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AT30 - Eagle Eye Power Solutions

1. AQ TERMINAL DESCRIPTION TYPE CONNECTION TAlc POS NEG OUTPUT TERMINALS CU ALUMINUM COMPRESSION LUG ap AWG 350 MCM REM SENSEC POS NEG REMOTE SENSE TERMINALS 1 4 20 ZPS STLDS 1 4in RING LUG 2 TBl GND USER GROUND TERMINAL CLI ALLIMINLIM COMPRESSION LUG 14 170 AWG TBI L1 L2 L3 AC INPUT TERMINALS CU ALUMINUM COMPRESSION LUG 14 170 AWG TB3 SUMMARY ALARM TERMINAL BLOCK SDLDERLESS COMPRESSION 22 14 AWG TB4 AUXILIARY ALARM TERM BLOCK SOLDERLESS COMPRESSION 22 14 AWG TB8 TEMPCO PROBE A10 INTERCONNECTION TERMINAL BLOCK 22 14 AWG This internal component layout drawing JE5089 99 depicts an AT30 Series battery charger housed in a Style 5030 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 AT30s configured with such options SIDE SECTION FRONT VIEW D 17x ned EJ wE o Ca Da Ea La LU 4 1 m CRA s CRA LL CI U 5 L u R2 Al TBI Ri o o CH e 9 1 Poe 7 NOTE 2 5 D o o ii A 8 E Al d SCR MOO SCR MODULE ASSY A15 e cus m ASSY AIB r2 WA TB8
2. LIGHTNING RECTIFIER ASSEMBLY A16 TRANSE a TBI emu CBI A S ay i AN FRI GC d Hi ZI F B aah ay Le U N J 1 EN FIC AKA A L3 0 ING we NL pyres Ha i lt GND D CHASSIS SEE GROUND 72 NOTES 1 FOR COMPONENT DETAILS OF ALL PE BOAROS wa CAL AIS A17 etc SEE DRAWING JE5091 39 2 ALL ALARM CONTACTS SHOWN IN NON ALARM STATE WITH Wi CHARGER ENERGIZED AND AA EV ENERGIZED CFAIL SAFE ALL ALARM CONTACTS WILL CHANGE STATE WHEN TER CHARGER IS POWERED DOWN CONTACT RATING IS 0 5A e IZ5VAL VIC RESISTIVE 3 SIX B S Rs G1 G6 ARE CONTAINEO WITHIN ONE MOLLE JB PRODUCING G PLLSE RECTIFICATION 4 RESISTIRS RA RG amp RIA FEATLRED INTERNALLY DN GATE DRIVER PC BOARD A 5 IN 48VDC AND 130VDC UNITS BALLAST RESISTOR 83 IS FEATURED EXTERNAL TO MAIN CONTROL CIRCUIT AS SHOWN 14 z amp IgA LEBE TAH 3 qB4 HGE SS ex SUMMARY ALARM TERMINAL BLOCK ALIX ALARM RELAY TB3 NOTE 2 PC BOARD AS SCH 8 JI HIGH DC LOW DC DC OUTPUT AC GROUND SUMMARY VOLTAGE VOLTAGE FAILURE FAILURE DETECT ALARM AUXILIARY ALARM GES IEX 4 1 et et et E et E TERMINAL BLOCK 1 215141516 glo alt dag ie 7l ES EES ES EES EZE EES EJE 335 35 TBA NOTE 2 UC CRIT NCNO E NE Nd C NCN E NE Nd OC NCNI C NCNOC NENI C NC NI WM STANDARD AT3D COMPONENTS STANDARD AT30 COMPONENT
3. 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 Vdc 1 12 INSTALLING FOR REMOTE COMMUNICATION OPTIONAL Refer to separate Operating Instructions JA0102 04 1 13 INSTALLING FOR FORCED LOAD SHARING OPTIONAL Refer to Appendix F on page 92 or Operating Instructions JA5054 00 23 OPERATING THE AT30 2 OPERATING THE AT30 BATTERY CHARGER 2 1 STARTING THE AT30 2 1 1 Understanding the startup seguence The AT30 is set up at the factory to work with most common batteries and loads without further adjustment When you start the AT30 for the first time the factory settings float voltage egualize voltage etc control the operation of the charger You can change the settings after you start the AT30 The FACTORY SETTINGS are listed in table on page 25 The AT30 startup routine takes about five seconds The microprocessor that controls the AT30 initializes the charger by reading the settings that are stored internallv The control circuitrv then soft starts the AT30 and the dc output voltage and current increase graduallv to the rated value Checking the installation Be sure that vou h
4. Style 5030 O Terminal Board TB1 Detail user supplied ac input wiring m Style 163 I O Terminal Q Board TB1 Detail L2 L3 GN NOTES __AcauTion The ac input terminal hardware fastens other components mounted to the I O panel TB1 L Be careful not to disconect any other component leads Conduit must be properly grounded and in compliance with the national wiring rules of the country where installed Use copper or aluminum conductors only 13 INSTALLING THE AT30 1 8 MAKING THE DC OUTPUT CONNECTIONS It is the responsibility of the installer of the AT30 to provide suitable dc output batterv and dc load wiring Follow these steps to connect the batterv to the AT30 1 Size the dc wiring to minimize voltage drop The acceptable wire size depends on vour installation As a guideline the voltage drop should not exceed 1 of nominal output voltage at full current 2 Size the dc output wiring per your battery manufacturer s specifications and local codes for the rating of the batteries and or load 3 The AT30 is factory wired to regulate the 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 4 Do not run the external dc power wiring through the same conduit of the AT30 enc
5. APPENDIK C Standard Drawings Schematic AT30 Battery Charger Standard w o Options JE5092 00 CB2 A LI nn IEN u 1 t l Lo d a REM H Get de SENSE oS l H bt oh Br A CRA l REM EJ gt Pelo 39 R ro u AMAN x Lari o L SYSTEM 4 COMMON INT FEEDBACK CURRENT LIMIT CTRL CIRCUIT REF EXTERNAL FEEDBACK gt EXTERNAL FEEDBACK POWER SLPPLY R3 NOTE 5 Bake eg MAIN CONTROL 425 THIRO CC ami PROJECTION 071312 IRAN BY MCR 051706 t amp AT30 BATTERY CHARGER MAINFRAME SCHEMATIC STANDARD W 0 OPTIONS 013007 ELECTRONIC APPROVAL SIGNATURES MAINTAINED BY NFG ECN LOG TRING Ne REV 092 00 051705 BEER ISSA ETS JES032 00 JB DATE SCALE NTS PART Na JE5092 00 SHET f F 1 http www ATSeries net PDFs JE5092 00 pdf 81 APPENDIK C Standard Drawings Schematic AT30 Battery Charger w Common Options JE5092 99
6. Style 5018 O Terminal Board TB1 Detail user supplied dc output wiring POSITIVE LINE NEGATIVE LINE DC OT OUTPUT L Style 5030 O Terminal Board TB1 Detail Style 163 O Terminal DC Board TB1 OUTPUT Detail POSITIVE NEGATIVE LINE LINE user supplied dc output wiring 15 INSTALLING THE AT30 1 9 WIRING THE AT30 FOR REMOTE SENSING RECTIFIER You can wire the AT30 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 AT30 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 AT30 for remote sensing by installing twisted pair cabling from the AT30 remote sense terminals to the battery terminals The AT30 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 AT30 detects the fault and displays E 06 on the front panel meter See Section 3 2 for details The AT30 cannot protect against short circuit
7. x 24 VOLTS 2 48 VOLTS AUXILARY ALARM RELAY PC BOARD A5 PROCEDURE 1 De energize and lock out all ac and dc voltages to the AT30 2 Allow internal voltages to dissipate then check with a voltmeter 3 Remove the Plexiglas safety shield if supplied 4 Route your remote annunciator wiring into the enclosure through one of the unused conduit knockouts on the side of the enclosure 5 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 6 Strip each wire 0 25in 6 4mm and securely tighten the terminal screws 7 Replace the safety shield if supplied and restart the AT30 NOTES 1 Alarm contacts are rated at 0 5A 125 Vac or Vdc 2 Terminal block TB4 is compression type accepting 722 14 AWG wire 3 Terminals are labeled in non alarm condition 4 Fora detailed view of the optional Auxiliary Alarm Relay PC Board A5 refer to drawing JE5091 39 listed in Appenix C on Page 78 19 INSTALLING THE AT30 1 11 INSTALLING THE TEMPCO PROBE ASSEMBLY OPTIONAL The temperature compensation or TempCo probe contains a temperature dependent resistor in an epozy module that you install near your battery There are three 3 steps in installing the assembly 1 Mounting the probe assembly near the battery 2 Installing the interconnection cable from the probe a
8. 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 will light When the equalize timer is finished the AT30 reverts automatically to the float mode and the FLOAT indicator lights 28 OPERATING THE AT30 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 display 8888 and all status amp alarm indicators will light The LAMP TEST kev 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 LAMP TEST key does not operate when ac power is off To test the action of the AT30 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
9. 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 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 AT30 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 AT30 2 3 3 2 3 4 Setting the Egualize 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 v
10. C 00 MAIN CONTROL CARO PC BOARD ASSY AJ el 8 gJ e CHASSIS GROUND a5 STi TBA NEL 9 e STYLE 5018 o se daR INPUT OUTPUT Lozi tree TERMINAL BOARD DC OUTPUT TBA AUXILIARY ALARM RELAY CONTACTS VR3 AC INPUT LIGHTNING ARRESTOR CIRCUIT BREAKER ACCUATOR CUT OUT WINDOW DI Li e IC CIRCUIT D a SE o St ter gir S 9J L IB 8 COPPER GROUND BUS BAR USE COPPER IR ALUM OCT ONLY GNI AC INPUT AC FUSES FIMB C ACEO NEAR BATTERY CELL gt o O I ft 7 62m CABLE THIRD e ANGLE PROJECTION 071312 RAN BY MCR 020607 JTMLE AT30 SERIES BATTERY CHARGER OPTIONAL INTERNAL COMPONENT LAYOUT STYLE 5018 ELECTRONIC APPROVAL SIGNATURES 050108 LRA BY Mtt SECH DRAWING No _ REV TAL JESOBB 99 2 B DATE SCALE NTS PART Na JE5088 99 Fr http www ATSeries net PDFs JE5088 99 pdf 73 APPENDIX C Standard Drawings Internal Component Layout AT30 Battery Charger Style 5030 Enclosure w Common Options JE5089 99
11. 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 TempCo probe defective E 10 open internal feedback loop E12 internal over temp circuit defective E 13 rectifier over temperature occurrence E 14 forced load sharing not working properly A01 manual equalize enabled for more than 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 AT30 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 Displaying equalize hours remaining only The EQLZ HRS REMAINING indicator lights If the AT
12. NOTICE Never leave the AT30 unattended in the egualize mode with the manual equalize method selected A sustained overcharge may cause permanent damage to the battery Auto Equalize Timer Method Choose 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 by at least half of its rated capacity during an ac power failure When ac power is restored to the AT30 it turns on in the equalize mode automatically and the EQLZ indicator lights At the end of the equalize charging time that you select the AT30 reverts automatically to the float mode and the FLOAT indicator lights At any time during the equalize charge you can switch the AT30 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 falure Mode after ac failure duration ac failure FLOAT gt m FLOAT less than Resume EQUALIZE EQUALIZE gt 12 seconds gt with time remaining FLOAT or gt 12 seconds gt EQUALIZE EQUALIZE or greater with full time
13. DATE SALES NTS PART No JE5086 00 http www ATSeries net PDFs JE5086 00 pdf 69 APPENDIX C Standard Drawings Outline AT30 Battery Charger NEMA 1 Style 163 Enclosure JE5095 00 FRONT VIEW SIDE VIEW CONTROL PANEL SEE DETAIL DRAWING JE5091 3 EL i tf m CHI AC ICB2 DC 1 CIRCUIT CIRCUIT BREAKER BREAKER Br l l l l l l 23 06 637 G x NANI pe 3 d L Re x S E RS eS eX aa SER RESTE GOGON IX KI ER X lt be Oh RI RI SOK eS SRS be e RS Ce 18 00 MTB 457 MTG KA BS NH SS BS x XS X WA Sp Si SS RR DER za lt x NANG Se 8 RI x OX RS RS RS RS RS RS URN PMO x Nt RI di OX RS e RS be e Nt e x e ex KXXX XXX XXX XI XX x eS x be LXX XX Fb VA be dE ee ES PSK kk C 0x bse SS K gt 40 50 MTG IL 0 75 1029 MTG 19 1 BOTTOM VIEW 70 APPENDIK C Standard Drawings NOTES Outline AT30 Battery Charger NEMA 1 Style 163 Enclosure JE5095 00 1 ENCLOSURE IS A NEMA 1 7 IP2O TYPE STEEL CABINET WITHOUT GASKETS FINISH IS ANSI 61 GRAY EPOXY POWDERCOAT ALLOW 12in 7 305mm OF FREE AIR ON TOP SIDES AND FRONT OF CABINET F
14. 2 Check the Float and Equalize voltages and adjust them if necessary Consult your battery manufacturer for the proper voltage settings 3 Be sure the transformer primary taps T1 H1 H2 and H3 are wired correctly for your input voltage See Section 1 6 for details 4 Check terminals and wiring between T1 and the rectifier bridge assembly main inductor L1 dc filtering assembly if present dc breaker CB2 optional dc fuses F3 F4 and the output terminals TB1 Repair as needed 5 Use an ac voltmeter to measure the voltage between the SCR gate leads on each SCR module If you measure about 1 0V rms but there is no output current replace the rectifier module s A16 as needed 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 Gate Driver PC Board A15 7 Use an ac voltmeter to measure the ac voltage between the transformer secondary taps T1 X1 T1 X2 amp T1 X3 The line to line voltage is normally the same as the rated dc output voltage If itis too low check the wiring of the transformer primary taps T1 H1 T1 H2 amp T1 H3 See Section 1 6 for details If the ac voltage on the transformer secondary taps is zero replace T1 8 Disconnect the wiring from inductor L1 and measure the resistance between the terminals If itis an open circuit replace L1 Repeat for inductor L2 if the optional dc filter is installed 9 D
15. Hitp vvvw ATSeries ne PDFs F5045 00 pdf Proper Sizing of Industrial Battery Chargers 95 GUICK 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 vou don t press anv kev for 25 seconds the AT30 resumes normal operation automaticallv 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 SE itl key to toggle from Float mode to EG g b Pressthe 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 El gt Press the HN key The DC VOLTS and FLOAT indicators light and the digital display flashes the present float voltage setting gt Press the or key until the digital display indicates the desired float voltage ES gt Press the amp 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 j E
16. The AT30 is eguipped 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 AT30 control circuitrv A low batterv voltage triggers the safetv circuit Main Control PC Board Al hardware not software maintains the low level detect circuit Therefore to remotelv monitor this alarm user connections must be made at terminal block TB3 The summarv alarm contacts TB4 on the Auxiliary 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 U N NI A TsERIES aj TITTIT 00 9 sento ITT T JI gt J HINDLEPOWER INC Disconnect all ac and dc power sources from the AT30 and connect your dc power supply to the dc output terminals of the charger 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 AT30 Main Control PC Board A1 Adjust RA1 with a small jeweler s screwdriver clockwi
17. lt lt 7 w m B o i A16C A 16B AIBA NOTE E EIS NUMBER TYPE AND ARRANGEMENT OF CONTROL CONTACTS ON B PLILSE AA D RE DOES vain TRING RECTIFICATION SCHEMATIC LABEL ON SIDE OF SCR Miu ECS ALSO DETAILS CONTROL CONTACT PAINTS DC SHUNT 6 PULSE SCR 91 06 MODULE RECTIFIER HEATSINK ASSY AI6 PRI TER SEC 43 SANTA o N 25 Ke Ki O Wi 4 OH x10 S ka vo B van gt x 5 MO Ye E REMOTE SENSE u ro W2 a NITE 3 yi g FU j N B om Z x2 0 AT30 SERIES ra B 4 mo I 0 TERMINAL D gt fo BOARD TBI 51 ke NOTE 5 10 GR YE CHASSIS GROUND ou xi oJ 86 APPENDIK C Standard Drawings Connection Diagram AT30 Battery Charger Control Signal Wiring JE5094 00 47 GR YE UI DOOR amp UND 3 14 1 RIRJRIEIRIE THREE PHASE GATE DRIVER PC BOARD A15 L FILTER INDUCTOR Ill 9 em TL o E LI MAIN ES E INOUCTOR _ MAIN CONTROL PC BOARD CAI J NOTES L gt CHARGER COMPONENTS ARE CONNECTEO WITH FLAME RETARDANT 5 TERMINAL ORIENTATION ON I O PANEL TBI DIFFERS SWITCHBOARO INSULATION SYSTEM SIS TYPE NIRING WITH UNIT ENCLOSURE TYPE CSTYLE 5030 SHOWN IDENTIFIED ON EACH END WITH NUMAE
18. 012607 DRAWING No JESO93 99 B UNLESS Watt NOTED DU Be ARE IN INCHES TOLERANCES DATE SCALE NTS PART JESQ93 99 E 3 http www ATSeries net PDFs JE5093 99 pdf 85 APPENDIX C Standard Drawings Connection Diagram AT30 Battery Charger Control Signal Wiring JE5094 00 BI Pal B ES i B0 pe 199 64 mm 150 ee 28 51 deet 53 po gt a Ba il pizza 77 Una JS SL Sis 182 J33 PENES J34 re SNUBBER Si ASSY AI7C 7 J 67 TE 71 T 58 167 1 im E pe 75 EE D7 le Da i J33 DOR J34 BI GROUNI SNLIBBER x ASSY A17B n J 55 155 73 E rss EU ss AI SU eman Lipzjo3 174 74 TE 71 Ze J33 J34 SNUBBER van hl ASSY CA17A N CH Q gt E D a a J W up WAO e Ojo jm un jon gt jal jinj jal jej iwj jin lt
19. RI male SIN l ated eo th 1 l 1 1 gi CHASSIS l GROUND T1 TRANSFORMER CIRCUIT BREAKER ACTUATOR CLIT DILITS J O AS AUXILIARY ALARM RELAY FC BOARD AIO EXTERNAL TEMPCO PROBE Al2 COMMUNICATIONS MOOLLE PC BOARD Cix OC OUTPUT FILTER CAPACITOR L2x BATTERY ELIMINATOR FILTER CAP RI POLARITY DICDE E13 INDUCTOR INTER CONNECT POINT Fix AC INPUT FUSES LI L2 L3 F3 DC OUTPUT FUSE LEG FA DC OUTPUT FUSE LEG L2 FILTER INJLCTIR Rd FILTER CAP C1 BLEED RESISTOR RZQ COMM PCB A125 P R RES 130VDL TBA AUX ALARM PCB TERMINAL BLOCK VR3 AC INPUT LIGHTNING ARRESTOR 3US BAR SION LUG XXt 7 XXmm 3 A10 TO BE PLACED NEAR BATTERV CELL M 1 0 TERMINAL DESCRIPTION TYPE CONNECTION LLI mn UM TBl POS OUTPUT TERMINAL CU ALUMINUM COMPRESSION LUG 6 AWG 350 MCM wa TBit NEGC OUTPUT TERMINAL CU ALUMINUM COMPRESSION LUG 6 AWG 350 MCM m REM SENSE 7 POS NEG REMOTE SENSE TERMINALS 174 20 ZPS STUDS 1 4in RING LUG H i Z 2 TBI CND USER GROUND TERMINAL CU ALUMINUM COMPRESSION LUG 6 AWG 350 MCM MW oS TBI L112 43 AC INPUT TERMINALS CU ALUMINUM COMPRESSION LUG 6 AWG 350 MCM CB2 wa TB3 SUMMARY ALARM TERMINAL BLOCK SOLDERLESS COMPRESSION 322 14 AWG s TB4 AUXILIARY ALARM RELAY PC BOARD AS TERMINAL BLOCK 422 14 AWG gureur N TB8 TEMPCO PROBE A10 INTERCONNECTION TERMINAL BLOCK 422 14
20. 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 AT30 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 Page 45 for all error and status codes 32 OPERATING THE AT30 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 up 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 ke
21. and Installation Instructions JA0091 03 for the rack mounting procedure When rack mounting the AT30 consider the following 1 Therelav rack must be strong enough to properlv support the weight of the AT30 Comprehensive weight data for the different models is available in the AT30 product literature JE5018 00 The weight of vour AT30 mav be different from the literature value depending on supplied features options or accessories 2 Be conscious of planned ac input and dc output wiring to the AT30 selecting conduit entrances carefully Note the standard pre fab conduit knockouts located on the sides of the enclosures Ensure that planned conduit is accessible after the AT30 is rack mounted 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 EI0191 02 For kit availability see ordering information in Appendix B on page 65 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 Gm 152mm of free air on all vented surfaces for cooling 5 Allow at least 36in 914mm front clearance for access to the AT30 for operation and maintenance PROCEDURE 1 Attach the two 2 relay rack mounting brackets to the sides of the Style 5018 enclosure using the four 4 small pre fab knockouts as guides 2 Mount th
