Your AT10.1 model number is coded to describe the options that are included. Please find the model
number on the data nameplate and write it in the spaces provided below. Then follow the chart to
determine the configuration of your battery charger.
AT10 X X
A B C D E F K L M N P Q R
DESCRIPTION CODE FEATURE DESCRIPTION CODE FEATURE
A SERIES AT10 AT10.1 CHARGER S STANDARD
NOMINAL
B
DC OUTPUT
VOLTAGE
NOMINAL
C
DC OUTPUT
CURRENT
D FILTERING
AC INPUT
E
VOLTAGE
DESCRIPTION CODE FEATURE DESCRIPTION CODE FEATURE
1 - 120/208/240 Vac multi-tap input - Unit is wired and shipped from factory at specified voltage.
2 - 480 Vac input requires addition of medium or high ampere interrupting capacity circuit breakers.
3 - Special order, consult factory for availability.
012 12 Vdc M MEDIUM AIC
024 24 Vdc
048 48 Vdc
130 130 Vdc AUX SUPPLIED
006 6 Adc
012 12 Adc
016 16 Adc G SUPPLIED
020 20 Adc
025 25 Adc
INPUT AND OUTPUT CIRCUIT BREAKER INTERRUPTING RATINGS
CODE TYPE
S STANDARD 240 Vac: 10,000 AIC
M MEDIUM AIC
H HIGH AIC
4 - Rating applies to 130Vdc 16-25 Adc units.
5 - Approximate rating applies to all other units.
(ALL INPUT VOLTAGES)
240 Vac: 25,000 AIC
480 Vac: 18,000 AIC
240 Vac: 65,000 AIC
480 Vac: 25,000 AIC
NOTE
The model number listed on the charger data nameplate does not include any field-installed
options. Also, certain accessories are not included in the model number, even if they are shipped with the
charger. Check off below any accessories that were included, or that you install yourself.
CIRCUIT
BREAKER
F
RATING
(SEE TABLE)
AUX ALARM
K
RELAY BOARD
L GROUND PAD
LIGHTNING
M
ARRESTOR
FUNGUS
N
PROOFING
STATIC
P
PROOFING
NOT USED
NOT USED
AC RATINGS
H HIGH AIC
XXX NOT SUPPLIED
X NOT SUPPLIED
X NOT SUPPLIED
X NOT APPLIED
X NOT APPLIED
X
X
DC RATINGS
(125 Vdc)
10,000 AIC
5,000 AIC
10,000 AIC
20,000 AIC
4
5
floor/rack mounting brackets analog ac voltmeter (penthouse-mounted)
NEMA-2 type drip shield assembly analog ac ammeter (penthouse-mounted)
NEMA-4/12/13 type enclosure barrier type auxiliary alarm terminal block(s)
cabinet heater assembly external temperature compensation probe
pad lock for front panel door DNP3 Level 2 / Modbus communications module
zero-center ground detect meter forced load sharing interconnection cable
Please find the serial number on the
data nameplate and record it here:
IMPORTANT SAFETY INSTRUCTIONS
PLEASE READ AND FOLLOW
ALL SAFETY INSTRUCTIONS
1. Before using this equipment, read all instructions and cautionary
markings on: A) this equipment, B) battery, and C) any other equipment
to be used in conjunction with this equipment.
2. This manual contains important safety and operating instructions, and
therefore should be filed for easy access.
3. Remove all jewelry, watches, rings, etc. before proceeding with
installation or service.
4. Do not touch any uninsulated parts of this equipment, especially the
input and output connections, as there is the possibility of electrical
shock.
5. During normal operation, batteries may produce explosive gas. Never
smoke, use an open flame, or create arcs in the vicinity of this equipment
or the battery.
6. Maintain at least 6in / 152mm clearance from all obstructions on the top,
bottom and sides of this equipment. Allow sufficient clearance to open
the front panel for servicing.
7. Turn this equipment off before connecting or disconnecting the battery
to avoid a shock hazard and/or equipment damage.
8. Connect or disconnect the battery only when the battery charger is off to
prevent arcing or burning.
9. De-energize all ac and dc inputs to the battery charger before servicing.
10. Do not operate battery charger if it has been damaged in any way. Refer
to qualified service personnel.
11. Do not disassemble battery charger. Only qualified service personnel
should attempt repairs. Incorrect reassembly may result in explosion,
electrical shock, or fire.
12. Do not install the battery charger outdoors, or in wet or damp locations
unless specifically ordered for that environment.
