Exide Technologies 94.30 User Manual

10.1

SERIES CHARGERS

INSTALLATION & OPERATING

Section 94.30

2011-11

JA0128-02

INSTRUCTIONS

FOR

AT10.1 SERIES

BATTERY CHARGER

GROUP II

(30-100 ADC OUTPUT)

I & O MANUALS

HOW TO READ THE AT10.1 MODEL NUMBER

GROUP II RATINGS (30-100 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

A B C D E F G H J K L M N P

DESCRIPTION CODE FEATURE

SERIES AT10 AT10.1 CHARGER S STANDARD

NOMINAL

DC OUTPUT VOLTAGE

NOMINAL

DC OUTPUT CURRENT

F SUPPLIED

FILTERING

G SUPPLIED

AC INPUT

VOLTAGE

DESCRIPTION CODE FEATURE

INPUT AND OUTPUT INTERRUPTING CAPACITY RATINGS

ORDER

CODE

S STANDARD 5,000 AIC 5,000 AIC M MEDIUM AIC 25,000 AIC 10,000 AIC 200,000 AIC 20,000 AIC H HIGH AIC 65,000 AIC 25,000 AIC

* Contact your sales representative for 500-600 Vac circuit breaker AIC ratings.

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.

floor/wall/rack mounting brackets zero-center ground detection meter w/test switch NEMA-2 type drip shield end of discharge alarm relay NEMA-4/12/13 type enclosure battery discharge alarm relay cabinet heater strips barrier type auxiliary alarm terminal block(s) pad/key lock for front panel door external temperature compensation probe analog ac voltmeter DNP3 Level 2 / Modbus communications module analog ac ammeter forced load sharing signal interconnection cable

Please find the serial number on the

data nameplate and record it here:

DESCRIPTION CODE FEATURE AC CIRCUIT

BREAKER

RATING (SEE TABLE)

AC FUSES

(200 kAIC) DC CIRCUIT

BREAKER

RATING (SEE TABLE)

DC FUSES

(20 kAIC) AUX ALARM

RELAY BOARD

GROUND BUS

LIGHTNING

ARRESTOR FUNGUS

PROOFING STATIC

PROOFING DESCRIPTION CODE FEATURE

OPTIONAL AC

0 NO AC BREAKER

X NOT SUPPLIED

0 NO DC BREAKER

X NOT SUPPLIED

X NOT APPLIED

FUSE RATING

(208-600 Vac)

OPTIONAL DC FUSE RATING

(12/24/48/130 Vdc)

CIRCUIT

BREAKER

TYPE

012 12 Vdc M MEDIUM AIC 024 24 Vdc H HIGH AIC 048 48 Vdc 130 130 Vdc F SUPPLIED 030 30 Adc 040 40 Adc S STANDARD 050 50 Adc M MEDIUM AIC 075 75 Adc H HIGH AIC 100 100 Adc

U UNFILTERED F FILTERED A SUPPLIED E ELIMINATOR

120 120 Vac 60 Hz 208 208 Vac 60 Hz L SUPPLIED 240 240 Vac 60 Hz 480 480 Vac 60 Hz F APPLIED 220 220 Vac 50/60 Hz 380 380 Vac 50/60 Hz S APPLIED 416 416 Vac 50/60 Hz

AC CIRCUIT

BREAKER RATINGS

(208/240/480 Vac) *

DC CIRCUIT

BREAKER RATINGS

(125/250 Vdc)

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

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 (optional)..............................................................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 probe (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...................................................................29

2.2.6 Testing the Auxiliary Relay Board (optional) .................................................29

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

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..................................................................................62

Replacement parts tables (begin on)....................................................................62

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

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

APPENDIX C: Standard Drawings *

Outline: AT10.1 Group II Battery Charger NEMA-1 Style-5017 Enclosure.................................. 72

Outline: AT10.1 Group II Battery Charger NEMA-1 Style-5018 Enclosure..................................74

Internal Component Layout: AT10.1 Style-5017 Enclosure w/Common Options.........................76

Internal Component Layout: AT10.1 Style-5018 Enclosure w/Common Options.........................78

Instrument Panel / PC Board Detail: AT10.1 Group II Battery Charger .......................................80

Schematic: AT10.1 Group II Battery Charger - Standard w/o Options......................................... 82