22. bridge 3 Defective 3 Test by disconnecting wires 7 8 amp 9 from the transformer transformer T1 secondary taps T1 X1 X2 and X3 If ac breaker still trips test by disconnecting wires 42 43 44 45 35 and 36 from the tertiary taps T1 YO Y 1 Y2 Y3 W1 and W2 If ac breaker still trips replace the transformer T1 AC breaker 1 Loose 1 Check and tighten connections as required trips or fuses connection to clear after a breaker fuse few minutes 2 Wrong ac 2 Be sure the transformer primary taps T1 H1 H2 and H3 are wired correctly for your input voltage See Section 1 6 for details 3 Use a clamp on ammeter to measure the current in wires 7 8 amp 9 between T1 and the rectifier modules If it less than 5096 of the dc output current one of the six 6 SCRs or diodes is defective Replace the rectifier module s A16 4 Disconnect the wire harness plug from connector J26 on the top of the Gate Driver PC Board A15 and restart the AT30 If you are able to measure output current one of the SCRs is defective Test and replace the rectifier module s A16 as needed 49 SERVICING THE AT30 Gate Driver PC Board A15 5 Defective Main Control PC Board A1 PROBABLE SYMPTOM 9 RECOMMENDED ACTION CAUSE DC breaker 1 Battery 1 Check and correct battery wiring if necessary trips or fuses connected with clear reverse polarity immediately 2 Defective 2 Test by d
23. restart the AT30 per Section 2 1 E 07 open dc breaker CB2 or internal dc wiring failure If the dc breaker CB2 is open open the ac breaker CB1 Restart by closing the dc breaker CB2 first followed by the ac breaker CB1 If the dc breaker trips again see the troubleshooting chart in Section 3 4 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 AT30 may display an E 07 code Restart the AT30 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 temperature compensation probe See Application Note JD5003 00 for more detailed user instructions If a remote temperature compensation probe A10 is connected to the AT30 the control circuitry detects the probe on startup and uses the 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 AT30 detects the failure and displays E 08 on the front panel meter 46 SERVICING THE AT30 Error A l Meanin Repair Procedure Code 9 p E 08 defective Disconnect the wiring at the probe and measure the resistance across the
24. AT10 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 Ethernet Gateway Interface for MODBUS AT Comm EJ5226 0 Ethernet Gateway Interface for DNP AT Comm EJ5226 1 Fiber Optic Modem w Interface for AT Comm EJ5230 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 91 APPENDIX F FORCED LOAD SHARING ONLINE SUPPLEMENT http www ATSeries net PDFs 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 AT30s 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 AT30 which forces units to share dc load equally The accessory ordering p n EJ5126 cons
25. NOT FEATURED OC OUTPUT M DC FUSES 2 a 29 qe je Io e AC FUSES 2 DIA NITE B gt ARBE oj en Us zim m m 02A CB2 DC VR3 ka l B Fe OUTPUT LIGHTNING CIRCUIT ARRESTOR o FIC oa BREAKER ala NITE D NOTE A al D SNOTE E OJO N gt 3 CBI AC INPUT 5 i5 is lus um CIRCLIIT SB S S 98 3 3 S DN BREAKER T 1 PRI a O OIIOO OO TER x m m DN DN OO gt X rad IT e zz rt om gt E TI TRANSFORMER CR4 FREE WHEEL ING X3 x2 xi DIODE 9 0 O O SEE UI a CD b o o o m ea NITES Wi 1 CHARGER COMPONENTS ARE CONNECTED WITH FLAME RETARDANT SWITCHBOARO INSULATION SVSTEN jiu SIS TYPE WIRING IDENTIFIED ON EACH END WITH NUMBER CODEN MARKERS GROUND WIRE 10 IS GREEN WITH YELLOW STRIPE 2 THIS DRAVING DEPICTS THE MAINFRAME POWER WIRING ANO LER CONNECTION CONTACTS TO CONTROL PC auras Al amp AS SEE SIGNAL CONNECTION DIAGRAM 5094 00 FOR STANDARD SCR FIRING NITE 5 gt fl PLILSE SCR CL CONTROL WIRING INCLUDING REMOTE SENSE MODIFICATIONS RECTIFIER HEATS 3 STANDARD USER ALARM CONTACTS TBI ga etc gt ARE SOLDERLESS COMPRESSION SCREW TERMINALS ACCEPTING 22 14 AWG NIRE 4 FREE WHEELING OIODE ERA IS AN NIDE MOUNTED COMPONENT AND CONNECTS DIRECTLY TO EITHER AL6t OBUS AS SHOWN OR TD RI 1 FEATURED OPTIONS 5 NUMBER TYPE AND ARRANGEMENT OF CERTAIN COMPONENTS SPECIFICALLY 1 0 PANEL TBI STD DC OUTPUT FILTERING OLFFER WITH UNIT ENCLOSURE TYPE SEE DETAIL DRAWING lt JES B3 O0 gt OR CORRESFONJING INTERNAL CO
26. PROBE R3 A12 COMMUNICATIONS MIDLLE PC BOARD e Elx OC OUTPUT FILTER CAPACITOR 9 2x BATTERY ELIMINATOR CAPACITOR R29 ER POLARITY DIDDE E13 alte INTER CONNECT POINT R Fix AC INPUT FUSES L1 L2 L3 LND CB AC CB2 DC F3 OC OUTPUT FUSE LEG D FA OC OUTPUT FUSE LEG CIRCUIT CIRCUIT E BREAKER BREAKER RQ FILTER CAP CCI BLEED RESISTOR R29 COMM MOD BALLAST RES lt 130VDC gt CIRCUIT BREAKER 5 TBA AUXILIARY ALARM RELAY CONTACTS ACTUATOR VR3 AC INPUT LIGHTINING ARRESTIR CUT OUT WINDOW L 0 TERMINAL BOARD CTB1 DETAIL AC ENT IN D JB DC L1 La L3 GNO POS OUTPUT NEG 2 el o el e o e o STANDARD DRAWING NOTES A ARRANGEMENT AND NUMBER OF COMPONENTS MAY DIFFER SLIGHTLY BASED UPON UNIT RATING AND FEATURED OPTIONS ray RAD vis J B SEE JE5163 00 FOR A16 DETAILS 7 CS Ke oO MOUNTED VR7 Z BEHIND e Ma PANEL S REM REM SENSE SENSE OTES N 1 FOR DETAIL VIEWS OF ALL PC BOARDS Al A5 A15 Al7 etc SEE DRAWING JE5091 39 2 I O PANEL TERMINAL BOARD TB1 NOT SHOWN FOR CLARITY OF VIEW SEE DETAIL TO RIGHT THIRD c ANGLE PROJECTION DRAW BY MCR 020607 TIME AT30 SERIES BATTERY CHARGER OPTIONAL INTERNAL COMPONENT LAYOUT STYLE 5030 071312 KPA uem ena 020507 Ef eatem Wai DATE SCALE Mrs Pei WW JEGOBB 99 http ww
27. PROVIDEO AS SHOWN FOR lin 25nn CONDUIT ENTRY IF ADDITIONAL CONDUIT ENTRANCES ARE REQUIRED ENCLOSURE SHOULD BE FIELD MODIFIED BY INSTALLER 3 4 5 BATTERY CHARGER SHIPPING WEIGHT CSEE PRODUCT LITERATURE in nn DUAL DIMENSIONS THIRD ANGLE PROJECTION eg TITLE DRAWN BY MCR 092506 AT30 SERIES BATTERY CHARGER OUTLINE Gent WAA STO NEMA 1 STYLE 5018 ENCLOSURE 071412 AINTAINED BY MFG ECN LOG mr JESO85 00 UNLESS OTHERWISE NITEU DIMENSIONS 082508 Le IN INCHES TOLERANCES ARE SCALE PART No DATE NTS JES5085 00 http www ATSeries net PDFs JE5085 00 pdf 67 APPENDIX C Standard Drawings Outline AT30 Battery Charger NEMA 1 Style 5030 Enclosure JE5086 00 SIDE VIEW LEE Pa KK ORA GN NOTE 3 FRONT VIEW BOTTOM VIEW CONTROL PANEL SEE DETAIL DRAWING JES091 3 gt Am o CO Si oo 0 H e OOAA O SS SSS te ca ET IE kas Ta TE sl 54 25 1378 H 1 A CBI AC CB2 DC CIRCUIT CIRCUIT BREAKER BREAKER SS mi or ei oc D EE Lesen eg EE een H est SSS L 30 00 762 1 15 29 1 D o a 1 D D g g 15 00 MTG gt 381 MTG 0 B 8 8 D D H 27 95 MTG 710 lt MTG gt 68 APPENDIK C Stan
28. RK0017 14 Y CR1 Polarity Diode 500 600 Adc ratings RK0028 12 Y CR1 Polarity Diode 800 1KO Adc ratings PM0003 00 Y CR4 Free Wheeling Diode 25 50 Adc ratings RK0013 14 Y CR4 Free Wheeling Diode 75 Adc rating RK0014 14 Y CR4 Free Wheeling Diode 100 400 Adc ratings RK0017 14 Y CR4 Free Wheeling Diode 500 600 Adc ratings RK0028 12 Y CR4 Free Wheeling Diode 800 1K0 Adc ratings PM0003 00 Y 62 SERVICING THE AT30 Reference Description Factory Part Number Rec Designator 12Vdc 24Vdc 48Vdc 130Vdc Spare F1A B C AC Input Fuses see supplied Parts Data Package Y F3 F4 DC Output Fuses see supplied Parts Data Package Y L1 Main Inductor see supplied Parts Data Package L2 Optional Filter Inductor see supplied Parts Data Package P5 Jumper for disabling Ground Detection circuit RCO100 00 P7 Jumper for voltage selection on A5 pc board RCO100 00 P9 Jumper for front panel lockout feature on A1 RCO100 00 RI Main DC Shunt 25 Adc RB0008 13 R1 Main DC Shunt 30 100 Adc RB0008 03 R1 Main DC Shunt 125 400 Adc RB0008 10 R1 Main DC Shunt 500 800 Adc RB0008 18 R1 Main DC Shunt 1000 Adc RB0008 19 R2 Current Rating Resistor see supplied Parts Data Package Ra Poner Suppi Balast Resistor Ec E R4 Positive External Scaling Resistor ins E MI OR Be R6 Voltage Crowbar Resistor RJ0063 76 RJ
29. Surge withstand capability test per ANSI C37 90 1 1989 no erroneous outputs Reverse current from battery ac input power failure no options installed 90 mA maximum Audible noise average for four 4 sides 5ft 1 5m from enclosure less than 65 dBA Cooling natural convection Ambient temperature operating 32 122 F 0 50 C Elevation Relative humidity 3 000ft 1 000m without derating 0 to 9596 non condensing Alarm relay contact rating 120 Vac 125 Vdc 0 5A resistive 64 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 AT30 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 Kit Part Number standard DC Output Filtering per NEMA PE5 1996 contact your sales rep Battery Eliminator Filtering per NEMA PE5 1996 contact your sales rep Auxiliary Alarm Relay PC Board A5 option EI0213 02 03 04 Copper Ground Bus with one 1 box lug EI0195 02 03 03 AC Input Lightning Arrestor VR3 option EJ1074 02 Wall Mounting Kit for S
30. VR7 DC OUTPUT SURGE SUPPRESSOR 4 TO GROUND H3 SILICON CONTROLLEO RECTIFIER CAI6BH NITE 3 DA SILICON CONTROLLEO RECTIFIER ALGE NITE 3 HS SILICON CONTROLLEO RECTIFIER CALGC NITE 3 OB SILICON CONTROLLEO RECTIFIER CAL NITE 3 82 APPENDIK C Standard Drawings Schematic AT30 Battery Charger w Common Options JE5092 99 ee CB2 A 20 kare LI L F3 A TBI I KS 1 all REM H KSE SENSE tm CS ei C2 C e l ut i WA Se A CRA ua WA REM E gt nee Ta Lu SENSE i wc FYETE Wa i R 5 d FA HHA ro U a tN nr 1 9 3 A SYSTEM V CON NOTE 7 E INT FEEDBACK e CURRENT LIMIT Lg Tol CTRL CIRCUIT REF EXTERNAL FEEDBACK gt EXTERNAL FEEDBACK 4 R2 POWER SUPPLY R3 uu MISBROT ODES J25 425 THREE PHASE NOTES Aas GATE DRIVER 12 PC BOARD AIS 7 OC OUTPUT CTBl IS RARALLELED AND SECOND UNIT l OF IDENTICAL RATING ERCONNEC TED m P17 27 WITH SECON UNIT FOR delt CONTROL FOR FORCED LOAD SHARING DETAILS SEE DRAWING 5154 00 E MAIN CONTROL 8 PC BOARD Al TEMPERATURE 2 COMPENSATION PROBE A10 O COMPONENTS FE
31. above procedure but start with the lead on TBI Tighten all hardware Replace cut wire ties if possible Nola The dc EMI filter networks are not polarized 60 SERVICING THE AT30 Replacing the power ballast resistor R3 48 and 130 Vdc units only For 48 Vdc and 130 Vdc AT30s R3 is mounted with metal brackets onto the back panel of the enclosure Cut wires 49 and 51 connected to R3 as close to the resistor leads as possible Strip off 0 25in 6 4mm of insulation from the cut ends of the wires Unscrew the top mounting bracket and remove the existing resistor Mount the new R3 and replace the top mounting bracket Polarity is not vital Carefully re solder the cut wires to R3 remount the resistor and top bracket For further information refer to Service Instruction JD5010 00 Replacing resistors R3 R4 R6 amp R14 on the Gate Driver PCB A15 In all AT30s resistors R4 R6 and R14 are soldered directly onto the Gate Driver PC Board A15 For 12 Vdc and 24 Vdc AT30s R3 is also soldered directly onto A15 For proper location see the figure below THREE PHASE GA RIVE PC BOARD CA15 oi R14 o 9 R3 o RBA po web RE moi D PO oA P17 o TITTI 1 J5 MAIN CONTROL PC BOARD CAI If any of these resisto
32. affects meter accuracy such as the Main Control PC Board A1 or 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 AT30 changes Do this adjustment with a fully charged battery and with 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 EaLz MTHD key The DC VOLTS METER mode indicator will light and the meter display flashes the output voltage reading Measure the output voltage of the AT30 using a de meter accurate to 0 25 or better While watching the meter connected to the AT30 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 AT30 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 ur or key When you are finished adjusting the output voltage the AT30 waits five 5 seconds then the display returns to normal operation 37 OPERATING THE AT30 2 3 8 Using the Low Level Detector LLD
33. blown with an Ohmmeter or fuse tester and replace F1A F1B and or F1C as needed edle if replacement fuses immediately blow see the Sections titled AC breaker trips immediately and AC breaker trips after a few minutes for further troubleshooting hints 3 Check terminals and wiring between T1 and the rectifier bridge assembly main inductor L1 dc filtering assembly if present dc breaker CB2 optional dc fuses F3 F4 and the output terminals TB1 Check wires 42 through f 45 from T1 YO through T1 Y3 to the Gate Driver PC Board connector J25 Repair as necessary 4 Use an ac voltmeter to measure the ac voltage from T1 X1 to T1 X2 and T1 X3 It is normally 5096 to 8096 higher than the rated dc output voltage If it is too low check the wiring of the transformer primary taps T1 H1 through T 1 H3 See Section 1 6 for details If the ac primary voltage is zero replace the T1 No output current but AC ON lamp is on and ac and dc breakers are on 1 Battery is fully charged 2 Float or Equalize voltage set too low 3 Wrong ac input voltage or mis tapped T1 4 Defective wiring 5 Defective rectifier bridge 6 Defective Gate Driver PC Board A15 7 Defective transformer T1 8 Defective inductor L1 or L2 9 Defective dc breaker CB2 1 This is normal operation in a system with little or no dc load As long as the AT30 maintains Float voltage it is operating normally
34. error code was formerly used to indicate a reverse battery connection It is not available in the AT30 E 06 defective R4 or R14 resistor or remote sense wiring failure Locate R4 and R14 on the Gate Driver PC Board A15 mounted to the back side of the front instrument panel Remove the wire harness plugs from J25 8 J26 and remove A15 from the Main Control PC Board A1 Use an Ohmmeter to measure the values of R4 and R14 see table 3 1 for the correct value If either resistor is not within 1 of the specified value the entire Gate Driver PC Board A15 must be replaced If you are using remote sense wiring from the battery to the AT30 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 AT30 displays error code E 06 if it detects this wiring failure You should respond to this problem quickly to make sure that the AT30 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 AT30 operation using the optional DNP Level 3 MODBUS Communications Module JA0102 04 If you have a failure in remote sense wiring the AT30 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
35. 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 AT30 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 AT30s 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 connectors 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 AT30s and anchor it in place at both ends before connecting Connect each end to the Main Control PC Boards AL 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 AT30 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 ofall dc cabling before making connections 92 APPENDIX F OPERATING THE AT30 WITH FORCED LOAD SHARING Restore external power connections to both AT30s and restart according to the normal procedure in the AT30 Operating and Service Instructions A
36. 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 Do not use a dc voltmeter The ripple voltage on a battery is a very small ac voltage 41 OPERATING THE AT30 SAMPLE PREVENTIVE MAINTENANCE PROCEDURE AT30 BATTERY CHARGER JD0064 00 Suggested Frequency every six 6 months Maintenance date Performed by High voltages appear at several points inside the AT30 Use extreme caution when working inside the enclosure Do not attempt to work inside the AT30 unless you are a qualified technician or electrician Step Instructions Results standard features Clean AT30 e All vents clean and open O OK e Remove dust and debris from inside unit OK Check all e TBI connections all tight O OK electrical e Internal wiring connections tight slip on OK connections connectors fully seated Wire and lug and wiring insulation in satisfactory condition e Terminations at battery or dc bus are tight O OK and corrosion free Check ac input e Measure between TBI LI TB1 L2 amp voltage TBI L3 using an ac voltmeter Value Input Vac must be within 10 amp 12 of nominal voltage Check dc e Measure at TBI and TBI using a dc output voltage voltmeter Value should agree with the Float Vdc front panel voltmeter within 0 25 and must be correct values for
37. mer E zi l QAD SHARING i DETAILS SEE ES oAsus 1 pamo mat AA Wa J13 1 Seh ambi N JI 1 ki Mindtarayor Inc l Ha ira 2 aS 1 1 ROL PC BOARD A1 MAIN CONTROL PC BOARD Al 1 l G CHARGER DOOR WHEN INSTALLED L BACK VIEW FACING CHARGER COMPONENTS WHEN INSTALLED USER JUMPERS SWITCHES Jl MAINFRAME SIGNAL HARNESS NOT USEO WITH 3PH S1 METER MODE SNUBBER J2 AUX ALARM RELAY BOARD A5 SERIAL CONNECTOR S2 CHARGER MODE IARD CAL7X JA FORCEO LOAQ SHARING CABLE INTERCONNECTOR S3 EQUALIZE METHOD 2 2 J5 GROUND FAULT ENABLE OISABLE S4 AADJUST 3 RER D JG EARTH GROUND CONNECTOR S5 VADJUST CHARGER JH FRONT PANEL ENABLE DISABLE LOCKOUT SB EDIT ENTER J13 COMMUNICATIONS PC BOARD A12 INTERCONNECTOR S7 PROCESSOR MANUAL RESET J17 3PH GATE DRIVER PC BOARD CA15 INTERCONNECTOR J25 MAINFRAME CONTROL SIGNAL HARNESS TERMINAL BLOCKS J26 SCR FIRING CONTROL HARNESS 3 PHASE 6 PULSE TB3 SUMMARY ALARM RELAY CONTACTS J27 3PH GATE ORIVER PC BOARD A15 INTERCONNECTOR TBA AUX ALARM RELAY CONTACTS J29 LATCHING ALARMS ENABLE DISABLE TB8 OPTIONAL TEMPCO PROBE A10 J30 TEMPCO VOLTAGES COMPENSATEO UNCOMP SELECTOR INTERCONNEC TOR CONTROLS HA EF ous 1 bw 5 Oc NM GROUND FAULT 020812 PROJECTION SENSITIVITY i 120209 Amer MCR 051705 ms AT30 SERIES BATTERY CHARGER OPTIONAL IN NE TR 041109 Set ien spes INSTRUMENT PANEL PC BOARD DETAIL TRMMI
38. must be strong enough to properly support the weight of the AT30 and the mounting brackets Comprehensive weight data for the different models is available in the AT30 product literature JF5018 00 The weight of vour AT30 mav be different from the literature value depending on supplied features options or accessories Be conscious of planned ac input and dc output wiring to the AT30 selecting conduit entrances carefullv Note the standard pre fab conduit knockouts located on the sides the Stvle 5018 enclosure 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 EIO191 0 For kit availability see ordering information in Appendix B on page 65 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 PROCEDURE oo Mount the triangular brackets to the wall Allow at least 36in 914mm front clearance for access to the AT30 for operation and maintenance Install eight 8 0 25in 6 4mm anchor bolts not supplied rated to support the AT30 weight plus a safety factor of at least two 2 times into the wall Carefully lift the Style 5018 enclosure onto the mounted triangular brackets Use the supplied 0 25in 6 4
39. part number s listed on the report The following table mav specifv part replacement kits that include other materials such as installation instructions and packaging materials Vou mav order spare parts using either the report part number or listed kit The factory may make necessarv adjustments to vour order to ensure proper deliverv of a complete kit Refer to the table below for the most common items Table 3 1 REPLACEMENT PARTS Reference MA Factorv Part Number Rec Designator Description 12 Vdc 24 Vdc 48 Vdc 130 Vdc Spare Al Main Control PC Board EN5002 00 EJ1243 10 Y A5 Auxiliary Relay PC Board EN0027 00 EJ1243 03 Y A10 Temperature Compensation Probe assembly See Appendix B Table 2 A15 Gate Driver PC Board EN5008 0 EJ5199 01 EJ5199 02 EJ5199 03 EJ5199 04 Y Ai6 SCR Rectifier Module s 01 06 see supplied Parts Data Package Y A17x SCRSnubber PC Board EN5012 00 EJ5200 00 C1 Filter Capacitor standard see supplied Parts Data Package Y C2 Filter Capacitor battery eliminator see supplied Parts Data Package Y C4 EMI Filter Capacitor see VR6 C4 C5 EMI Filter Capacitor see VR7 C5 CB1 JAC Input Circuit Breaker see supplied Parts Data Package CB2 DC Output Circuit Breaker see supplied Parts Data Package CR1 Polarity Diode 25 50 Adc ratings RKOO13 14 Y CR1 Polarity Diode 75 Adc rating RK0014 14 Y CR1 Polarity Diode 100 400 Adc ratings
