Exide Technologies 94.40 User Manual

SERIES CHARGERS

INSTALLATION & OPERATING

SECTION 94.40

2011-11

JA0128-03

INSTRUCTIONS

FOR

AT30 SERIES

BATTERY CHARGER

(25-1000 ADC OUTPUT)

I & O MANUALS

HOW TO READ THE AT30 MODEL NUMBER

Your AT30 model number is coded to describe the options that are included. Please find the model number on the data nameplate and write it in the spaces provided below. Then follow the chart to determine the configuration of your battery charger.

AT30

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

DESCRIPTION CODE FEATURE

SERIES AT30 AT30 CHARGER S STANDARD

NOMINAL

DC OUTPUT VOLTAGE

NOMINAL

DC OUTPUT CURRENT

FILTERING

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.

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 w/sel switch DNP3 Level 2 / Modbus communications module analog ac ammeter w/sel switch forced load sharing interconnection cable

Please find the serial number on the

data nameplate and record it here:

DESCRIPTION CODE FEATURE

012 12 Vdc M MEDIUM AIC 024 24 Vdc H HIGH AIC 048 48 Vdc 130 130 Vdc F SUPPLIED

CODE FEATURE CODE FEATURE

025 25 Adc 200 200 Adc S STANDARD 030 30 Adc 250 250 Adc M MEDIUM AIC 040 40 Adc 300 300 Adc H HIGH AIC 050 50 Adc 400 400 Adc 075 75 Adc 500 500 Adc F SUPPLIED 100 100 Adc 600 600 Adc 125 125 Adc 800 800 Adc A SUPPLIED 150 150 Adc 1K0 1,000 Adc

U UNFILTERED G SUPPLIED F FILTERED

E ELIMINATOR L SUPPLIED 208 208 Vac 60 Hz 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

CIRCUIT

BREAKER

TYPE

AC CIRCUIT

BREAKER RATINGS

(208/240/480 Vac) *

DC CIRCUIT

BREAKER RATINGS

(125/250 Vdc)

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

FUSE RATING

(208-600 Vac)

0 NO AC BREAKER

X NOT SUPPLIED

0 NO DC BREAKER

X NOT SUPPLIED

X NOT APPLIED

OPTIONAL DC FUSE RATING

(12/24/48/130 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, 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 AT30 MODEL NUMBER .............................................Inside Front Cover

IMPORTANT SAFETY INSTRUCTIONS ......................................................................................i

1 Receiving and Installing the AT30 Battery Charger

1.1 Storing the AT30 ....................................................................................................2

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

1.3 Unpacking and inspecting the AT30 ......................................................................2

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

1.4 Moving the AT30 ....................................................................................................3

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

1.5 Mounting the AT30.................................................................................................4

1.5.1 Floor-Mounting the AT30 (standard)................................................................4

1.5.2 Wall-Mounting the AT30 (optional)..................................................................6

1.5.3 Rack-Mounting the AT30 (optional).................................................................8

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

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

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

1.9 Wiring the AT30 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 AT30 for remote communications (optional)...................................23

1.13 Installing the AT30 for forced load sharing (optional) ..........................................23

2 Operating the AT30 Battery Charger

2.1 Starting the AT30

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

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

2.1.3 Starting the AT30...........................................................................................24

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

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

2.2 Using the AT30 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 AT30 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 AT30 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

APPENDIX A: AT30 Performance Specifications ...................................................................64

APPENDIX B: Field Installable Accessories...........................................................................65

APPENDIX C: Standard Drawings *

Outline: AT30 Battery Charger NEMA-1 Style-5018 Enclosure...................................................66

Outline: AT30 Battery Charger NEMA-1 Style-5030 Enclosure...................................................68

Outline: AT30 Battery Charger NEMA-1 Style-163 Enclosure.....................................................70

Internal Component Layout: AT30 Style-5018 Enclosure w/Common Options............................72

Internal Component Layout: AT30 Style-5030 Enclosure w/Common Options............................74

Internal Component Layout: AT30 Style-163 Enclosure w/Common Options..............................76

Instrument Panel / PC Board Detail: AT30 Series Battery Charger.............................................78

Schematic: AT30 Series Battery Charger - Standard w/o Options ..............................................80

Schematic: AT30 Battery Charger - with Common Options......................................................... 82