Schematic: AT10.1 Group II Battery Charger - with Common Options........................................84

Connection Diagram: AT10.1 Group II Battery Charger - Standard w/o Options.........................86

Connection Diagram: AT10.1 Group II Battery Charger - with Common Options........................88

APPENDIX D: Recommended Float/Equalize Voltages / Temp. Compensation ...............90

APPENDIX E: DNP3 Level 2 / Modbus Communications Module.........................................91

APPENDIX F: Forced Load Sharing.........................................................................................92

MANUAL SPECIFICATIONS (document control information / online availability) .....................94

* Note: A customized record drawing package is available for your AT10.1, featuring an itemized internal component layout, electrical schematic with component ratings, and a full connection diagram. If the standard drawings and wire list featured in this manual are not sufficient, please contact your Sales Representative for drawing availability from the battery charger manufacturer.

iii

RECEIVING THE AT10.1

1. RECEIVING THE AT10.1

1.1. STORING THE AT10.1

If you store the AT10.1 for more than a few days before installation, you should store it in its original shipping container, and in a temperature controlled, dry climate. Ambient temperatures of 32 to 122° F / 0 to 50° C are acceptable. Storage should not exceed 2 years due to the limited shelf life of the dc filter capacitors when they are not in service.

1.2. REPORTING SHIPPING DAMAGE

If, on delivery of the AT10.1 or related goods, you discover any damage or shortage, make notation on all copies of delivering carrier's delivery receipt before signing, and notify the delivery person of your findings. If loss or damage is discovered after delivery, notify delivering carrier immediately and request an inspection. The manufacturer does not assume any liability for damage during transportation or handling.

Should the goods require an inspection by or return to the manufacturer, please contact your sales representative for further instructions. Any returned material must be properly packed in compliance with shipping regulations. It is preferable to use the original shipping materials if possible. Mark the outside of the shipping container with the Return Material Authorization (RMA) number issued by the manufacturer.

1.3. UNPACKING AND INSPECTING THE AT10.1

Carefully remove all shipping materials from the AT10.1. Remove the AT10.1 from the shipping pallet for inspection. Save all shipping materials until you are sure that there is no shipping damage.

Once the AT10.1 is unpacked, inspect the unit for possible shipping damage, using the checklist below. If shipping damage has occurred, refer to Section 1.2 on this page for proper reporting.

INSPECTION CHECKLIST

o Enclosure exterior and interior are not marred or dented. o There is no visible damage to exterior or interior components. o All internal components are secure. o Printed circuit boards are firmly seated on their standoffs. o All hardware is tight. o All wire terminations are secure. o The User's Manual is included. o You received all items on the packing list.

INSTALLING THE AT10.1

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 Type And Shipping Weight Table

Group II Cabinets (Style-5017 / Style-5018)

Output

Voltage 30 Adc 40 Adc 50 Adc 75 Adc 100 Adc

Ampere Rating

Style-5017

12 Vdc

24 Vdc

48 Vdc

130 Vdc

NOTE: Actual unit is approximately 20 lbs / 9kg below listed shipping weight in table.

140 lbs

63 kg

Style-5017

150 lbs

68 kg

Style-5017

170 lbs

77 kg

Style-5017

220 lbs

100 kg

Style-5017

155 lbs

70 kg

Style-5017

180 lbs

82 kg

Style-5017

220 lbs

100 kg

Style-5018

300 lbs

136 kg

Style-5017

170 lbs

77 kg

Style-5017

190 lbs

86 kg

Style-5017

240 lbs

109 kg

Style-5018

320 lbs

145 kg

Style-5018

220 lbs

100 kg

Style-5018

250 lbs

113 kg

Style-5018

340 lbs

154 kg

Style-5018

440 lbs

200 kg

Style-5018

280 lbs

127 kg

Style-5018

320 lbs

145 kg

Style-5018

440 lbs

200 kg

n/a

The Style-5017 & 5018 enclosures do not feature lifting eyes for moving. Instead, whenever possible move the unit with a forklift truck using the supplied shipping pallet. To hoist the unit into a wall-mount or rack-mount location, use a heavy-duty sling applicable to the enclosure size and unit weight. To relocate the Style-5017 enclosure, use the aforementioned sling on a hoist or forklift truck. To relocate the Style- 5018 enclosure, use a forklift truck by lifting the unit through the 3in / 76mm gap located between the mounting legs.

