Home

servicing the at10.1

1. STANDARD COMPONENT DESCRIPTION Al MAIN CONTROL PC BOARD All HIGH OUTPUT GATE DRIVE PC BOARD C4 EMI OUTPUT FILTER CAP NEG C5 EMI OUTPUT FILTER CAP POS CBl AC INPUT CIRCUIT BREAKER CD2 CB2 DC OLTPUT CIRCUIT BREAKER CD2 CR4 FREE WHEELING DIODE Ll MAIN INDUCTOR Gl SILICON CONTROLLED RECTIFIER HIGH DLITPUT G2 STLICON CONTROLLED RECTIFIER RS GATE DRIVE RI MAIN DC SHUNT PC BUARD ASSY All R2 RATING RESISTOR wm R3x EXT BALLAST RESISTOR 130VDC cry CLEAR SAFETY COVER PROTECTS T1 POWER TRANSFORMER LJ USER ERO AME L VD TAGES i SEREENED TB1 1 0 TERMINAL BOARD TB3 SUMMARY ALARM CONTACTS IMPORTANT SAFETY INSTRUCTIONS TBB TEMPCO PROBE TERMINAL BLOCK COMPO ENT CAYO S VRI OUTPUT SURGE SUPPRESSOR BUICK OPERATIDN INSTRUCTIONS VR2 INPUT SURGE SUPPRESSOR MAIN CONTROL CARD COMMON ERROR CODES VR4 INPUT SURGE SUPPRESSOR PC BOARD ASSY Al VRS INPUT SURGE SUPPRESSOR VRS OUTPUT SURGE SUPPRESSOR o VR7 DUTPUT SURGE SUPPRESSOR SE Tes WI COPPER BUS BAR POS LEG L W2 COPPER BUS BAR NEG LEG gt m j SYM OPTIONAL COMPONENT DESCRIPTION SENS RAS AE AL eke AS AUXILIARY ALARM RELAY PC BOARD d SEED MINE papal ee A10 TEMPERATURE COMPENSATION PROBE Cl FILTER CAPACITOR C2 BATTERY ELIMINATOR FILTER CAP CRI POLARITY DIODE E13 INDUCTOR INTER CONNECT POINT FIA AC INPUT FUSE VR3 MTD FIB AC INPUT FUSE BEHIND F3 DC HUT
2. CIRCUIT BREAKER DC CIRCUIT BREAKER TRANSFORMER T1 TO BE PLACED NEAR BATT Ter DESCRIPTION TYPE I 0 TERMINAL CONNECT ION TBI64 REM SENSE POS NEG REMOTE SENSE TERMINALS POS NEG OUTPUT TERMINALS CU ALUMINUM COMPRESSION LUG 1 4 20 SCREW HARDWARE TB1 GND TBI L1 L2 TB3 GROUND TERMINAL CLI ALLIMINLIM COMPRESSION LUG AC INPUT TERMINALS CU ALUMINUM COMPRESSION LUG SUMMARY ALARM TERMINAL BLOCK SOLDERLESS COMPRESSION TB4 TBB AUXILIARY ALARM TERM BLOCK SOLDERLESS COMPRESSION TEMPCO PROBE A10 INTERCONNECTION TERMINAL BLOCK 14 1 0 AWG 1 4in RING LUG 14 1 0 AWG 14 1 0 AWG 22 14 AWG 22 14 AWG 22 14 AWG Note This internal component layout drawing JE5029 99 depicts an AT10 1 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 AT10 1 chargers configured with such options 78 APPENDIX C Standard Drawings Internal Component Layout AT10 1 Group II Battery Charger Style 5018 Enclosure w Common Options JE5029 99 R2 HIGH DLUTPLIT GATE DRIVE PC BOARD ASSY All HEATSINK ASSEMBLY SAFETY COVER PROTECTS FUL VOLTAGES SCREENED O Bu RATIO
3. Exercise front Switch from float to equalize then back O OK panel controls to float Turn off the dc circuit breaker E 07 may OK appear on display requires at least 5 of rated output current Reset breaker Cycle through meter modes Cl voLTs OK Cl amps OK O Hours OK Cycle through equalize methods MANUAL TIMER OK L MANUAL EqLz OK Cl 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 FLOAT OK and alarm settings See page 30 Cl EQUALIZE OK settings Cl HvDC alarm OK L Lvpc alarm OK Current limit Adc Final checks Make sure plexiglas safety cover is in OK place Restore charger to normal operation L OK Close latch on front panel L OK Step Instructions Results optional features Test auxiliary Press LAMP TEST key and hold for 4 O OK alarm relays seconds Alarm relays will transfer Check Remote sense wiring See page 16 OK integrity of Temperature compensation wiring See L OK remote wiring page 20 O OK Temperature compensation probe See page 20 Final checks Close padlock or key lock O OK A downloadable worksheet of this Preventive Maintenance Procedure JD0064 00 is available online http www AT Series net PDFs JD0064 00 pdf 43 SERVICING THE AT10 1 3 SERVICING THE AT10 1 3 1 A STEP BY STEP TROUB
4. CAPACITOR CAPACITOR CI CAPACITOR AC FUSES FIB FIA AC CIRCUIT BREAKER CBI CAPACITOR C1 C2 DC CIRCUIT BREAKER CB2 I 0 TERMINAL DESCRIPTION TYPE CONNECTION TB1 REM SENSE TB1 GND TBI L1 L2 TB3 TB4 TBB POS NEG OUTPUT TERMINALS CU ALUMINUM COMPRESSION LUG POS NEG REMOTE SENSE TERMINALS 1 4 20 SCREW HARDWARE GROUND TERMINAL CLI ALLIMINLIM COMPRESSION LUG AC INPUT TERMINALS CU ALUMINUM COMPRESSION LUG SUMMARY ALARM TERMINAL BLOCK SOLDERLESS COMPRESSION AUXILTARY ALARM TERM BLOCK SOLDERLESS COMPRESSION TEMPCO PROBE A10 INTERCONNECTION TERMINAL BLOCK 14 1 0 AWG 1 4in RING LUG 14 1 0 AWG 14 1 0 AWG 22 14 AWG 22 14 AWG 22 14 AWG Note This internal component layout drawing JE5028 99 depicts an AT10 1 Series battery charger housed in a Style 5017 enclosure with ALL available options Standard components A1 through VR7 are supplied in all such units Optional components A5 through VR3 are supplied only in those AT10 1 chargers configured with such options 76 APPENDIX C Standard Drawings Internal Component Layout AT10 1 Group II Battery Charger Style 5017 Enclosure w Common Options JE5028 99
5. If you set the equalize time to zero hours the equalize mode is disabled e Press the EDIT ENTER key The new equalize timer duration is saved internally The same timer setting works for both the manual timer and the auto equalize timer If you want to adjust the alarm settings skip to Section 2 3 4 OR If you want to exit the Edit mode now press the EDIT ENTER key three 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 AT10 1 for each of the following alarm conditions e High DC Voltage e Low DC Voltage e DC Output Failure e AC Input Failure e Ground Fault Detection e Ground Fault Detection When an alarm occurs the indicators will light immediately The AT10 1 also features a summary alarm relay with one form C contacts TB3 rated 0 5A 125 Vac Vdc If an alarm condition lasts for 30 seconds or longer the summary alarm relay contacts transfer 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 AT10 1
6. NOTE 4 BREAKER BREAKER 03 04 86 APPENDIX C Standard Drawings Connection Diagram AT10 1 Group Il Battery Charger Standard w o Options JE5034 00 NOTE 2 SUMMARY ALARM C NC NO HIGH OUTPUT GATE DRIVE PC BOARD All MAIN CONTROL PC BOARD Al TTTTTTTTTTTTTTT M P17 47 56 GR YE DOOR GROUND el O R38 Off CB DC NOTE 5 OUTPUT CIRCUIT BREAKER DC OUTPUT C O REMOTE Cy SENSE REMOTE O SENSE CBI AC INPUT CIRCUIT BREAKER O NITE 3 56 GR YE TE AC BREAKER WIRING FOR STYLE 5018 ENCLOSURE SHOWN TOP BOTTOM ORIENTATION OF WIRES O1 THRU 04 ARE REVERSED IN STYLE 5017 ENCLOSURES 10 GR YE 56 GR YE CHASSIS GROUND 500000 r ITE 4 THIRD Oc ANGLE PROJECTION ORAN BY MCR 040703 UTE ATIO 1 SERIES BATTERY CHARGER CONN DIAGRAM GROUP II 30 100ADC STANDARD W O OPTIONS E2141 091305 040703 E A TB E1204 040703 QA WEIN INES Tolerances ASE SCALE NTS PAT mw JE5034 00 1 6o http www ATSeries net PDFs JE5034 00 pdf lt ER KER 87 APPENDIX C Standard Drawings Connection Diagram AT10 1 Group II Battery Charger w Common Options JE5034 99 CI L1 MAIN INDLICTOR 20 91 16 62 ci FILTER E CAPACITOR IND
7. RED LOW DC VOLTAGE DS06 AMBER EQUALIZE DS15 RED DC DLITPLIT FAILURE DSO7 AMBER MANUAL TIMER DS16 RED AC INPUT FAILURE DSO8 AMBER MANUAL EGLIALIZE DS17 RED POSITIVE GROUND DS09 AMBER AUTO EQUALIZE TIMER DS18 RED NEGATIVE GROUND O O ac IN SERIES osol DISPL O o vars 5 Advanced Technology DSO2 O ux aves DSO3 EQLZ HRS d BATTERY CHARGER REMAINING RECTIFIER 9 DSO4 O raw HIGH DC O mz VOLTAGE LOW DC O MANUAL TIMER VOLTAGE 4 DSO7 o 0 O mANUAL EDLz brea 4 DSOB auto Ea z TIMER AC INPUT DSOS FAILURE m LAMP TEST O Pos am O nes om DISABLE so ENABLE o quar eren IO T ines S LUE ene SENS Ka HAZARD DF ELECTRICAL SHOCK BLALIFIED PERSONNEL ONLY D NOT REMOVE THIS LABEL INSTRUMENT PANEL MAIN CONTROL PC BL PART No FKO151 01 FRUNT VIEW FACING CHARGER D NOTE UNLESS OTHERWISE SPECIFIED ALL ALARM TERMINAL BLOCKS TB3 TB4 TB8 ARE SULDERLESS COMPRESSION TERMINALS CONTACT RATING IS 0 5A e 125VAC DC ACCEPTING 22 14 AWG WIRE FAILURE FAILURE oc mr oc nur GROUND GROUND Lvoc AC FAIL ac ran Same REN Summary summary male xc noje NG me NG Nc NC NO C sc mal NC a c NG a c NG a c NG NO a fio i 12 13 14 asis 17 18 19 20 21 22 23 24 25 25 27 20 29 30 si 32 33 34 35 36
8. 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 Reconnect wire 38 to the dc output terminal Reconnect wire 36 to the dc output terminal Restart the AT10 1 according to the instructions in Section 2 1 17 INSTALLING THE AT10 1 1 10 WIRING TO THE REMOTE ALARM CONTACTS Built in Summary Common Alarm Relay standard The Main Control PC Board Al mounted on the back of the front door is equipped with eases one form C WIRE HARNESS Summary Alarm contact TB3 that i transfers for any alarm Follow the procedure below to wire an annunciator to this contact See Section 2 2 7 fora description of d the alarm functions GATE DRIVE PC BOARD MAIN CONTROL PC BOARD A1 4 mo 3 5 o o Js CUSTOMER WIRING SUMMARY ALARM INTERCONNECTION DETAIL ALARM RELAY 1 12 5 2 SAFETY SHIELD CUSTOMER WIRING PROCEDURE 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 prope
9. Section 94 30 2011 11 JA0128 02 INSTALLATION amp OPERATING INSTRUCTIONS FOR AT10 1 SERIES BATTERY CHARGER GROUP II 30 100 ADC OUTPUT HOW TO READ THE AT10 1 MODEL NUMBER GROUP II RATINGS 30 100 Adc Your AT10 1 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 AT10 AT10 1 CHARGER AC CIRCUIT S STANDARD 012 12 Vdc F BREAKER M MEDIUM AIC 5 AND 024 24 Vdc prt em H HIGH AIC VOLTAGE 048 48 Vdc 0 NO AC BREAKER 130 130 Vdc G AC FUSES F SUPPLIED 030 30 Adc 200 kAIC x NOT SUPPLIED NOMINAL 040 40 Adc DC CIRCUIT s STANDARD C DC OUTPUT 050 50 Adc BREAKER M MEDIUM AIC CURRENT 075 75 Adc H RATING H HIGH AIC 100 100 Adc SEE TABLE 0 NO DC BREAKER J DC FUSES F SUPPLIED U UNFILTERED 20 kAIC x NOT SUPPLIED D FILTERING F FILTERED k AUX ALARM A SUPPLIED E ELIMINATOR RELAY BOARD x NOT SUPPLIED L GROUND BUS x SUPPHED 120 120 Vac 60 Hz X NOT SUPPLIED 208 208 Vac 60 Hz M LIGHTNING L SUPPLIED 240 240 Vac 60 Hz ARRESTOR x NOT SUPPLIED E 480 480 Vac 60 Hz FUNGUS APPLIED 220 220 Vac 50 60 Hz PROOFING x NOT APPLIED 380
10. of at least 2 times AT10 1 on the bolts add appropriate mounting hardware and tighten securely See the diagram below for the Style 5017 enclosure footprint and wall mounting pattern Dimensions are in mm Style 5017 Enclosure 26 75 679 NCLOSUR OOTPRINT NCLOSUR FOOTPRINT CD EO St uL N O 10 lO Ng 19 29 490 INSTALLING THE AT10 1 1 5 2 Floor Mounting the AT10 1 To floor mount the AT10 1 you must consider the following 1 Floor mounting the Style 5018 enclosure is standard If you are floor mounting a charger in the Style 5017 enclosure you will need the floor mount kit part number El0192 00 For kit availability see ordering information in Appendix B on page 71 The kit contains brackets that elevate the top of the AT10 1 approximately 47in 1194mm above floor level with provisions for floor anchoring The kit includes dimensions and instructions for locating the floor mounting holes Placement of conduit entrances Note the standard pre fab conduit knockouts located on the sides of the charger See outline drawings in Appendix C 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 71 e Should be between 32 and 122 F O and 50 C with relative humidity between 5 and 95 non condensing e Must be free of flamma
11. 1 35 V for Ni Cd 2 Locate R4 and R14 on the Gate Driver pc board A11 on the back of the front panel 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 196 of the specified value replace R4 and 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 AT10 1 PROBABLE SYMPTOM CAUSE RECOMMENDED ACTION Lamp test key 1 No Vac 1 The lamp test key doesn t 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 on 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 key 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 don t 2 Main Control 2 Open the front panel and be sure that the control circuit board work board A1 is not is firmly seated on the standoffs on th
12. 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 control board may be defective Unplug the system harness connector J18 from the Gate Driver pc board A11 If the output current goes to zero replace the Main Control board A1 52 SERVICING THE AT10 1 PROBABLE SYMPTOM CAUSE RECOMMENDED ACTION Output 1 Temperature 1 If the optional temperature compensation probe is installed voltage does compensation the output voltage may be different from the selected float or not agree probe is equalize voltage The difference in the voltages depends on with front installed the probe temperature The front panel meter always displays panel meter the selected voltage as if the battery were at 77 F 25 C 2 Circuit board 2 Recalibrate meter as described in Section 2 3 7 or another component may have been replaced 3 R4 or R14 is 3 Locate R4 and R14 on the Gate Driver pc board A11 on defective or the back of the front panel 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
13. 75 Adc EJ5031 03 EJ5031 08 EJ5031 13 EJ5031 18 100 Adc EJ5031 04 EJ5031 09 EJ5031 14 n a Table 3 3 DC FILTER ASSEMBLIES ELIMINATOR C2 REQUIRES STANDARD FILTER Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 30 Adc EJ5031 20 EJ5031 25 EJ5031 30 EJ5031 35 40 Adc EJ5031 21 EJ5031 26 EJ5031 31 EJ5031 36 50 Adc EJ5031 22 EJ5031 27 EJ5031 32 EJ5031 37 75 Adc EJ5031 23 EJ5031 28 EJ5031 33 EJ5031 38 100 Adc EJ5031 24 EJ5031 29 EJ5031 34 n a Table 3 4 STANDARD AC CIRCUIT BREAKERS CB1 120 Vac Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 30 Adc RE0015 04 RE0015 06 RE0015 09 RE0015 15 40 Adc RE0015 05 RE0015 07 RE0015 10 RE0015 19 50 Adc RE0015 05 RE0015 09 RE0015 12 RE0217 02 75 Adc RE0015 07 RE0015 10 RE0015 15 RE0217 04 100 Adc RE0015 09 RE0015 15 RE0015 19 n a Table 3 5 STANDARD AC CIRCUIT BREAKERS CB1 208 240 Vac Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 30 Adc RE0015 04 RE0015 04 RE0015 06 RE0015 10 40 Adc RE0015 04 RE0015 05 RE0015 07 RE0015 15 50 Adc RE0015 04 RE0015 06 RE0015 09 RE0015 15 75 Adc RE0015 05 RE0015 07 RE0015 12 RE0015 19 100 Adc RE0015 06 RE0015 09 RE0015 15 n a 64 Table 3 6 STANDARD AC CIRCUIT BREAKERS CB1 480 Vac SERVICING THE AT10 1 Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 30 Adc RE0015 03 RE0015 03 RE0015 04 RE0015 06 40 Adc RE0015 03
14. ANAL TEMP http www ATSeries net PDFs JE5030 29 pdf 81 APPENDIX C Standard Drawings Schematic AT10 1 Group Il Battery Charger Standard w o Options JE5032 00 TI CONNECTION TABLE INPUT JUMPER BUS BAR WiC STANDARD H1 H3 H2 H5 TRANSFORMER H2 H4 2 uU H2 H3 2 N D1 aN TRANSFORMER 1 u TI PRI SEC 5S CBI 44A Z H4 vl TIN 3 TB1 L1 CO I HS E i Dr 1 H2 at o VR2 I H3 zx j N m 8 AN TBI L2 US HI N NOTE 5 KA TB1 GND CHASSIS GROUND SET NOTES 1 FOR COMPONENT DETAILS OF ALL PC BOARDS Al AS All etc SEE DRAWING JE5030 2 2 ALL ALARM CONTACTS SHOWN IN NON ALARM STATE CONTACT RATING IS 0 5A e 125VAC VDC RESISTIVE E 3 WHEN REMOTE SENSE IS LISED THE VOLTAGE SENSE LEADS RUN FROM A11 J18 06 TO REMOTE SENSEC AND FROM A11 J18 08 TO REMOTE ER SENSE REFER TO CONNECTION DIAGRAM FOR WIRING DETAILS ax SLIMMARY ALARM 4 UNLESS SPECIALLY ORDERED POWER ISOLATION TRANSFORMER T1 IS TERMINAL BLOCK 3 NOT RE TAPPABLE AND IS ONLY RATED FOR LISTED AC INPUT VOLTAGE OPTIONAL 480VAC INPUT TRANSFORMER T1 DOES NOT FEATURE TAPS TB3 NOTE 2 LEB H2 H3 8 H4 5 AC INPLIT PROTECTION CONSISTS OF ONE 1 TWO POLE CIRCUIT BREAKER CB1 OC OUTPUT PROTECTION CONSISTS OF ONE C1 TWO POLE CIRCUIT BREAKER CB2 FEATURED OPTIONS BALLAST RESISTORS R3A R3B ARE FEATURED EXTERNALLY AS SHOWN FO
15. AT Series net PDFs JA5054 00 pdf INTRODUCTION Multiple battery chargers are sometimes employed in dc power systems to provide redundancy Two or more chargers of the same voltage rating can be connected in parallel each of them capable of powering the connected dc load and charging the battery If a battery charger should fail during normal operation the parallel charger can continue to supply the entire required dc load current and maintain charge on the battery When two 2 AT10 1s operate in parallel they normally will not share the load current equally Since any two chargers will have slightly different characteristics one of the two chargers in a system will have a slightly higher dc output voltage and will therefore assume more of the burden of providing necessary load current This section describes an optional accessory for the AT10 1 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 AT10 1 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
16. Style 5017 220 lbs 100 kg 100 kg Style 5017 Style 5018 Style 5018 Style 5018 Style 5018 300 Ibs 320 Ibs 136 kg 145 kg Style 5018 440 lbs 200 kg NOTE Actual unit is approximately 20 Ibs 9kg below listed shipping weight in table The Style 5017 amp 5018 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 Style 5017 enclosure use the aforementioned sling on a hoist or forklift truck To relocate the Style 5018 enclosure use a forklift truck by lifting the unit through the 3in 76mm gap located between the mounting legs 1 5 MOUNTING THE AT 10 1 Chose the mounting method for the unit enclosure from the table below Rack Mounting MANUAL ENCLOSURE MOUNTING METHOD SECTION Style 5017 Style 5018 1 5 1 Wall Mounting STANDARD OPTIONAL 1 5 2 Floor Mounting OPTIONAL STANDARD 19in 483mm Rack Mounting OPTIONAL N A 1 5 3 24i E eee Om OPTIONAL OPTIONAL INSTALLING THE AT10 1 1 5 1 Wall Mounting the AT10 1 In planning for wall mounting of the AT10 1 consider the following 1 Wall mounting the Style 5017 enclosure is standard If you are wall mounting a charger in the Style 5018 enclosure you need the wall mounti
