AT30 SERIES Operating and Service Instructions MICROPROCESSOR-CONTROLLED FLOAT BATTERY CHARGER THREE PHASE INPUT Advanced-Technology microprocessor control
HOW TO READ THE AT30 MODEL NUMBER Your AT30 model number is coded to describe the options that are included. Please find the model number on the data nameplate and write it in the spaces provided below. Then follow the chart to determine the configuration of your battery charger.
IMPORTANT SAFETY INSTRUCTIONS READ AND FOLLOW ALL SAFETY INSTRUCTIONS 1. 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. 2. This manual contains important safety and operating instructions, and therefore should be filed for easy access. 3. Remove all jewelry, watches, rings, etc. before proceeding with installation or service. 4.
TABLE OF CONTENTS QUICK OPERATION .................................................................................................. Back Cover HOW TO READ THE AT30 MODEL NUMBER .............................................Inside Front Cover IMPORTANT SAFETY INSTRUCTIONS ......................................................................................i 1 Receiving and Installing the AT30 Battery Charger 1.1 Storing the AT30 ..............................................................................
TABLE OF CONTENTS 2.3 Setting the AT30 parameters 2.3.1 Understanding parameter settings .................................................................32 2.3.2 Setting the Float and Equalize voltages.........................................................33 2.3.3 Setting the Equalize timer ..............................................................................34 2.3.4 Setting the Alarms..........................................................................................
RECEIVING THE AT30 1. RECEIVING THE AT30 1.1. STORING THE AT30 If you store the AT30 for more than a few days before installation, you should store it in its original shipping container, and in a temperature controlled, dry climate. Ambient temperatures of 32 to 122° F / 0 to 50° C are acceptable. Storage should not exceed 2 years due to the limited shelf life of the dc filter capacitors when they are not in service. 1.2.
INSTALLING THE AT30 1.4. MOVING THE AT30 Once you have established that the AT30 is undamaged, identify the enclosure style and weight of your unit. Refer to the table below.
INSTALLING THE AT30 1.5. MOUNTING THE AT30 Chose the mounting method for the unit enclosure from the table below. ENCLOSURE ENCLOSURE MANUAL MOUNTING METHOD SECTION Style-5018 Style-5030/5031 1.5.1 1.5.2 1.5.3 Floor-Mounting Wall-Mounting 19in / 483mm Rack-Mounting 23-24in / 584-610mm Rack-Mounting STANDARD OPTIONAL STANDARD n/a n/a n/a OPTIONAL n/a 1.5.1. Floor-Mounting the AT30 (standard) To floor mount the AT30, you must locate the anchor-bolt holes at least 4.
INSTALLING THE AT30 PROCEDURE (Style-5018) To floor-mount the AT30, install four (4) .25in / 6.4mm bolts into the floor. Place the AT30 on the bolts, add appropriate mounting hardware, and tighten securely. See the diagram below for the Style5018 enclosure footprint and floormounting pattern. Dimensions are in/mm. NOTE: For further enclosure size, mounting dimensions and specifications of the AT30 Style-5018 enclosure, refer to the custom outline drawing (JE5085######) supplied with the unit.
INSTALLING THE AT30 PROCEDURE (Style-5030) To floor-mount the AT30, install four (4) .25in / 6.4mm bolts into the floor. Place the AT30 on the bolts, add appropriate mounting hardware, and tighten securely. See the diagram below for the Style5030 enclosure footprint and floormounting pattern. need perspective image of Style-5030 enclosure Dimensions are in/mm.
INSTALLING THE AT30 PROCEDURE (Style-5031) To floor-mount the AT30, install four (4) .25in / 6.4mm bolts into the floor. Place the AT30 on the bolts, add appropriate mounting hardware, and tighten securely. See the diagram below for the Style5031 enclosure footprint and floormounting pattern. need perspective image of Style-5031 enclosure Dimensions are in/mm.
