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SERVICING THE AT10.1

44

3. SERVICING THE AT10.1

3.1. A STEP-BY-STEP TROUBLESHOOTING PROCEDURE

The AT10.1 is fully tested and calibrated from the factory, and should
work for years with a minimum of attention. If you do encounter trouble,
there are three (3) steps you should take to identify the problem and return
the AT10.1 to service.

1. Check the front panel meter for an error code. The microprocessor control

circuitry is able to diagnose common problems with the AT10.1, or with the
installation or application. If the front panel displays an error code, see
Section 3.2,

Interpreting Front Panel Error Messages

, for help in

interpreting the code and solving the problem.

2. If the AT10.1 does not work properly, but there is no front panel error code,

shut the unit down. Turn off (open) both front panel circuit breakers, and/or
lock out ac and dc power externally. Restart the AT10.1 by restoring dc
power

first

, followed by ac power second. This will return the AT10.1 to

normal operation as long as there is no internal component failure.

NOTICE

Perform Step 2 only once. If the AT10.1 does not resume
normal operation, go on to Step 3.

3. If the AT10.1 still does not work properly, make a list of the symptoms that

you observe. Turn to

Using the troubleshooting chart

in Section 3.3. The

troubleshooting chart relates common trouble symptoms to their causes, and
gives the proper procedures for correcting the problem.

4. If the symptom does not appear on the troubleshooting chart, or if the

recommended repair does not work, consult your sales or service
representative to arrange for on-site or factory service.

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Содержание AT10.1 SERIES

Страница 1: ...ons AT10 1SERIES MICROPROCESSOR CONTROLLED FLOAT BATTERY CHARGER SINGLE PHASE INPUT GROUP II 30 100 Adc OUTPUT Address N56 W16665 Ridgewood Drive Menomonee Falls WI 53051 Tel 800 554 2243 Fax 262 703...

Страница 2: ...OOFING X NOT APPLIED 380 380 Vac 50 60 Hz S APPLIED E AC INPUT VOLTAGE 416 416 Vac 50 60 Hz P STATIC PROOFING X NOT APPLIED DESCRIPTION CODE FEATURE DESCRIPTION CODE FEATURE INPUT AND OUTPUT INTERRUPT...

Страница 3: ...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 o...

Страница 4: ...ces 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 re...

Страница 5: ...rect reassembly may result in explosion electrical shock or fire 8 Do not install the AT10 1 outdoors or in wet or damp locations unless specifically ordered for that environment 9 Do not use the AT10...

Страница 6: ...Alarm Relay PC Board optional 19 1 11 Installing the temperature compensation probe optional 20 Using temperature compensation 22 1 12 Installing the AT10 1 for remote communications optional 23 1 13...

Страница 7: ...es 71 APPENDIX C Standard Drawings Outline AT10 1 Group II Battery Charger NEMA 1 Style 5017 Enclosure 72 Outline AT10 1 Group II Battery Charger NEMA 1 Style 5018 Enclosure 74 Internal Component Layo...

Страница 8: ...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 origina...

Страница 9: ...pproximately 20 lbs 9kg below listed shipping weight in table The Style 5017 Style 5018 enclosures do not feature top lifting eyes for moving Move the AT10 1 with a forklift whenever possible using th...

Страница 10: ...ckouts located on the sides of the enclosures 4 The location Should be free of drips and splatter If falling particles and liquids are a problem install NEMA 2 type drip shield accessory EI0191 01 For...

Страница 11: ...ated to support the unit weight plus a safety factor of at least two 2 times into the wall Place the AT10 1 on the anchor bolts add appropriate mounting hardware and tighten securely Refer to the grap...

Страница 12: ...1 02 For kit availability see ordering information in Appendix B on page 71 Should be between 0 and 122 F 18 and 50 C with relative humidity between 5 and 95 non condensing Must be free of flammable o...

Страница 13: ...0 1 above the anchor bolts using the methods described in Section 1 4 Guide the enclosure onto the floor bolt pattern and lower it into place Add appropriate mounting hardware to the anchor bolts and...

Страница 14: ...130 Vdc 40 75 Adc n a EI0193 03 MOUNTING KIT When rack mounting the AT10 1 consider the following 1 The rack must be strong enough to properly support the weight of the AT10 1 See the Weight Table loc...

