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AT Series - 10 - Group 1

1. PROCEDURE 1 Allow 30 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 two 2 wire ties and allow a 4 6in 102 153mm loop for the hinge 3 Trim wires to the proper length for connecting to TB3 Strip 0 25in 6 4mm of insulation from the wires Make the connections at TB3 and securely tighten the screws NOTES 1 Alarm contacts are rated at 0 5A 125 Vac or Vdc 2 Summary Alarm relay terminal block TB3 is compression type accepting wire sizes 22 14 AWG 3 Terminals are labeled in non alarm condition 18 INSTALLING THE AT10 1 Auxiliary Relay Board optional The optional Auxiliary Alarm Relay PC Board A5 mounted inside the separate top enclosure penthouse provides two 2 form C contacts TB4 1 through TB4 36 for each of the following individual alarms e High DC Voltage Low DC Voltage DC Output Failure AC Failure Ground Fault Detection positive or negative Summary common Alarm Alarm contacts TB4 are as follows shown in non alarm condition DC OUTPUT DC OUTPUT GROUND GROUND HVDC HVDC LVDC LVDC FAILURE FAILURE AC FAIL AC FAIL DETECT DETECT SUMMARY SUMMARY 123 456 789 10 11 12 13 14 15 16 17 18 19 20 21
2. e Press the EDIT ENTER key The new float voltage setting is saved internally The EQLZ and DC VOLTS indicators light and the display flashes the present value of the equalize voltage Press and release the DOWN key to increase or decrease the value in the display by one count or press and hold the key to scroll the value in the display upward 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 UP or key again to reach the voltage you want to set e Press the EDIT ENTER key The new equalize voltage setting is saved internally If you want to adjust the equalize timer duration skip to Section 2 3 3 OR If you want to exit the Edit mode now press the 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 15 not saved 31 10 1 2 3 3 2 3 4 Setting the Equalize Timer e Press 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 equa
3. REMOTE SENSE NITE 3 NOTE 5 TBIC J CB2 XXA forsatinoinog sor mem 55 5687 MAIN CONTROL PC Al THIRD ANGLE PROJECTION 2 E1742 091004 MCR 022003 t ATIO 1 SERIES BATTERY CHARGER SCHEMATIC 8 25ADC GROUP 1 STD W O OPTIONS E1203 040703 022003 DRAWING No REV UNLESS DTHERWISE NOTED DIMENSIUNS 5031 00 2 ARE IN INCHES TOLERANCES ARE SCALE NTS PART No 5031 00 ur 1 http Awww ATSeries net PDFs JE5031 00 pdf 81 APPENDIX C Standard Drawings Schematic AT10 1 Group I Battery Charger with Common Options JE5031 99 T1 TABLE INPUT JUMPER HI H3 2 5 STANDARD TRANSFORMER H2 H4 2 CNOTE 4 22 LIGHTNING ARRESTOR TRANSFORMER T1 gt SCR MODULE ASSY A16 XX kAIC CB1 XXA PRE 5 H4 m N TBI LI o m 5 H5 gt Dc TB5 3 2 Les 5 X VR2 H3 an 4S ea xg TBI L2 o TB8 2 7 6 4 NOTE 6 Y2 TB1 GND Yi CHASSIS GROUND TRANSFORMER NITE 7 gt PE F1 PRI SEC g 4 x TB5 3 274 xo zu gt lt 1 SLIMMARY ALARM E TERMINAL BLOCK HI TB3 2 HIGH DC LOW DC DC OUTPUT AC GR
4. PROBABLE RECOMMENDED ACTION CAUSE AT 10 1 never 1 Current limit 1 If the AT10 1 is in the Edit mode press the reaches float set too low EDIT ENTER key five times until the meter display flashes the or equalize current limit value in Amperes If the current limit is less than voltage 110 adjust it to 110 as described See Setting the Current within 196 Limit Value Section 2 3 5 for details 2 Defective 2 Check each cell of the battery If one or more cells are battery or dc shorted the AT10 1 may not be able to reach the Float load or load is voltage You may have the same problem if the normal load too great current is more than the rated output current of the charger 3 Wrong ac 3 Make sure the T1 primary taps are wired correctly for your input voltage or voltage too low input voltage See Changing Transformer Taps Section 1 6 for details The actual ac input voltage must be at least 88 of the or T1 wired rated value for the charger to produce full output power incorrectly 4 Defecive 4 Use a clamp on ammeter to measure the current in wire rectifier bridge 12 or 11 If it less than 70 of the dc output current one of the SCRs or diodes is defective Replace the rectifier module 5 Defective 5 Turn off both front panel circuit breakers Then turn on the control circuit breaker followed by the ac breaker If the AT10 1 output board A1 current is below the current limi
5. TRANSFORMER 1 5 H4 m TBI LI amp o H5 gt 5 1 04 2 Les By VR2 Bou aon zo URN gt 95 TBI L2 N H1 TB1 GND CHASSIS GROUND Yi TRANSFORMER NITE 73 Tl Fi XXA PRI SEC g 4 TB5 3 ad SUMMARY ALARM TERMINAL BLOCK TB3 NOTE 2 8 NOTES 1 FOR COMPONENT DETAILS OF ALL PC BOARDS AS All etc SEE DRAWING 5030 10 2 ALL ALARM CONTACTS SHOWN IN NON ALARM STATE CONTACT RATING IS 5 125 RESISTIVE 3 WHEN REMOTE SENSE IS USED THE VOLTAGE SENSE LEADS RUN FROM R14 TO REMOTE SENSEC 2 FROM TBS 2 TO REMOTE SENSEC REFER FEATURED OPTIONS CONNECTION DIAGRAM FOR WIRING DETAILS AC INPUT CIRCUIT BREAKER 4 POWER TRANSFORMER T1 HAS MULTIPLE TAPS FOR 120 208 240 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 DC BREAKER 082 IN THE NEGATIVE BUSS OPTIONAL 480 VAC INPLIT TRANSFORMER FEATURES TAPS BUT 1 PDLE AC FUSE F1 AND MED AIC BREAKERS ARE REQUIRED 80 APPENDIX C Standard Drawings Schematic AT10 1 Group I Battery Charger Standard w o Options JE5031 00 TBIC REMOTE SENSE NOTE 3 OUTPUT XXXVDC XXADC
6. 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 10 1 only when necessary to make the sensitivity adjustment If your battery is grounded do not attempt this procedure Remove the safety cover Connect the test resistor between TB1 and chassis ground as shown to the right Adjust RA3 counterclockwise until the front panel indicator goes out then adjust slowly clockwise until the POS GND indicator just lights Make this adjustment slowly the indicator is updated once in every four seconds De energize and lock out power to the 10 1 then remove the test resistor and verify that the indicator goes out 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 TEST RESISTOR 34 10 1 2 3 5 Using Ground Detection in Charger Standby Mode If you put the AT10 1 into standby mode by opening the dc circuit breaker CB2 the ground detection circuit will send an erroneous negative ground alarm There are two ways to work around this e Disable the ground detection circuit w
7. 86 APPENDIX C Standard Drawings Connection Diagram AT10 1 Group Battery Charger with Common Options JE5033 99 IAIN TOR OO MAIN CONTROL PC FILTERING CAPCS R9 p NITE 7 5 CB2 DC 14 14 BREAKER NOTE 6 6 AKER THIRD PROJECTION AKER DRAWN BY RD MCR 040703 APPROVED e 040703 UNLESS OTHERWISE NOTED DIMENSIONS ARE IN INCHES TOLERANCES ARE 1 E1742 081004 1204 040703 XX X EJ SHIELDED X Xn LONG CABLE TEMPERATLIRE COMPENSATION PROBE 10 GROUND AUXILIARY ALARM RELAY PC BOARD 5 J4 P4 24y o o 48 e 130 J3 MOVE JUMPER PROPER PINS Te S e pepe pps 455 p C NC NO C NC C NC NO HIGH DC LOW DC DC OUT VOLTAGE VOLTAGE FAILURE C NC NO C NC NO GROUND DETECT C NC NO SUMMARY ALARM AC_IN NOTE 2 LIGHTNING ARRESTOR 5515 NV GROUND TITLE 1 SERIES BATTERY CHARGER CONN DIAG 6 25ADC GROUP 12 W COMMON OPTIONS REV DRAWING No 5033 99 1 B SCALE PART No NTS 5033 99 http Awww ATSeries
8. 84 Connection Diagram AT10 1 Group Battery Charger with Common Options 86 APPENDIX D Recommended Float Equalize Voltages Temp Compensation 88 APPENDIX E Communications 4 4444222 enne nn nnne nnne 89 APPENDIX Forced Load Sharing eese nennen nenne nennen 90 APPENDIX UL e 92 MANUAL SPECIFICATIONS document control information online availability 94 Note A customized record drawing package is available for your AT10 1 battery charger featuring an itemized internal component layout electrical schematic with component ratings and a full connection diagram If the standard drawings featured in this manual are not sufficient please contact your Sales Representative for drawing availability from the battery charger manufacturer RECEIVING THE AT10 1 1 RECEIVING THE AT10 1 1 1 STORING THE AT10 1 If you store the AT10 1 for more than a few days before installation you should store it in its original shipping container and in a temperature controlled dry climate Ambient temperatures of 32 to 122 F 0 to 50 C are acceptable Storage should not exceed 2 years due to the limited shelf life of the dc filter capacitors when they are not in service 1 2 REPORTING SHIPPING DAMAGE If on delivery of the AT10 1 or re
9. 27 Manual Equalize sss 28 Auto Equalize Timer 9 28 2 2 5 Testing the front panel indicators amp Summary Alarm Relays 29 2 2 6 Testing the Auxiliary Relay Board sse 29 2 2 7 Interpreting the alarm indicators ene 29 TABLE CONTENTS 2 3 Setting the AT10 1 parameters 2 3 1 Understanding parameter settings 30 2 3 2 Setting the Float and Equalize 5 31 2 3 3 Setting the Equalize nenne 32 2 34 Setting the Alarms edet e did ce d edid 32 Setting the high and low dc voltage alarms 33 Adjusting ground detection sensitivity see 34 Disabling the ground detection sss 35 2 3 5 Setting the current limit value menn 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 24 Performing routine 40 Sample preventive maintenance procedure 42 3 Servicing the AT10 1 Batter
10. PROBABLE RECOMMENDED ACTION DC breaker 3 Defective 3 Remove wire 13 from the rectifier control pc board A3 trips free wheeling Test the SCR module s internal free wheeling diode by immediately diode in SCR measuring the resistance from E2 to E10 on with i module A16 Ohmmeter The reading should be at least 100 000 Ohms in continued one polarity less than 1 000 Ohms in the other polarity Replace the entire A16 SCR module if it is defective 4 Defective 4 Remove wire 15 from terminal E14 on the CR1 heat sink polarity diode Measure the resistance from the heat sink to E8 on the if filter rectifier control pc board at the left front of the AT10 1 check assembly is both polarities If the resistance is less than 1 000 Ohms in installed both directions replace the filter assembly 5 Defective 5 Check spacing of terminals check wiring for signs of wiring insulation damage burns etc Repair as necessary DC breaker 1 Loose 1 Check and tighten connections as required trips aftera connection to few minutes breaker 2 Open SCR 2 Use a clamp on ammeter to measure the current in wire 12 or 11 If itless than 7096 of the dc output current then one of the SCRs or diodes is defective Replace the rectifier module 3 SCR not 3 Disconnect wire 24 from terminal E3 of the rectifier controllable assembly near the left front of the enclosure Restart the AT 10 1 If You are able to me
11. 15 24m Modem Cable EH5026 02 89 APPENDIX FORCED LOAD SHARING INTRODUCTION Multiple battery chargers are sometimes employed in dc power systems to provide redundancy Two or more chargers of the same voltage rating can be connected in parallel each of them capable of powering the connected dc load and charging the battery If a battery charger should fail during normal operation the parallel charger can continue to supply the entire required dc load current and maintain charge on the battery When two 10 15 operate in parallel they normally will not share the load current equally Since any two chargers will have slightly different characteristics one of the two chargers in a system will have a slightly higher dc output voltage and will therefore assume more of the burden of providing necessary load current This section describes an optional accessory for the AT10 1 battery charger that system operators can use to force units to share load equally The accessory consists of an interconnecting cable to provide such communication SYSTEM REQUIREMENTS The forced load sharing feature is designed only to work with two AT10 1 Series battery chargers You cannot force load sharing with three or more chargers The units must have the same dc voltage and current rating and have the same dc filtering level e Both chargers must have the same ac input source and the same phase rotation e Both chargers must f
12. Option without battery 12 Adc rating full load 96 67 00 72 00 78 00 85 00 Efficiency 25 Adc rating full load 96 73 00 77 00 85 00 91 00 196 rms t 2 rms Unfiltered with battery Sms OR gt at battery terminals Filtered with battery 20y me Mew i wi Output ripple voltage at battery terminals per NEMA PE5 1996 Filtered without battery 196 rms typ 2 rms Battery Eliminator Filter 30 mV rms 100 mV Surge withstand capability ANSI 37 90 1 1989 No erroneous outputs Current limit Adjustable 50 110 of rated output current Soft start O to 100 load 4 seconds Float Vdc 11 0 14 5 22 0 29 5 44 0 58 0 110 141 Equalize Vdc 11 7 15 5 23 4 31 0 46 8 59 0 117 143 Voltage adjustment ranges High DC Voltage alarm Vdc 12 19 24 38 48 76 120 175 Low DC Voltage alarm Vdc 7 14 5 15 29 5 30 58 80 141 Voltmeter range Vdc 0 21 0 42 0 75 0 195 Ammeter range Adc All ratings 0 30 Test per 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 F 0 50 C Elevation 3000ft 1000m without derating Relative humidity 0 to 9590 non condensing Alarm relay contact rating 120 Vac 125 Vdc 0 5 Aresistive
13. 70 APPENDIX B 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 Factory part number and description from the table below Model number and serial number of your battery charger Quantity required Contact your sales representative to place an order for accessories options Description Kit Part Number standard DC Output Filtering per NEMA PE5 1996 see table 3 2 Battery Eliminator Filtering per NEMA PE5 1996 see table 3 1 Auxiliary Relay PC Board A5 for standard circuit breakers 210213 00 Auxiliary Relay PC Board 5 for med high AIC circuit breakers 210213 01 Copper Ground Bus with one 1 box lug for 14 6 AWG 210195 00 AC Input Lightning Arrestor EJ1074 00 Floor Mounting Kit for Style 586 594 Enclosure EIO 192 00 Relay Rack Mounting Kit for Style 586 594 Enclosure 210193 00 2 Shield Assembly for Style 586 594 Enclosure 210191 00 NEMA 4 12 13 Enclosure for Style 586 594 Enclosure 210214 Cabinet Heater Assembly Style 586 594 Enclosure EJ1223 00 Padlock for Style 586 594 Enclosure Front Panel Door 210215 00 Remote Temperature Compensation Probe Assembly A10 see below DNP3 Level 2 Modbus Communications Module see Appendix E
14. 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 conductive carefully vacuum out the interior Be sure to clean surfaces of circuit boards and around electrical terminals The 10 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 th
15. 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 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 PROCEDURE 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 b