PLEASE READ AND FOLLOW
ALL SAFETY INSTRUCTIONS
i
TABLE OF CONTENTS
QUICK OPERATION.................................................................................................. Back Cover
HOW TO READ THE AT10.1 MODEL NUMBER.......................................... Inside Front Cover
IMPORTANT SAFETY INSTRUCTIONS...................................................................................... i
1 Receiving and Installing the AT10.1 Battery Charger
1.1 Storing the AT10.1................................................................................................. 2
APPENDIX G: UL Data..............................................................................................................92
MANUAL SPECIFICATIONS (document control information / online availability).....................94
* Note: A customized record drawing package is available for your AT10.1 battery charger, featuring an
itemized internal component layout, electrical schematic with componen t ratings, and a full connection
diagram. If the standard drawings featured in this manual ar e not sufficient, please contact your Sales
Representative for drawing availability from the battery charger manufacturer.
iii
RECEIVING THE AT10.1
1. RECEIVING THE AT10.1
1.1. STORING THE AT10.1
If you store the AT10.1 for more than a few days before installation, you
should store it in its original shipping container, and in a temperature
controlled, dry climate. Ambient temperatures of 32 to 122° F / 0 to 50° C
are acceptable. Storage should not exceed 2 years due to the limited shelf
life of the dc filter capacitors when they are not in service.
1.2. REPORTING SHIPPING DAMAGE
If, on delivery of the AT10.1 or related goods, you discover any damage
or shortage, make notation on all copies of delivering carrier's delivery
receipt before signing, and notify the delivery person of your findings. If
loss or damage is discovered after delivery, notify delivering carrier
immediately and request an inspection. The manufacturer does not assume
any liability for damage during transportation or handling.
Should the goods require an inspection by or return to the manufacturer,
please contact your sales representative for further instructions. Any
returned material must be properly packed in compliance with shipping
regulations. It is preferable to use the original shipping materials if
possible. Mark the outside of the shipping container with the Return
Material Authorization (RMA) number issued by the manufacturer.
1.3. UNPACKING AND INSPECTING THE AT10.1
Carefully remove all shipping materials from the AT10.1. Remove the
AT10.1 from the shipping pallet for inspection. Save all shipping
materials until you are sure that there is no shipping damage.
Once the AT10.1 is unpacked, inspect the unit for possible shipping
damage, using the checklist below. If shipping damage has occurred, refer
to Section 1.2 on this page for proper reporting.
INSPECTION CHECKLIST
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.
All wire terminations are secure.
The User's Manual is included.
You received all items on the packing list.
2
1.4. MOVING THE AT10.1
Once you have established that the AT10.1 is undamaged, identify the
enclosure style and weight of your unit. Refer to the table below.
AT10.1 Enclosure Style and Shipping Weight Table
Group I NEMA-1 Cabinets (Style-586 / Style-594)
Output
Voltage 6 Adc 12 Adc 16 Adc 20 Adc 25 Adc
INSTALLING THE AT10.1
Ampere Rating
Style-586
12 Vdc
24 Vdc
48 Vdc
130 Vdc
NOTE: Actual unit is approximately 20 lbs / 9kg below listed shipping weight in table.
44 lbs
20 kg
Style-586
44 lbs
20 kg
Style-586
58 lbs
26 kg
Style-586
80 lbs
36 kg
Style-586
44 lbs
20 kg
Style-586
58 lbs
26 kg
Style-586
75 lbs
34 kg
Style-594
147 lbs
67 kg
Style-586
67 lbs
30 kg
Style-586
75 lbs
34 kg
Style-594
110 lbs
50 kg
Style-594
193 lbs
88 kg
Style-586
67 lbs
30 kg
Style-586
75 lbs
34 kg
Style-594
110 lbs
50 kg
Style-594
193 lbs
88 kg
Style-586
67 lbs
30 kg
Style-586
75 lbs
34 kg
Style-594
110 lbs
50 kg
Style-594
193 lbs
88 kg
The AT10.1 Style-586 & Style-594 enclosures do not feature lifting eyes
for moving. Whenever possible, move the unit with a forklift truck, using
the supplied shipping pallet. To lift or relocate the AT10.1 into a wallmount or rack-mount location, use a heavy-duty sling on a hoist or forklift
truck applicable for the enclosure size and unit weight listed above.
For further AT10.1 standard cabinet information, see the outline drawings
for the Style-586 (JE5023-03
) and Style-594 (JE5024-03) enclosures in
Appendix C on pages 72 and 73.
1.5. MOUNTING THE AT10.1
Chose the mounting method for the unit enclosure from the table below.
MANUAL
SECTION
1.5.1 Wall-Mounting
1.5.2 Floor-Mounting OPTIONAL OPTIONAL
1.5.3
3
MOUNTING METHOD
STANDARD STANDARD
19in / 483mm Rack-MountingOPTIONAL N/A
23-24in / 584-610mm
Rack-Mounting
OPTIONAL OPTIONAL
ENCLOSURE
Style-586 Style-594
INSTALLING THE AT10.1
1.5.1. Wall-Mounting the AT10.1
Wall-mounting the AT10.1 is the standard means to install the Group I
enclosures (Style-586 & Style-594). In planning for wall mounting of the
AT10.1, consider the following:
1. The wall must be strong enough to properly support the weight of the
AT10.1. See the Weight Table located in Section 1.4 on page 3. The weight
of your AT10.1 may be different from the table value, depending on options
or accessories you ordered.
2. Select conduit entrances carefully. Use of the pref-fab knockouts on the
sides or bottom of the enclosure will allow removal of the cabinet shroud
(and internal access for servicing) without removal of unit from the wall.
