,, SERVICE MANUAL 5962 Installation and Maintenance CCR-A RECTIFIERS. CONTENTS Page I. II. III. IV. v. VI. INTRODUCTION.. DESCRIPTION. A. ELECTRICAL.... B. PHYSICAL C. OPERATING TEMPERATURE D. THEORY OF OPERATION OPERATION.. A. BATTERY CHARGING.. B. LOW RATE MONITOR SWITCH. C. PROTECTIVE CIRCUITS INSTALLATION. A. MOUNTING REQUIREMENTS. B. ELECTRICAL CONNECTIONS. C. HIGH CHARGE RATE (MAXIMUM CURRENT). ADJUSTMENT D. LOW CHARGE RATE ADJUSTMENT MAINTENANCE A. ROUTINE MAINTENANCE B. FIELD REPAIR. C. SHOP REPAIR. 7 8 8 8 9 PARTS LISTS. 11 2 2 2 2 2 2 5 5 5 5, 6 6 6 6 TABLE I. INPUT/OUTPUT TEST. 10 FIGURE 1. CCR-A SCHEMATIC DIAGRAM 3 2. CCR-A WIRING DIAGRAM... 7 3. CCR-A TEST SETUP... 9 4. CCR-A RECTIFIER. 12 5. CCR-A PRINTED CIRCUIT BOARD. 15 PARTS LOCATION May, 1981 B-1 /84-250-1773-1 UNION SWITCH & SIGNAL DIVISION AMERICAN STANDARD INC./ SWISSVALE, PA 15218, >RiNTED IN USA
UNION SWITCH ~ SIGNAL I I INTRODUCTION" The Style CCR-A rectifier is a self contained full-wave rectifier designed for automatic battery charging service. It has an adjustable high rate and an adjustable low rate of charge and automatically cycles between the two rates. It incorporates features which protect it from overloads and incorrect connections on the output terminals. II, DESCRIPTION A. ELECTRICAL Input - 120/240 vac, 50/60 Hz Output - 12V nominal (for 6 cells of lead-acid battery over normal battery range) Adjustable to zero (0) charge rate High rate turn-on at 13.02 vdc High rate turn-off at 13.4 vdc (approx.) Transient Voltage - The rectifier will withstand a dielectric test voltage of 3000V, 60 Hz for 1 minute. B. PHYSICAL The CCR-A rectifier is shown in Figure 4 at the end of this manual. This figure_provides all pertinent dimensions and parts location. C. OPERATING TEMPERATURE The rectifier is designed to operate continuously in an ambient temperature of -40oF to 1600F. The electronic circuitry is temperature compensated (Sl Sensistor) to provide for a change in battery terminal voltage of 1% for each 10 change in ambient temperature from the 400F calibration point of 13.02V for 6 cells of lead-acid battery. D. THEORY OF OPERATION As an aid in understanding the theory of operation of the CCR-A rectifier, reference may be made to the schematic diagram shown in Figure 1. 5962, p. 2
.. <.n \D.. N ' '"d w TO AC SOURCE 1,-R-EA-C-TIV_E_ J r-r-ec-tifi-er- j :~! TRANTM'~~+i I : BRIDGE.! LOW CHARGE RATE R2 R~ ""''-- ~c '.., " 0 1 LOW CHARGE FUSE TO RESITOR NOT 7.5A BATTERY PART OF CCR A RECTIFIERS 3 P 11 - +~,----------~H~l~GH~C~H~A;RG~E~R~A=~E~isl-:::Q~3~(S~CR~)-----------, 2Pp 1', I -----------1,~+) I _J,----2N4073G. - I Rl5 Q2 03 +DC I I o. 51.Cl IN3277. IK R. Rl2 I I 2R I IK 04 1 I R I I I IN3277 ~ I LOW I TP4 w. Rl3 I RATE TPI RI I 15K TP5 3 I I I IR MONITOR I (+) SWITCH. QI IK DI I I I 2N3643 RS 510.Q Cl R2 MRI032B L _ J I IN962B 33UF IK TP2 I -- R6 TP3 IOK R3 I l.210k I 1% R? C2 R4 I 7. I 5 K.1.UF. 3.0IK SI 0, 1 1.5K j,o BK. Figure 1. I -DC I L Pc_no_ARD --- ---- J CCR-A Schematic Diagram 0 TO BATTERY -DC c z 0 z I ~ :i: flt 0 is ~,... a3
