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AT30 Charger I&O Manual Section 94.40

1. LEFT SIDE TOP VENT AC FUSES FTAZFIB FIC A DC FUSES AC FUSES F1A F1B F 10 F3 FA gt DC FUSES F3 F4 SEE NOTE cj SEE NOTE C ej 951 Go i B A17C A17B ALTA 2 jo ml ml E e CR4 7 le w ie floe Ur EM AE ReBZS per KO R288 Teen NOTE 1 rer lk a 0 gt H D Se NOTE 2 SI 40 CR4 j ge SoH Wl l gt Lee 5 5 RI f o S S BE th ck ze ell L27 SCR MODULE ASSY A16 1 R9 LU I Pe SI 1 a IP de e D ol i CRI E l l l A i zasa SE JE T 7 elaj A a da la la I jo A oe ili jo l l I Ep G Walon i LI 55 6 I I Us z ck l CBI AC em kl um q UUuUYyuUUuPUU We CIRCUIT CIRCUIT ap BREAKER BREAKER JC a ua ry I I a z I l I 9 EE l I SE l I 1 lg I SE 1 I E m H 1 TRANSFORMER 7 TRANSFORMER i CH Go T l TI 1 IS l E I SE l IL I 1 CHASSIS a GROUND EE STLD L 1 jo COPPER GROUND BUS BAR W CU AL COMPRESSION LUG A10 G TO BE PLACED NEAR BATTERY CELL gt XXft X Xm CABLE
2. RAZ DS11 DS12 RAB es KE E o I o o a COMMUNICATIONS ti MODULE PC BOARD di ASSEMBLY A12 E I SEE DRAWING k De JE5107 00 su RAL a FOR DETAILS S6 z m T WARNING 1 BIEL EJ Jo 5 oe a I Dee rer Q o o amp o o S E a FOR_FURCED fi LOAD SHARING d DETAILS SEE oben i NINY i Sg CN m ds l JE5154 e J us HindlePower Inc TROL PC BOARD A1 MAIN CONTROL PC BOARD A1 I G CHARGER DOOR WHEN INSTALLED H BACK VIEW FACING CHARGER COMPONENTS WHEN INSTALLED USER JUMPERS SWITCHES Jl MAINFRAME SIGNAL HARNESS NOT USED WITH 3PH SI METER MODE SNUBBER J2 AUX ALARM RELAY BOARD AS SERIAL CONNECTOR S2 CHARGER MODE JARD A17x J3 AUX ALARM RELAY BOARD AS RIBBON CONNECTOR S3 EQUALIZE METHOD S gt JA FORCED LOAD SHARING CABLE INTERCONNECTOR S4 AADJUST 3 REH D J5 GROUND FAULT ENABLE DISABLE S5 VADJUST HARGER JG EARTH GROUND CONNECTOR S6 EDIT ENTER JS FRONT PANEL ENABLE DISABLE LOCKOUT gt S7 PROCESSOR MANUAL RESET J13 COMMUNICATIONS PC BOARD A12 INTERCONNECTOR J17 3PH GATE DRIVER PC BOARD A15 INTERCONNECTOR TERMINAL BLOCKS J25 MAINFRAME CONTROL SIGNAL HARNESS TB3 SUMMARY ALARM RELAY CONTACTS J26 SCR FIRING CONTROL HARNESS 3 PHASE 6 PULSE 1B4 AUX ALARM RELAY CONTACTS J27 3PH GATE DRIVER PC BOARD A15 INTERCONNECTOR TBB OPTIONAL TEMPCO PROBE A10 J29 future INTE
3. NOTE 4 CBI AC CB2 DC LE CIRCUIT CIRCUIT BREAKER BREAKER gt o 14 47 367 L 20 90 J 16 77 531 426 BOTTOM VIEW 9 00 MIG 229 MIG 18 54 MTG gt 471 MTG 66 APPENDIX C Standard Drawings Outline AT30 Battery Charger NEMA 1 Style 5018 Enclosure JE5085 00 IDE VIEW NOTES ENCLOSURE IS A NEMA 1 IP20 TYPE STEEL CABINET WITHOUT GASKETS FINISH IS ANSI 61 GRAY EPOXY POWDERCOAT 16 77 ALLOW 12in 305mm DF FREE AIR TLP AND FRONT OF CABINET FOR VENTILATION R N a N w OUR 4 lin x 0 623in 25mm x 16mm LOOR MOUNTING SLOTS ARE PROVIDED ON OTTOM OF ENCLOSURE AS SHOWN ES WO 2 1 3lin 33mm DIA STANDARD PRE FAB EY SLOT KNOCKOUTS ARE PROVIDED AS SHOWN OR lin Z 25mm CONDUIT ENTRY IF ADDITIONAL ONDUIT ENTRANCES ARE REQUIRED ENCLOSURE HOULD BE FIELD MODIFIED BY INSTALLER anma WTN 5 BATTERY CHARGER SHIPPING WEIGHT SEE PRODUCT LITERATURE in mm THIRD PROJECTION DRAWN BY MCR 092506 Immr AT30 SERIES BATTERY CHARGER OUTLINE MT NEMA 1 STYLE 5018 ENCLOSURE DRAWING No REV a AT ERZE dE SCALE NTS PART fe JESO85 00 LI htto Awww ATS
4. MAIN CONTROL CARD NOTE Do not try to adjust the upper potentiometer labeled RA2 BALANCE This adjustment is made at the factory for proper circuit operation CAUTION 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 sensitivity adjustment If your battery is grounded do not attempt this procedure Remove the safety cover Connect the test resistor between TB1 and the ground terminal Refer to the standard internal component layout drawings starting on Page 72 in Appendix C For I O panel layout and all terminal wire specifications Adjust RA3 counterclockwise until the front panel indicator goes out and adjust slowly clockwise until the POS GND indicator just lights Make this adjustment slowly for the indicator is updated once every four seconds De energize and lock out power to the AT30 Remove the test resistor and verify that the indicator goes out Connect the test resistor between TB1 and chassis ground Verify that the NEG GND indicator lights If not adjust RA3 clockwise until it does Remove the test resistor U on 7 Llar IQ TU A KO 77 auteur SCH pote TBI 6 S
5. 20 40 60 80 100 120 Temperature Degrees Fahrenheit EXAMPLE Suppose you have a lead acid battery whose temperature is 100 F 37 87 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 Instructions JA5054 0 23 OPERATING THE AT30 2 OPERATING THE AT30 BATTERY CHARGER 2 1 STARTING THE AT30 2 1 1 Understanding the startup sequence 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 equalize voltage etc control the operation of the charger You can change the settings after you start the charger The FACTORY SETTINGS are shown 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 internally The control circuit then soft starts the charger and the dc output voltage and current increase gradually to the rated value Checking the installation Using the Digital Meter Be sure that you have
6. GROUND 52 GR YE R R NI o THREE PHASE GATE DRIVER PC BOARD A15 L2 FILTER INDUCTOR m 5 413 e e NOTE 7 u Ek 2 LI MAIN INDLICTOR MAIN CONTROL PC BOARD A1 Ke J NOTES NOTES O O O O O o ERPS N NNJWIZ O N 1 CHARGER COMPONENTS ARE CONNECTED WITH FLAME RETARDANT 5 TERMINAL ORIENTATION ON 1 0 PANEL TB1 DIFFERS SWITCHBOARD INSULATION TYPE WIRING IDENTIFIED ON EACH WITH UNIT ENCLOSURE TYPE SEE APPROPRIATE END WITH NUMBER CODED MARKERS INTERNAL COMPONENT DRAWING FOR EXACT LAYOUT OF INDIVIDUAL 1 0 PANELS STYLE 5030 TYPE SHOWN 2 GROUND WIRES 10 47 amp 52 ARE GREEN W YELLOW STRIPE SEC 6 OVER TEMP CIRCUIT COMPONENTS R28x S2x AND 3 WHEN REMOTE SENSE IS USED WIRE 38 CONNECTS J25 08 TO WIRES 34 AND 54 ARE NOT USED IN UNITS RATED Kei REM SENSE AND 40 CONNECTS J25 10 TO REM SENSEC 75 Adc DR LOWER 4 130 VDC R3A B ARRANGEMENT SHOWN IN 48 VOC UNITS R3 72 IN FILTERED UNITS WIRE 50 CONNECTS TO INDUCTOR IS ONE 1 RESISTOR IN 12 24 VDC UNITS R3 IS INTERCONNECT POINT 13 AS SHOWN WIRE 50 INTERNAL TO GATE DRIVE PCB A15 AND WIRES 49 amp 51 CONNECTS TO CB2 1 4 IN UNFILTERED UNITS x10 ARE NOT USED THIRD o cl ANGLE PROJECTION x20 DRAWN BY MCR 012307 TTE AT3O SERIES BATTERY CHARGER CONNECTION DIAGRAM MAIN CONTROL SIGNAL gt WIRING 1
7. nee we o CB2 CB1 CIRCUIT BREAKERS CUIT BREAKER TING BRACKET DETAIL BELOW 1 STANDARD DRAWING NOTES A ARRANGEMENT AND NUMBER OF COMPONENTS MAY DIFFER SLIGHTLY m BASED UPON UNIT RATING AND s FEATURED OPTIONS ZN 2 B SEE JE5163 00 FOR A16 DETAILS L TOR INDUCTOR COPPER GROUND BUS Di W CLI AL COMPRESSION L AS 1 0 TERMINAL BOARD TB1 DETAIL AC INPUT NE 10 JO EE LI C2 B GND CB1 O O O AC INPUT DC OUTPUT wes VRE Wi VRS ca yes CIRCUIT BREAKERS O VRI o sko w NOTES N X o Vie 1 FOR DETAIL VIEWS OF ALL PC BOARDS AL AS A15 A17 etc SEE DRAWING JE5091 39 SEE 2 CIRCUIT BREAKER S MOUNTED ON SIDE BRACKET NOT SHOWN FOR CLARITY OF VIEW Note 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 AT30 battery chargers configured with such options 76 APPENDIX C Standard Drawings Internal Component Layout AT30 Battery Charger Style 163 Enclosu
8. LEB STANDARD AT30 COMPONENTS Al MAIN CONTROL PC BOARD NOTE 1 Ai THREE PHASE GATE DRIVE PC BOARD NOTE 1 AI6 6 PULSE SCR 01 06 MODULE NOTE 3 A17A SCR SNUBBER ASSY PC BOARD NOTE 1 A17B SCR SNUBBER ASSY PC BOARD NOTE 1 A17C SCR SNUBBER ASSY PC BOARD NOTE 1 C4 DC OUTPUT EMI FILTER CAPACITOR TO GROUND CS DC OUTPUT EMI FILTER CAPACITOR TO GROUND CBI AC INPUT CIRCUIT BREAKER CB2 DC OUTPUT CIRCUIT BREAKER CR4 FREE WHEELING DIODE LI MAIN INDUCTOR BI SILICON CONTROLLED RECTIFIER A16A NOTE 3 D2 SILICON CONTROLLED RECTIFIER AIGA NOTE 3 03 SILICON CONTROLLED RECTIFIER AI6B NOTE 3 04 SILICON CONTROLLED RECTIFIER A16B NOTE 3 OS SILICON CONTROLLED RECTIFIER A16C NOTE 3 SILICON CONTROLLED RECTIFIER A16C 3 STANDARD AT30 COMPONENTS MAIN DC SHUNT CURRENT RATING RESISTOR POWER SUPPLY BALLAST RESISTOR EXTERNAL SCALING RESISTOR INTERNAL SCALING RESISTOR EXTERNAL SCALING RESISTOR POWER ISOLATION TRANSFORMER INPUT OUTPUT TERMINAL BLOCK SUMMARY ALARM TERMINAL BLOCK OPTIONAL TEMPCO PROBE A10 INTERCONNECTOR OUTPUT SURGE SUPPRESSOR TO OPTIONAL AT30 COMPONENTS NOTE 2 INPLIT SURGE SUPPRESSOR LINE 1 INPUT SURGE SUPPRESSOR LINE 2 INPUT SURGE SUPPRESSOR LINE 3 OUTPUT SURGE SUPPRESSOR TO GROUND DLITPLIT SURGE SUPPRESSOR TO GROUND 80 APPENDIX C Standard Drawings Schematic AT30 Battery Charger Standa
9. E13 INDUCTOR INTER CONNECT POINT CHASSIS FIA C AC INPUT FUSES GROUND FOR DETAIL VIEWS OF ALL PC F3 DC OUTPUT FUSE LEG STUD BOARDS A1 AS AI7 etc F4 DC OUTPUT FUSE LEG SEE DRAWING JE5091 39 L2 FILTER INDUCTOR 6 R9 FILTER CAP C1 BLEED RESISTOR Z TB4 AUXILIARY ALARM RELAY CONTACTS A VR3 AC INPUT LIGHTNING ARRESOR CIRCUIT BREAKER ACCUATOR Oy CUT OUT WINDOW o et STYLE 5018 TUE INPUT OUTPUT SEE DETAL e TERMINAL BOARD f LITPL W TBI DETAIL DC CIRCUIT Mikal mn le DC DUTPUT BREAKER O FIS REMOTE REMOTE SENSE Et e COPPER GROUND Les m BUS BAR Cre AC INPLIT 3PH GND AC FUSES L2 F1A B C ACED NEAR BATTERY CELL 0 INPUT XXft X XXm CABLE THIRD ANGLE PROJECTION DRAWN BY MCR 020607 E AT30 SERIES BATTERY CHARGER OPTIONAL INTERNAL COMPONENT LAYOUT STYLE 5018 1 21121 050108 ste weg ENG Ve no o 20537 020807 Te ag E oes IP REv ECN No SCALE NTS PART ne JESOBB 99 1 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
10. Output voltage regulation Temp 32 122 F 0 50 C Freq 60 3 Hz Specification Conditions 12 Vdc 24 Vdc 48 Vdc 130 Vdc Vac 10 12 0 to 100 load 0 25 see product literature for specific data Transient response 20 100 load change with battery connected Output voltage change 4 maximum Recovery to 2 0 in 200 ms Recovery to 0 5 in 500 ms Efficiency All ratings 82 90 Output ripple voltage per NEMA PE5 1996 1 rms t 2 rms Unfiltered with battery SHE 2 at battery terminals 30 mV rms max 100 mV Filtered with battery at battery terminals Filtered without battery 1 rms typ 2 rms Battery Eliminator Filter 30 mV rms 100 mV Option without battery Current limit Adjustable 50 110 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 d Equalize 11 7 15 5 23 4 31 0 46 8 59 0 117 143 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 Surge withstand capability Test per ANSI C37 90 1 1989 No erroneous outputs Reverse cu
11. 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 2 years due to the limited shelf life of the dc filter capacitors when they are not in service 1 2 REPORTING SHIPPING DAMAGE If on delivery of the AT30 or related goods you discover any damage or shortage make notation on all copies of delivering carrier s delivery receipt before signing and notify the delivery person of your findings If loss or damage is discovered after delivery notify delivering carrier immediately and request an inspection The manufacturer does not assume any liability for damage during transportation or handling Should the goods 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 al
12. I 0 TERMINAL DESCRIPTION TVPE CONNECTION TBI 4 REM SENSE 4 2 TBI GND TB1 L1 L2 L3 POS NEG OUTPUT TERMINALS CU ALUMINUM COMPRESSION LUG POS NEG REMOTE SENSE TERMINALS 1 4 20 ZPS STUDS GROUND TERMINAL CL ALLIMINLIM COMPRESSION LUG AC INPUT TERMINALS CU ALUMINUM COMPRESSION LUG SUMMARY ALARM TERMINAL BLOCK SOLDERLESS COMPRESSION AUXILIARY ALARM TERM BLOCK SOLDERLESS COMPRESSION TEMPCO PROBE A10 INTERCONNECTION TERMINAL BLOCK 6 AWG 350 MCM 0 250 RING LUG 14 170 AWG 14 1 0 AWG 22 14 AWG 22 14 AWG 22 14 AWG STANDARD DR A ARRANGEM COMPONEN BASED LIF FEATUREC B SEE JESI C FOR CERT AC AND C ENCLOSLIR TO LARGE NOTES 1 FOR Als 2 10 FOR Note 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 Al through VR7 are supplied in all such units Optional components A5 through VR3 are supplied only in those AT30 battery chargers configured with such options 74 APPENDIX C Standard Drawings A R3x EXT BALLAST RES 130VDC R28x THERMOSTAT S2x SENSE RESISTOR gt S2 SCR MODULE A16 THERMOSTAT I Mao a TI POWER ISOLATION TRANSFORMER FE EIS TBI 1 0 TERMINAL BOARD EU TB3 SUMMARY ALARM CONTACTS R2 AIS NOTE 1 Gz i TB8 TEMPC
13. E 06 R4 or R14 is defective or remote sense wiring failed Locate R4 and R14 on the Gate Driver pc board A15 mounted on the back of the front panel Remove the wire harness plugs from J25 8 J26 and remove A15 from the main control 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 the error code if it detects this wiring failure You should respond to this problem quickly to be 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 or monitor the AT30 operation using the optional DNP 3 MODBUS communications board 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 restart the AT30 per Section 2 1 E 07 DC breaker open or internal failure If the dc breaker is open open the ac breaker then reclose the dc and ac
14. Style 5018 Style 5030 Style 163 see outline see outline see outline JE5085 00 JE5086 00 JE5095 00 INSTALLING THE AT30 1 5 2 Wall Mounting the AT30 Style 5018 enclosure only AT30 battery chargers housed in the floor mounted Style 5018 enclosure can be wall mounted You do not need to modify the standard Style 5018 enclosure for wall mounting but a special wall mounting kit EI5008 00 is required For kit availability see ordering information in Appendix B on page 65 The kit includes two 2 mounting brackets hardware and special instructions for the wall mounting procedure In planning for wall mounting of the AT30 you should consider the following 1 The wall must be strong enough to properly support the weight of the AT30 The weight of your AT30 may be different from the table value depending on options or accessories you ordered See the Weight Table located in Section 1 4 on page 3 Placement of conduit entrances Note the standard pre fab conduit knockouts located on the sides of the charger See the outline drawing JE5085 00 in Appendix C on Page 66 The location e Should be free of drips and splatter If dripping liquids are a problem install a drip shield kit 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 Maintain at
15. SECTION 94 40 2011 11 JA0128 03 INSTALLATION amp OPERATING INSTRUCTIONS FOR AT30 SERIES BATTERY CHARGER 25 1000 ADC OUTPUT SIVANVW OST a U PE HB a mi JEJ 3 GB E HOW TO READ THE AT30 MODEL NUMBER Your AT30 model number is coded to describe the options that are included Please find the model number on the data nameplate and write it in the spaces provided below Then follow the chart to determine the configuration of your battery charger DESCRIPTION CODE FEATURE DESCRIPTION CODE FEATURE A SERIES AT30 AT30 CHARGER AC CIRCUIT S STANDARD 012 12 Vdc BREAKER M MEDIUM AIC S Ge 024 24 Vdc le H HIGH AIC VOLTAGE 048 48 Vdc 0 NO AC BREAKER 130 130 Vde AC FUSES F SUPPLIED CODE FEATURE CODE FEATURE 200 kAIC x NOT SUPPLIED 025 25 Adc 200 200 Adc DC CIRCUIT S STANDARD 030 30 Adc 250 250 Adc 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 Adc DC FUSES F SUPPLIED 100 100 Adc 600 600 Adc 20 kAIC x NOT SUPPLIED 125 125 Adc 800 800 Adc AUX ALARM A SUPPLIED 150 150 Adc 1KO 1 000 Adc RELAV BOARD x NOT SUPPLIED U UNFILTERED G SUPPLIED D FILTERING F FILTERED ROOTA X NOT SUPPLIED E ELIMINATOR LIGHTNING L SUPPLIED 208 2
16. key on the front panel The FLOAT indicator goes off and the yellow EQLZ indicator lights Press the the float mode CHRG MODE key again to return the charger to The table below shows 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 Nominal Vdc Parameter 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 110 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 message When you apply power to the AT30 for the first time the micro processor control circuit performs a diagnostic check of the system If it finds anything wrong it writes an error code to the display such as E 01 Below is a list of these error codes See Section 3 2 on page 45 for a full explanation of each code Error Code Explanation E 01 resistor R2 is open or defective E 02 short circuit on dc output E 03 high dc volt
17. CHASSIS L2 FILTER INDUCTOR 3ELOW GROUND RQ FILTER CAP CI BLEED RESISTOR l TB4 AUX ALARM PCB TERMINAL BLOCK Taea VR3 AC INPUT LIGHTINING ARRESTOR L2 I TRANSFORMER ADLICTDR ee 20ND BUS BAR XXft 7 Vin A10 TO BE PLACED IMPRESSION LUG NEAR BATTERY CELL A A I O TERMINAL DESCRIPTION TYPE CONNECTION ise TB10 POS NEG OUTPUT TERMINALS CU ALUMINUM COMPRESSION LUG 6 AWG 350 MCM I REM SENSE 4 POS NEG REMOTE SENSE TERMS 0 375 16 ZPS STUD 0 375 SIZED LLIG _ TB1 GND GROUND TERMINAL CL ALLIMINLIM COMPRESSION LUG 6 AWG 350 MCM TB1 L1 L2 L3 AC INPUT TERMINALS CU ALUMINUM COMPRESSION LUG 6 AWG 350 MCM CB2 TB3 SUMMARY ALARM TERMINAL BLOCK SOLDERLESS COMPRESSION 22 14 AWG TBB TEMPCO PROBE A10 INTERCONNECTION TERMINAL BLOCK 22 14 AWG OUTPUT TB4 AUXILIARY ALARM RELAY PC BOARD A5 TERMINAL BLOCK 22 14 AWG AKERS cl THIRD ANGLE PROJECTION DRAWN BY MCR 020607 mr AT3O SERIES BATTERY CHARGER OPTIONAL 3 enen INTERNAL COMPONENT LAYOUT STYLE 163 4 DRAWING No REV 20537 020607 ae Ree te ae JESOSB 99 o B htto www ATSeries net PDFs JE5098 99 pdf 77 APPENDIX C Standard Drawings Instrument Panel PC Board Detail AT30 Battery Charger w Optional Auxiliary Alarm Relay Board JE5091 39 DSO1 Dso2 DS03 DS04 DSOS DSO6 DSO7 DS08 DSOS GREEN RED
