[applies only to product(s) delivered within United States and Canada]
Product Details:
Battery Charger Model:
Factory Ordering Code:
Battery Charger Serial Number:
Date Shipped:
Date Energized:
Standard Warranty
This product is warranted to be free from defects in material and
workmanship for a period of five (5) years from date of manufacture.
During the term of the warranty period: parts, assemblies, or
components deemed to be defective will be repaired or replaced at the
manufacturer’s option, free of charge. All costs related to removal,
reinstallation and transportation will be paid by the purchaser/
customer and/or operator of the product. Evaluation, repair and/or
replacement of any defective part(s) are FOB manufacturer’s factory.
This warranty does not cover products or parts that are damaged from
improper use or abuse, as determined by the manufacturer. Accessory
items or additional items carry only their respective manufacturer’s
warranty. Consumable items (such as fuses and electrolytic
capacitors), which wear out under normal use are specifically not
covered by this standard warranty. Any consequential damage due
to diagnosis or repair by any party other than the manufacturer’s
authorized personnel is not covered under this warranty.
ATevo
iii
Manufacturer's Warranty
Extended Spare Parts Warranty
The manufacturer’s extended warranty includes all items as mentioned
in the ‘Standard Warranty’ as previously listed, plus reasonable in/
out freight costs related to a warranty claim for parts. Said freight
cost is based on either standard UPS rates or common carrier only, as
appropriate. Contact your sales representative for more information
& pricing regarding the extended spare parts warranty.
Magnetic Parts 25-Year Extended Warranty
(equal to 5% of the original purchase price)
Lifetime warranty (limited to 25 years from date of shipment) covers
battery charger major electromagnetic components (T1 transformer,
L1 inductor & L2 inductor) as applicable. Coverage is for 100%
replacement of any covered magnetic component that fails during
normal use. Abuse, neglect, and damage from outside sources
or improper application will make this warranty null and void. The
manufacturer reserves the right to make final determination regarding
the application of this warranty. The manufacturer will be responsible
for costs related to inbound and outbound freight of warranted
magnetic components (T1, L1 & L2).
Freight cost is based on standard UPS rates or common carrier only,
as appropriate. Costs related to removal and/or reinstallation of
warranted magnetic components will be the responsibility of the
purchaser/customer and/or operator of the product. Contact your
sales representative for more information & pricing regarding the
magnetic parts extended warranty.
NOTICE Requests for returns or warranty claims
via manufacturer’s Return Material Authorization (RMA) instructions and
assignment. Contact your sales representative for more information &
pricing regarding returns or warranty claims. Returns that do not follow
this procedure will not be honored.
Election to any of the above offered extended warranties must be done
within the terms of the initial standard warranty.
iv
ATevo
must
be made
SAFETY INSTRUCTIONS
PLEASE READ AND FOLLOW TO AVOID
SERIOUS INJURY OR DEATH
EQUIPMENT/MANUAL SAFETY WARNINGS
WARNINGMEANING
Imminently hazardous situation,
which if not avoided, WILL
result in death or serious injury.
Potentially hazardous situation,
which if not avoided, could
result in death or serious injury.
Potentially hazardous situation,
which if not avoided, could
result in minor or moderate
injury (e.g. minor burns,
bruising from pinch points,
minor chemical irritation).
May also be used to alert
against unsafe practices.
ATevo
Important information not
related to personal injury (e.g.
messages related to equipment
or property damage).
LOCKOUT TAGOUT is required
before servicing.
VENTILATION MANDATORY.
Maintain at least 6in / 152mm
of free air on all vented surfaces
for cooling. Allow sufficient
clearance to open front panel
for servicing.
v
SAFETY INSTRUCTIONS
PLEASE READ AND FOLLOW TO AVOID
SERIOUS INJURY OR DEATH
EQUIPMENT/MANUAL SAFETY WARNINGS
WARNINGMEANING
Refer to manual.
SAFETY ALERT. Indicates that a
hazardous situation exists. TO
REDUCE RISK OF INJURY OR
DEATH, refer to accompanying
documents, and follow all steps
or procedures as instructed.
DANGEROUS HIGH VOLTAGE
inside product enclosure.
TO REDUCE RISK OF FIRE
OR ELECTRIC SHOCK, do not
attempt to open enclosure or
gain access to areas where you
are not instructed to do so.
SERVICING IS TO BE DONE
ONLY BY QUALIFIED SERVICE
PERSONNEL.
vi
Allow at least 3 minutes
for internal components to
discharge to a safe level
after performing lockout
tagout to prevent exposure to
DANGEROUS HIGH VOLTAGE.
