Home

Group I Operating Manual - Eagle Eye Power Solutions

1. 0501 GREEN 0510 RED LOW LEVEL DETECT 0502 RED DC VOLTS 0511 RED METER DISPLAY DS03 RED DC AMPS 0512 RED METER HISPL Y 0504 RED EQUALIZE HRS REMAINING 0513 RED HIGH DC VOLTAGE 0505 GREEN FLOAT DS14 RED LOW DC VOLTAGE 0506 AMBER EQUALIZE 0515 RED OC OUTPUT FAILURE 0507 AMBER MANUAL TIMER 0516 RED AC INPUT FAILURE 0508 AMBER MANUAL EQUALIZE 0517 RED POSITIVE GROUND 0509 AMBER AUTO ERLIALIZE TIMER 0518 RED NEGATIVE GROUNO Aw SERIES o AT404 om onm dvanced Techrolopy S7 BATTERY CHARGER Um 0503 AA BN RECTIFIER nso4 d DS non B ps mz E 0506 O WE 0507 o Pattee 5 osos O ano ez rien Ac INT 0509 FAILLRE 4 test uno RAL or s DISABLE _ J 85 ENABLE E S J o i o PEET a Raa Sea mr o o E CECE INSTRUMENT PANEL MAIN CONTROL PC BL PART No FK0151 01 gt FRONT VIEW FACING CHARGER C NOTE UNLESS OTHERWISE SPECIFIED ALL ALARM TERMINAL BLOCKS 4 8 ARE SOLDERLESS COMPRESSION TERMINALS C 0 5 e 125VAC DC ACCEPTING 22 14 AWG WIRE ONTACT RATING IS 21 MEL ERE ro ha t 23 24 z0 29 27 I I
2. nennen 24 Factory seltings table u a i a ive ie de 25 2 2 Using the AT10 1 front panel features 2 2 1 If the meter displays an error 26 2 2 2 Selecting the meter mode edenda en nina ann nnn 26 2 2 3 Selecting the Float or Equalize mode sss 27 2 2 4 Choosing the Equalize method ssssesesee 27 Manual Timer method eme emen 27 Manual Equalize method eset 28 Auto Equalize Timer method 28 2 2 5 Testing the front panel indicators amp Summary Alarm Relays 29 2 2 6 Testing the Auxiliary Alarm Relay PC 29 2 2 7 Interpreting the alarm 29 TABLE OF CONTENTS 23 Setting the AT10 1 parameters 2 3 1 Understanding parameter settings a 30 2 3 2 Setting the Float and Equalize voltages 31 2 3 3 Setting the Equalize timer u ee 32 2 54 Setting the Alarms fo u it e o ee echte daw Pet ue re Pe D iy ayasa 32 Setting the high and low dc voltage alarms 33 Adjusting ground detection sensitivity
3. NITE B CHASSIS NOTE 8 GROUND THIRD ANGLE PROJECTION c TITLE 1 SERIES BATTERY CHARGER 081004 ow MCR 040703 CONN DIAG 6 25ADC GROUP 1 W COMMON OPTIONS 040703 REV ECN No DATE TORIS He 040703 DRAWING No B REV UNLESS DEM NOTED DIMENSIONS JE503 3 990 1 CHES SHEET F ARE IN IN TOLERANCES ARE PART No SIAE NTS JE5033 99 http www ATSeries net PDFs JE5033 99 pdf 87 APPENDIX D RECOMMENDED FLOAT AND EQUALIZE VOLTAGES This table contains suggested values for commonly used batteries Consult your battery manufacturer s documentation for specific values and settings for your battery type Recommended Recommended Battery Cell Type Float Voltage cell Equalize Voltage cell Antimony 1 215 Sp Gr 2 33 Antimony 1 250 Sp Gr 2 33 2 33 2 40 Calcium 1 215 Sp Gr 2 33 Calcium 1 250 Sp Gr 2 33 Selenium 1 240 Sp Gr Lead Acid Types Absorbed Gelled Electrolyte sealed lead acid type Nickel Cadmium Ni Cd 1 42 1 47 Sealed lead acid battery types should not be used in ambient temperatures above 95 35 and should not normally be equalized Consult your battery manufacturer s documentation for specific equalizing recommendations TEMPERATURE COMPENSATION If your batteries are to see
4. 3 1 5 Mounting the AT 10 Wise dei e HP dus A een en eor ape 3 1 5 1 Wall Mounting the ATTO Torsi u uu u emen 4 1 5 2 Floor Mounting the AT10 1 6 1 5 3 Rack Mounting the ATTO uU He 8 1 6 Changing transformer taps 10 1 7 Making the ac input connections emn 12 1 8 Making the dc output connections mH 14 1 9 Wiring the AT10 1 for remote sensing a 16 1 10 Wiring to the remote alarm contacts sssssee 18 Auxiliary Alarm Relay PC Board 19 1 11 Installing the temperature compensation assembly optional 20 Using temperature compensation mmm 22 1 12 Installing the AT10 1 for remote communications optional 23 1 13 Installing the AT 10 1 for forced load sharing optional 23 2 Operating the AT10 1 Battery Charger 2 1 Starting the AT10 1 2 1 1 Understanding the start up sequence 24 2 1 2 Checking the installation m 24 2 1 3 Starting the AT 10 1 ster mL bec b dines 24 Using the digital Meler cser
5. Style 586 Enclosure Style 594 Enclosure INSTALLING THE AT10 1 PROCEDURE Install four 4 0 25in 6 4mm anchor bolts not supplied rated to support the weight of the AT10 1 plus a safety factor of at least two 2 times into the wall Place the AT10 1 onto the anchor bolts add appropriate mounting hardware and tighten securely Refer to the graphics below for AT10 1 Style 586 amp Style 594 wall mounting patterns and specifications GRAPHICS WALL MOUNTING THE AT10 1 USE 0 25in 6 4mm DIA BOLTS FOUR 4 PLACES o AT10 1 MOUNTING DIMENSION 10 00in 254mm ENCLOSURE DIM A Style 586 15 00in 381mm Style 594 i Lig M Oo yle 18 25in 464mm MOUNTING BOLT PATTERN 312In Bmm DIA FLAT WASHER EN LOCKWASHER 25in 6 4mm DIA BOLT SS WY S Wyo x L 750in 19mm ENCLOSURE MOUNTING FLANGE 750in 19mm DIA WALL KEYHOLE SLOT USED ON RECOMMENDED MOUNTING AT10 1 MOUNTING FLANGE HARDWARE LOADING INSTALLING THE AT10 1 1 5 2 Floor Mounting the AT10 1 To mstallthe AT10 1 onto a horizontal surface the standard Style 586 and Style 594 enclosures do not need to be modified but a special floor mounting accessory El0192 00 is required For kit availability see ordering information in Appendix B on page 71 The kit includes a set of mounting brackets that elevate the
6. High voltages appear at several points inside the AT10 1 Use extreme caution when working inside the enclosure Do not attempt to work inside the AT10 1 unless you are a qualified technician or electrician Step Instructions Results standard features Clean AT10 1 All vents clean and open O oK Remove dust and debris from inside unit OK Check all TBI connections all tight OK electrical Internal wiring connections tight slip on OK connections connectors fully seated Wire and lug and wiring insulation in satisfactory condition Terminations at battery or dc bus are tight O OK and corrosion free Check ac input Measure between TB1 L1 and TB1 L2 voltage using an ac voltmeter Value must be Input Vac within 10 amp 12 of nominal voltage Check dc Measure at TB1 and using a dc output voltage voltmeter Value should agree with front Float Vdc panel voltmeter within 0 25 and must be correct values for your battery If Equalize Vdc the AT10 1 is using a temperature compensation probe see the graph on page 23 to determine correct battery voltage You need to know the battery temperature for this step Check ripple Measure at battery terminals using an ac voltage voltmeter set to the milliVolts scale Check against specification in Appendix Ripple mVac A on page 70 Test font panel Press LAMP TEST key on front panel OK indicators Test summary Press LAMP TEST
7. NOTE NI e 0 10 00 15 63 254 MANUAL 397 MTG gt POCKET AC INPUT DC OUTPUT m E 5 00 MTG Paar 381 MTG 1 00 89 63 re 25 10 25 NOTE 4 413 260 NOTES 1 ENCLOSURE IS A NEMA 1 1P2D TYPE CABINET WITHOUT GASKETS 2 ALLOW Gin 152mm OF FREE AIR TOP ANO FRONT OF CABINET FOR VENTILATION 3 FOR 4 KEY HOLE SLOTS ARE PROVIDEO ON THE BACK OF ENCLOSURE AS SHOWN FOR WALL MOLNT ING WITH 25in 6 25 HARDWARE 4 FOR 4 1 31in733mm DIA KNOCKOUTS ARE PROVIDED AS SHOWN WITH TWO 2 gt ADOITIONAL KNOCKOUTS FEATUREO ON BOTTOM PANEL OF ENCLOSURE USE OF ANY DF THESE FOUR 4 LOWER CONOUIT KNOCKOUTS WILL ALLOW REMOVAL OF THE CABINET SHROUO WITHOUT REMOVAL OF EXTERNAL WIRING 5 DATA NAMEPLATE WITH CHARGER RATINGS MOUNTED ON LEFT SIDE OF ENCLOSURE 6 BATTERY CHARGER SHIPPING WEIGHT RANGE APPROXIMATELY 44 20 Ibs 80 36 kg DUAL DIMENSIONS i THIRO cl ANGLE PROJECTION DRAWN BY MCR 012304 APPRINED UNLESS OTHERWISE NOTEO DIMENSIONS E1542 ARE IN INCHES TOLERANCES ARE 012304 REV ECN No DATE APA TIME AT10 1 SERIES BATTERY CHARGER OUTLINE NEMA 1 STYLE 588 ENCLOSURE DRAWING No JE5023 03 REV A SCALE NTS PART No JE5023 03 SHEET 1 F FILENAME JE5023 03 PRT http www ATSeries net PDFs JE5023 03 pdf 72 APPENDIX C Standard
8. Reference Description Factory Part Number Rec Designator 12Vdc 24Vde 48Vdc 130Vdc Spare F1 480 Vac M H AIC AC Input Fuse See Table 3 14 Y L1 Main Inductor See Table 3 9 L2 DC Filter Inductor See Table 3 13 P5 Jumper for disabling Ground Detection circuit RC0100 00 P7 Jumper for voltage selection on A5 pc board RC0100 00 P9 Jumper for front panel lockout feature on A1 RC0100 00 R2 Rating resistor See Table 3 10 R3 Power Supply Ballast Resistor E ANA ind du RUNE EJ cea Y R4 Scaling resistor positive side ps REA Ta ARG png R6 Voltage crowbar resistor EJ1135 00 1135 01 1135 02 EJ1135 03 R9 Filter capacitor C1 bleed resistor EJ1137 00 1137 00 EJ1137 01 EJ1137 02 R14 Scaling resistor negative side errs T1 Main transformer 120 208 240 Vac See Table 3 11 T1 Main transformer 480 Vac See Table 3 12 TB1 x terminal box lug for 14 6 AWG RC0056 04 VR1 Output Surge Suppressor EJ1132 01 Y VR2 Input Surge Suppressor 120 208 240 Vac EJ1132 01 Y VR2 Input Surge Suppressor 480 Vac EJ1132 02 Y VR3 Input Lightning Arrestor EJ1074 00 VR4 5 Surge Suppressor 120 208 240 Vac EJ1132 01 Y VR4 5 Input Surge Suppressor 480 Vac EJ1132 02 Y VR6 C4 DC EMIFilter Network EJ5021 01 VR7 C5 DC EMIFilter Network EJ5021 01 Note 1 In 130 Vdc AT 10 1 Group units two 2 different Power Supply Ballast Resistor assemblies R3 are used mounted behind the I
9. SCALE PART Na NTS JE5030 19 http www ATSeries net PDFs JE5030 19 pdf 79 APPENDIX C Standard Drawings Schematic AT10 1 Group Battery Charger Standard w o Options JE5031 00 1 CONNECTION TABLE INPUT JUMPER stanoaro 129 H H3 2 5 TRANSFORMER 20B H2 H4 2 CNOTE 4 546 ia SCR MODULE TRANSFORMER ASSY A16 T PR1 SEC i DO TBI L e I H5 s a a5 To l H2 m 7S Foe ES VR2 T EN 23 oS A Qa TBI L2 Hl O TBI GND O 2 CHASSIS s GROUND TRANSFORMER NOIE 7 Tl COPT TN Fl BRI SEC a I 1 ES Z I EM i lt SUMMARY ALARM E TERMINAL BLOCK iD TB3 NOTE 2 TB6 4 NOTES 12 FOR COMPONENT DETAILS OF ALL PC BOARDS AS AJ1 etc SEE DRAWING JES030 10 2 ALL ALARM CONTACTS SHOWN IN NON ALARM STATE CONTACT RATING IS O 5A m 125VAC VDC RESISTIVE 3 WHEN REMOTE SENSE IS THE VOLTAGE SENSE LEAUS RUN FROM R14 TO REMOTE SENSEC AND FROM TB5 2 TO REMOTE SENSE REFER TO FEATUREO OPTIONS CONNECTION DIAGRAM F R WIRING DETAILS AC INPUT CIRCUIT BREAKER 4 POWER TRANSFORMER TI HAS MULTIPLE TAPS FUR 120 208 240 VAC AC FUSE Fl IS ONLY USEO ON UNITS SPECIFIED WITH 480 VAC INPUT DC OUTPUT CIRCUIT BREAKER 5 STANDARO 12 24 AND 48VDC UNITS CONTAIN SINGLE PULE
10. button on the front instrument panel and simultaneously AT10 1 may Controller pressing S7 reset switch This will restart the control board and have no restore all settings to factory default Reset parameters per output Section 2 3 of this manual 1C Remove all power from AT10 1 to allow control board to discharge all voltages This can be done by opening the AC circuit breaker and disconnecting the control board plug s Keep power removed for approximately five 5 minutes to allow voltages to discharge AC breaker 1 Shorted 1 Disconnect wire 12 from the rectifier Gate Driver PC Board CB1 trips rectifier diode A3 X1 Measure the resistance between the two top rectifier immediately jor SCR terminals labeled AC on the connection diagram checking both polarities It should be at least 100 000 Q If resistance is low in either direction replace the Rectifier Assembly A6 2 Defective 2 Check spacing of terminals Check wiring for signs of wiring to T1 or insulation damage burns etc Repair as necessary to the rectifier heat sink assembly A6 3 Defective 3 Test by disconnecting wires from X1 X4 Y1 and Y2 If ac transformer T1 breaker still trips replace T1 AC breaker 1 Loose 1 Check and tighten connections as required CB1 trips connection to after a few breaker minutes 2 Wrong ac 2 Be sure the T1 primary taps are wired correctly for your voltage or T1 input voltage See Section 1 6 for details ta
11. e Press the EDIT ENTER key The new low dc voltage alarm setting is entered into permanent memory If you want to adjust the Current Limit setting skip to Section 2 3 5 OR If you want to exit the Edit Mode now press the EDIT ENTER key again to return the AT10 1 to normal operation 33 OPERATING THE AT10 1 Adjusting Ground Detection Sensitivity The AT10 1 ground detection alarm i E sensitivity is adjustable from 5 to 30 kQ You eo 9 MTT must have a test resistor whose Ohmic J5 6 value 1 required ground sensitivity E small jeweler s screwdriver for adjustment SENS The ground detection sensitivity is adjusted MAIN commo equally from 5 to 10 kO but slightly less PC BOARD A1 equally from 10 to 30 kQ Adjustments are made via potentiometer labeled RA3 SENS located on Control PC Board 1 as shown in the figure at the right d sa a T 4 d Bs wees n Do not try to adjust the upper potentiometer labeled RA2 BALANCE This adjustment is made at the factory for proper circuit operation Before connecting or disconnecting a test resistor t o the AT10 1 de energize and lock out all ac and dc voltage sources Check with a voltmeter before proceeding Resta rt the AT10 1 only when necessary to make the sensitivity adjustment If your batter
12. Using a flat head screwdriver securely tighten the compression screws on the lugs to 35 45 in lb 4 0 5 1 Nm Reinstall the safety shield after you have made and checked all connections 14 INSTALLING THE AT10 1 MAKING THE DC OUTPUT CONNECTIONS GRAPHICS S CUSTOMER SAFETY EN DC OUTPUT COVER in 12 7mm WIRING ie 22 REMOTE REVOTE SENSE SENSE CONSULT USER S MANUAL FOR ADJUSTING TRANSFORMER S INPUT VOLTAGE U COPPER OR ALUMINUM CONDUCTORS L1 AC INPUT L2 TB1 d GND NOTES 1 The drawing above does not show other components mounted to the I O panel Be careful not to disconect any other component leads Always use a proper ground 3 Use copper or aluminum conductors only 15 INSTALLING THE AT10 1 1 9 WIRING THE AT10 1 FOR REMOTE SENSING RECTIFIER You can wire the AT10 1 to regulate the output voltage at the battery terminals instead of at the charger output terminals TB1 Remote sensing provides the following 1 Compensates for voltage drop in the dc wiring between the AT10 1 and the battery 2 Directly monitors the battery or dc bus voltage The front panel meter displays the actual voltage on the battery or dc bus SCHEMATIC REMOTE SENSE AT10 1 LEADS DC BUS BATTERY You wire the AT10 1 for remote sensing by installing twisted pair cabling from the AT10 1 remote sens
13. 70 APPENDIX B Field Installable Accessories 71 APPENDIX C Standard Drawings Outline AT10 1 Group Battery Charger NEMA 1 Style 586 Enclosure 72 Outline AT10 1 Group Battery Charger NEMA 1 Style 594 Enclosure 74 Internal Component Layout AT10 1 Style 586 594 Enclosure w Common Options 76 Instrument Panel PC Board Detail AT10 1 Group Battery Charger 78 Schematic AT10 1 Group Battery Charger Standard w o Options 80 Schematic AT10 1 Group Battery Charger with Common Options 82 Connection Diagram AT10 1 Group Battery Charger Standard w o Options 84 Connection Diagram AT10 1 Group Battery Charger with Common Options 86 APPENDIX D Recommended Float Equalize Voltages Temp Compensation 88 APPENDIX E Communications Module 89 APPENDIX F Forced Load eene eese nnne nnne nnn nnne 90 APPENDIX G CE Grounding Compliance amp UL Data 92 MANUAL SPECIFICATIONS document control information online availability 94 A customized record drawing package is available for your particular AT10 1 featuring an itemized internal
14. essen 34 Disabling the ground detection alarm seen 35 2 3 5 Setting the Current Limit value essem 35 2 3 6 Enabling the high dc voltage shutdown feature 36 2 3 7 Adjusting the Voltmeter accuracy me 37 2 3 8 Using the Low Level Detector 0 38 2 3 9 Using the front panel security 39 2 4 Performing routine maintenance mee 40 Sample preventive maintenance 42 3 Servicing the AT10 1 Battery Charger 3 1 A step by step troubleshooting procedure 44 3 2 Interpreting front panel error 45 3 3 Using the troubleshooting chart u me 48 3 4 Troubleshooting chart begins on eee 49 3 5 Replacing defective components 58 3 6 Ordering replacement parts 64 Replacement parts tables begin on 64 APPENDIX A AT10 1 Performance Specifications
15. 1 RG CL EG gt Press the key to toggle from Float mode to Equalize mode Press again to toggle back to Float The green or yellow indicator identifies the current mode Setting Float Voltage Equalize Voltage Equalize Timer High DC Voltage Low DC Voltage Current Limit zul EJ gt Press the key The DC VOLTS and FLOAT indicators light and the digital display flashes the present float voltage setting gt Press the f or 1 key until the digital display indicates the desired float voltage El gt Press the key to save the new setting internally gt The EDIT sequence advances to the equalize voltage as shown by the front panel indicators Repeat the above steps until you have set all parameters PERIOD EAGLEEYE SALES amp SUPPORT EE call 1 414 962 EEPS 3377 toll free 1 877 805 EEPS 3377 email info eepowersolutions com www EEPOWERSOLUTIONS com
16. F 25 O When you enter the Edit Mode to adjust the Float or Equalize voltage see Section 2 3 2 the front panel meter displays the 77 F 25 C value for the Float or Equalize voltage even if the battery is warmer or cooler than 77 F 25 C The actual output voltage of the AT10 1 may be different from the value displayed on the front panel meter if the battery is warmer or cooler than 77 F 25 C Use a digital meter to measure the actual output voltage of the AT10 1 If you know the temperature at the temperature compensation probe you can use the graph below to determine that the output voltage is correct If the battery temperature goes below 32 F 0 C there will be no further increase in AT10 1 output voltage Likewise if the battery temperature goes above 122 F 50 C there is no further decrease in output voltage OUTPUT VOLTAGE VS BATTERY TEMPERATURE Lead Acid A z ic el Cadmium n Example 100 Deg F 97 Output lt Voltage 20 40 60 80 100 120 Temperature Degrees Fahrenheit EXAMPLE Suppose you have a lead acid battery whose temperature is 100 F 37 8 C As shown on the graph the output voltage should be approximately 97 of the 77 F voltage If the float voltage is set on the front panel to 132 Vdc the actual output voltage will be 132 x 0 97 128 1 12 INSTALLING FOR REMOTE COMMUNICATION OPTIONAL
17. The AT10 1 is cooled by natural convection At least once a year vacuum the vents at the top and bottom of the enclosure to ensure that there is an adequate supply of cooling air If you have an extremely dusty environment especially if airborne dust is conductive carefully vacuum out the interior Clean the surfaces of circuit boards and clean around electrical terminals The AT10 1 is rated for operation up to 122 F 50 C If your installation is in a warmer environment or at an elevation over 3000ft 914m contact your sales representative for operating information Check power and signal connections Check the tightness of all field connections inside the AT10 1 and connections to the battery A loose or corroded connection at the battery terminals can be a fire or explosion hazard and may cause erroneous operation of the AT10 1 Check remote sense wiring optional If you wired the AT10 1 for remote sense check the signal connections to the battery or load making sure insulation is in satisfactory condition If there is a failure of the remote sense signal wiring the AT10 1 displays the error code E 06 The AT10 1 returns to local control sensing the output voltage at the charger output terminals TB1 OPERATING THE AT10 1 2 4 4 2 4 5 2 4 6 Check temperature compensation probe optional If you are using the optional temperature compensation probe make sure that the probe A10 is secure
18. The top vents are required for cooling Hazardous ac and dc voltages are present inside the AT10 1 on the I O panel TB1 terminals and certain internal components Removing the enclosure shroud You may need to remove the enclosure shroud in order to make some internal measurements and to replace or repair components Turn off and remove all power to the AT10 1 Disconnect the battery from the output terminals TB1 Remove the eleven 11 screws that hold the shroud on the rear and bottom of the enclosure then the two screws on the left side that hold the rectifier heat sink assembly Support the front panel and lift the shroud straight up to remove it Be sure to save the plastic washers from the door hinge The heat sink assembly is supported from the rear panel Avoid putting any mechanical stress on the heat sink Replacing the enclosure shroud Lower the shroud onto the enclosure base Install and tighten the eleven 11 screws that hold the shroud on the rear and bottom of the base before you install the two screws that support the heat sink assembly on the left side wall Remember to reinstall the plastic washers on the door hinge SERVICING THE AT10 1 Replacing the Main Control Printed Circuit Board A1 For details of this procedure refer to Service Instruction JD5012 00 NOTICE Printed circuit boards are sensitive to damage from static discharges Leave replacement boards in their anti static bags unti
19. or key If you go past the voltage you want press the uP or DOWN key again to reach the voltage you want to set e Press the EDIT ENTER key The new equalize voltage setting is saved internally If you want to adjust the equalize timer duration skip to Section 2 3 3 OR If you want to exit the Edit Mode now press the DIT ENTER key four more times until the AT10 1 returns to normal operation If you do not press any front panel key for 25 seconds Edit Mode ends automatically and any change you made to the last setting is not saved 31 OPERATING THE AT10 1 2 3 3 2 3 4 Setting the Equalize Timer e Press the EDIT ENTER key until the EQLZ HRS REMAINING MANUAL TIMER and AUTO EQLZ TIMER indicators light and the display flashes the present value of the equalize timer duration in hours Press and release the uP or key to increase or decrease the value in the display by one count or press and hold the UP or DowN key to scroll the value in the display upward or downward When the meter displays the desired equalize time in hours release the UP or bowN key If you go past the number of hours you want press the uP or key again to reach the number you want to set If you set the equalize time to zero hours the equalize mode is disabled e Press the EDIT ENTER key The new equalize timer duration is saved i
20. 1 G1 Aux Alarm Relay Field Install DC5016 00 JD0052 00 http www ATS eries net P DF s DC5016 00 pdf http www ATS eries net P DF s D0052 00 pdf AT Series AC Input Current Tables Battery Discharge Dual Operation Note JD5002 00 http www ATS eries net P DF s D5002 00 pdf DC Motor Starting Application Note JD5006 00 JD5013 00 http www ATS eries net P DF s D5006 00 pdf http w ww ATS eries net P DF s J D5013 00 pdf Alt amp Temp De Rating Application Note AC Ripple Specification Application Note JD5032 00 http www ATS eries net P DF s D5032 00 pdf Ground Fault Detection Application Note JF5039 00 JF5045 00 http www ATS eries net P DF s F5039 00 pdf http www ATS eries net P DF s F5045 00 pdf AT10 1 AT30 3rd Party Agency Approvals Proper Sizing of Industrial Battery Chargers 95 QUICK OPERATION For unpacking and installation instructions See section 1 on page 2 in this manual To learn how to use the equalize timers see sections 2 2 4 on page 27 and 2 3 3 on page 32 For details on setting parameters see section 2 3 starting on page 30 If you don t press any key for 25 seconds the AT10 1 resumes normal operation automatically Startup gt Turn on the dc breaker labeled DC OUTPUT gt Turn on the ac breaker labeled AC INPUT Changing between Float and Equalize Modes