INSTALLING THE AT30 1.5.2. Wall-Mounting the AT30 (Style-5018 enclosure only) In planning for wall mounting of the AT30 consider the following: 1. If you are wall-mounting a charger in the Style-5018 enslosure, you need the wall mounting bracket kit (part number EI5008-00). For kit availability see ordering information in Appendix B on page 73. The kit includes dimensions and instructions for locating the wall mounting holes. 2. The wall must be strong enough to properly support the weight of the AT30.
INSTALLING THE AT30 PROCEDURE To wall-mount the AT30, install eight (8) .25in / 6.4mm bolts on the wall rated to support the AT30 weight plus a safety factor of at least 2 times. Place the AT30 on the bolts, add appropriate mounting hardware, and tighten securely. See the diagram below for the Style-5018 enclosure footprint and wall-mounting pattern. need perspective image of Style-5018 enclosure with wall-mounting brackets Dimensions are in/mm.
INSTALLING THE AT30 1.5.3. Rack-Mounting the AT30 (Style-5018 enclosure only) AT30 battery chargers housed in the Style-5018 enclosure can be installed in most relay racks with standard EIA hole spacing. A relay rackmounting kit (EI0193-03) is required. For kit availability see ordering information in Appendix B on page 73. Each kit includes mounting brackets, hardware and the necessary instructions to install one AT30 battery charger.
INSTALLING THE AT30 PROCEDURE To rack mount the AT30, first install the brackets into the rack using the supplied hardware. Second, install the AT30 onto the brackets. Tighten all hardware securely. Provide at least 6in / 152mm of free air space above and below the AT30 enclosure in the rack for cooling. You do not need to modify the AT30 enclosures for standard rack-mounting. See the diagrams below for the Style-5018 enclosure rack-mounting configuration. Style-5018 Rack-Mounting NOTES: 1.
INSTALLING THE AT30 1.6. CHANGING THE TRANSFORMER TAPS IMPORTANT: The AT30 Battery Charger is designed for a single ac supply voltage. Note the ac voltage listing on the data nameplate and the tag attached to the front panel. If your particular ac supply voltage does not match your AT30 ac input requirements, you MUST change the ac input circuit breaker (and/or fuses) and the input surge suppressors. In addition, you must replace or rewire the transformer as described below.
INSTALLING THE AT30 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 AT30. Change the jumpers on the main transformer (T1) as shown in the table below.
INSTALLING THE AT30 1.7. MAKING THE AC INPUT CONNECTIONS Follow these steps to connect ac power to the AT30: 1. Use a branch circuit breaker or fused disconnect switch, properly sized for the maximum input current of the AT30, as shown in the table below. This device should have lockout capability so that the ac input can be deenergized and locked out for maintenance. A time delay circuit breaker or slow-blow fuse is recommended.
INSTALLING THE AT30 MAKING THE AC INPUT CONNECTIONS - GRAPHICS I/O Terminal Board (TB1) Detail Style-5018 I/O Terminal Board (TB1) Detail Style-5030 / Style-5031 NOTES: 1. The drawings above do 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. Wire insulation must be rated for 194° F / 90° C or better. 4. Use copper or aluminum conductors only. 5.
INSTALLING THE AT30 1.8. MAKING THE DC OUTPUT CONNECTIONS Follow these steps to connect the battery to the AT30: 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. 2. Size the dc output wiring per your battery manufacturer's specifications and local codes for the rating of the batteries and/or load. 3.
INSTALLING THE AT30 MAKING THE DC OUTPUT CONNECTIONS - GRAPHICS I/O Terminal Board (TB1) Detail Style-5018 I/O Terminal Board (TB1) Detail Style-5030 / Style-5031 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. Wire insulation must be rated for 194° F / 90° C or better. 4. Use Copper or aluminum conductors only. 5.
