* * * * * * * * * INSTALLATION AND MAINTENANCE
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1 .-- )., TYPE CCRP RECTFERS * * * * * * * * * NSTALLATON AND MANTENANCE SERVCE MANUAL 595 CONTENTS Page... V. v. V. TABLE... V. NTRODUCTON..... DESCRPTON. OPERATON... A. NPUT VOLTAGE... B. CHARGNG BATTERES.. NSTALLATON.. A. MOUNTNG. B. NPUT & OUTPUT ELECTRCAL CONNECTONS C. NTERNAL CONNECTONS. D. CHARGNG.... E. CHARGNG RATE ADJUSTMENT.. F. TWO-RATE CHARGE MANTENANCE.. PARTS LSTS. CCRP ELECTRCAL CHARACTERSTCS CONNECTONS FOR CCRP-6 RECTFERS CONNECTONS FOR CCRP-10 RECTFERS-PART. NUMBER N , -090, and -090 CONNECTONS FOR CCRP-10 RECTFERS. PART NUMBER N FGURE SCHEMATC DAGRAM, TYPE CCRP-6 RECTFER 4 SUFFX NUMBERS & SCHEMATC DAGRAM, TYPE CCRP-10, RECTFER. 4 SUFFX NUMBERS -0901, -090, & -090 SCHEMATC DAGRAM, TYPE CCRP-10, SUFFX 5 NUMBER RECTFER TYPE CCRP-6 AND CCRP-10 (EXCEPT CCRP SUFFX -1101) RECTFERS TYPE CCRP-10 SUFFX RECTFER 14 A0.7-lM-1765.l February ',."to
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3 WABCO, NTRODUCTON The Constant Current Rectifier (CCRP) is a self contained full wave rectifier containing a heavy duty transformer and a silicon diode bridge rectifier. The CCRP rectifier provides full wave rectification and efficient current regulation for battery charging service., DESCRPTON The CCRP rectifier is shown in Figures 4 and 5 at the end of this manual. These figures provide all pertinent dimensions and p arts location. Refer to Table 1 for part numbers, style numbers,and specifications of the various CCRP rectifiers. TABLE CCRPELECTRCAL CHARACTERSTCS AC DC Part No. Style (input) (output) Battery Appl. (N4517-) Volts Hz Volts Amps #Cells Type* 0901 CCRP-10 40/8/16 50/ LA LA 090 CCRP-10 40/8/16 50/ LA LA 090 CCRP-10 10/114/108 50/ LA LA 0904 CCRP-6 10/114 50/60/ LA 14-0 N 0905 CCRP-6 40/_8 50/60/ LA 14-0 N 1101 CCRP-10 55/110 5/ LA 14-0 N *LA is Lead Acid, N.. is Nickel ron ll, OPERATON The type CCRP rectifiers provide full wave rectification and efficient current regulation for battery charging service. The rectifiers use a silicon avalanche integrated circuit bridge rectifier with a heavy duty transformer. The DC circuit is insulated from the housing and from the primary of the transformer to withstand,000 volts. That is, the AC input and the DC output are connected by transformer coupling only. 595, p.