40. temperature quick connect leads with an Ohmmeter The resistance should measure compensation approximately 10 000 Q 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 probe and the AT30 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 AT30 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 50 Also check the harness connector J25 on the Gate Driver PC Board A15 E 11 not used This error code is not implemented at this time E 12 defective The AT30 rectifier heat sinks assemblies A16 are equipped with over internal temperature thermostats S2x On startup the AT30 tests the thermostat thermostats and displays E 12 if one or more are defective Chec
41. x RATING AND FEATUREO OPTIONS L4 EMI DUTPUT FILTER CAP CRG END gt FRONT VIEW Es EMI OUTPUT FILTER CAP EIS 3 DI AC INPUT CIRCUIT BREAKER C03 CE2 OC OUTPUT CIRCUIT BREAKER C02 RA FREE EEL ING O1O0E LI MIN NOU TOR N OC IT R2 CURRENT RATING RESISTOR 8 R3 R SLPPLY BALLAST RES 130VDC THREE PHASE n WER ISOLATICN TRANSFORMER pme GATE DRIVER PC Tal 1 0 TERMINAL BOARO GRUND R2 BOARD ASSY AIS o TE3 SUMMARY ALARM CONTACTS STUD THA TEMPCO PROBE TERMINAL BLOCK o o WRI OUTPUT SURGE SUPPRESSOR T0 gt e c VR2 INPUT SURGE SUPPRESSOR LINE 1 l 2 9 VRA INPUT SURGE SUPPRESSOR LINE 2 o VRS INPUT SURGE SUPPRESSOR LINE 3 o VRB OUTPUT SURGE SUPPRESSOR wi OUTPUT SURGE SUPPRESSOR SYM OPTIONAL COMPONENT DESCRIPTION AS AUXILIARY ALARM RELAY PC BOARD A 12 igo A ALO TEMPERATURE COMPENSATION PROBE 1BB TB3 Al2 COMMUNICATIONS MOOLLE PC BOARD Clix OC OUTPUT FILTER CAPACITOR x E 2 BATTERY ELIMINATOR CAPACITOR Di POLARITY DIE e i EI3 INDUCTOR INTER C CT POINT FOR DETAIL VIEWS DF ALL PC THID TAL BOARDS CAI AS AIS AUT etc Ee AC INPUT FISES o EILAT 3i SEE DRAWING JE5091 39 fu FA DC OUTPUT FUSE LEG L2 FILTER INJUCTOR um gt RI FILTER CAP C1 BLEED RESISTOR RZQ COMM MID BALLAST RES 130VDC gt jo N gt Oy Du gt N UU oO In N r1 SCR SNUBBER ASSY SEE NOTE
42. your Equalize Vde battery Ifthe AT30 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 e Measure at battery terminals using an ac voltage voltmeter set to the milliVolts scale Check against specification in Appendix Ripple mVac A on page 64 Test font panel e Press LAMP TEST key on front panel OK indicators Test summary e Press LAMP TEST key and hold for four O OK alarm relay 4 seconds Summary alarm relay at TB3 will transfer 42 OPERATING THE AT30 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 O vo_ts OK O amperes OK LI Hours OK Cycle through equalize methods D MANUAL TIMER OK O MANUAL EQLZ OK LI AUTOEQLZTIMER OK Turn off ac circuit breaker The AC O Alarm OK INPUT FAILURE indicator should light Reset breaker Check voltage Use key to scroll through FLOAT OK and alarm settings See page 30 D EQUALIZE OK settings HvDC alarm OK D LvDC alarm OK Current Limit Adc Final checks Make sure Plexiglas safety shield is in OK place 1f supplied Restore charger to normal operation O OK Close latch
43. 0064 11 RJ0064 41 RJ0064 80 R9 Filter Capacitor C1 Bleed Resistor RJ0028 25 RJ0028 25 RJ0028 27 RJ0036 40 R14 Negative External Scaling Resistor iss SE Dese Ee Bet T1 Main Power Isolation Transformer see supplied Parts Data Package Er Rcoose ia Mee ae kaa fori 4 1 0 AWG dene Teer ae ee 350 MCM BE EE RCO056 03 VR1 Output Surge Suppressor Style 5018 EJ1132 11 Y VR1 Output Surge Suppressor Style 5030 EJ1132 21 Y VR1 Output Surge Suppressor Style 163 EJ1132 31 Y VR2 4 5 208 240 Vac Input Surge Suppressor St 5018 EJ1132 11 Y VR2 4 5 208 240 Vac Input Surge Suppressor St 5030 EJ1132 21 Y VR2 4 5 208 240 Vac Input Surge Suppressor St 163 EJ1132 31 Y VR2 4 5 480 Vac Input Surge Suppressor Style 5018 EJ1132 12 Y VR2 4 5 480 Vac Input Surge Suppressor Style 5030 EJ1132 22 Y VR2 4 5 480 Vac Input Surge Suppressor Style 163 EJ1132 32 Y VR3 AC Input Lightning Arrestor EJ1074 02 VR6 C4 JEMI Output Filter Network Style 5018 EJ5021 03 Y VR6 C4 EMI Output Filter Network Style 5030 EJ5021 04 Y VR7 C5 EMI Output Filter Network Style 163 EJ5021 05 Y Note 1 In older 130 Vdc units the 5002 50W power supply resistor R3 mounted to the galvanized base may be comprised of an assembly of two 2 2509 resistors connected in series Note 2 Listed part numbers subject to change without notice Refer to data listed in AT30 Parts Data Package report 63 APPENDIK A SPECIFICATIONS Except as noted all sp
44. 2 Be sure that the Low DC Voltage alarm setting is lower than the closed Voltage alarm Float voltage setting See Sections 2 3 2 and 2 3 4 ac input and Float voltage is voltage settings 3 Use a clamp on ammeter to measure the current in wires 7 8 amp 9 between T1 and the rectifier modules If it less than 50 of the dc output current one of the SCRs or diodes is defective Replace the rectifier module s A16 as needed 4 Turn off both front panel breakers If the AT30 does not have breakers fuses instead lock out ac and dc power to the AT30 externally Wait one minute Return dc power to the AT30 first followed by ac power If the AT30 output voltage is normal but the LOW DC VOLTAGE indicator is still on replace the Main Control PC Board A1 5 Disconnect the battery and connect a light dc load to the AT30 Measure the dc voltage across TB1 and TB1 with the breaker on If no voltage is measured replace the dc circuit breaker CB2 DC OUTPUT FAILURE indicator is on but ac input voltage is normal and ac amp dc breakers are closed 1 Defective rectifier bridge 2 Defective Main Control PC Board A1 3 Defective transformer T1 4 Defective dc circuit breaker CB2 1 Use a clamp on ammeter to measure the current in wire 7 8 and 9 between T1 and the rectifier module s If it less than 5096 of the dc output current one of the SCRs or diodes is defective Replace the rect
45. 30 is not in a timed equalize mode the meter displays the full programmed equalize time Bo e When the AT30 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 AT30 2 2 3 2 2 4 Selecting the Float or Egualize mode The AT30 has two output voltage settings Float and Egualize Use the Float mode for all normal battery charging and to operate your dc system Use the Egualize 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 egualize charging your battery e Press the CHRG MODE key to change to the equalize mode If the egualize method is set to manual timer or auto egualize timer the AT30 will revert to the float mode at the end of the selected egualize time e You can press the CHRG MODE key again at any time to change back to the float mode Choosing the Equalize method Press the EQLZ MTHDI key to choose the desired equalize method The indicator next to the desired equalize method will light Three 3 equalize methods are available in the AT30 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 ba
46. 6 to the Gate Driver PC Board A15 matching the orientation when removed Replace any user wiring to the various Main Control PC Board A1 terminals e g TB3 TB8 J6 J3 etc See Section 2 1 for the steps to restart the AT30 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 ac input or dc output circuit breaker CB1 CB2 Turn off and remove all power to the AT30 Remove the Plexiglas safety shield Disconnect the battery from the dc output terminals TB1 This includes remote sense wires if they were installed Check with a voltmeter before proceeding Remove the mounting screws from the circuit breaker on the mounting bracket and carefully remove the breaker from the AT30 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 fasteners are tight Install the replacement breaker into the bracket reversing the procedure above using the original mounting screws SERVICING THE AT30 Replacing the ac surge suppressors VR2 VR4 or VR5 Turn off and remove all power to the AT30 Remove the Pleziglas safety shield Disconnect the battery from the dc output terminals TB1 For VR2 connected to L1 VR4 connected to L2 or VR5 connected to L3 remove the har
47. A1 52 SERVICING THE AT30 PROBABLE SYMPTOM CAUSE RECOMMENDED ACTION 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 selected voltage as if the battery were at 77 F 25 C 2 Main Control 2 Recalibrate the voltmeter accuracy as described in Section PC Board A1 2 3 7 or another component may have been replaced 3 R4 or R14 is 3 See page 61 of Section 3 5 Locate R4 and R14 on the defective or Gate Driver PC Board A15 Remove one end of each resistor wrong value and measure its value with an Ohmmeter See the table in Section 3 6 for resistance values If either resistor is not within 196 of the specified value replace R4 and or R14 as needed 4 Defective 4 Turn off both front panel breakers If the AT30 does not Main Control have breakers fuses instead lock out ac and dc power to the PC Board A1 AT30 externally Wait one minute Return dc power to the AT30 first followed by ac power If the AT30 still has the wrong output voltage replace the Main Control PC Board A1 Charger 1 Current Limit 1 If the AT30 is not in the Edit Mode press the never set too low key five t
48. AGLEEYE SALES amp SUPPORT LATICES call 1 414 962 EEPS 3377 toll free 1 877 805 EEPS 3377 email info eepowersolutions com www EEPOWERSOLUTIONS com
49. AM Mm NOTICE 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 de energize and lock out all ac and dc voltage sources to the AT30 Check with a voltmeter before proceeding Restart the AT30 only when necessary to make the sensitivitv adjustment If your batterv is grounded do not attempt this procedure Refer to the image at the right and the internal component lavout drawings in lS Appendix C for specific I O panel FI Bl E configurations and terminal specs Lo A A Connect the test resistor between TB1 and ground Adjust RA3 counter EE clockwise until the front panel indicator goes out then adjust clockwise until the jil Io POS GND indicator just lights Make c INPUT GND this adjustment slowly for the indicator is ui m only updated once every four seconds Q Q Q TEST RESISTOR 5 30 kOhm De energize and lock out power to the AT30 Remove the test resistor and verify the POS GND indicator goes out Connect the test resistor between TB1 and ground Verify that the NEG GND indicator lights If not adjust RAS clockwise until it just does Remove the test resistor and return the AT30 to normal operation 34 OPERATING THE AT30 2 3 5 Using
50. AT30 SERIES Operating and Service Instructions MICROPROCESSOR CONTROLLED FLOAT BATTERY CHARGER THREE PHASE INPUT 25 1 000 Adc UY EAGLEEYE HiNDLEPOoOWER Eagle Eye Power Solutions JA5011 03 4230 N Oakland Ave 176 Milwaukee WI 53211 Phone 877 805 3377 Web www eepowersolutions com HOW TO READ THE AT30 MODEL NUMBER The AT30 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 AT30 DESCRIPTION CODE FEATURE DESCRIPTION CODE FEATURE A SERIES AT30 AT30 BATTERY CHARGER AC CIRCUIT S STANDARD 012 12 Vdc p BREAKER M MEDIUM AIC E DU Oum 024 24 Vdc SANG ya H HIGH AIC VOLTAGE 048 48 Vdc 0 NO AC BREAKER 130 130 Vdc AC FUSES F SUPPLIED G CODE FEATURE CODE FEATURE 200 kAIC X NOT SUPPLIED 025 25 Adc 200 200 Adc GEES S STANDARD 030 30 Adc 250 250 Adc u BREAKER M MEDIUM AIC NOMINAL 040 40 Adc 300 300 Adc RATING H HIGH AIC C DC OUTPUT 050 50 Adc 400 400 Adc SEE TABLE 0 NO DC BREAKER CURRENT 075 75 Adc 500 500 Ade DC FUSES F SUPPLIED 100 100 Adc 600 600 Adc J 20 kA X NOT SUPPLIED 125 125Adc 800 800Adc x AUXALARM A S
51. ATURED A130 OPTION COMPONENTS RELAY PC BOARD NOTE 1 OC FILTERING ASSEMBLY TERMINAL BLOCK NITE 2 C1 DC OUTPUT FILTERING CAPACITOR CRI POLARITY DIE ATURE COMPENSATION PROBE EL INGUCTOR INTERCONNECTION POINT 10 gt RESISTOR L2 FILTERING INOUCTR 10 gt THERMISTOR RI FILTER CIRCULT BLEED RESISTOR 2 BATTERY ELININATIR FILTER CAPACITOR MODULE PC BOARD NITE 1 yR3 AL INPUT LIGHTING ARRESTIR LINE D R2B THERMOSTAT S2 SENSING RESISTOR LINE 2 S2 SER MOOQULE THERMOSTATS PART OF Alb LINE 3 B2 SCR MOOULE CHI Hb COOLING FAN PART OF ALB CEA Ihre GE ION 071312 lm BY MCR 051706 TTE AT30 BATTERY CHARGER MAINFRAME SCHEMATIC WITH COMMON OPTIONS 013007 Nantes SE ae RE 051706 ES ges NOTED oasis JE5092 99 2 B IN INCHES TOLERANCES ARE SCALE Ts PART Na JE5092 99 DF http www ATSeries net PDFs JE5092 99 pdf 83 APPENDIX C Standard Drawings Connection Diagram AT30 Battery Charger Mainframe Power Wiring w Common Options JE5093 99 I 0 TERMINAL 10 GR YE BOARD lt TB12 CH SSIS H NITE 5 GROLINO NOTES AC PROTECTION A IN UNITS WITHOUT AC FUSES FIA FIB FIC WIRES Q1A D2B AN D2A ARE NOT FEATLRED B IN UNITS WITHOUT OC FUSES F3 F4 gt WIRES 28 AND 29 ARE
52. AWG 3REAKER Oct INE PR LECTIN CA BY MCR 020607 TITLE 23260 071312 UNG By MFG ECN LOG CTRONIC APPROVAL SIGNATURES AT30 SERIES BATTERY CHARGER OPTIONAL INTERNAL COMPONENT LAYOUT STVLE 163 20537 ECN No 020607 DATE UNLESS OTHE ARE IN INCHES E NOTED DIMENSIONS TOLERANCES ARE DRAWING No JE5098 99 SCALE NTS B F PART No JE5098 99 http www ATSeries net PDFs JE5098 99 pdf 77 APPENDIX C Standard Drawings Instrument Panel PC Board Detail AT30 Battery Charger w Optional Auxiliarv Alarm Relay PC Board JE5091 39 INDICATUR LIGHTS lt LEOs DSOI GREEN AC ON DSIO RED DS02 RED DC VOLTS DSI1 RED DS03 RED DC AMPERES DSI2 RED DSO4 RED EQUALIZE HRS REMAINING DSI3 RED DSOS GREEN FLOAT DSI4 RED DS06 AMBER EQUALIZE DSI5 RED DSO7 AMBER MANUAL TIMER DSI6 RED DSO8 AMBER MANUAL EQUALIZE DSI7 RED DS09 AMBER AUTO EHLIALIZE TIMER DSI8 RED LOW LEVEL DETECT METER DISPLAY METER DISPLAY HIGH DC VOLTAGE LOW DC VOLTAGE DC OUTPUT FAILURE AC INPUT FAILURE POSITIVE GROUND NEGATIVE GROUND OAN O mvars DE AMPERES O S pm O taz Ei EH E Ed ATQ Advanced Technology BATTERY CHARGER RECTIFIER 154 OC O IS O OS O Pate O BJ O pp oo ken Bo A
53. D COMPONENTS AI MAIN CONTROL PC BOARO NOTE 1 gt AIS THREE PHASE GATE DRIVER PC BOARD NOTE 102 16 G PLLSE SER lt 01 06 gt MODULE NOTE 3 AITA SCR SNLEBER ASSY FC BOARD NOTE 1 gt 17B SCR SNLEBER ASSY PC BOARD NOTE 12 17C SCR SNLEBER ASSY PC BOARD NOTE 102 LA DL OUTPUT EMI FILTER CAPACITOR TO GROUND cso DC OUTPUT EMI FILTER CAPACITOR TO GROUND cal AL INPUT CIRCUIT BREAKER CB2 DE OUTPUT CIRCUIT BREAKER FREE WHEEL ING O100E L1 MAIN INJULTOR DI SILICON CONTROLLEO RECTIFIER A1BA gt NOTE 3 H2 SILICON CONTROLLEO RECTIFIER A1BA gt NOTE 3 H3 SILICON CONTROLLEO RECTIFIER 1BB NOTE 3 DA SILICON CONTROLLEO RECTIFIER AIP NOTE 3 HS SILICON CONTROLLEO RECTIFIER A1BC gt NOTE 35 OB SILICON CONTROLLEO RECTIFIER A1BC gt NOTE 35 STANDARO AT3D COMPONENTS Ri MAIN OC SHUNT R2 CURRENT RATING RESISTOR R3 POWER SUPPLY BALLAST RESISTOR RA EXTERNAL SCALING RESISTOR 4 RB INTERNAL SCALING RESISTIR EXTERNAL SCALING RESISTIR Ti POWER ISOLATION TRANSFORMER TBI NPUT OUTPUT TERMINAL BLOCK SUMMARY ALARM TERMINAL BLOCK TBB VRI OC OUTPUT SURGE SUPPRESSOR TO H INPUT SURGE SUPPRESSOR LINE 1 INPUT SURGE SUPPRESSOR LINE 2 INPUT SURGE SUPPRESSOR LINE 3 VRE OC OUTPUT SURGE SUPPRESSOR TO GROUND VR7 OC OUTPUT SURGE SLPPRESSOR TO GROUND VR2 AC VRS AC OPTIONAL TEMPCO PROBE A1O INTERLONNELTOR NOTE 2 80
54. 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 AT30s are alarm setting Refer to Section 2 3 4 connected in parallel both sense the output voltage If To enable the shutdown feature one AT30 runs away it will e The AT30 must be in normal operation not SUPPIY all the output the Edit Mode to enable High DCV Shutdown current The other has zero output current The high dc e Press and hold the UP key then voltage shutdown does not e Press the key operate in an AT30 with zero output current so that The HIGH DC VOLTAGE indicator lights and only the defective AT30 of the display flashes ON You can toggle the mm shuts down The other shutdown feature OFF and ON by pressing the AT30 will continue to CHRG MODE key repeatedly supply the load normally 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 key for this feature If the AT30 shuts down because of a high dc voltage the meter displays error code E 03 Reset the AT30 by turning the ac input circuit breaker CB1 off then on again 36 OPERATING THE AT30 2 3 7 Adjusting the Voltmeter Accuracy The AT30 voltmeter is adjusted at the factory to display the actual output voltage within 0 25 If you replace any component that
55. Detail AT30 Battery Charger UO Panels amp Rectifier Assemblies JE5163 00 FIGURE 5 FIGURE 6 150 250A RECTIFIER ASSY 300A RECTIFIER ASSY A16 PM5007 07 A16 PM5007 08 FIGURE 7 400A RECTIFIER ASSY A16 PM5007 09 m E 37 3 4 54 RI MAIN DC SHUNT PRI TER 52 GR VE d FAN B2C JA TI TRANSFORMER 52 GR VE THIRO A CHASSIS PET BOE 042908 RAM BY MCR 013007 TITLE AT30 SERIES BATTERY CHARGER CONNECTION DETAILS IZO PANEL amp RECTIFIER ASSY Alb 120107 RN Ne ares AE ccc yo 013007 RER MENTARE ETS elmi ema DATE SCALE Ts PART Na JE5163 00 REV http www ATSeries net PDFs JE5163 00 pdf 89 APPENDIK D RECOMMENDED FLOAT AND EGUALIZE 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 Float Voltage cell Egualize Voltage cell 2 33 Battery Cell Type An
56. ENTERI key the AT30 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 AT30 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 AT30 moves to the next parameter When you are finished adjusting the sixth parameter Current Limit press the EDIT ENTER key again The AT30 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 AT30 2 3 2 Setting the Float and Egualize 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 kev 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
57. EV This internal component layout drawing JE5098 99 depicts an AT30 Series battery charger housed in a Style 163 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 AT30s configured with such options 76 APPENDIK C Standard Drawings Internal Component Layout AT30 Battery Charger Style 163 Enclosure w Common Options JE5098 99 OF FRONT DOOR SYM STANDARD nid DESCRIPTION AL MAIN CONTRI BOARD ALS THREE SEH GATE DRIVER FC H ALG ka Rus R MODULE HEATSINK ise R PC BOARD OTY R SNIE ER OUTPUT FILTER CAP NEG ND Do EMI OUTPUT FILTER CAP ka UND DI AC INPUT CIRCUIT BREAKER C03 LH2 OC OUTPUT RT SC meh RA FREE WEE ING ING 0 LI WAIN A NOTE 1 IN DC SH NG RZ CURRENT RATING RESISTIR RA FIR SLPPLY BALLAST RES L t WER ISOLATION TRANSFORMER TBi 1 0 TERMINAL BOARD TB3 SUMMARY ALARM CONTACTS Tea OPT TEMPCO PROBE TERM BLOCK VI OUTPUT SURGE SUPPRESSOR TO gt VR2 INPUT SURGE SUPPRESSOR LINE 1 VRA INPUT SURGE SUPPRESSOR LINE 2 YRS INPUT SURGE SUPPRESSOR LINE 3 VRG OUTPUT SURGE SUPPRESSOR l 2 WI OUTPUT SURGE SUPPRESSOR SYM OPTIONAL COMPONENT DESCRIPTION RONT VIEW BACK SIDE B D o sata E S el BIH c s A B C YR DOOR Ge GROUND
