Exide Technologies 94.20 User Manual

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Page 1

10.1

SERIES CHARGERS

Section 94.20

INSTALLATION & OPERATING

INSTRUCTIONS

FOR

2011-11

JA0128-01

AT10.1 SERIES

BATTERY CHARGER

GROUP I

(6-25 ADC OUTPUT)

I & O MANUALS

Page 2

HOW TO READ THE AT10.1 MODEL NUMBER

GROUP I RATINGS (6-25 Adc)

Your AT10.1 model number is coded to describe the options that are included. Please find the model number on the data nameplate and write it in the spaces provided below. Then follow the chart to determine the configuration of your battery charger.

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

DC OUTPUT VOLTAGE

NOMINAL

DC OUTPUT CURRENT

D FILTERING

AC INPUT

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

U UNFILTERED L SUPPLIED F FILTERED

E ELIMINATOR 120 120 Vac 60 Hz 1 F APPLIED 208 208 Vac 60 Hz 1 240 240 Vac 60 Hz 1 S APPLIED 480 480 Vac 60 Hz 2 220 220 Vac 50/60 Hz 3 380 380 Vac 50/60 Hz 3 Q 416 416 Vac 50/60 Hz 3 R

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

RATING (SEE TABLE)

AUX ALARM

RELAY BOARD

L GROUND PAD

LIGHTNING

ARRESTOR

FUNGUS

PROOFING STATIC

PROOFING

NOT USED NOT USED

AC RATINGS

H HIGH AIC

XXX NOT SUPPLIED

X NOT SUPPLIED

X NOT APPLIED

X X

DC RATINGS

(125 Vdc)

10,000 AIC

5,000 AIC 10,000 AIC

20,000 AIC

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:

Page 3

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

Page 4

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

1.2 Reporting shipping damage...................................................................................2

1.3 Unpacking and inspecting the AT10.1...................................................................2

Inspection checklist................................................................................................ 2

1.4 Moving the AT10.1.................................................................................................3

Enclosure type and weight table............................................................................3

1.5 Mounting the AT10.1 ............................................................................................. 3

1.5.1 Wall-Mounting the AT10.1............................................................................... 4

1.5.2 Floor-Mounting the AT10.1..............................................................................6

1.5.3 Rack-Mounting the AT10.1..............................................................................8

1.6 Changing transformer taps .................................................................................. 10

1.7 Making the ac input connections......................................................................... 12

1.8 Making the dc output connections....................................................................... 14

1.9 Wiring the AT10.1 for remote sensing.................................................................16

1.10 Wiring to the remote alarm contacts.................................................................... 18

Auxiliary Relay Board (optional) .......................................................................... 19

1.11 Installing the temperature compensation assembly (optional)............................20

Using temperature compensation........................................................................ 22

1.12 Installing the AT10.1 for remote communications (optional)............................... 23

1.13 Installing the AT10.1 for forced load sharing (optional).......................................23

2 Operating the AT10.1 Battery Charger

2.1 Starting the AT10.1

2.1.1 Understanding the start-up sequence...........................................................24

2.1.2 Checking the installation ............................................................................... 24

2.1.3 Starting the AT10.1 ....................................................................................... 24

Using the digital meter................................................................................... 24

Factory settings table.................................................................................... 25

2.2 Using the AT10.1 front panel features

2.2.1 If the meter displays an error message......................................................... 26

2.2.2 Selecting the meter mode ............................................................................. 26

2.2.3 Selecting the Float or Equalize mode ........................................................... 27

2.2.4 Choosing the Equalize method.....................................................................27

Manual Timer method ................................................................................... 27

Manual Equalize method...............................................................................28

Auto-Equalize Timer method......................................................................... 28

2.2.5 Testing the front panel indicators & Summary Alarm Relays........................29

2.2.6 Testing the Auxiliary Relay Board.................................................................29

2.2.7 Interpreting the alarm indicators.................................................................... 29

Page 5

TABLE OF CONTENTS

2.3 Setting the AT10.1 parameters

2.3.1 Understanding parameter settings ................................................................30

2.3.2 Setting the Float and Equalize voltages........................................................31

2.3.3 Setting the Equalize timer..............................................................................32

2.3.4 Setting the Alarms.........................................................................................32

Setting the high and low dc voltage alarms...................................................33

Adjusting ground detection sensitivity ...........................................................34

Disabling the ground detection alarm............................................................35

2.3.5 Setting the current limit value........................................................................35

2.3.6 Enabling the high dc voltage shutdown feature.............................................36

2.3.7 Adjusting the Voltmeter accuracy..................................................................37

2.3.8 Using the Low Level Detector (LLD)..............................................................38

2.3.9 Using the front panel security feature............................................................39

2.4 Performing routine maintenance..........................................................................40

Sample preventive maintenance procedure..................................................42

3 Servicing the AT10.1 Battery Charger

3.1 A step-by-step troubleshooting procedure...........................................................44

3.2 Interpreting front panel error messages...............................................................45

3.3 Using the troubleshooting chart...........................................................................48

3.4 Troubleshooting chart begins on..........................................................................49

3.5 Replacing defective components.........................................................................58

3.6 Ordering replacement parts .................................................................................64

Replacement parts tables (begin on)...................................................................64

APPENDIX A: AT10.1 Performance Specifications ...............................................................70

APPENDIX B: Field Installable Accessories ..........................................................................71

APPENDIX C: Standard Drawings *

Outline: AT10.1 Group I Battery Charger NEMA-1 Style-586 Enclosure..................................... 72

Outline: AT10.1 Group I Battery Charger NEMA-1 Style-594 Enclosure..................................... 73

Optional AT10.1 Group I Enclosure Dimensions (with penthouse and/or drip shield) ................. 74

Internal Component Layout: AT10.1 Style-586/594 Enclosure w/Common Options....................76

Instrument Panel / PC Board Detail: AT10.1 Group I Battery Charger........................................ 78

Schematic: AT10.1 Group I Battery Charger - Standard w/o Options.......................................... 80

Schematic: AT10.1 Group I Battery Charger - with Common Options......................................... 82

Connection Diagram: AT10.1 Group I Battery Charger - Standard w/o Options.......................... 84

Connection Diagram: AT10.1 Group I Battery Charger - with Common Options.........................86

APPENDIX D: Recommended Float/Equalize Voltages / Temp. Compensation...............88

APPENDIX E: Communications Module.................................................................................89

APPENDIX F: Forced Load Sharing........................................................................................90

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

Page 6

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.

Page 7

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

MOUNTING METHOD

STANDARD STANDARD

19in / 483mm Rack-Mounting OPTIONAL N/A

23-24in / 584-610mm

Rack-Mounting

OPTIONAL OPTIONAL

ENCLOSURE

Style-586 Style-594

Page 8

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.

Style-586 Enclosure Style-594 Enclosure

Page 9

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.

Page 10

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

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.

Page 11

INSTALLING THE AT10.1

FLOOR-MOUNTING THE AT10.1 - GRAPHICS

DIMENSION (in / mm)

ENCLOSURE

Style-586 Style-594

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

Page 12

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.

RACK WIDTH CHARGER RATING

Vdc Adc

12 Vdc all Yes Yes Yes 24 Vdc all Yes Yes Yes 48 Vdc 6-12 Adc Yes Yes Yes 48 Vdc 16-25 Adc 130 Vdc 6 Adc Yes Yes Yes 130 Vdc 12-25 Adc

19in / 483mm 23in / 584mm 24in / 610mm

Yes Yes

Page 13

RACK-MOUNTING THE AT10.1 - GRAPHICS

Style-586 Enclosure

INSTALLING THE AT10.1

Style-594 Enclosure

NOTES

1. Units are installed from the front.

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.

Page 14

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.

Page 15

INSTALLING THE AT10.1

CHANGING TRANSFORMER TAPS - GRAPHICS

T1 CONNECTION TABLE

INPUT VAC JUMPERS

120 H1-H3, H2-H5 208 H2-H4 (2) JUMPERS 240 H2-H3 (2) JUMPERS 480 NONE

TYPICAL FOR TRANSFORMER IN 586 ENCLOSURE

480 V

PRIMARY

120/208/240 V

PRIMARY

SECONDARY

H5 H2 H3

TRANSFORMER SCHEMATIC

PROCEDURE:

1) BE SURE ALL VOLTAGES ARE DE-ENERGIZED AND LOCKED OUT.

2) BE SURE TERMINALS ARE FULLY SEATED (586 ENCL).

3) BE SURE STUD TERMINALS ARE TIGHT (594 ENCL).

4) CHECK YOUR WORK AFTER COMPLETION.

5) FOR ADDITIONAL INFORMATION, SEE WIRING DIAGRAM IN APPENDIX.

TYPICAL FOR TRANSFORMER IN 594 ENCLOSURE

X4 Y2

JUMPERS (2)

F1-5R2

Page 16

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.

Page 17

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.

Page 18

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)

Page 19

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.

Page 20

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 (+).

Page 21

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.

Page 22

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.

2. Summary Alarm relay terminal block (TB3) is compression type, accepting

wire sizes #22-14 AWG.

3. Terminals are labeled in non-alarm condition.

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).

Page 23

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

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

FAILURE

DC OUT

FAILURE

AC FAIL AC FAIL

GROUND

DETECT

GROUND

DETECT

SUMMARY

PROCEDURE

1. Deenergize and lock out all ac and dc voltages to the AT10.1.

2. Allow internal voltages to dissipate, then check with a voltmeter.

3. Remove the top panel from the penthouse enclosure (on top of charger).

4. Route your remote annunciator wiring into the penthouse enclosure through

one of the unused knockouts on the side of the enclosure.

5. Connect the wiring (use #22-14 AWG) to the appropriate terminals of TB4

on the Auxiliary Relay Relay board (as shown in the figure above). Strip each wire 0.25in / 6.4mm, and securely tighten the terminal screws.

6. Replace the top panel on the penthouse enclosure and restart the AT10.1. NOTES

1. Alarm contacts are rated at 0.5A / 125 Vac or Vdc.

2. Terminal block (TB4) is compression type, accepting #22-14 AWG wire.

3. Terminals are labeled in non-alarm condition.

4. For a detailed view of the optional Auxiliary Alarm Relay PC Board (A5),

refer to drawing (JE5030-19) listed in Appenix C on Page 78.

Page 24

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:

• 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.

Page 25

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.

Page 26

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.

Page 27

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

20 40 60 80 100 120

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

Page 28

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.

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.

Page 29

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

Page 30

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.

METER MODE key 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

Page 31

OPERATING THE AT10.1

2.2.3. Selecting the Float or Equalize mode

The AT10.1 has two output voltage settings, Float and Equalize. Use the Float mode for all normal battery charging and to operate your dc system. Use the Equalize mode if it is necessary to balance the level of charge among the cells of the battery. Consult your battery data sheets for information on equalize-charging your battery.

• Press the CHRG MODE key to change to the equalize mode.

If the equalize method is set to manual timer or auto-equalize timer, the charger will revert to the float mode at the end of the selected equalize time.

• You can press the CHRG MODE key at any time to change back to the float

mode.

2.2.4. Choosing the Equalize method

Press the EQLZ MTHD key to choose the desired equalize method. The indicator next to the desired equalize method will light. Three equalize methods are available in the AT10.1:

• Manual Timer

• Manual Equalize

• Auto-Equalize Timer

These equalize methods are described below.

Manual Timer Method

Choose the manual timer method if you perform regularly scheduled equalize charging, or if you base your equalize charging on regular readings of the specific gravity of each cell of your battery (for lead-acid batteries). When your battery requires equalize charging, adjust the manual timer to 1-2 hours for each 100 AH of battery capacity (see Section 2.3.3 to learn how to adjust the equalize time). The battery manufacturer can help you determine the best equalizing schedule for your battery.

After you select the manual timer method, press the

CHRG MODE key to put

the charger into the equalize mode. The EQLZ indicator will light. When the equalize timer is finished, the charger reverts automatically to the float mode, and the FLOAT indicator lights.

At any time during the equalize charge, you can switch the charger back to float mode by pressing the

CHRG MODE key. The FLOAT indicator will

light. If there is an ac power failure during a timed equalize charge, the AT10.1

remembers the remaining equalize time. When ac power is restored, it resumes the equalize charge where it left off.

Page 32

OPERATING THE AT10.1

Manual Equalize Method

Choose the manual equalize method when you want to equalize charge the battery, but only when you are able to monitor the battery voltage and gassing rate. After you select the manual equalize method, press the

CHRG MODE key to put the charger into the equalize mode. The EQLZ

indicator will light. Press the

CHRG MODE key again to return the charger to the float mode. The

FLOAT indicator will light.

NOTE: Never leave the AT10.1 unattended in the equalize mode with the manual equalize method selected, because a sustained overcharge may cause permanent damage to the battery.

Auto-Equalize Timer Method

Choose the auto-equalize timer method if you have a flooded (non-sealed) battery that is subject to infrequent discharges, or when the battery will be discharged by at least half of its rated capacity during an ac power failure. When ac power is restored to the charger, it turns on in the equalize mode automatically, and the EQLZ indicator lights. At the end of the equalize charging-time that you select, the charger reverts automatically to the float mode, and the FLOAT indicator lights. At any time during the equalize charge, you can switch the charger back to float mode by pressing the

CHRG MODE key. The FLOAT indicator will light.

Consult your battery manufacturer's instructions before using the autoequalize timer method with sealed (valve-regulated) lead-acid batteries.

Whenever the ac supply fails for 12 seconds or longer, the auto-equalize timer is enabled. For shorter periods, the timer behaves as shown below:

Mode before

ac failure

FLOAT

EQUALIZE

FLOAT or

EQUALIZE

AC falure

duration

less than

12 seconds

less than

12 seconds 12 seconds

or greater

Mode after

ac failure

FLOAT

Resume EQUALIZE

with time remaining

EQUALIZE

with full time

Switching to Equalize Mode with Auto-Equalize Timer Method Selected

You can start an equalize charge at any time.

Press the CHRG MODE key. The EQLZ indicator lights.

•

When the equalize timer is finished, the charger reverts automatically to the float mode, and the FLOAT indicator lights.

Page 33

OPERATING THE AT10.1

2.2.5. Testing the front panel indicators

• Press the DOWN key. This is also the LAMP TEST key.

The meter will display 8888, and all status & alarm indicators will light.

LAMP TEST key does not test the AC ON indicator. The AC ON

The indicator lights whenever ac power is present and the ac circuit breaker is turned on. The

To test the action of the AT10.1 summary alarm relay, press and hold the

LAMP TEST key for four seconds to transfer the relay. If you are monitoring

the relay with a remote annunciator, it will detect the alarm condition.