17. Use a dc voltmeter to measure the dc voltage from J18 pin 19 on the Gate Driver pc board A11 to TB1 It is normally 12 Vdc when the rated output voltage is at TB1 compensation probe optional 4 Defective Main Control board A1 dc voltage is and TB1 If it isn t then remove all power from the charger present at and measure the resistance from TB1 to J18 pin 19 see TB1 the table in Section 3 6 for the proper resistance value If the resistance is not within 1096 of the table value replace R3 2 Defective 2 Remove the safety shield and check the wiring to and from wiring TB1 and the control circuit board for signs of insulation damage or burns Repair any damaged wiring Charger 1 Defective 1 Disconnect wires 51 52 and 53 54 from the SCR gate output SCR lead terminals these are the small gauge twisted pairs Be voltage too sure to note the original polarity so that they can be replaced high not with the same polarity Restart the charger If You are able to controllable measure output current one of the SCRs is defective Replace the rectifier modules 2 RA or R14 is 2 Locate R4 and R14 on the Gate Driver pc board A11 on defective or the back of the front panel Remove one end of each resistor wrong value and measure its value with an Ohmmeter See the table in Section 3 6 for resistance values If either resistor is not within 196 of the specified value replace R4 and or R14 as needed
18. 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 AT10 1 using a dc meter accurate to 0 25 or better While watching the meter connected to the AT10 1 output not the front panel meter press the upl 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 AT10 1 output voltage by a small amount Continue to press UP or DOWN until the actual output voltage agrees with the front panel reading within 190 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 AT10 1 waits 5 seconds then the display returns to normal operation 37 OPERATING THE AT10 1 2 3 8 Using the Low Level Detector LLD The AT10 1 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 mo
19. 02 egualize mode If you set the equalize timer to zero hours the equalize mode is inhibited inhibited When you try to put the AT10 1 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 1 or more hours 47 SERVICING THE AT10 1 3 3 USING THE TROUBLESHOOTING CHART WARNING High voltages appear at several points inside the AT10 1 Use extreme caution when working inside the unit Do not attempt to work inside the ATI0 1 unless you are a qualified technician or electrician Disconnect and lock out all power from the AT10 1 before starting to remove or replace any components Turn the ac power off at the distribution panel upstream from the charger Disconnect the battery from the AT10 1 output terminals TB 1 47 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 AT10 1 s condition including the trouble symptoms 2 Find the symptom s in the first column of the chart 3 The middle column contains common causes for the problem you observe in order of probability 4 Follow the action described in the right hand column to correct the problem and return the AT10 1 to normal service Determining the condition of the ch
20. 1 Group Il Battery Charger NEMA 1 Style 5017 Enclosure JE5025 00 TOP VIEW NOTES 1 ENCLOSURE IS A NEMA 1 TYPE CABIN 2 ALLOW 12in 305mm OF FREE AIR FOR VENTILATION ag SSS KY SSL 55 gan Ss 3 EIGHT 8 KEY HOLE SLOTS ARE PRO ENCLOSURE AS SHOWN FOR WALL MOLI HARDWARE lt OK QS RS 4 TWO 2 1 31in 33nm DIA STANDARD PROVIDED SHOWN ON THE LOWER RIGI FOR UP TO lin 25mm CONDUIT IF ENTRANCES ARE REQUIRED BY LISER FIELD MODIFIED BY INSTALLER KS 29 IA 2 5 e 5 5 BATTERY CHARGER SHIPPING WEIGHT APPROXIMATELY 130 250 lbs 59 SIDE VIEW y C ROL PANEL SEE DE DRAWING JE5030 2 MANUAL POCKET CB AC CB2 DC CIRCUIT CIRCUIT BREAKER BREAKER 17 92 MTG 2 455 MTG 19 29 490 72 APPENDIX C Standard Drawings Outline AT10 1 Group Il Battery Charger NEMA 1 Style 5017 Enclosure JE5025 00 TYPE CABINET WITHOUT GASKETS FREE AIR TOP AND FRONT OF CABINET ITS ARE PROVIDED ON THE BACK DF IR WALL MOUNTING WITH 25in 6 25nn A STANDARD PRE FAB KNOCKOUTS ARE LOWER RIGHT SIDE OF ENCLOSURE IDUIT IF ADDITIONAL CONDUIT BY U
21. 100 Adc AP0339 10 AP0339 10 AP0339 10 n a 68 SERVICING THE AT10 1 Table 3 22 RATING RESISTOR R2 Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc EJ1133 00 EJ1133 05 EJ1133 10 EJ1133 15 30 Adc 34 8 KO 13 0 KQ 5 11 KO 1 50 KQ EJ1133 01 EJ1133 06 EJ1133 11 EJ1133 16 ay Ege 40 2 KQ 15 4 KQ 6 19 KQ 2 21 KO EJ1133 02 EJ1133 07 EJ1133 12 EJ1133 17 50 Adc 53 6 KO 19 6 KO 7 50 KO 2 74 KQ EJ1133 03 EJ1133 08 EJ1133 13 EJ1133 18 75 Adc 78 7 KQ 23 7 KQ 9 09 KO 3 57 KQ EJ1133 04 EJ1133 09 EJ1133 14 100 AUC 118 KQ 29 4 KO 11 0 KQ Ls Connector terminal exira t di Tao Molex P N 11 03 0044 Table 3 23 MAIN TRANSFORMER T1 120 208 240 Vac Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 30 Adc AB1545 10 AB1569 10 AB1613 10 AB1589 10 40 Adc AB1561 10 AB1541 10 AB1597 10 AB1601 10 50 Adc AB1561 10 AB1541 10 AB1597 10 AB1601 10 75 Adc AB1520 10 AB1720 10 AB1553 10 AB1641 10 100 Adc AB1565 10 AB1633 10 AB1549 10 n a Table 3 24 MAIN TRANSFORMER T1 480 Vac Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 30 Adc AB1546 10 AB1570 10 AB1614 10 AB1590 10 40 Adc AB1562 00 AB1542 10 AB1598 10 AB1602 10 50 Adc AB1562 10 AB1542 10 AB1598 10 AB1602 10 75 Adc AB1249 10 AB1257 10 AB1554 10 AB1642 10 100 Adc AB1566 10 AB1516 10 AB1550 10 n a 69 APPENDIX A SPECIFICATIONS Except as noted all specificatio
22. 2 091305 DRAW BY MCR 022003 TITLE AT10 1 SERIES BATTERY CHARGER SCHEMATIC A GROUP II 30 100ADC W ALL COMMON OPTIONS 1 E1203 040703 I e Q 022003 7 DRAWING No REV zu o E1142 022003 UNLESS OTHERWISE NOTED DIMENSIDNS JESO32 99 2 B ARE IN INCHES TOLERANCES ARE ECN No DATE SCALE NTS PART No JE5032 99 1 OF 1 http www ATSeries net PDFs JE5032 99 pdf 85 APPENDIX C Standard Drawings Connection Diagram AT10 1 Group II Battery Charger Standard w o Options JE5034 00 CI L1 MAIN INDLICTOR O Y2 O Yi TI TRANSFORMER 05 O x5 A ATO 7 O XI HOA HEATSINK HEATSINK kad 1 CHARGER COMPONENTS ARE CONNECTED WITH FLAME RETARDANT SWITCHBOARD INSULATION TYPE WIRING IDENTIFIED ON EACH END WITH NUMBER CODED MARKERS GROUND WIRE 56 IS GREEN WITH YELLOW STRIPE DIODES CRI 8 CR4 ARE ANODE MOUNTED TYPE WIRE TO CATHODE FEATURED OPTIONS 2 CUSTOMER ALARM CONTACTS TB3 TB4 etc ARE SOLDERLESS PLUG IN TERMINALS AND WILL ACCEPT 22 14 AWG WIRE AC INPUT CIRCUI 3 DC OUTPUT CIRCU WHEN REMOTE SENSE IS USED WIRE 36 CONNECTS A11 J18 06 TO REMOTE SENSE AND WIRE 38 CONNECTS A11 J18 08 TO REMOTE SENSE SEE SCHEMATIC FOR TRANSFORMER T1 PRIMARY CONNECTION TABLE IN 130 VDC UNITS TWO 2 BALLAST RESISTORS R3A B ARE SUPPLIED EXTERNALLY AS SHOWN H O HS O H2 O H3 O HI O PRI
23. 6 CB1 AC Circuit Breaker medium AIC 480 Vac See Table 3 9 CB1 AC Circuit Breaker high AIC 480 Vac See Table 3 12 CB2 DC Circuit Breaker standard See Table 3 16 CB2 DC Circuit Breaker medium AIC See Table 3 17 CB2 DC Circuit Breaker high AIC See Table 3 18 62 SERVICING THE AT10 1 Factory Part Number Rec Symbol Description 12 Vdc 24 Vdc 48 Vdc 130 Vdc Spares CR1 Polarity Diode 30 40 amp 50 Adc ratings EJ5106 00 Y CR1 Polarity Diode 75 Adc rating EJ5106 01 Y CR1 Polarity Diode 100 Adc rating RK0017 14 Y CR4 Free Wheeling Diode 30 40 50 Adc ratings EJ5108 00 Y CR4 Free Wheeling Diode 75 Adc rating EJ5108 01 Y CR4 Free Wheeling Diode 100 Adc rating RK0017 14 Y Fix AC Input Fuses optional See Tables 3 13 3 14 3 15 Y F3 F4 DC Output Fuses optional See Table 3 19 Y L1 Main Inductor See Table 3 20 L2 Filter Inductor See Table 3 21 SN a RC0100 0 aa Rcoto000 P9 Men Control PC Board AT RESIDEO Q1 Q2 Rectifier Module 30 Adc amp 40 Adc ratings RM0001 00 Y Q1 Q2 Rectifier Module 50 Adc ratings RM0001 01 Y Q1 Q2 Rectifier Module 75 Adc amp 100 Adc ratings RM0004 00 Y R1 Main DC Shunt RB0008 03 R2 Current Rating Resistor See Table 3 22 RJ0007 26 RJ0035 25 EJ1127 02 EJ1127 03 1222W 68211W 150250W note 1 RJ0056 48 RJ0056 81 RJ0075 14 RJ0075 56 31600 69802 14 0KQ 38 3K0 R6 Voltage Crowb
24. A1 and corresponding Rev 6 or higher software programs e We recommend that both chargers use the same 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 board 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 AT10 1 may be selected as Primary or Secondary but you may wish to choose the unit that is more accessible to be the Primary The Primary charger controls the dc output voltage of both AT10 1s You may run the interconnection cable through conduit if necessary However do not run the cable through the same conduit with power wiri
25. AT10 1 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 AT10 1 door and locate the small plastic jumper J9 on the right side of the main control board See the figure below Jor ND FAULT ENAELE TB8 1 S IEIR Move the jumper up to the DISABLE position pins 2 and 3 With this setting only the front panel METER MODE and CHRG MODE keys will function All indicators will still work normally Return the jumper down to the ENABLE position pins 1 and 2 to return all front panel key functionality 39 OPERATING THE AT10 1 2 4 24 1 2 4 2 2 4 3 Performing routine maintenance WARNING High voltages appear at several points inside the AT10 1 Use extreme caution when working inside the unit Do not attempt to work inside the ATI0 1 unless you are a qualified technician or electrician Disconnect and lock out all power from the AT10 1 before starting to remove or replace any components Turn the ac power off at the distribution panel upstream from the charger Disconnect the battery from the AT10 1 output te
26. OTHER CONTROLS RAI LOW LEVEL WARNING DETECT ADJUST RA2 GROUND FAULT BALANCE RA3 GROUND FAULT SENSITIVITY NON LISER ACCESSED JUMPERS J12 BOARD PROGRAMMING J14 OLD FORCED LOAD SHARING AUXILIARY ALARM RELAY PC BUARD AS asco ACTOR TIG TEST Note This instrument panel drawing JE5030 29 depicts the optional Auxiliary Alarm Relay PC Board A5 which provides two 2 sets of individual form c contacts TB4 for all alarm conditions Standard AT10 1 battery chargers feature one 1 set of form c summary common alarm contacts TB3 80 APPENDIX C Standard Drawings Instrument Panel PC Board Detail AT10 1 Group II Battery Charger w Optional Auxiliary Alarm Relay Board JE5030 29 E DRIVER PC BOARD A11 HIGH LLITPLIT GATE DRIVER PC BOARD All HindlePover Inc ENSOS L RE 1 Le Jig O o 000000000000 000000000000 o DISPLAY DS11 DS12 o 0 COMMUNICATIONS MODULE PC BOARD ASSEMBLY A12 SEE DRAWING f JE5107 00 sap RAI FOR DETAILS S6 WARNING PANEL J8 ess KEY ORIENTAT EN o 915i O o Ng 1 FOR FORCED LOAD SHARING DETAILS SEE JESIB4 00 J4 5 HINOLEPOWER INC _EN5002 OREVO ta J ININAYA 5 mg BATT naan r
27. UP key then operate in a charger with zero output current so that only the defective charger of two or more in parallel The HIGH DC VOLTAGE indicator lights and Shuts down The other the display flashes ON You can toggle the charger continues to supply shutdown feature OFF and ON by pressing the the load normally CHRG MODE key repeatedly e Press the CHRG MODE key If you don t press any key within 4 seconds the last state indicated ON or OFF is saved internally Note that you don t use the EDIT ENTER key for this feature If the AT10 1 shuts down because of a high dc voltage the meter display shows error code E 03 Reset the charger by turning the ac breaker off then on again 36 OPERATING THE AT10 1 2 3 7 Adjusting the Voltmeter Accuracy The AT10 1 voltmeter is adjusted at the factory to display the actual output voltage within 0 25 If you replace any component that affects meter accuracy such as the main control PC board 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
28. ac circuit breaker is turned on The LAMP TEST key does not operate when ac power is off To test the action of the AT10 1 summary alarm relay press and hold the LAMP TEST key for four seconds to transfer the relay If you are monitoring the relay with a remote annunciator it will detect the alarm condition Testing the Auxiliary 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 HIGH DC VOLTAGE lights whenever the dc output voltage exceeds the specified alarm voltage setting See Section 2 3 4 to learn how to adjust the HVDC alarm setting e LOW DC VOLTAGE lights whenever the dc output voltage is below the specified alarm voltage setting See Section 2 3 4 to learn how to adjust the LVDC alarm setting e DC OUTPUT FAILURE lights whenever the 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 PO
29. 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 AT10 1 2 OPERATING THE AT10 1 BATTERY CHARGER 2 1 STARTING THE AT10 1 2 1 1 Understanding the startup sequence The AT10 1 is set up at the factory to work with most common batteries and loads without further adjustment When you start the AT10 1 for the first time the factory settings float voltage equalize voltage etc control the operation of the charger You can change the settings after you start the charger The FACTORY SETTINGS are shown in table on page 25 The AT10 1 startup routine takes about five seconds The microprocessor that controls the AT10 1 initializes the charger by reading the settings that are stored internally The control 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 followed the installation When you first start the AT10 1 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 bn x QM mg s
30. all settings to factory default Reset parameters per Section output 2 3 of this manual 1C Remove all power from charger 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 wire 6 from the rectifier module on trips or fuses rectifier diode the right heat sink or if possible at the other end from T1 X1 clear or SCR Measure resistance between the ac terminals bottom immediately terminals on the rectifier modules It should be at least 100 000 Ohms check both polarities Replace rectifier modules if resistance is low in either direction 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 the rectifier bridge assembly 3 Defective 3 Test by disconnecting wires from X1 X5 Y1 and Y2 If ac transformer T1 breaker still trips replace the transformer T1 AC breaker 1 Loose 1 Check and tighten connections as required trips or fuses connection to clear aftera breaker fuse few minutes 2 Wrong ac 2 Be sure the T1 primary taps are wired correctly for your voltage or T1 input voltage See Section 1 6 for details taps miswired 3 Open SCR 3 Use a clamp on ammeter to measure the current in wire 5 or 6 between
31. blow when the battery is reversed 24 OPERATING THE AT10 1 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 AT10 1 then next time it starts Turn on the front panel ac circuit breaker The digital meter displays the output voltage and current See Using the Digital Meter on page 24 You should hear a soft hum from the AT10 1 as the output current increases NOTE If you turn on the ac breaker before the dc breaker and you have a filtered model of the AT10 1 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 AT10 1 by turning on the dc breaker first The green FLOAT indicator lights Press the CHRG MODE key on the front panel The FLOAT indicator goes off and the yellow EQLZ indicator lights Press the CHRG MODE key again to return the charger to the float mode The table below shows the normal factory settings for float and equalize voltage equalize time
32. both front panel circuit breakers or turn off ac and Main Control dc power externally if the charger doesn t have breakers board A1 Then turn on the dc breaker followed by the ac breaker If the charger still has the wrong output voltage replace the Main Control board A1 Charger 1 Current limit 1 If the AT10 1 is not in the Edit mode press the never set too low EDIT ENTER key five times until the meter display flashes the reaches float current limit value in Amperes If the current limit is less than or equalize 11096 adjust it to 11096 as described See Setting the Current voltage Limit 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 charger may not be able to reach the Float load or load is voltage You may have the same problem if the normal load too great current is more than the rated output current of the charger 3 Wrong ac 3 Be sure the transformer T1 primary taps are wired input voltage or voltage too low or T1 wired incorrectly 4 Defective rectifier bridge 5 Defective control circuit board A1 correctly for your input voltage See Changing Transformer Taps Section 1 6 The actual ac input voltage must be at least 8896 of the rated value for the charger to produce full output power 4 Use a clamp on ammeter to measure the current in wire 5 or 6 between the transformer T1 and the rectifier