UNION SWITCH & SIGNAL The CCR-A rectifier consists of three basic sections; the reactive transformer, the integrated circuit full wave bridge rectifier, and an electronic sensing and control circuit. The reactive transformer output can be increased or decreased by moving the sliding transformer core block. Moving this block varies the lux linkage which in turn varies the output of the transformer. Basically, the output of the transformer is applied to the rectifier bridge where it is changed to full wave rectified de. The de output is then applied to the control circuit where it takes one of two paths to the battery. One is the High Charge path (through Q3), the other the Low Charge path (through resistor chosen by user across terminals Rl and R2). 1. High Charge Circuit The'high charge circuit is used for rapid recharging of the battery. The printed circuit board controls the power application to the battery being charged by sensing the battery voltage and applying and removing charging current at preset battery voltages. Battery voltage sensing is accomplished by the resistive voltage divider comprised of resistors Rl, R2, R3, R4 and Sl which is a sensistor used for temperature compensation. The voltage at the junction of R2 and R3 is connected via R6 to the inverting input, pin 4 of ICl. Ql which is connected through R9 to pin 9 of ICl, is kept non-conducting as long as pin 4 of ICl is above the voltage at pin 5 and 6 of ICl. The reference voltage at pin 6 is established within ICl. When the voltage at pin 4 drops below that at pin 6, the output of ICl at pin 9 goes positive supplying base current to Ql causing it to conduct, which in turn then supplies base current to Q2 causing it to conduct. When Q2 conducts, gate current is supplied to the gate of the rectifier Q3 causing it to conduct. Current is al~o supplied via diode 04 and resistor Rl3 to resistor R8. The voltage drop across R8 as a result of the current flow keeps pin 5 of ICl approximately 0.5 volts above the reference level and requires voltage at pin 4 of ICl to rise approximately 0.5 volts higher than the turn-on voltage before the output of ICl at pin 9 can become negative to cut Ql off. Thus, the turn-on and turn-off differential is established by the current flowing through R8. When Ql becomes non-conducting, Q2 is cut off, removing gate current from Q3 causing it to shut off. 5962, p. 4
UNION SWITCH & SIGNAL Diode Dl provides protection against reverse connections to the battery by providing a bypass of the electronic circuitry. 2. Low Charge Circuit When Q3 is shut-off (battery voltage within limits, thus Ql and Q2 non-conducting), current must flow through the low charge circuit consisting of the resistor across terminals Rl and R2. III, OPERATION A - Battery Charging The style CCR-A rectifier is designed primarily for battery charging service. It has two modes of operation1 automatic high rate and automatic low rate.. ' During the automatic high rate operation, the rectifier supplies a high charge rate that is electronically maintained as long as the battery voltage -is below a certain pre-set level (volts/cell~ When the battery voltage raises beyond this level, the charge is automatically interrupted. When the battery voltage drops to below a pre..;:set level, the charge is re-initiated. The voltage differential between cut-in and cut-out is approximately 0.4 VDC. During the automatic Low Rate mode of operation, the cycle begins at the time the high rate is cut-out and ends when the battery voltage decreases to the high rate turn on point. The user controls the amount of charge by the resistor value applied across the Rl - R2 terminals. Since the low rate can cause over-charging care must be taken to ensure that the low charge rate is less than or does not exceed the value of the average battery load plus battery losses. (See Section III-D.