18. If you have shut down the AT30 for service restart it according to Section 2 1 E 03 High DC Voltage Shutdown To restart the AT30 turn the ac breaker off then on Check the Equalize voltage and High DC Voltage alarm settings The 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 Charger output not controllable of the troubleshooting chart on page 52 of Section 3 4 45 SERVICING THE AT30 failure Error e Meanin Repair Procedure Code g p E 04 Internal memory Any parameters that you set such as Float or Equalize voltage are saved internally The internal memory is tested on startup If the memory test fails E 04 appears on the front panel display The error may also appear if the controller was trying to write to the memory while a power failure occured If an E 04 appears try restarting the AT30 by turning the ac and dc breakers off then on 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 control circuit board See Section 3 6 for parts ordering information E 05 Not used This error code was formerly used to indicate a reverse battery connection It is not available in the AT30
19. 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 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 Meter 1 Defective or 1 Turn off the AT30 With a light dc load connected to the battery be sure each cell reads the nominal cell voltage 2 0V for lead 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 See page 61 of Section 3 5 Locate R4 and R14 on the Gate Driver pc board A15 Remove one end of each resistor and measure its value with an Ohmmeter See the table in Section 3 6 for resistance values If either resistor is not within 1 of the specified value replace R4 and or R14 as needed 3 If the output voltage is constant but the front panel meter is erratic replace the Main Control board A1 54 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 Control circuit board A1 is not 2 Open the front panel and be sure that the control circuit board is securely mounted on the standoffs o
20. R7 REMOTE REMOTE dO SENSE SENSE J re So Be x u AJ ie G AE C INPU es KE L 218 LI LP LB GN KK pa FN FN FN e O EQ OD ef ler le 34 OPERATING THE AT30 2 3 5 Using 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 negative ground alarm There are two ways to work around this e Disable the ground detection circuit while the charger is in standby as described below e Put the charger into standby by opening the ac input circuit breaker CB1 and leaving the dc circuit breaker closed Operating the charger with the ac breaker CB1 closed and the dc breaker CB2 open is an abnormal condition and 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 De energize and lock out all ac and dc voltage sources to the AT30 Check with a voltmeter before proceeding This includes remote sense wires if they were installed e Open the AT30 front panel and locate jumper J5 at the top left of the Control Circuit Board shown on the previous page Move the jumper to the DISABLE position The POS GND and NEG GND indicators and the summary alarm relay will not res
21. RED RED GREEN AMBER AMBER AMBER AMBER INDICATOR LIGHTS LEDs AC DN OS10 RED LOW LEVEL DETECT DC VOLTS DS11 RED METER DISPLAY DC AMPS DS12 RED METER DISPLAY ELLALIZE HRS REMAINING DS13 RED HIGH DC VOLTAGE FLOAT DS14 RED LOW DC VOLTAGE ELLALIZE DS1S RED DC OUTPUT FAILURE MANUAL TIMER DS16 RED AC INPUT FAILURE MANUAL EQUALTZE DS17 RED POSITIVE GROUND AUTO EQUALIZE TIMER DS18 RED NEGATIVE GROUND pce ATIO O oc vars 7 Advanced Technology O oc aves d EBLZ HRS U BATTERY CHARGER REMAINING RECTIFIER O Faar HIGH DC O mz VOLTAGE LOW DC MANUAL TIMER VOLTAGE DC OUTPUT O wua EGLZ FAILURE auto EBLZ TIMER AC INPUT FAILURE e LAMP TEST o POS GND ADJUST EE O vn GND D r EI TUP OFF EXTERNAL AL POKER AD big THE U Ze BIEL l TAD A Gr ML TAGE Bs SERVICING e Fen me NN HAZARD DE ELECTRICAL SHOCK QUALIFIED PERSONNEL ONLY DO NOT REMOVE THIS LABEL INSTRUMENT PANEL PART No FK0151 02 NOTE UNLESS OTHERWISE SPECIFIED ALL ALARM TERMINAL BLOCKS TB3 TB4 TBB ARE SULDERLESS COMPRESSION TERMINALS CONTACT RATING IS O 5A e 125VAC DC ACCEPTING 22 14 AWG WIRE oc Dur oc our GROUND GROUND GE AC Fan ac ran Semen Summary SUMMARY moje alc NC najc NC NaC NC Na wait NC Na 10 u 12 13
22. and TB1 using a dc output voltage voltmeter Value should agree with the Float Vde front panel voltmeter within 0 25 and must be correct values for your Equalize Vde battery If the 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 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 Press LAMP TEST key on front panel O OK indicators Test common Press LAMP TEST key and hold for 4 O OK alarm relay seconds Common alarm relay 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 vours OK O amps OK LI Hours OK Cycle through equalize methods CI MANUAL TIMER OK O MANUAL EQLZ OK LI auto EQLZ TIMER OK Turn off ac circuit breaker The AC O Alarm OK INPUT FAILURE indicator should light Reset breaker Check voltage Use EDIT ENTER key to scroll through L FLOAT OK and alarm settings See page 30 Cl EQUALIZE OK settings CI HvDC alarm OK LI LVDC alarm OK Currentlimit Adc Final ch
23. produce a High DC Voltage alarm See Parallel Operation portion in Section 2 3 6 2 Turn off both front panel circuit breakers CB1 CB2 or turn off ac and dc power externally if the AT30 does not have breakers Wait one minute before returning the dc connection followed by the ac connection If the charger output voltage is above the alarm setting but the HIGH DC VOLTAGE indicator still does not light replace the Main Control board A1 55 SERVICING THE AT30 there is output current voltage settings are mismatched 3 Defective rectifier bridge 4 Defective Main Control board A1 5 Defective dc circuit breaker CB2 PROBABLE SYMPTOM RACE RECOMMENDED ACTION 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 and dc battery voltage is above the Low DC Alarm voltage breakers are 2 Low DC 2 Be sure that the Low DC Voltage alarm setting is lower than the closed ac Voltage alarm _ Float voltage setting See Sections 2 3 2 and 2 3 4 input voltage and Float is normal 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
24. 14 15 16 17 19 19 20 21122 23 24 25 26 27128 28 30131 32 23134 36 36 AUXILIARY ALARM RELAY PC BOARD A5 THREE PHASE GATE DRIVER PC o o 000000000000 o00000000000 gz a a ps oF DISABLE ENABLE MAIN CONTROL PC BI FRONT VIEW FACING CHARGER D SCR SNLIBBER PC BOARD A17 THREE 3 REL PER CHARGER OTHER CONTROLS RAI LOW LEVEL WARNING DETECT ADJLIST RA2 GROUND FALLT KOBIETA RA3 GROUND FAULT SENSITIVITY LI ONINSWA i NIN LISER ACCESSED JLMPERS J12 BOARD PROGRAMMING J14 OLD FORCED LOAD SHARING JIS MANUFACTURING TEST J16 OLD INTERNAL TEMP Note 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 APPENDIX C Standard Drawings Instrument Panel PC Board Detail AT30 Battery Charger w Optional Auxiliary Alarm Relay Board JE5091 39 JRIVER PC BOARD A15 THREE PHASE GATE DRIVER PC BUARD A15 o 000000000 o00o000000 ooooo0o0000000 oooooo0o000000 DISPLAY e
25. 16 1 10 Wiring to the remote alarm contacts snanar 18 Auxiliary Relay Board optional nn aaa 19 1 11 Installing the temperature compensation probe optional 20 Using temperature compensation ooo aaa aaa aaa aaa aaa nnn 22 1 12 Installing the AT30 for remote communications optional 23 1 13 Installing the AT30 for forced load sharing optional eeeeeeseeeeeseeesereseennnns 23 2 Operating the AT30 Battery Charger 2 1 Starting the AT30 2 1 1 Understanding the start up seguence aaa aa aaa aaa 24 2 1 2 Checking the installation 24 2 1 3 Starting the ATIO aaa gts eee a bia EWA it EA CA 24 Osing the digital Meter eee a i danin aa dE Eege 24 Factory settings table se sinniet sas nee fatta 25 2 2 Using the AT30 front panel features 2 2 1 If the meter displays an error message nn 26 2 2 2 Selecting the meter mode 26 2 2 3 Selecting the Float or Equalize mode sma 27 2 2 4 Choosing the Equalize method nanna 27 Manual Timer method 27 Manual Equalize method rna 28 Auto Equalize Timer method nn 28 2 2 5 Testing the front panel indicators nn 29 2 2 6 Testing the Auxiliary Relay Board optional nn 29 2 2 7 Interpreting the alarm indicators rent 29 TABLE OF CONTENTS 2 3 Setting the AT30 parameters 2 3 1 Understanding parameter settings 2 2 seen nanna nn 30 2 3 2 Setting the Float and Equalize voltages sa 31 2 3 3 Setting the Equalize timer na 32
26. 2 3 4 Setting the Alams ss nn an arana nanna 32 Setting the high and low dc voltage alarms L 33 Adjusting ground detection sensitivitv seen 34 Disabling the ground detection alarm near 35 2 3 5 Setting the current limit value nn aaa aaa nn nanna 35 2 3 6 Enabling the high dc voltage shutdown feature 36 2 3 7 Adjusting the Voltmeter accuracy nn nnnnnnnnn mnn n nn nanna nanna 37 2 3 8 Using the Low Level Detector UL Di 38 2 3 9 Using the front panel security feature eee nnneennnnnzznnnnenznna 39 2 4 Performing routine maintenance nn nn nn nn aaa 40 Sample preventive maintenance procedure nn 42 3 Servicing the AT30 Battery Charger 3 1 A step by step troubleshooting procedure nn 44 3 2 Interpreting front panel error MESSAGES nanna nanna 45 3 3 Using the troubleshooting chart nn 48 3 4 Troubleshooting Chart begins ON nn 49 3 5 Replacing defective Componente eee aaa aaa aaa 58 3 6 Ordering replacement Darts 62 APPENDIX A AT30 Performance Specifications sr 64 APPENDIX B Field Installable Accessories nr 65 APPENDIX C Standard Drawings Outline AT30 Battery Charger NEMA 1 Style 5018 Enclosure e eennnennnzznzznnnnnnznn 66 Outline AT30 Battery Charger NEMA 1 Style 5030 Enclosure ss ennennnennnnnnnnna 68 Outline AT30 Battery Charger NEMA 1 Style 163 Enclosure ss eennnnnnnzznzznnnnenznnn 70 Internal Component Layout AT30 Style 5018
27. 21120 043008 ELECTRONIC APPROVAL SIGNATURES 2 120107 MAINTAINED BY MFG ECN LOG DRAWING No REV UNLESS OTHERWISE NOTED DIMENSIONS JE5093 99 2 B ARE IN INCHES TOLERANCES ARE SCALE NTS PART No JE5093 99 OF 1 http www ATSeries net PDFs JE5093 99 pdf D 20527 012607 ECN No DATE 85 APPENDIX C Standard Drawings Connection Diagram AT30 Battery Charger Control Signal Wiring JE5094 00 SNUBBER ASSY A170 SNUBBER ASSY A17B SNLIBBER ASSY A17A NOTE NUMBER TYPE UNIT RATING SPECIFIC SCR AND ARRANGEMENT OF CONTROL CONTACTS ON 6 PULSE RECTIFIER ASSY A16 VARIES BASED UPON SEE DETAIL DRAWING JES163 00 FOR MODULE CONTROL WIRING RECTIFICATION SCHEMATIC LABEL ON SIDE OF SCR MODULES ALSO DETAILS CONTROL CONTACT POINTS o 02 AC INP O ul Le NOTE 5 NIE SS 10 GR YE AT30 SERIES I U TERMINAL BOARD TBI 6 PULSE SCR Q1 Q6 MODULE RECTIFIER ASSEMBLY A16 C EMOTE SENS NOTE 3 H 10 GRZYE 51 CHASSIS GROUND R3B Ciel 49 Da NOTE 4 RZA Je RI MAIN DC SHLINT His PRI TER TRANSFORMER x3 O 86 APPENDIX C Standard Drawings Connection Diagram AT30 Battery Charger Control Signal Wiring JE5094 00 47 GR YE
28. 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 inserting the connector into J4 until it is completely seated NOTE DC power cabling for the battery charger battery and load interconnection is not supplied with the AT Series Forced Load sharing option All user supplied system wiring should meet National Electric Code NEC standards as well as local site codes Confirm polarity of all dc cabling before making connections 92 APPENDIX F OPERATING CHARGERS WITH LOAD SHARING Restore external power connections to both AT30s and restart according to the normal procedure in the AT Series Battery Charger Operating and Service Instructions After the AT30s restart the Primary charger attempts to establish communication with the Secondary If communication is successful the chargers behave as follows e The Primary charger displays the message LS P Load Share Primary on the front panel 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 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
29. AT30 output voltage 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 22 100 Percent Output Voltage INSTALLING THE AT30 Note the following You should set the Float and Equalize 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 shows the 77 F 25 C value for the Float or Equalize voltage even if the battery is warmer or cooler than 77 F 25 O The actual output voltage of the AT30 may be different from the value shown on the front panel meter if the battery is warmer or cooler than 71 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 charger 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 K z ic kel Cadmium Example 100 Deg F 97 Output Voltage
30. CABINET FOR VENTILATION FOUR 4 0 625in 16mm FLOOR MOUNTING HOLES ARE PROVIDED ON BOTTOM OF ENCLOSURE AS SHOWN SIX 6 1 3lin 33mm DIA STANDARD PRE FAB CONDUIT KNOCKOUTS ARE PROVIDED AS SHOWN FOR lin 25mm CABLE ENTRY BOTTOM CONDUIT ENTRY IS POSSIBLE THROUGH EXPANDED METAL LINDERSIDE IF ADDITIONAL CONDUIT ENTRANCES ARE REQUIRED ENCLOSURE SHOULD BE FIELD MODIFIED BY INSTALLER BATTERY CHARGER SHIPPING WEIGHT SEE PRODUCT LITERATURE DUAL DIMENSIONS 17 mm THIRD ANGLE PROJECTION DRAWN BY MCR 092506 T AT30 BATTERY CHARGER OUTLINE APRN NEMA 1 STYLE 163 ENCLOSURE DRAWING No REV 20343 092506 UNLESS OTHERWISE NOTED DIMENSIONS JE5095 00 0 ARE IN INCHES TOLERANCES ARE SCALE NTS PART No JE5095 00 htto Awww 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 PLEXIGLAS SAFETY COVER PLEXIGLAS SAFETY COVER NDUCTOR LI E13 NDUCTOR L2 m a al CB2 E JEJE CIRCUIT m sia sj BREAKER Z lt Z CBI lt N lt j WL CE SC lge l N PA Z w 4 b XIX 7 ef Se Kee lt TRANSFORMER ls Sg BEN PS d See GE N As A Ee Le F e p lt CX I
31. 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 are equipped with over internal temperature thermostats On startup the AT30 tests the thermostats thermostat and displays E 12 if one or more are defective You can check a thermostat by disconnecting the wiring from the thermostat terminals and measuring continuity The thermostat should be closed NC at normal room temperature E 13 Internal over Une or more of the rectifier assembly thermostats has detected an over temperature temperature condition If the rectifier is equipped with fans check all fans for proper operation Also be 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 Verify both AT30s are functioning properly sharing not Ensure that the forced load sharing interconnection cable assembly is not working broken is properly installed and that the connector for the Secondary properly 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 equalize If AT30 was accidentally left in manual equalize mode switch unit back to enabl
32. DETAIL 456 789 1011 12 13 14 15 19 20 21 22 2324 25 26 27 28 29 30 31 32 33 ER TB4 KI a 12 VOLTS 24 VOLTS oo 48 VOLTS mm 130 VOLTS AUXILARY ALARM RELAY PC BOARD A5 PROCEDURE 1 Deenergize and lock out all ac and dc voltages to the AT30 Allow internal voltages to dissipate then check with a voltmeter 2 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 Connect the wiring use 22 14 AWG to the appropriate terminals of TB4 on the Auxiliary Alarm Relay board as shown in the figure above Strip each wire 0 25in 6 4mm and securely tighten the terminal screws 6 Replace the safety shield if supplied and restart the AT30 NOTES 1 Alarm contacts are rated at 0 5A 125 Vac or Vdc ere Terminal block TB4 is compression type accepting 22 14 AWG wire Terminals are labeled in non alarm condition For a detailed view of the optional Auxiliary Alarm Relay PC Board A5 refer to drawing JE5091 39 listed in Appenix C on Page 78 19 INSTALLING THE AT30 1 11 INSTALLING THE TEMPCO PROBE ASSEMBLY OPTIONAL The temperature compensation probe contains a temperature dependent resistor in an epoxy module that you install near
33. PC BOARD A1 HINDLEPOWER INC Relay SUMMARY ALARM INTERCONNECTION DETAIL 1 Allow 30in 762mm of wire inside the enclosure excess will be trimmed 2 Route wires to front door by following the existing harness through the door hinge as shown Use 2 wire ties and allow a 4 6in 102 153mm loop for the hinge 3 Trim wires to the proper length for connecting to TB3 Strip 0 25in 6 4mm of insulation from the wires Make the connections at TB3 and securely tighten the screws NOTES 1 Alarm contacts are rated at 0 5A 125 Vac or Vdc 2 Terminal block is a compression type accepting wire sizes 22 14 AWG 3 Terminals are labeled in non alarm condition INSTALLING THE AT30 Auxiliary Relay Board optional The optional Auxiliary Alarm Relay 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 TB4 are as follows shown in non alarm condition HVDC DC OUT DC OUT GROUND GROUND HVDC LVDC LVDC FAILURE FAILURE ACFAIL ACFAIL DETECT DETECT SUMMARY SUMMARY 34 35 36 C NC NO C NC NO C NC NO NC NO S NC NO B NC NO B NC NO B NC NO NC NO C NC NO C NC NO C NC NO 16 17 18 123 VOLTAGE SELECTOR SWITCH
34. SERVICING THE AT30 Seite D oti Factory Part Number Rec mbo escription y P 12 Vdc 24 Vdc 48 Vdc 130 Vdc Spares L1 Main Inductor see supplied Parts Data Package L2 Optional Filter Inductor see supplied Parts Data Package Jumper for disabling Ground Detection circuit E PS on Main Control PC Board A1 RC0100 00 Jumper for voltage selection on o ES Auxiliary Relay PC Board A5 RCO100 00 Jumper for front panel lockout feature on P9 Main Control PC Board A1 RC0100 00 R1 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 o RJ0007 26 RJ0035 25 EJ1127 02 EJ1127 03 R3 Power Supply Ballast Resistor 120 2w 680 11W 1500 50W note 1 S A RJ0056 48 RJ0056 81 RJ0075 14 RJ0075 56 R4 Positive External Scaling Resistor 31609 69809 14 0KQ 38 3KQ R6 Voltage Crowbar Resistor RJ0063 76 RJ0064 11 RJ0064 41 RJ0064 80 R9 Filter Capacitor C1 Bleed Resistor RJ0028 25 RJ0028 25 RJ0028 27 RJ0036 40 7 RJ0074 48 RJ0074 81 RJ0075 14 RJ0075 56 R14 Negative External Scaling Resistor 31609 69809 14 0KQ 38 3KQ T1 Main Power Isolation Transformer see supplied Parts Data Package Style 5018 input output
