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Alcad AT30 SERIES, Operating And Service Instructions

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Alcad AT30 SERIES Operating And Service Instructions Download Page 56

SERVICING THE AT30 

52 

SYMPTOM 

PROBABLE 

CAUSE 

RECOMMENDED ACTION 

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

1. Control 
boards are not 
connected 

 
2. Defective 
Main Control 
board A1 

3. Defective 
wiring 

1. Make sure the Gate Driver board (A15) is firmly connected 
to the Main Control board (A1) via plugs (J17 to P17). Make 
sure the two signal harness plugs are firmly inserted into the 
Gate Driver 

board (A15) connectors (J25 and J26). 

2. If the 

AC ON

 indicator is lit, but the rest of the front panel is 

dead, replace the Main Control board (A1). 

 
3. Check the two harness wirings to the Gate Driver board 
(A15) connectors (J25 and J26) for signs of insulation 
damage, burns, etc. Confirm all wires are securely crimped in 
the connector. 

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

1. Defective 
power resistor 
R3 
 
 
 
 

2. Defective 
wiring 
 

1. Use a dc voltmeter to measure the dc voltage from TB1(-) to 
J25 pin # 

25

 on the Gate Driver board (A15). It is normally 12 

Vdc when the rated output voltage is at TB1(+) and TB1(-). If it 
is not, remove all power from the AT30, and measure the 
resistance from TB1(+) to J25 pin # 

19

 (see the table in 

Section 3.6 for the proper resistance value). If the resistance is 
not within 10% of the table value, replace R3. 

2. Remove the safety shield, and check the wiring to and from 
TB1 and the Main Control board (A1) for signs of insulation 
damage or burns. Repair any damaged wiring. 

Charger 
output 
voltage too 
high, not 
controllable 

1. Defective 
SCR 

 
 
2. R4 or R14 is 
defective, or 
wrong value 
 
 

3. Defective 
temperature 
compensation 
probe (optional) 

4. Defective 
Main Control 
board A1 

1. Disconnect the wire harness plug from connector J26 on the 
top of the Gate Driver board (A15) and restart the AT30. If you 
are able to measure output current, one of the SCRs is 
defective. Replace the rectifier module(s) (A16) as needed. 

2. See page 61 of Section 3.5. Locate R4 and R14 on the 
Gate Driver board (A15). Remove one end of each resistor 
and measure its value with an Ohmmeter. See the table in 
Section 3.6 for resistance values. If either resistor is not within 
1% of the specified value, replace R4 and/or R14 as needed.  

3. Remove one of the probe leads from TB8 and measure its 
resistance. At 77° F / 25° C the resistance should be about 
10K Ohms. If it is not, replace the probe assembly (A10). 
 

4. If the front panel meter shows more than 110% of rated dc 
current, the Main Control board (A1) may be defective. Unplug 
the system harness connectors (J25 & J26) from the Gate 
Driver board (A15). If the output current drops to zero, replace 
the Main Control board (A1). 

 

 

 

 

 

 

 

 

 

 

 

 

Summary of Contents for AT30 SERIES

Page 1: ...d Service Instructions AT30SERIES MICROPROCESSOR CONTROLLED FLOAT BATTERY CHARGER THREE PHASE INPUT 25 1 000 Adc 3 Powdered Metals Drive North Haven CT 06473 3209 Tel 203 985 2500 Fax 203 985 2539 www alcadusa com ...

Page 2: ...STATIC PROOFING 0 UNFILTERED N TREATMENTS 0 NOT INCLUDED 1 FILTERED 1 INSTALLED E OUPUT FILTERING 2 BATTERY ELIMINATOR P NEMA 2 TYPE DRIP SHIELD 0 NOT SUPPLIED DESCRIPTION CODE FEATURE DESCRIPTION CODE FEATURE INPUT AND OUTPUT INTERRUPTING CAPACITY RATINGS ORDER CODE CIRCUIT BREAKER TYPE AC CIRCUIT BREAKER RATINGS 208 240 480 Vac DC CIRCUIT BREAKER RATINGS 125 250 Vdc OPTIONAL AC FUSE RATING 208 6...

Page 3: ...his 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 ...

Page 4: ...s 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...