ATevo
SAFETY INSTRUCTIONS
PLEASE READ AND FOLLOW TO AVOID
SERIOUS INJURY OR DEATH
EQUIPMENT/MANUAL SAFETY WARNINGS
WARNINGMEANING
DANGER! Risk of Arc Flash
(only for ATevo units with input
voltage over 416 Vac)
EXPLOSIVE GAS can be
produced from batteries during
normal operation.
Never smoke, use an open
flame, or create arcs in the
vicinity of the ATevo or the
battery.
Do not operate equipment
without all guards and/or
covers in place.
ATevo
vii
SAFETY INSTRUCTIONS
PLEASE READ AND FOLLOW TO AVOID
SERIOUS INJURY OR DEATH
Use of equipment in a manner not specified by
manufacturer may impair protection provided by ATevo.
EXAMPLES OF EQUIPMENT MISUSE
SYMBOLEXAMPLE
Do not use the equipment for
any purpose not described in
this manual.
Do not operate this equipment
without all guards and covers in
place.
Do not operate this equipment
from any power source that
does not match voltage rating
stamped on equipment.
Refer to Manufacturer’s
Identification Label for
operational requirements.
1. Do not touch any uninsulated parts of ATevo, especially the
input and output connections, as there is the possibility of
electrical shock.
2. During normal operation, batteries may produce EXPLOSIVE GAS! Never smoke, use an open flame, or create arcs in the
vicinity of ATevo, or the battery.
viii
ATevo
SAFETY INSTRUCTIONS
PLEASE READ AND FOLLOW TO AVOID
SERIOUS INJURY OR DEATH
1. Before using ATevo, read all instructions and cautionary
markings on: a) this equipment, b) battery, and c) any other
equipment to be used in conjunction with ATevo
2. Do not use ATevo for ANY purpose not described in this manual.
3. Do not install ATevo outdoors, or in wet or damp locations,
unless specifically equipped for that environment.
4. Do not operate ATevo with any power source that does not
match the specified ac and dc voltage ratings. Refer to the data
nameplate decal affixed to the outside panel for operational
requirements.
5. Turn OFF ATevo before connecting or disconnecting the battery
to avoid electrical shock hazards, arcing, burning, and/or
equipment damage.
6. Do not operate ATevo with the safety shield or any other
supplied guards removed or improperly installed.
7. Do not operate ATevo if it has been damaged in any way. Refer
to qualified service personnel.
8. De-energize and lock out all ac and dc power sources to ATevo
before servicing.
9. Do not disassemble ATevo. Only qualified service personnel
should attempt repairs. Incorrect reassembly could result in
explosion, electrical shock or fire.
10. Remove all jewelry, watches, rings, etc. before proceeding with
installation or servicing to avoid electrical shock hazards.
1. This manual contains important safety and operating
instructions, and therefore should be filed for easy access.
2. Maintain at least 6in / 152mm of free air on all vented surfaces
for cooling. Allow sufficient clearance to open the front panel
for servicing.
Appendix C - Document Control Information . . . . . . . . . . . . . . . 146
� � � � � � � �
� � � � � � �
142
144
ATevo
xvii
1 Receiving & Mounting
1.1 Storing ATevo
If you store ATevo for more than a few days before installation, store
it in its original shipping container, in a temperature-controlled,
dry climate. Ambient temperatures of 0 to 122 °F / -18 to 50 °C are
acceptable. Storage should not exceed two (2) years due to limited
shelf life of dc filter capacitors when they are not in service.
1.2 Receiving ATevo
The manufacturer does not assume any liability for damage during
transportation or handling. Therefore, upon receipt of ATevo (or
related products) immediately unpack, inspect for damage or
shortage (per Section 1.3), and report issues found (per Section 1.4).
1.3 Unpacking and Inspecting ATevo
Carefully remove all shipping materials from ATevo, and save until
you are sure ATevo is undamaged. Remove ATevo from shipping
pallet. Inspect for possible damage, using checklist below. If
damage found, see Section 1.4 for proper reporting.
1.3.1 Inspection Checklist
□ Enclosure exterior and interior are not marred or dented.
□ No visible damage to exterior or interior components.
□ Internal components are secure.
□ Printed circuit boards are firmly seated on their standoffs.
□ Hardware is tight.
□ Wire terminations are secure.
□ User’s Manual is included.
□ Includes all items on packing list.
