Home

Chevrolet 2001 Offroad Vehicle User Manual

1. SBN THIRD DRAWN BY MCR 012304 E 10 1 SERIES BATTERY CHARGER OUTLINE NEMA 1 5 5 ENCLOSURE ORAWING No 0 E1S42 012304 M nee Sees ae JES023 03 0 A REV No DATE APP SCALE 75 5023 03 BE 1 FILENAME 5023 03 Note Online standard drawings saved in Adobe Acrobat Portable Document Format PDF for the AT10 1 Series Battery Charger are available for downloading and printing Please contact your sales representative for document availability or see the manufacturer s web site listed on the back cover of this manual 72 APPENDIX C Standard Drawings Outline AT10 1 Group Battery Charger NEMA 1 Style 594 JE5024 03 4 00 3 sl 102 e H 5 5 10 00 ma p MTG gt MANUAL gt ac pc nurPur 58 gr 18 25 MTG 464 MTG gt 19
2. 10 1 Replacing the main transformer T1 Deenergize and lock out all ac and dc voltage sources to the 10 1 Check with a voltmeter before proceeding This includes remote sense wires if they were installed Remove the enclosure shroud and the safety shield Disconnect the harness wires 28 and 29 from the upper row of transformer terminals Disconnect wires 11 and 12 from the top of the rectifier heat sink Disconnect harness wires 3 and 4 from the lower row of terminals leave both jumpers in place on the lower row Remove the four screws or nuts that secure the transformer to the rear panel Support the transformer by the top of the core and lift it up to get the bottom bracket off the rear panel Remove the transformer from the charger Check the jumpers on the bottom row of terminals of the replacement transformer Make sure they are connected to the same terminals as the jumpers on the transformer you just removed from the charger For details see section 1 6 Changing the Transformer Taps Hold the replacement transformer with the terminals labeled H1 through H5 at the bottom facing you Place the transformer against the rear panel and slide the bottom of the transformer bracket into the slots on the rear panel Install the four screws or nuts onto the mounting bracket of the transformer Rewire the transformer following the steps above in reverse Refer to section 1 6 and verify that th
3. C NC NO C NC NO 19 20 21 22 2324 J4 gt 12 VOLTS 24 VOLTS s 48 VOLTS 130 VOLTS AUXILIARY ALARM RELAY PC BOARD A5 VOLTAGE SELECTOR SWITCH Follow the procedure below to wire annunciators to one or more of these alarm contacts PROCEDURE 1 Remove the top panel from the penthouse enclosure on top of the main charger enclosure 2 Route your remote annunciator wiring into the penthouse enclosure through one of the unused knockouts in the side of the enclosure 3 Connect the wiring use 22 14 AWG to the appropriate terminals of TB4 on the back wall of the penthouse enclosure as shown in the drawing at the right Strip each wire 25in 6 4mm and securely tighten the terminal screws The terminals are labeled in the non alarm condition 4 Replace the top panel on the penthouse enclosure NOTES 1 Alarm contacts are rated at 0 5A 125 Vac or Vdc 2 Terminal block 1 a compression type accepting wire sizes 22 14 AWG 3 Terminals are labeled in non alarm condition 19 INSTALLING THE 10 1 1 11 INSTALLING TEMP COMPENSATION ASSEMBLY OPTIONAL The temperature compensation assembly consists of a probe containing 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
4. BE BOARA al RELAY BDARD 5 2 move JUMPER TO 192 PROPER PINS teaa 1 2 3 7 e e 5 2 es ooo ea DA f 4 5 60 18 22 23 24 5 25 0 4 35 56 53 C NC NOJ C NC NOJ C NC NOJ C NC NOJ C NC NOJ C NC NO HIGH OC LOW OC OC OUT IN GROUND SUMMARY FILTERING VOLTAGE VOLTAGE FAILURE FAILURE ALARM CAPCS NOTE 2 R9 7 E17 REMOTE SENSE 5 188 gt LIGHTNING 2 oc fo MES SUR Epi BREAKER j NOTE 6 NDTE 6 Crs CHASSIS GROUND NOTE THIRO Q cp uw PROJECTION ww BY MCR 040703 7118 ATIO 1 SERIES BATTERY CHARGER CONN DIAG 6 25 0 GROUP I W COMMON OPTIONS E1742 091004 GY 040703 E1204 040703 JE5033 99 DATE SCALE NTS JE5033 99 1 87 APPENDIX D RECOMMENDED FLOAT AND EQUALIZE VOLTAGES This table contains suggested values for commonly used batteries Consult your battery manufacturer s documentation for specific values and settings for your battery type Recommended Recommended Battery Cell Type Float Voltage cell Equalize Voltage cell Antimony 1 215 Sp Gr Antimony 1 250 Sp Gr Calcium 1 215 Sp Gr Calcium 1 250 Sp Gr Absorbed Gelled Electrolyte sealed Lead Acid typ
5. LN ALARM TEMP Q RELAY 1 2 B3 OO 599 xl 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 proper length for connecting to TB3 Strip 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 or Vdc 2 Terminal block is a compression type accepting wire sizes 22 14 AWG 3 Terminals are labeled in non alarm condition 18 INSTALLING THE AT10 1 Auxiliary Relay Board optional The Auxiliary Alarm Relay PC Board A5 mounted inside the separate top enclosure penthouse provides two form C contacts 4 1 through TB4 36 for each of the following individual alarms High DC Voltage Low DC Voltage DC Output Failure AC Failure Ground Fault Detection positive or negative Summary Alarm DC OUT DC OUT GROUND GROUND HVDC HVDC LVDC LVDC FAILURE FAILURE AC FAIL AC FAIL DETECT DETECT SUMMARY SUMMARY C NC NO 123 C NC NO 34 35 36 C NC NO 456 C NC NO 789 C NC NO 10 11 12 C NC NO 13 14 15 C NC NO 16 17 18 C NC NO C NC NO C NC NO 25 26 27 28 29 30 31 32 33
6. NC x shio w 1516 17 wafia 20 zi 22 23 22125 26 27 28 25 0 3 2 C C C C C CC CC AUXILIARY ALARM RELAY PC BOARD AS Note Online standard drawings saved in Adobe Acrobat Portable Document Format PDF for the AT10 1 Series Battery Charger are available for downloading and printing Please contact your sales representative for document availability or see the manufacturer s web site listed on the back cover of this manual 78 APPENDIX C Standard Drawings Instrument Panel Detail AT10 1 Group Battery Charger w Optional Auxiliary Relay PC Board JE5030 19 DISPLAY Js DISABLE 3 ENABLE J5 2 0511 0512 0513 9 g 0514 B E 0515 9 8 0516 2 0510 85 asas Ms 0518 y 5 HS 5 314 z i OL BOARD Al MAIN CONTROL PC BOARD Al gt CHARGER ODOR WHEN INSTALLED BACK VIEW FACING CHARGER COMPONENTS WHEN INSTALLED JUMPERS SWITCHES J MAINFRAME SIGNAL HARNESS 51 METER MODE 73 AUXILIARY ALARM RELAY BOARD AS INTERCONNECTOR S2 CHARGER MODE 25 GROUND FAULT 3 EQUALIZE METHOD JB EARTH GROUND S4 AADJUST 29 FRONT PANEL LOCKOUT S5 VADJUST 112 BOARD PROGRAMMING SB EDIT ENTER 213 COM
7. sss nene 22 2 Operating the AT10 1 Battery Charger 2 1 Starting the AT10 1 2 1 1 Understanding the start up 24 2 1 2 Checking the 24 2 1 3 Starting the AT 10 1 sedet ede cour e doa ud dd 24 Using the digital 24 Factory settings table assises tended tnde 25 2 2 Using the AT10 1 front panel features 2 2 1 If the meter displays an error 26 2 2 2 Selecting the meter 26 2 2 3 Selecting the Float or Equalize mode sse 27 2 2 4 Choosing the Equalize 27 Manual Timer method iei eene entente inerte nnd nba 27 Manual Equalize eene 28 Auto Equalize Timer method eene 28 2 2 5 Testing the front panel indicators amp Summary Alarm Relays 29 2 2 6 Testing the Auxiliary Relay Board sss 29 2 2 7 Interpreting the alarm indicators 29 TABLE CONTENTS 2 3 Setting the AT10 1 parameters 2 3 1 Understanding parameter 30 2 3 2 Setting the Float and Equalize 5 31 2 3 3 Setting the Equalize ifera een 32 2 3 4 Setting the Alarms I eid eie edd e d ecd 32 Setting the high
8. CONSULT USER S MANUAL FOR ADJUSTING TRANSFORMER S INPUT VOLTAGE Z T s The drawing above does not show other components mounted to the I O panel Be careful not to disconect any other component leads Always use a proper ground Wire insulation must be rated for 194 F 90 C or better Use copper or aluminum conductors only INSTALLING THE 10 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 a two wire cable from the AT10 1 remote sense terminals to the battery terminals The 10 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 To wire
9. 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 53 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 e Float voltage Equalize voltage Equalize time in hours e High 4 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 THE AT10 1 SAMPLE PREVENTIVE MAINTENANCE PROCEDURE Maintenance date AT10 1 BATTERY CHARGER Suggested frequency every 6 months Performed by Step Instructions Results standard features Clean battery All vents clean and open OK charger Remove dust and debris from inside of OK unit Ch
10. oS ZS TBI L2 2 TB6 4 NOTE Y2 TB1 GND O 1 CHASSIS GROUND TRANSFORMER NOTE 7 m sek 1 5 X1 a lt zu 1 pe 1 not SUMMARY ALARM E TERMINAL BLOCK Hl DEE 183 NOTE 2 TBS HIGH DC LOW DC DC OUTPUT GROUND SUMMARY VOLTAGE VOLTAGE FAILURE FAILURE DETECT ALARM 7 efo hoh 5 1 718 19 2021 22 23 24 25 26 27 28 25 6 1 32 3 4 35 35 NOTES 12 FOR COMPONENT DETAILS OF ALL PC BOARDS Al SEE DRAWING 5030 19 AS All etc 2 ALL ALARM CONTACTS SHOWN IN NON ALARM STATE 0 5 125VAC VDC RESISTIVE CONTACT RATING IS 3 WHEN REMOTE SENSE IS USED THE VOLTAGE SENSE LEADS RUN FROM R14 TO REMOTE SENSE AND FROM 5 2 TO REMOTE REFER TO CONNECTION DIAGRAM FOR WIRING OETAILS 42 POWER TRANSFORMER HAS MULTIPLE TAPS FOR 120 208 240 5 TWO POLE OC CIRCUIT BREAKER IS SUPPLIED ON 130VDC UNITS AND ALL UNITS WITH MEDIUM HIGH AMPERE INTERRUPTING CAPACITY BREAKERS 6 gt CIRCUIT BREAKER INTERCONNECTION TERMINAL BLOCK TB6 IS USED WHEN MEOIUM HIGH AMPERE INTERRUPTING CAPACITY BREAKERS ARE SUPPLIED 7 OPTIONAL 480 VAC INPUT TRANSFORMER FEATURES NO TAPS BUT 1 POLE AC FUSE Fl AND MED BREAKERS ARE REQUIRED FEATURED OPTIONS LEBE 12 AUX ALARM REL PC BOARD AS AUXILIARY ALARM TERMINAL BLOCK TB4 NOTE 2
11. operation of both chargers 3 Defective 3 Turn off both front panel circuit breakers Then turn on the control circuit breaker followed by the ac breaker If some of the front board A1 panel keys still do not work replace the control circuit board Two chargers 1 Check for 1 The AT 10 1 is not designed to share the load current when are normal two or more chargers are connected in parallel so it is normal for one of a pair to have no output current You can check the operation of the off charger by increasing its Float voltage until it starts to deliver output current When you have finished the test be sure both chargers are set to the same Float and Equalize voltages 54 10 1 PROBABLE SYMPTOM CAUSE RECOMMENDED ACTION HIGH DC 1 High DC 1 Be sure that the High DC Voltage alarm setting is higher VOLTAGE Voltage alarm than the Equalize voltage setting See sections 2 3 2 and indicator is on and Equalize voltage settings are mismatched 2 Defective rectifier bridge 2 3 4 2 Disconnect wire 24 from terminal of rectifier assembly near the left front of the enclosure Restart the charger If You are able to measure output current one of the SCRs is defective Replace the rectifier assembly 3 Defective 3 Turn off both front panel circuit breakers Then turn on the control circuit breaker followed by the ac breaker If the charger out
12. Standard NEMA 1 Enclosure Outline 586 72 Standard NEMA 1 Enclosure Outline 594 73 Optional Enclosure Outline Drawings with penthouse and or drip shield 74 Internal Component Layout Detail w Common 76 Instrument Panel Detail w Optional Auxiliary Relay PC Board 78 Schematic AT10 1 Group Battery Charger Standard w o Options 80 Schematic AT10 1 Group Battery Charger with Common Options 82 Connection Diagram AT10 1 Group Battery Charger Standard w o Options 84 Connection Diagram AT10 1 Group I Battery Charger with Common Options 86 APPENDIX D Recommended Float Equalize Voltages eee 88 APPENDIX E DNP3 Level 2 Modbus Communications 89 APPENDIX F UL Data u Irene 89 CUSTOMER NOTES manual 90 TABLE OF CONTENTS 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 climat
13. amp C5 SURGE SUPPRESSORS VR2 VR4 VRS VRB amp VR7 3 DATA NAMEPLATE IS LOCATED ON EXTERIOR LEFT SIDE WALL OF ENCLOSURE USER S MANUAL POCKET IS LOCATED ON EXTERIOR RIGHT SIDE WALL OF ENCLOSURE 4 SAFETY COVER DISPLAYS COMPONENT LAYOUT DIAGRAM SCHEMATIC amp INSTALLATION NOTES S BATTERY ELIMINATOR FILTER CAPACITOR C2 IS NORMALLY LOCATED IN FRONT OF Cl 130VDC 12ADC THRU 130VDC 25ADC UNITS UTILIZE TWO 2 Cls THEREFORE C2 IS SHIFTED TO LOWER RIGHT HAND CORNER OF ENCLOSURE AS SHOWN TO BE PLACED 6 IF 0 1 HAS 480VAC INPUT OR IS CUSTOMER SPECIFIED WITH MEDIUM HIGH NEAR BATTERY CELL AMPERE INTERRUPTING CAPACITY CIRCUIT BREAKERS AND CB2 ARE RELOCATED TO PENTHOUSE ENCLOSURE AND IS ADDED THIRD ANGLE PROJECTION ORAWN BY MCR 022703 TE ATIO 1 SERIES BATTERY CHARGER OPTIONAL 2 INTERNAL COMPONENT LAYOUT STYLE 586 584 E1742 091004 APPROVED H 022803 E 1154 022703 MES TIERS NETS 5027 99 B Note This particular internal component layout drawing JE5027 99 depicts an AT10 1 Group I battery charger with ALL available options Standard components A1 through are featured in all Group I units Optional components A5 through VR3 are featured only on those 10 1 battery chargers configured with such options 77 APPENDIX C Standard Drawings Instrument Panel Detail AT10 1 Group Batte
14. 0 63V 1 3V 1 7V 2 1V 2 6V 8 0 40V 0 80V 1 1V 1 3V 1 7V 0 25V 0 50V 0 66V 0 83V 1 1V 4 0 16V 0 32V 0 42V 0 52V 0 65V EXAMPLE 100ft 30 5m of 8 AWG wire at 16A has 1 1V drop 2 3 specific requirements of your facility take precedence over these instructions The 10 1 is factory wired to regulate output voltage at the output terminals If the total voltage drop is greater than 1 e g 1 3V fora 130 Vdc system remote sense wiring is recommended see section 1 9 PROCEDURE l 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 Run the dc wiring to terminals TB1 and TB1 on the I O panel in the enclosure Compression lugs accepting wire sizes 714 6 AWG supplied for your convenience To make these connections strip the insulation 50in 12 7mm on the incoming wires 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 45 1 16 4 0 5 1 Nm Reinstall the safety cover after you have made and checked all connections 14 INSTALLING THE AT10 1 MAKING THE DC OUTPUT CONNECTIONS GRAPHICS CUSTOMER DC OUTPUT 12 7mm WIRING Z
15. 40 60 80 100 120 Temperature Degrees Fahrenheit EXAMPLE Suppose you have a lead acid battery whose temperature is 100 F 37 8 As shown on the graph the output voltage should be approximately 97 of the 77 F voltage If the float voltage is set on the front panel to 132 the actual output voltage will be 132 x 0 97 128 23 10 1 2 OPERATING THE AT10 1 BATTERY CHARGER 2 1 STARTING THE AT10 1 2 1 1 Understanding the startup sequence The 10 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 10 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 8 AT10 1 the meter display instructions carefully Check the ac input alternates between dc output supply voltage and the battery voltage and be
16. 50 470 EN NOTES 12 ENCLOSURE IS A 1 1 20 CABINET WITHOUT GASKETS 2 ALLOW Gin 152mm OF FREE AIR AND FRONT OF CABINET FOR VENTILATION 3 FOUR 4 KEY HOLE SLOTS ARE PROVIDED ON THE BACK OF ENCLOSURE AS SHOWN FOR WALL MOUNTING WITH 25in 6 25 HARDWARE 42 FOUR 4 1 3lin 33nn DIA KNOCKOUTS ARE PROVIDED AS SHOWN WITH TWO 25 ADDITIONAL KNOCKOUTS FEATUREO ON BOTTOM PANEL OF ENCLOSURE USE OF ANY OF THESE FOUR 4 LOWER CONOUIT KNOCKOUTS WILL ALLOW REMOVAL OF THE CABINET SHROUD WITHOUT REMOVAL OF EXTERNAL WIRING 5 DATA NAMEPLATE WITH CHARGER RATINGS MOUNTED ON LEFT SIDE OF ENCLOSURE BATTERY CHARGER SHIPPING WEIGHT RANGE APPROXIMATELY 110 193 Ibs 50 88 kg in DUAL DIMENSIONS mm FAN THIRD DRAWN BY MCR 012304 TE 10 1 SERIES BATTERY CHARGER OUTLINE 1 STYLE 594 ENCLOSURE DRAWING No 0 E1S42 012304 IT IDE JES024 03 REV SCALE 75 5024 03 en ug FILENAME 5024 03 Note Online standard drawings saved in Adobe Acrobat Portable Document Format PDF for the AT10 1 Series Battery Charger are available for downloading and printing Please contact your sales representative for document availability or see the manufacturer s web site listed on the back cover of this manual 73 APPENDIX C S