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 STANDARD OPTIONAL

1.5.2 Floor-Mounting OPTIONAL STANDARD

1.5.3

MOUNTING METHOD

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

23-24in / 584-610mm

Rack-Mounting

ENCLOSURE

Style-5017 Style-5018

OPTIONAL OPTIONAL

INSTALLING THE AT10.1

1.5.1. Wall-Mounting the AT10.1

In planning for wall mounting of the AT10.1 consider the following:

1. Wall-mounting the Style-5017 enclosure is standard. If you are wallmounting a charger in the Style-5018 enclosure, you need the wall mounting bracket kit (part number EI5008-00). For kit availability see ordering information in Appendix B on page 71. The kit includes dimensions and instructions for locating the wall mounting holes.

2. The wall must be strong enough to properly support the weight of the AT10.1. The weight of your AT10.1 may be different from the table value, depending on options or accessories you ordered. See the Weight Table located in Section 1.4 on page 3.

3. Placement of conduit entrances. Note the standard pre-fab conduit knockouts located on the sides of the charger. See outline drawings in Appendix C.

4. The location:

• Should be free of drips and splatter. If dripping liquids are a problem,

install a drip shield kit. For kit availability see ordering information in Appendix B on page 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 flammable or explosive materials.

5. Maintain at least 6in / 152mm of free air on top, bottom and both sides for cooling air.

6. Allow 36in / 914mm front clearance for access to the charger for operation and maintenance.

PROCEDURE

To wall-mount the AT10.1, install eight (8) 0.25in / 6.4mm bolts onto the wall, rated to support the AT10.1 weight plus a safety factor of at least 2 times. Place the AT10.1 on the bolts, add appropriate mounting hardware, and tighten securely. See the diagram below for the Style-5017 enclosure footprint and wallmounting pattern. Dimensions are in/mm.

INSTALLING THE AT10.1

Style-5017 Enclosure

INSTALLING THE AT10.1

1.5.2. Floor-Mounting the AT10.1

To floor mount the AT10.1, you must consider the following:

1. Floor-mounting the Style-5018 enclosure is standard. If you are floor mounting a charger in the Style-5017 enclosure you will need the floormount kit (part number 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 provisions for floor anchoring. The kit includes dimensions and instructions for locating the floor mounting holes.

2. Placement of conduit entrances. Note the standard pre-fab conduit knockouts located on the sides of the charger. See outline drawings in Appendix C.

3. The location:

• Should be free of drips and splatter. If dripping liquids are a problem,

install a drip shield. See ordering information in Appendix B on page 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 flammable or explosive materials.

4. Maintain at least 6in / 152mm of free air on top, bottom and both sides for cooling air.

5. Allow 36in / 914mm front clearance for access to the charger for operation and maintenance.

PROCEDURE

To floor-mount the AT10.1, install four (4) 0.25in / 6.4mm bolts into the floor. Place the AT10.1 on the bolts, add appropriate mounting hardware, and tighten securely. See the diagram below for the Style5018 enclosure footprint and floormounting pattern. Dimensions are in/mm.

INSTALLING THE AT10.1

Style-5018 Enclosure

INSTALLING THE AT10.1

1.5.3. Rack-Mounting the AT10.1

All ratings of the AT10.1 can be installed in most relay racks with standard EIA hole spacing. A relay rack-mounting kit is required. For kit availability see ordering information in Appendix B on page 71. Order the appropriate rack mounting kit for your charger, as shown in the following table.

CHARGER RATING

Voltage Current

12 Vdc 30-50 Adc EI0193-01 EI0193-02 12 Vdc 75-100 Adc N/A EI0193-03

24 Vdc 30-50 Adc EI0193-01 EI0193-02 24 Vdc 75-100 Adc N/A EI0193-03

48 Vdc 30-40 Adc EI0193-01 EI0193-02 48 Vdc 50-100 Adc N/A EI0193-03

130 Vdc 30 Adc EI0193-01 EI0193-02 130 Vdc 40-75 Adc N/A EI0193-03

RACK WIDTH

19in /

483mm

MOUNTING KIT

584-610mm

23-24in /

Each kit includes mounting brackets, hardware and the necessary instructions to install one AT10.1 battery charger. The kit also includes dimensions and detailed instructions for rack-mounting.