Page 5: ...Style 5030 Enclosure 68 AT30 Series Battery Charger Outline NEMA 1 Style 163 Enclosure 70 AT30 Series Battery Charger Internal Component Layout Style 5018 Enclosure 72 AT30 Series Battery Charger Internal Component Layout Style 5030 Enclosure 74 AT30 Series Battery Charger Internal Component Layout Style 163 Enclosure 76 AT30 Series Battery Charger Instrument Panel PC Board Detail w Aux Relay PC B...

Page 6: ...ct 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 mate...

Page 7: ... 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 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 please refer to the table below and the standard drawings in Appendix C Co...

Page 8: ...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 condu...

Page 9: ...n 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 hard...

Page 10: ...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 explosi...

Page 11: ...ALLING THE AT30 7 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 Style 5018 enclosure ...

Page 12: ...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 ...

Page 13: ...tyle 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 Style 5018 enclosure ...

Page 14: ...ement 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 ordered with 208 240 Vac 60Hz input and you need to change the factory wired input voltage do so by changing the jum...

Page 15: ...ways use all three 3 jumpers 5 Be sure all connections are tight 6 Check your work before reenergizing the charger MAIN TRANSFORMER T1 CONNECTION TABLE TYPICAL TRANSFORMER T1 208 240 Vac 60 Hz INPUT TYPICAL TRANSFORMER T1 480 Vac 60 Hz INPUT 208 Vac Jumper Setting 240 Vac Jumper Setting Jumper Setting H1 H2 H3 to 1 H1 H2 H3 to 2 NONE SCHEMATIC SCHEMATIC NOTE 1 Refer to the AT30 Standard Schematics...

Page 16: ...ty 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 wi...

Page 17: ...INPUT CONNECTIONS GRAPHICS Style 5018 I O Terminal Board TB1 Detail user supplied ac input wiring 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 ...

Page 18: ...een 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 lug...

Page 19: ...TPUT 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 ...

Page 20: ...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 wirin...

Page 21: ...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 Ins...

Page 22: ...tions 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...

Page 23: ...f these alarm contacts PROCEDURE 1 Deenergize and lock out all ac and dc voltages to the AT30 Check with a voltmeter 2 Remove the safety shield if supplied 3 Route your remote annunciator wiring into the enclosure through one of the unused knockouts in the side of the enclosure 4 Connect the wiring use 22 14 AWG to the appropriate terminals of TB4 on the Auxiliary Relay board as shown in the drawi...

Page 24: ...charger unless you are a qualified technician or electrician Disconnect and lock out all power to the battery charger before starting to remove or replace any components Turn the ac power off at the distribution panel upstream from the battery charger Disconnect the battery from the charger output terminals PROCEDURE 1 De energize and lock out all ac and dc voltage sources to the AT30 Check with a...

Page 25: ...e cable within the AT30 enclosure so that 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 tie th...

Page 26: ...30 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 AT30 to activate the probe as described in Section 2 1 Using temperature compensation Whenever an electric storage battery is being charged the terminal voltage of the battery changes a ...

Page 27: ...ne 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 94 96 98 100 102 104 106 108 20 40 60 80 100 120 Temperature Degrees Fahrenheit Percent Output Voltage Lead Acid...

Page 28: ...ou are sure that all connections to the AT30 are properly made follow these steps to start up the AT30 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...

Page 29: ...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 r...

Page 30: ...back loop E 11 not implemented at this time E 12 defective internal thermostat E 13 internal over temperature E 14 forced load sharing not working properly A 02 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...

Page 31: ... These equalize methods are described below Manual Timer Method Choose the manual timer method if you perform regularly scheduled equalize charging or if you base your equalize charging on regular readings of the specific gravity of each cell of your battery for lead acid batteries When your battery requires equalize charging adjust the manual timer to 1 2 hours for each 100 AH of battery capacity...

Page 32: ...e mode automatically and the EQLZ indicator lights At the end of the equalize charging time that you select the charger reverts automatically to the float mode and the FLOAT indicator lights At any time during the equalize charge you can switch the charger back to float mode by pressing the CHRG MODE key The FLOAT indicator will light Consult your battery manufacturer s instructions before using t...

Page 33: ...OLTAGE lights whenever the dc output voltage exceeds the specified alarm voltage setting See Section 2 3 4 to learn how to adjust the HVDC alarm setting LOW DC VOLTAGE lights whenever the dc output voltage is below the specified alarm voltage setting See Section 2 3 4 to learn how to adjust the LVDC alarm setting DC OUTPUT FAILURE lights whenever the charger cannot provide its full rated output vo...

