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.
AT30
A
B
C
D
E
DESCRIPTION
CODE
FEATURE
A
SERIES
AT30
AT30 CHARGER
B
NOMINAL
DC OUTPUT
VOLTAGE
C
D
E
NOMINAL
DC OUTPUT
CURRENT
FILTERING
AC INPUT
VOLTAGE
DESCRIPTION
012
12 Vdc
024
24 Vdc
048
48 Vdc
130
130 Vdc
G
H
J
DESCRIPTION
F
CODE
FEATURE
CODE
FEATURE
0025
25 Adc
200
200 Adc
0030
30 Adc
250
250 Adc
0040
40 Adc
300
300 Adc
0050
50 Adc
400
400 Adc
0075
75 Adc
500
500 Adc
0100
100 Adc
600
600 Adc
0125
125 Adc
800
800 Adc
0150
150 Adc
1K0
1000 Adc
U
UNFILTERED
F
FILTERED
E
ELIMINATOR
208
208 Vac 60 Hz
240
240 Vac 60 Hz
480
480 Vac 60 Hz
220
220 Vac 50/60 Hz
380
380 Vac 50/60 Hz
416
416 Vac 50/60 Hz
CODE
F
FEATURE
AC CIRCUIT
BREAKER
RATING
(SEE TABLE)
G
AC FUSES
(200 KAIC)
H
DC CIRCUIT
BREAKER
RATING
(SEE TABLE)
J
DC FUSES
(20 KAIC)
K
AUX ALARM
RELAY BOARD
L
GROUND PAD
M
LIGHTNING
ARRESTOR
N
TREATMENTS
P
DRIP SHIELDS
DESCRIPTION
K
CODE
L
M
N
FEATURE
S
STANDARD
M
MEDIUM AIC
H
HIGH AIC
0
NO AC BREAKER
F
SUPPLIED
X
NOT SUPPLIED
S
STANDARD
M
MEDIUM AIC
H
HIGH AIC
0
NO DC BREAKER
F
SUPPLIED
X
NOT SUPPLIED
A
SUPPLIED
X
NOT SUPPLIED
G
SUPPLIED
X
NOT SUPPLIED
L
SUPPLIED
X
NOT SUPPLIED
F
FUNGUS PROOFING
S
STATIC PROOFING
X
NOT INCLUDED
D
INSTALLED
X
NOT SUPPLIED
CODE
P
FEATURE
INPUT AND OUTPUT CIRCUIT BREAKER INTERRUPTING RATINGS
CODE
TYPE
AC RATINGS
(208/240/480 Vac)
DC RATINGS
(125 Vdc)
DC RATINGS
(250 Vdc)
S
STANDARD
5,000 AIC
5,000 AIC
–
M
MEDIUM AIC
25,000 AIC
10,000 AIC
10,000 AIC
H
HIGH AIC
65,000 AIC
25,000 AIC
25,000 AIC
NOTE:
The model number listed on the charger data nameplate does not include any field-installed
options. Also, certain accessories are not included in the model number, even if they are shipped with the
charger. Check off below any accessories that were included, or that you install yourself.
Wall/rack mounting brackets
Lockable enclosure door
Cabinet heater strips
NEMA-4/12/13 type enclosure
Auxiliary alarm terminal block
Please find the serial number on the
data nameplate and record it here:
External temperature compensation probe
Analog ac voltmeter
Analog ac ammeter
Ground detection dc voltmeter w/switch
DNP3 Level 2 / Modbus communications module
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.
Do not touch any uninsulated parts of this equipment, especially the
input and output connections, as there is the possibility of electrical
shock.
5.
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.
6.
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.
7.
Turn this equipment off before connecting or disconnecting the battery
to avoid a shock hazard and/or equipment damage.
8.
Connect or disconnect the battery only when the battery charger is off to
prevent arcing or burning.
9.
De-energize all ac and dc inputs to the battery charger before servicing.
10. Do not operate battery charger if it has been damaged in any way. Refer
to qualified service personnel.
11. Do not disassemble battery charger. Only qualified service personnel
should attempt repairs. Incorrect reassembly may result in explosion,
electrical shock, or fire.
12. Do not install the battery charger outdoors, or in wet or damp locations
unless specifically ordered for that environment.
SAVE THESE INSTRUCTIONS
i
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 ....................................................................................................2
1.2 Reporting shipping damage ...................................................................................2
1.3 Unpacking and inspecting the AT30 ......................................................................2
Inspection checklist ................................................................................................2
1.4 Moving the AT30 ....................................................................................................3
Enclosure type and weight table ............................................................................3
1.5 Mounting the AT30 .................................................................................................4
1.5.1 Floor-Mounting the AT30 (standard)................................................................4
1.5.2 Wall-Mounting the AT30 (optional) ..................................................................8
1.5.3 Rack-Mounting the AT30 (optional) ...............................................................10
1.6 Changing the transformer taps.............................................................................12
1.7 Making the ac input connections ..........................................................................14
1.8 Making the dc output connections........................................................................16
1.9 Wiring the AT30 for remote sensing.....................................................................18
1.10 Wiring to the remote alarm contacts ....................................................................20
Auxiliary Relay Board (optional) ...........................................................................21
1.11 Installing the temperature compensation probe (optional) ...................................22
Using temperature compensation ........................................................................24
2
Operating the AT30 Battery Charger
2.1 Starting the AT30
2.1.1 Understanding the start-up sequence............................................................26
2.1.2 Checking the installation ................................................................................26
2.1.3 Starting the AT30 ...........................................................................................26
Using the digital meter ...................................................................................26
Factory settings table.....................................................................................27
2.2 Using the AT30 front panel features
2.2.1 If the meter displays an error message .........................................................28
2.2.2 Selecting the meter mode..............................................................................28
2.2.3 Selecting the Float or Equalize mode ............................................................29
2.2.4 Choosing the Equalize method......................................................................29
Manual Timer method....................................................................................29
Manual Equalize method ...............................................................................30
Auto-Equalize Timer method .........................................................................30
2.2.5 Testing the front panel indicators...................................................................31
2.2.6 Testing the Auxiliary Relay Board (optional) .................................................31
2.2.7 Interpreting the alarm indicators ....................................................................31
ii
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..........................................................................................34
Setting the high and low dc voltage alarms ...................................................35
Adjusting ground detection sensitivity............................................................36
Disabling the ground detection alarm ............................................................37
2.3.5 Setting the current limit value.........................................................................37
2.3.6 Enabling the high dc voltage shutdown feature .............................................38
2.3.7 Adjusting the Voltmeter accuracy ..................................................................39
2.3.8 Using the Low Level Detector (LLD) ..............................................................40
2.3.9 Using the front panel security feature ............................................................41
2.4 Performing routine maintenance ..........................................................................42
Sample preventive maintenance procedure.........................................................44
3
Servicing the AT30 Battery Charger
3.1 A step-by-step troubleshooting procedure ...........................................................46
3.2 Interpreting front panel error messages ...............................................................47
3.3 Using the troubleshooting chart............................................................................50
3.4 Troubleshooting chart begins on ..........................................................................51
3.5 Replacing defective components..........................................................................60
3.6 Ordering replacement parts * ...............................................................................64
APPENDIX A: AT30 Performance Specifications...................................................................72
APPENDIX B: Field Installable Accessories ...........................................................................73
APPENDIX C: Standard Drawings (not used**) .......................................................................74
APPENDIX D: Recommended Float / Equalize Voltages .......................................................76
APPENDIX E: DNP3 Level 2 / Modbus Communications Module.........................................77
CUSTOMER NOTES (manual specifications).............................................................................78
ADDITIONAL DOCUMENTATION
1. Custom Parts Data Package
2. Custom Record Drawing Package
2.1.
2.2.
2.3.
2.4.
2.5.
2.6.
JE5075
JE508x
JE508x
JE5091
JE5092
JE5093
AT30 SERIES BATT CHGR DRAWING LIST / DATA NAMEPLATE DETAIL
AT30 SERIES BATTERY CHARGER OUTLINE DRAWING
AT30 SERIES BATTERY CHARGER INTERNAL COMPONENT LAYOUT
AT30 SERIES INSTRUMENT PANEL / PC BOARD DETAIL
AT30 SERIES BATTERY CHARGER SCHEMATIC
AT30 SERIES BATTERY CONNECTION DIAGRAM
Note: In lieu of standard replacement part tables* and standard drawings** within
this manual, all AT30s currently ship with a custom Parts Data Package and a custom
Record Drawing Package.
iii
RECEIVING THE AT30
1. RECEIVING THE AT30
1.1. STORING THE AT30
If you store the AT30 for more than a few days before installation, you
should store it in its original shipping container, and in a temperature
controlled, dry climate. Ambient temperatures of 32 to 122° F / 0 to 50° C
are acceptable. Storage should not exceed 2 years due to the limited shelf
life of the dc filter capacitors when they are not in service.
1.2. REPORTING SHIPPING DAMAGE
If, on delivery of the AT30 or related goods, you discover any damage or
shortage, make notation on all copies of delivering carrier's delivery
receipt before signing, and notify the delivery person of your findings. If
loss or damage is discovered after delivery, notify delivering carrier
immediately and request an inspection. The manufacturer does not assume
any liability for damage during transportation or handling.
Should the goods require an inspection by or return to the manufacturer,
please contact your sales representative for further instructions. Any
returned material must be properly packed in compliance with shipping
regulations. It is preferable to use the original shipping materials if
possible. Mark the outside of the shipping container with the Return
Material Authorization (RMA) number issued by the manufacturer.
1.3. UNPACKING AND INSPECTING THE AT30
Carefully remove all shipping materials from the AT30. Remove the
AT30 from the shipping pallet for inspection. Save all shipping materials
until you are sure that there is no shipping damage.
Once the AT30 is unpacked, inspect the unit for possible shipping
damage, using the checklist below. If shipping damage has occurred, refer
to section 1.2 on this page for proper reporting.
INSPECTION CHECKLIST
o Enclosure exterior and interior are not marred or dented.
o There is no visible damage to exterior or interior components.
o All internal components are secure.
o Printed circuit boards are firmly seated on their standoffs.
o All hardware is tight.
o All wire terminations are secure.
o The User's Manual is included.
o You received all items on the packing list.
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.
AT30 Enclosure Type And Shipping Weight Table
Standard Cabinet Styles (5018 / 5030 / 5031)
Ampere
Rating
12 Vdc
Output Voltage
24 Vdc
48 Vdc
25 Adc
30 Adc
40 Adc
50 Adc
75 Adc
100 Adc
125 Adc
150 Adc
200 Adc
250 Adc
300 Adc
400 Adc
500 Adc
600 Adc
800 Adc
1,000 Adc
n/a
n/a
n/a
5018
5018
5018
5018
5018
5018
5030*
5030*
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
5018
5018
5018
5018
5018
5018
5030*
5030*
5030*
5030*
5030*
5031**
5031**
n/a
n/a
n/a
5018
5018
5018
5018
5018
5018
5030*
5030*
5030*
5031**
5031**
5031**
5031**
130 Vdc
5018
5018
5018
5018
5018
5018
5030*
5030*
5030*
5030*
5030*
5031**
5031**
5031**
5031**
5031**
Comprehensive AT30 cabinet weight information is not available at this
time. Refer to the custom outline drawing and other documentation
supplied with the unit for particular AT30 battery charger shipping weight
and/or custom enclosure type. Actual unit is approximately 20 lbs / 9kg
below listed shipping weight. Style-163 and Style-198 enclosures may be
substituted for Style-5030 and Style-5031 enclosures respectfully. Please
refer to the table below for the appropriate physical layout drawing.
Enclosure
Style-5018
* Style-163
** Style-198
Outline Drawing
JE5085-######
JE5095-######
JE5096-######
Internal Drawing
JE5088-######
JE5098-######
JE5099-######
The standard AT30 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 rackmount location, use a heavy-duty sling applicable to the enclosure size
and unit weight. To relocate the enclosure, use a forklift truck by lifting
the unit through the gap located between the mounting legs.
3
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
4.25in / 108mm from any wall, to allow clearance for the charger
enclosure behind the mounting brackets. In addition, you must consider
the following:
1. Floor-mounting the Style-5018, 5030 & 5031 enclosures is standard.
2. Placement of conduit entrances. Note the standard pre-fab conduit
knockouts located on the sides of the charger. See outline drawings in
Appendix C.