17. AC INPUT CIRCUIT BREAKER MEDZHI INT CAPACITY gt DC OUTPUT CIRCUIT BREAKER MED HI INT CAPACITY AUXILIARY RELAY PC BOARD DC OUTPUT FILTERING ELIMINATOR FILTER EXTERNAL PROBE LIGHTNING ARRESTOR Note Online standard drawings saved in Adobe Acrobat Portable Document Format PDF for the AT10 1 Series Battery Charger are available for downloading and printing Please contact your sales representative for document availability or see the manufacturer s web site listed on the back cover of this manual 82 APPENDIX C Standard Drawings Schematic AT10 1 Group Battery Charger with Common Options JE5031 99 DC FILTERING ASSEMBLY A7 XX kAIC CB2 L2 CR2 Ela I I I I I TBIE 3 REMOTE SENSE I I NOTE 3 I I 3 lt EC gt VR 5 gt gt gt W a REMOTE SENSE NOTE 3 NOTE 5 TBIE 3 TB6 14 786 15 NOTE 6 RM RELA 98 MAIN CONTROL AI TEMPERATLIRE 10 THIRD ANGLE PROJECTION DRAWN BY MCR 022003 TIE AT10 1 SERIES BATTERY CHARGER Z a Z 033005 SCHEMATIC 6 25 0 GROUP I W COMMON OPTIONS 4 DRAWING REV UNLESS OTHERWISE NOTED JE 50 3 1 9G 2 B ARE IN INCHES TOLERANCES ARE
18. Accuracy The 10 1 voltmeter is adjusted at the factory to display the actual output voltage within 1 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 P key then press the The DC VOLTS EQLZ MTHD key 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 uP or DOWN matches the float setting on the front panel meter key until the actual output voltage Each time you press bowN you change the AT10 1 output voltage by a small amount Continue to press or DOWN until the actual output voltage agrees with the front panel reading within 1 NOTE Allow one or two seconds for the output voltage to stabilize each time you pre
19. Format PDF they are readily available for downloading and printing Please contact your sales representative for document availability or see the manufacturer s web site listed on the back cover of this manual 90 QUICK OPERATION For unpacking and Startup installation instructions see section 1 on page 2 in this manual on the dc breaker labeled DC OUTPUT gt Turn on the ac breaker labeled AC INPUT To learn how to use the Changing between Float and Equalize Modes equalize timers see sections 2 2 4 on page 27 2 3 3 32 gt Press the 1 key to toggle from Float mode to Equalize mode Press again to toggle back to Float The green or yellow indicator identifies the current mode For details on setting Setting Float Voltage parameters see section Equalize Voltage 2 3 starting on page 30 Equalize Timer High DC Voltage Low DC Voltage If you don t press any key y press the key The DC VOLTS and for 25 seconds the AT10 1 resumes normal operation FLOAT indicators light and the digital display automatically flashes the present float voltage setting gt Press the or 1 key until the digital display indicates the desired float voltage EDIT gt Press the key to save the new setting internally The EDIT sequence advances to the equalize voltage as shown by the front panel indicators Repeat the above
20. NOTE This table does not apply to AT10 1 chargers with 480 Vac input 89 CUSTOMER NOTES MANUAL REVISION The text and graphics contained within this manual are controlled by the battery charger manufacturer s internal part number JA5023 00 The revision level of this manual s text and graphics are featured in the electronic filename listed below The revision dates are also listed below and supercede all other available dates The first two and last two pages of this manual are reserved for company specific front and back cover artwork Any revision levels revision dates or document numbers featured on the first two and last two pages of this manual refer to the cover artwork only DOCUMENT INFORMATION Document Number JA5023 00 Revision Level 2 Document Change Number E1741 Filename JA5023 00 Rev 2 AT10 1 Group 1 Manual doc Last Date Saved 9 16 2004 10 24 AM Last Date Printed 9 16 2004 10 24 AM DRAWINGS Any job specific custom drawings supplied with this battery charger 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 ON LINE AVAILABILITY Electronic versions of this manual and or any custom or standard drawings for the AT10 1 Series Battery Charger are available online Saved in Adobe Acrobat Portable Document
21. 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 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 or 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 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 10 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 10 1 moves to the next parameter When you are finished adjusting the sixth parameter current limit press the EDIT ENTER key again The 10 1 saves all adjustments you made internally and reverts to nor
22. code The 10 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 service 44 10 1 3 2 INTERPRETING FRONT PANEL ERROR MESSAGES If the AT10 1 control circuit detects a hardware or wiring problem it may display an error code on the front panel To solve the problem use the table starting below which lists the error codes and the procedures to
23. 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 10 1 then remove the test resistor and verify that the indicator goes out TEST RESISTOR Now 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 34 THE AT10 1 2 3 5 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 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 10 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
24. current from the battery positive terminal to ground exceeds a specified threshold see note NEG GND lights whenever leakage current from the battery negative terminal to ground exceeds a specified threshold see note 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 The indicators light immediately when an alarm occurs The AT10 1 also has a summary alarm relay with one form C contact rated 0 5A 125 Vac Vdc If an alarm condition lasts for 30 seconds or longer the summary alarm relay contact transfers When the alarm condition is corrected the relay and all indicators reset automatically 29 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 Equalize voltage Equalize timer in hours High dc voltage alarm setting Low dc voltage alarm setting e Current limit value in Amperes e High dc voltage shutdown feature on or off
25. 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 or DOWN key to increase or decrease the value in the display by one count or press and hold the UP or powN key to scroll the value in the display upward or downward When the display shows the current limit value that you want to set release the 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 THE AT10 1 2 3 6 Enabling the High DC Voltage shutdown feature The 10 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 reads E 03 and the summary alarm relay contact t
26. 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 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
27. 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 586 amp 594 enclosures use the aforementioned sling on a hoist or forklift truck 1 5 MOUNTING THE AT10 1 Chose the mounting method for the unit enclosure from the table below ENCLOSURE MANUAL MOUNTING METHOD SECTION Style 586 Style 594 1 5 1 Wall Mounting STANDARD STANDARD 1 5 2 Floor Mounting OPTIONAL OPTIONAL 19in 483mm Rack Mounting OPTIONAL OPTIONAL 1 5 3 T 4 23 24in 584 610mm OPTIONAL OPTIONAL Rack Mounting INSTALLING THE 10 1 1 5 1 Wall Mounting the AT10 1 Wall mounting the AT10 1 battery charger is the standard way to install the Group I enclosures Style 586 594 In planning for wall mounting of the AT10 1 consider the following l PROCEDURE To wall mount the AT10 1 install four 4 25in 6 4mm bolts on the wall rated to support the AT10 1 weight plus a safety factor of at least 2 times Place the 10 1 on the bolts add appropriate mounting hardware and tighten Reference the graphics on the next page For more information see Outline Drawings in Appendix C on page 72 The wall must be strong enough to properly support the weight of the AT10 1 See the W
28. 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 key at any time to change back to the float mode Choosing the Equalize method Press the EQLz key to choose the desired equalize method The indicator next to the desired equalize method will light Three equalize methods are available in the 10 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 key to put the charger into the equalize mode The EQLZ indicator will light When the equalize timer is finished the charger reverts automatically to the float mode and the FLOAT indicator lights At any time during the equalize charge you can switch the charger back to float mode by pressing key The FLOA
29. release the UP or key to increase or decrease the value in the display by one count or press and hold the UP 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 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 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 DOWN key to increase or decrease the value in the display by one count or press and hold the UP DOWN key to scroll the value in the display upward or downward When the display shows the low dc voltage alarm point that you want to set release the UP or DOWN key If you go past the voltage you want press the 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
30. sense terminals on the I O panel as shown in the lower right figure CUSTOMER CUSTOMER SUPPLIED SUPPLIED um NU SENSE LEAD SENSE LEAD 6 Check your work thoroughly Replace the safety shield before reeneregizing the charger 7 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 17 INSTALLING THE 10 1 1 10 WIRING TO THE REMOTE ALARM CONTACTS Built in common alarm relay The Primary Alarm 5 functions are WIR R SIGNAL ESS Immo included as standard us equipment with the AT10 1 The Common Alarm relay located on the main control circuit board on the back of the door provides one form C summary alarm common alarm contact that transfers for any alarm Follow the procedure below to wire a remote annunciator to this contact See section 2 2 7 fora description of the alarm functions s 1 217 I 70 gt HINDLEPQWER INC c cn ARY ALARM INTERCONNECT LUN DETAIL
31. steps until you have set all parameters JA5011 01
32. sure that the board is fully seated on the standoffs Replace wire 30 on the quick connect terminal and connect the harness plug to the board at the top edge Replace any optional wiring such as the temperature compensation probe See section 2 1 for the steps to restart the charger If your charger parameters float voltage etc are different from the factory preset values you should program in the new values now See section 2 3 You should also recalibrate the dc voltmeter according to section 2 3 7 Replacing the rectifier heat sink assembly A6 Refer to the customer instruction supplement JA0086 01 supplied with your replacement rectifier heat sink assembly EJ1243 00 Deenergize and lock out all ac and dc voltage sources to the AT10 1 This includes remote sense wires if they were installed Check with a voltmeter before proceeding Remove the enclosure shroud as described in the previous section Make sure the rectifier heat sink has cooled and remove the entire assembly by the front edge Remove all wires attached to the rectifier control pc board as you pull the assembly out of the enclosure Hold the replacement rectifier assembly in front of the AT10 1 in the same orientation as the old and reconnect all wires removed from the old assembly as you insert it into the enclosure To ensure correct replacement see the wiring diagrams in Appendix C of this manual or the customer instruction supplement JA0086 01 supplied with
33. the ordering code on the inside front cover Order and install filter option if necessary 2 Be sure battery is connected Inspect battery according to the manufacturer s instructions 3 Check the measured ripple against the specification for your AT 10 1 model on page 70 The ripple rating is for a battery whose Ampere hours are four 4 times the charger ampere rating For a smaller battery ripple voltage may be higher 4 Test with capacitance meter replace as necessary 53 10 1 PROBABLE readings are disconnected SYMPTOM RECOMMENDED ACTION CAUSE eno Charger very 1 Loose 1 Remove the enclosure shroud Check and tighten all noisy hardware or component mounting hardware Replace the shroud being enclosure panel sure all assembly hardware is secure 2 Defective 2 Use a clamp on ammeter to measure the ac current in wire rectifier bridge 11 or 12 connected between T1 and the rectifier assembly If it less than 70 of the dc output current one of the SCRs or diodes is defective Replace the rectifier module Meter 1 Defective 1 Turn off the charger With a light dc load connected to the battery be sure each cell reads the nominal cell voltage 2 0V circuit board A1 is not secured to front panel erratic battery for lead acid 1 25V for Ni Cd Restart the charger Each cell should now read the nominal Float voltage 2 2V for lead acid
34. troubleshooting chart that begins on the next page is divided into three columns To use the chart 1 Make list of the charger s condition including the trouble symptoms 2 Find the symptom s in the first column of the chart 3 The middle column contains common causes for the problem you observe in order of probability 4 Follow the action described in the right hand column to correct the problem and return the charger to normal service Determining the condition of the charger e 5 the front panel AC ON indicator lit e What is the ac voltage at the input terminals measured with an voltmeter e What is the dc voltage at the output terminals measured with a dc voltmeter the meter on the front panel display any voltage or current Are any alarm indicators lit Do the front panel status indicators work Charge Mode for example Can you change the charger to the Equalize mode and back to Float e Is the charger making any noise Is it unusually loud sthere 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 10 1 3 4 TROUBLESHOOTING CHART 2 Defective rectifier bridge if unfiltered charger 3 Defective free wheeling diode in SCR module A16 4 Defective polarity diode if fil
35. 01 1134 02 EJ1134 03 R4 5 resistor positive side 31600 69800 14 0KQ 38 3KQ R6 Crowbar resistor EJ1135 00 EJ1135 01 EJ1135 02 EJ1135 03 R9 resistor EJ1137 00 EJ1137 00 EJ1137 01 EJ1137 02 EJ1222 00 EJ1222 01 EJ1222 02 EJ1222 03 R14 Scaling resistor negative side 31600 69800 14 0KQ 38 3KQ T1 Main transformer 120 208 240 Vac See Table 3 11 T1 Main transformer 480 Vac See Table 3 12 TB1 X I O terminal box lug for 14 6 AWG 0056 04 Terminal block for Medium and terminal section RC0014 00 8 req d TB6 Mp High AIC circuit breakers end section RC0014 01 1 req d VR1 Output Surge Suppressor EJ1132 01 VR2 Input Surge Suppressor 120 208 240 Vac EJ1132 01 VR2 Input Surge Suppressor 480 Vac EJ1132 02 Input Lightning Arrestor EJ1074 00 VRE Input Surge Suppressor 120 208 240 Vac EJ1132 01 Y VR4 VR5 Input Surge Suppressor 480 Vac EJ1132 02 Y VR6 C4 EMI Filter Network EJ5021 01 VR7 C5 EMI Filter Network EJ5021 01 65 10 1 Table 3 2 DC FILTER ASSEMBLIES L2 C1 R9 CR1 CR2 Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 6A EJ1072 00 EJ1072 00 EJ1072 02 EJ1072 03 12A EJ1072 00 EJ1072 00 EJ1072 02 EJ1072 06 16A EJ1072 01 EJ1072 01 EJ1072 07 EJ1072 04 20A EJ1072 01 EJ1072 01 EJ1072 07 EJ1072 04 25A EJ1072 01 EJ1072 01 EJ1072 07 EJ1072 05 Table 3 3 STANDARD A