16. lt 55 00 FILTER 5 gt ASSEMBLY SEE DETAIL CRI i T N RIGT 4 eG E Oji U o Q CR2 2 le JX CHASSIS N GROUND STUD eese o TB8 XXft X XXn CABLE CLEAR Le Ce SAFETY COVER CNET E NITE 4 10 1 GROUP I STANDARD COMPONENTS SYMBOL DESCRIPTION SYMBOL DESCRIPTION Al MAIN CONTROL PRINTED CIRCUIT BOARD AC INPUT SURGE SUPPRESSOR L1 GND A6 RECTIFIER ASSY A3 AIE HEATSINK VRS AC INPUT SURGE SUPPRESSOR 12 GND C4 DC OUTPUT EMI FILTER CAPACITOR VRE DC OUTPUT SURGE SUPPRESSOR GND C5 DC OUTPUT EMI FILTER CAPACITOR VR7 C OUTPUT SURGE SUPPRESSOR GND AC INPUT CIRCUIT BREAKER M H CB2 DC OUTPUT CIRCUIT BREAKER AIC OPTIONAL COMPONENTS B Ll MAIN INDUCTOR 5 AUXILIARY ALARM RELAY PC BOARD NEAR 22 CURRENT RATING RESISTOR ALO EXTERNAL TEMPERATLIRE COMPENSATION PROBE BALLAST RESISTORS 130 VDC FILTER CAPACITUR R4 SCALING RESISTOR POSITIVE LEG C2 BATTERY ELIMINATUR FILTER VOLTAGE CROWBAR RESISTOR CRI POLARITY DIODE R14 SCALING RESISTOR NEGATIVE LEG CR2 BLOCKING DIODE POWER ISOLATION TRANSFORMER Fl AC INPUT FUSE 480 VAC INPUT ONLY T83 SUMMARY ALARM CONTACTS L2 FILTER INDUCTOR 785 RESISTOR TERMINAL BLOCK RB FILTER CAPACITOR C1 BLEED RESISTOR TBB PROBE A10 TER
17. TBIL REMOTE SENSE NOTE 3 lt x gt lt vrai gt x UJ REMOTE SENSE NITE 3 NOTE 5 TBIL TB6 14 TB6 16 NOTE 6 ARM RELAY RDAS MAIN CONTROL Al TEMPERATURE COMPENSATION PROBE 10 ANGLE PROJECTION DRAWN BY MCR 022003 10 1 SERIES BATTERY CHARGER A 022003 SCHEMATIC 6 25ADC GROUP 1 W COMMON OPTIONS DRAWING No REV UNLESS OTHERWISE NOTED DIMENSIONS JE5031 99 2 B A ARE IN INCHES TOLERANCES ARE AKER 2 1742 091004 E1203 040703 1142 022003 ARD SCALE NTS PART No JE5031 99 ur 1 http Awww ATSeries net PDFs JE5031 99 pdf 83 APPENDIX Standard Drawings Connection Diagram AT10 1 Group Battery Charger Standard w o Options JE5033 00 L1 MAIN INDUCTOR X1 X4 Y2 TRANSFORMER HI H3 H2 H5 H4 SCR rf MODULE ASSY 16 em en em EX N E2 E10 7 E5 EB PC BOARD ASSY zd nz ES tv ew u tv NOTES 1 CHARGER COMPONENTS ARE CONNECTED WITH FLAME RETARDANT SWITCHBOARD 3 CBI AC INSULATION TYPE WIRING IDENTIFIED ON EACH END WITH NUMBER CODED MARKERS CUSTOMER ALARM CONTACTS lt 4 etc ARE SULDERLESS PLUG IN
18. 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 normal then check the wiring at the dc output terminals for a short circuit If the battery voltage is normal and all external wiring is OK check the dc breaker on the 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
19. 12 ENCLOSURE IS A 1 1 20 TYPE CABINET WITHOUT GASKETS 22 ALLOW Bin 152mm OF FREE AIR AND FRONT OF CABINET FOR VENTILATION 35 FOUR 4 KEY HOLE SLOTS ARE PROVIDED THE BACK DF ENCLOSURE AS SHOWN FOR WALL MOUNTING WITH 25in 6 25mm HARDWARE 4 FOUR 4 1 31 in 33mm DIA KNOCKOUTS ARE PROVIDED AS SHOWN WITH TWO 25 ADDITIONAL KNOCKOUTS FEATURED ON BOTTOM PANEL OF ENCLOSURE USE OF ANY OF THESE FOUR 4 LOWER CONDUIT KNOCKOUTS WILL ALLOW REMOVAL OF THE CABINET SHROUD WITHOUT REMOVAL OF EXTERNAL WIRING 55 DATA NAMEPLATE WITH CHARGER RATINGS MOUNTED DN x h 3 LEFT SIDE DF ENCLDSLRE SN 6 BATTERY CHARGER SHIPPING WEIGHT RANGE APPROXIMATELY 44 20 Ibs 80 36 kg DUAL DIMENSIONS nn THIRD Lo ANGLE W PROJECTION DRAWN BY MCR 012304 AT10 1 SERIES BATTERY CHARGER OUTLINE APPROVED NEMA 1 STYLE 586 ENCLOSURE DRAWING N 1542 012304 ME Ret SEE ELS JES023 03 SCALE 5023 03 SHEET 1 D uq FILENAME 5023 03 http Awww ATSeries net PDFs JE5023 03 pdf
20. 22 2324 25 26 27 28 29 30 313233 34 35 36 C NC NO C NC NO C NC NO C NC NO C NC NO C NC NO C NC NO C NC NO C NC NO C NC NO C NC NO C NC NO VOLTAGE SELECTOR SWITCH DETAIL MEM 4 m N 12 VOLTS 24 0115 co 48 VOLTS 130 VOLTS AUXILARY ALARM RELAY PC BOARD A5 Follow the procedure below to wire annunciators to one or more of these remote 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 annunciator wiring use 22 14 AWG to the appropriate terminals of TB4 on the back wall of the penthouse enclosure as shown in the figure above Strip each wire 0 25in 6 4mm and securely tighten the terminal screws 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 Auxiliary Alarm Relay terminal block TB4 is compression type accepting wire sizes 22 14 AWG 3 Terminals are labeled in non alarm condition 19 INSTALLING THE AT10 1 1 11 INSTALLING TEMP COMPENSATION ASSEMBLY OPTIONAL
21. ASSY A16 Sz ES een ez e N 7 aa 1 PLUG IN 2 E7 ES CHARGER COMPONENTS ARE CONNECTED WITH FLAME RETARDANT SWITCHBOARD INSULATION TYPE WIRING IDENTIFIED ON EACH END WITH MARKERS CUSTOMER ALARM CONTACTS TB3 TB4 etc ARE SULDERLESS PLUG IN TERMINALS AND WILL ACCEPT 22 14 AWG WIRE WHEN REMOTE SENSE IS USED THE LLIGGED END OF R14 CONNECTS REMOTE SENSEC 2 AND WIRE 21 CONNECTS 5 2 REMOTE AC FUSE F1 IS ONLY USED DN UNITS SPECIFIED WITH INPUT A TWO POLE DC CIRCUIT BREAKER IS SUPPLIED DN 1 UNITS AND ALL UNITS WITH MEDIUM HIGH AMPERE INTERRUPTING CAPACITY BREAKERS CIRCUIT BREAKER INTERCONNECTION TERMINAL BLOCK IS USED WHEN MEDIUM OR HIGH AMPERE INTERRUPTING CAPACITY BREAKERS ARE SUPPLIED FILTER CAPACITOR C1 CONSIST OF 2 CAPACITORS CONNECTED IN PARALLEL FOR 130VDC UNITS RATED 12 25 L1 MAIN INDUCTOR L2 FILTER INDUCTOR DE FILTERING ASSEMBLY A7 AC BREAKER NOTE 6 FEATURED OPTIONS AC INPUT CIRCUIT BREAKER INT CAPACITY DC OUTPUT CIRCUIT BREAKER INT CAPACITY AUXILIARY RELAY PC BOARD DC OUTPUT FILTERING BATT ELIMINATOR FILTER EXTERNAL PROBE LIGHTNING ARRESTOR FIL NITE 7 51 54 60 01 02
22. 2 Defective rectifier bridge if unfiltered charger SYMPTOM RECOMMENDED ACTION CAUSE Front panel 1 An external 1 Soft Reset of control board by pressing S7 reset switch meter surge has 57 is located inside the AT10 1 on the control board s right displays all interrupted edge as viewed from the rear of the front panel This will segments operation of the restart the control board without modifying any settings On or all microprocessor 4B Hard Reset of control board by pressing and holding the segments or the display UP button on the front panel and simultaneously pressing Off AT10 1 controller S7 reset switch This will restart the control board and restore may have no all settings to factory default Reset parameters per Section output 2 3 of this manual 1C Remove all power from AT 10 1 to allow control board to discharge all voltages This can be done by opening the AC circuit breaker and disconnecting the control board plug s Keep power removed for approximately 5 minutes to allow voltages to discharge 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
23. 356 DD 13 25 337 25 00 635 W 19 50 495 12 75 324 with Drip Shield WW 22 00 559 DD 12 50 318 HH 21 75 552 W 19 50 495 13 25 337 with Penthouse amp Drip Shield WW 18 75 476 DD 13 25 337 HH 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 OPTIONAL PENTHOUSE ENCLOSURE E HOUSE SPECIAL CIRCUIT BREAKER AND AUXILIARY ALARM PC BOARD ALARM j RELAY BOARD AS Tm SIGNAL NITE 129 HARNESS DC OUTPUT 158 MP M 121 4 i I 1 JO i VR3 Em MAIN CONTROL 7 PC BOARD m 7 ESL NOTE 1 ii P 2 me mi
24. Forced Load Sharing Accessory EJ5126 XX Remote Temperature Compensation Probe The temperature compensation assembly consists of two 2 components 1 To order a replacement probe or puck request part number EJ5032 00 This probe is good for all charger output voltages and all battery types 2 The standard temperature compensation assembly is supplied with a 25ft 7 6m interconnection cable If you need a longer cable order it from the table below which also shows the ordering part number for a complete probe kit Temperature Compensation Probe Kits Cable Length Kit Part Number Replacement Cable feet m includes probe Part Number 25 7 6 EJ5033 00 EJ5011 00 50 15 2 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 I Battery Charger NEMA 1 Style 586 JE5023 03 3 1 2 BS 65 y 4771 5 7 8 8 10 i es MANLIAL moa o 2 C 3 LAC DC outeur 15 00 MTG 381 MTG gt 16 25 413 mm NOTES
25. 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 AT10 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 normal operation The new settings take effect immediately Edit mode ends automatically if you don t press any front panel key within 25 seconds and any change you made to the last setting 15 not saved 30 10 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 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 or 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 DOWN key again to reach the voltage you want to set
26. the AT10 1 displays LEAD on the front panel indicating that the temperature compensation is set up for lead acid batteries While this is being displayed you can press any front panel key to change the display to read NICD to change the temperature compensation setup for nickel cadmium batteries The choice you make is saved internally and will be used again by the 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 damag
27. 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 14 forced load See Appendix F on page 90 Verify both chargers are functioning sharing not properly Ensure that the forced load sharing interconnection cable working assembly is not broken is properly installed and that the connector properly for the Secondary charger has the jumper as described Ensure that both chargers are connected to the same ac supply and that source phase rotation is the same for both chargers 02 equalize mode If you set the equalize timer to zero hours the equalize mode is inhibited 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 fro
28. 03 12A EJ1072 00 EJ1072 00 EJ1072 02 EJ1072 06 16A EJ1072 01 EJ1072 01 EJ1072 07 EJ1072 04 20A EJ1072 01 EJ1072 01 EJ1072 07 EJ1072 04 25A EJ1072 01 EJ1072 01 EJ1072 07 EJ1072 05 Table 3 3 STANDARD AC CIRCUIT BREAKERS 1 120 208 240 Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 6A 159 11 159 11 159 11 159 13 12 159 11 159 11 RE0159 13 159 16 16 159 11 RE0159 12 RE0159 13 159 19 20 159 11 RE0159 12 159 14 159 20 25 159 11 RE0159 12 RE0159 15 159 20 Table 3 4 MEDIUM INTERRUPTING CAPACITY BREAKERS CB1 120 208 240 Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 6A 171 00 171 00 REO0171 00 171 01 12 171 00 171 00 171 01 171 04 16 171 00 REO0171 00 REO0171 01 171 07 20 REO0171 00 171 00 REO0171 02 REO0171 08 25A 171 00 171 00 171 03 0171 08 Table 3 5 HIGH INTERRUPTING CAPACITY BREAKERS CB1 120 208 240 Vac Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 6A 043 00 043 00 043 00 043 01 12 043 00 043 00 043 01 043 04 16 043 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
29. 72 APPENDIX C Standard Drawings Outline AT10 1 Group I Battery Charger NEMA 1 Style 594 JE5024 03 12 ENCLOSURE IS A 1 1 20 TYPE CABINET WITHOUT GASKETS 22 ALLOW Bin 152mm OF FREE AIR AND FRONT OF CABINET FOR VENTILATION 3 FOUR 4 KEY HOLE SLOTS ARE PROVIDED THE BACK DF ENCLOSURE AS SHOWN FOR WALL MOUNTING WITH 25in 6 25mm HARDWARE 42 FOUR 4 1 31 in 33mm DIA KNOCKOUTS ARE PROVIDED AS SHOWN WITH TWO 25 ADDITIONAL KNOCKOUTS FEATURED ON BOTTOM PANEL OF ENCLOSURE USE OF ANY OF THESE FOUR 4 LOWER CONDUIT KNOCKOUTS WILL ALLOW REMOVAL OF THE CABINET SHROUD WITHOUT REMOVAL OF EXTERNAL WIRING 55 DATA NAMEPLATE WITH CHARGER RATINGS MOUNTED DN LEFT SIDE OF ENCLOSURE 6 gt BATTERY CHARGER SHIPPING WEIGHT RANGE APPROXIMATELY 110 193 Ibs 7 50 kg 4 00 3 4 102 O le 6 5 8 18 00 2 CO amp 457 MANLIAL Ac input nureur 6 18 25 MTG gt 464 MTG gt 4 18 50 470 NOTES DUAL DIMENSIONS in SAN THIRD MEE DRAWN BY MCR 012304 AT10 1 SERIES BATTERY CHARGER OUTLINE APPROVED 1 STYLE 584 ENCLOSURE DRAWING Ni 0 1542 012304 A I
30. 7V 8 2V 10 5V 14 1 6V 3 2V 4 2V 5 3V 6 6V 12 1 0V 2 0V 2 6V 3 3V 4 2V 10 0 63V 1 3V 1 7V 2 1 2 6V 38 0 40V 0 80V 1 1V 1 3V 1 7V 6 0 25V 0 50V 0 66V 0 83V 1 1 4 0 16V 0 32V 0 42V 0 52V 0 65V EXAMPLE 100ft 30 5m of 8 AWG wire at 16A has a 1 1V drop 2 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 system remote sense wiring is recommended see Section 1 9 3 Do not run external ac and dc power wiring feeding the battery charger through the same conduit 4 All specific requirements of your facility take precedence over these instructions PROCEDURE 1 Usea dc disconnect switch or circuit breaker between the AT10 1 and dc bus This device should have lockout capability to allow the AT10 1 to be disconnected from the dc bus for maintenance 2 Remove the safety cover 3 Run dc wiring to terminals TB1 and on the I O panel in the enclosure Compression lugs accepting wire sizes 14 6 AWG are 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 4 Using a flat head screwdriver securely tighten the compression screws on the lugs to 35 45 in lb 4 0 5 1 Nm 5 Reinstall the safety cover after you have made and checked all connections 14 INS
31. AP0926 00 AP0926 00 AP0931 00 20A AP0926 00 AP0926 00 AP0926 00 AP0931 00 25A AP0926 00 AP0926 00 AP0926 00 AP0931 00 67 SERVICING THE AT10 1 Table 3 10 RATING RESISTOR R2 Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 6A EJ1133 00 EJ1133 05 EJ1133 10 EJ1133 15 34 8 13 0 5 11 1 50 12A EJ1133 01 EJ1133 06 EJ1133 11 EJ1133 16 40 2 15 4 6 19 kQ 2 21 16A EJ1133 02 EJ1133 07 EJ1133 12 EJ1133 17 53 6 19 6 7 50 2 74 20 1133 03 1133 08 1133 13 1133 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 a Molex Part No 11 03 0044 Table 3 11 MAIN TRANSFORMER T1 120 208 240 Vac Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 6A 0718 00 0719 00 2023 00 1868 00 12A 0718 00 0719 00 2023 00 1857 00 16A 0720 00 AB1855 00 AB1856 00 1858 00 20A 0720 00 1855 00 AB1856 00 1858 00 25A 0720 00 AB1855 00 AB1856 00 1858 00 Table 3 12 MAIN TRANSFORMER T1 480 Vac 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 00 203
32. 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 AT10 1 very 1 Loose 1 Remove the enclosure shroud Check and tighten all noisy hardware or component mounting hardware Replace the shroud being enclosure panel sure all assembly hardware is secure 2 Defective 2 Use a clamp on ammeter to measure the ac current in wire rectifier bridge 11 or 12 connected between 1 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 AT10 1 With a light dc load connected to the battery be sure each cell reads the nominal cell voltage 2 0V operation of both chargers 2 5126 option erratic battery for lead acid 1 25V for Ni Cd Restart the AT10 1 Each cell should now read the nominal Float voltage 2 2V for lead acid 1 35V for 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 voltag