21. A1 A5 etc SEE DRAWING 5030 19 2 I O PANEL PROTECTION SHOWN ONLY ON DETAIL CONSISTS OF EMI FILTER CAPACITORS C4 amp C5 AND SURGE SUPPRESSORS VR1 VR2 VRA VRS VRB amp VR7 3 DATA NAMEPLATE IS LOCATED ON EXTERIOR LEFT SIDE WALL OF ENCLOSURE USER 5 MANUAL POCKET IS LOCATED ON EXTERIOR RIGHT SIDE WALL OF ENCLOSURE 4 SAFETY COVER DISPLAYS COMPONENT LAYOUT DIAGRAM SCHEMATIC amp INSTALLATION NOTES 5 BATTERY ELIMINATOR FILTER CAPACITOR C2 IS NORMALLY LOCATED IN FRONT OF 130VDC 12ADC THRU 130VDC 25ADC UNITS UTILIZE TWO 2 Cls THEREFORE C2 IS SHIFTED TO LOWER RIGHT HAND CORNER OF ENCLOSURE AS SHOWN BE PLACED IF ATIO HAS 480VAC INPLIT OR IS CUSTOMER SPECIFIEO WITH iy lial RE NEAR BATTERY CELL AMPERE INTERRLPTING CAPACITY CIRCUIT BREAKERS AND CB2 RELOCATED TO PENTHOUSE ENCLOSURE AND 6 IS ADDED c MEE 042805 ORAW BY MCR 022703 111 ATIO 1 SERIES BATTERY CHARGER OPTIONAL gt INTERNAL COMPONENT LAYOUT STYLE 586 594 DRAWING No REV 091004 aee Gy 022803 022703 ER RSet sk AEs el cea i SCALE NTS 5027 99 http www ATSeries net PDFs JE5027 99 pdf 77 APPENDIX C Standard Drawings Instrument Panel PC Board Detail AT10 1 Group Battery Charger w Optional Auxiliary Alarm Relay PC Board JE5030 19 INDICATUR LIGHTS LEDs AC ON
22. AT10 1 door and locate the small plastic jumper J9 on the right side of the Main Control PC Board A1 See the figure below AT series _ i rrr 227 99086 III J6 Ji 317 arse J5 PT ENABLE lt in E amp DSIO RA e I DETECT cH DISABLE ENABLE 9 59 9 ns J3 we 3J9 TEMP RELAY 2 O 12 3 oo 3558 1B8 MEL J13 ALARM Move the jumper up to the DISABLE position pins 2 and 3 With this setting only the front panel METER MODE and cHRG keys will function All indicators will still work normally Return the jumper down to the ENABLE position pins 1 and 2 to return all front panel key functionality 39 OPERATING THE AT10 1 2 4 PERFORMING ROUTINE MAINTENANCE High voltages appear at several points inside the AT10 1 Use extreme caution when working inside the enclosure Do not attempt to work inside the AT10 1 unless you are a qualified technician or electrician Disconnect and lock out all power from the AT10 1 before starting to remove or replace any components Turn the ac power off at the distribution panel upstream from the charger Disconnect the battery from the AT10 1 output terminals TB 1 Keep it clean
23. DC BREAKER 2 IN THE NEGATIVE BUSS 7 OPTIONAL 480 AC FUSE Fl AC INPUT TRANSFORMER FEATURES NO TAPS BUT 1 POLE ND MED AIC BREAKERS ARE REQUIRED lt 80 APPENDIX C Standard Drawings Schematic AT10 1 Group Battery Charger Standard w o Options JE5031 00 AKER MAIN CONTROL PC BOARD Al TBIC REMOTE TU REg 185 c5 VR7 EM a evar IG aS 17 Li AW CA R4 I VRG Q AA Q TES TB5 REMOTE ai C10 8s NOTE 5 TBI CB2 XXA ecl THIRD ANGLE PROJECTION DRANN BY MCR 022003 TIME AT10 1 SERIES BATTERY CHARGER APPROVEO e 022003 SCHEMATIC 6 25ADC GROUP I STO 0 OPTIONS DRAWING Na UNLESS OTHER I ARE IN THES SE NUTEU DIMENSIUNS JE503 1 00 TOLERANCES ARE SCALE NTS PART No JE5031 00 SHEET 1 OF http www ATSeries net PDFs JE5031 00 pdf 81 APPENDIX C Standard Drawings Schematic AT10 1 Group Battery Charger w Common Options JE5031 99 CONNECTION TABLE INPUT JUMPER STANDARD 120 HI H3 H2 H5 TRANSFORMER 208 H2 H
24. I I a ole a a e N0027 LORE AUXILIARY ALARM RELAY BOARD CAS JIS MANUFACTURING TEST HINDLET C A5 J1 CONNECTED TO Al J2 VIA 5045 OTHER CONTROLS 8 PIN SERIAL CABLE RAL LOW LEVEL DETECT ADJUST RAZ GRIND FAULT BALANCE GROND FAULT SENSITIVITY NON USER ACCESSED JUMPERS J3 5 RIEBUN CONNECTOR ER INC e 2008 312 BOARD PROGRAMMING L FIKCED LOAD SHARING L INTERNAL TEMP This instrument panel drawing JE5030 19 depicts the optional Auxiliary Alarm Relay PC Board A5 which provides two 2 sets of individual form c contacts TB4 for all alarm conditions Standard AT10 1s feature one 1 set of form c summary common alarm contacts TB3 78 APPENDIX C Standard Drawings Instrument Panel PC Board Detail AT10 1 Group Battery Charger DISPLAY w Optional Auxiliary Alarm Relay PC Board JE5030 19 05 3 0514 05 19 05 6 05 7 o Tsatts HindigPoyer Inc HINOLEPOWER INC EN5002 CREYO IROL PC BOARD Al G CHARGER DOOR WHEN INSTALLED JUMPERS SWITCHES MAINFRAME SIGNAL HARNESS S1 METER AUX ALARM RELAY BOARD A5 SERIAL CONNECTOR S2 CHARGER MODE FORCED LOAD
25. O panel TB1 12 25 EJ1127 03 consists of one 1 5000 100W resistor b 6 Adc EJ1127 23 consists of two 2 2500 50W resistors connected in series Note 2 Listed part numbers subject to change without notice Refer to data listed in AT 10 1 Parts Data Package report 65 SERVICING THE AT10 1 Table 3 2 DC FILTER ASSEMBLIES L2 C1 R9 CR1 CR2 Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 6A EJ1072 00 EJ1072 00 EJ1072 02 EJ1072 03 12A EJ1072 00 EJ1072 00 EJ1072 02 EJ1072 06 16A EJ1072 01 EJ1072 01 EJ1072 07 EJ1072 04 20A EJ1072 01 EJ1072 01 EJ1072 07 EJ1072 04 25A EJ1072 01 EJ1072 01 EJ1072 07 EJ1072 05 Table 3 3 STANDARD AC CIRCUIT BREAKERS CB1 120 208 240 Vac Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 6A RE0159 11 RE0159 11 RE0159 11 RE0159 13 12A RE0159 1 1 RE0159 1 1 RE0159 13 RE0159 16 16A RE0159 11 RE0159 12 RE0159 13 RE0159 19 20A RE0159 1 1 RE0159 12 RE0159 14 RE0159 20 25A RE0159 11 RE0159 12 RE0159 15 RE0159 20 Table 3 4 MEDIUM INTERRUPTING CAPACITY AC BREAKERS CB1 120 208 240 Vac Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 6A RE0171 00 RE0171 00 RE0171 00 REO0171 01 12A RE0171 00 RE0171 00 RE0171 01 0171 04 16 RE0171 00 RE0171 00 RE0171 01 0171 07 20 RE0171 00 RE0171 00 RE0171 02 RE0171 08 25A RE0171 00 RE0171 00 RE0171 03 RE0171 08 Table 3 5 HIGH INTERRUPTING CAPACITY AC BR
26. Refer t o separate Operating Instructions JA0102 04 1 13 INSTALLING FOR FORCED LOAD SHARING OPTIONAL Refer t o Appendix F on page 90 or Operating Instructions 5054 00 23 OPERATING THE AT10 1 2 OPERATING THE AT10 1 BATTERY CHARGER 2 1 STARTING THE AT10 1 2 1 1 Understanding the startup sequence The AT10 1 is set up at the factory to work with most common batteries and loads without further adjustment When you start the AT10 1 for the first time the factory settings float voltage equalize voltage etc control the operation of the charger You can change the settings after you start the AT10 1 The FACTORY SETTINGS are listed in table on page 25 The AT10 1 startup routine takes about five seconds The microprocessor that controls the AT10 1 initializes the charger by reading the settings that are stored internally The control circuitry then soft starts the AT10 1 and the dc output voltage and current increase gradually to the rated value Checking the installation Using the Digital Meter Be sure that you have followed the installation When you first start the instructions carefully Check the ac input ATION eee ey alternates between dc output supply voltage and the battery voltage and be voltage and dc output current sure that they match the information on the Each reading is held for two AT10 1 nameplate Verify that the jumpers on C seconds Lights to the left of the display indic
27. SHARING CABLE INTERCONNECTOR S3 EBUALIZE METHOD GROUND FAULT ENABLE DISABLE 54 AADLILIST EARTH GROUND CONNECTOR S5 VADJUST FRONT PANEL ENABLE DISABLE LOCKOUT gt S6 EHIT ENTER COMMUNICATIONS PC BOARD A12 INTERCONNECTOR S7 PROCESSOR MANUAL RESET HO GATE DRIVER PC BOARD All INTERCONNECTOR TERMINAL BLOCKS NOT USED 3PH GATE DRIVER PCB INTERCONNECTOR TB3 SUMMARY ALARM RELAY CONTACTS future TBA AUX ALARM RELAY CONTACTS DISABLE ENABLE RA2 RAB Rea eee 1 COMNUNICATIONS 1 PC BOARO 1 ASSEMBLY A12 SEE DRAWING 5107 00 FOR DETAILS 1 1 i x i T sire 7 pA J2 ESIS4 DD LI ALI 4 E 13 l IDs s gl Jib TBB MAIN CONTROL PC BOARD Al 1 1 L BACK VIEW FACING CHARGER COMPONENTS WHEN INSTALLED TB8 OPTIONAL TEMPCO PROBE A10 INTERCONNECTOR THIRO ANGLE c PROJECTION TITLE DRAWN BY MCR 022003 10 1 SERIES BATTERY CHARGER GROUP I INSTRUMENT PANEL PC BOARD DETAIL OPTIONAL wwe Gy 022003 m JESO30 19 UNLESS OTHERWISE NITED OLMENSLONS ARE IN jd TOLERANCES ARE CONTROLS LOW LEVEL ADJUST gt GROUND FAULT 120209 SENSITIVITY 041 108 IBN ERECT MT 051705 de 022003 AAL TEMP DATE
28. Table 3 12 MAIN TRANSFORMER T1 480 Vac Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 6A AA0733 00 AA0734 00 AB2038 00 AB2039 00 12A AA0733 00 AA0734 00 AB2038 00 AB2032 00 16A AA0735 00 AB2035 00 AB2036 00 AB2037 00 20A AA0735 00 AB2035 00 AB2036 00 AB2037 00 25A AA0735 00 AB2035 00 AB2036 00 AB2037 00 68 SERVICING THE AT10 1 Table 3 13 FILTER INDUCTOR L2 Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 6A AP0928 00 AP0928 00 AP0928 00 AP1081 00 12A AP0928 00 AP0928 00 AP0928 00 AP0928 00 16A AP0927 00 AP0927 00 AP0926 00 AP0926 00 20A AP0927 00 AP0927 00 AP0926 00 AP0926 00 25A AP0927 00 AP0927 00 AP0926 00 AP0926 00 Table 3 14 480 Vac INPUT FUSE F1 Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 6A RE0008 00 RE0008 00 RE0008 02 RE0008 06 12A RE0008 00 RE0008 02 RE0008 06 RE0008 08 16A RE0008 02 0008 06 RE0008 08 RE0008 09 20A RE0008 02 RE0008 06 RE0008 08 REO0008 11 25A RE0008 02 RE0008 06 RE0008 08 REO0008 11 NOTE Listed part numbers subject to change without notice Refer to data listed in AT10 1 Parts Data Package report 69 APPENDIX A SPECIFICATIONS Except as noted all specifications apply at 77 F 25 C nominal ac line voltage amp nominal float voltage Output voltage regulation Temp 32 122 F 0 50 C Freq 60 3 Hz Specification Conditions 12 24 Vdc 48 13
29. VOLTS METER indicator will light and the meter display flashes the output voltage reading Measure the output voltage of the AT10 1 using a de meter accurate to 0 25 or better While watching the meter connected to the AT10 1 output not the front panel meter press the UP or key until the actual output voltage matches the float setting on the front panel meter Each time you press UP or DOWN you change the AT10 1 output voltage by a small amount Continue to press UP or until the actual output voltage agrees with the front panel reading within 0 25 NOTICE Allow one or two seconds for the output voltage to stabilize each time you press the uP or key When you are finished adjusting the output voltage the AT10 1 waits five 5 seconds then the display returns to normal operation 37 OPERATING THE AT10 1 2 3 8 Using the Low Level Detector LLD The AT10 1 is equipped with a summary common alarm relay safety override circuit This feature forces the alarm relay contact to transfer sending an alarm even if there is a catastrophic failure of the AT10 1 control circuitry A low battery voltage triggers the safety circuit Main Control PC Board A1 hardware not software maintains the low level detect circuit Therefore to remotely monitor this alarm user connections must be made at terminal block TB3 The summary alarm contacts TB4 on the Aux
30. a list of these 1 alarms status codes form C B alarm contacts are provided and SLIMMARY ALARM accessible via terminal E DRE NNECTIDN block TB3 as shown figure to the E 27 right E Ea SSS Follow the procedure below to wire a remote annunciator to this NE contact PROCEDURE 1 Allow 30in 762mm of wire inside the enclosure Excess will be trimmed 2 Route annunciator wires to the AT10 1 front panel door by following the existing harness through the door hinge as shown Use two 2 wire ties and allow a 4 6in 102 153mm loop for the hinge 3 Trim wires to the proper length for connecting to TB3 Strip 0 25in 6 4mm of insulation from the wires 4 Make the connections at TB3 and securely tighten compression screws NOTES 1 Alarm contacts are rated at 0 5A 125 Vac or Vdc 2 Summary Alarm relay terminal block TB3 is compression type accepting wire sizes 22 14 AWG 3 Terminals are labeled in non alarm condition 4 Ifuser alarm contacts TB3 and or TB4A B are to drive inductive dc loads e g a larger dc relay an external protective diode must be applied at the dc relay to avoid equipment damage See Application Note JD501 1 00 18 INSTALLING THE AT10 1 Auxiliary Alarm Relay PC Board optional The optional Auxiliary Alarm Relay PC Board A5 mounted Inside the separate top enclosure penthouse provides tw
31. action described in the right hand column to correct the problem and return the AT10 1 to normal service Determining the condition of the AT10 1 e Is the front panel AC ON indicator lit e What is the ac voltage at the input terminals measured with an ac voltmeter e What is the dc voltage at the output terminals measured with a dc voltmeter e Does the front panel meter display any voltage or current e Are any alarm indicators lit e Do the front panel status indicators work Charge Mode for example e Can you change the AT10 1 to the Equalize mode then back to Float e 5 AT10 1 making any noise Is it unusually loud e Is there any sign or smell of smoking or burning While using the Troubleshooting Chart refer to the internal component layout drawings and connection diagrams in Appendix C For instructions on replacing components see Section 3 5 SERVICING THE AT10 1 3 4 TROUBLESHOOTING CHART sympTom PROBABLE RECOMMENDED ACTION CAUSE Front panel 1 An external 1A Soft Reset of control board by pressing S7 reset switch meter surge has S7 is located inside the AT10 1 on the control board s right displays all interrupted edge as viewed from the rear of the front panel This will segments on operation of the restart the control board without modifying any settings or all microprocessor 4B Hard Reset of control board by pressing and holding the segments off jor the display
32. brackets using the supplied kit hardware Provide at least 6in 152mm of free air above and below the AT10 1 for cooling Refer to the graphics on the opposite page for the rack mounting configurations INSTALLING THE AT10 1 GRAPHICS RACK MOUNTING THE AT10 1 Style 586 Enclosure 2 25in 8 50 57mm 216mm b ALLOW 6in 153mm FOR 6in 153mm COOLING ABOVE UNIT COOLING 9 o 9 9 RACK MTG BRACKET ASSY x AT10 1 MU 10193 00 4 Co Co ALLOW 6in 153mm FOR STANDARD 6in 153mm COOLING BELOW UNIT EIA SPACING COOLING 25in 6 4mm MTG BOLTS Style 594 Enclosure __ 4 00in _ 8 50in _ _ _ _ _ 102mm 216mm ALLOW 6in 153mm FOR i COOLING ABOVE UNIT t yo PER 6in 153mm a COOLING RACK MTG AT10 1 BRACKETASSY Fm J 1 Mv EI0193 00 RI T o g f A AC I KI Jl ALLOW amp in 153mm FOR STANDARD 4 A COOLING BELOWUNIT EIA SPACING l 6in 153mm 4 COOLING 1 25in 6 4mm MTG BOLTS NOTES 1 Mounting brackets and AT10 1 enclosures are installed from the front 2 Above installations are shown without optional penthous
33. component layout electrical schematic with component ratings and a full connection diagram If the standard drawings featured in this manual are not sufficient please contact your Sales Representative for drawing availability from theAT10 1 manufacturer RECEIVING THE AT10 1 1 RECEIVING THE AT10 1 1 1 STORING THE AT10 1 If you store the AT10 1 for more than a few days before installation you should store it in its origmal shipping container and in a temperature controlled dry climate Ambient temperatures of 32 to 122 F 0 to 50 C are acceptable Storage should not exceed two 2 years due to the limited shelf life of the dc filter capacitors when they are not in service 1 2 REPORTING SHIPPING DAMAGE Upon delivery of the AT10 1 or related products if you discover any damage or shortage make notation on all copies of delivering carrier s delivery receipt before signing and notify the delivery person of your findings If loss or damage is discovered after delivery notify delivering carrier immediately and request an inspection The manufacturer does not assume any liability for damage during transportation or handling Should the products require an inspection by or return to the manufacturer please contact your sales representative for further instructions Any returned material must be properly packed in compliance with shipping regulations It is preferable to use the original shipping materials if possible Mark t
34. is still on replace the Main Control PC Board A1 5 Disconnect the battery and connect a light dc load to the AT10 1 Measure the dc voltage from the input terminal to the output terminal of the circuit breaker with the breaker on It is normally no more than 50 millivolts If it is near the rated output voltage replace the breaker CB2 55 SERVICING THE AT10 1 PROBABLE SYMPTOM RECOMMENDED ACTION CAUSE DC OUTPUT 1 Defective 1 Use a clamp on ammeter to measure the current in wire FAILURE rectifier bridge 12 or 11 If it is less than 70 of the dc output current one PC Board A1 indicator is of the SCRs or diodes is defective Replace the rectifier on but ac amp module dc breakers 2 Defective 2 Turn off both front panel circuit breakers Restart by turning CB1 CB2 Main Control on the dc breaker CB2 first followed by the ac breaker are closed PC Board A1 CB1 If the AT10 1 output voltage and current are normal ac input but the DC OUTPUT FAILURE indicator is still on replace the voltage is Main Control PC Board A1 normal 3 Defective 3 Use an ac voltmeter to measure the ac voltage from T1 X1 Transformer to X4 It is normally 5096 to 80 higher than the rated dc T1 output voltage If it is too low check the wiring of the primary taps See Section 1 6 for details If it is zero replace T1 4 Defective dc 4 Disconnect the battery and connect a light dc load to the
35. kg Style 586 Style 586 Style 586 Style 586 Style 586 24 44 lbs 58 Ibs 75 lbs 75 lbs 75 lbs 20 kg 26 kg 34 kg 34 kg 34 kg Style 586 Style 586 Style 594 Style 594 Style 594 48 Vdc 58 Ibs 75 lbs 110 Ibs 110 165 26 kg 34 kg 50 kg 50 kg Style 586 Style 594 Style 594 Style 594 Style 594 130 Vdc 80 Ibs 147 lbs 193 Ibs 193 Ibs 36 kg 67 kg 88 kg 88 kg Actual unit weight is approximately 20 Ibs 9kg below listed shipping weight in table The Style 586 amp Style 594 enclosures do not feature top lifting eyes for moving Move the AT10 1 with a forklift whenever possible using the supplied shipping pallet Lift the AT10 1 into a wall mount or rack mount installation using a heavy duty sling or a scissor lift For further AT10 1 standard cabinet information see the outline drawings for the Style 586 JE5023 03 and Style 594 JE5024 03 enclosures in Appendix C on pages 72 and 74 1 5 MOUNTING THE AT10 1 The AT10 1 must be installed in manner that allows easy access to the front ac CB1 and dc CB2 circuit breakers Chose a mounting method for the AT10 1 enclosure from the table below ENCLOSURE MANUAL MOUNTING METHOD SECTION Style 586 Style 594 1 5 1 Wall Mounting STANDARD STANDARD 1 5 2 Floor Mounting OPTIONAL OPTIONAL 19in 483mm Rack Mounting OPTIONAL N A 1 5 3 Py 23 24in 584 610 OPTIONAL OPTIONAL Rack Mounting INSTALLING THE AT10 1 1 5 1 Wall Mounting t
36. lead of the ac surge suppressor Install one lead of the replacement surge suppressor onto the L1 terminal Replace the other wires and the hardware Repeat procedure for the left ground stud Tighten all hardware For VR5 repeat procedure for the ac surge suppressor connected to the L2 terminal and the right ground terminal Tighten all hardware 1 The ac surge suppressors are not polarized 61 SERVICING THE AT10 1 Replacing the dc surge suppressor VR1 Turn off and remove all power to the AT10 1 Remove the Plexiglas safety shield Disconnect the battery from the output terminals TB1 Remove the hardware from the output terminal TB1 and remove the lead of the dc surge suppressor Install one lead of the replacement surge suppressor Replace the other wires and the hardware Repeat for the output terminal TB1 Tighten all hardware Nolaz The dc surge suppressor is not polarized Replacing the dc EMI filter networks VR6 C4 VR7 C5 Replace these networks as assemblies Do not replace individual parts Turn off and remove all power to the AT10 1 Remove the Plexiglas safety shield Disconnect the battery from the output terminals TB1 To replace the network VR6 C4 remove the hardware from the output terminal TB1 and remove the lead of the network Cut the plastic wire ties holding the assembly tight against the I O panel Install one lead of the replacement network Replace the other wires and
37. mode automatically and the EQLZ indicator will light At the end of the equalize charging time that you select the AT10 1 reverts automatically back to float mode and the FLOAT indicator lights At any time during the equalize charge you can switch the AT10 1 back to float mode by pressing the cHRG MODE key The FLOAT indicator will light Consult your battery manufacturer s instructions before using the auto equalize timer method with sealed valve regulated lead acid batteries Whenever the ac supply fails for 12 seconds or longer the auto equalize timer is enabled For shorter periods the timer behaves as listed below mode before ac failure mode after ac failure duration ac failure less than FLOAT 2 7 FLOAT less than resume EQUALIZE EGMAEIEE gt 12 seconds gt with time remaining FLOAT or 12 seconds gt EQUALIZE EQUALIZE or greater with full time Switching to Equalize Mode with Auto Equalize Timer Method Selected You can start an equalize charge at any time e Press the CHRG MODE key The EQLZ indicator lights When the equalize timer is finished the AT10 1 reverts automatically to float mode and the FLOAT indicator lights 28 OPERATING THE AT10 1 2 2 5 2 2 6 2 2 7 Testing the front panel indicators e Press the DOWN key This is also the LAMP TEST key The meter will displa
38. on Page 37 Reconnect the TempCo cable to TB8 and active restart the AT10 1 See Application Note JD5003 00 for further details A 05 dc output at The AT10 1 is in Current Limit mode This will occur when there is a large Current Limit setting load on the dc bus or the battery has discharged Make sure that the AT10 1 is sized correctly for the application and that the Current Limit value has been set correctly See Section 2 3 5 on Page 35 47 SERVICING THE AT10 1 3 3 USING THE TROUBLESHOOTING CHART High voltages appear at several points inside the AT10 1 Use extreme caution when working inside the enclosure Do not attempt to work inside the AT10 1 unless you are a qualified technician or electrician Disconnect and lock out all power from the AT10 1 before starting to remove or replace any components Turn the ac power off at the distribution panel upstream from the charger Disconnect the battery from the AT10 1 output terminals TB1 Before you try to use the troubleshooting chart be sure that you have followed the steps in Section 3 1 The troubleshooting chart that begins on the next page is divided into three 3 columns To use the chart 1 Make a list of the AT10 1 s condition including the trouble symptoms 2 Find the symptom s in the first column of the chart 3 The middle column contains common causes for the problem you observe in order of probability 4 Follow the
