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SERVICE MANUAL 5963 STYLE CPR-A RECTIFIER
* * * * * * * * * INSTALLATION AND MAINTENANCE CONTENTS
I: II.
INTRODUCTION. . . • . . •.•....• DESCRIPTION . • . . . . • . . . • . . . • A. ELECTRICAL. . .•.•.. B. OPERATING TEMPERATURE . . . . . . . . . . C. PHYSICAL . • . . . . . . . . . . . . . . . • • D. THEORY OF OPERATION . . . . . . . . . . . III. OPERATION. . . . . • . . . . . . . • . . . . A. FLOAT OPERATION . • . . . . . . • B. EQUALIZE OPERATION . . . . . . . . . . IV. INSTALLATION • . . . . • . . . • • . . . . . . . • . A. MOUNTING REQUIREMENTS . . . . B. ELECTRICAL CONNECTIONS . . v. MAINTENANCE . . . . . . A. ROUTINE MAINTENANCE . . . . . . B. FIELD MAINTENANCE . . . . C. SHOP MAINTENANCE . . . . VI. PARTS LIST . • . . . • . .
. . . . . . . . . . . . . . . . . . . . . . . . . .
CUT-OFF VALU:C TABLE I. II. TEST REQUIREMENTS III. TYPICAL VALUES WITH OUTPUT SHORTED THROUGH AMMETER IV. TYPICAL VALUES WITH LOW BATTERY VOLTAGE. FIGURE 1. 2. 3. 4. 5.
AO. 73-lII-177 4 .1 July, 197 3
. . . CPR-A RECTIFIER SCHEMATIC DIAGRAM. . . . . . . . . CPR-A RECTIFIER WIRING DIAGRAM . . . . . . . . CPR-A RECTIFIER TEST SETUP . . CPR-A PARTS LOCATION . . . . . . . . PRINTED CIRCUIT PARTS LOCATION . . . . .
Page 2 2 2 2 2 3 3
5 5 5 5 5 7 7 7 7 9
10 11 12 i2 4 8 7
14 16
WESTINGHOUSE AIR BRAKE COMPANY UNION SWITCH & SIGNAL DIVISION Swissvale Post Office, Pittsburgh, Pa. 15218 An American-Standard Company
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INTRODUCTION
The Style CPR-A Rectifier is an automatic battery charger that automatically controls the charging rate such that the charging current is related to the battery tcrm:i.nal voltage. Equalizing capability is pr.ovi.deattery. '(-'Jhen the :_:>attery voltage increases, the reactor control current is decreased, lowering the voltage applied to the battery. Operation of the electronic control circuit can be divided into two functions, voltage sensing and current control. The voltage sensing circuit is a voltage divider circuit consisting of R8, R9, RlO, Rll, and Rl2 connected across tl1e :Oattery. T,vo reference voltages are established by this voltage divider. One of these voltages, developed at the junction of RlO and Rll, is used for 11 float 11 operation. The other is developed at ti.1e junction of Rll and Rl2 and used for equalizing. The voltage used is determined by the FLOAT/ BQUALIZE switch mounted on the front panel of the rectifier. The voltage ci.1osen by the FLOAT/EQUALIZE switch is applied to pin 4 of ICl. T~1is voltage is referenced to the voltage at pin 5 of ICl, established by zener diode DS. The output of ICl controls the conduction level of Ql, and thereby the current to the adjusta0le reactor. The diode bridge rectifier 3Rl supplies DC power to the T2 and also provides t!1e DC pmver for t:'le printed circuit board.
·5963, p. 3
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USE 35 ON MAIN TRANSFORMER (Tl) FOR 6 CELLS L.A. OR 9 CELLS N.I. USE 2S ON MAIN TRANSFORMER (Tl) FOR 5 CELLS L.A. OR 7 CELLS N. I. Tl " MAIN TRANSFORMER T2; VARIABLE REACTOR INPUT = 120V :!: 10%, 60 HZ AT TERMINALS MARKED AC
Figure 1. CPR-A Rectifier Schematic Diagram
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III, OPERATION The CPR-A is designed primarily for battery charging service. It has two modes of operation, float and equalize. The FLOAT/EQUALIZE switch on the front of the rectifier is used to set the mode of operation. A. FLOAT OPERATION Float operation is the normal operating mode. In this mode the charger will maintain the battery at a high level of charge by continually adjusting its output to correspond to the battery load. B. EQUALIZE OPERATION The equalize mode is only used when the charger has been operating with a battery for a period of time and it is felt that equa+izing is necessary to reduce sulfation. In the equalize mode the charger assumes a different reference voltage and charges the battery to higher voltage. After equalizing, the charger should be returned to the float mode of operation by returning the FLOAT/EQUALIZE switch to the FLOAT position.