2.2.6. Testing the Auxiliary Alarm Relay PC Board (optional)

If you have the optional Auxiliary Relay Board (A5) installed, you can similarly test the six individual alarm relays. Press and hold the key for four seconds to transfer the relays. If you are monitoring the relays with a remote annunciator, it will detect the alarm conditions.

2.2.7. Interpreting the alarm indicators

There are six red alarm indicators at the right side of the front panel. An indicator lights for each of the following alarm conditions:

LAMP TEST key does not operate when ac power is off.

LAMP TEST

• HIGH DC VOLTAGE: lights whenever the dc output voltage exceeds the

specified alarm voltage setting. See Section 2.3.4 to learn how to adjust the HVDC alarm setting.

• LOW DC VOLTAGE: lights whenever the dc output voltage is below the

specified alarm voltage setting. See Section 2.3.4 to learn how to adjust the LVDC alarm setting.

• DC OUTPUT FAILURE: lights whenever the AT10.1 cannot provide its full

rated output voltage or its full rated output current. You cannot adjust this alarm setting.

• AC INPUT FAILURE: lights whenever the ac power supply to the AT10.1 is

interrupted.

• POS GND: lights whenever leakage current from the battery positive (+)

terminal to ground exceeds a specified threshold (see note).

• NEG GND: lights whenever leakage current from the battery negative (-)

terminal to ground exceeds a specified threshold (see note).

NOTE: You can adjust the sensitivity of the ground fault detection from 5K to 50k ohms. Adjusting the ground fault sensitivity affects the positive and negative ground fault sensitivities equally.

When an alarm occurs, the indicators will light immediately. The AT10.1 also features a summary alarm relay with one form-C contacts (TB3) rated

0.5A / 125 Vac/Vdc. If an alarm condition lasts for 30 seconds or longer, the summary alarm relay transfers. Under standard settings, when the alarm condition is corrected, the corresponding relay and indicator resets automatically. Latching alarm capability for the AT10.1 battery charger is available, featured in a supplemental document (JA5098-00

Page 34

OPERATING THE AT10.1

2.3. SETTING PARAMETERS IN TH E A T1 0 . 1

2.3.1. Understanding Parameter Settings

You can change the settings of the AT10.1 while the charger is operating, using the front panel controls. The changes you make take effect immediately, and are saved internally. If the charger is taken out of service, and then later returned to service, it restarts using the last values you set. You can adjust the following parameters:

• Float voltage

• Equalize voltage

• Equalize timer (in hours)

• High dc voltage alarm setting

• Low dc voltage alarm setting

• Current limit value (in Amperes)

• High dc voltage shutdown feature (on or off)

Your choice of equalize method is also saved internally. When you want to change any parameter, press the

EDIT/ENTER key to put

the AT10.1 into EDIT mode. The meter display flashes about once per second, and the status indicators prompt you to adjust the respective parameter. You adjust each parameter by pressing the

UP or DOWN key

until the reading you want shows on the meter display. You can make the display scroll up or down continuously by pressing and holding the

DOWN key.

UP or

You cannot exceed certain upper and lower limits for the operating parameters. To see what the limits are for your charger, refer to the AT10.1 Specifications in Appendix A on page 70.

When you first press the

EDIT/ENTER key, the AT10.1 prompts you to

adjust the first parameter in the list above (float voltage). When you obtain the value you want on the display, press the

EDIT/ENTER key again. The

AT10.1 saves the new setting internally, and then prompts you to adjust the second parameter. You continue this way to adjust the first six parameters in the list above. If you want to skip adjusting any parameter, just press the

EDIT/ENTER key again. The AT10.1 moves to the next

parameter. When you are finished adjusting the sixth parameter (current limit), press

the

EDIT/ENTER key again. The AT10.1 saves all adjustments you made

internally, and reverts to normal operation. The new settings take effect immediately.

Edit mode ends automatically if you don't press any front panel key within 25 seconds, and any change you made to the last setting is not saved.

Page 35

OPERATING THE AT10.1

2.3.2. Setting the Float and Equalize voltages

• Press the EDIT/ENTER key.

The FLOAT and DC VOLTS indicators light, and the display flashes the present value of the float voltage. Press and release the increase or decrease the value in the display by one count, or press and hold the downward. When the display shows the float voltage you want to set, release the

UP or DOWN key again to reach the voltage you want to set.

The EQLZ and DC VOLTS indicators light, and the display flashes the present value of the equalize voltage. Press and release the key to increase or decrease the value in the display by one count, or press and hold the downward. When the display shows the equalize voltage you want to set, release the

UP or DOWN key again to reach the voltage you want to set.

UP or DOWN key to scroll the value in the display upward or

UP or DOWN key. If you go past the voltage you want, press the

• Press the EDIT/ENTER key. The new float voltage setting is saved

internally.

UP or DOWN key to scroll the value in the display upward or

UP or DOWN key. If you go past the voltage you want, press the

UP or DOWN key to

UP or DOWN

• Press the EDIT/ENTER key. The new equalize voltage setting is saved

internally.

If you want to adjust the equalize timer duration, skip to Section 2.3.3. OR If you want to exit the Edit mode now, press the

EDIT/ENTER key four more

times until the charger returns to normal operation. Edit mode ends automatically if you don't press any front panel key within

25 seconds, and any change you made to the last setting is not saved.

Page 36

OPERATING THE AT10.1

2.3.3. Setting the Equalize Timer

• Press the EDIT/ENTER key until the EQLZ HRS REMAINING,

MANUAL TIMER and AUTO EQLZ TIMER indicators light, and the

display flashes the present value of the equalize timer duration in hours.

Press and release the UP or DOWN key to increase or decrease the value in the display by one count, or press and hold the UP or DOWN key to scroll the value in the display upward or downward. When the display shows the equalize time, in hours, that you want to set, release the key. If you go past the number of hours you want, press the UP or DOWN key again to reach the number you want to set.

If you set the equalize time to zero hours, the equalize mode is disabled.

• Press the EDIT/ENTER key. The new equalize timer duration is saved

internally. The timer setting works for both the manual timer and the auto-equalize timer.

If you want to adjust the alarm settings, skip to Section 2.3.4. OR

If you want to exit the Edit mode now, press the more times until the charger returns to normal operation.

UP or DOWN

EDIT/ENTER key three

2.3.4. Setting the Alarms

After you save the equalize timer setting, the Edit mode automatically prompts you to adjust the settings of the high dc voltage and low dc voltage alarms. There is a red indicator light on the front panel of the AT10.1 for each of the following alarm conditions:

• High DC Voltage

• Low DC Voltage

• DC Output Failure

• AC Input Failure

• Ground Fault Detection (+)

• Ground Fault Detection (-)

When an alarm occurs, the indicators will light immediately. The AT10.1 also features a summary alarm relay with one form-C contacts (TB3), rated 0.5A / 125 Vac/Vdc. If an alarm condition lasts for 30 seconds or longer, the summary alarm relay contacts transfer, and can be monitored remotely from TB3. When the alarm condition is corrected, the relay and all indicators reset automatically. If latching alarms/relays are enabled the relay will need to be reset manually, see Section 2.2.7 on page 29.

The summary alarm contacts (TB3) also transfer when the AT10.1 detects certain secondary errors, indicated by codes (E 03, E 04, E 06, E 07, E 08, E 09, E 10, E 12, E 13, and A 01) on the meter display, rather than a red alarm light. See Section 3.2 on Page 45 for all error and status codes.

Page 37

OPERATING THE AT10.1

Setting the High DC Voltage Alarm

• Press the EDIT/ENTER key until the HIGH DC VOLTAGE indicator

flashes, and the display flashes the present value of the high dc voltage alarm.

Press and release the UP or DOWN key to increase or decrease the value in the display by one count, or press and hold the UP or DOWN key to scroll the value in the display upward or downward. When the display shows the high dc voltage alarm point that you want to set, release the key. If you go past the voltage you want, press the UP or DOWN key again to reach the voltage you want to set.

• Press the EDIT/ENTER key. The new high dc voltage alarm setting is

entered into permanent memory.

Setting the low DC Voltage Alarm

• Press the EDIT/ENTER key until the LOW DC VOLTAGE indicator

flashes, and the display flashes the present value of the low dc voltage alarm.

Press and release the UP or DOWN key to increase or decrease the value in the display by one count, or press and hold the UP or DOWN key to scroll the value in the display upward or downward. When the display shows the low dc voltage alarm point that you want to set, release the key. If you go past the voltage you want, press the UP or DOWN key again to reach the voltage you want to set.

UP or DOWN

• Press the EDIT/ENTER key. The new low dc voltage alarm setting is

entered into permanent memory.

If you want to adjust the current limit setting, skip to Section 2.3.5.

If you want to exit the Edit mode now, press the

EDIT/ENTER key again to

return the charger to normal operation.

Page 38

OPERATING THE AT10.1

Adjusting Ground Detection Sensitivity

You can adjust the sensitivity of the ground detection alarm circuit. You must have a test resistor whose value is the sensitivity you want. You can adjust the sensitivity from 5 to 50 kΩ.

The potentiometer for adjusting ground detection circuit sensitivity is located on the main control circuit board. It is the lower of the two potentiometers labeled RA3 SENS, as shown in the figure at the right.

NOTE: Do not try to adjust the upper potentiometer labeled RA2 BALANCE. This adjustment is made at the factory for proper

circuit operation. CAUTION: Before connecting or disconnecting a test resistor,

de-energize and lock out all ac and dc voltage sources to the AT10.1. Check with a voltmeter before proceeding. Restart the AT10.1 only when necessary to make the sensitivity adjustment. If your battery is grounded, do not attempt this procedure.

Remove the safety cover. Connect the test resistor between TB1(+) and chassis ground, as shown to the right. Adjust RA3 counterclockwise until the front panel indicator goes out, then adjust slowly clockwise until the POS GND indicator just lights.

Make this adjustment slowly; the indicator is updated once in every four seconds. De-energize and lock out power to the AT10.1, then remove the test resistor and verify that the indicator goes out.

Now connect the test resistor between TB1(-) and chassis ground. Verify that the NEG GND indicator lights. If not, adjust RA3 clockwise until it does. Remove the test resistor.

Page 39

OPERATING THE AT10.1

Using Ground Detection in Charger Standby Mode

If you put the AT10.1 into standby mode by opening the dc circuit breaker (CB2), the ground detection circuit will send an erroneous negative ground alarm. There are two ways to work around this:

• Disable the ground detection circuit while the charger is in standby, as

described below.

• Put the charger into standby by opening the ac input circuit breaker

(CB1), and leaving the dc circuit breaker closed.

Operating the charger with the ac breaker (CB1) closed and the dc breaker (CB2) open is an abnormal condition, and is not recommended.

Disabling the Ground Detection Alarm

You can disable the ground detection alarm circuit, and isolate the circuit from chassis ground. If your battery is normally grounded, or you want to defeat the alarm for any other reason, follow these steps:

• De-energize and lock out all ac and dc voltage sources to the AT10.1.

Check with a voltmeter before proceeding. This includes remote sense wires if they were installed.

• Open the AT10.1 front panel, and locate jumper J5 at the top left of the

Control Circuit Board (shown on the previous page). Move the jumper to the DISABLE position. The POS GND and NEG GND indicators and the summary alarm relay will not respond to a ground fault.

Restart the AT10.1, following the instructions in Section 2.1.

2.3.5. Setting the current limit value

The AT10.1 automatically limits its dc output current in case of overload or battery discharge. You can adjust the value of the current limit from 50% to 110% of rated current. The factory setting is 110%.

The current limit adjustment is the last step in the normal Edit sequence. If the AT10.1 is not in the Edit mode, press the until the meter display flashes the value of current limit, in Amperes. Press and release the

UP or DOWN key to increase or decrease the value in the

display by one count, or press and hold the UP or DOWN key to scroll the value in the display upward or downward. When the display shows the current limit value that you want to set, release the go past the number you want, press the UP or DOWN key again to reach the number you want to set.

• Press the EDIT/ENTER key. The new current limit setting is saved

internally.

Edit mode ends automatically if you don't press any front panel key within 25 seconds, and any change you made to the last setting is not saved.

EDIT/ENTER key five times,

UP or DOWN key. If you

Page 40

OPERATING THE AT10.1

2.3.6. Enabling the High DC Voltage shutdown feature

The AT10.1 has a built-in high dc voltage shutdown feature. In case of any maladjustment or internal failure that results in a continuous output voltage that is too high, the AT10.1 shuts down after 30 seconds to protect the battery. The digital display reads E 03, and the summary alarm relay contact transfers.

The AT10.1 is shipped with the high dc voltage shutdown feature disabled. You can adjust the high dc voltage shutdown

(the setting is the same as the high dc voltage alarm setting). Refer to Section 2.3.4.

The charger must be in normal operation (not the Edit mode) to enable the high dc voltage shutdown.

To enable the shutdown feature:

• Press and hold the UP key, then

• Press the CHRG MODE key.

The HIGH DC VOLTAGE indicator lights, and the display flashes ON. You can toggle the shutdown feature OFF and ON by pressing the

CHRG MODE key repeatedly.

Parallel Operation

If two (or more) AT10.1 chargers are connected in parallel, both sense the output voltage. If one charger runs away, it will supply all the output current; the other has zero output current. The high dc voltage shutdown does not operate in a charger with zero output current, so that only the defective charger (of two or more in parallel) shuts down. The other charger continues to supply the load normally.

If you don't press any key within 4 seconds, the last state indicated (ON or

OFF) is saved internally. Note that you don't use the

EDIT/ENTER key for

this feature. If the AT10.1 shuts down because of a high dc voltage, the meter display

shows error code E 03. Reset the charger by turning the ac breaker off, then on again.

Page 41

2.3.7. Adjusting the Voltmeter Accuracy

The AT10.1 voltmeter is adjusted at the factory to display the actual output voltage within ±0.25%. If you replace any component that affects meter accuracy, such as the main control circuit board or R4, you should readjust the meter. This adjustment procedure is different from all others, because the meter reading remains constant, while the output voltage of the charger changes. Do this adjustment with a fully charged battery and with no load connected.

First, use the Edit procedure to adjust the float voltage to the desired value. See Section 2.3.2 for instructions on setting the float voltage. Second, press and hold the

UP key, then press the EQLZ MTHD key.

The DC VOLTS METER MODE indicator will light, and the meter display flashes the output voltage reading. Measure the output voltage of the AT10.1 using a dc meter accurate to ±0.25% or better.

