EEVO
VO AT
AT SERIES
SERIES B
BATTERY
ATTERY C
CHARGER
HARGER
AT SERIES BATTERY CHARGER
A
P R O D U C T
OPERATION & SERVICE
INSTRUCTIONS
EVO - Microprocessor Controlled Float Battery Charger
SINGLE PHASE INPUT - GROUP 1 (6-25 ADC)
JA5011-51
NOTICE
! WARNING
Table of Contents - ATevo
TABLE OF
CONTENTS
1. RECEIVING & UNPACKING THE EVO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Storing the EVO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Reporting Shipping Damage . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Unpacking and Inspecting the EVO . . . . . . . . . . . . . . . . . . . . . 2
1.3.1 Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.4 Moving the EVO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4.1 EVO Weight Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.5 Mounting the EVO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5.1 Wall-Mounting the EVO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.5.2 Floor-Mounting the EVO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.5.3. Rack-Mounting the EVO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2. WIRING THE EVO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 Mechanical Diagram and Component Location . . . . . . . . . 12
2.1.1 Main Control Board (A1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1.2 Power Board (A2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1.3 Capacitor Board (A3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1.4 Auxiliary I/O Board (A4) - optional . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1.5 Ethernet Communications Adapter (A5) – optional . . . . . . . . . . . . . . 14
2.1.6 Serial Communication Adapter (A6) – optional . . . . . . . . . . . . . . . . . 15
2.1.7 Eliminator Filter Capacitor (C2) - optional. . . . . . . . . . . . . . . . . . . . . 15
2.1.8 AC Input Circuit Breaker (CB1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1.9 DC Output Circuit Breaker (CB2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1.10 Filter Inductor #1 (L1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1.11 Filter Inductor #2 (L2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1.12 Main Transformer (T1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1.13 AC MOV Board (A7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2 Removing the Protective Safety Shield . . . . . . . . . . . . . . . . . 16
2.3 EVO with Selectable Input Voltage (optional). . . . . . . . . . . . 17
2.3.1 Determine if the Multi-Tap Option is Present. . . . . . . . . . . . . . . . . . . 17
2.3.2 Verify the Multi-Tap AC Input Voltage Setting . . . . . . . . . . . . . . . . . . 17
2.3.3 Modify the Multi-Tap AC Input Voltage Setting . . . . . . . . . . . . . . . . . 18
2.4 Making the AC Input Connections . . . . . . . . . . . . . . . . . . . . . 18
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2.5 Making the DC Output Connections . . . . . . . . . . . . . . . . . . .
2.6 EVO Remote Voltage Sense . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7 Wiring the EVO Common Alarm . . . . . . . . . . . . . . . . . . . . . .
2.8 Wiring the Relays on Auxiliary I/O Board . . . . . . . . . . . . . . .
2.9 Wiring the Temperature Compensation Probe . . . . . . . . . . .
2.10 Wiring the Serial Communication Adapters . . . . . . . . . . . .
2.11 Wiring the Ethernet Adapter Board . . . . . . . . . . . . . . . . . . .
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3. EVO STARTUP & CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.1 Front Panel Controls and Indicators . . . . . . . . . . . . . . . . . . . 27
3.1.1 Main EVO Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.1.2 Navigation and Control Button Group . . . . . . . . . . . . . . . . . . . . . . . 28
3.1.3 Operation Modes and Methods Button Group . . . . . . . . . . . . . . . . . 28
3.1.4 Alarm Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.1.5 Hindle Health System (HHS) Section . . . . . . . . . . . . . . . . . . . . . . . 28
3.1.6 AC Input and DC Output Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.2 Starting the EVO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.2.1 Understanding the Startup Sequence. . . . . . . . . . . . . . . . . . . . . . . . 29
3.2.2 Checking the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.2.3 Powering Up the EVO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.2.4 The EVO Home Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.3 Configuring Standard EVO Set Points and Alarms . . . . . . . 36
3.3.1. Understanding the General Parameter Settings . . . . . . . . . . . . . . . . 36
3.3.2 Setting the Float Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.3.3 Setting the Equalize Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.3.4 Setting the Equalize Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.3.5 Setting the High DC Voltage Alarm . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.3.6 Setting the Low DC Voltage Alarm . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.3.7 Setting the Current Limit Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.4 Configuring of Advanced EVO Settings . . . . . . . . . . . . . . . . . 44
3.4.1 Entering Advanced Configuration Mode . . . . . . . . . . . . . . . . . . . . .44
3.4.2 Enabling the High Voltage Shutdown. . . . . . . . . . . . . . . . . . . . . . . . 45
3.4.3 Setting the High Level Detect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.4.4 Setting the End of Discharge (EOD) Alarm . . . . . . . . . . . . . . . . . . . . 48
3.4.5 Setting the Low Voltage Level Detect . . . . . . . . . . . . . . . . . . . . . . . . 49
3.4.6 Setting the Ripple Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.4.7 Setting the Positive Ground Fault Sensitivity Level . . . . . . . . . . . . . . . 51
3.4.8 Setting the Negative Ground Fault Sensitivity Level. . . . . . . . . . . . . . 52
3.4.9 Enabling the Battery Temperature Compensation. . . . . . . . . . . . . . . 53
3.4.10 Selecting Battery Type for Temperature Compensation . . . . . . . . . . 54
3.5 Configuring of the System Settings . . . . . . . . . . . . . . . . . . . . 56
3.5.1 Entering System Settings Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.5.2 Setting the EVO System Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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3.5.3 Setting the EVO System Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.5.4 EVO Display Backlight ON/OFF Control . . . . . . . . . . . . . . . . . . . . . 60
3.5.5 Adjusting EVO Display Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.5.6 Adjusting EVO Display Backlight Brightness . . . . . . . . . . . . . . . . . . . 63
3.5.7 EVO Display Reverse Image Control . . . . . . . . . . . . . . . . . . . . . . . . 64
3.6 Configuring the EVO Relays . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.6.1 Configuring the Common Alarm Relay . . . . . . . . . . . . . . . . . . . . . . . 65
3.6.2 Configuring the Auxiliary I/O Board Relays . . . . . . . . . . . . . . . . . . . 69
3.7 Disabling Alarms in the Common Alarm List . . . . . . . . . . . .
3.8 Configuring the EVO Serial Adapter . . . . . . . . . . . . . . . . . . .
3.9 Configuring the EVO Ethernet Adapter . . . . . . . . . . . . . . . . .
3.10 Enable/Disable the High Level Detect . . . . . . . . . . . . . . . . .
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4. BASIC OPERATION OF THE EVO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
4.1 The EVO Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.1.1 The EVO HOME Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.1.2 The EVO Configuration Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.1.3 The EVO Status Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.1.4 The Hindle Health System Screens . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.2 Standard EVO mode Operation . . . . . . . . . . . . . . . . . . . . . . . 76
4.2.1 Changing the Display Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.2.2 Changing the Charge Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.2.3 Changing the Equalize Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.2.4 Lamp Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
4.2.5 Resetting Latched Relays (legacy method) . . . . . . . . . . . . . . . . . . . . 80
4.3 High Voltage Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.4 Low Level Detect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.5 High Level Detect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5. ADVANCED OPERATION OF THE EVO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.1 The EVO Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.1.1 The Basic Settings Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.1.2 The Advanced Settings Icon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.1.3 The System Settings Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.1.4 Save|Reset Configuration Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.1.5 The Relays Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.1.6 The Event Logs Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.1.7 The System information Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.1.8 The Security Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.1.9 The Communications Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.1.10 The Common Alarm Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.1.11 The AUX Inputs Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.1.12 The Testing Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
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5.2 The EVO Alarm Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.3 The EVO Health Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.4 Security and Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.4.1 Three (3) Levels of Password Protection . . . . . . . . . . . . . . . . . . . . . . 93
5.4.2 Accessing the Security Features and Password Configuration . . . . . . 93
5.4.3 Setting the EVO Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.4.4 Setting the Default Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5.4.5 Logging In to a Password Authorization Level . . . . . . . . . . . . . . . . . 97
5.4.6 Logging Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.5 Features Supported By the Optional SD Memory Card . . 100
5.5.1 The SD Memory Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.5.2 Storing the Event Log File to the SD Memory Card . . . . . . . . . . . . . 101
5.5.3 Storing and Recalling the Configuration Settings to/from the
SD Memory Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.5.4 Upgrading the Main Control Board Firmware via the
SD Memory Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
6. EVO ALARMS & INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
6.1 EVO Legacy Alarms and Indicators . . . . . . . . . . . . . . . . . . . . 110
6.1.1 AC ON Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
6.1.2 High DC Voltage Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
6.1.3 Low DC Voltage Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
6.1.4 DC Output Failure Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
6.1.5 AC Input Failure Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
6.1.6 Positive Ground Fault Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
6.1.7 Negative Ground Fault Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6.2 EVO Common Alarm Indicator . . . . . . . . . . . . . . . . . . . . . . . . 113
6.2.1 Configuring The Common Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . 114
6.3 Active Alarm Bar, Alarm View, and Alarm Log . . . . . . . . . . . 114
6.3.1 The Active Alarm Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
6.3.2 The Active Alarm List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
6.3.3 The Alarm Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
6.4 EVO Advanced Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
6.4.1 High Voltage Shutdown Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
6.4.2 Low Level Detect Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
6.4.3 End of Discharge (EOD) Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6.4.4 High Ripple Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6.4.5 Battery Temperature Probe Failure Alarm . . . . . . . . . . . . . . . . . . . 119
6.4.6 Rectifier Over Temperature Alarm . . . . . . . . . . . . . . . . . . . . . . . . . 119
6.4.7 External Feedback Failure Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6.4.8 Internal Feedback Failure Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . 120
6.4.9 Open DC Breaker Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
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6.4.10 Open AC Breaker Alarm (optional). . . . . . . . . . . . . . . . . . . . . . . . 121
6.4.11 DC Power Supply Failure Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . 121
6.4.12 SCR Failure Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
6.5 Reset Latch Alarm Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
6.6 Open Battery Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
6.6.1 Open Battery Test Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
6.6.2 Run the Open Battery Test Periodically . . . . . . . . . . . . . . . . . . . . . 127
6.6.3 Run the Open Battery Test Manually . . . . . . . . . . . . . . . . . . . . . . . 130
6.6.4 Resetting the Battery Open Alarm . . . . . . . . . . . . . . . . . . . . . . . . . 131
7. HINDLE HEALTH SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
7.1 Hindle Health System - Overview . . . . . . . . . . . . . . . . . . . . . . 134
7.2 Hindle Health System Components . . . . . . . . . . . . . . . . . . . . 134
7.2.1 Self-Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
7.2.2 Hindle Health Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
7.2.3 Hindle Health LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
7.3 Hindle Health System Screens . . . . . . . . . . . . . . . . . . . . . . . . 136
7.3.1 Introduction and Warning Screens . . . . . . . . . . . . . . . . . . . . . . . . . 137
7.3.2 Choosing What to Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
7.3.3 The Test Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
8. EVO EVENT LOGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
8.1 EVO Event Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2 View The Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3 View the Hindle Health Log . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4 Clearing the Event Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.5 Copy the Event Logs to the SD Memory Card. . . . . . . . . . . .
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9. EVO BATTERY TEMPERATURE COMPENSATION . . . . . . . . . . . . . . . . . . . .147
9.1 EVO Battery Temperature Compensation . . . . . . . . . . . . . . . 148
9.2 Installing the TEMPCO Option . . . . . . . . . . . . . . . . . . . . . . . . 148
9.2.1 Configuring the TEMPCO Option . . . . . . . . . . . . . . . . . . . . . . . . . . 151
9.3 Using the TEMPCO Option . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
9.3.1 Home Screen with TEMPCO Option . . . . . . . . . . . . . . . . . . . . . . . . 153
9.4 Temperature Compensation Curves . . . . . . . . . . . . . . . . . . . 154
10. REMOTE SENSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
10.1 EVO Remote Voltage Sense . . . . . . . . . . . . . . . . . . . . . . . . . . 156
10.2 Remote Sense Connection . . . . . . . . . . . . . . . . . . . . . . . . . . 156
10.3 Procedure for Wiring Remote Sense . . . . . . . . . . . . . . . . . . 157
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10.4 Configuring the Remote Sense Jumpers . . . . . . . . . . . . . . . 159
10.4.1 Locating Remote Sense Configuration Jumpers . . . . . . . . . . . . . . 159
10.4.2 Enable Remote Sense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
10.4.3 Enable Local Sense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
10.5 Disabling the Remote Sense . . . . . . . . . . . . . . . . . . . . . . . . . 160
11. AUXILIARY INPUTS/OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
11.1 EVO Auxiliary Relay Board Types . . . . . . . . . . . . . . . . . . . . . 162
11.1.1 Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
11.1.2 Binary Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
11.1.3 Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
11.2 Connections to the Auxiliary I/O Board . . . . . . . . . . . . . . . 165
11.2.1 System Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
11.2.2 Wiring the Relays Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 165
11.2.3 Wiring the Binary Input Connections . . . . . . . . . . . . . . . . . . . . . . 166
11.2.4 Wiring the Analog Input Connections . . . . . . . . . . . . . . . . . . . . . 168
11.3 Hardware Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
11.3.1 Auxiliary I/O Board Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
11.3.2 Binary Input Voltage Configuration . . . . . . . . . . . . . . . . . . . . . . . 170
11.4 Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
11.4.1 Auxiliary I/O Board Relay Alarm Configuration . . . . . . . . . . . . . . . 171
11.4.2 Auxiliary I/O Board Relay Latch Configuration . . . . . . . . . . . . . . . 173
11.4.3 Auxiliary I/O Board Relay Time Delay Configuration . . . . . . . . . . . 176
11.5 Software Configuration for Auxiliary I/O Board
Binary Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
11.5.1 Binary Input Name Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . 178
11.5.2 Binary Active State Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . 181
11.5.3 Binary Input Alarm Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
11.5.4 Binary Input Action Assignment. . . . . . . . . . . . . . . . . . . . . . . . . . 186
11.5.5 Factory Default Binary Input Configuration . . . . . . . . . . . . . . . . . 188
11.6 Software Configuration for Auxiliary I/O Board
Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
11.6.1 Analog Input Name Assignment . . . . . . . . . . . . . . . . . . . . . . . . . 189
11.6.2 Analog Input Primary Unit Assignment . . . . . . . . . . . . . . . . . . . . 192
11.6.3 Analog Input Scaling Assignment . . . . . . . . . . . . . . . . . . . . . . . . 194
11.6.4 Analog Input Alarm and Trigger Assignment . . . . . . . . . . . . . . . . 198
11.6.5 Analog Input Alarm Threshold Assignment . . . . . . . . . . . . . . . . . 201
11.6.6 Analog Input Action Assignment . . . . . . . . . . . . . . . . . . . . . . . . . 204
11.6.7 Factory Default Analog Input Configuration . . . . . . . . . . . . . . . . . 207
12. DRAWINGS & APPENDICIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209
AT SERIES BATTERY CHARGER
vii
1. RECEIVING &
UNPACKING THE
EVO
AT SERIES BATTERY CHARGER
1 Receiving & Mounting the AT SERIES EVO
1.1 Storing the EVO
If you store the EVO 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 0 to 122 °F / -18 to
50°C are acceptable. Storage should not exceed two (2) years due to
the limited shelf life of the DC filter capacitors when they are not in
service.
1.2 Reporting Shipping Damage
Upon delivery of the EVO (or related products) if 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 products 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 EVO
Carefully remove all shipping materials from the EVO. Remove
the EVO from the shipping pallet for inspection. Save all shipping
materials until you are sure that there is no shipping damage. Once
the EVO is unpacked, inspect the unit for possible shipping damage,
using the checklist below. If shipping damage has occurred, refer to
Section 1.2 for proper reporting.
1.3.1 Inspection Checklist
□ Enclosure exterior and interior are not marred or dented.
□ There is no visible damage to exterior or
interior components.
□ All internal components are secure.
□ Printed circuit boards are firmly seated on their standoffs.
□ All hardware is tight.
2
AT SERIES BATTERY CHARGER
1 Receiving & Mounting the AT SERIES EVO
□ All wire terminations are secure.
□ The User’s Manual is included.
□ You received all items on the packing list.
1.4 Moving the EVO
Once you have established that the EVO is undamaged, identify
the weight of your unit. Refer to the table below.
1.4.1 EVO Weight Table
Output
Voltage
24 VDC
48VDC
130VDC
260VDC
6ADC
TBD
TBD
83 lbs
38 kg
97 lbs
44 kg
TBD
TBD
AMPERE RATING
12ADC 16ADC 20ADC
TBD
TBD
101 lbs
TBD
TBD
46 kg
96 lbs
112 lbs 108 lbs
44 kg
51 kg
48 kg
125 lbs 125 lbs 193 lbs
57 kg
57 kg
88 kg
193 lbs
N/A
N/A
88 kg
N/A
N/A
25ADC
101 lbs
46 kg
108 lbs
48 kg
193 lbs
88 kg
N/A
N/A
The EVO enclosure does not feature top lifting eyes for moving.
Move the EVO with a forklift whenever possible, using the supplied
shipping pallet. Lift the EVO into a wall-mount or rack-mount
installation, using a heavy-duty sling or a scissor lift.
1.5 Mounting the EVO
The EVO must be installed in manner that allows easy access to the
front AC (CB1) and DC (CB2) circuit breakers. Choose a mounting
method for the EVO enclosure from the following choices.
1.5.1 Wall-Mounting the EVO
Wall-mounting is the standard means of installing the EVO. When
wall-mounting the EVO, consider the following:
1. Refer to the enclosure outline drawing at the back of this
AT SERIES BATTERY CHARGER
3
1 Receiving & Mounting the AT SERIES EVO
2.
3.
4.
5.
6.
manual.
The wall must be strong enough to properly support the weight
of the EVO, plus a safety factor. See the Weight Table featured
in Section 1.4.1 The weight of your EVO may be different,
depending on the features, options, and accessories ordered
with the unit.
Be conscious of planned AC input and DC output wiring to the
EVO, selecting conduit entrances carefully. Use of the pre-fab
knockouts on the sides or bottom of the enclosure will allow
removal of the cabinet shroud (and internal access for servicing)
without removal of the unit from the wall.
The location:
» Should be free of drips and splatter. If falling particles and
liquids are a problem, install a NEMA-2 type drip shield
accessory.
» Should be between 0 and 122 °F / -18 and 50 °C, with
relative humidity between 0% and 95% non-condensing.
» Must be free of flammable or explosive materials.
Maintain at least 6in / 152mm of free air on all vented surfaces
for cooling.
Allow at least 36in / 914mm front clearance for access to the
EVO for operation and maintenance.
PROCEDURE
Install four (4) 0.25in / 6.4mm anchor bolts (not supplied) rated to
support the weight of the EVO, plus a safety factor of at least two
(2) times, into the wall. Place the EVO onto the anchor bolts, add
appropriate mounting hardware, and tighten securely. Refer to the
following graphics for EVO wall-mounting pattern and specification.
4
AT SERIES BATTERY CHARGER
1 Receiving & Mounting the AT SERIES EVO
LQ
>PP@
',$
(1&/2685(
02817,1*
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AT SERIES BATTERY CHARGER
5
1 Receiving & Mounting the AT SERIES EVO
1.5.2 Floor-Mounting the EVO
To install the EVO onto a horizontal surface, the standard enclosure
does not need to be modified, but a special floor mounting accessory
EI0192-00 is required. The kit includes a set of mounting brackets
that elevate the top of the EVO approximately 47in /1194mm above
floor level, with provisions for floor anchoring. The kit also includes
appropriate hardware and installation instructions for the floormounting procedure.
When floor-mounting the EVO, consider the following:
1. Locate anchor bolt holes at least 4.25in /108mm from any wall,
to allow clearance behind the mounting brackets.
2. Be conscious of planned AC input and DC output wiring to the
EVO, selecting conduit entrances carefully. Use of the pre-fab
knockouts on the sides or bottom of the enclosure will allow
removal of the cabinet shroud (and internal access for servicing)
without removal of the unit from the floor stand.
3. The location:
» Should be free of drips and splatter. If falling particles and
liquids are a problem, install a NEMA-2 type drip shield
accessory.
» Should be between 0 and 122 °F / -18 and 50 °C, with
relative humidity between 0% and 95% non-condensing.
» Must be free of flammable or explosive materials.
4. Maintain at least 6in /152mm of free air on all vented surfaces
for cooling.
5. Allow 36in /914mm front clearance for operation and
maintenance.
PROCEDURE
Install four (4) 0.25in / 6.4mm anchor bolts (not supplied) rated to
support the unit weight plus a safety factor of at least two (2) times,
into the floor.
Assemble the floor-mounting accessory to the anchor bolts as shown.
Place the EVO onto the vertical posts, add appropriate mounting
hardware, and tighten.
Refer to the following graphics for floor mounting patterns and
enclosure footprints.
6
AT SERIES BATTERY CHARGER
1 Receiving & Mounting the AT SERIES EVO
LQ
PP
LQPP
)/22507*+2/(
)2853/$&(6
LQ
PP
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1.5.3. Rack-Mounting the EVO
The EVO can be installed into most 23in/584mm and 24in/610mm
relay racks with standard EIA hole spacing. The EVO enclosure
does not need to be modified for rack mounting, but a special kit is
required.
The kit includes two (2) mounting brackets, appropriate hardware,
and Installation Instructions for the rack-mounting procedure.
AT SERIES BATTERY CHARGER
7
1 Receiving & Mounting the AT SERIES EVO
When rack-mounting the EVO, consider the following:
1. The rack must be strong enough to properly support the weight
of the EVO. See the Weight Table located in Section 1.4.1
2. Be conscious of planned AC input and DC output wiring to the
EVO, selecting conduit entrances carefully. Note the standard
pre-fab conduit knockouts located on the sides, top, and bottom
of the enclosures. Ensure that planned conduit is accessible
after the EVO is rack-mounted.
3. The location:
» Should be free of drips and splatter. If falling particles and
liquids are a problem, install a NEMA-2 type drip shield
accessory.
» Should be between 0 and 122 °F / -18 and 50 °C, with
relative humidity between 0% and 95% non-condensing.
» Must be free of flammable or explosive materials.
4. Maintain at least 6in /152mm of free air on all vented surfaces
for cooling.
5. Allow at least 36in /914mm front clearance for access to the
EVO for operation and maintenance.
PROCEDURE
To rack mount the EVO, first install the mounting brackets into the
rack using proper hardware (not supplied). Second, mount the EVO
onto the installed brackets, using the supplied kit hardware. Provide
at least 6in /152mm of free air above and below the EVO for cooling.
Refer to the following graphics for the rack-mounting configurations.