58. Enclosure type and weight ole 3 Mounting the AT IA b pp bb eek 4 5 1 Floor Mounting the ATS30 nn menn 4 5 2 Wall Mounting the AT30 nn eene 6 5 3 Rack Mounting the AT3O L nn menn 8 Changing the transformer Lopes 10 Making the ac input connections mme 12 Making the dc output Connection 14 Wiring the AT30 for remote sensing sesee eH 16 Wiring to the remote alarm contacts nn eaaa eaaa nawa anaa aana 18 Auxiliary Alarm Relay PC Board optional 19 Installing the temperature compensation probe optional 20 Using temperature compensation sesasi e eaaa eaaa aana mme 22 Installing the AT30 for remote communications optional 23 Installing the AT30 for forced load sharing optional nn 23 2 Operating the AT30 Battery Charger 2 1 Starting the AT30 2 1 1 Understanding the start up seguence nn 24 2 1 2 Checking the installation AAA AUA AA WAA 24 2 1 9 Starting the AT 30 EE 24 Using the digital meer ss nanna 24 Factory settings table iade p p e KEN dasa p cede Fn 25 2 2 Using the AT30 front panel features 2 2 1 If the meter displays an error message 26 2 2 2 Selecting the meter mode i i ette ener nnne ata 26 2 2 3 Selecting the Float or Equalize mode sse 27 2 2 4 Choosing the Equalize method 27 Manual Timer method wwwwsawawwnaaanwnnwanuna
59. Ground Detection in Charger Standby Mode If you put the AT30 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 AT30 is in standby as described below e Put the AT30 into standby by opening the ac input circuit breaker CB1 and leaving the dc circuit breaker CB2 closed Operating the AT30 with the ac breaker CB1 closed but the dc breaker CB2 open is an abnormal condition It is not recommended 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 AT30 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 AT30 following the instructions in Section 2 1 Setting the Current Limit value The AT30 automatically limits its dc output current in case of overload or battery d
60. KKG KG 4576 4576 GKKG 4576 CHASSIS SErERFIE GROUND 10 GR YE 40 38 al 52 GR VE O REMOTE NITE 2 CA l FIGURE 9 STVLE 5030 1 0 TERMINAL BOARD TBI gt CHASSIS GROUND S2 GR YE FIGURE 8 STYLE 5018 I O TERMINAL BOARD TBI NOTES 1 ALL COMPONENTS ARE CONNELTEO WITH FLAME RETARDANT 8 SWITCHB ARD INSULATION SYSTEM SIS TYPE WIRING IDENTIFIED ON EACH END WITH NLMBER CODED MARKERS 10 GR YE 52 GR YE WHEN REMOTE SENSE IS SE WIRE 3B CONNECTS TO REMOTE NOTE 2 SENSE gt AND WIRE 4D CONNECTS TO REMOTE SENSE REMOTE 1 0 PANELS AND RECTIFIER ASSEMBLIES ARE NOT DRAWN TO SCALE o ba FUR AFFRIRRLATE RECTIFIER Faery REFER m Te EE CHASSIS PARTS DATA PACKAGE REPORT AND IDENTIFV THE FACTORY PART NUMBER BY CIRCUIT SYMBOL Alb NS LI PIGRE igs GROUND FOR APPROPRIATE I O PANEL LAYOUT REFER TO THE AT30 USER S 1 0 TERMINAL NANJAL TO IUENTIFY ENCLOSURE TYPE STVLE 5018 5030 163 BOARD TB1 SEE STANOARO DRAVING JESOB4 DO FOR FULL SIGNAL WIRING FROM DISPLAYED COMPONENTS A1B amp TBL TO CONTROL COMPONENTS AIS Al7x RI R3 amp TID 88 APPENDIK C Standard Drawings Connection
61. MPONENT DRAWING FOR EXACT LAYOUT OF INDIVIDUAL 1 0 PANELS BATT ELIMINATOR FILTER CAP AC INPUT CKT BKR amp FLISES BASED UPON UNIT RATING SEE DETAIL DRAWING E5163 00 OR RECTIFICATION SCHEMATIC LABEL ON SIDE OF SCR MIDULECS gt FOR APPRIFRIATE CONTACT POINTS ALIXILIARY ALARM RELAY PC BOARD AC INPUT LIGHTNING ARRESTOR 6 NUMBER TYPE AND ARRANGEMENT OF CONTACTS ON B PULSE RECTIFIER ASSY A16 VARIES S DC OUTPUT CKT BKR amp FUSES EXTERNAL TEMPCO REMOTE PROBE 7 PHYSICAL MOUNTING OF CERTAIN COMPONENTS MAY DOUBLE AS ELECTRICAL CONNECTIONS ELIMINATING THE NEED FOR CERTAIN WIRES SUCH AS 415 AND A This connection diagram JE5093 99 depicts the mainframe power wiring of an AT30 Series battery charger with ALL features and options available from the standard ordering code Refer to the model number featured on the data nameplate and the supplied Parts Data Package report to identify which components are applicable to each individual unit 84 APPENDIK C Standard Drawings Connection Diagram AT30 Battery Charger Mainframe Power Wiring w Common Options JE5093 99 E TEMPERATURE NOTE 3 COMPENSATION CHASSIS SUMMARY SHIELDED PROBE AIO GROUND THREE PHASE ALARM GROLND GATE DRIVER t NC NG PC BOARD AIS JA PA AUXILIARY ALARM i RELAY PC BOARD AS 126 MAIN CONTROL ra ap PC BOARD Al 1 2 3 7 e a I 3l al s tal2o 21 25 26 27131 22 33 TBAB 4 a tout i tve
62. NCE High voltages appear at several points inside the AT30 Use extreme caution when working inside the enclosure Do not attempt to work inside the AT30 unless vou are a qualified technician or electrician Disconnect and lock out all power from the AT30 before starting to remove or replace anv components Turn the ac power off at the distribution panel upstream from the charger Disconnect the batterv from the AT30 output terminals TBI 4 Keep it clean The AT30 charger is cooled bv natural convection At least once a vear vacuum the vents at the top and bottom of the enclosure to ensure that there is an adeguate supply of cooling air If you have an extremelv dustv environment especially if airborne dust is conductive carefully vacuum out the interior Clean the surfaces of circuit boards and clean around electrical terminals The AT30 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 AT30 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 AT30 Check remote sense wiring optional If you wired the AT30 for remote sense check the signal connections to the battery or
63. NG AINTAINEO BY NFG ECN LOG DRAWING No m D LOAD SHARING RG TEST 051705 Ais EE Sa en gis JE5091 39 5 B DATE SCALE we PARTNo JE5091 39 SEET IF http www ATSeries net PDFs JE5091 39 pdf 79 APPENDIX C Standard Drawings Schematic AT30 Battery Charger Standard w o Options JE5092 00 RECTIFIER ASSEMBLY A16 TBI toj aaa TRANSFORMER TN AN PRI SEC nc Li 9 Zz n VR2 N ji am L n AN E l RA j gt UG FP VRS 3 lt GND D GR LND NOTES 1 FOR COMPONENT DETAILS OF ALL PC BOARDS CAL A18 A17 etc SEE ORAWING JESOBIL 30 2 CHARGER ENERGIZED AN AL SAFE ALL ALARM CONTACTS CHARGER IS POWERED DOWN C 0 5A e I25VAL VOC RESISTIVE 3 A RESISTORS R4 R6 amp RIA FEATURED INTERNALLY ON GATE DRIVER PC BOARD A15 5 FEATURED EXTERNAL TO SLIMMARY ALARM SUMMARY ALARM TERMINAL BLOCK TB3 NOTE 2 ALL ALARM CONTACTS SHOWN IN NON ALARM STATE WITH vi ARM RELAYS ENERGIZEU FAIL ILL CHANGE STATE WHEN TACT RATING IS SIX 6 SERs 01 05 ARE CONTAINED WITHIN NE MOLLE CAIB2 PROOUCING B PLLSE RECTIFICATION IN 48VDC AND 130VIC Li ITS BALLAST RESISTOR 835 IS IN CONTROL CIRCUIT AS SHOWN ya STANDARU AT3
64. NI SERVICE SERVICE J kI B LR CODE AlSpries net ENERGIZEU FAIL SAFE IS POWERED DOWN INSTRUMENT PANEL PART No FKOIS1 01 NOTE UNLESS OTHERWISE SPECIFIED ALL ALARM TERMINAL BLOCKS TB3 TBA TBB ARE SQLOERLESS COMPRESSION TERMINALS ACCEPTING 22 14 AWG WIRE CONTACTS SHOWN IN NON ALARM STATE WITH CHARGER ENERBIZEU AND ALARM RELAYS ALL ALARM CONTACTS WILL CHANGE STATE WHEN CHARGER CONTACT RATING IS 0 5A e 125VACANDE RESISTIVE ALL ALARM THREE PHASE GATE DRIVER PC o o apsaanoooanan apsaanopoanan COMPENSATED UNCOMPENSATEO DISABLE ENABLE RAJ OISABLE ENABLE MAIN CONTROL PC BL MEL E ES BIER vie Faku AC FAIL Ac Fan Sen Ise Spier aper E Naje X N C ke kalc ME HE ME aje Nc aje NC Naje IX wir 10 13 i2 fa 44 6 i8 7 wlan 21 22 72 24 28 77120 20 20 34 3 sala wA NE m y Yo TES Em wa wx wx T wx to talc ie bale ve 13 aj amp Bj au CO TITTITI olofolojololojojofojofojolololojolololojefojojojo o o olo 732314335783 4 420202221 24 A ES AUXILIARY ALARM RELAY PC BOARD A52 FRONT VIEW FACING CHARGER 0 HINDLEPOWE
65. OR VENTILATION FOUR 4 0 625in 16mm FLOOR MOUNTING HOLES ARE PROVIDED ON BOTTOM OF ENCLOSURE AS SHOWN SIK 6 1 3lin 7 33mm DIA STANDARD PRE FAB CONDUIT KNOCKOUTS ARE PROVIDED AS SHOWN FOR lin 7 25mm CABLE ENTRY BOTTOM CONDUIT ENTRY IS POSSIBLE THROUGH EXPANDED METAL LINDERSIDE IF ADDITIONAL CONDUIT ENTRANCES ARE REQUIRED ENCLOSURE SHOULO BE FIELO MODIFIED BY INSTALLER BATTERY CHARGER SHIPPING WEIGHT SEE PRODUCT LITERATURE gt in DUAL DIMENSIONS THIRD e El ANGLE PROJECTION DRAWN BY MCR 092506 TITLE AT30 BATTERY CHARGER OUTLINE 23261 NEMA 1 STVLE 163 ENCLOSURE 071412 ELECTRONIC APPROVAL SIGNATLRES 20343 MAINTAINED BY NFG ECN LOG DRAWING No ME S EECH JES095 00 ECN No DATE SCALE NTS PART Na JES085 00 http www ATSeries net PDFs JE5095 00 pdf 71 APPENDIX C Standard Drawings Internal Component Layout AT30 Battery Charger Style 5018 Enclosure w Common Options JE5088 99 SIDE SECTION FRINT VIEW d e lt E l d L INDUCTOR ja m f tU gt EI a e NL e Bi 4 x 0 d EB 8 e e z E x d INDUCTOR 5 x a l a E E VR3 CB2 E LOACATED CIRCUIT b ESA BEHINO BREAKER Joe a RES CAPACITORS E CBI Ve LEM LILI u L 1 1 1 f Be CB2 e d IL AC CIRCUIT DC CIRCUIT BREAKER BREAKER TRAN
66. PC Board A1 Board A1 SERVICING THE AT30 PROBABLE SYMPTOM CAUSE RECOMMENDED ACTION Lamp test key 1 No Vac 1 The lamp test key does not work during an ac power failure does not work or some lamps 2 Main Control PC Board A1 is 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 do not light not secured to the panel All indicators should extend about 0 125in 3 18mm front panel through the front of the panel 3 Defective 3 When you press the LAMP TEST key if some but not all Main Control PC indicators light or the digital meter does not display 8888 Board A1 replace the Main Control PC Board A1 One or more 1 Front panel is 1 Open the front panel and be sure that jumper J9 on the Main front panel locked Control PC Board A1 is in the ENABLE position keys donot 2 Main Ctrl PCB 2 Open the front panel and be sure that the Main Control PC work is not secured to Board A1 is firmly seated on the standoffs on the back of the front panel panel Front panel keys must operate freely 3 Defective 3 Turn off both front panel breakers If the AT30 does not have Main Control PC breakers fuses instead lock out ac and dc power to the AT30 Board A1 externally Wait one minute Return dc power to the AT30 first followed by ac power If some of the front panel keys still do not work replace the Main Cont
67. Quick Setup Sheet are supplied You received all items on the packing list OO L1 L1 L1 L1 00 INSTALLING THE AT30 1 4 MOVING THE AT30 Once you have established that the AT30 is undamaged identify the enclosure style of your unit Refer to the table below Standard AT30 NEMA 1 Type Enclosures Style 5018 Style 5030 Style 163 Style 198 Output Voltage Ampere Rating 25 Adc 12 Vdc 24 Vdc 48 Vdc 130 Vdc 30 Adc 40 Adc 50 Adc n a n a n a Style 5018 n a n a n a Style 5018 Style 5018 Style 5018 Style 5018 Style 5018 Style 5018 75 Adc Style 5018 Style 5018 Style 5018 Style 5018 100 Adc 125 Adc 150 Adc Style 5018 Style 5030 Style 5030 Style 5018 Style 5030 Style 5030 Style 5018 Style 5030 Style 5030 Style 5030 Style 5030 Style 5030 200 Adc 250 Adc Style 5030 Style 5030 Style 5030 Style 5030 Style 5030 Style 5030 Style 5030 Style 163 300 Adc 400 Adc Style 5030 Style 5030 Style 163 Style 5030 Style 163 Style 163 Style 163 500 Adc Style 163 600 Adc Style 163 Style 163 Style 198 Style 198 Style 198 800 Adc Style 198 Style 198 Style 198 1 000 Adc Style 198 Style 198 Style 198 Comprehensive weight data for the different models is available in the AT30 product literature JF5018 00 The four standard NEMA 1 type enclosures do not feature top lifting eyes for mo
68. R one Jitz P SE ess SCR SNLIBBER PC BOARD A17 THREE 3 RED l a PER CHARGER 3 AS J1 CONNECTED TO A1 J2 VIA EH5045 XX OTHER CONTROLS 8 PIN SERIAL CABLE RAI LOW LEVEL DETECT ADJUST GROUND FAULT BALANCE GROUND FAULT SENSITIVITY RAZ RAJ NON USER ACCESSED JLNPERS 43 OLD 45 RIBBIN CONNECTOR BOARD FROGRAMMING OLD FORCED LOAD SHARING NANUFACTURING TEST OLD INTERNAL TEMP JIZ J14 IIS JIB This instrument panel drawing JE5091 39 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 AT30 battery chargers feature one 1 set of form c summary common alarm contacts TB3 78 APPENDIK C Standard Drawings Instrument Panel PC Board Detail AT30 Battery Charger w Optional Auxiliary Alarm Relay PC Board JE5091 39 JRIVER PC BOARD A15 HREE PHASE GATE DRIVER PC BOARD AI5 o paappoann paappoanp DISPLAY D ee JEBB So I3 J T C3 m2 DS11 DS12 RAB Ds13 Ga r 1 z co med ai di p ULI osis B A i ASSEM Y A12 i pa uza usi gi euch ji FM 0817 e FOR DETAILS 2 0510 yl 1 E s Ges e n ds o S i E o 03 20 Ji 9 H E lt u
69. R COOED MARKERS SEE DETAIL ORAWING lt JESIE3 00 OR CORRESPONDING INTERNAL COMPONENT DRAWING FOR EXACT LAYOUT OF SEC 2 GROUND WIRES 10 47 amp 52 ARE GREEN W YELLOW STRIPE INDIVIDUAL Lef PANELS YA ER WHEN REMITE SENSE IS USED WIRE 39 CONNECTS J25 08 TO B IN FILTERED UNITS WIRE 450 CONNECTS TD INOUCTOR REM SENSE AND 40 CONNECTS J25 10 TO REM SENSEC INTERCONNECT POINT EJ3 gt AS SHOWN WIRE 50 CONNECTS TD CB2 1C4 IN UNFILTERED UNITS 4 48 130 VOC ARRANGEMENT SHOWN IN 12 24 VOC UNITS R3 IS INTERNAL 10 GATE DRIVER PCB AIS 7 AND WIRES x10 49 amp 51 ARE NOT USED Ye jen S ur DRAW BY MER 012307 JUTE AT30 SERIES BATTERY CHARGER CONNECTION ELECTRONIC APPROVAL SIGNATURES DIAGRAM MAIN CONTROL SIGNAL WIRING MAINTAINED BY WG ECN LOG DRAWING No REV UNLESS Waat NOTED DESTINS JE 50 94 00 ARE IN INCHES TOLERANCES ARE SCALE we PARTNa JESQg4 00 http www ATSeries net PDFs JE5094 00 pdf 87 APPENDIX C Standard Drawings Connection Detail AT30 Battery Charger O Panels 4 Rectifier Assemblies JE5163 00 FIGURE 1 FIGURE 3 FIGURE 4 25 50A RECTIFIER ASSY 75 100A RECTIFIER ASSY 125A RECTIFIER ASSY A16 PM5007 10 A16 PM5007 01 16 PM5007 0B G
70. S FEATURED AT30 OPTION COMPONENTS A1 MAIN CONTROL PC BOARO NITE 1 RI NA IN DC SHLNT AS ALIXILIARY ALARM RELAY PC BOAF AIS THREE PHASE GATE RIVER PL BOARD NOTE 1 R2 CURRENT RATING RESISTOR TBA AUXILIARY ALARM TERMINAL BL ANG B PLLSE SER lt 01 06 MODULE NITE 3 R3 POWER SUPPLY BALLAST RESISTOR KNOTE 5 AITA SER SNLEBER ASSY PC BOARD NITE 1 RA EXTERNAL SCALING RESISTOR NOTE 4 ALO EXTERNAL TEMPERATURE COMPENS A17B SCR SNLEBER ASSY PC BOARD NITE 1 RE INTERNAL SCALING RESISTOR NDTE 4 RI3 TEMPCO PROBE AIO RESISTOR A 17C SER SNLEBER ASSY PC BOARD NITE 1 R14 EXTERNAL SCALING RESISTOR l 2 lt NOTE 4 T TEMPCO PROBE A10 THERMISTOR CA DC OUTPUT EMI FILTER CAPACITOR C TO GROUND TI POWER ISOLATION TRANSFORNER Ala COMMUNICATIONS MOOULE PC BOAF cs DE OUTPUT EMI FILTER CAPACITOR TO GROUND TRI INPUT OUTPUT TERNINAL BLOCK FIA AC INPUT FUSE LINE 12 CB AE INPUT CIRCUIT BREAKER TB3 SUMMARY ALARM TERMINAL BLOLK NOTE 2 FIB AC INPUT FUSE LINE 22 CBZ DC OUTPUT CIRCUIT BREAKER TB8 OPTIONAL TEMPCO PROBE AJO INTERCONNECTOR FIC AC INPUT FUSE LINE 3 F3 DC OUTPUT FUSE 4 CRA FREE WHEELING DILE VRI OC OUTPUT SURGE SUPPRESSOR gt TO FA DC QITPUT FUSE VR2 AC INPUT SURGE SUPPRESSOR LINE 1 LI MAIN INDUCTOR VRA AC INPUT SLRGE SUPPRESSOR LINE 2 VRS AC INPUT SURGE SUPPRESSOR LINE 3 DI SILICON CONTROLLEO RECTIFIER C L6 NOTE 3 VR6 QC OUTPUT SURGE SUPPRESSOR gt TO GROUND H2 SILICON CONTROLLEO RECTIFIER AL6A NOTE 3
71. SFORMER TRANSFORMER TI E Ti gen PLEKIGLAS SAFETY COVER AC FUSES FIC B A TO BE PLACED NEAR BATT O ID TERMINAL DESCRIPTION TYPE CONNECTION TAlc POS NEG OUTPUT TERMINALS CLI ALUMINUM COMPRESSION LUG 14 170 ANG REM SENSEC POS NEG REMOTE SENSE TERMINALS 1 4 20 ZPS STUDS 1 4in RING LUG 2 TBl GND USER GROUND TERMINAL CLI ALUMINUM COMPRESSION LUG 814 170 AWG TBL LI L2 L3 AC INPUT TERMINALS CU ALUMINUM COMPRESSION LUG 14 1 0 AWG TB3 SUMMARY ALARM TERMINAL BLOCK SOLOERLESS COMPRESSION 422 14 AWG TB4 AUXILIARY ALARM TERM BLOCK SOLDERLESS COMPRESSION 22 14 AWG TB8 TEMPCO PROBE ALO INTERCONNECTION TERMINAL BLOCK 22 14 AWG This internal component layout drawing JE5088 99 depicts an AT30 Series battery charger housed in a Style 5018 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 AT30s configured with such options 72 APPENDIK C Standard Drawings Internal Component Layout AT30 Battery Charger Style 5018 Enclosure w Common Options JE5088 99 SYM STANDARD COMPONENT DESCRIPTION STANDARD DRAWING NOTES AL MAIN CONTROL FC BOARD A gt ARRANGEMENT AND NUMBER OF COMPONENTS AIS THREE PHASE GATE DRIVER PC BRD MAY DIFFER SLIGHTLY BASED UPON UNIT E kal Sa Cae BI x taj
72. Series Charger Quick Setup Sheet EJ5088 XX EJ5130 XX http www AT Series net PDFs E 5088 XX pd Ft Laun A Tee rei DLC 5130 XX pcF AT Series Ground Detection Voltmeter AT Series Barrier Type Alarm Terminals EJ5136 XX Hip WwWw ATSeries net PDFs E 5136XX pdf AT Series Battery Discharge Alarm EJ5137 XX Hip WwWw ATSeries net PDFS E 5137 XX pdf AT Series End Of Discharge Alarm JA0091 03 hitp www ATSeries net PDFs A0091 03 pdf AT30 Style 5018 Rack Mtg Instructions JA0092 02 hitp www ATSeries net PDFs A0092 02 pdf AT30 Style 5018 NEMA 2 Drip Shield JA0092 03 Hitp WwWw ATSeries net PDFs A0092 03 pdf AT30 Style 5030 NEMA 2 Drip Shield JA0092 04 Fttp www ATSeries net PDFs A0092 04 pdf AT30 Style 163 NEMA 2 Drip Shield JA0108 01 hitp Wwww ATSeries net PDFs AO108 01 pdf AT30 St 5018 5030 Cab Padlock Acsy JA5060 03 hitp www ATSeries net PDFs A5060 03 pof AT30 Style 5018 Cabinet Heater Acsy JA5060 04 F wt Al See rel A5060 04 pdf AT30 Style 5030 Cabinet Heater Acsy JA5063 00 L wan Ales FPE A5063 00 pcf AT30 Style 5018 Wall Mtg Instructions JD0064 00 http www ATSeries net PDFs D0064 00 pdf Preventative Maintenance Procedure JD0064 01 http www ATSeries net PDFs D0064 01L pdf AT Series Charger Start up Procedure JD5003 00 h
73. Tt gr 1 I u clo EI s gt a gt i STUD 1 1 ES ar 5 L8 amp S Jz E JE IE s Be golog li OF ii JA cat Ac cae oc 8 SISS po CIRCUIT CIRCUIT __ BREAKER _ BREAKER STANDARD C A ARRANGE o COMPONE HASED L 2 TRANSFORMER 3 TRANSFORMER I FEATURE TI a n B SEE JES CHASSIS MASS FUSES E STLD D F T le al d LI LI el AC FLISES A BA x AC Fuse EE NOTES NEAR BATTERY 1 FOR CELL A15 A10 Sj XXf amp 7 X Xn CABLE 2 1 0 FOR 74 APPENDIK C Standard Drawings Internal Component Layout AT30 Battery Charger Style 5030 Enclosure w Common Options JE5089 99 SYM STANDARD COMPONENT DESCRIPTION A MAIN CONTROL FC BOARD As THREE PHASE GATE DRIVER PC BRO SI ER BOARD 4 ei Wi cgorhos BREAKER MOUNTING BRACKET BI AC INPUT CIRCUIT BREAKER D3 Li N I AIN DC SHUNT RI R2 CURRENT RATING RESISTOR gi R3 ENG SUPPLY BALLAST RES L3DVDC POWER ISOLATION TRANSFORMER 1B1 1 0 TERMINAL BOARD 1B3 SUMMARY ALARM CONTACTS 188 1EMPCO PROBE TERMINAL BLOCK VRI OUTPUT SURGE SUPPRESSOR TO INPUT SURGE SUPPRESSOR LINE 1 VRA INPUT SURGE SUPPRESSOR LINE 2 VRG INPUT SURGE SUPPRESSOR LINE 3 VRE OUTPUT SURGE SUPPRESSOR l 2 VR7 OUTPUT SURGE SUPPRESSOR gt NOTE 1 o CI FILTER T a CAPACITORS 7 n MANLIAL POCKET SYM OPTIONAL COMPONENT DESCRIPTION 9 AS AUXILIARY ALARM RELAY PC BDARD Ap TEMPERATURE COMPENSATION