39. probe and the AT10 1 Also check the connection of the cable to TB8 on the Main Control PC Board A1 on the back of the front panel If the wiring is satisfactory the probe needs to be replaced Once you have replaced the probe you must restart the AT 10 1 to activate temperature compensation E 09 misadjusted This code has been discontinued with Main Ctrl PCB firmware version Current Limit 6 52 See Application Note JD5035 00 for a description of this code E 10 open internal A redundant internal feedback loop control loop is provided to increase feedback loop reliability when remote sensing is used If there is a problem with the internal loop wiring the front panel meter will display E 10 Check the internal wiring in the signal harness especially wire 33 Also check the harness connector J1 on the Main Control PC Board A1 E 11 not used This error code is not implemented at this time E 12 defective The AT 10 1 rectifier heat sink assembly has been equipped with a non internal standard over temperature thermostat S2 On startup the AT10 1 tests thermostat the thermostat and displays E 12 if it is defective Check the thermostat S2 for continuity Disconnect the wiring and resistor R28 from the quick connect terminals The thermostat switch should be closed NC at normal room temperature E 13 internal over The non standard rectifier thermostat 52 has detected an over temperature temp
40. the hardware Repeat for the other lead of the network on the ground terminal For the 7 5 network use the above procedure but start with the lead TB1 Tighten all hardware Replace cut wire ties if possible The dc EMI filter networks are not polarized Replacing the power supply ballast resistor R3 Shut down and remove all power to the AT10 1 Remove the Plexiglas safety shield Disconnect the battery from the output terminals TB1 Locate the power supply ballast resistor R3 near the I O panel TB1 In 12 amp 24 Vdc units R3 is installed at the top right corner connected to E17 and 1 In 48 amp 130 Vdc units is mounted on the bracket behind the I O panel In 130 Vdc 6Adc units R3 is comprised of an assembly of two 2 resistors connected in series mounted to the bracket Disconnect the lead of R3 connected to TB1 and replace it with the corresponding lead of the replacement power resistor Remove the other lead of R3 from terminal E17 on the I O panel and replace it with the remaining lead of the replacement power resistor Tighten all hardware In 12 amp 24 Vdc units tuck the new R3 resistor behind the I O panel so that leads are properly spaced In 48 amp 130 Vdc units remove the screws that mount the old R3 resistor s to the bracket and replace with the new resistor s Tighten all mounting hardware and restart the AT10 1 For further information refer to Service Instruct
41. unless you are a qualified technician or electrician Disconnect and lock out all power from the AT10 1 before starting to remove or replace any components Turn the ac power off at the distribution panel upstream from the charger Disconnect the battery from the AT10 1 output terminals TB1 PROCEDURE 1 De energize and lock out all ac and dc voltage sources to the AT10 1 and check with a voltmeter before proceeding 2 Mount the probe on a clean dry surface as close to the battery as possible such as the battery rack DO NOT mount the probe e onthe battery itself e onunpainted wood or bare galvanized metal e on plastic surfaces 3 To apply the probe clean the mounting surface with isopropyl alcohol and allow to dry thoroughly Remove the protective backing from the double faced adhesive tape on the probe and securely press it onto the surface 4 Install the cable supplied with the temperature compensation probe kit e Start at the AT10 1 The end of the cable with two stripped wires and a quick connect terminal will be installed inside the AT10 1 e Leave 30in 762mm of cable inside the enclosure and route the other end to the probe at the battery 20 INSTALLING THE AT10 1 e Run the cable though a conduit if possible but not through a conduit containing any power wiring e Route the other end to the probe at the battery and coil up excess cable NOTICE If the standard 25ft 7 6m cable is
42. 0 Vdc Vac 10 12 0 to 100 load 0 25 see product literature for specific data Transient response 20 100 load change with battery connected output voltage change 4 maximum recovery to 2 0 in 200 ms recovery to 0 5 in 500 ms 12 Adc rating full load 96 67 00 72 00 78 00 85 00 Efficiency 25 Adc rating full load 96 73 00 77 00 85 00 91 00 19 typ 29 Unfiltered with battery Tous YP Bins at battery terminals Filtered with battery 30 mV rms max 100 mV wi Output ripple voltage y at battery terminals per NEMA PE5 1996 Filtered without battery 1 rms typ 2 rms Battery Eliminator Filter Option without battery rms 100 mv Surge withstand capability ANSI C37 90 1 1989 Current Limit adjustable 50 110 of rated output current Soft start 0 to 100 load 4 seconds Float Vdc 11 0 14 5 22 0 29 5 44 0 58 0 110 141 Vallagasa qaa at tange Equalize Vdc 11 7 16 0 23 4 32 0 46 8 61 0 117 149 High DC Voltage alarm Vdc 12 19 24 38 48 76 120 175 Low DC Voltage alarm Vdc 7 14 5 15 29 5 30 58 80 141 Voltmeter range Vdc 0 21 0 42 0 75 0 195 Ammeter range Adc all ratings 0 30 test per no erroneous outputs Reverse current from battery ac input power failure 90 mA maximum Audible noise average for four 4 sides 5ft 1 5m from enclosure less than 65 dBA Coolin
43. 3 04 RE0043 04 RE0043 04 RE0043 04 Table 3 9 MAIN INDUCTOR L1 Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 6A AP0928 00 AP0928 00 AP0928 00 AP1122 00 12A AP0928 00 AP0928 00 AP0928 00 AP0930 00 16A AP0926 00 AP0926 00 AP0926 00 AP0931 00 20A AP0926 00 AP0926 00 AP0926 00 AP0931 00 25A AP0926 00 AP0926 00 AP0926 00 AP0931 00 NOTE Listed part numbers subject to change without notice Refer to data listed in AT10 1 Parts Data Package report 67 SERVICING THE AT10 1 Table 3 10 RATING RESISTOR R2 Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 6A EJ1133 00 EJ1133 05 EJ1133 10 EJ1133 15 34 8 13 0 kQ 5 11 1 50 12A EJ1133 01 EJ1133 06 EJ1133 11 EJ1133 16 40 2 15 4 6 19 kO 2 21 16A EJ1133 02 EJ1133 07 EJ1133 12 EJ1133 17 53 6 19 6 7 50 2 74 20A EJ1133 03 EJ1133 08 EJ1133 13 EJ1133 18 78 7 23 7 9 09 3 57 25A EJ1133 04 EJ1133 09 EJ1133 14 EJ1133 19 118 kQ 29 4 kQ 11 0 4 32 mone or inne Molex Part No 11 03 0044 extraction tool Table 3 11 MAIN TRANSFORMER T1 120 208 240 Vac Current Rating 12 24 Vdc 48 Vdc 130 Vdc 6A AA0718 00 AA0719 00 AB2023 00 AB1868 00 12A AA0718 00 AA0719 00 AB2023 00 AB1857 00 16A AA0720 00 AB1855 00 AB1856 00 AB1858 00 20A AA0720 00 AB1855 00 AB1856 00 AB1858 00 25A AA0720 00 AB1855 00 AB1856 00 AB1858 00
44. 4 2 4 H H3 25 RENS RANSFORMER STD gt PRI SEC m m s9 TBI LI DJ 2 w 1 HS gt Os I TBG 3 To H2 Ud 53 V H3 way Zo UR oN Ss TBI L2 D a N HI TER TB6 2 TB amp 4 NOTE 5 TB1 GND LJ t Y1 CHASSIS 7 7 GROUND TRANSFORMER NOTE 7 TI gt PRI SEC a 1 2 3r 34 3 I mea 1 TBA I zx AUX ALARM RELAY ax ety PC BOARD A5 SUMMARY ALARM 4 E TERMINAL BLOCK i x4 ID NOTE 2 TBE 4 HIGH DC LOW OC OUTPUT AC GROUND SUMMARY VOLTAGE VOLTAGE FAILURE FAILURE DETECT ALARM AUXILIARY ALARM 1 1 1 1 1 1 LIEL fel 1 1 i TERMINAL BLOCK 1 2 3 5 6 7 8 910711211334 re t8 7 18 re p20 21 221232425 28 27 2829 30 31 32 33 34935 8 TB4 NOTE 2 NOTES 12 FOR COMPONENT DETAILS OF ALL PC BOARDS AS 11 etc SEE DRAWING JESO30 18 2 ALL ALARM CONTACTS SHOWN IN NON ALARM STATE CONTACT RATING IS O 5A m 125VAC VDC RESISTIVE 3 WHEN REMOTE SENSE 15 USED THE VOLTAGE SENSE LEAUS RUN FROM R14 TO REMOTE SENSEC AND FROM TB5 2 TO REMOTE SENSE REFER TO FEATUREO OPTIONS CONNECTION DIAGRAM FOR WIRING DETAILS AC INPUT CIRCUIT BREAKER 4 POWER TRANSFORMER TI HAS MLLTIPLE TAPS FOR 120472087240 VAC MED HL INT CAPACITY 5 gt A TWO POLE OC CIRCUIT BREAKER IS SUPPLIED ON 130VDt UNITS AND E Cec L UNITS WITH MEGIUM HIGH AMPERE INTERRUPTING CAPACITY BR
45. 6 Section 2 3 6 above High 2 Defective 2 Turn off both front panel breakers Turn on the dc breaker DC Voltage Main Control CB2 first followed by the ac breaker CB1 If the AT10 1 setting PC Board A1 output voltage is above the alarm setting but the HIGH DC VOLTAGE indicator still does not light replace the Main Control PC Board A1 LOW DC 1 Battery is 1 After an ac power failure or a battery discharge for any VOLTAGE discharged other reason it may take several hours to recharge the indicator is battery It is normal for the LOW DC VOLTAGE indicator to be on but ac amp on until the battery voltage is above the Low DC Alarm dc breakers voltage CB1 CB2 2 Low DC 2 Be sure that the Low DC Voltage alarm setting is lower than are closed Voltage alarm the Float voltage setting See Sections 2 3 2 and 2 3 4 ac input and Float voltage is voltage settings normal but are mismatched there is output current 3 Defective rectifier bridge 4 Defective Main Control PC Board A1 5 Defective dc breaker CB2 3 Use a clamp on ammeter to measure the current in wire 11 or 12 If it less than 70 of the dc output current one of the SCRs or diodes is defective Replace the rectifier assembly 4 Turn off both front panel circuit breakers Restart by turning on the dc breaker CB2 first followed by the ac breaker CB1 If the AT10 1 output voltage is normal but the LOW DC VOLTAGE indicator
46. 9 50 495 13 25 337 with OPTIONAL Penthouse PENTHOUSE WW 14 00 356 DD 13 25 337 HH 25 00 635 W 19 50 495 12 75 324 with Drip Shield WW 22 00 559 DD 12 50 318 HH 21 75 552 W 19 50 495 D 13 25 337 with Penthouse amp Drip Shield WW 18 75 476 DD 13 25 337 HH 28 75 729 W 19 50 495 D 12 75 324 75 APPENDIX C Standard Drawings Internal Component Layout AT10 1 Group Battery Charger Style 586 594 Enclosure w Common Options JE5027 99 OPTIONAL PENTHOUSE ENCLOSURE HOUSE SPECIAL CIRCUIT BREAKER AND AUXILIARY ALARM PC BOARD SIGNAL LI HARNESS Gue x 121 INE BER gt P i p 1 I D 8 MAIN CONTRO w L A Oeeeeeo 1 d PC BOARD Al m Ee CNOTE 1 a a n F go Bl fa I 1 maa T 2 B me 5 z e 9 TBI O l se I GI o Ol _ I SEE DETAIL ERI TO RIGHT Oo R2 CHASSIS I GROUND STun o NoTE 6 gt f 7 TB8 a XXft X XXn CA
47. AT10 1 SERIES Operating and Service Instructions MICROPROCESSOR CONTROLLED FLOAT BATTERY CHARGER SINGLE PHASE INPUT GROUP 6 25 Adc e EAGLEEYE HiwpLEPoOwER Eagle Eye Power Solutions JA5011 01 4230 N Oakland Ave 176 Milwaukee WI 53211 Phone 877 805 3377 Web www eepowersolutions com HOW TO READ THE AT10 1 MODEL NUMBER GROUP I RATINGS 6 25 Adc The AT10 1 configured model number is coded to describe the unit s features and options Please identify the model number printed on the data nameplate decal and write it in the spaces provided below Follow the chart below to determine the configuration of the AT10 1 1 120 208 240 Vac multi tap input AT10 1 is wired and shipped from factory at specified voltage 2 Special order consult factory for availability INPUT AND OUTPUT CIRCUIT BREAKER INTERRUPTING RATINGS The factory configured model number printed on the AT10 1 data nameplate decal does not feature certain options and accessories Nor does it feature any field installed options Check off below any options and or accessories that are initially included or are installed after shipment Please find the serial number on the data nameplate and record it here DESCRIPTION CODE FEATURE DESCRIPTION CODE FEATURE A SERIES AT10 AT10 1 BATTERY CHGR CIRCUIT S STANDARD
48. BLE CLEAR 12 js SAFETY COVER NOTE 5 NOTE 4 AT10 1 GROUP 1 STANDARO COMPONENTS SYMBOL DESCRIPTION SYMBOL DESCRIPTION Al MAIN CONTROL PRINTED CIRCUIT BOARD yR4 AC INPUT SLRGE SUPPRESSOR L1 TO END AG RECTIFIER ASSY CA3 ALB HEATSINKO yR5 AC INPUT SLRGE SUPPRESSOR L2 TO ENDO C4 DC OUTPUT EMI FILTER CAPACITOR VRE DC OUTPUT SURGE SUPPRESSOR ENDO C5 DC OUTPUT EMI FILTER CAPACITOR 7 C OUTPUT SLRGE SUPPRESSOR TO GND AC INPUT CIRCUIT BREAKER M H AIC CH2 DC OUTPUT CIRCUIT BREAKER AIC OPTIONAL COMPONENTS To L1 MAIN INDLICTUR A5 ALIXILIARY ALARM RELAY PC BOARD NEAR R2 CURRENT RATING RESISTOR ALO EXTERNAL TEMPERATURE COMPENSATION PROBE R3A B BALLAST RESISTORS 130 VDC Cl FILTER CAPACITOR R4 SCALING RESISTOR POSITIVE LEG r2 BATTERY ELIMINATOR FILTER CAPACITOR RG VOLTAGE CROWBAR RESISTOR ERI POLARITY DIODE R14 SCALING RESISTOR NEGATIVE LEG R2 BLOCKING DIODE Ti POWER ISOLATION TRANSFORMER FI AC INPUT FUSE 480 VAC INPUT ONLY SUMMARY ALARM CONTACTS L2 FILTER INDUCTOR TBS RESISTOR TERMINAL BLOCK RS FILTER CAPACITOR Cl BLEED RESISTOR TB8 TEMPCO PROBE A105 TERMINAL BLOCK AUXILIARY ALARM RELAY TERMINAL BLOCK VRI DC OUTPUT SURGE SUPPRESSOR TO TB6 MEDZHIGH AIC CIRCUIT BREAKER JUNCTION BLOCK AC INPUT SURGE SUPPRESSOR LI TO 12 VR3 AC LIGHTNING ARRESTOR LOCATED BEHIND 1 0 This internal component layout drawing JE5027 99 depicts an AT10 1 Series battery charger housed in a Sty
49. BREAKER 012 12 Vdc RATING M MEDIUM AIC NOMINAL Erie 024 24 Vdc SEE TABLE H HIGH AIC VOLTAGE 048 48 Vdc 130 130 Vdc AUXALARM AUX SUPPLIED 006 6 Adc RELAY BOARD XXX NOT SUPPLIED NOMINAL 012 12 Adc C DC OUTPUT 016 16 Adc L COPPER G SUPPLIED CURRENT 020 20 Adc GROUND BUS x NOT SUPPLIED 025 25 Adc DC UNFILTERED LIGHTNING L SUPPLIED ARRESTOR D FILTERING F FILTERED STANDARD x NOT SUPPLIED E BATT ELIMINATOR FILTER 120 120 Vac 60 Hz N FUNGUS F APPLIED 208 208 Vac 60 Hz PROOFING x NOT APPLIED m 240 240 Vac 60 Hz STATIC S APPLIED PROOFING E VOLTAGE 480 480 Vac 60 Hz x NOT APPLIED 220 220 Vac 50 60 Hz 380 380 Vac 50 60 Hz NOTUSED x 416 416 Vac 50 60 Hz R NOTUSED x DESCRIPTION CODE FEATURE DESCRIPTION CODE FEATURE AC RATINGS DC RATINGS CODE TYRE ALL INPUT VOLTAGES 125 Vdc 240 Vac 10 000 AIC 10 000 AIC 4 s STANDARD 480 Vac 5 000 AIC 5 000 AIC 240 Vac 25 000 AIC M MEDIUM AIC 10 000 AIC H HIGH AIC 240 Vac 65 000 AIC 20 000 AIC floor rack mounting brackets NEMA 2 type drip shield assembly NEMA 4 12 13 type enclosure cabinet heater assembly pad lock for front panel door zero center ground detect meter 480 Vac 25 000 AIC 4 Rating applies to 130Vdc 16 25 Adc units 5 Approximate rating applies to all other units analog ac voltmeter penthouse mounted analog ac ammeter penthouse mounted barrier type auxiliary alarm terminal block s external temperature c
50. CK WIDTH Vdc Adc 19in 483mm 23in 584mm 24in 610mm 12 Vdc all Yes Yes Yes 24 Vdc all Yes Yes Yes 48 Vdc 6 12 Adc Yes Yes Yes 48 Vdc 16 25 Adc No Yes Yes 130 Vdc 6 Adc Yes Yes Yes 130 Vdc 12 25 Adc No Yes Yes When rack mounting the AT10 1 consider the following 1 The rack must be strong enough to properly support the weight of the AT10 1 See the Weight Table located in Section 1 4 on page 3 2 Be conscious of planned ac input and dc output wiring to the AT10 1 selecting conduit entrances carefully Note the standard pre fab conduit knockouts located on the sides top and bottom of the enclosures Ensure that planned conduit is accessible after the AT10 1 is rack mounted 3 The location e Should be free of drips and splatter If falling particles and liquids are a problem install NEMA 2 type drip shield accessory 0191 00 For kit availability see ordering information in Appendix B on page 71 e Should be between 32 and 122 F 0 and 50 C with relative humidity between 5 and 95 non condensing e Must be free of flammable or explosive materials 4 Maintain at least 6in 152mm of free air on all vented surfaces for cooling 5 Allow at least 36in 914mm front clearance for access to the AT10 1 for operation and maintenance PROCEDURE To rack mount the AT10 1 first install the mounting brackets into the rack using proper hardware not supplied Second mount the AT10 1 onto the installed
51. DFs JA5054 00 pdf INTRODUCTION Multiple battery chargers are sometimes employed in dc power systems to provide redundancy Two or more chargers of the same voltage rating can be connected in parallel each of them capable of powering the connected dc load and charging the battery If a battery charger should fail during normal operation the parallel charger can continue to supply the entire required dc load current and maintain charge on the battery When two 2 AT10 1s operate in parallel they normally will not share the load current equally Since any two chargers will have slightly different characteristics one of the two chargers in a system will have a slightly higher dc output voltage and will therefore assume more of the burden of providing necessary load current This section describes an optional accessory for the AT10 1 which forces units to share dc load equally The accessory ordering p n EJ5126 consists of an interconnecting cable to provide such communication and operating instructions SYSTEM REQUIREMENTS e The forced load sharing feature is designed only to work with two 2 AT10 1 Series battery chargers You cannot force load sharing with three 3 or more AT10 15 e Both AT10 1s must have the same dc voltage amp current rating and have the same dc filtering e Both AT10 1s must have the same ac input source and the same phase rotation e Both AT10 1s must feature Rev 6 or higher builds of the Main Control PC Bo
52. Drawings Optional Enclosure Dimensions AT10 1 Group Battery Charger w Penthouse and Drip Shield Style 586 Enclosure DIMENSION in mm Standard WW 16 25 495 DD 12 50 324 HH 15 63 457 W 16 25 495 10 75 337 with Penthouse OPTIONAL MS WW 14 00 356 DD 10 75 337 HH 22 63 572 W 16 25 495 D 10 00 324 with Drip Shield WW 18 75 559 DD 12 50 318 HH 19 50 552 W 16 25 495 D 10 75 337 WH with DRIP SHIELD Penthouse amp Drip Shield OPTIONAL PENTHOUSE WW 18 75 476 DD 12 50 337 HH 26 50 729 W 16 25 495 10 00 324 73 APPENDIX C Standard Drawings Outline AT10 1 Group Battery Charger NEMA 1 Style 594 Enclosure JE5024 03 1 ENCLOSURE IS A NEMA 1 1P2D TYPE CABINET WITHOUT GASKETS 2 ALLOW Gin 152mm OF FREE AIR TOP ANO FRONT OF CABINET FOR VENTILATION 3 FOR 4 KEY HOLE SLOTS ARE PROVIDEO ON THE BACK OF ENCLOSURE AS SHOWN FOR WALL MOLNT ING WITH 25in 6 25 HARDWARE 4 FOR 4 1 31in733mm DIA KNOCKOUTS ARE PROVIDED AS SHOWN WITH TWO 2 ADDITIONAL KNOCKOUTS FEATURED ON BOTTOM PANEL OF ENCLOSURE USE
53. EAKERS OC OUTPUT FILTERING ELIMINATOR FILTER EXTERNAL TEMPCO PROBE LIGHTNING ARRESTOR B CIRCUIT BREAKER INTERCONNECTION TERMINAL BLOCK IS USED WHEN MEDIUM OR HIGH AMPERE INTERRUPTING CAPACITY BREAKERS ARE SUPPLIED 7 OPTIONAL 480 VAC INPUT TRANSFORMER FEATURES NO TAPS BUT 1 POLE AC FUSE AND MED AIL BREAKERS ARE REQUIRED 82 C FILTERING ASSEMBLY APPENDIX C Standard Drawings Schematic AT10 1 Group Battery Charger w Common Options JE5031 99 01 34 oe eg Sov eG ie RI X Lil L2 CR2 E14 pu AAJ LI I 0 9 s TBI TB6 15 TB6 17 REMOTE 10 RE c l em I C5 Ass e 1 VR7 4 77 i 2 VR aH Z 17 LI AA 1 CA t RA I VRB Q A Q TES gi TES 77 REMOTE w 9 RS NOTE 5 TBI 25 TB6 14 TB6 15 NOTE B2 B5z608regss8s qso J3 3 MAIN CONTROL 77 TEMPERATLIRE COMPENSATION PROBE A10 THIRO ANGLE PROJECTION 091004 DRANN BY MCR 022003 TIME AT10 1 SERIES BATTERY CHARGER 040703 APPROVEO e 022003 SCHEMATIC 5 25ADC GROUP I W COM
54. EAKERS CB1 120 208 240 Vac Current Rating 12 24 48 Vdc 130 Vdc 6A RE0043 00 RE0043 00 RE0043 00 RE0043 01 12A RE0043 00 RE0043 00 RE0043 01 RE0043 04 16A RE0043 00 RE0043 00 RE0043 01 RE0043 07 20A RE0043 00 RE0043 00 RE0043 02 RE0043 08 25A RE0043 00 RE0043 00 RE0043 03 RE0043 08 66 SERVICING THE AT10 1 Table 3 6 STANDARD DC CIRCUIT BREAKERS CB2 Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 6A RE0159 01 RE0159 01 RE0159 01 RE0159 12 12A RE0159 02 RE0159 02 RE0159 02 RE0159 13 16A RE0159 03 RE0159 03 RE0159 03 RE0159 14 20A RE0159 04 RE0159 04 RE0159 04 RE0159 15 25A RE0159 06 RE0159 06 RE0159 06 RE0159 17 Table 3 7 MEDIUM AMPERE INTERRUPTING CAPACITY DC CIRCUIT BREAKERS CB2 Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 6A RE0171 00 RE0171 00 RE0171 00 RE0171 00 12A RE0171 01 RE0171 01 RE0171 01 RE0171 01 16A RE0171 02 RE0171 02 RE0171 02 RE0171 02 20A RE0171 03 RE0171 03 RE0171 03 RE0171 03 25A RE0171 04 RE0171 04 RE0171 04 RE0171 04 Table 3 8 HIGH AMPERE INTERRUPTING CAPACITY DC CIRCUIT BREAKERS CB2 Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 6A RE0043 00 RE0043 00 RE0043 00 RE0043 00 12A RE0043 01 RE0043 01 RE0043 01 RE0043 01 16A RE0043 02 RE0043 02 RE0043 02 RE0043 02 20A RE0043 03 RE0043 03 RE0043 03 RE0043 03 25A RE004
55. IONS AC INPUT CIRCUIT BREAKER MED HI INT CAPACITY DC DLITPLIT CIRCUIT BREAKER X MED HI INT CAPACITY ALIXILIARY RELAY PC BOARD DC OUTPUT FILTERING BATT ELIMINATOR FILTER EXTERNAL TEMPCO PROBE LIGHTNING ARRESTOR 86 APPENDIX C Standard Drawings Connection Diagram AT10 1 Group Battery Charger w Common Options JE5033 99 ININ MAIN CONTROL PC BOARD Al XX X X Xn LONG CABLE TEMPERATLIRE s COMPENSATION PROBE AIO SHIELDEU GROUND JA PA AUXILIARY ALARM 33 RELAY PC BOARD AS MOVE APER uam PROPER PINS 15 19 20 21 25 26 27 31 32 33 c NC NO L NC Noy C NC NO c NC NO CNC NJ CNC NO HIGH DC VOLTAGE LOW DC OW IN VOLTAGE FAILURE FAILURE GR LINO OETECT SUNNARY ALARN E NC NOTE 2 SUMMARY ALARM DOOR ROUND 32 C 2 5 E 7 O 5 SENSE SENSE NOTE 5 TB6 o1 02 02 02 1 NOTES 7 RO vet 3 1 uem NIS BREAKER a 32
56. JA0091 00 http www ATS eries net P DF s A0091 00 pdf AT10 1 St 586 594 Rack Mtg Instructions JA0092 00 http www ATS eries net P DF 5 A0092 00 pdf AT10 1 St 586 594 NEMA 2 Drip Shield JA0107 00 http Wwww ATS eries net P DF s A0107 00 pdf AT10 1 St 586 594 Cabinet Heater Acsy JA0108 00 http www ATS eries net P DF s A0108 00 pdf AT10 1 St 586 594 Cabinet Padlock Acsy JD0064 00 http www ATSeri ies net P DFs J D0064 00 pdf Preventative Maintenance Procedure JD0064 01 JD5003 00 http www ATSeri ies net P DFs J D0064 01 pdf http www ATS eries net P DF s D5003 00 pdf AT Series Charger Start up Procedure TempCo Probe Application Note JD5008 00 http www ATS eries net P DF s D5008 00 pdf AT Comm Module Field Installation JD5009 00 JD5010 00 http www ATS eries net P DF s D5009 00 pdf http www ATS eries net P DF s D5010 00 pdf AT10 1 G1 Rectifier Field Installation AT Power Res R3 Field Installation JD5011 00 http www ATS eries net P DFs J D5011 00 pdf Ext Free Wheeling Diode Application Note JD5012 00 JD5014 00 http www ATS eries net P DFs J D5012 00 pdf http www ATS eries net P DF s J D5014 00 pdf Main Ctrl PC Board A1 Field Installation AT10 1 St 586 594 Encl Keylock Acsy JD5025 00 http www ATS eries net P DF s D5025 00 pdf AT10