Page 34: ...ant shows on the meter display You can make the display scroll up or down continuously by pressing and holding the UP or DOWN key You cannot exceed certain upper and lower limits for the operating parameters To see what the limits are for your charger refer to the AT30 Specifications in Appendix A on page 64 When you first press the EDIT ENTER key the AT30 prompts you to adjust the first parameter...

Page 35: ...tors light and the display flashes the present value of the equalize voltage Press and release the UP or DOWN key to increase or decrease the value in the display by one count or press and hold the UP or DOWN key to scroll the value in the display upward or downward When the display shows the equalize voltage you want to set release the UP or DOWN key If you go past the voltage you want press the ...

Page 36: ...nd the auto equalize timer If you want to adjust the alarm settings skip to Section 2 3 4 OR If you want to exit the Edit mode now press the EDIT ENTER key three more times until the charger returns to normal operation 2 3 4 Setting the Alarms After you save the equalize timer setting the Edit mode automatically prompts you to adjust the high dc voltage and low dc voltage alarms There is a red ind...

Page 37: ... into permanent memory Setting the low DC Voltage Alarm Press the EDIT ENTER key until the LOW DC VOLTAGE indicator flashes and the display flashes the present value of the low dc voltage alarm Press and release the UP or DOWN key to increase or decrease the value in the display by one count or press and hold the UP or DOWN key to scroll the value in the display upward or downward When the display...

Page 38: ... to the AT30 Check with a voltmeter before proceeding Restart the AT30 only when necessary to make the sensitivity adjustment If your battery is grounded do not attempt this procedure Remove the safety cover Connect the test resistor between TB1 and the ground terminal Refer to the standard internal component layout drawings starting on Page 72 in Appendix C For I O panel layout and all terminal w...

Page 39: ...ard shown on the previous page Move the jumper to the DISABLE position The POS GND and NEG GND indicators and the summary alarm relay will not respond to a ground fault Restart the AT30 following the instructions in Section 2 1 2 3 5 Setting the current limit value The AT30 automatically limits its dc output current in case of overload or battery discharge You can adjust the value of the current l...

Page 40: ... the UP key then Press the CHRG MODE key The HIGH DC VOLTAGE indicator lights and the display flashes ON You can toggle the shutdown feature OFF and ON by pressing the CHRG MODE key repeatedly Parallel Operation If two or more AT30 chargers are connected in parallel both sense the output voltage If one charger runs away it will supply all the output current the other has zero output current The hi...

Page 41: ...ond press and hold the UP key then press the EQLZ MTHD key The DC VOLTS METER MODE indicator will light and the meter display flashes the output voltage reading Measure the output voltage of the AT30 using a dc meter accurate to 0 25 or better While watching the meter connected to the AT30 output not the front panel meter press the UP or DOWN key until the actual output voltage matches the float s...

Page 42: ...larm relay pc board at TB4 will not signal a low level detect alarm If you have a dc power supply you can adjust the battery voltage that triggers the alarm On the back of the main control circuit board find the potentiometer RA1 as shown in the figure below Disconnect all ac and dc power sources from the AT30 and connect your dc power supply to the dc output terminals of the charger positive to p...

Page 43: ...high dc voltage shutdown feature To disable the front instrument panel keys open the AT30 door and locate the small plastic jumper J9 on the right side of the main control board See the figure below Move the jumper up to the DISABLE position pins 2 and 3 With this setting only the front panel METER MODE and CHRG MODE keys will function All indicators will still work normally Return the jumper down...

Page 44: ... is conductive carefully vacuum out the interior Be sure to clean surfaces of circuit boards and around electrical terminals The AT30 is rated for operation up to 122 F 50 C If your charger is in a warmer environment or at an elevation over 3000ft 914m contact your sales representative for operating information 2 4 2 Check power and signal connections Check the tightness of all field connections i...

Page 45: ...meter 1 The ripple voltage should be no higher than shown in the specifications in Appendix A on page 64 if the battery ampere hour capacity is at least 4 times the output current rating of the charger If you suspect that the output ripple voltage is too high see Output ripple voltage too high of the Troubleshooting Chart in Section 3 4 page 54 2 4 6 Viewing the voltage and alarm settings You can ...