74. UPPLIED 150 150 Adc 1KO 1 000 Adc RELAY BOARD K NOT SUPPLIED U UNFILTERED L COPPER G SUPPLIED D ae F FILTERED STANDARD GROUND BUS x NOT SUPPLIED E BATT ELIMINATOR FILTER m LIGHTNING L SUPPLIED 208 208 Vac 60 Hz ARRESTOR X NOT SUPPLIED 240 240 Vac 60 Hz p ACINPUT 480 480 Vac 60 Hz n FUNGUS F APPLIED VOLTAGE 220 220 Vac 50 60 Hz PROOFING X NOT APPLIED 380 380Vac50f0Hz p STATIC S APPLIED 416 416 Vac 50 60 Hz PROOFING X NOT APPLIED DESCRIPTION CODE FEATURE DESCRIPTION CODE FEATURE INPUT AND OUTPUT INTERRUPTING CAPACITY RATINGS ORDER CIRCUIT AC CIRCUIT DC CIRCUIT OPTIONAL AC OPTIONAL DC CODE BREAKER BREAKER RATINGS BREAKER RATINGS FUSE RATING FUSE RATING TYPE 208 240 480 Vac 125 250 Vdc 208 600 Vac 12 24 48 130 Vdc S STANDARD 5 000 AIC 5 000 AIC M MEDIUM AIC 25 000 AIC 10 000 AIC 200 000 AIC 20 000 AIC H HIGH AIC 65 000 AIC 20 000 AIC Contact your sales representative for 500 600 Vac circuit breaker AIC ratings The factory configured model number printed on the AT30 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 wall rack mounting brackets zero center ground detection meter w test switch NEMA 2 type drip shield end of discharge alarm relay NEMA 4 12 13 type enclosure battery discharge alarm relay cabinet heater strips bar
75. ait one minute Return dc power to the AT30 first followed bv ac power If the AT30 output voltage is normal but the HIGH DC VOLTAGE indicator is still on replace the Main Control PC Board A1 No alarm but output voltage is above High DC Voltage setting 1 Output current is below 2 2 Defective Main Control PC Board A1 1 Output current must be greater than 2 of rated current to produce a High DC Voltage alarm See Parallel Operation portion in Section 2 3 6 2 Turn off both front panel breakers If the AT30 does not have breakers fuses instead lock out ac and dc power to the AT30 externally Wait one minute Return dc power to the AT30 first followed by ac power If the AT30 output voltage is above the alarm setting but the HIGH DC VOLTAGE indicator still does not light replace the Main Control PC Board A1 55 SERVICING THE AT30 normal but there is output current are mismatched 3 Defective rectifier bridge 4 Defective Main Control PC Board A1 5 Defective dc circuit breaker CB2 svMpTOM PROBABLE RECOMMENDED ACTION CAUSE LOW DC 1 Battery is 1 After an ac power failure or a battery discharge for any other VOLTAGE discharged reason it may take several hours to recharge the battery It is indicator is on normal for the LOW DC VOLTAGE indicator to be on until the but ac amp dc battery voltage is above the Low DC Alarm voltage breakers are Low DC
76. alue in the display upward or downward When the meter displays the desired equalize time in hours release the UP or DOWN 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 internally The same 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 the EDIT ENTER key three 3 more times until the AT30 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 AT30 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 AT30 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
77. ane 44 3 2 Interpreting front panel error messages 45 3 3 Using the troubleshooting chart eea nana ena ena Hee 48 3 4 Troubleshooting chart begins ON nanna nn 49 3 5 Replacing defective components nn 58 3 6 Ordering replacement parts 62 APPENDIX A AT30 Performance Specifications eese 64 APPENDIX B Field Installable Accessories ss mmmnnnzznnnnnnznnnnnanzznnnnznnzznnnznnzzznzn 65 APPENDIX C Standard Drawings Outline AT30 Battery Charger NEMA 1 Style 5018 Enclosure sess 66 Outline AT30 Battery Charger NEMA 1 Style 5030 Enclosure esses 68 Outline AT30 Battery Charger NEMA 1 Style 163 Enclosure sse 70 Internal Component Layout AT30 Style 5018 Enclosure w Common Options 72 Internal Component Layout AT30 Style 5030 Enclosure w Common Options 74 Internal Component Layout AT30 Style 163 Enclosure w Common Options 76 Instrument Panel PC Board Detail AT30 Series Battery Charger ss eaaa eaaa anana ane 78 Schematic AT30 Series Battery Charger Standard w o Options ne 80 Schematic AT30 Series Battery Charger with Common Options asasaran eaaa anane nenen anae 82 Connection Diagram AT30 Battery Charger Power Wiring w Common Options 84 Connection Diagram AT30 Battery Charger Control Signal Wiring e
78. anzunawazunaaanunaanunaaazunawazuna 27 Manual Equalize meibod nanna nn nn nn nat nn nn 28 Auto Equalize Timer method e eeenennnennnnnan mnn mee 28 2 2 5 Testing the front panel indicators sese 29 2 2 6 Testing the Auxiliary Alarm Relay PC Board optional 29 2 2 7 Interpreting the alarm indicators eaaa aee eaaa eaaa eaaa anaa naa anazaa 29 TABLE OF CONTENTS 2 3 Setting the AT30 parameters 2 3 1 Understanding parameter settings aaa eaaa eaaa naen aana nn nn 30 2 3 2 Setting the Float and Equalize voltages nn aana anana 31 2 3 3 Setting the Equalize mer 32 2 3 4 Setting the Alarms tog it e o ee a ga i 32 Setting the high and low dc voltage alarms eenen 33 Adjusting ground detection sensitivity essen 34 Disabling the ground detection aarm 35 2 3 5 Setting the Current Limit value essem 35 2 3 6 Enabling the high dc voltage shutdown feature eseeeeeseeeeeeeeeeeerrenene 36 2 3 7 Adjusting the Voltmeter acCuracy nn eaaa me 37 2 3 8 Using the Low Level Detector LD 38 2 3 9 Using the front panel security feature nennen 39 2 4 Performing routine maintenance nn nanna nanna nanna 40 Sample preventive maintenance Drocedure nn 42 3 Servicing the AT30 Battery Charger 3 1 A step by step troubleshooting procedure anaa aa aana a nean nenen a ren
79. 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 AT30s are connected to the same ac supply and that to ac power sources 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 Board A1 noting system requirements to restore correct load sharing operation 93 MANUAL SPECIFICATIONS DOCUMENT NUMBER The tekt and graphics contained within this manual are controlled by the battery charger manufacturer s internal part number JA5030 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 companv 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 JA5030 00 Revision Level 6 Engineering Change Number 23265 Electronic Filename JA5030 00 Rev6 doc Last Date Saved 8 28 2012 11 28 AM Last Date Printed 8 28 2012 11 35 AM PARTS DATA PACKAGE Any job specific customized Parts Data Package report supplied with this battery charger and or th
80. 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 Hyperlink Description JA0102 01 Hitp Www ATSeries net PDFs A0102 01 pof AT10 1 G1 Manual unlabeled JA0102 02 hitp www ATSeries net PDFs A0102 02 pdf AT10 1 G2 Manual unlabeled JA0102 03 hitp www ATSeries net PDFs AO102 03 pdf AT30 Manual unlabeled JA0102 04 http www ATSeries net PDFs AO102 04 pdf AT Comm Module Manual unlabeled JA0102 05 hitp www ATSeries net PDFs A0102 05 pdf AT DC Dist Panel Manual unlabeled JA5015 00 Hitp WwWw ATSeries net PDFs A5015 00 pdf AT TempCo Probe Acsy Instructions JA5054 00 Htip Aww ATSeries net PDFS A5054 00 pcf AT Forced Load Sharing Instructions JA5098 00 http www ATSeries net PDFs A5098 00 pdf AT Latching Alarm Relays Instructions JC5020 00 Hip WwWwWw ATSeries net PDFs C5020 00 pdf AT
81. ave followed the installation instructions carefully Check the ac input supplv voltage and the batterv voltage and be sure that thev match the information on the AT30 nameplate Verify that the jumpers on the main transformer T1 are correct for your ac supply voltage Open the front panel and check the battery polarity at the TB1 and terminals Starting the AT30 When you are sure that all connections to the AT30 are properly made follow these steps to start up the AT30 Using the Digital Meter When you first start the AT30 the meter display alternates between dc output voltage and dc output current Each reading is held for two 2 seconds Indicator lights to the left of the display indicate whether the meter is displaying voltage or current If you want to freeze the meter to display only voltage press the METER MODE key on the front panel To freeze the meter to display only current press the key again Press the key twice more to 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
82. d fuses 3 Defective 3 Measure ac voltage at the transformer primary taps T1 H1 T1 wiring H2 amp T1 H3 It should be the same as the ac supply voltage 4 Defective 4 Turn off both front panel breakers If the AT30 does not have Main Control PC breakers fuses instead lock out ac and dc power to the AT30 Board A1 externally Wait one minute Return dc power to the AT30 first followed by ac power If the AC ON and AC INPUT FAILURE indicators are both still on replace the Main Control PC Board A1 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 1 Shut down and disconnect the AT30 from the batterv and dc bus Check the batterv and dc bus for a ground fault See Application Note JD5032 00 for assistance 2 If the AT30 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 AT30 and is not recommended Close the dc breaker and the alarm should end To place the AT30 in standby open both front panel circuit breakers CB 1 CB2 3 Calibrate the AT30 ground detection sensitivity See Section calibration 2 3 4 4 Defective 4 Tum off both front panel breakers If the AT30 does not have wiring breakers fuses instead lock out ac and dc power to the AT30 externally Wait one minute Return
83. dard Drawings SIDE VIEW Kd de SN Sx SOR RL za Si 2020 AE EE aaa d Rx PRK KKK ROR RK CH lt gt g 2 RR E di 2 dE dE NNN ER SX di es xx g dy OR EKS te RRS dx xX E aa rans AN Outline AT30 Battery Charger NEMA 1 Style 5030 Enclosure JE5086 00 NOTES 1 ENCLOSURE IS A NEMA 1 7 IP20 TYPE STEEL CABINET WITHOUT GASKETS FINISH IS ANSI 61 GRAY EPOXY POWDERCOAT 2 ALLOW 12in 7 305mm OF FREE AIR ON TOP SIDES AND FRONT OF CABINET FOR VENTILATION 3 FOUR 4 0 B25in l6nm ARE PROVIDED ON BOTTOM FLOOR MOLINTING HOLES OF ENCLOSURE AS SHOWN 4 NINE 9 1 3lin 7 33mm DIA STANDARD PRE FAB KEY SLOT KNOCKOUTS ARE PROVIDEO AS SHOWN FOR lin 7 25mm CONDUIT ENTRY IF ADDITIONAL CONDUIT ENTRANCES ARE REQUIREO ENCLOSURE SHOULD BE FIELD MODIFIED BY INSTALLER 5 BATTERY CHARGER SHIPPING WEIGHT SEE PRODUCT LITERATURE in ram DUAL DIMENSIONS THIRD ANGLE PROJECT ION Qc TITLE DRAWN BY MCR 092506 AT30 SERIES BATTERY CHARGER OUTLINE NEMA STYLE 5030 ENCLOSURE APPR A 071412 ERE EM NES rr JESOBB OO UNLESS OTHERWISE NOTEQ DINENSICNS ARE IN INCHES TOLERANCES ARE 092506
84. dc power to the AT30 first followed by ac power 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 the AT30 off 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 Defective 5 Turn off both front panel breakers If the AT30 does not have Main Control PC breakers fuses instead lock out ac and dc power to the AT30 Board A1 externally Wait one minute Return dc power to the AT30 first followed by ac power If you are sure there is no ground fault on the external bus or within the AT30 but the POS GND or NEG GND indicator is still on replace the Main Control PC Board A1 6 Paralleled 6 Restart all other AT30s connected in parallel with unit that is AT10 1 s are experiencing ground fault Otherwise disconnect and lock out shut down from the dc bus all shut down AT30s Summary 1 Defective 1 Turn off both front panel breakers If the AT30 does not have alarm relay is Main Control PC breakers fuses instead lock out ac and dc power to the AT30 in alarm Board A1 externally Wait one minute Return dc power to the AT30 first mode but no followed by ac power If the relay remains i
85. drawing JE5086 00 2 Carefullv lift the AT30 above the anchor bolts using the methods described in Section 1 4 Guide the enclosure onto the floor bolt pattern and lower it into place 3 Add appropriate mounting hardware onto the floor mounting anchor bolts and tighten securely PROCEDURE Style 163 Style 198 1 Install four 4 0 5in 12 7mm anchor bolts into the floor per the mounting dimensions featured in the outline drawings JE5095 00 JE5096 00 2 Carefully lift the AT30 above the anchor bolts using the methods described in Section 1 4 Guide the enclosure onto the floor bolt pattern and lower it into place 3 Add appropriate mounting hardware onto the floor mounting anchor bolts and tighten securely GRAPHICS STANDARD NEMA 1 TYPE AT30 ENCLOSURES Style 5018 Style 5030 Style 163 see outline drawing see outline drawing see outline drawing JE5085 00 JE5086 00 JE5095 00 INSTALLING THE AT30 1 5 2 Wall Mounting the AT30 Style 5018 enclosure only To install the AT30 onto a vertical surface the standard Style 5018 enclosure does not need to be modified buta special wall mounting accessory EI5008 00 is required For kit availability see ordering information in Appendix B on page 65 The kit includes two 2 mounting brackets appropriate hardware and Installation Instructions JA5063 00 for the wall mounting procedure When wall mounting the AT30 consider the following 1 The wall
86. dware from the input terminal Lx and remove the lugged lead of the ac surge suppressor Install one lead of the replacement surge suppressor onto the Lx terminal Replace the other wires and the Lx terminal hardware Repeat procedure for the I O ground stud Tighten all hardware Nolaz The ac surge suppressors are not polarized Replacing the dc surge suppressor VR1 Turn off and remove all power to the AT30 Remove the Plexiglas safety shield Disconnect the battery from the dc 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 AT30 Remove the Plexiglas safety shield Disconnect the battery from the dc 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 the hardware Repeat for the other lead of the network on the I O ground stud For the network VR7 C5 use the
87. e brackets to the AT30 using the supplied 0 25in 6 4mm hardware and tighten securely 3 Using a scissor lift guide the AT30 into the front face of the 23in 584mm EIA relay rack 4 Adjust the height of the AT10 and mount in place using appropiate hardware not supplied 5 Refer to the graphics on the opposite page for the rack mounted enclosure footprint INSTALLING THE AT30 GRAPHICS RACK MOUNTING THE AT30 22 31in 567mm 21 50in 546mm ag ALLOW 6in 152mm ABOVE AND BELOW UNIT FOR COOLING NOTES 37 95in 964mm 7 75in 197mm 16 77in 426mm S 2 RRR 1 Rack mount AT30 Style 5018 enclosures are installed from the front 2 Refer to the Style 5018 enclosure outline drawing JE5085 00 in Appendix C on Page 66 for overall size and cabinet specifications 3 Refer to the detailed Installation Instructions JA0091 03 supplied with the kit for the special rack mounting procedure INSTALLING THE AT30 1 6 CHANGING THE TRANSFORMER TAPS AT30s are normally designed for a single ac input supply voltage Verify the ac voltage listed on the data nameplate decal and the CAUTION tag attached to the ac input circuit breaker CB1 The AT30 ac input transformer T1 is designed with a voltage tolerance of 10 to 12 If your particular site ac suppl
88. e 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 AT30 The end of the cable with two stripped wires and a quick connect terminal will be installed inside the AT30 e Leave 30in 762mm of cable inside the enclosure and route the other end to the probe at the battery 20 INSTALLING THE AT30 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 not long enough longer cable assemblies are available in lengths of 50 100 amp 200ft 15 2 30 5 amp 61 0m See Appendix B on page 65 for ordering information e Make sure wiring conforms to NEC local and site requirements Attach the interconnection cable to the AT30 as shown in the figure below QUICK CONNECT WIPIGGV Em mt BACK e Route the cable within MAIN CONTROL J30 the AT30 PC BOARD A1 enclosure so it runs with the wire harness to the back of the front panel and easily reaches the Main NG Control PC STRIPPED LEADS Board Al TO TB8 e At the Main Control PC Board Al insert one of the bare wires from the cable into each terminal of TB8 Polarity is not vita
89. ecifications apply at 77 F 25 C nominal ac line voltage amp nominal float voltage Specification Conditions 12 Vdc 24 Vdc 48 Vdc 130 Vdc Vac 10 12 0 to 100 load 0 25 Output voltage regulation Temp 32 122 F 0 50 C Freq 60 3 Hz 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 Efficiency Output ripple voltage per NEMA PE5 1996 All ratings 82 90 1 typ 29 Unfiltered with battery EMENDI b rms at batterv terminals 30 mV 100 mV Filtered with battery mV rms max m at battery terminals Filtered without battery 196 rms typ 2 rms Battery Eliminator Filter mU mS p Option without battery Current Limit adjustable 50 110 96 of rated output current Soft start 0 to 100 load 4 seconds Float 11 0 14 5 22 0 29 5 44 0 58 0 110 141 A Equalize 11 7 16 0 23 4 32 0 46 8 61 0 117 149 Voltage adjustment ranges High DC Voltage alarm 12 19 24 38 48 76 120 175 Low DC Voltage alarm 7 14 5 15 29 5 30 58 80 141 Voltmeter range Vdc 0 21 0 42 0 75 0 195 25 Adc nom output 0 30 30 100 Adc nom output 0 150 Ammeter range Adc 125 400 Adc nom output 0 500 500 800 Adc nom output 0 1000 1 000 Adc nom output 0 1 200
90. ed with the standard AIC ac input circuit breaker no ac fuses you need a feeder breaker or fuse rated to interrupt the short circuit current of your ac supply 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 AT30 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 1f supplied 2 Run the ac input supply wiring into the AT30 ending at terminals TBI LI TBI L2 TB1 L3 and TBI GND on the I O panel board 3 The AT30 features four 4 CU AL compression lugs on the ac input terminals e Style 5018 and Style 5030 enclosure ac lugs accept 14 1 0 AWG wire e Style 163 and Style 198 enclosure ac lugs accept 6 AWG 350 MCM wire 4 Strip 0 50in 13mm from the insulation of the incoming ac input supply wiring 5 Connect the wires to the appropriate ac lugs as shown on the next page 6 Using proper tools securely tighten the compression screws on the ac lugs to proper torque specifications 7 Check all connections and reinstall the Plexiglas safety shield if supplied 1 pA INSTALLING THE AT30 MAKING THE AC INPUT CONNECTIONS GRAPHICS Style 5018 O Terminal Board TB1 Detail
91. emental Operating Instructions JA5098 00 29 OPERATING THE AT30 2 3 2 3 1 SETTING PARAMETERS IN THE AT30 Understanding Parameter Settings You can change the settings of the AT30 while it is operating using the front panel controls The changes you make take effect immediately and are saved internally If the AT30 is taken out of service and then later returned to service it restarts using the last values you set You 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 AT30 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 are for your AT30 refer to the Specifications in Appendix A on page 64 When you first press the EDIT
92. er 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 The presence of the interconnection cable and a proper interconnection forces the two 2 AT30s into load sharing Controlling load sharing from the front panel is neither necessary nor possible WHEN TEMPERATURE COMPENSATION IS INSTALLED The AT Series forced load sharing feature is compatible with the AT Series external temperature compensation accessory Both AT30s must have a temperature probe installed and the probes should be located as close as possible to each other When AT30s 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 AT30s are unequal refer to the following table PROBABLE RECOMMENDED ACTION CAUSE 1 Connection cable 1 Ensure that the interconnection signal cable