3. The location:
• Should be free of drips and splatter. If dripping liquids are a problem,
install a drip shield. See ordering information in Appendix B on page 73.
• Should be between 32 and 122 °F / 0 and 50 °C, with relative humidity
between 5 and 95% non-condensing.
• Must be free of flammable or 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 access to the charger for operation
and maintenance.
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.
5
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.
need footprint drawing
of Style-5030 enclosure
with mounting dimensions
NOTE:
For enclosure sizes, mounting dimensions and specifications on all other
AT30 enclosures (standard and custom) refer to the custom outline drawing
(JE5086-######) supplied with the unit.
6
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.
need footprint drawing
of Style-5031 enclosure
with mounting dimensions
NOTE:
For enclosure sizes, mounting dimensions and specifications on all other
AT30 enclosures (standard and custom) refer to the custom outline drawing
(JE5087-######) supplied with the unit.
7
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.
The weight of your AT30 may be different from the table value, depending
on options or accessories you ordered. See the Weight Table located in
section 1.4 on page 3.
3. Placement of conduit entrances. Note the standard pre-fab conduit
knockouts located on the sides of the charger. See outline drawings in
Appendix C.
4. The location:
• Should be free of drips and splatter. If dripping liquids are a problem,
install a drip shield kit. For kit availability see ordering information in
Appendix B on page 73.
• Should be between 32 and 122 °F / 0 and 50 °C, with relative humidity
between 5 and 95% non-condensing.
• Must be free of flammable or explosive materials.
5. Maintain at least 6in / 152mm of free air on top, bottom and both sides for
cooling air.
6. Allow 36in / 914mm front clearance for access to the charger for operation
and maintenance.
8
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.
need footprint drawing
of Style-5018 enclosure
with wall-mounting brackets
featuring mounting dimensions
NOTE:
For enclosure sizes, mounting dimensions and specifications on all other
AT30 enclosures (standard and custom) refer to the custom outline drawing
(JE5085-######) supplied with the unit.
9
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. The kit also includes
dimensions and detailed instructions for rack-mounting.
When rack mounting the AT30, you must consider the following:
1. The rack must be strong enough to properly support the weight of the AT30.
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 between 32-122° F / 0-50° C, with relative humidity between
5 and 95% non-condensing.
• Must be free of flammable or 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 access to the charger for operation
and maintenance.
10
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. Units are installed from the front.
2. For enclosure sizes, mounting dimensions and specifications on all
other AT30 enclosures (standard and/or custom) refer to the custom
outline drawing (JE5085-######) supplied with the unit.
11
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. Failure to use the properly rated
components may damage the charger.
NOTE: If your AT30 Battery Charger was ordered with 480 Vac 60Hz input or 220 Vac - 50/60 Hz input the transformer accepts
only the listed voltage. Do not attempt to rewire these transformers.
If a different ac input voltage is desired for the AT30, please contact
your sales representative for ordering replacement parts.
Before you connect ac power to the AT30, check the wiring of the main
transformer (T1) to be sure it is connected for the desired ac input voltage.
The main transformer was wired at the factory for the input voltage
specified and listed on the data nameplate.
If your AT30 was ordered with 208/240 Vac - 60Hz input and you need to
change the factory-wired input voltage, do so by changing the jumpers on
the main transformer (T1). If your AT30 was ordered with 380/416 Vac 50/60 Hz and you need to change the factory-wired input voltage, please
consult the factory for special instructions.
NOTE: Before starting work, disconnect and lock out all external ac and
dc power sources to the AT30. Note that just turning off the front panel
ac and dc circuit breakers is not sufficient to eliminate live voltages
inside the enclosure. Use a voltmeter at the ac terminals TB1-L1, TB1L2 & TB1-L3 (ac), and the dc terminals TB1(+), TB1(-), the remote sense
terminals (+/-), and any external wiring, to alarm relay contacts to verify
that no voltage is present inside the enclosure.
12
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.
MAIN TRANSFORMER (T1) CONNECTION TABLE
TYPICAL TRANSFORMER (T1)
208/240 Vac - 60 Hz INPUT
TYPICAL TRANSFORMER (T1)
480 Vac - 60 Hz INPUT
208 Vac
Jumper Setting
240 Vac
Jumper Setting
Jumper Setting
H1, H2, H3 to 1
H1, H2, H3 to 2
NONE
SCHEMATIC
SCHEMATIC
PROCEDURE
1. Be sure all voltages are de-energized and locked out.
2. Always use all three (3) jumpers.
3. Be sure all connections are tight. Check your work before reenergizing the charger.
4. For further information, refer to the custom AT30 Schematic (JE5092-######)
supplied with the unit.
13
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.
NOTE: If your charger is wired for 480 Vac input, and is equipped with
the standard AIC ac circuit breaker (no ac fuses), you need a feeder
breaker or fuse rated to interrupt the short-circuit current of your ac
supply.
2. Size the ac input wiring per the National Electric Code (NEC) and local
codes for the rating of the branch circuit breaker or fused disconnect switch.
3. All specific requirements of your facility take precedence over these
instructions.
4. Be sure the AT30 main transformer (T1) is properly connected for your ac
input voltage. See section 1.6 for details.
PROCEDURE
1. Remove the safety cover.
2. Run the ac wiring to terminals TB1-L1, TB1-L2, TB1-L3 and TB1-GND on
the I/O panel board in the enclosure.
3. AT30 units in Style-5018 enclosures are supplied with CU-AL compression
lugs for your convenience, accepting wire sizes #14-1/0 AWG. These ac
lugs are located at the bottom of the I/O terminal board (TB1). To make
these connections, strip the insulation .5in / 12.7mm on the incoming ac
wires and connect the wires to the appropriate lugs as shown on the next
page. Using a flat-head screwdriver, securely tighten the compression screws
on the lugs to 35-50 in-lb / 4.0-5.7 Nm.
4. AT30 units in Style-5030 & Style-5031 enclosures are supplied with 0.37516 zinc-plated steel (ZPS) stud hardware, accepting appropriately sized
customer wiring. These ac studs are located at the top of the I/O terminal
board (TB1). To make these connections, crimp a 0.375 ring lug onto the
incoming ac wires and connect the lugs to the appropriate studs as shown on
the next page. Using socket-wrench, securely tighten the stud hardware.
5. Reinstall the safety cover after you have made and checked all connections.
14
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. For I/O Panel layout and all wire terminal specifications, refer to the custom
Internal Component Layout Drawing (JE508x-######) supplied with the
unit.
15
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. All specific requirements of your facility take precedence over these
instructions.
4. The AT30 is factory wired to regulate the output voltage at the output
terminals. If the total voltage drop is greater than 1% (e.g., 1.3V for a 130
Vdc system), remote sense wiring is recommended, see section 1.9.
PROCEDURE
1. Use a dc disconnect switch or circuit breaker between the AT30 and dc bus.
This device should have lockout capability to allow the AT30 to be
disconnected from the dc bus for maintenance.
2. Remove the safety cover.
3. Run the dc wiring to terminals TB1(+) and TB1(-) on the I/O panel board in
the enclosure.
4. AT30 units in Style-5018 enclosures are supplied with CU-AL compression
lugs for your convenience, accepting wire sizes #14-1/0 AWG. These dc
lugs are located at the top of the I/O terminal board (TB1). To make these
connections, strip the insulation .5in / 12.7mm on the incoming ac wires and
connect the wires to the appropriate lugs as shown on the next page. Using a
flat-head screwdriver, securely tighten the compression screws on the lugs to
35-50 in-lb / 4.0-5.7 Nm.
5. AT30 units in Style-5030 & Style-5031 enclosures are supplied with 0.37516 zinc-plated steel (ZPS) stud hardware, accepting appropriately sized
customer wiring. These ac studs are located at the bottom of the I/O
terminal board (TB1). To make these connections, crimp a 0.375 ring lug
onto the incoming ac wires and connect the lugs to the appropriate studs as
shown on the next page. Using socket-wrench, securely tighten the stud
hardware.
6. Reinstall the safety cover after you have made and checked all connections.
16
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. For I/O Panel layout and all wire terminal specifications, refer to the custom
Internal Component Layout Drawing (JE508x-######) supplied with the
unit.
17
INSTALLING THE AT30
1.9. WIRING THE AT30 FOR REMOTE SENSING
You can wire the AT30 to regulate the output voltage at the battery
terminals, instead of at the charger output terminals. Remote sensing does
the following:
1. Compensates for voltage drop in the dc wiring between the AT30 and the
battery.
2. Directly monitors the battery or dc bus voltage. The front panel meter
displays the actual voltage on the battery or dc bus.
You wire the AT30 for remote sensing by installing a two-wire cable from
the AT30 remote sense terminals to the battery terminals. The AT30
control circuitry then measures the dc voltage at the battery terminals, and
controls the output of the charger to maintain the battery voltage at the
desired float or equalize voltage.
NOTE: If the remote sense wiring fails, the AT30 detects the fault, and
displays E 06 on the front panel meter. See section 3.2 for details.
CAUTION: The AT30 cannot protect against short circuits in the
remote sense wiring. You should install a 1.0A fuse at the battery or dc
bus end of the remote sense cable.
To wire the AT30 for remote sensing, follow the procedure and diagram
on the next page.
If you ever need to disable remote sense, follow the steps below:
•
•
De-energize and lock out all ac and dc voltages to the AT30. Check with
a voltmeter.
Disconnect the remote sense wires from the battery or dc bus terminals
first.
CAUTION: You must do the steps above first.
• Remove the remote sense leads from the remote sense (+) and (-)
terminals on the I/O panel. Insulate each lead separately. Coil up the
wires and leave them in the bottom of the charger, in case you want to
wire for remote sense again in the future.
• Reconnect wire # 40 to the dc output (+) terminal.
• Reconnect wire # 38 to the dc output (-) terminal.
• Restart the AT30 according to the instructions in section 2.1.
18
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. Connect the external remote sense leads from the battery or dc bus to the
remote sense terminals on the I/O panel as shown in the lower right figure.
6. Check your work thoroughly. Replace the safety shield before reeneregizing
the charger.
7. Restart the AT30 according to the instructions in section 2.1.
NOTES:
1.
2.
3.
4.
5.
Use #16 AWG. twisted pair.
Maximum current is 150 mA.
Run leads in their own conduit.
Fuse the wiring at the battery or dc bus.
For I/O Panel layout and all wire terminal specifications, refer to the custom
Internal Component Layout Drawing (JE508x-######) supplied with the
unit.
19
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. Route wires to front door by following the existing harness through the door
hinge as shown. Use (2) wire ties and allow a 4-6in / 102-153mm loop for
the hinge.
3. Trim wires to the proper length for connecting to TB3. Strip .25in / 6.4mm
of insulation from the wires. Make the connections at TB3, and securely
tighten the screws.
NOTES:
1. Alarm contacts are rated at 0.5A / 125 Vac or Vdc.
2. Terminal block is a compression type, accepting wire sizes #22-14 AWG.
3. Terminals are labeled in non-alarm condition.
20
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. Deenergize and
lock out all ac and
dc voltages to the
AT30. Check with
a voltmeter.
2. Remove the safety
shield.
3. Route your remote
annunciator
wiring into the
enclosure through
one of the unused
knockouts in the
side of the
enclosure.
4. Connect wiring to the appropriate terminals of TB4 on the Auxiliary Relay
board (as shown in the drawing above). Strip each wire .25in / 6.4mm and
securely tighten the terminal screws. The terminals are labeled in the nonalarm condition.
5. Replace the safety shield.
NOTES:
1. Alarm contacts are rated at 0.5A / 125 Vac or Vdc.
2. Terminal block is a compression type, accepting wire sizes #22-14 AWG.
3. Terminals are labeled in non-alarm condition.
4. For a detailed view of the optional Auxiliary Alarm Relay PC Board (A5),
refer to drawing (JE5091-######) supplied with the unit.
5. For location and arrangement of the optional Auxiliary Alarm Relay PC
Board (A5), refer to drawing (JE508x-######) supplied with the unit.
21
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.