Page 46: ...1 L2 TB1 L3 using an ac voltmeter Value must be within 10 and 12 of nominal voltage Input Vac Check dc output voltage Measure at TB1 and TB1 using a dc voltmeter Value should agree with the front panel voltmeter within 1 and must be correct values for your battery If the AT30 is using a temperature compensation probe see the graph on page 23 to determine correct battery voltage You need to know th...

Page 47: ...through settings See page 30 o FLOAT OK o EQUALIZE OK o HVDC alarm OK o LVDC alarm OK Current limit Adc Final checks Make sure plexiglas safety cover is in place Restore charger to normal operation Close latch on front panel o OK o OK o OK Step optional features Instructions Results Test auxiliary alarm relays Press LAMP TEST key and hold for 4 seconds Alarm relays will transfer o OK Check integri...

Page 48: ... charger does not work properly but there is no front panel error code turn off the front panel circuit breakers or disconnect ac and dc power externally Then turn the dc and ac power back on This will return the charger to normal operation as long as there is no internal component failure Note Do this only once If the charger does not resume normal operation go to the next step 3 If the charger s...

Page 49: ...rt the charger according to Section 2 1 E 02 Short circuit on output You may get this error code if the battery is discharged to less than 6 volts When the battery charges to greater than 6 volts the error code disappears If you have a seriously discharged battery allow the charger to run for 24 hours and check the battery voltage again If it has not increased to the normal voltage rating consult ...

Page 50: ...iring The AT30 charger displays the error code if it detects this wiring failure You should respond to this problem quickly to be sure that the AT30 regulates the output voltage properly Wire an annunciator e g buzzer to the summary alarm relay TB3 to get a remote indication of any charger problem or monitor the charger operation using the optional DNP 3 MODBUS communications board If you have a f...

Page 51: ... 10 Open internal feedback loop A redundant internal feedback loop control loop is provided as redundancy to increase reliability when remote sensing is used If there should be a problem with the internal loop wiring the charger displays E 10 Check the internal wiring in the signal harness especially wire 50 Also check the harness connector J25 on the Gate Driver circuit board A15 E 11 Not used Th...

Page 52: ...oms 2 Find the symptom s in the first column of the chart 3 The middle column contains common causes for the problem you observe in order of probability 4 Follow the action described in the right hand column to correct the problem and return the charger to normal service Determining the condition of the charger Is the front panel AC ON indicator lit What is the ac voltage at the input terminals me...

Page 53: ...d on the main heat sink s or at the main transformer T1 Measure resistance between the ac terminals bottom terminals on the rectifier module s It should be at least 100 000 Ohms check both polarities If resistance is low in either direction replace the rectifier module s A16 as needed 2 Check spacing of terminals and check wiring for signs of insulation damage burns etc Repair as necessary 3 Test ...

Page 54: ...th polarities It should be at least 100 000 Ohms in one polarity and less than 1 000 Ohms in the other polarity Replace CR1 if it is defective 5 Check spacing of terminals and check wiring for signs of insulation damage burns etc Repair as necessary DC breaker trips or fuses clear after a few minutes 1 Loose connection to breaker 2 Open SCR 3 SCR not controllable 4 Defective Gate Driver circuit bo...

Page 55: ...ductor L1 or L2 9 Defective dc breaker CB2 1 This is normal operation in a system with little or no dc load As long as the AT30 maintains Float voltage it is operating normally 2 Check the Float and Equalize voltages and adjust them if necessary Consult your battery manufacturer for the proper voltage settings 3 Be sure the transformer primary taps T1 H1 H2 and H3 are wired correctly for your inpu...

Page 56: ...e value If the resistance is not within 10 of the table value replace R3 2 Remove the safety shield and check the wiring to and from TB1 and the Main Control board A1 for signs of insulation damage or burns Repair any damaged wiring Charger output voltage too high not controllable 1 Defective SCR 2 R4 or R14 is defective or wrong value 3 Defective temperature compensation probe optional 4 Defectiv...

Page 57: ...imit set too low 2 Defective battery or dc load or load is too great 3 Wrong ac input voltage or voltage too low or T1 wired incorrectly 4 Defective rectifier bridge 5 Defective Main Control board A1 1 If the AT30 is not in the Edit mode press the EDIT ENTER key five times until the meter display flashes the current limit value in Amperes If the current limit is less than 110 adjust it to 110 as d...