4 TYPE CCRP RECTFERS * * * * * * * * * NSTALLATON AND MANTENANCE SERVCE MANUAL V. v. V. CONTENTS NTRODUCTON DESCRPTON.. OPERATON... A. NPUT VOLTAGE. B. CHARGNG BATTERES.. NSTALLATON A. MOUNTNG. B. NPUT & OUTPUT ELECTRCAL CONNECTONS C. NTERNAL CONNECTONS... D. CHARGNG. E. CHARGNG RATE ADJUSTMENT F. TWO-RATE CHARGE... MANTENANCE.. PARTS LSTS.... Page TABLE... V. CCRP ELECTRCAL CHARACTERSTCS. CONNECTONS FOR CCRP-6 RECTFERS. CONNECTONS FOR CCRP-10 RECTFERS-PART. NUMBER N , -090, and -090 CONNECTONS FOR CCRP-10 RECTFERS PART NUMBER N FGURE SCHEMATC DAGRAM, TYPE CCRP-6 RECTFER 4 SUFFX NUMBERS & SCHEMATC DAGRAM, TYPE CCRP-10, RECTFER. 4 SUFFX NUMBERS -0901, -090, & -090 SCHEMATC DAGRAM, TYPE CCRP-10, SUFFX. 5 NUMBER RECTFER TYPE CCRP-6 AND CCRP-10 (EXCEPT CCRP SUFFX -1101) RECTFERS TYPE CCRP-10 SUFFX RECTFER 14 A0.7-lM February 197
5 A. NPUT VOLTAGE WABCC The AC input voltages listed in Table 1 are the normal values. A lower AC input may be used when less than maximum charge is required. B. CHARGNG BATTERES The rectifiers may be used to charge any type and number of cells in series providing: 1. The charging current does not exceed the maximum for the rectifier.. The maximum voltage of the battery does not exceed the maximum voltage of the rectifier. V, NSTALLATON. ' A. MOUNTNG The rectifier should be installed in a dry place. t may be wall mounted keeping the front panel vertical, or it may be set on a shelf. Other equipment should not be installed too close so as to impede circulation of air around the rectifier. The ambient air temperature should not exceed 1600F for all models except for the style CCRP-10 suffix number 1101 rectifier for which the ambient air temperature should not exceed 10 F. B. NPUT AND OUTPUT ELECTRCAL CONNECTONS n making AC connections, there are no polarity requirements. n making DC connections, connect the positive (+) terminal of the rectifier to the positive (+) side of the battery and the negative (-) side of the rectifier to the negative (-) side of the battery. C. NTERNAL CONNECTONS As an aid in making internal connections, schematic diagrams for the rectifiers are shown in Figures 1,, and. CCRP-6 Rectifiers These rectifiers are intended for use with the AC voltages and frequencies specified in Table. They are shipped wired for 50/60 Hz operation at the maximum tabulated voltage. f the rectifiers are to be used at any of the other voltages or frequencies listed in Table, the terminal board connections specified in Table must be made. 595, p.
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7 WABCD 151<. Figure 1. Schematic Diagram, Type CCRP-6 Rectifier Suffix Numbers & Figure. Schematic Diagram, Type CCRP-10, Rectifier Suffix Numbers -0901, -090, & , p. 4
8 A. NPUT VOLTAGE WABCO 'v.'4 The AC input voltages listed in Table 1 are the normal values. A lower AC input may be used when less than maximum charge is required. B. CHARGNG BATTERES The rectifiers may be used to charge any type and number of cells in series providing: 1. The charging current does not exceed the maximum for the rectifier.. The maximum voltage of the battery does not exceed the maximum voltage of the rectifier. v NSTALLATON A. MOUNTNG The rectifier should be installed in a dry place. t may be wall mounted keeping the front panel vertical, or it may be set on a shelf. Other equipment should not be installed too close so as to impede circulation of air around the rectifier. The ambient air temperature should not exceed 1600F for all models except for the style CCRP-10 suffix number 1101 rectifier for which the ambient air temperature should not exceed 10 F. B. NPUT AND OUTPUT ELECTRCAL CONNECTONS n making AC connections, there are no polarity requirements. n making DC connections, connect the positive (+) terminal of the rectifier to the positive (+) side of the battery and the negative (-) side of the rectifier to the negative (-) side of the battery. C. NTERNAL CONNECTONS As an aid in making internal connections, schematic diagrams for the rectifiers are shown in Figures 1,, and. CCRP-6 Rectifiers These rectifiers are intended for use with the AC voltages and frequencies specified in Table. They are shipped wired for 50/60 Hz operation at the maximum tabulated voltage. f the rectifiers are to be used at any of the other voltages or frequencies listed in Table, the terminal board connections specified in Table must be made. 595, p.