The actual tempco probe is the same for all battery types and all output
voltages of the AT30. The kit part numbers differ depending on cable
length ordered. See the tables in Appendix B on page 73 for ordering
information. Each kit contains detailed installation instructions (JA501500). The main elements of the installation are outlined below.
WARNING:
High voltages appear at several points inside the battery charger. Use
extreme caution when working inside the charger. Do not attempt to
work inside the charger unless you are a qualified technician or
electrician.
Disconnect and lock out all power to the battery charger before starting
to remove or replace any components. Turn the ac power off at the
distribution panel upstream from the battery charger. Disconnect the
battery from the charger output terminals.
1. De-energize and lock out all ac and dc voltage sources to the AT30. Check
with a voltmeter before proceeding.
2. Mount the probe on a clean, dry surface, as close to the battery as possible,
such as the battery rack. Do not mount the probe:
• on the battery itself
• on unpainted wood or bare galvanized metal.
• on plastic surfaces
3. To apply the probe, clean the mounting surface with isopropyl alcohol, and
allow to dry thoroughly. Remove the protective backing from the doublefaced adhesive tape on the probe, and securely press it onto the surface.
4. Install the cable supplied with the temperature compensation probe kit:
• Start at the AT30. 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.
22
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. Attach the interconnection cable to the AT30 as shown in the figure below:
• Route the
cable within
the AT10.1
enclosure so
that it runs
with the wire
harness to the
back of the
front panel,
and easily
reaches the
main control
circuit board.
• At the main
control circuit
board, insert
one of the bare
wires from the
cable into each
terminal of
TB8. Polarity
is not
important.
• Plug the connector at the end of the nylon-shielded wire of the cable
assembly onto J6.
• 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. At the battery, connect the quick-connect terminals to the temperature
compensation probe. Polarity is unimportant. Coil up any excess wire and tape
or tie it together to prevent damage.
23
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. While this is being displayed,
you can press any front panel key to change the display to read NICD, to
change the temperature compensation setup for nickel cadmium batteries.
The choice you make is saved internally, and will be used again by the
AT30 the next time it starts.
9. Adjust the output float and equalize voltages to the battery manufacturer's
recommended values, using the AT30'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 AT30, is damaged and becomes an
open circuit, the AT30 detects the damage and displays E 08
on the display. The charger then reverts to normal nontemperature-compensated operation until the probe or wiring
is repaired. Once the probe is repaired, you must restart the
AT30 to activate the probe, as described in section 2.1.
Using temperature compensation
Whenever an electric storage battery is being charged, the terminal
voltage of the battery changes a small amount whenever the battery
temperature changes. As the battery temperature increases, its terminal
voltage decreases. When the battery is being charged with a float type
charger, with a constant output voltage, the float current increases when
the temperature increases. This results in overcharging the battery, which
can result in damage to the materials, or at least the need for more
frequent maintenance.
When the AT30 is equipped with a temperature compensation probe, it is
able to adjust the output voltage applied to the battery to keep the float
current constant, thereby avoiding overcharging. The probe senses the
ambient temperature at the battery and adjusts the output float/equalize
voltages to compensate for variations in temperature. If the ambient
temperature increases, the AT30 output voltage decreases.
24
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).
The actual output voltage of the AT30 may be different from the value
shown on the front panel meter, if the battery is warmer or cooler than
77° F (25° C).
Use a digital meter to measure the actual output voltage of the AT30. If
you know the temperature at the temperature compensation probe, you
can use the graph below to determine that the output voltage is correct.
If the battery temperature goes below 32° F (0° C), there will be no
further increase in charger output voltage. Likewise, if the battery
temperature goes above 122° F (50° C), there is no further decrease in
output voltage.
OUTPUT VOLTAGE VS BATTERY TEMPERATURE
108
Lead-Acid
106
Percent Output Voltage
104
102
N ickel-Cadmium
Example:
100
100 Deg. F
9 7 % O u tput
Voltage
98
96
94
20
40
60
80
100
120
Temperature, Degrees Fahrenheit
EXAMPLE: Suppose you have a lead-acid battery whose temperature
is 100° F / 37.8° C. As shown on the graph, the output voltage should
be approximately 97% of the 77° F voltage. If the float voltage is set
on the front panel to 132 Vdc, the actual output voltage will be:
132 X 0.97 = 128 Vdc.
25
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.
The AT30 startup routine takes about five seconds. The microprocessor
that controls the AT30 initializes the charger by reading the settings that
are stored internally. The control circuit then "soft starts" the charger, and
the dc output voltage and current increase gradually to the rated value.
2.1.2. Checking the installation
Be sure that you have followed the installation
instructions carefully. Check the ac input
supply voltage and the battery voltage, and be
sure that they match the information on the
AT30 nameplate. Verify that the jumpers on the
main transformer T1 are correct for your ac
supply voltage. Open the front panel, and check
the battery polarity at the TB1 (+) and (-)
terminals.
2.1.3. Starting the AT30
When you are sure that all connections to the
AT30 are properly made, follow these steps to
start up the AT30:
•
Using the Digital Meter
When you first start the
AT30, the meter display
alternates between dc output
voltage and dc output current.
Each reading is held for two
seconds; indicator lights to the
left of the display indicate
whether
the
meter
is
displaying voltage or current.
If you want to “freeze” the
meter to display only voltage,
press the METER MODE
key on the front panel. To
freeze the meter to display
only current, press the key
again. Press the key twice
more to revert to the
alternating display.
Turn on the front panel dc circuit breaker. The digital meter indicates the
battery voltage only. If the meter display does not light, do not proceed.
Turn off the dc breaker, and check all connections and the battery
polarity again. Also check the battery voltage. It must be above 50% of
nominal voltage to turn on the display. If you cannot find the problem,
refer to the Troubleshooting Procedure in section 3.1 on page 46.
CAUTION: If you try to turn on the dc circuit breaker with the battery
connected in reverse polarity, the circuit breaker will immediately
trip. Do not try to close the dc breaker again, since this may damage
the battery charger. Correct the battery polarity before proceeding. If
your charger is equipped with dc fuses, one or both fuses will blow
when the battery is reversed.
26
OPERATING THE AT30
•
•
•
If you have an optional temperature compensation probe installed, the
front panel displays LEAD during startup, indicating that the
temperature compensation is set up for lead-acid batteries. While this is
being displayed, you can press any front panel key to change the display
to read NICD, to change the temperature compensation setup for nickel
cadmium batteries. The choice you make is saved internally, and will be
used again by the AT30 then next time it starts.
Turn on the front panel ac circuit breaker. The digital meter displays the
output voltage and current. See Using the Digital Meter on page 26. You
should hear a soft hum from the AT30 as the output current increases.
NOTE: If you turn on the ac breaker before the dc breaker,
and you have a filtered model of the AT30, there is a
possibility that the dc breaker will trip when you try to turn it
on. This is caused by the filter capacitors discharging into the
battery. To get around this problem, turn off the ac breaker.
Restart the AT30 by turning on the dc breaker first.
The green FLOAT indicator lights. Press the CHRG MODE key on the
front panel. The FLOAT indicator goes off, and the yellow EQLZ
indicator lights. Press the CHRG MODE key again to return the charger to
the float mode.
The table below shows the normal factory settings for float and equalize
voltage, equalize time, current limit setting, and alarm settings. If your
purchase order specified other float or equalize voltage settings, a tag
attached to the front panel of the AT30 lists the actual voltage settings.
FACTORY SETTINGS FOR ALL PARAMETERS
Parameter
Float Voltage
Equalize Voltage
HVDC Alarm
LVDC Alarm
Equalize Time
Equalize Method
Current Limit
HVDC Shutdown
12
Nominal Vdc
24
48
130
13
26
52
131
14
28
56
139
14.4
28.8
57.6
144
12
24
48
120
24 Hours
Manual Timer
110% of nominal output current
Disabled
27
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.
E 02
Short circuit on output
E 03
HVDC Shutdown has occurred
E 04
Internal memory failure
E 05
Not used
E 06
Failure in Remote Sense wiring
E 07
DC breaker is open, or internal or external
output wiring is defective.
E 08
Defective temperature compensation probe
E 09
Misadjusted current limit
E 10
Open internal feedback loop
A 02
Equalize mode is inhibited
2.2.2. Selecting the meter mode
• Press the METER MODE key to change the meter display mode. The digital
meter has four operating modes:
1. Alternating between output voltage and output current. When the
charger is in a timed equalize mode, the meter alternates between
output voltage, output current, and equalize hours remaining.
2. Displaying output voltage only. The DC Volts indicator lights.
3. Displaying output current only. The DC Amps indicator lights.
4. Displaying equalize hours remaining only. The EQLZ HRS
REMAINING indicator lights. If the AT30 is not in a timed equalize
mode, the meter displays the full programmed equalize time.
• When the charger starts initially, the meter alternates, showing output
voltage and output current. The DC VOLTS and DC AMPS indicators light
alternately to indicate what is being displayed.
28
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.
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 MODE key again at any time to change back to the
float mode.
2.2.4. Choosing the Equalize method
Press the EQLZ MTHD key to choose the desired equalize method. The
indicator next to the desired equalize method will light. Three equalize
methods are available in the AT30:
•
•
•
Manual Timer
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 capacity (see
section 2.3.3 to learn how to adjust the equalize time). The battery
manufacturer can help you determine the best equalizing schedule for
your battery.
After you select the manual timer method, press the CHRG MODE key to put
the charger into the equalize mode. The EQLZ indicator will light. When
the equalize timer is finished, the charger reverts automatically to the float
mode, and the FLOAT indicator lights.
At any time during the equalize charge, you can switch the charger back
to float mode by pressing the CHRG MODE key. The FLOAT indicator will
light.
If there is an ac power failure during the equalize charge, the AT30
remembers the remaining equalize time. When ac power is restored, it
resumes the equalize charge where it left off.
29
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.
NOTE: Never leave the AT30 unattended in the equalize mode with the
manual equalize method selected, because a sustained overcharge may
cause permanent damage to the battery.
Auto-Equalize Timer Method
Choose the auto-equalize timer method if you have a flooded (non-sealed)
battery, that is subject to infrequent 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
CHRG MODE key. The FLOAT indicator will light.
Consult your battery manufacturer's instructions before using the autoequalize 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 failure
AC falure
duration
Mode after
ac failure
FLOAT
less than
12 seconds
FLOAT
EQUALIZE
less than
12 seconds
Resume EQUALIZE
with time remaining
FLOAT or
EQUALIZE
12 seconds
or greater
EQUALIZE
with full time
Switching to Equalize Mode with Auto-Equalize Timer Method Selected
You can start an equalize charge at any time.
•
Press the CHRG MODE key. The EQLZ indicator will light.
When the equalize timer is finished, the charger reverts automatically to
the float mode, and the FLOAT indicator lights.
30
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. The relay transfers. If you are monitoring
the relay with a remote annunciator, it detects the alarm condition.
2.2.6. Testing the Auxiliary Relay Board (optional)
If you have the optional Auxiliary Relay Board installed, you can test the
action of the alarm relays. Press and hold the LAMP TEST key for four
seconds. The six auxiliary alarm relays on the Auxiliary Relay Board
transfer. Remote annunciators connected to these relays will indicate this.
2.2.7. Interpreting the alarm indicators
There are six alarm indicators at the right side of the front panel. An
indicator lights for each of the following alarm conditions:
•
•
•
•
•
•
HIGH DC VOLTAGE: lights whenever the dc output voltage exceeds
the specified alarm voltage setting. See section 2.3.4 to learn how to
adjust the HVDC alarm setting.
LOW DC VOLTAGE: lights whenever the dc output voltage is below
the specified alarm voltage setting. See section 2.3.4 to learn how to
adjust the LVDC alarm setting.
DC OUTPUT FAILURE: lights whenever the charger cannot provide
its full rated output voltage or its full rated output current. You cannot
adjust this alarm setting.
AC INPUT FAILURE: lights whenever the ac power supply to the
charger is interrupted.
POS GND: lights whenever leakage current from the battery positive
terminal to ground exceeds a specified threshold.
NEG GND: lights whenever leakage current from the battery negative
terminal to ground exceeds a specified threshold.
NOTE: You can adjust the sensitivity of the ground fault detection
from 5K to 50k ohms. Adjusting the ground fault sensitivity affects
the positive and negative ground fault sensitivities equally.