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 between 32-122° F / 0-50° C, with relative humidity between

5 and 95% non-condensing.

• Must be free of flammable or explosive materials.

4. Maintain at least 6in / 152mm of free air on top, bottom and both sides for cooling air.

5. Allow 36in / 914mm front clearance for access to the charger for operation and maintenance.

INSTALLING THE AT10.1

PROCEDURE

To rack mount the AT10.1, first install the brackets into the rack using the supplied hardware. Second, install the AT10.1 onto the brackets. Tighten all hardware securely. Provide at least 6in / 152mm of free air space above and below the AT10.1 enclosure in the rack for cooling. You do not need to modify the AT10.1 enclosures for standard rack-mounting. See the diagrams below for the Group II enclosure rack-mounting configurations.

Style-5017 Rack-Mounting

Style-5018 Rack-Mounting

NOTES

1. Units are installed from the front.

2. Refer to the outline drawings in Appedix C for enclosure dimensions.

INSTALLING THE AT10.1

1.6. CHANGING THE TRANSFORMER TAPS

IMPORTANT: AT10.1 Group II battery chargers (rated 30-100 Adc) are designed for a single ac input supply voltage. Note the ac voltage listing on the data nameplate, and tag attached to the ac circuit breaker.

If your particular site ac supply voltage does not match your AT10.1 ac input requirements, you MUST change the ac input circuit breaker (and/or fuses), and input surge suppressors. In addition, you must replace or rewire the transformer as described below.

Failure to use properly rated components may damage the AT10.1.

NOTE: If your AT10.1 battery charger was supplied with 480Vac-60Hz input, or 220Vac-50/60Hz input, the transformer will only accept the listed voltage. Do not attempt to rewire these transformers. If a different ac input voltage is desired for the AT10.1, please contact your sales representative for ordering replacement parts.

Before you wire ac power to the AT10.1, check the wiring of the main transformer (T1), to be sure it is connected for the desired ac input voltage. The main transformer was wired at the factory for the input voltage specified and listed on the data nameplate.

If your AT10.1 was supplied with 120, 208 or 240Vac - 60Hz input, and you need to change the factory-wired input voltage, you do so by changing jumpers on T1. If you are changing from 120Vac to 208/240Vac, or the reverse, you also need to change the input surge suppressors and the input circuit breaker (and/or ac input fuses). See Section 3.6 on page 62 for part requirements.

If your AT10.1 was ordered with 380 or 416 Vac - 50/60 Hz, and you need to change the factory-wired input voltage, consult the factory for special instructions.

NOTE: Before starting work, disconnect and lock out all external ac and dc power sources to the AT10.1. Note that just turning off the front panel ac and dc circuit breakers is not sufficient to eliminate live voltages inside the enclosure. Use a voltmeter at the ac terminals TB1-L1 and TB1-L2, the dc terminals TB1(+) & TB1(-), the dc remote sense terminals, and any external wiring to alarm relay contacts, to verify that no voltage is present inside the enclosure.

INSTALLING THE AT10.1

PROCEDURE

1. Verify that all voltages whithin the AT10.1 are de-energized and locked out.

2. See Section 3.5 for necessary steps to follow when accessing internal components within the AT10.1.

3. Change the jumpers on the transformer (T1) as shown in the table below.

4. If your transformer is supplied with two (2) jumpers, always use both as specified in the table.

5. Make sure all connections are tight.

6. Check your work before re-energizing the AT10.1.

7. For more information, see the schematics & wiring diagrams in Appendix C.

MAIN POWER TRANSFORMER (T1) CONNECTION TABLE

120/208/240 Vac - 60Hz 480 Vac - 60 Hz

INPUT JUMPERS INPUT JUMPERS

120 Vac - 60 Hz H1-H3, H2-H5 208 Vac - 60 Hz H2-H4 (2) JUMPERS 480 Vac - 60 Hz NONE 240 Vac - 60 Hz H2-H3 (2) JUMPERS

INSTALLING THE AT10.1

1.7. MAKING THE AC INPUT CONNECTIONS

Follow these steps to connect ac power to the AT10.1:

1. Use a branch circuit breaker or fused disconnect switch, properly sized for the maximum input current of the AT10.1, as shown in the table below. This device should have lockout capability so that the ac input can be deenergized and locked out for maintenance. A time delay circuit breaker or slow-blow fuse is recommended.