9 WABCO ( \ TOP VEW OF RECTFER Figure. Schematic Diagram, Type CCRP-10, Suffix Number Rectifier TABLE CONNECTONS FOR CCRP-6 RECTFERS Line to Bridge to Part No. Part No. Primary Secondary N N Connection Connections 10 VAC, 50/60 Hz 40 VAC, 50/60 Hz lp-sp 1S-S 10 VAC, 100 Hz 40 VAC, 100 Hz 1P-P 1S-S 114 VAC, 50/60 Hz 8 VAC, 50/60 Hz 1P-4P 1S-S 114 VAC, 100 Hz 8 VAC, 100 Hz 1P-P 15-S 595, p. 5
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11 WABCD CCRP-10 Rectifiers (excluding Part No. N ) These rectifiers are intended for normal use on the AC voltages and frequencies specified in Table. The rectifiers are shipped wired for the highest voltage specified in Table. Two taps are provided for the other given line voltages. Table lists the connections to be made when using the rectifiers at the other recommended voltages. TABLE CONNECTONS FOR CCRP-10 RECTFERS PART NUMBERS N , -090 AND -090 AC Line/Primary Tap Connections Li:rie Voltage lp & 4P lp & 4P 8 lp & P lp & P 16 lp & P lp & P 10 lp & 4P 114 lp & P 108 lp & P CCRP-10 Rectifier (Part No. N only) This rectifier is designed for 55/110 VAC, 5/60 Hz operation. Table V lists the connections which must be made for the various line voltage and frequency combinations. TABLE V NOTE: CONNECTONS FOR CCRP-10 RECTFERS PART NUMBER N AC line is permanently wired to lp & 4P AC 55V, Line X and Y Connectors Connecting Links Across 5 Hz Connected together lp & P and P & 4P 55V, 60 Hz Disconnected and Y connected lp & P and P to 5 {X not used) & 4P llov, 5 Hz Connected together Both across P & P llov, 60 Hz Disconnected and Y connected Both across P to 5 (X not used) & P 595, p. 6
12 WABCD J o a x y ,t-A - - LJ -il Lr 7., \...::.. COARSE ' l} FNE P j P S :o S o 5 TED.BACK & TAPED AC ty (} r-0 6 AC SW ( : ---, i t El HJ > Ls. B ie ze. XY TOP VEW OF RECTFER Figure. Schematic Diagram, Type CCRP-10, Suffix Number Rectifier TABLE CONNECTONS FOR CCRP-6 RECTFERS Line to Bridge to Part No. Part No. Primary Secondary N N Connection Connections 10 VAC, 50/60 Hz 40 VAC, 50/60 Hz 1P-5P 1S-S 10 VAC, 100 Hz 40 VAC, 100 Hz 1P-P 1S-S 114 VAC, 50/60 Hz 8 VAC, 50/60 Hz 1P-4P 1S-S 114 VAC, 100 Hz 8 VAC, 100 Hz 1P-P 1S-S 595,_p. 5
13 WABCC D. CHARGNG The charging current is determined by the panel mounted ammeter or by inserting a DC permanent magnet type ammeter in the positive terminal lead connected such that the positive (+) terminal of the ammeter is connected to the positive (+) terminal of the rectifier and the negative {-) or unmarked terminal of the ammeter is connected to the positive (+) terminal of the battery. E. CHARGNG RATE ADJUSTMENT All Styles except CCRP-10 Part No. N The charging rate can be adjusted by loosening the four nuts on the top of the transformer and varying the air gap between the transformer and the top bar. To facilitate this adjustment, spacers of paper, wood, cardboard, fibre, or any other insulating material may be used. The air gap need not be the same length on both ends. After the required charging current has been obtained, the four nuts must be tightened to maintain the adjusted charging rate. CCRP-10 Part No. N The charging rate can be adjusted by turning the COURSE and FNE controls on the front panel. A COURSE step is approximately equal to four FNE steps. F. TWO-RATE CHARGE The CCRP rectifier may be used for two-rate charging by using a two-rate charging relay {PN156, DNL 46, DNL 47 or equivalent). The relay- shall be connected to the rectifier as follows: 1. Remove the connecting link between the Sand R terminals.. Connect a suitable variable resistor between terminals Sand R.. Connect the contacts of the two-rate charge relay across the resistor. 