8
AT SERIES BATTERY CHARGER
1 Receiving & Mounting the AT SERIES EVO
$//2:LQPP)25
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AT SERIES BATTERY CHARGER
9
2. WIRING THE
EVO
AT SERIES BATTERY CHARGER
2 Wiring the AT SERIES EVO
2.1 Mechanical Diagram and Component Location
The EVO has the following mechanical layout and wiring diagram
screen printed on the patented protective PlexiGlas shield internal to
the charger.
The EVO is composed of the following basic components and
subsections
• A1 – Main Control Board
• A2 – Power Board
• A3 – Capacitor Board
• A4 – Auxiliary I/O Board - optional
• A5 – Ethernet Communications Adapter - optional
• A6 – Serial Communications Adapter(s) – optional
• A7 – AC MOV Board
• C2 – Eliminator Filter Capacitor – optional
• CB1 – AC Input Circuit Breaker
• CB2 – DC Output Circuit Breaker
• L1 – Filter Inductor #1
• L2 – Filter Inductor #2
• T1 – Main Transformer
12
AT SERIES BATTERY CHARGER
P1
RELAY1 RELAY2 RELAY3 RELAY4 RELAY5 RELAY6
JP103 LOCAL JP104
RIBBON CABLE TO
A1 MAIN CONTROL
AT SERIES BATTERY CHARGER
REMOTE SENSE
TB1
SIG 1
GND 2
NEG 3
REMOTE SENSE BATT TEMP
GROUND DETECT
ENABLED
JP102
DISABLED
TB8
13
OUTPUT
J101
J104
A8 DC POWER
SUPPLY
EN5037-XX
GROUND
AC MOV
TP3
EARTH
OUTPUT
POS
TP4
JP101
TP2 (+)
J105
TBS1
TBS2
HIGH VOLTAGE
DANGER
NEG
EN5042-XX
J102
P1
P1
P1
P1
RE-FLASH
ENABLE
P13
SW13
EN5031-XX
J1
EN
DIS
TB6
1
C
2
C2
Capacitor
L2-2
CB2 AUX CONTACTS
EN5039-XX
A7 MOV BOARD
3
NC NO ALARM
COMMON
HIGH LEVEL
DETECT SHUTDOWN
A1 Main Control Card
JP4
P1
CB2
CB1
120 VOLTS INPUT
H1 H3 H2 H5 H4 H2
240 VOLTS INPUT
H1 H3 H2 H5 H4 H2
DC OUTPUT
L2 / Neutral
L1 / Line
AC INPUT
208 VOLTS INPUT
H1 H3 H2 H5 H4 H2
(OPTION NOT AVAILABLE ON SINGLE INPUT UNITS)
USE BOTH JUMPERS WHEN MAKING SELECTIONS
AC INPUT VOLTAGE SELECTION
MAIN CONTROL CARD VIEWED FROM BACK OF DOOR
P2
PUSH TO
RESET
NORM PRGM
H1 H3 H2 H5 H4 H2
ETHERNET
P12
PORT 3
P11
PORT 2
P10
PORT 1
PUSH CARD IN
TO EJECT
IA5014-00 SHEET 1 OF 3
USE COPPER CONDUCTOR ONLY
STRIP WIRE INSULATION 1/2 IN.
TORQUE SCREWS TO 31 Lb-In.
Positive
L2 Inductor
EN5035-XX
A5 Ethernet
Adapter
EN5034-XX
A6 Serial
Adapter
EN5034-XX
A6 Serial
Adapter
EN5034-XX
A6 Serial
Adapter
SD MEMORY
CARD
Negative
J1
RXD/RA (-)
TXD/TA (-)
CTS/RB (+)
RTS/TB (+)
GND
SHIELD
L1 Inductor
CB2 POS
EN5038-XX
RXD/RA (-)
TXD/TA (-)
CTS/RB (+)
RTS/TB (+)
GND
SHIELD
RXD/RA (-)
TXD/TA (-)
CTS/RB (+)
RTS/TB (+)
GND
SHIELD
T1 Transformer
CB2 NEG
Y2
Y1
L1-1
L1-2
L2-1
X1
X4
DANGER
HIGH VOLTAGE
POS
A3 Cap
Board
Component Layout
ATevo Series
A2 Power Board
P1
S1
TB2
TB3
RIBBON CABLE TO
A2 POWER BOARD
POS 1
TP1 (-)
TP3 Output (-)
TP4 Output (+)
EN5040-XX
A4 Aux Relay
Board
B1 (+)
B1 (-)
B2 (+)
B2 (-)
B3 (+)
B3 (-)
B4 (+)
B4 (-)
TB4
AN 1
AN 2
AN 3
AN 4
COM
NC
NO
COM
NC
NO
COM
NC
NO
COM
NC
NO
COM
NC
NO
COM
NC
NO
COM
TB1
2 Wiring the AT SERIES EVO
C2 (-)
C2 (+)
COMM
CB2
CB1
2 Wiring the AT SERIES EVO
2.1.1 Main Control Board (A1)
The Main Control Board shown on the top right of the silkscreen is
mounted on the EVO door. The Main Control Board contains the
display, buttons, alarm indicators, and is responsible for charger
controls.
2.1.2 Power Board (A2)
The Power Board shown on the bottom left of the silkscreen is
mounted on the heat sink along the left side of the charger. The
Power Board contains the rectifier and most power electronics
connections as well as terminal blocks for the remote sense and
battery temperature compensation options.
2.1.3 Capacitor Board (A3)
The Capacitor Board is shown near the top left of the silkscreen.
The Capacitor Board is bolted to the top of the Power Board. The
capacitors create the filter for standard filtered EVO.
2.1.4 Auxiliary I/O Board (A4) - optional
The Auxiliary I/O Board is shown at the top left of the silkscreen and
is bolted to the heat sink along the left side of the EVO above the
Power Board. The Auxiliary I/O Board plugs directly into the Power
Board.
The Auxiliary I/O Board has six relays, four binary inputs, and four
analog inputs. The relays can be configured to indicate the status
of six different alarms or status points. The independently isolated
binary inputs can be configured to report the ON/OFF status of four
controls. The analog inputs include input scaling and can report the
status of four analog controls referenced to the DC bus.
2.1.5 Ethernet Communications Adapter (A5) – optional
The Ethernet Communications Adapter is shown directly to the
bottom left of the Main Control Board. The Ethernet Adapter Board
plugs into the Main Control Board at location P13. This option will
support 10/100 copper Ethernet connections and Modbus and
DNP3.0 protocols.
14
AT SERIES BATTERY CHARGER
2 Wiring the AT SERIES EVO
2.1.6 Serial Communication Adapter (A6) – optional
The Serial Communication Adapter(s) are shown above the Ethernet
Communications adapter on the silkscreen. The EVO Main Control
Board can support up to three Serial Communication Adapter
boards. The Serial Communication Adapter Boards plug into the
Main Control Board at locations, P10, P11, and P12.
The Serial Communication Adapters can be configured to support
two wire or four wire RS-232 connections or two wire or four wire RS485 connections. They support Modbus and DNP3.0 protocols and
are also used for connecting other serial options to the Main Control
board such as forced load share.
2.1.7 Eliminator Filter Capacitor (C2) - optional
The Eliminator Filter Capacitor is shown below the Power Board on
the silkscreen. The Capacitor is mounted on the bottom left corner
of the charger under the Power Board. This capacitor provides the
additional ripple filtering required for the filtered eliminator option.
2.1.8 AC Input Circuit Breaker (CB1)
The AC Input breaker is located at the center of the charger about
one third from the bottom. The AC Input Circuit Breaker protects the
EVO AC wiring and can be used to disconnect the EVO from the AC
source.
2.1.9 DC Output Circuit Breaker (CB2)
The DC Output breaker is located at the center bottom of the charger
below the AC Input Breaker. The DC Output Circuit Breaker protects
the EVO DC wiring and can be used to disconnect the EVO from the
battery and system load.
2.1.10 Filter Inductor #1 (L1)
The L1 Filter Inductor is shown in the center of the silkscreen and
is located on the bottom left of the back wall of the charger. This
inductor is part of the DC ripple filter.
AT SERIES BATTERY CHARGER
15
2 Wiring the AT SERIES EVO
2.1.11 Filter Inductor #2 (L2)
The L2 Filter Inductor is shown in the center bottom of the silkscreen
and is located on the bottom back wall of the charger directly to the
right of the L1 Filter Inductor. This inductor is part of the ripple filter.
2.1.12 Main Transformer (T1)
The Main Transformer is shown near the center on the silkscreen and
is located on the back wall of the charger above the Filter Inductors.
The Main Transformer provides isolation and converts the AC input
voltage to the appropriate level prior to rectification.
A multi-tap input option is available. EVO chargers with the multi-tap
option will have a terminal block for tap selection above the AC Input
Breaker. The jumper positions are shown on the silk screen to the
direct right of the Main Transformer.
2.1.13 AC MOV Board (A7)
The AC MOV Board shown to the left of the AC breaker on the
silkscreen is mounted to the top left side of the breaker bracket. This
board contains the AC input surge suppression and filtering. It is
located for easy access, examination, and replacement in case an
input transient event should occur.
2.2 Removing the Protective Safety Shield
In order to prevent injuries, the EVO safety shield must always be
installed when the charger is in operation and/or energized.
A standard flat blade screwdriver is required to remove the safety
shield.
• Open the EVO front door to access the safety shield.
• Locate the two screws that attach the safety shield to the EVO
charger.
» One is located above the AC Input Breaker, the other is
located below the DC Output Breaker
• Remove the two screws.
• Grab the safety shield on both the left and right sides and gently
lift the safety shield up and off of the AC Input and DC Output
Breakers.
• Reverse this procedure for reinstalling the safety shield.
16
AT SERIES BATTERY CHARGER
2 Wiring the AT SERIES EVO
2.3 EVO with Selectable Input Voltage (optional)
EVO may be equipped with a Multi-Tap AC input voltage option.
There are two Multi-Tap input voltage options that allow the charger
to be field configured. The first option supports input voltages of
120 VAC, 208 VAC, or 240 VAC, the second option supports input
voltages of 120 VAC, 220 VAC, or 240 VAC.
2.3.1 Determine if the Multi-Tap Option is Present
Check the EVO nameplate. If the AC Input Voltage is listed as
120/208/240 or 120/220/240 VAC the EVO is equipped with the
Multi-Tap option. If the nameplate is not visible:
• Open the EVO front door.
• Look for a gray terminal block directly above the AC Input
breaker (behind the safety shield).
» Reference the Input Voltage Selection silk screened on the
center right of the safety shield.
» If this terminal block is present, the EVO is equipped with the
Multi-Tap AC Input Voltage option.
2.3.2 Verify the Multi-Tap AC Input Voltage Setting
Before you connect AC power to the EVO,
inspect the present AC Input Voltage setting
and confirm the correct jumper positions for
the desired AC Input supply voltage. The MultiTap AC Input Voltage setting can be verified
without removing the safety shield.
• Open the EVO front door and locate
the Multi-Tap terminal block above
the AC Input Breaker.
• Observe the relative locations of the
RED jumpers in the Multi-Tap terminal
block.
• Refer to the adjacent diagram to
confirm the present AC Input Voltage
Setting is correct.
AT SERIES BATTERY CHARGER
17
2 Wiring the AT SERIES EVO
2.3.3 Modify the Multi-Tap AC Input Voltage Setting
Before changing the voltage selection jumper, shut down the EVO
and lock out AC and DC power supplies. Merely turning off (opening)
the EVO’s internal circuit breakers does not eliminate live voltages
inside the enclosure.
A standard flat blade screwdriver will be required to change the
voltage selection jumper.
• Remove the EVO safety shield (see Section 2.2).
• Locate the Multi-Tap terminal block.
• Determine the correct location of the RED jumpers for the
desired AC Input Voltage.
» Reference Section 2.3.2 for jumper settings.
• Move any jumpers that are not in the required positions.
» Use flat blade screwdriver to carefully pry out jumpers in
wrong locations.
» Re-install jumpers in correct locations for desired AC Input
Voltage.
• Re-check the jumper locations and confirm the jumpers are
properly seated.
2.4 Making the AC Input Connections
The EVO is a commercial product, and not intended for use at
any time in a residential environment or to be powered by lowvoltage public mains.
It is the responsibility of the installer of the EVO to provide
suitable AC supply wiring. Wiring must be approved for use in
the country in which the EVO is installed. When selecting wire
sizes, consult the data nameplate decal affixed to the EVO for
voltage and current requirements.
Follow these steps to supply proper AC power to the EVO:
1. Confirm that the EVO nameplate voltage rating is correct for
your AC input supply voltage. If the EVO has the Multi-Tap AC
Input Voltage option, make sure the AC Input Voltage setting
matches the AC input supply voltage (refer to Section 2.3.2).
18
AT SERIES BATTERY CHARGER
2 Wiring the AT SERIES EVO
2. Use a branch circuit breaker or fused disconnect switch
upstream from the EVO. This device should have lockout
capabilities so that the AC input supply to the EVO can be deenergized for unit maintenance. A time delay circuit breaker or
slow-blow fuse is recommended.
3. Size the branch circuit breaker or fused disconnect switch for
the maximum AC input current of the EVO. This rating is listed
on the EVO data nameplate.
4. Size AC input wiring per the National Electric Code (NEC),
Canadian Electrical Code, and local codes for the trip rating of
the branch circuit breaker or fused disconnect switch.
5. Do not run external AC input power wiring through the same
conduit as external DC wiring.
6. All site requirements of your facility take precedence over these
instructions.
NOTES

Conduit must be properly grounded, and in compliance with
the national wiring rules of the country where installed.
AT SERIES BATTERY CHARGER
19
2 Wiring the AT SERIES EVO


Use copper or aluminum conductors only.
On 120 VAC input, connect the neutral leg to the terminal L2.
PROCEDURE
1.
2.
3.
4.
5.
6.
Remove the safety shield (see Section 2.2).
Run the AC input supply wiring into the EVO, ending at
the AC Input Breaker (CB1) and the Ground stud.
Connect the wires to the appropriate locations on the
AC Input Breaker (CB1) and the system ground stud as
indicated on the drawing.
Using a flat-blade screwdriver, securely tighten the
compression screws on CB1.
Securely tighten the ground wire on the system ground
stud.
Check all connections and reinstall the safety shield.
2.5 Making the DC Output Connections
It is the responsibility of the installer of the EVO to provide suitable
DC output, battery, and DC load wiring.
Follow these steps to connect the battery to the EVO:
1. Size the DC wiring to minimize voltage drop. The acceptable
wire size depends on your installation. As a guideline,
the voltage drop should not exceed 1% of nominal output
voltage at full current. Refer to the following table to
determine the voltage drops for various wire sizes, currents
and distances.
20
AT SERIES BATTERY CHARGER
2 Wiring the AT SERIES EVO
WIRE SIZING CHART
VOLTAGE DROP PER 100ft / 30.5m OF WIRE
(for copper at 68 °F / 20 °C)
WIRE
DC CURRENT (Amperes)
SIZE
6
12
16
20
25
(AWG)
#16
2.5V
5.0V
6.7V
8.2V
10.5V
#14
1.6V
3.2V
4.2V
5.3V
6.6V
#12
1.0V
2.0V
2.6V
3.3V
4.2V
#10
0.63V
1.3V
1.7V
2.1V
2.6V
#8
0.40V
0.80V
1.1V
1.3V
1.7V
#6
0.25V
0.50V
0.66V
0.83V
1.1V
#4
0.16V
0.32V
0.42V
0.52V
0.65V
EXAMPLE: 100ft / 30.5m of #8 AWG wire at 16A has a 1.1V drop.
2.
3.
4.
The EVO is factory wired to regulate 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 10.0.
Do not run external AC and DC power wiring, feeding the
EVO, through the same conduit.
All specific requirements of your facility take precedence
over these instructions.
AT SERIES BATTERY CHARGER
21
2 Wiring the AT SERIES EVO
PROCEDURE
1.
Use a DC disconnect switch or circuit breaker between the EVO
and DC bus. This device should have lockout capability to allow
the EVO to be disconnected from the DC bus for maintenance.
2.
3.
4.
Remove the safety shield (see Section 2.2).
Run the DC wiring to the DC Output Breaker (CB2).
Connect the wires to the appropriate locations on the DC Output
Breaker (CB2) as indicated on the drawing above.
Using a flat-blade screwdriver, securely tighten the compression
screws on the DC Output Breaker (CB2).
Reinstall the safety shield after you have made and checked all
connections.
5.
6.
22
AT SERIES BATTERY CHARGER
2 Wiring the AT SERIES EVO
2.6 EVO Remote Voltage Sense
You can wire the EVO to regulate the output voltage at the
battery terminals instead of at the charger output terminals
(CB2). See Section 10.0 for information and wiring
instructions on the EVO Remote Voltage Sense feature.
2.7 Wiring the EVO Common Alarm
The EVO Main Control Board (A1) is equipped with a “common”
Summary Alarm relay. This relay contact transfers when any one
or more of the standard EVO alarm(s) become active. One form -C
alarm contact is provided and is accessible via terminal block (TB6)
on the Main Control Board (refer to figure below).
AT SERIES BATTERY CHARGER
23
2 Wiring the AT SERIES EVO
PROCEDURE
1.
2.
3.
4.
Allow 30in / 762mm of wire inside the enclosure. Excess
should be trimmed.
Route annunciator wires to the EVO front panel door by
following the existing harness past the door hinge. Use
two (2) wire ties and allow a 4-6in / 102-153mm loop for
the hinge.
Trim wires to the proper length for connecting to TB6.
Strip 0.25in / 6.4mm of insulation from the wires.
Make the connections at TB6, and securely tighten
compression screws.
NOTES
1.
2.
3.
4.
Alarm contacts are rated at 0.5A / 125 VAC or VDC.
Summary Alarm relay terminal block (TB6) is
compression type, accepting wire sizes #22-14 AWG.
Terminals are labeled in non-alarm condition.
If user alarm contacts (TB6) are to drive inductive DC
loads (e.g. a larger DC relay) an external protective
diode must be installed at the DC relay to avoid
equipment damage. See Application Note
JD5011-00.
2.8 Wiring the Relays on Auxiliary I/O Board
The optional Auxiliary Alarm I/O Board (A4) when provided is
mounted to the heat sink above the Power Board along the left
side of the charger. See Section 11 for more information and
wiring instructions for the Auxiliary I/O Board.
2.9 Wiring the Temperature Compensation Probe
The battery temperature compensation (or TEMPCO) probe contains
a temperature dependent resistor in an epoxy module that you install
on your battery. See Section 9.0 for more information and wiring
instructions for the TEMPCO Board Probe
.
24
AT SERIES BATTERY CHARGER
2 Wiring the AT SERIES EVO
2.10 Wiring the Serial Communication Adapters
The EVO will support up to three optional Serial Communication
Adapter Boards. The Serial Communication Adapter Board(s) mount
to the EVO door and plug directly into the Main Control Board
via connection points P10, P11, and P12. See the supplementary
EVO Communications Manual for more information and wiring
instructions for the Serial Adapter Boards.
2.11 Wiring the Ethernet Adapter Board
The EVO will support an optional Ethernet Adapter Board. The
Ethernet Adapter Board mounts to the EVO door and plugs directly
into the Main Control Board via connection point P13. See the
supplementary EVO Communications Manual for more information
and wiring instructions for the Ethernet Adapter Boards.
AT SERIES BATTERY CHARGER
25
3. EVO STARTUP &
CONFIGURATION
AT SERIES BATTERY CHARGER
3 AT SERIES EVO Startup & Configuration
3.1 Front Panel Controls and Indicators
The EVO front panel controls and indicators are organized into 5
major groups or Sections.
ALARM
SECTION
MODES &
METHODS
MAIN
DISPLAY
NAVIGATION
& CONTROLS
HINDLE
HEALTH
AC INPUT &
DC OUTPUT
BREAKERS
AT SERIES BATTERY CHARGER
27
3 AT SERIES EVO Startup & Configuration
3.1.1 Main EVO Display
The EVO main Liquid Crystal Display (LCD) is back-lit and shows all
charger status and configuration information.
3.1.2 Navigation and Control Button Group
This group of buttons (MENU, ESC, EDIT/ENTER, LEFT, RIGHT, UP and
DOWN) is used to navigate through the screens and menus of the
EVO.
3.1.3 Operation Modes and Methods Button Group
This group of buttons (DISPLAY MODE, CHARGE MODE, and
EQUALIZE METHOD) is used to select the EVO mode of operation.
3.1.4 Alarm Section
The alarm section consists of the discrete alarm indication LEDs, the
AC ON indicator (LED), and the ALARM button. The discrete alarm
indicators will light when the associated alarm is active. The AC ON
indicator is lit when AC power is detected by the EVO control board.
The ALARM button is used to enter the ALARM screens which display
all alarm status.
3.1.5 Hindle Health System (HHS) Section
The Hindle Health System section consists of the HEALTH BUTTON
(HH) and the RED and GREEN health indication LEDs at the bottom
of the panel.
3.1.6 AC Input and DC Output Breakers
The AC Input Breaker is located directly below the front control
panel. When open, the AC Input Breaker disconnects all internal
EVO connections from the AC source except for the breaker terminal
where the AC input feed is connected.
The DC Output breaker is located directly below the AC Input
Breaker. When opened, the DC breaker disconnects the EVO output
from the DC bus.
NOTE:
There still may be live DC connected to some of the EVO internal boards
(this will include areas such any relays wetted by the battery voltage)
28
AT SERIES BATTERY CHARGER
3 AT SERIES EVO Startup & Configuration
3.2 Starting the EVO
3.2.1 Understanding the Startup Sequence
The EVO is configured at the factory to work with most common
batteries and loads without further adjustment. When you start the
EVO for the first time, the charger will utilize these factory default
settings (float voltage, equalize voltage, etc). You can change these
settings after you start the EVO. The FACTORY SETTINGS are listed
in the following tables. The EVO startup routine takes about 15
seconds. The control circuitry will “soft start” the EVO, such that the
DC output voltage and current increase gradually to the rated value.