The indicators light immediately when an alarm occurs. The AT30 also
has a summary alarm relay with one form C contact rated 0.5A at 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.
31
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. 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 (in Amperes)
High dc voltage shutdown feature (on or off)
Your choice of equalize method is also saved internally.
When you want to change any parameter, press the EDIT/ENTER key to put
the AT30 into Edit mode. The meter display flashes about once per
second, and the status indicators prompt you to adjust the respective
parameter. You adjust each parameter by pressing the UP or DOWN key
until the reading you want shows on the meter display. You can make the
display scroll up or down continuously by pressing and holding the UP or
DOWN key.
You cannot exceed certain upper and lower limits for the operating
parameters. To see what the limits are for your charger, refer to the AT30
Specifications in Appendix A on page 72.
When you first press the EDIT/ENTER key, the AT30 prompts you to adjust
the first parameter in the list above (float voltage). When you obtain the
value you want on the display, press the EDIT/ENTER key again. The AT30
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 AT30 moves to the next parameter.
When you are finished adjusting the sixth parameter (current limit), press
the EDIT/ENTER key again. The AT30 saves all adjustments you made
internally, and reverts to normal operation. The new settings take effect
immediately.
Edit mode ends automatically if you do not press any front panel key
within 25 seconds, and any change you made to the last setting is not
saved.
32
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. If you go past the voltage you want, press the
UP or DOWN key again to reach the voltage you want to set.
•
Press the EDIT/ENTER key. The new float voltage setting is saved
internally.
The EQLZ and DC VOLTS indicators light, and the display flashes the
present value of the equalize voltage. Press and release the UP or DOWN
key to increase or decrease the value in the display by one count, or press
and hold the UP or DOWN key to scroll the value in the display upward or
downward. When the display shows the equalize voltage you want to set,
release the UP or DOWN key. If you go past the voltage you want, press the
UP or DOWN key again to reach the voltage you want to set.
•
Press the EDIT/ENTER key. The new equalize voltage setting is saved
internally.
If you want to adjust the equalize timer duration, skip to section 2.3.3.
OR
If you want to exit the Edit mode now, press the EDIT/ENTER key four more
times until the charger returns to normal operation.
Edit mode ends automatically if you do not press any front panel key
within 25 seconds, and any change you made to the last setting is not
saved.
33
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. When the display shows the
equalize time, in hours, that you want to set, release the UP or DOWN key.
If you go past the number of hours you want, press the UP or DOWN key
again to reach the number you want to set.
If you set the equalize time to zero hours, the equalize mode is disabled.
•
Press the EDIT/ENTER key. The new equalize timer duration is saved
internally. The same timer setting works for both the manual timer and
the auto-equalize timer.
If you want to adjust the alarm settings, skip to section 2.3.4.
OR
If you want to exit the Edit mode now, press the EDIT/ENTER key three
more times until the charger returns to normal operation.
2.3.4. 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 AT30 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 AT30 also
has a summary alarm relay with one form C contact rated 0.5A at 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 AT30 detects certain errors, and displays
E 03, E 06, E 07 or E 10 on the front panel meter.
34
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. If you go past the voltage you want, press the UP or DOWN key again
to reach the voltage you want to set.
•
Press the EDIT/ENTER key. The new high dc voltage alarm setting is
entered into permanent memory.
Setting the low DC Voltage Alarm
• Press the EDIT/ENTER key until the LOW DC VOLTAGE indicator
flashes, and the display flashes the present value of the low dc voltage
alarm.
Press and release the UP or DOWN key to increase or decrease the value in
the display by one count, or press and hold the UP or DOWN key to scroll
the value in the display upward or downward. When the display shows the
low dc voltage alarm point that you want to set, release the UP or DOWN
key. If you go past the voltage you want, press the UP or DOWN key again
to reach the voltage you want to set.
•
Press the EDIT/ENTER key. The new low dc voltage alarm setting is
entered into permanent memory.
If you want to adjust the current limit setting, skip to section 2.3.5.
OR
If you want to exit the Edit mode now, press the EDIT/ENTER key again to
return the charger to normal operation.
35
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.
NOTE: Do not try to adjust the upper potentiometer labeled RA2
BALANCE. This adjustment is made at the factory for proper
circuit operation.
CAUTION: Before connecting or disconnecting a test resistor,
de-energize and lock out all ac and dc voltage sources to the
AT30. Check with a voltmeter before proceeding. Restart the
AT30 only when necessary to make the sensitivity adjustment. If
your battery is grounded, do not attempt this procedure.
Remove the safety cover. Connect the test resistor between TB1(+) and
the ground terminal. For I/O Panel layout, refer to the custom Internal
Component Layout Drawing (JE508x-######) supplied with the unit.
Adjust RA3 counterclockwise until the
front panel indicator goes out, and adjust
slowly clockwise until the POS GND
indicator just lights.
Make this adjustment slowly, for the
indicator is updated once every four
seconds. De-energize and lock out power
to the AT30. Remove the test resistor
and verify that the indicator goes out.
Connect the test resistor between TB1(-)
and chassis ground Verify that the NEG
GND indicator lights. If not, adjust RA3
clockwise until it does. Remove the test
resistor.
36
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.
Open the AT30 front panel, and locate jumper J5 at the top left of the
Control Circuit Board (shown on the previous page). Move the jumper to
the DISABLE position. The POS GND and NEG GND indicators and
the summary alarm relay will not respond to a ground fault.
Restart the AT30, following the instructions in section 2.1.
2.3.5. Setting the current limit value
The AT30 automatically limits its dc output current in case of overload or
battery discharge. You can adjust the value of the current limit from 50%
to 110% of rated current. The factory setting is 110%.
The current limit adjustment is the last step in the normal Edit sequence. If
the AT30 is not in the Edit mode, press the EDIT/ENTER key five times, until
the meter display flashes the value of current limit, in Amperes. Press and
release the UP or DOWN key to increase or decrease the value in the display
by one count, or press and hold the UP or DOWN key to scroll the value in
the display upward or downward. When the display shows the current
limit value that you want to set, release the UP or DOWN key. If you go past
the number you want, press the UP or DOWN key again to reach the number
you want to set.
•
Press the EDIT/ENTER key. The new current limit setting is saved
internally.
Edit mode ends automatically if you do not press any front panel key
within 25 seconds, and any change you made to the last setting is not
saved.
37
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.
You can adjust the high dc voltage shutdown
(the setting is the same as the high dc voltage
alarm setting). Refer to section 2.3.4.
The charger must be in normal operation (not
the Edit mode) to enable the high dc voltage
shutdown.
To enable the shutdown feature:
•
•
Press and hold the UP key, then
Press the CHRG MODE key.
The HIGH DC VOLTAGE indicator lights, and
the display flashes ON. You can toggle the
shutdown feature OFF and ON by pressing the
CHRG MODE key repeatedly.
Parallel Operation
If two (or more) AT30
chargers are connected in
parallel, both sense the
output voltage. If one
charger runs away, it will
supply all the output
current; the other has zero
output current. The high dc
voltage shutdown does not
operate in a charger with
zero output current, so that
only the defective charger
(of two or more in parallel)
shuts down. The other
charger continues to supply
the load normally.
If you do not press any key within 4 seconds, the last state indicated (ON
or OFF) is saved internally. Note that you do not use the EDIT/ENTER key
for this feature.
If the AT30 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.
38
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.
First, use the Edit procedure to adjust the float voltage to the desired
value. See section 2.3.2 for instructions on setting the float voltage.
Second, press and hold the UP key, then press the EQLZ MTHD key.
The DC VOLTS METER MODE indicator will light, and the meter display
flashes the output voltage reading. Measure the output voltage of the
AT30 using a dc meter accurate to ±0.25% or better.
While watching the meter connected to the AT30 output (not the front
panel meter), press the UP or DOWN key until the actual output voltage
matches the float setting on the front panel meter.
Each time you press UP or DOWN , you change the AT30 output voltage by
a small amount. Continue to press UP or DOWN until the actual output
voltage agrees with the front panel reading within ±1%
NOTE: Allow one or two seconds for the output voltage to stabilize
each time you press the UP or DOWN key.
When you are finished adjusting the output voltage, the AT30 waits 5
seconds, then the display returns to normal operation.
39
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. On the back of the main control circuit board, find the
potentiometer RA1, as shown in the figure below.
Disconnect all ac and dc power sources from the AT30, and connect your
dc power supply to the output terminals (positive of the supply to the
positive output of the charger). Adjust the power supply to the voltage that
you want to activate the alarm.
NOTE: You need at least 50% of the nominal output voltage to power the
circuit board.
Adjust RA1 until the alarm just activates. There is a red LED indicator
next to RA1 that indicates when the alarm is active.
40
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. Now, only the front panel
METER MODE and CHRG MODE keys work. All indicators still work normally.
41
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. Disconnect the battery from
the charger output terminals.
2.4.1. Keep it clean
The AT30 charger is cooled by natural convection. At least once a year,
vacuum the vents at the top and bottom of the enclosure to ensure that
there is an adequate supply of cooling air. If you have an extremely dusty
environment (especially if airborne dust is conductive), carefully vacuum
out the interior. Be sure to clean surfaces of circuit boards, and around
electrical terminals.
The AT30 is rated for operation up to 122° F / 50° C. If your charger is in
a warmer environment, or at an elevation over 3000ft / 914m, contact your
sales representative for operating information.
2.4.2. 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 AT30 charger.
2.4.3. Check remote sense wiring (optional)
If you wired the AT30 charger for remote sense, check the signal
connections to the battery or load, and check the wiring to be sure the
insulation is in good condition. If there is a failure of the remote sense
signal wiring, the AT30 charger displays the error code E 06, and goes
back to local control, sensing the output voltage at the charger output
terminals.
42
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. Measuring the output ripple voltage (filtered models only)
If your AT30 charger is a filtered model, at least once a year measure the
ac ripple voltage at the battery terminals. Use an rms responding ac
voltmeter.1 The ripple voltage should be no higher than shown in the
specifications in Appendix A on page 72, 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 55.
2.4.6. Viewing the voltage and alarm settings
You can review the parameter settings in the AT30 charger by pressing
the EDIT/ENTER key on the front panel. Each time you press the key, a
different parameter displays, in the following order:
•
•
•
•
•
•
1
Float voltage
Equalize voltage
Equalize time (in hours)
High dc voltage alarm setting
Low dc voltage alarm setting
Current limit, in Amperes
Don't use a dc voltmeter. The ripple voltage on a battery is a very small ac voltage.
43
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.
TB1 connections all tight.
Internal wiring connections tight, slip-on
connectors fully seated. Wire and lug
insulation in good condition.
Terminations at battery or bus are tight
and corrosion free.
Measure between TB1-L1, TB1-L2 &
TB1-L3 using an ac voltmeter. The
voltage must be within +10%, -12% of
nominal.
Measure at TB1 (+) and (-) using a dc
voltmeter. The voltage should agree with
the front panel voltmeter within 1%, and
must be correct values for your battery. If
the AT30 is using a temperature
compensation probe, see the graph on
page 25 to determine the correct battery
voltage. You need to know the battery
temperature for this step.
Measure at battery terminals using ac
voltmeter set to millivolts scale. Check
against specification in Appendix A on
page 72.
Press LAMP TEST key on front panel.
o OK
o OK
Press LAMP TEST key and hold for 4
seconds. Common alarm relay will
transfer.
o OK
o OK
o OK
o OK
Input
Vac
Float
Vdc
Equal.
Vdc
Ripple
mVac
o OK
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.
•
Check voltage
and alarm
settings
•
Final checks
•
•
•
•
Step
Instructions
(optional features)
Test auxiliary
alarm relays
Check
integrity of
remote sense
or temperature
compensation
wiring
Be sure safety cover is in place.
Restore charger to normal operation.
Close latch on front panel.
Close padlock if installed.
•
•
•
•
Press LAMP TEST key and hold for 4
seconds. Alarm relays will transfer.
Remote sense wiring.
Temperature compensation wiring.