Страница 15: ...scissor lift guide the AT10 1 into the gap of the relay rack Adjust height and mount in place using appropriate hardware not supplied PROCEDURE Style 5018 Refer to the detailed Instructions JA0091 03...

Страница 16: ...ltage NOTICE Do not attempt to rewire the 480Vac transformer If a different ac input voltage for the AT10 1 is desired please contact your sales representative for ordering replacement parts T1 CB1 VR...

Страница 17: ...ac jumper setting 240 Vac H1 H3 H2 H5 H2 H4 2 JUMPERS H2 H3 2 JUMPERS 6 If your transformer is supplied with two 2 jumpers always use both as specified in the table 7 NOTICE If you are changing from 1...

Страница 18: ...ac input current of the AT10 1 This rating is listed on the left hand side of the AT10 1 data nameplate For a comprehensive list of these maximum ac input values access standard DC5016 00 NOTICE If y...

Страница 19: ...other components mounted to the I O panel Be careful not to disconect any other component leads 2 Conduit must be properly grounded and in compliance with the national wiring rules of the country wher...

Страница 20: ...3 1 Volt drop 2 The AT10 1 is factory wired to regulate the output voltage at the output terminals If the total voltage drop is greater than 1 e g 1 3V for a 130 Vdc system remote sense wiring is reco...

Страница 21: ...UTPUT CONNECTIONS GRAPHICS CAUTION NOTES 1 The drawing above does not show other components mounted to the I O panel Be careful not to disconect any other component leads 2 Always use a proper ground...

Страница 22: ...e sense terminals to the battery terminals The AT10 1 control circuitry then measures the dc voltage at the battery terminals and controls the output of the charger to maintain the battery voltage at...

Страница 23: ...un 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 1 De energize and lock out all ac and dc...

Страница 24: ...cess will be trimmed 2 Route annunciator wires to the AT10 1 front panel door by following the existing harness through the door hinge as shown Use two 2 wire ties and allow a 4 6in 102 153mm loop for...

Страница 25: ...20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 PROCEDURE 1 Deenergize and lock out all ac and dc voltages to the AT10 1 2 Allow internal voltages to dissipate then check with a voltmeter 3 Remove...

Страница 26: ...inside the enclosure Do not attempt to work inside the AT10 1 unless you are a qualified technician or electrician Disconnect and lock out all power from the AT10 1 before starting to remove or replac...

Страница 27: ...rness to the back of the front panel and easily reaches the Main Control PC Board A1 At the Main Control PC Board A1 insert one of the bare wires from the cable into each terminal of TB8 Polarity is n...

Страница 28: ...s to normal non temperature compensated operation until the probe or wiring is repaired Once the probe is repaired you must restart the AT10 1 to activate the probe as described in Section 2 1 Using t...

Страница 29: ...ge is correct If the battery temperature goes below 32 F 0 C there will be no further increase in AT10 1 output voltage Likewise if the battery temperature goes above 122 F 50 C there is no further de...

Страница 30: ...he AT10 1 When you are sure that all connections to the AT10 1 are properly made follow these steps to start up the AT10 1 Using the Digital Meter When you first start the AT10 1 the meter display alt...

Страница 31: ...t CB2 will trip when you try to turn it on This is caused by the dc filter capacitors C1 C2 discharging into the battery To get around this problem turn off the ac breaker and restart the AT10 1 by tu...

Страница 32: ...n Yes E 16 remote shutdown Yes A 01 manual equalize enabled for more than 24 hours Yes A 02 equalize mode inhibited No A 04 voltmeter calibration inhibited w TempCo active No A 05 dc output at Current...

Страница 33: ...t Three 3 equalize methods are available in the AT10 1 Manual Timer Manual Equalize Auto Equalize Timer These equalize methods are described below Manual Timer Method Choose the manual timer method if...

Страница 34: ...ode automatically and the EQLZ indicator lights At the end of the equalize charging time that you select the AT10 1 reverts automatically to the float mode and the FLOAT indicator lights At any time d...

Страница 35: ...r 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 DS14 lights whenever the dc output voltage is below t...

Страница 36: ...s the desired reading 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 T...

Страница 37: ...ators 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 U...

Страница 38: ...l the AT10 1 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 settings of the high dc voltage and lo...