33. current limit setting and alarm settings If your purchase order specified other float or equalize voltage settings a tag attached to the front panel of the AT10 1 lists the actual voltage 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 11096 of nominal output current HVDC Shutdown Disabled 25 OPERATING THE AT10 1 2 2 USING THE AT10 1 FRONT PANEL FEATURES 2 2 1 If the meter displays an error message When you apply power to the AT10 1 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 voltage 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 feed
34. e I 225 52825 SS to KO oS 0 eS o KO SS eS 5 x gt gt gt o x eo KS Ks KSI NOTES 1 ENCLOSURE IS A NEMA 1 TYPE CABINET WITHOUT GASKETS 16 77 1 2 ALLOW 12in 305mm DF FREE AIR TOP 42b AND FRONT DF CABINET FOR VENTILATION 3 FOUR 4 lin x 625in 25nn x 16nn FLUOR MOLINTING SLOTS ARE PROVIDED UN BOTTOM OF ENCLOSLRE AS SHOWN 4 TWO 2 1 31in 33mm DIA STANDARD PRE FAB KNOCKOUTS ARE PROVIDED SHOWN UN THE LOWER RIGHT SIDE OF ENCLUSURE FOR UP TO lin 25mn CONDUIT IF ADDITIONAL CONDUIT ENTRANCES ARE REQUIRED BY USER ENCLOSURE SHOULD BE FIELD MUDIFIED BY INSTALLER S BATTERY CHARGER SHIPPING WEIGHT RANGE APPROXIMATELY 205 660 Ibs 93 300 kg DUAL DI THIRD ANGLE PROJECTION DRAW BY MCR 022603 7 AT10 1 SERIES BATTERY CHARGER OUTLINE NEMA 1 STYLE 5018 ENCLOSURE 1 E1541 012304 oo Q 022603 RE ED 1B 0 E1151 022603 ARE IN INCHES TOLERANCES ARE S J SCALE NTS PART JES026 00 1 http www ATSeries net PDFs JE5026 00 pdf 75 APPENDIX C Standard Drawings Internal Component Layout AT10 1 Group II Battery Charger Style 5017 Enclosure w Common Options JE5028 99 PLEXIGLAS SAFETY COVER PLEXIGLAS SAFETY COVER CIRCUIT BREAKER HEATSINK ASSEMBLY CHASSIS GROUND STUD
35. 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 50 C Elevation 3000ft 1000m without derating Relative humidity 0 to 9596 non condensing Alarm relay contact rating 120 Vac 125 Vdc 0 5 A resistive 70 APPENDIX B FIELD INSTALLABLE ACCESSORIES AND OPTIONS All options and accessories listed below are available in kits for field installation Kits contain all parts and hardware with detailed installation instructions To order accessories options please provide the following information for each kit 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 standard DC Output Filtering per NEMA PE5 1996 see table 3 2 Battery Eliminator Filtering per NEMA PE5 1996 see table 3 3 Auxiliary Alarm Relay PC Board A5 E10213 02 Ground Bus with one 1 box lug for 14 1 0 AWG E10195 01 AC Input Lightning Arrestor VR3 EJ1074 01 Floor Mounting Kit for Style 5017 Enclosure E10192 00 Relay Rack Mounting Kit for Style 5017 Enclosure 19in 483mm E10193 01 Relay Rack Mtg Kit for Style 5017 Enclosure 23 24in 584 610mm E10193 02 Cabine
36. 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 Symbol Description Mosca digi ud Ree 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 A7 DCFilter assembly See Table 3 2 ni ss Seo Table 3 3 A10 Temperature Compensation Probe assembly See Appendix B A11 Gate Driver PC Board assembly EJ5047 01 EJ5047 02 EJ5047 03 EJ5047 04 Y C1 Filter Capacitor standard RP5001 20 RP5001 20 RP5001 20 RP5001 40 Y C2 Filter Capacitor battery eliminator RP5001 20 RP5001 20 RP5001 20 RP5001 40 Y C4 EMI Filter Capacitor See VR6 C4 C5 EMI Filter Capacitor See VR7 C5 CB1 AC Circuit Breaker standard 120 Vac See Table 3 4 CB1 AC Circuit Breaker medium AIC 120 Vac See Table 3 7 CB1 AC Circuit Breaker high AIC 120 Vac See Table 3 10 CB1 AC Circuit Breaker standard 208 240 Vac See Table 3 5 CB1 AC Circuit Breaker medium AIC 208 240 Vac See Table 3 8 CB1 AC Circuit Breaker high AIC 208 240 Vac See Table 3 11 CB1 AC Circuit Breaker standard 480 Vac See Table 3
37. n a Note 1 Not available with 120 Vac input Input current is 67 Aac at 240 Vac 1 To determine the input current lac for other input voltages use the formula 120 V ac I I x qc where Vac is the new input voltage and Ir is the input current from the table above 12 INSTALLING THE AT10 1 MAKING THE AC INPUT CONNECTIONS GRAPHICS L1 AC INPUT L2 CU AL COMPRESSION TYPE LUG 50in 12 7mm CUSTOMER f AC INPUT WIRING LINE 1 LINE2 GROUND NOTES 1 The drawing above does not show other components mounted to the I O panel Be careful not to disconect any other component leads 2 Always use a proper ground 3 Use copper or aluminum conductors only 4 On 120 Vac input connect the neutral leg to the terminal L2 INSTALLING THE AT10 1 1 8 MAKING THE DC OUTPUT CONNECTIONS Follow these steps to connect the battery to the AT10 1 1 Size the dc wiring to minimize voltage drop The acceptable wire size depends on your installation As a guideline the voltage drop should not exceed 1 of nominal output voltage at full current Refer to the table below to determine the voltage drops for various wire sizes currents and distances WIRE SIZING CHART VOLTAGE DROP PER 100ft 30 5m OF WIRE for copper at 68 F 20 C WIRE SIZE DC CURRENT AMPERES AWG 30 40 50 75 100 10 3 0V 4 0V 5 0V notrecommended notrecommended 8 1 9V 2 5
38. number issued by the manufacturer 1 3 UNPACKING AND INSPECTING THE AT10 1 Carefully remove all shipping materials from the AT10 1 Remove the AT10 1 from the shipping pallet for inspection Save all shipping materials until you are sure that there is no shipping damage Once the AT10 1 is unpacked inspect the unit for possible shipping damage using the checklist below If shipping damage has occurred refer to Section 1 2 on this page for proper reporting INSPECTION CHECKLIST Enclosure exterior and interior are not marred or dented There is no visible damage to exterior or interior components All internal components are secure Printed circuit boards are firmly seated on their standoffs All hardware is tight All wire terminations are secure The User s Manual is included You received all items on the packing list L L1 L1 L1 L1 L1 L1 E 1 4 MOVING THE AT10 1 Once you have established that the AT10 1 is undamaged identify the enclosure style and weight of your unit Refer to the table below AT10 1 Enclosure Type And Shipping Weight Table Group Il Cabinets Style 5017 Style 5018 Output Voltage 40 Adc Style 5017 155 Ibs 70 kg INSTALLING THE AT10 1 Ampere Rating 75 Adc Style 5017 Style 5018 100 Adc Style 5018 280 Ibs 127 kg Style 5017 180 Ibs 82 kg Style 5017 Style 5018 Style 5018 320 Ibs 145 kg Style 5017 220 Ibs 130 Vdc
39. sharing feature is compatible with the external temperature compensation accessory It is recommended that each AT10 1 have a tempco probe and that the probes be located as close as possible to each other When the AT10 1s 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 AT10 1s are unequal refer to the following table PROBABLE RECOMMENDED ACTION CAUSE 1 Connection cable 1 Ensure that the interconnection signal cable assembly is properly missing or installed installed and that the connector for the Secondary charger has the incorrectly jumper as described at the top of page 3 2 Incorrect connections 2 Ensure that both AT10 1s are connected to the same ac supply and to ac power sources that source phase rotation is the same for both chargers 3 Defective or improper 3 Replace the Main Control circuit board in one charger at a time noting Main Control circuit Syste
40. than the AT10 1 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 AT10 1 can supply all the current required by the load and still charge the battery The current limit should be set to at least 596 greater than the maximum continuous dc load current NOTE The common alarm relay is not set for this condition E 10 open internal A redundant internal feedback loop control loop is provided as feedback loop redundancy to increase reliability when remote sensing is used If there is a problem with the internal loop wiring the AT10 1 will display E 10 Check the internal wiring in the signal harness especially wire 50 Also check the harness connector on the main control circuit board E 14 forced load See Appendix F on page 92 Verify both AT10 1s are functioning sharing not properly Ensure that the forced load sharing interconnection cable working assembly is not broken is properly installed and that the connector for properly the Secondary charger has the jumper as described Ensure that both AT10 1s are connected to the same ac supply and that source phase rotation is the same for both AT10 1s A 01 manual equalize If AT10 1 was accidentally left in manual equalize mode switch unit back enabled for to float manual equalize timer or auto equalize timer mode more than 24 hours A
41. 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 C The actual output voltage of the AT10 1 may be different from the value shown on the front panel meter if the battery is warmer or cooler than TIS F 25 O Use a digital meter to measure the actual output voltage of the AT10 1 If you know the temperature at the temperature compensation probe you can use the graph below to determine that the output voltage is correct If the battery temperature goes below 32 F 0 C there will be no further increase in 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 ic Pha K kel Cadmium Example 100 Deg F 97 Output Voltage 20 40 60 80 100 120 Temperature Degrees Fahrenheit EXAMPLE Suppose you have a lead acid battery whose temperature is 100 F 37 8 C As shown on the graph the output voltage should be approximately 9796 of the 77 F voltage If the float voltage is set on the front panel to 132 Vdc the
42. the sixth parameter current limit press the EDIT ENTER key again The AT10 1 saves all adjustments you made internally and reverts to normal operation The new settings take effect immediately Edit mode ends automatically if you don t press any front panel key within 25 seconds and any change you made to the last setting is not saved 30 OPERATING THE AT10 1 2 3 2 Setting the Float and Equalize voltages e Press the EDIT ENTER key The FLOAT and DC VOLTS indicators light and the display flashes the present value of the float voltage Press and release the UP or 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 upl 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 The EQLZ and DC VOLTS indicators light and the display flashes the present value of the equalize voltage Press and release the upl or DOWN key to increase or decrease the value in the display by one count or press and hold the UP or Downj key to scroll the value in the display upward or downward When the display shows the equalize vo
43. to 80 higher than the rated dc output voltage If it is too low check the wiring of the primary taps See Section 1 6 for details If it is zero replace the transformer T1 No output 1 Battery is fully 1 This is normal operation in a system with little or no dc load As current but ac charged long as the charger maintains Float voltage it is operating and dc normally breakers are 2 Float or 2 Check the Float and Equalize voltages and adjust them if on AC ON Equalize voltage necessary Consult your battery manufacturer for the proper lamp is on set too low voltage settings 3 Wrong ac 3 Be sure the main transformer T1 primary taps are wired input voltage or correctly for your input voltage See Section 1 6 for details T1 taps miswired 4 Defective 4 Check terminals and wiring between the transformer T1 and wiring the rectifier bridge assembly main inductor L1 dc filter assembly if present the dc breaker and or fuses and the output terminals Repair as necessary 5 Defective 5 Use an ac voltmeter to measure the voltage between the two rectifier bridge 6 Defective Gate Driver pc board A11 7 Defective transformer T1 8 Defective inductor L1 or L2 9 Defective dc circuit breaker CB2 SCR gate leads on each SCR module If you measure about 1 0 Volt rms but there is no output current replace the rectifier module 6 If you do not measure any ac voltage in step 5 above and the battery vo
44. web site listed on the back cover of this manual RELATED DOCUMENTS Doc No Online Hyperlink Description JA0102 01 http 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 Mtg 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 Appl
45. 0193 01 El0193 02 48 Vdc 50 100 Adc N A El0193 03 130 Vdc 30 Adc El0193 01 El0193 02 130 Vdc 40 75 Adc N A El0193 03 MOUNTING KIT Each kit includes mounting brackets hardware and the necessary instructions to install one AT10 1 battery charger The kit also includes dimensions and detailed instructions for rack mounting When rack mounting the AT10 1 you must consider the following 1 The rack must be strong enough to properly support the weight of the AT10 1 See the Weight Table located in Section 1 4 on page 3 Placement of conduit entrances 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 between 32 122 F 0 50 C with relative humidity between 5 and 9596 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 for cooling air Allow 36in 914mm front clearance for access to the charger for operation and maintenance INSTALLING THE AT10 1 PROCEDURE To rack mount the AT10 1 first install the brackets into the rack using the supplied hardware Second install the AT10 1 onto the brackets Tighten all hardware securely Provide at least 6in 152mm of free air space above and below the AT10 1 enclosure in the rack for cooling You do not need to modify the AT10 1 enclosures for standard rack mounting See the diagram
46. 1 After an ac power failure or a battery discharge for any VOLTAGE discharged other reason it may take several hours to recharge the indicator is battery It is normal for the LOW DC VOLTAGE indicator to be on but ac on until the battery voltage is above the Low DC Alarm and dc voltage breakers are 2 Low DC 2 Be sure that the Low DC Voltage alarm setting is lower than closed ac Voltage alarm the Float voltage setting See Sections 2 3 2 and 2 3 4 input voltage and Float is normal voltage settings there is are mismatched 3 Use a clamp on ammeter to measure the current in wire 5 or 6 between the transformer 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 4 Turn off both front panel circuit breakers or turn off ac and dc power externally if the charger doesn t have breakers Then turn on the dc breaker followed by the ac breaker 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 charger 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 and dc breakers are closed ac input voltage is normal 1 Defective rectifier bridge 2 Defective Main Cont
47. 2 100 Adc RE0217 03 RE0217 03 RE0217 03 n a 67 SERVICING THE AT10 1 Table 3 18 HIGH AMPERE INTERRUPTING CAPACITY DC CIRCUIT BREAKERS CB2 Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 30 Adc RE0043 07 RE0043 07 RE0043 07 RE0043 07 40 Adc RE0043 08 RE0043 08 RE0043 08 RE0043 08 50 Adc RE0043 10 RE0043 10 RE0043 10 RE0043 10 75 Adc RE0043 12 RE0043 12 RE0043 12 RE0043 12 100 Adc RE0188 06 RE0188 06 RE0188 06 n a Table 3 19 DC OUTPUT FUSES F3 F4 Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 30 Adc RE0061 18 RE0061 18 RE0061 18 RE0061 18 40 Adc RE0061 19 RE0061 19 RE0061 19 RE0061 19 50 Adc RE0061 21 RE0061 21 RE0061 21 RE0061 21 75 Adc RE0061 23 RE0061 23 RE0061 23 RE0061 23 100 Adc RE0061 26 RE0061 26 RE0061 26 n a Table 3 20 MAIN INDUCTOR L1 Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 30 Adc AP0604 10 AP0604 10 AP0604 10 AP0604 10 40 Adc AP0604 10 AP0604 10 AP0604 10 AP0482 10 50 Adc AP0481 10 AP0481 10 AP0481 10 AP0482 10 75 Adc AP0314 10 AP0808 10 AP0833 10 AP5001 00 100 Adc AP0339 10 AP0339 10 AP0827 10 n a Table 3 21 FILTER INDUCTOR L2 Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 30 Adc AP0604 10 AP0604 10 AP0604 10 AP0604 10 40 Adc AP0604 10 AP0604 10 AP0604 10 AP0604 10 50 Adc AP0481 10 AP0481 10 AP0481 10 AP0482 10 75 Adc AP0314 10 AP0314 10 AP0833 10 AP0377 10
48. 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 floor wall rack mounting brackets zero center ground detection meter w test switch NEMA 2 type drip shield end of discharge alarm relay NEMA 4 12 13 type enclosure battery discharge alarm relay cabinet heater strips barrier type auxiliary alarm terminal block s pad key lock for front panel door external temperature compensation probe analog ac voltmeter DNP3 Level 2 Modbus communications module analog ac ammeter forced load sharing signal interconnection cable Please find the serial number on the data nameplate and record it here 10 11 12 IMPORT