INSTALLING THE AT30 1.9. WIRING THE AT30 FOR REMOTE SENSING You can wire the AT30 to regulate the output voltage at the battery terminals, instead of at the charger output terminals. Remote sensing does the following: 1. Compensates for voltage drop in the dc wiring between the AT30 and the battery. 2. Directly monitors the battery or dc bus voltage. The front panel meter displays the actual voltage on the battery or dc bus.
INSTALLING THE AT30 PROCEDURE 1. De-energize and lock out all ac and dc voltages within the AT30 enclosure. Check with a voltmeter. 2. Remove safety shield. 3. Wire the AT30 remote sense to the dc bus as shown in the figure below. 4. Move wires #38 and #40 from the TB1 (-) and (+) dc output terminals to the corresponding remote sense terminals as shown in the lower left figure. 5.
INSTALLING THE AT30 1.10. WIRING TO THE REMOTE ALARM CONTACTS Built-in Common Alarm Relay The Common Alarm relay, located on the main control circuit board on the back of the door, provides one form C summary alarm contact that transfers for any alarm. Follow the procedure below to wire an annunciator to this contact. See section 2.2.7 for a description of the alarm functions. PROCEDURE 1. Allow 30in / 762mm of wire inside the enclosure (excess will be trimmed). 2.
INSTALLING THE AT30 Auxiliary Relay Board (optional) The Auxiliary Relay Board is located in the main wiring compartment, behind the safety shield. This board provides two form C contacts for each of the following individual alarms: • • • • • • High DC Voltage Low DC Voltage DC Output Failure AC Failure Ground Fault Detection (positive or negative) Summary Alarm Follow the procedure below to wire annunciators to one or more of these alarm contacts. TB4 TERMINAL BLOCK (2 FORM-C) CONTACTS PROCEDURE 1.
INSTALLING THE AT30 1.11. INSTALLING THE TEMP. COMEPNSATION PROBE (OPTIONAL) The temperature compensation probe contains a temperature-dependent resistor in an epoxy module that you install near your battery. There are three steps in installing the assembly: 1. Mounting the probe assembly near the battery. 2. Installing an interconnection cable from the probe assembly to the AT30. 3. Wiring the charger end of the cable to a terminal block on the main control circuit board.
INSTALLING THE AT30 • • 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 is not long enough, longer cable assemblies are available in lengths of 50, 100 & 200ft / 15.2, 30.5 & 61.0m. See Appendix B on page 73 for ordering information. • Be sure your wiring conforms to the NEC and your facility requirements. 5.
INSTALLING THE AT30 7. Check your work. Be sure that: • All connections are secure. • The shield is connected to ground at the charger end only (on the main circuit board). • The cable is connected to TB8 on the circuit board. Other terminal blocks may look similar. 8. Restart the AT30 using the startup procedure in section 2.1. During startup, the AT30 displays LEAD on the front panel, indicating that the temperature compensation is set up for lead-acid batteries.
INSTALLING THE AT30 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).
OPERATING THE AT30 2. OPERATING THE AT30 BATTERY CHARGER 2.1. STARTING THE AT30 2.1.1. Understanding the startup sequence The AT30 is set up at the factory to work with most common batteries and loads without further adjustment. When you start the AT30 for the first time, the factory settings (float voltage, equalize voltage, etc.) control the operation of the charger. You can change the settings after you start the charger. The FACTORY SETTINGS are shown in table on page 27.
OPERATING THE AT30 • • • If you have an optional temperature compensation probe installed, the front panel displays LEAD during startup, indicating that the temperature compensation is set up for lead-acid batteries. While this is being displayed, you can press any front panel key to change the display to read NICD, to change the temperature compensation setup for nickel cadmium batteries. The choice you make is saved internally, and will be used again by the AT30 then next time it starts.
OPERATING THE AT30 2.2. USING THE AT30 FRONT PANEL FEATURES 2.2.1. If the meter displays an error message When you apply power to the AT30 for the first time, the micro-processor control circuit performs a diagnostic check of the system. If it finds anything wrong, it writes an error code to the display, such as E 01. Below is a list of 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.