} B. LOW RATE MONITOR SWITCH Since the low rate is not automatic, care must be taken to ensure that the low charge rate does not exceed the value of the average battery load p~us losses. To facilitate measuring the low charge rate, a LOW RATE MONITOR switch has been provided which will disable the high rate charging circuit and permit monitoring of the low charge rate. C. PROTECTIVE CIRCUITS The rectifier is protected against damage due to shorting of the output terminals by the reactive transformer which will limit the output current to a value below the fuse limit (7.5 amps). A reverse polarity application will not damage the rectifier but will blow the fuse in the de output line. 5962, p. 5
UNION SWITCH & SIGNAL IV I INSTALLATION A. MOUNTING REQUIREMENTS The rectifier must be mounted in a dry location. It may be wall mounted, keeping the transformer at the top, or it may be set on a shelf. Other equipment should not be mounted too close so as to impede circulation of air around the rectifier. The ambient temperature in the vicinity of the rectifier should not exceed 160oF. B. ELECTRICAL CONNECTIONS As an aid in making the following connections, reference may be made to the wiring diagram in Figure 2. 1. 120 VAC Connection When the input voltage is 120 vac, connect a jumper between terminals +lp and +3P and a jumper between terminals 2P and 4P. No attention need be given to polarity of input. 2. 240 VAC Connection When the input voltage is 240 vac, connect a jumper between terminals +3P and 2P. No attention need be given to polarity of input. 3. DC Connections In making de connections from rectifier to battery being charged, the positive {+) terminal of the rectifier should be connected to the positive (+) side of the battery and the negative (-) side of the rectifier should be connected to the negative (-) side of the battery. C. HIGH CHARGE RATE (MAXIMUM CURRENT) ADJUSTMENT The charging current may be determined by inserting a permanent magnet type de ammeter in series with the positive (+) terminal lead such that the positive (+) 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. To adjust the high charge rate proceed as follows: 1. Loosen the large nut on the transformer and turn the adjusting nut. (The adjusting nut shifts the iron block, thereby changing the flux linkage of the transformer and in turn changes the current. 5062, p. 6
UNION SWITCH & SIGNAL m LOW RATE MONITOR #20WHITE #20 ORANGE #18 ORANGE TWISTED PAIR +IP 2P 4P #14 BLACK #14RED #18 RED AC LINE TO +IP a 4P I 15V INPUT JUMPER +IP TO 3P a 2P TO 4P 230V INPUT JUMPER +3P TO 2P Figure 2. CCR-A Wiring Diagram NOTE The markings on the transformer are for reference only and do not indicate any definite char~ing current. D. LOW CHARGE RATE ADJUSTMENT If the value of the average battery load plus losses is in question, the low charge can be omitted by not connecting a resistor across terminals Rl and R2, or a trickle charge may be chosen. NOTE If a trickle charge is chosen or if the low charge is omitted, the rectifier will cycle more rapidly. Equalizing should seldom be required if the battery is permitted to cycle between the high charge rate cut-in and cut-out points. The low charge rate chosen will slow up the cycling and can only cause overcharging if the average load calculated decreases drastically over an extended period of time. 5962, p. 7