49. 6 volts the error code disappears If you have a seriously discharged battery allow the AT10 1 to run for 24 hours and check the battery voltage again If it has not increased to the normal voltage rating consult the battery manufacturer for help If the battery voltage is normal 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 AT10 1 If itis tripped try once to reset it If it trips again immediately there may be an internal short circuit in the AT10 1 Check the internal wiring If the AT10 1 is filtered check the dc filter capacitors and the polarity diode The AT10 1 normally recovers automatically from an E 02 condition If you have shut down the AT10 1 for service restart it according to Section 2 1 E 03 High DC To restart the AT10 1 turn the ac breaker off then on Check the Voltage Equalize voltage and High DC Voltage alarm settings The alarm Shutdown setting must be higher than the Equalize voltage setting activated 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 in Section 3 4 45 SERVICING THE AT10 1 failure Error Meanin Repair Procedure Code g p E 04 internal memory Any parameters that you set such as Float or Equalize vol
50. ANT 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 bottom 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 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
51. BREAKERS CB1 120 Vac Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 30 Adc RE0043 00 RE0043 01 RE0043 04 RE0043 09 40 Adc RE0043 00 RE0043 02 RE0043 05 RE0043 12 50 Adc RE0043 00 RE0043 04 RE0043 07 RE0219 02 75 Adc RE0043 02 RE0043 05 RE0043 09 RE0219 04 100 Adc RE0043 04 RE0043 09 RE0043 12 n a Table 3 11 HIGH AMPERE INTERRUPTING CAPACITY AC CIRCUIT BREAKERS CB1 208 240 Vac Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 30 Adc RE0043 00 RE0043 00 RE0043 01 RE0043 05 40 Adc RE0043 00 RE0043 00 RE0043 02 RE0043 09 50 Adc RE0043 00 RE0043 01 RE0043 04 RE0219 09 75 Adc RE0043 00 RE0043 02 RE0043 07 RE0219 12 100 Adc RE0043 01 RE0043 04 RE0043 09 n a Table 3 12 HIGH AMPERE INTERRUPTING CAPACITY AC CIRCUIT BREAKERS CB1 480 Vac Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 30 Adc RE0152 09 RE0152 09 RE0152 09 RE0152 00 40 Adc RE0152 09 RE0152 09 RE0152 09 RE0152 10 50 Adc RE0152 09 RE0152 09 RE0152 09 RE0152 11 75 Adc RE0152 09 RE0152 09 RE0152 00 RE0152 03 100 Adc RE0152 09 RE0152 09 RE0152 10 n a Table 3 13 AC INPUT FUSES F1 F2 120 Vac Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 30 Adc RE0061 09 RE0061 12 RE0061 14 RE0061 21 40 Adc RE0061 11 RE0061 13 RE0061 16 RE0061 23 50 Adc RE0061 11 RE0061 14 RE0061 18 RE0061 26 75 Adc RE0061 13 RE0061 16 RE0061 21 RE0061 28 100 Adc RE0061 14 RE0061 21 RE0061 23 n
52. E DRIVE PC BOARD All C NC NO TB3 TB8 Ja p4 AUXILIARY ALARM Ja wp RELAY PC BOARD AS J17 MOVE JUMPER TU PROPER PINS NOTE 2 ra 27700451 po sopra ay 648 s s s hoitelee MAIN CONTROL PC BOARD Al C NC NO C NC NOJ C NC NOJ C NC NO C NC NOJ C NC NG HIGH DC LOW DC OC QUT AC IN GROUND SUMMARY VOLTAGE VOLTAGE FAILURE FAILURE DETECT ALARM 47 gn S6 GR YE DOUR GROUND el O R3B Off OUTPUT CIRCUIT BREAKER oc OUTPUT Ca O REMOTE REMOTE O CBI AC INPLIT CIRCUIT BREAKER 56 GR YE TE AC BREAKER WIRING FOR STYLE 5018 ENCLOSURE SHOWN TOP BOTTOM ORIENTATION OF WIRES O1 THRU 04 ARE REVERSED IN STYLE 5017 ENCLOSURES 2 FIA AC FUSE 1 lt 01 10 GR YE 56 GR YE D zu er 2 EM TU og DZ Ja LU I EE or VR3 CHASSIS 2 FlB AC FUSE 1 GROLIND o cj ANGLE PROJECTION DRAWN BY MCR 040703 TITLE AT10 1 SERIES BATTERY CHARGER CONN DIAGRAM APPROVED GROUP II 30 100ADC W ALL COMMON OPTIONS EE 4 040703 DRAWING No JE5034 99 REV 1 B E1204 040703 G i IN INGES TOLERANCES Amr SCALE NTS PART No JE5034 99 1 D 1 http www ATSeries net PDFs JE5034 99 pdf 89 APPENDIX D RECOMMENDED FLOAT AND EQUALIZE
53. Gate Driver pc board A11 on page 59 If any of these resistors must be replaced without replacing A11 select the proper part number listed in the table starting on page 62 and order it from the factory or your sales representative Remove A11 as described on page 59 Using wire cutters clip the soldered leads of the old resistor and remove it from A11 Carefully solder on the new resistor making sure not to damage any other components on A11 Polarity is not important for these resistors Once the solder cools replace A11 as described on page 59 61 SERVICING THE AT10 1 3 6 ORDERING REPLACEMENT PARTS All AT10 1 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 AT10 1 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
54. H5 TRANSFORMER H2 H4 2 NOTE 4 H2 H3 2 BLIS BAR W1C 1 FOR COMPONENT DETAILS OF ALL PC BOARDS Al AS All etc SEE DRAWING JESO30 2 2 ALL ALARM CONTACTS SHOWN IN NON ALARM STATE CONTACT RATING IS O SA e I25VAC VDC RESISTIVE 3 WHEN REMOTE SENSE IS USED THE VOLTAGE SENSE LEADS RUN FROM A11 J18 06 TO REMOTE SENSEC AND FROM A11 J18 08 TO REMOTE SENSE REFER TO CONNECTION DIAGRAM FOR WIRING DETAILS 4 UNLESS SPECIALLY ORDERED POWER ISOLATION TRANSFORMER T1 IS NOT RE TAPPABLE AND IS ONLY RATED FOR LISTED AC INPUT VOLTAGE OPTIONAL 480VAC INPUT TRANSFORMER TI DOES NOT FEATURE TAPS H2 H3 8 H4 S AC INPUT PROTECTION CONSISTS OF TWO 2 FUSES F1 F2 IN SERIES WITH ONE 1 2 PDLE CIRCUIT BREAKER CB1 DC OUTPUT PROTECTION CONSISTS OF TWO 2 FUSES F3 F4 IN SERIES WITH DNE 1 2 PDLE CIRCUIT BREAKER CB2 BALLAST RESISTORS R3A R3B ARE FEATURED EXTERNALLY AS SHOWN FOR FEATURED INTERNALLY ON GATE DRIVE PC BOARD A112 AND J18 19 CONNECTION IS NOT USED 220 380 OR 416 VAC 50 60 Hz FEATURED OPTIONS 130VDC UNITS 48VDC UNITS FEATURE DNE 1 EXTERNAL BALLAST RESISTOR R3 FOR 12 8 24VDC UNITS BALLAST RESISTOR R3 IS 8 SPECIAL AC INPUT VOLTAGE OPTIONS ALSO AVAILABLE on TRANSFORMER gi i LU CO A FIA A PRI SEC 58 200 kAIC BI A zu TN 3 TB1 L1 ice I HS t
55. ING High voltages appear at several points inside the AT10 1 Use extreme caution when working inside the unit Do not attempt to work inside the AT10 1 unless you are a qualified technician or electrician Disconnect and lock out all power from the AT10 1 before starting to remove or replace any components Turn the ac power off at the distribution panel upstream from the charger Disconnect the battery from the AT10 1 output terminals TB1 NOTE Refer to the drawings in Appendix C while performing the following procedures Removing the safety shield Some of the repair procedures described below requires removal of the clear plastic safety shield that covers the internal components mounted inside the enclosure Remove the plexiglas shield by removing the fasteners from the front lip of the enclosure Do not lay the shield on top of the AT10 1 The top vents are required for cooling CAUTION Hazardous ac and dc voltages are present on the O panel terminals and several internal components 58 SERVICING THE AT10 1 Replacing the Main Control A1 and or Gate Driver A11 pc boards For details of this procedure refer to service instruction JD5012 00 CAUTION Printed circuit boards A1 and A11 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 ba
56. LESHOOTING PROCEDURE The AT10 1 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 AT10 1 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 disconnect 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 doesn t appear on the troubleshooting chart or if the recommended repair doesn t work consult your sales or service representative to arrange for on site or factory se
57. MATIC BREAKER REMOTE SENSE AT10 1 LEADS 1 RECTIFIER MEER T DC BUS BATTERY PROCEDURE 1 De energize and lock out all ac and dc voltages within the AT10 1 enclosure Check with a voltmeter Remove safety shield Remove the two 2 dc output CU AL compression lugs Move wire 36 from TB1 to REM SENSE Move wire 38 from TB1 to REM SENSE x E O tO INSTALLING THE AT10 1 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 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 before reeneregizing the charger 9 Restart the AT10 1 according to the instructions in Section 2 1 NOTES 1 Use 16 AWG twisted pair 2 Maximum current is 150 mA 3 Run leads in their own conduit 4 Fuse the wiring at the battery or dc bus DISABLING REMOTE SENSE If you ever need to disable remote sense follow the steps below De energize and lock out all ac and dc voltages to the AT10 1 Check with a voltmeter Disconnect the remote sense wires from the battery or dc bus terminals first CAUTION You must do the steps above first
58. N INSTRUCTIONS COMMON ERROR CODES MAIN CONTROL CARD PC BOARD ASSY Al TB8 TB3 o o o J CHASSIS GROUND STUD TBI 8 E o SEE DETAIL TO RIGHT FOR DETAIL VIEWS DF ALL PC BOARDS Al SEE DRAWING JE5030 24 AS All etc CIRCUIT BREAKER A CUT OUT WIND CCUATOR DW INPUT OUTPUT TERMINAL BOARD MANUAL POCKET MER AC FUSES FIA FIB ACED NEAR BATTERY CELL ic LENGTH TBD Qc DRAWN BY MCR TB1 DETAIL REMOTE SENSE f COPPER GROUND le crue g NEG DC OUTPUT POS STANDARD COMPONENT DESCRIPTION Al MAIN CONTROL PC BOARD All HIGH DUT GATE DRIVER PC BOARD C4 EMI OUTPUT FILTER CAP NEG C5 EMI DUTPUT FILTER CAP POS CB1 AC INPUT CIRCUIT BREAKER CB2 DC OUTPUT CIRCUIT BREAKER CR4 FREE WHEELING DIODE LI MAIN INDUCTOR Ql SILICON CONTROLLED RECTIFIER D2 SILICON CONTROLLED RECTIFIER R1 MAIN DC SHUNT R2 RATING RESISTOR R3x EXT BALLAST RESISTOR C130VDC Td POWER TRANSFORMER TB1 1 0 TERMINAL BOARD TB3 SUMMARY ALARM CONTACTS TBB TEMPCO PROBE TERMINAL BLOCK VRI OUTPUT SURGE SUPPRESSOR VR2 INPUT SURGE SUPPRESSOR VR4 INPUT SURGE SUPPRESSOR VRS INPUT SURGE SUPPRESSOR VR6 OUTPUT SURGE SUPPRESSOR VR7 OUTPUT SURGE SUPPRESS
59. OR vi COPPER BUS BAR POS LEG w2 COPPER BUS BAR NEG LEG SYM OPTIONAL COMPONENT DESCRIPTION AS AUXILIARY ALARM RELAY PC BOARD A10 TEMPERATURE COMPENSATION PROBE Ci FILTER CAPACITOR C2 BATTERY ELIMINATOR FILTER CAP CRI POLARITY DIODE E13 INDUCTOR INTER CUNNECT POINT FIA AC INPUT FUSE FiB AC INPUT FUSE F3 DC OUTPUT FUSE F4 DC OUTPUT FUSE L2 FILTER INDUCTOR R9 FILTER CAP BLEED RESISTOR TB4 AUXILIARY ALARM RELAY CONTACTS VR3 INPLIT LIGHTNING ARRESUR O RE EMOTE SENSE Zl TB1 GND AC INPLIT THIRD ANGLE PROJECTION 022703 1 E2140 091205 O E1154 022703 APPROVED Qu UNLESS OTHERWISE NOTED DIMENSIONS ARE IN INCHES TOLERANCES ARE 022803 TITE ATIO 1 SERIES BATTERY CHARGER OPTIONAL INTERNAL COMPONENT LAYOUT STYLE 5018 DRAWING No JES028 89 1 REV B SCALE h NTS PART No JE5029 99 1 ttp www ATSeries net PDFs JE5029 99 pdf 79 APPENDIX C Standard Drawings Instrument Panel PC Board Detail AT10 1 Group II Battery Charger w Optional Auxiliary Alarm Relay Board JE5030 29 INDICATOR LIGHTS LEDs DSO1 GREEN AC UN DS10 RED LOW LEVEL DETECT DS02 RED DC VOLTS DS11 RED METER DISPLAY DS03 RED DC AMPS DS12 RED METER DISPLAY DSO4 RED EQUALIZE HRS REMAINING DS13 RED HIGH DC VOLTAGE HIGH OUTPUT GATE DRIVER DSOS GREEN FLOAT DS14
60. OUTPUT CONNECTIONS GRAPHICS NEGATIVE POSITIVE LINE LINE CUSTOMER DC OUTPUT WIRING 50in 12 7mm COMPRESSION TYPE LUG NOTES 1 The drawing above does not show other components mounted to the I O panel Be careful not to disconect any other component leads 2 Always use a proper ground 3 Use copper or aluminum conductors only INSTALLING THE AT10 1 1 9 WIRING THE AT10 1 FOR REMOTE SENSING You can wire the AT10 1 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 AT10 1 and the battery 2 Directly monitors the battery or dc bus voltage The front panel meter displays the actual voltage on the dc bus You wire the AT10 1 for remote sensing by installing twisted pair cabling from the AT10 1 remote sense terminals to the battery terminals The AT10 1 control circuitry then measures the dc voltage at the battery terminals and controls the output of the charger to maintain the battery voltage at the desired float or equalize voltage NOTE If the remote sense wiring fails the AT10 1 detects the fault and displays E 06 on the front panel meter See Section 3 2 for details CAUTION The AT10 1 cannot protect against short circuits in the remote sense wiring You should install a 1 0A fuse at the battery or dc bus end of the remote sense cable SCHE
61. PUT FUSE LEG FA DC ouTPUT FUSE LEG L2 FILTER INDUCTOR R9 FILTER CAP BLEED RESISTOR TB4 AUXILIARY ALARM RELAY CONTACTS VR3 INPUT LIGHTNING ARRESOR CIRCUIT BREAKER ACCUATOR INPUT OUTPUT CUT OUT WINDOW TERMINAL BOARD f LITPLIT TB1 DETAIL C LENGTH TBD TO BE PLACED NEAR BATTERY CELL REMOTE SENSE A10 COPPER GROUND BUS BAR TBI GND AC INPLIT SINGLE PHASE THIRD Qc PREJECT ION DRAWN BY MCR 022703 THE ATIO 1 SERIES BATTERY CHARGER OPTIONAL APPROVED Qu 022803 DRAWING No E2140 081205 E1154 022703 me oe e REV JE5028 99 1 PART No INTERNAL COMPONENT LAYOUT STYLE 5017 UNLESS OTHERWISE NOTED DIMENSIONS ARE IN INCHES TOLERANCES ARE SCALE NTS JE5028 99 1 http www ATSeries net PDFs JE5028 99 pdf 77 APPENDIX C Standard Drawings Internal Component Layout AT10 1 Group II Battery Charger Style 5018 Enclosure w Common Options JE5029 99 PLEXIGLAS SAFETY CDVER r x g xi VR3 d CIRCUIT E an Ez BEHIND BREAKER B E a CAPACITORS n a EH IN xto dI Ten c PLEXIGLAS SAFETY COVER COMPO CONNEC GUICK COMMDY
62. R AC INPUT CIRCUIT BREAKER 130VDC UNITS 48VDC UNITS FEATURE DNE 1 EXTERNAL BALLAST DC OUTPUT CIRCUIT BREAKER RESISTOR R3 FOR 12 amp 24VDC UNITS BALLAST RESISTOR R3 IS FEATURED INTERNALLY ON GATE DRIVE PC BOARD A112 AND J18 19 CONNECTION IS NOT USED SPECIAL AC INPUT VOLTAGE OPTIONS ALSO AVAILABLE 220 380 OR 416 VAC 50 60 Hz 82 APPENDIX C Standard Drawings Schematic AT10 1 Group Battery Charger Standard w o Options JE5032 00 CB2 A TN TB1L 1 O 1 I REMOTE I SENSE NOTE 35 l l l 14 au 1 m i Hz I TE DU 1 a i HK 1 1 LJ NOTE 7 I a R3A R3 I REMOTE SENSE NOTE 3 ZAK NITE 6 TB1 LOGSTCINANAN 88285358122 JIB HIGH OUTPUT GATE DRIVE PC BOARD A11 MAIN CUNTRUL PC BOARD Al SUMMARY ALARM THIRD cl ANGLE PROJECTION ER AKER 091305 DRAW BY MCR 022003 TITLE AT10 1 SERIES BATTERY CHARGER SCHEMATIC A GROUP II 30 100ADC STANDARD W O OPTIONS 040703 A nes g 022003 DRAWING No REV 022003 KTS TAS JE 5082 99 2 B REV APP SCALE NTS PART JESO32 00 1 http www ATSeries net PDFs JE5032 00 pdf 83 APPENDIX C Standard Drawings Schematic AT10 1 Group Il Battery Charger w Common Options JE5032 99 TI CONNECTION TABLE INPUT JUMPER STANDARD H1 H3 H2
63. RE0015 04 RE0015 04 RE0015 07 50 Adc RE0015 03 RE0015 04 RE0015 05 RE0015 09 75 Adc RE0015 04 RE0015 04 RE0015 06 RE0015 12 100 Adc RE0015 04 RE0015 05 RE0015 07 n a Table 3 7 MEDIUM AMPERE INTERRUPTING CAPACITY AC CIRCUIT BREAKERS CB1 120 Vac Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 30 Adc RE0171 00 RE0171 01 RE0171 04 RE0171 09 40 Adc RE0171 00 RE0171 02 RE0171 05 RE0171 12 50 Adc RE0171 00 RE0171 04 RE0171 07 RE0217 02 75 Adc RE0171 02 RE0171 05 RE0171 09 RE0217 04 100 Adc RE0171 04 RE0171 09 RE0171 12 n a Table 3 8 MEDIUM AMPERE INTERRUPTING CAPACITY AC BREAKERS CB1 208 240 Vac Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 30 Adc RE0171 00 RE0171 00 RE0171 01 RE0171 05 40 Adc RE0171 00 RE0171 00 RE0171 02 RE0171 09 50 Adc RE0171 00 RE0171 01 RE0171 04 RE0171 09 75 Adc RE0171 00 RE0171 02 RE0171 07 RE0171 12 100 Adc RE0171 01 RE0171 04 RE0171 09 n a Table 3 9 MEDIUM AMPERE INTERRUPTING CAPACITY AC CIRCUIT BREAKERS CB1 480 Vac Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 30 Adc RE0043 00 RE0043 00 RE0043 00 RE0043 01 40 Adc RE0043 00 RE0043 00 RE0043 00 RE0043 02 50 Adc RE0043 00 RE0043 00 RE0043 00 RE0043 04 75 Adc RE0043 00 RE0043 00 RE0043 01 RE0043 07 100 Adc RE0043 00 RE0043 00 RE0043 02 n a 65 SERVICING THE AT10 1 Table 3 10 HIGH AMPERE INTERRUPTING CAPACITY AC CIRCUIT
64. S 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 AT10 1 also features a summary alarm relay with one form C contacts TB3 rated 0 5A 125 Vac Vdc If an alarm condition lasts for 30 seconds or longer the summary alarm relay transfers Under standard settings when the alarm condition is corrected the corresponding relay and indicator resets automatically Latching alarm capability for the AT10 1 battery charger is available featured in a supplemental document JA5098 00 29 OPERATING THE AT10 1 2 3 2 3 1 SETTING PARAMETERS IN THE AT10 1 Understanding Parameter Settings You can change the settings of the AT10 1 while 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 ho
65. SER ENCLOSURE SHOULD BE ALLER NG WEIGHT RANGE lbs 59 113 kg DUAL DIMENSIONS nn THIRD 6 ANGLE PROJECTION DRAW BY MCR 022603 ATIO 1 SERIES BATTERY CHARGER OUTLINE ma G NEMA 1 STYLE 5017 ENCLOSURE UNLESS OTHERWISE NOTED DIMENSIONS JE5025 DO 1 B ARE IN INCHES TOLERANCES ARE SCALE NTS PAN JES025 00 1 1 mm m O o N oO N O Oo Oo Wa http www ATSeries net PDFs JE5025 00 pdf 73 APPENDIX C Standard Drawings Outline AT10 1 Group II Battery Charger NEMA 1 Style 5018 Enclosure JE5026 00 SIDE VIEW FRONT VIEW SIDE VIEW CONTROL PANEL SEE DETAIL DRAWING JESO30 2 CBI AC CB2 DC CIRCUIT CIRCUIT BREAKER BREAKER AA 0 000 KN I TTT NS KSS KSS KIS KSS KL LLS LLS KI o 15 50 394 L 20 90 16 77 531 426 BOTTOM VIEW 1 3 53 89 7 i 9 00 MIG 229 MIG 18 54 MTG gt 471 MTG 74 APPENDIX C Standard Drawings Outline AT10 1 Group Il Battery Charger NEMA 1 Style 5018 Enclosure JE5026 00 IDE VIEW cd SSS XX 2 2 KO KS IS SIY SS aces 225 S X eed 5 UN 5 e SxS SxS SxS IG KX