Page 58: ...inst the specification for your AT30 model on page 64 The ripple rating is for a battery whose Ampere hours are four 4 times the charger Ampere rating For a smaller battery ripple voltage may be higher 4 Test with capacitance meter and replace as needed AT30 very noisy 1 Loose hardware or enclosure panel 2 Defective rectifier bridge 1 Check and tighten all component mounting hardware and panel har...

Page 59: ...0s are connected in parallel without this option it is normal for one of the units to have no output current You can check the operation of the off charger by increasing its Float voltage until it starts to deliver output current When you have finished the test be sure both AT30s are set to the same Float and Equalize voltages 2 See Appendix F on page 92 for troubleshooting of Forced Load Sharing ...

Page 60: ...ery and connect a light dc load to the AT30 Measure the dc voltage across TB1 and TB1 with the breaker on If no voltage is measured replace the dc circuit breaker CB2 DC OUTPUT FAILURE indicator is on but ac input voltage is normal and ac dc breakers are closed 1 Defective rectifier bridge 2 Defective Main Control board A1 3 Defective transformer T1 4 Defective dc circuit breaker CB2 1 Use a clamp...

Page 61: ... the AT30 to be in standby open the ac circuit breaker CB1 3 Calibrate ground detection sensitivity See Section 2 3 4 4 Turn off both front panel circuit breakers CB1 CB2 or turn off ac and dc power externally if the AT30 does not have breakers Wait one minute and disconnect the AT30 from the battery and dc bus Turn on the AT30 and measure the voltage from TB1 to chassis and from TB1 to chassis Th...

Page 62: ...drawings featured in Appendix C Removing the safety shield if present Some AT30 enclosures feature a clear plexiglas safety shield as a second protective barrier between the user and the internal components Some of the following repair procedures require you to remove this shield to access internal components Open the front door and remove the clip fasteners from the front of the plexiglas shield ...

Page 63: ...andoffs Separate the boards if you are replacing only one and then reconnect the replacement board Put the replacement board s in place on the front panel with the same orientation and push them onto the standoffs Be sure that the boards are fully seated on all ten standoffs Re connect the signal wire harness plug to the boards matching the orientation when removed If earlier removed reconnect any...

Page 64: ...the lead of the dc surge suppressor Install one lead of the replacement surge suppressor Replace the other wires and the hardware Repeat for the output terminal TB1 Tighten all hardware NOTE The dc surge suppressor is not polarized Replacing the dc surge suppressor networks VR6 C4 VR7 C5 Replace these networks as assemblies do not replace individual parts Turn off all power to the charger Disconne...

Page 65: ...ttery chargers R3 is soldered directly onto A15 In all AT30 battery chargers R4 R6 and R14 are soldered directly onto A15 See detail of the gate driver pc board below for proper location If any of these resistors need to be replaced we suggest you order a new A15 board See Replacing the control pc board A1 and or gate driver pc board A15 on page 59 If any of these resistors must be replaced withou...

Page 66: ...ory Part Number Symbol Description 12 Vdc 24 Vdc 48 Vdc 130 Vdc Rec Spares A1 Main Control PC Board assembly EJ1243 10 Y A5 Auxiliary Relay PC Board assembly optional EJ1243 03 Y A10 Temperature Compensation Probe assembly See Appendix B A15 Three Phase Gate driver PC Board assembly EJ5199 01 EJ5199 02 EJ5199 03 EJ5199 04 Y A16 SCR Rectifier Module s Q1 Q6 see supplied Parts Data Package Y A17x SC...

Page 67: ...0075 56 38 3KΩ T1 Main Power Isolation Transformer see supplied Parts Data Package TB1 X Style 5018 input output ground terminal CU AL compression lug for 14 1 0 AWG RC0056 18 TB1 AC Style 5030 input ground terminal CU AL compression lug for 14 1 0 AWG RC0056 18 TB1 DC Style 5030 output terminal CU AL comp lug for 6 AWG 350 MCM RC0056 03 TB1 X Style 163 input output ground terminal CU AL comp lug ...