4. With the relay contacts closed, set the high charge rate as outlined in E above. 5. With the relay contacts open, set the low charge rate by adjusting the variable resistor. 595, p. 7
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15 WABCD V, MANTENANCE NOTE The assembly of the rectifiers is a highly skilled operation. The manufacturer does not assume the responsibility for the operation of any rectifiers which have been at any time or way dismantled. Maintenance, other than ordinary cleaning and visual inspection, is not required for the Type CCRP rectifier. n event of part failure the replacement part must be selected in accordance with the parts listing which follows. V, PARTS LSTS The following tabulations are keyed to Figures 4 and 5. The first tabulation lists the major components (Reactor, Transformer, etc.) of the CCRP rectifiers. The second tabulation lists the secondary parts {terminals, resistors, etc.) common to all rectifiers except the type CCRP-10, N The third tabulation lists the secondary parts (terminals, resistors, etc.) for the type CCRP-10, N only. 595, p. 8
16 WABCD D. CHARGNG The charging current is determined by the panel mounted ammeter or by inserting a DC permanent magnet type ammeter in the positive terminal lead connected such that the positive (+) terminal of the ammeter is connected to the positive {+) terminal of the rectifier and the negative {-) or unmarked terminal of the ammeter is connected to the positive (+) terminal of the battery. E. CHARGNG RATE ADJUSTMENT All Styles except CCRP-10 Part No. N The charging rate can be adjusted by loosening the four nuts on the top of the transformer and varying the air gap between th transformer and the top bar. To facilitate this adjustment, spacers of paper, wood, cardboard, fibre, or any other insulating material may be used. The air gap need not be the same length on both ends. After the required charging current has been obtained, the four nuts must be tightened to maintain the adjusted charging rate. CCRP-10 Part No. N The charging rate can be adjusted by turning the COURSE and FNE controls on the front panel. A COURSE step is approximately equal to four FNE steps. F. TWO-RATE CHARGE The CCRP rectifier may be used for two-rate charging by using a two-rate charging relay (PN156, DNL 46, DNL 47 or equivalent). The relay shall be connected to the rectifier as follows: 1. Remove the connecting link between the Sand R terminals.. Connect a suitable variable resistor between terminals Sand R.. Connect the contacts of the two-rate charge relay across the resistor. 4. With the relay contacts closed, set the high charge rate as outlined in E above. 5. With the relay contacts open, set the low charge rate by adjusting the variable resistor. 595, p. 7
