.located on the front of the
Rectifier, to the "STANDBY" position.
C. Turn the AC Circuit Breaker, for the Rectifier being
removed, to the "OFF" position.
D. Turn the Output Circuit Breaker, located below the
Rectifier, to the "OFF" position.
E. Remove the Rectifier from the Rectifier Cage.
F. This completes the "removal" of a Rectifier.

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SM50F48PMPD
(

RECTIFIER MODULE
SM50F48PM

(-48V)

Produced By:

PECO II, Inc.

1376 State Route 598
Galion, OH 44833-0910

08

880 2851 P

03-l E-00 VLD

07

880 1271 P

02-07-00 VLD

See E. C. History
DESCRIPTION

ISS

ISSUE
File Name: .%450F48PMPD.W80

ISSUB 8. M a r 2000

Eng

D.D

Awr

D.D

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PECO II, Inc.

SM50F46PMPD
Issue 6. Mar 2000

TABLE OF CONTENTS
Section/Pars

Description

Paqe

Front Matter

TOC

i- ii

List of Figures

iii

Referenced Information

iv

Foreword

Cautions and Warnings

Section I

General Information
l-01

1.1
1.2

Specifications

I-01

1.3

Standard Features

l-01

1.3.1

Voltage Control

l-02

1.3.2

Remote Sensing

l-02

1.3.3

Load Sharing

l-02

1.3.4

Current Walk-In

l-02
I-02

1.3.5
1.3.6

Over Temperature

l-02

1.3.7

Alarm Indication

l-02

1.4

Controls, Alarm Features, and Indicators

l-02

1.4.1

Test Points

I-02

1.4.2

Test LED

l-02

1.4.3

Standby/ON Switch

l-02

1.4.4

GO LED

l-02

1.4.5

Float Adjust

l-02

1.4.6

Equalize Adjust

I-02

1.4.7

Current Limit

l-02

1.46

High Voltage

l-02

1.4.9

Float/Equalize

l-02

1.4.10

Fail LED

l-02

1.4.11

Select Switch

l-02

PECO II, Inc.

SM50F48PMPD
Issue 8, Mar 2000

TABLE OF CONTENTS Continued

I

SectionlPara

Description

1.5

Agency Approvals

l-02

1.6

Environment Specifications

l-02

Section II

Rectifier Module Installation

2.1

General

2-01

2.2

installation

Z-01

2.3

Initial Turn On

2-02

2.4

Tools Required

2-02

Section Ill

Maintenance and Adjustments

3.1

General

3-01

3.2

Maintenance

3-01

3.3

Adjustments

3-01

3.4

Factory Settings

3-01

3.5

Tools Required

3-01

Section IV

Troubleshooting

4.1

General

4-01

4.2

Troubleshooting

4-01

4.3

Tools Required

4-01

ii

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PECO Ii, Inc.

SM50F48PMPD
Issue 8, Mar 2000

LIST OF FIGURES
Name

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~1
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Fisure Number

Rectifier

Module

Rectifier

Module(Front

Rectifier Module(Rear

l-l
View)

1-2

View)

2-1

PECO II, Inc.

SM50F48PMPD
Issue 8, Mar 2000

REFERENCED

INFORMATION
I

EQUIPMENT
Eauipment

Nomenclature

Digital Multi meter

Part Number

Manufacturer

Fluke 87

John Fluke
Mfg. Co. Inc.,
Everett, WA

Standard Shop Tools

TECHNICAL DOCUMENTATION OR SPECIFICATIONS
Nomenclature

ID Number

Manufacturer

Part Number

Manufacturer

Part Number

Manufacturer

See Front Matter

CONSUMABLESIFIECOMMENDED

SPARES

Consumables
Nomenclature
N/A
Recommended Spares
Nomenclature
N/A

iv

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PECO II, Inc.

SM50F48PMPD
Issue 8, Mar 2000

FOREWORD
1. Give the PECO II part number and engineering level
of the equipment.
2. If the part is electrical, please include the circuit
reference numbers and the PECO II part numbers.
3. If the part is mechanical in nature, please give a
description as to where the equipment is used.