35. ama 043008 SRR ES ux gt gol a L tel oss Te geen JE5094 00 1 B ev ECN No SCALE vis PART Na JES094 00 http www ATSeries net PDFs JE5094 00 pdf 87 APPENDIX C Standard Drawings Connection Detail AT30 Battery Charger I O Panels amp Rectifier Assemblies JE5163 00 AC IN a o DI i 162 o Al6 c gt 1 GKKG 4576 GKKG 4576 G9 09 69 09 ta g 167 o A16B ln CH 171 A16A 3x2 SCR 4 MODULES B GKKG 4576 CO GQ Py la a FIGURE 3 100A RECTIFIER ASSY A16 PM5007 01 FIGURE 1 FIGURE 2 25 50A RECTIFIER ASSY 75A RECTIFIER ASSY A16A B C 3 RMOOOS 00 A16 PM5007 00 FIGURE 8 CHASSTS 52 GRZYE STYLE 5018 1 0 TERMINAL 10 GRZYE BOARD TBI LU gt N D D IN mm O REMOTE REMOTE SENSE SENSE 10 GR YE FIGURE 9 STYLE 5030 I O TERMINAL cya BOARD TB L 10 GRZYE NOTES 10 GRZYE 52 GRZYE 1 ALL COMPONENTS ARE CONNECTED WITH FLAME RETARDANT SWITCHBOARD INSULATION TYPE WIRING IDENTIFIED ON EACH END WITH NUMBER CODED MARKERS REMOTE SENSE O WHEN REMOTE SENSE IS USED WIRE 38 CONNECTS TO REMOTE S SENSE AND WIRE 40 CONNECTS TO REMOTE SENSEC DE CHASSIS OUTPUT N A GROUND NOTE 2 I O PANELS AND RECTIFIER ASSEMBLIES ARE NOT DRAWN TO SCALE FOR APPROPRIATE RECTIFIER ASSEMBLY REFER TO THE SUPPLIED FIGURE 10 PARTS DATA PACKAGE REP
36. as needed 4 Turn off both front panel circuit breakers CB1 CB2 or turn off ac and dc power externally if the AT30 does not have breakers Wait one minute before returning the dc connection followed by the ac connection If the charger output voltage is normal but the LOW DC VOLTAGE indicator is still on replace the Main Control 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 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 50 of the dc output current one of the SCRs or diodes is defective Replace the rectifier module 2 Turn off both front panel circuit breakers CB1 CB2 or turn off ac and dc power externally if the AT30 does not have breakers Wait one minute before returning the dc connection followed by the ac connection If the charger output voltage and current are normal but the DC OUTPUT FAILURE indicator is still on replace the Main Control board A1 3 Use an ac voltmeter to measure the ac voltage between
37. battery connected in reverse polarity the circuit breaker will immediately trip Do not try to close the dc breaker again since this may damage the battery charger Correct the battery polarity before proceeding If your charger is equipped with dc fuses one or both fuses will blow when the battery is reversed 24 OPERATING THE AT30 If you have an optional temperature compensation probe installed the front panel displays LEAD during startup indicating that the temperature compensation is set up for lead acid batteries 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 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 NOTE If you turn on the ac breaker before the dc breaker and you have a filtered model of the AT30 there is a possibility that the dc breaker will trip when you try to turn it on This is caused by the filter capacitors 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 The green FLOAT indicator lights Press the CHRG MODE
38. breakers If the dc breaker trips again see the troubleshooting chart in Section 3 4 If the dc breaker is closed but you have an E 07 display check your battery If the battery is disconnected and you then disconnect the load the AT30 may display an E 07 code Restart the AT30 according to Section 2 1 If the battery and load are OK see the troubleshooting chart in chart in Section 3 4 for help in locating the problem E 08 Defective temperature compensation probe If a temperature compensation probe is connected to the AT30 the control circuit detects the probe on startup and uses the temperature measured by the probe to control the output voltage of the AT30 To understand temperature compensation see Section 1 11 If the temperature compensation probe or the wiring that connects it to the AT30 fails during normal operation the AT30 detects the failure and shows E 08 on the front panel meter Disconnect the wiring from the probe and measure the resistance of the probe with an Ohmmeter The resistance should be approximately 10 000 Ohms at normal room temperature 77 F 25 C If the probe reads open or shorted it needs to be replaced 46 SERVICING THE AT30 Error Code Meaning Repair Procedure E 08 Defective temperature compensation probe continued If the probe checks good examine the wiring between the probe and the AT30 Also check the connection of the cable
39. current for normal check the operation of the off charger by increasing its Float operation of both chargers 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 EJ5126 2 See Appendix F on page 92 for troubleshooting of Forced Load option Sharing feature HIGH DC 1 HDCV alarm 1 Be sure that the High DC Voltage alarm setting is higher than VOLTAGE and Equalize the Equalize voltage setting See Sections 2 3 2 and 2 3 4 indicator is on voltage settings are mismatched 2 Defective rectifier bridge 3 Defective Main Control board A1 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 circuit breakers CB1 CB2 or turn off ac and dc power externally if the AT30 does not have breakers Wait one minute before returning the dc connection followed by the ac connection If the charger output voltage is normal but the HIGH DC VOLTAGE indicator is still on replace the Main Control board A1 No alarm but output voltage is above High DC Voltage setting 1 Output current is below 2 2 Defective Main Control board A1 1 Output current must be greater than 2 of rated current to
40. it has been damaged in any way Refer to qualified service personnel Do not disassemble battery charger Only qualified service personnel should attempt repairs Incorrect reassembly may result in explosion electrical shock or fire Do not install the battery charger outdoors or in wet or damp locations unless specifically ordered for that environment PLEASE READ AND FOLLOW ALL SAFETY INSTRUCTIONS TABLE OF CONTENTS QUICK OPERATION iii d a L st Back Cover HOW TO READ THE AT30 MODEL NUMBER 1 2 11 2 s Inside Front Cover IMPORTANT SAFETY INSTRUCTIONS sssee sono oe een seen saw za aaa H anawa asza awa emm An i 1 Receiving and Installing the AT30 Battery Charger TA Stoning the ATIO kasa bwiet Rad ri EZ ry Ardea O w na 2 1 2 Reporting shipping damage eee eee aaa aaa aaa aaa aaa aaa aaa 2 1 38 Unpacking and inspecting the Al20 nn near nn nanna 2 InSpection ChECKIISEa soki Nd a in ak ae 2 E le Vue Bn 3 Enclosure type and weight table AA 3 1 8 Mounting the ME 4 1 5 1 Floor Mounting the AT30 standard nn aaa nanna 4 1 5 2 Wall Mounting the AT30 optional nanna 6 1 5 3 Rack Mounting the AT30 optional near nanna 8 1 6 Changing the transformer ops ss nanna anna 10 1 7 Making the ac input connections seesmine inanin aaa aaa ai 12 1 8 Making the dc output connechons seren ena nn aaa tna 14 1 9 Wiring the AT30 for remote sensing eee a aaa aaa n ernati
41. not be able to reach the Float voltage load orload 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 board A1 correctly for your input voltage See Changing Transformer Taps Section 1 6 The actual ac input voltage must be at least 88 of the rated value for the AT30 to produce full output power 4 Use aclamp 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 circuit breakers CB1 CB2 or turn off ac and dc power externally if the AT30 does not have breakers Wait one minute before returning the dc connection followed by the ac connection If the charger output current is below the current limit value but it still has the wrong output voltage replace the Main Control board A1 53 SERVICING THE AT30 rectifier bridge 3 Defective T1 PROBABLE SYMPTOM gt RECOMMENDED ACTION CAUSE Input current 1 Wrong ac 1 Be sure the T1 primary taps are wired correctly for your input too high input voliage or voltage See Changing Tra
42. program version since the load sharing option has not been tested using a different program version in each charger To view the program version press the LAMP TEST button on the front panel of the charger When you release the button the version number is shown on the front panel display for two 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 EH5041 00 A 25ft 7 6m long cable EH5041 01 and a 50ft 15 2m long cable EH5041 01 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 A1 One end of the cable features an extra jumper in the connector and should be identified for use with the Secondary charger The other end of the cable connects to the Primary charger Either 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 lb 20
43. to the control circuit board on the back of the front panel If the wiring is OK then the probe needs to be replaced Once you have replaced the probe you must restart the AT30 to activate temperature compensation E 09 Misadjusted current limit The output current limit is set at the factory to 110 of the rated output current e g for a 50 Adc charger the current limit is set to 55 Adc You can adjust the current limit downward to as low as 50 of the output current if you have special requirements such as limited ac power available You should do this only if the normal dc load on the system is smaller than the current limit If you do reduce the current limit setting below 100 of rated current your connected load might require more current than the AT30 can deliver If this happens the battery will not charge properly If this occurs the front panel displays the error code E 09 You should increase the current limit setting so that the AT30 can supply all the current required by the load and still charge the battery The current limit should be set to at least 5 greater than the maximum continuous dc load current NOTE The common alarm relay is not set for this condition E 10 Open internal feedback loop A redundant internal feedback loop control loop is provided as redundancy to increase reliability when remote sensing is used If there is a problem with the internal loop wiring the AT30 will display E 10
44. type auxiliary alarm terminal block s external temperature compensation probe DNP3 Level 2 Modbus communications module forced load sharing interconnection cable 10 11 12 IMPORTANT SAFETY INSTRUCTIONS PLEASE READ AND FOLLOW ALL SAFETY INSTRUCTIONS Before using this equipment read all instructions and cautionary markings on A this equipment B battery and C any other equipment to be used in conjunction with this equipment This manual contains important safety and operating instructions and therefore should be filed for easy access Remove all jewelry watches rings etc before proceeding with installation or service Do not touch any uninsulated parts of this equipment 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 this equipment or the battery Maintain at least 6in 152mm clearance from all obstructions on the top and sides of this equipment Allow sufficient clearance to open the front panel for servicing Turn this equipment off before connecting or disconnecting the battery to avoid a shock hazard and or equipment damage Connect or disconnect the battery only when the battery charger is off to prevent arcing or burning De energize all ac and dc inputs to the battery charger before servicing Do not operate battery charger if
45. value in the display upward or downward When the display shows the equalize time in hours that you want to set release the UP or DOWN key If you go past the number of hours you want press the UP or DOWN 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 ENTERI key three more times until the charger 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 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
46. voltage the meter display shows error code E 03 Reset the charger by turning the ac breaker 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 affects meter accuracy such as the main control PC board 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 charger changes Do this adjustment with a fully charged battery and with no load connected First use the Edit procedure to adjust the float voltage to the desired value See Section 2 3 2 for instructions on setting the float voltage Second press and hold the uP key then press the EQLZ MTHD key The DC VOLTS METER MODE indicator will light and the meter display flashes the output voltage reading Measure the output voltage of the AT30 using a dc 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 DOWN 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 DOWN until the actual output voltage agrees with the
47. wo JSE Sir ba ENABLE Z ir C S f T Z 4 2 PRA Eeh L U OL jee J3 rae 3 J9 a m e ENABLE o jj Hia pat o Ei TB3 R 2 Bee LSS o le ln 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 NOTE You need at least 50 of the nominal output voltage to power the AT30 control circuit board Adjust RA1 with a small jeweler s screwdriver clockwise until the alarm just activates A red LED indicator DS10 next to RA1 indicates when the alarm is active 38 OPERATING THE AT30 2 3 9 Using the front panel security feature The AT30 charger is shipped with all the front instrument panel keys enabled You can disable the following front panel functions e Selecting Equalize method e Changing settings using the EDIT ENTER key e Toggling the high dc voltage shutdown feature To disable the front instrument panel keys open the AT30 door and locate the small plastic jumper J9 on the right side of the main control board See the figure below JS FE ND FAULT ENABLE TB8 1 NN IEIR Move the jumper up to the DISABLE position pins 2 and 3 With this set
48. www ATSeries net PDFs JA0102 01 pdf AT10 1 G1 Manual unlabeled JA0102 02 http www ATSeries net PDFs JA0102 02 pdf AT10 1 G2 Manual unlabeled JA0102 03 http www ATSeries net PDFs JA0102 03 pdf AT30 Manual unlabeled JA0102 04 http www ATSeries net PDFs JA0102 04 pdf AT Comm Module Manual unlabeled JA0102 05 http www ATSeries net PDFs JA0102 05 pdf AT DC Dist Panel Manual unlabeled JA0083 00 http www ATSeries net PDFs JA0083 00 pdf AT10 1 Floor Mtg Instructions JA0091 00 http www ATSeries net PDFs JA0091 00 pdf AT10 1 St 586 594 Rack Mig Instructions JA0091 02 http www ATSeries net PDFs JA0091 02 pdf AT10 1 Style 5017 Rack Mtg Instructions JA0091 03 http www ATSeries net PDFs JA0091 03 pdf AT Style 5018 Rack Mtg Instructions JA5015 00 http www ATSeries net PDFs JA5015 00 pdf AT TempCo Probe Acsy Instructions JA5054 00 http www ATSeries net PDFs JA5054 00 pdf AT Forced Load Sharing Instructions JA5098 00 http www ATSeries net PDFs JA5098 00 pdf AT Latching Alarm Relays Instructions JD0064 00 http www ATSeries net PDFs JD0064 00 pdf Preventative Maintenance Procedure JD5003 00 http www ATSeries net PDFs JD5003 00 pdf TempCo Probe Application Note JD5008 00 http www ATSeries net PDFs JD5008 00 pdf AT Comm Module Field Installation JD5009 00 ht
49. your battery There are three steps in installing the assembly 1 Mounting the probe assembly near the battery 2 Installing an interconnection cable from the probe assembly to the AT30 3 Wiring the charger end of the cable to a terminal block on the main control circuit board The actual tempco probe is the same for all battery types and all output voltages of the AT30 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 The main elements of the installation are outlined below WARNING High voltages appear at several points inside the AT30 Use extreme caution when working inside the unit 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 TB1 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 on unpainted wood or bare galvanized metal e on plastic surfaces 3 To a
50. 08 Vac 60 Hz ARRESTOR X NOT SUPPLIED 240 240 Vac 60 Hz E AC INPUT 480 480 Vac 60 Hz FUNGUS F APPLIED VOLTAGE 220 220 Vac 50 60 Hz PROOFING x NOT APPLIED 380 380 Vac 50 60 Hz 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 25 000 AIC Contact your sales representative for 500 600 Vac circuit breaker AIC ratings NOTE The model number listed on the charger data nameplate does not include any field installed options Also certain accessories are not included in the model number even if they are shipped with the charger Check off below any accessories that were included or that you install yourself wall rack mounting brackets NEMA 2 type drip shield NEMA 4 12 13 type enclosure cabinet heater strips pad key lock for front panel door analog ac voltmeter w sel switch analog ac ammeter w sel switch Please find the serial number on the data nameplate and record it here zero center ground detection meter w test switch end of discharge alarm relay battery discharge alarm relay barrier
51. 085 00 2 Using the methods described in Section 1 4 carefully lift the AT30 above the floor mounting bolts Guide the enclosure onto the floor bolt pattern and lower it into place 3 Add appropriate mounting hardware 0 25in 6 4mm onto the floor mounting bolts and tighten securely INSTALLING THE AT30 PROCEDURE Style 5030 1 Install four 4 0 375 9 5mm or 0 5in 12 7mm bolts into the floor per mounting dimensions featured in the outline drawing JE5086 00 2 Using the methods described in Section 1 4 carefully lift the AT30 above the floor mounting bolts Guide the enclosure onto the floor bolt pattern and lower it into place 3 Add appropriate mounting hardware 0 375 9 5mm or 0 5in 12 7mm onto the floor mounting bolts and tighten securely PROCEDURE Style 163 1 Install four 4 0 5in 12 7mm bolts into the floor per mounting dimensions featured in the outline drawing JE5095 00 2 Using the methods described in Section 1 4 carefully lift the AT30 above the floor mounting bolts Guide the enclosure onto the floor bolt pattern and lower it into place 3 Add appropriate mounting hardware 0 5in 12 7mm onto the floor mounting bolts and tighten securely STANDARD NEMA 1 AT30 ENCLOSURE TYPES