57. JD5008 00 are also provided for user support A field retrofit kit p n EJ5037 1 for the AT Series Communications Module is also available for installed AT10 1 units already in use An Ethernet Gateway accessory for AT Series Communication is available for either Modbus or DNP Level 2 Also available is a fiber optic modem kit or an industry standard 56Kbps V 92 modem with interconnection cable Contact your sales representative to place an order for the AT Series Communication Module and or accessories Refer to the table below for ordering information Installed Communications Option for 12 Vdc AT10 1 EJ5037 01 Installed Communications Option for 24 Vdc AT10 1 EJ5037 02 Installed Communications Option for 48 Vdc AT10 1 EJ5037 03 Installed Communications Option for 130 Vdc AT10 1 EJ5037 04 Installed Communications Option for AT10 130 006 EJ5037 05 Communications Module Field Kit for 12 Vdc AT10 1 EJ5037 11 Communications Module Field Kit for 24 AT 10 1 EJ5037 12 Communications Module Field Kit for 48 Vdc AT10 1 EJ5037 13 Communications Module Field Kit for 130 Vdc AT10 1 EJ5037 14 Communications Module Field Kit for AT10 130 006 EJ5037 15 Ethernet Gateway Interface for MODBUS AT Comm EJ5226 0 Industry Standard Modem w 10ft Cable EJ5084 00 Industry Standard Modem w 25ft Cable EJ5084 01 Industry Standard Modem w 50ft Cable EJ5084 02 89 APPENDIX F FORCED LOAD SHARING ONLINE SUPPLEMENT http www ATSeries net P
58. MON OPTIONS DRAWING Na 022003 DATE SE NOTED DIMENSIUNS JE503 1 99 TOLERANCES ARE SCALE NTS PART No JE5031 99 SHEET 1 OF http www ATSeries net PDFs JE5031 99 pdf 83 APPENDIX C Standard Drawings Connection Diagram AT10 1 Group Battery Charger Standard w o Options JE5033 00 L1 MAIN INOUCTOR TRANSFORMER 13 H H3 H2 H5 H4 NITE 4 rars NN Y ine V mA Z u A2 m E 0 a G11 5 162 x 30060 GO a Xu i 1a lt Ea beet Aem ug L r J Dg Ha wi E10 E7 E5 E6 NOTES L CHARGER COMPONENTS ARE CONNECTED WITH FLAME RETARDANT SWITCHBOARD CBI AC 4 INSULATION TYPE WIRING IDENTIFIED ON EACH END WITH NUMHER CODED MARKERS BREAKER 2 CUSTOMER ALARM CONTACTS TB3 TB4 etc ARE SOLOERLESS PLUG IN TERMINALS ANU WILL ACCEPT 22 14 AWG WIRE WHEN REMOTE SENSE IS LISED THE LUGGED END OF R14 CONNECTS TH REMOTE SENSEL O AND WIRE 21 CONNECTS TBS 2 TO REMOTE SENSE FEATURED OPTIONS 4 SEE SCHEMATIC FOR TRANSFORMER T PRIMARY CONNECTION TABLE AC INPUT CIRCUIT BREAKER 5 STANDARO 12 24 AND 48 VOC UNITS CONTAIN A SINGLE POLE OC BREAKER CB2 IN THE NEGATIVE BUSS FOR THESE UNITS WIRE 15 TERMINATES OC OUTPUT CIRCUIT BREAKER AT TBIC AND WIRE 17 IS NOT USED 84 APPENDIX C Standard Draw
59. OF ANY DF THESE FOUR 4 LOWER CONOUIT KNOCKOUTS WILL ALLOW REMOVAL OF THE CABINET SHROUO WITHOUT REMOVAL OF EXTERNAL WIRING 5 DATA NAMEPLATE WITH CHARGER RATINGS MOUNTED ON LEFT SIDE OF ENCLOSURE 6 BATTERY CHARGER SHIPPING WEIGHT RANGE APPROXIMATELY 110 193 Ibs 7 50 88 kg 4 00 NOTE R 102 EE 1 NOTE 5 B a I NU aM 18 00 Z 8 457 MANLIAL POCKET ac INPUT DC HUTPLT i T f 18 25 MTG gt m lesol 464 MTG gt 1 a NOTE 4 25 L 19 50 12 75 470 324 NOTES DUAL DIMENSIONS 10 THIRO Ql ANGLE PROJECTION DRAWN BY MCR 012304 ATIO 1 SERIES BATTERY CHARGER OUTLINE APPROVED NEMA 1 STYLE 594 ENCLOSURE DRAWING No REV o Ets42 oizso RR Se 5024 03 REV ECN DATE APR SCALE NTS PART No JE5024 03 SHEET FILENAME JES024 03 PRTJ http www ATSeries net PDFs JE5024 03 pdf 74 APPENDIX C Standard Drawings Optional Enclosure Dimensions AT10 1 Group Battery Charger w Penthouse and Drip Shield Style 594 Enclosure DIMENSION in mm Standard WW 19 50 495 DD 12 75 324 HH 18 00 457 W 1
60. S AND WILL ACCEPT 22 14 AWG WIRE 3 WHEN REMOTE SENSE IS LISEU THE LUGGED END OF R14 CONNECTS REMOTE SENSE 2 AND WIRE 21 CONNECTS 5 2 TO REMOTE SENSEC 4 FUSE F1 IS ONLY USEO ON UNITS SPECIFIED WITH 480VAC INPUT 5 A TWO POLE DL CIRCUIT BREAKER IS SUPPLIED ON 13DVOC UNITS AND ALL LNITS WITH MEQLUM HIGH AMPERE INTERRUPTING CAPACITY BREAKERS b CIRCUIT BREAKER INTERCONNECTION TERMINAL BLOCK TES IS USEO WHEN MEDILM OR HIGH AMPERE INTERRLPTING CAPACITY BREAKERS ARE SUPPLIED 7 FILTER CAPACITOR CJ CONSIST OF TWO 2 CAPACITORS CONNECTED IN PARALLEL FOR 130VDC UNITS RATED 12 25 0 TI TRANSFORMER H H5 moneda a PRIQ Whe n ipe Ko L Wii L2 FILTER FIL PN INOUCTOR POLARITY DIAC DIODE aur 1 CRI NOTE 7 ACL 2 u AC oti G amp A 162 x 13950 1 Kn Ee i 24 i 04 a E mont eumd I Hug FN J I a _ rm BLOCK ING U DIODE 2 E10 EB E7 Es gg PE x 2 DC FILTERING ASSEMBLY 7 S S X 3 RIS Bye emer PR he ee See ES F1 AC NOTES FUSE 03 03 03 01 L gt CHARGER COMPONENTS ARE CONNECTED FLAME RETARDANT SWITCHBOARD 3 tgp ac 4 H INSULATION YPE WIRING IDENTIFIED ON EACH ENO WITH NU NET NOTE 4 gg BREAKER oz 2 CUSTOMER ALARM CONTACTS TBJ TB4 etc ARE SOLOERLESS PLUG IN NOTE BD FEATURED OPT
61. age 45 for all error and status codes 32 OPERATING THE AT10 1 Setting the High DC Voltage Alarm e Press the EDIT ENTER key until the HIGH DC VOLTAGE indicator flashes and the display flashes the present value of the high dc voltage alarm Press and release the uP or key to increase or decrease the value in the display by one count or press and hold the or DowN key to scroll the value in the display upward or downward When the meter displays the desired high dc voltage alarm point release the UP or DOWN key If you go past the voltage you want press the uP or key again to reach the voltage you want to set e Press the EDIT ENTER key The new high dc voltage alarm setting is entered into permanent memory Setting the low DC Voltage Alarm e Press the EDIT ENTER key until the LOW DC VOLTAGE indicator flashes and the display flashes the present value of the low dc voltage alarm Press and release the uP or DowN key to increase or decrease the value in the display by one count or press and hold the or key to scroll the value in the display upward or downward When the meter displays the desired low dc voltage alarm point release the uP or DowN key If you go past the voltage you want press the UP or Down key again to reach the voltage you want to set
62. ailure 2 Open the front panel and make sure that the Main Control PC Board A1 is securely mounted on the standoffs on the back of the panel All indicators should extend about 0 125in 3 2mm through the front of the panel 3 When you press the LAMP TEST key if some but not all of the indicators light or the digital meter does not display all 8 s replace the Main Control PC Board A1 One or more 1 Front panel 1 Open the front panel and be sure that jumper J9 on the operation of both AT10 1s 2 EJ5126 option front panel is locked Main Control PC Board A1 is in the ENABLE position keys do not 2 Main Control 2 Open the front panel and be sure that the Main Control PC work PC Board A1 Board A1 is firmly seated on the standoffs on the back of the is not secured panel Front panel keys must operate freely to front panel 3 Defective 3 Turn off both front panel circuit breakers Turn on the dc Main Control breaker CB2 first followed by the ac breaker CB1 If some PC Board A1 of the front panel keys still do not work replace the Main Control PC Board A1 Two AT10 1s 1 If the forced 1 Multiple AT10 1s are not designed to share load current connected in load sharing without the optional forced load sharing cable installed When parallel but option is not two or more AT10 1s are connected in parallel without this only one has supplied check option it is norm
63. al for one of the units to have no output output current for normal current You can check the operation of the off AT10 1 by increasing its Float voltage until it starts to deliver output current When you have finished the test be sure both AT10 1s are set to the same Float and Equalize voltages 2 See Appendix F on page 90 for troubleshooting of Forced Load Sharing feature 54 SERVICING THE AT10 1 PROBABLE SYMPTOM CAUSE RECOMMENDED ACTION HIGH DC 1 High DC 1 Be sure that the High DC Voltage alarm setting is higher VOLTAGE Voltage alarm than the Equalize voltage setting See Sections 2 3 2 and indicator is on and Equalize 2 3 4 voltage settings are mismatched 2 Defective rectifier bridge 3 Defective Main Control PC Board A1 2 Disconnect wire 24 from terminal E3 of the rectifier assembly near the left front of the enclosure Restart the AT10 1 If You are able to measure output current one of the SCRs is defective Replace the rectifier assembly 3 Turn off both front panel circuit breakers Turn on the dc breaker CB2 first followed by the ac breaker CB1 If the AT10 1 output voltage is normal but the HIGH DC VOLTAGE indicator is still on replace the Main Control PC Board A1 No alarm but 1 Output 1 Output current must be greater than 2 of rated current to output current is below produce a High DC Voltage alarm See Parallel Operation in voltage is 29
64. an 24 hours A 02 equalize mode inhibited A 04 voltmeter calibration inhibited w TempCo active A 05 dc output at Current Limit setting Pb nicd battery type for active temperature compensation LS P LS S forced load sharing status primary secondary Codes E 05 E 09 E 11 and A 03 are not used See Section 3 2 on page 45 for a full explanation of each code 2 2 2 Selecting the meter mode e Press the METER MODE key to change the meter display mode The digital meter has four operating modes 1 Alternating between output voltage and output current When the AT10 1 is in a timed equalize mode the meter alternates between output voltage output current and equalize hours remaining 2 Displaying output voltage only The DC Volts indicator lights Displaying output current only The DC Amperes indicator lights 4 Displaying equalize hours remaining only The EQLZ HRS REMAINING indicator lights If the AT10 1 is not in a timed equalize mode the meter displays the full programmed equalize time e When the AT10 1 starts initially the meter alternates displaying output voltage and output current The DC Volts and DC Amperes indicators light alternately to indicate what is being displayed 26 OPERATING THE AT10 1 2 2 3 2 2 4 Selecting the Float or Equalize mode The AT10 1 has two output voltage settings Float and Equalize Use the Float mode for all normal battery charging and to operate y
65. ards A1 and corresponding Rev 6 or higher software programs e Both AT10 1s must use the same the same program version since the forced load sharing option has not been tested using different program versions in each unit To view the program version press the LAMP TEST button on the front instrument panel of the AT10 1 When you release the button the front panel meter displays the version number for two 2 seconds e The interconnecting signal cable length should be no more than 50ft 15m INSTALLING THE INTERCONNECTION CABLE The AT Series forced load sharing accessory is normally supplied by the factory with a standard 15ft 4 6m interconnection cable A 25ft 7 6m long cable and a 50ft 15 2m long cable are also available The interconnection cable is terminated at each end with a 6 pin connector that mates with the plastic connector J4 on lower right corner of the Main Control PC Board 1 One end of the cable features an extra jumper in the connector and should be identified for use with the Secondary charger The other end of the cable connects to the Primary charger Either AT10 1 may be selected as Primary or Secondary but you may wish to choose the unit that is more accessible to be the Primary The Primary charger controls the dc output voltage of both AT10 1s You may run the interconnection cable through conduit if necessary However do not run the cable through the same conduit with power wiring Do not remove the co
66. ate the main transformer T1 are correct for your ahehe vane de ac supply voltage Open the front panel and displaying voltage or current check the battery polarity at the TB1 and If you want to freeze the terminals meter to display only voltage press the METER MODE 5 Starting the AT10 1 key on the front panel To When you are sure that all connections to the deis the d to Paid AT10 1 are properly made follow these steps 21 CU press ne again Press the key twice to start up the AT10 1 more fo revert to the alternating display e Turn on the front panel dc circuit breaker The digital meter indicates the battery voltage only If the meter display does not light do not proceed Turn off the dc breaker and check all connections and the battery polarity again Also check the battery voltage It must be above 50 of nominal voltage to turn on the display If you cannot find the problem refer to the Troubleshooting Procedure in Section 3 1 on page 44 NOTICE If you attempt to turn on the dc circuit breaker CB2 with the battery connected in reverse polarity the breaker will immediately trip Do not try to close the dc breaker again since this may damage the AT10 1 Correct the battery polarity before proceeding 24 OPERATING THE AT10 1 If you have an optional temperature compensation probe installed the front panel displays Pb during startup indicating that temperature compensation is se
67. ay flashes the or equalize Current Limit value in Amperes If the Current Limit is less voltage than 11096 adjust it to 11096 as described See Setting the within 196 Current Limit value Section 2 3 5 for details 2 Defective 2 Check each cell of the battery If one or more cells are battery or dc shorted the AT10 1 may not be able to reach the Float load or load is voltage You may have the same problem if the normal load too great current is more than the rated output current of the AT10 1 3 Wrong ac 3 Make sure the T1 primary taps are wired correctly for your input voltage or voltage too low or T1 wired incorrectly 4 Defective rectifier bridge 5 Defective Main Control PC Board A1 input voltage See Changing Transformer Taps Section 1 6 for details The actual ac input voltage must be at least 88 of the rated value for the AT10 1 to produce full output power 4 Use a clamp on ammeter to measure the current in wire 12 or 11 If it less than 70 of the dc output current one of the SCRs or diodes is defective Replace the rectifier module 5 Turn off both front panel breakers Turn on the dc breaker CB2 first followed by the ac breaker CB1 If the AT10 1 output current is below the Current Limit value but it still has the wrong output voltage replace the Main Control PC Board A1 Input current too high 1 Wrong ac input voltage or transformer T1 wired incorrectly 2 Defective rectif
68. batteries may produce explosive gas Never smoke use an open flame or create arcs in the vicinity of the AT10 1 or the battery Turn the AT10 1 off before connecting or disconnecting the battery to avoid a shock hazard and or equipment damage De energize and lock out all ac and dc power sources to the AT10 1 before servicing Do not operate the AT10 1 with any power source that does not match the specified ac and dc voltage ratings Refer to the data nameplate decal affixed to the outside panel for operational requirements Do not operate the AT10 1 with the Plexiglas safety shield or any other supplied guards removed or improperly installed TABLE OF CONTENTS QUICK OPERATION oi u I q gu save an dx Ya se eR a saei a arenae a Back Cover HOW TO READ THE AT10 1 MODEL Inside Front Cover IMPORTANT SAFETY nennen nennen i 1 Receiving and Installing the AT10 1 Battery Charger Tet Storingithe AT 10 1 iie ob HO Heo pot Ple e o Heap po be et 2 1 2 Reporting shipping 2 1 3 Unpacking and inspecting the AT10 1 2 Inspection Checklist s s tt d Po d c tte ac CEDERE Pe ERES 2 1 4 Moving the eth toe Hb eee best aah a seh cee aes 3 Enclosure type and weight table
69. bolts as shown Place the AT10 1 onto the vertical posts add appropriate mounting hardware and tighten Refer to the graphics on the opposite page for the AT10 1 Style 586 amp Style 594 floor mounting patterns and enclosure footprints See Installation Instructions JA0083 00 for the special floor mounting procedure INSTALLING THE AT10 1 GRAPHICS FLOOR MOUNTING THE AT10 1 DIM B F D 4 FLOOR DRILLING PATTERN T 437in 11mm FLOOR MTG HOLE FOUR 4 PLACES 10 00in 254mm 10 00in 254mm 375in 9 5mm FLOOR MOUTING HARDWARE FOUR 4 PLACES DIMENSION in mm ENCLOSURE A B C D Style 586 16 50 419 46 63 1184 11 75 298 15 00 381 Style 594 19 75 502 47 75 1213 14 25 361 18 25 463 INSTALLING THE AT10 1 1 5 3 Rack Mounting the AT10 1 The AT10 1 can be installed into most relay racks with standard EIA hole spacing The Style 586 and Style 594 enclosures do not need to be modified for rack mounting but a special kit EIO193 00 is required For kit availability see the ordering information in Appendix B on page 71 The kit includes two 2 mounting brackets appropriate hardware and Installation Instructions JA0091 00 for the rack mounting procedure Refer to the table below for allowable combinations CHARGER RATING RA
70. breaker 2 AT10 1 Measure the dc voltage from the input terminal to the output terminal of the circuit breaker with the breaker on It is normally no more than 50 millivolts If it is near the rated output voltage replace the breaker AC INPUT 1 AC power 1 If the ac input power fails the front panel AC ON indicator FAILURE failure goes out and the AC INPUT FAILURE indicator goes on indicator is 2 Upstream 2 Be sure the front panel ac circuit breaker is closed Measure feed the ac voltage at TB1 L1 and L2 If it is zero check upstream breaker fuse is distribution breakers and fuses tripped 3 Defective 3 Measure ac voltage at T1 H1 and T1 H5 It should be the wiring same as the ac supply voltage 4 Defective 4 Turn off both front panel breakers Restart by turning on the Main Control dc breaker CB2 first followed by the ac breaker CB1 If the AC ON and AC INPUT FAILURE indicators are both still on replace the Main Control PC Board A1 56 SERVICING THE AT10 1 SYMPTOM PROBABLE CAUSE RECOMMENDED ACTION POS GND or NEG GND indicator is on 1 Ground fault on external dc bus 2 DC circuit breaker is open and POS GND indicator is on 3 Alarm needs calibration 4 Defective wiring 5 Defective Main Control PC Board A1 1 Shut down and disconnect the AT10 1 from the battery and dc bus Check the battery and dc bus for a ground fault See Application Note JD5032 00 f
71. ck feeder circuit breaker or current but failure fuse ac amp dc 2 Input Fuse 2 Remove the 480 Vac Input Fuse F1 from its fuse holder breakers F1 is blown located on the bottom of the enclosure and check with an E 480 Vac input Ohmmeter or fuse tester Replace if required only Aoil If the new fuse blows see the sections titled AC AC lamp breaker trips immediately and AC breaker trips after a few is ou minutes for further troubleshooting hints 3 Check the terminals and wiring between the transformer T1 and the rectifier assembly inductor L1 dc filter if present the dc breaker CB2 and the output terminals TB1 Check wire 29 from T1 Y1 and wire 28 from T1 Y2 to the Main Control PC Board connector A1 J1 Repair as necessary 4 Use an ac voltmeter to measure the ac voltage from T1 X1 to X4 It is normally 50 to 80 higher than the rated dc output voltage If it is too low check the wiring of the primary taps See Section 1 6 for details If it is zero replace T1 50 SERVICING THE AT10 1 PROBABLE SYMPTOM CAUSE RECOMMENDED ACTION No output 1 Battery is 1 This is normal operation in a system with little or no dc load current but fully charged As long as the AT10 1 maintains Float voltage it is operating ac amp dc normally breakers 2 Float or 2 Check the Float and Equalize voltages and adjust them if Cb1 CB2 Equalize necessary Consult your battery manufa
72. cturer for the proper are on voltage set too voltage settings AC ON lamp low is on 3 Wrong ac input voltage or T1 taps mis wired 4 Defective wiring 5 Defective rectifier bridge 6 Defective Main Ctrl PC Board A1 7 Defective transformer T1 8 Defective inductor L1 or L2 9 Defective CR2 10 Defective dc breaker 3 Be sure the T1 primary taps are wired correctly for your input voltage See Section 1 6 for details 4 Check terminals and wiring between T1 and the rectifier assembly inductor L1 dc filter if present the dc breaker and the output terminals Repair as necessary 5 Use an ac voltmeter to measure the voltage between terminals E3 and E4 of the Gate Driver PC Board A3 If you measure about 1 0 Vrms but there is no output current replace the entire Rectifier Assembly A6 6 If you do not measure any ac voltage in Step 5 above and the battery voltage is less than the Float voltage setting replace the Main Control PC Board A1 7 Use an ac voltmeter to measure the ac voltage from T1 X1 to X4 It is normally 5096 to 80 higher than the rated dc output voltage If it is too low check the wiring of the primary taps See Section 1 6 for details If it is zero replace T1 8 Disconnect the wiring from L1 and measure the resistance between the terminals If it is an open circuit replace L1 Repeat for L2 if the optional dc filter is installed 9 Disconnect wire 52 from L1 t
73. cure the transformer to the rear panel Support the transformer by the top of the core and lift it up to get the bottom bracket off the rear panel Remove the transformer from the enclosure Check the jumpers on the bottom row of terminals of the replacement transformer Make sure they are connected to the same terminals as the jumpers on the transformer you just removed from the AT10 1 For details see Section 1 6 Changing the Transformer Taps Hold the replacement transformer with the terminals labeled H1 through H5 at the bottom facing you Place the transformer against the rear panel and slide the bottom of the transformer bracket into the slots on the rear panel Install the four screws or nuts onto the mounting bracket of the transformer Rewire the transformer following the steps above in reverse Refer to Section 1 6 and verify that the transformer is properly connected for your input voltage Replacing the ac surge suppressors VR2 VR4 or VR5 Turn off and remove all power to the AT10 1 Remove the Plexiglas safety shield Disconnect the battery from the output terminals TB1 For VR2 remove the hardware from the input terminal L1 and remove the lead of the ac surge suppressor Install one lead of the replacement surge suppressor onto the L1 terminal Replace the other wires and the hardware Repeat procedure for the L2 terminal Tighten all hardware For VR4 remove the hardware from the input terminal L1 and remove the
74. d remove all power to the AT10 1 Remove the Plexiglas safety shield Disconnect the battery from the output terminals TB1 Find the flying lead from the inductor L2 wire 50 and disconnect the other end from the center terminal of inductor L1 at the upper right corner of the rear panel Disconnect wire 15 from the quick connect terminal at the top center of the diode heat sink and remove wire 54 from terminal E7 on the front circuit board on the rectifier assembly Carefully note which terminal the wire is connected to Remove the four 4 screws at the top of the dc filter bracket The bracket and the inductor will both fall forward away from the rear panel Lift the filter bracket up about 0 25in 6 4mm to release it from the clips at the bottom of the bracket Swing the filter assembly outward to the left rotating it so that the heat sink comes out first and the capacitor s last Install the replacement filter assembly by inserting the capacitor end first and rotating the assembly inward so that the heat sink is last to go in Push the bottom edge of the bracket into the clips in the rear panel and install the four screws at the top of the bracket Connect wire 15 to the quick connect terminal at the top center of the diode heat sink Route the flying lead from the inductor L2 wire 50 and connect it to the center terminal 2 of the inductor L1 Reconnect wire 54 to terminal E7 of the front circuit board on the