1.4 Reporting Damage or Shortage
If damage or shortage is found, notify the delivery person and make
notation on all copies of carrier’s receipt before signing. If such is
discovered after delivery, notify carrier immediately and request an
inspection. Should the products require an inspection by (or return
to) the manufacturer, please contact your sales representative for
further instructions.
2
ATevo
1 Receiving & Mounting
1.5 Returning Damaged Equipment
Returned material must be packed in compliance with shipping
regulations. It is preferable to use original shipping materials
if possible. Mark the outside of the shipping container with
manufacturer’s Return Material Authorization (RMA) number.
1.6 Moving ATevo
Once you have established that ATevo is undamaged, identify the
weight of the unit using the table below.
1.6.1 ATevo Weight Table
ATevo Weight by Model
Output
Voltage
24 Vdc
48 Vdc
130 Vdc
260 Vdc
6 Adc12 Adc16 Adc20 Adc25 Adc
33 lb33 lb88 lb101 lb101 lb
15 kg15 kg40 kg46 kg46 kg
83 lb96 lb112 lb108 lb108 lb
38 kg44 kg51 kg48 kg48 kg
97 lb125 lb125 lb193 lb193 lb
44 kg57 kg57 kg88 kg88 kg
128 lb193 lbn/an/an/a
58 kg88 kgn/an/an/a
Ampere Rating
ATevo’s Style-5054 enclosure does not feature top-lifting eyes for
moving. Move ATevo with a forklift using the supplied shipping
pallet. Lift ATevo into a wall-mount or rack-mount installation, using
a heavy-duty sling or a scissor lift.
ATevo
3
1 Receiving & Mounting
1.7 Mounting ATevo
Mount the ATevo Style-5054 enclosure to easily access the front
panel AC Input (CB1) and DC Output (CB2) Circuit Breakers. Choose
from the following mounting methods:
1.7.1 Wall-Mounting
Wall-mounting is the standard method. When wall-mounting ATevo,
consider the following:
1. Refer to the Style-5054 enclosure outline drawing in Appendix B.
2. The wall must be strong enough to properly support ATevo’s
weight, plus a safety factor. Refer to Weight Table in Section
1.6.1. The weight of ATevo may be different, depending on the
features, options, and accessories ordered with the unit.
3. Select conduit entrances with planned ac input and dc output
wiring in mind. By using pre-fab knockouts on enclosure sides
or bottom, the cabinet shroud can be removed for internal
servicing without removing ATevo from the wall.
4. Location requirements:
» Free of drips and splatter. If falling particles and liquids are
a problem, install a NEMA Type 2 drip shield accessory.
» Between 0 and 122 °F / -18 and 50 °C, with relative humidity
between 0% and 95% non-condensing.
» Must be free of flammable or explosive materials.
5. Maintain at least 6in / 152mm of free air on all vented surfaces
for cooling.
6. Allow at least 36in / 914mm front clearance for operation and
maintenance.
PROCEDURE
Install four (4) 0.25in / 6.4mm anchor bolts (not supplied) rated
to support ATevo’s weight plus a minimum safety factor of two (2)
times, into the wall. Place ATevo onto anchor bolts, add appropriate
mounting hardware, and tighten securely. Refer to the following
graphics for ATevo wall-mounting pattern and specification.
4
ATevo
GRAPHICS
ENCLOSURE
MOUNTING
FLANGE
FLAT WASHER
LOCKWASHER
0.25in / 6.4mm
DIA BOLT
1 Receiving & Mounting
0.312in
[8.00mm]
DIA
0.750in
[19.00mm]
WALL
0.750in
[19.00mm]
DIA
RECOMMENDED MOUNTING KEYHOLE SLOT USED ON
HARDWARE LOADING STYLE-5054 MOUNTING FLANGE
USE 0.25in / 6.4mm DIA
BOLTS - FOUR (4) PLACES
254mm
464mm
ATevo STYLE-5054 ENCLOSURE
WALL-MOUNTING PATTERN
ATevo
5
1 Receiving & Mounting
1.7.2 Floor-Mounting
To install ATevo onto a horizontal surface, the standard enclosure
does not need to be modified, but a special floor mounting accessory
is required. The kit includes a set of mounting brackets that elevate
the top of ATevo approximately 47in /1194mm above floor level,
with provisions for floor anchoring. The kit also includes appropriate
hardware and installation instructions for the floor-mounting
procedure.
When floor-mounting ATevo, consider the following:
1. Locate anchor bolt holes at least 4.25in /108mm from any wall,
to allow clearance behind the mounting brackets.
2. Select conduit entrances with planned ac input and dc output
wiring in mind. By using pre-fab knockouts on enclosure sides
or bottom, the cabinet shroud can be removed for internal
servicing without removing ATevo from the floor stand.