IV, INSTALLATION A. MOUNTING REQUIREMENTS The rectifier must be mounted in a dry location. It may be wall mounted or 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 ± 10%, connect to AC Terminals. No attention need be given to polarity of input. 2. DC Connections In making DC 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. 5963, p. 5
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Figure 2. CPR-A Rectifier Wiring Diagram
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V, MAINTENANCE A. ROUTINE MAINTENANCE Routine maintenance consists only of periodically equalizing the battery and normal cleaning and visual inspection. B. FIELD MAINTENANCE Field maintenance should be limited to replacing an inoperative unit with an operating one. Any repair of a malfunctioning rectifier should be performed in the shop. To determine if a unit is functioning properly proceed as follows: 1. Measure the battery voltage and current. When functioning properly, the battery voltage will be between the values listed in Table I and the load values listed in Table II. NOTE Adjusting R9 (Float Adjust) upward from zero ohms will cause the battery to float above the manufacturer's recommended levels and may cause excessive charging during equalizing periods. 2. If battery voltage is below the listed values (Tables I and II) check the average load on the battery. If in excess of 6 amps the CPR-A battery charger will not be able to maintain an adequate charge in the battery. 3. If the average battery load is below 6 amps and the battery voltage is below the values listed in Tables I and II the unit should be replaced and repaired in the shop. C. SHOP MAINTENANCE Before performing any test or troubleshooting procedures, thoroughly examine the entire assembly for broken wires, solder joints, or other potential problem areas. Assembly Test and Calibration TEST A 1. Connect the test circuit shown in Figure 3. Note that the red voltage sensing lead connected between the fuse and the +DC terminal of the printed circuit board is disconnected, and the positive lead from the regulated power supply is connected to the +DC terminal of the printed circuit board.
5963, p. 7
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CHARGING CURRENT
MODE SWITCH
LOAD CURRENT
0-1.5 AC
CPR-A +DC TERMINAL
Oscilloscope
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PROVIDE SWITCH FOR CONVENIENCE
RED VOLTAGE SENSING LEAD FROM PC BOARD REMOVED FROM FUSE
VARIABLE - - - - ~ RESISTIVE LOAD ADJUST AS REQUIRED PER TABLE I
Regulated Power Supply (Hp 6266A or equivalent)
MODEL #I VOLTMETER (1/2% OR LESS) 0-15 VOLTS
Figure 3. CPR-A Rectifier Test Setup
• 2. Adjust the regulated power supply and the FLOAT ADJUST potentiometer, RlO, to the values listed in Table 1 for Test A' and the unit being tested. Adjust R9 until the charging current is zero (or less than .05 A). CAUTION Do not adjust R9 above the point necessary to reach zero amps. 3. Cycle the AC source supply on and off and recheck the cut-off point (zero charge current). 4. Vary the regulated power supply output and verify that the cut-off point is as specified in Table I "Battery Voltage" for Test A. CAUTION It may be necessary to load the battery during test to avoid overcharging the battery. 5963, p. 8
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TEST B 1. Set the mode switch to equalize. 2. Vary the output of the regulated power supply and verify that cut-off occurs within the battery voltage limits listed in Table I for Test B. TEST C 1. Return the mode switch to the FLOAT position and set the FLOAT ADJUST, RlO potentiometer to maximum. 2. Vary the output of the regulated power supply and verify that the cut-off voltage falls within the limits specified in Table I for Test c. TEST D 1. Turn off the AC power source and reconnect the voltage sensing lead to the B+ terminal of the PCB, and disconnect regulated power supply. 2. Set the FLOAT ADJUST potentiometer, RlO, to zero and the FLOAT/EQUALIZE switch to FLOAT. 3. Turn the AC source on and load the battery to the value listed in Table II "Load Amps" for Test D. 4. Adjust Rl until the rectifier output equals the load value (at the listed battery voltage). Allow time for the circuit to stabilize between adjustments. Lock final adjustment. TEST E 1. Apply AC source as specified in Table II for Test E. 2. Connect rectifier to battery with terminal voltage as indicated on Table II for Test E. 3. Verify that the charging current does not exceed the values listed in Table II for Test E. 4. If charging current exceeds stated amount readjust Rl and repeat Test D. VI, PARTS LI ST
The parts tabulations are keyed to Figures 4 and 5. The first tabulation lists the major parts of the rectifier and is keyed to Figure 4. The second tabulation lists the parts on the printed circuit board and is keyed to Figure 5. 5963, p. 9
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TABLE I
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CUT-OFF VALUES
'"O 0
AC Input
Mode Switch Position
v
Battery Cells/Type
Battery Volts
Charge Amperes
N451372-1501 N451372-1501 N451372-1501
6/LA 6/LA 6/LA
13.02 ± 1/2% 14 to 14.2 13.25 to 13.3
0 0 0
0 0 50
Float Equalize Float
120 120 120
0.1 max. 0.1 max. 0.1 max.