75. de energized and locked out before proceeding Except those with the 480Vac feature AT10 1 Group I power isolation transformers have two 2 jumpers The transformers used in the smaller Style 586 enclosure use piggyback quick connect terminals Those used in the larger Style 594 enclosure use 10 32 stud terminals NOTICE This procedure refers only to Group I AT 10 1 battery chargers rated 6 25 Adc A different procedure exists for Group 1 AT10 1 battery chargers rated 30 100 Adc Refer to the Operating and Service Instructions specific to the Group Il AT10 1 battery charger for changing the transformer taps on these larger units Otherwise damage to your AT10 1 and equipment may occur PROCEDURE 1 See Section 3 5 for necessary steps to follow when accessing internal components within the AT10 1 2 Shut down the AT10 1 and verify that no internal voltages are present 3 8 9 10 11 12 INSTALLING THE AT10 1 Refer to the Images below and identify the primary taps T1 H on the AT10 1 Group I power isolation transformer T1 480 120 208 240 Vac PRIMARY i PRIMARY SECONDARY H4 o X1 H5 o H5 x DT o i i x H3 E NM STYLE 586 ENCLOSURE TYPICAL TRANSFORMER STYLE 594 ENCLOSURE TYPICAL TRANSFORMER JUMPERS 2 480Vac transformers only feature TI H1 amp T1 H5 and are not re ta
76. dicator will light When the equalize timer is finished the AT10 1 reverts automatically to the float mode and the FLOAT indicator lights At any time during equalize charge you can switch the AT10 1 back to float mode by pressing CHRG key The FLOAT indicator will light If there is an ac power failure during a timed equalize charge the AT10 1 remembers the remaining equalize time When ac power is restored it resumes the equalize charge where it left off 27 OPERATING THE AT10 1 Manual Equalize Method Choose the manual equalize method when you want to equalize charge the battery but only when you are able to monitor the battery voltage and gassing rate After you select the manual equalize method press the ICHRG MODE key to put the AT10 1 into the equalize mode The EQLZ indicator will light Press the cHRG MODE key again to return the AT10 1 to float mode The FLOAT indicator will light NOTICE Never leave the AT10 1 unattended in the equalize mode with the manual equalize method selected A sustained overcharge may cause permanent damage to the battery Auto Equalize Timer Method Select the auto equalize timer method if you have a flooded non sealed battery that is subject to infrequent discharges or when the battery will be discharged to at least half of its rated capacity during an ac power failure When ac power is restored to the AT10 1 it will turn on in the equalize
77. e Cabinet for Style 586 594 Enclosure 10214 0 Cabinet Heater Assembly for Style 586 594 Enclosure EJ1223 00 Padlock for Style 586 594 Enclosure Front Panel Door 10215 00 Remote Temperature Compensation Probe Assembly 10 see below DNP3 Level 2 Modbus Communications Module see Appendix E Forced Load Sharing Accessory EJ5126 Remote Temperature Compensation Probe The temperature compensation accessory consists of two 2 components 1 To order a replacement probe or puck request part number EJ5032 00 This probe A10 is good for all AT10 1 output voltages and all battery types 2 The standard temperature compensation assembly is supplied with a 25ft 7 6m interconnection cable If you need a longer cable order it from the table below which also lists the ordering part number for a complete accessory Temperature Compensation Probe Kits Cable Length Kit Part Number Replacement Cable feet m includes probe Part Number 25 7 6 EJ5033 00 EJ5011 00 50 15 2 EJ5033 01 EJ5011 01 100 30 5 EJ5033 02 EJ5011 02 200 61 0 EJ5033 03 EJ5011 03 Use a single cable assembly Do not try to splice cables together to increase the length 71 APPENDIX C Standard Drawings Outline AT10 1 Group Battery Charger NEMA 1 Style 586 Enclosure JE5023 03 NOTE 3
78. e enclosure If penthouse is supplied add 7in 178mm to top of enclosure 3 Refer to the outline drawings for the Style 586 JE5023 03 and Style 594 JE5024 03 enclosures in Appendix C on pages 72 and 74 INSTALLING THE AT10 1 1 6 CHANGING TRANSFORMER TAPS The AT10 1 power isolation transformer T1 is wired at the factory for the ac input supply voltage specified and listed on the CAUTION tag attached to the ac input circuit breaker CB1 Units with a multi tap ac input feature e g 120 208 240 Vac will list all available ratings on the data nameplate decal AT10 1 transformers are designed with an input voltage tolerance of 10 to 12 Before you connect ac power to the AT10 1 inspect the wiring of the transformer inside the enclosure and confirm it is jumpered for the desired ac input supply voltage Ifa different ac input supply is desired identify the AT10 1 ac input feature and whether or not the transformer T1 is re tappable e 120 208 240 Vac 60Hz re tappable e 480 Vac 60Hz non tappable e 120 220 240 Vac 50 60Hz re tappable e 380 416 Vac 50 60Hz re tappable Before changing the T1 taps turn off and lock ac and dc supplies to the AT10 1 Merely turning off opening the unit s ac and dc circuit breakers CB1 CB2 does not eliminate live voltages inside the enclosure Also de energize any external wiring to the AT10 1 alarm relay contacts TB3 TB4 Verify that all voltages within the AT10 1 are
79. e next parameter When you are finished adjusting the sixth parameter Current Limit press the EDIT ENTER key again The AT10 1 saves all adjustments you made internally and reverts to normal operation The new settings take effect immediately If you do not press any front panel key for 25 seconds Edit Mode ends automatically and any change you made to the last setting is not saved 30 OPERATING THE AT10 1 2 3 2 Setting the Float and Equalize voltages e Press the EDIT ENTER key The FLOAT and DC VOLTS indicators light and the display flashes the present value of the float voltage Press and release the uP or key to increase or decrease the value in the display by one count or press and hold the up or key to scroll the value in the display upward or downward When the meter displays the desired float voltage release the or key If you go past the voltage you want press the UP or key again to reach the voltage you want to set e Press the EDIT ENTER key The new float voltage setting is saved internally The EQLZ and DC VOLTS indicators light and the display flashes the present value of the equalize voltage Press and release the uP or key to increase or decrease the value in the display by one count or press and hold the UP or key to scroll the value in the display upward or downward When the meter displays the desired equalize voltage release the UP
80. e shutdown does not e Press the CHRG MODE key operate im an ATIO with The HIGH DC VOLTAGE indicator lights 2500 the display flashes ON You can toggle the of two or more in parallel shutdown feature OFF and by pressing the shuts down The other cina NODE key repeatedly ms If you do not press any key within four 4 seconds the last state indicated ON or OFF is saved internally Note that you do not use the EDIT ENTER key for this feature If the AT10 1 shuts down because of a high dc voltage the meter displays error code E 03 Reset the AT10 1 by turning the ac input circuit breaker CB1 off then on again 36 OPERATING THE AT10 1 2 3 7 Adjusting the Voltmeter Accuracy The AT10 1 voltmeter is adjusted at the factory to display the actual output voltage within 0 25 If you replace any component that affects meter accuracy such as the Main Control PC Board A1 or resistor R4 you should readjust the meter This adjustment procedure is different from all others because the meter reading remains constant while the output voltage of the AT10 1 changes Do this adjustment with a fully charged battery and no load connected First enter Edit Mode to adjust the float voltage to the desired value See Section 2 3 2 for instructions on setting the float voltage Second press and hold the up key then press the EQLZ MTHD key The DC
81. e terminals to the battery terminals The AT10 1 control circuitry then measures the dc voltage at the battery terminals and controls the output of the charger to maintain the battery voltage at the desired float or equalize voltage NOTICE If the remote sense wiring fails the AT 10 1 detects the fault and displays E 06 on the front panel meter See Section 3 2 for details The AT10 1 cannot protect against short circuits in the remote sense wiring You should install a 1 0A fuse at the battery or dc bus end of the remote sense cable PROCEDURE 1 De energize and lock out all ac and dc voltages within the AT10 1 enclosure Check with a voltmeter 2 Remove safety shield 3 Remove the two 2 dc output CU AL compression lugs 16 INSTALLING THE AT10 1 4 Move lugged end of R14 with wire 20 from TB1 to REM SENSE Move wire 21 from TB1 to REM SENSE Connect user supplied external remote sense leads from the battery or dc bus to the remote sense terminals on the I O panel CUSTOMER SUPPLIED REMOTE SENSE LEADS DC DC OUTPUT Se SENEE OUTPUT z 7 Replace the two 2 dc output CU AL compression lugs and tighten all hardware 8 Check your work thoroughly Replace the safety shield before re energizing the AT10 1 9 Restart the AT10 1 according to the instructions in Section 2 1 NOTES 1 Use 16 AWG twisted pair wire 2 Maximum current is 150 mA 3 Run l
82. eads in their own conduit 4 Fuse the wiring at the battery or dc bus DISABLING REMOTE SENSE If you ever need to disable remote sense follow the steps below 1 De energize and lock out all ac and dc voltages to the AT10 1 2 Check with a voltmeter 3 4 Remove the remote sense leads from the remote sense and terminals Disconnect the remote sense wires from the battery or dc bus first on the I O panel TB1 second Insulate each lead separately coil up the wires and leave them in the bottom of the AT10 1 in case you want to wire for remote sense in the future Reconnect the lugged end of R14 with wire 20 to TB1 Reconnect wire 21 to TB1 Restart the AT10 1 according to the instructions in Section 2 1 17 INSTALLING THE AT10 1 1 10 WIRING TO THE REMOTE ALARM CONTACTS Built in Summary Common Alarm Relay standard The AT10 1 Main Ann H Control PC Board Al WIRE NE E is equipped with a eee In common Summary KERA Alarm relay This relay NUN a ama contact transfers when ER a any one or more of the t MAIN CONTROL standard AT10 1 t PC BOARD E alarms exist t gt See Sections 2 2 7 and I 2 3 4 for
83. ed Disabling the Ground Detection Alarm You can disable the ground detection alarm circuit and isolate the circuit from chassis ground If your battery is normally grounded or you want to defeat the alarm for any other reason follow these steps e Shut down the AT10 1 and lock out all ac and dc voltage sources This includes alarm and remote sense wires if they were installed Open the front panel door and check with a voltmeter before proceeding e Locate jumper J5 at the top left of the Main Control PC Board A1 as shown on the previous page Move the jumper to the DISABLE position The POS GND and NEG GND indicators and the summary alarm relay TB3 will not respond to a ground fault Restart the AT10 1 following the instructions in Section 2 1 Setting the Current Limit value The AT10 1 automatically limits its dc output current in case of overload or battery discharge You can adjust the value of the Current Limit from 50 to 110 of rated current The factory setting is 110 The Current Limit adjustment is the last step in the normal Edit Mode sequence If the AT10 1 is not in the Edit Mode press the key five times until the meter display flashes the value of the Current Limit setting in Amperes Press and release the uP or key to increase or decrease the value in the display by one count or press and hold the uP or key to scroll the value in the display upward or downward When the meters display the desired Current Limit
84. erature condition If the rectifier is equipped with a fan B2 check the fan for proper operation Also make sure that all enclosure vents are clear of debris and that the ambient temperature is below 50 C 122 F E 14 forced load See Appendix F on page 90 sharing not Verify both AT10 1s are functioning properly Ensure that the forced load working sharing interconnection cable assembly is not broken is properly installed properly and that the connector for the Secondary charger has the jumper as described Ensure that both AT10 1s are connected to the same ac supply and that source phase rotation is the same for both AT10 1s A 01 manual eqlz If the AT10 1 was accidentally left in manual equalize mode switch the enabled for unit back to float manual equalize timer or auto equalize timer mode more than 24 hr according to Section 2 2 4 on Page 27 02 equalize mode If you set the equalize timer to zero 0 hours the equalize mode is inhibited inhibited When you try to put the AT10 1 into equalize mode from the front panel controls the meter displays status code A 02 If you want to enable the equalize mode set the equalize timer to one 1 or more hours A 04 voltmeter While using temperature compensation the AT10 1 internal dc voltmeter calibration cannot be calibrated Disconnect one wire of the TempCo cable from TB8 inhibited on A1 Restart the AT10 1 and perform the voltmeter calibration according w TempCo to Section 2 3 7
85. eries forced load sharing feature is compatible with the AT Series external temperature compensation accessory Both AT10 1s must have a temperature probe installed and the probes should be located as close as possible to each other When AT10 1s are load sharing the primary charger will determine the temperature compensated voltage and adjust the output accordingly The voltage displayed by the master and secondary may be different if either temperature probe is defective or not installed A slight difference in the displayed voltages may also occur if the two probes are not located in close proximity of each other See user Application Note JD5003 00 for further details regarding temperature compensation TROUBLE SHOOTING If the AT Series Forced Load Sharing option is installed but the output currents of the AT10 1s are unequal refer to the following table PROBABLE RECOMMENDED ACTION CAUSE 1 Connection cable 1 Ensure that the interconnection signal cable assembly is properly missing or installed installed and that the connector for the Secondary charger has the incorrectly jumper as described at the top of page 3 2 Incorrect connections 2 Ensure that both AT10 1s are connected to the same ac supply and to ac power sources that source phase rotation is the same for both chargers 3 Defective or improper 3 Replace the Main Control PC Board A1 in one charger at a time Main Control PCB A1 noting system requirement
86. eries net PDFs JD0064 00 pdf 43 SERVICING THE AT10 1 3 SERVICING THE AT10 1 3 1 A STEP BY STEP TROUBLESHOOTING PROCEDURE The AT10 1 is fully tested and calibrated from the factory and should work for years with a minimum of attention If you do encounter trouble there are three 3 steps you should take to identify the problem and return the AT10 1 to service 1 Check the front panel meter for an error code The microprocessor control circuitry is able to diagnose common problems with the AT10 1 or with the installation or application If the front panel displays an error code see Section 3 2 Interpreting Front Panel Error Messages for help in interpreting the code and solving the problem If the AT10 1 does not work properly but there is no front panel error code turn off both front panel circuit breakers CB1 CB2 or disconnect ac and de power externally Turn back on de power first followed by ac power This will return the AT10 1 to normal operation as long as there is no internal component failure NOTICE Perform Step 2 only once If the AT10 1 does not resume normal operation go on to Step 3 If the AT10 1 still does not work properly make a list of the symptoms that you observe Turn to Using the troubleshooting chart in Section 3 3 The troubleshooting chart relates common trouble symptoms to their causes and gives the proper procedures for correcting the problem If the symptom does not appear o
87. ese steps to supply proper ac power to the AT10 1 1 Confirm that the AT10 1 main power transformer T1 is properly jumpered for your ac input supply voltage See Section 1 6 for details 2 Use a branch circuit breaker or fused disconnect switch upstream from the AT10 1 This device should have lockout capability so that the ac input supply to the AT10 1 can be de energized for unit maintenance A time delay circuit breaker or slow blow fuse is recommended 3 Size the branch circuit breaker or fused disconnect switch for the maximum ac input current of the AT10 1 This rating is listed on the left hand side of the AT10 1 data nameplate For a comprehensive list of these maximum ac input values access standard DC5016 00 4 Size ac input wiring per the National Electric Code NEC and local codes for the trip rating of the branch circuit breaker or fused disconnect switch 5 Do not run external ac input power wiring through the same conduit of the AT10 1 enclosure as external dc output power wiring 6 Allsite requirements of your facility take precedence over these instructions PROCEDURE 1 Remove the Plexiglas safety shield 2 Run the ac input supply wiring into the AT10 1 ending at terminals TB1 L1 TB1 L2 and TB1 GND on the I O panel board 3 The AT10 1 features three 3 CU AL compression lugs on the ac input terminals which accept 14 6 AWG wire Strip 0 50in 13mm from the insulation of the incoming ac input supply wiri
88. esistance from TB1 and E17 See the table in Section 3 6 for the proper resistance values If the resistance is not within 10 of the table value replace R3 2 Main Control PC Board A1 or another component may have been replaced 3 R4 or R14 is defective or wrong value 4 Defective Main Control PC Board A1 2 Defective 2 Remove the enclosure shroud and check the wiring to and wiring from TB1 and the Main Control PC Board A1 for signs of insulation damage or burns Repair any damaged wiring AT10 1 1 Defective 1 Disconnect wire 24 from terminal E3 of the rectifier output SCR assembly near the left front of the enclosure Restart the voltage too AT10 1 If You are able to measure output current one of the high or not SCRs is defective Replace the rectifier assembly controllable 2 R4 or R14 is 2 Remove one end of R4 from on the back of the front defective or panel Repeat for R14 connected to TB1 Measure their wrong value values with an Ohmmeter See the table in Section 3 6 for resistance values If either resistor is not within 1 of the specified value it must be replaced 3 Defective 3 Remove the leads from the probe and measure its temperature resistance At 77 F 25 C the resistance should be about compensation 10 000 If it is not replace the probe assembly probe optional 4 Defective 4 f the front panel meter displays more than 110 of rated dc Main Control cu
89. g natural convection Ambient temperature operating 32 122 F 0 50 C Elevation 3000ft 1000m without de rating Relative humidity 0 to 95 non condensing Alarm relay contact rating 120 Vac 125 0 5 A resistive 70 APPENDIX B FIELD INSTALLABLE ACCESSORIES AND OPTIONS All options and accessories listed below are available in kits for field installation Kits contain all parts and hardware with detailed installation instructions To order accessories options please provide the following information for each kit e Model number enclosure style and serial number of your AT10 1 e Factory part number and description from the table below e Quantity required Contact your sales representative to place an order for options amp accessories Description Kit Part Number standard DC Output Filtering per NEMA PE5 1996 see table 3 2 Battery Eliminator Filtering per NEMA PE5 1996 see table 3 1 Auxiliary Alarm Relay PC Board A5 for standard circuit breakers 10213 00 Auxiliary Alarm Relay Board 5 for med high AIC circuit breakers 10213 01 Copper Ground Bus with 1 box lug for 14 6 AWG 10195 00 AC Input Lightning Arrestor option EJ1074 00 Floor Mounting Kit for Style 586 594 Enclosure 10192 00 Relay Rack Mounting Kit for Style 586 594 Enclosure 10193 00 NEMA 2 Type Drip Shield for Style 586 594 Enclosure 10191 00 NEMA 4 12 13 Typ
90. gs FACTORY SETTINGS FOR ALL PARAMETERS Nominal Vdc penne 12 24 48 130 Float Voltage 13 26 52 131 Equalize Voltage 14 28 56 139 HVDC Alarm 14 4 28 8 57 6 144 LVDC Alarm 12 24 48 120 Equalize Time 24 Hours Equalize Method Current Limit Manual Timer 110 of nominal output current HVDC Shutdown Disabled 25 OPERATING THE AT10 1 2 2 USING THE AT10 1 FRONT PANEL FEATURES 2 2 1 If the meter displays an error or status message The AT10 1 microprocessor control circuitry performs diagnostic checks of the battery charger during system start up then continuously during operation If it detects a failure or special status an intermittent code will appear on the front instrument panel displayed between dc output values The following table is a list of these error E and status A codes Code Explanation E 01 rating resistor R2 open or defective E 02 short circuit on dc output E 03 high dc voltage shutdown occurrence E 04 internal memory failure E 06 voltage sense failure internal external remote E 07 dc breaker open or dc output wiring defective E 08 remote temperature compensation probe defective E 10 open internal feedback loop E 12 internal over temp circuit defective E 13 rectifier over temperature occurrence E 14 forced load sharing not working properly A 01 manual equalize enabled for more th
91. harger controls all voltage settings for both AT10 1s You may adjust any voltage float equalize alarm settings etc at the front panel of the Primary charger The front panel of the Secondary charger will not allow any settings to be changed e AT10 1 loses ac power or is turned off the remaining charger returns to independent operation whether it was originally the Primary or Secondary For this reason it is important to set up both AT10 1s initially for the same operating voltages If an alarm condition occurs both AT10 1s revert to independent operation for the duration of the alarm e Inthe event ofa fault in the interconnection any other problem with communication the AT10 1s return to independent operation and the front panel on each charger displays the message E 14 indicating the fault e There is a delay of up to four 4 seconds for the two 2 AT10 1s to establish forced load sharing communication If communication is broken or power is lost for one charger there is up to a four 4 second delay for the other charger to resume independent operation e If you need to interchange the Primary and Secondary chargers simply reverse the interconnection cable e presence of the interconnection cable and a proper interconnection forces the two 2 AT10 1s into load sharing Controlling load sharing from the front panel is neither necessary nor possible WHEN TEMPERATURE COMPENSATION IS INSTALLED The AT S