33. NEGATIVE GROUND OC VOLTS Tz Advanced Technology AMPS EULZ HRS Ll d BATTERY CHARGER REMAINING RECTIFIER HIGH DC VOLTAGE Low 0 MANUAL TIMER DC OUTPUT MANUAL ERLZ FAILURE AUTO EDLZ TIMER AC INPLIT FAILURE RAL DISABLE ENABLE YORSEF READ AD HIS LEL TEF AC AQ DIRECT OC VOLTAGE SERVICING QUALIFIED PERSONNEL ONLY 00 NOT REMOVE THIS LABEL INSTRUMENT PANEL MAIN CONTROL PC BE PART No 0151 012 FRONT VIEW FACING CHARGER D NOTE UNLESS OTHERWISE SPECIFIED ALL ALARM TERMINAL BLOCKS TB3 TB4 1B8 ARE SULDERLESS COMPRESSION TERMINALS CONTACT RATING IS 0 5 125VAC DC ACCEPTING 22 14 AWG WIRE mcum our ac pay vx GERD sume uc ic ne nofe ne woj e mc uc i 2 sja 17 telis Es 25 27 28 29 1 az 35 OTHER CONTROLS RAI LOW LEVEL WARNING ADJUST RA2 GROUND FALLT 7 BALANCE G
34. Table 3 6 STANDARD DC CIRCUIT BREAKERS 2 Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 6A 159 01 RE0159 01 159 01 159 12 12 159 02 159 02 159 02 159 13 16 159 03 159 03 159 03 159 14 20 159 04 159 04 159 04 159 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 0171 00 171 00 171 00 12 0171 01 171 01 0171 01 171 01 16 171 02 REO0171 02 171 02 171 02 20 REO0171 03 171 03 REO0171 03 171 03 25 REO0171 04 171 04 REO0171 04 171 04 Table 3 8 HIGH INTERRUPTING CAPACITY DC CIRCUIT BREAKERS 2 Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 6A 043 00 043 00 043 00 043 00 12 043 01 043 01 043 01 043 01 16 043 02 043 02 043 02 043 02 20 043 03 043 03 043 03 043 03 25 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 AP0926 00
35. 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 JD5009 00 supplied with 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 10 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 10 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 connec
36. 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 negative 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 sleeving from the soldered joint to wire 20 you may have to remove a harness tie and cut the resistor lead near the solder joint 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 SERVICING THE AT10 1 3 6 ORDERING REPLACEMENT PARTS All 10 1 Series battery chargers ship with a supplemental parts data package itemizing all components within the unit Contact your sales representative to place an order for spare or replacement parts Please provide the following information for each component Circuit
37. if necessary However do not run the cable through the same conduit with power wiring Do not remove the connectors in order to fish the cable through the conduit Maximum pulling tension is 46 lb 20 9kg The cable has plenum rated outer jacket and passes the NFPA 262 flame propagation test Install the cable between the chargers and anchor it in place at both ends before connecting Connect each end to the main control circuit boards inserting the connector into J4 until it is completely seated NOTE DC power cabling for the battery charger battery and load interconnection is not supplied with the AT Series Forced Load sharing option All user supplied system wiring should meet National Electric Code NEC standards as well as local site codes Confirm polarity of all dc cabling before making connections 90 APPENDIX F OPERATING CHARGERS WITH LOAD SHARING Restore external power connections to the battery chargers and restart according to the normal procedure in the AT Series Battery Charger Operating and Service Instructions After the chargers restart the Primary charger attempts to establish communication with the Secondary If communication is successful the chargers behave as follows Primary charger displays the message LS P Load Share Primary on the front panel alternating with the normal display of output voltage and current secondary charger displays the message LS S Load Share Secon
38. net PDFs JE5033 99 pdf 87 APPENDIX D RECOMMENDED FLOAT AND EQUALIZE VOLTAGES This table contains suggested values for commonly used batteries Consult your battery manufacturer s documentation for specific values and settings for your battery type Recommended Recommended Battery Cell Type Float Voltage cell Equalize Voltage cell Antimony 1 215 Sp Gr 2 33 Antimony 1 250 Sp Gr 2 33 Selenium 1 240 Sp Gr 2 33 2 40 Calcium 1 215 Sp Gr 2 33 Calcium 1 250 Sp Gr 2 33 Absorbed Gelled Electrolyte A sealed lead acid type Nickel Cadmium 1 42 1 47 Sealed lead acid battery types should not be used in ambient temperatures above 95 F 35 C and should not normally be equalized Consult your battery manufacturer s documentation for specific equalizing recommendations Lead Acid Types TEMPERATURE COMPENSATION If 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 K Temperature Temperature K K CF Lead Acid Nickel Cadmium 88 APPENDIX E COMMUNICATIONS MODULE Your 10 1 Microprocessor controlled Battery Charger has provisions for an optional Communications Module
39. on the front panel Each time you press the key a different parameter displays in the following order Float voltage Equalize voltage Equalize time in hours High dc voltage alarm setting e Low dc voltage alarm setting Current limit in Amperes 1 Don t use a dc voltmeter The ripple voltage on a battery is a very small ac voltage 41 10 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 e vents clean and open OK charger Remove dust and debris from inside of OK unit Check 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 Terminations at battery or bus are tight OK and corrosion free Check ac input Measure between TB1 L1 and TB1 L2 voltage using an ac voltmeter Value must be Input Vac within 10 12 of nominal voltage Check dc Measure at 1 and TB1 using a dc output voltage voltmeter Value should agree with front Float Vdc panel voltmeter within 196 and must be correct values for your battery If the Equalize Vde AT10 1 is using a temperature ERE compensation probe see the g
40. 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 INSTALLING THE AT10 1 1 4 MOVING THE AT10 1 Once you have established that the AT10 1 is undamaged identify the enclosure style and weight of your unit Refer to the table below AT10 1 Enclosure Type And Shipping Weight Table Group I Cabinets Style 586 Style 594 Output Ampere Rating Voltage 12 Vdc 24 Vdc 48 Vdc 130 6 Style 586 44 Ibs 20 kg 12 Adc Style 586 44 Ibs 20 kg 16 Adc Style 586 67 Ibs 30 kg 20 Adc Style 586 67 105 30 kg 25 Adc Style 586 67 Ibs 30 kg Style 586 44 Ibs 20 kg Style 586 58 Ibs 26 kg Style 586 58 Ibs 26 kg Style 586 80 Ibs 36 kg Style 586 75 Ibs 34 kg Style 586 75 Ibs 34 kg Style 594 Style 586 75 Ibs 34 kg Style 594 110 Ibs 50 kg Style 586 75 105 34 kg Style 594 110 165 50 kg Style 594 Style 594 147 Ibs 67 kg Style 594 193 Ibs 88 kg Style 594 193 Ibs 88 kg NOTE Actual unit is approximately 20 lbs 9kg below listed shipping weight in table The Style 586 amp 594 enclosures do not feature lifting eyes for moving Instead whenever possible move the unit with a forklift truck using the supplied shipping pallet To hoist the unit into a wall mount or rack mount location use a heavy duty sl
41. power to the charger Disconnect the battery from the output terminals Remove the safety shield Remove the hardware from the output terminal TB1 and remove the lead of the dc surge suppressor Install one lead of the replacement surge suppressor Replace the other wires and the hardware Repeat for the output terminal Tighten all hardware NOTE The surge suppressor is not polarized Replacing the dc surge suppressor networks VR6 C4 VR7 C5 Replace these networks as assemblies do not replace individual parts Turn off 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 TB1 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 behind the I O panel In 12 amp 24 Vdc units R3 is installed at the top right
42. 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 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 1 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 edg
43. side 3160 6980 0 14 0 38 3 R6 Voltage crowbar resistor EJ1135 00 EJ1135 01 EJ1135 02 EJ1135 03 R9 Filter capacitor C1 bleed resistor EJ1137 00 EJ1137 00 EJ1137 01 1137 02 EJ1222 00 EJ1222 01 EJ1222 02 EJ1222 03 R14 Scaling resistor negative side 3160 0 6980 0 14 0 38 3 1 Main transformer 120 208 240 Vac See Table 3 11 T1 Main transformer 480 Vac See Table 3 12 TB1 X terminal box lug for 14 6 AWG RC0056 04 TB6 Terminal block for Medium and terminal section RC0014 00 8 req d High AIC circuit breakers end section RC0014 01 1 req d VR1 Output Surge Suppressor EJ1132 01 Y VR2 Input Surge Suppressor 120 208 240 Vac EJ1132 01 Y VR2 Input Surge Suppressor 480 Vac EJ1132 02 Y VR3 Input Lightning Arrestor EJ1074 00 Min Input Surge Suppressor 120 208 240 Vac EJ1132 01 Y Input Surge Suppressor 480 Vac EJ1132 02 Y VR6 C4 Filter Network EJ5021 01 VR7 C5 Filter Network EJ5021 01 Note 1 In 130 Vdc units 5000 50W power supply resistor mounted behind the panel be comprised of an assembly of two 2 2500 resistors connected in series 65 SERVICING THE AT10 1 Table 3 2 DC FILTER ASSEMBLIES L2 C1 R9 CR1 CR2 Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 6A EJ1072 00 EJ1072 00 EJ1072 02 EJ1072
44. that allows the user to remotely monitor and control the unit over a serial connection This option supports DNP3 Level 2 and Modbus protocols over RS 232 or RS 485 half duplex Industry standard SCADA Supervisory Control And Data Acquisition systems will be able to control monitor and log the events of the battery charger when this option is supplied The system can also be used with a modem for telephone communications All features of the 10 1 battery charger s front instrument panel are accessible remotely using the Communications Module The AT Series Communications Module EJ5037 xx includes the Communication PC Board A12 external power supply resistor s R29x an Operating Instructions manual and a field retrofit instruction sheet JD5008 00 An unlabeled copy of the Communications Module Operations Manual is available for free online http www ATSeries net PDFs JAO102 04 pdf A compatible industry standard modem and modem cable are also available Contact your sales representative to place an order for the AT Series Battery Charger Communication Module Refer to the table below for ordering information __________ PartNo Communications Module for 12 AT 10 1 EJ5037 01 Communications Module for 24 Vdc AT10 1 EJ5037 02 Communications Module for 48 AT 10 1 EJ5037 03 Communications Module for 130 AT 10 1 EJ5037 04 10ft 3 05m Modem Cable EH5026 00 2bft 7 62m Modem Cable EH5026 01
45. the cable to the control circuit board on the back of the front panel If the wiring is OK then the probe needs to be replaced Once you have replaced the probe you must restart the AT10 1 to activate temperature compensation E 09 misadjusted current limit The output current limit is set at the factory to 11096 of the rated output current e g for a 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 you do reduce the current limit setting below 10096 of rated current your connected load might require more current than the charger can deliver If this happens the battery will not charge properly If this occurs the front panel displays the error code E 09 You should increase the current limit setting so that the charger can supply all the current required by the load and still charge the battery The current limit should be set to at least 5 greater than the maximum continuous dc load current NOTE The common alarm relay is not set for this condition E 10 open internal feedback loop A redundant internal feedback loop control loop is provided as redundancy to increase reliability when remote sensing is used If there should be a problem with the internal loop wiring
46. wiring for signs of wiring to T1 or 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 or 12 If it less than 70 of the dc output current one of the SCRs or diodes is defective Replace the rectifier module 4 SCR not 4 Disconnect wire 24 from terminal of the rectifier controllable assembly near the left front of the enclosure Restart the AT 10 1 If You are able to measure output current one of the SCRs is defective Replace the rectifier module DC breaker 1 Battery 1 Check and correct battery wiring if necessary trips connected with immediately reverse 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 49 10 1
47. 1 Should be between 32 and 122 0 and 50 C with relative humidity between 5 and 95 non condensing e Must be free of explosive materials 4 Maintain at least 152mm of free air on top bottom and both sides for cooling air 5 Allow 36in 914mm front clearance for operation and maintenance L Style 586 Enclosure Style 594 Enclosure INSTALLING THE AT10 1 PROCEDURE To wall mount the AT10 1 install four 4 25in 6 4mm bolts on the wall rated to support the charger weight plus a safety factor of at least two 2 times Place the AT10 1 on the bolts add appropriate mounting hardware and tighten Refer to the graphics below for mounting dimensions and specifications WALL MOUNTING THE AT10 1 GRAPHICS USE 0 25in 6 4mm DIA BOLTS FOUR 4 PLACES 71 O43 AT10 1 MOUNTING DIMENSION 10 00 ENCLOSURE DIM A 254mm Style 586 15 00in 381mm Style 594 25 18 25in 464mm Lu ee ee H DIM MOUNTING BOLT PATTERN 312in DIA FLAT WASHER LOCKWASHER 25in 6 4mm DIA BOLT 4 750in 19mm ENCLOSURE MOUNTING FLANGE 750in 19mm DIA WALL KEYHOLE SLOT USED ON RECOMMENDED MOUNTING AT10 1 MOUNTING FLANGE HARDWARE LOADING NOTE 1 For further AT10 1 standard cabinet information see the outline drawings f
48. 6 00 2037 00 25 0735 00 2035 00 2036 00 2037 00 68 10 1 Table 3 13 FILTER INDUCTOR L2 Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 6A AP0928 00 AP0928 00 AP0928 00 AP1081 00 12A AP0928 00 AP0928 00 AP0928 00 AP0928 00 16A AP0927 00 AP0927 00 AP0926 00 AP0926 00 20A AP0927 00 AP0927 00 AP0926 00 AP0926 00 25A AP0927 00 AP0927 00 AP0926 00 AP0926 00 Table 3 14 480 Vac INPUT FUSE F1 Current Rating 12 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 08 008 11 25 0008 02 0008 06 0008 08 008 11 69 APPENDIX SPECIFICATIONS Except as noted all specifications apply at 77 F 25 C nominal ac line voltage amp nominal float voltage Output voltage regulation Temp 32 122 F 0 50 C Freq 60 3 Hz Specification Conditions 12 24 48 130 10 12 to 100 load 0 25 see product literature for specific data Transient response 20 100 load change with battery connected Output voltage change 4 maximum Recovery to 2 0 in 200 ms Recovery to 0 5 in 500 ms