This manual is intended to help the user of the Rectifier

install, test, troubleshoot, and remove the Module. For
information on the Rectifier Module, refer to the
applicable sections in this manual. If you should have
any questions or problems with the installation or
maintenance of the system you should contact one of
the following sources:

Return and Repair

Service
Equipment may be returned to the factory for repair, To
send any equipment for repair, please do the following:

If you should need any assistance on any of the

equipment produced by PECO II, Inc. we have complete
Engineering and Field Service Groups available in our
Galion, OH facility. For any engineering or field service
support, please contact:

1. Contact the Field Service Group at one of the above

numbers.
2. Request a Returned Material Authorization (RMA)
number for the equipment.
3. Return the material postage paid (prepaid) to the
following address:

(419) 468-7700 (direct line to the Field Service Group)

(419) 468-7600 (Operator, ask to speak to the Field
Service Group)
Parts

PECO II, Inc.

1376 State Route 598
Galion, OH 44833-0910

Information/Ordering

For parts replacement or ordering information please

contact the Field Service Group at one of the above
listed numbers. If you have all pertinent information,
you may simply forward a purchase order to one of the
following:
PECO II, Inc.
P.O. Box 910
Galion, OH 44833-0910
or
Fax to (419) 462-8180
Be sure to include the following information:

PECO II, Inc.

SM50F48PMPD
Issue 8, Mar 2000

CAUTIONS AND WARNINGS

Note:

A CAUTION is defined as any precaution that, if not

followed properly, may cause equipment damage or
failure.

Note:

A WARNING is defined as any precaution that, if not

followed properly, may cause personnel injury and/or
death.

WARNINGS:
1. ELECTRlCAL SHOCK HAZARD. DO NOT.ATIEMPT TO REMOVE, MAlNTAlN. OR INSTALL MIS EQUIPMENT WITH POWER APPLIED.
PERSONNEL THAT ATTEMPT TO WORK ON THIS EQUIPMENT WlTHOUT THE PROPER TRAINING MAY SUBJECT THEMSELVES
OR OTHERS TO ELECTRICAL SHOCK THAT MAY CAUSE SERIOUS INJURY OR DEATH.

smcny

2. THE A,TEMPTED USE OF THIS EGUIPMENT BY UNAU THORIZED OR UNTRAINED PERSONNEL IS

FORBIDDEN . PERSONNEL
THAT ATTEMPT TO WORK ON THIS E9UIPMENT WITHOUT THE PROPER TRAlNlNG MAY SUBJECT THEMSELVES OR OTHERS TO
ELECTRICAL SHOCK THAT MAY CAUSE SERIOUS INJURY OR DEATH

3. DO NOT A,TEMPT TO WORK ON THIS EGUIPMENT IF IT IS OR HAS SEEN EXPOSED TO A HIGH MOISTURE CONDITION. IT IS
RECOMMENDED THE EGUIPMENT BE RETURNED TO PECO II TO BE PROPERLY TESTED. WORKING ON THIS EQUIPMENT
DURING A HIGH MOISTURE CONDITION SUBJECTS THE USER TO ELECTRICAL SHOCK THAT MAY CAUSE SERIOUS INJURY OR
DEATH.

4. USE OF AN AITACHMENTOTHER
THAN ONE THAT HAS SEEN APPROVED BY PECO II IS FORBIDDEN. THE AlTEMPTED USE OF
UNAUTHORlZED AITACHMENTS WILL VOID ANY AN D ALL WARRANTIES, IMPLlED OR OTHER, AND WILL INCREASE RISK OF
FIRE, OR MAY POSSIBLY CAUSE ELECTRICAL SHOCK, INJURY. OR DEAT TO PERSONNEL.

5. DO NOT OPERATE THIS EQUIPMENT IF IT HAS BEEN DROPPED OR OTHERWISE HAS POSSIBLY SEEN DAMAGED. TRYING TO
OPERATE THlS EGUIPMENT IF IT HAS BEEN DAMAGED SUBJECTS YOURSELF OR OTHERS TO ELECTRICAL SHOCK THAT MAY
CAUSE SERIOUS INJURY OR DEATH.

6. ONLY RECTlFlER MODULES CAN SE INSTALLED INTO A WORKING SYSTEM. FOR ALL OTHER MODULES, REMOVE SYSTEM POWER
BEFORE ATTEMPTlNG ANY MAINTENANCE. FAILURE TO REMOVE POWER COULD CAUSE SYSTEM DAMAGE AND INCREASES
THE POSSIBILITY OF ELECTRICAL SHOCK THAT COULD CAUSE SERIOUS PERSONNEL INJURY OR POSSIBLE DEATH.