Страница 39: ...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...

Страница 40: ...ing a test resistor to the AT10 1 de energize and lock out all ac and dc voltage sources Check with a voltmeter before proceeding Restart the AT10 1 only when necessary to make the sensitivity adjustm...

Страница 41: ...vious page Move the jumper to the DISABLE position The POS GND and NEG GND indicators and the summary alarm relay TB3 will not respond to a ground fault Restart the AT10 1 following the instructions i...

Страница 42: ...ss and hold the UP key then Press the CHRG MODE key The HIGH DC VOLTAGE indicator lights and the display flashes ON You can toggle the shutdown feature OFF and ON by pressing the CHRG MODE key repeate...

Страница 43: ...tically and any change made to the last setting is not saved After successfully exiting Edit Mode you may adjust the voltmeter accuracy Press and hold the UP key then press the EQLZ MTHD key The DC VO...

Страница 44: ...ry Alarm Relay PC Board 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 PC Board A1 fi...

Страница 45: ...high dc voltage shutdown feature To disable the front instrument panel keys open the AT10 1 door and locate the small plastic jumper J9 on the right side of the Main Control PC Board A1 See the figur...

Страница 46: ...st is conductive carefully vacuum out the interior Clean the surfaces of circuit boards and clean around electrical terminals The AT10 1 is rated for operation up to 122 F 50 C If your installation is...

Страница 47: ...ry Ampere hour capacity is at least four 4 times the output current rating of the AT10 1 the ripple voltage should be no higher than the value featured in the specifications in Appendix A on page 70 I...

Страница 48: ...tery or dc bus are tight and corrosion free OK OK OK Check ac input voltage Measure between TB1 L1 and TB1 L2 using an ac voltmeter Value must be within 10 12 of nominal voltage Input Vac Check dc out...

Страница 49: ...l through settings See page 30 FLOAT OK EQUALIZE OK HVDC alarm OK LVDC alarm OK Current Limit _ Adc Final checks Make sure Plexiglas safety shield is in place Restore AT10 1 to normal operation Close...

Страница 50: ...roperly but there is no front panel error code shut the unit down Turn off open both front panel circuit breakers and or lock out ac and dc power externally Restart the AT10 1 by restoring dc power fi...

Страница 51: ...he AT10 1 according to Section 2 1 E 02 short circuit on dc output The AT10 1 may display this error code if the battery is discharged to less than 6 Volts When the battery re charges to greater than...

Страница 52: ...iring failure You should respond to this problem quickly to make sure the AT10 1 regulates the output voltage properly Wire an annunciator e g buzzer to the summary alarm relay contact TB3 for remote...

Страница 53: ...rmostats S2x has detected an over temperature condition If the rectifier is equipped with fans B2x check all fans for proper operation Also make sure that all enclosure vents are clear of debris and t...

Страница 54: ...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...

Страница 55: ...ansformer 1 Disconnect wire 6 from the right side SCR module Q2 or at the main power transformer T1 X1 Measure the resistance between the ac bottom terminals of the SCR modules Q1 Q2 checking both pol...

Страница 56: ...d less than 1 000 in the other polarity If it is defective replace the polarity diode CR1 5 Check spacing of terminals Check wiring for signs of insulation damage burns etc Repair as necessary DC brea...

Страница 57: ...er 8 Defective inductor L1 or L2 9 Defective dc output circuit breaker CB2 1 This is normal operation in a charger battery system with little or no dc load As long as the AT10 1 maintains Float voltag...

Страница 58: ...lue replace R3 2 Remove the clear safety shield Check the wiring to and from TB1 and the Main Control PC Board A1 for signs of insulation damage or burns Repair any damaged wiring AT10 1 output voltag...

Страница 59: ...Main Control PC Board A1 AT10 1 never reaches Float or Equalize voltage within 1 1 Current limit set too low 2 Defective battery or dc load or load is too great 3 Wrong ac voltage or Vac too low or T1...

Страница 60: ...tery Ampere hours rating which is four 4 times the charger Ampere rating For a smaller battery ripple may be higher 4 Shut down the AT10 1 and wait several minutes to allow capacitors to discharge Ope...