49. ACK MOUNTING THE AT10 1 GRAPHICS Style 586 Enclosure ALLOW 6in 153mm FOR COOLING ABOVE UNIT AT10 1 ALLOW 6in 153mm FOR COOLING BELOW UNIT Style 594 Enclosure ALLOW 6in 153mm FOR COOLING ABOVE UNIT ALLOW 6in 153mm FOR NOTES RACK MTG BRACKET ASSY E10193 00 STANDARD EIA SPACING RACK MTG BRACKET ASSY E10193 00 STANDARD EIA SPACING 1 Units are installed from the front 2 178mm to top of enclosure 3 2 25in 8 50in 57mm 216mm N 6in 153mm in COOLING R 4 6in 153mm COOLING V 25in 6 4mm MTG BOLTS __ 4 00in 8 50in 102mm 216mm 6in 153mm COOLING 1 1 6in 153mm COOLING 25in 6 4mm MTG BOLTS Units shown above without penthouse enclosure If penthouse is used add Refer to the outline drawings in Appedix C for enclosure dimensions INSTALLING THE AT10 1 1 6 CHANGING TRANSFORMER TAPS Before you wire ac power to the AT10 1 check the wiring of main transformer T1 to be sure it is connected for your ac input voltage The AT10 1 accepts standard input voltages of 120 208 or 240 Vac by changing jumpers on No other c
50. ALUMINUM COMPRESSION LUG 14 6 TB1 L1 L2 INPUT TERMINALS CU ALUMINUM COMPRESSION LUG 14 6 B3 LIMMARY ALARM TERMINAL BLOCK SOLDERLESS COMPRESSION 22 14 AWG B4 LIXILIARY ALARM TERM BLOCK SOLDERLESS COMPRESSION 22 14 B8 EMPCO PROBE A10 INTERCONNECTION TERMINAL BLOCK 22 14 AWG NOTES 1 2 3 4 5 w Common Options JE5027 99 STYLE 586 594 INPUT OUTPUT TERMINAL BOARD TB1 DETAIL NOTE 2 DC NEG DC OUTPUT POS TABLE VOLTAGE 120 Vac 206 vac 240 VAL COPPER GROUND BUS BAR CONSULT USER S MANUAL FOR ADJUSTING TRANSFORMER S INPUT VOLTAGE REMOTE SENSE USE COPPER UR ALUMINUM CONDUCTORS ONLY AC INPUT SINGLE PHASE FOR DETAIL VIEWS OF ALL PC BOARDS 1 AS etc SEE DRAWING JES030 18 IZO PANEL PROTECTION SHOWN ONLY ON CAPACITORS C4 amp C5 AND SURGE SUPPRESSORS DETAIL CONSISTS EMI FILTER VR2 VR4 VRS VRE amp VR7 DATA NAMEPLATE IS LOCATED ON EXTERIOR LEFT SIDE WALL OF ENCLOSURE USER S MANUAL POCKET IS LOCATED ON EXTERIOR RIGHT SIDE WALL OF ENCLOSURE SAFETY COVER DISPLAYS COMPONENT LAYOUT DIAGRAM SCHEMATIC amp INSTALLATION NOTES BATTERY ELIMINATOR FILTER CAPACITOR C2 IS NORMALLY LOCATED IN FRONT OF C1 130VDC 12ADC THRU 130VDC 25ADC UNITS UTILI
51. MINAL BLOCK AUXILIARY ALARM RELAY TERMINAL BLOCK VRI DC OUTPUT SURGE SUPPRESSOR TO MED HIGH AIC CIRCUIT BREAKER JUNCTION BLOCK AC INPUT SURGE SUPPRESSOR LI TU L2 AC LIGHTNING ARRESTOR LOCATED BEHIND 1 0 Note This internal component layout drawing JE5027 99 depicts an AT10 1 Series battery charger housed in a Style 586 or Style 594 enclosure with ALL available options Standard components A1 through VR7 are supplied in all such units Optional components A5 through VR3 are supplied only in those 10 1 chargers configured with such options A custom internal component layout drawing is available for any AT10 1 battery charger based upon a quote or a manufactured unit For document availability please contact your sales representative with the model number options features and other specifications for the 10 1 Series battery charger in question 76 APPENDIX C Standard Drawings Internal Component Layout Detail AT10 1 Group Battery Charger ENCLOSURE USED JIT BREAKERS NOTE 6 4 BOARD 5 SIGNAL HARNESS NEAR BATTERY CELL 1 4 TURN DOOR FASTENER TERMINAL ESCRIPTION TYPE CONNECTION 1 OS NEG OUTPUT TERMINALS CLI ALLIMINLIM COMPRESSION LUG 14 6 AWG REM SENSE OS NEG REMOTE SENSE TERMINALS 10 32 SCREW HARDWARE 10 RING LUG 2 TBI GND ROUND TERMINAL CU
52. N INCHES TOLERANCES MES JES024 03 REV DATE APP SCALE NTS PART No JE5024 03 SHEET 1 1 FILENAME 5024 03 http Awww ATSeries net PDFs JE5024 03 pdf 73 APPENDIX Standard 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 W 16 25 495 10 75 337 with Penthouse WW 14 00 356 DD 10 75 337 HH 22 63 572 W 16 25 495 10 00 324 with Drip Shield WW 18 75 559 DD 12 50 318 HH 19 50 552 W 16 25 495 10 75 337 with Penthouse amp Drip Shield WW 18 75 476 DD 12 50 337 HH 26 50 729 W 16 25 495 10 00 324 74 10 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 HH 18 00 457 W 19 50 495 D 13 25 337 with Penthouse WW 14 00
53. OUND SUMMARY VOLTAGE VOLTAGE FATLURE FATLURE DETECT ALARM AUX ALARM RELAY PC BOARD AS ALIXILIARY ALARM TERMINAL BLOCK 184 NOTE 2 NOTES 1 FOR COMPONENT DETAILS OF ALL PC BOARDS AS All etc SEE DRAWING 5030 19 2 ALL ALARM CONTACTS SHOWN IN NON ALARM STATE CONTACT RATING IS 5 125VAC VDC RESISTIVE 3 WHEN REMOTE SENSE IS USED THE VOLTAGE SENSE LEADS RUN FROM R14 TO REMOTE 5 5 FROM TBS 2 TO REMOTE SENSEC REFER CONNECTION DIAGRAM FOR WIRING DETAILS 4 POWER TRANSFORMER T1 HAS MULTIPLE TAPS FOR 120 208 240 VAC 5 TWO POLE DC CIRCUIT BREAKER IS SUPPLIED ON 130VDC UNITS AND ALL UNITS WITH MEDIUM HIGH AMPERE INTERRUPTING CAPACITY BREAKERS 6 CIRCUIT BREAKER INTERCONNECTION TERMINAL BLOCK 6 IS USED WHEN MEDIUM OR HIGH AMPERE INTERRUPTING CAPACITY BREAKERS ARE SUPPLIED 7 OPTIONAL 480 VAC INPUT TRANSFORMER FEATURES TAPS BUT 1 PDLE AC FUSE Fl AND MED AIC BREAKERS ARE REQUIRED FEATURED OPTIONS AC INPUT CIRCUIT BREAKER INT CAPACITY DC OUTPUT CIRCUIT BREAKER INT CAPACITY ALIXILIARY RELAY PC BOARD OUTPUT FILTERING BATT ELIMINATOR FILTER EXTERNAL TEMPCO PROBE LIGHTNING ARRESTUR 82 APPENDIX C Standard Drawings Schematic AT10 1 Group I Battery Charger with Common Options JE5031 99 DC FILTERING ASSEMBLY A7 XX kAIC CB2 XXA
54. Operating and Service Instructions 0 1 SERIES MICROPROCESSOR CONTROLLED FLOAT BATTERY CHARGER SINGLE PHASE INPUT GROUP 6 25 Adc OUTPUT ALCAD STANDBY BATTERIES 3 Powdered Metals Drive North Haven CT 06473 3209 Tel 203 985 2500 Fax 203 985 2539 www alcadusa com HOW TO READ THE ALCAD 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 De FD DESCRIPTION CODE FEATURE DESCRIPTION CODE FEATURE A SERIES AT10 AT10 1 CHARGER 0 UNFILTERED 012 12 Vdc F FILTERING 1 FILTERED NOMINAL 024 24 Vdc 2 BATT ELIMINATOR B DC OUTPUT VOLTAGE 048 48 Vdc 2 STANDARD 130 130 Vdc NO AUX BOARD 006 6 Adc AUX RELAY BOARD G ALARMS 3 NOMINAL 012 12 Adc STANDARD BKRS DC OUTPUT 016 16 Adc 4 AUX RELAY BOARD CURRENT 020 20 Adc MED HI AIC BKRS 025 25 Adc H LIGHTNING 0 NOT SUPPLIED 0 120 208 240 Vac 60 Hz ARRESTOR 1 SUPPLIED 1 480 Vac 60 Hz 0 NOT SUPPLIED D AC INPUT 3 J GROUND BUS VOLTAGE 2 220 Vac 50 60 Hz 1 SUPPLIED 3 380 Vac 50 60 Hz 3 0 NONE 4 416 Vac 50 60 Hz 1 FUNGUS PROOFING CIRCUIT 1 STANDARD SPECIAL 2 STATIC PROOFING TREA
55. PTIONAL PROBE A10 INTERCONNECTOR CONTROLS LEVEL DETECT ADJUST HINDLEPOWER INC 5002 5 Instrument Panel Detail AT10 1 Group Battery Charger w Optional Auxiliary Relay PC Board JE5030 19 DISABLE 1 COMMUNICATIONS MODULE PC BOARD ASSEMBLY 12 SEE DRAWING 1 5107 00 FOR DETAILS o 9122 FOR_FORCED LDAD SHARING DETAILS SEE 5154 00 4 MAIN CONTROL PC BOARD BACK VIEW FACING CHARGER COMPONENTS WHEN INSTALLED THIRD GROUND FAULT BALANCE GROUND FAULT ANGLE PROJECTION SENSITIVITY 041108 DRAWN BY MCR 022003 1115 SERIES BATTERY CHARGER GROUP I JUMPERS JGRAMMING 051705 INSTRUMENT PANEL 7 PC BOARD DETAIL OPTIO DRAWING No REV APPROVED Qu 022003 20 LOAD SHARING JRING TEST TEMP REV 022003 JES030 19 2 PART No UNLESS OTHERWISE DIMENSIUNS ARE IN INCHES TOLERANCES ARE SCALE NTS JE5030 18 http Awww ATSeries net PDFs JE5030 19 pdf 79 APPENDIX Standard Drawings Schematic AT10 1 Group I Battery Charger Standard w o Options JE5031 00 T1 TABLE INPLIT JLIMPER STANDARD H1 H3 2 5 TRANSFDRMER H2 H4 2 NDTE 4 22 SCR MODULE ASSY A16
56. R module EJ5094 00 C1 DC Output Filter capacitor RP0019 09 RP0019 08 Y C2 Battery Eliminator Filter capacitor RP0019 09 RP0019 08 Y C4 EMI filter capacitor See 6 4 C5 EMI filter capacitor See VR7 C5 CB1 breaker standard 120 208 240 Vac See Table 3 3 CB1 breaker medium AIC 120 208 240 Vac See Table 3 4 CB1 breaker high AIC 120 208 240 Vac See Table 3 5 CB1 circuit breaker medium AIC 480 0171 00 1 circuit breaker high AIC 480 Vac 0043 00 CB2 circuit breaker standard See Table 3 6 CB2 circuit breaker medium AIC See Table 3 7 CB2 circuit breaker high AIC See Table 3 8 64 10 1 Factory Part Number Rec Symbol Description 12 Vdc 24 Vdc 48 Vdc 130 Vdc Spares CR1 diode EJ1243 04 Y CR2 Blocking diode EJ1243 05 F1 480 AC Input Fuse See Table 3 14 Y L1 Main Inductor See Table 3 9 L2 Filter Inductor See Table 3 13 Jumper for disabling Ground Detection circuit 0100 00 Alann Relay creuit board A5 RCO100 00 P9 Jumper for front panel lockout feature on A1 0100 00 R2 Rating resistor See Table 3 10 R3 Supply Ballast Resistor EJ1127 00 EJ1127 01 EJ1127 02 EJ1127 03 Y 120 2W 680 11W 1500 50W note 1 EJ1134 00 EJ1134 01 EJ1134 02 EJ1134 03 R4 Scaling resistor positive
57. ROUND FAULT SENSITIVITY NON LISER ACCESSED JUMPERS cape 12 BOARD PROGRAMMING 414 OLD FORCED LOAD SHARING AUXILIARY ALARM RELAY PC BOARD A5 ES erg TEST Note This instrument panel drawing JE5030 19 depicts the optional Auxiliary Alarm Relay PC Board 5 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 78 APPENDIX C Standard Drawings DISPLAY 0511 0512 0513 6 0514 0515 0516 0517 56 0518 HindlePower Inc ROL PC BOARD CHARGER DOOR WHEN INSTALLED USER JUMPERS SWITCHES J1 MAINFRAME SIGNAL HARNESS S1 METER MODE 22 AUX ALARM RELAY BOARD AS SERIAL CONNECTOR S2 CHARGER MDDE J3 AUX ALARM RELAY BOARD RIBBON CONNECTOR S3 EQUALIZE METHOD FORCED LOAD SHARING CABLE INTERCONNECTOR 54 AADJUST J5 GROUND FAULT ENABLE DISABLE S5 VADJUST JB EARTH GROUND CONNECTOR 56 EDIT ENTER 28 FRONT PANEL ENABLE OISABLE LOCKOUT gt 57 PROCESSOR MANUAL RESET J13 COMMUNICATIONS PC BOARD A12 INTERCONNECTOR J17 GATE DRIVER PC BOARD A112 INTERCONNECTOR TERMINAL BLOCKS TB3 SUMMARY ALARM RELAY CONTACTS J27 NOT USED 3PH GATE DRIVER PCB INTERCUNNECTOR TB4 AUX ALARM RELAY CONTACTS J29 future TB8 O
58. Refer to Section 2 3 4 parallel Sense ie The charger must be in normal operation not output voltage If one the Edit mode to enable the high dc voltage chat eet uus Aay 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 UP key then operate in a charger with e Press the MODE ke zero output current so that gt 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 2 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 key for this feature Ifthe 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 10 1 2 3 7 Adjusting the Voltmeter Accuracy The AT10 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 circuit board or R4 you should readjust the meter This a
59. 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 Code Meaning Repair Procedure E 04 internal memory Any parameters that you set such as Float or Equalize voltage are saved internally The internal memory is tested on startup If the memory test fails E 04 appears on the front panel display The error may also appear if the controller was trying to write to the memory while a power failure occured If an E 04 appears try restarting the AT10 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 has failed E 05 used This error code was formerly used to indicate a reverse battery connection It is not available in the AT10 1 E 06 R4orR14 is L
60. TALLING THE AT10 1 MAKING THE DC OUTPUT CONNECTIONS GRAPHICS VA CUSTOMER V SAFETY DC OUTPUT COVER 12 7mm WIRING T1 CONNECTION TABLE S 2 SENSE SENSE CONSULT USER S MANUAL FOR ADJUSTING TRANSFORMER S INPUT VOLTAGE USE COPPER OR ALUMINUM CONDUCTORS 11 ACINPUT 5 1 The drawing above does not show other components mounted to the I O panel Be careful not to disconect any other component leads 2 Always use a proper ground 3 Use copper or aluminum conductors only INSTALLING THE AT10 1 1 9 WIRING THE AT10 1 FOR REMOTE SENSING You can wire the AT10 1 to regulate the output voltage at the battery terminals instead of at the charger output terminals Remote sensing does the following 1 Compensates for voltage drop in the dc wiring between the AT10 1 and the battery 2 Directly monitors the battery or dc bus voltage The front panel meter displays the actual voltage on the battery or dc bus You wire the AT10 1 for remote sensing by installing twisted pair cabling from the AT10 1 remote sense terminals to the battery terminals The AT10 1 control circuitry then measures the dc voltage at the battery terminals and controls the output of the charger to maintain the battery voltage at the desired float or equalize voltage NOTE If the remote sens
61. TERMINALS AND WILL ACCEPT 22 14 AWG WIRE WHEN REMOTE SENSE TS USED THE LUGGED END OF R14 CONNECTS REMOTE SENSE AND WIRE 21 CONNECTS 5 2 TO REMOTE SENSE FEATURED OPTIONS SEE SCHEMATIC FOR TRANSFORMER CTI PRIMARY CONNECTION TABLE AC INPUT CIRCUIT BREAKER STANDARD 12 24 AND 48 VOC UNITS CONTAIN A SINGLE POLE DC BREAKER 2 IN THE NEGATIVE BUSS FOR THESE UNITS WIRE 15 TERMINATES DC OUTPUT CIRCUIT BREAKER AND WIRE 17 IS NOT USED 84 APPENDIX C Standard Drawings Connection Diagram AT10 1 Group Battery Charger Standard w o Options JE5033 00 TR 12 P p MAIN CONTROL PC mu NOTE 2 N J NOTE 5 14 CB2 DC 2 18 BREAKER 4 AC AKER CHASSIS 2 GROUND THIRD ANGLE PROJECTION MER 040703 JUTE 10 1 SERIES BATTERY CHARGER APPROVED e 040703 CONN DIAG B 25ADC GROUP 12 STD W O OPTIONS DRAWING No REV ace E JE5033 00 SCALE NTS PART No JES5033 00 OF 1 http Awww ATSeries net PDFs JE5033 00 pdf KER 1 E1742 081004 0 1204 040703 85 APPENDIX Standard Drawings Connection Diagram AT10 1 Group Battery Charger with Common Options JE5033 99 RECTIFIER CTRL 1 2 3 5 8 7 PC BOARD ASSY NOTES SCR MODULE
62. TMENTS BREAKER E BATING 2 MEDIUM AIC 3 FUNGUS amp STATIC SEE TABLE 3 HIGH AIC PROOFING DESCRIPTION CODE FEATURE DESCRIPTION CODE FEATURE 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 ACRATINGS DC RATINGS CODE E ALL INPUT VOLTAGES 125 Vdc 10 000 AIC 1 STANDARD 240 Vac 10 000 AIC E00 AIC 240 Vac 25 000 AIC 2 MEDIUM AIC donec TE 000 ATE 10 000 AIC 3 HIGH AIC 240 Vac 65 000 AIC 25 000 AIC NOTE 480 25 000 AIC 4 Rating applies to 130Vdc 16 25 Adc units 5 Approximate rating applies to all other units The model number listed on the charger data nameplate does not include any field installed options Also certain accessories are not included in the model number even if they are shipped with the charger Check off below any accessories that were included or that you install yourself floor rack mounting brackets NEMA 2 type drip shield assembly 4 12 13 type enclosure cabinet heater assembly pad lock for front panel door zero center ground detect meter Please find the serial number on the data nameplate and record it here analog ac voltmeter penthouse mounted analog ac ammeter pentho