66. 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 4 SCR not 4 Disconnect wires 51 52 and 53 54 from the SCR gate controllable lead terminals these are the small gauge twisted pairs Be sure to note the original polarity so that they can be replaced with the same polarity Restart the charger If You are able to measure output current one of the SCRs is defective Replace the rectifier modules 49 SERVICING THE AT10 1 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 immediately 2 Defective 2 Test by disconnecting wire 6 from the rectifier module on the rectifier bridge if right heat sink or if possible at the other end from T1 X1 unfiltered Measure resistance between the ac terminals bottom terminals charger on the rectifier modules It should be at least 100 000 Ohms check both polarities Replace rectifier modules if resistance is low in either direction 3 Defective 3 Disconnect wire 15 from the lower bus bar W1 on the heat diode CR4 sink assembly Measure the resistance through the diode it s mounted on the other bus bar 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 the free
67. UCTOR SNIIE BD O v2 almo 03 O vi amp H5 O o all H2 H o O x5 z H3 O 04 O xi ud HI O NOTES HEATSINK HEATSINK SEC PRI 1 CHARGER COMPONENTS ARE CONNECTED WITH FLAME RETARDANT SWITCHBOARD INSULATION TYPE WIRING IDENTIFIED ON EACH END WITH NUMBER CODED MARKERS GROLIND WIRE 56 IS NITE 4 GREEN WITH YELLOW STRIPE DIODES CRI amp CR4 ARE ANODE MOLINTED TYPE WIRE TO CATHODE FEATURED OPTIONS 2 CUSTOMER ALARM CONTACTS TB3 TB4 etc ARE SOLDERLESS PLUG IN TERMINALS AND WILL ACCEPT 22 14 ANG WIRE AC INPUT CKT BKR amp FUSES DC OUTPUT CKT BKR amp FUSES 3 WHEN REMOTE SENSE IS USED WIRE 36 CONNECTS A11 J18 06 TO REMOTE SENSE AND WIRE 38 CONNECTS Al1 J18 0B TU REMOTE SENSE AUXILIARY RELAY PC BUARD DC OUTPUT FILTERING 4 SEE SCHEMATIC FOR TRANSFORMER T1 PRIMARY CONNECTION TABLE BATT ELIMINATOR FILTER 5 IN 130 VOC UNITS TWO 2 BALLAST RESISTORS R3A B ARE SUPPLIED EXTERNALLY AS SHOWN EXTERNAL TEMPCU PROBE AC IN LIGHTNING ARRESTOR FILTER CAPACITOR C1 CONSIST OF TWO 2 CAPS CONNECTED IN PARALLEL FOR CERTAIN UNITS 88 APPENDIX C Standard Drawings Connection Diagram AT10 1 Group Il Battery Charger w Common Options JE5034 99 LENGTH TBD gt TEMPERATURE NOTE 2 PE COMPENSATION SLIMMARY SHIELDED PROBE A10 ALARM GROLIND HIGH OUTPUT GAT
68. Unplug board A11 the A11 from the Main Control board A1 If the output current does not go to zero replace A11 5 Defective 5 If the front panel meter shows more than 11096 of rated dc Main Control current the control board may be defective Unplug the system board A1 harness connector J18 from the Gate Driver pc board A11 If the output current goes to zero replace the Main Control board A1 50 SERVICING THE AT10 1 PROBABLE SYMPTOM CAUSE RECOMMENDED ACTION No output 1 AC supply 1 If AC ON indicator is out the check feeder circuit breaker or current but ac and dc breakers are failure 2 Input fuse F1 or F2 is blown fuse 2 Remove the ac fuses F1 F2 from the fuse holder and check with an Ohmmeter or fuse tester Replace ac fuses F1 F2 if on AC ON required lamp is out NOTE If the new fuse blows see the Sections titled AC breaker trips immediately and AC breaker trips after a few minutes for further troubleshooting hints 3 Defective 3 Check terminals and wiring between the transformer T1 and wiring the rectifier bridge assembly main inductor L1 dc filter assembly if present the dc breaker and or fuses and the output terminals Check wire 44 from T1 Y1 and wire 45 from T1 Y2 to the Gate Driver pc board connector J18 Repair as necessary 4 Defective 4 Use an ac voltmeter to measure the ac voltage from T1 X1 to transformer T1 X5 It is normally 50
69. V 3 1V not recommended not recommended 6 1 2V 1 6V 2 0V 3 0V not recommended 4 0 7V 1 0V 1 2V 1 9V 2 5V 2 0 5V 0 5V 0 8V 1 2V 1 6V 0 0 3V 0 4V 0 5V 0 7V 1 0V EXAMPLE 100ft 30 5m of 8 AWG wire at 50A has a 3 1 Volt drop 2 The AT10 1 is factory wired to regulate the output voltage at the output terminals If the total voltage drop is greater than 1 e g 1 3V for a 130 Vdc system remote sense wiring is recommended see Section 1 9 Do not run external ac and dc power wiring feeding the battery charger through the same conduit 4 Allspecific requirements of your facility take precedence over these instructions PROCEDURE 1 Use a dc disconnect switch or circuit breaker between the AT10 1 and dc bus This device should have lockout capability to allow the AT10 1 to be disconnected from the dc bus for maintenance 2 Remove the safety cover 3 Run the dc wiring to terminals TB1 and TB1 on the I O panel in the enclosure Compression lugs accepting wire sizes 14 1 0 AWG are supplied for your convenience To make these connections strip the insulation 0 5in 12 7mm on the incoming wires 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 Ib 4 0 5 7 Nm 5 Reinstall the safety cover after you have made and checked all connections INSTALLING THE AT10 1 MAKING THE DC
70. VOLTAGES This table contains suggested values for commonly used batteries Consult your battery manufacturer s documentation for specific values and settings for your battery type Recommended Recommended Float Voltage cell Equalize Voltage cell 2 33 Antimony 1 250 Sp Gr 2 33 Selenium 1 240 Sp Gr 2 33 2 40 Battery Cell Type Antimony 1 215 Sp Gr Calcium 1 215 Sp Gr 2 33 Calcium 1 250 Sp Gr 2 33 Absorbed Gelled Electrolyte sealed lead acid type Nickel Cadmium 1 42 1 47 Lead Acid Types 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 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 AT10 1 Microprocessor controlled Battery Charger has provisions for an optional Communications Module that allows the user to remotely monitor and control the unit over a seri
71. a 66 SERVICING THE AT10 1 Table 3 14 AC INPUT FUSES F1 F2 208 240 Vac Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 30 Adc RE0061 08 RE0061 09 RE0061 12 RE0061 16 40 Adc RE0061 08 RE0061 11 RE0061 13 RE0061 21 50 Adc RE0061 09 RE0061 12 RE0061 14 RE0061 21 75 Adc RE0061 11 RE0061 13 RE0061 18 RE0061 23 100 Adc RE0061 12 RE0061 15 RE0061 21 n a Table 3 15 AC INPUT FUSES F1 F2 480 Vac Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 30 Adc RE0008 06 RE0008 06 RE0008 08 RE0008 12 40 Adc RE0008 06 RE0008 08 RE0008 09 RE0008 13 50 Adc RE0008 06 RE0008 08 RE0008 11 RE0008 14 75 Adc RE0008 08 RE0008 09 RE0008 12 RE0008 18 100 Adc RE0008 08 RE0008 11 RE0008 13 n a Table 3 16 STANDARD DC CIRCUIT BREAKERS CB2 Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 30 Adc RE0015 30 RE0015 30 RE0015 30 RE0015 30 40 Adc RE0015 31 RE0015 31 RE0015 31 RE0015 31 50 Adc RE0015 34 RE0015 34 RE0015 34 RE0015 34 75 Adc RE0015 36 RE0015 36 RE0015 36 RE0015 36 100 Adc RE0217 03 RE0217 03 RE0217 03 n a Table 3 17 MEDIUM AMPERE INTERRUPTING CAPACITY DC CIRCUIT BREAKERS CB2 Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 30 Adc RE0170 07 RE0170 07 RE0170 07 RE0170 07 40 Adc RE0170 08 RE0170 08 RE0170 08 RE0170 08 50 Adc RE0170 10 RE0170 10 RE0170 10 RE0170 10 75 Adc RE0170 12 RE0170 12 RE0170 12 RE0170 1
72. ack 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 AT10 1 remembers the remaining equalize time When ac power is restored it resumes the equalize charge where it left off 27 OPERATING THE AT10 1 Manual Equalize Method Choose the manual equalize method when you want to equalize charge the battery but only when you are able to monitor the battery voltage and gassing rate After you select the manual equalize method press the CHRG MODE key to put the charger into the equalize mode The EQLZ indicator will light Press the cHRG MODE key again to return the charger to the float mode The FLOAT indicator will light NOTE Never leave the AT10 1 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 discharges or when the battery will be discharged by at least half of its rated capacity during an ac power failure When ac power is restored to the 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 lig
73. al connection This option supports DNP3 Level 2 and Modbus protocols over RS 232 or RS 485 half duplex Industry standard 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 ATIO 1 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 Awww 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 Communications Module for 12 Vdc AT10 1 EJ5037 01 Communications Module for 24 Vdc AT10 1 EJ5037 02 Communications Module for 48 Vdc AT10 1 EJ5037 03 Communications Module for 130 Vdc AT10 1 EJ5037 04 10ft 3 05m Modem Cable EH5026 00 2bft 7 62m Modem Cable EH5026 01 50ft 15 24m Modem Cable EH5026 02 91 APPENDIX F FORCED LOAD SHARING ONLINE SUPPLEMENT http www
74. ar Resistor RJ0063 76 RJ0064 11 RJ0064 41 RJ0064 80 R9 Filter Capacitor C1 Bleed Resistor RJ0028 25 RJ0028 25 RJ0028 27 RJ0036 40 RJ0074 48 RJ0074 81 RJ0075 14 RJ0075 56 31600 69802 14 0KQ 38 3K0 R3 Power Supply Ballast Resistor R4 Positive External Scaling Resistor R14 Negative External Scaling Resistor TI Main Transformer 120 208 240 Vac See Table 3 23 T1 Main Transformer 480 Vac See Table 3 24 TB GUAL compression lug for 14 1 0 AWG RC0056 18 VR1 Output Surge Suppressor EJ1132 10 Y VR2 Input Surge Suppressor 120 208 240 Vac EJ1132 11 Y VR2 Input Surge Suppressor 480 Vac EJ1132 12 Y VR3 AC Input Lightning Arrestor EJ1074 01 VR4 5 Input Surge Suppressor 120 Vac EJ1132 10 Y VR4 5 Input Surge Suppressor 208 240 Vac EJ1132 11 Y VR4 5 Input Surge Suppressor 480 Vac EJ1132 12 Y VR6 C4 EMI Filter Network EJ5021 03 Y VR7 C5 EMI Filter Network EJ5021 03 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 SERVICING THE AT10 1 Table 3 2 DC FILTER ASSEMBLIES STANDARD L2 C1 R9 CR1 Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 30 Adc EJ5031 00 EJ5031 05 EJ5031 10 EJ5031 15 40 Adc EJ5031 01 EJ5031 06 EJ5031 11 EJ5031 16 50 Adc EJ5031 02 EJ5031 07 EJ5031 12 EJ5031 17
75. arger 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 Is there any sign or smell of smoking or burning Refer to the wiring diagrams and parts layout drawings in Appendix C while using the chart For instructions on replacing components see Section 3 5 48 SERVICING THE AT10 1 3 4 TROUBLESHOOTING CHART SYMPTOM PROBABLE RECOMMENDED ACTION CAUSE Front panel 1 An external 1A Soft Reset of control board by pressing S7 reset switch meter surge has S7 is located inside the 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 segments 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
76. arger controls all voltage settings for both AT10 1s You may adjust any voltage float equalize alarm settings etc at the front panel of the Primary charger The front panel of the Secondary charger will not allow any settings to be changed e If 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 AT10 1s 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 AT10 1s 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
77. ase the UP or DOWN key If you go past the voltage you want press the UP or DOWN key again to reach the voltage you want to set e Press the EDIT ENTER key The new low dc voltage alarm setting is entered into permanent memory If you want to adjust the current limit setting skip to Section 2 3 5 OR If you want to exit the Edit mode now press the EDIT ENTER key again to return the charger to normal operation 33 OPERATING THE AT10 1 Adjusting Ground Detection Sensitivity You can adjust the sensitivity of MON ije the ground detection alarm circuit JUYPER 1 2 Pins You must have a test resistor IN whose value is the sensitivity you 7 want You can adjust the an 3 sensitivity from 5 to 50 KQ FAULT ENABLE MAIN NES JUMPER 2 3 PINS 477 RAZ CONTRI The potentiometer for adjusting 2 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 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 a
78. back loop E 14 forced load sharing not working properly A 01 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 2 Displaying output voltage only The DC Volts indicator lights 3 Displaying output current only The DC Amps indicator lights 4 Displaying equalize hours remaining only The EQLZ HRS REMAINING indicator lights If the AT10 1 is not in a timed equalize mode the meter displays the full programmed equalize time e When the 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 AT10 1 2 2 3 2 2 4 Selecting the Float or Equalize mode The AT10 1 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
79. ble or explosive materials Maintain at least 6in 152mm of free air on top bottom and both sides for cooling air Allow 36in 914mm front clearance for access to the charger for operation and maintenance INSTALLING THE AT10 1 PROCEDURE To floor mount the AT10 1 install four 4 0 25in 6 4mm bolts into the floor Place the AT10 1 on the bolts add appropriate mounting hardware and tighten securely See the diagram below for the Style 5018 enclosure footprint and floor mounting pattern Dimensions are in mm Style 5018 Enclosure 20 90 ENCLOSURE 531 FOOTPRINT 81 18 54 MTG 20 471 MTG BACK OF CHARGER 3 36 besg AA Yr 8542 m I ENS nn il 16 77 9 00 MTG 311 1 LT 426 229 CMIG ENCLOSURE EN 1 FOOTPRINT BR ak 3 53 B9 7 EE FRONT OF CHARGER INSTALLING THE AT10 1 1 5 3 Rack Mounting the AT10 1 All ratings of the AT10 1 can be installed in most relay racks with standard EIA hole spacing A relay rack mounting kit is required For kit availability see ordering information in Appendix B on page 71 Order the appropriate rack mounting kit for your charger as shown in the following table CHARGER RATING RACK WIDTH Voltage Current 19in 23 24in 483mm 584 610mm 12 Vdc 30 50 Adc El0193 01 El0193 02 12 Vdc 75 100 Adc N A El0193 03 24 Vdc 30 50 Adc El0193 01 El0193 02 24 Vdc 75 100 Adc N A El0193 03 48 Vdc 30 40 Adc El
80. c and dc voltage sources to the AT10 1 Check with a voltmeter before proceeding Restart the AT10 1 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 chassis ground as shown to the right Adjust RA3 counterclockwise until the front panel indicator goes out then adjust slowly clockwise until the POS GND indicator just lights Make this adjustment slowly the indicator is updated once in every four seconds De energize and lock out power to the AT10 1 then 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 TEST RESISTOR 34 OPERATING THE AT10 1 2 3 5 Using Ground Detection in Charger Standby Mode If you put the AT10 1 into standby mode by opening the dc circuit breaker CB2 the ground detection circuit will send an erroneous 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 c
81. ck of the door Handle these boards only by their edges Turn off and remove all power to the AT10 1 Disconnect the battery from the output terminals Note that Al and A11 are mounted together as a pair Remove the signal wire harness plug from J18 at the upper left edge of A11 If present remove the summary alarm contact wires from TB3 at the bottom of A1 If present remove the serial cable connecting J3 on the main control board to the Auxiliary Alarm Relay pc board A5 If the optional temperature compensation probe is installed remove the main wires from TB8 on the bottom of Al and remove the shield 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 If you are replacing only one board carefully separate the existing boards and reconnect the replacement board Put the replacement board s 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 Re connect the signal wire harness plug to the boards matching the orientation when removed If earlier removed reconnect any wires to on Al See Section 2 1 for the steps to restart the AT10 1 If your charger parameters float voltage etc are different from the factory preset values you should pro
82. detects certain secondary errors indicated by codes E 03 E 04 E 06 E 07 E 08 E 09 and E 10 on the 4 digit meter display rather than a red alarm light See Section 3 2 on Page 45 for all error codes 32 OPERATING THE AT10 1 Setting the High DC Voltage Alarm Press the EDIT ENTER key until the HIGH DC VOLTAGE indicator flashes and the display flashes the present value of the high dc voltage alarm Press and release the uP or 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 ENTER key until the LOW DC VOLTAGE indicator flashes and the display flashes the present value of the low dc voltage alarm Press and release the UP or Down key to increase or decrease the value in the display by one count or press and hold the 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 rele