,,A RACK,SHELF MAY CONTAlN SEVERAL OPERATING SYSTEMS. IF THERE IS ANOTHER SYSTEM IN THE GENERAL AREA YOU WANT
TO ,NSTALL THlS SYSTEM, SE CAUTlOUS OF ANY EXPOSED CONNECTORS OR WIRES AND, WITH PERMISSION, REMOVE
POWER TO THE OTHER SYSTEMS. FAJLURE TO TAKE THE NECESSARY SAFETY PRECAUTIONS SUBJECTS THE INSTALLER OR
MAINTENANCE PERSONNEL TO SEVERE ELECTRICAL SHOCK THAT MAY CAUSE SERIOUS INJURY OR DEATH.

8. DO NOT PLUG THE OTHER END OF THE POWER CORDS INTO THE AC SERVICE. POWER WILL SE APPLIED DURING THE
OPERATlONAL CHECKOUT PROCEDURE.
CAUTIONS:

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1. THE SYSTEM IS DELICATE AS COMPARED TO THE MGER POWER EGUIPMENT. DO NOT APPLY TOO MUCH FORCE TO THE
MOUNT,NG SCREWS, RETAINERS. ETC. OR DAMAGE TO THE EOUIPMENT MAY OCCUR.

2. THE MODULE SHOULD SLIDE EASILY INTO THE CAGE. DO NOT FORCE THE MODULE INTO THE CAGE. DAMAGE TO THE MODULE OR
SYSTEM BACKPLANE COULD OCCUR.

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PECO II, Inc.

SMSOF48PMPD
Issue 8, Mar 2000

Section I
General Information
1.1 GENERAL.
The paragraphs that follow contain information that is
intended to help the user with the understanding of the
Rectifier Module. This Rectifier is a -48 VDC 50 Amp
self contained unit. The Rectifier is a fully regulated, DC
isolated output Switchmode Rectifier designed to
charge batteries while supplying power to
telecommunication equipment. The Rectifier can also
operate as a Battery Eliminator not requiring external
batteries. The Rectifier is of modular design for easy
upgrading or replacement in a PECO II shelf
configuration.

Dynamic: Voltage transient is less than

5% and will return and stay within the
1 .O% band within 300MS when a 50%
load step is applied or removed within
the Rectifier load range of 10% to
100% load.
Noise

Measured at the Battery with an AH

rating of four (4) times the Rectifiels
rated output for all AC input and output
load condition.
Voice Band: Maximum of 32 dBm Cmessage weighing (Typical max 28
dBm).
Wide Band: Maximum of 250 millivolts
peak-to-peak over a bandwidth of (10
Hz-IOOMHz).
Maximum of 100 millivolts RMS in any 3
KHz band between 1OKHz and 100
KHz.

Over Voltage

An individual Rectifier, with an output

load of greater than lo%, will shutdown.
Rectifiers, when operated in parallel,
will selectively shutdown if the output
voltage reaches 58.0 VDC (factory
setting).

Protection

Output: Electronic Current Limit limits

the output current to 51 .O Amps or
102% of rated output.(Factory
setting)
Short Circuit: Electronic Current Limited
(Internal fuse if the electronic current
limit fails).

Mechanical
Specifications

Size: 5.10 in. wide x 9.38 in. high x

13.00 in. deep.
Weight: 18.00 Lbs.

1.2 SPECIFICATIONS.
The following infonation is intended to give the user a
quick reference to information that is necessary to install
and operate the system. Included are input
requirements, output signal characteristics, size, weight,
and generated system noise.

Input Requirements
Voltage/
Current

Single Phase, 178-285 Volts AC,

47-63 Hz, 13.7 Aac (Nom), 18.5 Aac
(Max).

TIF

Telephone Influence Factor of the AC

current wave has a typical I.T. product
less than 500 at 230VAC.

Efficiency

88 to 90% at 50-100%
@50ADC.

Power Factor

0.90 Lagging lo-100% Output Load

0.95 to 0.99 Lagging Typical.

AC Input
Protection

20Amp Fuse in series with AC Input line

(Fuse is not Field Replaceable).