52. 2 AND TRANSFORMER WINDING TAPS T1 Z1 Z2 ARE ONLY SUPPLIED WITH AT30 UNITS RATED 400 ADC OR HIGHER 20530 20211 013007 APPROVED MCT 051705 051706 MCT hee in INCHES TOLERANCES ARE TITLE AT30 BATTERY CHARGER MAINFRAME SCHEMATIC WITH COMMON OPTIONS DRAWING No JESO92 99 11B SCALE NTS PART No JE5092 99 1 htto 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 U TERMINAL BOARD TBI NOTE 5 TRI NOTE 2 O DC OUTPUT 10 GR YE AC FUSES LIGHTNING ARRESTOR NOTES WITH YELLOW STRIPE 2 INCLUDING REMOTE SENSE MODIFICATIONS 3 TERMINALS ACCEPTING 22 14 AWG WIRE 4 EITHER AIB BUS AS SHOWN OR TO R1 1 5 FOR EXACT PHYSICAL CONFIGURATION 6 FOR APPROPRIATE CONTACT POINTS 7 ELIMINATING THE NEED FOR CERTAIN WIRES SUCH AS 15 AND 25 1 CHARGER COMPONENTS ARE CONNECTED WITH FLAME RETARDANT SWITCHBOARD INSULATION TYPE WIRING IDENTIFIED ON EACH END WITH NUMBER CODED MARKERS GROUND WIRE 10 IS GREEN THIS DRAWING SHOWS MAINFRAME POWER WIRING AND CUSTOMER CONNECTION CONTACTS TO CONTROL PC BOARDS Al amp AS SEE DRAWING JE5094 00 FOR ALL CONTROL SIGNAL 3 WIRING STANDARD CUSTOMER ALARM CONTACTS TB3
53. 5088 99 STANDARD COMPONENT DESCRIPTION STANDARD DRAWING NOTES Al MAIN CONTROL PC BOARD A15 THREE PHASE GATE DRIVE PC BOARD AI WAY DIFFER SLIGHTLY BASED UPON UNIT AIG 3PH SCR MODULE ASSY 1x5 1 06 RATING AND FEATURED OPTIONS Al7x SCR SNUBBER PC BOARD BTY 3 CA EMI OUTPUT FILTER CAP NEG GND cs EMI OUTPUT FILTER CAP POS GND CBI AC INPUT CIRCUIT BREAKER CD3 oS CB2 DC OUTPUT CIRCUIT BREAKER CD2 el El CR4 FREE WHEELING DIODE EMG e LI MAIN INDUCTOR 5 RN RI MAIN OC SHUNT HO R2 CURRENT RATING RESISTOR 4 E EXT BALLAST RES 130VDC gt THREE_PHASE TI POWER ISOLATION TRANSFORMER 4 A17B GATE DRIVE PC TB I O TERMINAL BOARD 2 4 R2 BOARD ASSY AIS o TB3 SUMMARY ALARM CONTACTS U ull i TB8 TEMPCO PROBE TERMINAL BLOCK a es i VRI DUTPLIT SURGE SUPPRESSOR T0 8 ZS 3 VR2 INPUT SURGE SUPPRESSUR LINE 1 ol Z AIA i e VRA INPUT SURGE SUPPRESSOR LINE 2 1 VRS INPUT SURGE SUPPRESSOR LINE 3 SI 5 VRS OUTPUT SURGE SUPPRESSOR n e SAS VR7 OUTPUT SURGE SUPPRESSOR MAIN CONTROL CARD SYM OPTIONAL COMPONENT DESCRIPTION oN Recut ER eas AS AUXILIARY ALARM RELAY PC BOARD erp SOON Ale DETAILS o Ai TEMPERATURE COMPENSATION PROBE Gages CI DE OUTPUT FILTER CAPACITOR d C2 BATTERY ELIMINATOR CAPACITOR Ez o CRI POLARITY DIODE
54. 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 important Carefully re solder the cut wires to R3 remount the resistor and top bracket Replacing resistors R3 R4 R6 amp R14 on the Gate Driver board 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 See the figure below of the Gate Driver pc board A15 for proper location THREE PHASE GATE DRIVE PC BOARD A15 J26 o R3 bo RBA La DISABLE J5 J5 E NTROL PC BOARD A If any of these resistors 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 415 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
55. Drip Shield for Style 5018 5030 163 Enclosure EI0191 02 03 04 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 XX Remote Temperature Compensation Probe The temperature compensation assembly consists of two 2 components 1 To order a replacement probe or puck request part number EJ5032 00 This probe is good for all charger 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 shows the ordering part number for a complete probe kit Temperature Compensation Probe Kits Cable Length Kit Part Number Replacement Cable feet m includes probe Part Number 25 7 6 EJ5033 00 EJ5011 00 50 15 2 EJ5033 01 EJ5011 01 100 30 5 EJ5033 02 EJ5011 02 200 61 0 EJ5033 03 EJ5011 03 Use a single cable assembly Do not try to splice cables together to increase the length 65 APPENDIX C Standard Drawings Outline AT30 Battery Charger NEMA 1 Style 5018 Enclosure JE5085 00 SIDE VIEW FRONT VIEW SIDE VIEW CONTROL PANEL SEE DETAIL DRAWING JESOS1 3x
56. E LINE 3 F3 DC OUTPUT FUSE F4 DC OUTPUT FUSE 82 APPENDIX C Standard Drawings GREEKS MAIN CONTROL PC BOARD Al DC FILTERING CIRCUIT Schematic AT30 Battery Charger w Common Options JE5092 99 CB2 A 1 20 kAIC F3 GHA js Sec U ao lt L SE EN U o0 t 20 kAIC F4 A u E SYSTEM COMMON INT FEEDBACK CURRENT LIMIT CTRL CIRCUIT REF EXTERNAL FEEDBACK gt EXTERNAL FEEDBACK POWER SUPPLY RBA ER NOTE 5 o TEMPERATURE COMPENSATION PROBE A10 ENTS RELAY PC BOARD NOTE 1 TERMINAL BLOCK NOTE 2 ATURE COMPENSATION PROBE 10 RESISTOR 10 THERMISTOR MODULE PC BOARD NOTE 1 LINE 1 LINE 2 LINE 3 OPTIONAL AT30 COMPONENTS DC FILTERING ASSEMBLY Ci DC OUTPUT FILTERING CAPACITOR CRI POLARITY DIODE E13 INDUCTOR INTERCONNECTION POINT L2 FILTERING INDUCTOR NOTE 6 R9 FILTER CAPACITOR C1 BLEED RESISTOR C2 BATTERY ELIMINATOR FILTER CAP VR3 AC INPUT LIGHTING ARRESTOR R28 THERMOSTAT S2 SENSING RESISTOR S2 SCR MODULE THERMOSTAT S B2 SCR MODULE 01 06 COOLING FAN THIRD cl ANGLE PROJECTION DRAWN BY MCR 051706 NOTE 7 PART OF AIB PART OF A16 SPECIAL NOTES 1 SCR MODULE THERMOSTAT S2 AND SENSING RESISTOR R28 ARE ONLY SUPPLIED WITH AT30 UNITS HOUSED IN ENCLOSURE STYLES 5030 163 AND 198 2 SCR MODULE FAN B
57. Enclosure w Common Optons 72 Internal Component Layout AT30 Style 5030 Enclosure w Common Opiions 11111 74 Internal Component Layout AT30 Style 163 Enclosure w Common Options 76 Instrument Panel PC Board Detail AT30 Series Battery Charger nn 78 Schematic AT30 Series Battery Charger Standard w o Options eee 80 Schematic AT30 Battery Charger with Common Optons e nneennnnn nn nenn nn nar nn 82 Connection Diagram AT30 Battery Charger Power Wiring w Common Options 84 Connection Diagram AT30 Battery Charger Control Signal Wiring L eenna 86 Connection Detail AT30 Battery Charger I O Panels amp Rectifier Assemblies 88 APPENDIX D Recommended Float Equalize Voltages Temp Compensation 90 APPENDIX E DNP3 Level 2 Modbus Communications Module nn 91 APPENDIX F Forced Load Sharing ss see nnnnnnnnnnnnnnnnnnnnnn nn aaa azze nani aaa azan nn nnrmmn nanna na 92 MANUAL SPECIFICATIONS document control information online availability 94 Note A customized record drawing package is available for your 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 battery charger manufacturer
58. I d AC FUSES F1C B A SCR SNUBBER ASSY SEE NOTE VR3 LOACATED BEHIND CAPACITORS AC CIRCUIT BREAKER DC CIRCUIT BREAKER TRANSFORMER I O TERMINAL DESCRIPTION TYPE CONNECTION TBI H POS NEG OUTPUT TERMINALS CU ALUMINUM COMPRESSION LUG 14 1 70 AWG REM SENSE POS NEG REMOTE SENSE TERMINALS 1 4 20 ZPS STUDS 1 4in RING LUG 2 TBI GND GROUND TERMINAL CU ALUMINUM COMPRESSION LUG 14 170 AWG TB1 L1 L2 L3 AC INPUT TERMINALS CL ALLIMINLIM COMPRESSION LUG 14 1 70 AWG TB3 SUMMARY ALARM TERMINAL BLOCK SOLDERLESS COMPRESSION 22 14 AWG TB4 AUXILIARY ALARM TERM BLOCK SOLDERLESS COMPRESSION 22 14 AWG TBB TEMPCO PROBE A10 INTERCONNECTION TERMINAL BLOCK 22 14 AWG TO BE PLACED NEAR BATT A10 S Note 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 AT30 battery chargers configured with such options 72 APPENDIX C Standard Drawings Internal Component Layout AT30 Battery Charger Style 5018 Enclosure w Common Options JE
59. IDED AS SHOWN FOR lin 25mm CONDUIT ENTRY IF ADDITIONAL CONDUIT ENTRANCES ARE REQUIRED ENCLOSURE SHOULD BE FIELD MODIFIED BY INSTALLER BATTERY CHARGER SHIPPING WEIGHT SEE PRODUCT LITERATURE DUAL DIMENSTONS ANGLE PROJECTION DRAWN BY MCR 092506 LF AT30 SERIES BATTERY CHARGER OUTLINE APPROVED NEMA 1 STYLE 5030 ENCLOSURE DRAWING No REV 20343 092506 TE gees JESO86 00 o B htto Awww 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 DETAIL DRAWING JES091 3x 62 63 1591 CB2 DC CIRCUIT BREAKER 3 00 Iie pS LESS SZL POCO SA 1 D H ARON X A 18 00 MTG gt SxS e L 457 MTG ARA ei RQ R KS Lose CKO PORZ Ss 0X POS 40 50 MTG 1029 MTG BOTTOM VIEW 70 APPENDIX C Standard Drawings Outline AT30 Battery Charger NEMA 1 Style 163 Enclosure JE5095 00 NOTES 1 ENCLOSURE IS A NEMA 1 IP20 TYPE STEEL CABINET WITHOUT GASKETS FINISH IS ANSI 61 GRAY EPOXY PUOWDERCUAT ALLOW 12in 305mm OF FREE AIR TOP AND FRONT OF
60. LIGHTNING ARRESTOR CIRCUIT BREAKER ACCUATOR CUT OUT WINDOW I O TERMINAL BOARD TBI DETAIL ARRANGEMENT AND NUMBER OF COMPONENTS MAY DIFFER SLIGHTLY BASED UPON UNIT RATING AND FEATURED OPTIONS SEE JE5163 00 FOR A16 DETAILS FOR CERTAIN RATINGS INCLUSION OF AC AND OR DC FUSES IN STYLE 5030 ENCLOSURE MAY NECCESSITATE UPGRADE TO LARGER CABINET STYLE MOUNTED BEHIND 1 0 PANEL L REM REM SENSE SENSE NOTES 1 FOR DETAIL VIEWS OF ALL PC BOARDS AL AS Als A17 etc SEE DRAWING JE5S091 39 2 I O PANEL TERMINAL BOARD TBI NOT SHOWN FOR CLARITY OF VIEW SEE DETAIL TO RIGHT THIRD ANGLE PROJECTION DRAWN BY MCR 020607 E AT30 SERIES BATTERY CHARGER OPTIONAL INTERNAL COMPONENT LAYOUT STYLE 5030 DRAWING No REV 20537 020607 UNLESS OTHERWISE NOTED DIMENSIONS JE5089 99 e B ARE IN INCHES TOLERANCES ARE REV APP SCALE NTS PART No JESOBO 99 1 1 APPROVED htto Awww 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 FIA B C INPUT OUTPUT PANEL al al lal a d A16 l SEE DETAIL BELOW LI L2 L3GND ISL A17
61. O PROBE TERMINAL BLOCK E TY VRI OUTPUT SURGE SUPPRESSOR TO 7 Na VR2 INPUT SURGE SUPPRESSOR LINE 1 a VR4 INPLIT SURGE SUPPRESSOR LINE 2 sk VRS INPUT SURGE SUPPRESSOR LINE 3 VR6 DUTPUT SURGE SUPPRESSOR Al J H VR7 OUTPUT SURGE SUPPRESSOR TBB TB3 CR4 SYM OPTIONAL COMPONENT DESCRIPTION a MANUAL R3B AS AUXILIARY ALARM RELAY PC BOARD 9 POCKET AlO TEMPERATURE COMPENSATION PROBE R3A CI DC OUTPUT FILTER CAPACITOR ej b C2 BATTERY ELIMINATOR CAPACITOR CRI POLARITY DIODE STANDARD DRAWING NOTES A B E Internal Component Lavout AT30 Batterv Charger Stvle 5030 Enclosure w Common Options JE5089 99 STANDARD COMPONENT DESCRIPTION Al MAIN CONTROL PC BOARD A15 THREE PHASE GATE DRIVE PC BOARD AIG 1x6 SCR 01 06 MODULE ASSY Alix SCR SNUBBER PC BOARD GTY 3 TOP VIEW OF CIRCUIT C4 EMI OUTPUT FILTER CAP NEG GND C5 EMI OUTPUT FILTER CAP POS GND BREAKER MOUNTING BRACKET CBI AC INPUT CIRCUIT BREAKER CD3 CB2 DC OUTPUT CIRCUIT BKR KAL2 R9 CR4 FREE WHEELING DIODE LI MAIN INDUCTOR RI MAIN DC SHLINT R2 CURRENT RATING RESISTOR E13 _ INDUCTOR INTER CONNECT POINT Fone eee 1 Ee BE INPUT FOS Cr LEG NOTE 3 CIRCUIT CIRCUIT LEG BREAKER BREAKER 2 FILTER INDUCTOR IT WI R9 FILTER CAP C1 BLEED RESISTOR TB4 AUXILIARY ALARM RELAY CONTACTS VR3 3PH AC INPUT
62. ORT AND IDENTIFY THE FACTORY PART STYLE 163 NUMBER BY CIRCUIT SYMBOL AI6 I O TERMINAL z FOR APPROPRIATE Lo PANEL LAYOUT REFER TO THE AT30 USER S BOARD TB1 MANUAL TO IDENTIFY ENCLOSURE TYPE STYLE 5018 5030 163 88 APPENDIX C Standard Drawings Connection Detail AT30 Battery Charger I O Panels amp Rectifier Assemblies JE5163 00 FIGURE 4 FIGURE 5 125A RECTIFIER ASSY 150 200A RECTIFIER ASSY A16 PM5007 06 A16 PM5007 07 D o w bd a w gt 5 D 5 N n 80 FIGLRE 7 FIGURE 6 400A 250 300A RECTIFIER ASSY RECTIFIER ASSY A16 PM5007 08 A16 PMS007 09 THIRD a ANGLE PROJECTION 2 21118 042908 PRAWN BY MCR 013007 JUTE AT30 SERIES BATTERY CHARGER CONNECTION 1 D 52 GR YE 120107 ELECTRONIC APPROVAL SIGNATURES DETAILS I O PANEL amp RECTIFIER ASSY A16 MAINTAINED BY MFG ECN LOG 30529 013007 UNLESS STHERWISE NOTED DIMENSTONS PAY JE5163 00 pe B ARE IN INCHES TOLERANCES ARE REV SCALE vis nmn JE5163 00 ry http www ATSeries net PDFs JE5163 00 pdf 89 APPENDIX D RECOMMENDED FLOAT AND EQUALIZE VOLTAGES This table contains suggested values for commonly used batteries Consult your battery manufacture
63. OTE 1 C4 DC OUTPUT EMI FILTER CAPACITOR TO GROUND CS DC OUTPUT EMI FILTER CAPACITOR TO GROUND CBI AC INPUT CIRCUIT BREAKER CB2 DC OUTPUT CIRCUIT BREAKER CR4 FREE WHEELING DIODE LI MAIN INDUCTOR BI SILICON CONTROLLED RECTIFIER A16A NOTE 3 D2 SILICON CONTROLLED RECTIFIER AIGA NOTE 3 83 SILICON CONTROLLED RECTIFIER A16B NOTE 3 04 SILICON CONTROLLED RECTIFIER A16B NOTE 3 OS SILICON CONTROLLED RECTIFIER A16C NOTE 3 SILICON CONTROLLED RECTIFIER A16C 3 STANDARD AT30 COMPONENTS R1 MAIN DC SHUNT R2 CURRENT RATING RESISTOR R3 POWER SUPPLY BALLAST RESISTOR NOTE 5 R4 EXTERNAL SCALING RESISTOR NOTE 4 R6 INTERNAL SCALING RESISTOR NOTE 4 R14 EXTERNAL SCALING RESISTOR CNOTE 4 T1 POWER ISOLATION TRANSFORMER TBL INPUT OUTPUT TERMINAL BLOCK TB3 SUMMARY ALARM TERMINAL BLOCK NOTE 2 TBB OPTIONAL TEMPCO PROBE A10 INTERCONNECTOR VRI DC OUTPUT SURGE SUPPRESSOR TO VR2 AC INPUT SURGE SUPPRESSOR LINE 1 VR4 AC INPUT SURGE SUPPRESSOR LINE 2 VRS AC INPUT SURGE SUPPRESSOR LINE 3 VR6 OC OUTPUT SURGE SUPPRESSOR TO GROUND VR7 DC OUTPUT SURGE SUPPRESSOR TO GROUND OPTIONAL AT30 COMPONENTS AS AUXILIARY ALARM RELAY PC BLAF TB4 AUXILIARY ALARM TERMINAL BLOC A10 EXTERNAL TEMPERATURE COMPENS R13 TEMPCO PROBE A10 RESISTOR IE TEMPCO PROBE A10 THERMISTOF A12 COMMUNICATIONS MODULE PC BOAF FIA AC INPUT FUSE LINE 1 FIB AC INPUT FUSE LINE 2 FIC AC INPUT FUS
64. RCONNECTOR CONTROLS LOW LEVEL DETECT ADJLIST THIRD SC OEI Zi GROUND FAULT SAN DRAW BY MER 051705 TITLE AT30 SERIES BATTERY CHARGER OPTIONAL 2D JUMPERS INSTRUMENT PANEL PC BOARD DETAIL GRAMMING D LOAD SHARING JRING TEST ANAL TEMP 1 21097 041108 J PPROVEID TWH 051705 AGE Go o lezoaal 051705 UMESS OTHERWISE NOTED DIMENSIONS JE5091 39 1 B ARE IN INCHES TOLERANCES ARE ev ECN No SCALE vis nmn JESOBI 39 1 htto www ATSeries net PDFs JE5091 39 pdf 79 APPENDIX C Standard Drawings Schematic AT30 Battery Charger Standard w o Options JE5092 00 TRANSFORMER TI TBI CBI A oN a LI zi gt 3 U lt D CHASSIS GROUND NOTES 1 FOR COMPONENT DETAILS OF ALL PC BOARDS CAL AIS A17 etc SEE DRAWING JESO91 3 2 ALL ALARM CONTACTS SHOWN IN NON ALARM STATE CONTACT RATING IS O 5A e 125VAC VDC RESISTIVE 3 SIX 6 SCRs Q1 Q6 ARE CONTAINED WITHIN ONE MODULE A16 PRODUCING 6 PULSE RECTIFICATION 4 RESISTORS R4 R6 amp R14 FEATURED INTERNALLY ON GATE DRIVE PC BOARD A15 5 BALLAST RESISTORS R3A R3B ARE FEATURED EXTERNALLY AS SHOWN FOR 130VDC UNITS SUMMARY ALARM SUMMARY ALARM TERMINAL BLOCK TB3 NOTE 2 C NC NO TER RECTIF ER ASSEMBLY A16
65. S rane I CHASSIS GROUND NOTES 1 FOR COMPONENT DETAILS OF ALL PC BOARDS CAL AIS A17 etc SEE DRAWING JESO91 3 2 ALL ALARM CONTACTS SHOWN IN NON ALARM STATE CONTACT RATING IS 0 5A e 125VAC VDC RESISTIVE 3 SIX 6 SCRs Q1 Q6 ARE CONTAINED WITHIN ONE MODULE A16 PRODUCING 6 PULSE RECTIFICATION 4 RESISTORS R4 R6 amp R14 FEATURED INTERNALLY ON GATE DRIVE PC BOARD A15 5 BALLAST RESISTORS R3A R3B ARE FEATURED EXTERNALLY AS SHOWN FOR 130VDC UNITS 6 C1 CRI L2 8 RQ ARE ONLY SUPPLIED IN UNITS WITH DC OUTPUT FILTERING EI C2 IS ONLY SUPPLIED IN UNITS WITH BATTERY ELIMINATOR OC OUTPUT FILTERING SUMMARY ALARM SUMMARY ALARM TERMINAL BLOCK TB3 NOTE 2 C NC NO HIGH DC LOW DC DC OUTPUT AC VOLTAGE VOLTAGE FAILURE FAILURE W2 Wi TER TB4 AUX ALARM RELAY PC BOARD AS MA PC GROUND SUMMARY DETECT ALARM 1B4 NOTE 2 C NCNO C NC NZ C NCNOC NCNOC NCNOC NCNO C NCNO C NCNO C NCNOC NCNO C NCNOC NC NO AUXILIARY ALAR TERMINAL BLOCK LEB STANDARD AT30 COMPONENTS Al MAIN CONTROL PC BOARD NOTE 1 AIS THREE PHASE GATE DRIVE PC BOARD NOTE 1 AI6 6 PULSE SCR 01 06 MODULE NOTE 3 A17A SCR SNUBBER ASSY PC BOARD NOTE 1 A17B SCR SNUBBER ASSY PC BOARD NOTE 1 A17C SCR SNUBBER ASSY PC BOARD N
66. Style 163 300 Adc Style 5030 Style 5030 Style 5030 Style 163 400 Adc Style 163 Style 163 Style 163 500 Adc Style 163 Style 163 600 Adc Style 163 Style 198 Style 198 800 Adc Style 198 Style 198 Style 198 1 000 Adc Style 198 Style 198 Style 198 Note Style 163 and Style 198 AT30 enclosures are substituted for the previously listed Style 5031 and Style 5034 enclosures respectfully For enclosure dimensions and internal component layouts refer to the table below and the standard drawings in Appendix C Comprehensive weight data for the AT30 product line is available in the product literature 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 Standard AT30 NEMA 1 type enclosures do not feature lifting eyes for moving Instead whenever possible move the unit with a forklift truck using the supplied shipping pallet To hoist the unit into a wall mount or rack mount location use a heavy duty sling applicable to the enclosure size and unit weight To relocate the enclosure use a forklift truck by lifting the unit through the gap located between the cabinet mounting legs 3 INSTALLING THE AT30 1 5 MOUNTING THE AT30 Chose the mounting method for the unit enclosure from the tab
67. TB4 etc ARE SULDERLESS COMPRESSION SCREW NUMBER TYPE AND ARRANGEMENT OF CERTAIN COMPONENTS SPECIFICALLY I O PANEL TBI DIFFER WITH UNIT ENCLOSURE TYPE SEE CORRESPONDING INTERNAL COMPONENT LAYOUT DRAWING NUMBER TYPE AND ARRANGEMENT OF CONTACTS ON 6 PULSE RECTIFIER ASSY A16 VARIES BASED UPON UNIT RATING SEE RECTIFICATION SCHEMATIC LABEL DN SIDE OF SCR MODULES PHYSICAL MOUNTING OF CERTAIN COMPONENTS MAY DOUBLE AS ELECTRICAL CONNECTIONS 10 GRZYE CHASSIS GROLIND NOTES A IN UNITS WITHOUT AC FUSES WIRES O1A 02B AND O2A ARE NOT FEATURED B IN UNITS WITHOUT DC FLISES WIRES SEE 28 AND 29 ARE NOT FEATURED NOTE DC FUSES 2 zl a lt Sjel 01010 1 375 CBI AC INPLIT CIRCUIT 5 BREAKER A CR4 FREE K WHEELING DIODE o NO NOTE 6 KH o AL 6 PULSE SCR 01 0 RECTIFIER ASSEMB FREE WHEELING DIODE CR4 IS AN ANODE MOUNTED COMPONENT AND CONNECTS DIRECTLY TO FEATURED OPTIONS AC INPUT CKT BKR amp FUSES DC OUTPUT CKT BKR amp FUSES AUXILIARY RELAY PC BOARD DC OUTPUT FILTERING BATT ELIMINATOR FILTER INPUT LIGHTNING ARRESTOR EXTERNAL TEMPCO PROBE Note This connection diagram JE5093 99 depicts the mainframe power wiring of an AT30 Series battery charger with ALL options available from the standard ordering code Refer to the model number featured on the data nameplate and the supplied Parts Data Package r