Connection Diagram: AT30 Battery Charger - Power Wiring w/Common Options ......................84

Connection Diagram: AT30 Battery Charger - Control (Signal) Wiring........................................86

Connection Detail: AT30 Battery Charger - I/O Panels & Rectifier Assemblies...........................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 AT30, featuring an 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.

iii

RECEIVING THE AT30

1. RECEIVING THE AT30

1.1. STORING THE AT30

If you store the AT30 for more than a few days before installation, you should store it in its original shipping container, and in a temperature controlled, dry climate. Ambient temperatures of 32 to 122° F / 0 to 50° C are acceptable. Storage should not exceed 2 years due to the limited shelf life of the dc filter capacitors when they are not in service.

1.2. REPORTING SHIPPING DAMAGE

If, on delivery of the AT30 or related goods, you discover any damage or shortage, make notation on all copies of delivering carrier's delivery receipt before signing, and notify the delivery person of your findings. If loss or damage is discovered after delivery, notify delivering carrier immediately and request an inspection. The manufacturer does not assume any liability for damage during transportation or handling.

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

1.3. UNPACKING AND INSPECTING THE AT30

Carefully remove all shipping materials from the AT30. Remove the AT30 from the shipping pallet for inspection. Save all shipping materials until you are sure that there is no shipping damage.

Once the AT30 is unpacked, inspect the unit for possible shipping damage, using the checklist below. If shipping damage has occurred, refer to Section 1.2 on this page for proper reporting.

INSPECTION CHECKLIST

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

1.4. MOVING THE AT30

Once you have established that the AT30 is undamaged, identify the enclosure style of your unit by referring to the table below.

Standard AT30 NEMA-1 Type Enclosures

( Style-5018 / Style-5030 / Style-163 / Style-198 )

Ampere

Rating

25 Adc n/a n/a n/a Style-5018 30 Adc n/a n/a n/a Style-5018 40 Adc n/a n/a n/a Style-5018

50 Adc Style-5018 Style-5018 Style-5018 Style-5018

75 Adc Style-5018 Style-5018 Style-5018 Style-5018 100 Adc Style-5018 Style-5018 Style-5018 Style-5030 125 Adc Style-5030 Style-5030 Style-5030 Style-5030

150 Adc Style-5030 Style-5030 Style-5030 Style-5030 200 Adc Style-5030 Style-5030 Style-5030 Style-5030

250 Adc Style-5030 Style-5030 Style-5030 Style-163 * 300 Adc Style-5030 Style-5030 Style-5030 Style-163 *

400 Adc n/a Style-163 * Style-163 * Style-163 * 500 Adc n/a Style-163 * Style-163 * Style-198 * 600 Adc n/a Style-163 * Style-198 * Style-198 * 800 Adc n/a Style-198 * Style-198 * Style-198 *

1,000 Adc n/a Style-198 * Style-198 * Style-198 *

12 Vdc 24 Vdc 48 Vdc 130 Vdc

* Note: Style-163 and Style-198 AT30 enclosures are substituted for the previously listed Style-5031 and Style-5034 enclosures respectfully. For enclosure dimensions and internal component layouts, refer to the table below, and the standard drawings in Appendix C. Comprehensive weight data for the AT30 product line is available in the product literature.

Enclosure Outline Drawing Internal Layout Drawing

INSTALLING THE AT30

Output Voltage

Style-5018 JE5085-00 JE5088-99 Style-5030 JE5086-00 JE5089-99

Style-163 JE5095-00 JE5098-99 Style-198 JE5096-00 JE5099-99

Standard AT30 NEMA-1 type 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 enclosure, use a forklift truck by lifting the unit through the gap located between the cabinet mounting legs.

INSTALLING THE AT30

1.5. MOUNTING THE AT30

Chose the mounting method for the unit enclosure from the table below.

MANUAL

SECTION

MOUNTING METHOD

ENCLOSURE ENCLOSURE

Style-5018 Style-5030/163/198

1.5.1 Floor-Mounting STANDARD STANDARD

1.5.2 Wall-Mounting OPTIONAL n/a 19in / 483mm

Rack-Mounting

1.5.3

23-24in / 584-610mm

Rack-Mounting

OPTIONAL n/a

1.5.1. Floor-Mounting the AT30 (standard)

To floor mount the AT30, you must consider the following:

1. Overall footprint of enclosure. Refer to the standard outlines drawing listed in Appendix C, starting on Page 66.

2. 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 65.