While watching the meter connected to the AT10.1 output (not the front panel meter), press the

UP or DOWN key until the actual output voltage

matches the float setting on the front panel meter.

OPERATING THE AT10.1

Each time you press

UP or DOWN, you change the AT10.1 output voltage

by a small amount. Continue to press UP or DOWN until the actual output voltage agrees with the front panel reading within ±0.25%.

NOTE: Allow one or two seconds for the output voltage to stabilize each time you press the

UP or DOWN key.

When you are finished adjusting the output voltage, the AT10.1 waits 5 seconds, then the display returns to normal operation.

Page 42

OPERATING THE AT10.1

2.3.8. Using the Low Level Detector (LLD)

The AT10.1 battery charger is equipped with a summary alarm safety override circuit. This feature forces the summary alarm (common alarm) relay contact to transfer, sending an alarm, even if there is a catastrophic failure of the charger's control circuitry. A low battery voltage triggers the safety circuit. Main control circuit board hardware, not software, maintains the low level detect circuit. Therefore, to remotely monitor this alarm, user connections must be made at TB3. The summary alarm contacts on the auxiliary alarm relay pc board at TB4 will not signal a low level detect alarm.

If you have a dc power supply, you can adjust the battery voltage that triggers the alarm. On the back of the main control circuit board, find the potentiometer RA1, as shown in the figure below.

Disconnect all ac and dc power sources from the AT10.1, and connect your dc power supply to the dc output terminals of the charger (positive to positive and negative to negative). Adjust the power supply to the voltage at which you want to activate the alarm.

NOTE: You need at least 50% of the nominal output voltage to power the AT10.1 control circuit board.

Adjust RA1 with a small jeweler's screwdriver clockwise until the alarm just activates. A red LED indicator (DS10) next to RA1 indicates when the alarm is active.

Page 43

OPERATING THE AT10.1

2.3.9. Using the front panel security feature

The AT10.1 charger is shipped with all the front instrument panel keys enabled. You can disable the following front panel functions:

• Selecting Equalize method

• Changing settings using the EDIT/ENTER key

• Toggling the high dc voltage shutdown feature

To disable the front instrument panel keys, open the AT10.1 door and locate the small plastic jumper J9 on the right side of the main control circuit board. See the figure below.

Move the jumper up to the DISABLE position (pins 2 and 3). With this setting, only the front panel

METER MODE and CHRG MODE keys will

function. All indicators will still work normally. Return the jumper down to the ENABLE position (pins 1 and 2) to return all front panel key functionality.

Page 44

OPERATING THE AT10.1

2.4. Performing routine maintenance

WARNING 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.

2.4.1. Keep it clean

The AT10.1 charger is cooled by natural convection. At least once a year, vacuum the vents at the top and bottom of the enclosure to ensure that there is an adequate supply of cooling air. If you have an extremely dusty environment (especially if airborne dust is conductive), carefully vacuum out the interior. Be sure to clean surfaces of circuit boards, and around electrical terminals.

The AT10.1 is rated for operation up to 122° F / 50° C. If your charger is in a warmer environment, or at an elevation over 3000ft / 914m, contact your sales representative for operating information.

2.4.2. Check power and signal connections

Check the tightness of all field connections inside the charger, and connections to the battery. A loose or corroded connection at the battery terminals can be a fire or explosion hazard, and may cause erroneous operation of the AT10.1 charger.

2.4.3. Check remote sense wiring (optional)

If you wired the AT10.1 charger for remote sense, check the signal connections to the battery or load, and check the wiring to be sure the insulation is in good condition. If there is a failure of the remote sense signal wiring, the AT10.1 charger displays the error code E 06, and goes back to local control, sensing the output voltage at the charger output terminals.

Page 45

OPERATING THE AT10.1

2.4.4. Check temperature compensation probe (optional)

If you are using the optional temperature compensation probe, be sure that the probe is securely installed. Be sure the connectors and the wiring from the probe to the AT10.1 charger are in good condition.

If there is a failure of the temperature compensation probe, or the wiring, the AT10.1 charger displays the error code E 08.

2.4.5. Measuring the output ripple voltage (filtered models only)

If your AT10.1 charger is a filtered model, at least once a year measure the ac ripple voltage at the battery terminals. Use an rms responding ac voltmeter. specifications in Appendix A on page 70, if the battery ampere-hour capacity is at least 4 times the output current rating of the charger.

If you suspect that the output ripple voltage is too high, see "Output ripple voltage too high" of the Troubleshooting Chart in Section 3.4, page 53.

2.4.6. Viewing the voltage and alarm settings

You can review the parameter settings in the AT10.1 charger by pressing the

EDIT/ENTER key on the front panel. Each time you press the key, a

different parameter displays, in the following order:

The ripple voltage should be no higher than shown in the

• Float voltage

• Equalize voltage

• Equalize time (in hours)

• High dc voltage alarm setting

• Low dc voltage alarm setting

• Current limit, in Amperes

Don't use a dc voltmeter. The ripple voltage on a battery is a very small ac voltage.

Page 46

OPERATING THE AT10.1

SAMPLE PREVENTIVE MAINTENANCE PROCEDURE

AT10.1 BATTERY CHARGER

Suggested frequency: every 6 months

Maintenance date Performed by

Step

(standard features)

Clean battery charger

Check all electrical connections and wiring

Check ac input voltage

Check dc output voltage

Check ripple voltage

Test font panel indicators Test common alarm relay

• All vents clean and open.

• Remove dust and debris from inside of

unit.

• TB1 connections all tight.

• Internal wiring connections tight, slip-on

connectors fully seated. Wire and lug insulation in good condition.

• Terminations at battery or bus are tight

and corrosion free.

• Measure between TB1-L1 and TB1-L2

using an ac voltmeter. Value must be within +10%, -12% of nominal voltage.

• Measure at TB1(+) and TB1(-) using a dc

voltmeter. Value should agree with front panel voltmeter within 0.25%, and must be correct values for your battery. If the AT10.1 is using a temperature compensation probe, see the graph on page 23 to determine correct battery voltage. You need to know the battery temperature for this step.

• Measure at battery terminals using an ac

voltmeter set to the milliVolts scale. Check against specification in Appendix A on page 70.

• Press

seconds. Common alarm relay will transfer.

Instructions Results

 OK  OK

 OK

Input Vac

LAMP TEST key on front panel.

LAMP TEST key and hold for 4

Float

Equalize

Ripple

 OK  OK

Vdc

mVac

Page 47

Exercise front panel controls

Check voltage and alarm settings

Final checks

OPERATING THE AT10.1

• Switch from float to equalize, then back

to float.

• Turn off the dc circuit breaker. E 07 may

appear on display (requires at least 5% of rated output current). Reset breaker.

• Cycle through meter modes.

• Cycle through equalize methods.

• Turn off ac circuit breaker. The AC

INPUT FAILURE indicator should light. Reset breaker.

• Use

• Make sure plexiglas safety cover is in

• Restore charger to normal operation.

• Close latch on front panel.

EDIT/ENTER key to scroll through

settings. See page 30.

place.

 OK  OK

 VOLTS OK  AMPS OK  HOURS OK  MANUAL TIMER OK  MANUAL EQLZ OK  AUTO EQLZ TIMER OK  Alar m OK

 FLOAT OK  EQUALIZE OK  HVDC alarm OK  LVDC alarm OK

Current limit

Adc

 OK  OK

 OK

Step

(optional features)

Test auxiliary alarm relays

Check integrity of remote wiring

Final checks

• Press LAMP TEST key and hold for 4

seconds. Alarm relays will transfer.

• Remote sense wiring. See page 16.

• Temperature compensation wiring. See

page 20.

• Temperature compensation probe. See

page 20.

• Close padlock or key lock.

Instructions Results

 OK  OK

 OK

A downloadable worksheet of this Preventive Maintenance Procedure (JD0064-00) is available online.

Page 48

SERVICING THE AT10.1

3. SERVICING THE AT10.1

3.1. A STEP-BY-STEP TROUBLESHOOTING PROCEDURE

The AT10.1 battery charger is fully tested and calibrated at the factory and should work for years with a minimum of attention. If you do encounter trouble, there are three steps you should take to find the problem and return the charger to service.

1. Check the front panel meter for an error code. The AT10.1 is able to

diagnose common problems with the battery charger, or with the application or installation. If the front panel displays an error code, see Section 3.2, Interpreting Front Panel Error Messages, for help in interpreting the code and solving the problem.

2. If the charger does not work properly, but there is no front panel error code,

turn off the front panel circuit breakers (or disconnect ac and dc power externally). Then turn the dc and ac power back on. This will return the charger to normal operation as long as there is no internal component failure.

Note: Do this only once. If the charger does not resume normal operation, go to the next step.

3. If the charger still does not work properly, make a list of the symptoms that

you observe, then turn to Using the troubleshooting chart in Section 3.3. The troubleshooting chart relates common trouble symptoms to their causes, and gives the proper procedures for correcting the problem.

4. If the symptom doesn't appear on the troubleshooting chart, or if the

recommended repair doesn't work, consult your sales or service representative to arrange for on-site or factory service.

Page 49

SERVICING THE AT10.1

3.2. INTERPRETING FRONT PANEL ERROR MESSAGES

If the AT10.1 control circuit detects hardware or wiring problems, it may display an error code on the front panel. To solve an error code problem, refer to the table below, which lists the codes and procedures to use.

WARNING 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.

Error Code

E 01

E 02

E 03

Meaning Repair Procedure

resistor R2 open or defective

short circuit on dc output

High DC Voltage Shutdown activated

Resistor R2 is installed at the back of the front panel, in the control circuit board input connector. R2 is measured by the control circuit on startup, and is used to determine some of the AT10.1's parameters, such as the float voltage.

If the AT10.1 finds that R2 is defective, it must be replaced. See Section

3.6 for parts ordering information. When you have completed the repair, restart the AT10.1 according to Section 2.1.

You may get this error code if the battery is discharged to less than 6 volts. When the battery charges to greater than 6 volts, the error code disappears. If you have a seriously discharged battery, allow the AT10.1 to run for 24 hours and check the battery voltage again. If it has not increased to the normal voltage rating, consult the battery manufacturer for help.

If the battery voltage is normal, then check the wiring at the dc output terminals for a short circuit.

If the battery voltage is normal and all external wiring is OK, check the dc breaker on the AT10.1. If it is tripped, try once to reset it. If it trips again immediately, there may be an internal short circuit in the AT10.1. Check the internal wiring. If the AT10.1 is filtered, check the dc filter capacitors and the polarity diode.

The AT10.1 normally recovers automatically from an E 02 condition. If you have shut down the AT10.1 for service, restart it according to Section

2.1. To restart the AT10.1, turn the ac breaker off, then on. Check the

Equalize voltage and High DC Voltage alarm settings. The alarm setting must be higher than the Equalize voltage setting.

If you get another High DC Voltage shutdown after a few minutes of operation, there may be an internal component failure. See Charger output not controllable of the troubleshooting chart in Section 3.4.

Page 50

SERVICING THE AT10.1

Error Code

E 04

E 05 E 06

E 07

E 08

Meaning Repair Procedure

internal memory failure

not used

defective R4 or R14, or remote sense wiring failure

dc breaker open, or internal dc wiring failure

defective temperature compensation probe

Any parameters that you set, such as Float or Equalize voltage, are saved internally. The internal memory is tested on startup. If the memory test fails, E 04 appears on the front panel display. The error may also appear if the controller was trying to write to the memory while a power failure occured.

If an E 04 appears, try restarting the AT10.1 by turning the ac and dc breakers off, then on. If the AT10.1 restarts normally, you must reenter any changes you made to the factory settings (float voltage, etc.).

If E 04 appears repeatedly, the internal memory has been damaged. You must replace the control circuit board. See Section 3.6 for parts ordering information.

This error code was formerly used to indicate a reverse battery connection. It is not available in the AT10.1.

Locate R4 mounted on TB5, on the back of the front panel. Remove the resistor and measure its value with an Ohmmeter (see table 3-1 for the correct value). If the resistor is not within 1% of the specified value, it must be replaced.

Locate R14 inside the enclosure, connected to TB1(-). Remove the lugged end and measure the resistor's value with an Ohmmeter (see table 3-1 for the correct value). If the resistor is not within 1% of the specified value, it must be replaced.

If you are using remote sense wiring from the battery to the AT10.1, the wiring may have failed. The usual failure is an open circuit; a short circuit will usually be indicated by smoke or fire in the wiring.

The AT10.1 displays the error code if it detects this wiring failure. You should respond to this problem quickly to be sure that the AT10.1 regulates the output voltage properly. Wire an annunciator (e.g. buzzer) to the summary alarm relay contact (TB3) for remote indication of any charger problem, or monitor the AT10.1 operation using the optional DNP3/MODBUS communications board.

If a failure exists in remote sense wiring, the AT10.1 regulates its output voltage locally until you correct the problem, see Section 1.9. The locally controlled voltage may not reflect the true requirements of the battery.

When you complete the repair, restart the AT10.1 per Section 2.1. If the dc breaker is open, open the ac breaker, then reclose the dc and ac

breakers. If the dc breaker trips again, see the troubleshooting chart in Section 3.4.

If the dc breaker is closed, but you have an E 07 display, check your battery. If the battery is disconnected, and you then disconnect the load, the AT01.1 may display an E 07 code. Restart the AT10.1 according to Section 2.1.

If the battery and load are OK, see the troubleshooting chart in Section 3.4 for help in locating the problem.

See Application Note (JD5003-00) for more detailed user instructions. If a temperature compensation probe is connected to the AT10.1, the

control circuit detects the probe on startup, and uses the temperature measured by the probe to control the output voltage of the AT10.1. To understand temperature compensation, see Section 1.11.

If the temperature compensation probe, or the wiring that connects it to the AT10.1, fails during normal operation, the AT10.1 detects the failure, and shows E 08 on the front panel meter.

Page 51

SERVICING THE AT10.1

Error Code

E 08

E 09 E 10

E 11 E 12

E 13

E 14

A 01

A 02

A 04

A 05

Meaning Repair Procedure

defective temperature compensation probe (continued)

misadjusted current limit

open internal feedback loop

not used

defective internal thermostat

internal overtemperature

forced load sharing not working properly

manual eqlz enabled for more than 24 hr

equalize mode inhibited

voltmeter calibration inhibited w/tempco active

dc output at Current Limit setting

Disconnect the wiring from the probe, and measure the resistance of the probe with an Ohmmeter. The resistance should be approximately 10,000 Ohms at normal room temperature (77° F / 25° C). If the probe reads open or shorted, it needs to be replaced.