68. Use a voltmeter at the ac terminals TB1 L1 TB1 L2 amp TB1 L3 the dc terminals TB1 amp TB1 the dc remote sense terminals and any external wiring to alarm relay contacts to verify that no voltage is present inside the enclosure INSTALLING THE AT30 PROCEDURE 1 Verify that all voltages within the AT30 are de energized and locked out 2 See Section 3 5 for necessary steps to follow when accessing internal components within the AT30 Change the jumpers on the transformer T1 as shown in the table below Always use all three 3 jumpers Make sure all connections are tight Check your work before reenergizing the AT30 SN PS For more information see the schematics amp wiring diagrams in Appendix C MAIN TRANSFORMER T1 CONNECTION TABLE TYPICAL TRANSFORMER T1 TYPICAL TRANSFORMER T1 208 240 Vac 60 Hz INPUT 480 Vac 60 Hz INPUT 208 Vac 240 Vac jumper setting jumper setting jumper setting H1 H2 H3 to 1 H1 H2 H3 to 2 none SCHEMATIC SCHEMATIC 208 240 Vac 60 Hz transformer T1 480 Vac 60 Hz transformer T1 SEL SEC eg XI qg ahha he X2 5 X3 a SI PI EL 235 i e Mi e 11 INSTALLING THE AT30 1 7 MAKING THE AC INPUT CONNECTIONS Follow these steps to connect ac power to the AT30 1 Use a branch circuit breaker or fused disconnect sw
69. able 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 shows more than 110 of rated dc current the Gate Driver pc board A15 may be defective Unplug A15 from the Main Control board A1 If the output current DOES NOT drop to zero replace the Gate Driver pc board A15 5 If the front panel meter shows more than 110 of rated dc current the Main Control 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 board A1 50 SERVICING THE AT30 SYMPTOM PRC RECOMMENDED ACTION 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 lamp 2 Input fuse 2 Remove the ac fuses F1A F1B and F1C from the fuse Is Gen butac F1A B C blown holder s and check if blown with an Ohmmeter or fuse tester and de breakers are on 3 Defective wiring 4 Defective transformer T1 Replace F1A EIB and or F1C as needed NOTE If the 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
70. age shutdown has occurred E 04 Internal memory failure E 05 not used E 06 failure in remote sense wiring E 07 dc breaker is open or internal or external output wiring is defective E 08 defective temperature compensation probe E 09 misadjusted current limit E 10 open internal feedback loop E 11 not implemented at this time E 12 defective internal thermostat E 13 internal over temperature E 14 forced load sharing not working properly A01 manual equalize enabled for more than 24 hrs A 02 equalize mode is inhibited 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 charger is in a timed equalize mode the meter alternates between output voltage output current and equalize hours remaining Displaying output voltage only The DC Volts indicator lights Displaying output current only The DC Amps indicator lights e 4 Displaying equalize hours remaining only The EQLZ HRS REMAINING indicator lights If the AT30 is not in a timed equalize mode the meter displays the full programmed equalize time e When the charger starts initially the meter alternates showing output voltage and output current The DC Volts and DC Amps indicators light alternately to indicate what is being displayed 26 OPERATING THE AT30 2 2 3 2 2 4 Selecting the Float or Equalize m
71. ales 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 94 MANUAL SPECIFICATIONS 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 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 RELATED DOCUMENTS Doc No Online Hyperlink Description JA0102 01 http
72. and can be monitored remotely from TB3 When the alarm condition is corrected the relay and all indicators reset automatically If latching alarms relays are enabled the relay will need to be reset manually see Section 2 2 7 on page 29 The summary alarm contacts TB3 also transfer immediately when the AT30 detects certain secondary errors indicated by codes E 03 E 04 E 06 E 07 E 08 E 09 E 10 E 12 amp E 13 on the 4 digit meter display rather than a red alarm light See Section 3 2 for all error codes 32 OPERATING THE AT30 Setting the High DC Voltage Alarm e Press the JEDIT ENTERI 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 DOWN 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 display shows the high dc voltage alarm point that you want to set 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 high dc voltage alarm setting is entered into permanent memory Setting the low DC Voltage Alarm e Press the EDIT JENTER key until the LOW DC VOLTAGE indicator flashes and the dis
73. ard SCADA Supervisory Control And Data Acquisition systems will be able to control monitor and log the events of the battery charger when this option is supplied The system can also be used with a modem for telephone communications All features of the AT30 battery charger s front instrument panel are accessible remotely using the Communications Module The AT Series Communications Module option EJ5037 xx includes the Communication PC Board A12 external power supply resistor s R29x an Operating Instructions manual and a field retrofit instruction sheet JD5008 00 An unlabeled copy of the Communications Module Operations Manual is available for free online http www ATSeries net PDFs JA0102 04 pdf A compatible industry standard modem and modem cable are also available Contact your sales representative to place an order for the AT Series Battery Charger Communication Module Refer to the table below for ordering information Description PartNo Communications Module for 12 Vdc AT30 EJ5037 01 Communications Module for 24 Vdc AT30 EJ5037 02 Communications Module for 48 Vdc AT30 EJ5037 03 Communications Module for 130 Vdc AT30 EJ5037 04 10ft 3 05m Modem Cable EH5026 00 25ft 7 62m Modem Cable EH5026 01 50ft 15 24m Modem Cable EH5026 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 d
74. areful 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 INSTALLING THE AT30 MAKING THE DC OUTPUT CONNECTIONS GRAPHICS user supplied dc output wiring NEGATIVE POSITIVE LINE LINE DC OUTPUT Style 5018 I O Terminal Board TB1 Detail user supplied dc output wiring POSITIVE NEGATIVE LINE LINE DC OUTPUT Li DE UTPU Style 5030 I O Terminal Board TB1 Detail Style 163 I O Terminal DC Board TB1 OUTPUT Detail POSITIVE NEGATIVE LINE LINE user supplied dc output wiring INSTALLING THE AT30 1 9 WIRING THE AT30 FOR REMOTE SENSING You can wire the AT30 to regulate the output voltage at the battery terminals instead of at the charger output terminals Remote sensing does 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 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 de
75. arger 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 JEDIT ENTERI key on the front panel Each time you press the key a different parameter displays in the following order e Float voltage e Equalize voltage e Equalize time in hours e High dc voltage alarm setting e Low dc voltage alarm setting e Current limit in Amperes 1 Don t 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 Suggested frequency every 6 months Maintenance date Performed by Step Instructions Results standard features Clean battery All vents clean and open O OK charger Remove dust and debris from inside of O OK unit Check all TBI connections all tight O OK electrical Internal wiring connections tight slip on O OK connections connectors fully seated Wire and lug and wiring insulation in good condition Terminations at battery or bus are tight O OK and corrosion free Check ac input Measure between TB1 L1 TB1 L2 amp voltage TB1 L3 using an ac voltmeter Value Input Vac must be within 10 and 12 of nominal voltage Check dc Measure at TB1
76. ation and maintenance Mount the two 2 relay rack mounting brackets to the sides of the Style 5018 enclosure using the four 4 pre fab knockouts on each side as guides Mount the brackets to the AT30 using the supplied 0 25in 6 4mm hardware and tighten securely Locate the charger bracket assembly onto the front face of the 23in 584mm EIA relay rack and mount using appropiate hardware not supplied See the diagram on the opposite page for the rack mounted Style 5018 enclosure footprint and mounting pattern INSTALLING THE AT30 Style 5018 Rack Mounting 22 31in a 567mm 21 50in 37 95in 964mm ac A ALLOW 6in 152mm ABOVE AND BELOW E UNIT FOR COOLING NOTES 1 Units are installed from the front 2 16 77in 426mm 3 SEN O O Refer to the outline drawing JE5085 00 in Appendix C on Page 66 for overall size mounting dimensions and cabinet specifications for the Style 5018 enclosure INSTALLING THE AT30 1 6 CHANGING THE TRANSFORMER TAPS IMPORTANT AT30 battery chargers are designed for a single ac input supply voltage Note the ac voltage listing on the data nameplate and tag attached to the ac circuit breaker If your partic
77. aves 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 Edit mode ends automatically if you do not press any front panel key within 25 seconds and any change you made to the last setting is not saved 30 OPERATING THE AT30 2 3 2 Setting the Float and Equalize voltages e Press the EDIT ENTER key The FLOAT and DC VOLTS indicators light and the display flashes the present value of the float voltage Press and release the UP or Down 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 display shows the float voltage you want to set 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 float voltage setting is saved internally Th
78. ber Rec Symbol Description 12 Vdc 24 Vdc 48 Vdc 130 Vdc Spares A1 Main Control PC Board assembly EJ1243 10 Y A5 Auxiliary Relay PC Board assembly optional EJ1243 03 Y A10 Temperature Compensation Probe assembly See Appendix B A15 Three Phase Gate driver PC Board assembly EJ5199 01 EJ5199 02 EJ5199 03 EJ5199 04 Y A16 SCR Rectifier Module s Q1 Q6 see supplied Parts Data Package Y A17x SCR Snubber Sub Assembly PC Board EN5012 00 C1 Filter Capacitor standard see supplied Parts Data Package Y cz Filter Capacitor battery eliminator see supplied Parts Data Package Y CA EMI Filter Capacitor see VR6 C4 CR EMI Filter Capacitor see VR7 C5 CB1 AC 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 RK0013 14 Y CR1 Polarity Diode 75 Adc rating RKOO14 14 Y CR1 Polarity Diode 100 400 Adc ratings RKOO17 14 Y CR1 Polarity Diode 500 600 Adc ratings RKOO28 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 RKOO14 14 Y CR4 Free Wheeling Diode 100 400 Adc ratings RKOO17 14 Y CR4 Free Wheeling Diode 500 600 Adc ratings RK0028 12 Y CR4 Free Wheeling Diode 800 1KO Adc ratings PM0003 00 Y F1A B C AC Input Fuses see supplied Parts Data Package Y F3 F4 DC Output Fuses see supplied Parts Data Package Y 62
79. 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 45 from T1 Y0 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 50 to 80 higher than the rated dc output voltage If it is too low check the wiring of the transformer primary taps T1 H1 through T1 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 mistapped 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 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 rect
80. c 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 that system operators can use to force units to share load equally The accessory consists of an interconnecting cable to provide such communication 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 chargers e The units must have the same dc voltage and current rating and have the same dc filtering level e Both chargers must have the same ac input source and the same phase rotation e Both chargers must feature Rev 6 or higher builds of the main control circuit boards A1 and corresponding Rev 6 or higher software programs e We recommend that both chargers use the same
81. e EQLZ and DC VOLTS indicators light and the display flashes the present value of the equalize voltage Press and release the Up or DOWN key to increase or decrease the value in the display by one count or press and hold the Up or DOWN key to scroll the value in the display upward or downward When the display shows the equalize voltage you want to set release the uP or Own 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 EDIT ENTERI key four more times until the charger returns to normal operation Edit mode ends automatically if you do not press any front panel key within 25 seconds and any change you made to the last setting is not saved 31 OPERATING THE AT30 2 3 3 2 3 4 Setting the Equalize Timer e Press the EDIT ENTER key until the EQLZ HRS REMAINING MANUAL TIMER and AUTO EQLZ TIMER indicators light and the display flashes the present value of the equalize timer duration in hours Press and release the uP or DOWN 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
82. e 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 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 board connectors J25 and J26 present at 2 Defective 2 If the AC ON indicator is lit but the rest of the front panel is TBI Main Control dead replace the Main Control board A1 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 compensation probe optional 4 Defective Main Control 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 19 see the table in present at Section 3 6 for the proper resistance value If the resistance is TB1 not within 10 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 board A1 for signs of insulation damage or burns Repair any damaged wiring Charg
83. e 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 Wrongac 12 Be sure the transformer primary taps T1 H1 H2 and H3 are wired correcily 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 50 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 trips or fuses clear connected with reverse polarity PROBABLE SYMPTOM CAUSE RECOMMENDED ACTION DC breaker 1 Battery 1 Check and correct battery wiring if necessary Gate Driver pc board board A15 5 Defective Main Control board A1 immediately 2 Defective 2 Test by disconnecting 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 Ohms check both po
84. ecks Make sure plexiglas safety cover is in O OK place Restore charger to normal operation O OK Close latch on front panel O OK Step Instructions Results optional features Test auxiliarv Press LAMP TEST key and hold for 4 O OK alarm relavs 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 A downloadable worksheet of this Preventive Maintenance Procedure JD0064 00 is available online http Awww ATSeries net PDFs JD0064 00 pdf 43 SERVICING THE AT30 3 SERVICING THE AT30 3 1 ASTEP BY STEP TROUBLESHOOTING PROCEDURE The AT30 battery charger is fully tested and calibrated at the factory and should work for years with a minimum of attention If you do encounter trouble there are three steps you should take to find the problem and return the charger to service 1 Check the front panel meter for an error code The AT30 is able to diagnose common problems with the battery charger or with the application or installation If the front panel displays an error code see Section 3 2 Interpreting Front Panel Error Messages for help in interpreting the code and solving the problem If the charger does not work properly but there is no front panel error code turn off the front panel circuit breakers or disc
85. ed for float manual equalize timer or auto equalize timer mode more than 24 hours A 02 Equalize mode jif you set the equalize timer to zero hours the equalize mode is inhibited inhibited When you try to put the AT30 into equalize mode with a front panel control the display shows the message A 02 If you want to enable the equalize mode set the equalize timer to one 1 or more hours 47 SERVICING THE AT30 3 3 USING THE TROUBLESHOOTING CHART WARNING High voltages appear at several points inside the AT30 Use extreme caution when working inside the unit 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 TB1 Before you try to use the troubleshooting chart be sure that you have followed the steps in Section 3 1 The troubleshooting chart that begins on the next page is divided into three columns To 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 probl
86. em and return the charger to normal service Determining the condition of the charger e Is the front panel AC ON indicator lit e What is the ac voltage at the input terminals measured with an ac voltmeter e What is the dc voltage at the output terminals measured with a dc voltmeter e Does the meter on the front panel 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 s there any sign or smell of smoking or burning For instructions on replacing components see Section 3 5 on page 58 For information on identifying internal components refer to the standard drawings featured in Appendix C 48 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 inside the charger on the control board s right displays all interrupted edge as viewed from the rear of the front panel This will segments operation of the restart the control board without modifying any settings On or all microprocessor 1B Hard Reset of control board by pressing and holding the segme
87. eport to identify by circuit symbol which components are applicable to each individual unit 84 APPENDIX C Standard Drawings Connection Diagram AT30 Battery Charger Mainframe Power Wiring w Common Options JE5093 99 XXft 7 XX Xm LONG CABLE NOTE 3 e TEMPERATURE eu COMPENSATION PROBE A10 SUMMARY SHIELDED SE THREE PHASE ALARM GROUND GATE DRIVE NENG PC BOARD A15 E Ja p AUXILIARY ALARM E Bow RELAY PC BOARD AS SEE E aay o NOTE 2 l J17 48 E MAIN CONTROL MEA F PC BOARD Al C NC NOJ C NC NO C NC NO C NC NOJ C NC NO CN NO HIGH DC LOW DC OC OUT AC IN GROUND SUMMARY VOLTAGE VOLTAGE FAILURE FAILURE DETECT ALARM NOTES C C NUMBER AND ARRANGMENT OF FILTER T CAPACITORS C1 C2 VARIES BASED q RI b IT UPON UNIT RATING ER D IN UNFILTERED UNITS WIRE 12 CONNECTS FROM Ll 2 DIRECTLY TO CB2 2 3 wn Wo FLI li HH MUJ of k i Em SXIT zg INI HU e DN De eg lt LU JO EIET o EH C2 BATTERY C ELIMINATOR n CAPACITOR 7 FREE ELING 15 DE NOTE 4 CI D 8 M 5 gt gt SCR Bl 06 MODULE TER ASSEMBLY A16 LI MAIN L2 FILTER INDUCTOR INDUCTOR THIRD o Cl ANGLE PROJECTION DRAWN BY MCR 012607 TE AT30 BATTERY CHARGER CONN DIAGRAM MAIN POWER WIRING W ALL COMMON OPTIONS 2 2