Страница 61: ...this option it is normal for one of the units to have no dc output current You can check the operation of the off AT10 1 by increasing its Float voltage until it starts to deliver dc output current W...

Страница 62: ...cuit breaker CB2 DC OUTPUT FAILURE indicator is on ac dc breakers CB1 CB2 are closed ac input voltage is normal 1 Defective SCR module 2 Defective Main Control PC Board A1 3 Defective transformer T1 4...

Страница 63: ...3 4 for details 4 Turn off both front panel circuit breakers or lock out ac and dc power externally if the AT10 1 has fuses only Disconnect the AT10 1 from the battery and dc bus Restart the AT10 1 M...

Страница 64: ...he standard drawings in Appendix C for information on identifying internal components Removing the safety shield AT10 1 Style 5017 and Style 5018 enclosures feature a Plexiglas safety shield as a seco...

Страница 65: ...l with the same orientation and push them onto the standoffs Make sure the board is fully seated on all ten 10 standoffs Reconnect the signal wire harness plug J18 to the Gate Driver PC Board A11 matc...

Страница 66: ...lock out all power to the AT10 1 Open the door and remove the safety shield Disconnect the battery from the output terminals Remove the hardware from the output terminal TB1 and remove the lead of th...

Страница 67: ...stors R4 R6 and R14 are soldered directly onto the Gate Driver PC Board A11 In 12 Vdc and 24 Vdc AT10 1s rated 30 100 Adc R3 is also soldered directly onto A11 See detail of the Gate Driver PC Board A...

Страница 68: ...3 1 REPLACEMENT PARTS Factory Part Number Reference Designator Description 12 Vdc 24 Vdc 48 Vdc 130 Vdc Rec Spare A1 Main Control PC Board EN5002 00 EJ1243 10 Y A5 Auxiliary Relay PC Board EN0027 00 E...

Страница 69: ...50W EJ1127 13 500 100W R4 Positive External Scaling Resistor RJ0056 48 3160 RJ0056 81 6980 RJ0075 14 14 0 k RJ0075 56 38 3 k R6 Voltage Crowbar Resistor RJ0063 76 RJ0064 11 RJ0064 41 RJ0064 80 R9 Fil...

Страница 70: ...2 EJ5031 27 EJ5031 32 EJ5031 37 75 Adc EJ5031 23 EJ5031 28 EJ5031 33 EJ5031 38 100 Adc EJ5031 24 EJ5031 29 EJ5031 34 n a Table 3 4 STANDARD AC CIRCUIT BREAKERS CB1 120 Vac Current Rating 12 Vdc 24 Vdc...

Страница 71: ...100 Adc RE0171 04 RE0171 09 RE0171 12 n a Table 3 8 MEDIUM AMPERE INTERRUPTING CAPACITY AC BREAKERS CB1 208 240 Vac Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 30 Adc RE0171 00 RE0171 00 RE0171 01 RE...

Страница 72: ...dc RE0043 00 RE0043 01 RE0043 04 RE0219 09 75 Adc RE0043 00 RE0043 02 RE0043 07 RE0219 12 100 Adc RE0043 01 RE0043 04 RE0043 09 n a Table 3 12 HIGH AMPERE INTERRUPTING CAPACITY AC CIRCUIT BREAKERS CB1...

Страница 73: ...00 Adc RE0008 08 RE0008 11 RE0008 13 n a Table 3 16 STANDARD DC CIRCUIT BREAKERS CB2 Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 30 Adc RE0015 30 RE0015 30 RE0015 30 RE0015 30 40 Adc RE0015 31 RE0015...

Страница 74: ...Adc RE0061 21 RE0061 21 RE0061 21 RE0061 21 75 Adc RE0061 23 RE0061 23 RE0061 23 RE0061 23 100 Adc RE0061 26 RE0061 26 RE0061 26 n a Table 3 20 MAIN INDUCTOR L1 Current Rating 12 Vdc 24 Vdc 48 Vdc 13...

Страница 75: ...MAIN TRANSFORMER T1 120 208 240 Vac Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 30 Adc AB1545 10 AB1569 10 AB1613 10 AB1589 10 40 Adc AB1561 10 AB1541 10 AB1597 10 AB1601 10 50 Adc AB1561 10 AB1541 10...

Страница 76: ...age per NEMA PE5 1996 Battery Eliminator Filter Option without battery 30 mV rms 100 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...