83. e back of the panel Front secured to front panel keys must operate freely panel 3 Defective 3 Turn off both front panel circuit breakers or turn off ac and dc Main Control power externally if the charger doesn t have breakers Then turn board A1 on the dc breaker followed by the ac breaker If some of the front panel keys still do not work replace the Main Control board A1 Two AT10 1s 1 Ifthe forced 1 Multiple AT10 1s are not designed to share load current connected in load sharing without the optional forced load sharing cable installed When parallel but option is not two or more AT10 1s are connected in parallel without this option only one has supplied check it is normal for one of the units to have no output current You can output current for normal check the operation of the off charger by increasing its Float operation of both chargers voltage until it starts to deliver output current When you have finished the test be sure both AT10 1s are set to the same Float and Equalize voltages 2 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 wires 51 52 a
84. e 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 AT10 1 to activate the probe as described in Section 2 1 Using temperature compensation When an electric storage battery is being charged the terminal voltage of the battery changes a small amount whenever the battery temperature changes As the battery temperature increases its terminal voltage decreases When a 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 AT10 1 is equipped with a temperature compensation probe it is able to adjust the output voltage applied to the battery to keep the float current constant thereby avoiding overcharging The probe senses the ambient temperature at the battery and adjusts the output float equalize voltages to compensate for variations in temperature If the ambient temperature increases the AT10 1 output voltage decreases If you are experiencing any inconsistencies in the AT10 1 when the temperature compensation probe is utilized temporarily disconnect the probe and refer to the Application Note JD5003 00 for further details 22 100 Percent Output Voltage INSTALLING THE AT10 1 Note
85. e your remote annunciator wiring into the enclosure through one of the Deenergize and lock out all ac and dc voltages to the AT10 1 Allow internal voltages to dissipate then check with a voltmeter Remove the plexiglas safety shield unused conduit knockouts on the side of the enclosure 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 Replace the safety shield and restart the AT 10 1 NOTES Na 19 Alarm contacts are rated at 0 5A 125 Vac or Vdc Terminal block TB4 is compression type accepting 422 14 AWG wire Terminals are labeled in non alarm condition For a detailed view of the optional Auxiliary Alarm Relay PC Board A5 refer to drawing JE5030 29 listed in Appenix C on Page 80 19 INSTALLING THE AT10 1 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 your battery There are three steps in installing the assembly 1 Mounting the probe assembly near the battery 2 Installing an interconnection cable from the probe assembly to the AT10 1 3 Wiring the charger end of the cable to a terminal block on the main control circuit board The actual tempco probe is the same for all battery types and all output voltages of
86. econds indicator lights to the AT10 1 nameplate Verify that the jumpers on of the display dadicale the main transformer Tl are correct for your whether the meter is ac supply voltage Open the front panel and displaying voltage or current check the battery polarity at the TB1 and If you want to freeze the terminals meter to display only voltage press the METER MODE Starting the AT10 1 key on the front panel To freeze the meter to displa When you are sure that all connections to the paka only current press the key AT10 1 are properly made follow these steps again Press the key twice to start up the AT10 1 more to revert to the alternating display e Turn on the front panel dc circuit breaker The digital meter indicates the battery voltage only If the meter display doesn t 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 5096 of nominal voltage to turn on the display If you can t 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 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
87. ed 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 AT10 1 main transformer T1 is properly connected for your ac input voltage See Section 1 6 for details 4 Do not run external ac and dc power wiring feeding the battery charger through the same conduit 5 All specific requirements of your facility take precedence over these instructions PROCEDURE 1 Remove the safety cover 2 Run the ac wiring to terminals TB1 L1 TB1 L2 and TB1 GND on the I O panel in the enclosure Compression lugs accepting wire sizes 14 1 0 AWG are supplied for your convenience To make these connections strip the insulation 0 5in 12 7mm on the incoming wires and connect the wires to the appropriate lugs as shown on the next page Using a flat head screwdriver securely tighten the compression screws on the lugs to 35 50 in Ib 4 0 5 7 Nm 4 Reinstall the safety cover after you have made and checked all connections MAXIMUM INPUT CURRENT AT 120 Vac Example shaded OUTPUT OUTPUT VOLTAGE A 130 Vdc 40 Adc ios ESI AE Ala 71 Aas at 120 Vae 30 7 2 13 23 54 40 9 6 17 30 71 All currents shown 50 12 21 38 89 are 10 75 18 32 57 Note1 100 24 42 75
88. ee BT O ma LANE pa O ATsERIES J13 HindlePower Inc ROL PC BOARD A1 MAIN CONTROL PC BOARD AL G CHARGER DOOR WHEN INSTALLED HI BACK VIEW FACING CHARGER COMPONENTS WHEN INSTALLED USER JUMPERS SWITCHES Jl MAINFRAME SIGNAL HARNESS NOT USED IN 30 100A S1 METER MODE J2 AUX ALARM RELAY BOARD AS SERIAL CONNECTOR S2 CHARGER MODE J3 AUX ALARM RELAY BOARD AS RIBBON CONNECTOR S3 EQUALIZE METHOD J4 FORCED LOAD SHARING CABLE INTERCONNECTOR S4 AADJUST J5 GROUND FAULT ENABLE DISABLE S5 VADJUST J6 EARTH GROUND CONNECTOR S6 EDIT ENTER J8 FRONT PANEL ENABLE DISABLE LOCKOUT S7 PROCESSOR MANUAL RESET J13 COMMUNICATIONS PC BOARD A12 INTERCONNECTOR J17 HO GATE DRIVER PC BOARD A11 INTERCONNECTOR TERMINAL BLOCKS J18 MAINFRAME SIGNAL HARNESS 30 100A OUTPUT gt TB3 SLIMMARY ALARM RELAY CONTACTS J27 NOT USED 3PH GATE DRIVER PCB INTERCUNNECTOR TB4 AUX ALARM RELAY CONTACTS J29 future TB8 OPTIONAL TEMPCO PROBE A10 INTERCONNECTOR CONTROLS LOW LEVEL DETECT ADJUST THIRD gabo Pl Qc NL GROUND FAULT SENSTINITY 041108 oN BY MCR 022003 J TLE AT10 1 SERIES BATTERY CHARGER GROUP II INSTRUMENT PANEL PC BOARD DETAIL OPTIO DRAWING No REV 022003 UNLESS OTHERWISE NOTED DIMENSTONS JE5030 29 2 ARE IN INCHES TOLERANCES ARE FRAMING 051705 APrrven GY 022003 20 LOAD SHARING JRING TEST
89. emperature measured by the probe to control the output voltage of the AT10 1 To understand temperature compensation see Section 1 11 If the temperature compensation probe or the wiring that connects it to the AT10 1 fails during normal operation the AT10 1 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 If the probe checks good examine the wiring between the probe and the AT10 1 Also check the connection of the cable 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 AT10 1 to activate temperature compensation E 09 misadjusted current limit The output current limit is set at the factory to 11096 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
90. failure You should respond to this problem quickly to be sure that the AT10 1 regulates the output voltage properly Wire an annunciator e g buzzer to the summary alarm relay contact TB3 for remote indication of any charger problem or monitor the AT10 1 operation using the optional DNP 3 MODBUS communications board If you have a failure in remote sense wiring the AT10 1 regulates its output voltage locally until you correct the problem see Sections 1 9 The locally controlled voltage may not reflect the true requirements of the battery When you complete the repair restart the AT10 1 per Section 2 1 E 07 DC breaker open or internal failure If the dc breaker is open open the ac breaker then reclose the dc and ac 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 AT10 1 may display an E 07 code Restart the AT 10 1 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 46 SERVICING THE AT10 1 Error Code Meaning Repair Procedure E 08 defective temperature compensation probe If a temperature compensation probe is connected to the AT10 1 the control circuit detects the probe on startup and uses the t
91. 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 AT10 1 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 AT10 1 using the startup procedure in Section 2 1 During startup the AT10 1 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 AT10 1 the next time it starts 9 Adjust the output float and equalize voltages to the battery manufacturer s recommended values using the AT10 1 front panel meter as described in Section 2 3 2 NOTE If the temperature compensation probe or the wiring from the probe to the AT10 1 is damaged and becomes an open circuit the AT10 1 detects the damage and displays E 08 on th
92. ger NEMA 1 Style 5017 Enclosure 72 Outline AT10 1 Group II Battery Charger NEMA 1 Style 5018 Enclosure 74 Internal Component Layout AT10 1 Style 5017 Enclosure w Common Options 76 Internal Component Layout AT10 1 Style 5018 Enclosure w Common Options 78 Instrument Panel PC Board Detail AT10 1 Group II Battery Charger 80 Schematic AT10 1 Group II Battery Charger Standard w o Options 82 Schematic AT10 1 Group II Battery Charger with Common Options 84 Connection Diagram AT10 1 Group II Battery Charger Standard w o Options 86 Connection Diagram AT10 1 Group II Battery Charger with Common Options 88 APPENDIX D Recommended Float Equalize Voltages Temp Compensation 90 APPENDIX E DNP3 Level 2 Modbus Communications Module 91 APPENDIX F Forced Load Sharing U U nnne nennen nana 92 MANUAL SPECIFICATIONS document control information online availability 94 Note A customized record drawing package is available for your AT10 1 featuring an itemized internal component layout electrical schematic with component ratings and a full connection dia
93. ggested frequency every 6 months Maintenance date Performed by Step Instructions Results standard features Clean battery All vents clean and open OK charger Remove dust and debris from inside of O OK unit Check all TB I connections all tight OK electrical Internal wiring connections tight slip on 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 and TB1 L2 voltage using an ac voltmeter Value must be Input Vac within 1090 12 of nominal voltage Check dc Measure at TB1 and TB1 using a dc output voltage voltmeter Value should agree with front Float Vdc panel voltmeter within 0 25 and must be correct values for your battery If Equalize Vdc the AT10 1 is using a temperature compensation probe see the graph on page 23 to determine correct battery voltage You need to know the battery temperature for this step Check ripple Measure at battery terminals using an ac voltage voltmeter set to the milliVolts scale Check against specification in Appendix Ripple mVac A on page 70 Test font panel Press LAMP TEST key on front panel OK indicators Test common Press LAMP TEST key and hold for 4 OK alarm relay seconds Common alarm relay will transfer 42 OPERATING THE AT10 1
94. global reach operations in more than 80 countries in sales and service GNB Industrial Power is best positioned to satisfy 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 30 2011 11 M Sprin er 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 Na 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
95. gram If the standard drawings and wire list featured in this manual are not sufficient please contact your Sales Representative for drawing availability from the battery charger manufacturer RECEIVING THE AT10 1 1 RECEIVING THE AT10 1 1 1 STORING THE AT10 1 If you store the AT10 1 for more than a few days before installation you should store it in its original shipping container and in a temperature controlled dry climate Ambient temperatures of 32 to 122 F Oto 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 AT10 1 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
96. gram in the new values now See Section 2 3 You should also recalibrate the dc voltmeter according to Section 2 3 7 Replacing the ac input or dc output circuit breaker CB1 CB2 Turn off and remove all power to the AT10 1 Disconnect the battery from the output terminals This includes remote sense wires if they were installed Check with a voltmeter before proceeding Open the front panel and remove the plexiglas safety shield Remove the mounting screws for the circuit breaker on the circuit breaker bracket and carefully remove the circuit breaker from the AT10 1 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 AT10 1 Replacing the ac surge suppressors VR2 VR4 or VR5 Turn off and remove all power to the AT10 1 Open the door and remove the safety shield Disconnect the battery from the output terminals For VR2 remove the hardware from the input terminal L1 and remove the lead of the ac surge suppressor Install one lead of the replacement surge suppressor onto the L1 terminal Replace the other wires and the hardware Repeat procedure for the L2 terminal Tighten all hardware For VR4 remove the hardware from the input terminal L1 and remove the lead of the ac surge suppress
97. hassis The voltage readings should be equal each approximately half of the total output voltage If there is more than a 1096 imbalance turn off the charger and inspect all wiring from TB1 to the dc circuit breaker CB2 the main inductor L1 filter assembly if present and the rectifier bridge Look for evidence of insulation damage insufficient spacing between terminals and chassis or wires run too close to metal edges 5 Turn off both front panel circuit breakers CB1 CB2 If the charger does not have breakers but fuses F1 F2 and F3 F4 turn off ac and dc power externally Start up by turning on the dc breaker followed by the ac breaker 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 If the charger does not have breakers but fuses F1 F2 and F3 F4 turn off ac and dc power externally Start up by turning on the dc breaker followed by the ac breaker If the relay remains in alarm mode check the Low Level Detect indicator on main control board See Section 2 3 8 If no other alarm is on replace the Main Control board A1 57 SERVICING THE AT10 1 3 5 REPLACING DEFECTIVE COMPONENTS WARN
98. he current limit value that you want to set release the UP or DOWN key If you go past the number you want press the UP 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 don t press any front panel key within 25 seconds and any change you made to the last setting is not saved 35 OPERATING THE AT10 1 2 3 6 Enabling the High DC Voltage shutdown feature The AT10 1 has a built in high dc voltage shutdown feature In case of any maladjustment or internal failure that results in a continuous output voltage that is too high the AT10 1 shuts down after 30 seconds to protect the battery The digital display shows E 03 and the summary alarm relay contact transfers The AT10 1 is shipped with the high dc voltage shutdown feature disabled You can adjust the high dc voltage shutdown Parallel Operation the setting is the same as the high dc voltage pa two or more soa alarm setting Refer to Section 2 3 4 Saul v ERN ice uc The charger must be in normal operation not output voltage If one the Edit mode to enable the high dc voltage charger tuns away dt WU supply all the output shutdown current the other has zero To enable the shutdown feature ou pateni n el nu voltage shutdown does not e Press and hold the
99. hts 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 gt 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 Press the CHRG 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 lights 28 OPERATING THE AT10 1 2 2 5 2 2 6 2 2 T 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
100. ication Note JD5008 00 http www ATSeries net PDFs JD5008 00 pdf AT Comm Module Field Installation JD5009 00 http 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 JD0052 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 net PDFs JD501 1 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