3. Location requirements:
» Free of drips and splatter. If falling particles and liquids are
a problem, install a NEMA Type 2 drip shield accessory.
» Between 0 and 122 °F / -18 and 50 °C, with relative humidity
between 0% and 95% non-condensing.
» Must be free of flammable or explosive materials.
4. Maintain at least 6in /152mm of free air on all vented surfaces
for cooling.
5. Allow 36in /914mm front clearance for operation and
maintenance.
PROCEDURE
Install four (4) 0.25in / 6.4mm anchor bolts (not supplied) rated
to support the unit weight plus a minimum safety factor of two (2)
times, into floor.
Assemble the floor-mounting accessory on to the anchor bolts as
shown. Place ATevo onto vertical posts, add appropriate mounting
hardware, and tighten.
Refer to the following graphics for floor mounting patterns and
enclosure footprints.
6
ATevo
GRAPHICS
19.75in
502mm
1 Receiving & Mounting
47.75in
1213mm
0.437in / 11mm
FLOOR MTG HOLE
FOUR (4) PLACES
10.00in
ATevo STYLE-5054 ENCLOSURE
FLOOR-MOUNTNG PATTERN
WALL
4.25in
min.
108mm
18.25in
463mm
0.375in / 9.5mm
FLOOR-MOUNTING
HARDWARE
FOUR (4) PLACES
ATevo
10.00in
254mm
7
1 Receiving & Mounting
1.7.3 Rack-Mounting
ATevo can be installed into most 23in/584mm and 24in/610mm relay
racks with standard EIA hole spacing. ATevo’s enclosure does not
need to be modified for rack mounting, but a special kit is required.
The kit includes two (2) mounting brackets, appropriate hardware,
and Installation Instructions for the rack-mounting procedure.
When rack-mounting ATevo, consider the following:
1. Rack must be strong enough to properly support the unit’s
weight. Refer to Weight Table in Section 1.6.1.
2. Select conduit entrances such that planned ac input and dc
output conduit is accessible after rack-mounting. Note the
standard pre-fab conduit knockouts located on the sides, top,
and bottom of the enclosures.
3. Location requirements:
» Free of drips and splatter. If falling particles and liquids are
a problem, install a NEMA Type 2 drip shield accessory.
» Between 0 and 122 °F / -18 and 50 °C, with relative humidity
between 0% and 95% non-condensing.
» Must be free of flammable or explosive materials.
4. Maintain at least 6in /152mm of free air on all vented surfaces
for cooling.
5. Allow at least 36in /914mm front clearance for operation and
maintenance.
PROCEDURE
To rack mount ATevo, first install mounting brackets into rack using
proper hardware (not supplied). Second, mount ATevo onto installed
brackets, using supplied kit hardware. Provide at least 6in /152mm
of free air above and below ATevo for cooling. Refer to the following
graphics for rack-mounting configurations.
8
ATevo
GRAPHICS
6in/153mm
COOLING
6in/153mm
COOLING
8.50in
216mm
4.00in
57mm
RAC
K
1 Receiving & Mounting
ATevo STYLE-5054 RACK-MOUNTING
4.00in
57mm
8.50in
216mm
6in/153mm
COOLING
6in/153mm
COOLING
R
A
C
K
ATevo
0.25in/6.4mm
MTG. BOLTS
9
2 Wiring
2.1 Mechanical Diagram and Component Location
ATevo has the following mechanical layout and wiring diagram
screen-printed onto its patented, internal acrylic safety shield.
ATevo is composed of these components and subsections:
• A1 - Main Control PC Board
• A2 - Power Board
• A4 - Auxiliary I/O Board - optional
• A7 - Filter Capacitor (C1x) Board
• A9 - AC Surge Suppressor MOV Board
• A10 - Remote Temperature Probe - optional
• A12 - Serial Communications Adapter(s) - optional
Shown on top-right of silkscreen. Mounted on the ATevo front panel
door. Contains display, buttons, alarm indicators, and is responsible
for battery charger controls.
2.1.2 Power Board (A2)
Shown on bottom-left of silkscreen. Mounted on heat sink along
left side of ATevo. Contains most power electronic connections,
and terminal blocks for remote sense and battery temperature
compensation options.
2.1.3 Auxiliary I/O Board (A4) - optional
Shown at top-left of silkscreen. Bolted to heat sink on the left side,
above the Power Board. Plugs directly into Power Board (A2).