92. he AT10 1 Wall mounting is the standard means of installing the AT10 1 Group I enclosures When wall mounting the AT10 1 consider the following 1 Refer to the outline drawings for the Style 586 JE5023 03 and Style 594 JE5024 03 enclosures in Appendix C on pages 72 and 74 The wall must be strong enough to properly support the weight of the AT10 1 plus a safety factor See the Weight Table featured in Section 1 4 on page 3 The weight of your AT10 1 may be different depending on the feature options and accessories ordered with the unit Be conscious of planned ac input and dc output wiring to the AT10 1 selecting conduit entrances carefully Use of the pref fab knockouts on the sides or bottom of the enclosure will allow removal of the cabinet shroud and internal access for servicing without removal of the unit from the wall The location e Should be free of drips and splatter If falling particles and liquids are a problem install a NEMA 2 type drip shield accessory 0191 00 For kit availability see ordering information in Appendix B on page 71 e Should be between 32 and 122 F 0 and 50 C with relative humidity between 5 and 95 non condensing e Must be free of flammable or explosive materials Maintain at least 6in 152mm of free air on all vented surfaces for cooling Allow at least 36in 914mm front clearance for access to the AT10 1 for operation and maintenance
93. he outside of the shipping container with the Return Material Authorization RMA number issued by the manufacturer 1 3 UNPACKING AND INSPECTING THE AT10 1 Carefully remove all shipping materials from the AT10 1 Remove the AT10 1 from the shipping pallet for inspection Save all shipping materials until you are sure that there is no shipping damage Once the AT10 1 is unpacked inspect the unit for possible shipping damage using the checklist below If shipping damage has occurred refer to Section 1 2 on this page for proper reporting INSPECTION CHECKLIST Enclosure exterior and interior are not marred or dented There is no visible damage to exterior or interior components All internal components are secure Printed circuit boards are firmly seated on their standoffs All hardware is tight All wire terminations are secure The User s Manual is included You received all items on the packing list L1 L1 L1 L1 L1 L1 L1 LI INSTALLING THE AT10 1 1 4 MOVING THE AT10 1 Once you have established that the AT10 1 is undamaged identify the enclosure style and weight of your unit Refer to the table below AT10 1 Enclosure Style and Shipping Weight Table Group I NEMA 1 Cabinets Style 586 Style 594 Ampere Rating Output Voltage 6 Adc 12 Adc 16 Adc 20 Adc 25 Adc Style 586 Style 586 Style 586 Style 586 Style 586 12 Vdc 44 lbs 44 lbs 67 lbs 67 lbs 67 lbs 20 kg 20 kg 30 kg 30 kg 30
94. ier bridge 1 Be sure the T1 primary taps are wired correctly for your input voltage See Changing Transformer Taps Section 1 6 for details The actual ac input voltage must be at least 88 of the rated value for the AT10 1 to produce full output power 2 Disconnect wire 24 from terminal E3 of the rectifier assembly near the left front of the enclosure Restart the AT10 1 If You are able to measure output current one of the SCRs is defective Replace the rectifier assembly 3 Defective 3 Test by disconnecting wires from X1 X4 Y1 and Y2 If ac Transformer T1 input current is still too high replace T1 Output ripple 1 AT10 1 is 1 Verify by checking nameplate against the ordering code on voltage too UN filtered the inside front cover Order and install filter option if high necessary 2 Battery is 2 Be sure battery is connected Inspect battery according to disconnected or the manufacturer s instructions defective 3 Battery too 3 Check the measured ripple against the specification for your small for AT10 1 model on page 70 The ripple rating is for a battery charger rating 4 One or more defective filter capacitors C1 or C2 whose Ampere hours are four 4 times the charger Ampere rating For a smaller battery ripple voltage may be higher 4 Test with capacitance meter Replace as necessary 53 SERVICING THE AT10 1 PROBABLE does not work or some lamps do not l
95. ight 2 Main Control PC Board A1 is not secured to front panel 3 Defective Main Control PC Board A1 SYMPTOM CAUSE RECOMMENDED ACTION AT10 1 very 1 Loose 1 Remove the enclosure shroud Check and tighten all noisy hardware or component mounting hardware Replace the shroud being enclosure panel sure all assembly hardware is secure 2 Defective 2 Use a clamp on ammeter to measure the ac current in wire rectifier bridge 11 or 12 connected between T1 and the rectifier assembly If it less than 70 of the dc output current one of the SCRs or diodes is defective Replace the rectifier module Meter 1 Defective or 1 Turn off the AT10 1 With a light dc load connected to the readings are disconnected battery be sure each cell reads the nominal cell voltage 2 0V erratic battery for lead acid 1 25V for Ni Cd Restart the AT10 1 Each cell should now read the nominal Float voltage 2 2V for lead acid 1 35V for Ni Cd 2 Defective 2 Remove one end of R4 from TB5 on the back of the front scaling resistor panel Repeat for R14 connected to TB1 Measure their R4 or R14 values with an Ohmmeter See the table in Section 3 6 for resistance values If either resistor is not within 1 of the specified value it must be replaced 3 Defective 3 If the output voltage is constant replace the Main Control Main Control PC Board A1 PC Board A1 Lamp test key 1 No Vac 1 The lamp test key does not work during an ac power f
96. iliary Alarm Relay PC Board will not signal a low level detect alarm If you have a dc power supply you can adjust the battery voltage that triggers the alarm On the back of the Main Control PC Board A1 find the potentiometer RA1 as shown in the figure below L N A TsERIES aj TTT sento T Jl J HINDLEPOWER INC Disconnect all ac and dc power sources from the AT10 1 and connect your dc power supply to the charger dc output terminals TB1 positive to positive and negative to negative Adjust the power supply to the voltage at which you want to activate the alarm NOTICE You need at least 50 of the nominal output voltage to power the AT10 1 Main Control PC Board 1 Adjust RA1 with a small jeweler s screwdriver clockwise until the alarm just activates A red LED indicator DS10 next to RA1 indicates when the alarm is active 38 OPERATING THE AT10 1 2 3 9 Using the front panel security feature The AT10 1 is shipped from the factory with all front instrument panel keys enabled You can disable the following front panel functions e Selecting Equalize method e Changing settings using the EDIT ENTER key e Toggling the high dc voltage shutdown feature To disable the front instrument panel keys open the
97. ings Connection Diagram AT10 1 Group Battery Charger Standard w o Options JE5033 00 MAIN CONTROL PC BOARD Al mum E NC NO NOTE 2 SUMMARY ALARM 15 DOOR N y C EI7 O eur O o 2 SENSE SENSE 45 gt 32 15 NOTE 5 15 14 2 2 15 BREAKER 01 AKER 2 02 CHASSIS GROUND lt ER THIRD ANGLE PROJECTION DRAWN BY MCR 040703 TATE AT10 1 SERIES BATTERY CHARGER CONN DIAG 6 25ADC GROUP 1 STD W O OPTIONS 091004 Z 040703 N DRAWING No B 040703 y ESS OTERNISE NOTED peine JE5033 00 REV ECN No DATE NTS JE5033 00 SHET fe AKER REV 1 IN IND TOLERANCES ARE http www ATSeries net PDFs JE5033 00 pdf 85 APPENDIX C Standard Drawings Connection Diagram AT10 1 Group Battery Charger w Common Options JE5033 99 X1 4 2 L1 MAIN INDUCTOR TERMINAL
98. ion JD5010 00 62 SERVICING THE AT10 1 Replacing the positive scaling resistor R4 Locate the scaling resistor R4 mounted to TB5 on the back of the front panel just above the Main Control PC Board A1 The resistor R4 is the one on the left is mounted on two quick connect terminals Remove the resistor by grasping the terminals by the plastic insulation and pulling out and downward Install the replacement resistor by pushing the terminals firmly onto the quick connect blades on the terminal block TBS Replacing the voltage crowbar resistor R6 Locate the resistor R6 mounted to TB5 on the back of the front panel just above the Main Control PC Board A1 The resistor R6 is the one on the right is mounted on two quick connect terminals Remove the resistor by grasping the terminals by the plastic insulation and pulling out and downward Install the replacement resistor by pushing the terminals firmly onto the quick connect blades on the terminal block TB5 Replacing the negative scaling resistor R14 Turn off and remove all power to the AT10 1 Remove the Plexiglas safety shield Disconnect the battery from the output terminals 1 The scaling resistor R14 is connected to TB with a ring lug The other lead of the resistor is soldered to wire 20 Remove the insulating sleeving from the soldered joint to wire 20 you may have to remove a harness tie and cut the resistor lead near the solder joint Disc
99. iption JA0102 01 http www ATS eres net P DFs J A0102 01 pdf AT10 1 G1 Manual unlabeled JA0102 02 http www ATS eries net P DFs J A0102 02 pdf AT10 1 G2 Manual unlabeled JA0102 03 http www ATS eries net P DF s A0102 03 pdf AT30 Manual unlabeled JA0102 04 http www ATS eries net P DF s A0102 04 pdf AT Comm Module Manual unlabeled JA0102 05 http www ATS eries net P DF s A0102 05 pdf AT DC Dist Panel Manual unlabeled JA5015 00 http www ATS eries net P DFs J A5015 00 pdf AT TempCo Probe Acsy Instructions JA5054 00 http www ATS eries net P DF s A5054 00 pdf AT Forced Load Sharing Instructions JA5098 00 http www ATS eries net P DF s A5098 00 pdf AT Latching Alarm Relays Instructions JC5020 00 http w ww ATS eries net P DF s C5020 00 pdf AT Series Charger Quick Setup Sheet EJ5088 XX http www ATS eries net P DF s EJ 5088 XX pdf AT Series Ground Detection Voltmeter EJ5130 XX http www ATS eries net P DF s EJ 5130 XX pdf AT Series Barrier Type Alarm Terminals EJ5136 XX http www ATS eries net P DF s E 5136 XX pdf AT Series Battery Discharge Alarm EJ5137 XX http www ATS eries net P DFs E 5137 XX pdf AT Series End Of Discharge Alarm JA0083 00 http www ATS eries net P DF s A0083 00 pdf AT10 1 Floor Mtg Instructions
100. ired you must restart the AT10 1 to activate the probe as described in Section 2 1 Using temperature compensation When an electric storage battery is being charged the terminal voltage of the battery changes a small amount whenever the battery temperature changes As the battery temperature increases its terminal voltage decreases When a constant output voltage float type rectifier charges a battery float current increases when the temperature increases This results in overcharging the battery which can result in damage to the materials or at least the need for more frequent maintenance When the AT10 1 is equipped with a temperature compensation probe it is able to adjust the output voltage applied to the battery to keep the float current constant thereby avoiding overcharging The probe senses the ambient temperature at the battery and adjusts the output float equalize voltages to compensate for variations in temperature If the ambient temperature increases the AT10 1 output voltage decreases If you are experiencing any inconsistencies in the AT10 1 when the temperature compensation probe is utilized temporarily disconnect the probe and refer to Application Note JD5003 00 for further details 22 INSTALLING THE AT10 1 106 104 102 100 Percent Output Voltage 98 96 94 Note the following You should set the Float and Equalize voltages to the values recommended by your battery manufacturer for 77
101. key and hold for four O OK alarm relay 4 seconds Summary alarm relay at TB3 will transfer 42 OPERATING THE AT10 1 Exercise front Switch from float to equalize then back O OK panel controls to float Turn off the dc circuit breaker E 07 may O OK appear on display requires at least 5 of rated output current Reset breaker Cycle through meter modes OK O amperes OK O nouns OK Cycle through equalize methods L MANUAL TIMER OK O MANUAL EQLz OK C AUTO EQLZ TIMER OK Turn off ac circuit breaker The AC Alarm OK INPUT FAILURE indicator should light Reset breaker Check voltage Use key to scroll through FLOAT OK and alarm settings See page 30 L EQUALIZE OK settings Hvpc alarm OK Lvpc alarm OK Current Limit Adc Final checks Make sure Plexiglas safety shield is in O oK place Restore AT10 1 to normal operation O OK Close latch on front panel O oK _Step Instructions Results optional features Test auxiliary Press LAMP TEST key and hold for four OK alarm relays 4 seconds Alarm relays will transfer Check Remote sense wiring See page 16 O oK integrity of Temperature compensation wiring See L OK remote wiring page 20 OK Temperature compensation probe See page 20 Final checks Close padlock or key lock OK ONLINE SUPPLEMENTS Preventive Maintenance Procedure Downloadable Worksheet http www ATS
102. l you are ready to install them Ground yourself before handling the board by touching the ground stud on the back of the door Always handle printed circuit boards by their edges Turn off and remove all power to the AT10 1 Disconnect the battery from the output terminals Remove any optional user wiring from the various Main Control PCB A1 terminals e g TB3 TB8 J6 J3 etc Remove the harness plug J1 from the upper left edge of the Main Control PC Board A1 and unplug wire 30 from the quick connect terminal in the upper left corner of the board The board is mounted on six 6 plastic standoffs Compress the tab on each standoff and pull the board toward you until it clears all standoffs Insert the replacement A1 board onto the instrument panel with the same orientation and push it onto the standoffs Make sure the board is fully seated on all six 6 standoffs Reconnect the harness plug J1 to the A1 board at the upper left edge Replace wire 30 on the quick connect terminal Replace any user wiring to the various A1 terminals See Section 2 1 for steps to restart the AT10 1 If your parameters float voltage etc are different from the factory preset values you should program in the new values now See Section 2 3 You should also recalibrate the dc voltmeter according to Section 2 3 7 Replacing the Rectifier Heat Sink Assembly A6 For details of this procedure refer to Service Instruction JD5009 00 Turn off a
103. le 586 or Style 594 enclosure with ALL available options Standard components A1 through VR7 are supplied in all such units Optional components A5 through VR3 are supplied only in those AT10 1s configured with such options 76 APPENDIX C Standard Drawings Internal Component Layout AT10 1 Group Battery Charger Style 596 594 Enclosure w Common Options JE5027 99 ENCLOSURE USED TO JIT BREAKERS NOTE 6 STYLE 586 584 4 PC BOARD C AS INPUT OUTPUT TERMINAL BOARD TBI DETAIL NOTE 2 SIGNAL HARNESS um vic vic zio ve x gt 9 144 TURN COPPER GROUNO DOOR BUS BAR FASTENER CONSULT LER S MAMIAL FOR iD ISTO MG TRANSFORMERS INPUT VO USE COPPER OR ALINE rpS ONLY A T Rat 1 0 TERMINAL DESCRIPTION TYPE CONNECTION TBlC POS NEG OUTPUT TERMINALS LLI ALLIMINUM COMPRESSION LUG 14 6 AWG REM SENSEC gt POS NEG REMOTE SENSE TERMINALS 10 32 SCREW HARDWARE 10 RING LUG 2 TB GND GROUND TERMINAL CLI ALUMINUM COMPRESSION LUG 114 6 AWG TBI L1 L2 AC INPUT TERMINALS CL ALLIMINLM COMPRESSION LUG 414 6 AWG TH3 SUMMARY ALARM TERMINAL BLOCK SOLDERLESS COMPRESSION 22 14 AVG 4 AUXILIARY ALARM TERM BLOCK SOLDERLESS COMPRESSION 22 14 AWG TB8 TEMPCO PROBE A10 INTERCONNECTION TERMINAL BLOCK 22 14 AWG NOTES 1 FOR DETAIL VIEWS OF ALL PC BOARDS
104. ly installed Make sure the connectors and the wiring from the probe to the AT10 1 are in satisfactory condition If there is a failure of the temperature compensation probe or the wiring the AT10 1 displays the error code E 08 Measuring the output ripple voltage filtered models only If your AT10 1 is a filtered model measure the ac ripple at the battery terminals at least once a year Use an rms responding ac voltmeter If the battery Ampere hour capacity is at least four 4 times the output current rating of the AT10 1 the ripple voltage should be no higher than the value featured in the specifications in Appendix A on page 70 If you suspect that the output ripple voltage is too high see Output ripple voltage too high of the Troubleshooting Chart in Section 3 4 page 53 Viewing the voltage and alarm settings You can review the parameter settings in the AT10 1 by pressing the key on the front instrument panel Each time you press the key a different parameter displays in the following order e Float voltage e Equalize voltage e Equalize time in hours e High dc voltage alarm setting e Low dc voltage alarm setting e Current Limit in Amperes 1 Do not use a dc voltmeter The ripple voltage on a battery is a very small ac voltage 41 OPERATING THE AT10 1 SAMPLE PREVENTIVE MAINTENANCE PROCEDURE AT10 1 BATTERY CHARGER JD0064 00 Suggested Frequency every six 6 months Maintenance date Performed by
105. n the troubleshooting chart or if the recommended repair does not work consult your sales or service representative to arrange for on site or factory service 44 SERVICING THE AT10 1 3 2 INTERPRETING FRONT PANEL ERROR MESSAGES If the AT10 1 control circuitry detects hardware or wiring problems it may display an error code on the front panel meter Certain non error status codes are also displayed To solve an error code problem refer to the table below which lists the codes and procedures to use High voltages appear at several points inside the AT10 1 Use extreme caution when working inside the enclosure Do not attempt to work inside the AT10 1 unless you are a qualified technician or electrician Disconnect and lock out all power from the AT10 1 before starting to remove or replace any components Turn the ac power off at the distribution panel upstream from the charger Disconnect the battery from the AT10 1 output terminals TB1 on dc output Error Meanin Repair Procedure Code g p E 01 resistor R2 The Rating Resistor R2 is installed at the back of the front panel in the open or Main Control PC Board A1 input connector J1 R2 is measured by the defective control circuitry on startup and is used to determine some of the AT10 1 model specific parameters such as the float voltage If the AT10 1 detects that R2 is defective or improper it must be replaced See Section 3 6 for part
106. nd lock shut down out from the dc bus all shut down AT10 1s Summary 1 Defective 1 Turn off both front panel circuit breakers Restart by turning alarm relay is Main Control on the dc breaker CB2 first followed by the ac breaker in alarm PC Board A1 CB1 If the relay remains in alarm mode check the Low mode but no Level Detect indicator on Main Control PC Board A1 See front panel Section 2 3 8 If no other alarm is on replace the Main Control alarm PC Board A1 indicator is on 57 SERVICING THE AT10 1 3 5 REPLACING DEFECTIVE COMPONENTS High voltages appear at several points inside the AT10 1 Use extreme caution when working inside the enclosure Do not attempt to work inside the AT10 1 unless you are a qualified technician or electrician Disconnect and lock out all power from the AT10 1 before starting to remove or replace any components Turn the ac power off at the distribution panel upstream from the charger Disconnect the battery from the AT10 1 output terminals TB1 NOTICE While performing the following procedures refer to the standard drawings in Appendix C for information on identifying internal components Removing the safety shield Some of the repair procedures described below requires removal of the Plexiglas safety shield mounted in front of the I O panel Unscrew the wing nuts and remove the washers to detach the shield Do not lay the shield on the top of the AT10 1
107. nd remove all power to the AT10 1 Remove the Plexiglas safety shield Disconnect the battery from the output terminals Check with a voltmeter before proceeding Remove the enclosure shroud as described in the previous section Make sure the rectifier heat sink has cooled and remove the entire assembly by the front edge Remove all wires attached to the rectifier pc board s as you pull the assembly out Hold the replacement Rectifier Assembly A6 in front of the AT10 1 in the same orientation as the old Reconnect all wires removed from the old rectifier as you insert it into the enclosure To ensure correct replacement refer to the standard drawings in Appendix C of this manual or the service instruction supplied with the replacement assembly Make sure all wires are connected to the proper terminals and lugs are fully seated If any lug does not fit snugly disconnect it and carefully tighten the ears of the lug using long nosed pliers Then reconnect SERVICING THE AT10 1 Rotate the rectifier assembly into position in the enclosure Line up the metal tab with the mounting hole on the back panel of the AT10 1 and slide the assembly into position Replace the shroud as described in the previous section Tighten all screws and restart the AT10 1 Replacing the optional dc filter assembly A7 The dc filter assembly consists of a diode heat sink inductor L2 and one or two capacitors C1x installed on a single bracket Turn off an
108. ng 4 Connect the wires to the appropriate ac lugs as shown on the next page 5 Using a flat head screwdriver securely tighten the compression screws on the ac lugs to 35 45 in Ib 4 0 5 1 Nm 6 Check all connections and reinstall the Plexiglas safety shield INSTALLING THE AT10 1 MAKING THE AC INPUT CONNECTIONS GRAPHICS REPLACE SAFETY COVER AFTER CONNECTIONS ARE MADE FIA Q Q h SAFETY COVER Z Y COMPRESSION SCREW TYP CUSTOMER on 13mm AC INPUT WIRING GROUND LINE 1 LINE 2 NOTES 1 The drawing above does not show other components mounted to the I O panel Be careful not to disconect any other component leads 2 Conduit must be properly grounded and in compliance with the national wiring rules of the country where installed See Appendix G for details 3 Use copper or aluminum conductors only 4 On 120 Vac input connect the neutral leg to the terminal L2 13 INSTALLING THE AT10 1 1 8 MAKING THE DC OUTPUT CONNECTIONS It is the responsibility of the installer of the AT10 1 to provide suitable dc output battery and dc load wiring Follow these steps to connect the battery to the AT10 1 1 Size the dc wiring to minimize voltage drop The acceptable wire size depends on your installation As a guideline the voltage drop should not exceed 1 of nominal output voltage at full current Refer to the table below to determine the voltage dro