OPERATING THE AT30 2.2.3. Selecting the Float or Equalize mode The AT30 has 2 output voltage settings, Float and Equalize. Use the Float mode for all normal battery charging and to operate your dc system. Use the Equalize mode if it is necessary to balance the level of charge among the cells of the battery. Consult your battery data sheets for information on equalize charging your battery. • Press the CHRG MODE key to change to the equalize mode.
OPERATING THE AT30 Manual Equalize Method Choose the manual equalize method when you want to equalize charge the battery, but only when you are able to monitor the battery voltage and gassing rate. After you select the manual equalize method, press the CHRG MODE key to put the charger into the equalize mode. The EQLZ indicator will light. Press the CHRG MODE key again to return the charger to the float mode. The FLOAT indicator will light.
OPERATING THE AT30 2.2.5. Testing the front panel indicators • Press the DOWN key. This is also the LAMP TEST key. The meter will display 8888, and all status & alarm indicators will light. The LAMP TEST key does not test the AC ON indicator. The AC ON indicator lights whenever ac power is present, and the ac circuit breaker is turned on. The LAMP TEST key does not operate when ac power is off. To test the action of the summary alarm relay, press and hold the LAMP TEST key for four seconds.
OPERATING THE AT30 2.3. SETTING PARAMETERS IN THE AT30 2.3.1. Understanding Parameter Settings You can change the settings of the AT30 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.
OPERATING THE AT30 2.3.2. Setting the Float and Equalize voltages • Press the EDIT/ENTER key. The FLOAT and DC VOLTS indicators light, and the display flashes the present value of the float voltage. Press and release the UP or DOWN key to increase or decrease the value in the display by one count, or press and hold the UP or DOWN key to scroll the value in the display upward or downward. When the display shows the float voltage you want to set, release the UP or DOWN key.
OPERATING THE AT30 2.3.3. Setting the Equalize Timer • Press the EDIT/ENTER key until the EQLZ HRS REMAINING, MANUAL TIMER and AUTO EQLZ TIMER indicators light, and the display flashes the present value of the equalize timer duration in hours. Press and release the UP or DOWN key to increase or decrease the value in the display by one count, or press and hold the UP or DOWN key to scroll the value in the display upward or downward.
OPERATING THE AT30 Setting the High DC Voltage Alarm • Press the EDIT/ENTER key until the HIGH DC VOLTAGE indicator flashes, and the display flashes the present value of the high dc voltage alarm. Press and release the UP or DOWN key to increase or decrease the value in the display by one count, or press and hold the UP or DOWN key to scroll the value in the display upward or downward. When the display shows the high dc voltage alarm point that you want to set, release the UP or DOWN key.
OPERATING THE AT30 Adjusting Ground Detection Sensitivity You can adjust the sensitivity of the ground detection alarm circuit. You must have a test resistor whose value is the sensitivity you want. You can adjust the sensitivity from 5 to 50 kΩ. 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.
OPERATING THE AT30 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 AT30. Check with a voltmeter before proceeding. This includes remote sense wires if they were installed.
OPERATING THE AT30 2.3.6. Enabling the High DC Voltage shutdown feature The AT30 has a built-in high dc voltage shutdown feature. In case of any maladjustment or internal failure that results in a continuous output voltage that is too high, the AT30 shuts down after 30 seconds to protect the battery. The digital display shows E 03, and the summary alarm relay contact transfers. The AT30 is shipped with the high dc voltage shutdown feature disabled.
OPERATING THE AT30 2.3.7. Adjusting the Voltmeter Accuracy The AT30 voltmeter is adjusted at the factory to display the actual output voltage within ±1%. If you replace any component that affects meter accuracy, such as the main control PC board or R4, you should readjust the meter. This adjustment procedure is different from all others, because the meter reading remains constant, while the output voltage of the charger changes. Do this adjustment with a fully charged battery and with no load connected.