b'::j UNION SWITCH & SIGNAL V, MAINTENANCE A. ROUTINE MAINTENANCE NOTE It is oft-en desirable to underestimate the low charge rate and allow the automatic high charge rate to compensate for any varying load conditions. Maintenance other than normal cleaning and visual inspection is not required. B. FIELD REPAIR In the event of a failure in the field, use the following procedure.as a guide. 1. Check the fuse for continuity. 2. Check the cycling of the rectifier. The rectifier shall cycle between battery voltages of 13.02 vdc and approximately 13.4 vdc. 3. If the battery voltage is above 13.5 vdc: a. Check the low charge rate and ensure it is not excessive. b. Remove the low rate resistor. The charging rate should drop to zero (assuming the battery voltage is above 13.5 vdc). If the high rate remains on either the SCR or the control board is at fault and the rectifier should be removed from service. 4. If the battery voltage is below 13.02 vdc: a. Remove the low charge rate resistor and move the sliding block to the maximum charge position (position E) b. Measure the charging rate. If the charging rate is zero, the voltage between the R2 terminal and the -de terminal should be approximately 22.5 vdc. A reading of 22.5 vdc on an inoperative rectifier indicates a printed circuit board failure, and a reading below 22.5 vdc indicates a probable bridge rectifier failure. In either case, the rectifier should be removed from.service. 5962, p. 8
UNION SWITCH & SIGNAL ffi C. SHOP REPAIR Rectifiers returned to the shop for repair shall be tested in the.following sequence. 1. Check the fuse for continuity. 2. Remove the top two screws holding the back cover in pi:ace. 3. Unsolder the +de reference lead (red AWG No. 18 wire of the printed circuit board) from the bottom terminal of the fuse. 4. Connect the rectifier into the test circuit shown in. figure 3. Do not connect the de regulated power supply at this time. Apply the ac input voltage to the input terminals of the rectifier. Place the sliding block on the transformer in the maximum current position (position E). / START TESTS WITH FULLY CHARGED BATTERY. (BATTERIES MUST BE IN GOOD CONDITION, I.E., HAVE LOW INTERNAL RESISTANCE. + -.-- 16 CELLS OF I LEAD BATTERY I 7.5A FUSE LOW RATE MONITOR APPLY RATED A.C. VOLTAGE a FREQUENCY. VARIAC MODEL #I (1/2% OR LESS) 0-15 VOLTS + REGULATED POWER SUPPLY Figure 3. CCR-A Test Setup 5962, p. 9
UNION SWITCH & SIGNAL 5. Verify that the charge rate is zero (+de reference lead still disconnected} and that the voltage between the R2 terminal and the -de terminal is 22.5 vdc. A voltage of 22.5 vdc on an inoperative rectifier indicates a malfunction on the printed circuit board. A reading below 22.5 vdc indicates a bridge rectifier fault. A reading of battery voltage plus 1.0 vdc indicates the SCR has an anode to cathode short. 