• 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.

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

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

5. Be conscious of future input and output wiring to the AT30. Note the standard pre-fab conduit knockouts located on the sides (and sometimes top) of the enclosure, featured on the standard outline drawings listed in Appendix C, starting on Page 66.

PROCEDURE (Style-5018)

1. Install four (4) 0.25in / 6.4mm bolts into the floor per mounting dimensions featured in the outline drawing (JE5085-00).

2. Using the methods described in Section 1.4, carefully lift the AT30 above the floor-mounting bolts. Guide the enclosure onto the floor bolt pattern and lower it into place.

3. Add appropriate mounting hardware (0.25in / 6.4mm), onto the floormounting bolts and tighten securely.

n/a n/a

INSTALLING THE AT30

PROCEDURE (Style-5030)

1. Install four (4) 0.375 / 9.5mm or 0.5in/12.7mm bolts into the floor per mounting dimensions featured in the outline drawing (JE5086-00).

2. Using the methods described in Section 1.4, carefully lift the AT30 above the floor-mounting bolts. Guide the enclosure onto the floor bolt pattern and lower it into place.

3. Add appropriate mounting hardware (0.375 / 9.5mm or 0.5in/12.7mm), onto the floor-mounting bolts and tighten securely.

PROCEDURE (Style-163)

1. Install four (4) 0.5in/12.7mm bolts into the floor per mounting dimensions featured in the outline drawing (JE5095-00).

2. Using the methods described in Section 1.4, carefully lift the AT30 above the floor-mounting bolts. Guide the enclosure onto the floor bolt pattern and lower it into place.

3. Add appropriate mounting hardware (0.5in/12.7mm), onto the floormounting bolts and tighten securely.

STANDARD NEMA-1 AT30 ENCLOSURE TYPES

Style-5018

see outline

JE5085-00

Style-5030

see outline

JE5086-00

Style-163

see outline

JE5095-00

INSTALLING THE AT30

1.5.2. Wall-Mounting the AT30 (Style-5018 enclosure only)

AT30 battery chargers housed in the floor-mounted Style-5018 enclosure can be wall-mounted. You do not need to modify the standard Style-5018 enclosure for wall mounting, but a special wall-mounting kit (EI5008-00) is required. For kit availability see ordering information in Appendix B on page 65. The kit includes two (2) mounting brackets, hardware and special instructions for the wall mounting procedure. In planning for wall mounting of the AT30, you should consider the following:

1. The wall must be strong enough to properly support the weight of the AT30. The weight of your AT30 may be different from the table value, depending on options or accessories you ordered. See the Weight Table located in Section 1.4 on page 3.

2. Placement of conduit entrances. Note the standard pre-fab conduit knockouts located on the sides of the charger. See the outline drawing (JE5085-00) in Appendix C, on Page 66.

3. 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 65.

• 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 of the enclosure for air cooling.

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

PROCEDURE

1. Install eight (8) 0.25in / 6.4mm bolts (not supplied), rated to support the AT30 weight plus a safety factor of at least two (2) times, onto the wall.

2. Place the AT30 Style-5018 enclosure onto the mounted triangular brackets.

3. Use the supplied 0.25in / 6.4mm hardware to mount the enclosure to the wallmounting brackets and tighten securely.

4. See the diagram on the opposite page for the wall-mounted Style-5018 enclosure footprint and mounting pattern.

5. Dimensions are in/mm.

INSTALLING THE AT30

Style-5018 Wall-Mounting

NOTE

1. Refer to the outline drawing (JE5085-00) in Appendix C, on Page 66 for overall size, mounting dimensions and cabinet specifications for the Style5018 enclosure.

INSTALLING THE AT30

1.5.3. Rack-Mounting the AT30 (Style-5018 enclosure only)

AT30 battery chargers housed in the floor-mounted Style-5018 enclosure can be installed in most relay racks with standard EIA hole spacing. You do not need to modify the standard Style-5018 enclosure for rack mounting, but a special rack-mounting kit (EI0193-03) is required. For kit availability see ordering information in Appendix B on page 65. Each kit includes two (2) mounting brackets, hardware and special instructions with for the rack mounting procedure. In planning for rack mounting of the AT30, you should consider the following:

1. The rack must be strong enough to properly support the weight of the AT30. The weight of your AT30 may be different from the table value, depending on options or accessories you ordered. See the Weight Table located in Section 1.4 on page 3.