OPERATING THE AT30 2.3.8. Using the Low Level Detector (LLD) The AT30 charger is equipped with a summary alarm safety override circuit. This safety feature forces the summary alarm (common alarm) relay contact to transfer, sending an alarm, even if there is a catastrophic failure of the control circuitry. A low battery voltage triggers the safety circuit. If you have a dc power supply, you can adjust the battery voltage that triggers the alarm.
OPERATING THE AT30 2.3.9. Using the front panel security feature The AT30 charger is shipped with all the front panel keys enabled. You can disable these front panel functions: • Selecting Equalize method • Changing settings using the EDIT/ENTER key • Toggling the high dc voltage shutdown feature Open the front panel, and locate the small plastic jumper J9 on the right side of the main control board, as shown in the figure below. DISABLE Move the jumper to the DISABLE position.
OPERATING THE AT30 2.4. Performing routine maintenance WARNING: High voltages appear at several points inside the battery charger. Use extreme caution when working inside the charger. Do not attempt to work inside the charger unless you are a qualified technician or electrician. Disconnect and lock out all power to the battery charger before starting any maintenance procedures. Turn the ac power off at the distribution panel upstream from the battery charger.
OPERATING THE AT30 2.4.4. Check temperature compensation probe (optional) If you are using the optional temperature compensation probe, be sure that the probe is securely installed. Be sure the connectors and the wiring from the probe to the AT30 charger are in good condition. If there is a failure of the temperature compensation probe, or the wiring, the AT30 charger displays the error code E 08. 2.4.5.
OPERATING THE AT30 SAMPLE PREVENTIVE MAINTENANCE PROCEDURE AT30 BATTERY CHARGER Suggested frequency: every 6 months Maintenance date Step Instructions (standard features) Clean battery charger • • Check all electrical connections and wiring • • • Check ac input voltage • Check dc output voltage • Check ripple voltage Test font panel indicators Test common alarm relay 44 Performed by • • • Results All vents clean and open. Remove dust and debris from inside of unit.
OPERATING THE AT30 Exercise front panel controls • • Switch from float to equalize, then back to float. Turn off the dc circuit breaker. E 07 should appear on display (requires at least 5% of rated output current). Reset breaker. Cycle through meter modes. • Cycle through equalize methods. • Turn off ac circuit breaker. The AC INPUT FAILURE indicator should light. Reset breaker. Use EDIT/ENTER key to scroll through settings.
SERVICING THE AT30 3. SERVICING THE AT30 3.1. A STEP-BY-STEP TROUBLESHOOTING PROCEDURE The AT30 battery charger is fully tested and calibrated at the factory and should work for years with a minimum of attention. If you do encounter trouble, there are three steps you should take to find the problem and return the charger to service. 1. Check the front panel meter for an error code. The AT30 is able to diagnose common problems with the battery charger, or with the application or installation.
SERVICING THE AT30 3.2. INTERPRETING FRONT PANEL ERROR MESSAGES If the AT30 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.
SERVICING THE AT30 Error Code E 04 Meaning Repair Procedure Internal memory Any parameters that you set, such as Float or Equalize voltage, are failure saved internally. The internal memory is tested on startup. If the memory test fails, E 04 appears on the front panel display. The error may also appear if the controller was trying to write to the memory while a power failure occured. If an E 04 appears, try restarting the AT30 by turning the ac and dc breakers off, then on.
SERVICING THE AT30 Error Code E 08 Meaning Repair Procedure Defective temperature compensation probe If a temperature compensation probe is connected to the AT30, the control circuit detects the probe on startup, and uses the temperature measured by the probe to control the output voltage of the charger. To understand temperature compensation, see section 1.11.
SERVICING THE AT30 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.