NOTE: If your charger is wired for 480 Vac input, and is equipped with the standard AIC ac circuit breaker (no ac fuses), you need a feeder breaker or fuse rated to interrupt the short-circuit current of your ac supply.

2. Size the ac input wiring per the National Electric Code (NEC) and local codes for the rating of the branch circuit breaker or fused disconnect switch.

3. Be sure the AT10.1 main transformer (T1) is properly connected for your ac input voltage. See Section 1.6 for details.

4. Do not run external ac and dc power wiring, feeding the battery charger, through the same conduit.

5. All specific requirements of your facility take precedence over these instructions.

PROCEDURE

1. Remove the safety cover.

2. Run the ac wiring to terminals TB1-L1, TB1-L2 and TB1-GND on the I/O panel in the enclosure. Compression lugs, accepting wire sizes #14-1/0 AWG, are supplied for your convenience. To make these connections, strip the insulation 0.5in / 12.7mm on the incoming wires and connect the wires to the appropriate lugs as shown on the next page.

3. Using a flat-head screwdriver, securely tighten the compression screws on the lugs to 35-50 in-lb / 4.0-5.7 Nm.

4. Reinstall the safety cover after you have made and checked all connections.

MAXIMUM INPUT CURRENT AT 120 Vac1

OUTPUT

CURRENT

30 40 50 75

100

Note 1: Not available with 120 Vac input. Input current is 67 Aac at 240 Vac.

To determine the input current, Iac, for other input voltages, use the formula:

where Vac is the new input voltage, and IT is the input current from the table above.

OUTPUT VOLTAGE

12 24 48 130

7.2 13 23 54

9.6 17 30 12 21 38 89 18 32 57 24 42 75 n/a

120

×=

Tac

Note 1

Example (shaded): A 130 Vdc/40 Adc

battery charger draws 71 Aac at 120 Vac.

All currents shown are ±10%.

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.

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)

#10

#8 #6 #4 #2 #0

30 40 50 75 100

3.0V 4.0V 5.0V

1.9V 2.5V 3.1V

1.2V 1.6V 2.0V 3.0V

0.7V 1.0V 1.2V 1.9V 2.5V

0.5V 0.5V 0.8V 1.2V 1.6V

0.3V 0.4V 0.5V 0.7V 1.0V

EXAMPLE: 100ft / 30.5m of #8 AWG wire at 50A has a 3.1 Volt drop.

2. The AT10.1 is factory wired to regulate the output voltage at the output terminals. If the total voltage drop is greater than 1% (e.g., 1.3V for a 130 Vdc system), remote sense wiring is recommended, see Section 1.9.

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.

DC CURRENT (AMPERES)

not recommended not recommended not recommended not recommended

not recommended

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 #14-1/0 AWG, are supplied for your convenience. To make these connections, strip the insulation 0.5in / 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 35-50 in-lb / 4.0-5.7 Nm.

5. Reinstall the safety cover after you have made and checked all connections.

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.

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 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 wire # 36 from TB1(-) to REM SENSE(-).

5. Move wire # 38 from TB1(+) to REM SENSE (+).

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 compression lugs and tighten all hardware.

8. Check your work thoroughly. Replace the safety shield before reeneregizing the charger.

9. Restart the AT10.1 according to the instructions in Section 2.1.

NOTES

1. Use #16 AWG twisted pair.

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 wire # 38 to the dc output (+) terminal.

• Reconnect wire # 36 to the dc output (-) terminal.

• Restart the AT10.1 according to the instructions in Section 2.1.

INSTALLING THE AT10.1

1.10. WIRING TO THE REMOTE ALARM CONTACTS

Built-in Summary (Common) Alarm Relay (standard)

The Main Control PC Board (A1), mounted on the back of the front door, is equipped with one form C Summary Alarm contact (TB3) that transfers for any alarm.

Follow the procedure below to wire an annunciator to this contact. See Section

2.2.7 for a description of the alarm functions.