Страница 77: ...Relay Rack Mtg Kit for Style 5018 Enclosure 23 24in 584 610mm EI0193 03 NEMA Type 2 Drip Shield for Style 5017 Style 5018 Enclosure EI0191 01 02 Cabinet Heater Strips for Style 5017 Enclosure EJ5041...

Страница 78: ...APPENDIX C 72 Outline AT10 1 Group II Battery Charger NEMA 1 Style 5017 Enclosure JE5025 00...

Страница 79: ...APPENDIX C 73 http www ATSeries net PDFs JE5025 00 pdf...

Страница 80: ...APPENDIX C 74 Outline AT10 1 Group II Battery Charger NEMA 1 Style 5018 Enclosure JE5026 00...

Страница 81: ...APPENDIX C 75 http www ATSeries net PDFs JE5026 00 pdf...

Страница 82: ...OTICE This internal component layout drawing JE5028 99 depicts an AT10 1 Series battery charger housed in a Style 5017 enclosure with ALL available options Standard components A1 through VR7 are suppl...

Страница 83: ...APPENDIX C 77 http www ATSeries net PDFs JE5028 99 pdf...

Страница 84: ...OTICE This internal component layout drawing JE5029 99 depicts an AT10 1 Series battery charger housed in a Style 5018 enclosure with ALL available options Standard components A1 through VR7 are suppl...

Страница 85: ...APPENDIX C 79 http www ATSeries net PDFs JE5029 99 pdf...

Страница 86: ...arm Relay PC Board JE5030 29 NOTICE This instrument panel drawing JE5030 29 depicts the optional Auxiliary Alarm Relay PC Board A5 which provides two 2 sets of discreet form C contacts TB4 for the mai...

Страница 87: ...APPENDIX C 81 http www ATSeries net PDFs JE5030 29 pdf...

Страница 88: ...APPENDIX C 82 Schematic AT10 1 Group II Battery Charger Standard w o Options JE5032 00...

Страница 89: ...APPENDIX C 83 http www ATSeries net PDFs JE5032 00 pdf...

Страница 90: ...APPENDIX C 84 Schematic AT10 1 Group II Battery Charger w Common Options JE5032 99...

Страница 91: ...APPENDIX C 85 http www ATSeries net PDFs JE5032 99 pdf...

Страница 92: ...APPENDIX C 86 Connection Diagram AT10 1 Group II Battery Charger Standard w o Options JE5034 00...

Страница 93: ...APPENDIX C 87 http www ATSeries net PDFs JE5034 00 pdf...

Страница 94: ...APPENDIX C 88 Connection Diagram AT10 1 Group II Battery Charger w Common Options JE5034 99...

Страница 95: ...APPENDIX C 89 http www ATSeries net PDFs JE5034 99 pdf...

Страница 96: ...d batteries 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 TE...

Страница 97: ...s Communications Module Operating Instructions JA0102 04 and field installation instructions JD5008 00 are also provided for user support A field retrofit kit p n EJ5037 1 for AT Series Communications...

Страница 98: ...view the program version press the LAMP TEST button on the front instrument panel of the AT10 1 When you release the button the front panel meter displays the version number for 2 seconds The interco...

Страница 99: ...e independent operation If you need to interchange the Primary and Secondary chargers simply reverse the interconnection cable The presence of the interconnection cable with proper orientation forces...

Страница 100: ...ere installed The ground wire must be approved for use in the country in which the AT10 1 is installed or bear the W HAR X mark A separate bi color ground wire green with a 30 yellow stripe must be ru...

Страница 101: ...USER NOTES 95...

Страница 102: ...ut 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 av...

Страница 103: ...ATSeries net PDFs JA0092 02 pdf AT10 1 Style 5018 NEMA 2 Drip Shield JA0108 01 http www ATSeries net PDFs JA0108 01 pdf AT10 1 St 5017 5018 Cab Padlock Acsy JA5060 01 http www ATSeries net PDFs JA5060...

Страница 104: ...lead you through a quick setup of the industry s most USER FRIENDLY battery charger Address N56 W16665 Ridgewood Drive Menomonee Falls WI 53051 Tel 800 554 2243 Fax 262 703 3073 Online www SBSBattery...

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