SERVICING THE AT30 3.4. TROUBLESHOOTING CHART SYMPTOM PROBABLE CAUSE AC breaker 1. Shorted trips (or fuses rectifier diode clear) or SCR immediately RECOMMENDED ACTION 1. Test by disconnecting wires # 7, 8 & 9 at the rectifier module(s) (A16) mounted on the main heat sink(s), or at the main transformer (T1). Measure resistance between the ac terminals (bottom terminals) on the rectifier module(s). It should be at least 100,000 Ohms (check both polarities).
SERVICING THE AT30 SYMPTOM PROBABLE CAUSE 4. Defective Polarity Diode CR1 (if filter assembly is installed) 5. Defective wiring DC breaker trips (or fuses clear) after a few minutes No output current, and AC ON lamp is out, but ac and dc breakers are on 52 1. Loose connection to breaker 2. Open SCR RECOMMENDED ACTION 4. Disconnect wire # 17 from the dc circuit breaker (CB2), or the optional dc fuse (F3).
SERVICING THE AT30 SYMPTOM No output current, but AC ON lamp is on, and ac and dc breakers are on PROBABLE CAUSE 1. Battery is fully charged 2. Float or Equalize voltage set too low 3. Wrong ac input voltage, or miswired T1 taps 4. Defective wiring RECOMMENDED ACTION 1. This is normal operation in a system with little or no dc load. As long as the charger maintains Float voltage, it is operating normally. 2. Check the Float and Equalize voltages and adjust them if necessary.
SERVICING THE AT30 SYMPTOM PROBABLE CAUSE Front panel 1. Defective dies during ac power resistor power failure R3 and dc voltage is present at TB1 2. Defective wiring RECOMMENDED ACTION 1. Use a dc voltmeter to measure the dc voltage from TB1(-) to J25 pin # 25 on the Gate Drive board (A15). It is normally 12 Vdc when the rated output voltage is at TB1(+) and TB1(-). If it is not, remove all power from the charger, and measure the resistance from TB1(+) to J25 pin # 19 (see the table in section 3.
SERVICING THE AT30 SYMPTOM PROBABLE CAUSE 1. Current limit Charger set too low never reaches float (or equalize) voltage (within 1%) 2. Defective battery or dc load, or load is too great 3. Wrong ac input voltage, or voltage too low, or T1 wired incorrectly 4. Defective rectifier bridge 5. Defective Main Control board A1 RECOMMENDED ACTION 1. If the AT30 is not in the Edit mode, press the EDIT/ENTER key five times, until the meter display flashes the current limit value (in Amperes).
SERVICING THE AT30 SYMPTOM PROBABLE CAUSE Charger very 1. Loose noisy hardware or enclosure panel 2. Defective rectifier bridge RECOMMENDED ACTION 1. Check and tighten all component mounting hardware and panel hardware. 2. Use a clamp-on ammeter to measure the current in wires # 7, 8 & 9, between T1 and the rectifier modules. If it less than 50% of the dc output current, one of the SCRs or diodes is defective. Replace the rectifier module(s) (A16) as needed. 1. Turn off the charger.
SERVICING THE AT30 SYMPTOM PROBABLE CAUSE HIGH DC 1. High DC VOLTAGE Voltage alarm indicator is on and Equalize voltage settings are mismatched 2. Defective rectifier bridge 3. Defective Main Control board A1 RECOMMENDED ACTION 1. Be sure that the High DC Voltage alarm setting is higher than the Equalize voltage setting. See sections 2.3.2 and 2.3.4. 2. Disconnect the wire harness plug from connector J26 on the top of the Gate Drive board (A15) and restart the charger.
SERVICING THE AT30 SYMPTOM PROBABLE CAUSE RECOMMENDED ACTION 1. Use a clamp-on ammeter to measure the current in wire #7, #8 and #9, between T1 and the rectifier module(s). If it less than 50% of the dc output current, one of the SCRs or diodes is defective. Replace the rectifier module. 2. Defective 2. Turn off both front panel circuit breakers (CB1/CB2), or turn Main Control off ac and dc power externally if the charger does not have board A1 breakers.