63. Understanding Parameter Settings You can change the settings of the 10 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 Float voltage Equalize voltage Equalize timer in hours High dc voltage alarm setting Low dc voltage alarm setting Current limit value Amperes High dc voltage shutdown feature on off Your choice of equalize method is also saved internally When you want to change any parameter press the EDIT ENTER key to put the AT10 1 into EDIT mode The meter display flashes about once per second and the status indicators prompt you to adjust the respective parameter You adjust each parameter by pressing the uP or Down key until the reading you want shows on the meter display You can make the display scroll up or down continuously by pressing and holding the 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 A on page 70 When you first press the EDIT ENTER key the AT10 1 prompts you to adjust the first parameter in the list above float voltage
64. YMPTOM CAUSE RECOMMENDED ACTION No output 1 Battery is 1 This is normal operation in a system with little or no dc load current but fully charged As long as the AT10 1 maintains Float voltage it is operating ac 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 7 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 E4 of the rectifier circuit board A3 If you 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 ou
65. ZE TWO 2 Cls THEREFORE C2 IS SHIFTED TO LOWER RIGHT HAND CORNER OF ENCLOSURE AS SHOWN IF ATIO 1 HAS 480VAC INPUT OR IS CUSTOMER SPECIFIED WITH MEDIUM HIGH AMPERE INTERRUPTING CAPACITY CIRCUIT BREAKERS AND CB2 ARE RELOCATED TO PENTHOUSE ENCLOSURE AND IS ADDED THIRD ANGLE PROJECTION 2 E2028 042805 DRAWN TITLE ATIO 1 SERIES BATTERY CHARGER OPTIONAL MCR 022703 E1742 081004 INTERNAL COMPONENT LAYOUT STYLE 586 584 022803 APPROVED H REV 1154 022703 JES027 89 2 PART No UNLESS OTHERWISE NOTED DIMENSIONS ARE IN INCHES TOLERANCES ARE DRAWING No B 5027 99 1 SCALE NTS http Awww ATSeries net PDFs JE5027 99 pdf 77 APPENDIX Standard Drawings Instrument Panel Detail AT10 1 Group Battery Charger w Optional Auxiliary Relay PC Board JE5030 19 INDICATUR LIGHTS LEDs 0501 GREEN AC ON 0510 RED LOW LEVEL DETECT 0502 RED DC VOLTS 0511 RED METER DISPLAY 0503 RED DC AMPS 0512 RED METER DISPLAY 0504 RED EBLALIZE HRS REMAINING 0513 RED HIGH DC VOLTAGE 0505 GREEN FLOAT 0514 RED LOW DC VOLTAGE 0506 AMBER EHLIALIZE 0515 RED DC OUTPUT FAILURE 0507 AMBER MANUAL TIMER 0516 RED AC INPUT FAILURE 0508 AMBER MANLIAL EHLIALIZE 0517 RED POSITIVE GROUND 0509 AMBER EQUALIZE TIMER 0518 RED
66. adusa com 2008 Alcad Standby Batteries
67. and check all connections and the battery polarity again Also check the battery voltage It must be above 50 of nominal voltage to turn on the display If you can t find the problem refer to the Troubleshooting Procedure in Section 3 1 on page 44 CAUTION If you try to turn on the dc circuit breaker with the battery connected in reverse polarity the circuit breaker will immediately trip Do not try to close the dc breaker again since this may damage the battery charger Correct the battery polarity before proceeding 24 10 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 1s 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 10 1 then next time it starts Turn on the front panel ac circuit breaker The digital meter displays the output voltage and current See Using the Digital Meter on page 24 You should hear a soft hum from the AT10 1 as the output current increases NOTE If you turn on the ac breaker before the dc breaker and you have a filtered model of the AT10 1 there is a possibility that the dc breaker will trip when you try to turn it on This is caus
68. and easily reaches the main control circuit board Atthe 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 Agi 05102 exe x 429 ENABLE ALARM CABLE ASSY J STRIPPED LEADS TO TB8 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 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 AT10 1 7 Check your work Be sure that e 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 10 1 using the startup procedure in Section 2 1 During startup
69. and standard drawings for the AT Series battery charger line are available online at www ATSeries net Saved in Adobe Acrobat Portable Document Format PDF they are readily available for downloading and printing Please contact your sales representative for document availability of private labeled manuals and or standard drawings or visit the web site listed on the back cover of this manual PARTS DATA PACKAGE Any job specific customized Parts Data Package report supplied with this battery charger and or this manual supercedes the information featured in the standard parts list starting on page 64 The data in this document is applicable only to the battery charger featuring the same serial number listed on the Parts Data Package report DRAWINGS A customized record drawing package is available for your AT 10 1 featuring a unit specific drawing list data nameplate detail outline drawing itemized internal component layout electrical schematic with component ratings and a full connection diagram If the standard drawings featured in this manual are not sufficient please contact your Sales Representative for drawing availability from the battery charger manufacturer 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 jo
70. anel 1 Defective 1 Use a dc voltmeter to measure the dc voltage from E17 on dies during ac power resistor the I O panel to TB1 It is normally 12 when the rated power failure R3 output voltage is at TB1 and TB1 Remove all power from dc voltage is the AT10 1 and measure the resistance from TB1 and E17 present at See the table in Section 3 6 for the proper resistance values If TB1 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 AT10 1 1 Defective 1 Disconnect wire 24 from terminal E3 of the rectifier output SCR assembly near the left front of the enclosure Restart the voltage too AT 10 1 If You are able to measure output current one of the high not SCRs is defective Replace the rectifier assembly controllable 12 R4 or R14 is 2 Remove one end of R4 from on the back of the front defective or panel Repeat for R14 connected to TB1 Measure their wrong value values with an Ohmmeter See the table in Section 3 6 for resistance values If either resistor is not within 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 pro
71. asure 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 Main Control current the control board may be defective Disconnect wire circuit 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 15 blown 480 and check with an Ohmmeter or fuse tester on AC ON 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 Defective 3 Check terminals and wiring between T1 and the rectifier wiring 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 Repair as necessary 4 Defective 4 Use ac voltmeter to measure the ac voltage from 1 1 transformer T1 X4 It is normally 50 to 80 higher than the rated dc output voltage If it is too low check the wiring of the primary taps See Section 1 6 for details If it is zero replace T1 50 SERVICING THE AT10 1 PROBABLE S
72. ater 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 breakers 2 ow DC 2 Be sure that the Low DC Voltage alarm setting is lower than closed ac Voltage alarm Float voltage setting See Sections 2 3 2 and 2 3 4 input voltage Float 5 normal voltage settings there is 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 or 12 If it less than 70 of the dc output current one of the SCRs or diodes is defective Replace the rectifier assembly 4 Turn off both front panel circuit breakers Then turn on the dc breaker followed by the ac breaker If the
73. attery as possible such as the battery rack Do not mount the probe on the battery itself on unpainted wood or bare galvanized metal e on plastic surfaces 3 To apply the probe clean the mounting surface with isopropyl alcohol and allow to dry thoroughly Remove the protective backing from the double faced adhesive tape on the probe and securely press it onto the surface 4 Install the cable supplied with the temperature compensation probe kit e Start at the AT10 1 The end of the cable with two stripped wires and one lead with a quick connect terminal will be connected inside the enclosure Leave 30in 762mm of cable inside the enclosure and route the other end to the probe at the battery 20 INSTALLING THE AT10 1 e Run the cable though a conduit if possible but not through a conduit containing any power wiring 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 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 Route the cable within the 10 1 QUICK enclosure so CONNECT that it runs W PIGGY with the wire BACK harness to the s back of the NS front panel
74. b specific custom drawings are supplied 94 QUICK OPERATION For unpacking and installation instructions see section 1 on page 2 in this manual To learn how to use the equalize timers see sections 2 2 4 on page 27 and 2 3 3 on page 32 For details on setting parameters see section 2 3 starting on page 30 If you don t press any key for 25 seconds the AT10 1 resumes normal operation automatically JA0100 01 Rev 11 2008 Startup gt Turn on the dc breaker labeled DC OUTPUT gt Turn on the ac breaker labeled AC INPUT Changing between Float and Equalize Modes gt Press the key to toggle from Float mode to Equalize mode Press again to toggle back to Float The green or yellow indicator identifies the current mode Setting Float Voltage Equalize Voltage Equalize Timer High DC Voltage Low DC Voltage Current Limit Pressthe key The DC VOLTS and FLOAT indicators light and the digital display flashes the present float voltage setting gt Press the f key until the digital display indicates the desired float voltage gt Press the Em 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 steps until you have set all parameters STANDBY BATTERIES 3 Powdered Metals Drive North Haven CT 06473 3209 Tel 203 985 2500 Fax 203 985 2539 www alc
75. be 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 E3 of the rectifier assembly near the left front of the enclosure Restart the AT10 1 If the output current goes to zero replace the control board Output 1 Temperature 1 If the optional temperature compensation probe is installed voltage does compensation 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 Circuit board 2 meter as described in Section 2 3 7 or another component may have been replaced 3 or R14 is 3 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 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 AT10 1 still has board A1 the wrong output voltage replace the control circuit board 52 SERVICING THE AT10 1
76. 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 AT10 1 Measure the dc voltage from the input terminal to the output terminal of the circuit breaker with the breaker on It is normally no more than 50 millivolts If it is near the rated output voltage replace the breaker 55 10 1 PROBABLE RECOMMENDED ACTION CAUSE DC OUTPUT 1 Defective 1 Use a clamp on ammeter to measure the current in wire FAILURE rectifier bridge 12 or 11 If itis 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 and dc 2 Defective 2 Turn off both front panel circuit breakers Then turn on the breakers control circuit breaker followed by the ac breaker If the charger output closed ac board A1 voltage and current are normal but the DC OUTPUT input voltage 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 X4 It is normally 50 to 80 higher than the rated dc output voltage If it is too low check the wiring of the primary taps See Section 1 6 for details If itis zero replace T1 4 Defective dc 4 Disconnect the battery and connect a light dc loa
77. city see Section 2 3 3 to learn how to adjust the equalize time The battery manufacturer can help you determine the best equalizing schedule for your battery After you select the manual timer method press the CHRG MODE key to put the charger into the equalize mode The EQLZ indicator will light When the equalize timer is finished the charger reverts automatically to the float mode and the FLOAT indicator lights At any time during the equalize charge you can switch the charger back to float mode by pressing the CHRG MODE key The FLOAT indicator will light If there is an ac power failure during a timed equalize charge the AT10 1 remembers the remaining equalize time When ac power is restored it resumes the equalize charge where it left off 27 10 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 EQLZ indicator will light Press the cHRG 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 ba
78. corner of the I O panel In 48 units R3 is mounted on the bracket behind the I O panel In 130 Vdc units R3 is comprised of an assembly of two 2 resistors connected in series mounted to the bracket behind the I O panel Disconnect the lead of R3 connected 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 amp 24 Vdc units tuck the new R3 behind the I O panel so that the leads are properly spaced In 48 amp 130 Vdc chargers remove the screws that mount the old resistor s and replace with the new resistor s Tighten all mounting hardware For further instructions refer to service instructions JD5010 00 62 10 1 Replacing the positive scaling resistor R4 Locate the scaling resistor R4 on TBS 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 TB5 on the back of the front panel just above the control
79. crease 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 low dc voltage alarm point that you want to set release the or DOWN key If you go past the voltage you want press the UP or powN key again to reach the voltage you want to set e Press the EDIT ENTER key The new low dc voltage alarm setting is entered into permanent memory If you want to adjust the current limit setting skip to Section 2 3 5 OR If you want to exit the Edit mode now press key again to return the charger to normal operation 33 10 1 Adjusting Ground Detection Sensitivity You can adjust the sensitivity of MUN ijg the ground detection alarm circuit 1 2 Pins You must have a test resistor IN whose value is the sensitivity you want You can adjust the T sensitivity from 5 to 50 FAULT ENABLE JUMPER 2 3 PINS 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 cu N