Temperature compensation probe.
o OK
o OK
o VOLTS OK
o AMPS OK
o HOURS OK
o MANUAL TIMER OK
o MANUAL EQLZ OK
o AUTO EQLZ TIMER OK
o Alarm OK
o
o
o
o
OK
OK
HVDC alarm OK
LVDC alarm OK
Adc
Current limit
o OK
o OK
o OK
FLOAT
EQUALIZE
Results
o OK
o OK
o OK
o OK
A full-size reprint of this Preventive Maintenance Procedure is available
from your sales representative. Ask for form (JD0064-00).
45
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. 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.
2. If the charger does not work properly, but there is no front panel error code,
turn off the front panel circuit breakers (or disconnect ac and dc power
externally). Then turn the dc and ac power back on. This will return the
charger to normal operation as long as there is no internal component failure.
Note: Do this only once. If the charger does not resume normal
operation, go to the next step.
3. If the charger still does not work properly, make a list of the symptoms that
you observe, then turn to Using the troubleshooting chart in section 3.3. The
troubleshooting chart relates common trouble symptoms to their causes, and
gives the proper procedures for correcting the problem.
4. If the symptom does not appear on the troubleshooting chart, or if the
recommended repair does not work, consult your sales or service
representative to arrange for on-site or factory service.
46
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.
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
Code
E 01
Meaning
Repair Procedure
Resistor R2
open or
defective
A current resistor (R2) is installed at the back of the front panel in the
Gate Drive circuit board (A15) input connector (J25). R2 is measured
by the control circuit on startup, and is used to determine some of the
AT30 charger's parameters, such as the float voltage.
If the AT30 finds that R2 is defective, it must be replaced. See section
3.6 for parts ordering information. When you have completed the
repair, restart the 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 AT30 normally recovers automatically from an E 02 condition. If
you have shut down the charger for service, restart it according to
section 2.1.
E 03
High DC
Voltage
Shutdown
To restart the charger, turn the ac breaker off, then on. Check the
Equalize voltage and High DC Voltage alarm settings. The alarm
setting must be higher than the Equalize voltage setting.
If you get another High DC Voltage shutdown after a few minutes of
operation, there may be an internal component failure. See Charger
output not controllable of the troubleshooting chart on page 54 of
section 3.4.
47
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. 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.
E 05
Not used
This error code was formerly used to indicate a reverse battery
connection. It is not available in the AT30.
E 06
R4 or R14 is
defective, or
remote sense
wiring failed
Locate R4 and R14 on the Gate Drive circuit board (A15), mounted
on the back of the front panel. Remove the wire harness plugs from
J25 & J26, and remove A15 from the main control board (A1). Use an
Ohmmeter to measure the values of R4 and R14 (see table 3-1 for
the correct value). If either resistor is not within 1% of the specified
value, the entire Gate Drive circuit board (A15) must be replaced.
If you are using remote sense wiring from the battery to the AT30, the
wiring may have failed. The usual failure is an open circuit; a short
circuit will usually be indicated by smoke or fire in the wiring.
The AT30 charger displays the error code if it detects this wiring
failure. You should respond to this problem quickly to be sure that the
AT30 regulates the output voltage properly. Wire an annunciator (e.g.
buzzer) to the summary alarm relay (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 AT30 regulates its
output voltage locally until you correct the problem, see sections 1.9.
The locally controlled voltage may not reflect the true requirements of
the battery.
When you complete the repair, restart the charger as described in
section 2.1.
E 07
DC breaker
If the dc breaker is open, open the ac breaker, then reclose the dc
open, or internal and ac breakers. If the dc breaker trips again, see the troubleshooting
failure
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 chart
in section 3.4 for help in locating the problem.
48
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.
If the temperature compensation probe, or the wiring that connects it
to the AT30, fails during normal operation, the AT30 detects the
failure, and shows E 08 on the front panel meter.
Disconnect the wiring from the probe, and measure the resistance of
the probe with an Ohmmeter. The resistance should be approximately
10,000 Ohms at normal room temperature (77° F / 25° C). If the
probe reads open or shorted, it needs to be replaced.
If the probe checks good, examine the wiring between the probe and
the AT30. Also check the connection of the cable to the control circuit
board on the back of the front panel. If the wiring is OK, then the
probe needs to be replaced. Once you have replaced the probe, you
must restart the AT30 to activate temperature compensation.
E 09
Misadjusted
current limit
The output current limit is set at the factory to 110% of the rated
output current (e.g. for a 50 Adc charger, the current limit is set to 55
Adc). You can adjust the current limit downward to as low as 50% of
the output current, if you have special requirements such as limited
ac power available. You should do this only if the normal dc load on
the system is smaller than the current limit.
If the load current becomes larger than the current limit setting, the
battery will not charge properly. The charger displays E 09. You
should increase the current limit setting to supply the current required
by the load.
NOTE: The common alarm relay is not set for this condition.
E 10
Open internal
feedback loop
A 02
Equalize mode
inhibited
A redundant internal feedback loop (control loop) is provided as
redundancy, to increase reliability when remote sensing is used. If
there should be a problem with the internal loop wiring, the charger
displays E 10. Check the internal wiring in the signal harness,
especially wire # 50. Also check the harness connector (J25) on the
Gate Drive circuit board (A15).
If you set the equalize timer to zero hours, the equalize mode is
inhibited. When you try to put the charger into equalize mode with a
front panel control, the display shows the message A 02. If you want
to enable the equalize mode, set the equalize timer to 1 or more
hours.
49
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. Disconnect the
battery from the charger output terminals.
Before you try to use the troubleshooting chart, be sure that you have
followed the steps in section 3.1.
The 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:
•
•
•
•
•
•
•
•
•
Is the 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?
Are any alarm indicators lit?
Do the front panel status indicators work (Charge Mode, for example)?
Can you change the charger to the Equalize mode and back to Float?
Is the charger making any noise? Is it unusually loud?
Is there any sign or smell of smoking or burning?
For instructions on replacing components, see section 3.5 on page 60. For
information on identifying internal components, refer to the custom
Record Drawing Package supplied with the unit and described in
Appendix C on page 74.
50
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). If
resistance is low in either direction, replace the rectifier
module(s) (A16) as needed.
2. Check spacing of terminals and check wiring for signs of
insulation damage, burns, etc. Repair as necessary.
2. Defective
wiring to T1 or
to rectifier
bridge
3. Test by disconnecting wires # 7, 8 & 9 from the transformer
3. Defective
transformer T1 secondary taps (T1-X1, X2 and X3). If ac breaker still trips,
test by disconnecting wires # 42, 43, 44, 45, 35 and 36 from
the tertiary taps (T1-Y0, Y1, Y2, Y3, W1 and W2). If ac breaker
still trips, replace the transformer (T1).
AC breaker
trips (or fuses
clear) after a
few minutes
1. Loose
connection to
breaker/fuse
2. Wrong ac
voltage, or T1
taps miswired
3. Open SCR
4. SCR not
controllable
DC breaker
trips (or fuses
clear)
immediately
1. Battery
connected with
reverse polarity
2. Defective
rectifier bridge
(if unfiltered
charger)
1. Check and tighten connections as required.
2. Be sure the transformer primary taps (T1-H1, H2 and H3)
are wired correctly for your input voltage. See section 1.6 for
details.
3. 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 six (6) SCRs or
diodes is defective. Replace the rectifier module(s) (A16).
4. Disconnect the wire harness plug from connector J26 on the
top of the Gate Drive board (A15) and restart the charger. If
you are able to measure output current, one of the SCRs is
defective. Test and replace the rectifier module(s) (A16) as
needed.
1. Check and correct battery wiring if necessary.
2. 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). If
resistance is low in either direction, replace the rectifier
module(s) (A16) as needed.
3. Disconnect wire # 15 from SCR module mounted on the
3. Defective
Free-Wheeling heat sink assembly or from the positive bus bar. Measure the
diode CR4
resistance through the Free-Wheeling diode (CR4). Check
both polarities; it should be at least 100,000 Ohms in one
polarity, and less than 1,000 Ohms in the other polarity.
Replace CR4 if it is defective.
51
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). Measure the resistance through the
Polarity Diode (CR1), mounted to the negative filter capacitor
bus bar. Check both polarities. It should be at least 100,000
Ohms in one polarity, and less than 1,000 Ohms in the other
polarity. Replace CR1 if it is defective.
5. Check spacing of terminals and check wiring for signs of
insulation damage, burns, etc. Repair as necessary.
1. Check and tighten connections as required.
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).
3. Disconnect the wire harness plug from connector J26 on the
3. SCR not
top of the Gate Drive board (A15) and restart the charger. If
controllable
you are able to measure output current, one of the SCRs is
defective. Replace the rectifier module(s) (A16) as needed.
4. If the front panel meter shows more than 110% of rated dc
4. Defective
current, the Gate Drive board (A15) may be defective. Unplug
Gate Drive
A15 from the Main Control board (A1). If the output current
circuit board
DOES NOT drop to zero, replace the Gate Drive board (A15).
A15
5. If the front panel meter shows more than 110% of rated dc
5. Defective
current, the Main Control board (A1) may be defective. Unplug
Main Control
the system harness connectors (J25 and J26) from the Gate
board A1
Drive board (A15). If the output current drops to zero, replace
the Main Control board (A1).
1. If the AC ON indicator is out, check the feeder circuit
1. AC supply
failure
breaker or fuse.
2. Input fuse
2. Remove the ac fuses (F1A, F1B and F1C) from the fuse
F1A/B/C blown holder(s) and check if blown with an Ohmmeter or fuse tester.
Replace F1A, F1B, and/or F1C as needed.
NOTE: If the replacement fuses immediately blow, see the
sections titled "AC breaker trips immediately" and "AC breaker
trips after a few minutes" for further troubleshooting hints.
3. Defective
3. Check terminals and wiring between T1 and the rectifier
wiring
bridge assembly, main inductor (L1), dc filtering assembly (if
present), dc breaker (CB2), optional dc fuses (F3/F4), and the
output terminals (TB1+/-). Check wires # 42 through # 45 from
T1-Y0 through T1-Y3 to the Gate Drive circuit board (A15)
connector (J25). Repair as necessary.
4. Defective
4. Use an ac voltmeter to measure the ac voltage from T1-X1
transformer T1 to T1-X2 and T1-X3. It is normally 50% to 80% higher than the
rated dc output voltage. If it is too low, check the wiring of the
transformer primary taps (T1-H1 through T1-H3). See section
1.6 for details. If the ac primary voltage is zero, replace the T1.
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. Consult your battery manufacturer for the proper
voltage settings.
3. Be sure the transformer primary taps (T1-H1, H2 and H3)
are wired correctly for your input voltage. See section 1.6 for
details.
4. Check terminals and wiring between T1 and the rectifier
bridge assembly, main inductor (L1), dc filtering assembly (if
present), dc breaker (CB2), optional dc fuses (F3/F4), and the
output terminals (TB1+/-). Repair as needed.
5. Use an ac voltmeter to measure the voltage between the
5. Defective
rectifier bridge SCR gate leads on each SCR module. If you measure about
1.0V rms, but there is no output current, replace the rectifier
module(s) (A16) as needed.
6. If you do not measure any ac voltage in step 5 above, and
6. Defective
the battery voltage is less than the Float voltage setting,
Gate Drive
replace the Gate Drive circuit board (A15).
circuit board
7. Use an ac voltmeter to measure the ac voltage between the
7. Defective
transformer T1 transformer secondary taps (T1-X1, T1-X2 & T1-X3). The lineto-line voltage is normally the same as the rated dc output
voltage. If it is too low, check the wiring of the transformer
primary taps (T1-H1, T1-H2 & T1-H3). See section 1.6 for
details. If the ac voltage on the transformer secondary taps is
zero, replace T1.
8. Disconnect the wiring from the main inductor (L1) and
8. Defective
inductor L1 or measure the resistance between the terminals. If it is an open
circuit, replace L1. Repeat for inductor (L2) if the optional dc
L2
filter is installed.
9. Defective dc 9. Disconnect the battery, and connect a light dc load to the
breaker (CB2) charger. Measure the dc voltage across TB1(+) and TB1(-),
with the dc circuit breaker (CB2) on. If no voltage is
measured, replace CB2.
Front panel is
dead, but ac
and dc
voltages are
present at
TB1
1. Control
boards are not
connected
2. Defective
Main Control
board A1
3. Defective
wiring
1. Make sure the Gate Drive board (A15) is firmly connected to
the Main Control board (A1) via plugs (J17 to P17). Make sure
the two signal harness plugs are firmly inserted into the Gate
Drive board (A15) connectors (J25 and J26).