Load 54.5VDC

output
Voltage

Voltage
Regulation

Float Adjust (Minimum 50 to 55 VDC)

Equalize Ajust (O-6 VDC above FloatNot to exceed 60.0 VDC).
Static: +/-1% for all AC input, output
load, and temperature conditions.

No. ot
Modules

Shelf Output
Current

BTUMR

50 Amp

1122

1.3 STANDARD FEATURES.

The Rectifier Module comes with many standard
features. These features are detailed in the following
paragraphs.

PECO II, Inc.

SM50F48PMPD
Issue 8. Mar 2000

1.3.1 Voltage Control. The Float/Equal switch, located

on the front panel, selects float or equalize modes of
operation. The FL and EQ adjust potentiometers are
provided to make adjustments for each voltage
requirements.

1.4.5 Float Adjust. The Float Adjust pot is used to

adjust the float voltage output of the Rectifier.
1.4.6 Equalize Adjust. The Equalize Adjust pot is
used to adjust the equalize voltage output of the
Rectifier.

1.3.2 Remote Sensing. Negative Sense lead can be

connected to the batteries for optimum regulation.

1.4.7 Current Limit. The Current Limit(CL) pot is

sealed and must not be adjusted. This is for factory
setting only.

1.3.3 Load Sharing. A circuit is provided so Rectifiers

can proportionally share the load with other like
Rectifiers within c/-2% of rated Load.

1.4.6 High Voltage. The High Voltage pot is used

to adjust the high voltage setting of the Rectifier.

1.3.4 Current Walk-In. Upon turn-on of the Rectifier,

the output current will gradually increase to its lequired
output load in approximately eight (8) seconds.

1.4.9 Float/Equalize. The ECI LED(Amber) will light

when the Float/EQ switch is in the equalize position.

1.3.5 Meter (Digital). Selectable Voltmeter/Ammeter.

located on the front panel, accuracy is +/-1%.

1.4.10 Fail LED. The Fail LED(Red) will light when the
Rectifier fails to operate.

1.3.6 Over Temperature. Rectifier will shutdown due

to an internal over temperature condition. This could be
the result of a fan failure or other abnormal condition.

1.4.11 Select Switch. The Select Switch turns Rectifier

Output meter to either A (Amps) or V (Volts) reading.
1.5 AGENCY APPROVALS.

1.3.7 Alarm Indication. Any condition resulting in

Rectifier failure, including AC turn-off or a fan failure
will provide a signal to the Office Alarm terminals and
will light the RFA LED (RED), located on the front panel.

UL Recognized-UL 1950 (Information Technology

Equipment).
C-UL Recognized-CSA C22.2 NO. 950-95 (ITE).
CE/CB Scheme to IEC950 (ITE).
CISPR22 class B (ITE).

1.4 CONTROLS, ALARM FEATURES, AND

INDICATORS.

1.6 ENVIRONMENTAL SPECIFICATIONS.

The Rectifier alarm features and indicators, located on

the front panel of each Rectifier, are contained in the
following section.

A. STORAGE AMBIENT TEMPERATURE: -40C to

+85C (-40F to +185F)

1.4.1 Test Points. Test Points are available to monitor

the Rectifiers Voltage and Current with respect to the
COM Test Point.

B. OPERATING AMBIENT TEMPERATURE:

Sea Level to 4800 ft: 0C to +5OC (+32F to +122F)

1.4.2 Test LED. The Test LED(Amber) will light when

the Rectifier has an open (-) Negative Sense lead.
When the Test Lamp is ON, the Rectifier will be in a
Local Sense Mode.

4800ftto7000ft: 0Cto+45C(+32Fto+113F)
7000ftto10.000ft: OCto+40C(+32Fto+104F)
Humidity: 95% Non-condensing (Maximum).

1.4.3 Standby/ON Switch. The Standby/ON Switch

puts the Rectifier in a stand-by condition.

C. COOLING:

1.4.4 GO LED. The GO LED(Green) will light when AC

input voltage (>18OV) is present.

Forced Air - Keep ventilating passage ways to the unit

unobstructed to insure adequate cooling during
operation. Otherwise over temperature
protection alarm may be activated.
l-02

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PECO II, Inc.

SM5OF48PMPD
Issue 8, Mar 2000

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Figure l-l.
Rectifier Module
l-03

PECO Ii, Inc.

SMSOF48PMPD
Issue 8, Mar 2000

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Figure 1-2.
Rectifier Module(Front View)
l-04

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PECO II, Inc.