2. Placement of conduit entrances. Note the standard pre-fab conduit knockouts located on the sides of the charger. See the outline drawing (JE5085-00) in Appendix C, on Page 66. 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. For kit availability see ordering information in Appendix B on page 65.

• 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 of the enclosure for air cooling.

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

PROCEDURE

1. Mount the two (2) relay rack-mounting brackets to the sides of the Style-5018 enclosure, using the four (4) pre-fab knockouts on each side as guides.

2. Mount the brackets to the AT30, using the supplied

0.25in / 6.4mm hardware and tighten securely.

3. Locate the charger/bracket assembly onto the front face of the 23in / 584mm EIA relay rack, and mount using appropiate hardware (not supplied).

4. See the diagram on the opposite page for the rackmounted Style-5018 enclosure footprint and mounting pattern.

INSTALLING THE AT30

Style-5018 Rack-Mounting

NOTES

1. Units are installed from the front.

2. Refer to the outline drawing (JE5085-00) in Appendix C, on Page 66 for overall size, mounting dimensions and cabinet specifications for the Style5018 enclosure.

INSTALLING THE AT30

1.6. CHANGING THE TRANSFORMER TAPS

IMPORTANT: AT30 battery chargers 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 AT30 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 AT30.

NOTE: If your AT30 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 AT30, please contact your sales representative for ordering replacement parts.

Before you connect ac power to the AT30, check the wiring of the main transformer (T1), to be sure it is connected for the desired ac input voltage. The main transformer was wired at the factory for the input voltage specified and listed on the data nameplate.

If your AT30 was supplied with 208/240 Vac - 60 Hz input, and you need to change the factory-wired input voltage, you do so by changing jumpers on the main transformer (T1).

If your AT30 was ordered with 380/416 Vac - 50/60 Hz, and you need to change the factory-wired ac 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 AT30. Note that just turning off the front panel ac and dc circuit breakers is not sufficient to eliminate live voltages inside the enclosure. Use a voltmeter at the ac terminals TB1-L1, TB1-L2 & TB1-L3, 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 AT30

PROCEDURE

1. Verify that all voltages within the AT30 are de-energized and locked out.

2. See Section 3.5 for necessary steps to follow when accessing internal components within the AT30.

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

4. Always use all three (3) jumpers.

5. Make sure all connections are tight.

6. Check your work before reenergizing the AT30.

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

MAIN TRANSFORMER (T1) CONNECTION TABLE

TYPICAL TRANSFORMER (T1)

208/240 Vac - 60 Hz INPUT

208 Vac

jumper setting

H1, H2, H3 to 1 H1, H2, H3 to 2

240 Vac

jumper setting

SCHEMATIC

208/240 Vac - 60 Hz transformer (T1)

TYPICAL TRANSFORMER (T1)

480 Vac - 60 Hz INPUT

jumper setting

none

SCHEMATIC

480 Vac - 60 Hz transformer (T1)

INSTALLING THE AT30

1.7. MAKING THE AC INPUT CONNECTIONS

Follow these steps to connect ac power to the AT30:

1. Use a branch circuit breaker or fused disconnect switch, properly sized for the maximum ac input current of the AT30. This rating is listed on the lefthand side of the charger's data nameplate. This device should have lockout capability so that the ac input can be de-energized for charger 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 AT30 main transformer (T1) is properly connected for your ac input voltage. See Section 1.6 for details.

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

5. Do not run the external ac power wiring through the same conduit of the battery charger enclosure as the external dc power wiring.

PROCEDURE

1. Remove the safety cover (if supplied).

2. Run the ac wiring to terminals TB1-L1, TB1-L2, TB1-L3 and TB1-GND on the I/O panel board in the enclosure.

3. For your convenience, all AT30 Series battery chargers are supplied with CU-AL ac input compression lugs. Style-5018 and Style-5030 enclosure ac input lugs accept #14-1/0 AWG wire. Style-163 enclosure ac input lugs accept #6 AWG - 350 MCM wire. To make these connections, strip the insulation 0.5in / 12.7mm on the incoming ac wires and 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 (if supplied) after you have made and checked all connections.

NOTES

1. The ac input terminal hardware fastens 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. Refer to images on the following page for I/O panel layout.