88. equalizing schedule for your battery After you select the manual timer method press the CHRG MODE key to put the charger into the equalize mode The EQLZ indicator will light When the equalize timer is finished the charger reverts automatically to the float mode and the FLOAT indicator lights At any time during the equalize charge you can switch the charger 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 Equalize Method Choose the manual equalize method when you want to equalize charge the battery but only when you are able to monitor the battery voltage and gassing rate After you select the manual equalize method press the CHRG MODE key to put the charger into the equalize mode The EQLZ indicator will light Press the CHRG MODEJ key again to return the charger to the float mode The FLOAT indicator will light NOTE Never leave the AT30 unattended in the equalize mode with the manual equalize method selected because 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 disc
89. er 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 59 SERVICING THE AT30 Replacing the ac surge suppressors VR2 VR4 or VR5 Turn off and remove all power to the AT30 Remove the plexiglas 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 hardware 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 NOTE 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 o
90. er 1 Defective 1 Disconnect the wire harness plug from connector J26 on the output SCR top of the Gate Driver pc board A15 and restart the AT30 If voltage too you are able to measure output current one of the SCRs is high not defective Replace the rectifier module s A16 as needed controllable 2 R4 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 1 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 10K Ohms If it is not replace the probe assembly A10 4 If the front panel meter shows more than 110 of rated dc current the Main Control 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 board 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 volta
91. eries net PDFs JE5085 00 pdf DUAL DIMENSTONS 20343 092506 ECN No DATE 67 APPENDIX C Standard Drawings Outline AT30 Battery Charger NEMA 1 Style 5030 Enclosure JE5086 00 SIDE VIEW FRONT VIEW CONTROL PANEL SEE DE DRAWING JE5091 3x CBI AC CIRCUIT BREAKER CIRCUIT BREAKER MTG MTG 27 95 MIG BOTTOM VIEW 710 MTG 68 APPENDIX C Standard Drawings Outline AT30 Battery Charger NEMA 1 Style 5030 Enclosure JE5086 00 NOTES 1 ENCLOSURE IS A NEMA 1 IP20 TYPE STEEL CABINET WITHOUT GASKETS FINISH IS ANSI 61 GRAY EPOXY POWDERCUAT ALLOW 12in 305mm OF FREE AIR TOP AND FRONT OF CABINET FOR VENTILATION FOUR 4 0 625in 16mm FLOOR MOUNTING HOLES ARE PROVIDED ON BOTTOM OF ENCLOSURE AS SHOWN NINE 9 1 31in 33mm DIA STANDARD PRE FAB KEY SLOT KNOCKOUTS ARE PROV
92. field connections inside the charger 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 charger Check remote sense wiring optional If you wired the AT30 charger for remote sense check the signal connections to the battery or load and check the wiring to be sure the insulation is in good condition If there is a failure of the remote sense signal wiring the AT30 charger displays the error code E 06 and goes back to local control sensing the output voltage at the charger output terminals 40 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 be sure that the probe is securely installed Be sure the connectors and the wiring from the probe to the AT30 charger are in good condition If there is a failure of the temperature compensation probe or the wiring the AT30 charger displays the error code E 08 Measuring the output ripple voltage filtered models only If your AT30 charger is a filtered model at least once a year measure the ac ripple voltage at the battery terminals Use an rms responding ac voltmeter The ripple voltage should be no higher than shown in the specifications in Appendix A on page 64 if the battery ampere hour capacity is at least 4 times the output current rating of the ch
93. followed the installation When you first start the AT30 the meter display instructions carefully Check the ac input alternates between dc output supply voltage and the battery voltage and be voltage and dc output current sure that they match the information on the Each ee S SE S 5 seconds indicator lights to the AT30 nameplate Verify that the jumpers on the jen of the ET main transformer TI are correct for your ac whether the meter is supply voltage Open the front panel and check displaying voltage or current the battery polarity at the TB1 and If you want to freeze the terminals meter to display only voltage press the METER MODE Starting the AT30 key on the front panel To freeze the meter to display only current press the key AT30 are properly made follow these steps to again Press the key twice start up the AT30 more to revert to the alternating display When you are sure that all connections to the 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 CAUTION If you try to turn on the dc circuit breaker with the
94. front panel of the Primary charger The front panel of the Secondary charger will not allow any settings to be changed e H one charger 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 chargers initially for the same operating voltages If an alarm condition occurs both chargers revert to independent operation for the duration of the alarm e In the event of a fault in the interconnection or any other problem with communication the chargers 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 4 seconds for the two 2 AT30s to establish forced load sharing communication If communication is broken or power is lost for one charger there is up to a 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 good 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 external temperature compensation accessory It is recommended that each AT30 have a tempco p
95. front panel reading within 1 NOTE Allow one or two seconds for the output voltage to stabilize each time you press the up or Down key When you are finished adjusting the output voltage the AT30 waits 5 seconds then the display returns to normal operation 37 OPERATING THE AT30 2 3 8 Using the Low Level Detector LLD The AT30 battery charger is equipped with a summary alarm safety override circuit This feature forces the summary alarm common alarm relay contact to transfer sending an alarm even if there is a catastrophic failure of the charger s control circuitry A low battery voltage triggers the safety circuit Main control board hardware not software maintains the low level detect circuit Therefore to remotely monitor this alarm user connections must be made at TB3 The summary alarm contacts on the auxiliary alarm relay pc board at TB4 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 circuit board find the potentiometer RA1 as shown in the figure below A SERIES r 5 MMI J27 o N YO 907180 ITIIT D JI JI7
96. ges 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 Circuit board 2 Recalibrate the voltmeter accuracy as described in Section or another 2 3 7 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 1 of the specified value replace R4 and or R14 as needed 4 Defective 4 Turn off both front panel circuit breakers CB1 CB2 or turn Main Control off ac and dc power externally if the AT30 does not have board A1 breakers Wait one minute before returning the dc connection followed by the ac connection If the charger still has the wrong output voltage replace the Main Control board A1 Charger 1 Current limit 1 If the AT30 is not in the Edit mode press the EDIT ENTER never set too low key five times 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 110 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
97. ground terminal 3 TB1 X GUEAL compression lug for 14 1 0 AWG RC0056 18 d Style 5030 input ground terminal l ET CU AL compression lug for 14 1 0 AWG RC0056 18 4 Stvle 5030 output terminal l TB1 DC CD AC comp lug for 6 AWG 350 MCM RC0056 03 Style 163 input output ground terminal S TB1 X CU AL comp lug for 6 AWG 350 MCM RC0056 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 Three Phase 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 VRZ C5 JEMI Output Filter Network Style 163 EJ5021 05 Y Note 1 In 130 Vdc units a 5002 50W power supply resistor R3 mounted to the galvanized base may be comprised of an assembly of two 2 250Q resistors connected in series 63 APPENDIX A SPECIFICATIONS Except as noted all specifications apply at 77 F 25 C nominal ac line voltage amp nominal float voltage
98. h front panel circuit breakers CB1 CB2 or turn off ac and dc power externally if the AT30 does not have breakers Wait one minute before returning the dc connection followed by the ac connection If you are sure there is no ground fault on the external bus or within the charger but the POS GND or NEG GND indicator is still on replace the Main Control board A1 Summary alarm relay is in alarm mode but no front panel alarm indicator is on 1 Defective Main Control board A1 1 Turn off both front panel circuit breakers CB1 CB2 or turn off ac and dc power externally if the AT30 does not have breakers Wait one minute before returning the dc connection followed by the ac connection If the relay remains in alarm mode check the Low Level Detect indicator on Main Control board A1 See Section 2 3 8 If no other alarm is on replace the Main Control board A1 57 SERVICING THE AT30 3 5 REPLACING DEFECTIVE COMPONENTS WARNING High voltages appear at several points inside the AT30 Use extreme caution when working inside the unit 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 TB1 For information on iden
99. harges 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 charger 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 charger reverts automatically to the float mode and the FLOAT indicator lights At any time during the equalize charge you can switch the charger 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 shown below Mode before AC falure Mode after ac failure duration ac failure less than FLOAT gt 12 seconds gt FLOAT less than Resume EQUALIZE EQUALIZE SCH 12 seconds gt with time remainin g FLOAT or 12 seconds EQUALIZE EQUALIZE gt or greater gt with full time Switching to Equalize Mode with Auto Equalize Timer Method Selected You can start an equalize charge at any time e Press the HRG MODE key The EQLZ indicator will light When the equalize timer is finished the charger reverts automatically to the float mode and the FLOAT indicator light
100. he AT30 output terminals TB1 output Error f Meanin Repair Procedure Code g p E 01 Resistor R2 A current 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 bv the defective control circuit on startup and is used to determine some of the AT30 s parameters such as the float voltage If the AT30 finds that R2 is defective 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 on You may get this error code if the battery is discharged to less than 6 volts When the battery charges to greater than 6 volts the error code disappears 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 then check the wiring at the dc output terminals for a short circuit If the battery voltage is normal and all external wiring is OK check the dc breaker on the AT30 If it is tripped try once to reset it If it trips 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 and the polarity diode The AT30 normally recovers automatically from an E 02 condition
101. ifier 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 it is 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 it is an open circuit replace L1 Repeat for inductor L2 if the optional dc filter is installed 9 Disconnect 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 Mak
102. ify the standard Style 5018 enclosure for rack mounting but a special rack mounting kit EI0193 03 is required For kit availability see ordering information in Appendix B on page 65 Each kit includes two 2 mounting brackets hardware and special instructions with for the rack mounting procedure In planning for rack mounting of the AT30 you should consider the following 1 PROCEDURE 1 2 3 The rack must be strong enough to properly support the weight of the AT30 The weight of your AT30 may be different from the table value depending on options or accessories you ordered See the Weight Table located in Section 1 4 on page 3 Placement of conduit entrances Note the standard pre fab conduit knockouts located on the sides of the charger See the outline drawing JE5085 00 in Appendix C on Page 66 Be sure the knockouts on the sides or bottom of the charger are accessible after the charger is rack mounted The location e Should be free of drips and splatter If dripping liquids are a problem install a drip shield kit 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 Maintain at least 6in 152mm of free air on top bottom and both sides of the enclosure for air cooling Allow 36in 914mm front clearance for access to the charger for oper
103. ir 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 e De energize and lock out all ac and dc voltages to the AT30 Check with a voltmeter e Disconnect the remote sense wires from the battery or dc bus terminals first CAUTION You must do the steps above first e Remove the remote sense leads from the remote sense and terminals on the I O panel Insulate each lead separately Coil up the wires and leave them in the bottom of the charger in case you want to wire for remote sense again in the future e Reconnect wire 40 to the dc output terminal e Reconnect wire 38 to the dc output terminal e 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 a standard The Main Control PC Board A1 mounted on the back of the front door is equipped with one form C Summary Alarm contact TB3 that transfers for any alarm Follow the procedure below to wire an annunciator to this contact See Section 2 2 7 for a description of the alarm functions PROCEDURE DOOR GROUND THREE PHASE jj GATE DRIVE PC BOARD A15 P17 III Q ATI J JIE E EI Do E MAIN CONTROL
104. itch properly sized for the maximum ac input current of the AT30 This rating is listed on the left hand side of the charger s data nameplate This device should have lockout capability so that the ac input can be de energized for charger maintenance A time delay circuit breaker or slow blow fuse is recommended NOTE If your charger is wired for 480 Vac input and is equipped with the standard AIC ac circuit breaker no ac fuses you need a feeder breaker or fuse rated to interrupt the short circuit current of your ac supply 2 Size the ac input wiring per the National Electric Code NEC and local codes for the rating of the branch circuit breaker or fused disconnect switch 3 Be sure the AT30 main transformer T1 is properly connected for your ac input voltage See Section 1 6 for details 4 All specific requirements of your facility take precedence over these instructions 5 Do not run the external ac power wiring through the same conduit of the battery charger enclosure as the external dc power wiring PROCEDURE 1 Remove the safety cover if supplied 2 Run the ac wiring to terminals TB1 L1 TB1 L2 TB1 L3 and TB1 GND on the I O panel board in the enclosure 3 For your convenience all AT30 Series battery chargers are supplied with CU AL ac input compression lugs Style 5018 and Style 5030 enclosure ac input lugs accept 14 1 0 AWG wire Style 163 enclosure ac input lugs accept 6 AWG 350 MCM wire To make these connecti
105. l 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 Quick Setup Sheet are supplied You received all items on the packing list OOOOOOQOLU INSTALLING THE AT30 1 4 MOVING THE AT30 Once you have established that the AT30 is undamaged identify the enclosure style of your unit by referring to the table below Standard AT30 NEMA 1 Type Enclosures Style 5018 Style 5030 Style 163 Style 198 Ampere Output Voltage Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 25 Adc Style 5018 30 Adc Style 5018 40 Adc Style 5018 50 Adc Style 5018 Style 5018 Style 5018 Style 5018 75 Adc Style 5018 Style 5018 Style 5018 Style 5018 100 Ade Style 5018 Style 5018 Style 5018 125Adc Style 5030 Style 5030 Style 5030 Style 5030 150Adc Style 5030 Style 5030 Style 5030 Style 5030 200Adc Style 5030 Style 5030 Style 5030 Style 5030 250 Adc Style 5030 Style 5030 Style 5030
106. larities 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 Ohms in one polarity and less than 1 000 Ohms 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 CR1 if filter Diode CR1 mounted to the negative filter capacitor bus bar assembly is Check both polarities It should be at least 100 000 Ohms in one installed polarity and less than 1 000 Ohms in the other polarity Replace CRI if it is 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 jconnection to clear after a breaker few minutes 2 Open SCH 2 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 3 SCR not 3 Disconnect the wire harness plug from connector J26 on the controll