SMSOF48PMPD
Issue 8. Mar 2000

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Section II
Rectifier Module Installation
2.1 GENERAL.

11-CLSO
CONTROLLED LOAD SHARE
lead. When connected between other like Rectifiers
Modules will Load Share within c/-2% of rated load.
12- RFA-NO
13- RFA-COM
14- RFA-NC RECTIFIER FAILURE ALARM
(RFA). These leads are from a set of relay contacts
called Fon C contacts. The RFA relay alarm contacts
are shown in their alarm state (De-energized). Relays
release on alarm conditions, slam-t circuits are
energized in their Normal no alarm condition.
15-VI
CURRENT MONITOR lead is
provided for Remote Monitoring of the Rectifiers output
current. A 1 .O volt/lO.O Amp current signal referenced
to the Negative Sense lead is provided for use with a
remote Monitoring System.
16- Vacant
17- BTC
BATTERY TEMPERATURE
COMPENSATOR lead is provided to vary the output
voltage of the Rectifier to compensate for battery
temperature in the range of 10C to 65C.
18- Vacant
REMOTE HIGH VOLTAGE lead
19- RHV
will accept an external high voltage signal (Battery) from
a system controller. If the Rectifiers output current is
more than 10%. this signal will shut down the Rectifier
Module.
2CI- RM-EQ
REMOTE EQUALIZE lead will
accept an external equalize signal (Ground) from a
system controller or other external system to raise the
plant battery voltage for the purpose of battery
maintenance.

This section gives the procedures to install the Rectifier

Module. Included are all installer interfaces and
associated reference material to be used when installing
the equipment.
The Rectifiers Input and Output connections are
plugable connectors for the purpose of paralleling and
HOT Insertion into a working system(See Figure 2-l).
2.2 INSTALLATION.
A. AC Input Connections(See Figure 2-l).

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(1) Input Connections (A Module):

l Ll connects to AC Input Line 1
l CHAS GRD connects to AC Ground (Earth GRD)
l L2 connects to AC Input Line 2
8. Output Connections.
(1) Output Power Connections

(B Module):

Pin Number
(+)
Positive Power Output connection.
Negative Power Output connection.
(4

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(2) Alarm & Control connections (B Module):

Pin Number
l-vacant
2- Vacant
3- Vacant
4- Vacant
5- Vacant
6- Vacant
7- Vacant
8- (4)
NEGATIVE SENSE lead. It is
used by the chop secondary control to regulate its
output to that Sense Point.
POWER SUPPLY INHIBIT
9- PSI
(Remote Restart and Shutdown). By applying a ground
signal to this lead, the Rectifier can be remotely
shutdown and restarted from a remote location or
remotely controlled.
lo- SCOM
SECONDARY COMMON is the
(-) minus output lead of the Rectifier.

2-01

PECO II, Inc.

SM50F48PMPD
Issue 8, Mar 2000

I
G. The Rectifier will come on line. The GO LED
(Green) will light. The digital meter will indicate the
output voltage or current, depending on the position of
the V/A switch (Volts/Amps), located to the right of the
meter. Upon turn-on of the Rectifier, the output current
will gradually increase to its required load,
approximately eight (8) seconds to full output.

2.3 INITIAL TURN ON.

A. Make sure that the AC Input Circuit Breaker, located
in the AC Power Service Cabinet or Shelf, for the new
Rectifier is in the OFF position.
B. Make sure that the Output Circuit Breaker, located
on shelf below the Rectifier, for the new Rectifier is
OFF.

Note: If the Rectifier is connected to batteries that are

discharged or new, the Rectifier may go into a Current
Limit mode, during which the Rectifier gives a constant
current, but the voltage will be something less than the
adjusted voltage. As the batteries charge up, the
voltage will increase up to the normal output voltage.

C. Insert the new Rectifier into the Rectifier Shelf.

D. If equipped, press and hold the Cap Charge
switch, located on the shelf below the Rectifier, for five
(5) seconds. Turn ON the Output Circuit Breaker.

Note: The Rectifiers are Factory Set per Section 3.4. If

other than factory settings are required refer to Section
3.2 Float/Equalize Adjust.

E. Turn ON the AC Circuit Breaker, located in the AC

Power Service Cabinet or Shelf, for the new Rectifier.
F. Turn the STANDBY/ON switch, located on the front
of the Rectifier, to the ON position.