AT SERIES BATTERY CHARGER
29
30
Low Range Set Point
22.0
23.4
(50% rating)
0.1
24.0
14.0
24.0
24.0
15.0
15.0
20
10
10
Parameter
Float Voltage
Equalize Voltage
Current Limit
Equalize Time
High VDC Alarm
Low VDC Alarm
HVDC Shutdown
AT SERIES BATTERY CHARGER
High Level Detect
Low Level Detect
End of Discharge
Ripple Alarm
Ground Fault (+)
Ground Fault (-)
40
40
250
24.0
24.0
38.0
38.0
25.0
38.0
99.0
(110% rating)
32.0
29.5
High Range Set Point
15
15
20
21.0
21.0
28.8
28.8
24.0
28.8
24.0
(110% rating)
28.0
26.0
Nominal (Default)
24 Volt Charger Set Points & Defaults
Kilo-ohms
Kilo-ohms
milli-volts
volts
volts
volts
volts
volts
volts
hours
amperes
volts
volts
Units
3 AT SERIES EVO Startup & Configuration
Low Range Set Point
44.0
46.0
(50% rating)
0.1
48.0
28.0
48.0
48.0
33.0
33.0
20
10
10
Parameter
Float Voltage
Equalize Voltage
Current Limit
Equalize Time
High VDC Alarm
Low VDC Alarm
HVDC Shutdown
High Level Detect
AT SERIES BATTERY CHARGER
Low Level Detect
End of Discharge
Ripple Alarm
Ground Fault (+)
Ground Fault (-)
40
40
250
48.0
48.0
76.0
76.0
50.0
76.0
99.0
(110% rating)
61.0
58.0
High Range Set Point
15
15
20
42.0
42.0
57.6
57.6
48.0
57.6
24.0
(110% rating)
56.0
52.0
Nominal (Default)
48 Volt Charger Set Points & Defaults
Kilo-ohms
Kilo-ohms
milli-volts
volts
volts
volts
volts
volts
volts
hours
amperes
volts
volts
Units
3 AT SERIES EVO Startup & Configuration
31
32
Low Range Set Point
110.0
117.0
(50% rating)
0.1
120.0
70.0
120.0
120.0
87.0
87.0
20
10
10
Parameter
Float Voltage
Equalize Voltage
Current Limit
Equalize Time
High VDC Alarm
Low VDC Alarm
HVDC Shutdown
AT SERIES BATTERY CHARGER
High Level Detect
Low Level Detect
End of Discharge
Ripple Alarm
Ground Fault (+)
Ground Fault (-)
40
40
250
120.0
120.0
175.0
175.0
141.0
175.0
99.0
(110% rating)
149.0
140.0
High Range Set Point
15
15
70
105.0
105.0
144.0
144.0
120.0
144.0
24.0
(110% rating)
139.0
131.0
Nominal (Default)
130 Volt Charger Set Points & Defaults
Kilo-ohms
Kilo-ohms
milli-volts
volts
volts
volts
volts
volts
volts
hours
amperes
volts
volts
Units
3 AT SERIES EVO Startup & Configuration
Low Range Set Point
220.0
234.0
(50% rating)
0.1
240.0
140.0
240.0
240.0
177.0
177.0
20
10
10
Parameter
Float Voltage
Equalize Voltage
Current Limit
Equalize Time
High VDC Alarm
Low VDC Alarm
HVDC Shutdown
High Level Detect
AT SERIES BATTERY CHARGER
Low Level Detect
End of Discharge
Ripple Alarm
Ground Fault (+)
Ground Fault (-)
40
40
250
244.0
244.0
288.0
288.0
282.0
288.0
99.0
(110% rating)
298.0
282.0
High Range Set Point
15
15
70
210.0
210.0
350.0
350.0
240.0
350.0
24.0
(110% rating)
278.0
262.0
Nominal (Default)
260 Volt Charger Set Points & Defaults
Kilo-ohms
Kilo-ohms
milli-volts
volts
volts
volts
volts
volts
volts
hours
amperes
volts
volts
Units
3 AT SERIES EVO Startup & Configuration
33
3 AT SERIES EVO Startup & Configuration
3.2.2 Checking the Installation
Confirm that you have followed the installation instructions carefully.
Check the AC input supply voltage and the battery voltage, and
make sure they match the information on the EVO nameplate. If the
EVO has the Multi-tap option, verify that the AC input jumpers on
the INPUT VOLTAGE SELECTION terminal block are correct for your
AC supply voltage (see Section 2.3.2). Open the front panel, and
check the battery polarity at the DC Output Breaker (CB2).
3.2.3 Powering Up the EVO
When you are sure that all connections to the EVO are properly
made, follow these steps to start up the EVO.
• Turn on (close) the AC Input Circuit Breaker (CB1) first. You
should hear a soft hum from the EVO as the output increases.
• The Main EVO Display should start up and indicate the DC
output voltage. If the display does not light, do not proceed.
Turn off (open) the AC breaker (CB1).
• Check all connections.
NOTICE:
If you attempt to turn on the DC circuit breaker (CB2) first, the DC breaker
may trip due to the filter capacitor in rush.
• Turn on the front panel DC Output Breaker (CB2).
• If any error codes or alarms appear on the Main EVO Display
and/or the Alarm Indicator LEDs, refer to Section 6.0 to
interpret the origin and resolution of the indication before
proceeding.
3.2.4 The EVO Home Screen
The default HOME Screen should now be present on the Main EVO
Display. The DEFAULT Screen will show the DC Bus Voltage and DC
Charger Current.
34
AT SERIES BATTERY CHARGER
3 AT SERIES EVO Startup & Configuration
The HOME screen indicates the CHARGER MODE status and the
active EQUALIZE METHOD on the top line of the display. The top left
of the display will indicate “Float” when the charger is in FLOAT mode
and “Equalize” when the charger is in EQUALIZE mode. The top right
of display will indicate “Eqlz Mthd:” followed either by “Auto” or
“Man”. “Man” will be displayed if the EQUALIZE METHOD is set for
MANUAL TIMER or “Auto” will be displayed if the EQUALIZE METHOD
is set for AUTOMATIC TIMER. The CHARGER MODEs and EQUALIZE
METHODs are described in Section 4.2
The EVO will automatically switch back to the HOME Screen if any
other display screen is active and no buttons have been pushed
within ten minutes. Pressing the ESC button (escape) will return you
to the HOME Screen as well. Each press of the ESC button will return
back one level to the previous screen until you return back to the
HOME Screen.
AT SERIES BATTERY CHARGER
35
3 AT SERIES EVO Startup & Configuration
3.3 Configuring Standard EVO Set Points and
Alarms
The EVO charger is the second generation of the AT charger series.
It was designed such that users of legacy AT battery chargers will
easily be able to adapt to using the new EVO. This section details
how to configure the standard EVO set points and alarms that are
present on legacy AT series chargers. Users of legacy AT chargers
will notice that the configuration button sequence is identical.
3.3.1. Understanding the General Parameter Settings
You can change the settings of the EVO using the front panel controls
while it is operating. The changes you make take effect immediately
and are saved internally. If the EVO is taken out of service (powered
down), and then later returned to service, it restarts using the last
values you set. The standard EVO set points are:
• Float Voltage
• Equalize Voltage
• Equalize Timer
• High DC Voltage Alarm
• Low DC Voltage Alarm
• Current Limit Level
To change any parameter, press the EDIT/ENTER button to enter
the AT Standard Edit Mode. The Main EVO Display will show the
parameter to be edited and the present value. Navigation and
control instruction icons (UP, DOWN, LEFT, RIGHT, ESC, & ENTER)
appear on the bottom, top right and middle right side of the
display. Adjust the parameter by pressing the UP or DOWN key
until the desired value is displayed. Pressing and holding the UP
or DOWN arrow will scroll the value until you release the button.
Each parameter has a minimum and maximum allowable set
point range. Once the endpoint of the allowable set point range is
reached, pushing the UP or DOWN buttons will no longer increment
or decrement the set point value to prevent you from entering a set
point outside of the allowable range. To see what the limits are for
each parameter, refer to the chart in Section 3.2.1.
36
AT SERIES BATTERY CHARGER
3 AT SERIES EVO Startup & Configuration
When you first press the EDIT/ENTER key, the EVO prompts you to
adjust the first parameter in the list (Float Voltage). When you obtain
the value you want on the display, press the EDIT/ENTER key again.
The EVO saves the new setting internally, and then prompts you to
adjust the second parameter. You continue this way to adjust the six
(6) parameters in the list.
If you want to skip adjusting any parameter, press the EDIT/ENTER
(or RIGHT arrow) key again to bypass that parameter. When you
are finished adjusting the sixth parameter (Current Limit), press the
EDIT/ENTER key again. The EVO saves all adjustments you made
internally, switches back to the HOME Screen, and returns to normal
operation.
The new settings take effect immediately. If you do not press any
front panel key for 10 minutes, Edit Mode ends automatically and the
display will return to the HOME Screen. Any change you made to the
last setting will not be stored.
NOTE:
The Standard EVO Set Point mode can also be entered from the Main
Menu by selecting the CHARGER SETTINGS icon.
AT SERIES BATTERY CHARGER
37
3 AT SERIES EVO Startup & Configuration
3.3.2 Setting the Float Voltage
Press the EDIT/ENTER button. The Edit Float Voltage Screen appears.
To skip past the Edit Float Voltage Screen, press the RIGHT arrow
button. To change Float Voltage setting, follow the steps below.
• “Float Voltage” is shown at the top of the display indicating that
you are editing the Float Voltage. The present set point for Float
Voltage will be displayed.
• Press and release the UP or DOWN buttons to adjust the set
point to the desired Float Voltage level.
• Once the desired Float Voltage is displayed, press the EDIT/
ENTER button to store the set point. After pressing EDIT/ENTER,
the display will change to the Edit Equalize Voltage Screen.
• You can now either adjust/verify the Equalize Voltage set point
or press the ESC button to return to the HOME Screen.
38
AT SERIES BATTERY CHARGER
3 AT SERIES EVO Startup & Configuration
3.3.3 Setting the Equalize Voltage
If the Edit Equalize Voltage Screen is presently being displayed
(“Equalize Voltage” on top of display) continue to the instructions
below. If the HOME Screen is presently being displayed, press the
EDIT/ENTER button twice to advance to the Edit Equalize Voltage
Screen.
• “Equalize Voltage” is shown at the top of the display indicating
that you are editing the Equalize Voltage. The present set point
for Equalize Voltage will be displayed.
• Press and release the UP or DOWN buttons to adjust the set
point to the desired Equalize Voltage level.
• Once the desired Equalize Voltage is displayed, press the EDIT/
ENTER button to store the set point. After pressing EDIT/ENTER,
the display will change to the Edit Equalize Timer Screen.
• You can now either adjust/verify the Equalize Timer set point or
press the ESC button to return to the HOME Screen.
AT SERIES BATTERY CHARGER
39
3 AT SERIES EVO Startup & Configuration
3.3.4 Setting the Equalize Timer
If the Edit Equalize Timer Screen is presently being displayed (“Eqlz.
Time(hours)” on top of display) continue to the instructions below. If
the HOME Screen is presently being displayed, press the EDIT/ENTER
button three times to advance to the Edit Equalize Timer Screen.
• “Eqlz Time(hours)” is shown at the top of the display indicating
that you are editing the Equalize Timer. The present set point for
the Equalize Timer will be displayed.
• Press and release the UP or DOWN buttons to adjust the set
point to the desired Equalize Timer timeout.
• Once the desired Equalize Time is displayed, press the EDIT/
ENTER button to store the set point. After pressing EDIT/ENTER,
the display will change to the Edit High DC Voltage Alarm
Screen.
• You can now either adjust/verify the High DC Voltage Alarm set
point or press the ESC button to return to the HOME Screen.
40
AT SERIES BATTERY CHARGER
3 AT SERIES EVO Startup & Configuration
3.3.5 Setting the High DC Voltage Alarm
If the Edit High DC Voltage Alarm Screen is presently being displayed
(“High DC Alarm (V)” on top of display) continue to the instructions
below. If the HOME Screen is presently being displayed, press
the EDIT/ENTER button four times to advance to the Edit High DC
Voltage Alarm Screen.
• “High DC Alarm (V)” is shown at the top of the display indicating
that you are editing the High DC Voltage Alarm. The present set
point for the High DC Voltage Alarm will be displayed.
• Press and release the UP or DOWN buttons to adjust the set
point to the desired High DC Voltage Alarm level.
• Once the desired High DC Voltage Alarm level is displayed, press
the EDIT/ENTER button to store the set point. After pressing
EDIT/ENTER, the display will change to the Edit Low Voltage DC
Alarm Screen.
• You can now either adjust/verify the Low Voltage DC Alarm set
point or press the ESC button to return to the HOME Screen.
AT SERIES BATTERY CHARGER
41
3 AT SERIES EVO Startup & Configuration
3.3.6 Setting the Low DC Voltage Alarm
If the Edit Low DC Voltage Alarm Screen is presently being displayed
(“Low DC Alarm (V)” on top of display) continue to the instructions
below. If the HOME Screen is presently being displayed, press the
EDIT/ENTER button five times to advance to the Edit Low DC Voltage
Alarm Screen.
• “Low DC Alarm (V)” is shown at the top of the display indicating
that you are editing the Low DC Voltage Alarm. The present set
point for the Low DC Voltage Alarm will be displayed.
• Press and release the UP or DOWN buttons to adjust the set
point to the desired Low DC Voltage Alarm level.
• Once the desired Low DC Voltage Alarm level is displayed, press
the EDIT/ENTER button to store the set point. After pressing
EDIT/ENTER, the display will change to the Edit Current Limit
Screen.
• You can now either adjust/verify the Current Limit Level set point
or press the ESC button to return to the HOME Screen.
42
AT SERIES BATTERY CHARGER
3 AT SERIES EVO Startup & Configuration
3.3.7 Setting the Current Limit Level
If the Edit Current Limit Level Screen is presently being displayed
(“Current Limit(A)” on top of display) continue to the instructions
below. If the HOME Screen is presently being displayed, press the
EDIT/ENTER button six times to advance to the Edit Current Limit
Level Screen.
• “Current Limit (A)” is shown at the top of the display indicating
that you are editing the Current Limit Level. The present set
point for the Current Limit Level will be displayed.
• Press and release the UP or DOWN buttons to adjust the set
point to the desired Current Limit level.
• Once the desired Current Limit level is displayed, press the EDIT/
ENTER button to store the set point. After pressing EDIT/ENTER,
the configuration of the Standard EVO Set Points and Alarms is
complete and the display returns to the HOME screen.
AT SERIES BATTERY CHARGER
43
3 AT SERIES EVO Startup & Configuration
3.4 Configuring of Advanced EVO Settings
This Section details the configuration of the new, more advanced
features of the EVO charger and features that may have been
present in the legacy AT series chargers where the configuration
process has been changed or simplified.
3.4.1 Entering Advanced Configuration Mode
To enter the Advanced Settings mode, you need to access the Main
Menu.
• Press the MENU button. The EVO menu selection icons will
appear on the display.
• Use the UP, DOWN, LEFT and RIGHT buttons to navigate to the
ADVANCED SETTINGS icon. Note that there are multiple pages
of icons, observe the arrow(s) at the top right of the display
to determine which direction to scroll to view the next page of
icons.
• Press the EDIT/ENTER button when the ADVANCED SETTINGS
icon is selected (shown in inverse video). The EVO will enter the
Advance Settings Mode and the first page of parameters will be
displayed.
44
AT SERIES BATTERY CHARGER
3 AT SERIES EVO Startup & Configuration
• Navigate through the list of ADVANCED SETTING parameters
using the UP and DOWN arrow buttons. The list of parameters
extends beyond the displayable screen. The scroll bar at the right
of the screen indicates the location within the parameter list.
• To change a parameter, navigate to the parameter using the UP
and DOWN button and select the parameter by pressing the
EDIT/ENTER button.
• Press the LEFT and RIGHT arrow buttons to navigate to the digit
to be modified and press the UP and DOWN button to change
the value of the setting. Once the desired setting is displayed,
press the EDIT/ENTER button to store the set point.
• Press the ESC button to abort the editing process and return to
the previous screen.
3.4.2 Enabling the High Voltage Shutdown
The High Voltage Shutdown control is accessed via the Advanced
Configuration Menu. Refer to Section 4.3 for a description of
the High Voltage Shutdown feature. To change the High Voltage
Shutdown status (enable/disable), follow the steps below.
• From the HOME SCREEN, press the MENU button, navigate to
the ADVANCE SETTINGS icon and then press the EDIT/ENTER
button.
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3 AT SERIES EVO Startup & Configuration
• Press the UP or DOWN button to navigate to the “HVDC
shutdown:” parameter and press the EDIT/ENTER button.
• Press the UP or DOWN button to enable or disable the High
Voltage Shutdown feature and then press the EDIT/ENTER
button to store the setting.
3.4.3 Setting the High Level Detect
The High Level Detect set point is accessed via the Advanced
Configuration Menu. Refer to Section 4.5 for a description of the
High Level Detect feature. To change the High Level Detect set point,
follow the steps below.
• From the HOME SCREEN, press the MENU button, navigate to
the ADVANCE SETTINGS icon and then press the EDIT/ENTER
button.
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• Press the UP or DOWN button to navigate to the “High level
detect” parameter and press the EDIT/ENTER button.
• Press the LEFT or RIGHT buttons to navigate to the digit to
change and the UP or DOWN button to increment or decrement
the set point value. Press the EDIT/ENTER button to store the
new set point value.
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3.4.4 Setting the End of Discharge (EOD) Alarm
The End of Discharge set point is accessed via the Advanced
Configuration Menu. To change the End of Discharge set point,
follow the steps below.
• From the HOME SCREEN, press the MENU button, navigate to
the ADVANCE SETTINGS icon and then press the EDIT/ENTER
button.
• Press the UP or DOWN button to navigate to the “End of
discharge” parameter and press the EDIT/ENTER button.
• Press the LEFT or RIGHT buttons to navigate to the digit to
change and the UP or DOWN button to increment or decrement
the set point value. Press the EDIT/ENTER button to store the
new set point value.
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3.4.5 Setting the Low Voltage Level Detect
The Low Level Detect set point is accessed via the Advanced
Configuration Menu. Refer to Section 4.4 for a description of the Low
Level Detect feature. To change the Low Level Detect set point, follow
the steps below.
• From the HOME SCREEN, press the MENU button, navigate to
the ADVANCE SETTINGS icon and then press the EDIT/ENTER
button.
• Press the UP or DOWN button to navigate to the “Low level
detect” parameter and press the EDIT/ENTER button.
• Press the LEFT or RIGHT buttons to navigate to the digit to
change and the UP or DOWN button to increment or decrement
the set point value. Press the EDIT/ENTER button to store the
new set point value.
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3 AT SERIES EVO Startup & Configuration
3.4.6 Setting the Ripple Alarm
The Ripple Alarm set point is accessed via the Advanced
Configuration Menu. To change the Ripple Alarm set point, follow
the steps below.
• From the HOME SCREEN, press the MENU button, navigate to
the ADVANCE SETTINGS icon and then press the EDIT/ENTER
button.
• Press the UP or DOWN button to navigate to the “Ripple alarm”
parameter and press the EDIT/ENTER button.
• Press the LEFT or RIGHT buttons to navigate to the digit to
change and the UP or DOWN button to increment or decrement
the set point value. Press the EDIT/ENTER button to store the
new set point value.
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3.4.7 Setting the Positive Ground Fault Sensitivity Level
The Positive Ground Fault Sensitivity set point is accessed via the
Advanced Configuration Menu. To change the Positive Ground Fault
Sensitivity set point, follow the steps below.
• From the HOME SCREEN, press the MENU button, navigate to
the ADVANCE SETTINGS icon and then press the EDIT/ENTER
button.
• Press the UP or DOWN button to navigate to the “(+) ground
fault” parameter and press the EDIT/ENTER button.
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3 AT SERIES EVO Startup & Configuration
• Press the LEFT or RIGHT buttons to navigate to the digit to
change and the UP or DOWN button to increment or decrement
the set point value. Press the EDIT/ENTER button to store the
new set point value
3.4.8 Setting the Negative Ground Fault Sensitivity Level
The Negative Ground Fault Sensitivity set point is accessed via the
Advanced Configuration Menu. To change the Negative Ground
Fault Sensitivity set point, follow the steps below.
• From the HOME SCREEN, press the MENU button, navigate to
the ADVANCE SETTINGS icon and then press the EDIT/ENTER
button.
• Press the UP or DOWN button to navigate to the “(-) ground
fault” parameter and press the EDIT/ENTER button.
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• Press the LEFT or RIGHT buttons to navigate to the digit to
change and the UP or DOWN button to increment or decrement
the set point value. Press the EDIT/ENTER button to store the
new set point value.
3.4.9 Enabling the Battery Temperature Compensation
The Battery Temperature Compensation control (TEMPCO) is
accessed via the Advanced Configuration Menu. Refer to Section 9.0
for a description of the Battery Temperature Compensation feature.
To change the Battery Temperature Compensation status (enable/
disable), follow the steps below.
• From the HOME SCREEN, press the MENU button, navigate to
the ADVANCE SETTINGS icon and then press the EDIT/ENTER
button.
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3 AT SERIES EVO Startup & Configuration
• Press the UP or DOWN button to navigate to the “Temp
compensation:” parameter and press the EDIT/ENTER button.
• Press the UP or DOWN button to turn ‘ON’ or turn ‘OFF’ the
Battery Temperature Compensation feature and then press the
EDIT/ENTER button to store the setting.
NOTE:
Turning on the Battery Temperature Compensation feature without a
battery temperature probe connected to EVO will generate a battery
temperature probe failure alarm.
3.4.10 Selecting Battery Type for Temperature Compensation
The Battery Type for Temperature Compensation control (TEMPCO) is
accessed via the Advanced Configuration Menu. Refer to Section 9.0
for a description of the Battery Temperature Compensation feature.
To change the Battery Type for Temperature Compenation, follow the
steps below
• From the HOME SCREEN, press the MENU button, navigate to
the ADVANCE SETTINGS icon and then press the EDIT/ENTER
button.
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• Press the UP or DOWN button to navigate to the “Battery Type:”
parameter and press the EDIT/ENTER button.
• Press the UP or DOWN button to turn scroll through the different
battery chemistries available and press the EDIT/ENTER button
to store the setting when the desired chemistry is in inverse
video.
NOTE:
This setting is irrelevant unless a Battery Temperature Compensation
probe is connected to the EVO, and the probe is enabled.
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3.5 Configuring of the System Settings
This Section details the configuration of the EVO system parameters.
The system parameters include date, time, and the LCD controls
(brightness, contrast, etc.).
3.5.1 Entering System Settings Mode
To enter the System Settings mode, you need to access the Main
Menu.
• Press the MENU button. The EVO menu selection icons will
appear on the display.
• Use the UP, DOWN, LEFT and RIGHT buttons to navigate to the
SYSTEM SETTINGS icon. Note that there are multiple pages
of icons, observe the arrow(s) at the top right of the display
to determine which direction to scroll to view the next page of
icons.