Page 68: ... mV Current limit Adjustable 50 110 of rated output current Soft start 0 to 100 load 4 seconds Float 11 0 14 5 22 0 29 5 44 0 58 0 110 141 Equalize 11 7 15 5 23 4 31 0 46 8 59 0 117 143 High DC Voltage alarm 12 19 24 38 48 76 120 175 Voltage adjustment ranges Low DC Voltage alarm 7 14 5 15 29 5 30 58 80 141 Voltmeter range Vdc 0 21 0 42 0 75 0 195 25 Adc nom output 0 30 30 100 Adc nom output 0 150...

Page 69: ... Strips for Style 5018 Enclosure EJ5042 00 Cabinet Heater Strips for Style 5030 Enclosure EJ5166 00 Cabinet Heater Strips for Style 163 Enclosure EJ5183 00 NEMA 2 Type Drip Shield for Style 5018 5030 163 Enclosure EI0191 02 03 04 Padlock for Style 5018 5030 163 Enclosure Front Panel Door EI0215 01 01 02 Remote Temperature Compensation Probe Assembly A10 see table below DNP3 Level 2 Modbus Communic...

Page 70: ...APPENDIX C Standard Drawings 66 Outline AT30 Battery Charger NEMA 1 Style 5018 Enclosure JE5085 00 ...

Page 71: ...APPENDIX C Standard Drawings 67 Outline AT30 Battery Charger NEMA 1 Style 5018 Enclosure JE5085 00 http www ATSeries net PDFs JE5085 00 pdf ...

Page 72: ...APPENDIX C Standard Drawings 68 Outline AT30 Battery Charger NEMA 1 Style 5030 Enclosure JE5086 00 ...

Page 73: ...APPENDIX C Standard Drawings 69 Outline AT30 Battery Charger NEMA 1 Style 5030 Enclosure JE5086 00 http www ATSeries net PDFs JE5086 00 pdf ...

Page 74: ...APPENDIX C Standard Drawings 70 Outline AT30 Battery Charger NEMA 1 Style 163 Enclosure JE5095 00 ...

Page 75: ...APPENDIX C Standard Drawings 71 Outline AT30 Battery Charger NEMA 1 Style 163 Enclosure JE5095 00 http www ATSeries net PDFs JE5095 00 pdf ...

Page 76: ...andard components A1 through VR7 are supplied in all such units Optional components A5 through VR3 are supplied only in those AT30 battery chargers configured with such options A custom internal component layout drawing is available for any AT30 battery charger based upon a quote or a manufactured unit For document availability please contact your sales representative with the model number options...

Page 77: ...APPENDIX C Standard Drawings 73 Internal Component Layout Drawing AT30 Battery Charger Style 5018 with ALL options JE5088 99 http www ATSeries net PDFs JE5088 99 pdf ...

Page 78: ...andard components A1 through VR7 are supplied in all such units Optional components A5 through VR3 are supplied only in those AT30 battery chargers configured with such options A custom internal component layout drawing is available for any AT30 battery charger based upon a quote or a manufactured unit For document availability please contact your sales representative with the model number options...

Page 79: ...APPENDIX C Standard Drawings 75 Internal Component Layout Drawing AT30 Battery Charger Style 5030 with ALL options JE5089 99 http www ATSeries net PDFs JE5089 99 pdf ...

Page 80: ...ndard components A1 through VR7 are supplied in all such units Optional components A5 through VR3 are supplied only in those AT30 battery chargers configured with such options A custom internal component layout drawing is available for any AT30 battery charger based upon a quote or a manufactured unit For document availability please contact your sales representative with the model number options ...

Page 81: ...APPENDIX C Standard Drawings 77 Internal Component Layout Drawing AT30 Battery Charger Style 163 with ALL options JE5098 99 http www ATSeries net PDFs JE5098 99 pdf ...

Page 82: ...y Alarm Relay PC Board JE5091 39 Note This instrument panel drawing JE5091 39 depicts the optional Auxiliary Alarm Relay PC Board A5 which provides two 2 sets of individual form c contacts TB4 for all alarm conditions Standard AT30 battery chargers feature one 1 set of form c summary common alarm contacts TB3 ...

Page 83: ...APPENDIX C Standard Drawings 79 Instrument Panel PC Board Detail AT30 Battery Charger with optional Auxiliary Alarm Relay PC Board JE5091 39 http www ATSeries net PDFs JE5091 39 pdf ...