36. 0927 00 AP0927 00 AP0926 00 AP0926 00 25A AP0927 00 AP0927 00 AP0926 00 AP0926 00 Table 3 14 480 Vac INPUT FUSE 1 Current Rating 12 24 48 130 0008 00 0008 00 0008 02 RE0008 06 12A 0008 00 0008 02 0008 06 RE0008 08 16A 0008 02 0008 06 0008 08 RE0008 09 20A 0008 02 0008 06 0008 08 0008 11 25 0008 02 0008 06 0008 08 RE0008 11 69 SPECIFICATIONS specifications apply at 77 F 25 C 120 Vac nominal Float voltage except as noted Temp 32 122 0 50 Freq 60 3 Hz Specification Conditions 12 Vdc 24 Vdc 48 Vdc 130 Vdc Vac 10 12 0 to 100 load Output voltage regulation t 0 2596 Transient response 20 100 load change with battery connected Output voltage change 4 maximum Recovery to 2 0 in 200 ms Recovery to 0 5 in 500 ms Efficiency 12 Adc rating full load 67 00 72 00 78 00 85 00 25 rating full load 96 73 00 77 00 85 00 91 00 Output ripple voltage per NEMA PE5 1996 Unfiltered with battery 296 typ at battery terminals Filtered with battery 30 mV rms max at battery terminals Filtered without battery 196 rms typ With battery eliminator option without battery 30 mV 100 mV Surge withstand capabi
37. 1 35V for 2 Defective 2 Remove one end of R4 from TB5 on the back of the front scaling resistor panel Repeat for R14 connected to TB1 Measure their R4 or R14 values with an Ohmmeter See the table in section 3 6 for resistance values If either resistor is not within 196 of the specified value it must be replaced 3 Defective 3 If the output voltage is constant replace the control circuit control circuit board board A1 Lamp test key 1 No Vac 1 The lamp test key doesn t work during an ac power failure doesn t work 2 Control 2 Open the front panel and be sure that the control circuit or some _ circuit board A1 board is securely mounted on the standoffs on the back of the lamps don t lisnotsecured panel All indicators should extend about 125in 3 2mm light to front panel through the front of the panel 3 Defective 3 When you press the LAMP TEST key if some but not all of control circuit the indicators light or the digital meter does not display all 8 s board A1 replace the control circuit board One or more 1 Front panel 1 Open the front panel and be sure that jumper J9 on the front panel is locked main control board is in the ENABLE position T don t 2 Control 2 Open the front panel and be sure that the control circuit wor board is firmly seated on the standoffs on the back of the panel Front panel keys must operate freely connected in parallel but only one has output current
38. 159 04 0159 15 25 0159 06 0159 06 0159 06 0159 17 Table 3 7 MEDIUM AMPERE INTERRUPTING CAPACITY DC CIRCUIT BREAKERS CB2 Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 6A REO0171 00 REO0171 00 REO0171 00 0171 00 12 0171 01 0171 01 0171 01 0171 01 16 REO0171 02 REO0171 02 REO0171 02 0171 02 20 REO0171 03 REO0171 03 REO0171 03 0171 03 25 REO0171 04 REO0171 04 REO0171 04 0171 04 Table 3 8 HIGH AMPERE INTERRUPTING CAPACITY DC CIRCUIT BREAKERS 2 Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 6A RE0043 00 RE0043 00 RE0043 00 RE0043 00 12A RE0043 01 RE0043 01 RE0043 01 RE0043 01 16A RE0043 02 RE0043 02 RE0043 02 RE0043 02 20A RE0043 03 RE0043 03 RE0043 03 RE0043 03 25A RE0043 04 RE0043 04 RE0043 04 RE0043 04 Table 3 9 MAIN INDUCTOR L1 Current Rating 12 24 48 130 AP0928 00 AP0928 00 AP0928 00 AP1122 00 12A AP0928 00 AP0928 00 AP0928 00 AP0930 00 16A AP0929 00 AP0929 00 AP0929 00 AP0931 00 20A AP0929 00 AP0929 00 AP0929 00 AP0931 00 25A AP0929 00 AP0929 00 AP0929 00 AP0931 00 67 10 1 Table 3 10 RATING RESISTOR R2 Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 6A EJ1133 00 EJ1133 05 E
39. 2 i 2 29 TBI LI v gt D Jw uot 6 I 2 DoT VR2 H3 2 CN 2S TBI L2 N cm TER TB1 GND t 2 CHASSIS Y GROUND TRANSFORMER NOTE 7 Fl 1 HS 1 a lt zu 1 not SUMMARY ALARM E TERMINAL BLDCK Hl DEDE 183 NOTE 2 TBS NOTES 12 FOR COMPONENT DETAILS OF ALL PC BOARDS AI AS All etc SEE DRAWING JES030 10 2 ALL ALARM CONTACTS SHOWN IN NON ALARM STATE CONTACT RATING IS 0 5 e 125VAC VDC RESISTIVE 3 WHEN REMOTE SENSE IS USED THE VOLTAGE SENSE LEADS RUN FROM R14 TO REMOTE SENSE AND FROM 5 2 TO REMOTE REFER FEATURED OPTIONS CONNECTION DIAGRAM FOR WIRING DETAILS AC INPLIT CIRCUIT BREAKER 4 POWER TRANSFORMER T1 HAS MULTIPLE TAPS FOR 120 208 240 VAC AC FUSE F1 IS ONLY USED ON UNITS SPECIFIED WITH 480 VAC INPUT DC OUTPUT CIRCUIT BREAKER STANDARD 12 24 AND 48VDC UNITS CONTAIN A SINGLE POLE BREAKER CB2 IN THE NEGATIVE BUSS OPTIONAL 480 VAC INPUT TRANSFORMER FEATURES NO TAPS BUT 1 POLE AC FUSE Fl AND MED AIC BREAKERS ARE REQUIRED Note Online standard drawings saved in Adobe Acrobat Portable Document Format PDF for the AT10 1 Series Battery Charger are available for downloading and printing Please contact your sales representative for document availability or see the manufacturer s web site listed on the back cover
40. 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 internal components are secure Printed circuit boards are firmly seated on their standoffs hardware is tight wire terminations are secure The User s Manual is included You received all items on the packing list 00000000 RECEIVING THE AT10 1 1 4 MOVING THE AT10 1 Once you have established that the AT10 1 is undamaged identify the enclosure style and weight of your unit Refer to the table below AT10 1 Enclosure Type And Shipping Weight Table Group Cabinet Styles 586 594 Ampere Rating Output Voltage 126 Adc Style 586 Style 586 Style 586 Style 586 Style 586 44 165 44 165 67 Ibs 67 Ibs 67 Ibs 20 kg 20 kg 30 kg 30 kg 30 kg Style 586 Style 586 Style 586 Style 586 Style 586 44 Ibs 58 Ibs 75 lbs 75 lbs 75 lbs 20 kg 26 kg 34 kg 34 kg 34 kg Style 586 Style 586 Style 594 Style 594 Style 594 58 Ibs 75 lbs 110 165 110 Ibs 110 16 26 kg 34 kg 50 kg 50 kg 50 kg Style 586 Style 594 Style 594 Style 594 Style 594 130 80 Ibs 147 lbs 193 Ibs 193 16 36 kg 67 kg 88 kg 88 kg NOTE Actual unit is approximately 20 lbs 9kg below listed shipping weight in table 48 Vdc The Style 586 amp 594 enclosures do not
41. 37 28 75 729 W 19 50 495 12 75 324 75 APPENDIX C Standard Drawings Internal Component Layout Detail AT10 1 Group Battery Charger w Common Options JE5027 99 m Dun OPTIONAL PENTHOUSE ENCLOSURE EB HOUSE SPECIAL CIRCUIT BREAKE 3 AND AUXILIARY ALARM AL INPLI ae AUX ALARM 9 n RELAY PC 3 5 1080 ab SIGNAL 1 0 Ue ul HARNESS DE TB6 mm er Ve 0008 BRE GROUND IT lt L i UE E Ja MAIN CONTROL 09000000 1 i PC BOARD Al EE uu NOTE 1 e B eg A me I I R9 5 CIN FILTER LES 99 E CRI ASSEMBLY SEE DETAIL o s Ae 9G b 12 tR2 11 Z 5515 GROUND A I STUD o NOTE 62 ED o Ic s q SAFETY COVER NOTE 53 NOTE 4 ATIO 1 GROUP I STANDARD COMPONENTS SYMBOL DES
42. 4mm to release it from the clips at the bottom of the bracket Swing the filter assembly outward to the left rotating it so that the heat sink comes out first and the capacitor s last Install the replacement filter assembly by inserting the capacitor end first and rotating the assembly inward so that the heat sink 1 last to go in Push the bottom edge of the bracket into the clips in the rear panel and install the four screws at the top of the bracket Connect wire 15 to the quick connect terminal at the top center of the diode heat sink Route the flying lead from the inductor L2 wire 50 and connect it to the center terminal 2 of the inductor L1 Reconnect wire 54 to terminal E7 of the front circuit board on the rectifier assembly Replace the shroud and the safety shield Replacing the ac input or dc output circuit breaker CB1 CB2 Deenergize and lock out all ac and dc voltage sources to the 10 1 Check with a voltmeter before proceeding This includes remote sense wires if they were installed Remove the two circuit breaker mounting screws on the front panel and carefully rotate the circuit breaker upward and pull it out of the charger Remove the wires from the terminals one at a time and transfer the wires to the terminals of the replacement breaker Be sure the terminal screws are tight Install the replacement breaker into the front panel rotating it downward into place Install the two mounting screws 60
43. 5 QUICK OPERATION 2 2 rnt t nt Pene nr kann enu kane Back Cover HOW TO READ THE AT10 1 MODEL NUMBER Inside Front Cover IMPORTANT SAFETY INSTRUCTIONS i 1 Receiving and Installing the AT10 1 Battery Charger tr Storing the AT AOA tee RR Rc men 2 1 2 Reporting shipping damage 2 1 3 Unpacking and inspecting the AT 10 1 meme 2 Inspection sre nn ne 2 1 4 Moving MEAT IU L u e rtt ena erre oe En ARI AeA E RATE 3 Enclosure type and weight table 3 1 5 AT T0 T i coii gotten Eg 3 1 5 1 Wall Mounting the 01 4 1 5 2 Floor Mounting the 01 6 1 5 3 Rack Mounting the 01 eene 8 1 6 Changing transformer 10 1 7 Making the ac input 12 1 8 Making the dc output een 14 1 9 Wiring the AT10 1 for remote sem 16 1 10 Wiring to the remote alarm contacts 18 Auxiliary Relay Board eene 19 1 11 Installing the temperature compensation assembly optional 20 Using temperature compensation
44. 5033 00 5011 00 50 15 2 5033 01 EJ5011 01 100 30 5 EJ5033 02 EJ5011 02 200 61 0 EJ5033 03 EJ5011 03 Use a single cable assembly Do not try to splice cables together to increase the length 71 APPENDIX C Standard Drawings Outline AT10 1 Group Battery Charger NEMA 1 Style 586 JE5023 03 3 2 62 65 5 H 10 u H 25 trie 29 MT CO oc nur g 88 381 MTG gt 16 25 413 NOTES 12 ENCLOSURE IS 1 1 20 TYPE CABINET WITHOUT GASKETS 2 ALLOW Gin 152mm OF FREE AIR TOP AND FRONT OF CABINET FOR VENTILATION 3 FOUR 4 KEY HOLE SLOTS ARE PROVIDED ON THE BACK OF ENCLOSURE AS SHOWN FOR WALL MOUNTING WITH 25in 6 25 HARDWARE 42 FOUR 4 1 3lin 33nn DIA KNOCKOUTS ARE PROVIDED AS SHOWN WITH TWO 2 ADDITIONAL KNOCKOUTS FEATUREO ON BOTTOM PANEL OF ENCLOSURE USE OF OF THESE FOUR 4 LOWER CONDUIT KNOCKOUTS WILL ALLOW REMOVAL OF THE CABINET SHROUD WITHOUT REMOVAL OF EXTERNAL WIRING 5 DATA NAMEPLATE WITH CHARGER RATINGS MOUNTED LEFT SIDE OF ENCLOSURE BATTERY CHARGER SHIPPING WEIGHT RANGE APPROXIMATELY 44 20 165 7 BO 36 kg 15 00 MTG DUAL DIMENSIONS nn MANUAL POCKET
45. A 02 Equalize mode is inhibited 2 2 2 Selecting the meter mode e Press the METER 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 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 THE AT10 1 2 2 3 2 2 4 Selecting the Float or Equalize mode The 10 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 Press the CHRG MODE key to change to the equalize mode If the equalize method is set to manual timer
46. AT10 1 SERIES Operating and Service Instructions MICROPROCESSOR CONTROLLED FLOAT BATTERY CHARGER SINGLE PHASE INPUT GROUP 6 25 Adc HOW READ THE AT10 1 MODEL NUMBER GROUP I RATINGS 6 25 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 CIRCUIT 5 STANDARD 012 12 BREAKER M MEDIUM AIC NOMINAL RATING 024 24 Vd H HIGH AIC B DC OUTPUT SEE TABLE VOLTAGE 048 48 Vdc 130 130 Vdc K AUX ALARM AUX SUPPLIED 006 6 Adc RELAY BOARD XXX NOT SUPPLIED NOMINAL 012 12 Adc DC OUTPUT 016 16 Adc L GROUND PAD G SUPPLIED CURRENT 020 20 Adc x NOT SUPPLIED 025 25 Adc 0 UNFILTERED M LIGHTNING L SUPPLIED D FILTERING F FILTERED ARRESTOR x NOT SUPPLIED ELIMINATOR 120 120 Vac 60 Hz N FUNGUS F INCLUDED 208 208 Vac 60 Hz PROOFING x NOT INCLUDED 240 240 Vac 60 Hz STATIC s INCLUDED ACINPUT 480 480 Vac 60 Hz 2 P PROOFING x NOT INCLUDED VOLTAGE 220 220 Vac 50 60 Hz 380 380 Vac 50 60 Hz Q NOT USED x 416 416 Vac 50 60 Hz R CANADIAN BILINGUAL LABELING DESCRIPTION CODE FEATURE DESCRIPTION CODE FEAT
47. C CIRCUIT BREAKERS CB1 240 Vac Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 6A RE0159 11 RE0159 1 1 RE0159 1 1 RE0159 13 12A RE0159 1 1 RE0159 1 1 RE0159 13 RE0159 16 16A RE0159 1 1 RE0159 12 RE0159 13 REO159 19 20A RE0159 1 1 RE0159 12 RE0159 14 RE0159 20 25A RE0159 1 1 RE0159 12 RE0159 15 RE0159 20 Table 3 4 MEDIUM AMPERE INTERRUPTING CAPACITY BREAKERS 240 Vac Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 6A REO0171 00 REO0171 00 REO0171 00 0171 01 12 REO0171 00 REO0171 00 0171 01 0171 04 16 REO0171 00 REO0171 00 0171 01 0171 07 20 REO0171 00 REO0171 00 REO0171 02 REO0171 08 25A 0171 00 REO0171 00 REO0171 03 REO0171 08 Table 3 5 HIGH AMPERE INTERRUPTING CAPACITY AC BREAKERS 1 240 Vac Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 6A RE0043 00 RE0043 00 RE0043 00 RE0043 01 12A RE0043 00 RE0043 00 RE0043 01 RE0043 04 16A RE0043 00 RE0043 00 RE0043 01 RE0043 07 20A RE0043 00 RE0043 00 RE0043 02 RE0043 08 25A RE0043 00 RE0043 00 RE0043 03 RE0043 08 66 10 1 Table 3 6 STANDARD DC CIRCUIT BREAKERS 2 Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 6A REO0159 01 REO0159 01 0159 01 0159 12 12 0159 02 0159 02 0159 02 RE0159 13 16A 0159 03 0159 03 0159 03 0159 14 20 0159 04 0159 04 0
48. CRIPTION SYMBOL DESCRIPTION Al MAIN CONTROL PRINTED CIRCUIT BOARD VR4 AC INPUT SURGE SUPPRESSOR L1 TO GND A6 RECTIFIER ASSY A3 A1B HEATSINK VRS INPUT SURGE SUPPRESSOR L2 TO GND C4 DC OUTPUT EMI FILTER CAPACITOR VRE DC OUTPUT SURGE SUPPRESSOR TO GND 5 DC QUTPUT EMI FILTER CAPACITOR VR7 C OUTPUT SURGE SUPPRESSOR TO GND CBI AC INPUT CIRCUIT BREAKER AIC DC QUTPUT CIRCUIT BREAKER AIC OPTIONAL COMPONENTS LI MAIN INDUCTOR 5 AUXILIARY ALARM RELAY PC B ARD NEAI R2 CURRENT RATING RESISTOR 10 EXTERNAL TEMPERATURE COMPENSATION PROBE R3 BALLAST RESISTOR 48 130 VDC FILTER CAPACITOR R4 SCALING RESISTOR POSITIVE LEG c2 BATTERY ELIMINATOR FILTER CAPACITOR VOLTAGE CROWBAR RESISTOR CRI POLARITY DIODE 214 SCALING RESISTOR NEGATIVE LEG CR2 BLOCKING DIODE n ISDLATIUN TRANSF RMER Fl AC INPUT FUSE 480 VAC INPUT ONLY TB3 SUMMARY ALARM CONTACTS L2 FILTER INDUCTOR TBS RESISTOR TERMINAL BLOCK R9 FILTER CAPACITOR C1 BLEED RESISTOR TBB TEMPCO PROBE AIO TERMINAL BLOCK AUXILIARY ALARM RELAY TERMINAL BLOCK VRI DC OUTPUT SURGE SUPPRESSOR TD 185 MED HIGH AIC CIRCUIT BREAKER JUNCTION BLOCK AC INPUT SURGE SUPPRESSOR L1 L2 AC LIGHTNING ARRESTOR LOCATED BEHIND 1 0 Note Online standard drawings saved in Adobe Acrobat Portable Document Format PDF for the AT10 1 Series Battery Charger are available for downloading and printing Please contact your sales representative for docu
49. ED END OF R14 CONNECTS REMOTE AND WIRE 21 CONNECTS TBS 2 TO REMOTE SENSE FEATURED OPTIONS AC FUSE Fl IS ONLY USED ON UNITS SPECIFIED WITH 480VAC INPUT AC INPUT CIRCUIT BREAKER 5 A TWO POLE DC CIRCUIT BREAKER IS SUPPLIED ON 130VOC UNITS MED HI INT CAPACITY ALL UNITS WITH MEDIUM HIGH AMPERE INTERRUPTING CAPACITY BREAKERS DC OUTPUT CIRCUIT BREAKER MED HI INT CAPACITY AUXILIARY RELAY PC BOARD CIRCUIT BREAKER INTERCONNECTION TERMINAL BLOCK IS USED WHEN DC OUTPUT FILTERING MEDIUM OR HIGH AMPERE INTERRUPTING CAPACITY BREAKERS ARE SUPPLIED 2 ELIMINATOR FILTER 7 FILTER CAPACITOR C1 CONSIST OF TWO 2 CAPACITORS CONNECTED EXTERNAL TEMPCO PROBE IN PARALLEL FOR 130VDC UNITS RATED 12 25 LIGHTNING ARRESTOR Note Online standard drawings saved in Adobe Acrobat Portable Document Format PDF for the AT10 1 Series Battery Charger are available for downloading and printing Please contact your sales representative for document availability or see the manufacturer s web site listed on the back cover of this manual 86 APPENDIX C Standard Drawings Connection Diagram AT10 1 Group I Battery Charger with Common Options JE5033 99 XX X Xn LONG CABLE TEMPERATURE E SHIELDED IN i GROUND 1 gt 3 P p MAIN CONTROL AUXILIARY ALARM PR BE A10