6. Attach the Regulated Power Supply as shown in the test circuit in figure 3. Connect the load by closing Sl in the test circuit. CAUTION At no time should the power supply output exceed 15 vdc across the battery in order to avoid overcharging of the battery during tests. 7. Adjust the ac input supply and the Regulated Power Supply inputs to the values given in Table I and verify that current readings correspond to those shown. TABLE I INPUT/OUTPUT TEST AC DC Power Charger Input Voltage AC Input Supply Voltage Output {rms) Current (amps) 120 l.5a 12.42 5.1 120 l.4la 13.00 4.8 120 0.2a 13.5 *O (max turn-off point} *The turn-on voltage is controlled by trimpot Rl. The turn-off voltage is controlled by the circuitry but should not exceed 13.5 volts. 8. Disconnect the voltage sensing lead (red AWG no. 18 printed circuit board lead) from the de power supply and connect it to the bottom terminal of the fuse by means of a jumper. If the battery voltage is above 13.5 vdc the rectifier should turn-off. Load the battery to approximately 1.5 amps. 5962, p. 10
UNION SWITCH & SIGNAL 9. Verify that the rectifier turns on at 13.02 vdc (using a voltmeter accurate to 1/2%) and turns off at approximately 13.4 v~c (maximum of 13.5 vdc). Fine adjustments for the turnon voltage should be made at this time. If satisfactory operation is achieved solder the voltage sensing lead to the bottom terminal of the fuse. 10. Check the operation of the low charge rate by shorting the Rl and R2 terminals. Maximum charge S?OUld result. 11. Check the operation of the LOW RATE MONITOR switch by pushing the switch and noting that the high charge rate cuts off. VI I PARTS LISTS The following tabulations are keyed to figures 4 and 5. The first tabulation lists the major parts of the rectifiers and is keyed to figure 4. The second tabulation lists the parts on the printed circuit board and is keyed to figure 5. 5962, p. 11
u, 0 ' N... re. DIM. "A" I-' N I 3/4" 1" 1 1/2 11 2" 48 46 I. SCREW 36 CLAMP 11 BOLT 12 DIM. PT.NO. LGTH. 8735 SH. 835148 SH. "e" J522079 1 1/4 11 M100463 838 M437126 6 5 1/4 11 J052384 1-1/2" Ml00854 838 M437128 6 5 1/2 11 J522045 2 II MI00856 838 M437129 6 6" J522062 2 1/2 11 M100857 838 M437130 6 6 1/2 11.Jl!11..P I 3 16 17 TO 24 27 49 33 5 ~ I w~4,43 EE c z 5 z i =i 0 :::t II, en ci z )> r 31 45 SECTION "A A" 38 32 39 11 6 11 --~-...i -~ ~ ' I -13 <- ii I I I, 15 ~~it I I~ I~ I : ~ i, j nil i 2 1 1 I I_ 6 ' 26 J.+-! -1 44 34 47 ii 37, 43, 42. i! :::\~ $ 1-~~ W9 8 7 ; ~ 1 I ""-- u ----9 12 36.10 I 4-11a"----i..--36 Figure 4. CCR-A Rectifier ' / "
UNION SWITCH & SIGNAL t:l:j CCR-A Rectifier Parts List (See Figure 4) ITEM DESCRIPTION US&S PART NO. 1 2 3 4 5 6 7 8 9 10 11 12* 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28* 29 30 31 32 33 34 35** 36 37 38 39 40 41 42 43 Mounting Bracket Mounting Bracket Bridge Rectifier Spacer Spacer Reactive Transformer Guide Plate Guide Plate Support Sl_i,ding Core Clamp Bolt Adjusting Screw Adjusting Nut Washer Terminal Board Tag (Rl) Tag (R2) Tag (-DC) Tag (+DC) Tag (+lp) Tag (+JP) Tag (2P) Tag (4P) Washer Nut Pushbutton Switch Nut 1/4-20 Hex, Steel Fuse Post Fuse, 7.5 amp, 32 v, 3 AG Standoff Terminal Screw, tlo x 3/8 in. Rd, nzn Tp Screw, flo x 1/2 in. Rd, nzn Tp Screw, 12 x 3/16 in. Rd, DR, Tp Screw, 18 x 3/8 Bdg, Stl, Tp Screw, ta Fil, Stl, Tp Nut, 18-32 Hex, Stl, Tp Nut, 18-32 Hex, Stl, Tp Insulation Screw, 16-32 x 3/8 Pan, Tp