2. If the AC ON indicator is lit, but the rest of the front panel is
dead, replace the Main Control board (A1).
3. Check the two harness wirings to the Gate Drive board
(A15) connectors (J25 and J26) for signs of insulation
damage, burns, etc. Confirm all wires are securely crimped in
the connector.
53
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 3.6 for the proper resistance value). If the resistance is
not within 10% of the table value, replace R3.
2. Remove the safety shield, and check the wiring to and from
TB1 and the Main Control board (A1) for signs of insulation
damage or burns. Repair any damaged wiring.
Charger
output
voltage too
high, not
controllable
1. Disconnect the wire harness plug from connector J26 on the
top of the Gate Drive board (A15) and restart the charger. If
you are able to measure output current, one of the SCRs is
defective. Replace the rectifier module(s) (A16) as needed.
2. R4 or R14 is 2. See page 63 of section 3.5. Locate R4 and R14 on the Gate
defective, or
Drive board (A15). Remove one end of each resistor and
wrong value
measure its value with an Ohmmeter. See the table in section
3.6 for resistance values. If either resistor is not within 1% of
the specified value, replace R4 and/or R14 as needed.
3. Defective
3. Remove one of the probe leads from TB8 and measure its
temperature
resistance. At 77° F / 25° C the resistance should be about
compensation 10K Ohms. If it is not, replace the probe assembly (A10).
probe (optional)
4. If the front panel meter shows more than 110% of rated dc
4. Defective
current, the Main Control board (A1) may be defective. Unplug
Main Control
the system harness connectors (J25 & J26) from the Gate
board A1
Drive board (A15). If the output current drops to zero, replace
the Main Control board (A1).
Output
voltage does
not agree
with front
panel meter
1. Temperature
compensation
probe is
installed
54
1. Defective
SCR
1. If the optional temperature compensation probe is installed,
the output voltage may be different from the selected float or
equalize voltage. The difference in the voltages depends on
the probe temperature. The front panel meter always displays
the selected voltage as if the battery were at 77° F / 25° C.
2. Circuit board, 2. Recalibrate the voltmeter accuracy as described in section
or another
2.3.7.
component may
have been
replaced
3. R4 or R14 is 3. See page 63 of section 3.5. Locate R4 and R14 on the Gate
defective, or
Drive board (A15). Remove one end of each resistor and
wrong value
measure its value with an Ohmmeter. See the table in section
3.6 for resistance values. If either resistor is not within 1% of
the specified value, replace R4 and/or R14 as needed.
4. Defective
4. Turn off both front panel circuit breakers (CB1/CB2), or turn
Main Control
off ac and dc power externally if the charger does not have
breakers. Wait one minute before returning the dc connection,
board A1
followed by the ac connection. If the charger still has the
wrong output voltage, replace the Main Control board (A1).
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). If the current limit is less than 110%,
adjust it to 110% as described. See Setting the Current Limit
Value, section 2.3.5 for details.
2. Check each cell of the battery. If one or more cells are
shorted, the charger may not be able to reach the Float
voltage. You may have the same problem if the normal load
current is more than the rated output current of the charger.
3. Be sure the main transformer (T1) primary taps are wired
correctly for your input voltage. See Changing Transformer
Taps, section 1.6. The actual ac input voltage must be at least
88% of the rated value for the charger to produce full output
power.
4. 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.
5. Turn off both front panel circuit breakers (CB1/CB2), or turn
off ac and dc power externally if the charger does not have
breakers. Wait one minute before returning the dc connection,
followed by the ac connection. If the charger output current is
below the current limit value, but it still has the wrong output
voltage replace the Main Control board (A1).
1. Be sure the T1 primary taps are wired correctly for your
input voltage. See Changing Transformer Taps, section 1.6.
The actual ac input voltage must be at least 88% of the rated
value for the charger to produce full output power.
2. Disconnect the wire harness plug from connector J26 on the
top of the Gate Drive board (A15) and restart the charger. If
you are able to measure output current, one of the SCRs is
defective. Replace the rectifier module(s) (A16) as needed.
3. Defective T1 3. Test by disconnecting wires # 7, 8 & 9 from the transformer
secondary taps and wires # 42, 43, 44, 45, 35 and 36 from the
tertiary taps. If ac input current is still too high, replace T1.
Input current
too high
1. Wrong ac
input voltage, or
T1 wired
incorrectly
2. Defective
rectifier bridge
Output ripple
voltage too
high
1. Charger is
unfiltered
2. Battery is
disconnected or
defective
3. Battery too
small for
charger rating
4. Defective
filter capacitors
C1 and/or C2
1. Verify by checking the data nameplate against the ordering
code on page ii. Order and install the dc filter option if desired.
2. Be sure battery is connected. Inspect battery according to
the manufacturer's instructions.
3. Check the measured ripple against the specification for your
AT30 model on page 72. The ripple rating is for a battery
whose Ampere-hours are four (4) times the charger Ampere
rating. For a smaller battery, ripple voltage may be higher.
4. Test with capacitance meter and replace as needed.
55
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. With a light dc load connected to the
battery, be sure each cell reads the nominal cell voltage (2.0V
for lead-acid / 1.25V for Ni-Cd). Restart the charger. Each cell
should now read approximately the nominal Float voltage
(2.2V for lead-acid / 1.35V for Ni-Cd).
2. See page 63 of section 3.5. Locate R4 and R14 on the Gate
2. Defective
scaling resistor Drive board (A15). Remove one end of each resistor and
measure its value with an Ohmmeter. See the table in section
R4 or R14
3.6 for resistance values. If either resistor is not within 1% of
the specified value, replace R4 and/or R14 as needed.
3. If the output voltage is constant, but the front panel meter is
3. Defective
erratic, replace the Main Control board (A1).
Main Control
board A1
Meter
readings are
erratic
1. Defective or
disconnected
battery
Lamp test key
does not
work, or
some lamps
do not light
1. No Vac
2. Control
circuit board A1
is not secured
to front panel
3. Defective
Main Control
board A1
1. The lamp test key does not work during an ac power failure.
2. Open the front panel, and be sure that the control circuit
board is securely mounted on the standoffs on the back of the
panel. All indicators should extend about .125in / 3.18mm
through the front of the panel.
3. When you press the LAMP TEST key, if some but not all
indicators light, or the digital meter does not display "8888",
replace the Main Control board (A1).
One or more
front panel
keys do not
work
1. Front panel
is locked
2. Main Control
board A1 is not
secured to front
panel
3. Defective
Main Control
board A1
1. Open the front panel, and be sure that jumper (J9) on the
Main Control board (A1) is in the ENABLE position.
2. Open the front panel, and be sure that the control circuit
board is firmly seated on the standoffs on the back of the
panel. Front panel keys must operate freely.
1. Check for
normal
operation of
both chargers
1. The AT10.1 is not designed to share the load current when
two or more chargers are connected in parallel, so it is normal
for one of a pair to have no output current. You can check the
operation of the "off" charger by increasing its Float voltage
until it starts to deliver output current. When you have finished
the test, be sure both chargers are set to the same Float and
Equalize voltages.
Two chargers
connected in
parallel, but
only one has
output current
56
3. Turn off both front panel circuit breakers (CB1/CB2), or turn
off ac and dc power externally if the charger does not have
breakers. Wait one minute before returning the dc connection,
followed by the ac connection. If some of the front panel keys
still do not work, replace the Main Control board (A1).
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. If
you are able to measure output current, one of the SCRs is
defective. Replace the rectifier module(s) (A16) as needed.
3. Turn off both front panel circuit breakers (CB1/CB2), or turn
off ac and dc power externally if the charger does not have
breakers. Wait one minute before returning the dc connection,
followed by the ac connection. If the charger output voltage is
normal, but the HIGH DC VOLTAGE indicator is still on,
replace the Main Control board (A1).
No alarm, but
output
voltage is
above High
DC Voltage
setting
1. Output
current is below
2%
2. Defective
Main Control
board A1
1. Output current must be greater than 2% of rated current to
produce a High DC Voltage alarm. See Parallel Operation
portion in section 2.3.6.
2. Turn off both front panel circuit breakers (CB1/CB2), or turn
off ac and dc power externally if the charger does not have
breakers. Wait one minute before returning the dc connection,
followed by the ac connection. If the charger output voltage is
above the alarm setting, but the HIGH DC VOLTAGE indicator
still does not light, replace the Main Control board (A1).
LOW DC
VOLTAGE
indicator is
on, but ac
and dc
breakers are
closed; ac
input voltage
is normal;
there is
output current
1. Battery is
discharged
1. After an ac power failure, or a battery discharge for any
other reason, it may take several hours to recharge the
battery. It is normal for the LOW DC VOLTAGE indicator to be
on until the battery voltage is above the Low DC Alarm
voltage.
2. Be sure that the Low DC Voltage alarm setting is lower than
the Float voltage setting. See sections 2.3.2 and 2.3.4.
2. Low DC
Voltage alarm
and Float
voltage settings
are mismatched
3. Defective
3. Use a clamp-on ammeter to measure the current in wires #
rectifier bridge 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.
4. Defective
4. Turn off both front panel circuit breakers (CB1/CB2), or turn
off ac and dc power externally if the charger does not have
Main Control
breakers. Wait one minute before returning the dc connection,
board A1
followed by the ac connection. If the charger output voltage is
normal, but the LOW DC VOLTAGE indicator is still on,
replace the Main Control board (A1).
5. Defective dc 5. Disconnect the battery, and connect a light dc load to the
circuit breaker charger. Measure the dc voltage across TB1(+) and TB1(-),
CB2
with the breaker on. If no voltage is measured, replace the dc
circuit breaker (CB2).
57
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. Wait one minute before returning the dc connection,
followed by the ac connection. If the charger output voltage
and current are normal, but the DC OUTPUT FAILURE
indicator is still on, replace the Main Control board (A1).
3. Defective
3. Use an ac voltmeter to measure the ac voltage between the
transformer T1 transformer secondary taps (T1-X1, T1-X2 & T1-X3). The lineto-line voltage is normally the same as the rated dc output
voltage. If it is too low, check the wiring of the transformer
primary taps (T1-H1, T1-H2 & T1-H3). See section 1.6 for
details. If the ac voltage on the transformer secondary taps is
zero, replace T1.
4. Defective dc 4. Disconnect the battery, and connect a light dc load to the
circuit breaker charger. Measure the dc voltage across TB1(+) and TB1(-),
with the breaker on. If no voltage is measured, replace the dc
CB2
circuit breaker (CB2).
1. If the ac input power fails, the front panel AC ON indicator
AC INPUT
1. AC power
goes out, and the AC INPUT FAILURE indicator goes on.
FAILURE
failure
indicator is on 2. Upstream
2. Be sure the front panel ac circuit breaker (CB1) is closed.
Measure the ac voltage at the battery charger input terminals
feed
breaker/fuse is (TB1-L1, TB1-L2 and TB1-L3). If it is zero, check the upstream
distribution breakers and fuses.
tripped
3. Measure ac voltage at the transformer primary taps (T1-H1,
3. Defective
T1-H2 and T1-H3). It should be the same as the ac supply
wiring
voltage.
4. Turn off both front panel circuit breakers (CB1/CB2), or turn
4. Defective
off ac and dc power externally if the charger does not have
Main Control
breakers. Wait one minute before returning the dc connection,
board A1
followed by the ac connection. If the AC ON indicator is on, but
the AC INPUT FAILURE indicator is still on, replace the Main
Control board (A1).
DC OUTPUT
FAILURE
indicator is
on, but ac
input voltage
is normal,
and ac & dc
breakers are
closed
58
1. Defective
rectifier bridge
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. Turn off both front panel circuit breakers (CB1/CB2), or turn
off ac and dc power externally if the charger does not have
breakers. Wait one minute and disconnect the charger from
the battery and dc bus. Turn the charger on and measure the
voltage from TB1(+) to chassis, and from TB1(-) to chassis.
The voltage readings should be equal, each approximately
half of the total output voltage. If there is more than a 10%
imbalance, turn off the charger and inspect all wiring from TB1
to the dc circuit breaker (CB2), dc filter inductor (L1) if present,
and the rectifier bridge. Look for evidence of insulation
damage, insufficient spacing between terminals and chassis,
or wires run too close to metal edges.