3. The location:
• Should be free of drips and splatter. If dripping liquids are a problem,
install a drip shield kit (EI0191-00). For kit availability, see ordering
information in Appendix B on page 71.
• Should be between 32 and 122 °F / 0 and 50 °C, with relative humidity
between 5 and 95% non-condensing.
• Must be free of explosive materials.
4. Maintain at least 6in / 152mm of free air on top, bottom and both sides for
cooling air.
5. Allow 36in / 914mm front clearance for operation and maintenance.
4
Style-586 Enclosure Style-594 Enclosure
INSTALLING THE AT10.1
PROCEDURE
To wall-mount the AT10.1, install four (4) .25in / 6.4mm bolts on the wall
rated to support the charger weight plus a safety factor of at least two (2)
times. Place the AT10.1 on the bolts, add appropriate mounting hardware
and tighten. Refer to the graphics below for mounting dimensions and
specifications.
WALL-MOUNTING THE AT10.1 - GRAPHICS
NOTE
1. For further AT10.1 standard cabinet information, see the outline
drawings for the Style-586 (JE5023-03
) and Style-594 (JE5024-03)
enclosures in Appendix C on pages 72 and 73.
5
INSTALLING THE AT10.1
1.5.2. Floor-Mounting the AT10.1
To floor mount the AT10.1, you must use the floor mounting accessory kit
(EI0192-00). For kit availability, see ordering information in Appendix
B on page 71. The kit contains brackets that elevate the top of the AT10.1
approximately 47in / 1194mm above floor level, with provision for floor
anchoring. The kit includes an instruction sheet (JA0083-00
assembly dimensions and mounting details.
You must locate the anchor-bolt holes at least 4.25in / 108mm from any
wall, to allow clearance for the charger enclosure behind the mounting
brackets. In addition, you must consider the following:
1. Placement of conduit entrances (use the knockouts on the sides or bottom of
the charger to allow access for servicing without removing the unit from the
mounting brackets).
2. The location:
• Should be free of drips and splatter. If dripping liquids are a problem,
install a drip shield kit (EI0191-00). For kit availability, see ordering
information in Appendix B on page 71.
• Should be between 32 and 122 °F / 0 and 50 °C, with relative humidity
between 5 and 95% non-condensing.
• Must be free of explosive materials.
3. Maintain at least 6in / 152mm of free air on top, bottom and both sides for
cooling air.
4. Allow 36in / 914mm front clearance for operation and maintenance.
PROCEDURE
) showing
6
To floor-mount the AT10.1,
follow the directions featured in
instruction sheet (JA0083-00
),
included with your floormounting kit (EI0192-00).
These instructions showing
assembly dimensions and
mounting details.
Place the AT10.1 assembly on
the mounting bolts, add
appropriate mounting hardware
and tighten.
Reference the graphics on the
next page.
INSTALLING THE AT10.1
FLOOR-MOUNTING THE AT10.1 - GRAPHICS
DIMENSION (in / mm)
ENCLOSURE
Style-586
Style-594
7
A B C D
16.50 / 419 46.63 / 1184 11.75 / 298 15.00 / 381
19.75 / 502 47.75 / 1213 14.25 / 361 18.25 / 463
INSTALLING THE AT10.1
1.5.3. Rack-Mounting the AT10.1
The AT10.1 can be installed in most relay racks with standard EIA hole
spacing (see the table below for the allowable combinations). The rack
mounting kit (EI0193-00), includes mounting brackets and the necessary
hardware to install one AT10.1 battery charger. The kit includes an
instruction sheet (JA0091-00
availability see ordering information in Appendix B on page 71.
When rack mounting the AT10.1, you must consider the following:
1. The rack must be strong enough to properly support the weight of the
AT10.1. See the Weight Table located in Section 1.4 on page 3.
2. Placement of conduit entrances (be sure the knockouts on the sides or
bottom of the charger are accessible after the charger is rack-mounted).
3. The location:
• Should be free of drips and splatter. If dripping liquids are a problem,
install a drip shield kit (EI0191-00). For kit availability, see ordering
information in Appendix B on page 71.
• Should be between 32 and 122 °F / 0 and 50 °C, with relative humidity
between 5 and 95% non-condensing.
• Must be free of explosive materials.
4. Maintain at least 6in / 152mm of free air on top, bottom and both sides for
cooling air.
5. Allow 36in / 914mm front clearance for operation and maintenance.
PROCEDURE
) showing installation details. For kit
To rack mount the AT10.1 enclosure, first install the brackets onto the
rack. Second, mount the AT10.1 onto the rack-mounting brackets using
the hardware supplied. Provide at least 6in / 152mm of air space above
and below the AT10.1 in the rack for cooling. You do not need to modify
the AT10.1 enclosure. Rack-mount outline dimensions are shown on the
next page.
2. Units shown above without penthouse enclosure. If penthouse is used, add
7in / 178mm to top of enclosure.