If the probe checks good, examine the wiring between the probe and the AT10.1. Also check the connection of the cable to the control circuit board on the back of the front panel. If the wiring is OK, then the probe needs to be replaced. Once you have replaced the probe, you must restart the AT10.1 to activate temperature compensation.

This code has been discontinued with main ctrl pcb (A1) firmware version

6.52. See Application Note (JD5035-00 A redundant internal feedback loop (control loop) is provided as

redundancy, to increase reliability when remote sensing is used. If there is a problem with the internal loop wiring, the AT10.1 will display E 10.

Check the internal wiring in the signal harness, especially wire # 33. Also check the harness connector on the main control circuit board.

This error code is not implemented at this time. The AT10.1 rectifier heat sink assembly has beem equipped with a non-

standard over-temperature thermostat (S2). On startup, the AT10.1 tests the thermostat, and displays E 12 if it is defective.

Check the thermostat (S2) for continuity. Disconnect the wiring and resistor (R28) from the quick connect terminals. The thermostat switch should be closed (NC) at normal room temperature.

The non-standard rectifier thermostat (S2) has detected an overtemperature condition. If the rectifier is equipped with a fan (B2), check the fan for proper operation. Also make sure that all enclosure vents are clear of debris, and that the ambient temperature is below 50°C (122°F).

See Appendix F on page 90. Verify both AT10.1s are functioning properly. Ensure that the forced load

sharing interconnection cable assembly is not broken, is properly installed, and that the connector for the Secondary charger has the jumper as described. Ensure that both AT10.1s are connected to the same ac supply, and that source phase rotation is the same for both AT10.1s.

If the AT10.1 was accidentally left in manual equalize mode, switch the unit back to float, manual equalize timer, or auto-equalize timer mode, according to Section 2.2.4 on Page 27.

If you set the equalize timer to zero (0) hours, the equalize mode is inhibited. When you try to put the AT10.1 into equalize mode from the front panel controls, the display shows the message A 02. If you want to enable the equalize mode, set the equalize timer to one (1) or more hours.

While using temperature compensation, the AT10.1 internal dc voltmeter cannot be calibrated. Disconnect one wire of the tempco cable from TB8 on A1, and restart the AT10.1. Perform the voltmeter calibration according to Section 2.3.7 on Page 37. Reconnect the tempco cable to TB8 and restart the AT10.1. See Application Note (JD5003-00

The AT10.1 is in Current Limit mode. This will occur when there is a large load on the dc bus, or the battery has discharged. Make sure that the AT10.1 is sized correctly for the application, and that the Current Limit value has been set correctly. See Section 2.3.5 on Page 35.

) for a description of this code.

) for further details.

Page 52

SERVICING THE AT10.1

3.3. USING THE TROUBLESHOOTING CHART

WARNING 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.

Before you try to use the troubleshooting chart, be sure that you have followed the steps in Section 3.1.

The troubleshooting chart that begins on the next page is divided into three columns. To use the chart:

1. Make a list of the charger's condition, including the trouble symptoms.

2. Find the symptom(s) in the first column of the chart.

3. The middle column contains common causes for the problem you observe, in

order of probability.

4. Follow the action described in the right-hand column to correct the problem

and return the charger to normal service.

Determining the condition of the charger:

• Is the front panel AC ON indicator lit?

• What is the ac voltage at the input terminals (measured with an ac

voltmeter)?

• What is the dc voltage at the output terminals (measured with a dc

voltmeter)?

• Does the meter on the front panel display any voltage or current?

• Are any alarm indicators lit?

• Do the front panel status indicators work (Charge Mode, for example)?

• Can you change the charger to the Equalize mode and back to Float?

• Is the charger making any noise? Is it unusually loud?

• Is there any sign or smell of smoking or burning?

Refer to the wiring diagrams and parts layout drawings in Appendix C while using the chart. For instructions on replacing components, see Section 3.5.

Page 53

3.4. TROUBLESHOOTING CHART

SERVICING THE AT10.1

SYMPTOM

Front panel meter

displays all segments

"On" or all segments "Off." AT10.1 may have no output.

AC breaker trips immediately

AC breaker trips after a few minutes

DC breaker trips immediately

PROBABLE

CAUSE

1. An external surge has interrupted operation of the microprocessor or the display controller.

1. Shorted rectifier diode or SCR

2. Defective wiring to T1 or to the rectifier heat sink assembly

3. Defective transformer T1

1. Loose connection to breaker

2. Wrong ac voltage, or T1 taps miswired

3. Open SCR

4. SCR not controllable

1. Battery connected with reverse polarity

2. Defective rectifier bridge (if unfiltered charger)

1A. Soft Reset of control board by pressing S7 reset switch. S7 is located inside the AT10.1, on the control board's right edge (as viewed from the rear of the front panel). This will restart the control board without modifying any settings.

1B. Hard Reset of control board by pressing and holding the "UP" button on the front panel, and simultaneously pressing S7 reset switch. This will restart the control board and restore all settings to factory default. Reset parameters per Section

2.3 of this manual. 1C. Remove all power from AT10.1 to allow control board to

discharge all voltages. This can be done by opening the AC circuit breaker and disconnecting the control board plug(s). Keep power removed for approximately 5 minutes to allow voltages to discharge.

1. Test by disconnecting wire # 12 from the rectifier assembly. Measure resistance between the two top rectifier terminals (labeled "AC" on the wiring diagram); it should be at least 100,000 Ohms (check both polarities). Replace rectifier assembly if resistance is low in either direction.

2. Check spacing of terminals; check wiring for signs of insulation damage, burns, etc. Repair as necessary.

3. Test by disconnecting wires from X1, X4, Y1 and Y2. If ac breaker still trips, replace T1.

1. Check and tighten connections as required.

2. Be sure the T1 primary taps are wired correctly for your input voltage. See Section 1.6 for details.

3. Use a clamp-on ammeter to measure the current in wire # 11 or # 12. If it less than 70% of the dc output current, one of the SCRs or diodes is defective. Replace the rectifier module.

4. Disconnect wire # 24 from terminal E3 of the rectifier assembly (near the left front of the enclosure). Restart the AT10.1. If You are able to measure output current, one of the SCRs is defective. Replace the rectifier module.

1. Check and correct battery wiring if necessary.

2. Test by disconnecting wire # 12 from the rectifier assembly. Measure resistance between the two top rectifier terminals (labeled "AC" on the wiring diagram); it should be at least 100,000 Ohms (check both polarities). Replace rectifier assembly if resistance is low in either direction.

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SERVICING THE AT10.1

SYMPTOM

DC breaker trips immediately

(continued)

DC breaker trips after a few minutes

No output current, but ac and dc breakers are on; AC ON lamp is out

PROBABLE

CAUSE

3. Defective free-wheeling diode in SCR module A16

4. Defective polarity diode (if filter assembly is installed)

5. Defective wiring

1. Loose connection to breaker

2. Open SCR

3. SCR not controllable

4. Defective Main Control circuit board A1

1. AC supply failure

2. Input fuse F1 is blown (480 Vac input only)

3. Defective wiring

4. Defective transformer T1

3. Remove wire # 13 from the rectifier control pc board A3. Test the SCR module's internal free-wheeling diode by measuring the resistance from E2 to E10 on A3 with an Ohmmeter. The reading should be at least 100,000 Ohms in one polarity, and less than 1,000 Ohms in the other polarity. Replace the entire A16 SCR module if it is defective.

4. Remove wire # 15 from terminal E14 on the CR1 heat sink. Measure the resistance from the heat sink to E8 on the rectifier control pc board at the left front of the AT10.1 (check both polarities). If the resistance is less than 1,000 Ohms in both directions, replace the filter assembly.

5. Check spacing of terminals; check wiring for signs of insulation damage, burns, etc. Repair as necessary.

1. Check and tighten connections as required.

2. Use a clamp-on ammeter to measure the current in wire # 12 or # 11. If it less than 70% of the dc output current, then one of the SCRs or diodes is defective. Replace the rectifier module.

3. Disconnect wire # 24 from terminal E3 of the rectifier assembly (near the left front of the enclosure). Restart the AT10.1. If You are able to measure output current, one of the SCRs is defective. Replace the rectifier assembly.

4. If the front panel meter shows more than 110% of rated dc current, the control board may be defective. Disconnect wire # 24 as above. If the output current goes to zero, replace the control board.

1. If AC ON indicator is out, check feeder circuit breaker or fuse.

2. Remove F1 from its fuseholder (located on the bottom of the enclosure) and check with an Ohmmeter or fuse tester. Replace if required.

NOTE: If the new fuse blows, see the sections titled "AC breaker trips immediately" and "AC breaker trips after a few minutes" for further troubleshooting hints.

3. Check terminals and wiring between T1 and the rectifier assembly, inductor L1, dc filter (if present), the dc breaker, and the output terminals. Check wire # 29 from T1-Y1 and wire # 28 from T1-Y2 to the control circuit board connector J1. Repair as necessary.

4. Use an ac voltmeter to measure the ac voltage from T1-X1 to X4. It is normally 50% to 80% higher than the rated dc output voltage. If it is too low, check the wiring of the primary taps. See Section 1.6 for details. If it is zero, replace T1.

RECOMMENDED ACTION

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SERVICING THE AT10.1

SYMPTOM

No output current, but ac and dc breakers are on; AC ON lamp is on

Front panel is dead; ac and dc voltages are present at TB1

PROBABLE

CAUSE

1. Battery is fully charged

2. Float or Equalize voltage set too low

3. Wrong ac input voltage, or T1 taps miswired

4. Defective wiring

5. Defective rectifier bridge

6. Defective control circuit board A1

7. Defective transformer T1

8. Defective inductor L1 or L2

9. Defective CR2

10. Defective dc breaker

1. Control circuit board A1 is not connected

2. Defective control circuit board A1

3. Defective wiring

1. This is normal operation in a system with little or no dc load. As long as the AT10.1 maintains Float voltage, it is operating normally.

2. Check the Float and Equalize voltages and adjust them if necessary. Consult your battery manufacturer for the proper voltage settings.

3. Be sure the T1 primary taps are wired correctly for your input voltage. See Section 1.6 for details.

4. Check terminals and wiring between T1 and the rectifier assembly, inductor L1, dc filter (if present), the dc breaker, and the output terminals. Repair as necessary.

5. Use an ac voltmeter to measure the voltage between terminals E3 and E4 of the rectifier circuit board (A3). If you measure about 1.0 Vrms, but there is no output current, replace the rectifier assembly.

6. If you do not measure any ac voltage in step 5 above, and the battery voltage is less than the Float voltage setting, replace the control circuit board.

7. Use an ac voltmeter to measure the ac voltage from T1-X1 to X4. It is normally 50% to 80% higher than the rated dc output voltage. If it is too low, check the wiring of the primary taps. See Section 1.6 for details. If it is zero, replace T1.

8. Disconnect the wiring from L1 and measure the resistance between the terminals. If it is an open circuit, replace L1. Repeat for L2 if the optional dc filter is installed.

9. Disconnect wire # 52 from L1 to CR2, then check CR2 with an Ohmmeter (check both polarities). If CR2 is open, replace the filter assembly. This is a very rare occurrence.

10. Disconnect the battery, and connect a light dc load to the AT10.1. Measure the dc voltage from the input terminal to the output terminal of the circuit breaker, with the breaker on. It is normally no more than 50 millivolts. If it is near the rated output voltage, replace the breaker.

1. Make sure the connector at the top edge of the control circuit board is firmly seated.

2. If the AC ON indicator is lit, but the rest of the front panel is dead, replace the control circuit board.

3. Check the harness wiring to the control circuit board connector for signs of insulation damage, burns, etc. Be sure all wires are securely crimped in the connector.

RECOMMENDED ACTION

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SERVICING THE AT10.1

SYMPTOM

Front panel dies during ac power failure; dc voltage is present at TB1

AT10.1 output voltage too high, not controllable

Output voltage does not agree with front panel meter

PROBABLE

CAUSE

1. Defective power resistor R3

2. Defective wiring

1. Defective SCR

2. R4 or R14 is defective, or wrong value

3. Defective temperature compensation probe (optional)

4. Defective control circuit board A1

1. Temperature compensation probe is installed

2. Circuit board or another component may have been replaced

3. R4 or R14 is defective, or wrong value

4. Defective control circuit board A1

1. Use a dc voltmeter to measure the dc voltage from E17 on the I/O panel to TB1(-). It is normally 12 Vdc when the rated output voltage is at TB1(+) and TB1(-). Remove all power from the AT10.1, and measure the resistance from TB1(+) and E17. See the table in Section 3.6 for the proper resistance values. If the resistance is not within 10% of the table value, replace R3.

2. Remove the enclosure shroud, and check the wiring to and from TB1 and the control circuit board for signs of insulation damage or burns. Repair any damaged wiring.

1. Disconnect wire # 24 from terminal E3 of the rectifier assembly (near the left front of the enclosure). Restart the AT10.1. If You are able to measure output current, one of the SCRs is defective. Replace the rectifier assembly.

2. Remove one end of R4 from TB5 (on the back of the front panel). Repeat for R14 connected to TB1(-). Measure their values with an Ohmmeter. See the table in Section 3.6 for resistance values. If either resistor is not within 1% of the specified value, it must be replaced.

3. Remove the leads from the probe and measure its resistance. At 77° F / 25° C the resistance should be about 10,000 Ohms. If it is not, replace the probe assembly.

4. If the front panel meter shows more than 110% of rated dc current, the control board may be defective. Disconnect wire # 24 from terminal E3 of the rectifier assembly (near the left front of the enclosure). Restart the AT10.1. If the output current goes to zero, replace the control board.

1. If the optional temperature compensation probe is installed, the output voltage may be different from the selected float or equalize voltage. The difference in the voltages depends on the probe temperature. The front panel meter always displays the proper voltage for 77° F / 25° C.

2. Recalibrate meter as described in Section 2.3.7.

3. Remove one end of R4 from TB5 (on the back of the front panel). Repeat for R14 connected to TB1(-). Measure their values with an Ohmmeter. See the table in Section 3.6 for resistance values. If either resistor is not within 1% of the specified value, it must be replaced.

4. Turn off both front panel circuit breakers. Then turn on the dc breaker, followed by the ac breaker. If the AT10.1 still has the wrong output voltage, replace the control circuit board.