Washer, Lock, 16 Shake Tp Screw, 18-32 x 5/8 Flat Tp Washer, 18 Stl, Pl, Tp N451373-0104 N451373-0201 J726030-0l03 J731463 J731463 N436986 M436637 M436638 M451373-0202 Nl93705 See Table in Figure 4 See Table in Figure 4 M269724 M269836 M073129 Ml81829 J075510-0090 J075510-0091 J075510-0419 J075510-0431 J075510-0445 J075510-0460 J075510-0166 J075510-0205 J047818 J480300 J725750 J048002 J071889 J710083 N451170-0201 J052656 J052664 J052644 J507235 See Table in Figure 4 J480273 J048031 " M451171-1901 J507262 J407708 J052006 J047745 5962, p. 13
~ UNION SWITCH & SIGNAL CR-A Rectifier Parts List (Continued} IT.EM. DESCRIPTION US&S PART NO. 44 45 46 47 48 49 50 51 52*** 53 Rectifier Control Board (for suffix -1301) N451055-4001 (for suffix -1302) N451055-4002 Rectifier J723951 Terminal J730070 Nameplate J063433 Jam Nut, 1/4-20 Unc-2B J048003 Tag (Low Rate Monitor) M451425-3001 Tag (Output 7.5 Amps) M451125-3002 Fiber Shoulder Washer J475153 Washer, 18 Stl, Lk J047681 Nut, 18-32 Hex, Slt, Pl, Tp J048166 * Units manufactured prior to July, 1983 used 1/4-24 threads. Units manufactured after this date used 1/4-20 threads. When replacing item 12 or 28 on units made prior to July, 1983, both items must be replaced. ** For units manufactured before February, 1980. *** For units manufactured after February, 1980. 5962, p. 14
lo +DC R. -DC BK. G. w. o. ;-1 i tn I.O O"I!\.)... tt,.,... tn ( '\ Rn r l n n f) 01 n n ""--} n LJ L J Lto Llg'-' R12 u u R15 01 R3LJ C2 Q Q Q. Q TP3 TP4 n TP2 TP1 n () R2n n l!!j R& l.j R11 02 n02. u n n RB '--,., I R7LJ LJ LJ Sl D LJ Cl 11 n' l t) r1c1, i r1r5 L+Jv RI LJ I I C3 10 II QL..J L_ ",.rl TP5 Figure 5. In o~n n03 ~.., ~ I!!!! Lti n R13 I I u r+1 n C4L J UR14 CCR-A Printed Circuit Board Parts Location... z: = ~ c z 0 z I ~ ::c IP CII a z )>,... G
\lj UNION SWITCH & SIGNAL T PRINTED CIRCUIT BOARD PARTS :~.. ITEM DESCRIPTION PART NO. ICl * Ql Q2 Dl D2 D3,D4 Rl Rll Rl2 Rl4 R4 RS ** R6,Rl0 R7 R8 R9 Rl3 Rl5 Sl Cl C2 C3 C4 R2 R3 Integrated Circuit, Fairchild U6A7723393 or equivalent Transistor, Fairchild 2N3643 or equivalent Transistor, RCA 2N4037 or equivalent Transistor Mounting Pad Diode, Motorola MR1032B or equivalent Diode, Fairchild 1N962B or equivalent Diode, 1N3277 Potentiometer, 1 K ohms, 3/4 W, 15 turns, Trimpot, 10% Resistor, 1 K, 1/2 W, 10% Resistor, 3.0lK, 1/8 W, 1% Resistor, 510 ohm, 2 W, 10% Resistor, 510 Ohm, 2W, 10% Resistor, lok, 1/2 W, 10% Resistor, 7.SK, 1/2 w, 10% Resistor, 510 ohm, 1/2 W, 10% Resistor, 3.9K, 1/2 W, 10% Resistor, 15K, 1/2 W, 10% Resistor, 51 ohm, 1/2 W, 10% Sensistor, 1.SK, 1/2 W, 10% Texas Instrument TM 1/4 Capacitor, 33 ufd, 35 w voe, 10%, Sprague 150D336X903552 or equivalent Capacitor, 0.1 ufd, 200 V, 10% Capacitor, 0.001 ufd, 500 V, 10%, ceramic disc Capacitor, 4.7 ufd, 35 w voe, 10% Sprague 150D475X9035B2 Resistor, lk, l/2w, 10% (for suffix -4001) Resistor, l.3k, l/2w, 5% (for suffix -4002) Resistor, l.210k, l/8w, 1% (for suffix -4001) Resistor, 620 Ohms, l/2w, 5% (for suffix -4002) J715029-0070 J731282 J731291 J792072 J723962 J726150-0070 J723555 J620850-0033 J720882 J735519-0167 J721169 J722938 J720883 J721257 J721081 J720764 J720885 J721038 J731170 J706159 J706827 J706242 J706422 J720882 J723065 J735519-0117 J721253 * On units produced after 1978. ** On units produced before February, 1974. 5962, p. 16