50. FECTIVE COMPONENTS WARNING High voltages appear at several points inside the battery charger Use extreme caution when working inside the charger Do not attempt to work inside the charger unless you are a qualified technician or electrician Disconnect and lock out all power from the battery charger before starting to remove or replace any components Turn the ac power off at the distribution panel upstream from the battery charger Disconnect the battery from the charger output terminals NOTE Refer to the drawings in Appendix C while performing the following procedures Removing the safety shield Some of the repair procedures described below require you to remove the clear plastic safety shield over the I O input output panel inside the front panel You remove the shield by taking off the wing nuts on the front Don t lay the shield on the top of the charger the top vents are needed for cooling CAUTION Hazardous ac dc voltages are present on the I O panel terminals and several internal components Removing the enclosure shroud You may need to remove the enclosure shroud in order to make some internal measurements and to replace or repair some components Remove all power from the charger Remove the eleven screws that hold the shroud on the rear and bottom of the enclosure then the two screws on the left side that hold the rectifier heat sink assembly Support the front panel and lift the shroud straight
51. J1133 10 EJ1133 15 34 8 13 0 KO 5 11 1 50 12A EJ1133 01 EJ1133 06 EJ1133 11 EJ1133 16 40 2 15 4 6 19 2 21 KO 16A EJ1133 02 EJ1133 07 EJ1133 12 EJ1133 17 53 6 19 6 7 50 2 74 KO 20A EJ1133 03 EJ1133 08 EJ1133 13 EJ1133 18 78 7 23 7 9 09 3 57 25A EJ1133 04 EJ1133 09 EJ1133 14 EJ1133 19 118 29 4 11 0 4 32 KO Molex Part No 11 03 0044 Table 3 11 MAIN TRANSFORMER 1 120 208 240 Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 6A 0718 00 0719 00 2023 00 1868 00 12 0718 00 0719 00 2023 00 1857 00 16 0720 00 1855 00 1856 00 1858 00 20 0720 00 1855 00 1856 00 1858 00 25 0720 00 1855 00 1856 00 1858 00 Table 3 12 MAIN TRANSFORMER 1 480 Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 6A 0733 00 0734 00 2038 00 2039 00 12 0733 00 0734 00 2038 00 2032 00 16 0735 00 2035 00 2036 00 2037 00 20 0735 00 2035 00 2036 00 2037 00 25 0735 00 2035 00 2036 00 2037 00 68 Table 3 13 FILTER INDUCTOR L2 SERVICING THE AT10 1 Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 6A AP0928 00 AP0928 00 AP0928 00 AP1081 00 12A AP0928 00 AP0928 00 AP0928 00 AP0928 00 16A AP0927 00 AP0927 00 AP0926 00 AP0926 00 20A AP
52. MMENDED MOUNTING AT10 1 MOUNTING FLANGE HARDWARE LOADING INSTALLING THE 10 1 1 5 2 Floor Mounting the AT10 1 To floor mount the 10 1 you must use the floor mounting accessory kit part number 10192 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 471in 1194mm above floor level with provision for floor anchoring The kit includes an instruction sheet 0083 showing assembly dimensions and mounting details You must locate the anchor bolt holes at least 4 25in 108mm from any wall to allow clearance for the charger enclosure behind the mounting brackets In addition you must consider the following 1 Placement of conduit entrances use the knockouts on the sides or bottom of the charger to allow access for servicing without removing the unit from the mounting brackets 2 The location Should be free of drips and splatter If dripping liquids a problem install a drip shield kit part number 10191 00 For kit availability see ordering information in Appendix B on page 71 e Should be between 32 and 122 F 0 and 50 C with relative humidity between 5 and 95 non condensing Must be free of explosive materials 3 Maintain at least 6in 152mm of free air on top bottom and both sides for cooling air 4 Allow 36in 914mm front clearance for operation and maintenance PROCEDURE To
53. MUNICATIONS BOARD A12 INTERCONNECTOR 14 FORCED LOAD SHARING BOARD A13 INTERCONNECTOR TERMINAL BLOCKS 215 MANUFACTURING TEST 183 SUMMARY ALARM RELAY CONTACTS JIB RESERVED TB4 AUXILIARY ALARM RELAY CONTACTS 17 GATE DRIVE BOARD 11 INTERCONNECTOR TB8 OPTIONAL TEMPCO PROBE A102 INTERCONNECTION TERMINAL BLOCK UNLESS DTHERWISE SPECIFIED ALL ALARM TERMINAL BLOCKS TB3 TBA TBB ARE SULDERLESS COMPRESSION TERMINALS CONTACT RATING IS 5 e 125 ACCEPTING 22 14 AWG WIRE THIRO ANGLE PROJECTION DRAWN BY MCR 022003 TITLE AT10 1 SERIES BATTERY CHARGER APPROVED INSTRUMENT PANEL 7 PC BOARD DETAIL ORAWING No REV 022003 TC TU JES030 19 o B Note This instrument panel drawing JE5030 19 depicts the optional Auxiliary Alarm Relay PC Board A5 which provides two 2 sets of individual form c contacts TB4 for all alarm conditions Standard AT10 1 battery chargers feature one 1 set of form c summary common alarm contacts TB3 79 APPENDIX C Standard Drawings Schematic AT10 1 Group Battery Charger Standard w o Options JE5031 00 1 CONNECTION TABLE INPUT JUMPER STANDARD H1 H3 H2 HS TRANSFORMER H2 H4 2 CNOTE 4 H2 H3 2 SCR MODULE ASSY AIB TRANSFORMER D PRI
54. OR If you want to exit the Edit mode now press the EDIT ENTER key again to return the charger to normal operation 33 THE AT10 1 Adjusting Ground Detection Sensitivity You can adjust the sensitivity of the ground detection alarm circuit You must have a test resistor whose value is the sensitivity you want You can adjust the sensitivity from 5 to 50 The potentiometer for adjusting ground detection circuit sensitivity is located on the main control circuit board It is the lower of the two potentiometers labeled RA3 SENS as shown in the figure at the right GROUND FAULT DISABLE JUMPER 1 2 PINS IN GROUND FAULT ENABLE JUMPER 2 3 PINS s 212 BALANCE SENS MAIN CONTROL CARD NOTE Do not try to adjust the upper potentiometer labeled RA2 BALANCE This adjustment is made at the factory for proper circuit operation CAUTION Before connecting or disconnecting a test resistor de energize and lock out all ac and dc voltage sources to the 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 1 and chassis ground as shown to the right Adjust RA3
55. SCALE NTS PART NO 5031 99 1 1 2 E1742 091004 E1203 040703 E1142 022003 83 APPENDIX C Standard Drawings Connection Diagram AT10 1 Group I Battery Charger Standard w o Options JE5033 00 Ll MAIN INDUCTOR X4 Y Y2 MODULE ASSY 16 E2 E10 EB E7 PC BOARD ASSY A3 874 a x 5 NOTES 12 CHARGER 5 ARE CONNECTED WITH FLAME RETARDANT SWITCHBDARD INSULATION TYPE WIRING IDENTIFIED ON EACH END WITH NUMBER CODED MARKERS CUSTOMER ALARM CONTACTS 183 TB4 etc ARE SOLDERLESS PLUG IN TERMINALS AND WILL ACCEPT 22 14 AWG WIRE WHEN REMOTE SENSE IS USED THE LUGGED END OF R14 CONNECTS TO REMOTE SENSEC 2 WIRE 21 CONNECTS 5 2 TO REMOTE FEATURED OPTIONS SEE SCHEMATIC FOR TRANSFORMER Tl PRIMARY CONNECTION TABLE AC INPUT CIRCUIT BREAKER STANDARD 12 24 AND 48 VOC UNITS CONTAIN A SINGLE POLE OC BREAKER CB2 IN THE NEGATIVE BUSS FOR THESE UNITS WIRE 15 TERMINATES DC QUTPUT CIRCUIT BREAKER TB1 AND WIRE 17 IS NOT USED Note Online standard drawings saved in Adobe Acrobat Portable Document Format PDF for the AT10 1 Series Battery Charger are available for downloading and printing Please contact your sales representative for document availability or see the manufacturer s web site listed on the back cover of this m
56. T indicator will light If there is an ac power failure during a timed equalize charge the 10 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 10 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 lights At any time during the equalize charge you can s
57. UNTING THE AT10 1 GRAPHICS Style 586 Enclosure 225in _ 8501 57mm 216mm y N 6in 153mm COOLING ABOVE UNIT COOLING 19 RACK MTG R FE E 5 BRACKET ASSY 10 MU 10193 00 lo 10 J ALLOW 6in 153mm FOR STANDARD 6in 153mm COOLING BELOWUNIT EIA SPACING COOLING Jj 25in 6 4mm MTG BOLTS Style 594 Enclosure 4 00 8 50 102 216mm COOLINGABOVEUNIT 153 COOLING RACK MTG BRACKETASSY EI0193 00 ALLOW 6in 153mm FOR STANDARD COOLINGBELOWUNIT EIA SPACING 6in 153mm COOLING J 25in 6 4mm MTG BOLTS NOTES 1 Units are installed from the front 2 Units shown above without penthouse enclosure If penthouse is used add 178mm to top of enclosure 3 Refer to the outline drawings in Appedix C for enclosure dimensions INSTALLING THE 10 1 1 6 CHANGING TRANSFORMER TAPS Before you wire ac power to the AT10 1 check the wiring of the main transformer T1 to be sure it is connected for your ac input voltage The 10 1 accepts standard input voltages of 120 208 or 240 Va
58. URE 1 120 208 240 Vac multi tap input Unit is wired and shipped from factory at specified voltage 2 480 Vac input requires addition of medium or high ampere interrupting capacity circuit breakers 3 Special order Please consult factory for availability INPUT AND OUTPUT CIRCUIT BREAKER INTERRUPTING RATINGS CODE TEE ALL BUT VOLTAGES 5 240 10 000 on Eu M MEDIUM AIC 454 AC 10 000 AIC H HIGH AIC 21 Mn EA Ac 25 000 AIC 4 Rating applies to 130Vdc 16 25 Adc units 5 Approximate rating applies to all other units 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 Enclosure drip shield assembly Floor mounting brackets Rack mounting brackets Cabinet heater assembly Please find the serial number on the data nameplate and record it here NEMA 4 12 13 type enclosure Pad lock for front panel door External temperature compensation probe DNP3 Level 2 Modbus communications module IMPORTANT SAFETY INSTRUCTIONS 10 11 12 Before using this equipment read all instructions and cautionary markings on this equipment B battery and C any other equipment to be used in conjunction with this
59. an interconnection cable from the probe assembly to the 10 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 the AT10 1 The kit 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 battery charger Use extreme caution when working inside the charger Do not attempt to work inside the charger unless you are a qualified technician or electrician Disconnect and lock out all power to the battery charger before starting to remove or replace any components Turn the ac power off at the distribution panel upstream from the battery charger Disconnect the battery from the charger output terminals 1 De energize and lock out all ac and dc voltage sources to the AT10 1 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 onunpainted wood or bare galvanized metal on plastic surfaces 3 apply the probe clean the mounting surface with isopropyl alcohol and allow to dry thoroughly Remove the protecti
60. and low dc voltage alarms sss 33 Adjusting ground detection sensitivity esse 34 Disabling the ground detection alarm sss 35 2 3 5 Setting the current limit value u u een 35 2 3 6 Enabling the high dc voltage shutdown feature 36 2 3 7 Adjusting the Voltmeter accuracy 37 2 3 8 Using the Low Level Detector 38 2 3 9 Using the front panel security feature 39 2 4 Performing routine 2 40 Sample preventive maintenance procedure 42 3 Servicing the AT10 1 Battery Charger 31 A step by step troubleshooting procedure 44 3 2 Interpreting front panel error MESSAGES 45 3 3 Using the troubleshooting 48 3 4 Troubleshooting chart begins on sss emen 49 3 5 Replacing defective components a 58 3 6 Ordering replacement parts u n 64 Replacement parts tables begin on 64 APPENDIX A AT10 1 Performance nnna 70 APPENDIX Field Installable Accessories U U U U uu uu nnns 71 APPENDIX C Standard Drawings
61. anual 84 APPENDIX C Standard Drawings Connection Diagram AT10 1 Group I Battery Charger Standard w o Options JE5033 00 MAIN CONTROL PC BOARD Al NOTE 2 0008 GROUND 5 CB2 DC 1 BREAKER 0 5515 GROUND 1204 040703 THIRO PROJECTION DRAWN BY MCR 040703 TITLE ATIO 1 SERIES BATTERY CHARGER CONN DIAG 25 GROUP 12 STD W O OPTIONS E1742 091004 APPROVED H 040703 SEINS C 1 SCALE NTS JE5033 00 1 85 APPENDIX C Standard Drawings Connection Diagram AT10 1 Group I Battery Charger with Common Options JE5033 99 Ll MAIN INDUCTOR 1 O X4 Y Y2 L2 FILTER INDUCTOR POLARITY ODE NOTE 7 m a 51 o gt i 9o cO 2 54 x lt ion 60 2 10 7 5 DC FILTERING ASSEMBLY A7 NOTES FUSE 03 12 CHARGER COMPONENTS ARE CONNECTED WITH FLAME RETARDANT SWITCHBOARD INSULATION TYPE WIRING IDENTIFIED ON EACH END WITH NUMBER LDDEO MARKERS AC NOTE 4 o4 BREAKER 2 2 CUSTOMER ALARM CONTACTS TB3 TB4 etc ARE SOLOERLESS PLUG IN NOTE 6 TERMINALS AND WILL ACCEPT 22 14 AWG WIRE 3 WHEN REMOTE SENSE IS USED THE LUGG
62. c by changing jumpers on T1 No other changes are required The AT10 1 is wired at the factory for 240 Vac except on special order Models for 220 380 or 416 Vac at 50 60 Hz are available on special order EXCEPTION An AT10 1 battery charger rated for 480 Vac input uses a special transformer that has no taps or jumpers The 480 Vac transformer cannot be used for any other input voltage Before changing the T1 taps be sure that ac and dc supplies to the 10 1 are turned off and locked out Verify that no voltage is present by using a voltmeter at terminals TB1 L1 and TB1 L2 ac TB1 and TB1 dc and remote sense terminals dc Note that turning off the ac and dc circuit breakers on the AT10 1 does not eliminate live voltages inside the enclosure Also de energize any external wiring to the alarm relay contacts Verify that all voltages within the enclosure are de energized and locked out See section 3 5 for necessary steps to follow when accessing internal components within the AT10 1 Change the jumpers on as shown in the table on the next page transformers have 2 jumpers always use both as specified in the table The transformers used in the small enclosure 586 use piggyback quick connect terminals The transformers in the larger enclosure 594 use 10 32 stud terminals Models designed for 220 Vac 50 60 Hz have no jumpers and can be used only for that voltage Models designed for 380 or 416 Vac also have no ju
63. ctive Replace the rectifier assembly 4 Turn off both front panel circuit 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 control circuit board 5 Disconnect the battery and connect a light dc load to the charger Measure the dc voltage from the input terminal to the output terminal of the circuit breaker with the breaker on It is normally no more than 50 millivolts If it is near the rated output voltage replace the breaker 55 10 1 PROBABLE SYMPTOM CAUSE RECOMMENDED ACTION DC OUTPUT 1 Defective 1 Use a clamp on ammeter to measure the current in wire FAILURE rectifier bridge 12 or 11 If it is less than 70 of the dc output current one indicator is of the SCRs or diodes is defective Replace the rectifier on but ac module 45 2 Defective 2 Turn off both front panel circuit breakers Then turn on the control circuit breaker followed by the ac breaker If the charger output coses board A1 voltage and current are normal but the DC OUTPUT FAILURE indicator is still on replace the control circuit board 3 Defective 3 Use an ac voltmeter to measure the ac voltage from T1 X1 transformer T1 to X4 It is normally 50 to 80 higher than the rated dc output voltage If it is too low check the wiring of the primary taps See secti