17 - STYLE CCRP RECTFER TABULATON Part No. (N4517-) Style Transformer Ammeter AC Fuse DC Fuse Wiring per Figure Terminals per 0901 CCRP-10 N J06059(15A) J07118(A) J (lsa) 090 CCRP-10 N J06059 {lsa) J07118(A) J071018(15A) 090 CCRP-10 N J06059(15A) J071008(5A) J (lsa) 0904 CCRP-6 N J06058(10A) J071008(5A) J07101(10A) 0905 CCRP-6 N J06058(10A) J07118(A) J07101(10A) *1101 CCRP-10 N91 J06059(15A) J (lsa) J071018(15A) 1 1 As shown in Fig. 4 View A, Fig. 4 As shown in Fig. 4 As shown in Fig. 4 As shown in Fig. 4 As shown in Fig. 5 *With Voltmeter, Part No. J06169, and Reactor, Part No. J99 U1.O Ul w... l"(j..o 'i 8
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19 U1 \C> U1 w._ "CJ to 5 6 (FOR METRC THREADS) 4 a"max.. 14,5 6, SECTON " (METRC THREAD) ' -$- Figure :i lli1l-.. a 5 :;! a" --=...: Type CCRP-6 and CCRP-10 (except CCRP-10 Suffix -1101) Rectifiers
20 STYLE CCRP RECTFER TABULATON Part No. (N4517-) Style Transformer Ammeter AC Fuse DC Fuse Wiring per Figure Terminals per 0901 CCRP-10 N J06059(15A) J07118(A) J071018(15A) 090 CCRP-10 N J06059(15A) J07118(A) J071018(15A) 090 CCRP-10 N J06059(15A) J071008(5A) J071018(15A) 0904 CCRP-6 N J06058(10A) J071008(5A) J07101(10A) 0905 CCRP-6 N J06058(10A) J07118(A) J07101(10A) *1101 CCRP-10 N91 J06059(15A) J071018(15A) J071018(15A) 1 1 As shown in Fig. 4 View A, Fig. 4 As shown in Fig. 4 As shown in Fig. 4 As shown in Fig. 4 As shown in Fig. 5 *With Voltmeter, Part No. J06169, and Reactor, Part No. J99 Ul.O Ul w.. "O..O,1 8
21 WABCC { PARTS COMMON TO ALL CCRP RECTFERS EXCLUDNG CCRP-10, N TEM DESCRPTON PART NO *4 *5 * Base Side Board, Terminal Transformer Ammeter Switch, Double Pole Bridge, Rectifier Clip, Fuse Fuse, AC Fuse, DC Resistor, 1 Meg, 1/ W Terminal Washer Washer Connector, Terminal Tag, Wht. Mkg. AC Tag, Wht. Mkg. R Tag, Wht. Mkg. S Tag, Wht. Mkg. -DC Tag, Wht. Mkg. +DC Block, Terminal Washer Nut Block, Terminal Post, Binding Nut, Clamp Screw, # x /16 in. lg. RD DR TP Screw, #6 x 1/ in. lg. RD BRS NP Screw, 1/4 x 1/ in. lg. PAN SS Screw, 1/4 x 5/8 in. lg. RDS TP Screw, 1/4 x 7/8 in. lg. RDS TP Washer, Lock 1/4 S TP Nut, 1/4-0 HEX S TP Screw, #14-4 x 1 in. lg. RD BRS NP Screw, #1-4 x 1 in. lg. RDS TP Washer, #1 S LK TP Nut, #1-4 HEX S TP Screw, #10 x 1/ in. lg. RDS TP Washer, #10 S LK TP Nut, #10 HEX S TP N M M J07740 J7600-0l0 N J7089 J70044 M M09104 M04790 J J J J J Ml070 J M0910 M M8666 M40761 J05644 J0516 J J05505 J55185 J J04800 J J5545 J J J05565 J0477 J , p. 11
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23 WA8CC TEM DESCRPTON PART NO. 41 Screw, #8 x 5/8 in. lg. RDS TP J Washer Ml589 4 Washer, #8 s LK TP J Nut, #8 HEX S TP J nsulation (not shown) M nsulation {not shown) M Terminal (not shown) J Terminal (not shown) J Terminal (not shown) J7119 " 595, p.1
24 PARTS COMMON TO ALL CCRP RECTFERS EXCLUDNG CCRP-10, N WABCD TEM DESCRPTON PART NO. 1 Base Side Board, Terminal 4 Transformer 5 Ammeter 6 Switch, Double Pole 7 Bridge, Rectifier 8 Clip, Fuse 9 Fuse, AC 10 Fuse, DC 11 iesistor, 1 Meg, 1/ W 1 Terminal 1 Washer 14 Washer 15 Connector, Terminal 16 Tag, Wht. Mkg. AC 17 Tag, Wht. Mkg. R 18 Tag, Wht. Mkg. S 19 Tag, Wht. Mkg. -DC 0 Tag, Wht. Mkg. +DC 1 Block, Terminal Washer Nut *4 Block, Terminal *5 Post, Binding *6 Nut, Clamp 7 Screw, # x /16 in. lg. RD DR TP 8 Screw, #6 x 1/ in. lg. RD BRS NP 9 Screw, 1/4 x 1/ in. lg. PAN SS 0 Screw, 1/4 x 5/8 in. lg. RDS TP 1 Screw, 1/4 x 7/8 in. lg. RDS TP Washer, Lock 1/4 S TP Nut, 1/4-0 HEX S TP 4 Screw, #14-4 x 1 in. lg. RD BRS NP 5 Screw, #1-4 x 1 in. lg. RDS TP 6 Washer, #1 S LK TP 7 Nut, #1-4 HEX S TP 8 Screw, #10 x 1/ in. lg. RDS TP 9 Washer, #10 S LK TP 40 Nut, #10 HEX S TP N M M J07740 J N J7089 J70044 M M09104 M04790 J J J J J Ml070 J M0910 M M8666 M40761 J05644 J0516 J J05505 J55185 J J04800 J J5545 J J J05565 J0477 J , p. 11