• Press the EDIT/ENTER button when the SYSTEM SETTINGS icon
is selected (shown in inverse video). The EVO will enter the
System Settings Mode and the first page of parameters will be
displayed.
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• Pressing the ESC button while in the System Settings mode will
exit the System Settings mode and return the EVO to the Main
Menu Screen. The System Setting mode will also terminate and
return to the Main Menu Screen automatically after 10 minutes
of inactivity (no button pushes).
• Navigate through the list of SYSTEM SETTING parameters
using the UP and DOWN arrow buttons. The list of parameters
extends beyond the displayable screen. The scroll bar at the right
of the screen indicates the location within the parameter list.
• To change a parameter, navigate to the parameter using the UP
and DOWN button and select the parameter by pressing the
EDIT/ENTER button.
• Press the LEFT and RIGHT arrow buttons to navigate to the digit
to be modified and press the UP and DOWN button to change
the value of the setting. Once the desired setting is displayed,
press the EDIT/ENTER button to store the set point.
• Press the ESC button to abort the editing process and return to
the previous screen.
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3.5.2 Setting the EVO System Time
The System Time setting is accessed via the System Settings Menu.
To change the System Time, follow the steps below.
• From the HOME SCREEN, press the MENU button, navigate
to the SYSTEM SETTINGS icon and then press the EDIT/ENTER
button.
• Press the UP or DOWN button to navigate to the “Time”
parameter and press the EDIT/ENTER button.
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• Press the LEFT or RIGHT buttons to navigate to the digit to
change and the UP or DOWN button to increment or decrement
the time value. Press the EDIT/ENTER button to store the new
time.
NOTE:
The EVO uses a 24 clock. To set a time of 2:30 PM, enter a time of 14:30.
3.5.3 Setting the EVO System Date
The System Date setting is accessed via the System Settings Menu.
To change the System Date, follow the steps below.
• From the HOME SCREEN, press the MENU button, navigate
to the SYSTEM SETTINGS icon and then press the EDIT/ENTER
button.
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• Press the UP or DOWN button to navigate to the “Date:”
parameter and press the EDIT/ENTER button.
• Press the LEFT or RIGHT buttons to navigate to the digit to
change and the UP or DOWN button to increment or decrement
the date value. Press the EDIT/ENTER button to store the new
date.
3.5.4 EVO Display Backlight ON/OFF Control
The LCD Backlight control is accessed via the System Settings Menu.
To change the LCD Backlight setting (ON/OFF), follow the steps
below.
• From the HOME SCREEN, press the MENU button, navigate
to the SYSTEM SETTINGS icon and then press the EDIT/ENTER
button.
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• Press the UP or DOWN button to navigate to the “Backlight:”
parameter and press the EDIT/ENTER button.
• Press the UP or DOWN button to turn ‘ON’ or turn ‘OFF’ the LCD
Backlight and then press the EDIT/ENTER button to store the
setting.
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3.5.5 Adjusting EVO Display Contrast
The LCD Display Contrast setting is accessed via the System Settings
Menu. To change the LCD Display Contrast, follow the steps below.
• From the HOME SCREEN, press the MENU button, navigate
to the SYSTEM SETTINGS icon and then press the EDIT/ENTER
button.
• Press the UP or DOWN button to navigate to the “Contrast:”
parameter and press the EDIT/ENTER button.
• Press the LEFT and RIGHT buttons to navigate to the digit to
change and the UP or DOWN button to increment or decrement
the contrast value. Press the EDIT/ENTER button to store the
new contrast setting.
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3.5.6 Adjusting EVO Display Backlight Brightness
The LCD Display Backlight Intensity setting is accessed via the
System Settings Menu. To change the LCD Display Intensity, follow
the steps below.
• From the HOME SCREEN, press the MENU button, navigate
to the SYSTEM SETTINGS icon and then press the EDIT/ENTER
button.
• Press the UP or DOWN button to navigate to the “Backlight
intensity:” parameter and press the EDIT/ENTER button.
• Press the UP or DOWN button to increment or decrement the
backlight intensity value. Press the EDIT/ENTER button to store
the new intensity setting.
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3.5.7 EVO Display Reverse Image Control
The LCD Display Reverse Image control is accessed via the System
Settings Menu. To change the LCD Display Image preference, follow
the steps below.
• From the HOME SCREEN, press the MENU button, navigate
to the SYSTEM SETTINGS icon and then press the EDIT/ENTER
button.
• Press the UP or DOWN button to navigate to the “lcd color:”
parameter and press the EDIT/ENTER button.
• Press the LEFT and RIGHT buttons to navigate to the digit to
change and the UP or DOWN button to switch the LCD Image
control between normal and inverse modes. Press the EDIT/
ENTER button to store the image control setting.
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3.6 Configuring the EVO Relays
The Standard EVO is equipped with one Common Alarm Relay.
Optional Auxiliary I/O modules are also available which support six
additional relays. The EVO will support up to four optional Auxiliary
I/O modules (24 relays total).
3.6.1 Configuring the Common Alarm Relay
The Common Alarm Relay (or Main Board Relay) has three
configuration parameters that allow the relay:
• To be assigned to a fault condition or status point
• To be assigned a delay period to wait before activating the relay
after the alarm or status condition changes states
• To operate in a latching or non-latching mode
By default, the Common Alarm Relay is configured to indicate the
status of the Common Alarm. This relay configuration may be
changed such that the Main Control Board relay will indicate the
status of any EVO alarm or status state.
If this relay is configured to be “latching”, it will change to the active
state after the configured time delay, and remain in the active state
even if the alarming condition is no longer present. Latched relays
must be cleared manually to ensure that they are acknowledged by
the operator. See Section 6.5 for instructions on how to clear (or
reset) latched relays.
The Common Alarm Relay configuration is accessed via the Relays
Menu. To change the Common Alarm Relay configuration, follow the
steps below.
• From the HOME SCREEN, press the MENU button, navigate to
the RELAYS icon and then press the EDIT/ENTER button.
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3 AT SERIES EVO Startup & Configuration
• Press the UP or DOWN button to navigate to the “Relay
Configuration” parameter and press the EDIT/ENTER button.
• Press the UP or DOWN button to navigate to the “Main board
relay” parameter and press the EDIT/ENTER button.
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• To change the alarm condition assigned to the relay, press the
UP or DOWN button to navigate to the “Fault:” parameter and
press the EDIT/ENTER button.
• Press the UP or DOWN button to navigate to the fault condition
to assign to the Main Control Board relay. The fault list is
multiple pages in length, the scroll bar to the right of the screen
will indicate the position within the list. Press the EDIT/ENTER
button to assign the highlighted fault to the Main Board relay.
• To change the latching status of this relay, press the UP or
DOWN button to navigate to the “Latching:” parameter and
press the EDIT/ENTER button.
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3 AT SERIES EVO Startup & Configuration
• Press the UP or DOWN button to either disable or enable the
latching option and press the EDIT/ENTER button.
• To change the relay time delay, press the UP or DOWN button to
navigate to the “Delay:” parameter and press the EDIT/ENTER
button.
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• Press the LEFT or RIGHT buttons to navigate to the digit to
change and the UP or DOWN button to increment or decrement
the set point value. Press the EDIT/ENTER button to store the
new set point value.
• Pressing the ESC button will return to the previous menu.
Multiple ESC button presses will return the EVO to the HOME
screen.
3.6.2 Configuring the Auxiliary I/O Board Relays
The configuration for the relays on the optional Auxiliary I/O Board
is similar to the Common Alarm Relay configuration on the Main
Control Board. The Auxiliary I/O Board relays have the same three
configuration parameters as the relay on the Main Control Board.
Refer to Section 11.4, the Auxiliary I/O Board Section, for instructions
on how to configure the relays on the Auxiliary I/O Board.
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3.7 Disabling Alarms in the Common Alarm List
The COMMON ALARM by default will activate when any EVO alarm
is active. Alarms can be disabled in the COMMON ALARM list
such that the individual alarm will activate, but it will not cause the
COMMON ALARM to activate. The Common Alarm List configuration
is accessed via the Common Alarm icon in the Main Menu. For
detailed instruction on how to change the Common Alarm List
configuration, refer to Section 5.1.10.
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3.8 Configuring the EVO Serial Adapter
The EVO can support up to three optional Serial Adapter modules.
Each Serial Adapter module:
• can support SCADA protocols (Modbus or DNP3.0)
• can be used in various applications (such as load share)
• can be used as a standard communication interface to connect
to external serial devices.
Instructions on how to configure the Serial Communication Adapters
are specified in the EVO Communications Manual.
3.9 Configuring the EVO Ethernet Adapter
The EVO can support an optional Ethernet Adapter module.
The Ethernet Adapter module:
• can support SCADA protocols (Modbus or DNP3.0).
• will support an AT SERIES EVO web page interface (future).
• will permit a file transfer mechanism to upload/download files
for firmware upgrade and log file transfer (future).
Instructions on how to configure the Ethernet Adapter is specified in
the EVO Communications Manual.
3.10 Enable/Disable the High Level Detect
The AT SERIES EVO has a dedicated hardware circuit that can shut
down the charger should a catastrophic microprocessor failure occur
and the rectifier control gets locked to the full on state.
The Analog High Voltage Shutdown jumper setting determines
whether High Level Detect circuit is enabled or disabled.
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The High Voltage Shutdown jumper (J1) is located center right on the
Main Control Board.
To change the enable/disable status of the High Level Detect circuit:
• Turn both the AC and DC breakers OFF.
• Open the AT SERIES EVO front door.
• Locate the Main Control Board on the AT SERIES EVO door.
• Locate the jumper (J1) labeled “High Level Detect Shutdown”
located on the center right of the Main Control Board.
• Move the jumper shorting block to the desired location:
» ‘EN’ to enable the High Level Detect Shutdown
» ‘DIS’ to disable the High Level Detect Shutdown
• Close the AT SERIES EVO door and turn on both breakers.
Refer to Section 4.4 for more information on the High Level Detect
feature.
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OPERATION OF
THE EVO
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4 Basic Operation of the AT SERIES EVO
4.1 The EVO Display
The EVO Display is a back-lit graphical Liquid Crystal Display (LCD)
that is capable of displaying various font text sizes and graphical
objects. The graphical display, in combination with the front panel
control buttons, provides a powerful user interface that is easy
to use. The various EVO screens include user prompts and user
navigation icons to provide the user with an intuitive and hedonic
experience.
The EVO screens can be grouped, by function, into four basic types:
• HOME screen
• Configuration Screens
• Status Screens
• Hindle Health Screens (HHS)
4.1.1 The EVO HOME Screen
The HOME screen is the primary EVO screen and is active most of the
time the EVO in energized. The only time other screens are displayed
is during configuration changes, during testing, when the user
requests more detailed status than what is provided on the HOME
screen, or when the user wishes to utilize one of the advanced EVO
features.
• The Factory Default HOME Screen displays the DC Voltage and
DC Current in a large font for easy reading.
• “Float” or “Equalize” will appear on the left side of the top of the
display to indicate that the charger is actively in either FLOAT or
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EQUALIZE CHARGE MODE.
• “Eqlz Mthd: Man” or “Eqlz Mthd: Auto” will appear on the right
side of the top of the display to indicate that the EQUALIZE
METHOD is presently configured for MANUAL TIMER or
AUTOMATIC TIMER mode.
• If a Temperature Compensation (TEMPCO) Probe option is
installed and enabled, the present battery temperature and
normalized voltage set point will also appear on the display (see
Section 9 for more details on the TEMPCO option and display).
4.1.2 The EVO Configuration Screens
These screens are used for changing set points and configuration.
Many of these screens were described in the previous “EVO Startup
and Configuration” section. Additional configuration screens for
installed options will be described later in their respective installed
option sections.
4.1.3 The EVO Status Screens
The EVO Status screens do not permit any system changes and are
used only for viewing information. Most of the status screens are
covered in the Advanced EVO Operation Section. Examples of Status
Screens include: the Event Log and Active Alarm list. The HOME
screen can be thought of as a “special” Status Screen in that it can
indicate the DC Voltage, DC Amperes and Equalize/Float mode and
method status.
4.1.4 The Hindle Health System Screens
The Hindle Health System screens are associated with the Hindle
Health button. When the Hindle Health button (HH) is pressed, the
EVO enters a user assisted self-diagnostic mode. The screens prompt
the user to participate in and verify a series of tests that confirm that
the EVO is operating correctly. For more information, refer to the
Hindle Health System section. (see Section 7.0)
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4.2 Standard EVO mode Operation
The EVO operating mode and method selections are primarily
controlled by the three buttons (DISPLAY MODE, CHARGE
MODE, and EQUALIZE METHOD) located on the far left of the
control panel. The advanced features of the EVO are available
via the Main Menu selections which are accessed by pressing
the MENU button. The Main Menu is described in the “EVO
Advanced Operating Mode” Section.
DISPLAY
MODE
ESC
ALARMS
( ALARM RESET )
CHARGE
MODE
( LAMP TEST )
EQUALIZE
METHOD
MENU
4.2.1 Changing the Display Mode
The DISPLAY MODE button selects the HOME Screen display.
Pressing the DISPLAY MODE button will display a list of possible
display modes including:
• DC Voltage and DC Amperes
• DC Amperes (only)
• DC Voltage (only)
• Time and Date
To change the Display Mode, press the DISPLAY MODE button. The
Display Mode screen will appear on the display.
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Use the UP and DOWN ARROW buttons to select the desired
display mode and press the ENTER button. The display mode will be
highlighted when it is selected.
NOTE:
The DISPLAY MODE button is in the same relative location as the METER
MODE button on legacy AT chargers. The functionality is equivalent in that
it determines which measurements are to be shown on the HOME screen.
4.2.2 Changing the Charge Mode
The EVO has two output voltage settings, FLOAT and
EQUALIZE. Use the FLOAT mode for all normal battery charging.
Use the EQUALIZE mode if it is necessary to balance the voltage
among the cells of the battery. Consult your battery data sheets for
information on equalize-charging your battery.
The CHARGE MODE button switches the charger between FLOAT
and EQUALIZE modes. The present charge mode is displayed at the
top left of the HOME screen. “Float” appears when the charger is in
FLOAT mode, “Equalize” appears when the charger is in EQUALIZE
mode.
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4 Basic Operation of the AT SERIES EVO
To change the Charge Mode, press the CHARGE MODE button. The
Charge Mode screen will appear on the display.
Press the UP or DOWN arrow button to highlight the desired mode.
Press the enter button to switch to the desired mode.
When the EVO is placed in EQUALIZE mode, the charger will ramp up
to the EQUALIZE VOLTAGE set point and start the EQUALIZE TIMER.
The display will alternate between showing the HOME screen and a
screen showing the EQUALIZE TIME REMAINING.
The EVO will remain in EQUALIZE mode until either the EQUALIZE
TIMER expires or the charge mode is switched back to FLOAT mode
by accessing the CHARGE MODE display and selecting FLOAT mode.
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NOTE:
The CHARGE MODE button is in the same relative location as the CHGR
MODE button on legacy AT chargers. The functionality is equivalent in
that when pressed, it changes the charge mode between EQUALIZE and
FLOAT modes.
4.2.3 Changing the Equalize Method
The EQUALIZE METHOD button switches the equalize method
between MANUAL TIMER and AUTOMATIC. TIMER The present
equalize method is displayed at the top right of the HOME screen
“Eqlz Mthd: Man” specifies MANUAL TIMER and “Eqlz Mthd: Auto”
specifies AUTOMACTIC TIMER.
To change the Equalize Method, press the EQUALIZE METHOD
button. The Equalize Method screen will appear on the display.
Press the UP or DOWN arrow button to highlight the desired method.
Press the enter button to switch to the desired method.
When the AUTOMATIC TIMER method is selected, the EVO will
automatically switch to EQUALIZE mode and start the EQUALIZE
TIMER after a loss of AC power for greater than 12 seconds. The
EVO will remain in EQUALIZE mode until either the EQUALIZE TIMER
expires or the charge mode is switched back to FLOAT mode by
accessing the CHARGE MODE display and selecting FLOAT mode.
When the MANUAL TIMER method is selected, the charger will only
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4 Basic Operation of the AT SERIES EVO
switch to EQUALIZE MODE when the mode is manually change by
pressing the CHANGE MODE button and EQUALIZE is selected (see
Section 4.2.2).
NOTE:
The EQUALIZE METHOD button is in the same relative location as
the EQLZ MTHD button on legacy AT chargers. The functionality is
equivalent in that when pressed, it changes the equalize method. The
Manual Equalize Method (no timer) available in legacy AT chargers is not
supported by the EVO.
4.2.4 Lamp Test
The EVO has a Lamp Test mode that is activated by pressing and
holding the DOWN arrow button. When activated, the Lamp Test
will turn on all front panel LEDs (except for the AC ON LED) and keep
them on until the DOWN arrow button is released. The AC ON LED is
driven directly by the power supply and is not under software control
but will be lit during normal operating conditions.
When the DOWN arrow button is released, the EVO will briefly
display the firmware versions installed in the charger. The display
will than return to the HOME screen and the EVO will resume normal
operation.
NOTE:
The Lamp Test initiation (press & hold DOWN arrow) and function in the
EVO is identical to the Lamp Test on legacy AT series chargers.
4.2.5 Resetting Latched Relays (legacy method)
Latched relays can be RESET (or cleared) by pressing and holding the
UP arrow button. Press and hold the UP arrow until the AT SERIES
EVO displays the RESET LATCHED ALARMS confirmation screen.
NOTE:
The Reset Latched Alarms initiation (press & hold UP arrow) and function
on the AT SERIES EVO is identical to the Reset Latching Alarms on legacy
AT series chargers. Individual relays can be RESET or cleared or all relays
can also be RESET or cleared via the RELAYs menu. See Section 6.5 for
details on how to reset latched alarm relays via the RELAYS menu icon.
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4.3 High Voltage Shutdown
The EVO has a High Voltage Shutdown feature similar to the High
Voltage Shutdown feature in legacy AT chargers. The High Voltage
Shutdown is a software feature whereby the Main Control Board
monitors the DC voltage and will turn off the output drivers (rectifier
controllers) if the DC output voltage is too high.
The set point for the High DC Voltage Alarm is used as the threshold
for initiating the High Voltage Shutdown. The output voltage must
rise above the High DC Voltage Alarm set point and remain above
the set point for 30 seconds in order for the Shutdown to occur. If
a High Voltage Shutdown does occur, the High Voltage Shutdown
Alarm and the Common Alarm Relay is activated. Once the
shutdown occurs, the charger must be restarted (turn off both AC
and DC breakers) to clear the shutdown condition. The charger will
not turn on the rectifier controls until it is reset.
The High Voltage Shutdown feature can be enabled or disabled.
Refer to Section 3.4.2 for instructions on how to enable or disable
the High Voltage Shutdown feature.
NOTE:
The EVO has a hardware High Level Detect feature as well. Refer
to Section 4.5 for more information on the High Level Detect
hardware shutdown.
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4.4 Low Level Detect
The EVO has a Low Level Detect feature similar to the Low Level
Detect feature in legacy AT chargers. The Low Level Detect feature
is a dedicated hardware circuit that detects if the DC Bus voltage is
below a configurable set point. If the DC voltage drops below the set
point threshold, the Low Level Detect circuit will force the Common
Alarm Relay to the alarmed state.
The Low Level Detect circuit functions independent of microprocessor
control. It will trigger the Common Alarm if a catastrophic
microprocessor failure should occur to indicate that the DC Bus
voltage is critically low and immediate attention is required. The Low
Level Detect circuit includes a dedicated Analog Low Level alarm LED
that illuminates if the Low Level Detect condition is triggered.
The Analog Low Level alarm LED is on the Main Control Board. You
will need to open the EVO door to view the Analog Low Voltage
Alarm LED.
Refer to Section 3.4.5 for instructions on how to configure the
threshold for the Low Level Detect feature.
4.5 High Level Detect
The EVO High Level Detect has a dedicated hardware circuit that
detects if the DC Bus voltage is above a configurable set point. If
the DC voltage rises above the set point threshold for more than 30
seconds, the circuit disables the output drivers (rectifier controllers)
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and forces the Common Alarm Relay to the active state.
The High Level Detect is a true failsafe feature in that it can shut
down the charger by disabling the rectifier control signals. This
circuit works independent of the microprocessor and will override the
rectifier control. The High Level Detect will shut down the charger
output circuitry should a catastrophic microprocessor failure occur,
turning the rectifier to the full on condition.
If the High Level Detect shutdown occurs, the circuit latches until the
charger is restarted (by turning of both the AC and DC breakers).
The High Level Detect circuit has a dedicated Analog High Level
Detect Shutdown alarm LED that illuminates if the High Level Detect
condition is triggered. The Analog High Voltage Shutdown alarm LED
is on the Main Control Board. You will need to open the EVO door to
view the Analog High Voltage Shutdown alarm LED.
The High Level Detect circuit and associated shutdown can be
enabled or disabled. Refer to Section 3.10 for instructions on how
to enable or disable the High Level Detect feature. Refer to Section
3.4.3 for instructions on how to configure the threshold for the High
Level Detect feature
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5. ADVANCED
OPERATION OF
THE EVO
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5 Advanced Operation of the AT SERIES EVO
5.1 The EVO Main Menu
Press the “MENU” button to access the Main Menu. The first six
menu selection icons appear on the screen. Use the UP, DOWN,
LEFT, or RIGHT arrow buttons to navigate through the menu
selections. The icons appear in inverse video when they are selected.
The top of the screen indicates the Main Menu is being displayed
and to the far right of “Main Menu” an up and/or down arrow icon is
displayed. The arrow icon(s) indicate that more menu selection icons
are available if you continue to navigate in the direction of the arrow.
If a down arrow navigation icon is displayed, and either of the menu
icons on the bottom are presently selected, pressing the DOWN
arrow button again will display the next three menu icons.
Pressing the EDIT/ENTER button will activate the selected feature or
function. Pressing the ESC button will return back one menu level.
If the Main Menu is being displayed and the ESC button is pressed,
the display will return to the HOME screen. If you have selected
and entered the SYSTEM SETTINGS mode, pressing the ESC button
while in the SYSTEM SETTINGS screen will return to the Main Menu.
Pressing ESC again will return to the HOME screen.
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5.1.1 The Basic Settings Icon
When selected, this icon initiates the Basic EVO Set
Points and Alarms screens. These Set Points are the
typical legacy AT settings. The display will change to
the first configuration screen (EDIT FLOAT VOLTAGE)
of the Basic EVO Set Points and Alarms screens (see
Section 3.3.2 for details and instructions on how to proceed with
the Basic EVO configurations). The display will return back to the
Main Menu when all Basic EVO Set Points and Alarms have been
configured or if the ESC button is pressed any time during the editing
process.