109. nnectors in order to fish the cable through the conduit Maximum pulling tension is 46 Ib 20 9kg The cable has a plenum rated outer jacket and passes the NFPA 262 flame propagation test Install the cable between the AT10 1s and anchor it in place at both ends before connecting Connect each end to the Main Control PC Boards A1 inserting the connector into J4 until it is completely seated NOTICE Power cabling for the battery charger battery and dc load interconnection is not supplied with the AT10 1 or the AT Series Forced Load sharing option All user supplied system wiring should meet National Electric Code NEC standards as well as local site codes Confirm polarity of all dc cabling before making connections 90 APPENDIX F OPERATING THE AT10 1 WITH FORCED LOAD SHARING Restore external power connections to both AT10 1s and restart according to the normal procedure in the AT10 1 Operating and Service Instructions After the AT10 1s restart the Primary charger attempts to establish communication with the Secondary If communication is successful the AT10 1s behave as follows e The Primary charger displays the message LS P Load Share Primary on the front panel meter alternating with the normal display of output voltage and current e The Secondary charger displays the message LS S Load Share Secondary on the front panel meter alternating with the normal display of output voltage and current e The Primary c
110. not long enough longer cable assemblies are available in lengths of 50 100 amp 2001 15 2 30 5 amp 61 0m See Appendix B on page 71 for ordering information e Make sure wiring conforms to NEC local and site requirements Attach the interconnection cable to the AT10 1 as shown in the figure below QUICK CONNECT W PIGGY BACK P e Route the RAS cable within MAIN CONTROL J30 the AT10 1 PC BOARD A1 enclosure so it p runs with the 0510 wire harness gt to the back of oO the front lt panel and easily reaches m the Mam Control STRIPPED LEADS Board A1 TO TB8 e At the Main Control PC Board 1 insert one of the bare wires from the cable into each terminal of TB8 Polarity is not vital e Unplug the harness ground wire 30 from terminal J on the left edge of the Main Control PC Board A1 Plug the connector at the end of the nylon shielded wire of the cable assembly onto J6 Reconnect the ground wire 30 from the system harness onto the piggy back connector featured at the end of the nylon shielded wire e Using plastic wire ties fasten the interconnection cable loosely to the existing wire harness Make sure that the cable conforms to the service loop at the hinge end of the door Atthe battery connect the quick connect terminals to the temperature compensation probe Polarity is not vital Coil up any excess wire and tape or tie it
111. ntact your Sales Representative for drawing availability from the battery charger manufacturer Any job specific custom drawings supplied with your AT10 1 and or this manual supercede the standard drawings featured in Appendix C The standard drawings and corresponding page numbers featured in this section may not be included with custom printed manuals when job specific custom drawings are supplied ONLINE AVAILABILITY An unlabeled version of this operating and service instruction manual is available online at http www ATSeries net PDFs JA0102 01 pdf Other related product operating manuals feature and accessory special instructions standard drawings including the ones listed in this manual field service instructions and product application notes for the AT Series microprocessor controlled battery chargers and battery charger products are available online at http www ATSeries net Saved in Adobe Acrobat Portable Document Format PDF they are readily available for downloading and printing If revision levels differ between the drawings embedded in this manual and the full online PDF drawings refer to document with the higher revision level For document availability of private labeled manuals and or standard drawings please contact your sales representative or visit the web site listed on the back cover of this manual 94 MANUAL SPECIFICATIONS RELATED DOCUMENTS Doc No Online Hyperli nk Descr
112. nternally The timer setting works for both the manual timer and the auto equalize timer If you want to adjust the alarm settings skip to Section 2 3 4 OR If you want to exit the Edit Mode now press EDIT ENTER key three more times until the AT10 1 returns to normal operation Setting the Alarms After you save the equalize timer setting the Edit Mode automatically prompts you to adjust the settings of the high dc voltage and low dc voltage alarms There is a red indicator light on the front instrument panel of the AT10 1 for each of the following alarm conditions e High DC Voltage e Low DC Voltage e DC Output Failure e AC Input Failure e Ground Fault Detection e Ground Fault Detection When an alarm occurs the indicators will light immediately The AT10 1 also features a summary alarm relay with one form C contacts TB3 rated 0 5A 125 Vac Vdc If an alarm condition lasts for 30 seconds or longer the summary alarm relay contacts transfer This can be monitored remotely from TB3 When the alarm condition is corrected the relay and all indicators reset automatically If latching alarms relays are enabled the relay will need to be reset manually see Section 2 2 7 on page 29 The summary alarm contacts TB3 also transfer when the AT10 1 detects certain secondary errors indicated by meter display codes E 03 E 04 E 06 E 07 E 08 E 09 E 10 E 12 E 13 and A 01 rather than a red alarm light See Section 3 2 on P
113. o 2 form C contacts TB4 1 through TB4 36 for each of the following individual alarms High DC Voltage Low DC Voltage DC Output Failure AC Input Failure Ground Fault Detection positive or negative Summary common Alarm Alarm contacts TB4A B marked in non alarm condition are as follows P a N 12VOLT DCOUT DCOUT GROUND GROUND HVDC HVDC LVDC LVDC FAILURE FAILURE DETECT DETECT SUMMARYSUMMARY 28 29 30 31 32 33 34 35 36 C NC NO pens o uM 123 456 789 10 11 12 13 14 15 16 17 18 19 20 21 22 2324 25 26 27 VOLTAGE SELECTOR SWITCH DETAIL oo 24VOLTS oo 48 VOLTS mm 130 VOLTS AUXILARY ALARM RELAY PC BOARD A5 PROCEDURE 1 2 Allow internal voltages to dissipate then check with a voltmeter 3 4 Route your remote annunciator wiring into the penthouse enclosure through De energize and lock out all ac and dc voltages to the AT10 1 Remove the top panel from the penthouse enclosure on top of chassis one of the unused knockouts on the side of the enclosure As shown in the figure above connect the wiring use 22 14 AWG to the appropriate terminals of TB4 on the Auxiliary Alarm Relay PC Board A5 Strip each wire 0 25in 6 4mm and securely tighten the terminal screws 7 Replace the top panel on the pen
114. o CR2 then check CR2 with an Ohmmeter check both polarities If CR2 is open replace the filter assembly This is a very rare occurrence 10 Disconnect the battery and connect a light dc load to the AT10 1 Measure the dc voltage from the input terminal to the output terminal of the circuit breaker with the breaker on It is normally no more than 50 millivolts If it is near the rated output voltage replace the breaker Front panel is dead but ac amp dc voltages are present at TB1 1 Main Control PC Brd A1 is not connected 2 Defective Main Ctrl PC Board A1 3 Defective wiring 1 Make sure the connector at the top edge of the Main Control PC Board A1 J1 is firmly seated 2 If the AC ON indicator is lit but the rest of the front panel is dead replace the Main Control PC Board A1 3 Check the harness wiring to the Main Control PC Board connector A1 J1 for signs of insulation damage burns etc Be sure all wires are securely crimped in the connector 51 SERVICING THE AT10 1 SYMPTOM PROBABLE CAUSE RECOMMENDED ACTION Front panel dies during ac power failure but dc voltage is present at TB1 1 Defective Power Supply Ballast Resistor R3 1 Use a dc voltmeter to measure the dc voltage from E17 on the I O panel to TB1 It is normally 12 Vdc when the rated output voltage is at TB1 and TB1 Remove all power from the AT10 1 and measure the r
115. ompensation probe DNP3 Level 2 Modbus communications module forced load sharing signal interconnection cable Po IMPORTANT SAFETY INSTRUCTIONS PLEASE READ AND FOLLOW ALL SAFETY INSTRUCTIONS NOTICE Before using the AT10 1 read all instructions and cautionary markings on A this equipment B battery and C any other equipment to be used in conjunction with the AT10 1 This manual contains important safety and operating instructions and should therefore be filed for easy access Remove all jewelry watches rings etc before proceeding with installation or service Maintain at least 6in 152mm of free air on all vented surfaces for cooling Allow sufficient clearance to open the front panel for servicing Connect or disconnect the battery only when the AT10 1 is off to prevent arcing or burning Do not operate the AT10 1 if it has been damaged in any way Refer to qualified service personnel Do not disassemble the AT10 1 Only qualified service personnel should attempt repairs Incorrect reassembly may result in explosion electrical shock or fire Do not install the AT10 1 outdoors or in wet or damp locations unless specifically ordered for that environment Do not use the AT10 1 for any purpose not described in this manual Do not touch any uninsulated parts of the AT10 1 especially the input and output connections as there is the possibility of electrical shock During normal operation
116. on there may be an internal component failure See AT10 1 output voltage too high or not controllable of the troubleshooting chart on page 52 in Section 3 4 45 SERVICING THE AT10 1 Error Meanin Repair Procedure Code g p E 04 internal memory Any parameters that you set such as Float or Equalize voltage are saved failure internally The internal memory is tested on startup If the memory test fails E 04 appears on the front display The error may also appear if the controller was trying to write to the memory while a power failure occured If an E 04 code appears try shutting down the AT10 1 Restart by turning on the dc breaker CB2 first followed by the ac breaker CB1 If the AT10 1 restarts normally you must reenter any changes you made to the factory settings float voltage etc If E 04 appears repeatedly the internal memory has been damaged You must replace the Main Control PC Board A1 See Section 3 6 for parts ordering information E 05 not used This error code was formerly used to indicate a reverse battery connection Itis not available in the AT10 1 E 06 defective RA or Identify the Positive Scaling Resistor R4 mounted to TBS on the back R14 resistor or side of the front instrument panel Remove the resistor and measure its remote sense value with an Ohmmeter see table 3 1 for the correct value If the wiring failure resistor is not within 196 of the specified
117. onnect the lugged end of R14 from TB1 and discard the old resistor Using a soldering iron no larger than 35 Watts solder the bare lead of the new R14 to wire 20 Insulate the joint with plastic electrical tape Crimp a similar ring lug to the other lead ofthe new resistor Connect the lugged end of the new scaling resistor R14 to TBI 63 SERVICING THE AT10 1 3 6 ORDERING REPLACEMENT PARTS All AT10 1 Series battery chargers ship with a supplemental Parts Data Package report itemizing all components within the unit Contact your sales representative to place an order for spare or replacement parts Please provide the following information for each component Model number and serial number of your AT10 1 Series battery charger e Reference Designator factory part number and description e Quantity required NOTICE Some of the factory part numbers listed on the Parts Data Package report may differ from the standard replacement part numbers listed in this manual Custom parts may have replaced standard parts to satisfy your specification In that case you should order the part number s listed on the report The following table may specify part replacement kits that include other materials such as installation instructions and packaging materials You may order spare parts using either the report part number or listed kit The factory may make necessary adjustments to your order to ensure proper delivery of a complete ki
118. or assistance 2 If the AT10 1 has been placed into standby by opening the dc breaker CB2 the ground detection circuit supplies an erroneous alarm This is considered an abnormal condition for the AT10 1 and is not recommended Close the dc breaker CB2 and the alarm should end To place the AT10 1 in standby open both front panel circuit breakers CB1 CB2 3 Calibrate the AT10 1 ground detection sensitivity See Section 2 3 4 4 Disconnect the AT10 1 from the battery and dc bus Turn the AT10 1 back on and measure the voltage from TB1 to chassis and from TB1 to chassis The voltage readings should be equal each approximately half of the total output voltage If there is more than a 10 imbalance turn off the AT10 1 and inspect all wiring from TB1 to the dc circuit breaker CB2 and the rectifier bridge to the dc filter inductor L1 Look for evidence of insulation damage insufficient spacing between terminals and chassis or wires run too close to metal edges 5 Turn off both front panel circuit breakers Restart by turning on the dc breaker CB2 first followed by the ac breaker CB1 If you are sure there is no ground fault on the external bus or within the AT10 1 but the POS GND or NEG GND indicator is still on replace the Main Control PC Board A1 6 Paralleled 6 Restart all other AT10 1s connected in parallel with unit that AT10 1 s are is experiencing ground fault Otherwise disconnect a
119. our dc system Use the Equalize mode if it is necessary to balance the level of charge among the cells of the battery Consult your battery data sheets for information on equalize charging your battery e Press the CHRG key to change to the equalize mode If the equalize method is set to manual timer or auto equalize timer the AT10 1 will revert to float mode at the end of the selected equalize time e You can press the CHRG MODE key at any time to change back to the float mode Choosing the Equalize method Press the EQLZ MTHD key to choose the desired equalize method The indicator next to the desired equalize method will light Three equalize methods are available in the AT10 1 e Manual Timer e Manual Equalize e Auto Equalize Timer These equalize methods are described below Manual Timer Method Choose the manual timer method if you perform regularly scheduled equalize charging or if you base your equalize charging on regular readings of the specific gravity of each cell of your battery for lead acid batteries When your battery requires equalize charging adjust the manual timer to 1 2 hours for each 100 AH of battery capacity see Section 2 3 3 to learn how to adjust the equalize time The battery manufacturer can help you determine the best equalizing schedule for your battery After you select the manual timer method press the cHRG MODE key to put the AT10 1 into the equalize mode The EQLZ in
120. ppable Inspect the transformer inside the AT10 1 and identify the five 5 primary taps H3 H2 H5 amp T1 H4 arranged left to right Locate the two 2 jumpers on the primary side taps As needed change the jumpers on the transformer taps as listed in the table below making sure to always use both jumpers 120 Vac 208 Vac 240 Vac 480 Vac H1 to H2 to H5 H2 to H4 2 jumpers H2 to H3 2 jumpers none Check your work and make sure all connections are tight Restart the AT10 1 using the startup procedure in Section 2 1 For more information see the schematics amp wiring diagrams in Appendix C Confirm that the ac feeder breaker upstream from the AT10 1 is sized properly for the new ac input voltage For maximum ac input current values refer to standard DC5016 00 11 INSTALLING THE AT10 1 1 7 MAKING THE AC INPUT CONNECTIONS The AT10 1 is a commercial product and not intended for use at any time in a residential environment or to be powered by low voltage public mains It is the responsibility of the installer of the AT10 1 to provide suitable ac supply wiring Wiring must be approved for use in the country in which the AT10 1 is installed or bear the lt HAR f mark When selecting wire sizes consult the data nameplate decal affixed to the side panel of the AT10 1 for voltage and current requirements For CE compliance see Appendix G on page 92 for proper grounding Follow th
121. ps for various wire sizes currents and distances WIRE SIZING CHART VOLTAGE DROP PER 100ft 30 5m OF WIRE FOR COPPER AT 68 F 20 C WIRE SIZE DC CURRENT Amperes AWG 6 12 16 20 25 16 2 5V 5 0V 6 7V 8 2V 10 5V 14 1 6V 3 2V 4 2V 5 3V 6 6V 12 1 0V 2 0V 2 6V 3 3V 4 2V 10 0 63V 1 3V 1 7V 2 1V 2 6V 8 0 40V 0 80V 1 1V 1 3V 1 7V 6 0 25V 0 50V 0 66V 0 83V 1 1V 4 0 16V 0 32V 0 42V 0 52V 0 65V EXAMPLE 100ft 30 5 of 8 AWG wire at 16A has a 1 1V drop 2 The AT10 1 is factory wired to regulate output voltage at the output terminals If the total voltage drop is greater than 1 e g 1 3V for a 130 Vdc system remote sense wiring is recommended see Section 1 9 Do not run external ac and dc power wiring feeding the AT10 1 through the same conduit All specific requirements of your facility take precedence over these instructions PROCEDURE 1 Use a dc disconnect switch or circuit breaker between the AT10 1 and dc bus This device should have lockout capability to allow the AT10 1 to be disconnected from the dc bus for maintenance Remove the Plexiglas safety shield Run the de wiring to terminals TB1 and TB1 on the I O panel board in the enclosure Compression lugs accepting wire sizes 14 6 AWG are supplied for your convenience Strip the insulation 0 50in 12 7mm on the incoming wires Connect the wires to the appropriate dc lugs as shown on the next page
122. ps mis wired 3 Open SCR 3 Use a clamp on ammeter to measure the current in wire 11 or 12 If it less than 70 of the dc output current one of the SCRs or diodes is defective Replace the rectifier module 4 SCR not 4 Disconnect wire 24 from terminal E3 of the rectifier controllable assembly near the left front of the enclosure Restart the AT10 1 If You are able to measure output current one of the SCRs is defective Replace the rectifier module DC breaker 1 Battery 1 Check and correct battery wiring if necessary CB2 trips connected with immediately reverse polarity 2 Defective 2 Test by disconnecting wire 12 from the rectifier assembly rectifier bridge Measure resistance between the two top rectifier terminals if UN filtered labeled AC on the wiring diagram It should be at least AT10 1 100 000 Q check both polarities Replace rectifier assembly if resistance is low in either direction 49 SERVICING THE AT10 1 PROBABLE SYMPTOM CAUSE RECOMMENDED ACTION DC breaker 3 Defective 3 Remove wire 13 from the rectifier Gate Driver PC Board CB2 trips free wheeling Test the 16 SCR module s internal free wheeling diode immediately diode in SCR by measuring the resistance from E2 to E10 on with an continued module A16 Ohmmeter The reading should be at least 100 000 in one polarity and less than 1 000 O in the other polarity If it is defective replace the enti
123. raphics contained within this manual are controlled by the battery charger manufacturer s internal part number JA5023 00 The revision level and dates of this manual s text and graphics are listed below These controls supercede all other available dates The first two and last two pages of this manual are reserved for company specific front and back cover artwork Any revision levels revision dates or document numbers featured on the first two and last two pages of this manual refer to the cover artwork only DOCUMENT INFORMATION Document Number JA5023 00 Revision Level 10H Engineering Change Number 22499 Electronic Filename JA5023 00 Rev10H doc Last Date Saved 9 25 2012 12 05 PM Last Date Printed 9 25 2012 12 10 PM PARTS DATA PACKAGE Any job specific customized Parts Data Package report supplied with this battery charger and or this manual supercedes the information featured in the standard parts list starting on page 64 The data featured in that particular document is applicable only to the battery charger featuring the same serial number listed on the Parts Data Package report DRAWINGS A customized record drawing package is available for your AT10 1 featuring a unit specific drawing list data nameplate detail outline drawing itemized internal component layout electrical schematic with component ratings and a full connection diagram If the standard drawings featured in this manual are not sufficient please co
124. re Rectifier Assembly A6 3 Defective wiring 4 Defective transformer 1 4 Defective 4 Remove wire 15 from terminal E14 on the CR1 heat sink polarity diode Measure the resistance from the heat sink to E8 on the Gate if filter Driver PC Board A3 at the left front of the AT10 1 check both assembly is polarities If the resistance is less than 1 000 Q in both installed directions replace the filter assembly 5 Defective 5 Check spacing of terminals Check wiring for signs of wiring insulation damage burns etc Repair as necessary DC breaker 1 Loose 1 Check and tighten connections as required CB2 trips connection to after a few breaker minutes 2 OpenSCR 2 Use a clamp on ammeter to measure the current in wire 12 or 11 If it less than 7096 of the dc output current then one of the SCRs or diodes is defective Replace the rectifier module 3 SCR not 3 Disconnect wire 24 from terminal E3 of the rectifier controllable assembly near the left front of the enclosure Restart the AT10 1 If You are able to measure output current one of the SCRs is defective Replace the rectifier assembly 4 Defective 4 f the front panel meter displays more than 110 of rated dc Main Control current the control board may be defective Disconnect wire PC Board A1 24 as above If the output current goes to zero replace the Main Control PC Board A1 No output 1 AC supply 1 If AC ON indicator is out che