25 WABCO ( BLANK 595, p. 1
26
27 u,.o u, w 'O -' $ $- > $ -4-- ""'..J:=:= =:Fl ts r '0 15T'\ 1.,11 4 "-. 'i - :. -'/ e AC '\ -, )- CWS WABCO D... l) ; llctlflh CCP-10 l] ac HUS n ll :.".': fs!$ : AC U K n lit u \ --"\.r f :.!,,.;,-: ,:, :::: ;:':,:e,,;::.a :: i --- =..:,..,..=:.rljt,.. 111' r,r,.. f \ 'i' \. 'i' 'ljl 'r r,ri'\ ' tj1,, L1>H ', \..Jl.:."' \.:..:,...,..,i...,---,it,1..\.:.i_.,..l.,.:...\.(.i...,"'-.1..:_ Wf ' i t t W -$ $- $---tt--.._ 1/ , -/4" - -/4" 1/8 11 Figure /16" =- " 1; : 5 1, :.. 1,.. -.J Type CCRP-10 Suffix Rectifier 7 \ r : r \.. i..:..:..::..:: --_J 61 lc.'i ' "' rt,! H _, 44 r,--=.:r-4.=i- 45 L to 4 B.,,
28 WABCD BLANK 595, p. 1
29 WRSCC ( PARTS FOR CCRP-10, N RECTFER TEM DESCRPTON PART NO. l Chassis Heat Sink Plate, Top Plate, Name Plate, Name Reactor Transformer Separator Block, Terminal Board, Teinal S.upport, Terminal Board Bridge, Rectifier Resistor, 1 Meg, 1/ W Anuneter Voltmeter Clip, Fuse Fuse, AC Fuse, DC Switch, Tap Knob Switch, Double Pole, 50V Cover Cover nsulation, Fuse Tag, R Tag, S Tag, lp Tag, P Tag, P Tag, 4P Tag, 5 Tag, -DC Tag, +DC Tag, XY Tag, AC+ Tag, AC- Grommet Nut, 1/4-4 Screw, 1/4-0 x 1-1/4 in. lg. RDS TP Washer, 1/4 S PL TP Washer, Lock 1/4 S Nut, 1/4 HEX S Screw, #1-4 x 1 in. lg. RDS TP R M M M M M8011 M0818 Ml08410 M J J7089 N J75799 J7760 J07740 M M Ml988l J J J J J J J J J J J ll5 J J M017 J05667 J J J04800 J , p. 15
30
31 WABCO TEM DESCRPTON PART NO. 44 Washer, Lock #1 S TP 45 Nut, #1 HEX S 46 Screw, #10- x 5/8 in. lg. BOGS TP 47 Washer, Lock #10 S TP 48 Nut, #10- HEX S TP 49 Screw, #10- x /4 in. lg. RDS TP 50 Screw, 1/4-0 x 1/ in. lg. PAN SS 51 Screw, 1/4-0 x 5/8 in. lg. RDS TP 5 Screw, 1/4-0 x 7/16 in. lg. RDS TP 5 Screw, #6 x 1/4 in. lg. (Z) RDS TP 54 Screw, #6- x 1/ in. lg. RD s TP 55 Screw, #14-4 x 1 in. lg. RD BRS NP 56 Screw, #8- x 5/8 in. lg. RDS TP 57 Washer 58 Washer, #8 S LK TP 59 Nut, #8- HEX S TP 60 Washer 61 Nut 6 Nut, Binding 6 Connector, Terminal 64 Terminal 65 Terminal (not shown) 66 Terminal (not shown) 67 Terminal (not shown) J J J507 J0477 J04817 J05567 J J05505 J5506 J05655 J055 J J0560 Ml589 J J J M0910 M09101 M04790 J70044 J7011 J7119 J , p. 16
32 WABCO PARTS FOR CCRP-10, N RECTFER TEM DESCRPTON PART NO Chassis Heat Sink Plate, Top Plate, Name Plate, Name Reactor Transformer Separator Block, Terminal Board, Teinal,.Support, Terminal Board Bridge, Rectifier Resistor, 1 Meg, 1/ W Anuneter Voltmeter Clip, Fuse Fuse, AC Fuse, DC Switch, Tap Knob Switch, Double Pole, 50V Cover Cover nsulation, Fuse Tag, R Tag, S Tag, lp Tag, P Tag, P Tag, 4P Tag, 5 Tag, -DC Tag, +DC Tag, XY Tag, AC+ Tag, AC- Grommet Nut, 1/4-4 Screw, 1/4-0 x 1-1/4 in. lg. RDS TP Washer, 1/4 S PL TP Washer, Lock 1/4 S Nut, 1/4 HEX S Screw, #1-4 x 1 in. lg. RDS TP R M M M M M8011 M0818 Ml08410 M _ J J7089 N J75799 J7760 J07740 M M Ml9881 J J J J J J J J J J J J J M017 J05667 J J J04800 J , p. 15
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