Selecting the Basic Settings icon is equivalent to pressing the EDIT/
ENTER button while the HOME screen is being displayed. The direct
path to Basic EVO Set Points and Alarms screens from the HOME
screen is supported to ensure backward operation compatibility with
legacy AT series chargers.
5.1.2 The Advanced Settings Icon
When selected, this icon initiates the EVO Advanced
Configuration screens. The EVO will enter the Advance
Settings Mode and the first page of parameters
will be displayed. See Section 3.4.1 for details and
instructions on how to proceed with the advanced
setting configurations. The display will return back to the Main Menu
when the ESC button is pressed any time during the editing process.
5.1.3 The System Settings Icon
When selected, this icon initiates the EVO System
Settings Configuration screens. The EVO will enter
the System Settings Mode and the first page of
parameters will be displayed. See Section 3.5.1 for
details and instructions on how to proceed with the
system setting configurations. The display will return back to the
Main Menu when the ESC button is pressed any time during the
editing process.
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5.1.4 Save|Reset Configuration Icon
When selected, this icon initiates the EVO Backup/
Restore controls. The display will change to show
the backup and restore controls. An optional SD
memory card is required to store the EVO settings.
All configuration set points, alarm thresholds, and
communication settings can be stored on the SD memory card. The
SD card can be removed and inserted into another charger and
the configuration can be stored in to the new charger. This allows
a charger’s settings to be cloned to another charger automatically
eliminating the need to re-enter the configuration manually.
For more details on backing up and restoring the EVO configuration,
see Section 5.5 – Using the Optional SD Memory Card. Press the
ESC button to return to the Main Menu.
5.1.5 The Relays Icon
When selected, this icon initiates the EVO Relay
Configuration and Control options. The display will
change to a page with selections to configure the
relays and reset or clear any latched alarm relays.
To change a relay configuration, select “Relay configuration” and
press the EDIT/ENTER button. The screen will change to a list of all
available relays. Select the desired relay and press the EDIT/ENTER
button to view and edit the selected relay’s parameters. Refer to
Section 3.6 for details on changing the Main board relay parameters
and Section 11.4 for details on changing the Auxiliary Board relay
parameters.
See Section 6.5 for details on how to reset latched alarm relays.
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5.1.6 The Event Logs Icon
When selected, this icon initiates the EVO Event Log
functions. The display will change to the Event Logs
functions page with selections for viewing logged
events and utilities for copying the logs to the SD
memory card and clearing all events stored. Refer to
Section 8.0, EVO Event Logs for details on the event logging features
and controls.
5.1.7 The System information Icon
When selected, this icon initiates the EVO System
Information screens. The display will change to the
first page of the EVO system status. Follow the
navigation instructions displayed at the top right of
the screens to scroll through the EVO status pages.
Press the ESC button after viewing the System Information to return
to the Main Menu.
5.1.8 The Security Icon
When selected, this icon initiates the EVO password
setup and logon screens. The display will change
to the main Security Screen with a list of security
functions. Refer to Section 5.4 – Security and
Passwords for more details on how to implement the
security features of the EVO. Press the ESC button to return to the
Main Menu.
5.1.9 The Communications Icon
When selected, this icon initiates the EVO
Communication ports configuration. The EVO is
capable of supporting three serial communication
ports and one Ethernet port. Communication
ports are optional and may not be included with
the EVO. The display will show all communication ports as well as
whether or not they are assigned and configured. Two of the serial
communication ports support Modbus and DNP3.0 communications.
Refer to the supplementary EVO Communications manual for details
on how to configure these ports. Press the ESC button after viewing
the System Information to return to the Main Menu.
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5.1.10 The Common Alarm Icon
When selected, this icon permits alarms to be
excluded from the Common Alarm activation list. By
default, all alarms, when active, will annunciate the
Common Alarm. If it is desired to prevent an alarm
from annunciating the Common Alarm, follow the
instructions below to disable the selected alarm from activating the
Common Alarm.
• From the HOME SCREEN, press the MENU button, navigate
to the COMMON ALARM icon and then press the EDIT/ENTER
button.
• Press the UP or DOWN button to navigate through the list of
EVO alarms. The alarm list is multiple pages in length, the scroll
bar to the right of the screen will indicate the position within the
list.
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• Press the EDIT/ENTER button while an alarm is highlighted to
change the status of whether or not that alarm will activate the
COMMON ALARM. If an ‘[X]’ appears in the box to the left of
the alarm name, the alarm will activate the COMMON ALARM.
If ‘[ ]’ appears in the box to the left of the alarm name, the alarm
will not activate the COMMON ALARM.
• Pressing the ESC button will return to the previous menu.
Multiple ESC button presses will return the EVO to the HOME
screen.
5.1.11 The AUX Inputs Icon
When selected, this icon initiates the EVO Binary
Input and Analog Input configurations. The EVO
is capable of supporting up to four Auxiliary I/O
boards with each board containing a total of four
generic binary inputs and four generic analog inputs.
Auxiliary I/O boards are optional and may not be included with the
EVO. The display will have a selection for binary inputs and analog
inputs. Refer to the Section 11.5 for detailed instructions on how to
configure the binary inputs and Section 11.6 for detailed instructions
on how to configure the analog inputs. Press the ESC button to
return to the Main Menu.
5.1.12 The Testing Icon
When selected, this icon displays the Open Battery
Test configuration and controls. Refer to Section 6.6
for details and instruction on how to start, schedule,
and set up the parameters for the Open Battery Test.
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5.2 The EVO Alarm Button
When pressed, the ALARM button initiates the EVO Active Alarm
screen. The display will change to show the Active Alarm List. All
active alarm conditions are reported on the Active Alarm List. The
Active Alarm screen can only display four alarm conditions per page.
If more than four alarms are active use the UP and/or DOWN arrow
buttons to scroll through the list.
Not all EVO alarms have a dedicated LED alarm indicator on the
front panel. Alarms without a dedicated LED alarm indicator will
light the COMMON alarm LED on the front panel. Press the ESC
button when you have finished reviewing the Active Alarm List to
return to the Main Menu.
5.3 The EVO Health Button
When pressed, the HEALTH button initiates the EVO Hindle Health
System (HHS) screens. The Hindle Health System utilizes a sequence
of interactive screens that prompts the user through a series of tests
that verify that the charger is working properly. The Hindle Health
System will verify set points, test alarms and relays, verify calibration,
and test hardware.
Step by step instructions are provided on each screen for any
interaction required by the user. The results of the tests are logged
along with a time and date stamp. The health test can be aborted
at any point by pressing the ESC button. For more information and
detailed instructions on how to run the Hindle Health System health
test, refer to Section 7.0.
5.4 Security and Passwords
The EVO provides protection from unauthorized users from modifying
charger set points, accessing critical features, and changing alarm
settings. This protection is implemented by assigning and enabling
passwords to authorize access to different levels of the EVO
functionality.
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5.4.1 Three (3) Levels of Password Protection
The EVO incorporates three (3) levels of password authorization:
READ, READ/WRITE and ADMINISTRATOR. Each authorization level
requires a unique password to access the functions and features
associated with that level.
The READ authorization level is the lowest privilege level and permits
access to viewing the charger’s data and status. All measurements
and set points may be observed and verified but no configuration
changes are permitted.
The READ/WRITE authorization level is the mid privilege level.
This level permits access to viewing the charger’s data and status
as in the READ level, but also permits changing the charger’s
configuration and all set points except for passwords.
The ADMINISTRATOR level is the highest privilege level. This level
permits access to all functions and features in both the READ
and READ/WRITE privilege levels plus allows the passwords to be
changed. The ADMINISTRATOR level permits access to all EVO
charger features.
5.4.2 Accessing the Security Features and Password
Configuration
Each of the three (3) authorization levels has a unique password.
Each password is composed of a text string of up to 14 characters.
By default, the DEFAULT ACCESS level is ADMINISTRATOR. As stated
in the previous section, you will need ADMINISTRATOR privilege
to change any password or change the DEFAULT ACCESS level. To
access the security features and password configuration:
• Press the MENU button. The menu selection icons will appear on
the display.
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5 Advanced Operation of the AT SERIES EVO
• Use the UP, DOWN, LEFT and RIGHT buttons to navigate to the
SECURITY icon. Note that there are multiple pages of icons,
observe the arrow(s) at the top right of the display to determine
which direction to scroll to view the next page of icons.
• Press the EDIT/ENTER button when the SECURITY icon is selected
(shown in inverse video).
The EVO Security Screen will appear and prompt you to choose from
one of the security and password configuration selections.
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5.4.3 Setting the EVO Passwords
To change the passwords, use the UP and DOWN arrow buttons
to navigate to and select the “Set Passwords” feature. Press the
EDIT/ENTER button. The screen will change to display the three (3)
password authorization levels.
Use the UP and DOWN arrow buttons to navigate to and select the
READ password privilege level. Press the EDIT\ENTER button to view
the password configuration screen for the READ privilege level.
Use the UP and DOWN arrow buttons to scroll though the choices
for the first character of the password. When the desired character
is being displayed, press the RIGHT arrow button to move on to the
next character. Continue this procedure until the desired password
has been created. When the password had been created press the
EDIT/ENTER button to store the new password.
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NOTE: If you do not have ADMINISTRATOR privilege (the DEFAULT
ACCESS level is NOT set as ADMINISTRATOR or you are NOT logged
in with ADMINISTARTOR privilege), you will not be able to change the
passwords.
Use the same procedure to configure the READ/WRITE and
ADMINISTRATOR passwords by selecting them from the “Select
Access Level” Menu.
5.4.4 Setting the Default Access
The DEFAULT ACCESS setting determines the authorization and
password level when there is no log in. If you do not wish to
implement any password security, the DEFAULT ACCESS should be
set to ADMINISTRATOR, this is the default factory setting.
To change the DEFAULT ACCESS, use the UP and DOWN arrow
buttons to navigate to and select the “DEFAULT ACCESS” feature.
Press the EDIT/ENTER button. The screen will change to display the
three (3) password authorization levels.
Use the UP and DOWN arrow buttons to navigate to and select
the desired DEFAULT ACCESS privilege level. Press the EDIT\ENTER
button to set the selected privilege level as the default level (this will
be the authorization level when there is no log in).
NOTE: An ADMINISTRATOR password must be assigned before the
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DEFAULT ACCESS can be changed. If you do not have ADMINISTRATOR
privilege (the DEFAULT ACCESS must be set as ADMINISTRATOR or you a
must be logged in with ADMINISTRATOR privilege), you will not be able
to change the DEFAULT ACCESS.
5.4.5 Logging In to a Password Authorization Level
If you attempt to access a feature or change a parameter that is
configured at a higher privilege level than the DEFAULT ACCESS level
(or the present log in level), the EVO will prevent the action. You
will need to log in at the configured privilege level (or higher) to be
authorized to access the feature.
To LOG IN to a privilege level, use the UP and DOWN arrow buttons
to navigate to and select the “LOG IN” feature. Press the EDIT/
ENTER button. The screen will change to display the three (3)
password authorization levels.
Use the UP and DOWN arrow buttons to navigate to and select the
desired privilege level to log in to. Press the EDIT\ENTER button to
view the password entry screen for the associated privilege level.
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Use the UP and DOWN arrow buttons to scroll though the choices
for the first character of the password. When the correct character
is being displayed, press the RIGHT arrow button to move on to
the next character. Continue this procedure until the entire correct
password has been created. When the password had been created
press the EDIT/ENTER button to submit the password.
If the password you entered is correct, you will receive an
acknowledgement that you successfully logged into the new privilege
level and all features that are authorized for that privilege level will
become functional. The EVO will continue to allow access to all
features at the logged in privilege level as long as there is activity
(button presses). If there is no activity for more than ten minutes, the
EVO will automatically switch back to the DEFAULT ACCESS level.
If the password you entered is incorrect, you will not be authorized to
access the features in the new privilege level.
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5.4.6 Logging Out
In order for the password security features of the EVO to be secure,
it is necessary to log out after you have completed any operations
that require a higher privilege level. If you do not log out of the
higher privilege level, all protected operations will still be available
for anyone to access. When the LOG OUT operation is executed, the
EVO will return back to the DEFAULT ACCESS privilege level.
NOTE: The EVO will automatically log out of an authorization level that
was logged in to after ten minutes of inactivity.
To LOG OUT of the present privilege level, use the UP and DOWN
arrow buttons to navigate to and select the “LOG OUT” feature.
Press the EDIT/ENTER button. The screen will display a brief
message confirming that you successfully “logged out” of the present
privilege level and the screen will return to the Main Menu.
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5.5 – Features Supported By the Optional SD
Memory Card
The EVO provides a socket for an Optional SD Memory Card. The
socket is located on the top left of the back of the Main Control
Board. To access the SD Memory Card socket, open the EVO front
panel and locate the Main Control Board attached to the door.
5.5.1 The SD Memory Card
The optional SD Memory card should be purchased as an EVO
accessory from the supplier of the EVO battery charger. Although
the SD card format is standard, there are subtle differences between
different manufactures. Purchasing the SD card through your EVO
supplier will ensure that the SD card has been tested and verified to
work with the EVO charger.
When installing the SD Memory Card into the Main Control Board,
make sure the contacts are facing down and toward the Main
Control Board (door) when inserting the SD Memory Card in to
the socket. Gently press the card into the socket until you feel the
card locking mechanism “click”. To remove the SD Card, gently
press the card further into the socket and then allow it to “snap”
back to disengage the card locking mechanism. Once the card is
disengaged, you can gently pull the card from the socket.
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5.5.2 Storing the Event Log File to the SD Memory Card
The EVO Event Log can be transferred on to the SD Memory Card.
The Event Log can then be transferred to a Personal Computer (PC)
or other electronic device for archiving or evaluation. The file is
stored in an ASCII text file format such that the events cans easily be
imported into spreadsheets or other third party software.
To copy the Event Log to the SD Memory Card:
• Insert an EVO compatible SD Memory Card into the socket on
the Main Control Board.
• Press the MENU button. The menu selection icons will appear on
the display.
• Use the UP, DOWN, LEFT and RIGHT buttons to navigate to the
EVENT LOGS icon. Note that there are multiple pages of icons,
observe the arrow(s) at the top right of the display to determine
which direction to scroll to view the next page of icons.
• Press the EDIT/ENTER button when the EVENT LOGS icon is
selected (shown in inverse video).
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• The Event Log Operations screen will appear. Use the UP and
DOWN arrow buttons to navigate to the “Copy event log to SD
card” selection. Press the EDIT/ENTER button to copy the event
log file.
The screen will briefly display a message to confirm the file was
copied successfully. The event log file will be written to a file named
ATgvaixx.LOG where:
• ‘g’ specifies the charger family (1) <= 25 A,( 2) > 25A, (3) = 3
phase
• ‘v’ specifies the voltage (A) = 12VDC, (B)= 24VDC, (C) = 48VDC,
(D) = 130VDC, (E) = 260VDC
• ‘a’ specifies the current (A) = 6ADC, (B) = 12 ADC, (C) = 16ADC,
(D) = 20ADC, (E) = 25ADC
• ‘i’ specifies the charger iD (A-Z) - this is specified at the end of
the SYSTEM INFO menu
• ‘xx’ specifies a sequential assigned number
Each time the event log file is stored it will be written to a new file on
the SD Memory card whereby the ‘xx’ number is incremented by one.
This prevents previous event log files stored on the SD Memory Card
from being overwritten.
5.5.3 Storing and Recalling the Configuration Settings to/from
the SD Memory Card
All of the EVO configuration settings can be stored on to the SD
Memory Card. The configuration includes voltage and current
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set points, alarm thresholds, relay configuration and all other
configuration.
To copy the EVO Configuration to the SD Memory Card:
• Insert an EVO compatible SD Memory Card into the socket on
the Main Control Board.
• Press the MENU button. The menu selection icons will appear on
the display.
• Use the UP, DOWN, LEFT and RIGHT buttons to navigate to the
SAVE:RESET SETTINGS icon. Note that there are multiple pages
of icons, observe the arrow(s) at the top right of the display
to determine which direction to scroll to view the next page of
icons.
• Press the EDIT/ENTER button when the SAVE:EVENT SETTINGS
icon is selected (shown in inverse video).
• The Backup/Restore Settings screen will appear. Use the UP and
DOWN arrow buttons to navigate to the “Backup to Memory
Card” selection. Press the EDIT/ENTER button to copy the
configuration file.
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The screen will briefly display a message to confirm the file was
copied successfully. The configuration file will be written to a file
named ATgvai00.EVO where:
• ‘g’ specifies the charger family (1) <= 25A,( 2) > 25A, (3) = 3
phase
• ‘v’ specifies the voltage (A) = 12VDC, (B)= 24VDC, (C) = 48VDC,
(D) = 130VDC, (E) = 260VDC
• ‘a’ specifies the current (A) = 6ADC, (B) = 12 ADC, (C) = 16ADC,
(D) = 20ADC, (E) = 25ADC
• ‘i’ specifies the charger ID (A-Z) - this is specified at the end of
the SYSTEM INFO menu
This configuration file can be used to restore the saved configuration
in case someone inadvertently changes a setting and doesn’t
remember the original setting. It can also be used to clone the
configuration in to a similar charger to eliminate the need to setup
the parameters manually. Lastly it can be used to configure a new
Main Control Board automatically in case you ever need to replace
the existing one.
To copy the EVO Configuration from the SD Memory Card on to the
Main Control Board:
• Insert an EVO compatible SD Memory Card into the socket on
the Main Control Board.
• Press the MENU button. The menu selection icons will appear on
the display.
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• Use the UP, DOWN, LEFT and RIGHT buttons to navigate to the
SAVE:RESET SETTINGS icon. Note that there are multiple pages
of icons, observe the arrow(s) at the top right of the display
to determine which direction to scroll to view the next page of
icons.
• Press the EDIT/ENTER button when the SAVE:RESET SETTINGS
icon is selected (shown in inverse video).
• The Backup/Restore Settings screen will appear. Use the UP and
DOWN arrow buttons to navigate to the “Restore from Memory
Card” selection. Press the EDIT/ENTER button to copy the
configuration file.
The screen will briefly display a message to confirm the file was
copied successfully. The charger will then RESET and restart with the
restored configuration settings.
5.5.4 Upgrading the Main Control Board Firmware via the SD
Memory Card
One of the powerful and convenient new features of the EVO charger
is that the Main Control Board firmware (or software) can be easily
updated in the field without uninstalling the charger or any boards.
New features and firmware upgrades can be easily loaded in to the
charger in minutes.
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The first step in upgrading the EVO is to obtain the latest program
files from your EVO battery charger supplier. There are two
programing files used by the EVO:
• Mainapp.bin is the Main Control Application program
• Bruno.bin is the Display Application program
These programs can be updated independently or together at the
same time.
Once you obtain the latest firmware version of these files, you
will need to store them on to the SD Memory Card. This can be
accomplished by copying them on to the SD Card with a Personal
Computer (PC) that has a SD Memory Card slot, or by means of a
USB to SD Memory Card adapter. After the file(s) are present on
the SD Memory Card you will need to transfer them in to the EVO
charger.
• Open the charger door and locate the SD Memory Card socket
on the back of the Main Control Board.
• Directly below the socket will be a “RE-FLASH ENABLE JUMPER”.
Move the shorting block on the jumper to the “PRGM”
programming position.
• Insert the EVO compatible SD Memory Card with the program
files into the socket on the Main Control Board.
• Find the RESET button (SW13) located 3 inches directly below the
RE-FLASH JUMPER.
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• Press the RESET button and observe the display on the Main
Control Board. The following message should appear (assuming
you have the Mainapp.bin file stored on the SD Card).
• Select “YES” to upgrade the Main Application program. A
message will appear on the main display confirming that the
Main Application program has been updated.
• If the SD Memory Card has the Bruno.bin file stored on it, the
display will next prompt you to upgrade the Display Application
program.
•
• Select “YES” to upgrade the Display Application program. A
message will appear on the main display confirming that the
Display Application has been updated.
• The charger will reset and prompt again to upgrade the Main
Application program.
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• Move the RE-FLASH JUMPER shorting block back to the
“NORM”, normal operating position and press the RESEST
button.
• The charger will re-boot and when it restarts, it will be running
the new program(s) you installed.
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6. EVO ALARMS &
INDICATORS
AT SERIES BATTERY CHARGER
6 AT SERIES EVO Alarms & Indicators
6.1 EVO Legacy Alarms and Indicators
The EVO alarms can be divided in to two groups, the Legacy AT
Alarms and the Advanced Alarms.
The EVO Legacy Alarm group is a superset of the standard alarm
group recommended by the NEMA and IEEE standards (PE5) for
stationary battery chargers. These alarms have dedicated front
panel LED indicators and are referred to as legacy alarms since they
have the same functionality as the standard alarms available on
legacy AT10 and AT30 series battery chargers.
AC ON
HIGH DC VOLTAGE
LOW DC VOLTAGE
DC OUTPUT FAILURE
SCAN TO VIEW :
AC INPUT FAILURE
MANUAL
POSITIVE (+) GROUND
STANDARD
DRAWINGS
NEGATIVE (-) GROUND
SERVICE
INSTRUCTIONS
COMMON ALARM
ATSERIES.NET
6.1.1 AC ON Indicator
The AC ON LED indicator is illuminated when the Main Control Board
senses AC power. This green LED will be illuminated when AC power
is present on CB1 (the AC input breaker) and CB1 is closed.
6.1.2 High DC Voltage Alarm
The red High DC Voltage LED will illuminate when the High DC
Voltage alarm is active. The High DC Voltage alarm is activated
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when the DC Bus voltage sensed by the Main Control Board is higher
than the High DC Voltage alarm set point. The High DC Voltage set
point is configurable; refer to Section 3.3 for instructions on how
to adjust the alarm set points.
The High DC Voltage alarm will activate the Common Alarm relay.
The Common Alarm relay will change to the alarmed state after
a configured time delay. The High DC Voltage alarm will also be
reported by any installed optional protocol communication board
and may also be configured to activate a discrete relay on optional
Auxiliary I/O boards. Refer to Section 11 for instructions on how to
configure the relays.
6.1.3 Low DC Voltage Alarm
The red Low DC Voltage LED will illuminate when the Low DC Voltage
alarm is active. The Low DC Voltage alarm is activated when the
DC Bus voltage sensed by the Main Control Board is lower than the
Low DC Voltage alarm set point. The Low DC Voltage set point is
configurable; refer to Section 3.3 for instructions on how to adjust
the alarm set points.