RECOMMENDED ACTION

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SERVICING THE AT10.1

SYMPTOM

AT10.1 never reaches float (or equalize) voltage (within 1%)

Input current too high

Output ripple voltage too high

PROBABLE

CAUSE

1. Current limit set too low

2. Defective battery or dc load, or load is too great

3. Wrong ac input voltage, or voltage too low, or T1 wired incorrectly

4. Defecive rectifier bridge

5. Defective control circuit board A1

1. Wrong ac input voltage, or transformer T1 wired incorrectly

2. Defective rectifier bridge

3. Defective T1

1. Charger is unfiltered

2. Battery is disconnected or defective

3. Battery too small for charger rating

4. One or more defective filter capacitors, C1 or C2

1. If the AT10.1 is not in the Edit mode, press the EDIT/ENTER key five times, until the meter display flashes the

current limit value (in Amperes). If the current limit is less than 110%, adjust it to 110% as described. See Setting the Current Limit Value, Section 2.3.5 for details.

2. Check each cell of the battery. If one or more cells are

shorted, the AT10.1 may not be able to reach the Float voltage. You may have the same problem if the normal load current is more than the rated output current of the charger.

3. Make sure the T1 primary taps are wired correctly for your

input voltage. See Changing Transformer Taps, Section 1.6 for details. The actual ac input voltage must be at least 88% of the rated value for the charger to produce full output power.

4. Use a clamp-on ammeter to measure the current in wire #

12 or # 11. If it less than 70% of the dc output current, one of the SCRs or diodes is defective. Replace the rectifier module.

5. Turn off both front panel circuit breakers. Then turn on the

dc breaker, followed by the ac breaker. If the AT10.1 output current is below the current limit value, but it still has the wrong output voltage, replace the control circuit board.

1. Be sure the T1 primary taps are wired correctly for your

input voltage. See Changing Transformer Taps, Section 1.6 for details. The actual ac input voltage must be at least 88% of the rated value for the charger to produce full output power.

2. Disconnect wire # 24 from terminal E3 of the rectifier

assembly (near the left front of the enclosure). Restart the AT10.1. If You are able to measure output current, one of the SCRs is defective. Replace the rectifier assembly.

3. Test by disconnecting wires from X1, X4, Y1 and Y2. If ac

input current is still too high, replace T1.

1. Verify by checking nameplate against the ordering code on

the inside front cover. Order and install filter option if necessary.

2. Be sure battery is connected. Inspect battery according to

the manufacturer's instructions.

3. Check the measured ripple against the specification for your

AT10.1 model on page 70. The ripple rating is for a battery whose Ampere-hours are four (4) times the charger Ampere rating. For a smaller battery, ripple voltage may be higher.

4. Test with capacitance meter; replace as necessary.

RECOMMENDED ACTION

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SERVICING THE AT10.1

SYMPTOM

AT10.1 very noisy

Meter readings are erratic

Lamp test key does not work, or some lamps don't light

One or more front panel keys don't work

Two AT10.1s connected in parallel, but only one has output current

PROBABLE

CAUSE

1. Loose hardware or enclosure panel

2. Defective rectifier bridge

1. Defective or disconnected battery

2. Defective scaling resistor R4 or R14

3. Defective control circuit board A1

1. No Vac

2. Control circuit board A1 is not secured to front panel

3. Defective control circuit board A1

1. Front panel is locked

2. Control circuit board A1 is not secured to front panel

3. Defective control circuit board A1

1. If the forced load sharing option is not supplied, check for normal operation of both chargers

2. EJ5126-## option

1. Remove the enclosure shroud. Check and tighten all component mounting hardware. Replace the shroud, being sure all assembly hardware is secure.

2. Use a clamp-on ammeter to measure the ac current in wire # 11 or # 12 (connected between T1 and the rectifier assembly). If it less than 70% of the dc output current, one of the SCRs or diodes is defective. Replace the rectifier module.

1. Turn off the AT10.1. With a light dc load connected to the battery, be sure each cell reads the nominal cell voltage (2.0V for lead-acid; 1.25V for Ni-Cd). Restart the AT10.1. Each cell should now read the nominal Float voltage (2.2V for lead-acid;

1.35V for Ni-Cd).

3. If the output voltage is constant, replace the control circuit board.

1. The lamp test key doesn't work during an ac power failure.

2. Open the front panel, and be sure that the control circuit board is securely mounted on the standoffs on the back of the panel. All indicators should extend about 0.125in / 3.2mm through the front of the panel.

3. When you press the LAMP TEST key, if some but not all of the indicators light, or the digital meter does not display all 8's, replace the control circuit board.

1. Open the front panel, and be sure that jumper J9 on the main control circuit board is in the ENABLE position.

2. Open the front panel, and be sure that the control circuit board is firmly seated on the standoffs on the back of the panel. Front panel keys must operate freely.

3. Turn off both front panel circuit breakers. Then turn on the dc breaker, followed by the ac breaker. If some of the front panel keys still do not work, replace the control circuit board.

1. Multiple AT10.1s are not designed to share load current, without the optional forced load sharing cable installed. When two or more AT10.1s are connected in parallel without this option, it is normal for one of the units to have no output current. You can check the operation of the "off" charger by increasing its Float voltage until it starts to deliver output current. When you have finished the test, be sure both AT10.1s are set to the same Float and Equalize voltages.

2. See Appendix F on page 90 for troubleshooting of Forced Load Sharing feature.

RECOMMENDED ACTION

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SERVICING THE AT10.1

SYMPTOM

HIGH DC VOLTAGE

indicator is on

No alarm, but output voltage is above High DC Voltage setting

LOW DC VOLTAGE

indicator is on, but ac and dc breakers are closed; ac input voltage is normal; there is output current

PROBABLE

CAUSE

1. High DC Voltage alarm and Equalize voltage settings are mismatched

2. Defective rectifier bridge

3. Defective control circuit board A1

1. Output current is below 2%

2. Defective control circuit board A1

1. Be sure that the High DC Voltage alarm setting is higher

than the Equalize voltage setting. See Sections 2.3.2 and

2.3.4.

2. Disconnect wire # 24 from terminal E3 of the rectifier

assembly (near the left front of the enclosure). Restart the AT10.1. If You are able to measure output current, one of the SCRs is defective. Replace the rectifier assembly.

3. Turn off both front panel circuit breakers. Then turn on the

dc breaker, followed by the ac breaker. If the charger output voltage is normal, but the HIGH DC VOLTAGE indicator is still on, replace the control circuit board.

1. Output current must be greater than 2% of rated current to

produce a High DC Voltage alarm. See Parallel Operation in Section 2.3.6.

2. Turn off both front panel circuit breakers. Then turn on the

dc breaker, followed by the ac breaker. If the charger output voltage is above the alarm setting, but the

RECOMMENDED ACTION

HIGH DC VOLTAGE indicator still doesn't light, replace the

control circuit board.

1. Battery is discharged

2. Low DC Voltage alarm and Float voltage settings are mismatched

3. Defective rectifier bridge

4. Defective control circuit board A1

5. Defective dc breaker

1. After an ac power failure, or a battery discharge for any

other reason, it may take several hours to recharge the battery. It is normal for the LOW DC VOLTAGE indicator to be on until the battery voltage is above the Low DC Alarm voltage.

2. Be sure that the Low DC Voltage alarm setting is lower than

the Float voltage setting. See Sections 2.3.2 and 2.3.4.

3. Use a clamp-on ammeter to measure the current in wire #

11 or # 12. If it less than 70% of the dc output current, one of the SCRs or diodes is defective. Replace the rectifier assembly.

4. Turn off both front panel circuit breakers. Then turn on the

dc breaker, followed by the ac breaker. If the charger output voltage is normal, but the LOW DC VOLTAGE indicator is still on, replace the control circuit board.

5. Disconnect the battery, and connect a light dc load to the

AT10.1. Measure the dc voltage from the input terminal to the output terminal of the circuit breaker, with the breaker on. It is normally no more than 50 millivolts. If it is near the rated output voltage, replace the breaker.

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SERVICING THE AT10.1

SYMPTOM

DC OUTPUT FAILURE

indicator is on, but ac and dc breakers are closed; ac input voltage is normal

AC INPUT FAILURE

indicator is on

PROBABLE

CAUSE

1. Defective rectifier bridge

2. Defective control circuit board A1

3. Defective transformer T1

4. Defective dc breaker

1. Use a clamp-on ammeter to measure the current in wire # 12 or # 11. If it is less than 70% of the dc output current, one of the SCRs or diodes is defective. Replace the rectifier module.

2. Turn off both front panel circuit breakers. Then turn on the dc breaker, followed by the ac breaker. If the charger output voltage and current are normal, but the DC OUTPUT FAILURE indicator is still on, replace the control circuit board.

3. Use an ac voltmeter to measure the ac voltage from T1-X1 to X4. It is normally 50% to 80% higher than the rated dc output voltage. If it is too low, check the wiring of the primary taps. See Section 1.6 for details. If it is zero, replace T1.

4. Disconnect the battery, and connect a light dc load to the AT10.1. Measure the dc voltage from the input terminal to the

RECOMMENDED ACTION

output terminal of the circuit breaker, with the breaker on. It is normally no more than 50 millivolts. If it is near the rated output voltage, replace the breaker.

1. AC power failure

2. Upstream feed breaker/fuse is tripped

3. Defective wiring

4. Defective control circuit board A1

1. If the ac input power fails, the front panel AC ON indicator goes out, and the AC INPUT FAILURE indicator goes on.

2. Be sure the front panel ac circuit breaker is closed. Measure the ac voltage at TB1-L1 and L2. If it is zero, check upstream distribution breakers and fuses.

3. Measure ac voltage at T1-H1 and T1-H5. It should be the same as the ac supply voltage.

4. Turn off both front panel circuit breakers. Then turn on the dc breaker, followed by the ac breaker. If the AC ON indicator is on, but the AC INPUT FAILURE indicator is still on, replace the control circuit board.

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SERVICING THE AT10.1

SYMPTOM

POS GND or NEG GND

indicator is on

Summary alarm relay is in alarm mode, but no front panel alarm indicator is on

PROBABLE

CAUSE

1. Ground fault on external dc bus

2. DC circuit breaker is open and NEG GND indicator is on

3. Alarm needs calibration

4. Defective wiring

5. Defective Main Control circuit board A1

1. Defective Main Control circuit board A1

RECOMMENDED ACTION

1. Disconnect the AT10.1 from the battery and dc bus, and

check the battery and dc bus for a ground fault.

2. If the AT10.1 has been placed into standby by opening the

dc breaker (CB2), the ground detection circuit gives an erroneous alarm. Close the dc breaker and the alarm should end. If you want the AT10.1 to be in standby, open the ac circuit breaker (CB1).

3. Calibrate the ground detection sensitivity. See Section

2.3.4.

4. Disconnect the AT10.1 from the battery and dc bus. Turn

the AT10.1 back on, and measure the voltage from TB1(+) to chassis, and from TB1(-) to chassis. The voltage readings should be equal, each approximately half of the total output voltage. If there is more than a 10% imbalance, turn off the AT10.1, and inspect all wiring from TB1(+/-) to the dc circuit breaker (CB2), and the rectifier bridge to the dc filter inductor (L1). Look for evidence of insulation damage, insufficient spacing between terminals and chassis, or wires run too close to metal edges.

5. Turn off both front panel circuit breakers (CB1/CB2). Turn

on the dc breaker, followed by the ac breaker. Wait one minute before returning the dc connection, followed by the ac connection If you are sure there is no ground fault on the external bus or within the AT10.1, but the POS GND or NEG GND indicator is still on, replace the main control circuit board (A1).

1. Turn off both front panel circuit breakers (CB1/CB2). Then

turn on the dc breaker, followed by the ac breaker. Wait one minute before returning the dc connection, followed by the ac connection. If the relay remains in alarm mode, check the Low Level Detect indicator on main control circuit board. See Section 2.3.8. If no other alarm is on, replace the main control circuit board (A1).

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SERVICING THE AT10.1

3.5. REPLACING DEFECTIVE COMPONENTS

WARNING 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.

NOTE: Refer to the standard drawings in Appendix C while performing the following procedures.

Removing the safety shield

Some of the repair procedures described below requires removal of the plexiglas safety shield, mounted in front of the I/O panel. Unscrew the wing nuts and remove the washers to remove the shield. Do not lay the shield on the top of the AT10.1. The top vents are required for cooling.

CAUTION: Hazardous ac and dc voltages are present on the I/O panel terminals and several internal components.

Removing the enclosure shroud

You may need to remove the enclosure shroud in order to make some internal measurements, and to replace or repair components. Turn off and remove all power to the AT10.1. Disconnect the battery from the output terminals.

Remove the eleven (11) screws that hold the shroud on the rear and bottom of the enclosure, then the two screws on the left side that hold the rectifier heat sink assembly. Support the front panel and lift the shroud straight up to remove it. Be sure to save the plastic washers from the door hinge.

The heat sink assembly is supported from the rear panel. Avoid putting any mechanical stress on the heat sink.

Replacing the enclosure shroud

Lower the shroud onto the enclosure base. Install and tighten the eleven (11) screws that hold the shroud on the rear and bottom of the base before you install the two screws that support the heat sink assembly on the left side wall. Remember to reinstall the plastic washers on the door hinge.

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SERVICING THE AT10.1

Replacing the Main Control printed circuit board (A1)

For details of this procedure, refer to service instruction (JD5012-00).

CAUTION: The printed circuit board A1 is sensitive to damage from static discharges. Leave replacement boards in their anti-static bags until you are ready to install them. Ground yourself before handling the board by touching the ground stud on the back of the door. Handle boards only by their edges.

Turn off and remove all power to the AT10.1. Remove the plexiglas safety shield. Disconnect the battery from the output terminals. If the optional tempco probe is installed, disconnect the leads from TB8.

Remove the harness plug from the upper left edge of the Main Control pc board (A1), and unplug wire # 30 from the quick-connect terminal near the upper left corner of the board. The board is mounted on six plastic standoffs. Compress the tab on each standoff, and pull the A1 board toward you until it clears all the standoffs. Put the replacement board in place with the same orientation, and push it onto the standoffs. Be sure that the board is fully seated on the standoffs. Replace wire # 30 on the quick-connect terminal, and connect the harness plug to the board at the top edge. Replace any optional wiring, such as the tempco probe on TB8.

See Section 2.1 for steps to restart the AT10.1. If your charger parameters (float voltage, etc.) are different from the factory preset values, you should program in the new values now. See Section 2.3. You should also recalibrate the dc voltmeter according to Section 2.3.7.

Replacing the rectifier heat sink assembly (A6)

Refer to the customer instruction supplement (JD5009-00) supplied with your replacement rectifier heat sink assembly (EJ1243-00).

Turn off and remove all power to the AT10.1. Remove the plexiglas safety shield. Disconnect the battery from the output terminals. Check with a voltmeter before proceeding. Remove the enclosure shroud as described in the previous section. Make sure the rectifier heat sink has cooled, and remove the entire assembly by the front edge. Remove all wires attached to the rectifier pc board(s) as you pull the assembly out.