3. Refer to the outline drawings in Appedix C for enclosure dimensions.
9
INSTALLING THE AT10.1
1.6. CHANGING TRANSFORMER TAPS
Before you wire ac power to the AT10.1, check the wiring of the main
transformer (T1), to be sure it is connected for your ac input voltage. The
AT10.1 accepts standard input voltages of 120, 208 or 240 Vac by
changing jumpers on T1. No other changes are required. The AT10.1 is wired at the factory for 240 Vac, except on special order. Models for 220,
380 or 416 Vac at 50/60 Hz are available on special order.
EXCEPTION: An AT10.1 battery charger rated for 480 Vac input uses a
special transformer that has no taps or jumpers. The 480 Vac
transformer cannot be used for any other input voltage.
Before changing the T1 taps, be sure that ac and dc supplies to the AT10.1
are turned off and locked out. Verify that no voltage is present by using a
voltmeter at terminals TB1-L1 and TB1-L2 (ac), TB1(+) and TB1(-) (dc)
and remote sense terminals (dc). Note that turning off the ac and dc circuit
breakers on the AT10.1 does not eliminate live voltages inside the
enclosure. Also de-energize any external wiring to the alarm relay
contacts.
Verify that all voltages within the enclosure are de-energized and locked
out. See Section 3.5 for necessary steps to follow when accessing internal
components within the AT10.1. Change the jumpers on T1 as shown in
the table on the next page. All transformers have (2) jumpers; always use
both as specified in the table. The transformers used in the small enclosure
(586) use piggyback quick-connect terminals. The transformers in the
larger enclosure (594) use 10-32 stud terminals.
Models designed for 220 Vac, 50/60 Hz have no jumpers, and can be used
only for that voltage. Models designed for 380 or 416 Vac also have no
jumpers, and can be operated on either voltage.
NOTE: This procedure refers only to Group I AT10.1 battery chargers
(rated 6-25 Adc). A different procedure exists for Group II AT10.1
battery chargers (rated 30-100 Adc). Refer to the Operating and
Service Instructions specific to the Group II AT10.1 battery charger for
changing the transformer taps on these larger units. Otherwise, damage
to your charger and equipment may occur.
1) BE SURE ALL VOLTAGES ARE DE-ENERGIZED AND LOCKED OUT.
2) BE SURE TERMINALS ARE FULLY SEATED (586 ENCL).
3) BE SURE STUD TERMINALS ARE TIGHT (594 ENCL).
4) CHECK YOUR WORK AFTER COMPLETION.
5) FOR ADDITIONAL INFORMATION, SEE WIRING DIAGRAM
IN APPENDIX.
TYPICAL FOR TRANSFORMER
IN 594 ENCLOSURE
.
X1
X4
Y2
Y1
H1
H3
H2
H5
H4
JUMPERS (2)
H1
H3
H2
H5
H4
F1-5R2
11
INSTALLING THE AT10.1
1.7. MAKING THE AC INPUT CONNECTIONS
Follow these steps to connect ac power to the AT10.1:
1. Confirm that the AT10.1 main power transformer (T1) is properly jumpered
for your ac input supply voltage. See Section 1.6 for details.
2. Use a branch circuit breaker or fused disconnect switch upstream from the
AT10.1. This device should have lockout capability so that the ac input
supply to the AT10.1 can be de-energized for charger 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 AT10.1. This rating is listed on the left-hand side of
the AT10.1 data nameplate. For a comprehensive list of these maximum ac
input values, access standard (DC5016-00
4. Size ac input wiring per the National Electric Code (NEC) 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 of the
AT10.1 enclosure as external dc output power wiring.
6. All site requirements of your facility take precedence over these instructions.
).
PROCEDURE
1. Remove the plexiglas safety cover.
2. Run the ac input supply wiring into the AT10.1, ending at terminals TB1-L1,
TB1-L2, and TB1-GND on the I/O panel board.
3. The AT10.1 features three (3) CU-AL compression lugs on the ac input
terminals, which accept #14 - 6 AWG wire. Strip 0.50in / 13mm from the
insulation of the incoming ac input supply wiring.
4. Connect the wires to the appropriate ac lugs as shown on the next page.
5. Using a flat-head screwdriver, securely tighten the compression screws on
the ac lugs to 35-45 in-lb / 4.0-5.1 Nm.
6. Check all connections and reinstall the plexiglas safety cover.
12
INSTALLING THE AT10.1
MAKING THE AC INPUT CONNECTIONS - GRAPHICS
NOTES
1. The drawing above does not show other components mounted to the I/O
panel. Be careful not to disconect any other component leads.
2. Always use a proper ground.
3. Use copper or aluminum conductors only.
4. On 120 Vac input, connect the neutral leg to the terminal L2.
13
INSTALLING THE AT10.1
1.8. MAKING THE DC OUTPUT CONNECTIONS
Follow these steps to connect the battery to the AT10.1:
1. Size the dc wiring to minimize voltage drop. The acceptable wire size
depends on your installation. As a guideline, the voltage drop should not
exceed 1% of nominal output voltage at full current. Refer to the table below
to determine the voltage drops for various wire sizes, currents and distances.