The Low DC Voltage alarm will activate the Common Alarm relay.
The Common Alarm relay will change to the alarmed state after
a configured time delay. The Low DC Voltage alarm will also be
reported by any installed optional protocol communication board
and may also be configured to activate a discrete relay on optional
Auxiliary I/O boards. Refer to Section 11 for instructions on how to
configure the relays.
6.1.4 DC Output Failure Alarm
The red DC Output Failure LED will illuminate when the DC Output
Failure alarm is active. The DC Output Failure alarm is activated
when the charger cannot support the connected load. This condition
occurs if the DC Bus voltage is below the desired set point voltage
and the charger is NOT in current limit. Possible causes of this alarm
include an improperly tapped AC input or a defective rectifier. The
criteria for this alarm are not configurable.
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The DC Output Failure alarm will activate the Common Alarm relay.
The Common Alarm relay will change to the alarmed state after a
configured time delay. The DC Output Failure alarm will also be
reported by any installed optional protocol communication board
and may also be configured to activate a discrete relay on optional
Auxiliary I/O boards. Refer to Section 11 for instructions on how to
configure the relays.
6.1.5 AC Input Failure Alarm
The red AC Input Failure LED will illuminate when the AC Input Failure
alarm is active. The AC Input Failure alarm is activated when the
AC input voltage is detected to be below 75% of nominal. Possible
causes of this alarm include an improperly tapped AC input or a
missing phase. The criteria for this alarm are not configurable.
The AC Input Failure alarm will activate the Common Alarm relay.
The Common Alarm relay will change to the alarmed state after
a configured time delay. The AC Input Failure alarm will also be
reported by any installed optional protocol communication board
and may also be configured to activate a discrete relay on optional
Auxiliary I/O boards. Refer to Section 11 for instructions on how to
configure the relays.
6.1.6 Positive Ground Fault Alarm
The red Positive Ground Fault LED will illuminate when the Positive
Ground Fault alarm is active. The Positive Ground Fault alarm is
activated when the Main Control Board senses a leakage path from
the positive DC Bus (DC+) to earth ground. The leakage impedance
required to trigger the alarm is configurable; refer to Section 3.4
for instructions on how to adjust the alarm set points.
The Positive Ground Fault alarm will activate the Common Alarm
relay. The Common Alarm relay will change to the alarmed state
after a configured time delay. The Positive Ground Fault alarm will
also be reported by any installed optional protocol communication
board and may also be configured to activate a discrete relay on
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optional Auxiliary I/O boards. Refer to Section 11 for instructions
on how to configure the relays.
6.1.7 Negative Ground Fault Alarm
The red Negative Ground Fault LED will illuminate when the Negative
Ground Fault alarm is active. The Negative Ground Fault alarm is
activated when the Main Control Board senses a leakage path from
the negative DC Bus (DC-) to earth ground. The leakage impedance
required to trigger the alarm is configurable; refer to Section 3.4
for instructions on how to adjust the alarm set points.
The Negative Ground Fault alarm will activate the Common Alarm
relay. The Common Alarm relay will change to the alarmed state
after a configured time delay. The Negative Ground Fault alarm will
also be reported by any installed optional protocol communication
board and may also be configured to activate a discrete relay on
optional Auxiliary I/O boards. Refer to Section 11 for instructions
on how to configure the relays.
6.2 EVO Common Alarm Indicator
The red Common Alarm LED will illuminate when any EVO alarm
(legacy alarms and/or advanced alarms) is active. With the
exception of the six legacy alarms mentioned in the previous Section,
the EVO alarms do not have individual LED indicators. The Common
Alarm LED is used to indicate that one or more of these alarms are
active.
When the Common Alarm is active, the Common Alarm relay on
the Main Control Board will change to the alarmed state after a
configured time delay. The Common Alarm will also be reported by
any installed optional protocol communication board and may also
be configured to activate a discrete relay on optional Auxiliary I/O
boards. Refer to Section 11 for instructions on how to configure
the relays.
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6.2.1 Configuring The Common Alarm
By default, all EVO alarms when active are configured to annunciate
the Common Alarm. In some applications, it may be desirable to
prevent an EVO alarm from triggering the common alarm. As an
example, by default the current limit alarm will trigger the Common
Alarm. Any alarm can be individually removed from the list of alarms
that, when active, will trigger a Common Alarm. The Common Alarm
configuration is described in detail in Section 5.1.10
6.3 Active Alarm Bar, Alarm View, and Alarm Log
6.3.1 The Active Alarm Bar
The Active Alarm Bar is located at the bottom of the Home Screen.
Any and all active alarms will be reported at the bottom of the Home
Screen. If multiple alarms are active, the Active Alarm Bar will cycle
through and display each alarm. If no alarms are active, the Active
Alarm Bar portion of the Home Screen will be blank.
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6.3.2 The Active Alarm List
The Active Alarm List displays all active alarms. To view the Active
Alarm List, press the ALARM button.
The Active Alarm List can display up to four active alarms at one
time. If more than four alarms are active, use the ARROW buttons
to scroll through the list. Press the ESC button to return to the Home
Screen
6.3.3 The Alarm Logs
All alarms are considered system events and are stored in the EVO
event log. When an alarm becomes active, it is entered into the log
along with a time and date stamp. The clearing (return to non-alarm
state) of any alarm is also considered a system event. The clearing
of any and all alarms are entered in the EVO log along with the time
and date of when the alarm was cleared. Refer to Section 8.0 for
more information on the EVO logging feature.
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6.4 EVO Advanced Alarms
The EVO contains a wealth of alarming features. In an effort to
provide the utmost in flexibility and expansion capability and yet
maintain ease of use, the alarming features have been split in to
two groups; the Legacy Group and the Advanced Group. The Legacy
Alarms have been described earlier in this Section.
The following Advanced Alarms do not have dedicated LEDs to
indicate when they are active. When active, the Advanced Alarms
will illuminate the COMMON ALARM LED. The Advanced Alarms
will also appear on the Active Alarm Bar and Active Alarm List when
active. All Advanced Alarms are stored in the EVO event log along
with the time and date they occur and clear.
6.4.1 High Voltage Shutdown Alarm
The High Voltage Shutdown Alarm is activated when the EVO
initiates a High Voltage Shutdown. The High Voltage Shutdown must
be enabled for the shutdown to occur (refer to Section 3.4.2).
High Voltage Shutdown is initiated by the EVO micro-controller when
the DC Bus voltage sensed by the Main Control Board is higher than
the High DC Voltage set point for a minimum of 30 seconds. Refer to
Section 4.3 for more details on the High Voltage Shutdown feature.
The High Voltage Shutdown alarm will activate the Common Alarm
relay. The Common Alarm relay will change to the alarmed state
after a configured time delay. The High Voltage Shutdown alarm will
also be reported by any installed optional protocol communication
board and may also be configured to activate a discrete relay on
optional Auxiliary I/O boards. Refer to Section 11 for instructions
on how to configure the relays.
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6.4.2 Low Level Detect Alarm
The Low Level Detect Alarm is activated when the DC Bus voltage
sensed by the Main Control Board is lower than the Low Level Detect
set point. The Low Level Detect Alarm will activate the Common
Alarm.
The Low Level Detect feature contains dedicated hardware and
operates independent of microprocessor control. The Low Level
Detect is a true failsafe feature in that it can activate the common
alarm in response to a catastrophic failure such as a microprocessor
failure. The Low Level Detect hardware will illuminate a dedicated
LED located on the Main Control Board when alarm is active.
The Low Level Detect set point is configurable; refer to Advanced
Settings Section 3.4.5 for instructions on how to adjust the Low
Level Detect set point.
The Low Level Detect alarm will activate the Common Alarm relay.
The Common Alarm relay will change to the alarmed state after
a configured time delay. The Low Level Detect alarm will also be
reported by any installed optional protocol communication board
and may also be configured to activate a discrete relay on optional
Auxiliary I/O boards. Refer to Section 11 for instructions on how to
configure the relays.
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6.4.3 End of Discharge (EOD) Alarm
The End of Discharge alarm is activated when the DC Bus voltage
sensed by the Main Control is lower than the End of Discharge alarm
set point. The End of Discharge set point is configurable; refer to
Advanced Settings Section 3.4.4 for instructions on how to adjust
the End of Discharge set point.
The End of Discharge alarm will activate the Common Alarm relay.
The Common Alarm relay will change to the alarmed state after
a configured time delay. The End of Discharge alarm will also be
reported by any installed optional protocol communication board
and may also be configured to activate a discrete relay on optional
Auxiliary I/O boards. Refer to Section 11 for instructions on how to
configure the relays.
NOTE:
The End of Discharge alarm may be used to activate a battery disconnect
contactor by mapping the alarm to a discrete relay of an optional
Auxiliary I/O Board.
6.4.4 High Ripple Alarm
The High Ripple alarm is activated when the AC ripple voltage
measured by the Main Control Board is higher than the Ripple
Voltage alarm set point. The Ripple Voltage set point is configurable;
refer to Advanced Settings Section 3.4.6 for instructions on how to
adjust the High Ripple alarm set point.
The High Ripple alarm will activate the Common Alarm relay. The
Common Alarm relay will change to the alarmed state after a
configured time delay. The High Ripple alarm will also be reported
by any installed optional protocol communication board and may
also be configured to activate a discrete relay on optional Auxiliary
I/O boards. Refer to Section 11 for instructions on how to
configure the relays.
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6.4.5 Battery Temperature Probe Failure Alarm
The Battery Temperature Probe Failure alarm is activated when
the Main Control Board senses an out of range value from the
Battery Temperature probe. The EVO will switch to non-temperature
compensated mode to determine the output voltage (output voltage
will be adjusted for 25 °C). The set points for this alarm are fixed
internally and are not adjustable.
The Battery Temperature Probe Failure alarm will activate the
Common Alarm relay. The Common Alarm relay will change to
the alarmed state after a configured time delay. The Battery
Temperature Probe Failure alarm will also be reported by any
installed optional protocol communication board and may also be
configured to activate a discrete relay on optional Auxiliary I/O
boards. Refer to Section 11 for instructions on how to configure
the relays.
6.4.6 Rectifier Over Temperature Alarm
The Rectifier Over Temperature alarm is activated when the Main
Control Board senses that one or more of the SCRs are too hot. The
set points for this alarm are fixed internally and are not adjustable.
The Rectifier Over Temperature alarm will activate the Common
Alarm relay. The Common Alarm relay will change to the alarmed
state after a configured time delay. The Rectifier Over Temperature
alarm will also be reported by any installed optional protocol
communication board and may also be configured to activate a
discrete relay on optional Auxiliary I/O boards. Refer to Section 11
for instructions on how to configure the relays.
6.4.7 External Feedback Failure Alarm
The External Feedback Failure alarm is activated when the Main
Control Board senses the external voltage (post-filtered voltage) is
out of range. The external voltage maybe measured at the output
breaker or the battery if the remote sense option is connected.
This failure typically indicates a problem with the voltage sense
resistors. The set points for this alarm are fixed internally and are
not adjustable.
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The External Feedback Failure alarm will activate the Common
Alarm relay. The Common Alarm relay will change to the alarmed
state after a configured time delay. The External Feedback Failure
alarm will also be reported by any installed optional protocol
communication board and may also be configured to activate a
discrete relay on optional Auxiliary I/O boards. Refer to Section 11
for instructions on how to configure the relays.
6.4.8 Internal Feedback Failure Alarm
The Internal Feedback Failure alarm is activated when the Main
Control Board senses the internal voltage (pre-filtered voltage) is out
of range. The internal voltage is always measured inside the charger
before the output filter circuitry. This failure typically indicates a
problem with the voltage sense resistors. The set points for this
alarm are fixed internally and are not adjustable.
The Internal Feedback Failure alarm will activate the Common
Alarm relay. The Common Alarm relay will change to the alarmed
state after a configured time delay. The Internal Feedback Failure
alarm will also be reported by any installed optional protocol
communication board and may also be configured to activate a
discrete relay on optional Auxiliary I/O boards. Refer to Section 11
for instructions on how to configure the relays.
6.4.9 Open DC Breaker Alarm
The Open DC Breaker alarm is activated when the Main Control
Board senses that CB2, the DC Breaker, is open. The set point for this
alarm is fixed internally and are not adjustable.
The Open DC Breaker alarm will activate the Common Alarm relay.
The Common Alarm relay will change to the alarmed state after
a configured time delay. The Open DC Breaker alarm will also be
reported by any installed optional protocol communication board
and may also be configured to activate a discrete relay on optional
Auxiliary I/O boards. Refer to Section 11 for instructions on how to
configure the relays.
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6.4.10 Open AC Breaker Alarm (optional)
The Open AC Breaker alarm is activated when the Main Control
Board senses that CB1, the AC Breaker, is open. The set point for this
alarm is fixed internally and are not adjustable.
The Open AC Breaker alarm will activate the Common Alarm relay.
The Common Alarm relay will change to the alarmed state after
a configured time delay. The Open AC Breaker alarm will also be
reported by any installed optional protocol communication board
and may also be configured to activate a discrete relay on optional
Auxiliary I/O boards. Refer to Section 11 for instructions on how to
configure the relays.
6.4.11 DC Power Supply Failure Alarm
The DC Power Supply Failure alarm is activated when the Main
Control Board is not sensing power from its internal DC power
source. The EVO internal electronics are powered by both AC and
DC power sources. The EVO utilizes the AC power source when AC
power is applied to the charger and the DC power source when
there is no AC source. The EVO may be operating when this alarm is
active, but it may fail when the AC power is removed.
The set points for this alarm are fixed internally and are not
adjustable.
The DC Power Supply Failure alarm will activate the Common
Alarm relay. The Common Alarm relay will change to the alarmed
state after a configured time delay. The DC Power Supply Failure
alarm will also be reported by any installed optional protocol
communication board and may also be configured to activate a
discrete relay on optional Auxiliary I/O boards. Refer to Section 11
for instructions on how to configure the relays.
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6.4.12 SCR Failure Alarm
The SCR Failure Alarm is activated when the Main Control Board
detects that the rectifier is not working. This may indicate a defective
SCR or issues with the SCR firing control or driver. The set points for
this alarm are fixed internally and are not adjustable.
The SCR Failure Alarm will activate the Common Alarm Relay. The
Common Alarm Relay will change to the alarmed state after a
configured time delay. The SCR Failure Alarm will also be reported
by any installed optional protocol communication board and may
also be configured to activate a discrete relay on optional Auxiliary
I/O boards. Refer to Section 11 for instructions on how to
configure the relays.
6.5 Reset Latch Alarm Relays
Latched alarm relays can be reset or cleared two different ways. The
Legacy AT Series method may be used. Pressing and holding the UP
arrow button for a few seconds will reset or clear all latched alarm
relays. A confirmation message will briefly appear on the display
acknowledging all latched alarm relays have been reset.
Individual latched alarm relays or all latched alarm relays may also
be reset via the RELAYS icon from the Main Menu. . To reset an
individual latch alarm relay:
• From the HOME SCREEN, press the MENU button, navigate to
the RELAYS icon and then press the EDIT/ENTER button.
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• Press the UP or DOWN button to navigate to the “Unlatch
selected relays” control and press the EDIT/ENTER button.
• A list of alarm relays that are presently latched will appear.
• Press the UP or DOWN button to navigate to the relay to be
reset and press the EDIT/ENTER button.
To reset all latched alarm relays:
• From the HOME SCREEN, press the MENU button, navigate to
the RELAYS icon and then press the EDIT/ENTER button.
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• Press the UP or DOWN button to navigate to the “Unlatch all
relays (x)”. The number of presently latched relay will appear
between the ( ) where the X is located.
• Press the EDIT/ENTER button to reset all the latched alarm
relays. The number between the brackets will change to ‘0’.
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6.6 Open Battery Test
The Open Battery Test feature will detect if the connection between
the battery and the EVO has been lost. This test can also detect
a weak or faulty battery. The test lowers the charger voltage and
verifies whether the battery can assume the present DC load. This
test can be run manually or be scheduled to run periodically.
The Open Battery Test will fail and the test will end if the DC bus
drops below a configurable voltage set point. If the DC voltage drops
below the voltage set point, the test aborts immediately and the EVO
will raise the output voltage back to the present Float or Equalize
setting. The duration of the test is also configurable.
If the test fails a Battery Open alarm is generated. This alarm is a
latching alarm and can only be cleared by the Unlatch Battery Open
Alarm control.
6.6.1 Open Battery Test Settings
The settings of the Open Battery Test are accessed via the TESTING
icon from the Main Menu. To configure the Open Battery Test:
• From the HOME SCREEN, press the MENU button, navigate to
the TESTING icon and then press the EDIT/ENTER button.
• Press the UP or DOWN button to navigate to the “Test Settings”
control and press the EDIT/ENTER button.
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• Press the UP or DOWN button to navigate to the “Run test for up
to:” control and press the EDIT/ENTER button.
• Press the UP or DOWN button to adjust the duration of the test
and press the EDIT/ENTER button.
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• Press the UP or DOWN button to navigate to the “Setpoint:”
control and press the EDIT/ENTER button.
• Press the UP or DOWN button to adjust the voltage set point at
which to terminate the test if no battery is present and press the
EDIT/ENTER button.
6.6.2 Run the Open Battery Test Periodically
To schedule the EVO to run the Open Battery Test periodically:
• From the HOME SCREEN, press the MENU button, navigate to
the TESTING icon and then press the EDIT/ENTER button.
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• Press the UP or DOWN button to navigate to the “Test Settings”
control and press the EDIT/ENTER button.
• Press the UP or DOWN button to navigate to the “Run
periodically:” control and press the EDIT/ENTER button.
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• Press the UP or DOWN button to enable or disable the
automatic scheduling of the test and press the EDIT/ENTER
button.
• Press the UP or DOWN button to navigate to the “Every:” control
and press the EDIT/ENTER button.
• Press the LEFT or RIGHT buttons to select the digit to change.
Press the UP or DOWN button to adjust how often to run the
test.
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• Press the EDIT/ENTER button when the scheduled number of
days is displayed.
6.6.3 Run the Open Battery Test Manually
The Open Battery Test can be run manually on demand. To initiate
the Open Battery test:
• From the HOME SCREEN, press the MENU button, navigate to
the TESTING icon and then press the EDIT/ENTER button.
• Press the UP or DOWN button to navigate to the “Run now”
control and press the EDIT/ENTER button.
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6.6.4 Resetting the Battery Open Alarm
If the EVO detects an open battery condition and the Open Battery
Test alarm is activated, it can only be cleared by the Unlatch Battery
Open Alarm control. To initiate the Unlatch Battery Open Alarm
control and reset the Battery Open Alarm:
• From the HOME SCREEN, press the MENU button, navigate to
the TESTING icon and then press the EDIT/ENTER button.
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• Press the UP or DOWN button to navigate to the “Unlatch
battery open” control and press the EDIT/ENTER button.
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7. HINDLE HEALTH
SYSTEM
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7.1 Hindle Health System - Overview
The Hindle Health System (HHS) is a powerful, user friendly,
standard feature designed in to the EVO charger. The HHS
is composed of several subsystems that test and report the
operational health of the EVO. Some portions of the HHS
continuously run in the background and monitor the charger to
ensure everything is working as designed. Other parts of the
HHS require user intervention via stimulus or confirmation to
verify proper operation.
7.2 Hindle Health System Components
The Hindle Health System is composed of four major
components;
 a self-diagnostic utility that continuously runs in the
background
 Hindle Health Button
 Hindle Health LEDs
 Hindle Health Screens
7.2.1 Self-Diagnostics
The EVO microprocessors continuously run utilities that check to
make sure the hardware components are operating correctly. These
utilities test memory, communication interfaces, parameters, and
discrete hardware devices such as relays.
The microprocessors also test that all input values and
measurements are within tolerance of reasonable ranges. Some
critical parameters such as DC voltage and DC current are
sampled by multiple processors and have redundant qualification
requirements.
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Any errors detected by the self-diagnostic utilities are reported
immediately by means of alarms and/or status updates. Possible
causes of problem and proposed solution to resolve the issues are
also provided by the self-diagnostics utilities.
7.2.2 Hindle Health Button
The Hindle Health Button is located to the
lower right of the EVO control overlay.
When pressed, the Hindle Health Button
will start the user assisted portion of the
Hindle Health System. This process will
check and verify areas of the charger that
the continuous self-diagnostics may not be
able to test. For example, the charger cannot test whether a relay is
working correctly unless the test forces the relay to change states.
The user will be guided and prompted through the entire test
procedure via the Hindle Health Screens described later in this
Section. Pressing the Hindle Health Button starts this process.
7.2.3 Hindle Health LED Indicators
The Hindle Health LED Indicators are located at the bottom of the
front panel overlay.
 The GREEN LED, when lit, indicates that the EVO is healthy,
tested, and working as designed.
 The RED LED, when lit, indicates that the Hindle Health
System detected an issue with the EVO.
The RED LED may be blinking or on continuously. If the RED LED
is blinking, this indicates that there is a critical failure of the
microprocessor that drives the Main EVO LCD display and the front
panel controls. The Main LCD display may be blank, frozen, or
displaying corrupted data. The core microprocessor responsible for
charging the battery may still be operational.
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If the RED HHS LED is blinking, the Main Control Board should be
replaced immediately. If a spare Main Control Board is not readily
available, a new board should be ordered as soon as possible.
If the RED LED is illuminated and is not flashing, this indicates that
the EVO requires attention, but the issue is typically not as critical as
when the RED LED is blinking.
In most cases, if the Red LED is solid, the Main LCD display will be
operational and be able to report the issue creating the condition,
along with instructions on how to resolve the issue. The RED LED is
illuminated when the EVO detects any error condition, when any EVO
alarm is active, or when the Hindle Health System detects any nonnormal operating condition.
7.3 Hindle Health System Screens
The Hindle Health System screens provide the user with a means to
test the operation of the EVO to ensure it is operating correctly. The
screens permit the operator to simulate alarm conditions, check set
points and parameters, provide stimulus to exercise relays, and verify
all indicators are working as designed.
The Hindle Health System screens provide step-by-step instructions
and prompt the user through the entire testing process. To start the
Hindle Health System, press the Hindle Health Button.
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7.3.1 Introduction and Warning Screens
The first few health screens inform the user of how to navigate
through the testing process and how to track the progress through
the test process. The next few screens warn the user about any
hazardous conditions and explain what tools will be required to
complete the testing. To exit the health test at any point through the
process, press the ESC button.
7.3.2 Choosing What to Test
After the initial introduction and safety screens, a screen will appear
prompting the user to make a choice of what to test.