• six (6) relays, four (4) Binary Inputs, and four (4) Analog Inputs
• relays can be configured to indicate status of six (6) different alarms
or status points
• independently-isolated Binary Inputs can be configured to report ON/
OFF status of four (4) controls
• Analog Inputs include input scaling and can report the status of four
(4) analog controls referenced to the dc bus
2.1.4 Filter Capacitor Board (A7)
Shown near top-left of silkscreen. Bolted to top of the Power Board
(A2). The capacitors (C1x) filter ‘ripple’ from the dc output.
2.1.5 AC Surge Suppressor MOV Board (A9)
Shown to left of AC Circuit Breaker (CB1) on silkscreen. Mounted to
top-left side of breaker bracket. Contains ac input surge suppression
and filtering. It is located for easy access, examination, and
replacement in case an input transient event should occur.
2.1.6 Serial Communications Adapter (A12) - optional
Shown above Ethernet Comm. Adapter (A22) on silkscreen. Up
to three (3) Serial Communications Adapter boards (A12) can be
plugged into the Main Control Board (A1) at locations P10, P11, and
P12. This option supports DNP3 and Modbus protocols, and can be
configured to support 2-wire or 4-wire RS-232 connections, or 2-wire
or 4-wire RS-485 connections.
12
ATevo
2 Wiring
2.1.7 Forced Load Sharing Comm Adapter (A13) - optional
Mounted similarly to Serial Communications Adapter (A12).
Shown directly to bottom-left of Main Control Board (A1) on
silkscreen. Plugs into Main Board at P13. Supports DNP3 and
Modbus protocols via 10/100 copper Ethernet connection.
2.1.9 Eliminator Filter Capacitor (C2) - optional
Shown below Power Board on silkscreen. Mounted on bottom-left
under Power Board. Provides the additional ripple filtering, required
for the ‘filtered eliminator’ option.
2.1.10 AC Input Circuit Breaker (CB1)
Located in center of ATevo, about one third from bottom. Protects
ATevo ac wiring, and can be used to disconnect from ac source.
2.1.11 DC Output Circuit Breaker (CB2)
Located at bottom-center of ATevo. Protects ATevo dc wiring, and can
be used to disconnect ATevo from battery and system dc load(s).
2.1.12 Main Filter Inductor (L1)
Shown in center of silkscreen. Located on bottom-left of back wall. It
is part of the dc filter, lowering ripple.
2.1.13 Secondary Filter Inductor (L2)
Shown bottom-center of silkscreen. Located on bottom of back wall
to right of Filter Inductor (L1). It is also part of the dc filter.
2.1.14 Power Isolation Transformer (T1)
Shown at center of silkscreen. Located on back wall above the filter
inductors (L1/L2). Provides isolation and converts ac input voltage to
appropriate potential, prior to rectification.
NOTICE ATevos with the multi-tap ac input option (smart part
code ‘MT1/2’), feature a terminal block (TB-H#) mounted above
the AC Input Circuit Breaker (CB1) for voltage selection. Jumper
positions are shown on silkscreen to right of Power Isolation
Transformer (T1). See Section 2.3.
ATevo
13
2 Wiring
2.2 Removing Protective Safety Shield
!WARNING To prevent injuries, the ATevo safety shield
must always be installed when charger is in operation and/or
energized.
STEPS
• A standard flat blade screwdriver is required.
• Open the ATevo front panel door to access safety shield.
• Remove the two (2) screws that attach the safety shield to the
ATevo, one above AC Input Breaker (CB1), the other below the
DC Output Breaker (CB2).
• Grab the safety shield on both left and right sides, and gently lift
up and off of AC Input and DC Output Circuit Breakers.
• Reverse procedure for reinstalling the safety shield.
2.3 ATevo with Selectable Input Voltage - optional
ATevo may be equipped with a multi-tap ac input voltage, in two (2)
options for field configuration:
• 120, 208 or 240 Vac 60Hz - ‘MT1’ in smart part number
• 115, 220, or 240 Vac 50/60Hz - ‘MT2’ in smart part number
2.3.1 Determining if Multi-Tap Option is Present
Check the ATevo nameplate. If the ac input voltage is listed as
120/208/240 or 115/220/240 Vac, the ATevo is equipped with the
multi-tap option. If the nameplate is not visible:
• Open the ATevo front panel door.
• Behind the safety shield, look for a gray terminal block directly
above the AC Input Circuit Breaker (CB1).
» Reference the input voltage selection silk-screened on the
center-right of the safety shield.
» If this terminal block is present, the ATevo is equipped with
the multi-tap ac input voltage option.
14
ATevo
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