Hold the replacement assembly in front of the AT10.1 (in the same orientation as the old), and reconnect all wires removed from the old rectifier as you insert it into the enclosure. To ensure correct replacement, see the wiring diagrams in Appendix C of this manual or the customer instruction supplement, supplied with the replacement assembly. When you are done, check to ensure all wires are connected to the proper terminals, and all lugs are fully seated. If any lug does not fit snugly, disconnect it and carefully tighten the ears of the lug using long-nosed pliers and reconnect.

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SERVICING THE AT10.1

Rotate the rectifier assembly into position in the enclosure. Line up the metal tab with the mounting hole on the back panel of the AT10.1 and slide the assembly into position. Replace the shroud as described in the previous section. Tighten all screws and restart the AT10.1.

Replacing the optional dc filter assembly (A7)

The dc filter assembly consists of a diode heat sink, inductor L2, and one or two capacitors installed on a single bracket.

Turn off and remove all power to the AT10.1. Remove the plexiglas safety shield. Disconnect the battery from the output terminals TB1(+/-).

Find the flying lead from the inductor L2 (wire # 50) and disconnect the other end from the center terminal of inductor L1 (at the upper right corner of the rear panel). Disconnect wire # 15 from the quick-connect terminal at the top center of the diode heat sink, and remove wire # 54 from terminal E7 on the front circuit board on the rectifier assembly. Carefully note which terminal the wire is connected to. Remove the four screws at the top of the dc filter bracket. The bracket and the inductor will both fall forward, away from the rear panel.

Lift the filter bracket up about .25in / 6.4mm to release it from the clips at the bottom of the bracket. Swing the filter assembly outward to the left, rotating it so that the heat sink comes out first and the capacitor(s) last.

Install the replacement filter assembly by inserting the capacitor end first, and rotating the assembly inward so that the heat sink is last to go in. Push the bottom edge of the bracket into the clips in the rear panel, and install the four screws at the top of the bracket.

Connect wire # 15 to the quick-connect terminal at the top center of the diode heat sink. Route the flying lead from the inductor L2 (wire # 50) and connect it to the center terminal ("2") of the inductor L1. Reconnect wire # 54 to terminal E7 of the front circuit board on the rectifier assembly. Replace the shroud and the safety shield.

Replacing the ac input or dc output circuit breaker (CB1, CB2)

Turn off and remove all power to the AT10.1. Remove the plexiglas safety shield. Disconnect the battery from the output terminals TB1(+/-).

Check with a voltmeter before proceeding. This includes remote sense wires if they were installed. Remove the two circuit breaker mounting screws on the front panel, and carefully rotate the circuit breaker upward and pull it out of the enclosure. Remove the wires from the terminals, one at a time, and transfer the wires to the terminals of the replacement breaker. Be sure the terminal screws are tight. Install the replacement breaker into the front panel, rotating it downward into place. Install the two mounting screws.

Page 65

SERVICING THE AT10.1

Replacing the main transformer (T1)

Turn off and remove all power to the AT10.1. Remove the plexiglas safety shield. Disconnect the battery from the output terminals TB1(+/-).

Check with a voltmeter before proceeding. This includes remote sense wires if they were installed. Remove the enclosure shroud and the safety shield. Disconnect the harness wires # 28 and # 29 from the upper row of transformer terminals. Disconnect wires # 11 and # 12 from the top of the rectifier heat sink. Disconnect harness wires # 3 and # 4 from the lower row of terminals; leave both jumpers in place on the lower row.

Remove the four screws or nuts that secure the transformer to the rear panel. Support the transformer by the top of the core and lift it up to get the bottom bracket off the rear panel. Remove the transformer from the enclosure.

Check the jumpers on the bottom row of terminals of the replacement transformer. Make sure they are connected to the same terminals as the jumpers on the transformer you just removed from the AT10.1. For details see Section 1.6, Changing the Transformer Taps.

Hold the replacement transformer with the terminals labeled H1 through H5 at the bottom, facing you. Place the transformer against the rear panel, and slide the bottom of the transformer bracket into the slots on the rear panel. Install the four screws or nuts onto the mounting bracket of the transformer. Rewire the transformer, following the steps above in reverse. Refer to Section 1.6, and verify that the transformer is properly connected for your input voltage.

Replacing the ac surge suppressors (VR2, VR4 or VR5)

Turn off and remove all power to the AT10.1. Remove the plexiglas safety shield. Disconnect the battery from the output terminals TB1(+/-).

For VR2, remove the hardware from the input terminal L1, and remove the lead of the ac surge suppressor. Install one lead of the replacement surge suppressor onto the L1 terminal. Replace the other wires and the hardware. Repeat procedure for the L2 terminal. Tighten all hardware.

For VR4, remove the hardware from the input terminal L1, and remove the lead of the ac surge suppressor. Install one lead of the replacement surge suppressor onto the L1 terminal. Replace the other wires and the hardware. Repeat procedure for the left ground stud. Tighten all hardware.

For VR5, repeat procedure for the ac surge suppressor connected to the L2 terminal and the right ground terminal. Tighten all hardware.

NOTE: The surge suppressors are not polarized.

Page 66

SERVICING THE AT10.1

Replacing the dc surge suppressor (VR1)

Turn off and remove all power to the AT10.1. Remove the plexiglas safety shield. Disconnect the battery from the output terminals TB1(+/-).

Remove the hardware from the output terminal TB1(+), and remove the lead of the dc surge suppressor. Install one lead of the replacement surge suppressor. Replace the other wires and the hardware. Repeat for the output terminal TB1(-). Tighten all hardware.

NOTE: The surge suppressor is not polarized.

Replacing the dc surge suppressor networks (VR6/C4, VR7/C5)

Replace these networks as assemblies; do not replace individual parts. Turn off and remove all power to the AT10.1. Remove the plexiglas

safety shield. Disconnect the battery from the output terminals TB1(+/-). To replace the network VR6/C4, remove the hardware from the output

terminal TB1(-), and remove the lead of the network. Cut the plastic wire ties holding the assembly tight against the I/O panel. Install one lead of the replacement network. Replace the other wires and the hardware. Repeat for the other lead of the network on the ground terminal. For the VR7/C5 network, use the above procedure, but start with the lead on TB1(+). Tighten all hardware. Replace cut wire ties if possible.

NOTE: The surge suppressor networks are not polarized.

Replacing the power (ballast) resistor (R3)

Turn off and remove all power to the AT10.1. Remove the plexiglas safety shield. Disconnect the battery from the output terminals TB1(+/-).

Locate the power resistor R3 behind the I/O panel. In 12 & 24 Vdc units, R3 is installed at the top right corner of the I/O panel. In 48 Vdc units, R3 is mounted on the bracket behind the I/O panel. In 130 Vdc units, R3 is comprised of an assembly of two (2) resistors connected in series, mounted to the bracket behind the I/O panel.

Disconnect the lead of R3 connected to TB1(+), and replace it with the corresponding lead of the replacement power resistor. Remove the other lead of R3 from terminal E17 on the I/O panel and replace it with the remaining lead of the replacement power resistor. Tighten all hardware.

In 12 & 24 Vdc units, tuck the new R3 behind the I/O panel so that the leads are properly spaced. In 48 & 130 Vdc AT10.1s, remove the screws that mount the old resistor(s) to the bracket, and replace with the new resistor(s). Tighten all mounting hardware and restart the AT10.1

For further instructions, refer to service instructions (JD5010-00

Page 67

SERVICING THE AT10.1

Replacing the positive scaling resistor (R4)

Locate the scaling resistor R4 on TB5 on the back of the front panel, just above the control circuit board. The resistor (R4 is the one on the left) is mounted on two quick-connect terminals. Remove the resistor by grasping the terminals by the plastic insulation, and pulling out and downward. Install the replacement resistor by pushing the terminals firmly onto the quick-connect blades on the terminal block.

Replacing the voltage crowbar resistor (R6)

Locate the resistor R6 on TB5 on the back of the front panel, just above the control circuit board. The resistor (R6 is the one on the right) is mounted on two quick-connect terminals. Remove the resistor by grasping the terminals by the plastic insulation, and pulling out and downward. Install the replacement resistor by pushing the terminals firmly onto the quick-connect blades on the terminal block.

Replacing the negative scaling resistor (R14)

Turn off and remove all power to the AT10.1. Remove the plexiglas safety shield. Disconnect the battery from the output terminals TB1(+/-).

The scaling resistor R14 is connected to TB(-) with a ring lug. The other lead of the resistor is soldered to wire # 20.

Remove the insulating sleeving from the soldered joint to wire # 20 (you may have to remove a harness tie) and cut the resistor lead near the solder joint. Disconnect the lugged-end of R14 from TB1(-) and discard the old resistor.

Using a soldering iron no larger than 35 Watts, solder the bare lead of the new R14 to wire # 20. Insulate the joint with plastic electrical tape. Crimp a similar ring lug to the other lead of the new resistor. Connect the lugged end of the new scaling resistor R14 to TB1(-).

Page 68

SERVICING THE AT10.1

3.6. ORDERING REPLACEMENT PARTS

All AT10.1 Series battery chargers ship with a supplemental parts data package, itemizing all components within the unit. Contact your sales representative to place an order for spare or replacement parts. Please provide the following information for each component:

• Model number and serial number of your AT10.1 Series battery charger

• Circuit symbol, factory part number and description from the supplied

Parts Data Package report

• Quantity required

Note: Some of the factory part numbers listed on the Parts Data Package report may differ from the standard replacement part numbers listed in this manual. Custom parts may have replaced standard parts to satisfy your specification. In that case, you should order the part number(s) listed on the report. The following table may specify part replacement kits that include other materials, such as installation instructions and packaging materials. You may order spare parts using either part number. To be sure of getting the complete kit, specify "Complete Kit" on your order, and the factory will make the necessary adjustments.

Refer to the table below for the most common items.

Table 3-1: REPLACEMENT PARTS

Factory Part Number

Symbol

A1 Main Control pc board assembly EJ1243-10 Y A3 Rectifier Gate Driver pc board ass embly EJ5093-00 A5 Auxiliary Alarm Relay pc board assembly EJ1243-03 Y A6 Rectifier / Heat Sink assembly (A3 + A16) EJ1243-00 Y A7 DC Output Filter assembly See Table 3-2

Battery Eliminator Filter assembly

(requires filtered charger)

A10 Temperature Compensation Probe assembly See Appendix B, Table 2 A16 Rectifier SCR module EJ5094-00

C1 DC Output Filter capacitor RP0019-09 RP0019-08 Y C2 Battery Eliminator Filter capacitor RP0019-09 RP0019-08 Y C4 EMI filter capacitor See VR6/C4

C5 EMI filter capacitor See VR7/C5 CB1 AC breaker (standard) 120/208/240 Vac See Table 3-3 CB1 AC breaker (medium AIC) 120/208/240 Vac See Table 3-4 CB1 AC breaker (high AIC) 120/208/240 Vac See Table 3-5 CB1 AC circuit breaker (medium AIC) 480 Vac RE0171-00 CB1 AC circuit breaker (high AIC) 480 Vac RE0043-00 CB2 DC circuit breaker (standard) See Table 3-6 CB2 DC circuit breaker (medium AIC) See Table 3-7 CB2 DC circuit breaker (high AIC) See Table 3-8

Description 12 Vdc 24 Vdc 48 Vdc 130 Vdc

6Adc

12-25Adc

EJ1155-00

EJ1155-01 EJ1155-02

Rec.

Spare

Page 69

SERVICING THE AT10.1

Factory Part Number

Symbol Description

CR1 Polarity diode EJ1243-04 Y CR2 Blocking diode EJ1243-05

F1 480 Vac AC Input Fuse See Table 3-14 Y L1 Main Inductor See Table 3-9 L2 DC Filter Inductor See Table 3-13 P5 Jumper for disabling Ground Detection circuit RC0100-00

Jumper for voltage selection on

Auxiliary Alarm Relay circuit board (A5)

P9 Jumper for front panel lockout feature on A1 RC0100-00 R2 Rating resistor See Table 3-10

R3 Power Supply (Ballast) Resistor

R4 Scaling resistor (positive side) R6 Voltage crowbar resistor EJ1135-00 EJ1135-01 EJ1135-02 EJ1135-03

R9 Filter capacitor (C1) bleed resistor EJ1137-00 EJ1137-00 EJ1137-01 EJ1137-02

R14 Scaling resistor (negative side)

T1 Main transformer (120/208/240 Vac) See Table 3-11 T1 Main transformer (480 Vac) See Table 3-12

TB1-X I/O terminal box lug for #14-6 AWG RC0056-04

Terminal block for Medium and

TB6

High AIC circuit breakers

VR1 Output Surge Suppressor EJ1132-01 Y VR2 Input Surge Suppressor (120/208/240 Vac) EJ1132-01 Y VR2 Input Surge Suppressor (480 Vac) EJ1132-02 Y VR3 Input Lightning Arrestor EJ1074-00

VR4,

Input Surge Suppressor (120/208/240 Vac) EJ1132-01 Y

VR5

VR4,

Input Surge Suppressor (480 Vac) EJ1132-02 Y

VR5

VR6/C4 EMI Filter Network EJ5021-01 VR7/C5 EMI Filter Network EJ5021-01

12 Vdc 24 Vdc 48 Vdc 130 Vdc

RC0100-00

EJ1127-00

12Ω 2W

EJ1134-00

3160 Ω

EJ1222-00

3160 Ω

EJ1127-01

68Ω 11W

EJ1134-01

6980 Ω

EJ1222-01

6980 Ω

terminal section RC0014-00 (8 req'd)

end section RC0014-01 (1 req'd)

EJ1127-02 150Ω 50W

EJ1134-02

14.0 kΩ

EJ1222-02

14.0 kΩ

EJ1127-03

(note 1)

EJ1134-03

38.3 kΩ

EJ1222-03

38.3 kΩ

Note 1: In 130 Vdc units, a 500Ω 50W power supply resistor (R3), mounted behind the I/O panel, may be comprised of an assembly of two (2) 250Ω resistors connected in series.

Rec.