107. le below MANUAL ENCLOSURE ENCLOSURE MOUNTING METHOD SECTION Style 5018 Style 5030 163 198 Floor Mounting STANDARD STANDARD 1 5 2 Wall Mounting OPTIONAL n a 19in 483mm 1 5 3 Rack Mounting wa we 23 24in 584 610mm OPTIONAL Na Rack Mounting 1 5 1 Floor Mounting the AT30 standard To floor mount the AT30 you must consider the following 1 Overall footprint of enclosure Refer to the standard outlines drawing listed in Appendix C starting on Page 66 2 The location e Should be free of drips and splatter If dripping liquids are a problem install a drip shield 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 3 Maintain at least 6in 152mm of free air on top bottom and both sides of the enclosure for air cooling 4 Allow at least 36in 914mm front clearance for access to the charger for operation and maintenance 5 Be conscious of future input and output wiring to the AT30 Note the standard pre fab conduit knockouts located on the sides and sometimes top of the enclosure featured on the standard outline drawings listed in Appendix C starting on Page 66 PROCEDURE Style 5018 1 Install four 4 0 25in 6 4mm bolts into the floor per mounting dimensions featured in the outline drawing JE5
108. least 6in 152mm of free air on top bottom and both sides of the enclosure for air cooling Allow 36in 914mm front clearance for access to the charger for operation and maintenance PROCEDURE a 1 Sa Install eight 8 0 25in 6 4mm bolts not supplied rated to support the AT30 weight plus a safety factor of at least two 2 times onto the wall Place the AT30 Style 5018 enclosure onto the mounted triangular brackets Use the supplied 0 25in 6 4mm hardware to mount the enclosure to the wall mounting brackets and tighten securely See the diagram on the opposite page for the wall mounted Style 5018 enclosure footprint and mounting pattern Dimensions are in mm INSTALLING THE AT30 Style 5018 Wall Mounting FRONT VIEW SIDE VIEW 51 78 1315 9 00 MTG 229 MIG 18 44 MTG 468 MTG 2 33 20 90 59 531 NOTE 1 Refer to the outline drawing JE5085 00 in Appendix C on Page 66 for overall size mounting dimensions and cabinet specifications for the Style 5018 enclosure INSTALLING THE AT30 1 5 3 Rack Mounting the AT30 Style 5018 enclosure only AT30 battery chargers housed in the floor mounted Style 5018 enclosure can be installed in most relay racks with standard EIA hole spacing You do not need to mod
109. low 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 charger 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 charger 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 NOTE You can adjust the sensitivity of the ground fault detection from 5K to 50k ohms Adjusting the ground fault sensitivity affects the positive and negative ground fault sensitivities equally 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 battery charger is available featured in a supplemental document 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
110. n the back of the panel All do not light secured to front indicators should extend about 0 125in 3 18mm through the front panel of the panel 3 Defective 3 When you press the LAMP TEST kev if some but not all Main Control indicators light or the digital meter does not display 8888 board A1 replace the Main Control 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 board A1 is in the ENABLE position keys do not 2 Main Ctrl PCB 2 Open the front panel and be sure that the control circuit board work is not secured to is firmly seated on the standoffs on the back of the panel Front front panel panel keys must operate freely 3 Defective 3 Turn off both front panel circuit breakers CB1 CB2 or turn off Main Control ac and dc power externally if the AT30 does not have breakers board A1 Wait one minute before returning the dc connection followed by the ac connection If some of the front panel keys still do not work replace the Main Control board A1 Two AT30 s 1 Ifthe forced 1 Multiple AT30s are not designed to share load current without connected in jload 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 jis normal for one of the units to have no output current You can output
111. ndicator is on but the AC INPUT FAILURE indicator is still on replace the Main Control board A1 POS GND or NEG GND indicator is on 1 Ground fault on external dc bus 2 DC circuit breaker is open and NEG GND indicator is on 3 Alarm needs calibration 4 Defective wiring 5 Defective Main Control board A1 1 Disconnect the AT30 from the battery and dc bus and check the battery and dc bus for a ground fault 3 If the AT30 has been placed into standby by opening the dc breaker CB2 the ground detection circuit gives an erroneous alarm Close the dc breaker and the alarm should end If you want the AT30 to be in standby open the ac circuit breaker CB1 3 Calibrate ground detection sensitivity See Section 2 3 4 4 Turn off both front panel circuit breakers CB1 CB2 or turn off ac and dc power externally if the AT30 does not have breakers Wait one minute and disconnect the AT30 from the battery and dc bus Turn on the AT30 and measure the voltage from TB1 to chassis and from TB1 to chassis The voltage readings should be equal each approximately half of the total output voltage If there is more than a 10 imbalance turn 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 Turn off bot
112. nnect the battery from the dc output terminals TB1 Note that the Main Control pc board A1 and the Gate Driver pc board A15 are mounted together as a pair Remove the signal wire harness plugs from the top and left edges of the boards If present remove the summary alarm wiring from TB3 at the bottom of A1 If the optional temperature compensation probe is installed remove the wires from TB8 on the bottom of Al and remove the shielded wire from J6 at the top left side of Al Make sure all wires are detached from the two 2 pc boards The boards are mounted on ten 10 plastic standoffs Compress the tab on each standoff and pull the boards toward you until they clear all the standoffs Separate the boards if you are replacing only one and then reconnect the replacement board Put the replacement boards in place on the front panel with the same orientation and push them onto the standoffs Be sure that the boards are fully seated on all ten standoffs Reconnect the signal wire harness plugs to the boards matching the orientation when removed If earlier removed reconnect any wires to TB3 TB8 and J6 on Al See Section 2 1 for the steps to restart the AT30 If your charger 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 break
113. nsformer 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 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 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 readings are erratic disconnected battery 2 Defective scaling resistor R4 or R14 3 Defective Main Control board A1 Output ripple 1 AT30 is 1 Verify by 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 Battery is 2 Be sure battery is connected Inspect battery 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 JAT30 model on page 64 The ripple rating is 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
114. nts or the display Up button on the front panel and simultaneously pressing Off Charger controller S7 reset switch This will restart the control board and restore may have no all settings to factory default Reset parameters per Section output 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 5 minutes to allow voltages to discharge AC breaker 1 Shorted 1 Test by disconnecting wires 7 8 amp 9 at the rectifier trips or fuses rectifier diode modules A16 mounted on the main heat sink s or at the clear or SCR main transformer T1 Measure resistance between the ac immediately terminals bottom terminals on the rectifier module s It should be at least 100 000 Ohms check both polarities If resistance is low in either direction replace the rectifier module s A16 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 bridge 3 Defective 3 Test by disconnecting wires 7 8 amp 9 from the transformer transformer Ti 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 Y0 Y1 Y2 Y3 W1 and W2 If ac breaker still trips replac
115. ode The AT30 has 2 output voltage settings Float and Equalize Use the Float mode for all normal battery charging and to operate your dc system Use the Equalize mode if it is necessary to balance the level of charge among the cells of the battery Consult your battery data sheets for information on equalize charging your battery e Press the CHRG MODE key to change to the equalize mode If the equalize method is set to manual timer or auto equalize timer the charger will revert to the float mode at the end of the selected equalize 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 MTHD key to choose the desired equalize method The indicator next to the desired equalize method will light Three equalize methods are available in the 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 base your equalize charging on regular readings of the specific gravity of each cell of your battery for lead acid batteries When your battery requires equalize charging adjust the manual timer to 1 2 hours for each 100 AH of battery capacity see Section 2 3 3 to learn how to adjust the equalize time The battery manufacturer can help you determine the best
116. olarity is not important MAIN CONTROL PC BOARD A DS10 usa i JJa EDI ENABLE ALARM RELAY CABLE ASSY J STRIPPED LEADS TO TB8 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 6 At the battery connect the quick connect terminals to the temperature compensation probe Polarity is not important Coil up any excess wire and tape or tie it together to prevent damage 21 INSTALLING THE AT30 7 Check your work Be sure that e All connections are secure e The shield is connected to ground at the charger end only on the main circuit board e The cable is connected to TB8 on the circuit board Other terminal blocks may look similar 8 Restart the AT30 using the startup procedure in Section 2 1 During startup the AT30 displays LEAD on the front panel indicating that the temperature compensation is set up for lead acid batteries 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 9 Adjust the outpu
117. on A15 Polarity is not important 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 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 Circuit symbol factory part number and description from the supplied Parts Data Package report e Quantity required Note Some of the factory part numbers listed on the Parts Data Package report may differ from the standard replacement part numbers listed in this manual Custom parts may have replaced standard parts to satisfy your specification In that case you should order the part number s listed on the report The following table may specify part replacement kits that include other materials such as installation instructions and packaging materials You may order spare parts using either part number To be sure of getting the complete kit specify Complete Kit on your order and the factory will make the necessary adjustments Refer to the table below for the most common items Table 3 1 REPLACEMENT PARTS S Factory Part Num
118. onnect ac and dc power externally Then turn the dc and ac power back on This will return the charger to normal operation as long as there is no internal component failure Note Do this only once If the charger does not resume normal operation go to the next step If the charger still does not work properly make a list of the symptoms that you observe then 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 circuit detects hardware or wiring problems it may display an error code on the front panel To solve an error code problem refer to the table below which lists the codes and procedures to use WARNING High voltages appear at several points inside the AT30 Use extreme caution when working inside the unit 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 t
119. ons strip the insulation 0 5in 12 7mm on the incoming ac wires and connect the wires to the appropriate lugs as shown on the next page 4 Using a flat head screwdriver securely tighten the compression screws on the lugs to 35 50 in lb 4 0 5 7 Nm 5 Reinstall the safety cover if supplied after you have made and checked all connections NOTES 1 The ac input 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 INSTALLING THE AT30 MAKING THE AC INPUT CONNECTIONS GRAPHICS Style 5018 I O Terminal Board TB1 Detail user supplied ac input wiring user supplied ac input wiring N Style 5030 I O Terminal Board TB1 Detail Style 163 I O Terminal Board TB1 Detail INSTALLING THE AT30 1 8 MAKING THE DC OUTPUT CONNECTIONS Follow these steps to connect the battery to the AT30 1 Size the de wiring to minimize voltage drop The acceptable wire size depends on your installation As a guideline the voltage drop should not exceed 1 of nominal output voltage at full current Size the dc output wiring per your battery manufacturer s specifications and local codes for the rating of the batteries and or load The AT30 is factory wired
120. play flashes the present value of the low dc voltage alarm Press and release the UP or DOWN key to increase or decrease the value in the display by one count or press and hold the UP or Down key to scroll the value in the display upward or downward When the display shows the low dc voltage alarm point that you want to set 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 ENTERI key again to return the charger to normal operation 33 OPERATING THE AT30 Adjusting Ground Detection Sensitivity You can adjust the sensitivity of GROUND G S d FAULT DISABLE the ground detection alarm circuit JUMPER 1 2 PINS You must have a test resistor 1 ie whose value is the sensitivitv vou Z want You can adjust the A 3 sensitivity from 5 to 50 KQ FALT EMBE The potentiometer for adjusting ground detection circuit sensitivity is located on the main control circuit board It is the lower of the two potentiometers labeled RA3 SENS as shown in the figure at the right
121. pond 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 discharge You can adjust the value of the current limit from 50 to 110 of rated current The factory setting is 110 The current limit adjustment is the last step in the normal Edit sequence If the AT30 is not in the Edit mode press the EDIT ENTER key five times until the meter display flashes the value of current limit in Amperes Press and release the uP or DOWN key to increase or decrease the value in the display by one count or press and hold the up or DOWN key to scroll the value in the display upward or downward When the display shows the current limit value that you want to set release the UP or DOWN key If you go past the number you want press the Hp or DOWN key again to reach the number you want to set e Press the EDIT ENTER key The new current limit setting is saved internally Edit mode ends automatically if you do not press any front panel key within 25 seconds 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 re
122. pply the probe clean the mounting surface with isopropyl alcohol and allow to dry thoroughly Remove the protective backing from the double faced adhesive tape on the probe and securely press it onto the surface 4 Install the cable supplied with the temperature compensation probe kit e Start at the AT30 charger The end of the cable with two stripped wires and one lead with a quick connect terminal will be connected inside the AT30 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 NOTE 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 Be sure your wiring conforms to the NEC and your facility requirements 5 Attach the interconnection cable to the AT30 as shown in the figure below e Route the cable within the AT30 QUICK GATE DRIVE PC enclosure soit CONNECT BOARD A15 runs with the W PIGGY wire harness BACK to the back of Z the front Ei panel and easily reaches the main control circuit board e Atthe main control circuit board insert one of the bare wires from the cable into each terminal of TB8 P
123. r s documentation for specific values and settings for your battery type Recommended Recommended Battery Cell Type Float Voltage cell Equalize Voltage cell Antimony 1 215 Sp Gr 2 33 Antimony 1 250 Sp Gr 2 33 Selenium 1 240 Sp Gr S 2 33 2 40 Calcium 1 215 Sp Gr 2 33 Calcium 1 250 Sp Gr 2 33 Absorbed Gelled Electrolyte x sealed lead acid type Nickel Cadmium 1 42 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 batteries are to see temperature variations during charging a temperature compensation option A10 is recommended If this option is not part of your charger 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 C Lead Acid Nickel Cadmium 90 APPENDIX E COMMUNICATIONS MODULE Your AT30 Microprocessor controlled Battery Charger has provisions for an optional Communications Module that allows the user to remotely monitor and control the unit over a serial connection This option supports DNP3 Level 2 and Modbus protocols over RS 232 or RS 485 half duplex Industry stand
124. rd w o Options JE5092 00 CB2 A EZ U ao lt L He SS u oo gt t HE U oO SYSTEM V COMMON 06 05 INT FEEDBACK CURRENT LIMIT CTRL CIRCUIT REF EXTERNAL FEEDBACK EXTERNAL FEEDBACK POWER SUPPLY R3A R3B HEET _ B SBRS BED DES J26 J25 i THREE PHASE 30 GATE DRIVE PC BOARD A15 MAIN CONTROL PC BOARD Al ENTS OPTIONAL AT30 COMPONENTS SPECTAL NOTES 1 SCR MODULE THERMOSTAT S2 AND SENSING RESISTOR R28 ARE ONLY SUPPLIED WITH AT30 UNITS HOUSED IN ENCLOSURE STYLES 5030 153 AND 198 2 SCR MODULE FAN B2 AND TRANSFORMER WINDING R28 THERMOSTAT S2 SENSING RESISTOR TAPS T1 Z1 Z2 ARE ONLY SUPPLIED WITH AT30 S2 SCR MODULE THERMOSTAT S PART OF A16 UNITS RATED 400 ADC OR HIGHER B2 SCR MODULE 01 06 COOLING FAN PART OF A16 cl ANGLE PROJECTION DRAWN BY MCR 051706 E AT30 BATTERY CHARGER MAINFRAME SCHEMATIC STANDARD W O OPTIONS 20530 013007 APPROVED MCT 051706 DRAWING No REV 20211 051706 MCT META VE ME JES092 00 1 B htto www ATSeries net PDFs JE5092 00 pdf 81 APPENDIX C Standard Drawings Schematic AT30 Battery Charger w Common Options JE5092 99 LIGHTNING ARRESTOR 7 TBI 100 kAIC ZN FIA A JE go ki zi FIB A l il FIC A 13 U lt GND RECTIF ER ASSEMBLY A16 r CBI A TRA