80. currents shown 0 20 5 11 23 39 25 6 14 29 49 1 To determine the input current lac for other input voltages use the formula 1 21 x 220 V ac where Vac is the new input voltage and It 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 SAFETY COVER e COMPRESSION SCREW TYP AC INPUT 50i CUSTOMER 13mm AC INPUT WIRING GROUND LINE 1 LINE 2 NOTES 1 The drawing above does not show other components mounted to the I O panel Be careful not to disconect any other component leads 2 Always use a proper ground 3 Use copper or aluminum conductors only 4 On 120 Vac input connect the neutral leg to the terminal L2 INSTALLING THE AT10 1 1 8 MAKING THE DC OUTPUT CONNECTIONS Follow these steps to connect the battery to the 10 1 1 Size the dc wiring to minimize voltage drop The acceptable wire size depends on your installation As a guideline the voltage drop should not exceed 1 of nominal output voltage at full current Refer to the table below to determine the voltage drops for various wire sizes currents and distances WIRE SIZING CHART VOLTAGE DROP PER 100ft 30 5m OF WIRE FOR COPPER 68 20 WIRE SIZE DC CURRENT AMPERES AWG 6 12 16 20 25 16 2 5V 5 0V 6
81. d to the breaker AT10 1 Measure the dc voltage from the input terminal to the output terminal of the circuit breaker with the breaker on It is normally no more than 50 millivolts If it is near the rated output voltage replace the breaker AC INPUT 1 AC power 1 If the ac input power fails the front panel AC ON indicator FAILURE failure goes out and the AC INPUT FAILURE indicator goes on indicator is 2 Upstream 2 Be sure the front panel ac circuit breaker is closed Measure feed the ac voltage at TB1 L1 and L2 If it is zero check upstream breaker fuse is distribution breakers and fuses tripped 3 Defective 3 Measure ac voltage at T1 H1 and T1 H5 It should be the wiring same as the ac supply voltage 4 Defective 4 Turn off both front panel 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 SERVICING THE AT10 1 SYMPTOM PROBABLE CAUSE RECOMMENDED ACTION POS GND or NEG GND indicator is on 1 Ground fault on external dc bus 2 DC circuit breaker is open and NEG GND indicator is on 3 Alarm needs calibration 4 Defective wiring 5 Defective Main Control circuit board A1 1 Disconnect the AT10 1 from the battery and dc bus and check the battery and dc bus for a ground fault 2 If the AT10 1 has been placed int
82. dance with the National Electrical Code ANSI NFPA 70 Current Rating 12 Adc 16 Adc 20 Adc 25 Adc Charger Voltage Rating 48 Vdc 130 Vdc 48 Vdc 130 Vdc 25A 20A 15A 25A 12A 20A 20A 30A 15A 30A 25A 40A 20A 35A 208 Vac Branch Circuit Protection Amperes 240 Vac Branch Circuit Protection Amperes NOTE This table does not apply to AT10 1 chargers with 480 Vac input 92 93 MANUAL SPECIFICATIONS DOCUMENT NUMBER The text and graphics contained within this manual are controlled by the battery charger manufacturer s internal part number JA5023 00 The revision level and dates of this manual s text and graphics are listed below These controls supercede all other available dates The first two and last two pages of this manual are reserved for company specific front and back cover artwork Any revision levels revision dates or document numbers featured on the first two and last two pages of this manual refer to the cover artwork only DOCUMENT INFORMATION Document Number JA5023 00 Revision Level 8 Document Change Number 21352 Filename JA5023 00 Rev 8 AT 10 1 Group 1 Manual doc Last Date Saved 10 13 2008 12 10 00 PM Last Date Printed 10 13 2008 12 10 00 PM ON LINE AVAILABILITY An unlabeled version of this operating and service instruction manual is available online at http www ATSeries net PDFs JA0102 01 pdf Other manuals
83. dary on the front panel alternating with the normal display of output voltage and current The Primary charger controls all voltage settings for both chargers You may adjust any voltage float equalize alarm settings etc at the front panel of the Primary charger The front panel of the Secondary charger won t allow any settings to be changed If one charger loses ac power or is turned off the remaining charger returns to independent operation whether it was originally the Primary or Secondary For this reason it is important to set up both chargers initially for the same operating voltages If an alarm condition occurs both chargers revert to independent operation for the duration of the alarm In the event of a fault in the interconnection or any other problem with communication the chargers return to independent operation and the front panel on each charger displays the message E 14 indicating the fault There is a delay of up to 4 seconds for chargers to establish forced load sharing communication If communication is broken or power is lost for one charger there is up to a 4 second delay for the other charger to resume independent operation e If you need to interchange the Primary and Secondary chargers simply reverse the interconnection cable The presence of the interconnection cable and a good interconnection forces the two chargers into load sharing Controlling load sharing from the front panel is nei
84. djustment procedure is different from all others because the meter reading remains constant while the output voltage of the charger changes Do this adjustment with a fully charged battery and with no load connected First use the Edit procedure to adjust the float voltage to the desired value See Section 2 3 2 for instructions on setting the float voltage Second press and hold the UP key then press the EQLZ MTHD key The DC VOLTS METER indicator will light and the meter display flashes the output voltage reading Measure the output voltage of the AT10 1 using a de meter accurate to 0 25 or better While watching the meter connected to the AT10 1 output not the front panel meter press the or Down key until the actual output voltage matches the float setting on the front panel meter Each time you press or you change the AT10 1 output voltage by a small amount Continue to press UP or DOWN until the actual output voltage agrees with the front panel reading within 1 NOTE Allow one or two seconds for the output voltage to stabilize each time you press the up or boww key When you are finished adjusting the output voltage the AT10 1 waits 5 seconds then the display returns to normal operation 37 10 1 2 3 8 Using the Low Level Detector LLD Th
85. e 10 1 battery charger is equipped with a summary alarm safety override circuit This feature forces the summary alarm common alarm relay contact to transfer sending an alarm even if there is a catastrophic failure of the charger s control circuitry A low battery voltage triggers the safety circuit Main control circuit board hardware not software maintains the low level detect circuit Therefore to remotely monitor this alarm user connections must be made at TB3 The summary alarm contacts on the auxiliary alarm relay pc board at 4 will not signal a low level detect alarm If you have a dc power supply you can adjust the battery voltage that triggers the alarm On the back of the main control circuit board find the potentiometer 1 as shown in the figure below o o O HEN 360 J6 Jl J17 52 E ENABLE 2 nez n 4 D T DS10 N RA DISABLE rs JS gt a Se 0 TB3 00 999 _ EN E EET 0 Disconnect all ac dc power sources from 10 1 and connect your dc power supply to the dc output terminals of the charger positive to positive and negative to negative Adjust the power supply to the voltage at which you want to activa
86. e PROCEDURE To floor mount the AT10 1 follow the directions featured in instruction sheet JA0083 00 oS included with your floor ul 8 2 mounting kit 0192 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 C 1 DIM 437in 11mm FLOOR MTG HOLE FOUR 4 PLACES WALL DIM D _ 375in 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 1 1213 14 25 361 18 25 463 INSTALLING THE AT10 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 EIO 193 00 includes mounting brackets and the necessary hardware to install one 10 1 battery charger The kit includes an instruction sheet JA0091 00 showing installation details For kit availability see ordering information in Appendix B on page 71 When rack mounting the AT10 1 you must consider the following 1 The rack must be str
87. e 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 Meanin Repair Procedure Code 9 E 08 defective If a temperature compensation probe is connected to the AT 10 1 the temperature control circuit detects the probe on startup and uses the temperature compensation measured by the probe to control the output voltage of the charger probe To understand temperature compensation see Section 1 11 If the temperature compensation probe or the wiring that connects it to the AT10 1 fails during normal operation the AT10 1 detects the failure and shows E 08 on the front panel meter Disconnect the wiring from the probe and measure the resistance of the probe with an Ohmmeter The resistance should be approximately 10 000 Ohms at normal room temperature 77 F 25 C If the probe reads open or shorted it needs to be replaced If the probe checks good examine the wiring between the probe and the AT10 1 Also check the connection of
88. e is constant replace the control circuit control circuit board board A1 Lamp test key 1 Vac 1 The lamp test key doesn t work during an ac power failure does not 2 Control 2 Open the front panel and be sure that the control circuit Work or circuit board A1 board is securely mounted on the standoffs on the back of the Some lamps is not secured panel All indicators should extend about 0 125in 3 2mm don t 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 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 circuit board is in the ENABLE position keys don t 2 Control 2 Open the front panel and be sure that the control circuit Work circuit board A1 board is firmly seated on the standoffs on the back of the is not secured panel Front panel keys must operate freely to front panel 3 Defective 3 Turn off both front panel circuit breakers 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 AT10 1s 1 If the forced 1 Multiple AT10 1s are not designed to share load current connected in load sharing without the optional forced load shar
89. e 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 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 JD5009 00 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
90. e 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 10 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 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
91. e 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 overcharging The probe senses the ambient temperature at the battery and adjusts the output float equalize voltages to compensate for variations in temperature If the ambient temperature increases the AT10 1 output voltage decreases 22 INSTALLING THE AT10 1 104 Percent Output Voltage 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 77 F 25 GO Use a digital meter to measure the actual output voltage of the 10 1 If you know the temperature at the temperature compensation probe you can use the graph below to determine that the output voltage is correct If the battery temperature goes below 32 F 0 C there will be no further increase in charger output voltage Likewise if the battery
92. e 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 SCHEMATIC f REMOTE SENSE AT10 1 LEADS RECTIFIER MEER oN T DC BUS BATTERY PROCEDURE 1 De energize and lock out all ac and dc voltages within the AT10 1 enclosure Check with a voltmeter Remove safety shield Remove the two 2 dc output CU AL compression lugs Move lugged end of R14 with wire 20 from 1 to REM SENSE Move wire 21 from 1 to REM SENSE MA 3e 16 INSTALLING THE AT10 1 6 Connect user supplied external remote sense leads from the battery or dc bus to the remote sense terminals on the I O panel CUSTOMER SUPPLIED REMOTE SENSE LEADS DC SENSE OUTPUT SENSE 8 7 Replace the two 2 dc output CU AL compression lugs and tighten all hardware 8 Check your work thoroughly Replace the safety shield before reeneregizing the 10 1 9 Restart the AT10 1 according to the instructions in Section 2 1 NOTES 1 Use 16 AWG twisted pair wire 2 Maximum current is 150 mA 3 Run leads in their own conduit 4 Fuse the wiring at the battery or dc bus DISABLING REMOTE SENSE If you ever ne
93. eature Rev 6 or higher builds of the main control circuit boards A1 and corresponding Rev 6 or higher software programs We recommend that both chargers use the same program version since the load sharing option has not been tested using a different program version in each charger To view the program version press the LAMP TEST button on the front panel of the charger When you release the button the version number is shown on the front panel display for two seconds e The interconnecting signal cable length should be no more than 50ft 15m INSTALLING THE INTERCONNECTION CABLE The AT Series forced load sharing accessory is normally supplied by the factory with a standard 15ft 4 6m interconnection cable EH5041 00 A 25ft 7 6m long cable EH5041 01 and 50ft 15 2m long cable 5041 01 are also available interconnection cable is terminated at each end with a 6 pin connector that mates with the plastic connector J4 on lower right corner of the main control circuit board A1 One end of the cable features an extra jumper in the connector and should be identified for use with the Secondary charger The other end of the cable connects to the Primary charger Either charger may be selected as Primary or Secondary but you may wish to choose the charger that is more accessible to be the Primary The Primary charger controls the dc output voltage of both chargers You may run the interconnection cable through conduit
94. eatures Test auxiliary Press LAMP TEST key and hold for 4 O OK alarm relays seconds Alarm relays will transfer Check Remote sense wiring See page 16 O OK integrity of Temperature compensation wiring See O OK remote wiring page 20 O Temperature compensation probe See page 20 Final checks Close padlock or key lock O OK A downloadable worksheet of this Preventive Maintenance Procedure 00064 00 is available online http www ATSeries net PDFs JD0064 00 pdf 43 SERVICING THE AT10 1 3 SERVICING THE AT10 1 3 1 A STEP 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 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 interna
95. ed by the filter capacitors discharging into the battery To get around this problem turn off the ac breaker Restart the AT10 1 by turning on the dc breaker first The green FLOAT indicator lights Press the CHRG MODE key on the front panel The FLOAT indicator goes off and the yellow EQLZ indicator lights Press the CHRG key again to return the charger to the float mode The table below shows the normal factory settings for float and equalize voltages equalize time current limit setting and alarm settings If your purchase order specified other float or equalize voltage settings a tag attached to the front panel of the AT10 1 lists the actual voltage 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 10 1 2 2 USING THE AT10 1 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