SERVICING THE AT30 SYMPTOM PROBABLE CAUSE POS GND or 1. Ground fault NEG GND on external dc indicator is on bus 2. Alarm needs calibration 3. Defective wiring 4. Defective Main Control board A1 Summary 1. Defective alarm relay is Main Control in alarm board A1 mode, but no front panel alarm indicator is on RECOMMENDED ACTION 1. Disconnect the charger from the battery and dc bus, and check the battery and dc bus for a ground fault. 2. Calibrate the ground detection sensitivity. See section 2.3.4. 3.
SERVICING THE AT30 3.5. REPLACING DEFECTIVE COMPONENTS WARNING: High voltages and high temperatures 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.
SERVICING THE AT30 Replacing the control circuit board (A1) and/or gate drive board (A15) CAUTION: The main control printed circuit board (A1) is sensitive to damage from static discharges. Leave the 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.
SERVICING THE AT30 Replacing the ac surge suppressors (VR2, VR4 or VR5) Turn off all power to the charger. Disconnect the battery from the output terminals. Remove the safety shield. For VR2 (connected to L1), VR4 (connected to L2) or VR5 (connected to L3), remove the hardware from the input terminal Lx, and remove the lugged lead of the ac surge suppressor. Install one lead of the replacement surge suppressor onto the Lx terminal. Replace the other wires and the Lx terminal hardware.
SERVICING THE AT30 Replacing the power (ballast) resistor (R3) - 48 and 130 Vdc units only For 48 Vdc and 130 Vdc AT10.1 battery chargers rated 30-100 Adc, R3 is mounted with metal brackets onto the back panel of the enclosure. Cut wires # 49 and # 51 connected to R3, as close to the resistor leads as possible. Strip off .25in / 6.4mm of insulation from the cut ends of the wires. Unscrew the top mounting-bracket and remove the existing resistor. Mount the new R3 and replace the top mounting-bracket.
SERVICING THE AT30 3.6. ORDERING REPLACEMENT PARTS To order replacement parts, please provide the following information for each component: • • • • Circuit symbol from the Parts Data Package report and/or custom AT30 Schematic (JE5092-######) supplied with the unit.
SERVICING THE AT30 Symbol Description Factory Part Number 12 Vdc 24 Vdc 48 Vdc 130 Vdc Rec.
SERVICING THE AT30 Table 3-2: DC FILTER ASSEMBLIES - STANDARD (L2/C1/R9/CR1) Ampere Rating 25 Adc 30 Adc 40 Adc 50 Adc 75 Adc 100 Adc 125 Adc 150 Adc 12 Vdc AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 Output Voltage 24 Vdc 48 Vdc AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 130 Vdc AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA000
SERVICING THE AT30 Table 3-6: MEDIUM AMPERE INTERRUPTING CAPACITY AC BREAKERS (CB1) - 208/240 Vac Ampere Rating 25 Adc 30 Adc 40 Adc 50 Adc 75 Adc 100 Adc 125 Adc 150 Adc 12 Vdc AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 Output Voltage 24 Vdc 48 Vdc AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 130 Vdc AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA00
SERVICING THE AT30 Table 3-10: AC INPUT FUSES (F1A/F1B/F1C) - 208/240 Vac Ampere Rating 25 Adc 30 Adc 40 Adc 50 Adc 75 Adc 100 Adc 125 Adc 150 Adc 12 Vdc AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 Output Voltage 24 Vdc 48 Vdc AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 130 Vdc AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-0
SERVICING THE AT30 Table 3-14: HIGH AMPERE INTERRUPTING CAPACITY DC CIRCUIT BREAKERS (CB2) Ampere Rating 25 Adc 30 Adc 40 Adc 50 Adc 75 Adc 100 Adc 125 Adc 150 Adc 12 Vdc AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 Output Voltage 24 Vdc 48 Vdc AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 130 Vdc AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 A
SERVICING THE AT30 Table 3-18: DC SHUNT RESISTOR (R1) Ampere Rating 25 Adc 30 Adc 40 Adc 50 Adc 75 Adc 100 Adc 125 Adc 150 Adc 12 Vdc AA0000-00 00.0 kΩ AA0000-00 00.0 kΩ AA0000-00 00.0 kΩ AA0000-00 00.0 kΩ AA0000-00 00.0 kΩ AA0000-00 00.0 kΩ AA0000-00 00.0 kΩ AA0000-00 00.0 kΩ Output Voltage 24 Vdc 48 Vdc AA0000-00 AA0000-00 00.0 kΩ 00.0 kΩ AA0000-00 AA0000-00 00.0 kΩ 00.0 kΩ AA0000-00 AA0000-00 00.0 kΩ 00.0 kΩ AA0000-00 AA0000-00 00.0 kΩ 00.0 kΩ AA0000-00 AA0000-00 00.0 kΩ 00.0 kΩ AA0000-00 AA0000-00 00.