101. ltage is less than the Float voltage setting replace the Gate Driver pc board A11 7 Use an ac voltmeter to measure the ac voltage from T1 X1 to X5 It is normally 50 to 80 higher than the rated dc output voltage If it is too low check the wiring of the primary taps See Section 1 6 for details If it is zero replace the transformer T1 8 Disconnect the wiring from the main inductor L1 and measure the resistance between the terminals If it is an open circuit replace L1 Repeat for L2 if the optional dc filter is installed 9 Disconnect the battery and connect a light dc load to the charger Measure the dc voltage across TB1 and TB1 with the breaker on If no voltage is measured replace the breaker 51 SERVICING THE AT10 1 SYMPTOM PROBABLE CAUSE RECOMMENDED ACTION Front panel is dead ac and dc voltages 1 Main Control board A1 is not connected 1 Make sure the connector at the top edge of the Gate Driver pc board A11 is firmly seated dies during ac power failure power resistor R3 are present ai 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 harness wiring to the Gate Driver pc board wiring connector J18 for signs of insulation damage burns etc Be sure all wires are securely crimped in the connector Front panel 1 Defective 1
102. ltage you want to set release the upl 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 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 ENTER key four more times until the charger returns to normal operation Edit mode ends automatically if you don t press any front panel key within 25 seconds and any change you made to the last setting is not saved 31 OPERATING THE AT10 1 2 3 3 2 3 4 Setting the Equalize Timer e Press the EDIT ENTER key until the EQLZ HRS REMAINING MANUAL TIMER and AUTO EQLZ TIMER indicators light and the display flashes the present value of the equalize timer duration in hours Press and release the uP or Down key to increase or decrease the value in the display by one count or press and hold the lUP or DOWN key to scroll the 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 upl or DOWN key again to reach the number you want to set
103. m requirements to restore correct load sharing operation board A1 93 MANUAL SPECIFICATIONS DOCUMENT NUMBER The text and graphics contained within this manual are controlled by the battery charger manufacturer s internal part number JA5018 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 JA5018 00 Revision Level 6 Engineering Change Number 22150 Electronic Filename JA5018 00 Rev6 doc Last Date Saved 5 27 2010 7 15 PM Last Date Printed 5 27 2010 7 30 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 AT10 1 featuring a unit specific drawing list data nameplate detail outline drawing itemized internal component layout electrical schematic wi
104. mer sseesseesneeneeseeesetssnessrtenntsntrrnnrtnnernnernnenn nenn nenn 32 2 3 4 Setting the Alarms 4 32 Setting the high and low dc voltage alarms sse 33 Adjusting ground detection sensitivity nn 34 Disabling the ground detection alarm esse 35 2 3 5 Setting the current limit Value nnn 35 2 3 6 Enabling the high dc voltage shutdown feature 36 2 3 7 Adjusting the Voltmeter accuracy Nt 37 2 3 8 Using the Low Level Detector LLD eeee 38 2 3 9 Using the front panel security feature u uu 39 2 4 Performing routine maintenance U eene nennen 40 Sample preventive maintenance procedure sss 42 3 Servicing the AT10 1 Battery Charger 3 1 A step by step troubleshooting procedure 44 3 2 Interpreting front panel error MessageS kaka aa aa aaa ak aaa aaa aaa 45 3 3 Using the troubleshooting chart sse eene 48 3 4 Troubleshooting chart begins on 49 3 5 Replacing defective components 1 u uu u 58 3 6 Ordering replacement parts pp 62 Replacement parts tables begin oN 62 APPENDIX A AT10 1 Performance SpecificationS nn 70 APPENDIX B Field Installable Accessories U U u u 71 APPENDIX C Standard Drawings Outline AT10 1 Group II Battery Char
105. modules If it less than 50 of the dc output current one of the SCRs or diodes is defective Replace the rectifier module 5 Turn off both front panel circuit breakers or turn off ac and dc power externally if the charger doesn t have breakers Then turn on the dc breaker followed by the ac breaker If the charger output current is below the current limit value but it still has the wrong output voltage replace the control circuit board 53 SERVICING THE AT10 1 rectifier bridge PROBABLE SYMPTOM 2 RECOMMENDED ACTION CAUSE Input current 1 Wrong ac 1 Be sure the T1 primary taps are wired correctly for your input too high input voltage or voltage See Changing Transformer Taps Section 1 6 The actual T1 wired ac input voltage must be at least 88 of the rated value for the incorrectly charger to produce full output power 2 Defective 2 Disconnect wires 51 52 and 53 54 from the SCR gate lead terminals these are the small gauge twisted pairs Be sure to note the original polarity so that they can be replaced with the same polarity Restart the charger If You are able to measure output current one of the SCRs is defective Replace the rectifier modules readings are erratic disconnected battery 2 Defective scaling resistor R4 or R14 3 Defective Main Control pc board A1 3 Defective 3 Test by disconnecting wires from X1 X5 Y1 and Y2 If ac input Transformer T1 c
106. n probe optional 20 Using temperature compensation esses 22 1 12 Installing the AT10 1 for remote communications optional 23 1 13 Installing the AT10 1 for forced load sharing optional 23 2 Operating the AT10 1 Battery Charger 2 1 Starting the AT10 1 2 1 1 Understanding the start up SegquenCe RN 24 2 1 2 Checking the installati ltu uu a u itiren iana aaae 24 231 3 Starting thie ATTO e eter ath et tiga tui 24 Using The digital meter ucc a E eR UR ERR ER RR 24 Factory settings table ana aani 25 2 2 Using the AT10 1 front panel features 2 2 1 If the meter displays an error message pp 26 2 2 2 Selecting the meter Mode 26 2 2 3 Selecting the Float or Equalize mode sse 27 2 2 4 Choosing the Equalize method pp 27 Manual Timer method dd entren 27 Manual Equalize method sss 28 Auto Equalize Timer method sssssssnesennnnnnnneesnsnnnnnsnessnnnnnnesrensnnnnnnesrennnnn 28 2 2 5 Testing the front panel indicators pp 29 2 2 6 Testing the Auxiliary Relay Board optional pp 29 2 2 7 Interpreting the alarm indicators pp 29 TABLE OF CONTENTS 2 3 Setting the AT10 1 parameters 2 3 1 Understanding parameter settings u uu u 30 2 3 2 Setting the Float and Equalize voltages sees 31 2 3 3 Setting the Equalize ti
107. nd 53 54 from the SCR gate lead terminals these are small gauge twisted pairs Be sure to note original polarity so they can be replaced with the same polarity Restart the charger If You are able to measure output current one of the SCRs is defective Replace the rectifier modules 3 Turn off both front panel circuit breakers or turn off ac and dc power externally if the charger doesn t have breakers Then turn on the dc breaker followed by the ac breaker 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 296 2 Defective Main Control board A1 1 Output current must be greater than 296 of rated current to produce a High DC Voltage alarm See Parallel Operation portion in Section 2 3 6 2 Turn off both front panel circuit breakers or turn off ac and dc power externally if the charger doesn t have breakers Then turn on the dc breaker followed by the ac breaker If the charger output voltage is above the alarm setting but the HIGH DC VOLTAGE indicator still doesn t light replace the control circuit board 55 SERVICING THE AT10 1 PROBABLE output current 3 Defective rectifier bridge 4 Defective Main Control board A1 5 Defective dc breaker CB2 SYMPTOM CAUSE RECOMMENDED ACTION LOW DC 1 Battery is
108. ng Do not remove the connectors in order to fish the cable through the conduit Maximum pulling tension is 46 Ib 20 9kg The cable has a plenum rated outer jacket and passes the NFPA 262 flame propagation test Install the cable between the AT10 1s 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 AT10 1s and restart according to the normal procedure in the AT Series Battery Charger Operating and Service Instructions After the AT10 1s 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 ch
109. ng bracket kit part number E15008 00 For kit availability see ordering information in Appendix B on page 71 The kit includes dimensions and instructions for locating the wall mounting holes The wall must be strong enough to properly support the weight of the AT10 1 The weight of your AT10 1 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 outline drawings in Appendix C 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 71 e Should be between 32 and 122 F 0 and 50 C with relative humidity between 5 and 95 non condensing e Must be free of flammable or explosive materials Maintain at least 6in 152mm of free air on top bottom and both sides for cooling air Allow 36in 914mm front clearance for access to the charger for operation and maintenance INSTALLING THE AT10 1 PROCEDURE o 2 n e o lt o s S 3 o E o z el un o s8 E 8 e xt eZ o eg Ag AE O e z ab B os o s 3 hh gt D N o r2 3 o gt lt bn o z o lt Place the
110. nitor 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 RAT as shown in the figure below A SERIES fo 5 TTTTTT J27 o TN O 50180 THIT O mAy Jl J17 ue ss J5 L ONG L J ENABLE Z lm o T PRAM ra DETECT DI i EE J3 e JO P ENABLE o sitar NG pu 0 AN TB3 pow 29g SSS O o 0 EIN M Disconnect all ac and dc power sources from the AT10 1 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 AT10 1 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 AT10 1 2 3 9 Using the front panel security feature The
111. ns apply at 77 F 25 C nominal ac line voltage amp nominal float voltage Output voltage regulation Temp 32 122 F 0 50 C Freq 60 4 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 Option without battery 30 Adc rating full load 61 74 83 90 Efficiency 75 Adc rating full load 62 75 84 91 1 rms typ 2 rms Unfiltered with battery yp at battery terminals 30 mV rms max 100 mV Output ripple voltage Filtered with battery per NEMA PE5 1996 at battery terminals Filtered without battery 196 rms typ 2 rms Battery Eliminator Filter 30 mV rms 100 mV Surge withstand capability ANSI C37 90 1 1989 No erroneous outputs 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 vol de Equalize 11 7 15 5 23 4 31 0 46 8 59 0 117 143 High DC Voltage alarm 12 19 24 38 48 76 120 175 Low DC Voltage alarm 714 5 15 29 5 30 58 80 141 Voltmeter range Vdc 0 21 0 42 0 75 0 195 Ammeter range Adc All ratings 0 150 Test per Reverse current
112. ondition 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 AT10 1 Check with a voltmeter before proceeding This includes remote sense wires if they were installed Open the AT10 1 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 respond to a ground fault Restart the AT10 1 following the instructions in Section 2 1 Setting the current limit value The AT10 1 automatically limits its dc output current in case of overload or battery discharge You can adjust the value of the current limit from 50 to 110 of rated current The factory setting is 110 The current limit adjustment is the last step in the normal Edit sequence If the AT10 1 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 Downl 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 t
113. or Install one lead of the replacement surge suppressor onto the L1 terminal Replace the other wires and the hardware Repeat procedure for the left ground stud Tighten all hardware For VR5 repeat procedure for the ac surge suppressor connected to the L2 terminal and the right ground terminal Tighten all hardware NOTE The surge suppressors are not polarized Replacing the dc surge suppressor VR1 Turn off and remove all power to the AT10 1 Open the door and remove the safety shield Disconnect the battery from the output terminals 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 surge suppressor is not polarized Replacing the EMI filter networks VR6 C4 VR7 C5 Replace these networks as assemblies do not replace individual parts Turn off and remove all power to the AT10 1 Open the door and remove the safety shield Disconnect the battery from the output terminals 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 ground terminal F
114. or 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 surge suppressor networks are not polarized 60 SERVICING THE AT10 1 Replacing the power ballast resistor R3 48 and 130 Vdc units only For 48 Vdc and 130 Vdc AT10 1s rated 30 100 Adc resistor R3 is mounted with metal brackets onto the back panel of the enclosure Cut wires 49 and 55 connected to R3 as close to the resistor leads as possible Strip off 0 25in 6 4mm of insulation from the cut ends of the wires Unscrew the top mounting bracket and remove the existing resistor Mount the new R3 resistor and replace the top mounting bracket Carefully re solder the cut wires to R3 Polarity is not important Replacing resistors R3 R4 R6 R14 on the Gate Driver pc board A11 In all AT10 1s rated 30 100 Adc resistors R4 R6 and R14 are soldered directly onto the Gate Driver pc board A11 In 12 Vdc and 24 Vdc AT10 1s rated 30 100 Adc R3 is also soldered directly onto All See detail of the Gate Driver pc board A11 below for proper location HindlePower Inc EN5005 HIGH OUTPUT GATE DRIVE PC BOARD A11 MAIN CONTROL PC BOARD Al If any of these resistors need to be replaced we suggest you order a new Gate Driver pc board A11 See Replacing the Main Control pc board A1 and or
115. r 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 Vdc 2 Terminal block is a compression type accepting wire sizes 22 14 AWG 3 Terminals are labeled in non alarm condition INSTALLING THE AT10 1 Auxiliary Relay Board optional The optional Auxiliary Alarm Relay PC Board A5 mounted on the right side panel of the circuit breaker bracket 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 N co 12VOLTS DCOUT DCOUT GROUND GROUND HVDC HVDC LVDC LVDC FAILURE FAILURE ACFAIL ACFAIL DETECT DETECT SUMMARY SUMMARY 34 35 36 28 29 30 31 32 33 C NG NO C NC NO C NC NO b NC NO E NC NO b NC NO NG NO E NC NO NC NO C NC NO C NG NO C NG NO 123 456 789 10 11 12 13 14 15 16 17 18 19 20 21 22 2324 25 26 27 VOLTAGE SELECTOR SWITCH DETAIL E TB4 CJ a 24VOLTS eo 48 VOLTS mm 130 VOLTS I AUXILARY ALARM RELAY PC BOARD A5 PROCEDURE 1 2 3 4 Rout
116. rature compensation probe be sure that the probe is securely installed Be sure the connectors and the wiring from the probe to the AT10 1 charger are in good condition If there is a failure of the temperature compensation probe or the wiring the AT10 1 charger displays the error code E 08 Measuring the output ripple voltage filtered models only If your AT10 1 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 70 if the battery ampere hour capacity is at least 4 times the output current rating of the charger 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 AT10 1 charger by pressing the EDIT ENTER key on the front panel Each time you press the key a different parameter displays in the following order 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 Don t use a dc voltmeter The ripple voltage on a battery is a very small ac voltage 41 OPERATING THE AT10 1 SAMPLE PREVENTIVE MAINTENANCE PROCEDURE AT10 1 BATTERY CHARGER Su
117. rcuit breaker is closed Measure feed the ac voltage at TB1 L1 and TB1 L2 If it is zero check breaker fuse is upstream distribution breakers and fuses tripped 3 Defective 3 Measure ac voltage at T1 H1 and T1 H5 It should be the wiring same as the ac supply voltage 4 Defective 4 Turn off both front panel circuit breakers CB1 CB2 If the Main Control charger does not have breakers but fuses F1 F2 and F3 F4 board A1 turn off ac and dc power externally Start up by turning on the dc breaker followed by the ac breaker If the AC ON indicator 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 charger from the battery and dc bus and check the battery and dc bus for a ground fault 2 If the AT10 1 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 AT10 1 to be in standby open the ac circuit breaker CB1 3 Calibrate the ground detection sensitivity See Section 2 3 4 4 Disconnect the charger from the battery and dc bus Turn the charger on and measure the voltage from TB1 to chassis and from TB1 to c
118. res and one lead with a quick connect terminal will be connected inside the AT10 1 Leave 30in 762mm of cable inside the enclosure and route the other end to the probe at the battery 20 INSTALLING THE AT10 1 e Runthe 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 isn t 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 71 for ordering information e Be sure your wiring conforms to the NEC and your facility requirements 5 Attach the interconnection cable to the AT10 1 as shown in the figure below e Route the cable within the AT10 1 QUICK GATE DRIVE PC enclosure soit CONNECT BOARD A11 runs with the W PIGGY wire harness BACK to the back of the front panel and easily reaches the main control circuit board e At the main control circuit board insert one of the bare wires from the cable into each terminal of TB8 Polarity is not important DISABLE J5 MAIN CONTROL PC BOARD A1 DSID N mua n a yo 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