125. rectifier assembly Replace the shroud and the safety shield Replacing the ac input or dc output circuit breaker CB1 CB2 Turn off and remove all power to the AT10 1 Remove the Plexiglas safety shield Disconnect the battery from the output terminals TB1 Check with a voltmeter before proceeding This includes remote sense wires if they were installed Remove the two circuit breaker mounting screws on the front panel Carefully rotate the circuit breaker upward and pull it out of the enclosure Remove the wires from the terminals one at a time and transfer the wires to the terminals of the replacement breaker Be sure the terminal screws are tight Install the replacement breaker into the front panel rotating it downward into place Install the two mounting Screws 60 SERVICING THE AT10 1 Replacing the main transformer T1 Turn off and remove all power to the AT10 1 Remove the Plexiglas safety shield Disconnect the battery from the output terminals TB1 Check with a voltmeter before proceeding This includes remote sense wires if they were installed Remove the enclosure shroud and the safety shield Disconnect the harness wires 28 and 29 from the upper row of transformer terminals Disconnect wires 11 and 12 from the top of the rectifier heat sink Disconnect harness wires 3 and 4 from the lower row of terminals Leave both jumpers in place on the lower row Remove the four screws or nuts that se
126. rrent the Main Control PC Board A1 may be defective PC Board A1 Disconnect wire 24 from terminal E3 of the rectifier assembly near the left front of the enclosure Restart the AT10 1 If the output current goes to zero replace the Main Control PC Board A1 Output 1 Temperature 1 If the optional temperature compensation probe is installed voltage does compensation the output voltage may be different from the selected float or not agree probe is equalize voltage The difference in the voltages depends on with front installed the probe temperature The front panel meter always displays panel meter the proper voltage for 77 F 25 C 2 Recalibrate meter as described in Section 2 3 7 3 Remove one end of R4 from TB5 on the back of the front panel Repeat for R14 connected to TB1 Measure their values with an Ohmmeter See the table in Section 3 6 for resistance values If either resistor is not within 1 of the specified value it must be replaced 4 Turn off both front panel circuit breakers Restart by turning on the dc breaker CB2 first followed by the ac breaker CB1 If the AT10 1 still has the wrong output voltage replace the Main Control PC Board A1 52 SERVICING THE AT10 1 SYMPTOM RECOMMENDED ACTION AT10 1 never 1 Current Limit 1 If the AT10 1 is not in the Edit Mode press the reaches float set too low EDIT ENTER key five times until the meter displ
127. s to restore correct load sharing operation 91 APPENDIX G CE CONPLIANCE PROPER GROUNDING It is the responsibility of the installer of the AT10 1 to supply suitable grounding and ground wire The AT10 1 chassis must be grounded in accordance with the national electrical rules of the country where installed The ground wire must be approved for use in the country in which the AT10 1 is installed or bear 4 HAR P mark A separate bi color ground wire green with a 30 yellow stripe must be run in hard pipe conduit along with ac supply wiring There must be no switches splices or over current protection in the ground wire Refer to the Data Nameplate Decal affixed to the outside panel of the AT10 1 to determine maximum available operating current UL DATA To operate this battery charger from inputs other than 120 Vac you must use branch circuit protection To reduce the risk of fire use only on circuits provided with the following branch circuit protection in accordance with the National Electrical Code ANSI NFPA 70 Current Voltage Rating Rating 130 Vdc 48 130 Vdc 12 Adc 25A 20A 16 Adc 25A 20A 20 Adc 30A 30A 25 Adc 40A 35A 208 Vac Branch Circuit 240 Vac Branch Circuit Protection Amperes Protection Amperes This table does not apply to units with 480 Vac input 92 USER NOTES 93 MANUAL SPECIFICATIONS DOCUMENT NUMBER The text and g
128. s full rated output voltage or its full rated output current You cannot adjust this alarm setting e AC INPUT FAILURE lights whenever the ac power supply to the AT10 1 is interrupted e POS GND lights whenever leakage current from the battery positive terminal to ground exceeds a specified threshold e NEG GND lights whenever leakage current from the battery negative terminal to ground exceeds a specified threshold The ground fault detection sensitivity can be adjusted from 5 to 30 kO see Section 2 3 4 on Page 34 When an alarm occurs the indicators will light immediately The AT10 1 also features a summary alarm relay with one form C contacts TB3 rated 0 5A 125 Vac Vdc If an alarm condition lasts for 30 seconds or longer the summary alarm relay transfers Under standard settings when the alarm condition is corrected the corresponding relay and indicator resets automatically Latching alarm capability for the AT10 1 is available featured in a supplemental Operating Instructions 5098 00 29 OPERATING THE AT10 1 2 3 2 3 1 SETTING PARAMETERS IN THE AT10 1 Understanding Parameter Settings You can change the settings of the AT10 1 while it is operating using the front panel controls The changes you make take effect immediately and are saved internally If the AT10 1 is taken out of service and then later returned to service it restarts using the last values you set Yo
129. s ordering information When you have completed the repair restart the AT 10 1 according to Section 2 1 02 short circuit The AT10 1 may display this error code if the battery is discharged to less than 6 volts When the battery re charges to greater than 6 volts the error code will disappear If you have a seriously discharged battery allow the AT 10 1 to run for 24 hours and check the battery voltage again If it has not increased to the normal voltage rating consult the battery manufacturer for help If the battery voltage is normal check the wiring at the AT 10 1 dc output terminals TB1 for a short circuit If the battery voltage is normal and all external wiring is satisfactory check the AT10 1 dc breaker CB2 If itis tripped try once to reset it If it trips again immediately there may be an internal short circuit in the AT10 1 Check the internal wiring If the AT 10 1 is filtered check the dc filter capacitors C1 C2 and the polarity diode CR 1 The AT10 1 normally recovers automatically from an E 02 condition If you have shut down the AT 10 1 for service restart per Section 2 1 E 03 High DC Voltage Shutdown activated To restart the AT 10 1 turn the ac breaker CB 1 off then on Check the Equalize voltage and High DC Voltage alarm settings The HDCV alarm setting must be higher than the Equalize voltage setting If you get another High DC Voltage shutdown after a few minutes of operati
130. t Refer to the table below for the most common items Table 3 1 REPLACEMENT PARTS Reference Description Factory Part Number Rec Designator 12Vdc 24Vdc 48Vdc 130Vdc Spare A1 Main Control PC Board EN5002 00 EJ1243 10 Y A3 Rectifier Gate Driver PC Board EN501 1 00 EJ5093 00 A5 Auxiliary Relay PC Board EN0027 00 EJ1243 03 Y A6 Rectifier Heat Sink assembly A3 A16 EJ1243 00 Y A7 DC Output Filter assembly See Table 3 2 A10 Temperature Compensation Probe assembly See Appendix B Table 2 16 Rectifier SCR Module EJ5094 00 C1 DC Output Filter Capacitor RP0019 09 RP0019 08 Y C2 Battery Eliminator Filter Capacitor RP0019 09 RP0019 08 Y C4 EMIFilter Capacitor See VR6 C4 C5 EMIFilter Capacitor See VR7 C5 CB1 AC Breaker standard 120 208 240 Vac See Table 3 3 CB1 AC Breaker medium AIC 120 208 240 Vac See Table 3 4 CB1 Breaker high AIC 120 208 240 Vac See Table 3 5 CB1 AC Circuit Breaker medium AIC 480 Vac REO0171 00 CB1 AC Circuit Breaker high AIC 480 Vac RE0043 00 CB2 DC Circuit Breaker standard See Table 3 6 CB2 DC Circuit Breaker medium AIC See Table 3 7 CB2 DC Circuit Breaker high AIC See Table 3 8 CR1 Polarity Diode EJ1243 04 Y CR2 Blocking Diode EJ1243 05 64 SERVICING THE AT10 1
131. t up for lead acid battery types While this is being displayed you can press any front panel key to change the display to read nicd to change the temperature compensation setup for nickel cadmium batteries The choice you make is saved internally and will be used again by the AT10 1 then next time it starts Turn on the front panel ac circuit breaker The digital meter displays the output voltage and current See Using the Digital Meter on page 24 You should hear a soft hum from the AT10 1 as the output current increases NOTICE If you have a filtered model of the AT10 1 and you turn on the ac breaker first before the dc breaker CB2 there is possibility that the dc breaker will trip when you try to turn it on This is caused by the filter capacitors C1 discharging into the battery To get around this problem turn off the ac breaker Restart the AT10 1 by turning on the dc breaker first The green FLOAT indicator lights Press the CHRG MODE key on the front instrument panel The FLOAT indicator goes off and the yellow EQLZ indicator lights Press the CHRG key again to return the AT10 1 to the float mode The table below lists the normal factory settings for float and equalize voltages equalize time Current Limit setting and alarm settings If your purchase order specified other float or equalize voltage settings a tag attached to the front panel of the AT10 1 lists the actual voltage settin
132. temperature variations during charging a temperature compensation option EJ5033 0 is recommended If this option is not part of your AT10 1 manual adjustments should be made Refer to the equation and table below for temperature adjusted voltages temperature adjusted voltage charge voltage x K Temperature Temperature K K CF C Lead Acid Nickel Cadmium 88 APPENDIX E COMMUNICATIONS MODULE ONLINE SUPPLEMENTS Operating Instructions http www ATSeries net PDFs JA0102 04 pdf Field Installation http www ATSeries net PDFs JD5008 00 pdf INTRODUCTION Your AT10 1 Microprocessor controlled Float Battery Charger features provisions for an optional Communications Module which allows user s to remotely monitor and control the charger over a serial connection This option supports DNP3 Level 2 and Modbus protocols over RS 232 or RS 485 half duplex With this option installed industry standard SCADA Supervisory Control And Data Acquisition systems will be able to control monitor and log the events of the AT10 1 Using the Communications Module option all features of the AT10 1 front instrument panel are accessible remotely Installed within an AT10 1 the AT Series Communications Module option p n EJ5037 0 includes a Communications PC Board A12 and a dc power supply resistor R29 A special AT Series Communications Module Operating Instructions JA0102 04 and field Field Installation Instructions
133. thouse enclosure and restart the AT10 1 NOTES 1 Alarm contacts are rated at 0 5A 125 Vac or Vdc Be d p Terminal block TB4 is compression type accepting 22 14 AWG wire Terminals are labeled in non alarm condition For a detailed view of the optional Auxiliary Alarm Relay PC Board A5 refer to drawing JE5030 19 listed in Appenix C on Page 78 19 INSTALLING THE AT10 1 1 11 INSTALLING THE TEMPCO PROBE ASSEMBLY OPTIONAL The temperature compensation or TempCo probe contains a temperature dependent resistor in an epoxy module that you install near your battery There are three steps in installing the assembly 1 Mounting the probe assembly near the battery 2 Installing an interconnection cable from the probe assembly to the AT10 1 3 Wiring the charger end of the cable to a terminal block on the AT10 1 The actual temperature compensation probe A10 or puck is the same for all battery types and all output voltages of the AT10 1 The accessory part numbers differ depending on cable length ordered See the tables in Appendix B on page 71 for ordering information Each kit contains detailed Installation Instructions JA5015 00 and a separate Application Note JD5003 00 for further user details The main elements of the installation are outlined below High voltages appear at several points inside the AT10 1 Use extreme caution when working inside the enclosure Do not attempt to work inside the AT10 1
134. tion 3 4 wiring failure If the dc breaker CB2 is closed but the front panel meter dsiplays E 07 check your battery If the battery is disconnected and you then disconnect the dc load the AT01 1 may display an E 07 code Restart the AT10 1 according to Section 2 1 If the battery and dc load are satisfactory see the troubleshooting chart in Section 3 4 for help in locating the problem E 08 defective See Application Note JD5003 00 for more detailed user instructions temperature If aremote temperature compensation probe A10 is connected to the compensation AT10 1 the control circuitry detects the probe on startup and uses the probe temperature measured by the probe to control the output voltage of the charger To understand temperature compensation see Section 1 11 If the probe A10 or the wiring that connects it to the Main Control PC Board A1 fails during normal operation the AT10 1 detects the failure and displays E 08 on the front panel meter 46 SERVICING THE AT10 1 Error Meanin Repair Procedure Code g p E 08 defective Disconnect the wiring at the probe and measure the resistance across the temperature quick connect leads with an Ohmmeter The resistance should measure compensation approximately 10 000 at normal room temperature 77 F 25 C If the probe probe reads open or shorted it needs to be replaced continued If the probe is satisfactory examine the wiring between the
135. together to prevent damage Set jumper J30 on the Main Control PC Board A1 to positions 2 3 to use compensated voltages or to positions 1 2 to use uncompensated voltages 21 INSTALLING THE AT10 1 8 Check your work Be sure that e Allconnections are secure e The shield is connected to ground at the charger end only A1 J6 e The cable is connected to the 2 position terminal block TB8 on the Main Control PC Board A1 Other terminal blocks may look similar 9 Restart the AT10 1 using the startup procedure in Section 2 1 During startup the AT10 1 displays Pb on the front panel meter indicating that the temperature compensation is set up for lead acid battery types While this is being displayed you can press any front panel key to change the display to read nicd to change the temperature compensation setup for nickel cadmium batteries The choice you make is saved internally and will be used again by the AT10 1 the next time it starts 10 Adjust the output float and equalize voltages to the battery manufacturer s recommended values using the AT10 1 front panel meter as described in Section 2 3 2 NOTICE If the temperature compensation probe or the probe wiring is damaged and becomes an open circuit the AT10 1 detects the damage and displays E 08 on the front panel meter The AT10 1 then reverts to normal non temperature compensated operation until the probe or wiring is repaired Once the probe is repa
136. top of the AT10 1 approximately 47in 1194mm above floor level with provisions for floor anchoring The kit also includes appropriate hardware and Installation Instructions JA0083 00 for the floor mounting procedure When floor mounting the AT10 1 consider the following 1 Locate anchor bolt holes at least 4 25in 108mm from any wall to allow clearance behind the mounting brackets 2 Be conscious of planned ac input and dc output wiring to the AT10 1 selecting conduit entrances carefully Use of the pref fab knockouts on the sides or bottom of the enclosure will allow removal of the cabinet shroud and internal access for servicing without removal of the unit from the wall 3 The location e Should be free of drips and splatter If falling particles and liquids are a problem install a NEMA 2 type drip shield accessory El0191 00 For kit availability see ordering information in Appendix B on page 71 e Should be between 32 and 122 F 0 and 50 C with relative humidity between 5 and 95 non condensing e Must be free of flammable or explosive materials 4 Maintain at least 6in 152mm of free air on all vented surfaces for cooling 5 Allow 36in 914mm front clearance for operation and maintenance PROCEDURE Install four 4 0 25in 6 4mm anchor bolts not supplied rated to support the unit weight plus a safety factor of at least two 2 times into the floor Assemble the floor mounting accessory to the anchor
137. u can adjust the following parameters e Float voltage e Equalize voltage e Equalize timer in hours e High dc voltage alarm setting e Low dc voltage alarm setting e Current Limit value in Amperes e High dc voltage shutdown feature on or off Your choice of equalize method is also saved internally When you want to change any parameter press the EDIT ENTER key to put the AT10 1 into Edit Mode The meter display flashes about once per second and the status indicators prompt you to adjust the respective parameter Adjust each parameter by pressing the UP or Down key until the meter displays the desired reading You can make the display scroll up or down continuously by pressing and holding the UP or Down key You cannot exceed certain upper and lower limits for the operating parameters To see what the limits for your AT10 1 refer to the Specifications in Appendix A on page 70 When you first press the EDIT ENTER key the AT10 1 prompts you to adjust the first parameter in the list above float voltage When you obtain the value you want on the display press the EDIT ENTER key again The AT10 1 saves the new setting internally and then prompts you to adjust the second parameter You continue this way to adjust the first six parameters in the list above If you want to skip adjusting any parameter just press the EDIT ENTER key again The AT10 1 moves to th
138. value it must be replaced Identify the Negative Scaling Resistor R14 inside the enclosure connected to TB1 Remove the lugged end and measure the resistor s value with an Ohmmeter see table 3 1 for the correct value If the resistor is not within 196 of the specified value it must be replaced If you are using remote sense wiring from the battery to the AT 10 1 the wiring may have failed The usual failure is an open circuit A short circuit will usually be indicated by smoke or fire in the wiring The AT10 1 displays error code E 06 if it detects this wiring failure You should respond to this problem quickly to make sure the AT10 1 regulates the output voltage properly Wire an annunciator e g buzzer to the summary alarm relay contact TB3 for remote indication of any charger problem Otherwise monitor the AT10 1 operation using the optional DNP Level MODBUS Communications Module JA0102 04 If a failure exists in remote sense wiring the AT10 1 regulates its output voltage locally until you correct the problem see Section 1 9 The locally controlled voltage may not reflect the true requirements of the battery When you complete the repair restart the AT10 1 per Section 2 1 E 07 open dc If the dc breaker CB2 is open open the ac breaker CB1 Restart by breaker CB2 closing the dc breaker CB2 first followed by the ac breaker CB1 If the or internal dc dc breaker trips again see the troubleshooting chart in Sec
139. value release the uP or DOWN key If you go past the number you want press the uP or key again to reach the number you want to set e Press the EDIT ENTER key e The new Current Limit setting is saved internally If you do not press any front panel key for 25 seconds Edit Mode ends automatically and any change you made to the last setting is not saved 35 OPERATING THE AT10 1 2 3 6 Enabling the High DC Voltage shutdown feature The AT10 1 has a built in high dc voltage shutdown feature In case of any maladjustment or internal failure that results in a continuous output voltage that is too high the AT10 1 shuts down after 30 seconds to protect the battery The front panel meter displays code E 03 and the summary alarm relay contact TB3 transfers NOTICE The AT10 1 is normally shipped from the factory with the High DC Voltage Shutdown feature disabled You can adjust the high dc voltage shutdown Parallel Operation the setting is the same as the high dc voltage If two or more ATIO Is alarm setting Refer to Section 2 3 4 are connected in parallel both sense the output To enable the shutdown feature voltage If one AT10 1 runs away it will supply all the output current The other will have zero output e The AT10 1 must be in normal operation not the Edit Mode to enable High DCV Shutdown e Press and hold the UP key then current high dc voltag
140. y 8888 and all status amp alarm indicators will light The LAMP TEST key does not test the AC ON indicator The AC ON indicator lights whenever ac power is present and the ac circuit breaker is turned on The TEST key does not operate when ac power is off To test the action of the AT10 1 summary alarm relay press and hold the LAMP TEST key for four seconds to transfer the relay If you are monitoring the relay with a remote annunciator it will detect the alarm condition Testing the Auxiliary Alarm Relay PC Board optional If you have the optional Auxiliary Alarm Relay PC Board A5 installed you can similarly test the six individual alarm relays Press and hold the LAMP TEST key for four seconds to transfer the relays If you are monitoring the relays with a remote annunciator it will detect the alarm conditions Interpreting the alarm indicators There are six red alarm indicators at the right side of the front panel An indicator lights for each of the following alarm conditions e HIGH DC VOLTAGE lights whenever the dc output voltage exceeds the specified alarm voltage setting See Section 2 3 4 to learn how to adjust the HVDC alarm setting e LOW DC VOLTAGE lights whenever the dc output voltage is below the specified alarm voltage setting See Section 2 3 4 to learn how to adjust the LVDC alarm setting e DC OUTPUT FAILURE lights whenever the AT10 1 cannot provide it
141. y is grounded do not attempt this procedure Remove the Plexiglas safety shield at the I O panel board Connect the test resistor between TB1 and ground Adjust RA3 counter E clockwise until the front panel indicator goes out then adjust clockwise until the POS GND indicator just lights Make this adjustment slowly for the indicator is only updated once every four TB1 GND seconds TEST RESISTOR De energize and lock out power to the AT10 1 Rem ove the test resistor at TB1 and verify the POS GND indicator goes out Connect the test resistor between TB1 and ground Verify that the lights If not adjust clockwise until it just does NEG GND indicator Remove the test resistor and return the AT10 1 to normal operation 34 OPERATING THE AT10 1 2 3 5 Using Ground Detection in Charger Standby Mode If you put the AT10 1 into standby mode by opening the dc circuit breaker CB2 the ground detection circuit will send an erroneous positive ground fault alarm There are two ways to work around this e Disable the ground detection circuit while the AT10 1 is in standby as described below e Put the AT10 1 into standby by opening the ac input circuit breaker and leaving the dc output circuit breaker CB2 closed Operating the AT10 1 with the ac breaker CB1 closed but the dc breaker CB2 open is an abnormal condition It is not recommend

Group I Operating Manual - Eagle Eye Power Solutions

Contents

Download Pdf Manuals

Related Search

Related Contents