There are two testing choices:
 Operation, Set points, Alarms
 Operation, Set points
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The only difference between the two choices is that the second
choice will NOT run the alarm and relay tests. The alarm test will
exercise the alarms and relays. Any equipment monitoring the status
of the charger will see the alarms during testing if the first choice
is selected. Use the UP or DOWN button to highlight the desired
testing option and then press the ENTER button to begin the testing.
7.3.3 The Test Screens
The remaining screens are all test screens. These test screens
will prompt the user through an interactive process to verify the
operation of the EVO. The interactive process will require the user to
confirm that LED indicators are lit, confirm that relays change state,
and verify that the set points are correct. The alarm test screens will
simulate alarm conditions and prompt the user to verify the alarms
operate and are confirmed by any connected SCADA devices. The
calibration test screen explains how to verify the EVO calibration and
will automatically enter the calibration mode if required.
After the Hindle Health System runs and the testing is complete,
the EVO will return to the Home Screen. An event will be added to
the log file along with a time and date stamp to document when the
charger was last tested. The results of each of the tests are included
in the log file. The result status will indicate that each test; PASSED,
FAILED or was NOT RUN. The resulting log file can be used to prove
NERC compliance requirements for things such as verifying correct
float voltage.
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8. EVO EVENT
LOGS
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8 AT SERIES EVO Event Logs
8.1 EVO Event Logs
The Event Logging feature is accessed via the EVENT LOG
Main Menu. There are two event logs associated with the event
logging feature, one log is for the Hindle Health events, and the
other log is for all other events. In addition to the logs, there are
two controls associated with event logging, clearing the event
log and saving the event log to the SD memory card.
8.2 View The Event Log
To view the event log:
• From the HOME SCREEN, press the MENU button, navigate to
the EVENT LOGS icon and then press the EDIT/ENTER button.
• Press the UP or DOWN button to navigate to the “View event log
(X)”. The number of new events since the log was last read are
shown in the “( )”.
140
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8 AT SERIES EVO Event Logs
• Press the EDIT/ENTER button to view the first event.
The most recent event stored will appear on the display. Events
include set point changes and when an alarm becomes active and
when the alarm is cleared. The log will show the date and time the
event occurred, the event name, and the status change that created
the event.
The list of stored events can be scrolled through using the LEFT and
RIGHT arrow buttons. Follow the navigation instructions at the top
of the event log screens to scroll through the stored events. Press
the ESC button to return to the Event Logs function page. For more
information on the alarms listed in the charger event log refer to the
EVO Alarms in Section 6.0.
8.3 View the Hindle Health Log
To view the Hindle Health log:
• From the HOME SCREEN, press the MENU button, navigate to
the EVENT LOGS icon and then press the EDIT/ENTER button.
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8 AT SERIES EVO Event Logs
• Press the UP or DOWN button to navigate to the “View Hindle
Health log” selection.
• Press the EDIT/ENTER button to view the first Hindle Health
event.
142
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8 AT SERIES EVO Event Logs
The most recent event or test stored will appear on the display. The
log will show the date and time the event occurred, the event name,
and the pass or fail status of the test.
The list of stored events can be scrolled through using the LEFT
and RIGHT arrow buttons. Follow the navigation instructions at the
bottom of the event log screens to scroll through the stored events.
Press the ESC button to return to the Event Logs function page. For
more information on the events listed in the Health Checkup Event
log, refer to the Hindle Health System in Section 7.0.
8.4 Clearing the Event Logs
WARNING:
All stored event history will be deleted. It is strongly recommended that
you transfer a copy of the event logs to the SD memory card prior to
deleting the event logs or all of the event history will be lost.
The event logs are stored in internal nonvolatile memory on the Main
Control Board. The event logs can be erased by selecting the “Clear
Event Log” utility. This utility will clear both the Event Log and the
Hindle Health Log. To clear the logs:
• From the HOME SCREEN, press the MENU button, navigate to
the EVENT LOGS icon and then press the EDIT/ENTER button.
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8 AT SERIES EVO Event Logs
• Press the UP or DOWN button to navigate to the “Clear event
log” selection.
• Press the EDIT/ENTER button. A confirmation message will
appear on the display.
• Press the UP or DOWN button to select YES and press the EDIT/
ENTER button. Both logs are now deleted.
8.5 Copy the Event Logs to the SD Memory Card
The event logs can be copied to the removable SD memory card
located on the Main Control Board. The event logs will be stored in
a standard ASCII text file format that can be read by most Personal
Computers (with a USB adapter) or other similar devices.
To copy the event log files to the SD memory card:
144
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8 AT SERIES EVO Event Logs
• From the HOME SCREEN, press the MENU button, navigate to
the EVENT LOGS icon and then press the EDIT/ENTER button.
• Press the UP or DOWN button to navigate to the “Copy event log
to SD Card” selection
• Press the EDIT/ENTER button
Both log files are now stored on the SD memory card. If no card is
present in the EVO, an error message will appear.
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145
9. EVO BATTERY
TEMPERATURE
COMPENSATION
AT SERIES BATTERY CHARGER
9. AT SERIES EVO Temperature Compensation
9.1 EVO Battery Temperature Compensation
The battery manufacturer will specify recommended float and
equalize voltages at 25 °C (77 °F). Temperatures above or below
the nominal 25 degrees require a slightly lower or higher voltage
(respectively) in order to prolong battery life and ensure reliable
operation. The EVO Battery Temperature Compensation option
automatically adjusts the charger’s DC output voltage based upon
the battery temperature.
The EVO Battery Temperature Compensation (or TEMPCO) option
consists of a Battery Temperature Probe and a cable to connect the
temperature probe to the charger. The temperature compensation
probe contains a temperature-dependent resistor in an epoxy
module that you install on or near your battery. This option can be
purchased with the charger or field installed later.
9.2 Installing the TEMPCO Option
There are four (4) steps to install the assembly:
1. Mounting the probe assembly on or near the battery.
2. Installing an interconnection cable from the probe assembly to
the EVO.
3. Wiring the charger end of the cable to a terminal block on the
EVO Power Board.
4. Configuring the EVO to recognize the TEMPCO option.
The temperature compensation probe, or puck, is the same for all
battery types and all EVO chargers regardless of output voltage. The
accessory part numbers differ depending on cable length ordered.
PROCEDURE
1. De-energize and lock out all AC and DC voltages to the EVO.
2. Allow internal voltages to dissipate.
3. Remove the safety shield and verify no hazardous voltages are
present with a voltmeter.
4. Mount the probe on a clean dry surface on or as close to the
battery as possible. DO NOT mount the probe on:
148
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9. AT SERIES EVO Temperature Compensation
» unpainted wood
» bare galvanized metal
» plastic surfaces
NOTE:
Consult battery manufacturer for mounting restrictions and adhesive
compatibilities .
5. To apply the probe, clean the mounting surface with isopropyl
alcohol and allow it to dry thoroughly. Remove the protective
backing from the double-faced adhesive tape on the probe and
securely press it onto the surface.
6. Install the cable supplied with the temperature compensation
probe kit:
» The end of the cable with two (2) stripped wires and a quickconnect terminal will be installed inside the EVO.
» Leave 30in / 762mm of cable inside the enclosure. Run the
cable through a conduit that does not contain power wiring.
» Route the other end of the cable to the probe at the battery
and coil up excess cable.
» Make sure all wiring conforms to NEC, local, and site
requirements.
7. Attach the interconnection cable to the EVO Power Board at TB8
and the EARTH terminal as shown:
AT SERIES BATTERY CHARGER
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» Route the TEMPCO cable to the lower end of the Power
Board assembly.
» Locate TB8 on the Power Board and insert one of each of the
stripped wires from the twisted pair into each location on
the TB8 terminal block. Connection Points are not polartiy
sensitive.
150
AT SERIES BATTERY CHARGER
9. AT SERIES EVO Temperature Compensation
» Locate the EARTH quick connect terminal on the bottom
of the Power Board. Carefully pull off the quick connect
terminal and wire from the EARTH terminal.
» Plug the quick connect terminal attached to the end of the
shield wire of the TEMPCO cable assembly onto the EARTH
terminal of the Power Board.
» Reconnect the quick terminal removed from the EARTH
terminal to the Piggy Back terminal on the end of the shield
wire of the TEMPCO cable.
» Use plastic wire ties to fasten the TEMPCO cable to the
existing wire harness.
8. At the battery, connect the quick connect terminals to the
temperature compensation probe. Connection points are
not polarity sensitive. Coil up and wire tie any excess wire to
prevent damage.
9. Check your work. Confirm that:
» All connections are secure.
» Both the TEMPCO shield and the original ground wire are
connected to the EARTH quick connect terminal on the Power
Board.
» The twisted pair wires of the TEMPCO cable are connected to
TB8, the 2-position terminal block on the Power Board.
10. Replace the plastic safety shield and restart the EVO.
9.2.1 Configuring the TEMPCO Option
The EVO will need to be configured to enable the TEMPCO probe and
to select the battery type. Refer to Sections 3.4.9 and 3.4.10 for
instructions on how to configure the TEMPCO probe.
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151
9. AT SERIES EVO Temperature Compensation
9.3 Using the TEMPCO Option
When the EVO is equipped with a temperature compensation probe,
the charger auto-adjusts the output voltage applied to the battery to
keep the float current constant, thereby avoiding overcharging and
undercharging. The probe senses the temperature of the battery
and adjusts the output float/equalize voltages to compensate for
variations in temperature. If the battery temperature increases,
the EVO output voltage decreases. If you are experiencing any
inconsistencies in the EVO when the temperature compensation
probe is installed, temporarily disable the TMEPCO Option see
Section 3.4.9
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 or adjust the Float or Equalize voltage, the front
panel meter displays 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 EVO may be different from the
set point, assuming the battery is warmer or cooler than 77 °F /
25 °C.
• Use a digital meter to measure the actual output voltage of the
EVO. Determine the temperature at the compensation probe
and use the graph shown in Section 9.4 to verify that the
output voltage is correct.
• If the battery temperature falls below 32 °F / 0 °C, there will
be no further increase in EVO output voltage. Likewise, if the
battery temperature rises above 122 °F / 50 °C, there is no
further decrease in output voltage.
152
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9. AT SERIES EVO Temperature Compensation
9.3.1 Home Screen with TEMPCO Option
Additional parameters will appear on the HOME SCREEN when the
TEMPCO option is installed and enabled.
• The large voltage value (large font) is the actual charger
output voltage which is compensated for the present battery
temperature
• The 1st parameter in smaller font to the right of the actual
charger voltage is the present battery temperature (in degrees
C).
• The 2nd parameter in smaller font directly below the batery
temperature is the charger set point value (at 25°C).
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153
9. AT SERIES EVO Temperature Compensation
9.4 Temperature Compensation Curves
The following graph depicts the voltage correction applied to
the EVO output based on the battery temperature sensed by the
TEMPCO probe.
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
154
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10. REMOTE
SENSE
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10 Remote Sense
10.1 EVO Remote Voltage Sense
The EVO regulates the DC output voltage as measured at the
charger’s output connection (the DC breaker). The Remote
Voltage Sense feature permits the EVO to monitor and regulate
the DC output voltage at the battery. This feature is useful
for long battery cables where there may be a voltage drop
associated with the resistance of the cabling that connects the
EVO to the battery. All EVO chargers can be wired to utilize the
Remote Voltage Sense feature.
10.2 Remote Sense Connection
Remote sensing provides the following:
1. Compensates for voltage drop in the DC wiring between the
EVO 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.
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AT SERIES BATTERY CHARGER
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10 Remote Sense
To wire the EVO for remote sensing, install twisted pair cabling from
the EVO remote sense terminals to the battery terminals or DC bus.
The EVO control circuitry 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.
CAUTION:
The EVO cannot protect against short circuits in the remote sense wiring.
Install a 1.0A fuse at the battery or DC bus end of each remote sense
cable.
10.3 Procedure for Wiring Remote Sense
Route the twisted pair cable between the battery and EVO charger
and make the connections described below BEFORE you move the
Remote Sense enable jumpers to enable the Remote Sense feature.
1. De-energize and lock out all AC and DC voltages to the EVO.
2. Allow internal voltages to dissipate.
3. Remove the safety shield and verify no hazardous voltages are
present with a voltmeter.
4. Route a #16 AWG twisted pair cable from the bottom of the EVO
Power Board to the desired battery sense location.
5. Designate one of the wires of the twisted pair as DC+ and the
other as DC-.
6. Locate TB1, the Remote Sense terminal block, on the bottom
front of the EVO Power Board.
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157
10 Remote Sense
1.
2.
Connect the wire from the twisted pair designated as DC+
to the POS (positive) terminal of TB1. Connect the wire
designated as DC- to the NEG (negative) terminal of TB1.
Observing the correct polarity, connect the battery end
of the DC+ wire of the twisted pair to the positive sense
location on the battery. Connect the battery end of the
DC- wire of the twisted pair to the negative sense location
on the battery.
3.
Check and verify your connections.
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DO NOT energize the EVO until you configure the Remote
Sense jumpers (refer to Section 10.4).
5.
After the Remote Sense Jumpers have been correctly
configured, replace the safety shield and energize the
charger.
158
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10 Remote Sense
NOTES:
1.
Maximum current is 150mA.
2.
Run the twisted pair cable with the sense leads in a
dedicated conduit.
3.
Fuse each of the sense wires.
10.4 Configuring the Remote Sense Jumpers
The EVO must be configured to sense the DC output voltage
used for regulation at either the charger’s DC output or at
the voltage present on the Remote Sense terminal block.
This configuration is accomplished by moving shorting block
jumpers located on the EVO Power Board.
10.4.1 Locating Remote Sense Configuration Jumpers
The EVO Remote Sense Configuration Jumpers (JP103 and
JP104) are located on the EVO Power Board next to TB1, the
Remote Sense terminal block. Each Jumper consists of a three
pin header and a SHORTING BLOCK that shorts (or connects)
two pins of the header together.
10.4.2 Enable Remote Sense
To have the EVO regulate the DC output to the voltage present
at the Remote Sense leads, move both the Remote Sense
AT SERIES BATTERY CHARGER
159
10 Remote Sense
SHORTING BLOCKs (JP103 and JP104) to the REMOTE SENSE
side of the pin headers. The SHORTING BLOCKS should be
installed on the two pins closest to the edge of the board.
10.4.3 Enable Local Sense
To have the EVO regulate the DC output to the voltage present
at the charger output terminals (the DC breaker), move both
the Remote Sense SHORTING BLOCKs (JP103 and JP104) to
the LOCAL SENSE side of the pin headers. The SHORTING
BLOCKS should be installed on the two pins farthest from
the edge of the board. Local Sense is the factory default
configuration. Unless otherwise specified, all EVO chargers
are shipped configured to use the local sense.
10.5 Disabling the Remote Sense
If you need to temporarily disable the Remote Sense:
1.
De-energize and lock out all AC and DC voltages within the
EVO enclosure. Check with a voltmeter.
2.
Remove the safety shield.
3.
Move the SHORTING BLOCKs to the Local Sense
configuration (see Section 10.4.3).
4.
Replace the safety shield and energize the charger.
NOTE:
If the Remote Sense feature is to be disabled for extended periods of time
or permanently disabled, it is highly recommended that the sense leads
(the twisted pair cable) be disconnected from both the battery and from
the TB1 terminal block.
160
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11. AUXILIARY
INPUTS/OUTPUTS
AT SERIES BATTERY CHARGER
11 Auxilary Inputs/Outputs
11.1 EVO Auxiliary Relay Board Types
The Auxiliary I/O Board is an optional board that mounts near the
top of the heat sink along the left side of the charger. The Auxiliary
I/O Board is equipped with six relays, four generic binary inputs, and
four generic analog inputs.
The Auxiliary I/O Board communicates to the Main Control Board
via serial communications. The Serial Communications Connection
is part of the ribbon cable between the main control board and the
Power Board. A green communications LED is located adjacent to
the TB2 terminal block on the Auxiliary I/O Board. This LED will blink
to indicate active communication between the Auxiliary I/O Board
and the Main Control Board.
All relays are failsafe such that if communication is lost between
the Main Control Board and the Auxiliary I/O Board, the relays will
switch to the alarm state.
162
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11 Auxilary Inputs/Outputs
11.1.1 Relays
The Auxiliary I/O Board contains six configurable (1) Form-C relays.
The relay contacts are rated for 0.5A @ 125 VAC/VDC. Each relay is
configurable to:
• Change states based on the state of any one alarm condition or
status point.
• Be latching or non-latching.
• Delay switching to the active state based on a pre-programmed
interval of time.
Each relay has an associated red LED. The LED serves as a
debugging aid as it will illuminate when the respective relay is in the
alarmed state. In addition, each relay has a second contact set which
feeds back to the EVO main processor to indicate the state of the
relay.
11.1.2 Binary Inputs
The four Binary Inputs are optically isolated from the EVO and each
other. They can be configured via jumper selection to accept input
voltages of 12VDC, 24VDC, 48VDC, or 130VDC. Each Binary Input
has an associated yellow LED and a jumper selection block. The LED
serves as a debugging aid as it will illuminate when the associated
Binary Input is high (in the “ON” state).
The binary inputs may be configured to be active high or active low
and generate alarms and controls such as charger shutdown. The
configuration also permits each input to be assigned a custom name
(such as “2% Hydrogen”, or “Vent Fan Fail”). The EVO will report all
activity of the input (status, alarms or log files) by the generic default
name or the custom configured name.
11.1.3 Analog Inputs
The four Analog inputs are rated for 0-10 VDC. They utilize a common
ground (referenced to DC OUTPUT NEG) and can be used to import
generic analog values into the EVO. The EVO assigns each analog
input a unique generic name such as ”AUX 1 input AN1”. This name
can be changed to be better identified by the end user (for example:
“Ambient Temp”). EVO will report all status and alarms with the
default name or the custom name assigned.
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163
11 Auxilary Inputs/Outputs
The analog inputs include scaling configuration such that EVO can
report their values in primary units. For example, a temperature
transducer with a 0 to 10 VDC output can be configured to scale the
voltage value directly to the associated temperature represented by
the DC voltage. The associated “units” name can also be configured
such that when the analog input value is displayed, it will display as
“80.3 F” instead of “6.2 VDC”.
Each analog input can be configured to generate alarms based on
its value. The available trigger conditions on which to generate an
alarm include: below a threshold, above a threshold, within a range,
or outside a range. The threshold and range values are configurable
and are entered in the primary units (such as degrees F) based on the
scaling configuration.
164
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11 Auxilary Inputs/Outputs
11.2 Connections to the Auxiliary I/O Board
11.2.1 System Connections
The Auxiliary I/O Board plugs in to the top of the Power Board. All
system connections are factory wired when the Auxiliary I/O option
is ordered with the charger.
11.2.2 Wiring the Relays Connections
Connections to the Relays are made through terminal block TB4.
The terminal connections are labeled on the TB4 terminal block.
PROCEDURE
1. De-energize and lock out all AC and DC voltages to the EVO.
2. Allow internal voltages to dissipate.
3. Remove the safety shield and verify no hazardous voltages are
present with a voltmeter.
4. Route the remote annunciator wiring to the Auxiliary I/O Board
through one of the unused knockouts of the enclosure.
5. Connect the wiring (use #22-14 AWG) to the appropriate
terminals of TB4 on the Auxiliary I/O Board.
6. Strip each wire 0.25in / 6.4mm, and securely tighten the
terminal screws.
7. Replace the safety shield.
8. Re-energize the charger.
NOTES
• Alarm contacts are rated at 0.5A @ 125 VAC/VDC.
• Terminal block (TB4) is compression type, accepting #22-14 AWG
wire.
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165
11 Auxilary Inputs/Outputs
• Terminals are labeled in non-alarm condition.
11.2.3 Wiring the Binary Input Connections
Connections to the Binary Inputs are made through terminal block
TB1. The terminal block is removable to simplify wiring.
The terminal connections are labeled along the edge of the Auxiliary
I/O board next to the TB1 terminal block. Each Binary Input is
optically isolated and has a polarized pair of terminals. Observe the
(+) and (-) designators when wiring the terminal block.
166
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11 Auxilary Inputs/Outputs
NOTE
Before wiring the Binary Inputs, verify the Binary Input voltage selection
jumpers are configured for the correct input voltage (see Section
11.3.2). Incorrect voltage configuration may damage the Auxiliary I/O
Board.
PROCEDURE
1. De-energize and lock out all AC and DC voltages to the EVO.
2. Allow internal voltages to dissipate, and then check with a
voltmeter.
3. Remove the safety shield.
4. Route your Binary Input wiring to the Auxiliary I/O Board
through one of the unused knockouts of the enclosure.
5. Connect the wiring (use #22-14 AWG) to the appropriate
terminals of TB1 on the Auxiliary I/O Board.
6. Strip each wire 0.25in / 6.4mm, and securely tighten the
terminal screws.
7. Replace the safety shield.
8. Re-energize the charger.
NOTES
• Binary Inputs are configurable for 12VDC, 24VDC, 48VDC, or
130VDC.
• Terminal block (TB1) is compression type, accepting #22-14 AWG
wire.
• Correct polarization is required.
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167
11 Auxilary Inputs/Outputs
11.2.4 Wiring the Analog Input Connections
Connections to the Analog Inputs are made through terminal block
TB3. The terminal block is removable to simplify wiring.
The terminal connections are labeled along the edge of the Auxiliary
I/O board next to the TB3 terminal block. The Analog Inputs are NOT
isolated and must be referenced to the DC(-) bus.
PROCEDURE
1.
2.
3.
4.
De-energize and lock out all AC and DC voltages to the EVO.
Allow internal voltages to dissipate and verify with a voltmeter.
Remove the safety shield.
Route your remote analog inputs to the Auxiliary I/O Board
through one of the unused knockouts of the enclosure.
5. Connect the wiring (use #22-14 AWG) to the appropriate
terminals of TB3 on the Auxiliary I/O Board.
6. Strip each wire 0.25in / 6.4mm, and securely tighten the
terminal screws.
7. Replace the safety shield.
8. Re-energize the charger.
168
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11 Auxilary Inputs/Outputs
NOTES
• Analog Inputs are rated at 0-10VDC.
• Terminal block (TB3) is compression type, accepting #22-14 AWG
wire.
• All Analog Inputs (AN1, AN2, AN3, AN4) must be referenced to
the EVO DC(-) bus voltage (COM) terminal.
11.3 Hardware Configuration
The Auxiliary I/O Board requires two hardware configurations; the
Auxiliary I/O Board Address and the Binary Input Voltage settings.