PROCEDURE

1. Allow 30in / 762mm of wire inside the enclosure (excess will be trimmed).

2. Route wires to front door by following the existing harness through the door hinge as shown. Use (2) wire ties and allow a 4-6in / 102-153mm loop for the hinge.

3. Trim wires to the proper length for connecting to TB3. Strip 0.25in / 6.4mm of insulation from the wires. Make the connections at TB3, and securely tighten the screws.

NOTES

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

2. Terminal block is a compression type, accepting wire sizes #22-14 AWG.

3. Terminals are labeled in non-alarm condition.

INSTALLING THE AT10.1

Auxiliary Relay Board (optional)

The optional Auxiliary Alarm Relay PC Board (A5), mounted on the right side panel of the circuit breaker bracket, 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:

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

DC OUT

FAILURE

DC OUT

FAILURE

AC FAIL AC FAIL

GROUND

DETECT

GROUND

DETECT

SUMMARY 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 plexiglas safety shield.

4. Route your remote annunciator wiring into the enclosure through one of the unused conduit knockouts on the side of the enclosure.

5. Connect the wiring (use #22-14 AWG) to the appropriate terminals of TB4 on the Auxiliary Alarm Relay board (as shown in the figure above). Strip each wire 0.25in / 6.4mm and securely tighten the terminal screws.

6. Replace the safety shield 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 (JE5030-29) listed in Appenix C on Page 80.

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). The main elements of the installation are outlined below.

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.

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.

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 isn't 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.

• Plug the connector at the end of the nylon-shielded wire of the cable

assembly onto J6.

• 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.

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 batteries. While this is being displayed, you can press any front panel key to change the display to read NICD, to change the temperature compensation setup for nickel cadmium batteries. The choice you make is saved internally, and will be used again by the 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.

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, Degrees 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 92, or Instructions (JA5054-0).

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; indicator lights to the left of the display indicate whether the meter is displaying voltage or current.

If you want to “freeze” the meter to display only voltage, press the METER MODE key on the front panel. To freeze the meter to display only current, press the key again. Press the key twice more to revert to the alternating display.

CAUTION: If you try to turn on the dc circuit breaker with the battery connected in reverse polarity, the circuit breaker will immediately trip. Do not try to close the dc breaker again, since this may damage the battery charger. Correct the battery polarity before proceeding. If your charger is equipped with dc fuses, one or both fuses will blow when the battery is reversed.

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 batteries. While this is being displayed, you can press any front panel key to change the display to read NICD, to change the temperature compensation setup for nickel cadmium batteries. The choice you make is saved internally, and will be used again by the 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 voltage, equalize time, current limit setting, and alarm settings. If your purchase order specified other float or equalize voltage settings, a tag attached to the front panel of the 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

OPERATING THE AT10.1

2.2. USING THE AT10.1 FRONT PANEL FEATURES

2.2.1. If the meter displays an error message

When you apply power to the AT10.1 for the first time, the microprocessor control circuit performs a diagnostic check of the system. If it finds anything wrong, it writes an error code to the display, such as E 01.

Below is a list of these error codes. See Section 3.2 on page 45 for a full explanation of each code.

Error Code Explanation

E 01 E 02 E 03 E 04 E 05 E 06 E 07

resistor R2 is open or defective short circuit on dc output high dc voltage shutdown has occurred internal memory failure

not used

failure in remote sense wiring dc breaker is open, or internal or external

output wiring is defective

E 08 E 09 E 10 E 14 A 01 A 02

defective temperature compensation probe misadjusted current limit open internal feedback loop forced load sharing not working properly manual equalize enabled for more than 24 hrs equalize mode is inhibited

2.2.2. Selecting the meter mode

• Press the METER MODE key to change the meter display mode. The digital

meter has four operating modes:

1. Alternating between output voltage and output current. When the charger is in a timed equalize mode, the meter alternates between output voltage, output current, and equalize hours remaining.

2. Displaying output voltage only. The DC Volts indicator lights.

3. Displaying output current only. The DC Amps indicator lights.

4. Displaying equalize hours remaining only. The EQLZ HRS REMAINING indicator lights. If the AT10.1 is not in a timed equalize mode, the meter displays the full programmed equalize time.

• When the charger starts initially, the meter alternates, showing output

voltage and output current. The DC VOLTS and DC AMPS indicators light alternately to indicate what is being displayed.

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