4. Turn off both front panel circuit breakers (CB1/CB2), or turn
off ac and dc power externally if the charger does not have
breakers. Wait one minute before returning the dc connection,
followed by the ac connection. If you are sure there is no
ground fault on the external bus or within the charger, but the
POS GND or NEG GND indicator is still on, replace the Main
Control board (A1).
1. Turn off both front panel circuit breakers (CB1/CB2), or turn
off ac and dc power externally if the charger does not have
breakers. Wait one minute before returning the dc connection,
followed by the ac connection. If the relay remains in alarm
mode, check the Low Level Detect indicator on Main Control
board (A1). See section 2.3.8. If no other alarm is on, replace
the Main Control board (A1).
59
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. Disconnect the
battery from the charger output terminals.
For information on identifying internal components, refer to the custom
Record Drawing Package supplied with the unit and described in
Appendix C on page 74.
Removing the safety shield (if present)
AT30 Style-5018 and Style-5030 enclosures feature a clear plexiglas
safety shield, as a second protective barrier between the user and the
internal components. Some of the following repair procedures require you
to remove this shield to access internal components.
Open the front door and remove the clip fasteners from the front of the
plexiglas shield. Lay or lean the shield near the enclosure. Do not lay the
shield on the top of the charger. The top vents on the enclosure are
required for cooling of the unit.
Attach the plexiglas safety shield back onto the enclosure opening using
the clip fasteners after replacing components and before starting up the
unit.
CAUTION: Hazardous ac and dc voltages are present on the I/O
panel terminals and several internal components.
60
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. Note that the control circuit board and gate drive board are
mounted together as a pair. Remove the signal wire harness plug from the
upper left edge of the boards. If present, remove the summary alarm
contact remote wires from TB3 on the bottom of A1. If the optional
temperature compensation probe is installed, remove the main wires from
TB8 on the bottom of A1 and remove the shield wire from J6 at the topleft side of A1. Make sure all wires are detached from the two pc boards.
The boards are mounted on ten plastic standoffs. Compress the tab on
each standoff, and pull the boards toward you until they clear all the
standoffs. Separate the boards, if you are replacing only one, and then
reconnect the replacement board. Put the replacement board(s) in place on
the front panel with the same orientation, and push them onto the
standoffs. Be sure that the boards are fully seated on all ten standoffs. Reconnect the signal wire harness plug to the boards, matching the
orientation when removed. If earlier removed, reconnect any wires to
TB3, TB8 and J6 on A1. 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 ac input or dc output circuit breaker (CB1/CB2)
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. Open the front panel, and remove the safety
shield. Remove the mounting screws for the circuit breaker on the circuit
breaker bracket, and carefully remove the circuit breaker from 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 fasteners
are tight. Install the replacement breaker into the bracket, reversing the
procedure above, using the original mounting screws.
61
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. Repeat procedure for the I/O ground stud. Tighten all
hardware.
NOTE: The ac surge suppressors are not polarized.
Replacing the dc surge suppressor (VR1)
Turn off all 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 TB1(-). Tighten all hardware.
NOTE: The dc surge suppressor is not polarized.
Replacing the dc surge suppressor networks (VR6/C4, VR7/C5)
Replace these networks as assemblies; do not replace individual parts.
Turn off 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 I/O ground stud. For the
network VR7/C5, use the above procedure, but start with the lead on
TB1(+). Tighten all hardware. Replace cut wire ties if possible.
NOTE: The dc surge suppressor networks are not polarized.
62
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. Polarity is not
important. Carefully re-solder the cut wires to R3.
Replacing resistors (R3, R4, R6 & R14) on the gate drive pc board (A15)
For 12 Vdc and 24 Vdc AT30 battery chargers, R3 is soldered directly
onto A15. In all AT30 battery chargers, R4, R6 and R14 are soldered
directly onto A15. See detail of the gate drive pc board below for proper
location.
If any of these resistors need to be replaced we suggest you order a new
A15 board. See Replacing the control pc board (A1) and/or gate drive pc
board (A15) on page 61.
If any of these resistors must be replaced without replacing A15, please
select the proper part number listed in the table starting on page 64 and
order it from the factory or your sales representative.
Remove A15 as described on page 61. Using wire cutters, clip the
soldered leads of the old resistor and remove it from A15. Carefully solder
on the new resistor, making sure not to damage any other components on
A15. Polarity is not important for these resistors. Once the solder cools,
replace A15 as described on page 61.
63
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.
Factory part number and description from the Parts Data Package report
Model number and serial number of your battery charger
Quantity required
In lieu of replacement parts tables, all AT30s currently ship with a parts
data package and custom drawings. Contact your sales representative to
place an order for spare parts or replacement parts.
Table 3-1: REPLACEMENT PARTS
Symbol
Description
Factory Part Number
12 Vdc
24 Vdc
48 Vdc
130 Vdc
Rec.
Spares
A1
Main Control PC Board assembly
EJ1243-10
Y
A5
Auxiliary Relay PC Board assembly (optional)
A7
DC Filter assembly
see Table 3-2
EJ1243-03
Y
A8
Battery Eliminator Filter assembly
(requires filtered charger)
see Table 3-3
A10
Temperature Compensation Probe assembly
A15
Three Phase Gate Drive PC Board assembly
see supplied Parts Data Package
Y
A16
SCR Rectifier Module(s) - (Q1-Q6)
see supplied Parts Data Package
Y
A17
SCR Snubber Sub-Assembly
see supplied Parts Data Package
C1
Filter Capacitor (standard)
see supplied Parts Data Package
Y
C2
Filter Capacitor (battery eliminator)
see supplied Parts Data Package
Y
C4
EMI Filter Capacitor
see VR6/C4
C5
EMI Filter Capacitor
see VR7/C5
See Appendix B
CB1
AC Circuit Breaker (standard) 208/240 Vac
see Table 3-4
CB1
AC Circuit Breaker (medium AIC) 208/240 Vac
see Table 3-6
CB1
AC Circuit Breaker (high AIC) 208/240 Vac
see Table 3-8
CB1
AC Circuit Breaker (standard) 480 Vac
see Table 3-5
CB1
AC Circuit Breaker (medium AIC) 480 Vac
see Table 3-7
CB1
AC Circuit Breaker (high AIC) 480 Vac
see Table 3-9
CB2
DC Circuit Breaker (standard)
see Table 3-12
CB2
DC Circuit Breaker (Medium AIC)
see Table 3-13
CB2
DC Circuit Breaker (High AIC)
see Table 3-14
CR1
Polarity Diode (25-50 Adc ratings)
RK0013-14
Y
CR1
Polarity Diode (75 Adc rating)
RK0014-14
Y
CR1
Polarity Diode (100 Adc rating)
RK0017-14
Y
CR1
Polarity Diode (125+ Adc rating)
see supplied Parts Data Package
Y
64
SERVICING THE AT30
Symbol
Description
Factory Part Number
12 Vdc
24 Vdc
48 Vdc
130 Vdc
Rec.
Spares
CR4
Free-Wheeling Diode (25-50 Adc ratings)
RK0013-14
Y
CR4
Free-Wheeling Diode (75 Adc rating)
RK0014-14
Y
CR4
Free-Wheeling Diode (100 Adc rating)
RK0017-14
Y
CR4
Free-Wheeling Diode (125+ Adc rating)
see supplied Parts Data Package
Y
F1
A/B/C
AC Input Fuses (208/240 Vac)
see Table 3-10
Y
F1
A/B/C
AC Input Fuses (480 Vac)
see Table 3-11
Y
F3/F4
Y
DC Output Fuses
see Table 3-15
L1
Main Inductor
see Table 3-16
L2
Filter Inductor
see Table 3-17
P5
Jumper for disabling Ground Detection circuit
on Main Control PC Board (A1)
RC0100-00
P7
Jumper for voltage selection on
Auxiliary Relay PC Board (A5)
RC0100-00
P9
Jumper for front panel lockout feature on
Main Control PC Board (A1)
RC0100-00
R1
Main DC Shunt
see Table 3-18
R2
Current Rating Resistor
see Table 3-19
R3
Power Supply (Ballast) Resistor
RJ0007-30 RJ0035-27 RJ0021-00 RJ0023-03
18Ω
100Ω
250Ω
750Ω
R4
Positive External Scaling Resistor
RJ0056-48 RJ0056-81 RJ0075-14 RJ0075-56
3160Ω
6980Ω
14.0KΩ
38.3KΩ
R6
Voltage (Crowbar) Resistor
RJ0063-76 RJ0064-11 RJ0064-41 RJ0064-80
R9
Filter Capacitor (C1) Bleed Resistor
RJ0028-25 RJ0028-25 RJ0028-27 RJ0036-40
Negative External Scaling Resistor
RJ0074-48 RJ0074-81 RJ0075-14 RJ0075-56
3160Ω
6980Ω
14.0KΩ
38.3KΩ
R14
T1
T1
Main Transformer (208/240 Vac)
see Table 3-20
Main Transformer (480 Vac)
see Table 3-21
Input/output terminals (Style-5018)
CU-AL compression lug for #14-6 AWG.
RC0056-18
VR1
Output Surge Suppressor
EJ1132-01
Y
VR2
Input Surge Suppressor (208/240 Vac)
EJ1132-01
Y
VR2
Input Surge Suppressor (480 Vac)
EJ1132-02
Y
VR3
AC Input Lightning Arrestor
EJ1074-00
VR4,
VR5
Input Surge Suppressor (208/240 Vac)
EJ1132-01
Y
VR4,
VR5
Input Surge Suppressor (480 Vac)
EJ1132-02
Y
VR6+C4 EMI Filter Network
EJ5021-01
Y
VR7+C5 EMI Filter Network
EJ5021-01
Y
TB1-x
65
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
AA0000-00
Ampere
Rating
200 Adc
250 Adc
300 Adc
400 Adc
500 Adc
600 Adc
800 Adc
1,000 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
Table 3-3: DC FILTER ASSEMBLIES - ELIMINATOR (C2) - REQUIRES STANDARD FILTER
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
Ampere
Rating
200 Adc
250 Adc
300 Adc
400 Adc
500 Adc
600 Adc
800 Adc
1,000 Adc
12 Vdc
AA0000-00
AA0000-00
AA0000-00
AA0000-00
AA0000-00
AA0000-00
AA0000-00
AA0000-00
Output Voltage (Vdc)
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
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
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
Table 3-4: STANDARD AC CIRCUIT 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
AA0000-00
AA0000-00
AA0000-00
Ampere
Rating
200 Adc
250 Adc
300 Adc
400 Adc
500 Adc
600 Adc
800 Adc
1,000 Adc
12 Vdc
AA0000-00
AA0000-00
AA0000-00
AA0000-00
AA0000-00
AA0000-00
AA0000-00
AA0000-00
Table 3-5: STANDARD AC CIRCUIT BREAKERS (CB1) - 480 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
Ampere
Rating
200 Adc
250 Adc
300 Adc
400 Adc
500 Adc
600 Adc
800 Adc
1,000 Adc
12 Vdc
AA0000-00
AA0000-00
AA0000-00
AA0000-00
AA0000-00
AA0000-00
AA0000-00
AA0000-00
Note: Standard BOMs for all ratings of the AT30 line are not yet available. For
replacement parts, refer to the custom Parts Data Package supplied with the unit.
66
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
AA0000-00
AA0000-00
AA0000-00
Ampere
Rating
200 Adc
250 Adc
300 Adc
400 Adc
500 Adc
600 Adc
800 Adc
1,000 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
Table 3-7: MEDIUM AMPERE INTERRUPTING CAPACITY AC CIRCUIT BREAKERS (CB1) - 480 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
Ampere
Rating
200 Adc
250 Adc
300 Adc
400 Adc
500 Adc
600 Adc
800 Adc
1,000 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
Table 3-8: HIGH AMPERE INTERRUPTING CAPACITY AC CIRCUIT 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
AA0000-00
AA0000-00
AA0000-00
Ampere
Rating
200 Adc
250 Adc
300 Adc
400 Adc
500 Adc
600 Adc
800 Adc
1,000 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
Table 3-9: HIGH AMPERE INTERRUPTING CAPACITY AC CIRCUIT BREAKERS (CB1) - 480 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
Ampere
Rating
200 Adc
250 Adc
300 Adc
400 Adc
500 Adc
600 Adc
800 Adc
1,000 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
Note: Standard BOMs for all ratings of the AT30 line are not yet available. For
replacement parts, refer to the custom Parts Data Package supplied with the unit.