93. for a battery whose rating Ampere hours are four 4 times the charger Ampere rating For a smaller battery ripple voltage may be higher 4 Defective filter 4 Test with capacitance meter and replace as needed capacitors C1 and or C2 AT30 very 1 Loose 1 Check and tighten all component mounting hardware and panel noisy hardware or hardware enclosure panel 2 Defective 2 Use a clamp on ammeter to measure the current in wires 7 8 rectifier bridge 18 9 between T1 and the rectifier modules If it less than 50 of the dc output current one of the SCRs or diodes is defective Replace the rectifier module s A16 as needed Meter 1 Defective or 11 Turn off the AT30 With a light dc load connected to the battery readings are disconnected be sure each cell reads the nominal cell voltage 2 0V for lead erratic battery acid 1 25V for Ni Cd Restart the AT30 Each cell should now read approximately the nominal Float voltage 2 2V for lead acid 1 35V for Ni Cd 2 Defective 2 See page 61 of Section 3 5 Locate R4 and R14 on the Gate scaling resistor Driver PC Board A15 Remove one end of each resistor and R4 or R14 measure its value with an Ohmmeter See the table in Section 3 6 for resistance values If either resistor is not within 196 of the specified value replace R4 and or R14 as needed 3 Defective 3 If the output voltage is constant but the front panel meter is Main Control PC jerratic replace the Main Control
94. from the batterv or dc bus first on the I O panel TB1 second Insulate each lead separatelv coil up the wires and leave them in the bottom of the AT30 in case you want to wire for remote sense in the future Reconnect wire 40 to the dc output terminal Reconnect wire ff 38 to the dc output terminal Restart the AT30 according to the instructions in Section 2 1 17 INSTALLING THE AT30 1 10 WIRING TO THE REMOTE ALARM CONTACTS Built in Summary Common Alarm Relay standard The AT30 Main Control PC HE Board Al is eguipped with a common Summary Alarm SE relay This relay contact GROUND A transfers when any one or s THREE PHASE more of the standard AT30 HE ED A15 alarms exist III See Sections 2 2 7 and 2 3 4 ez s P TITTTTTT m for a list of these alarms and status codes One form C alarm contacts are provided and accessible via terminal block TB3 as shown in the figure on the right MAIN CONTROL PC BOARD A1 Follow the procedure below to wire an annunciator to this contact SUMMARY ALARM INTERCONNECTION DETAIL PROCEDURE 1 Allow 30in 762mm of wire inside the enclosure Excess will be trimmed 2 Route annunciator wires to the AT30 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
95. fter the AT30s restart the Primary charger attempts to establish communication with the Secondary If communication is successful the AT30s 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 charger controls all voltage settings for both AT30s 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 Ifone AT30 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 AT30s initially for the same operating voltages If an alarm condition occurs both AT30s revert to independent operation for the duration of the alarm e Inthe event ofa fault in the interconnection or any other problem with communication the AT30s 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 AT30s to establish forced load sharing communication If communication is broken or pow
96. he green FLOAT indicator lights Press the CHRG MODE key on the front instrument panel The FLOAT indicator goes off and the yellow CHRG MODE key again to return the EQLZ indicator lights Press the AT30 to the float mode The table below lists the normal factory settings for float and equalize voltage 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 AT30 lists the actual voltage settings FACTORY SETTINGS FOR ALL PARAMETERS Parameter Nominal Vdc 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 Manual Timer Current Limit 11096 of nominal output current HVDC Shutdown Disabled 25 OPERATING THE AT30 2 2 USING THE AT30 FRONT PANEL FEATURES 2 2 1 If the meter displays an error or status message The AT30 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
97. hours A 04 voltmeter While using temperature compensation the AT30 internal dc voltmeter calibration cannot be calibrated Disconnect one wire of the TempCo cable from TB8 inhibited on A1 Restart the AT30 and perform the voltmeter calibration according w TempCo to Section 2 3 7 on Page 37 Reconnect the TempCo cable to TB8 and active restart the AT30 See Application Note JD5003 00 for further details A 05 dc output at The AT30 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 AT30 is sized correctly for the application and that the Current Limit value has been set correctly See Section 2 3 5 Page 35 47 SERVICING THE AT30 3 3 USING THE TROUBLESHOOTING CHART High voltages appear at several points inside the AT30 Use extreme caution when working inside the enclosures Do not attempt to work inside the AT30 unless vou are a qualified technician or electrician Disconnect and lock out all power from the AT30 before starting to remove or replace anv components Turn the ac power off at the distribution panel upstream from the charger Disconnect the batterv from the AT30 output terminals TBI 4 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 T
98. ifier module 2 Turn off both front panel breakers If the AT30 does not have breakers fuses instead lock out ac and dc power to the AT30 externally Wait one minute Return dc power to the AT30 first followed by ac power If the AT30 output voltage and current are normal but the DC OUTPUT FAILURE indicator is still on replace the Main Control PC Board A1 3 Use an ac voltmeter to measure the ac voltage between the transformer secondary taps T1 X1 T1 X2 amp T1 X3 The line to line voltage is normally the same as the rated dc output voltage If itis too low check the wiring of the transformer primary taps T1 H1 T1 H2 amp T1 H3 See Section 1 6 for details If the ac voltage on the transformer secondary taps is zero replace T1 4 Disconnect the battery and connect a light dc load to the AT30 Measure the dc voltage across TB1 and TB1 with the breaker on If no voltage is measured replace the dc circuit breaker CB2 56 SERVICING THE AT30 svmprom PROBABLE RECOMMENDED ACTION CAUSE AC INPUT 1 AC power 1 If the ac input power fails the front panel AC ON indicator goes FAILURE failure out and the AC INPUT FAILURE indicator goes on indicator is on 2 Upstream 2 Be sure the front panel ac circuit breaker CB1 is closed feed Measure the ac voltage at the AT30 input terminals TB1 L1 TB1 breaker fuse is L2 and TB1 L3 If itis zero check the upstream distribution tripped breakers an
99. imes until the meter display flashes the Current Limit reaches float value in Amperes If the Current Limit is less than 110 or equalize adjust it to 11096 as described See Setting the Current Limit voltage value Section 2 3 5 for details within 1 2 Defective 2 Check each cell of the battery If one or more cells are battery or dc shorted the AT30 may not be able to reach the Float voltage load or load is You may have the same problem if the normal load current is too great more than the rated output current of the charger 3 Wrong ac 3 Be sure the main transformer T1 primary taps are wired input voltage or voltage too low or T1 wired incorrectly 4 Defective rectifier bridge 5 Defective Main Control PC Board A1 correctly for your input voltage See Changing Transformer Taps Section 1 6 The actual ac input voltage must be at least 8890 of the rated value for the AT30 to produce full output power 4 Use a clamp on ammeter to measure the current in wires 7 8 amp 9 between T1 and the rectifier modules If it less than 50 of the dc output current one of the SCRs or diodes is defective Replace the rectifier module s A16 as needed 5 Turn off both front panel breakers If the AT30 does not have breakers fuses instead lock out ac and dc power to the AT30 externally Wait one minute Return dc power to the AT30 first followed by ac power If the AT30 output current is below the Cur
100. is manual supercedes the information featured in the standard parts list starting on page 62 The data 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 AT30 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 contact your Sales Representative for drawing availability from the battery charger manufacturer Any job specific custom drawings supplied with your AT30 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 03 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
101. ischarge 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 AT30 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 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 AT30 2 3 6 Enabling the High DC Voltage shutdown feature The AT30 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 AT30 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 AT30 is normally shipped from the factory with the High
102. isconnect the battery and connect a light dc load to the AT30 Measure the dc voltage across TB1 and TB1 with the dc circuit breaker CB2 on If no voltage is measured replace CB2 51 SERVICING THE AT30 SYMPTOM PROBABLE CAUSE RECOMMENDED ACTION Front panel is 1 Control 1 Make sure the Gate Driver PC Board A15 is firmly dies during ac power failure power resistor R3 dead but ac boards are not connected to the Main Control PC Board A1 via plugs J17 to and dc connected P17 Make sure the two signal harness plugs are firmly voltages are inserted into the Gate Driver PCB connectors J25 and J26 present at 2 Defective 2 If the AC ON indicator is lit but the rest of the front panel is TB1 Main Control dead replace the Main Control PC Board A1 PC Board A1 3 Defective 3 Check the two harness wirings to the Gate Driver PC Board wiring A15 connectors J25 and J26 for signs of insulation damage burns etc Confirm all wires are securely crimped in the connector Front panel 1 Defective 1 Use a dc voltmeter to measure the dc voltage from TB1 to J25 pin 25 on the Gate Driver PC Board A15 It is normally 12 Vdc when the rated output voltage is at TB1 and TB1 PC Board A1 and dc If it is not remove all power from the AT30 and measure the voltage is resistance from TB1 to J25 pin f 19 see the table in present at Section 3 6 for the proper resi
103. isconnecting wires 7 8 amp 9 at the rectifier module s rectifier bridge if A16 mounted on the main heat sink s or at the main unfiltered AT30 transformer T1 Measure resistance between the ac terminals bottom terminals on the rectifier module s It should be at least 100 000 Q check both polarities If resistance is low in either direction replace the rectifier module s A16 as needed 3 Defective 3 Disconnect wire 15 from SCR module mounted on the heat Free Wheeling sink assembly or from the positive bus bar Measure the diode CR4 resistance through the Free Wheeling diode CR4 Check both polarities It should be at least 100 000 Q in one polarity and less than 1 000 Q in the other polarity Replace CR4 if it is defective 4 Defective 4 Disconnect wire 17 from the dc circuit breaker CB2 or the Polarity Diode optional dc fuse F3 Measure the resistance through the Polarity CRI if filter Diode CR1 mounted to the negative filter capacitor bus bar assembly is Check both polarities It should be at least 100 000 Q in one installed polarity and less than 1 000 Q in the other polarity Replace CR1 if itis defective 5 Defective 5 Check spacing of terminals and check wiring for signs of wiring insulation damage burns etc Repair as necessary DC breaker 1 Loose 1 Check and tighten connections as required trips or fuses connection to clear after a breaker few minutes 2 Open SCH 2 Use a clamp on am
104. ists 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 AT30 Series battery chargers You cannot force load sharing with three 3 or more AT30s e Both AT30s must have the same dc voltage amp current rating and have the same dc filtering e Both AT30s must have the same ac input source and the same phase rotation e Both AT30s must feature Rev 6 or higher builds of the Main Control PC Boards Al and corresponding Rev 6 or higher software programs e Both AT30s 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 AT30 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 Al One end of the cable
105. k each each thermostat S2x for continuity Disconnect the wiring and resistor R28x from the quick connect terminals The thermostat Switch should be closed NC at normal room temperature E 13 internal over One or more of the rectifier thermostats S2x has detected an over temperature temperature condition If the rectifier is equipped with fans B2x check all fans 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 92 sharing not Verify both AT30s 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 AT30s are connected to the same ac supply and that source phase rotation is the same for both AT30s A 01 manual eqiz If the AT30 was accidentally left in manual equalize mode switch the unit enabled for back to float manual equalize timer or auto equalize timer mode more than 24 hr according to Section 2 2 4 on Page 27 A 02 equalize mode jif you set the equalize timer to zero 0 hours the equalize mode is inhibited inhibited When vou trv to put the AT30 into equalize mode from the front panel controls the meter displavs status code A 02 If you want to enable the equalize mode set the equalize timer to one 1 or more
106. l DS10 CABLE ASSY J e Plug the connector at the end of the nylon shielded wire of the cable assembly onto J6 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 At the 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 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 AT30 8 Check your work Be sure that e All connections 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 AT30 using the startup procedure in Section 2 1 During startup the AT30 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 AT30 the next time it starts 10 Adj
107. l footprint of the Stvle 5018 Stvle 5030 and Stvle 163 enclosures 2 Be conscious of planned ac input and dc output wiring to the AT30 selecting conduit entrances carefullv Note the standard pre fab conduit knockouts located on the sides and sometimes tops of the enclosures 3 Thelocation e Should be free of drips and splatter If falling particles and liquids are a problem install NEMA 2 type drip shield accessory EIO191 0 For kit availability see ordering information in Appendix B on page 65 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 AT30 for operation and maintenance PROCEDURE Style 5018 1 Install four 4 0 25in 6 4mm anchor bolts into the floor per the mounting dimensions featured in the outline drawing JE5085 00 2 Carefully lift the AT30 above the anchor bolts using the methods described in Section 1 4 Guide the enclosure onto the floor bolt pattern and lower it into place 3 Add appropriate mounting hardware onto the floor mounting anchor bolts and tighten securely INSTALLING THE AT30 PROCEDURE Style 5030 1 Install four 4 0 375 9 5mm or 0 5in 12 7mm anchor bolts into the floor per the mounting dimensions featured in the outline
108. lex 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 AT30 Using the Communications Module option all features of the AT30 front instrument panel are accessible remotely Installed within an AT30 the AT Series Communications Module option p n EJ5037 0 includes a Communications PC Board A12 and a de power supply resistor R29 A special AT Series Communications Module Operating Instructions JA0102 04 and field installation instructions 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 Communications Module Field Kit for 12 Vdc AT10 1 EJ5037 11 Communications Module Field Kit for 24 Vdc
109. load making sure insulation is in satisfactory condition If there is a failure of the remote sense signal wiring the AT30 displays the error code E 06 The AT30 returns to local control sensing the output voltage at the charger output terminals TB1 OPERATING THE AT30 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 is securely installed Make sure the connectors and the wiring from the probe to the AT30 are in satisfactorv condition If there is a failure of the temperature compensation probe or the wiring the AT30 charger displavs the error code E 08 Measuring the output ripple voltage filtered models only If vour AT30 is a filtered model measure the ac ripple at the batterv 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 AT30 the ripple voltage should be no higher than the value featured in the specifications in Appendix A on page 64 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 54 Viewing the voltage and alarm settings You can review the parameter settings in the AT30 charger by pressing the key on the front instrument panel Each time you press the key a different parameter displays
110. losure as the external ac power wiring 5 All specific requirements of your facility take precedence over these instructions PROCEDURE 1 Use a dc disconnect switch or circuit breaker between the AT30 and the dc bus This device should have lockout capability to allow the AT30 to be disconnected from the dc bus for maintenance 2 Remove the Plexiglas safety shield if supplied 3 Run the dc wiring to terminals TB1 and TB1 on the I O panel board in the enclosure CU AL Compression lugs are supplied for your convenience e Style 5018 enclosure dc output lugs accept 14 1 0 AWG wire e Style 5030 163 enclosure dc output lugs accept 6 AWG 350 MCM wire 4 Strip the insulation 0 5in 12 7mm on the incoming ac wires and connect the wires to the appropriate dc lugs as shown on the next page 5 Using proper tools securely tighten the compression screws on the lugs to proper torque values 6 Check all connections and reinstall the Plexiglas safety shield 1f supplied AcAumoN NOTES 1 The dc output terminal hardware fastens other components mounted to the I O panel Be careful not to disconect any other component leads 2 Always use a proper ground 3 Use copper or aluminum conductors only 4 Refer to images on the following page for I O panel layout 14 INSTALLING THE AT30 MAKING THE DC OUTPUT CONNECTIONS GRAPHICS user supplied dc output wiring NEGATIVE POSITIVE LINE LINE DC OUTPUT