INSTALLING THE AT30

MAKING THE AC INPUT CONNECTIONS - GRAPHICS

Style-5018

I/O Terminal Board (TB1)

Detail

user-supplied ac input wiring

Style-5030

I/O Terminal Board (TB1)

Detail

user-supplied ac input wiring

Style-163

I/O Terminal Board (TB1)

Detail

INSTALLING THE AT30

1.8. MAKING THE DC OUTPUT CONNECTIONS

Follow these steps to connect the battery to the AT30:

1. Size the dc wiring to minimize voltage drop. The acceptable wire size depends on your installation. As a guideline, the voltage drop should not exceed 1% of nominal output voltage at full current.

2. Size the dc output wiring per your battery manufacturer's specifications and local codes for the rating of the batteries and/or load.

3. The AT30 is factory wired to regulate the output voltage at the output terminals. If the total voltage drop is greater than 1% (e.g., 1.3V for a 130 Vdc system), remote sense wiring is recommended, see Section 1.9.

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

5. Do not run the external dc power wiring through the same conduit of the battery charger enclosure as the external ac power wiring.

PROCEDURE

1. Use a dc disconnect switch or circuit breaker between the AT30 and dc bus. This device should have lockout capability to allow the AT30 to be disconnected from the dc bus for maintenance.

2. Remove the safety cover (if supplied).

3. Run the dc wiring to terminals TB1(+) and TB1(-) on the I/O panel board in the enclosure.

4. For your convenience, all AT30 Series battery chargers are supplied with CU-AL dc output compression lugs. Style-5018 enclosure dc output lugs accept #14-1/0 AWG wire. Style-5030 and Style-163 enclosure dc output lugs accept #6 AWG - 350 MCM wire. To make these connections, strip the insulation 0.5in / 12.7mm on the incoming ac wires and connect the wires to the appropriate lugs as shown on the next page.

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

6. Reinstall the safety cover (if supplied) after you have made and checked all connections.

NOTES

1. The dc output terminal hardware fastens 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. Refer to images on the following page for I/O panel layout.

INSTALLING THE AT30

MAKING THE DC OUTPUT CONNECTIONS - GRAPHICS

user-supplied dc output wiring

Style-5018

I/O Terminal Board (TB1)

Detail

user-supplied dc output wiring

Style-5030

I/O Terminal Board (TB1)

Detail

Style-163

I/O Terminal Board (TB1)

Detail

user-supplied dc output wiring

INSTALLING THE AT30

1.9. WIRING THE AT30 FOR REMOTE SENSING

You can wire the AT30 to regulate the output voltage at the battery terminals, instead of at the charger output terminals. Remote sensing does the following:

1. Compensates for voltage drop in the dc wiring between the AT30 and the battery.

2. Directly monitors the battery or dc bus voltage. The front panel meter displays the actual voltage on the battery or dc bus.

You wire the AT30 for remote sensing by installing twisted pair cabling from the AT30 remote sense terminals to the battery terminals. The AT30 control circuitry then measures the dc voltage at the battery terminals, and controls the output of the charger to maintain the battery voltage at the desired float or equalize voltage.

NOTE: If the remote sense wiring fails, the AT30 detects the fault, and displays E 06 on the front panel meter. See Section 3.2 for details.

CAUTION: The AT30 cannot protect against short circuits in the remote sense wiring. You should install a 1.0A fuse at the battery or dc bus end of the remote sense cable.

SCHEMATIC

PROCEDURE

1. De-energize and lock out all ac and dc voltages within the AT30 enclosure. Check with a voltmeter.

2. Remove safety shield (if supplied).

3. Remove the two (2) dc output CU-AL compression lugs.

4. Move wire # 38 from TB1(-) to REM SENSE(-).

5. Move wire # 40 from TB1(+) to REM SENSE (+).

INSTALLING THE AT30

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 (if supplied) before reeneregizing the AT30.

9. Restart the AT30 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 AT30. Check with

a voltmeter.

• Disconnect the remote sense wires from the battery or dc bus terminals

first.

CAUTION: You must do the steps above first.

• Remove the remote sense leads from the remote sense (+) and (-)

terminals on the I/O panel. Insulate each lead separately. Coil up the wires and leave them in the bottom of the charger, in case you want to wire for remote sense again in the future.

• Reconnect wire # 40 to the dc output (+) terminal.