A B
N451372-1502 N451372-1502 N451372-1502
5/LA 5/LA 5/LA
10.85 ± 1/2% 11.65 to 11.82 11.08 ± 1%
0 0 0
0 0 50
Float Equalize Float
120 120 120
0.1 max. 0.1 max. 0.1 max.
A B
N451372-1503 N451372-1503 N451372-1503
9/NI 9/NI 9/NI
13.5 ± 1/2% 14.4 to 14.6 13.75 to 13.8
0 0 0
0 0
120 120 120
0.1 max. 0.1 max. 0.1 max.
A
so
Float Equalize Float
N451372-1504 "N451372-1504 "N451372-1504
7/NI 7/NI 7/NI
10.5 ± 1/2% 11. 2 to 11. 4 10.75 to 10.8
0 0 0
0 0 50
120 Float Equalize · 120 Float 120
0.1 max. 0.1 max. 0.1 max.
A B
Piece No.
:-
R9 Float Adjust Ohms
Amp
Test
c
c B
c
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TABLE II TEST REQUIREMENTS (TEST MUST BE MADE WITH LOW INTERNAL RESISTANCE BATTERIES)
PIECE NO. N451372-1501
FLOAT MODE BATTERY ADJUST SWITCH CELLS/TYPE OHMS POSITION
CHARGE AMPS
LOAD AMPS
BATTERY VOLTS
v
AMPS
* HZ
TEST
6/LA 6/LA**
0 0
FLOAT FLOAT
6 8.0 max.
6 0
12.85-12.9 11. 5 appx.
120 120
1.25 1.5
60 60
D
N451372-1502
5/LA 5/LA**
0 0
FLOAT FLOAT
6 8.0 max.
6 0
10.7-10.75 9.6 appx.
120 120
0.97 1.22
60 60
D E
N451372-1503
9/NI 9/NI
0 0
FLOAT FLOAT
6 8.0 max.
6 0
13.3-13.35 11.5 appx.
120 120
1.3 1.5
60 60
E
7/NI 7/NI**
0 0
FLOAT FLOAT
6 8.0 max.
6 0
10.35-10.4 9.6 appx.
120 120
0.95 1.22
60 60
N451372-1504
E
D
D
E
** DROP l CELL IF NECESSARY FOR THIS TEST * MUST BE A SINE WAVE WITH VERY LITTLE DISTORTION
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TABLE III TYPICAL VALUES WITH OUTPUT SHORTED THROUGH AMMETER Battery Mode APPRO:{. Volts Switch DC Cells/Type Amps (Low) (High) Position
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Piece No. N451372-1501 N451372-1503 N451372-1502 N451372-1504
6/LA 9/NI 5/LA 7/NI
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0
5.0 5.5 5.5
0 0 0
0 0 0 0
Float Float Float Float
60Hz-Ac Input v A 120 120 120 120
1.2 1.2 1.1 1.1
TABLE IV TYPICAL VALUES WITH LOW BATTERY VOLTAGE
Piece No. N451372-1501 N451372-1503 N451372-1502 N451372-1504
5963, p. 12
Battery Battery Volts Cl.1arge Cells/Type (Apprx.) Amps 6/LA 9/rn 5/LA 7/NI
11.5 11. 5 9.6 9.6
8.0 max. &.O max. 8.0 max. 8.0 max.