64. e Nickel Cadmium 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 Please 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 Please refer to the equation and table below for temperature adjusted voltages temperature adjusted voltage charge voltage x Temperature Temperature K K CF Lead Acid Nickel Cadmium 88 APPENDIX COMMUNICATIONS MODULE Your 10 1 Battery Charger has provisions for an optional Communications Module that allows the user to remotely monitor and control the charger over a serial connection This PC Board Assembly A12 supports DNP3 Level 2 and Modbus protocols over RS 232 or RS 485 half duplex The system can be used with a modem for telephone communications features of the 10 175 front instrument panel are accessible remotely using this option SCADA Supervisory Control And Data Acquisition systems will be able to control monitor and log the events of the battery charger The standard Communications Module kit EJ5037 XX includes the Communications PC Board A12 an exte
65. e Ambient temperatures of 32 to 122 F 0 to 50 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 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 10 1 is unpacked inspect the unit for possible shipping damage using the checklist below If shipping damage has occurred please refer to section 1
66. e assembly See Appendix B Table 2 A16 _ Rectifier SCR module EJ5094 00 C1 DC Output Filter capacitor RP0019 09 RP0019 08 C2 Eliminator Filter capacitor RP0019 09 RP0019 08 C4 filter capacitor See VR6 C4 C5 EMI filter capacitor See VR7 C5 CB1 breaker standard 120 208 240 Vac See Table 3 3 CB1 breaker med AIC 120 208 240 See Table 3 4 CB1 breaker high AIC 120 208 240 Vac See Table 3 5 CB1 circuit breaker med AIC 480 Vac 0171 00 CB1 circuit breaker high AIC 480 Vac 0043 00 2 DC circuit breaker standard See Table 3 6 CB2 DC circuit breaker medium AIC See Table 3 7 CB2 DC circuit breaker high AIC See Table 3 8 CR1 diode EJ1243 04 Y CR2 Blocking diode EJ1243 05 64 SERVICING THE AT10 1 Factory Part Number Rec Symbol Description 12 Vdc 24 Vdc 48 Vdc 130 Spares F1 480 Vac AC Input Fuse See Table 3 14 Y L1 Main Inductor See Table 3 9 L2 DC Filter Inductor See Table 3 13 P5 Jumper for disabling Ground Detection circuit 0100 00 P7 Jumper for voltage selection on 0100 00 Auxiliary Relay circuit board P9 Jumper for front panel lockout feature on A1 0100 00 R2 Rating resistor See Table 3 10 Power resistor EJ1127 00 EJ1127 01 EJ1127 02 EJ1127 03 Y 180 1000 2500 7500 1134 00 41134
67. e the control circuit board board A1 3 Defective 3 Check the harness wiring to the control circuit board wiring connector for signs of insulation damage burns etc Be sure all wires are securely crimped in the connector 51 10 1 SYMPTOM PROBABLE CAUSE RECOMMENDED ACTION Front panel dies during ac power failure 1 Defective power resistor R3 1 Use a dc voltmeter to measure the dc voltage from E17 on the I O panel to TB1 It is normally 12 when the rated output voltage is at TB1 and TB1 Remove all power from 2 Circuit board or another component may have been replaced 3 or R14 is defective or wrong value 4 Defective control circuit board A1 dc voltage is the charger and measure the resistance from TB1 and present at E17 See the table in section 3 6 for the proper resistance TB1 values If the resistance is not within 1096 of the table value replace R3 2 Defective 2 Remove the enclosure shroud and check the wiring to and wiring from TB1 and the control circuit board for signs of insulation damage or burns Repair any damaged wiring Charger 1 Defective 1 Disconnect wire 24 from terminal E3 of the rectifier output SCR assembly near the left front of the enclosure Restart the voltage too charger If You are able to measure output current one of the high not SCRs is defective Replace the rectifier asse
68. e transformer is properly connected for your input voltage Replacing the ac surge suppressors VR2 VR4 VR5 Turn off all power to the charger Disconnect the battery from the output terminals Remove the safety shield 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 4 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 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 61 10 1 Replacing the dc surge suppressor Turn off all power to the charger Disconnect the battery from the output terminals Remove the safety shield Remove the hardware from the output terminal 1 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 suppr
69. eck all 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 e Terminations at battery or bus are tight OK and corrosion free Check ac input e Measure at TB1 L1 and TBI L2 using voltage voltmeter Must be within 1096 12 of Input Vac nominal Check dc e Measure at TB1 and 1 using dc output voltage voltmeter Should agree with front panel Float Vdc voltmeter within 196 and must be correct values for your battery If the AT10 1 is Equal Vdc using a temperature compensation probe see the graph on page 23 to determine the correct battery voltage You need to know the battery temperature for this step Check ripple e Measure at battery terminals using ac voltage voltmeter set to millivolts scale Check against specification in Appendix A on Ripple mVac page 70 Test font panel e 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 THE AT10 1 Exercise front Switch from float to equalize then back to O OK panel controls float Turn off the dc circuit breaker E 07 OK should appear on display requires at least 5 of rated output current Reset breaker Cycle thr
70. eight Table located in section 1 4 on page 3 The weight of your AT10 1 may be different from the table value depending on options Or accessories you ordered Select conduit entrances carefully Use of the pref fab knockouts on the sides or bottom of the enclosure will allow removal of the cabinet shroud and internal access for servicing without removal of unit from the wall The location Should be free of drips and splatter If dripping liquids are a problem install a drip shield kit part number 10191 00 For kit availability see ordering information in Appendix B on page 71 Should be between 32 and 122 F 0 and 50 C with relative humidity between 5 and 95 non condensing Must be free of 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 operation and maintenance INSTALLING THE AT10 1 WALL MOUNTING THE AT10 1 GRAPHICS USE 0 25in 6 4mm DIA BOLTS m 4 PLACES AT10 1 MOUNTING DIMENSION 10 00 ENCLOSURE DIM A 254mm Style 586 15 00 381mm Style 594 25 18 25 464mm DIM A MOUNTING BOLT PATTERN 312in 8mm DIA FLAT WASHER LOCKWASHER 71 25in 6 4mm DIA BOLT 750in 19mm ENCLOSURE MOUNTING FLANGE 750in 19mm DIA WALL KEYHOLE SLOT USED ON RECO
71. equalize time current limit setting and alarm settings If your purchase order specified other float or equalize voltage settings a tag attached to the front panel of the AT10 1 lists the actual voltage 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 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 the error codes See section 3 2 for a full explanation of each error code Error Code Explanation E 01 Resistor R2 is open or defective E 02 Short circuit on output E 03 HVDC Shutdown has occurred E 04 Internal memory failure E 05 Not used E 06 Failure in Remote Sense wiring E 07 DC breaker is open or internal or external output wiring is defective E 08 Defective temperature compensation probe E 09 Misadjusted current limit E 10 Open internal feedback loop
72. er assembly DC breaker 1 Battery 1 Check and correct battery wiring if necessary trips connected with immediately polarity 2 Test by disconnecting wire 12 from the rectifier assembly Measure resistance between the two top rectifier terminals labeled AC on the wiring diagram it should be at least 100 000 Ohms check both polarities Replace rectifier assembly if resistance is low in either direction 3 Remove wire 13 from the rectifier control pc board Test the SCR module s internal free wheeling diode by measuring the resistance from E2 to E10 on A3 with an Ohmmeter The reading should be at least 100 000 Ohms in one polarity and less than 1 000 Ohms in the other polarity Replace the entire 16 SCR module if it is defective 4 Remove wire 15 from terminal E14 on the heat sink Measure the resistance from the heat sink to E8 on the rectifier control pc board at the left front of the charger check both polarities If the resistance is less than 1 000 Ohms in both directions replace the filter assembly 5 Check spacing of terminals check wiring for signs of insulation damage burns etc Repair as necessary 49 10 1 PROBABLE 3 Defective wiring 4 Defective transformer T1 SYMPTOM CAUSE RECOMMENDED ACTION DC breaker 1 Loose 1 Check and tighten connections as required trips aftera connection to few minutes b
73. ercharging 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 22 Percent Output Voltage 104 INSTALLING THE AT10 1 Please note the following You should set the Float and Equalize voltages to the values recommended by your battery manufacturer for 77 F 25 C When you enter the Edit mode to adjust the Float or Equalize voltage see section 2 3 2 the front panel meter shows the 77 F 25 C value for the Float or Equalize voltage even if the battery is warmer or cooler than 77 F 25 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 TT F 25 C Use a digital meter to measure the actual output voltage of the AT10 1 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 z N ckel Cadmium Example 100 Deg F 97 Output Voltage
74. erly support the weight of the AT10 1 See the Weight Table located in section 1 4 on page 3 2 Placement of conduit entrances be sure the knockouts on the sides or bottom of the charger are accessible after the charger is rack mounted 3 The location Should be free of drips and splatter If dripping liquids are a problem install a drip shield kit part number 10191 00 For kit availability see ordering information in Appendix B on page 71 Should be between 32 and 122 0 and 50 with relative humidity between 5 and 95 non condensing Must be free of explosive materials 4 Maintain at least 6in 152mm of free air on top bottom and both sides for cooling air 5 Allow 36in 914mm front clearance for operation and maintenance PROCEDURE To rack mount the AT10 1 first install the brackets onto the rack Second mount the AT10 1 onto the rack mounting brackets using the hardware supplied Provide at least 6in 152mm of air space above and below the 10 1 in the rack for cooling You do not need to modify the 10 1 enclosure Rack mount outline dimensions are shown on the next page CHARGER RATING RACK WIDTH Vdc Adc 19in 483mm 23in 584mm 24in 610mm 12 Vdc all Yes Yes Yes 24 Vdc all Yes Yes Yes 48 Vdc 6 12 Adc Yes Yes Yes 48 Vdc 16 25 Adc No Yes Yes 130 Vdc 6 Adc Yes Yes Yes 130 12 25 Yes Yes INSTALLING THE AT10 1 RACK MO
75. ers align the new R3 next to the I O panel so that the leads are properly spaced In 130 Vdc chargers remove the two screws that mount the old resistor and put the new resistor in its place Tighten all hardware 62 10 1 Replacing the scaling resistor R4 Locate the scaling resistor R4 on 5 on the back of the front panel just above the control circuit board The resistor R4 is the one on the left is mounted on two quick connect terminals Remove the resistor by grasping the terminals by the plastic insulation and pulling out and downward Install the replacement resistor by pushing the terminals firmly onto the quick connect blades on the terminal block Replacing the voltage crowbar resistor R6 Locate the resistor R6 on 5 on the back of the front panel just above the control circuit board The resistor R6 is the one on the right is mounted on two quick connect terminals Remove the resistor by grasping the terminals by the plastic insulation and pulling out and downward Install the replacement resistor by pushing the terminals firmly onto the quick connect blades on the terminal block Replacing the scaling resistor R14 Turn off all power to the charger Disconnect the battery from the output terminals Remove the safety shield The scaling resistor R14 is connected to TB with a ring lug The other lead of the resistor is soldered to wire 20 Remove the insulating sleev
76. essor is not polarized Replacing the dc surge suppressor networks VR6 C4 VR7 C5 Replace these networks as assemblies do not replace individual parts Turn off all power to the charger Disconnect the battery from the output terminals Remove the safety shield 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 For the 7 5 network use the above procedure but start with the lead on 1 Tighten all hardware Replace cut wire ties if possible NOTE The surge suppressor networks are not polarized Replacing the power ballast resistor R3 Turn off all power to the charger Disconnect the battery from the output terminals Remove the safety shield Locate the power resistor R3 On 130 Vdc chargers it is mounted on the bracket behind the I O panel On all other chargers it is installed just to the right of the panel Disconnect the lead of R3 wired to 1 and replace it with the corresponding lead of the replacement power resistor Remove the other lead of R3 from terminal E17 on the I O panel and replace it with the remaining lead of the replacement power resistor Tighten all hardware In 12 Vdc through 48 Vdc charg
77. etection sensitivity See section 2 3 4 calibration 3 Defective 3 Disconnect the charger from the battery and dc bus Turn wiring the charger on and measure the voltage from TB1 to chassis and from TB1 to chassis The voltage readings should be equal each approximately half of the total output voltage If there is more than a 1096 imbalance turn off the charger and inspect all wiring from TB1 to CB2 the optional dc filter L1 and the rectifier bridge Look for evidence of insulation damage insufficient spacing between terminals and chassis or wires run too close to metal edges 4 Defective 4 Turn off both front panel circuit breakers Then turn on the control circuit dc breaker followed by the ac breaker If you are sure there is board A1 no ground fault on the external bus or within the charger but the POS GND or NEG GND indicator is still on replace the control circuit board Summary 1 Defective 1 Turn off both front panel circuit breakers or turn off ac and alarm relay is control circuit dc power externally if the charger doesn t have breakers in alarm board A1 Then turn on the dc breaker followed by the ac breaker If the mode but no relay remains in alarm mode check the Low Level Detect front panel indicator on main control board See section 2 3 8 If no other alarm alarm is on replace the control circuit board indicator is on 57 10 1 3 5 REPLACING DE
78. floor mount the AT10 1 follow the directions featured in lt instruction sheet 740083 ey included with your floor 0 85 22 mounting kit part number 10192 00 These instructions showing assembly dimensions and mounting details Place the AT10 1 assembly on the mounting bolts add appropriate mounting hardware and tighten Reference the graphics on the next page INSTALLING THE AT10 1 FLOOR MOUNTING THE AT10 1 GRAPHICS DIM B 437in 11mm FLOOR HOLE FOUR 4 PLACES 10 00in 254mm DIM D 375 9 5mm FLOOR MOUTING HARDWARE FLOOR DRILLING PATTERN FOUR 4 PLACES DIMENSION in mm ENCLOSURE A B C D Style 586 16 50 419 46 63 1184 11 75 298 15 00 381 Style 594 19 75 502 47 75 1213 14 25 361 18 25 463 INSTALLING THE 10 1 1 5 3 Rack Mounting the AT10 1 The 10 1 can be installed in most relay racks with standard EIA hole spacing see the table below for the allowable combinations The rack mounting kit part number EI0193 00 includes mounting brackets and the necessary hardware to install one 10 1 battery charger The kit includes an instruction sheet JA0091 showing installation details For kit availability see ordering information in Appendix B on page 71 When rack mounting the 10 1 you must consider the following 1 The rack must be strong enough to prop