• Reconnect wire # 38 to the dc output (-) terminal.

• Restart the AT30 according to the instructions in Section 2.1.

INSTALLING THE AT30

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 or Vdc.

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

3. Terminals are labeled in non-alarm condition.

INSTALLING THE AT30

Auxiliary Relay Board (optional)

The optional Auxiliary Alarm Relay PC Board (A5), mounted on plastic stand-offs inside the enclosure, 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 AT30.

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

3. Remove the plexiglas safety shield, if supplied.

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, if supplied, and restart the AT30.

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 (JE5091-39) listed in Appenix C on Page 78.

INSTALLING THE AT30

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 AT30.

3. Wiring the charger end of the cable to a terminal block on the main control circuit board.

The actual tempco probe is the same for all battery types and all output voltages of the AT30. The accessory part numbers differ depending on cable length ordered. See the tables in Appendix B on page 65 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 AT30. Use extreme caution when working inside the unit. Do not attempt to work inside the

AT30 unless you are a qualified technician or electrician.

Disconnect and lock out all power from the AT30 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 AT30 output terminals TB1(+/-).

PROCEDURE

1. De-energize and lock out all ac and dc voltage sources to the AT30, 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 AT30 charger. The end of the cable with two stripped wires

and one lead with a quick-connect terminal will be connected inside the AT30. Leave 30in / 762mm of cable inside the enclosure, and route the other end to the probe at the battery.

INSTALLING THE AT30

• Run the cable though a conduit if possible, but not through a conduit

containing any power wiring.

• Route the other end to the probe at the battery and coil up excess cable.

NOTE: If the standard (25ft / 7.6m) cable is not long enough, longer cable assemblies are available in lengths of 50, 100 & 200ft / 15.2,

30.5 & 61.0m. See Appendix B on page 65 for ordering information.

• Be sure your wiring conforms to the NEC and your facility requirements.

5. Attach the interconnection cable to the AT30 as shown in the figure below:

• Route the

cable within the AT30 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 AT30

7. Check your work. Be sure that:

• All connections are secure.

• The shield is connected to ground at the charger end only (on the main

circuit board).

• The cable is connected to TB8 on the circuit board. Other terminal

blocks may look similar.

8. Restart the AT30 using the startup procedure in Section 2.1. During startup, the AT30 displays LEAD on the front panel, indicating that the temperature compensation is set up for lead-acid batteries. While this is being displayed, you can press any front panel key to change the display to read NICD, to change the temperature compensation setup for nickel cadmium batteries. The choice you make is saved internally, and will be used again by the AT30 the next time it starts.

9. Adjust the output float and equalize voltages to the battery manufacturer's recommended values, using the AT30 front panel meter, as described in Section 2.3.2.

NOTE: If the temperature compensation probe, or the wiring from the probe to the AT30, is damaged and becomes an open circuit, the AT30 detects the damage and displays E 08 on the display. The charger then reverts to normal nontemperature-compensated operation until the probe or wiring is repaired. Once the probe is repaired, you must restart the AT30 to activate the probe, as described in Section 2.1.

Using temperature compensation

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 AT30 is equipped with a temperature compensation probe, it is able to adjust the output voltage applied to the battery to keep the float current constant, thereby avoiding overcharging. The probe senses the ambient temperature at the battery, and adjusts the output float/equalize voltages to compensate for variations in temperature. If the ambient temperature increases, the AT30 output voltage decreases.

If you are experiencing any inconsistencies in the AT30 when the temperature compensation probe is utilized, temporarily disconnect the probe, and refer to the Application Note (JD5003-00) for further details.

INSTALLING THE AT30

Note the following:

• You should set the Float and Equalize voltages to the values

recommended by your battery manufacturer for 77° F (25° C).

• When you enter the Edit mode to adjust the Float or Equalize voltage

(see Section 2.3.2), the front panel meter shows the 77° F (25° C) value for the Float or Equalize voltage, even if the battery is warmer or cooler than 77° F (25° C).

• The actual output voltage of the AT30 may be different from the value

shown on the front panel meter, if the battery is warmer or cooler than 77° F (25° C).

• Use a digital meter to measure the actual output voltage of the AT30. If

you know the temperature at the temperature compensation probe, you can use the graph below to determine that the output voltage is correct.