Mode Switch Float Float Float Float
60Hz-Ac Input A v 120 120 120 120
1.5 1. 5 1. 22 1-.22
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STYLE CPR-A RECTIFIER
PART NUMBER .
DC OUTPUT SYSTEM BATTERY AMPS VOLTAGE TYPE
-
N451372-1501
6
12
'6 cells LA
N451372-1502
6
10
5 cells LA
N451372-1503
6
12
9 cells
NI N451372-1504
6
10
N451372-1505*
-
-
7 cells NI
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*Front cover with Voltmeter and Ammeter.
5963, p. 13
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28,34,35
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22,23
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10 11 14 15 34
21
30 31 5,22, 23,24
7-3/4
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22,23,24
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VIEW WITH FRONT COVER REMOVED
Figure 4.
CPR-A Rectifier Parts Location
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CPR-A RECTIFIER PARTS ITEM 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 *44 45 46
DESCRIPTION Box Transformer Reactor Board, Pri-Cir Control Block, 2-Way Block, SAG Fuse Strip, 4-Way Terminal Grommet Screw, #8 x 3/4" lg. RD STL Washer, #8 Plate STL Nut, #8 Hex STL Insulator, Heat Sink Resistor ·screw, # 8 x 2-1/2 RD STL Washer, Insulating Heat Sink Fuse, SAG, 10 amp Cover, Front Meter, Ammeter, 0-10 amps Meter, Voltmeter, 0-15 volts Switch, Toggle Screw, #10 x 5/8" lg. RD STL Washer, Lock, #10 S Nut, #10-32 HEX S Nut Washer Nut "O" Ring Tag, AC Tag,+ Tag, • Bracket, Mounting Screw, #8 x 1/2" lg. PAN Washer, Lock #8 Screw, #8 - 32 x 3/4" lg. PAN SS Cover, Front Screw, #6 x 7/16" lg. RDS Washer, Lock #6 S Nut, #6 - 32 HEX S Rectifier Bridge Terminal (not shown) Terminal (not shown) Terminal (not shown) Terminal (not shown) Screw, #2 x 5/16" lg. PANS Bracket
PART NO. R451373-1001 N451039-2201 N451039-2501 N451055-4101 Ml81831 J713130 J724348 J751169 J525107 J047745 J048166 J772332 J720189 J525115 M278262 J792665 J710133 M451373-1501 J620898 J620897 J072821 J052566 J047733 J048172 M029103 J047818 M029101 J067447 J075510-0005 J075510-0427 J075510-0415 M451053-3503 J050968 J047681 J507295-0112 M451373-1502 J525095 J047662 J048148 J726030-0103 J730043 J730044 J730045 J730046 J052698 N451373-1403
*Part of Cover M451372-1505
596 3, p. 15
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PRINTED CIRCUIT BOARD PARTS ITEM
Ql HS-1 Dl,D2,D3 D4,D6 DS BRl !Cl Cl,C2 C3 C4
cs
C6 R2 R3 R4,R8,Rl2 R5,R6 R7 R9 RlO Rll
PART NO.
DESCRIPTION Transistor, MJlOOO Heat Sink Diode, IN4003
J731427 J792469 J723555
Diode, IN962B Rectifier, Bridge Integrated Circuit U6A741 Capacitor, 0.05 mfd, 100 V Capacitor, 10 mfd, 150 V Capacitor, 27 mfd, 20 V Capacitor, 68 mfd, 20 V Capacitor, 5 mfd, 200 V Resistor, 5.1 ohm, 3 watt Resistor, 100 Kohm, 1/2 watt Resistor, 1 Kohm, 1/2 watt Resistor, 51 K ohms, 1/4 watt Resistor, 300 ohm, 2 watt Potentiometer, 1 Kohm Potentiometer, 50 ohms, 2 watt Resistor, 75 ohm, 1/2 watt
J726150-0070 J726185 J715026 J709090 J706849 J706678 J706160 J706838 J073901 J720838 J720882 J735067 J720863 J620850-0033 J062297 J723222
Lug, Turret Screw, #4-40 x 1/2" lg. RD Washer, Locking #4 STL Nut, #4-40 HEX S
J714090 J525086 J047765 J480006
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5963, p. 17