111. meter to measure the current in wires 7 8 amp 9 between T1 and the rectifier modules If it less than 50 of the dc output current one of the SCRs or diodes is defective Replace the rectifier module s A16 3 SCR not 3 Disconnect the wire harness plug from connector J26 on the controllable top of the Gate Driver PC Board A15 and restart the AT30 If you are able to measure output current one of the SCRs is defective Replace the rectifier module s A16 as needed 4 Defective 4 If the front panel meter displays more than 110 of rated dc current the Gate Driver PC Board A15 may be defective Unplug A15 from the Main Control PC Board A1 If the output current does not drop to zero replace the Gate Driver PC Board A15 5 If the front panel meter displays more than 110 of rated dc current the Main Control PC Board A1 may be defective Unplug the system harness connectors J25 and J26 from the Gate Driver PC Board A15 If the output current drops to zero replace the Main Control PC Board A1 50 SERVICING THE AT30 syMPTOM PROBABLE RECOMMENDED ACTION CAUSE No output 1 AC supply 1 If the AC ON indicator is out check the feeder circuit breaker or current and failure fuse AC ON mp 2 Input fuse 2 Remove the ac input fuses F1A F1B 8 F1C from the fuse is out but ac and dc breakers are on F1A B C blown 3 Defective wiring 4 Defective transformer T1 holder s Check if
112. mm hardware to mount the enclosure to the wall mounting brackets and tighten securely Refer to the graphics on the opposite page for the AT30 Style 5018 wall mounting pattern and enclosure footprint Dimensions are in mm INSTALLING THE AT30 GRAPHICS WALL MOUNTING THE AT30 FRONT VIEW SIDE VIEW o 66 000 ET NC NH gag es e a O Fir 9 00 MTG 229 MIG 18 44 MTG 468 MTG 2 33 20 80 59 531 d e gt d E SESS oS RL SN x x RS o CC m GE e NG RL dei RI pasate SKS KRS AS SI di d Kes RS lt gt m TO NOTES 1 Refer to the Stvle 5018 enclosure outline drawing JE5085 00 in Appendix C on Page 66 for overall size mounting dimensions and cabinet specifications 2 See Installation Instructions JA5063 00 for the special Stvle 5018 wall mounting procedure INSTALLING THE AT30 1 5 3 Rack Mounting the AT30 Style 5018 enclosure only Smaller AT30s can be installed in 23 24in 584 610mm relay racks with standard EIA hole spacing The Style 5018 enclosure does not need to be modified for rack mounting but a special kit EIO193 0 is required For kit availabilitv see the ordering information in Appendix B on page 65 The kit includes two 2 mounting brackets hardware
113. n alarm mode check front panel the Low Level Detect indicator on Main Control PC Board A1 alarm indicator is on See Section 2 3 8 If no other alarm is on replace the Main Control PC Board A1 57 SERVICING THE AT30 3 5 REPLACING DEFECTIVE COMPONENTS High voltages appear at several points inside the AT30 Use extreme caution when working inside the enclosure Do not attempt to work inside the AT30 unless vou are a qualified technician or electrician Disconnect and lock out all power from the AT30 before starting to remove or replace anv components Turn the ac power off at the distribution panel upstream from the charger Disconnect the batterv from the AT30 output terminals TBI 4 NOTICE While performing the following procedures refer to the standard drawings in Appendix C for information on identifying internal components Removing the safety shield if present AT30 Style 5018 and Style 5030 enclosures feature a Plexiglas safety shield as a second protective barrier between the user and the internal components Some repair procedures requires removal of the shield to that covers the internal components mounted inside the enclosure Detach the shield by removing the side fasteners from the front lip of the enclosure Do not lay the shield on top of the AT30 since the top vents are required for cooling Always re install the Plexiglas safety shield before restarting the AT30 Hazard
114. n dc output Error A 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 Gate Driver PC Board A15 input connector J25 R2 is measured by the defective control circuitry on startup and is used to determine some of the AT30 model specific parameters such as the float voltage If the AT30 detects that R2 is defective or improperly sized it must be replaced See Section 3 6 for parts ordering information When you have completed the repair restart the AT30 according to Section 2 1 E 02 short circuit The AT30 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 AT30 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 AT30 dc output terminals TB1 for a short circuit If the battery voltage is normal and all external wiring is satisfactory check the AT30 dc circuit breaker CB2 If itis tripped try once to reset it If ittrips again immediately there may be an internal short circuit in the AT30 Check the internal wiring If the AT30 is filtered check the dc filter capacitors C 1 C2 and the polarity diode CR1 The AT30 normall
115. o normal operation as long as there is no internal component failure NOTICE Perform Step 2 only once If the AT30 does not resume normal operation go on to Step 3 If the AT30 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 on 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 AT30 3 2 INTERPRETING FRONT PANEL ERROR MESSAGES If the AT30 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 AT30 Use extreme caution when working inside the enclosure Do not attempt to work inside the AT30 unless you are a qualified technician or electrician Disconnect and lock out all power from the AT30 before starting to remove or replace anv components Turn the ac power off at the distribution panel upstream from the charger Disconnect the batterv from the AT30 output terminals TBI 4 o
116. o use the chart 1 Make a list of the charger 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 action described in the right hand column to correct the problem and return the charger to normal service Determining the condition of the AT30 e sthe 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 charger to the Equalize mode and back to Float e Is the charger 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 AT30 3 4 TROUBLESHOOTING CHART voltage or T1 taps miswired 3 Open SCR 4 SCR not controllable 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 in
117. ogether to increase the length 65 APPENDIX C Standard Drawings Outline AT30 Battery Charger NEMA 1 Style 5018 Enclosure JE5085 00 SIDE VIEW D b D SE Fees NG 0 0 0 0 0 0 0 0 40 OR EE EE 2829S alilia NS RS NOTE 3 FRONT VIEW CONTROL PANEL SEE DETAIL DRAWING JES091 3 H CBI AC CB2 DC CIRCUIT CIRCUIT BREAKER BREAKER 18 54 MTG gt 471 MTG SIDE VIEW IR KK KK SKA LU SRS IN RO KO SI Ge RR 3 di NG SSR RR A SICK LEE iii DANN RN 9 00 MTG 229 MTG gt 66 APPENDIK C Standard Drawings JE VIEW illi EEE SORRY DN ol KO o ELLE EEE NNN gek dee d Ka 000900000404 RO KPI SOPH Outline AT30 Battery Charger NEMA 1 Style 5018 Enclosure JE5085 00 NOTES L ENCLOSURE IS A NEMA 1 P20 TYPE STEEL CABINET WITHOUT GASKETS FINISH IS ANSI 61 GRAY EPOXY POWDERCDAT 2 ALLOW I2in 305mm OF FREE AIR ON TOP SIDES AND FRONT OF CABINET FOR VENTILATION FOUR 4 fin x 0 625in 7 25mm x 16mm FLOOR MOUNTING SLOTS ARE PROVIOEO ON BOTTOM OF ENCLOSURE AS SHOWN TWO 2 1 3lin 7 33mm DIA STANDARD PRE FAB KEY SLOT KNOCKOUTS ARE
118. oltage decreases If you are experiencing any inconsistencies in the AT30 when the temperature compensation probe is utilized temporarily disconnect the probe and refer to the Application Note JD5003 00 for further details 22 INSTALLING THE AT30 106 104 102 100 Percent Output Voltage 98 96 94 Note the following You should set the Float and Egualize voltages to the values recommended by your battery manufacturer for 77 F 25 C 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 AT30 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 AT30 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 AT30 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 p kel Cadmium Example 100 Deg F 97 Output Voltage
119. on front panel O OK Step Instructions Results optional features Test auxiliarv Press LAMP TEST key and hold for four O OK alarm relavs 4 seconds Alarm relavs will transfer Check Remote sense wiring See page 16 O OK integritv of Temperature compensation wiring See O OK remote wiring page 20 O OK Temperature compensation probe See page 20 Final checks Close padlock or kev lock O OK ONLINE SUPPLEMENTS Preventive Maintenance Procedure Downloadable Worksheet http www ATSeries net PDEs JDOO64 00 pdf 43 SERVICING THE AT30 3 SERVICING THE AT30 3 1 A STEP BV STEP TROUBLESHOOTING PROCEDURE The AT30 is fullv tested and calibrated from the factorv and should work for years with a minimum of attention If you do encounter trouble there are three 3 steps vou should take to identifv the problem and return the AT30 to service 1 Check the front panel meter for an error code The microprocessor control circuitrv is able to diagnose common problems with the AT30 or with the installation or application If the front panel displavs an error code see Section 3 2 Interpreting Front Panel Error Messages for help in interpreting the code and solving the problem If the AT30 does not work properlv but there is no front panel error code turn off the front panel circuit breakers or disconnect ac and dc power externally Turn back on dc power first followed by ac power This will return the charger t
120. ous ac and dc voltages are present inside the AT30 on the I O panel TB1 terminals and certain internal components SERVICING THE AT30 Replacing the Main Control A1 and or Gate Driver A15 PC Boards 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 until 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 AT30 Disconnect the battery from the dc output terminals Remove any optional user wiring from the various Main Control PC Board Al terminals e g TB3 TB8 J6 J3 etc Note that Al and A15 are mounted together as a pair Remove the signal wire harness plugs J25 J26 from the top and left edges of A15 The boards are mounted on ten 10 plastic standoffs Compress the tab on each standoff and pull the boards toward vou until thev clear all the standoffs If you are replacing only one board carefully separate the existing boards Al amp A15 and reconnect the replacement board Insert the replacement board s onto the instrument panel with the same orientation and push them onto the standoffs Make sure the board is fully seated on all ten 10 standoffs Reconnect the signal wire harness plugs J25 J2
121. rent Limit value but it still has the wrong output voltage replace the Main Control PC Board A1 53 SERVICING THE AT30 PROBABLE svmprom PRO RECOMMENDED ACTION CAUSE Input curent 1 Wrong ac 1 Be sure the T1 primary taps are wired correctly for your input too high input voltage or voltage See Changing Transformer Taps Section 1 6 The actual T1 wired ac input voltage must be at least 88 of the rated value for the incorrectly AT30 to produce full output power 2 Defective 2 Disconnect the wire harness plug from connector J26 on the rectifier bridge top of the Gate Driver PC Board A15 and restart the AT30 If you are able to measure output current one of the SCRs is defective Replace the rectifier module s A16 as needed 3 Defective T1 3 Test by disconnecting wires 7 8 amp 9 from the transformer secondary taps and wires 42 43 44 45 35 and 36 from the tertiary taps If ac input current is still too high replace T1 Output ripple 1 AT30 is 1 Verifv bv checking the data nameplate against the ordering voltage too unfiltered code on page i Order and install the dc filter option if desired high 2 Batterv is 2 Be sure batterv is connected Inspect batterv according to the disconnected or manufacturer s instructions defective 3 Battery too 3 Check the measured ripple against the specification for your small for AT30 AT30 model on page 64 The ripple rating is
122. rier type auxiliary alarm terminal block s pad key lock for front panel door external temperature compensation probe analog ac voltmeter w sel switch DNP3 Level 2 Modbus communications module analog ac ammeter w sel switch forced load sharing interconnection cable Please find the serial number on the data nameplate and record it here IMPORTANT SAFETY INSTRUCTIONS PLEASE READ AND FOLLOW ALL SAFETY INSTRUCTIONS NOTICE Before using the AT30 read all instructions and cautionary markings on A this equipment B batterv and C anv other equipment to be used in conjunction with the AT30 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 AT30 is off to prevent arcing or burning Do not operate the AT30 if it has been damaged in any way Refer to qualified service personnel Do not disassemble the AT30 Only qualified service personnel should attempt repairs Incorrect reassembly may result in explosion electrical shock or fire Do not install the AT30 outdoors or in wet or damp locations unless specifically ordered for that environment Do not use the AT30 for any purpo
123. ring 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 the outside of the shipping container with the Return Material Authorization RMA number issued by the manufacturer 1 3 UNPACKING AND INSPECTING THE AT30 Carefully remove all shipping materials from the AT30 Remove the AT30 from the shipping pallet for inspection Save all shipping materials until you are sure that there is no shipping damage Once the AT30 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 and
124. rol PC Board A1 Two AT30 s 1 Ifthe forced 1 Multiple AT30s are not designed to share load current without connected in load sharing the optional forced load sharing kit EJ5126 installed When parallel but option is not two or more AT30s are connected in parallel without this option it only one has supplied check is normal for one of the units to have no output current You can output current for normal check the operation of the off charger by increasing its Float HIGH DC VOLTAGE indicator is on operation of both chargers 2 EJ5126 option 1 HDCV alarm and Equalize voltage settings are mismatched 2 Defective rectifier bridge 3 Defective Main Control PC Board A1 voltage until it starts to deliver output current When you have finished the test be sure both AT30s are set to the same Float and Equalize voltages 2 See Appendix F on page 92 for troubleshooting of Forced Load Sharing feature 1 Be sure that the High DC Voltage alarm setting is higher than the Equalize voltage setting See Sections 2 3 2 and 2 3 4 2 Disconnect the wire harness plug from connector J26 on the top of the Gate Driver PC Board A15 and restart the AT30 If you are able to measure output current one of the SCRs is defective Replace the rectifier module s A16 as needed 3 Turn off both front panel breakers If the AT30 does not have breakers fuses instead lock out ac and dc power to the AT30 externally W
125. rrent values refer to standard DC5016 00 11 INSTALLING THE AT30 1 7 MAKING THE AC INPUT CONNECTIONS The A30 is a commercial product and not intended for use in a residential environment or to be powered bv low voltage public mains It is the responsibilitv of the installer of the AT30 to provide suitable ac supplv wiring Wiring must be approved for use in the countrv in which the AT30 is installed When selecting wire sizes consult the data nameplate decal affixed to the front panel of the AT30 for maximum voltage and current requirements The AT30 must also be grounded in accordance with the electrical rules of the countrv where installed Follow these steps to connect ac power to the AT30 1 Confirm that the AT30 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 AT30 This device should have lockout capability so that the ac input supply to the AT30 can be de energized for charger 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 AT30 This rating is listed on the left hand side of the AT30 data nameplate For a comprehensive list of these maximum ac input values access standard DC501 6 00 NOTICE If your AT30 is wired for 480 Vac input and is equipp
126. rs need to be replaced we suggest you order a new Gate Driver PC Board A15 See Replacing the Main Control PC Board A1 and or Gate Driver PC Board A15 on page 59 If any of these resistors must be replaced without replacing A15 select the proper part number listed in the table starting on page 62 and order it from the factory or your sales representative Remove A15 as described on page 59 Using wire cutters clip the soldered leads of the old resistor and remove it from A15 Carefully solder on the new resistor making sure not to damage any other components on A15 Polarity is not vital for these resistors Once the solder cools replace A15 as described on page 59 61 SERVICING THE AT30 3 6 ORDERING REPLACEMENT PARTS All AT30 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 e Model number and serial number of your AT30 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 satisfv your specification In that case you should order the
127. s 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 de voltages within the AT30 enclosure Check with a voltmeter 2 Remove safety shield if supplied 3 Remove the two 2 dc output CU AL compression lugs 16 INSTALLING THE AT30 4 Move wire 38 from TBI to REM SENSE CA Move wire f 40 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 NEG OC OUTPUT POS OUTPUT OUTPUT 7 Replace the two 2 dc output CU AL compression lugs and tighten all hardware 8 Check your work thoroughly Replace the safety shield if supplied before re eneregizing the AT30 9 Restart the AT30 according to the instructions in Section 2 1 NOTES 1 Use 16 AWG twisted pair 2 Maximum current is 150 mA 3 Run leads 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 AT30 2 Check with a voltmeter 3 4 Remove the remote sense leads from the remote sense and terminals Disconnect the remote sense wires
128. se not described in this manual Do not touch any uninsulated parts of the AT30 especially the input and output connections as there is the possibility of electrical shock During normal operation batteries may produce explosive gas Never smoke use an open flame or create arcs in the vicinity of the AT30 or the battery Turn the AT30 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 AT30 before servicing Do not operate the AT30 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 AT30 with the Plexiglas safety shield or any other supplied guards removed or improperly installed TABLE OF CONTENTS QUICK OPERATION 2 24z2 2aauau00naannu0nnaannnunnannnnnnnannnunnannnnnnnannnnnnnannnnnnnannnn Back Cover HOW TO READ THE AT30 MODEL NUMBER eee Inside Front Cover IMPORTANT SAFETY INSTRUCTIONS ll esee nennen nnne nnn n nnn nnn nnn EEN i 1 Receiving and Installing the AT30 Battery Charger 1 1 1 2 1 3 1 4 1 5 ch sech 1 6 1 7 1 8 1 9 1 10 1 11 1 12 1 13 Storing MN EC 2 Reporting shipping damage ii Aa 2 Unpacking and inspecting the AT3O L nar eee 2 Inspection checklist nanna 2 Moving EE EE 3