• If the battery temperature goes below 32° F (0° C), there will be no

further increase in charger output voltage. Likewise, if the battery temperature goes above 122° F (50° C), there is no further decrease in output voltage.

OUTPUT VOLTAGE VS BATTERY TEMPERATURE

108

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 AT30

2. OPERATING THE AT30 BATTERY CHARGER

2.1. STARTING THE AT30

2.1.1. Understanding the startup sequence

The AT30 is set up at the factory to work with most common batteries and loads without further adjustment. When you start the AT30 for the first time, the factory settings (float voltage, equalize voltage, etc.) control the operation of the charger. You can change the settings after you start the charger. The FACTORY SETTINGS are shown in table on page 25.

The AT30 startup routine takes about five seconds. The microprocessor that controls the AT30 initializes the charger by reading the settings that are stored internally. The control circuit then "soft starts" the charger, and the dc output voltage and current increase gradually to the rated value.

2.1.2. Checking the installation

Be sure that you have followed the installation instructions carefully. Check the ac input supply voltage and the battery voltage, and be sure that they match the information on the AT30 nameplate. Verify that the jumpers on the

main transformer T1 are correct for your ac

supply voltage. Open the front panel, and check

the battery polarity at the TB1 (+) and (-) terminals.

2.1.3. Starting the AT30

When you are sure that all connections to the AT30 are properly made, follow these steps to start up the AT30:

• Turn on the front panel dc circuit breaker. The digital meter indicates the

battery voltage only. If the meter display does not light, do not proceed. Turn off the dc breaker, and check all connections and the battery polarity again. Also check the battery voltage. It must be above 50% of nominal voltage to turn on the display. If you cannot find the problem, refer to the Troubleshooting Procedure in Section 3.1 on page 44.

Using the Digital Meter

When you first start the AT30, the meter display alternates between dc output voltage and dc output current. Each reading is held for two seconds; indicator lights to the left of the display indicate whether the meter is displaying voltage or current.

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

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 AT30

• If you have an optional temperature compensation probe installed, the

front panel displays LEAD during startup, indicating that the temperature compensation is set up for lead-acid batteries. While this is being displayed, you can press any front panel key to change the display to read NICD, to change the temperature compensation setup for nickel cadmium batteries. The choice you make is saved internally, and will be used again by the AT30 then next time it starts.

• Turn on the front panel ac circuit breaker. The digital meter displays the

output voltage and current. See Using the Digital Meter on page 24. You should hear a soft hum from the AT30 as the output current increases.

NOTE: If you turn on the ac breaker before the dc breaker, and you have a filtered model of the AT30, there is a possibility that the dc breaker will trip when you try to turn it on. This is caused by the filter capacitors discharging into the battery. To get around this problem, turn off the ac breaker. Restart the AT30 by turning on the dc breaker first.

• The green FLOAT indicator lights. Press the CHRG MODE key on the

front panel. The FLOAT indicator goes off, and the yellow EQLZ indicator lights. Press the CHRG MODE key again to return the charger to the float mode.

The table below shows the normal factory settings for float and equalize voltage, equalize time, current limit setting, and alarm settings. If your purchase order specified other float or equalize voltage settings, a tag attached to the front panel of the AT30 lists the actual voltage settings.

FACTORY SETTINGS FOR ALL PARAMETERS

Parameter

Float Voltage

Equalize Voltage

HVDC Alarm

LVDC Alarm

Equalize Time

Equalize Method

Current Limit

HVDC Shutdown

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 AT30

2.2. USING THE AT30 FRONT PANEL FEATURES

2.2.1. If the meter displays an error message

When you apply power to the AT30 for the first time, the micro-processor control circuit performs a diagnostic check of the system. If it finds anything wrong, it writes an error code to the display, such as E 01.

Below is a list of 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

E 08 E 09 E 10 E 11 E 12 E 13 E 14 A 01 A 02

2.2.2. Selecting the meter mode

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 defective temperature compensation probe misadjusted current limit open internal feedback loop

not implemented at this time

defective internal thermostat internal over-temperature forced load sharing not working properly manual equalize enabled for more than 24 hrs equalize mode is inhibited

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

meter has four operating modes:

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

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

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

4. Displaying equalize hours remaining only. The EQLZ HRS REMAINING indicator lights. If the AT30 is not in a timed equalize mode, the meter displays the full programmed equalize time.

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

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

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