11.3.1 Auxiliary I/O Board Address
The EVO charger will support up to eight Auxiliary I/O Boards.
Each Auxiliary I/O Board connected to the EVO must have a unique
address setting to identify it to the system. The Auxiliary I/O
dipswitch (S1) determines the Auxiliary I/O Board Address.
The Auxiliary I/O dipswitch contains three switches and is located
near the top center of the board.
The Auxiliary I/O Board address is determined as follows:
• Auxiliary I/O Board #1 – (OFF,OFF,OFF)
• Auxiliary I/O Board #2 – (OFF,OFF,ON)
• Auxiliary I/O Board #3 – (OFF,ON,OFF)
• Auxiliary I/O Board #4 – (OFF,ON,ON)
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169
11 Auxilary Inputs/Outputs
•
•
•
•
Auxiliary I/O Board #5 – (ON,OFF,OFF)
Auxiliary I/O Board #6 – (ON,OFF,ON)
Auxiliary I/O Board #7 – (ON,ON,OFF)
Auxiliary I/O Board #8 – (ON,ON,ON)
Note: switch positions are (3,2,1)
The switch setting will be factory set for your system and should not
need to be changed unless an Auxiliary I/O Board is being replaced
or added to the system. If an Auxiliary I/O Board is being replaced,
set the dipswitch settings on the new board to match the board
being replaced.
11.3.2 Binary Input Voltage Configuration
Each Binary Input has an associated input voltage configuration
jumper. The configuration jumpers (P3, P4, P6, and P7) are located
adjacent to the Binary Input Terminal Block (TB1) on the Auxiliary I/O
Board. The voltage jumper for Binary Input #1 is shown below.
To configure the Binary Input Voltage, move the SHORTING BLOCK
to connect the 2 header pins directly above the voltage rating (12,
24, 48, or 130). This process needs to be repeated for the remaining
three Binary Inputs using the associated configuration jumpers for
Binary Input #2, #3, and #4.
11.4 Software Configuration
The Auxiliary I/O Board’s inputs are generic and do not require any
configuration. The inputs (analog and binary) are defined by their
associated number. Binary Input #1 through Binary Input #4 and
Analog Input #1 through Analog Input #4 will reside on the Auxiliary
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I/O Board with its dipswitch configured for Auxiliary I/O Board #1.
Each relay has a dedicated configuration for:
• alarm condition or status point mapping
• latching or non-latching
• time delay
The Auxiliary I/O Board Relays can be mapped to indicate the state
of any EVO alarm or status point. Each relay can be independently
configured to latch when the alarm or status point associated
with the relay becomes active. Once latched, the relay must be
cleared manually by initiating the RESET LATCHED RELAY feature
(see section 6.5). All relays have a time delay configuration. The
relay will not change to the active state until the associated alarm
or status point has changed to the active state and remains in the
active state for the configured time delay.
11.4.1 Auxiliary I/O Board Relay Alarm Configuration
To change the alarm configuration for a relay on the Auxiliary I/O
board:
• From the HOME SCREEN, press the MENU button, navigate to
the RELAYS icon and then press the EDIT/ENTER button.
• Press the UP or DOWN button to navigate to the “Relay
Configuration” parameter and press the EDIT/ENTER button.
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• Press the UP or DOWN button to navigate to and highlight
the specific relay to configure. The Auxiliary I/O board relays
are specified by the Auxiliary I/O Board number and the relay
number on the associated board. For example “Aux 1 relay 3”
specifies the Relay #3 on Auxiliary I/O board #1, as specified by
the DIP SWITCH setting (see Section 11.3.1).
• To change the alarm condition assigned to the relay, press the
UP or DOWN button to navigate to the “Fault:” parameter and
press the EDIT/ENTER button.
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• Press the UP or DOWN button to navigate to the fault condition
to assign to the associated relay. The fault list is multiple pages
in length, the scroll bar to the right of the screen will indicate the
position within the list. Press the EDIT/ENTER button to assign
the highlighted fault to the associated relay.
• Pressing the ESC button will return to the previous menu.
Multiple ESC button presses will return the EVO to the HOME
screen.
11.4.2 Auxiliary I/O Board Relay Latch Configuration
To change the latching control configuration for a relay on the
Auxiliary I/O board:
• From the HOME SCREEN, press the MENU button, navigate to
the RELAYS icon and then press the EDIT/ENTER button.
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• Press the UP or DOWN button to navigate to the “Relay
Configuration” parameter and press the EDIT/ENTER button.
• Press the UP or DOWN button to navigate to and highlight
the specific relay to configure. The Auxiliary I/O board relays
are specified by the Auxiliary I/O Board number and the relay
number on the associated board. For example “Aux 1 relay 3”
specifies the Relay #3 on Auxiliary I/O board #1, as specified by
the DIP SWITCH setting (see Section 11.3.1).
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• To change the latching control of this relay, press the UP or
DOWN button to navigate to the “Latching:” parameter and
press the EDIT/ENTER button.
• Press the UP or DOWN button to either disable or enable the
latching option and press the EDIT/ENTER button.
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• Pressing the ESC button will return to the previous menu.
Multiple ESC button presses will return the EVO to the HOME
screen.
11.4.3 Auxiliary I/O Board Relay Time Delay Configuration
To change the delay time configuration for a relay on the Auxiliary
I/O board:
• From the HOME SCREEN, press the MENU button, navigate to
the RELAYS icon and then press the EDIT/ENTER button.
• Press the UP or DOWN button to navigate to the “Relay
Configuration” parameter and press the EDIT/ENTER button.
Press the UP or DOWN button to navigate to and highlight the
specific relay to configure. The Auxiliary I/O board relays are
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specified by the Auxiliary I/O Board number and the relay number on
the associated board. For example “Aux 1 relay 3” specifies the Relay
#3 on Auxiliary I/O board #1, as specified by the DIP SWITCH setting
(see Section 11.3.1).
• To change the relay time delay, press the UP or DOWN button to
navigate to the “Delay:” parameter and press the EDIT/ENTER
button.
• Press the LEFT or RIGHT buttons to navigate to the digit to
change and the UP or DOWN button to increment or decrement
the set point value. Press the EDIT/ENTER button to store the
new set point value.
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• Pressing the ESC button will return to the previous menu.
Multiple ESC button presses will return the EVO to the HOME
screen.
11.5 Software Configuration for Auxiliary I/O
Board Binary Inputs
The Auxiliary I/O board binary inputs are used to monitor, report,
and/or alarm on the status of any external switch or contact. Each
input can be independently configured to be active high or low,
activate an alarm, and/or activate a control. The EVO assigns a
unique generic name to each input and allows the user to replace the
generic name with a custom name.
11.5.1 Binary Input Name Assignment
To change the name of a binary input on the Auxiliary I/O board:
• From the HOME SCREEN, press the MENU button, navigate to
the AUX INPUTS icon and then press the EDIT/ENTER button.
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• Press the UP or DOWN button to navigate to the “Binary Input
Configuration” parameter and press the EDIT/ENTER button.
• Press the UP or DOWN button to navigate to and highlight
the specific binary input to configure. The Auxiliary I/O board
binary inputs default names are specified by the Auxiliary I/O
Board number and the binary input number on the associated
board. For example “Aux 1 input B2” specifies the binary input
#2 on Auxiliary I/O board #1, as specified by the DIP SWITCH
setting (see Section 11.3.1).
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• To change the name assigned to the binary input, press the UP
or DOWN button to navigate to the “Name:” parameter and
press the EDIT/ENTER button.
• Press the UP and DOWN buttons to scroll through the character
set and the LEFT and RIGHT buttons to change character
locations.
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• When the new name is complete, press the EDIT/ENTER button
to store the new name.
• Pressing the ESC button will return to the previous menu.
Multiple ESC button presses will return the EVO to the HOME
screen.
11.5.2 Binary Active State Assignment
The binary active state assignment determines the normal and alarm
state of the input. To change the active state of a binary input on the
Auxiliary I/O board:
• From the HOME SCREEN, press the MENU button, navigate to
the AUX INPUTS icon and then press the EDIT/ENTER button.
• Press the UP or DOWN button to navigate to the “Binary Input
Configuration” parameter and press the EDIT/ENTER button.
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• Press the UP or DOWN button to navigate to and highlight the
specific binary input to configure. The Auxiliary I/O board binary
inputs default names are specified by the Auxiliary I/O Board
number and the binary input number on the associated board.
For example “Aux 1 input B2” specifies the binary input #2 on
Auxiliary I/O board #1, as specified by the DIP SWITCH setting
(see Section 11.3.1).
• To change the active state assigned to the binary input, press the
UP or DOWN button to navigate to the “Active state:” parameter
and press the EDIT/ENTER button.
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• Press the UP and DOWN buttons to select either “high” or “low”
and press the EDIT/ENTER button. This will specify the alarmed
state of the input
• Pressing the ESC button will return to the previous menu.
Multiple ESC button presses will return the EVO to the HOME
screen
11.5.3 Binary Input Alarm Enable
The binary active alarm enable assignment determines whether the
binary input will generate an alarm when it senses the alarmed state.
Alarms generated by binary inputs will appear by their configured
name in the alarm list and on the bottom of the HOME screen. To
enable or disable the binary input alarm function:
• From the HOME SCREEN, press the MENU button, navigate to
the AUX INPUTS icon and then press the EDIT/ENTER button.
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• Press the UP or DOWN button to navigate to the “Binary Input
Configuration” parameter and press the EDIT/ENTER button.
• Press the UP or DOWN button to navigate to and highlight the
specific binary input to configure. The Auxiliary I/O board binary
inputs default names are specified by the Auxiliary I/O Board
number and the binary input number on the associated board.
For example “Aux 1 input B2” specifies the binary input #2 on
Auxiliary I/O board #1, as specified by the DIP SWITCH setting
(see Section 11.3.1).
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• To change the alarming status of the binary input, press the UP
or DOWN button to navigate to the “Alarm:” parameter and
press the EDIT/ENTER button.
• Press the UP and DOWN buttons to select either “enabled” or
“disabled” and press the EDIT/ENTER button. This will specify
the alarmed state of the input
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• Pressing the ESC button will return to the previous menu.
Multiple ESC button presses will return the EVO to the HOME
screen.
11.5.4 Binary Input Action Assignment
The binary input action assignment links the binary input to a
changer control. Examples of a charger control include charger
shutdown or float/equalize mode control. The EVO will execute the
assigned charger control when the binary input is in the active state.
To assign a control to a binary input:
• From the HOME SCREEN, press the MENU button, navigate to
the AUX INPUTS icon and then press the EDIT/ENTER button.
• Press the UP or DOWN button to navigate to the “Binary Input
Configuration” parameter and press the EDIT/ENTER button.
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• Press the UP or DOWN button to navigate to and highlight the
specific binary input to configure. The Auxiliary I/O board binary
inputs default names are specified by the Auxiliary I/O Board
number and the binary input number on the associated board.
For example “Aux 1 input B2” specifies the binary input #2 on
Auxiliary I/O board #1, as specified by the DIP SWITCH setting
(see Section 11.3.1).
• To change the control action status of the binary input, press the
UP or DOWN button to navigate to the “Action:” parameter and
press the EDIT/ENTER button.
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• Press the UP and DOWN buttons to scroll through the list of
possible control actions (including “none”). Press the EDIT/
ENTER button when the desired control action is selected.
• Pressing the ESC button will return to the previous menu.
Multiple ESC button presses will return the EVO to the HOME
screen.
11.5.5 Factory Default Binary Input Configuration
Unless otherwise specified, the EVO Auxiliary I/O Board will ship
from the factory with the following Binary Input Configuration:
Binary Input #1:
• Alarm: disabled
• Name: BI1-1
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• Action: none
• Active state: high
Binary Input #2:
• Alarm: disabled
• Name: BI1-2
• Action: none
• Active state: high
Binary Input #3:
• Alarm: disabled
• Name: BI1-3
• Action: none
• Active state: high
Binary Input #4:
• Alarm: disabled
• Name: BI1-14
• Action: none
• Active state: high
11.6 Software Configuration for Auxiliary I/O
Board Analog Inputs
The Auxiliary I/O board analog inputs are used to monitor, report,
and/or alarm on the status of any external transducer or sensor.
Each input can be scaled such that the value is reported in primary
units (degrees C, VAC, etc.). The analog inputs can also generate
alarms when their reported values are below, above, or out of range
of a configured valued. The EVO assigns a unique generic name to
each input and allows the user to replace the generic name with a
custom name.
11.6.1 Analog Input Name Assignment
To change the name of an analog input on the Auxiliary I/O board:
• From the HOME SCREEN, press the MENU button, navigate to
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the AUX INPUTS icon and then press the EDIT/ENTER button.
• Press the UP or DOWN button to navigate to the “Analog Input
Configuration” parameter and press the EDIT/ENTER button.
• Press the UP or DOWN button to navigate to and highlight
the specific analog input to configure. The Auxiliary I/O board
analog inputs default names are specified by the Auxiliary I/O
Board number and the analog input number on the associated
board. For example “Aux 1 input AN2” specifies the analog input
#2 on Auxiliary I/O board #1, as specified by the DIP SWITCH
setting (see Section 11.3.1).
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• To change the name assigned to the analog input, press the UP
or DOWN button to navigate to the “Name:” parameter and
press the EDIT/ENTER button.
• Press the UP and DOWN buttons to scroll through the character
set and the LEFT and RIGHT buttons to change character
locations.
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• When the new name is complete, press the EDIT/ENTER button
to store the new unit’s name.
• Pressing the ESC button will return to the previous menu.
Multiple ESC button presses will return the EVO to the HOME
screen
11.6.2 Analog Input Primary Unit Assignment
EVO can scale the analog input values such that they can be
represented in primary units. To change the name of the primary
measurement unit of an analog input on the Auxiliary I/O board:
• From the HOME SCREEN, press the MENU button, navigate to
the AUX INPUTS icon and then press the EDIT/ENTER button.
• Press the UP or DOWN button to navigate to the “Analog Input
Configuration” parameter and press the EDIT/ENTER button.
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• Press the UP or DOWN button to navigate to and highlight
the specific analog input to configure. The Auxiliary I/O board
analog inputs default names are specified by the Auxiliary I/O
Board number and the analog input number on the associated
board. For example “Aux 1 input AN2” specifies the analog input
#2 on Auxiliary I/O board #1, as specified by the DIP SWITCH
setting (see Section 11.3.1).
• To change the name assigned to the analog input’s unit, press
the UP or DOWN button to navigate to the “Units:” parameter
and press the EDIT/ENTER button.
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• Press the UP and DOWN buttons to scroll through the character
set and the LEFT and RIGHT buttons to change character
locations.
• When the new unit name is complete, press the EDIT/ENTER
button to store the new unit’s name.
• Pressing the ESC button will return to the previous menu.
Multiple ESC button presses will return the EVO to the HOME
screen.
11.6.3 Analog Input Scaling Assignment
EVO can scale the analog input values such that the measurement
can be represented in primary units. To adjust the scaling, enter the
primary value when the analog input is a 0.0 VDC and the primary
value when the analog input is at 10.0 VDC. EVO will report the
measurements and adjust the alarm thresholds in true primary units.
To change the scaling of an analog input on the Auxiliary I/O board:
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• From the HOME SCREEN, press the MENU button, navigate to
the AUX INPUTS icon and then press the EDIT/ENTER button.
• Press the UP or DOWN button to navigate to the “Analog Input
Configuration” parameter and press the EDIT/ENTER button.
• Press the UP or DOWN button to navigate to and highlight
the specific analog input to configure. The Auxiliary I/O board
analog inputs default names are specified by the Auxiliary I/O
Board number and the analog input number on the associated
board. For example “Aux 1 input AN2” specifies the analog input
#2 on Auxiliary I/O board #1, as specified by the DIP SWITCH
setting (see Section 11.3.1).
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• To change the low scale value assigned to the analog input,
press the UP or DOWN button to navigate to the “0V=:”
parameter and press the EDIT/ENTER button.
• Press the UP and DOWN buttons to change the digit and the
LEFT and RIGHT buttons to change numbers. This number must
represent the primary value when the input value is 0 VDC. If no
scaling is required, this number should be 0.
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• When the lower scaling is correct, press the EDIT/ENTER button
to store the new scaling.
• To change the high scale value assigned to the analog input,
press the UP or DOWN button to navigate to the “10V=:”
parameter and press the EDIT/ENTER button.
• Press the UP and DOWN buttons to change the digit and the
LEFT and RIGHT buttons to change numbers. This number must
represent the primary value when the input value is 10 VDC. If
no scaling is required, this number should be 10.
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• When the upper scaling is correct, press the EDIT/ENTER button
to store the new scaling.
• Pressing the ESC button will return to the previous menu.
Multiple ESC button presses will return the EVO to the HOME
screen.
11.6.4 Analog Input Alarm and Trigger Assignment
EVO can generate alarms based on the analog input value. There
are several triggers that can be assigned to define the alarm
condition. An alarm can be generated if the analog value is above
a threshold, below a threshold, within a defined range, or outside a
defined range. The threshold parameter(s) required will depend on
the trigger type selected. The threshold parameters must be entered
based on the scaling values such that the thresholds assigned are
within the range of the scaling. To assign an alarm trigger to an
analog input:
• From the HOME SCREEN, press the MENU button, navigate to
the AUX INPUTS icon and then press the EDIT/ENTER button.
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• Press the UP or DOWN button to navigate to the “Analog Input
Configuration” parameter and press the EDIT/ENTER button.
• Press the UP or DOWN button to navigate to and highlight
the specific analog input to configure. The Auxiliary I/O board
analog inputs default names are specified by the Auxiliary I/O
Board number and the analog input number on the associated
board. For example “Aux 1 input AN2” specifies the analog input
#2 on Auxiliary I/O board #1, as specified by the DIP SWITCH
setting (see Section 11.3.1).
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• To assign a trigger for an analog input alarm, press the UP or
DOWN button to navigate to the “Trigger:” parameter and press
the EDIT/ENTER button.
• Press the UP and DOWN buttons to scroll through the list of
alarm triggers.
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• Select the desired trigger and press the EDIT/ENTER button.
• Pressing the ESC button will return to the previous menu.
Multiple ESC button presses will return the EVO to the HOME
screen.
11.6.5 Analog Input Alarm Threshold Assignment
EVO can generate alarms based on the analog input value. The
alarm threshold is the set point(s) at which the alarm occurs. Each
analog input can be assigned an alarm with a trigger. Some triggers
only require one threshold. The “above a threshold” alarm trigger
requires a “high threshold” set point, the “below a threshold” trigger
requires a “low threshold set point.” Other range based triggers
require both a “low threshold” and a “high threshold” set point
to determine the range. EVO will automatically determine which
thresholds are required based on the trigger selected. Always set the
trigger before adjusting the thresholds. To adjust the alarm trigger
threholds for an analog input:
• From the HOME SCREEN, press the MENU button, navigate to
the AUX INPUTS icon and then press the EDIT/ENTER button.
• Press the UP or DOWN button to navigate to the “Analog Input
Configuration” parameter and press the EDIT/ENTER button.
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• Press the UP or DOWN button to navigate to and highlight
the specific analog input to configure. The Auxiliary I/O board
analog inputs default names are specified by the Auxiliary I/O
Board number and the analog input number on the associated
board. For example “Aux 1 input AN2” specifies the analog input
#2 on Auxiliary I/O board #1, as specified by the DIP SWITCH
setting (see Section 11.3.1).
• To adjust the low level threshold set point for a trigger for an
analog input alarm, press the UP or DOWN button to navigate
to the “Low threshold:” parameter and press the EDIT/ENTER
button.
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• Press the UP and DOWN buttons to change the digit and the
LEFT and RIGHT buttons to change numbers. This number
may be in primary values based on the scaling settings for the
associated analog input. The threshold set point configured will
be scaled by the associated analog input scaling.
• When the low threshold is correct, press the EDIT/ENTER button
to store the new set point.
• To adjust the high level threshold set point for a trigger for an
analog input alarm, press the UP or DOWN button to navigate
to the “High threshold:” parameter and press the EDIT/ENTER
button.
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• Press the UP and DOWN buttons to change the digit and the
LEFT and RIGHT buttons to change numbers. This number
may be in primary values based on the scaling settings for the
associated analog input. The threshold set point configured will
be scaled by the associated analog input scaling.
• When the high threshold is correct, press the EDIT/ENTER button
to store the new set point.
• Pressing the ESC button will return to the previous menu.
Multiple ESC button presses will return the EVO to the HOME
screen.
11.6.6 Analog Input Action Assignment
The analog input action assignment links the analog input alarm to
a changer control. Examples of a charger control include charger
shutdown or float/equalize mode control. The EVO will execute the
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assigned charger control when the analog input alarm is in the active
state. To assign a control to an analog input:
• From the HOME SCREEN, press the MENU button, navigate to
the AUX INPUTS icon and then press the EDIT/ENTER button.
• Press the UP or DOWN button to navigate to the “Analog Input
Configuration” parameter and press the EDIT/ENTER button.
• Press the UP or DOWN button to navigate to and highlight
the specific analog input to configure. The Auxiliary I/O board
analog inputs default names are specified by the Auxiliary I/O
Board number and the analog input number on the associated
board. For example “Aux 1 input AN2” specifies the analog input
#2 on Auxiliary I/O board #1, as specified by the DIP SWITCH
setting (see Section 11.3.1).
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• To change the control action status of the analog input, press
the UP or DOWN button to navigate to the “Action:” parameter
and press the EDIT/ENTER button.
• Press the UP and DOWN buttons to scroll through the list of
possible control actions (including “none”). Press the EDIT/
ENTER button when the desired control action is selected.
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• Pressing the ESC button will return to the previous menu.
Multiple ESC button presses will return the EVO to the HOME
screen.
11.6.7 Factory Default Analog Input Configuration
Unless otherwise specified, the EVO Auxiliary I/O Board will ship
from the factory with the following Analog Input Configuration:
Analog Input #1:
• Name: AN1-1
• Units: V
• 0V=: 0.0V
• 10V=: 10.0V
• Trigger: off
• Action: none
Analog Input #2:
• Name: AN1-2
• Units: V
• 0V=: 0.0V
• 10V=: 10.0V
• Trigger: off
• Action: none
Analog Input #3:
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•
•
•
•
•
•
Name: AN1-3
Units: V
0V=: 0.0V
10V=: 10.0V
Trigger: off
Action: none
Analog Input #4:
• Name: AN1-4
• Units: V
• 0V=: 0.0V
• 10V=: 10.0V
• Trigger: off
• Action: none
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12. DRAWINGS
& APPENDICIES
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