79. for other input voltages use the formula iy Sie V ac where Vac is the new input voltage and I is the input current from the table above 12 INSTALLING THE AT10 1 MAKING THE AC INPUT CONNECTIONS GRAPHICS REPLACE SAFETY COVER AFTER CONNECTIONS ARE MADE COMPRESSION SCREW TYP WIRING L2 CUSTOMER rm 13mm AC INPUT GROUND LINE 1 LINE 2 NOTES 1 The drawing above does not show other components mounted to the I O panel Be careful not to disconect any other component leads Always use a proper ground On 120 Vac input connect the neutral leg to the terminal L2 Wire insulation must be rated for 194 F 90 C or better Use copper or aluminum conductors only pode Uwe ps INSTALLING THE 10 1 1 8 MAKING THE DC OUTPUT CONNECTIONS Follow these steps to connect the battery to the 10 1 l 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 196 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 20 C WIRE SIZE DC CURRENT AMPERES AWG 6 12 16 20 25 16 2 5V 5 0V 6 7V 8 2V 10 5V 14 1 6V 3 2V 4 2V 5 3V 6 6 12 1 0V 2 0V 2 6V 3 3V 4 2V 10
80. g LEE EDI ENABLE ALARM RELAY CABLE ASSY STRIPPED LEADS TO TB8 e Unplug the harness ground wire 30 from terminal J6 on the left edge of the main control circuit board Plug the connector at the end of the nylon shielded wire of the cable assembly onto J6 Reconnect the ground wire 30 from the system harness onto the piggy back connector featured at the end of the nylon shielded wire e Using plastic wire ties tie the interconnection cable loosely to the existing wire harness Be especially sure that the cable conforms to the service loop at the hinge end of the door 6 Atthe 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 10 1 7 Check your work Be sure that connections are secure 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 1 set up for lead acid batteries While this 1s being displayed you can press any front panel key to change the display to read NICD to change the temperature compen
81. he new equalize timer duration is saved internally The timer setting works for both the manual timer and the auto equalize timer If you want to adjust the alarm settings skip to section 2 3 4 OR If you want to exit the Edit mode now press 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 high dc voltage and low dc voltage alarms There is a red indicator on the front panel of the AT10 1 for each of the following alarm conditions High DC Voltage Low DC Voltage DC Output Failure AC Input Failure Ground Fault Detection Ground Fault Detection The indicators light immediately when an alarm occurs The 10 1 also has a summary alarm relay with one form C contact rated 0 5A 125 Vac Vdc If an alarm condition lasts for 30 seconds or longer the summary alarm relay contact transfers When the alarm condition is corrected the relay and all indicators reset automatically The relay contact also transfers if the AT10 1 detects certain errors and displays E 03 E 06 E 07 or E 10 on the front panel meter 32 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
82. hmmeter See the table in section 3 6 for resistance values If either resistor is not within 196 of the specified value it must be replaced 4 Turn off both front panel circuit breakers Then turn on the dc breaker followed by the ac breaker If the charger still has the wrong output voltage replace the control circuit board 52 10 1 PROBABLE SYMPTOM CAUSE RECOMMENDED ACTION Charger 1 Current limit 1 If the AT10 1 is not in the Edit mode press the EDIT ENTER never set too low key five times until the meter display flashes the current limit reaches float value in Amperes If the current limit is less than 110 or equalize adjust it to 110 as described See Setting the Current Limit voltage Value section 2 3 5 for details within 1 2 Defective 2 Check each cell of the battery If one or more cells are battery or dc shorted the 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 Make sure the T1 primary taps are wired correctly for your input voltage or voltage too low or T1 wired incorrectly 4 Defecive rectifier bridge input voltage See Changing Transformer Taps section 1 6 for details The actual ac input voltage must be at least 88 of the rated value for the charger to produce full output power 4 U
83. ing from the soldered joint to wire 20 you may have to remove a harness tie and cut the resistor lead near the solder joint Disconnect the lugged end of R14 from 1 and discard the old resistor Using a soldering iron no larger than 35 Watts solder the bare lead of the new R14 to wire 20 Insulate the joint with plastic electrical tape Crimp a similar ring lug to the other lead of the new resistor Connect the lugged end of the new scaling resistor R14 to TB1 63 10 1 3 6 ORDERING REPLACEMENT PARTS To order replacement parts please provide the following information for each component e Circuit symbol from the schematic diagram see Appendix e Factory part number and description from the table below Model number and serial number of your battery charger Quantity required Call your sales representative to place an order for spare parts or replacement parts Table 3 1 REPLACEMENT PARTS Factory Part Number Symbol Description 12 Vdc 24 Vdc 48 Vdc 130 Vdc 2 A1 Main Control circuit board assembly EJ1243 10 Y A5 Auxiliary Relay circuit board assembly EJ1243 03 Y Rectifier control circuit board EJ5093 00 A6 Rectifier A16 Heat Sink assembly EJ1243 00 Y DCFilter assembly See Table 3 2 A8 EJ1155 00 EJ1155 01 A10 Temperature Compensation Prob
84. lity ANSI C37 90 1 1989 Current limit Adjustable 50 110 of rated output current Soft start 0 to 100 load 4 seconds Float 11 5 14 5 23 0 29 5 46 58 115 140 Equalize 12 15 5 24 31 48 61 124 143 High DC Voltage alarm 12 19 24 38 48 76 120 175 Low DC Voltage alarm 7 12 15 24 30 48 80 120 Voltmeter range Vdc 0 21 0 42 0 75 0 195 Ammeter range Adc ratings 0 30 Test per No erroneous outputs Reverse current from battery AC input power failure 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 0 50 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 FIELD INSTALLABLE ACCESSORIES AND OPTIONS accessories options listed below are available in kits for field installation Kits contain all parts and hardware with detailed installation instructions To order accessories options please provide the following information for each kit e Factory part number and description from the table below Model number and serial number of your battery charger e Quantity required Contact your sales representative to place an order for accessories options Auxiliary Relay PC Board A5 for
85. mal 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 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 Down key to scroll the value in the display upward downward When the display shows the float voltage you want to set release the 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 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 or DOWN key to increase or decrease the value in the display by one count or press and hold the or DOWN key to scroll the value in the display upward or downward When the display shows the equalize voltage you want to set release the or DOWN key If you go past the voltage you want press the or DoWN key again
86. mbly controllable 2 R4 or R14is 2 Remove one end of R4 from TB5 on the back of the front defective or panel Repeat for R14 connected to TB1 Measure their wrong value values with an Ohmmeter See the table in section 3 6 for resistance values If either resistor is not within 196 of the specified value it must be replaced 3 Defective 3 Remove the leads from the probe and measure its temperature resistance At 77 F 25 C the resistance should be about compensation 10 000 Ohms If it is not replace the probe assembly probe optional 4 Defective 4 If the front panel meter shows more than 110 of rated dc control circuit current the control board may be defective Disconnect wire board A1 24 from terminal of the rectifier assembly near the left front of the enclosure Restart the charger If the output current goes to zero replace the control board Output 1 Temperature 1 If the optional temperature compensation probe is installed voltage does compensation the output voltage may be different from the selected float or not agree probe is equalize voltage The difference in the voltages depends on with front installed the probe temperature The front panel meter always displays panel meter the proper voltage for 77 F 25 C 2 Recalibrate meter as described in section 2 3 7 3 Remove one end of R4 from TB5 on the back of the front panel Repeat for R14 connected to TB1 Measure their values with an O
87. ment availability or see the manufacturer s web site listed on the back cover of this manual 76 APPENDIX C Standard Drawings Internal Component Layout Detail AT10 1 Group Battery Charger w Common Options JE5027 99 NCLOSURE USED TO T BREAKERS NDTE 6 INPUT OUTPUT 2 BOARD AS TERMINAL BDARD m TBI DETAIL NOTE 2 SIGNAL HARNESS x COPPER GROUND BUSS BAR CONSULT USER S MANUAL FOR ADJUSTING TRANSFORMER 5 INPUT VOLTAGE 1 4 TURN 0008 FASTENER USE COPPER OR ALUMINUM CONDUCTORS ONLY AC_INPUT SINGLE PHASE 2 INPUT TERMINAL DESCRIPTION TYPE CONNECTION TBIC POS NEG OUTPUT TERMINALS CU ALUMINUM COMPRESSION LUG 14 6 AWG REM SENSE gt POS NEG REMOTE SENSE TERMINALS 10 32 SCREW HARDWARE 10 RING LUG 22 TBI GND GROUND TERMINAL CU ALUMINUM COMPRESSION LUG 14 6 AWG TBI L1 L2 AC INPUT TERMINALS CU ALUMINUM COMPRESSION LUG 14 6 SUMMARY ALARM TERMINAL BLOCK SOLDERLESS COMPRESSION 22 14 AWG B4 AUXILIARY ALARM TERM BLOCK SOLDERLESS COMPRESSION 22 14 AWG BB TEMPCO PROBE 10 gt INTERCONNECTION TERMINAL BLOCK 22 14 AWG NOTES 1 FOR DETAIL VIEWS OF ALL PC BOARDS AI AS etc SEE DRAWING JESO30 19 2 1 0 PANEL PROTECTION SHOWN ONLY ON DETAIL CONSISTS OF EMI FILTER 0 CAPACITORS C4
88. mpers and can be operated on either voltage NOTE This procedure refers only to Group I AT10 1 battery chargers rated 6 25 Ado different procedure exists for Group AT10 1 battery chargers rated 30 100 Please refer to the Operating and Service Instructions specific to the Group Il AT10 1 battery charger for changing the transformer taps on these larger units Otherwise damage to your charger and equipment may occur 10 INSTALLING THE AT10 1 CHANGING TRANSFORMER TAPS GRAPHICS 480 V 120 208 240 V T1 CONNECTION TABLE PRIMARY PRIMARY SECONDARY H4 o X1 INPUT VAC JUMPERS H5 H5 120 H1 H3 H2 H5 208 2 4 2 JUMPERS x Y H3 240 H2 H3 2 JUMPERS 480 NONE H1 1 TRANSFORMER SCHEMATIC PROCEDURE 1 BE SURE ALL VOLTAGES ARE DE ENERGIZED AND LOCKED OUT 2 BE SURE TERMINALS ARE FULLY SEATED 586 ENCL 3 BE SURE STUD TERMINALS ARE TIGHT 594 ENCL 4 CHECK YOUR WORK AFTER COMPLETION 5 FOR ADDITIONAL INFORMATION SEE WIRING DIAGRAM IN APPENDIX TYPICAL FOR TRANSFORMER IN 586 ENCLOSURE TYPICAL FOR TRANSFORMER IN 594 ENCLOSURE d JUMPERS 2 F1 5R2 11 INSTALLING THE 10 1 1 7 MAKING THE AC INPUT CONNECTIONS Follow these steps to connect ac power to the 10 1 l Use a branch circuit breaker or fused disconnect switch properly sized for the maximum input current of the 10 1 a
89. nductive 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 50 C If your charger is in a warmer environment or at an elevation over 3000ft 914m contact your sales representative for operating information Check power and signal connections Check the tightness of all 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 THE AT10 1 2 4 4 2 4 5 2 4 6 Check temperature compensation probe optional If you are using the optional temperature compensation probe 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
90. nel functions Selecting Equalize method e Changing settings using the EDIT ENTER key e Toggling the high dc voltage shutdown feature Open the front panel and locate the small plastic jumper J9 on the right side of the main control board See the figure below PANEL DISABLE JUMPER 2 3 PINS 3 PAN EDIT 4 ENAB 5 PANEL ENABLE JUMPER 1 2 PINS Move the jumper to the DISABLE position Now only the front panel METER MODE and CHRG keys work indicators still work normally 39 10 1 2 4 2 4 1 2 4 2 2 4 3 Performing routine maintenance WARNING High voltages appear at several points inside the battery charger Use extreme caution when working inside the charger Do not attempt to work inside the charger unless you are a qualified technician or electrician Disconnect and lock out all power to the battery charger before starting any maintenance procedures Turn the ac power off at the distribution panel upstream from the battery charger Disconnect the battery from the charger output terminals Keep it clean The 10 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 co
91. of this manual 80 APPENDIX C Standard Drawings Schematic AT10 1 Group Battery Charger Standard w o Options JE5031 00 TBIL REMOTE SENSE NOTE 3 VRI OUTPUT XXXVDC XXADC Bic REMOTE SENSE NOTE 3 NOTE 5 TBIL CB2 XXA MAIN CONTROL Al THIRD ANGLE PROJECTION DRAWN BY MCR 022003 ITE ATIO 1 SERIES BATTERY CHARGER Oy aree Qr 022003 SCHEMATIC 6 25ADC GROUP I STD W O OPTIONS 4 DRAWING REV UNLESS OTHERWISE NOTED J E 5 3 1 ARE IN INCHES TOLERANCES ARE SCALE P JESO31 00 1 1 2 1742 091004 1203 040703 0 E1142 022003 81 APPENDIX C Standard Drawings Schematic AT10 1 Group Battery Charger with Common Options JE5031 99 1 CONNECTION TABLE INPUT JUMPER HI H3 H2 H5 H2 H4 2 H2 H3 2 STANDARD TRANSFORMER CNOTE 4 LIGHTNING ARRESTOR TRANSFORMER STO gt SCR MODULE ASSY 16 ET ACIE GIL 1 62171 ace PC BOARD A3 RECTIFIER ASSEMBLY PRI SEC 5 H4 NO TBI LI F9 5 2 s ES VR2 H3 1
92. ommon alarm relay is not set for this condition E 10 Open internal feedback loop A redundant internal feedback loop control loop is provided as redundancy to increase reliability when remote sensing is used If there should be a problem with the internal loop wiring the charger displays E 10 Check the internal wiring in the signal harness especially wire 33 Also check the harness connector on the main control circuit board A 02 Equalize mode inhibited If you set the equalize timer to zero hours the equalize mode is inhibited When you try to put the charger 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 10 1 3 3 USING THE TROUBLESHOOTING CHART WARNING High voltages appear at several points inside the battery charger Use extreme caution when working inside the charger Do not attempt to work inside the charger unless you are a qualified technician or electrician Disconnect and lock out all power from the battery charger before starting to remove or replace any components Turn the ac power off at the distribution panel upstream from the battery charger Disconnect the battery from the charger output terminals Before you try to use the troubleshooting chart be sure that you have followed the steps in section 3 1 The