129. se until the alarm just activates A red LED indicator DS10 next to RA1 indicates when the alarm is active 38 OPERATING THE AT30 2 3 9 Using the front panel security feature The AT30 is shipped from the factory with all the front instrument panel keys enabled You can disable the following front panel functions e Selecting Egualize method e Changing settings using the DIT ENTER key e Toggling the high dc voltage shutdown feature To disable the front instrument panel keys open the AT30 door and locate the small plastic jumper J9 on the right side of the Main Control PC Board Al See the figure below Ale G i M Tr 27 Zuel III MT J6 Ji J17 ISADELE J5 PT E ENABLE D E amp l a DSIO RAI a l DETECT L O DISABLE ENABLE 9 5 0 is J3 we 3J9 TEMP RELAY 1 2 9 123 ao 183688 E 7TB8 MEL O O JI 3 gar ALARM o Move the jumper up to the DISABLE position pins 2 and 3 With this setting only the front panel METER MODE and CHRG MODE 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 AT30 2 4 PERFORMING ROUTINE MAINTENA
130. se 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 AT30 into the equalize mode The EQLZ indicator will light When the equalize timer is finished the AT30 reverts automatically to the float mode and the FLOAT indicator lights At any time during the equalize charge you can switch the AT30 back to float mode by pressing the CHRG MODE key The FLOAT indicator will light If there is an ac power failure during the equalize charge the AT30 remembers the remaining equalize time When ac power is restored it resumes the equalize charge where it left off 27 OPERATING THE AT30 Manual Egualize Method Choose the manual egualize method when you wantto egualize charge the battery but only when you are able to monitor the battery voltage and gassing rate After you select the manual egualize method press the CHRG MODE key to put the AT30 into the equalize mode The EQLZ indicator will light Press the cHRG MODE key again to return the AT30 to the float mode The FLOAT indicator will light
131. 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 AT30 cannot provide its 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 AT30 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 32 When an alarm occurs the indicators will light immediately The AT30 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 AT30 is available featured in a suppl
132. side the charger 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 1B Hard Reset of control board by pressing and holding the segments off jor the display Jp button on the front instrument panel and simultaneously AT30 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 the AT30 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 wires 7 8 amp 9 at the three 3 heat sink trips or fuses rectifier diode mounted rectifier modules A16x or at the main power clear or SCR transformer T1 X1 X2 X3 Measure the resistance between immediately the ac bottom terminals of the rectifier module s checking both polarities It should be at least 100 000 O If resistance is low in any direction replace the rectifier module s A16x as needed 2 Defective 2 Check spacing of terminals and check wiring for signs of wiring to T1 or insulation damage burns etc Repair as necessary to rectifier
133. ssembly to the AT30 3 Wiring the charger end of the cable to a terminal block on the AT30 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 65 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 AT30 Use extreme caution when working inside the enclosure Do not attempt to work inside the AT30 unless you are a qualified technician or electrician Disconnect and lock out all power from the AT30 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 AT30 output terminals TBI 4 PROCEDURE 1 De energize and lock out all ac and dc voltage sources to the AT30 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 on the 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 Remov
134. sses 86 Connection Detail AT30 Battery Charger I O Panels A Rectifier Assemblies 88 APPENDIX D Recommended Float Equalize Voltages Temp Compensation 90 APPENDIX E DNP3 Level 2 Modbus Communications Module 91 APPENDIX F Forced Load Sharing ssrsnnnnnnnnnzzzznnnnnnnnannnznzznznnnznnnnnznzznnnnnnnnnnmnznnz 92 MANUAL SPECIFICATIONS document control information online availability 94 A customized record drawing package is available for your particular AT30 featuring an 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 contact your Sales Representative for drawing availability from the AT30 manufacturer RECEIVING THE AT30 1 RECEIVING THE AT30 1 1 STORING THE AT30 If you store the AT30 for more than a few days before installation you should store it in its original 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 AT30 or related products if you discover any damage or shortage make notation on all copies of delive
135. stance value If the resistance is TB1 not within 1096 of the table value replace R3 2 Defective 2 Remove the safety shield and check the wiring to and from wiring TB1 and the Main Control PC Board A1 for signs of insulation damage or burns Repair any damaged wiring AT30 output 1 Defective 1 Disconnect the wire harness plug from connector J26 on the voltage too SCR top of the Gate Driver PC Board A15 and restart the AT30 If high or not you are able to measure output current one of the SCRs is controllable defective Replace the rectifier module s A16 as needed 2 RA or R14 is 2 See page 61 of Section 3 5 Locate R4 and R14 on the defective or Gate Driver PC Board A15 Remove one end of each resistor wrong value and measure its value with an Ohmmeter See the table in Section 3 6 for resistance values If either resistor is not within 196 of the specified value replace R4 and or R14 as needed 3 Defective 3 Remove one of the probe leads from TB8 and measure its temperature resistance At 77 F 25 C the resistance should be about compensation 110 000 Q If it is not replace the probe assembly A10 probe optional 4 Defective 4 f the front panel meter displays more than 110 of rated dc Main Control current the Main Control PC Board A1 may be defective Unplug the system harness connectors J25 amp J26 from the Gate Driver PC Board A15 If the output current drops to zero replace the Main Control PC Board
136. the dc remote sense terminals and any external wiring to alarm relay contacts 10 INSTALLING THE AT30 PROCEDURE 1 See Section 3 5 for necessary steps to follow when accessing internal components within the AT30 Shut down the AT30 and verify that no internal voltages are present Refer to the images below and identify the three 3 primary taps T1 H1 T1 H2 amp T1 H3 of the power isolation transformer AT30 THREE PHASE ISOLATION TRANSFORMER excludes 480 Vac non tappable variant TOP VIEW LAYOUT T1 SCHEMATIC T1 PRIMARY SECONDARY EIS E26 E WAN 9 Y3 Y2 a YO TERTIARY Inside the AT30 inspect the transformer wiring and identify the three 3 jumpers on the primary side wire taps T1 H1 H2 H3 Change the jumpers on the transformer taps as listed in the table below jumper setting jumper setting 208 or 220 or 380 or 550 Vac 240 or 416 or 600 Vac H1 H2 amp H3 set to 1 H1 H2 amp H3 set to 2 Check your work making sure no exposed wiring is touching ground Always use all three 3 jumpers and make sure all connections are tight Restart the AT30 using the startup procedure in Section 2 1 For more information see the schematics amp wiring diagrams in Appendix C 10 Contact the factory for a new data nameplate with revised ac input values 11 For a list of maxium ac input cu
137. timony 1 215 Sp Gr Antimony 1 250 Sp Gr 2 33 Selenium 1 240 Sp Gr 2 33 2 40 Calcium 1 215 Sp Gr 2 33 Calcium 1 250 Sp Gr 2 33 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 F 35 C and should not normally be equalized Consult your battery manufacturer s documentation for specific equalizing recommendations Lead Acid Types TEMPERATURE COMPENSATION If your batteries are to see temperature variations during charging a temperature compensation option EJ5033 0 is recommended If this option is not part of your AT30 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 F Lead Acid Nickel Cadmium 90 APPENDIK 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 AT30 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 dup
138. tiz te 22 o3 24 28 29 30 4 35 36 C NC NJ CN NOY C NC NOY E NE NG E Nc Naj C NC Nd HIGH OC LOW OC oc Gut AC IN IN SUNNARY KNOTE 2 VOLTAGE VOLTAGE FAILURE FAILURE DETECT ALARN NOTES OC FILTERING C E NUMBER AND ARRANGMENT OE DC FILTER CAPACITORS T C1 C2 VARIES BASED LPON UNIT RATING IT D IN UNFILTERED UNITS L2 E13 C1 RI C2 AND ER CORRESPONDING WIRES ARE NOT SUPPLIED WIRE 12 XXft XX Xn LUNG CABLE CONNECTS FROM L1 2 DIRECTLY TO CB2 X 20 E IN STANDARD FILTERED NON ELIMINATOR LNITS C2 AN WIRE 23 ARE NOT SLPPLIED WIRE 17 wu CONNECTS FROM CRI K DIRECTLY TO CB2 2 wu NOTE E gt Lu lt mnQ lt a U CRI NITE E mA ber TE wo o d RI MATN 2 BATTERY DC SHUNT 4 ELIMINATOR n INTET CAPACITOR 25 16 JLSE SCR 21 06 MODULE FIER HEATSINK ASSY AIG 071312 NOTE 0 etre LI MAIN INDUCTOR L2 FILTER NDUC TOR jir 022712 amp EJ PRELECTION 043008 120107 TITLE AT30 BATTERY CHARGER CONN DIAGRAM MAIN POWER WIRING W ALL COMMON OPTIONS gt RAN BY MCR 012607 ELECTRONIC APPROVAL SIGNATURES KEN TAINEO BY WG ECN LOG
139. to TB3 Strip 0 25in 6 4mm of insulation from the wires 4 Make the connections at TB3 and securely tighten the 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 722 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 AT30 Auxiliarv Alarm Relav PC Board optional The optional Auxiliarv Alarm Relav PC Board A5 mounted on plastic stand offs inside the enclosure provides two 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 DCOUT DCOUT GROUND GROUND HVDC HVDC DN LDC FAILURE FAILURE ACFAIL ACFAIL DETECT DETECT SUMMARY SUMMARY C NC NO C NC NO GC NC NO C NC NO C NC NO C NC NO C NC NO G NC NO C NC NO C NC NO C NC NO C NC NO 123 456 789 1012 1314125 1677 18 192021 22324 52627 282930 312 33 34 35 36 VOLTAGE SELECTOR SWITCH DETAIL
140. ttp www ATSeries net PDFs D5003 00 pdf TempCo Probe Application Note JD5008 00 http www ATSeries net PDFs D5008 00 pdf AT Comm Module Field Installation JD5010 00 http www ATSeries net PDFs D5010 00 pdf AT Power Res R3 Field Installation JD501 1 00 hitp ww ATSeries net PDFs D5011 00 pdf Ext Free Wheeling Diode Application Note JD5012 00 hitp ww ATSeries net PDFs D5012 00 pdf Main Ctrl PC Board A1 Field Installation JD5015 00 http www ATSeries net PDFs D5015 00 pdf Style 5018 Aux Alarm Relay Field Install JD5016 00 http www ATSeries net PDFs D5016 00 pdf Style 5030 Aux Alarm Relay Field Install JD5017 00 hitp ww ATSeries net PDFs D5017 00 pdf Style 163 198 Aux Alarm Relay Field Install DC5016 00 hitp www ATSeries net PDFs DC5016 00 pd AT Series AC Input Current Tables JD0052 00 Ato Aww ATSeries net PDF5 DOO52 00 pdf Battery Discharge Dual Operation Note JD5006 00 hip www AT Series ney PDFs D5006 00 pdf Alt amp Temp De Rating Application Note JD5013 00 hitp w ATSeries net PDFs D5013 00 pdf AC Ripple Specification Application Note JD5032 00 hito www ATSeres net PDFs D5032 00 pof Ground Fault Detection Application Note JF5039 00 F au Al See res F5039 00 pdf AT10 1 AT30 3rd Party Agency Approvals JF5045 00
141. tyle 5018 Enclosure E15008 00 Relay Rack Mtg Kit for Style 5018 Enclosure 23 24in 584 610mm EI0193 03 NEMA 2 Type Drip Shield for Style 5018 5030 163 Enclosure EI0191 02 03 04 Cabinet Heater Strips for Style 5018 Enclosure EJ5042 00 Cabinet Heater Strips for Style 5030 Enclosure EJ5166 00 Cabinet Heater Strips for Style 163 Enclosure EJ5183 00 Padlock for Style 5018 5030 163 Enclosure Front Panel Door EI0215 01 01 02 Remote Temperature Compensation Probe Assembly A10 see table 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 t
142. ust the output float and equalize voltages to the battery manufacturer s recommended values using the AT30 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 AT30 detects the damage and displavs E 08 on the front panel meter The AT30 then reverts to normal non temperature compensated operation until the probe or wiring is repaired Once the probe is repaired vou must restart the AT30 to activate the probe as described in Section 2 1 Using temperature compensation When an electric storage batterv is being charged the terminal voltage of the battery changes a small amount whenever the battery temperature changes As the batterv temperature increases its terminal voltage decreases When a constant output voltage float tvpe rectifier charges a batterv float current increases when the temperature increases This results in overcharging the batterv which can result in damage to the materials or at least the need for more frequent maintenance When the AT30 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 AT30 output v
143. ving Move the AT30 with a forklift whenever possible using the supplied shipping pallet Place the AT30 onto a floor mount installation using a forklift lifting the enclosure from the bottom between the mounting legs To lift the Style 5018 enclosure into a wall mount or rack mount installation use a heavy duty sling or a scissor lift For further AT30 standard cabinet information refer to the table below and the standard drawings featured in Appendix C starting on Page 66 NEMA 1 Enclosure Outline Drawing Internal Layout Drawing Style 5018 JE5085 00 JE5088 99 Style 5030 JE5086 00 JE5089 99 Style 163 JE5095 00 JE5098 99 Style 198 JE5096 00 JE5099 99 INSTALLING THE AT30 1 5 MOUNTING THE AT30 The AT30 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 AT30 enclosure from the table below MANUAL SECTION ENCLOSURE Style 5018 Style 5030 163 198 Floor Mounting STANDARD STANDARD MOUNTING METHOD Wall Mounting OPTIONAL 19in 483mm 153 Rack Mounting WA wa 23 24in 584 610mm OPTIONAL WA Rack Mounting 1 5 1 Floor Mounting the AT30 Floor mounting is the standard means of installing all the AT30 enclosures When floor mounting the AT30 consider the following 1 Refer to the outline drawings in Appendix C starting on Page 66 for the overal
144. w ATSeries net PDFs JE5089 99 pdf 75 APPENDIX C Standard Drawings Internal Component Layout AT30 Battery Charger Style 163 Enclosure w Common Options JE5098 99 SIDE SECTION SCR MOD FRONT VIEV HEATSINK ASSY A16 F1A B C CRA A16 CHASSIS a jl AFA LI d N INPUT OUTPUT PANEL Mac LS SEE DETAIL BELOW R ale Tel A B VR3JA17x At7x A BIC MT je ol 0 nes LU CRI fa iz CRI LLI a ag ts gia GIEH oj lo ci asked SEE NOTE 2 E TE gI ma LIE e STANDARD DRAWING NOTES E ae d KAEN A ARRANGEMENT AND NUMBER OF TI ea MAY DE MY IT m BASED LIPON UNIT RATING D w FEATURED OPTIONS S B SEE JE5163 00 FOR A16 DETAILS ENG ffe a fii COPPER GROUND BUS BAR WACU AL COMPRESSION LUG 1 0 TERMINAL BOARD TB1 DETAIL DEER AC INPUT PS 1 1 KA B CPI CB21 AC INPUT DC OUTPUT BREAKER BREAKER NOTES 1 FOR DETAIL VIEWS OF ALL PC BOARDS AL AS A15 A17 etc SEE DRAWING JESOGI 39 2 CIRCLIIT BREAKERCS MOLINTED ON LEFT SIDE f l 9 OC OUTPUT BRACKET NOT SHOWN FOR CLARITY OF VI
145. y recovers automatically from an E 02 condition If you have shut down the AT30 for service restart per Section 2 1 E 03 High DC Voltage Shutdown activated To restart the AT30 turn the ac breaker 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 operation there may be an internal component failure See AT30 output voltage too high or not controllable of the troubleshooting chart on page 52 of Section 3 4 45 SERVICING THE AT30 Error Code Meaning Repair Procedure E 04 internal memory failure Any parameters that you set such as Float or Egualize voltage are saved 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 f an E 04 code appears try shutting down the AT30 Restart by turning on the dc breaker CB2 first followed by the ac breaker CB1 If the AT30 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
146. y 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 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 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 AT30 to normal operation 33 OPERATING THE AT30 Adjusting Ground Detection Sensitivity The AT30 ground detection alarm sensitivity is adjustable from 5 to 30 kQ You must have Lee o II ji a test resistor whose Ohmic value is the J5 E required ground sensitivity and a small HAS d jeweler s screwdriver for adjustment SENS The ground detection sensitivitv is adjusted MAIN camai equally from 5 to 10 KQ but slightly less PC BOARD A1 equally from 10 to 30 kQ Adjustments are made via potentiometer labeled RA3 SENS E located on the Main Control PC Board A1 s S as shown in the figure at the right F we Spe d 3E 58 868884 bun A
147. y voltage does not match your AT30 ac input requirements you may need to change the ac input circuit breaker and or fuses and the input surge suppressors In addition you must replace or rewire the ac input power isolation transformer T1 as described below Failure to use properly rated components may damage the AT30 If your AT10 1 was supplied with the 480 Vac 60Hz ac input feature the transformer will only accept the listed voltage NOTICE Do not attempt to rewire the 480Vac transformer If a different ac input voltage feature for the AT30 is desired please contact your sales representative for ordering replacement parts T1 CB1 VR2 VR5 If your AT30 was supplied with one of the following ac input voltage features the transformer is re tappable e 208 or 240Vac 60Hz e 220 or 240Vac 50 60Hz e 380 or 416Vac 50 60Hz e 550 or 600Vac 50 60Hz Before you connect ac power to the AT30 inspect the primary wiring of the ac input transformer T1 Make sure it is tapped for the desired ac input supply voltage NOTICE Before starting work disconnect and lock out all external ac and dc power sources to the AT30 Merely turning off opening the front panel ac and dc circuit breakers CB1 CB2 is not sufficient to eliminate live voltages inside the enclosure Verify that no voltages are present inside the AT30 using a voltmeter at the ac terminals TB1 L1 TB1 L2 amp TB1 L3 the dc terminals TB1 amp TBI
148. 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 AT30 If your AT30 is equipped with dc fuses one or both fuses will blow when the battery is reversed Correct the battery polarity before proceeding 24 OPERATING THE AT30 e Ifyou have an optional temperature compensation probe installed the front panel displays Pb during startup indicating that 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 AT30 then next time it starts e 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 AT30 as the output current increases NOTICE If you have a filtered model of the AT30 and you turn on the ac breaker CB1 first before the dc breaker CB2 there is a 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 AT30 by turning on the dc breaker first e T

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