119. 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 mama BANAAG BK GA KARA aa Back Cover HOW TO READ THE AT10 1 MODEL NUMBER eene Inside Front Cover IMPORTANT SAFETY INSTRUCTIONS I u u u u u i 1 Receiving and Installing the AT10 1 Battery Charger 141 3Storingithe ATWO MS eed tit aahh ng iota rp maban a bagan 2 1 2 Reporting shipping damage 0 re i i 2 1 3 Unpacking and inspecting the AT10 1 0 2 Inspection Checklist e a a a 2 TA Moving the ATTO orte tee ecce oae ent doe ee ne en 3 Enclosure type and weight table snake tance eene 3 1 5 Mounting tlie AT 10712 i trente Pe ei L Q Da ana sa aa 3 1 5 1 Wall Mounting the ATTO ss a AT 4 1 5 2 Floor Mounting the AT10 1 00 6 1 5 3 Rack Mounting the AT10 1 optional 0 8 1 6 Changing transformer taps U a 10 1 7 Making the ac input connections enne 12 1 8 Making the dc output connections l u uu 14 1 9 Wiring the AT10 1 for remote sensing u 16 1 10 Wiring to the remote alarm contacts nn 18 Auxiliary Relay Board optional sseseeeeeeenesesenssesrrsssrrsssrrssinnsstinnnsrennnsnnnnne 19 1 11 Installing the temperature compensatio
120. rminals TB 1 Keep it clean The AT10 1 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 AT10 1 is rated for operation up to 122 F 50 C If your charger is in a warmer environment or at an elevation over 3 000ft 914m contact your sales representative for operating information Check power and signal connections Check the tightness of all 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 AT10 1 charger Check remote sense wiring optional If you wired the AT10 1 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 AT10 1 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 AT10 1 2 4 4 2 4 5 2 4 6 Check temperature compensation probe optional If you are using the optional tempe
121. rol board A1 3 Defective transformer T1 4 Defective dc breaker 1 Use a clamp on ammeter to measure the current in wire 5 or 6 between the transformer T1 and the rectifier modules If it less than 5096 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 If the charger does not have breakers but fuses F1 F2 and F3 F4 turn off ac and dc power externally Start up by turning on the dc breaker followed by the ac breaker 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 from T1 X1 to T1 X5 It is normally 50 to 80 higher than the rated dc output voltage If it is too low check the wiring of the primary taps See Changing Transformer Taps Section 1 6 If it is Zero replace the transformer T1 4 Disconnect the battery and connect a light dc load to the charger Measure the dc voltage across TB1 and TB1 with the breaker on If no voltage is measured replace the breaker 56 SERVICING THE AT10 1 SYMPTOM PROBABLE RECOMMENDED ACTION CAUSE AC INPUT 1 AC power 1 If the ac input power fails the front panel AC ON indicator FAILURE failure goes out and the AC INPUT FAILURE indicator goes on indicator is on 2 Upstream 2 Be sure the front panel ac ci
122. rvice 44 SERVICING THE AT10 1 3 2 INTERPRETING FRONT PANEL ERROR MESSAGES If the AT10 1 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 error codes and procedures to use WARNING High voltages appear at several points inside the AT10 1 Use extreme caution when working inside the unit Do not attempt to work inside the AT10 1 unless you are a qualified technician or electrician Disconnect and lock out all power from the AT10 1 before starting to remove or replace any components Turn the ac power off at the distribution panel upstream from the charger Disconnect the battery from the AT10 1 output terminals TB1 Error Meanin Repair Procedure Code g p E 01 resistor R2 Resistor R2 is installed at the back of the front panel in the Gate open or Driver pc board A11 input connector J18 R2 is measured by the defective control circuit on startup and is used to determine some of the AT10 1 s parameters such as the float voltage If the AT10 1 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 AT10 1 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 dc output volts When the battery charges to greater than
123. s below for the Group II enclosure rack mounting configurations Style 5017 Rack Mounting STANDARD RACK _ 1 ALLOW 6in 152mm FOR 1 T COOLING ABOVE UNIT W EIA SPACING X MOUNTING BRACKET Jal ALLOW 6in 152mm FOR ul 146mm FH x COOLING BELOW UNIT y Style 5018 Rack Mounting 22 31in 16 7 Tin 567mm E 426mm 21 50in 775i 546mm 37 95in 964mm ALLOW 6in 152mm ABOVE AND BELOW UNIT FOR COOLING NOTES Units are installed from the front 2 Referto the outline drawings in Appedix C for enclosure dimensions INSTALLING THE AT10 1 1 6 CHANGING THE TRANSFORMER TAPS IMPORTANT AT10 1 Group Il battery chargers rated 30 100 Adc 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 particular site ac supply voltage does not match your AT10 1 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 AT 10 1 NOTE If your AT10 1 battery charger was supplied with 480Vac 60Hz inp
124. t Heater Strips for Style 5017 Enclosure EJ5041 00 Wall Mounting Kit for Style 5018 Enclosure E15008 00 Relay Rack Mtg Kit for Style 5018 Enclosure 23 24in 584 610mm E10193 03 Cabinet Heater Strips for Style 5018 Enclosure EJ5042 00 NEMA 2 Type Drip Shield for Style 5017 5018 Enclosure E10191 01 02 Padlock for Style 5017 5018 Enclosure Front Panel Door E10215 01 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 Do attempt to splice cables together to increase the length If a longer cable is needed order it from the table below which also features ordering part numbers for a complete tempco 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 71 APPENDIX C Standard Drawings Outline AT10
125. tage 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 AT10 1 by turning the ac and dc breakers off then on If the AT10 1 restarts normally you must reenter any changes you made to the factory settings float voltage etc If E 04 appears repeatedly the internal memory has been damaged You must replace the control circuit board See Section 3 6 for parts ordering information defective or remote sense wiring failure E 05 not used This error code was formerly used to indicate a reverse battery connection It is not available in the AT10 1 E 06 R4 or R14 is Locate R4 and R14 on the Gate Driver pc board A11 on the back of the front panel Remove the wire harness plug from J18 and remove A11 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 196 of the specified value the entire Gate Driver pc board A11 must be replaced If you are using remote sense wiring from the battery to the AT10 1 the wiring may have failed The usual failure is an open circuit a short circuit will usually be indicated by smoke or fire in the wiring The AT10 1 displays the error code if it detects this wiring
126. th component ratings and a full connection diagram If the standard drawings featured in this manual are not sufficient please contact your Sales Representative for drawing availability from the battery charger manufacturer Any job specific custom drawings supplied with your AT10 1 and or this manual supercede the standard drawings featured in Appendix C The standard drawings and corresponding page numbers featured in this section may not be included with custom printed manuals when job specific custom drawings are supplied 94 MANUAL SPECIFICATIONS ONLINE AVAILABILITY An unlabeled version of this operating and service instruction manual is available online at http www ATSeries net PDFs JAO102 02 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
127. the AT10 1 The accessory part numbers differ depending on cable length ordered See the tables in Appendix B on page 71 for ordering information Each kit contains detailed installation instructions JA5015 00 The main elements of the installation are outlined below WARNING High voltages appear at several points inside the ATI0 1 Use extreme caution when working inside the unit Do not attempt to work inside the ATI0 1 unless you are a qualified technician or electrician Disconnect and lock out all power from the AT10 1 before starting to remove or replace any components Turn the ac power off at the distribution panel upstream from the charger Disconnect the battery from the AT10 1 output terminals TB1 PROCEDURE 1 De energize and lock out all ac and dc voltage sources to the AT10 1 and check with a voltmeter before proceeding 2 Mount the probe on a clean dry surface as close to the battery as possible such as the battery rack DO NOT mount the probe e on the battery itself e onunpainted wood or bare galvanized metal on plastic surfaces 3 To apply the probe clean the mounting surface with isopropyl alcohol and allow to dry thoroughly Remove the protective backing from the double faced adhesive tape on the probe and securely press it onto the surface 4 Install the cable supplied with the temperature compensation probe kit e Start at the AT10 1 charger The end of the cable with two stripped wi
128. 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 MTHp key to choose the desired equalize method The indicator next to the desired equalize method will light Three equalize methods are available in the AT10 1 e Manual Timer e Manual Equalize e Auto Equalize Timer These equalize methods are described below Manual Timer Method Choose the manual timer method if you perform regularly scheduled equalize charging or if you base your equalize charging on regular readings of the specific gravity of each cell of your battery for lead acid batteries When your battery requires equalize charging adjust the manual timer to 1 2 hours for each 100 AH of battery capacity see Section 2 3 3 to learn how to adjust the equalize time The battery manufacturer can help you determine the best equalizing schedule for your battery After you select the manual timer method press the CHRG MODE key to put the 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 b
129. ts to verify that no voltage is present inside the enclosure INSTALLING THE AT10 1 PROCEDURE 1 Verify that all voltages whithin the AT10 1 are de energized and locked out 2 See Section 3 5 for necessary steps to follow when accessing internal components within the AT10 1 3 Change the jumpers on the transformer T1 as shown in the table below 4 If your transformer is supplied with two 2 jumpers always use both as specified in the table 5 Make sure all connections are tight 6 Check your work before re energizing the AT10 1 7 For more information see the schematics amp wiring diagrams in Appendix C MAIN POWER TRANSFORMER T1 CONNECTION TABLE Q2 AC CB1 F1 CB1 F1 XS XS TER TER CB1 F1 J18 15 CB1 F1 J18 15 H1 Y2 H1 Y2 pe J18 14 sa J18 14 YI YI 480 Vac 60 Hz NONE XI XO SECONDARY TYPICAL TRANSFORMER N T V PRIMARY I H H3 u2 H5 H 2 JUMPERS 11 INSTALLING THE AT10 1 1 7 MAKING THE AC INPUT CONNECTIONS Follow these steps to connect ac power to the AT10 1 1 Use a branch circuit breaker or fused disconnect switch properly sized for the maximum input current of the AT10 1 as shown in the table below This device should have lockout capability so that the ac input can be de energized and locked out for maintenance A time delay circuit breaker or slow blow fuse is recommended NOTE If your charger is wired for 480 Vac input and is equipp
130. urrent is still too high replace the transformer T1 Output ripple 1 Charger is 1 Verify by checking nameplate against the ordering code on the voltage too unfiltered inside front cover Order and install the filter option if necessary 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 charger AT10 1 model on page 70 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 replace C1 and or C2 as needed capacitors C1 and or C2 Charger very 1 Loose 1 Check and tighten all component mounting hardware and panel noisy hardware or hardware enclosure panel 2 Defective 2 Use a clamp on ammeter to measure the current in wire 5 or rectifier bridge 6 between the transformer 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 Meter 1 Defective or 1 Turn off the charger With a light dc load connected to the battery be sure each cell reads the nominal cell voltage 2 0 V for lead acid 1 25 V for Ni Cd Restart the charger Each cell should now read approximately the nominal Float voltage 2 2 V for lead acid
131. urs e High dc voltage alarm setting e Low dc voltage alarm setting e Current limit value in Amperes e High dc voltage shutdown feature on or off Your choice of equalize method is also saved internally When you want to change any parameter press the EDIT ENTER key to put the AT10 1 into Edit Mode The meter display flashes about once per second and the status indicators prompt you to adjust the respective parameter 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 AT10 1 Specifications in Appendix A on page 70 When you first press the EDIT ENTER key the AT10 1 prompts you to adjust the first parameter in the list above float voltage When you obtain the value you want on the display press the EDIT ENTER key again The AT10 1 saves the new setting internally and then prompts you to adjust the second parameter You continue this way to adjust the first six parameters in the list above If you want to skip adjusting any parameter just press the EDIT ENTER key again The AT10 1 moves to the next parameter When you are finished adjusting
132. ut 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 AT10 1 please contact your sales representative for ordering replacement parts Before you wire ac power to the AT10 1 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 AT10 1 was supplied with 120 208 or 240Vac 60Hz input and you need to change the factory wired input voltage you do so by changing jumpers on Tl If you are changing from 120Vac to 208 240V ac or the reverse you also need to change the input surge suppressors and the input circuit breaker and or ac input fuses See Section 3 6 on page 62 for part requirements If your AT10 1 was ordered with 380 or 416 Vac 50 60 Hz and you need to change the factory wired 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 AT10 1 Note that just turning off the front panel ac and dc circuit breakers is not sufficient to eliminate live voltages inside the enclosure Use a voltmeter at the ac terminals TB1 L1 and TB1 L2 the dc terminals TB1 amp TB1 the dc remote sense terminals and any external wiring to alarm relay contac
133. wheeling diode CR4 if it is defective 4 Defective 4 Disconnect wire 17 from the dc circuit breaker CB2 or the polarity diode dc fuse F3 Measure the resistance through the polarity diode CR1 if filter CR1 mounted on the current shunt R1 Check both polarities it assembly is should be at least 100 000 Ohms in one polarity and less than installed 1 000 Ohms in the other polarity Replace the polarity diode CR1 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 connection to clear aftera breaker few minutes 2 Open SCR 2 Use a clamp on ammeter to measure the current in wire 5 or 6 between the transformer 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 3 SCR not 3 Disconnect wires 51 52 and 53 54 from the SCR gate lead controllable terminals these are the small gauge twisted pairs Be sure to note the original polarity so that they can be replaced with the same polarity Restart the charger If You are able to measure output current one of the SCRs is defective Replace the rectifier modules 4 Defective 4 If the front panel meter shows more than 110 of rated dc Gate Driver pc current the Gate Driver pc board A11 may be defective
134. x I Dr 1 H2 at VR2 I H3 lt F1B A 200 kAIC T N S TBI L2 RN NOTE 5 Hl Ye 2 BUS BAR TB1 GND D YI Wa CHASSIS SYSTEM GROUND COMMON HIGH DC LOW DC DC OUTPUT AC GROUND SUMMARY VOLTAGE VOLTAGE FAILURE FAILURE DETECT ALARM AUXILIARY ALARM TERMINAL BLOCK TB4 NOTE 2 AUX ALARM RELAY Te PC BOARD AS 14 Sz 45 wa SLIMMARY ALARM TERMINAL BLOCK 4 TB3 NOTE 2 Hl AC INPUT CKT BKR amp FUSES DC OUTPUT CKT BKR amp FUSES AUXILIARY RELAY PC BUARD DC OUTPUT FILTERING BATT ELIMINATOR FILTER EXTERNAL TEMPCO PROBE LIGHTNING ARRESTOR 84 APPENDIX C Standard Drawings Schematic AT10 1 Group Il Battery Charger w Common Options JE5032 99 FILTERING ASSEMBLY e e F3 44A r 7 CB2 44A L1 L2 20 kAIC I TB1L 1 1 l REMOTE I SENSE Rg 1 NITE 35 l l 1 I I e APA NU PRE E AAAH I ba au l QD 1 lt 3 l TE l DU l 1 i 1 UJ NITE 7 a R3A RIB I REMOTE CRI SENSE 1 NOTE 3 mpm aaa p Saat TBIC n F4 A di 20 kAIC SOBGTOS MARAN288 9535 2 J18 HIGH OUTPUT GATE DRIVE PC BOARD All mes M RELAY A5 HH MAIN CONTROL HO PC BUARD Al TEMPERATURE COMPENSATION PROBE A10 E Q T F Ad dd ARM JCK IN lai THIRD cl ANGLE PROJECTION sES oy

servicing the at10.1

Contents

Download Pdf Manuals

Related Search

Related Contents