Page 84: ...ns supplied Standard components A1 through VR7 are supplied in all such units A customized schematic featuring electrical ratings of applicable items is available for any AT30 based upon a quote or a manufactured unit For document availability please contact your sales representative with the model number options features and other specifications for the AT30 Series battery charger in question ...

Page 85: ...APPENDIX C Standard Drawings 81 Schematic AT30 Battery Charger Standard w o Options JE5092 00 http www ATSeries net PDFs JE5092 00 pdf ...

Page 86: ...dard components A1 through VR7 are supplied in all such units Optional components A5 through VR3 are supplied only in those AT30s configured with such options A customized schematic featuring electrical ratings of applicable items is available for any AT30 based upon a quote or a manufactured unit For document availability please contact your sales representative with the model number options feat...

Page 87: ...APPENDIX C Standard Drawings 83 Schematic AT30 Battery Charger with Common Options JE5092 99 http www ATSeries net PDFs JE5092 99 pdf ...

Page 88: ...ring code Please refer to the model number featured on the data nameplate and the supplied Parts Data Package report to identify by circuit symbol which components are applicable to each individual unit A customized connection diagram is available for any AT30 based upon a quote or a manufactured unit For document availability please contact your sales representative with the model number options ...

Page 89: ...APPENDIX C Standard Drawings 85 Connection Diagram AT30 Battery Charger Mainframe Power Wiring w Common Options JE5093 99 http www ATSeries net PDFs JE5093 99 pdf ...

Page 90: ...ckage 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 and wire list featured in this manual are not sufficient please contact your Sales Representative for drawing availability from the battery charger manufacturer ...

Page 91: ...APPENDIX C Standard Drawings 87 Connection Diagram AT30 Battery Charger Control Signal Wiring JE5094 00 http www ATSeries net PDFs JE5094 00 pdf ...

Page 92: ...ng 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 and wire list featured in this manual are not sufficient please contact your Sales Representative for drawing availability from the battery charger manufacturer ...

Page 93: ...APPENDIX C Standard Drawings 89 Connection Details AT30 Battery Charger I O Panels Rectifier Assemblies JE5163 00 http www ATSeries net PDFs JE5163 00 pdf ...

Page 94: ...battery types should not be used in ambient temperatures above 95 F 35 C and should not normally be equalized Consult your battery manufacturer s documentation for specific equalizing recommendations TEMPERATURE COMPENSATION If batteries are to see temperature variations during charging a temperature compensation option A10 is recommended If this option is not part of your charger manual adjustmen...

Page 95: ...unications Module option EJ5037 xx includes the Communication PC Board A12 external power supply resistor s R29x an Operating Instructions manual and a field retrofit instruction sheet JD5008 00 An unlabeled copy of the Communications Module Operations Manual is available for free online http www ATSeries net PDFs JA0102 04 pdf A compatible industry standard modem and modem cable are also availabl...

Page 96: ...ST button on the front panel of the charger When you release the button the version number is shown on the front panel display for two seconds The interconnecting signal cable length should be no more than 50ft 15m INSTALLING THE INTERCONNECTION CABLE The AT Series forced load sharing accessory is normally supplied by the factory with a standard 15ft 4 6m interconnection cable EH5041 00 A 25ft 7 6...

Page 97: ... 14 indicating the fault There is a delay of up to 4 seconds for chargers to establish forced load sharing communication If communication is broken or power is lost for one charger there is up to a 4 second delay for the other charger to resume independent operation If you need to interchange the Primary and Secondary chargers simply reverse the interconnection cable The presence of the interconne...

Page 98: ... readily available for downloading and printing For company specific private labeled manuals and or standard drawings please contact your sales representative or visit the web site listed on the back cover of this manual PARTS DATA PACKAGE Any job specific customized Parts Data Package report supplied with this battery charger and or this manual supercedes the information featured in the standard ...

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Page 100: ... 30 Setting Float Voltage Equalize Voltage Equalize Timer High DC Voltage Low DC Voltage Current Limit If you don t press any key for 25 seconds the AT30 resumes normal operation automatically Press the key The DC VOLTS and FLOAT indicators light and the digital display flashes the present float voltage setting Press the or key until the digital display indicates the desired float voltage Press th...

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