SERVICING THE AT30 Table 3-20: MAIN TRANSFORMER (T1) - 208/240 Vac Ampere Rating 25 Adc 30 Adc 40 Adc 50 Adc 75 Adc 100 Adc 125 Adc 150 Adc 12 Vdc AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 Output Voltage 24 Vdc 48 Vdc AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 130 Vdc AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 AA0000-00 Ampe
APPENDIX A SPECIFICATIONS Except as noted, all specifications apply at: 77° F / 25 °C, nominal ac line voltage & nominal Float voltage Specification Conditions 12 Vdc 24 Vdc 48 Vdc 130 Vdc Output voltage regulation Vac +10%, -12% 0 to 100% load Temp. 32-122° F / 0-50° C Freq. 60 ± 3 Hz ± 0.25% Transient response 20-100% load change, with battery connected Output voltage change ± 4% maximum Recovery to ± 2.0% in 200 ms Recovery to ± 0.
APPENDIX B FIELD INSTALLABLE ACCESSORIES AND OPTIONS All 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.
APPENDIX C (Standard Drawings) CUSTOM DRAWINGS In lieu of standard drawings within this manual, all AT30s currently ship with a custom Record Drawing Package, consisting of the following documents: • JE5075 AT30 Series Battery Charger Drawing List / Data Nameplate Detail Use this document to track the revision levels of your custom drawing package and to confirm the ratings listed on the AT30 data nameplate.
APPENDIX C (Standard Drawings) 75
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. Lead-Acid Types Battery Cell Type Antimony 1.215 Sp. Gr. Antimony 1.250 Sp. Gr. Calcium 1.215 Sp. Gr. Calcium 1.250 Sp. Gr. Absorbed / Gelled Electrolyte * (sealed Lead-Acid type) Nickel Cadmium Recommended Float Voltage/cell Recommended Equalize Voltage/cell 2.17 2.20 2.25 2.29 2.
APPENDIX E COMMUNICATIONS MODULE Your AT30 Battery Charger has provisions for an optional Communications Module that allows the user to remotely monitor and control the charger over a serial connection. This PC Board Assembly (A12) supports DNP3 Level 2 and Modbus protocols over RS-232 or RS-485 half-duplex. The system can be used with a modem for telephone communications. All features of the AT10.1’s front instrument panel are accessible remotely, using this option.
CUSTOMER NOTES MANUAL REVISION: The text and graphics contained within this manual are controlled by the battery charger manufacturer's internal part number (JA5030-00). The revision level of this manual's text and graphics are featured in the electronic filename listed below. The revision dates are also listed below and supercede all other available dates. The first two and last two pages of this manual are reserved for company-specific front and back cover artwork.
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 29 and 2.3.3 on page 34 Startup „ Turn on the dc breaker, labeled “DC OUTPUT”. „ Turn on the ac breaker, labeled “AC INPUT”. Changing between Float and Equalize Modes „ 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.