93. on 1 6 for details If it is zero replace T1 4 Defective dc 4 Disconnect the battery and connect a light dc load to the breaker charger Measure the dc voltage from the input terminal to the output terminal of the circuit breaker with the breaker on It is normally no more than 50 millivolts If it is near the rated output voltage replace the breaker AC INPUT 1 AC power 1 If the ac input power fails the front panel AC ON indicator FAILURE failure goes out and the AC INPUT FAILURE indicator goes on Indicator is 2 Upstream 2 Be sure the front panel ac circuit breaker is closed Measure feed the ac voltage at TB1 L1 and L2 If it is zero check upstream breaker fuse is distribution breakers and fuses tripped 3 Defective 3 Measure ac voltage at T1 H1 and T1 H5 It should be the wiring same as the ac supply voltage 4 Defective 4 Turn off both front panel circuit breakers Then turn on the control circuit dc breaker followed by the ac breaker If the ON indicator board A1 is on but the AC INPUT FAILURE indicator is still on replace the control circuit board 56 10 1 PROBABLE RECOMMENDED ACTION CAUSE POS GNDor 1 Ground fault 1 Disconnect the charger from the battery and dc bus and NEG GND on external check the battery and dc bus for a ground fault indicator is on bus 2 Ground detection circuit needs 2 Calibrate the ground d
94. ormal 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 charger If it is tripped try once to reset it If it trips again immediately there may be an internal short circuit in the charger Check the internal wiring If the charger 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 charger for service restart it according to section 2 1 E 03 High DC Voltage Shutdown To restart the charger turn the ac breaker off then on Check the Equalize voltage and High DC Voltage alarm settings The alarm setting must be higher than the Equalize voltage setting If you get another High DC Voltage shutdown after a few minutes of operation there may be an internal component failure See Charger output not controllable of the troubleshooting chart in section 3 4 45 10 1 failure Error i Code Meaning Repair Procedure 04 Internal memory parameters that you set such as Float or Equalize voltage 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 ap
95. ough meter modes OK O amps Hours Cycle through equalize methods MANUAL TIMER OK O MANUAL EqLz auto EQLZ TIMER OK Turn off ac circuit breaker The AC INPUT 0 Alarm OK FAILURE indicator should light Reset breaker Check voltage Use DIT ENTER key to scroll through FLOAT and alarm settings EQUALIZE OK settings HvDC alarm OK LvDC alarm OK Current limit Adc Final checks Be sure safety cover is in place OK Restore charger to normal operation OK Close latch on front panel close padlock OK if installed Step Instructions Results optional features Test auxiliary Press LAMP TEST key and hold for 4 OK alarm relays seconds Alarm relays will transfer Check Remote sense wiring OK integrity of Temperature compensation wiring OK remote sense Temperature compensation probe OK or temperature compensation wiring A full size reprint of this Preventive Maintenance Procedure is available Ask your sales representative for form JD0064 43 10 1 3 SERVICING THE AT10 1 3 1 ASTEP BY STEP TROUBLESHOOTING PROCEDURE The 10 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 l Check the front panel meter for an error
96. pair as necessary 4 Use an ac voltmeter to measure the ac voltage from T1 X1 to X4 It is normally 5096 to 8096 higher than the rated dc output voltage If it is too low check the wiring of the primary taps See section 1 6 for details If it is zero replace T1 50 10 1 PROBABLE SYMPTOM CAUSE RECOMMENDED ACTION No output 1 Battery is 1 This is normal operation in a system with little or no dc load current but fully charged As long as the charger maintains Float voltage it is operating ac and dc normally breakers are 2 Float or 2 Check the Float and Equalize voltages and adjust them if on AC ON Equalize necessary Consult your battery manufacturer for the proper lamp is on voltage set too voltage settings low 3 Wrong ac input voltage or T1 taps mis wired 4 Defective wiring 5 Defective rectifier bridge 6 Defective control circuit board A1 T Defective transformer T1 8 Defective inductor L1 or L2 9 Defective CR2 10 Defective 3 Be sure the T1 primary taps are wired correctly for your input voltage See section 1 6 for details 4 Check terminals and wiring between T1 and the rectifier assembly inductor L1 dc filter if present the dc breaker and the output terminals Repair as necessary 5 Use an ac voltmeter to measure the voltage between terminals E3 and 4 of the rectifier circuit board nearest the front of the charger If yo
97. pears try restarting the AT 10 1 by turning the ac and dc breakers off then on If the charger 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 failed E 05 Not used This error code was formerly used to indicate a reverse battery connection It is not available in the AT10 1 06 R14 is Locate mounted on 5 on the back of the front panel Remove the resistor and measure its value with an Ohmmeter see table 3 1 for the correct value If the resistor is not within 1 of the specified value it must be replaced Locate R14 inside the enclosure connected to TB1 Remove the lugged end and measure the resistor s value with an Ohmmeter see table 3 1 for the correct value If the resistor is not within 196 of the specified value it must be replaced If you are using remote sense wiring from the battery to the AT 10 1 the wiring may have failed The usual failure is an open circuit a short circuit will usually be indicated by smoke or fire in the wiring The AT10 1 charger displays the error code if it detects this wiring failure You should respond to this problem quickly to be sure that the AT10 1 regulates the output voltage properly Wire an annunciator buzze
98. put board A1 voltage is normal but the HIGH DC VOLTAGE indicator is still on replace the control circuit board No alarm but 1 Output 1 Output current must be greater than 296 of rated current to output current is below produce a High DC Voltage alarm See Parallel Operation in voltage is 296 section 2 3 6 above High 2 Defective 2 Turn off both front panel circuit breakers Then turn on the DC Voltage control circuit breaker followed by the ac breaker If the charger output setting board A1 voltage is above the alarm setting but the HIGH DC VOLTAGE indicator still doesn t light replace the control circuit board LOW DC 1 Battery is 1 After an ac power failure or a battery discharge for any VOLTAGE discharged other reason it may take several hours to recharge the indicator is battery It is normal for the LOW DC VOLTAGE indicator to be on but ac on until the battery voltage is above the Low DC Alarm and dc voltage pu are 2 Low DC 2 Be sure that the Low DC Voltage alarm setting is lower than Nb Id Voltage alarm the Float voltage setting See sections 2 3 2 and 2 3 4 input voltage and Float is normal 3 thareds voltage settings output current are mismatched 3 Defective rectifier bridge 4 Defective control circuit board A1 5 Defective dc breaker 3 Use a clamp on ammeter to measure the current in wire 11 12 If itless than 70 of the dc output current one of the SCRs or diodes is defe
99. r e g to the summary alarm relay TB3 to get a remote indication of any charger problem or monitor the charger 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 section 1 9 The locally controlled voltage may not reflect the true requirements of the battery When you complete the repair restart the charger as described in 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 charger may display an E 07 code Restart the charger according to section 2 1 If the battery and load are OK see the troubleshooting chart in section 3 4 for help in locating the problem 46 10 1 Meaning Repair Procedure E 08 Defective temperature compensation probe If a temperature compensation probe is connected to the AT 10 1 the control circuit detects the probe on startup and uses the temperature measured by the probe to control the output voltage of the charger To understand temperature compensation see
100. ransfers The 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 two more 22 chargers are connected In alarm setting Refer to section 2 3 4 parallel bolli Sense ilie The charger must be in normal operation not output voltage If the Edit mode to enable the high dc voltage Cheer Fane ENS XE SE supply all the output shutdown current the other has zero To enable the shutdown feature output current The high dc voltage shutdown does not e Press and hold the key then operate in a charger with e Press the MODE ke zero output current so that only the defective charger The HIGH DC VOLTAGE indicator lights and of two or more in parallel the display flashes ON You can toggle the shuts down The other shutdown feature OFF and ON by pressing the ch mar e load normally CHRG key repeatedly 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 EDITIENTER 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 THE AT10 1 2 3 7 Adjusting the Voltmeter
101. reaker 2 SCR 2 Use a clamp on ammeter to measure the current in wire 12 11 If it less than 70 of the dc output current then one of the SCRs or diodes is defective Replace the rectifier module 3 SCR not 3 Disconnect wire 24 from terminal E3 of the rectifier controllable assembly near the left front of the enclosure Restart the charger If You are able to measure output current one of the SCRs is defective Replace the rectifier assembly 4 Defective 4 If the front panel meter shows more than 110 of rated dc control circuit current the control board may be defective Disconnect wire board A1 24 as above If the output current goes to zero replace the control board No output 1 AC supply 1 If AC ON indicator is out check feeder circuit breaker or current but failure fuse ac and dc 2 Input fuse F1 2 Remove F1 from its fuseholder located on the bottom of the breakers blown 480 enclosure and check with an Ohmmeter or fuse tester ACON Vac input only Replace if 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 Check terminals and wiring between T1 and the rectifier assembly inductor L1 dc filter if present the dc breaker and the output terminals Check wire 29 from T1 Y1 and wire 28 from T1 Y2 to the control circuit board connector J1 Re
102. rnal power supply assembly A14 a separate AT Series Communications Module Operations Manual JA5026 00 and field retrofit instructions The Communications Module Operations Manual along with a sales catalog cut sheet is freely available for download from the web site featured on the back cover of this manual A compatible industry standard modem and modem cable are also available Contact your sales representative to place an order for the AT Series Battery Charger Communication Module Refer to the table below for ordering information Description PartNo Communications Module for 12 AT 10 1 EJ5037 01 Communications Module for 24 AT 10 1 EJ5037 02 Communications Module for 48 AT 10 1 EJ5037 03 Communications Module for 130 Vdc AT10 1 EJ5037 04 10ft 3 05m Modem Cable EH5026 00 25ft 7 62m Modem Cable EH5026 01 50ft 15 24m Modem Cable EH5026 02 UL DATA CAUTION To operate this charger from inputs other than 120 Vac you must use branch circuit protection To reduce the risk of fire use only on circuits provided with the following branch circuit protection in accordance with the National Electrical Code ANSI NFPA 70 Current Charger Voltage Rating Rating 48 Vdc 130 Vdc 48 Vdc 130 Vdc 12 Adc 25A 20A 16 Adc 15A 25A 12A 20A 20 Adc 20A 30A 15A 30A 25 Adc 25A 40A 20A 35A 208 Vac Branch Circuit 240 Vac Branch Circuit Protection Amperes Protection Amperes
103. ry Charger w Optional Auxiliary Relay PC Board JE5030 19 INDICATOR LIGHTS 0501 AC 0510 LOW LEVEL DETECT 0502 DC VOLTS 0511 METER DISPLAY 0503 DC AMPS 0512 METER DISPLAY gt 0504 EQUALIZE HOURS REMAINING 0513 HIGH DC VOLTAGE 0505 FLOAT 0514 LOW OC VOLTAGE 0506 EQUALIZE 0515 DC QUTPUT FAILURE 0507 MANUAL TIMER 0516 AC INPUT FAILURE 0508 MANUAL EQUALIZE 0517 POSITIVE GROUND 0509 AUTO EQUALIZE TIMER 0518 NEGATIVE GROUND O aw TIO 4 0501 gt 7 7 Advanced Technology 69 0502 BATTERY CHARGER e 503 Hi c RECTIFIER 0504 HIGH DC 99 0505 VOLTAGE 69 0506 0 MANUAL TIMER VOLTAGE G 0507 MANUAL EQLZ id 09 0508 AUTO EQLZ TIMER INPUT 0509 FAILURE LAMP TEST DISABLE POS GND o ENABLE ADJUST 5 56 TEES png an TET us uh v CM TS Ji rr 1 po wo 315 BKL NW Z enn SEE le S E Ku HAZARD DF ELECTRICAL SHOCK QUALIFIED PERSONNEL ONLY 00 NOT REMOVE THIS LABEL INSTRUMENT PANEL MAIN CONTROL PC PART 151 01 FRONT VIEW FACING CHARGER m oc woc ran 22000 SUN Sumruer summer NC NO Cc wc sc
104. ry polarity before proceeding 24 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 15 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 soft hum from the 10 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 key on the front panel The FLOAT indicator goes off and the yellow EQLZ indicator lights Press the CHRG key again to return the charger to the float mode The table below shows the normal factory settings for float and equalize voltages
105. s turned on The LAMP rEST key does not operate when ac power is off To test the action of the summary alarm relay press and hold the LAMP TEST key for four seconds The relay transfers If you are monitoring the relay with a remote annunciator it detects the alarm condition Testing the Auxiliary Relay Board optional If you have the optional Auxiliary Relay Board installed you can test the action of the alarm relays Press and hold the LAMP TEST key for four seconds The six auxiliary alarm relays on the Auxiliary Relay Board transfer Remote annunciators connected to these relays will indicate this Interpreting the alarm indicators There are six 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 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 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 AC INPUT FAILURE lights whenever the ac power supply to the charger is interrupted POS GND lights whenever leakage
106. s 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 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 specific requirements of your facility take precedence over these instructions Be sure the AT10 1 main transformer T1 is properly connected for your ac input voltage See section 1 6 for details Remove the safety cover 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 6 AWG wire are supplied for your convenience To make these connections strip the insulation 50in 13mm 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 45 in Ib 4 0 5 1 Nm 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 12 Adc CURRENT 12 24 48 130 battery charger draws 30 Aac at 6 2 4 8 14 120 12 3 7 14 30 16 4 9 18 32 currents shown are 10 20 5 11 23 39 25 6 14 29 49 To determine the input current lac
107. sation setup for nickel cadmium batteries The choice you make is saved internally and will be used again by the 10 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 s 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 the display The charger then reverts to normal non temperature compensated operation until the probe or wiring is repaired Once the probe is repaired you must restart the AT10 1 to activate the probe as described in section 2 1 Using temperature compensation Whenever 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 the battery is being charged with a float type charger with a constant output voltage the 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 10 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 ov