96. ed 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 e Disconnect the remote sense wires from the battery or dc bus terminals first CAUTION You must do the steps above first 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 the lugged end of R14 with wire 20 to TB1 Reconnect wire 21 to 1 e Restart the AT10 1 according to the instructions in Section 2 1 17 INSTALLING THE AT10 1 1 10 WIRING TO THE REMOTE ALARM CONTACTS Built in common alarm relay The Primary Alarm ADD functions are WIRE SIGNAL included as standard 1 zs equipment with the AT10 1 The Summary Alarm relay located on the Main Control pc board A1 provides one 1 form C summary common alarm contact TB3 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 HINOLEPOWER
97. ess the CHRG 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 10 1 2 2 5 2 2 6 2 2 7 Testing the front panel indicators e Press the DOWN key This is also the LAMP TEST key The meter will display 8888 and all status amp alarm indicators will light The LAMP key does not test the AC ON indicator The AC ON indicator lights whenever ac power is present and the ac circuit breaker is turned on The LAMP TEST key does not operate when ac power is off To test the action of the 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 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 e HIGH DC VOLTAGE lights whenever the dc outp
98. ge NOTE This procedure refers only to Group AT10 1 battery chargers rated 6 25 Adc A different procedure exists for Group Il 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 PRIMARY T1 CONNECTION TABLE SECONDARY H4 X1 INPUT VAC JUMPERS H5 H5 120 H1 H3 H2 H5 208 2 4 2 JUMPERS Sx 240 H2 H3 2 JUMPERS H1 y2 480 NONE H1 TRANSFORMER 5 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 594 ENCLOSURE TYPICAL FOR TRANSFORMER IN 586 ENCLOSURE H1 M JUMPERS 2 F1 5R2 11 INSTALLING THE AT10 1 1 7 MAKING THE AC INPUT CONNECTIONS Follow these steps to connect ac power to the 10 1 1 Besure the AT10 1 main transformer T1 is properly connected for your ac input voltage See Section 1 6 for details 2 U
99. hanges 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 AT10 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 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 T1 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 jumpers and can be operated on either volta
100. 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 10 1 Setting the High DC Voltage Alarm e Press the EDIT ENTER key until the HIGH DC VOLTAGE indicator flashes and the display flashes the present value of the high dc voltage alarm Press and release or key to increase or decrease the value in the display by one count or press and hold the UP or key to scroll the value in the display upward or downward When the display shows the high dc voltage alarm point that you want to set release the UP or DOWN key If you go past the voltage you want press the UP or powN key again to reach the voltage you want to set Press the EDIT ENTER key The new high dc voltage alarm setting is entered into permanent memory Setting the low DC Voltage Alarm e Press the EDIT ENTER key until the LOW DC VOLTAGE indicator flashes and the display flashes the present value of the low dc voltage alarm Press and release or DOWN key to in
101. he meter display flashes the value of current limit in Amperes Press and release UP or powN key to increase or decrease the value the display by one count or press and hold the or 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 or DOWN key If you go past the number you want press the UP or key again to reach the number you want to set e Press the EDIT ENTER key 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 10 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 transfers The 10 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
102. hile the charger is in standby as described below Put the charger into standby by opening the ac input circuit breaker CB1 and leaving the dc circuit breaker closed Operating the charger with the ac breaker closed and the dc breaker CB2 open is an abnormal condition and is not recommended Disabling the Ground Detection Alarm You can disable the ground detection alarm circuit and isolate the circuit from chassis ground If your battery is normally grounded or you want to defeat the alarm for any other reason follow these steps 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 discharge You can adjust the value of the current limit from 50 to 11096 of rated current The factory setting 15 11096 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 t
103. ing 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 N A 1 5 3 E 23 24in 584 610mm OPTIONAL OPTIONAL Rack Mounting INSTALLING THE AT10 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 1 The wall must be strong enough to properly support the weight of the AT10 1 See the Weight Table located in Section 1 4 on page 3 The weight of your AT10 1 may be different from the table value depending on options or accessories you ordered 2 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 3 The location e Should be free of drips and splatter If dripping liquids are a problem install a drip shield 10191 00 For kit availability see ordering information in Appendix B on page 7
104. ing cable installed When parallel but option is not two or more AT10 1s are connected in parallel without this only one has supplied check option it is normal for one of the units to have no output output current normal 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 AT10 1s are set to the same Float and Equalize voltages 2 See Appendix F on page 90 for troubleshooting of Forced Load Sharing feature 54 SERVICING THE AT10 1 PROBABLE SYMPTOM CAUSE RECOMMENDED ACTION HIGH DC 1 High DC 1 Be sure that the High DC Voltage alarm setting is higher VOLTAGE Voltage alarm than the Equalize voltage setting See Sections 2 3 2 and indicator is on and Equalize voltage settings are mismatched 2 Defective rectifier bridge 2 34 2 Disconnect wire 24 from terminal E3 of the rectifier assembly near the left front of the enclosure Restart the AT10 1 If You are able to measure output current one of the SCRs is defective Replace the rectifier assembly 3 Defective 3 Turn off both front panel circuit breakers Then turn on the control circuit dc breaker followed by the ac breaker If the charger output 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 gre
105. l component failure Note Do this only once If the charger does not resume normal operation go to the next step Ifthe 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 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 use 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 Error Repair Procedure Code 9
106. lated 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 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
107. lize timer duration in hours Press and release or key to increase or decrease the value in the display by one count or press and hold the or key to scroll the value in the display upward or downward When the display shows the equalize time in hours that you want to set release or DOWN key If you go past the number of hours you want press the Down key again to reach the number you want to set If you set the equalize time to zero hours the equalize mode is disabled e Press the EDIT ENTER key The new equalize timer duration is saved internally The 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
108. m 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 troubleshooting chart that begins on the next page is divided into three columns To use the chart 1 Make a list of the charger s condition including the trouble symptoms 2 Find the symptom s in the first column of the chart 3 The middle column contains common causes for the problem you observe in order of probability 4 Follow the action described in the right hand column to correct the problem and return the charger to normal service Determining the condition of the charger e Is front panel AC ON indicator lit What is the ac voltage at the input terminals measured with an ac voltmeter What is the dc voltage at the output terminals measured with a dc voltmeter Does the meter on the front panel display any voltage or current Areany alarm indicators lit Do front panel status indicators work Charge Mode for example e you change the charger to the Equalize mode and back to Float e Is the charger making any noise Is it unusually loud e Is there any sign or smell of smoking or burning Refer to the wiring diagrams and parts layout drawings in Appendix C while using the chart For instructions on replacing components see Section 3 5 48 10 1 3 4 TROUBLESHOOTING CHART
109. ng the ac input connections 12 18 Making the dc output 14 1 9 Wiring the AT10 1 for remote 16 1 10 Wiring to the remote alarm contacts 18 Auxiliary Relay Board 19 1 11 Installing the temperature compensation assembly optional 20 Using temperature compensation 2 eene 22 1 12 Installing the AT10 1 for remote communications optional 23 1 13 Installing the AT10 1 for forced load sharing optional 23 2 Operating the AT10 1 Battery Charger 2 1 Starting the AT 10 1 2 1 1 Understanding the start up cece eeeeeeeaeeeeeeeeeeeesnnaeees 24 2 1 2 Checking the 24 2 1 3 Starting the AT 10 1 see E tede ed tee d hide dd is 24 Using the digital Meter 24 Factory settings 8 25 2 2 Using the AT10 1 front panel features 2 2 1 If the meter displays an error message 26 2 2 2 Selecting the meter 26 2 2 3 Selecting the Float or Equalize mode 27 2 2 4 Choosing the Equalize 27 Manual Timer method enhn den
110. o standby by opening the dc breaker CB2 the ground detection circuit gives an erroneous alarm Close the dc breaker and the alarm should end If you want the AT10 1 to be in standby open the ac circuit breaker CB1 3 Calibrate the ground detection sensitivity See Section 2 3 4 4 Disconnect the AT10 1 from the battery and dc bus Turn the AT10 1 back on and measure the voltage from 1 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 AT10 1 and inspect all wiring from TB1 to the dc circuit breaker CB2 and the rectifier bridge to the dc filter inductor L1 Look for evidence of insulation damage insufficient spacing between terminals and chassis or wires run too close to metal edges 5 Turn off both front panel circuit breakers CB1 CB2 Turn on the dc breaker followed by the ac breaker Wait one minute before returning the dc connection followed by the ac connection If you are sure there is no ground fault on the external bus or within the AT10 1 but the POS GND or NEG GND indicator is still on replace the main control circuit board A1 Summary alarm relay is in alarm mode but no front panel alarm indicator is on 1 Defective Main Control circuit board A1 1 Turn off both front panel circuit breakers CB1 CB2 Then turn on the dc breaker followed b
111. ocate 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 196 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 AT10 1 the wiring may have failed The usual failure is an open circuit a short circuit will usually be indicated by smoke or fire in the wiring The AT10 1 charger displays the error code if it detects this wiring failure You should respond to this problem quickly to be sure that the AT 10 1 regulates the output voltage properly Wire an annunciator buzzer 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 wiring failure If th
112. 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 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 t
113. ong enough to properly 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 EIO 191 00 For kit availability see ordering information in Appendix B on page 71 Should be between 32 and 122 0 and 50 C 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 AT10 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 19in 483mm 23 584mm 24 610mm 12 Vdc all Yes Yes Yes 24 Vdc all Yes Yes Yes 48 Vdc 6 12 Adc Yes Yes Yes 48 Vdc 16 25 Adc No Yes Yes 130 Vdc 6 Adc Yes Yes Yes 130 Vdc 12 25 Adc No Yes Yes INSTALLING THE AT10 1 R
114. or the Style 586 JE5023 03 and Style 594 JE5024 03 enclosure in Appendix C on pages 72 and 73 INSTALLING THE AT10 1 1 5 2 Floor Mounting the AT10 1 To floor mount the AT10 1 you must use the floor mounting accessory kit 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 47in 1194mm above floor level with provision for floor anchoring The kit includes an instruction sheet JA0083 00 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 are a problem install a drip shield kit 10191 00 For kit availability see ordering information in Appendix B on page 71 Should be between 32 and 122 0 and 50 C with relative humidity between 5 and 95 non condensing e 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 914mm front clearance for operation and maintenanc
115. ot 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 CONTENTS QUICK OPERATION rer tru erattu RR tesa Back Cover HOW TO READ THE AT10 1 MODEL NUMBER Inside Front Cover IMPORTANT SAFETY INSTRUCTIONS essssseseeeeeeeennnennn nnnm ennt nnne i 1 Receiving and Installing the AT10 1 Battery Charger Storing the 10 i eed den e 2 1 2 Reporting shipping 2 1 3 Unpacking and inspecting the 101 2 Inspection 2 1 4 Moving the AT TOM bed ten R 3 Enclosure type and weight table sss eee 3 1 5 Mounting eere elucet nee eiie fe eaae 3 1 5 1 Wall Mounting the 1 nemen 4 1 5 2 Floor Mounting the 101 6 1 5 3 Rack Mounting the 01 eene 8 1 6 Changing transformer eene 10 1 7 Maki
116. played 26 10 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 e Press CHRG MODE key to change to the equalize mode If the equalize method is set to manual timer or auto equalize timer the charger will revert to the float mode at the end of the selected equalize time You can press the CHRG key at any time to change back to the float mode Choosing the Equalize method Press EaLz key to choose the desired equalize method The indicator next to the desired equalize method will light Three equalize methods are available in the AT10 1 e Manual Timer e Manual Equalize 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 capa