125. re w Common Options JE5098 99 STANDARD COMPONENT DESCRIPTION Al MAIN CONTROL PC BOARD AIS THREE PHASE GATE DRIVE PC BOARD A16 3PH SCR MODULE ASSY 1x6 01 06 A Alix SCR SNUBBER PC BOARD OTY 3 C4 EMI OUTPUT FILTER CAP NEG GND CS EMI OUTPUT FILTER CAP PLS GND CR AC INPUT CIRCUIT BREAKER CB2 DC OUTPUT CIRCUIT BREAKER CRA FREE WHEELING DIODE BACK SIDE OF FRONT DOOR ERA FREE WHEEL ING RI MAIN DC SHUNT R2 CURRENT RATING RESISTOR S2C B A R3x EXT BALLAST RESISTOR 130VDC R28x THERMOSTAT S2x SENSE RESISTOR NORSE Als S2x SCR MODULE A15 THERMOSTAT e TI POWER ISOLATION TRANSFORMER L na na 2 TB4 TBI 1 0 TERMINAL BUARD TB3 SUMMARY ALARM CONTACTS DI D Al TB8 OPT TEMPCO PROBE TERM BLOCK AIS S VRI DUTPUT SURGE SUPPRESSOR TO fo p VR2 INPUT SURGE SUPPRESSOR LINE 1 A5 188 183 VRA INPUT SURGE SUPPRESSOR LINE 2 CIBIA VRS INPUT SURGE SUPPRESSOR LINE 3 VR6 OUTPUT SURGE SUPPRESSOR VR7 OUTPUT SURGE SUPPRESSOR sA 4 R3B A ci SYM OPTIONAL COMPONENT DESCRIPTION GROLIND CIRCUIT BREAKER AS AUXILIARY ALARM RELAY PC BOARD AlO EXTERNAL TEMPCO PROBE ACTUATOR CUT DUTS C1 DC OUTPUT FILTER CAPACITOR C2 BATTERY ELIMINATOR FILTER CAP CR1 POLARITY DIODE E13 INDUCTOR INTER CONNECT POINT FIA C AC INPUT FUSES KE A FA DC OUTPUT FUSE LEG ACKE rq
126. robe and that the probes be located as close as possible to each other When the AT30s are load sharing the primary charger will determine the temperature compensated voltage and adjust the output voltage accordingly The primary charger and secondary charger will display the set point voltage not the temperature compensated output voltage The voltage displayed by the master and secondary may be different if either temperature probe is not installed or defective A slight difference in the displayed voltages may also occur if the two probes are not located in close proximity of each other 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 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 circuit board in one charger at a time noting Main Control circuit system requirements to restore correct load sharing operation board A1 93 MANUAL SPECIFICATIONS DOCUMENT NUMBER The te
127. rrent from battery AC input power failure no options installed 90 mA maximum Audible noise Average for 4 sides 5ft 1 5m from charger Less than 62 dB A Cooling Natural convection Ambient temperature Operating 32 122 F 0 507 Elevation 3 000ft 1 000m without derating Relative humidity 0 to 95 non condensing Alarm relay contact rating 120 Vac 125 Vdc 0 5A resistive 64 APPENDIX B FIELD INSTALLABLE ACCESSORIES AND OPTIONS All AT30 options accessories listed below are available in kits for field installation which contain all parts mounting hardware and detailed installation instructions Kit part numbers may be dependant upon enclosure type e g Style 5018 Style 5030 amp Style 163 To order accessories options please provide the following information for each kit e Model number and serial number of your battery charger e Factory part number and description from the table below e Quantity required Contact your sales representative to place an order for accessories options Auxiliary Alarm Relay PC Board A5 EI0213 02 03 04 Wall Mounting Kit for Style 5018 Enclosure EI5008 00 Relay Rack Mtg Kit for Style 5018 Enclosure 23 24in 584 610mm EI0193 03 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 NEMA 2 Type
128. s 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 key does not test the AC ON indicator The AC ON indicator lights whenever ac power is present and the ac circuit breaker is turned on The 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 Relay Board optional If you have the optional Auxiliary Relay Board A5 installed you can similarly test the six individual alarm relays Press and hold the LAMP TEST key for four seconds to transfer the relays If you are monitoring the relays with a remote annunciator it will detect the alarm conditions Interpreting the alarm indicators There are six red alarm indicators at the right side of the front panel An indicator lights for each of the following alarm conditions e HIGH DC VOLTAGE lights whenever the dc output voltage exceeds the specified alarm voltage setting See Section 2 3 4 to learn how to adjust the HVDC alarm setting e LOW DC VOLTAGE lights whenever the dc output voltage is be
129. sired float or equalize voltage NOTE If the remote sense wiring tails the AT30 detects the fault and displays E 06 on the front panel meter See Section 3 2 for details CAUTION The AT30 cannot protect against short circuits in the remote sense wiring You should install a 1 0A fuse at the battery or dc bus end of the remote sense cable SCHEMATIC REMOTE SENSE I AT10 1 LEADS i pas RECTIFIER DC BUS BATTERY PROCEDURE 1 De energize and lock out all ac and dc voltages within the AT30 enclosure Check with a voltmeter Remove safety shield if supplied Remove the two 2 dc output CU AL compression lugs Move wire f 38 from TB1 to REM SENSE Move wire 40 from TB1 to REM SENSE Sek Se Get INSTALLING THE AT30 6 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 DC OUTPUT PDS TE SENSE DC OUTPUT DC 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 reeneregizing 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 the
130. sults in a continuous output voltage that is too high the AT30 shuts down after 30 seconds to protect the battery The digital display shows E 03 and the summary alarm relay contact transfers The AT30 is shipped with the high dc voltage shutdown feature disabled You can adjust the high dc voltage shutdown the setting is the same as the high dc voltage alarm setting Refer to Section 2 3 4 The charger must be in normal operation not the Edit mode to enable the high dc voltage shutdown To enable the shutdown feature e Press and hold the Up key then e Press the CHRG MODE key The HIGH DC VOLTAGE indicator lights and the display flashes ON You can toggle the shutdown feature OFF and ON by pressing the CHRG MODE key repeatedly Parallel Operation If two or more AT30 chargers are connected in parallel both sense the output voltage If one charger runs away it will supply all the output current the other has zero output current The high dc voltage shutdown does not operate in a charger with zero output current so that only the defective charger of two or more in parallel shuts down The other charger continues to supply the load normally If you do not press any key within 4 seconds the last state indicated ON or OFF is saved internally Note that you do not use the JEDIT ENTER key for this feature If the AT30 shuts down because of a high dc
131. t float and equalize voltages to the battery manufacturer s recommended values using the AT30 front panel meter as described in Section 2 3 2 NOTE If the temperature compensation probe or the wiring from the probe to the AT30 is damaged and becomes an open circuit the AT30 detects the damage and displays E 08 on the display The charger then reverts to normal non temperature compensated operation until the probe or wiring is repaired Once the probe is repaired you must restart the AT30 to activate the probe as described in Section 2 1 Using temperature compensation When an electric storage battery is being charged the terminal voltage of the battery changes a small amount whenever the battery temperature changes As the battery temperature increases its terminal voltage decreases When a battery is charged by a float type charger with a constant output voltage float current increases when the temperature increases This results in overcharging the battery which can result in damage to the materials or at least the need for more frequent maintenance When the 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
132. 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 it is 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 PROBABLE SYMPTOM o 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 JL2 and TB1 L3 If it is zero check the upstream distribution tripped breakers and 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 circuit breakers CB1 CB2 or turn off Main Control ac and dc power externally if the AT30 does not have breakers board A1 Wait one minute before returning the dc connection followed by the ac connection If the AC ON i
133. tifying internal components refer to the standard drawings featured in Appendix C Removing the safety shield if present Some AT30 enclosures feature a clear plexiglas safety shield as a second protective barrier between the user and the internal components Some of the following repair procedures require the removal of this shield to access internal components Open the front door and remove the clip fasteners from the front of the plexiglas shield Lay or lean the shield near the enclosure Do not lay the shield on the top of the AT30 The top vents on the enclosure are required for cooling of the unit Attach the plexiglas safety shield back onto the enclosure opening using the clip fasteners after replacing components and before starting up the unit CAUTION Hazardous ac and dc voltages are present on the I O panel terminals and several internal components 58 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 CAUTION Printed circuit boards A1 and A15 are sensitive to damage from static discharges Leave replacement pc boards in their anti static bags until you are ready to install them Ground yourself before handling these boards by touching the ground stud on the back of the door Handle these boards only by their edges Turn off and remove all power to the AT30 Remove the plexiglas safety shield Disco
134. ting 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 2 4 1 2 4 2 2 4 3 Performing routine maintenance WARNING High voltages appear at several points inside the AT30 Use extreme caution when working inside the unit 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 TB1 Keep it clean The AT30 charger is cooled by natural convection At least once a year vacuum the vents at the top and bottom of the enclosure to ensure that there is an adequate supply of cooling air If you have an extremely dusty environment especially if airborne dust is conductive carefully vacuum out the interior Be sure to clean surfaces of circuit boards and around electrical terminals The AT30 is rated for operation up to 122 F 50 C If your charger 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
135. 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 All specific requirements of your facility take precedence over these instructions 5 Do not run the external dc power wiring through the same conduit of the battery charger enclosure as the external ac power wiring PROCEDURE 1 Use a dc disconnect switch or circuit breaker between the AT30 and dc bus This device should have lockout capability to allow the AT30 to be disconnected from the dc bus for maintenance 2 Remove the safety cover if supplied 3 Run the dc wiring to terminals TB1 and TB1 on the I O panel board in the enclosure 4 For your convenience all AT30 Series battery chargers are supplied with CU AL dc output compression lugs Style 5018 enclosure dc output lugs accept 14 1 0 AWG wire Style 5030 and Style 163 enclosure dc output lugs accept 6 AWG 350 MCM wire To make these connections strip the insulation 0 5in 12 7mm on the incoming ac wires and connect the wires to the appropriate lugs as shown on the next page 5 Using a flat head screwdriver securely tighten the compression screws on the lugs to 35 50 in lb 4 0 5 7 Nm 6 Reinstall the safety cover if supplied after you have made and checked all connections NOTES 1 The dc output terminal hardware fastens other components mounted to the I O panel Be c
136. tp www ATSeries net PDFs JD5009 00 pdf AT10 1 G1 Rectifier Field Installation JD5010 00 http www ATSeries net PDFs JD5010 00 pdf AT Power Res R3 Field Installation JD5012 00 http www ATSeries net PDFs JD5012 00 pdf Main Ctrl PC Board A1 Field Installation JDOO52 00 http www ATSeries net PDFs JD0052 00 pdf Battery Discharge Dual Operation Note JD5002 00 http www ATSeries net PDFs JD5002 00 pdf DC Motor Starting Application Note JD5006 00 http www ATSeries net PDFs JD5006 00 pdf Alt amp Temp De Rating Application Note JD501 1 00 http www ATSeries ne PDFs JD5011 00 pdf Ext Free Wheeling Diode Application Note JD5013 00 http www ATSeries net PDFs JD5013 00 pdf AC Ripple Specification Application Note 95 GNB Industrial Power The Industry Leader GNB Flooded m ABS LYTE 7ZlaSSic MARATHON LITHIUM POWER GNB Industrial Power a division of Exide Technologies is a global leader in network power applications including com munication data networks UPS systems for computers and control systems electrical power generation and distribution systems as well as a wide range of other industrial standby power applications With a strong manufacturing base in both North America and Europe and a truly global reach operations in more than 80 countries in sales and service GNB Industrial Power is best positioned to satisfy
137. ular site ac supply voltage does not match your AT30 ac input requirements you MUST change the ac input circuit breaker and or fuses and input surge suppressors In addition you must replace or rewire the transformer as described below Failure to use properly rated components may damage the AT30 NOTE If your AT30 battery charger was supplied with 480Vac 60Hz input or 220Vac 50 60Hz input the transformer will only accept the listed voltage Do not attempt to rewire these transformers If a different ac input voltage is desired for the AT30 please contact your sales representative for ordering replacement parts Before you connect ac power to the AT30 check the wiring of the main transformer T1 to be sure it is connected for the desired ac input voltage The main transformer was wired at the factory for the input voltage specified and listed on the data nameplate If your AT30 was supplied with 208 240 Vac 60 Hz input and you need to change the factory wired input voltage you do so by changing jumpers on the main transformer T1 If your AT30 was ordered with 380 416 Vac 50 60 Hz and you need to change the factory wired ac input voltage consult the factory for special instructions NOTE Before starting work disconnect and lock out all external ac and dc power sources to the AT30 Note that just turning off the front panel ac and dc circuit breakers is not sufficient to eliminate live voltages inside the enclosure
138. utput 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 NOTE The dc surge suppressor is not polarized Replacing the dc surge suppressor 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 TB 1 4 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 above procedure but start with the lead on TB1 Tighten all hardware Replace cut wire ties if possible NOTE The dc surge suppressor 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
139. while the charger is operating using the front panel controls The changes you make take effect immediately and are saved internally If the charger 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 You adjust each parameter by pressing the UP or DOWN key until the reading you want shows on the meter display 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 charger refer to the AT30 Specifications in Appendix A on page 64 When you first press the EDIT ENTER 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 s
140. xt 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 company specific front and back cover artwork Any revision levels revision dates or document numbers featured on the first two and last two pages of this manual refer to the cover artwork only DOCUMENT INFORMATION Document Number JA5030 00 Revision Level 5 Engineering Change Number 22151 Electronic Filename JA5030 00 Rev5 doc Last Date Saved 5 27 2010 7 52 PM Last Date Printed 5 27 2010 7 55 PM PARTS DATA PACKAGE Any job specific customized Parts Data Package report supplied with this battery charger and or this manual supercedes the information featured in the standard parts list starting on page 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 S
141. your backup power needs locally as well as all over the world GNB Industrial Power USA Tel 888 898 4462 Canada Tel 800 268 2698 www gnb com Section 94 40 2011 11 Sprinter Based on over 100 years of technological innovation the Network Power group leads the industry with the most recognized glo bal brands such as ABSOLYTE GNB FLOODED CLASSIC MARATHON ONYX RELAY GEL SONNENSCHEIN and SPRINTER They have come to symbolize quality reliability per formance and excellence in all markets served RELAY GEL 4 Sonnenschein GNB Industrial Power takes pride in its commitment to a bet ter environment Its Total Battery Management program an integrated approach to manufacturing distributing and recy cling of lead acid batteries has been developed to ensure a safe and responsible life cycle for all of its products GNB INDUSTRIAL POWER A Division of Exide Technologies

AT30 Charger I&O Manual Section 94.40

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AT30 Charger I&amp;O Manual Section 94.40

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AT30 Charger I&O Manual Section 94.40