108. se a clamp on ammeter to measure the current in wire 12 11 If it less than 70 of the dc output current one of the SCRs or diodes is defective Replace the rectifier module 5 Defective 5 Turn off both front panel circuit breakers Then turn on the control circuit breaker followed by the ac breaker If the charger output board A1 current is below the current limit value but it still has the wrong output voltage replace the control circuit board Input current 1 Wrong ac 1 Be sure the T1 primary taps are wired correctly for your too high input voltage or transformer T1 wired incorrectly 2 Defective rectifier bridge 3 Defective T1 input voltage See Changing Transformer Taps section 1 6 for details The actual ac input voltage must be at least 88 of the rated value for the charger to produce full output power 2 Disconnect wire 24 from terminal E3 of the rectifier assembly near the left front of the enclosure Restart the charger If You are able to measure output current one of the SCRs is defective Replace the rectifier assembly 3 Test by disconnecting wires from X1 X4 Y1 and Y2 If ac input current is still too high replace T1 Output ripple voltage too high 1 Charger is unfiltered 2 Battery is disconnected or defective 3 Battery too small for charger rating 4 One or more defective filter capacitors C1 or C2 1 Verify by checking nameplate against
109. 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 for a 20 Adc charger the current limit is set to 22 Adc You can adjust the current limit downward to as low as 5096 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 the load current becomes larger than the current limit setting the battery will not charge properly The charger displays E 09 You should increase the current limit setting to supply the current required by the load NOTE The c
110. ss 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 10 1 charger is equipped with a summary alarm safety override circuit This safety feature forces the summary alarm common alarm relay contact to transfer sending an alarm even if there is a catastrophic failure of the control circuitry A low battery voltage triggers the safety circuit 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 MAIN RA1 CONTROL LOW LEVEL CARD DETECT JON Disconnect all ac and dc power sources from the 10 1 and connect your 4 power supply to the output terminals positive of the supply to the positive output of the charger Adjust the power supply to the voltage that you want to activate the alarm NOTE You need at least 50 of the nominal output voltage to power the circuit board Adjust RA1 until the alarm just activates There is a red LED indicator next to RA1 that indicates when the alarm is active 38 OPERATING THE AT10 1 2 3 9 Using the front panel security feature The 10 1 charger is shipped with all the front panel keys enabled You can disable these front pa
111. standard circuit breakers 210213 00 Auxiliary Relay PC Board 5 for med high AIC circuit breakers 10213 01 Standard DC Output Filtering 30 mV RMS with battery See table 3 2 Battery Eliminator Filtering See table 3 1 Remote Temperature Compensation Probe Assembly A10 See below AC Input Lightning Arrestor VR3 EJ1074 00 Copper Ground Buss with one 1 box lug for 14 6 AWG 210195 00 Floor Mounting Kit for Style 586 594 Cabinet 210192 00 Relay Rack Mounting Kit for Style 586 594 Cabinet 210193 00 Drip Shield Assembly for Style 586 594 Cabinet 210191 00 Cabinet Heater Strip Assembly for Style 586 594 Cabinet EJ1223 00 NEMA 4 12 13 Type Enclosure for Style 586 594 Cabinet 210214 00 Padlock for Front Door 210215 00 DNP3 Level 2 Modbus Communications Module See Appendix E Temperature Compensation Assembly The temperature compensation assembly consists of two 2 components 1 To order a replacement probe or puck request part number EJ5032 00 This probe is good for all charger output voltages and all battery types 2 The standard temperature compensation assembly is supplied with a 25ft 7 6m interconnection cable If you need a longer cable order it from the table below which also shows the ordering part number for a complete probe kit Temperature Compensation Probe Kits Cable Length Kit Part Number Replacement Cable feet m includes probe Part Number 25 7 6
112. tandard Drawings AT10 1 Optional Enclosure Outline Drawings Stlye 586 with Penthouse and Drip Shield DIMENSION in mm Standard WW 16 25 495 DD 12 50 324 15 63 457 16 25 495 10 75 337 with Penthouse WW 14 00 356 10 75 337 22 63 572 16 25 495 10 00 324 with Drip Shield WW 18 75 559 DD 12 50 318 19 50 552 W 16 25 495 10 75 337 with Penthouse amp Drip Shield WW 18 75 476 12 50 337 26 50 729 16 25 495 10 00 324 74 AT10 1 Optional Enclosure Outline Drawings Stlye 594 with Penthouse and Drip Shield APPENDIX C Standard Drawings OPTIONAL PENTHOUSE P SHIELD DIMENSION in mm Standard WW 19 50 495 DD 12 75 324 H 18 00 457 W 19 50 495 13 25 337 with Penthouse WW 14 00 356 DD 13 25 337 H 25 00 635 W 19 50 495 12 75 324 with Drip Shield WW 22 00 559 DD 12 50 318 21 75 552 W 19 50 495 13 25 337 with Penthouse amp Drip Shield WW 18 75 476 13 25 3
113. ter assembly is installed 5 Defective wiring SYMPTOM RECOMMENDED ACTION CAUSE AC breaker 1 Shorted 1 Test by disconnecting wire 12 from the rectifier assembly trips rectifier diode Measure resistance between the two top rectifier terminals immediately SCR labeled AC on the wiring diagram it should be at least 100 000 Ohms check both polarities Replace rectifier assembly if resistance is low in either direction 2 Defective 2 Check spacing of terminals check wiring for signs of wiring to T1 or insulation damage burns etc Repair as necessary to the rectifier heat sink assembly 3 Defective 3 Test by disconnecting wires from X1 X4 Y1 and Y2 If ac transformer T1 breaker still trips replace T1 AC breaker 1 Loose 1 Check and tighten connections as required trips aftera connection to few minutes breaker 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 11 12 If itless than 70 of the dc output current one of the SCRs or diodes is defective Replace the rectifier module 4 SCR not 4 Disconnect wire 24 from terminal of the rectifier controllable assembly near the left front of the enclosure Restart the charger If You are able to measure output current one of the 5 is defective Replace the rectifi
114. the replacement heat sink assembly When you are done check to ensure all wires are connected to the proper terminals and all lugs are fully seated If any lug does not fit snugly disconnect it carefully tighten the ears of the lug using long nosed pliers and reconnect 59 SERVICING THE AT10 1 Rotate the rectifier assembly into position in the enclosure Line up the metal tab with the mounting hole on the back wall of the charger and slide the assembly into position Replace the shroud as described in the previous section Tighten all screws and restart the AT10 1 Replacing the optional dc filter assembly A7 The dc filter assembly consists of a diode heat sink inductor L2 and one or two capacitors installed on a single bracket Turn off all power to the charger Disconnect the battery from the output terminals Remove the safety shield Find the flying lead from the inductor L2 wire 50 and disconnect the other end from the center terminal of inductor L1 at the upper right corner of the rear panel Disconnect wire 15 from the quick connect terminal at the top center of the diode heat sink and remove wire 54 from terminal E7 on the front circuit board on the rectifier assembly Carefully note which terminal the wire is connected to Remove the four screws at the top of the dc filter bracket The bracket and the inductor will both fall forward away from the rear panel Lift the filter bracket up about 25in 6
115. the AT10 1 for remote sensing follow the procedure and diagram on the next page 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 e Remove the remote sense leads from the remote sense and terminals on the I O panel Insulate each lead separately Coil up the wires and leave them in the bottom of the charger in case you want to wire for remote sense again in the future Reconnect wire 74 to the dc output terminal Reconnect wire 72 to the dc output terminal Restart the AT10 1 according to the instructions in section 2 1 16 INSTALLING THE AT10 1 PROCEDURE 1 De energize and lock out all ac and dc voltages within the AT10 1 enclosure Check with a voltmeter 2 Remove safety shield 3 Wire the AT10 1 remote sense to the dc bus as shown in the figure below SENS AT10 1 LEADS ABT RECTIFIER a DC BUS 4 Move wires 72 and 74 the TBI and dc output terminals to the corresponding remote sense terminals as shown in the lower left figure 5 Connect the external remote sense leads from the battery or dc bus to the remote
116. to reach the voltage you want to set 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 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 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 uP Down key again to reach the number you want to set If you set the equalize time to zero hours the equalize mode is disabled Press the EDIT ENTER key T
117. u measure about 1 0 Vrms but there is no output current replace the rectifier assembly 6 If you do not measure any ac voltage in step 5 above and the battery voltage is less than the Float voltage setting replace the control circuit board 7 Use an ac voltmeter to measure the ac voltage from T1 X1 to X4 It is normally 5096 to 8096 higher than the rated dc output voltage If it is too low check the wiring of the primary taps See section 1 6 for details If it is zero replace T1 8 Disconnect the wiring from L1 and measure the resistance between the terminals If it is an open circuit replace L1 Repeat for L2 if the optional dc filter is installed 9 Disconnect wire 52 from L1 to CR2 then check CR2 with an Ohmmeter check both polarities If CR2 is open replace the filter assembly This is a very rare occurrence 10 Disconnect the battery and connect a light dc load to the dc breaker charger Measure the dc voltage from the input terminal to the output terminal of the circuit breaker with the breaker on It is normally no more than 50 millivolts If it is near the rated output voltage replace the breaker Front panel is 1 Control 1 Make sure the connector at the top edge of the control dead ac and circuit board A1 circuit board is firmly seated dc voltages not are present at connected TB1 2 Defective 2 If the AC ON indicator is lit but the rest of the front panel is control circuit dead replac
118. up to remove it Be sure to save the plastic washers from the door hinge The heat sink assembly is supported from the rear panel Avoid putting any mechanical stress on the heat sink Replacing the enclosure shroud Lower the shroud onto the enclosure base Install and tighten the eleven screws that hold the shroud on the rear and bottom of the base before you install the two screws that support the heat sink assembly on the left side wall Remember to reinstall the plastic washers on the door hinge 58 10 1 Replacing the control circuit board A1 CAUTION A1 is sensitive to damage from static discharges Leave the circuit board in its anti static bag until you are ready to install it Ground yourself before handling the board by touching the ground stud on the back of the door Handle the board only by the edges Turn off all power to the charger Disconnect the battery from the output terminals If the optional temperature compensation probe is installed disconnect the leads from TB8 Remove the harness plug from the upper left edge of the control circuit board and unplug wire 30 from the quick connect terminal near the upper left corner of the board The board is mounted on six plastic standoffs Compress the tab on each standoff and pull the board toward you until it clears all the standoffs Put the replacement board in place with the same orientation and push it onto the standoffs Be
119. use WARNING electrician High voltages appear at several points inside the battery charger Use extreme caution when working inside the charger Do not attempt to work inside the charger unless you are a qualified technician or Disconnect and lock out all power from the battery charger before starting to remove or replace any components Turn the ac power off at the distribution panel upstream from the battery charger Disconnect the battery from the charger output terminals Error Repair Procedure Code 9 p 01 Resistor R2 Resistor R2 is installed at the back of the front panel in the control open or circuit board input connector R2 is measured by the control circuit on defective startup and is used to determine some of the AT10 1 charger 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 charger according to section 2 1 E 02 Short circuit on output You may get this error code if the battery is discharged to less than 6 volts When the battery charges to greater than 6 volts the error code disappears If you have a seriously discharged battery allow the charger 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 n
120. ve backing from the double faced adhesive tape on the probe and securely press it onto the surface 4 Install the cable supplied with the temperature compensation probe kit e Start at the AT10 1 The end of the cable with two stripped wires and one lead with a quick connect terminal will be connected inside the enclosure Leave 30 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 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 enclosure so CONNECT that it runs W PIGGY with the wire BACK harness to the back of the ES front panel and easily reaches the main control circuit board e main control circuit board insert one of the bare wires from the cable into each terminal of TB8 Polarity is not important MAIN CONTROL PC BOARD A1 HINDLEPDWER 051095 nh A
121. voltage and dc output current sure that they match the information on the Each 270 Seconds lights to e leit AT10 1 nameplate Verify that the jumpers xc display whether the main transformer are correct for your the meter is displaying ac supply voltage Open the front panel and voltage or current check the battery polarity at the TB1 and you want to freeze the meter to display only voltage terminals press the METER MODE Starting the AT10 1 key on the front panel To freeze the meter to display When you are sure that all connections to the Gb eurent prese the Key 10 1 are properly made follow these steps again Press the key twice to start up the 10 1 more to revert to the alternating display 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 batte
122. witch the charger back to float mode by pressing the 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 gt 12 gt FLOAT less than Resume EQUALIZE gt 12 seconds gt with time remaining 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 lights When the equalize timer is finished the charger reverts automatically to the float mode and the FLOAT indicator lights 28 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 key does not test the AC ON indicator The AC indicator lights whenever ac power is present and the ac circuit breaker i

Chevrolet 2001 Offroad Vehicle User Manual

Contents

Download Pdf Manuals

Related Search

Related Contents