WIRE SIZING CHART
VOLTAGE DROP PER 100ft / 30.5m OF WIRE (FOR COPPER AT 68° F / 20° C)
WIRE SIZE
(AWG)
#16
#14
#12
#10
#8
#6
#4
EXAMPLE: 100ft / 30.5m of #8 AWG wire at 16A has a 1.1V drop.
6 12 16 20 25
2.5V 5.0V 6.7V 8.2V 10.5V
1.6V 3.2V 4.2V 5.3V 6.6V
1.0V 2.0V 2.6V 3.3V 4.2V
0.63V 1.3V 1.7V 2.1V 2.6V
0.40V 0.80V 1.1V 1.3V 1.7V
0.25V 0.50V 0.66V 0.83V 1.1V
0.16V 0.32V 0.42V 0.52V 0.65V
2. The AT10.1 is factory wired to regulate output voltage at the output
terminals. If the total voltage drop is greater than 1% (e.g., 1.3V for a 130
Vdc system), remote sense wiring is recommended, see Section 1.9.
3. Do not run external ac and dc power wiring, feeding the battery charger,
through the same conduit.
4. All specific requirements of your facility take precedence over these
instructions.
PROCEDURE
1. Use a dc disconnect switch or circuit breaker between the AT10.1 and dc
bus. This device should have lockout capability to allow the AT10.1 to be
disconnected from the dc bus for maintenance.
2. Remove the safety cover.
3. Run the dc wiring to terminals TB1(+) and TB1(-) on the I/O panel in the
enclosure. Compression lugs, accepting wire sizes #14-6 AWG, are supplied
for your convenience. To make these connections, strip the insulation .50in /
12.7mm on the incoming wires. Connect the wires to the appropriate lugs as
shown on the next page.
4. Using a flat-head screwdriver, securely tighten the compression screws on
the lugs to 35-45 in-lb / 4.0-5.1 Nm.
5. Reinstall the safety cover after you have made and checked all connections.
DC CURRENT (Amperes)
14
INSTALLING THE AT10.1
MAKING THE DC OUTPUT CONNECTIONS - GRAPHICS
NOTES
1. The drawing above does not show other components mounted to the I/O
panel. Be careful not to disconect any other component leads.
2. Always use a proper ground.
3. Use copper or aluminum conductors only.
15
INSTALLING THE AT10.1
1.9. WIRING THE AT10.1 FOR REMOTE SENSING
You can wire the AT10.1 to regulate the output voltage at the battery
terminals, instead of at the charger output terminals. Remote sensing does
the following:
1. Compensates for voltage drop in the dc wiring between the AT10.1 and the
battery.
2. Directly monitors the battery or dc bus voltage. The front panel meter
displays the actual voltage on the battery or dc bus.
You wire the AT10.1 for remote sensing by installing twisted pair cabling
from the AT10.1 remote sense terminals to the battery terminals. The
AT10.1 control circuitry then measures the dc voltage at the battery
terminals, and controls the output of the charger to maintain the battery
voltage at the desired float or equalize voltage.
NOTE: If the remote sense wiring fails, the AT10.1 detects the fault,
and displays E 06 on the front panel meter. See Section 3.2 for details.
CAUTION: The AT10.1 cannot protect against short circuits in the
remote sense wiring. You should install a 1.0A fuse at the battery or dc
bus end of the remote sense cable.
SCHEMATIC
PROCEDURE
1. De-energize and lock out all ac and dc voltages within the AT10.1 enclosure.
Check with a voltmeter.
2. Remove safety shield.
3. Remove the two (2) dc output CU-AL compression lugs.
4. Move lugged end of R14 (with wire # 20) from TB1(-) to REM SENSE(-).
5. Move wire # 21 from TB1(+) to REM SENSE (+).
16
INSTALLING THE AT10.1
6. Connect user-supplied external remote sense leads from the battery or dc bus
to the remote sense terminals on the I/O panel.
7. Replace the two (2) dc output CU-AL com p ression lugs and tighten all
hardware.
8. Check your work thoroughly. Replace the safety shield before reeneregizing
the AT10.1.
9. Restart the AT10.1 according to the instructions in Section 2.1.
NOTES
1. Use #16 AWG twisted pair wire.
2. Maximum current is 150 mA.
3. Run leads in their own conduit.
4. Fuse the wiring at the battery or dc bus.
DISABLING REMOTE SENSE
If you ever need to disable remote sense, follow the steps below:
• De-energize and lock out all ac and dc voltages to the AT10.1. Check
with a voltmeter.
• Disconnect the remote sense wires from the battery or dc bus terminals
first.
CAUTION: You must do the steps above first.
• Remove the remote sense leads from the remote sense (+) and (-)
terminals on the I/O panel. Insulate each lead separately. Coil up the
wires and leave them in the bottom of the charger, in case you want to
wire for remote sense again in the future.
• Reconnect the lugged end of R14 (with wire # 20) to TB1(-).
• Reconnect wire # 21 to TB1(+).
• Restart the AT10.1 according to the instructions in Section 2.1.
17
INSTALLING THE AT10.1
1.10. WIRING TO THE REMOTE ALARM CONTACTS
Built-in Summary (Common) Alarm Relay (standard)
The AT10.1 Main
Control PC Board (A1)
is equipped with a
"common" Summary
Alarm relay. This relay
contact transfers when
any one or more of the
standard AT10.1
alarms exist.
See Section 2.2.7 for a
description of the alarm
functions. One form-C
alarm contacts are
provided, and
accessible via terminal
block (TB3), as show
in the figure on the
right.
Follow the procedure
below to wire a remote
annunciator to this
contact.
PROCEDURE
1. Allow 30in / 762mm of wire inside the enclosure. Excess will be trimmed.
2. Route annunciator wires to the AT10.1 front panel door by following the
existing harness through the door hinge as shown. Use two (2) wire ties and
allow a 4-6in / 102-153mm loop for the hinge.
3. Trim wires to the proper length for connecting to TB3. Strip 0.25in / 6.4mm
of insulation from the wires.
4. Make the connections at TB3, and securely tighten compression screws.
NOTES
1. Alarm contacts are rated at 0.5A / 125 Vac or Vdc.
4. If user alarm contacts (TB3 and/or TB4A/B) are to drive inductive dc loads
(e.g. a larger dc relay) an external protective diode must be applied at the dc
relay to avoid equipment damage. See Application Note (JD5011-00).
18
INSTALLING THE AT10.1
Auxiliary Relay Board (optional)
The optional Auxiliary Alarm Relay PC Board (A5), mounted inside the
separate top enclosure (penthouse), provides two (2) form-C contacts
(TB4-1 through TB4-36) for each of the following individual alarms:
• High DC Voltage
• Low DC Voltage
• DC Output Failure
• AC Input Failure
• Ground Fault Detection (positive or negative)
• Summary (common) Alarm
Alarm contacts (TB4) are as follows, shown in non-alarm condition:
DC OUT
HVDC HVDC LVDC LVDC
C, NC, NO C, NC, NO C, NC, NO C, NC, NO C, NC, NO C, NC, NO C, NC, NO C, NC, NO C, NC, NO C, NC, NO C, NC, NO C, NC, NO
4. For a detailed view of the optional Auxiliary Alarm Relay PC Board (A5),
refer to drawing (JE5030-19) listed in Appenix C on Page 78.
19
INSTALLING THE AT10.1
1.11. INSTALLING THE TEMPCO PROBE ASSEMBLY (OPTIONAL)
The temperature compensation probe contains a temperature-dependent
resistor in an epoxy module that you install near your battery. There are
three steps in installing the assembly:
1. Mounting the probe assembly near the battery.
2. Installing an interconnection cable from the probe assembly to the AT10.1.
3. Wiring the charger end of the cable to a terminal block on the main control
circuit board.
The actual TempCo probe is the same for all battery types and all output
voltages of the AT10.1. The accessory part numbers differ depending on
cable length ordered. See the tables in Appendix B on page 71 for
ordering information. Each kit contains detailed installation instructions
(JA5015-00
user details. The main elements of the installation are outlined below.
WARNING
), and a separate Application Note (JD5003-00) for further
High voltages appear at several points inside the AT10.1. Use extreme
caution when working inside the unit. Do not attempt to work inside the
AT10.1 unless you are a qualified technician or electrician.
Disconnect and lock out all power from the AT10.1 before starting to
remove or replace any components. Turn the ac power off at the
distribution panel upstream from the charger. Disconnect the battery
from the AT10.1 output terminals TB1(+/-).
PROCEDURE
1. De-energize and lock out all ac and dc voltage sources to the AT10.1, and
check with a voltmeter before proceeding.
2. Mount the probe on a clean, dry surface, as close to the battery as possible,
such as the battery rack. DO NOT mount the probe:
• on the battery itself
• on unpainted wood, or bare galvanized metal
• on plastic surfaces
3. To apply the probe, clean the mounting surface with isopropyl alcohol, and
allow to dry thoroughly. Remove the protective backing from the doublefaced adhesive tape on the probe, and securely press it onto the surface.
4. Install the cable supplied with the temperature compensation probe kit:
20
• Start at the AT10.1 charger. The end of the cable with two stripped
wires and one lead with a quick-connect terminal will be connected
inside the AT10.1. Leave 30in / 762mm of cable inside the enclosure,
and route the other end to the probe at the battery.
INSTALLING THE AT10.1
• Run the cable though a conduit if possible, but not through a conduit
containing any power wiring.
• Route the other end to the probe at the battery and coil up excess cable.
NOTE: If the standard (25ft / 7.6m) cable is not long enough, longer
cable assemblies are available in lengths of 50, 100 & 200ft / 15.2,
30.5 & 61.0m. See Appendix B on page 71 for ordering information.
• Be sure your wiring conforms to the NEC and your facility requirements.
5. Attach the interconnection cable to the AT10.1 as shown in the figure below:
• Route the
cable within
the AT10.1
enclosure so it
runs with the
wire harness
to the back of
the front
panel, and
easily reaches
the main
control circuit
board.
• At the main
control circuit
board, insert
one of the bare
wires from the
cable into each
terminal of
TB8. Polarity
is not
important.
• Unplug the harness ground wire # 30 from terminal J6 on the left edge of
the main control circuit board. Plug the connector at the end of the
nylon-shielded wire of the cable assembly onto J6. Reconnect the
ground wire # 30 from the system harness onto the piggy-back connector
featured at the end of the nylon-shielded wire.
• Using plastic wire ties, fasten the interconnection cable loosely to the
existing wire harness. Make sure that the cable conforms to the service
loop at the hinge end of the door.
6. At the battery, connect the quick-connect terminals to the temperature
compensation probe. Polarity is not important. Coil up any excess wire and
tape or tie it together to prevent damage.
21
INSTALLING THE AT10.1
7. Check your work. Be sure that:
• All connections are secure.
• The shield is connected to ground at the charger end only (on the main
circuit board).
• The cable is connected to TB8 on the circuit board. Other terminal
blocks may look similar.
8. Restart the AT10.1 using the startup procedure in Section 2.1. During
startup, the AT10.1 displays LEAD on the front panel, indicating that the
temperature compensation is set up for lead-acid batterie s. While this is
being displayed, you can press any front panel key to change the display to
read NICD, to change the temperature compensation setup for nickel
cadmium batteries. The choice you make is saved internally, and will be
used again by the AT10.1 the next time it starts.
9. Adjust the output float and equalize voltages to the battery manufacturer's
recommended values, using the AT10.1 front panel meter, as described in
Section 2.3.2.
NOTE: If the temperature compensation probe, or the wiring
from the probe to the AT10.1, is damaged and becomes an
open circuit, the AT10.1 detects the damage and displays
E 08 on the display. The charger then reverts to normal non-
temperature-compensated operation until the probe or wiring
is repaired. Once the probe is repaired, you must restart the
AT10.1 to activate the probe, as described in Section 2.1.
Using temperature compensation
When an electric storage battery is being charged, the terminal voltage of
the battery changes a small amount whenever the battery temperature
changes. As the battery temperature increases, its terminal voltage
decreases. When a battery is charged by a float type charger with a
constant output voltage, float current increases when the temperature
increases. This results in overcharging the battery, which can result in
damage to the materials, or at least the need for more frequent
maintenance.
When the AT10.1 is equipped with a temperature compensation probe, it
is able to adjust the output voltage applied to the battery to keep the float
current constant, thereby avoiding overcharging. The probe senses the
ambient temperature at the battery, and adjusts the output float/equalize
voltages to compensate for variations in temperature. If the ambient
temperature increases, the AT10.1 output voltage decreases.
If you are experiencing any inconsistencies in the AT10.1 when the
temperature compensation probe is utilized, temporarily disconnect the
probe, and refer to the Application Note (
JD5003-00
) for further details.
22
INSTALLING THE AT10.1
Note the following:
• You should set the Float and Equalize voltages to the values
recommended by your battery manufacturer for 77° F (25° C).
• When you enter the Edit mode to adjust the Float or Equalize voltage
(see Section 2.3.2), the front panel meter shows the 77° F (25° C) value
for the Float or Equalize voltage, even if the battery is warmer or cooler
than 77° F (25° C).
• The actual output voltage of the AT10.1 may be different from the value
shown on the front panel meter, if the battery is warmer or cooler than
77° F (25° C).
• Use a digital meter to measure the actual output voltage of the AT10.1.
If you know the temperature at the temperature compensation probe, you
can use the graph below to determine that the output voltage is correct.
• If the battery temperature goes below 32° F (0° C), there will be no
further increase in charger output voltage. Likewise, if the battery
temperature goes above 122° F (50° C), there is no further decrease in
output voltage.
OUTPUT VOLTAGE VS BATTERY TEMPERATURE
108
106
104
102
Nickel-Cadmium
100
Percent Output Voltage
98
96
94
20406080100120
Temperature, D egrees Fahrenheit
Lead-Acid
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
Example:
100 Deg. F
97% Output
Voltage
1.12. INSTALLING FOR REMOTE COMMUNICATION (OPTIONAL)
Refer to separate Operating Instructions (JA0102-04
).
1.13. INSTALLING FOR FORCED LOAD SHARING (OPTIONAL)
Refer to Appendix F on page 90, or Instructions (JA5054-0
23
).
OPERATING THE AT10.1
2. OPERATING THE AT10.1 BATTERY CHARGER
2.1. STARTING THE AT10.1
2.1.1. Understanding the startup sequence
The AT10.1 is set up at the factory to work with most common batteries
and loads without further adjustment. When you start the AT10.1 for the
first time, the factory settings (float voltage, equalize voltage, etc.) control
the operation of the charger. You can change the settings after you start
the charger. The FACTORY SETTINGS are shown in table on page 25.
The AT10.1 startup routine takes about five seconds. The microprocessor
that controls the AT10.1 initializes the charger by reading the settings that
are stored internally. The control circuit then "soft starts" the charger, and
the dc output voltage and current increase gradually to the rated value.
2.1.2. Checking the installation
Be sure that you have followed the installation
instructions carefully. Check the ac input
supply voltage and the battery voltage, and be
sure that they match the information on the
AT10.1 nameplate. Verify that the jumpers on
the main transformer T1 are correct for your
ac supply voltage. Open the front panel, and
check the battery polarity at the TB1 (+) and (-)
terminals.
2.1.3. Starting the AT10.1
When you are sure that all connections to the
AT10.1 are properly made, follow these steps
to start up the AT10.1:
• Turn on the front panel dc circuit breaker. The digital meter indicates the
battery voltage only. If the meter display doesn't light, do not proceed.
Turn off the dc breaker, and check all connections and the battery
polarity again. Also check the battery voltage. It must be above 50% of
nominal voltage to turn on the display. If you can't find the problem,
refer to the Troubleshooting Procedure in Section 3.1 on page 44.
Using the Digital Meter
When you first start the
AT10.1, the meter display
alternates between dc output
voltage and dc output current.
Each reading is held for two
seconds; lights to the left of
the display indicate whether
the meter is displaying
voltage or current.
If you want to "freeze" the
meter to display only voltage,
press the METER MODE
key on the front panel. To
freeze the meter to display
only current, press the key
again. Press the key twice
more to revert to the
alternating display.
24
CAUTION: If you try to turn on the dc circuit breaker with the battery
connected in reverse polarity, the circuit breaker will immediately
trip. Do not try to close the dc breaker again, since this may damage
the battery charger. Correct the battery polarity before proceeding.
OPERATING THE AT10.1
• If you have an optional temperature compensation probe installed, the
front panel displays LEAD during startup, indicating that the
temperature compensation is set up for lead-acid batterie s. While this is
being displayed, you can press any front panel key to change the display
to read NICD, to change the temperature compensation setup for nickel
cadmium batteries. The choice you make is saved internally, and will be
used again by the AT10.1 then next time it starts.
• Turn on the front panel ac circuit breaker. The digital meter displays the
output voltage and current. See Using the Digital Meter on page 24. You
should hear a soft hum from the AT10.1 as the output current increases.
NOTE: If you turn on the ac breaker before the dc breaker,
and you have a filtered model of the AT10.1, there is a
possibility that the dc breaker will trip when you try to turn it
on. This is caused by the filter capacitors discharging into the
battery. To get around this problem, turn off the ac breaker.
Restart the AT10.1 by turning on the dc breaker first.
• The green FLOAT indicator lights. Press the CHRG MODE key on the
front panel. The FLOAT indicator goes off, and the yellow EQLZ
indicator lights. Press the CHRG MODE key again to return the charger to
the float mode.
The table below shows the normal factory settings for float and equalize
voltages, equalize time, current limit setting, and alarm settings. If your
purchase order specified other float or equalize voltage settings, a tag
attached to the front panel of the AT10.1 lists the actual voltage settings.
FACTORY SETTINGS FOR ALL PARAMETERS
Parameter
Float Voltage
Equalize Voltage
HVDC Alarm
LVDC Alarm
Equalize Time
Equalize Method
Current Limit
HVDC Shutdown
Nominal Vdc
12 24 48 130
13 26 52 131
14 28 56 139
14.4 28.8 57.6 144
12 24 48 120
24 Hours
Manual Timer
110% of nominal output current
Disabled
25
OPERATING THE AT10.1
2.2. USING THE AT10.1 FRONT PANEL FEATURES
2.2.1. If the meter displays an error or status message
The AT10.1 microprocessor control circuit performs diagnostic checks of
the battery charger during system start-up, then continuously during
operation. If it detects a failure or special status, an intermittent code will
appear on the front instrument panel, displayed between dc output values.
The following table is a list of these error (E ##) and status (A ##) codes.
Code Explanation
E 01
E 02
E 03
E 04
E 06
E 07
E 08
E 09
E 10
E 12
E 13
E 14
A 01
A 02
A 04
A 05
resistor R2 open or defective
short circuit on dc output
high dc voltage shutdown occurrence
internal memory failure
remote sense wiring failure
dc breaker open, or dc output wiring defective
temperature compensation probe defective
current limit setting misadjusted
internal feedback loop open
defective internal thermostat
internal over-temperature occurrence
forced load sharing not working properly
manual equalize enabled for more than 24 hrs
equalize mode inhibited
voltmeter calibration inhibited w/tempco active
dc output at Current Limit setting
Codes E 05, E 11, and A 03 are not used. See Section 3.2 on page 45 for
a full explanation of each code.
2.2.2. Selecting the meter mode
• Press the
meter has four operating modes:
• When the charger starts initially, the meter alternates, showing output
voltage and output current. The DC Volts and DC Amps indicators light
alternately to indicate what is being displayed.
26
METER MODEkey to change the meter display mode. The digital
1. Alternating between output voltage and output current. When the
charger is in a timed equalize mode, the meter alternates between
output voltage, output current, and equalize hours remaining.
2. Displaying output voltage only. The DC Volts indicator lights.
3. Displaying output current only. The DC Amps indicator lights.
4. Displaying equalize hours remaining only. The EQLZ HRS
REMAINING
equalize mode, the meter displays the full programmed equalize
time.
indicator lights. If the AT10.1 is not in a timed
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