67
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
AA0000-00
Ampere
Rating
200 Adc
250 Adc
300 Adc
400 Adc
500 Adc
600 Adc
800 Adc
1,000 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
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
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
Table 3-11: AC INPUT FUSES (F1A/F1B/F1C) - 480 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
Ampere
Rating
200 Adc
250 Adc
300 Adc
400 Adc
500 Adc
600 Adc
800 Adc
1,000 Adc
Table 3-12: STANDARD 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
AA0000-00
AA0000-00
Ampere
Rating
200 Adc
250 Adc
300 Adc
400 Adc
500 Adc
600 Adc
800 Adc
1,000 Adc
Table 3-13: MEDIUM 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
AA0000-00
AA0000-00
Ampere
Rating
200 Adc
250 Adc
300 Adc
400 Adc
500 Adc
600 Adc
800 Adc
1,000 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
Note: Standard BOMs for all ratings of the AT30 line are not yet available. For
replacement parts, refer to the custom Parts Data Package supplied with the unit.
68
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
AA0000-00
AA0000-00
Ampere
Rating
200 Adc
250 Adc
300 Adc
400 Adc
500 Adc
600 Adc
800 Adc
1,000 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
130 Vdc
AA0000-00
AA0000-00
AA0000-00
AA0000-00
AA0000-00
AA0000-00
AA0000-00
AA0000-00
Ampere
Rating
200 Adc
250 Adc
300 Adc
400 Adc
500 Adc
600 Adc
800 Adc
1,000 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
130 Vdc
AA0000-00
AA0000-00
AA0000-00
AA0000-00
AA0000-00
AA0000-00
AA0000-00
AA0000-00
Ampere
Rating
200 Adc
250 Adc
300 Adc
400 Adc
500 Adc
600 Adc
800 Adc
1,000 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
130 Vdc
AA0000-00
AA0000-00
AA0000-00
AA0000-00
AA0000-00
AA0000-00
AA0000-00
AA0000-00
Ampere
Rating
200 Adc
250 Adc
300 Adc
400 Adc
500 Adc
600 Adc
800 Adc
1,000 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
Table 3-15: DC OUTPUT FUSES (F3/F4)
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
Table 3-16: MAIN INDUCTOR (L1)
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
Table 3-17: FILTER INDUCTOR (L2)
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
Note: Standard BOMs for all ratings of the AT30 line are not yet available. For
replacement parts, refer to the custom Parts Data Package supplied with the unit.
69
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
00.0 kΩ
00.0 kΩ
AA0000-00 AA0000-00
00.0 kΩ
00.0 kΩ
AA0000-00 AA0000-00
00.0 kΩ
00.0 kΩ
130 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
Ampere
Rating
200 Adc
250 Adc
300 Adc
400 Adc
500 Adc
600 Adc
800 Adc
1,000 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
00.0 kΩ
00.0 kΩ
AA0000-00 AA0000-00
00.0 kΩ
00.0 kΩ
AA0000-00 AA0000-00
00.0 kΩ
00.0 kΩ
130 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
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
00.0 kΩ
00.0 kΩ
AA0000-00 AA0000-00
00.0 kΩ
00.0 kΩ
AA0000-00 AA0000-00
00.0 kΩ
00.0 kΩ
130 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
Table 3-19: CURRENT RATING RESISTOR (R2)
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
00.0 kΩ
00.0 kΩ
AA0000-00 AA0000-00
00.0 kΩ
00.0 kΩ
AA0000-00 AA0000-00
00.0 kΩ
00.0 kΩ
Connector terminal extraction tool
130 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
Ampere
Rating
200 Adc
250 Adc
300 Adc
400 Adc
500 Adc
600 Adc
800 Adc
1,000 Adc
Molex P/N 11-03-0038
Note: Standard BOMs for all ratings of the AT30 line are not yet available. For
replacement parts, refer to the custom Parts Data Package supplied with the unit.
70
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
Ampere
Rating
200 Adc
250 Adc
300 Adc
400 Adc
500 Adc
600 Adc
800 Adc
1,000 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
Ampere
Rating
200 Adc
250 Adc
300 Adc
400 Adc
500 Adc
600 Adc
800 Adc
1,000 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
Table 3-21: MAIN TRANSFORMER (T1) - 480 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
Note: Standard BOMs for all ratings of the AT30 line are not yet available. For
replacement parts, refer to the custom Parts Data Package supplied with the unit.
71
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 ± 0.5% in 500 ms
Efficiency
All ratings
Unfiltered, with battery
Output ripple voltage
(per NEMA PE5-1996)
Filtered, with battery
82-90%
2% (typ.) at battery terminals
30 mV rms (max.) at battery terminals
Filtered, without battery
1% rms (typ.)
With battery eliminator
option (without battery)
Current limit
Adjustable
Soft start
0 to 100% load
Voltage adjustment ranges
Float
Equalize
High DC Voltage alarm
Low DC Voltage alarm
Voltmeter range (Vdc)
Ammeter range (Adc)
30 Mv
50-110 % of rated output current
4 seconds
11.5-14.5 23.0-29.5
12-15.5
24-31
12-19
24-38
7-13
15-25
0 - 21
25 Adc nom. output
30-100 Adc nom. output
125-400 Adc nom. output
500-800 Adc nom. output
1,000 Adc nom. output
100 mV
0 - 42
46-58
48-61
48-76
36-50
115-140
123-145
120-175
80-126
0 - 75
0 - 195
0 - 30
0 - 150
0 - 500
0 - 1000
0 - 1,200
Surge withstand capability
Test per
ANSI C37.90.1-1989
Reverse current from
battery
AC input power failure,
no options installed
90 mA maximum
Audible noise
Average for 4 sides
5ft / 1.5m from charger
Less than 62 dB(A)
Cooling
Ambient temperature
Natural convection
Operating
Elevation
72
32-122° F / 0-50° C
3,000ft / 1,000m without derating
Relative humidity
Alarm relay contact rating
No erroneous outputs
0 to 95% non-condensing
120 Vac / 125 Vdc
0.5A resistive
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.
Description
Auxiliary Alarm Relay PC Board (A5)
Standard DC Output Filtering (30 mV with battery)
Battery Eliminator Filtering
External Temperature Compensation Probe Assembly (A10)
AC Input Lightning Arrestor (VR3)
Copper Ground Buss with one (1) box lug
Wall-Mounting Kit for Style-5018 Cabinet
23-24in Relay Rack-Mounting Kit for Style-5018
Drip Shield Assembly for Style-5018 Cabinet
DNP3 Level 2 / Modbus Communications Module
Kit Part Number
EI0213-02
contact your sales rep.
contact your sales rep.
see table below
EJ1074-00
contact your sales rep.
EI5008-00
EI0193-03
EI0191-02
see Appendix E
External Temperature Compensation Probe Assembly
The temperature compensation assembly consists of two (2) components:
1. To order a replacement probe (or puck), request part number EJ5032-00. This
probe is good for all charger output voltages and all battery types.
2. The standard temperature compensation assembly is supplied with a 25ft / 7.6m
interconnection cable. If you need a longer cable, order it from the table below, which
also shows the ordering part number for a complete probe kit.
Temperature Compensation Probe Kits
Cable Length
Kit Part Number
Replacement Cable
Part Number
(feet / m)
(includes probe)
25 / 7.6
EJ5033-00
EJ5011-00
50 / 15.2
EJ5033-01
EJ5011-01
100 / 30.5
EJ5033-02
EJ5011-02
200 / 61.0
EJ5033-03
EJ5011-03
Use a single cable assembly. Do not try to splice cables together to increase the length.
73
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.
• JE508x AT30 Series Battery Charger Outline Drawing
Refer to this document when reviewing the enclosure type, size, weight,
and mounting dimensions.
• JE508x AT30 Series Battery Charger Internal Component
Layout Drawing
Refer to this document when identifying internal components of the AT30
and sizing input/output wiring.
• JE5091 AT30 Series Instrument Panel / PC Board Detail
Refer to this document when reviewing the layout of the instrument panel
and identifying components of the printed circuit boards (A1, A15 & A5).
• JE5092 AT30 Series Battery Charger Schematic
Refer to this document when reviewing the electrical circuitry of the
AT30 battery charger and confirming component ratings.
• JE5093 AT30 Series Battery Charger Connection Diagram
Refer to this document when reviewing (or trouble-shooting) the internal
wiring of AT30 battery charger.
All drawings listed on the AT30 Series Battery Charger Drawing List /
Data Nameplate Detail (JE5075-######) are a complete package and
should not be separated from one another.
These drawings are created specifically for the AT30 battery charger
featuring the serial number listed on the data nameplate detail, and should
not be used as reference material for any other AT30 battery charger.
Electronic versions of these documents are available in AutoCAD (DWG)
format and/or Adobe Acrobat (PDF) format. Please contact your sales
representative for document availability.
74
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
2.33
2.33
2.33
2.33
2.25
*
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. Please consult your battery
manufacturer's documentation for specific equalizing recommendations.
TEMPERATURE COMPENSATION
If batteries are to see temperature variations during charging, a temperature
compensation option is recommended. If this option is not part of your charger, manual
adjustments should be made. Refer to the equation and table below for temperatureadjusted voltages.
temperature-adjusted voltage = charge voltage x K
76
Temperature
(°F)
Temperature
(°C)
K
(Lead Acid)
K
(Nickel Cadmium)
35
45
55
65
75
77
85
1.7
7.2
12.8
18.3
23.9
25.0
29.4
1.058
1.044
1.031
1.017
1.003
1.000
0.989
1.044
1.034
1.023
1.013
1.002
1.000
0.992
95
105
35.0
40.6
0.975
0.961
0.981
0.970
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. SCADA (Supervisory Control And Data
Acquisition) systems will be able to control, monitor and log the events of the battery
charger.
The standard Communications Module kit (EJ5037-XX) includes the Communications
PC Board (A12), an external power supply assembly (A14), a separate AT Series
Communications Module Operations Manual (JA5026-00), and field-retrofit
instructions. The Communications Module Operations Manual, along with a sales
catalog cut sheet, is freely available for download from the web site featured on the
back cover of this manual. A compatible industry-standard modem and modem cable
are also available. Contact your sales representative to place an order for the AT Series
Battery Charger Communication Module. Refer to the table below for ordering
information.
Description
Communications Module for 12 Vdc AT30
Communications Module for 24 Vdc AT30
Communications Module for 48 Vdc AT30
Communications Module for 130 Vdc AT30
Compatible Modem Option
10ft / 3.05m Modem Cable
25ft / 7.62m Modem Cable
50ft / 15.24m Modem Cable
Part No.
EJ5037-01
EJ5037-02
EJ5037-03
EJ5037-04
PM5005-00
EH5026-00
EH5026-01
EH5026-02
77
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. 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:
Electronic Filename [JA5030-00.Rev.0A.AT30.Manual.doc]
Last Date Saved [2/5/2004 11:42 AM]
Last Date Printed [2/5/2004 11:43 AM]
ON-LINE AVAILABILITY:
Electronic versions of this manual and/or any custom or standard drawings for the AT30
Series Battery Charger are available online. Saved in Adobe Acrobat Portable Document
Format (PDF), they are readily available for downloading and printing. Please contact your
sales representative for document availability or see the manufacturer's web site listed on the
back cover of this manual.
78
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.
For details on setting
parameters, see section
2.3 starting on page 32
Setting
If you don’t press any key
for 25 seconds, the AT10.1
resumes normal operation
automatically
„ Press the
Float Voltage
Equalize Voltage
Equalize Timer
High DC Voltage
Low DC Voltage
key. The DC VOLTS and
FLOAT indicators light, and the digital display
flashes the present float voltage setting.
„ Press the
or
key until the digital
display indicates the desired float voltage.
„ Press the
key to save the new setting
internally.
„ The EDIT sequence advances to the equalize
voltage as shown by the front panel indicators.
Repeat the above steps until you have set all
parameters.