Spares

Page 70

SERVICING THE AT10.1

Table 3-2: DC FILTER ASSEMBLIES (L2/C1/R9/CR1/CR2)

Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc

6A 12A 16A 20A 25A

Table 3-3: STANDARD AC CIRCUIT BREAKERS (CB1) - 120/208/240 Vac

EJ1072-00 EJ1072-00 EJ1072-02 EJ1072-03 EJ1072-00 EJ1072-00 EJ1072-02 EJ1072-06 EJ1072-01 EJ1072-01 EJ1072-07 EJ1072-04 EJ1072-01 EJ1072-01 EJ1072-07 EJ1072-04 EJ1072-01 EJ1072-01 EJ1072-07 EJ1072-05

Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc

6A 12A 16A 20A 25A

Table 3-4: MEDIUM INTERRUPTING CAPACITY AC BREAKERS (CB1) - 120/208/240 Vac

RE0159-11 RE0159-11 RE0159-11 RE0159-13 RE0159-11 RE0159-11 RE0159-13 RE0159-16 RE0159-11 RE0159-12 RE0159-13 RE0159-19 RE0159-11 RE0159-12 RE0159-14 RE0159-20 RE0159-11 RE0159-12 RE0159-15 RE0159-20

Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc

6A 12A 16A 20A 25A

Table 3-5: HIGH INTERRUPTING CAPACITY AC BREAKERS (CB1) - 120/208/240 Vac

RE0171-00 RE0171-00 RE0171-00 RE0171-01 RE0171-00 RE0171-00 RE0171-01 RE0171-04 RE0171-00 RE0171-00 RE0171-01 RE0171-07 RE0171-00 RE0171-00 RE0171-02 RE0171-08 RE0171-00 RE0171-00 RE0171-03 RE0171-08

Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc

6A 12A 16A 20A 25A

RE0043-00 RE0043-00 RE0043-00 RE0043-01 RE0043-00 RE0043-00 RE0043-01 RE0043-04 RE0043-00 RE0043-00 RE0043-01 RE0043-07 RE0043-00 RE0043-00 RE0043-02 RE0043-08 RE0043-00 RE0043-00 RE0043-03 RE0043-08

Page 71

SERVICING THE AT10.1

Table 3-6: STANDARD DC CIRCUIT BREAKERS (CB2)

Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc

6A 12A 16A 20A 25A

Table 3-7: MEDIUM AMPERE INTERRUPTING CAPACITY DC CIRCUIT BREAKERS (CB2)

RE0159-01 RE0159-01 RE0159-01 RE0159-12 RE0159-02 RE0159-02 RE0159-02 RE0159-13 RE0159-03 RE0159-03 RE0159-03 RE0159-14 RE0159-04 RE0159-04 RE0159-04 RE0159-15 RE0159-06 RE0159-06 RE0159-06 RE0159-17

Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc

6A 12A 16A 20A 25A

Table 3-8: HIGH AMPERE INTERRUPTING CAPACITY DC CIRC UIT BREAKERS (CB2)

RE0171-00 RE0171-00 RE0171-00 RE0171-00 RE0171-01 RE0171-01 RE0171-01 RE0171-01 RE0171-02 RE0171-02 RE0171-02 RE0171-02 RE0171-03 RE0171-03 RE0171-03 RE0171-03 RE0171-04 RE0171-04 RE0171-04 RE0171-04

Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc

6A 12A 16A 20A 25A

Table 3-9: MAIN INDUCTOR (L1)

RE0043-00 RE0043-00 RE0043-00 RE0043-00 RE0043-01 RE0043-01 RE0043-01 RE0043-01 RE0043-02 RE0043-02 RE0043-02 RE0043-02 RE0043-03 RE0043-03 RE0043-03 RE0043-03 RE0043-04 RE0043-04 RE0043-04 RE0043-04

Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc

6A 12A 16A 20A 25A

AP0928-00 AP0928-00 AP0928-00 AP1122-00 AP0928-00 AP0928-00 AP0928-00 AP0930-00 AP0926-00 AP0926-00 AP0926-00 AP0931-00 AP0926-00 AP0926-00 AP0926-00 AP0931-00 AP0926-00 AP0926-00 AP0926-00 AP0931-00

Page 72

SERVICING THE AT10.1

Table 3-10: RATING RESISTOR (R2)

Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc

6A 12A 16A 20A 25A

Connector terminal

extraction tool

Table 3-11: MAIN TRANSFORMER (T1) - 120/208/240 Vac

EJ1133-00

34.8 kΩ

EJ1133-01

40.2 kΩ

EJ1133-02

53.6 kΩ

EJ1133-03

78.7 kΩ

EJ1133-04

118 kΩ

EJ1133-05

13.0 kΩ

EJ1133-06

15.4 kΩ

EJ1133-07

19.6 kΩ

EJ1133-08

23.7 kΩ

EJ1133-09

29.4 kΩ

EJ1133-10

5.11 kΩ

EJ1133-11

6.19 kΩ

EJ1133-12

7.50 kΩ

EJ1133-13

9.09 kΩ

EJ1133-14

11.0 kΩ

Molex Part No. 11-03-0044

EJ1133-15

1.50 kΩ

EJ1133-16

2.21 kΩ

EJ1133-17

2.74 kΩ

EJ1133-18

3.57 kΩ

EJ1133-19

4.32 kΩ

Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc

6A 12A 16A 20A 25A

Table 3-12: MAIN TRANSFORMER (T1) - 480 Vac

AA0718-00 AA0719-00 AB2023-00 AB1868-00 AA0718-00 AA0719-00 AB2023-00 AB1857-00 AA0720-00 AB1855-00 AB1856-00 AB1858-00 AA0720-00 AB1855-00 AB1856-00 AB1858-00 AA0720-00 AB1855-00 AB1856-00 AB1858-00

Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc

6A 12A 16A 20A 25A

AA0733-00 AA0734-00 AB2038-00 AB2039-00 AA0733-00 AA0734-00 AB2038-00 AB2032-00 AA0735-00 AB2035-00 AB2036-00 AB2037-00 AA0735-00 AB2035-00 AB2036-00 AB2037-00 AA0735-00 AB2035-00 AB2036-00 AB2037-00

Page 73

SERVICING THE AT10.1

Table 3-13: FILTER INDUCTOR (L2)

Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc

6A 12A 16A 20A 25A

Table 3-14: 480 Vac INPUT FUSE (F1)

AP0928-00 AP0928-00 AP0928-00 AP1081-00 AP0928-00 AP0928-00 AP0928-00 AP0928-00 AP0927-00 AP0927-00 AP0926-00 AP0926-00 AP0927-00 AP0927-00 AP0926-00 AP0926-00 AP0927-00 AP0927-00 AP0926-00 AP0926-00

Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc

6A 12A 16A 20A 25A

RE0008-00 RE0008-00 RE0008-02 RE0008-06 RE0008-00 RE0008-02 RE0008-06 RE0008-08 RE0008-02 RE0008-06 RE0008-08 RE0008-09 RE0008-02 RE0008-06 RE0008-08 RE0008-11 RE0008-02 RE0008-06 RE0008-08 RE0008-11

Page 74

APPENDIX A

77° F / 25 °C, nominal ac line voltage & nominal float voltage

Specification Conditions

Output voltage regulation

Transient response

Efficiency

SPECIFICATIONS

Except as noted, all specifications apply at:

12 Vdc 24 Vdc 48 Vdc 130 Vdc

Vac +10%, -12% 0 to 100% load Temp. 32-122° F / 0-50° C Freq. 60 ± 3 Hz

20-100% load change, with battery connected

12 Adc rating, full load (%) 67.00 72.00 78.00 85.00 25 Adc rating, full load (%) 73.00 77.00 85.00 91.00

(see product literature for specific data)

Output voltage change ± 4% maximum

Recovery to ± 2.0% in 200 ms Recovery to ± 0.5% in 500 ms

± 0.25%

Unfiltered (with battery)

Output ripple voltage per NEMA PE5-1996

Current limit Adjustable 50-110 % of rated output current Soft start 0 to 100% load 4 seconds

Voltage adjustment ranges

Voltmeter range (Vdc) 0 - 21 0 - 42 0 - 75 0 - 195 Ammeter range (Adc) All ratings 0 - 30

Surge withstand capability Reverse current from

battery Audible noise

Cooling Natural convection Ambient temperature Operating Elevation 3000ft / 1000m without derating Relative humidity 0 to 95% non-condensing

Filtered (with battery)

Filtered (without battery) 1% rms (typ) 2% rms Battery Eliminator Filter

Option (without battery)

Float (Vdc) 11.0-14.5 22.0-29.5 44.0-58.0 110-141 Equalize (Vdc) 11.7-15.5 23.4-31.0 46.8-59.0 117-143 High DC Voltage alarm (Vdc) 12-19 24-38 48-76 120-175 Low DC Voltage alarm (Vdc) 7-14.5 15-29.5 30-58 80-141

Test per

ANSI C37.90.1-1989

AC input power failure 90 mA maximum Average for 4 sides,

5ft / 1.5m from charger

1% rms (typ) 2% rms

at battery terminals

30 mV rms (max) 100 mV

at battery terminals

30 mV rms 100 mV

No erroneous outputs

Less than 62 dB(A)

32-122° F / 0-50° C

Alarm relay contact rating 120 Vac / 125 Vdc 0.5 A resistive

Page 75

APPENDIX B

FIELD INSTALLABLE ACCESSORIES AND OPTIONS

All accessories/options listed below are available in kits for field installation. Kits contain all parts and hardware with detailed installation instructions. To order accessories/options, please provide the following information for each kit:

• Model number and serial number of your battery charger

• Factory part number and description, from the table below

• Quantity required

Contact your sales representative to place an order for accessories/options.

Description Kit Part Number

standard DC Output Filtering (per NEMA PE5-1996) Battery Eliminator Filtering (per NEMA PE5-1996) Auxiliary Relay PC Board (A5) for standard circuit breakers Auxiliary Relay PC Board (A5) for med/high AIC circuit breakers Copper Ground Bus with one (1) box lug for #14-6 AWG AC Input Lightning Arrestor (VR3) Floor Mounting Kit for Style-586/594 Enclosure Relay Rack Mounting Kit for Style-586/594 Enclosure NEMA-2 Type Drip Shield Assembly for Style-586/594 Enclosure NEMA-4/12/13 Type Enclosure for Style-586/594 Enclosure Cabinet Heater Assembly for Style-586/594 Enclosure Padlock for Style-586/594 Enclosure Front Panel Door Remote Temperature Compensation Probe Assembly (A10) DNP3 Level 2 / Modbus Communications Module Forced Load Sharing Accessory

see table 3-2 see table 3-1

EI0213-00 EI0213-01 EI0195-00

EJ1074-00

EI0192-00 EI0193-00 EI0191-00 EI0214-##

EJ1223-00

EI0215-00 see below

see Appendix E

EJ5126-##

Remote Temperature Compensation Probe

The temperature compensation assembly consists of two (2) components:

1. To order a replacement probe (or puck), request part number EJ5032-00. This

probe is good for all charger output voltages and all battery types.

2. The standard temperature compensation assembly is supplied with a 25ft / 7.6m interconnection cable. If you need a longer cable, order it from the table below, which also shows the ordering part number for a complete probe kit.

Temperature Compensation Probe Kits

Cable Length

(feet / m)

25 / 7.6 EJ5033-00 EJ5011-00

50 / 15.2 EJ5033-01 EJ5011-01 100 / 30.5 EJ5033-02 EJ5011-02 200 / 61.0 EJ5033-03 EJ5011-03

Use a single cable assembly. Do not try to splice cables together to increase the length.

Kit Part Number

(includes probe)

Replacement Cable

Part Number

Page 76

APPENDIX C (Standard Drawings)

Outline: AT10.1 Group I Battery Charger

NEMA-1 Style-586 Enclosure (JE5023-03)

http://www.ATSeries.net/PDFs/JE5023-03.pdf

Page 77

APPENDIX C (Standard Drawings)

Outline: AT10.1 Group I Battery Charger

NEMA-1 Style-594 Enclosure (JE5024-03)

http://www.ATSeries.net/PDFs/JE5024-03.pdf

Page 78

APPENDIX C (Standard Drawings)

Optional Enclosure Dimensions: AT10.1 Group I Battery Charger w/Penthouse and Drip Shield - Style-586 Enclosure

DIMENSION in

Standard

DD HH

16.25

12.50

15.63

16.25

10.75

495 324 457

495 337

with Penthouse

DD HH

with Drip Shield

DD HH

with Penthouse & Drip Shield

DD HH

14.00

10.75

22.63

16.25

10.00

18.75

12.50

19.50

16.25

10.75

18.75

12.50

26.50

16.25

10.00

356 337 572

495 324

559 318 552

495 337

476 337 729

495 324

Page 79

APPENDIX C (Standard Drawings)

Optional Enclosure Dimensions: AT10.1 Group I Battery Charger

w/Penthouse and Drip Shield - Style-594 Enclosure

DIMENSION

Standard

with Penthouse

with Drip Shield

with Penthouse & Drip Shield

DD HH

19.50

12.75

18.00

19.50

13.25

14.00

13.25

25.00

19.50

12.75

22.00

12.50

21.75

19.50

13.25

18.75

13.25

28.75

19.50

12.75

495 324 457

495 337

356 337 635

495 324

559 318 552

495 337

476 337 729

495 324

Page 80

APPENDIX C (Standard Drawings)

Internal Component Layout: AT10.1 Group I Battery Charger Style-586/594 Enclosure w/Common Options (JE5027-99)

Note: This internal component layout drawing (JE5027-99) depicts an AT10.1 Series battery charger housed in a Style-586 or Style-594 enclosure, with ALL available options. Standard components (A1 through VR7) are supplied in all such units. Optional components (A5 through VR3) are supplied only in those AT10.1 chargers configured with such options.

Page 81

APPENDIX C (Standard Drawings)

Internal Component Layout: AT10.1 Group I Battery Charger

Style-596/594 Enclosure w/Common Options (JE5027-99)

http://www.ATSeries.net/PDFs/JE5027-99.pdf

Page 82

APPENDIX C (Standard Drawings)

Instrument Panel / PC Board Detail: AT10.1 Group I Battery Charger w/Optional Auxiliary Alarm Relay Board (JE5030-19)

Note: This instrument panel drawing (JE5030-19) depicts the optional Auxiliary Alarm Relay PC Board (A5), which provides two (2) sets of individual form-c contacts (TB4) for all alarm conditions. Standard AT10.1 battery chargers feature one (1) set of form-c summary (common) alarm contacts (TB3).