2.4 TOOLS REQUIRED.

Note: Double Insulated Tools with an Insulation Rating
of 1000 Volts is required.
Digital Voltmeter
Slotted Screwdriver

2-02

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PECO Ii, Inc.

SM50F48PMPD
Issue 8, Mar 2000

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MODULE Ii
lNPUT
L2 /

T% -

AODULE 0
OUTPUT
C-1 -

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(+) -

Figure 2-I.
Rectifier Module (Rear View)
2-03

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PECO II, inc.

SM50F48PMPD
Issue 8, Mar 2000

Section III
Maintenance and Adjustments
(2) The Equalize Voltage is adjusted after the Float
Voltage is set. The Equalize Voltage is adjustable using
the EQUALIZE ADJ pot, located on the front panel of
the Rectifier. Before making adjustment on the
Equalize Adjust (EQ) pot, operate FLOAT/EQUAL
switch to the EQUAL position. A clockwise (CW)
direction will increase the Equalize Voltage and a
counterclockwise (CCW) direction will decrease the
Equalize Voltage setting.

3.1 GENERAL.
This section gives the procedures to perform
maintenance and adjustments on the Rectifier Module.
3.2 MAINTENANCE.
This section gives the procedures to perform
maintenance on the Rectifier Module.

B. Current Limit Adjust. The Current Limit Adjust is

adjustable using the Current Limit Adj pot, located on
the front panel of the Rectifier. The Current Limit is
factory set at 51 .O Amps.

A. Inspect the Rectifier Module for obstructed airflow to

the Module.
(1) Check to make sure fan is still operating.
(2) Check for any obstructions that may be impeding
the Rectifier airflow.
(3) If needed, remove any obstructions blocking
airflow.

Caution: Do not adjust the output current limit to a

value greater than 51.0 Amps or 102% of rated output.
Also , do not adjust greater than 100% if the Rectifier is
operating in parallel without any means for load sharing.

B. Inspect the pins on the. Rectifier for any signs of

arching.
(1) Remove the Rectifier from System.
(2) Check for any signs of arching on the pins of
the Rectifier.

Note: It is not recommended that the Current Limit be

adjusted. An external load would be required to reset
the Current Limit.

3.3 ADJUSTMENTS.

3.4 FACTORY SETTINGS.

This section gives the procedures to perform

adjustments on the Rectifier Module.

The following settings are factory set, and should not be

adjusted unless necessary. If the need does arise for
one or all to be changed, refer to Section Ill for the
proper instructions.

A. Float/Equalize Voltage Adjust. Operate the

STANDBY/ON switch, located on the Rectifier, to the
STANDBY position. Operate the Rectifier Shelf
Breaker/Switch to the OFF position. Now operate the
STANDBY/ON switch to the ON position.
(1) The Float Voltage is adjustable using the FLOAT
ADJ (FL) pot, located on the front panel of the Rectifier.
Note: Before making adjustment of the FLOAT
ADJUST pot, operate FLOAT/EQUAL switch to the
FLOAT position. A clockwise (CW) direction will
increase the Float Voltage and a counterclockwise
(CCW) direction will decrease the Float Voltage setting.

Plant setting

PM, -l,-2

PM-3

Float Voltage

54.48 VDC

54.48 VDC

Equalize Voltage

56.40 VDC

55.20 VDC

Current Limit

5 1 .OO Amps

51.00 VDC

High Voltage Alann

58.00 VDC

58.00 VDC

3.5 TOOLS REQUIRED.

Digital Voltmeter
Slotted Screwdriver (Fine Blade) or Tweaker

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PECO II, Inc.

SM50F4SPMPD
Issue 8, Mar 2000

Section IV
Troubleshooting
4.1 GENERAL.

4.3 TOOLS REQUIRED.

This section gives the procedures to troubleshoot the

Rectifier Module.

Digital Voltmeter
Slotted Screwdriver (Fine Blade) or Tweaker

4.2

TROUBLESHOOTING.

Troubleshooting of the Rectifier Module is limited to the

presence of an RFA. If an RFA exists, reseat the
Rectifier Module into the shelf. If the RFA terminates,
monitor the Rectifier in operation for approximately an
hour. If the RFA persists, contact PECO II Field Service
at the numbers listed in the front matter of this manual.

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