117. ransformer with the terminals labeled H1 through H5 at the bottom facing you Place the transformer against the rear panel and slide the bottom of the transformer bracket into the slots on the rear panel Install the four screws or nuts onto the mounting bracket of the transformer Rewire the transformer following the steps above in reverse Refer to Section 1 6 and verify that the transformer is properly connected for your input voltage Replacing the ac surge suppressors 2 4 or 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 VR4 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 VR1 Turn off all
118. raph on page 23 to determine correct battery voltage You need to know the battery temperature for this step Check ripple Measure at battery terminals using an ac voltage voltmeter set to the milliVolts scale Check against specification in Appendix Ripple mVac A on page 70 Test font panel Press LAMP key on front panel OK indicators Test common Press LAMP key and hold for 4 OK alarm relay seconds Common alarm relay will transfer 42 10 1 Exercise front Switch from float to equalize then back OK panel controls to float Turn off the dc circuit breaker E 07 may OK appear on display requires at least 5 of rated output current Reset breaker Cycle through meter modes OK amps Hours Cycle through equalize methods MANUAL TIMER manua auto EQLZ TIMER OK Turn off ac circuit breaker The AC O Alarm OK INPUT FAILURE indicator should light Reset breaker Check voltage Use key to scroll through FLOAT alarm settings See page 30 EQUALIZE OK settings HvDC alarm OK Lvpc alarm Current limit Adc Final checks Make sure plexiglas safety cover is in OK place Restore charger to normal operation OK Close latch on front panel OK _Step Instructions Results optional f
119. sea branch circuit breaker or fused disconnect switch properly sized for the maximum input current of the AT10 1 as shown in the table below This device should have lockout capability so that the ac input can be de energized and locked out for maintenance A time delay circuit breaker or slow blow fuse is recommended 3 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 4 Do not run external ac and dc power wiring feeding the battery charger through the same conduit 5 specific requirements of your facility take precedence over these instructions PROCEDURE 1 Remove the safety cover 2 Run the ac wiring to terminals TB1 L1 TB1 L2 and TB1 GND on the I O panel in the enclosure Compression lugs accepting wire sizes 714 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 lb 4 0 5 1 Nm 4 Reinstall the safety cover after you have made and checked all connections MAXIMUM INPUT CURRENT AT 120 Vac Example shaded OUTPUT OUTPUT VOLTAGE A 130 Vdc 12 Adc CURRENT 12 24 48 130 battery charger draws 30 Aac at 6 2 8 14 120 Vac 12 3 14 30 16 4 18 32 All
120. symbol factory part number and description from the supplied Parts Data Package report Model number and serial number of your AT10 1 Series battery charger Quantity required Note Some of the factory part numbers listed on the Parts Data Package report may differ from the standard replacement part numbers listed in this manual Custom parts may have replaced standard parts to satisfy your specification In that case you should order the part number s listed on the report The following table may specify part replacement kits that include other materials such as installation instructions and packaging materials You may order spare parts using either part number To be sure of getting the complete kit specify Complete Kit on your order and the factory will make the necessary adjustments Please refer to the table below for the most common items Table 3 1 REPLACEMENT PARTS Factory Part Number Rec Symbol Description 12 24 48 130 Spare A1 Main Control pc board assembly EJ1243 10 Y Gate Driver control pc board assy EJ5093 00 A5 Auxiliary Alarm Relay pc board assembly EJ1243 03 Y Rectifier Heat Sink assembly A16 EJ1243 00 Y A7 DC Output Filter assembly See Table 3 2 A10 Compensation Probe assembly See Appendix B Table 2 A16 SC
121. t 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 4mm to release it from the clips at the bottom of the bracket Swing the filter assembly outward to the left rotating it so that the heat sink comes out first and the capacitor s last Install the replacement filter assembly by inserting the capacitor end first and rotating the assembly inward so that the heat sink is last to go in Push the bottom edge of the bracket into the clips in the rear panel and install the four screws at the top of the bracket Connect wire 15 to the quick connect terminal at the top center of the diode heat sink Route the flying lead from the inductor L2 wire 50 and connect it to the center terminal 2 of the inductor L1 Reconnect wire 54 to terminal E7 of the front circuit board on the 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
122. t value but it still has the wrong output voltage replace the control circuit board Input current 1 Wrong 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 8896 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 AT 10 1 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 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 page 70 The ripple rating is for a battery whose Ampere hours are four 4 times the charger Ampere rating
123. te the alarm NOTE You need at least 50 of the nominal output voltage to power the ATIO 1 control circuit board Adjust with a small jeweler s screwdriver clockwise until the alarm just activates A red LED indicator DS10 next to RA1 indicates when the alarm is active 38 10 1 2 3 9 Using the front panel security feature The 10 1 charger is shipped with all the front instrument panel keys enabled You can disable the following front panel functions Selecting Equalize method e Changing settings using the EDIT ENTER key Toggling the high dc voltage shutdown feature To disable the front instrument panel keys open the AT10 1 door and locate the small plastic jumper J9 on the right side of the main control circuit board See the figure below n nz n 0510 RAL 3 Ie d L DISABLE a L3J9 N ENABLE O 2 215 setting only front panel METER MODE and cHRG keys will function indicators will still work normally Return the jumper down to the ENABLE position pins 1 and 2 to return all front panel key functionality 39 10 1 2 4 2 4 1 2 4 2 2 4 3 Performing routine maintenance
124. temperature goes above 122 F 50 C there is no further decrease in output voltage OUTPUT VOLTAGE VS BATTERY TEMPERATURE Lead Acid we N ckel Cadmium Example 100 Deg F 97 Output ewm 40 60 80 100 120 Temperature Degrees Fahrenheit EXAMPLE Suppose you have a lead acid battery whose temperature is 100 F 37 8 C As shown on the graph the output voltage should be approximately 9796 of the 77 F voltage If the float voltage is set on the front panel to 132 Vdc the actual output voltage will be 132 x 0 97 128 Vdc 1 12 INSTALLING FOR REMOTE COMMUNICATION OPTIONAL Please see separate Operating Instructions JA5026 00 1 13 INSTALLING FOR FORCED LOAD SHARING OPTIONAL Please see Appendix F on page 90 23 10 1 2 10 1 2 1 STARTING THE 10 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 10 1 initiali
125. 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 dc output E 03 high dc voltage shutdown has occurred E 04 internal memory failure E 05 not used E 06 failure in remote sense wiring E 07 dc breaker is open or internal or external output wiring is defective E 08 defective temperature compensation probe E 09 misadjusted current limit E 10 open internal feedback loop E 14 forced load sharing not working properly A 02 equalize mode is inhibited 2 2 2 Selecting the meter mode e Press the METER key to change the meter display mode The digital meter has four operating modes 1 Alternating between output voltage and output current When the charger is in a timed equalize mode the meter alternates between output voltage output current and equalize hours remaining 2 Displaying output voltage only The DC Volts indicator lights 3 Displaying output current only The DC Amps indicator lights 4 Displaying equalize hours remaining only The EQLZ HRS REMAINING indicator lights If the AT10 1 is not in a timed equalize mode the meter displays the full programmed equalize time e When the charger starts initially the meter alternates showing output voltage and output current The DC Volts and DC Amps indicators light alternately to indicate what is being dis
126. ther necessary nor possible WHEN TEMPERATURE COMPENSATION IS INSTALLED The AT Series forced load sharing feature is compatible with the external tempco probe accessory However only tempco for the Primary charger is active If you interchange the Primary and Secondary chargers or discontinue load sharing be sure to check that both temperature compensation probes are working properly TROUBLE SHOOTING If the AT Series Forced Load Sharing option is installed but the output currents of the chargers are unequal refer to the following table PROBABLE RECOMMENDED ACTION CAUSE 1 Connection cable 1 Ensure that the interconnection signal cable assembly is properly missing or installed installed and that the connector for the Secondary charger has the incorrectly jumper as described at the top of page 3 2 Incorrect connections 2 Ensure that both chargers are connected to the same ac supply to ac power sources and that source phase rotation is the same for both chargers 3 Defective or improper 3 Replace the Main Control circuit board in one charger at a time Main Control circuit noting system requirements to restore correct load sharing board A1 operation 91 APPENDIX 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 accor
127. tput 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 AT10 1 Measure the dc voltage from the input terminal to the output terminal of the circuit breaker with the breaker on It is normally no more than 50 millivolts If it is near the rated output voltage replace the breaker Front panel is 1 Control 1 Make sure the connector at the top edge of the control dead ac and circuit board 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 replace 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 PROBABLE RECOMMENDED ACTION CAUSE Front p
128. ttery 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 switch the charger back to float mode by pressing the 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 seconds 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 Pr
129. use mounted barrier type auxiliary alarm terminal block external temperature compensation probe DNP3 Level 2 Modbus communications module forced load sharing interconnection cable 10 11 12 IMPORTANT SAFETY INSTRUCTIONS PLEASE READ AND FOLLOW ALL SAFETY INSTRUCTIONS Before using this equipment read all instructions and cautionary markings on A this equipment B battery and C any other equipment to be used in conjunction with this equipment This manual contains important safety and operating instructions and therefore should be filed for easy access Remove all jewelry watches rings etc before proceeding with installation or service Do not touch any uninsulated parts of this equipment especially the input and output connections as there is the possibility of electrical shock During normal operation batteries may produce explosive gas Never smoke use an open flame or create arcs in the vicinity of this equipment or the battery Maintain at least 6in 152mm clearance from all obstructions on the top 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 n
130. ut 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 e POS GND lights whenever leakage 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 10 1 also has a summary alarm relay with one form C contact rated 0 5A 2 125 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 10 1 2 3 2 3 1 SETTING PARAMETERS IN THE AT10 1
131. y Charger 31 A step by step troubleshooting procedure 44 3 2 Interpreting front panel error messages sss mem 45 3 3 Using the troubleshooting 48 3 4 Troubleshooting chart begins 49 35 Replacing defective nnns nenene nn 58 3 66 Ordering replacement parts enne 64 Replacement parts tables begin on 64 APPENDIX A AT10 1 Performance 70 APPENDIX B Field Installable 420 2 22 22 71 APPENDIX C Standard Drawings Standard NEMA 1 Enclosure Outline 586 0 72 Standard NEMA 1 Enclosure Outline Style 594 seem 73 Optional Enclosure Dimensions with penthouse and or drip 74 Internal Component Layout Detail Style 586 495 with Common Options 76 Instrument Panel Detail with Optional Auxiliary Relay PC 78 Schematic AT10 1 Group Battery Charger Standard w o 80 Schematic AT10 1 Group Battery Charger with Common 82 Connection Diagram AT10 1 Group Battery Charger Standard w o Options
132. y the ac breaker Wait one minute before returning the dc connection followed by the ac connection If the relay remains in alarm mode check the Low Level Detect indicator on main control circuit board See Section 2 3 8 If no other alarm is on replace the main control circuit board A1 57 10 1 3 5 REPLACING DEFECTIVE 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 standard 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 and dc voltages are present on the I O panel terminals and several internal components Removing the enclosure shroud You may need to
133. zes the charger by reading the settings that are stored internally The control circuit then soft starts the charger and the dc output voltage and current increase gradually to the rated value Checking the installation Using the Digital Meter Be sure that you have followed the installation When you first start the AT10 1 the meter display instructions carefully Check the ac input alternates between de output supply voltage and the battery voltage be voltage and dc output current sure that they match the information on the Each reading is held for two seconds lights to the left of AT10 1 nameplate Verify that the jumpers on pe display whether the main transformer are correct for your the meter 15 displaying ac supply voltage Open the front panel and voltage or current check the battery polarity at the and I 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 Gulpecuneu AT10 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 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

AT Series - 10 - Group 1

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