Page 83

APPENDIX C (Standard Drawings)

Instrument Panel / PC Board Detail: AT10.1 Group I Battery Charger

w/Optional Auxiliary Alarm Relay Board (JE5030-19)

http://www.ATSeries.net/PDFs/JE5030-19.pdf

Page 84

APPENDIX C (Standard Drawings)

Schematic: AT10.1 Group I Battery Charger

Standard w/o Options (JE5031-00)

Page 85

APPENDIX C (Standard Drawings)

Schematic: AT10.1 Group I Battery Charger

Standard w/o Options (JE5031-00)

http://www.ATSeries.net/PDFs/JE5031-00.pdf

Page 86

APPENDIX C (Standard Drawings)

Schematic: AT10.1 Group I Battery Charger

w/Common Options (JE5031-99)

Page 87

APPENDIX C (Standard Drawings)

Schematic: AT10.1 Group I Battery Charger

w/Common Options (JE5031-99)

http://www.ATSeries.net/PDFs/JE5031-99.pdf

Page 88

APPENDIX C (Standard Drawings)

Connection Diagram: AT10.1 Group I Battery Charger

Standard w/o Options (JE5033-00)

Page 89

APPENDIX C (Standard Drawings)

Connection Diagram: AT10.1 Group I Battery Charger

Standard w/o Options (JE5033-00)

http://www.ATSeries.net/PDFs/JE5033-00.pdf

Page 90

APPENDIX C (Standard Drawings)

Connection Diagram: AT10.1 Group I Battery Charger

w/Common Options (JE5033-99)

Page 91

APPENDIX C (Standard Drawings)

Connection Diagram: AT10.1 Group I Battery Charger

w/Common Options (JE5033-99)

http://www.ATSeries.net/PDFs/JE5033-99.pdf

Page 92

APPENDIX D

RECOMMENDED FLOAT AND EQUALIZE VOLTAGES

This table contains suggested values for commonly used batteries. Consult your battery manufacturer's documentation for specific values and settings for your battery type.

Battery Cell Type

Antimony (1.215 Sp. Gr.) 2.17 2.33 Antimony (1.250 Sp. Gr.) 2.20 2.33 Selenium (1.240 Sp. Gr.) 2.23 2.33 - 2.40

Calcium (1.215 Sp. Gr.) 2.25 2.33 Calcium (1.250 Sp. Gr.) 2.29 2.33

Absorbed / Gelled Electrolyte *

Lead-Acid Types

* Sealed lead-acid battery types should not be used in ambient temperatures above 95° F / 35° C, and should not normally be equalized. Consult your battery manufacturer's documentation for specific equalizing recommendations.

(sealed lead acid type)

Nickel Cadmium 1.42 1.47

Recommended

Float Voltage/cell

2.25 *

Recommended

Equalize Voltage/cell

TEMPERATURE COMPENSATION

If batteries are to see temperature variations during charging, a temperature compensation option (A10) is recommended. If this option is not part of your charger, manual adjustments should be made. Refer to the equation and table below for temperature-adjusted voltages.

temperature-adjusted voltage = charge voltage x K

Temperature

(°F)

35 1.7 1.058 1.044 45 7.2 1.044 1.034 55 12.8 1.031 1.023 65 18.3 1.017 1.013 75 23.9 1.003 1.002 77 25.0 1.000 1.000 85 29.4 0.989 0.992 95 35.0 0.975 0.981

105 40.6 0.961 0.970

Temperature

(°C)

(Lead Acid) K (Nickel Cadmium)

Page 93

APPENDIX E

COMMUNICATIONS MODULE

ONLINE SUPPLEMENTS

Operating Instructions http://www.ATSeries.net/PDFs/JA0202-04.pdf Field Installation http://www.ATSeries.net/PDFs/JD5008-00.pdf

INTRODUCTION

Your AT10.1 Microprocessor-controlled Battery Charger features provisions for an optional Communications Module that allows the user to remotely monitor and control the unit over a serial connection. This option supports DNP3 Level 2 and Modbus protocols over RS-232 or RS-485 half-duplex. Industry-standard SCADA (Supervisory Control And Data Acquisition) systems will be able to control, monitor, and log the events of the AT10.1 when this option is supplied. Using the Communications Module, all features of the AT10.1's front instrument panel are accessible remotely. The AT Series Communications Module option (p/n EJ5037-0#), installed within a battery charger, includes the Communications PC Board (A12), a dc power supply resistor (R29), and an Operating Instructions manual (JA0102-04 Installation Kit (p/n EJ5037-1#) also includes special instructions (JD5008-00). Also available are a compatible industry standard modem with interconnection cable, or a fiber optic modem kit. Finally an Ethernet gateway option for either Modbus or DNP Level 2 is available. Contact your sales representative to place an order for the AT Series Battery Charger Communication Module. Refer to the table below for ordering information.

). The Field

Description Part No.

Installed Communications Option for 12 Vdc AT10.1 EJ5037-01 Installed Communications Option for 24 Vdc AT10.1 EJ5037-02 Installed Communications Option for 48 Vdc AT10.1 EJ5037-03 Installed Communications Option for 130 Vdc AT10.1 EJ5037-04 Installed Communications Option for AT10-130-006 EJ5037-05

Communications Module Field Kit for 12 Vdc AT10.1 EJ5037-11 Communications Module Field Kit for 24 Vdc AT10.1 EJ5037-12 Communications Module Field Kit for 48 Vdc AT10.1 EJ5037-13 Communications Module Field Kit for 130 Vdc AT10.1 EJ5037-14 Communications Module Field Kit for AT10-130-006 EJ5037-15

Industry Standard Modem w/10ft Cable EJ5084-00 Industry Standard Modem w/25ft Cable EJ5084-01 Industry Standard Modem w/50ft Cable EJ5084-02

Fiber Optic Modem w/Interface for AT Comm EJ5230-0# Ethernet Gateway Interface for MODBUS AT Comm EJ5226-0#

Ethernet Gateway Interface for DNP AT Comm EJ5226-1#

Page 94

APPENDIX F

FORCED LOAD SHARING

ONLINE SUPPLEMENT

http://www.ATSeries.net/PDFs/JA5054-00.pdf

INTRODUCTION

Multiple battery chargers are sometimes employed in dc power systems to provide redundancy. Two or more chargers of the same voltage rating can be connected in parallel, each of them capable of powering the connected dc load and charging the battery. If a battery charger should fail during normal operation, the parallel charger can continue to supply the entire required dc load current, and maintain charge on the battery.

When two (2) AT10.1s operate in parallel, they normally will not share the load current equally. Since any two chargers will have slightly different characteristics, one of the two chargers in a system will have a slightly higher dc output voltage, and will therefore assume more of the burden of providing necessary load current. This section describes an optional accessory for the AT10.1 that system operators can use to force units to share load equally. The accessory consists of an interconnecting cable to provide such communication.

SYSTEM REQUIREMENTS

• The forced load sharing feature is designed only to work with two (2) AT10.1 Series battery

chargers. You cannot force load sharing with three (3) or more chargers.

• The units must have the same dc voltage and current rating, and have the same dc filtering level.

• Both chargers must have the same ac input source and the same phase rotation.

• Both chargers must feature Rev. 6 (or higher) builds of the main control circuit boards (A1), and

corresponding (Rev. 6 or higher) software programs .

• We recommend that both chargers use the same program version, since the load sharing option

has not been tested using a different program version in each charger. To view the program version, press the LAMP TEST button on the front panel of the charger. When you release the button, the version number is shown on the front panel display for two seconds.

• The interconnecting signal cable length should be no more than 50ft (15m).

INSTALLING THE INTERCONNECTION CABLE

The AT Series forced load sharing accessory is normally supplied by the factory with a standard 15ft (4.6m) interconnection cable (EH5041-00). A 25ft (7.6m) long cable (EH5041-01) and a 50ft (15.2m) long cable (EH5041-01) are also available. The interconnection cable is terminated at each end with a 6-pin connector that mates with the plastic connector (J4) on lowerright corner of the Main Control pc board (A1). One end of the cable features an extra jumper in the connector, and should be identified for use with the Secondary charger. The other end of the cable connects to the Primary charger. Either AT10.1 may be selected as Primary or Secondary, but you may wish to choose the unit that is more accessible to be the Primary. The Primary charger controls the dc output voltage of both AT10.1s.

You may run the interconnection cable through conduit if necessary. However, do not run the cable through the same conduit with power wiring. Do not remove the connectors in order to "fish" the cable through the conduit. Maximum pulling tension is 46 lb. (20.9kg). The cable has a plenum-rated outer jacket, and passes the NFPA 262 flame propagation test. Install the cable between the AT10.1s, and anchor it in place at both ends before connecting. Connect each end to the Main Control pc boards, inserting the connector into J4 until it is completely seated.

NOTE: DC power cabling for the battery charger, battery, and load interconnection is not supplied with the AT Series Forced Load sharing option. All user-supplied system wiring should meet National Electric Code (NEC) standards, as well as local/site codes. Confirm polarity of all dc cabling before making connections.

Page 95

APPENDIX F

OPERATING CHARGERS WITH LOAD SHARING

Restore external power connections to both AT10.1s, and restart according to the normal procedure in the AT Series Battery Charger Operating and Service Instructions. After the AT10.1s restart, the Primary charger attempts to establish communication with the Secondary. If communication is successful, the chargers behave as follows:

• The Primary charger displays the message LS P (Load Share, Primary) on the front panel,

alternating with the normal display of output voltage and current.

• The Secondary charger displays the message LS S (Load Share, Secondary) on the front panel,

alternating with the normal display of output voltage and current.

• The Primary charger controls all voltage settings for both AT10.1s. You may adjust any voltage

(float, equalize, alarm settings, etc.) at the front panel of the Primary charger. The front panel of the Secondary charger will not allow any settings to be changed.

• If one charger loses ac power (or is turned off), the remaining charger returns to independent

operation, whether it was originally the Primary or Secondary. For this reason, it is important to set up both chargers initially for the same operating voltages. If an alarm condition occurs, both chargers revert to independent operation for the duration of the alarm.

• In the event of a fault in the interconnection, or any other problem with communication, the

chargers return to independent operation, and the front panel on each charger displays the message E 14, indicating the fault.

• There is a delay of up to 4 seconds for the two (2) AT10.1s to establish forced load sharing

communication. If communication is broken (or power is lost for one charger), there is up to a 4 second delay for the other charger to resume independent operation.

• If you need to interchange the Primary and Secondary chargers, simply reverse the

interconnection cable.

• The presence of the interconnection cable (and a good interconnection) forces the two (2)

AT10.1s into load sharing. Controlling load sharing from the front panel is neither necessary nor possible.

WHEN TEMPERATURE COMPENSATION IS INSTALLED

The AT Series forced load sharing feature is compatible with the external temperature compensation accessory. It is recommended that each AT10.1 have a tempco probe, and that the probes be located as close as possible to each other. When the AT10.1s are load sharing, the primary charger will determine the temperature compensated voltage and adjust the output voltage accordingly. The primary charger and secondary charger will display the set point voltage, not the temperature compensated output voltage. The voltage displayed by the master and secondary may be different, if either temperature probe is not installed or defective. A slight difference in the displayed voltages may also occur if the two probes are not located in close proximity of each other.

TROUBLE SHOOTING

If the AT Series Forced Load Sharing option is installed, but the output currents of the AT10.1s are unequal, refer to the following table.

PROBABLE

CAUSE

1. Connection cable missing or installed incorrectly.

2. Incorrect connections to ac power sources.

3. Defective or improper Main Control circuit board A1

1. Ensure that the interconnection signal cable assembly is properly installed, and that the connector for the Secondary charger has the jumper as described at the top of page 3.

2. Ensure that both AT10.1s are connected to the same ac supply and that source phase rotation is the same for both chargers.

3. Replace the Main Control circuit board in one charger at a time, noting system requirements, to restore correct load sharing operation.

RECOMMENDED ACTION

Page 96

APPENDIX G

To operate this charger from inputs other than 120 Vac, you must use branch circuit protection. To reduce the risk of fire, use only on circuits provided with the following branch circuit protection in accordance with the National Electrical Code, ANSI/NFPA 70.

Rating

12 Adc 16 Adc 20 Adc 25 Adc

NOTE: This table does not apply to AT10.1 chargers with 480 Vac input.

48 Vdc 130 Vdc 48 Vdc 130 Vdc

--- 25A --- 20A 15A 25A 12A 20A 20A 30A 15A 30A 25A 40A 20A 35A

208 Vac Branch Circuit

Protection (Amperes)

UL DATA

CAUTION

Charger Voltage Rating Current

240 Vac Branch Circuit

Protection (Amperes)

Page 97

Page 98

MANUAL SPECIFICATIONS

DOCUMENT NUMBER

The text and graphics contained within this manual are controlled by the battery charger manufacturer's internal part number (JA5023-00). The revision level and dates of this manual's text and graphics are listed below. These controls supercede all other available dates. The first two and last two pages of this manual are reserved for company-specific front and back cover artwork. Any revision levels, revision dates, or document numbers featured on the first two and last two pages of this manual refer to the cover artwork only.

DOCUMENT INFORMATION

Document Number: JA5023-00 Revision Level: 10 Engineering Change Number: 22499 Electronic Filename: [JA5023-00.Rev10.doc] Last Date Saved: [2/23/2011 8:30 PM] Last Date Printed: [2/23/2011 8:34 PM]

PARTS DATA PACKAGE

Any job-specific customized Parts Data Package report supplied with this battery charger and/or this manual supercedes the information featured in the standard parts list starting on page 64. The data featured in that particular document is applicable only to the battery charger featuring the same serial number listed on the Parts Data Package report.

DRAWINGS

A customized record drawing package is available for your AT10.1, featuring a unitspecific drawing list / data nameplate detail, outline drawing, itemized internal component layout, electrical schematic with component ratings, and a full connection diagram. If the standard drawings featured in this manual are not sufficient, please contact your Sales Representative for drawing availability from the battery charger manufacturer. Any job-specific custom drawings supplied with your AT10.1 and/or this manual, supercede the standard drawings featured in Appendix C. The standard drawings and corresponding page numbers featured in this section may not be included with custom printed manuals, when job-specific custom drawings are supplied.

Page 99

MANUAL SPECIFICATIONS

ONLINE AVAILABILITY

An unlabeled version of this operating and service instruction manual is available online at http://www.ATSeries.net/PDFs/JA0102-01.pdf feature and accessory special instructions, standard drawings (including the ones listed in this manual), field service instructions, and product application notes for the AT Series microprocessor-controlled battery chargers and battery charger products are available online at

http://www.ATSeries.net/

. Saved in Adobe Acrobat Portable Document Format (PDF), they are readily available for downloading and printing. If revision levels differ between the drawings embedded in this manual and the full online PDF drawings, refer to document with the higher revision level. For document availability of private-labeled manuals and/or standard drawings, please contact your sales representative or visit the web site listed on the back cover of this manual.

Exide Technologies 94.20 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual