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SBS AT10.1 series Operating And Service Instructions

Float battery charger single phase input group ii (30 - 100 adc output)
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Operating and Service Instructions
AT10.1
SERIES
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:
262-703-3073
Online:
www.SBSBattery.com

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  • Page 1 Operating and Service Instructions AT10.1 SERIES 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: 262-703-3073 Online: www.SBSBattery.com...

  • Page 2: How To Read The At10.1 Model Number

    HOW TO READ THE AT10.1 MODEL NUMBER GROUP II RATINGS (30-100 Adc) The AT10.1 configured model number is coded to describe the unit's features and options. Please identify the model number printed on the data nameplate decal, and write it in the spaces provided below. AT10 Follow the chart below to determine the configuration of the AT10.1.

  • Page 3: Manufacturer's Warranty

    MANUFACTURER'S WARRANTY FIVE-YEAR WARRANTY NEW PRODUCT - BATTERY CHARGER [applies only to product(s) delivered within the 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.
  • Page 4 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.

  • Page 5: Important Safety Instructions

    IMPORTANT SAFETY INSTRUCTIONS PLEASE READ AND FOLLOW ALL SAFETY INSTRUCTIONS NOTICE 1. Before using the AT10.1, read all instructions and cautionary markings on: A) this equipment, B) battery, and C) any other equipment to be used in conjunction with the AT10.1. 2.

  • Page 6: Table Of Contents

    TABLE OF CONTENTS HOW TO READ THE AT10.1 MODEL NUMBER........Inside Front Cover MANUFACTURER'S WARRANTY.............. Removable Form IMPORTANT SAFETY INSTRUCTIONS................i Receiving and Installing the AT10.1 Battery Charger Storing the AT10.1..................2 Reporting shipping damage................2 Unpacking and inspecting the AT10.1 ..............2 Inspection checklist..................2 Moving the AT10.1..................3 Enclosure type and weight table ..............3 Mounting the AT10.1..................3...
  • Page 7 TABLE OF CONTENTS Setting the AT10.1 parameters 2.3.1 Understanding parameter settings ............30 2.3.2 Setting the Float and Equalize voltages ........... 31 2.3.3 Setting the Equalize timer ............... 32 2.3.4 Setting the Alarms .................. 32 Setting the high and low dc voltage alarms..........33 Adjusting ground detection sensitivity ............

  • Page 8: Storing The At10.1

    RECEIVING THE AT10.1 1. RECEIVING THE AT10.1 1.1. STORING THE AT10.1 If you store the AT10.1 for more than a few days before installation, you should store it in its original shipping container, and in a temperature controlled, dry climate. Ambient temperatures of 0 to 122 °F / -18 to 50 °C are acceptable.

  • Page 9: Moving The At10.1

    INSTALLING THE AT10.1 1.4. MOVING THE AT10.1 Once you have established that the AT10.1 is undamaged, identify the enclosure style and weight of your unit. Refer to the table below. AT10.1 Enclosure Style and Shipping Weight Table Group II NEMA-1 Cabinets (Style-5017 / Style-5018) Ampere Rating Output Voltage...

  • Page 10: Wall-Mounting The At10.1

    INSTALLING THE AT10.1 1.5.1. Wall-Mounting the AT10.1 Wall-mounting is the standard means of installing the AT10.1 Style-5017 enclosure. When wall-mounting the AT10.1, consider the following: 1. Refer to the outline drawing (JE5025-00) in Appendix C on page 72 for the overall footprint of the Style-5017 enclosure.
  • Page 11 INSTALLING THE AT10.1 PROCEDURE (Style-5017 enclosure) To wall-mount the AT10.1, install eight (8) 0.25in / 6.4mm anchor bolts, rated 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.

  • Page 12: Floor-Mounting The At10.1

    INSTALLING THE AT10.1 1.5.2. Floor-Mounting the AT10.1 Floor-mounting is the standard means of installing the AT10.1 Style-5018 enclosure. When floor-mounting the AT10.1, consider the following: 1. Refer to the outline drawing (JE5026-00) in Appendix C on page 74 for the overall footprint of the Style-5018 enclosure.
  • Page 13 INSTALLING THE AT10.1 PROCEDURE (Style-5018 enclosure) To floor-mount the AT10.1, install four (4) 0.25in / 6.4mm anchor bolts into the floor. Carefully lift the AT10.1 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.

  • Page 14: Rack-Mounting The At10.1

    INSTALLING THE AT10.1 1.5.3. Rack-Mounting the AT10.1 The AT10.1 can be installed in most relay racks with standard EIA hole spacing. The Style-5017 and Style-5018 enclosures do not need to be modified for rack mounting, but a special kit (EI0193-0#) is required. For kit availability see the ordering information in Appendix B on page 71.
  • Page 15 INSTALLING THE AT10.1 PROCEDURE (Style-5017) Refer to the detailed Instructions (JA0091-02) supplied with the kit. • Make sure the side manual pocket is removed. • Attach the two (2) rack-mounting brackets to the sides of the Style-5017 enclosure, using the supplied 0.25in / 6.4mm hardware, and tighten securely. •...

  • Page 16: Changing Transformer Taps

    INSTALLING THE AT10.1 1.6. CHANGING THE TRANSFORMER TAPS AT10.1s (30-100 Adc Group II ratings) are normally designed for a single ac input supply voltage. Verify the ac voltage listed on the data nameplate CAUTION decal, and the tag attached to the ac input circuit breaker (CB1).
  • Page 17 INSTALLING THE AT10.1 PROCEDURE 1. Shut down the AT10.1 and verify that no internal voltages are present. 2. See Section 3.5 for necessary steps to follow when accessing internal components within the AT10.1. 3. Refer to the images below and indentify the primary "taps" (T1-H1 through T1-H5) of the power isolation transformer.

  • Page 18: Making The Ac Input Connections

    INSTALLING THE AT10.1 1.7. MAKING THE AC INPUT CONNECTIONS WARNING The AT10.1 is a commercial product, and not intended for use in a residential environment, or to be powered by low-voltage public mains. It is the responsibility of the installer of the AT10.1 to provide suitable ac supply wiring.
  • Page 19 INSTALLING THE AT10.1 MAKING THE AC INPUT 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. Conduit must be properly grounded, and in compliance with the national wiring rules of the country where installed.

  • Page 20: Making The Dc Output Connections

    INSTALLING THE AT10.1 1.8. MAKING THE DC OUTPUT CONNECTIONS It is the responsibility of the installer of the AT10.1 to provide suitable dc output, battery, and dc load wiring. Follow these steps to connect the battery to the AT10.1: 1. Size the dc wiring to minimize voltage drop. The acceptable wire size depends on your installation.
  • Page 21 INSTALLING THE AT10.1 MAKING THE DC OUTPUT 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. 3.

  • Page 22: Wiring The At10.1 For Remote Sensing

    INSTALLING THE AT10.1 1.9. WIRING THE AT10.1 FOR REMOTE SENSING You can wire the AT10.1 to regulate the output voltage at the battery terminals, instead of at the charger output terminals (TB1+/-). Remote sensing provides the following: 1. Compensates for voltage drop in the dc wiring between the AT10.1 and the battery.
  • Page 23 INSTALLING THE AT10.1 4. Move wire # 36 from TB1(-) to REM SENSE(-). 5. Move wire # 38 from TB1(+) to REM SENSE (+). 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.

  • Page 24: Wiring To The Remote Alarm Contacts

    INSTALLING THE AT10.1 1.10. WIRING TO THE REMOTE ALARM CONTACTS Built-in Summary "Common" Alarm Relay (standard) The AT10.1 Main Control PC Board (A1) is equipped with a "common" Summary Alarm relay. This relay contact transfers when any one or more of the standard AT10.1 alarms exist.

  • Page 25: Auxiliary Alarm Relay Pc Board (Optional)

    INSTALLING THE AT10.1 Auxiliary Alarm Relay PC Board (optional) The optional Auxiliary Alarm Relay PC Board (A5), mounted on the right side panel of the circuit breaker bracket, provides two (2) form-C contacts (TB4-1 through TB4-36) for each of the following individual alarms: •...

  • Page 26: Installing The Temperature Compensation Probe (Optional)

    INSTALLING THE AT10.1 1.11. INSTALLING THE TEMPCO PROBE ASSEMBLY (OPTIONAL) The temperature compensation (or TempCo) probe contains a temperature-dependent resistor in an epoxy module that you install near your battery. There are three (3) steps in installing the assembly: 1. Mounting the probe assembly near the battery. 2.
  • Page 27 INSTALLING THE AT10.1 • Run the cable though a conduit if possible, but not through a conduit containing any power wiring. • Route the other end to the probe at the battery and coil up excess cable. NOTICE If the standard (25ft / 7.6m) cable is not long enough, longer cable assemblies are available in lengths of 50, 100 &...

  • Page 28: Using Temperature Compensation

    INSTALLING THE AT10.1 8. Check your work. Confirm that: • All connections are secure. • The shield is connected to ground at the charger end only (A1-J6). • The cable is connected to the 2-position terminal block (TB8) on the Main Control PC Board (A1).

  • Page 29: Installing The At10.1 For Remote Communications (Optional)

    INSTALLING THE AT10.1 Note the following: • You should set the Float and Equalize voltages to the values recommended by your battery manufacturer for 77 °F / 25 °C. • When you enter the Edit Mode to adjust the Float or Equalize voltage (see Section 2.3.2), the front panel meter displays 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.

  • Page 30: Operating The At10.1 Battery Charger

    OPERATING THE AT10.1 2. OPERATING THE AT10.1 BATTERY CHARGER 2.1. STARTING THE AT10.1 2.1.1. Understanding the startup sequence The AT10.1 is set up at the factory to work with most common batteries and loads without further adjustment. When you start the AT10.1 for the first time, the factory settings (float voltage, equalize voltage, etc.) control the operation of the charger.

  • Page 31: Factory Settings Table

    OPERATING THE AT10.1 • If you have an optional temperature compensation probe installed, the front panel displays Pb during startup, indicating that temperature compensation is set up for lead-acid battery types. 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.

  • Page 32: Using The At10.1 Front Panel Features

    OPERATING THE AT10.1 2.2. USING THE AT10.1 FRONT PANEL FEATURES 2.2.1. If the meter displays an error or status message The AT10.1 microprocessor control circuitry performs diagnostic checks of the battery charger during system start-up, then continuously during operation. If it detects a failure (E ##) or special status (A ##), an intermittent code will appear on the front instrument panel, displayed between dc output values.

  • Page 33: Selecting The Float Or Equalize Mode

    OPERATING THE AT10.1 • When the AT10.1 starts initially, the meter alternates, displaying output voltage and output current. The DC VOLTS and DC AMPERES indicators light alternately to indicate what is being displayed. 2.2.3. Selecting the Float or Equalize mode The AT10.1 has two (2) output voltage settings, Float and Equalize.

  • Page 34: Manual Equalize Method

    OPERATING THE AT10.1 Manual Equalize Method Choose the manual equalize method when you want to equalize charge the battery, but only when you are able to monitor the battery voltage and gassing rate. After you select the manual equalize method, press the key to put the AT10.1 into the equalize mode.

  • Page 35: Testing The Front Panel Indicators

    OPERATING THE AT10.1 2.2.5. Testing the front panel indicators • Press the key. This is also the key. DOWN LAMP TEST The meter will display 8888, and all status & alarm indicators will light. key does not test the AC ON indicator. The AC ON LAMP TEST indicator lights whenever ac power is present, and the ac circuit breaker is turned on.

  • Page 36: Setting The At10.1 Parameters

    OPERATING THE AT10.1 2.3. SETTING PARAMETERS IN THE AT10.1 2.3.1. Understanding Parameter Settings You can change the settings of the AT10.1 while it is operating, using the front panel controls. The changes you make take effect immediately, and are saved internally. If the AT10.1 is taken out of service, and then later returned to service, it restarts using the last values you set.

  • Page 37: Setting The Float And Equalize Voltages

    OPERATING THE AT10.1 2.3.2. Setting the Float and Equalize voltages • Press the key. EDIT/ENTER The FLOAT and DC VOLTS indicators light, and the display flashes the present value of the float voltage. Press and release the key to DOWN increase or decrease the value in the display by one count, or press and hold the key to scroll the value in the display upward or...

  • Page 38: Setting The Equalize Timer

    OPERATING THE AT10.1 2.3.3. Setting the Equalize Timer • Press the key until the EQLZ HRS REMAINING, EDIT/ENTER MANUAL TIMER and AUTO EQLZ TIMER indicators light, and the display flashes the present value of the equalize timer duration in hours. Press and release the key to increase or decrease the value in DOWN...

  • Page 39: Setting The High And Low Dc Voltage Alarms

    OPERATING THE AT10.1 Setting the High DC Voltage Alarm • Press the key until the HIGH DC VOLTAGE indicator EDIT/ENTER flashes, and the display flashes the present value of the high dc voltage alarm. Press and release the key to increase or decrease the value in DOWN the display by one count, or press and hold the key to scroll...

  • Page 40: Adjusting Ground Detection Sensitivity

    OPERATING THE AT10.1 Adjusting Ground Detection Sensitivity The AT10.1 ground detection alarm Ω sensitivity is adjustable from 5 to 30 k . You must have a small jeweler's screwdriver for adjustment, along with a "test resistor" whose Ohmic value is sized for the required ground sensitivity.

  • Page 41: Disabling The Ground Detection Alarm

    OPERATING THE AT10.1 Using Ground Detection in Charger Standby Mode If you put the AT10.1 into standby mode by opening the dc circuit breaker (CB2), the ground detection circuit will send an erroneous positive (+) ground fault alarm. There are two (2) ways to work around this: •...

  • Page 42: Enabling The High Dc Voltage Shutdown Feature

    OPERATING THE AT10.1 2.3.6. Enabling the High DC Voltage shutdown feature The AT10.1 has a built-in High DC Voltage Shutdown feature. In case of any maladjustment or internal failure that results in a continuous output voltage that is too high, the AT10.1 shuts down after 30 seconds to protect the battery.

  • Page 43: Adjusting The Voltmeter Accuracy

    OPERATING THE AT10.1 2.3.7. Adjusting the Voltmeter Accuracy The AT10.1 voltmeter is adjusted at the factory to display the actual dc output voltage within ±0.25%. If you replace any component that affects meter accuracy, such as the Main Control PC Board (A1) or R4, you should readjust the meter.

  • Page 44: Using The Low Level Detector (Lld)

    OPERATING THE AT10.1 2.3.8. Using the Low Level Detector (LLD) The AT10.1 is equipped with a summary (common) alarm relay safety override circuit. This feature forces the alarm relay contact to transfer, sending an alarm, even if there is a catastrophic failure of the AT10.1 control circuitry.

  • Page 45: Using The Front Panel Security Feature

    OPERATING THE AT10.1 2.3.9. Using the front panel security feature The AT10.1 is shipped from the factory with all the front instrument panel keys enabled. You can disable the following front panel functions: • Selecting Equalize method • Changing settings using the EDIT/ENTER •...

  • Page 46: Performing Routine Maintenance

    OPERATING THE AT10.1 2.4. PERFORMING ROUTINE MAINTENANCE WARNING High voltages appear at several points inside the AT10.1. Use extreme caution when working 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 replace any components.
  • Page 47 OPERATING THE AT10.1 2.4.4. Check temperature compensation probe (optional) If you are using the optional temperature compensation probe, confirm the probe (A10) is securely installed. Make sure the connectors and the wiring from the probe to the AT10.1 are in satisfactory condition. If there is a failure of the temperature compensation probe, or the wiring, the AT10.1 displays the error code E 08.

  • Page 48: Sample Preventive Maintenance Procedure

    OPERATING THE AT10.1 SAMPLE PREVENTIVE MAINTENANCE PROCEDURE AT10.1 BATTERY CHARGER (JD0064-00) Suggested Frequency: every six (6) months Maintenance date Performed by WARNING High voltages appear at several points inside the AT10.1. Use extreme caution when working inside the enclosure. Do not attempt to work inside the AT10.1 unless you are a qualified technician or electrician.
  • Page 49 OPERATING THE AT10.1 • Switch from float to equalize, then back Exercise front to float. panel controls • Turn off the dc circuit breaker. E 07 may appear on display (requires at least 5% of rated output current). Reset breaker. •...

  • Page 50: A Step-By-Step Troubleshooting Procedure

    SERVICING THE AT10.1 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.

  • Page 51: Interpreting Front Panel Error Messages

    SERVICING THE AT10.1 3.2. INTERPRETING FRONT PANEL ERROR MESSAGES If the AT10.1 control circuitry detects hardware or wiring problems, it may display an error code on the front panel meter. Certain non-error status codes are also displayed. To solve an error code problem, refer to the table below, which lists the codes and procedures to use.
  • Page 52 SERVICING THE AT10.1 Error Meaning Repair Procedure Code Any parameters that you set, such as Float or Equalize voltage, are saved internal memory E 04 internally. The internal memory is tested on startup. If the memory test failure fails, E 04 appears on the front display. The error may also appear if the controller was trying to write to the memory while a power failure occured.
  • Page 53 SERVICING THE AT10.1 Error Meaning Repair Procedure Code Disconnect the wiring at the probe and measure the resistance across the defective E 08 quick-connect leads with an Ohmmeter. The resistance should measure temperature approximately 10,000 Ω at normal room temperature (77 °F / 25 °C). If the compensation probe reads open or shorted, it needs to be replaced.

  • Page 54: Using The Troubleshooting Chart

    SERVICING THE AT10.1 3.3. USING THE TROUBLESHOOTING CHART WARNING High voltages appear at several points inside the AT10.1. Use extreme caution when working 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 replace any components.

  • Page 55: Troubleshooting Chart Begins On

    SERVICING THE AT10.1 3.4. TROUBLESHOOTING CHART PROBABLE SYMPTOM RECOMMENDED ACTION CAUSE Front panel 1. An external 1A. Soft Reset of control board by pressing S7 reset switch. meter surge has S7 is located inside the AT10.1, on the control board’s right displays all interrupted edge (as viewed from the rear of the front panel).
  • Page 56 SERVICING THE AT10.1 PROBABLE SYMPTOM RECOMMENDED ACTION CAUSE DC breaker 1. Battery 1. Check battery wiring. Correct if necessary. (CB2) trips, or connected with dc fuses reverse polarity F3/F4 clear, 2. Defective 2. Test by disconnecting wire # 6 from the right side heat sink- immediately rectifier bridge mounted SCR module (Q2), or if possible at the other end from...
  • Page 57 SERVICING THE AT10.1 PROBABLE SYMPTOM RECOMMENDED ACTION CAUSE No output 1. Site ac supply 1. If AC ON indicator is out, check the external (site) feeder circuit current, but failure breaker or input fuses. AC ON lamp 2. Optional ac 2.
  • Page 58 SERVICING THE AT10.1 PROBABLE SYMPTOM RECOMMENDED ACTION CAUSE Front panel is 1. Control pc 1. Confirm the Gate Driver PC B oard (A11-P17) is firmly dead, but ac boards connected to the Main Control PC Board (A1-J17). Confirm & dc voltages (A1/A11) not the signal harness plug is firmly inserted into the Gate Driver are present at...
  • Page 59 SERVICING THE AT10.1 PROBABLE SYMPTOM RECOMMENDED ACTION CAUSE Output 1. Temperature 1. If the optional temperature compensation probe is installed, voltage does compensation the output voltage may be different from the selected float or not agree probe is equalize voltage. See Section 1.11, Step 11. The difference with front installed in voltages depends on the probe temperature.
  • Page 60 SERVICING THE AT10.1 PROBABLE SYMPTOM RECOMMENDED ACTION CAUSE Input current 1. Wrong ac 1. Confirm the primary taps (T1-H#) are wired correctly for your input voltage. See Section 1.6, Changing Transformer Taps. The too high voltage, or Vac too low, or T1 actual ac input voltage must be at least 88% of the rated value for mis-wired the AT10.1 to produce full output power.
  • Page 61 SERVICING THE AT10.1 PROBABLE SYMPTOM RECOMMENDED ACTION CAUSE Lamp Test key 1. No Vac 1. The Lamp Test key does not work during an ac power failure. does not work, 2. Main Control 2. Open the AT10.1 front panel door. Confirm the Main Control or some LEDs PC Board (A1) is PC Board (A1) is securely mounted to the nylon standoffs.
  • Page 62 SERVICING THE AT10.1 PROBABLE SYMPTOM RECOMMENDED ACTION CAUSE LOW DC 1. Battery is 1. After an ac power failure, or battery discharge for any other VOLTAGE discharged reason, it may take several hours to recharge the battery. It is normal for the LOW DC VOLTAGE indicator to be on until the indicator is on battery voltage is above the Low DC Voltage alarm setting.
  • Page 63 SERVICING THE AT10.1 PROBABLE SYMPTOM RECOMMENDED ACTION CAUSE AC INPUT 3. Defective 3. Measure ac voltage at the transformer primary taps (T1-H1 FAILURE wiring and T1-H5). It should be the same as the ac input supply indicator is on voltage. (continued) 4.

  • Page 64: Replacing Defective Components

    SERVICING THE AT10.1 3.5. REPLACING DEFECTIVE COMPONENTS WARNING High voltages appear at several points inside the AT10.1. Use extreme caution when working 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 replace any components.
  • Page 65 SERVICING THE AT10.1 Replacing the Main Control (A1) and/or Gate Driver (A11) PC Boards For details of this procedure, refer to Service Instruction (JD5012-00). NOTICE Printed circuit boards are sensitive to damage from static discharges. Leave replacement boards in their anti-static bags until you are ready to install them. Ground yourself before handling the board, by touching the ground stud on the back of the door.
  • Page 66 SERVICING THE AT10.1 Replacing the ac surge suppressors (VR2, VR4 or VR5) Shut down and lock out all power to the AT10.1. Open the door and remove the safety shield. Disconnect the battery from the output terminals. For VR2, remove the hardware from the input terminal L1, and remove the lead of the ac surge suppressor.
  • Page 67 SERVICING THE AT10.1 Replacing the power (ballast) resistor (R3) - 48 and 130 Vdc units only For 48 Vdc and 130 Vdc AT10.1s rated 30-100 Adc, resistor R3 is mounted with metal brackets onto the back panel of the enclosure. Cut wires # 49 and # 55, connected to R3, as close to the resistor leads as possible.

  • Page 68: Ordering Replacement Parts

    Please provide the following information for each component: • Model number and serial number of your AT10.1 Series battery charger • Reference Designator, factory part number and description • Quantity required...
  • Page 69 SERVICING THE AT10.1 Reference Factory Part Number Rec. Description Designator Spare 12 Vdc 24 Vdc 48 Vdc 130 Vdc Polarity Diode (30, 40 & 50 Adc ratings) EJ5106-00 Polarity Diode (75 Adc rating) EJ5106-01 Polarity Diode (100 Adc rating) RK0017-14 Free-Wheeling Diode (30/40/50 Adc ratings) EJ5108-00 Free-Wheeling Diode (75 Adc rating)
  • Page 70 SERVICING THE AT10.1 Table 3-2: DC FILTER ASSEMBLIES - STANDARD (L2/C1/R9/CR1) Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 30 Adc EJ5031-00 EJ5031-05 EJ5031-10 EJ5031-15 40 Adc EJ5031-01 EJ5031-06 EJ5031-11 EJ5031-16 50 Adc EJ5031-02 EJ5031-07 EJ5031-12 EJ5031-17 75 Adc EJ5031-03 EJ5031-08 EJ5031-13...
  • Page 71 SERVICING THE AT10.1 Table 3-6: STANDARD AC CIRCUIT BREAKERS (CB1) - 480 Vac Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 30 Adc RE0015-03 RE0015-03 RE0015-04 RE0015-06 40 Adc RE0015-03 RE0015-04 RE0015-04 RE0015-07 50 Adc RE0015-03 RE0015-04 RE0015-05 RE0015-09 75 Adc RE0015-04...
  • Page 72 SERVICING THE AT10.1 Table 3-10: HIGH AMPERE INTERRUPTING CAPACITY AC CIRCUIT BREAKERS (CB1) - 120 Vac Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 30 Adc RE0043-00 RE0043-01 RE0043-04 RE0043-09 40 Adc RE0043-00 RE0043-02 RE0043-05 RE0043-12 50 Adc RE0043-00 RE0043-04 RE0043-07...
  • Page 73 SERVICING THE AT10.1 Table 3-14: AC INPUT FUSES (F1A/F1B) - 208/240 Vac Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 30 Adc RE0061-08 RE0061-09 RE0061-12 RE0061-16 40 Adc RE0061-08 RE0061-11 RE0061-13 RE0061-21 50 Adc RE0061-09 RE0061-12 RE0061-14 RE0061-21 75 Adc RE0061-11 RE0061-13...
  • Page 74 SERVICING THE AT10.1 Table 3-18: HIGH AMPERE INTERRUPTING CAPACITY DC CIRCUIT BREAKERS (CB2) Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc 30 Adc RE0043-07 RE0043-07 RE0043-07 RE0043-07 40 Adc RE0043-08 RE0043-08 RE0043-08 RE0043-08 50 Adc RE0043-10 RE0043-10 RE0043-10 RE0043-10 75 Adc RE0043-12...
  • Page 75 SERVICING THE AT10.1 Table 3-22: RATING RESISTOR (R2) Current Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc EJ1133-00 EJ1133-05 EJ1133-10 EJ1133-15 30 Adc 34.8 kΩ 13.0 kΩ 5.11 kΩ 1.50 kΩ EJ1133-01 EJ1133-06 EJ1133-11 EJ1133-16 40 Adc 40.2 kΩ 15.4 kΩ...

  • Page 76: Appendix A: At10.1 Performance Specifications

    APPENDIX A SPECIFICATIONS Except as noted, all specifications apply at: 77 °F / 25 °C, nominal ac line voltage & nominal float voltage 12 Vdc 24 Vdc 48 Vdc 130 Vdc Specification Conditions Vac +10%, -12% ± 0.25% 0 to 100% load Output voltage regulation Frequency 60 ±...

  • Page 77: Appendix B: Field Installable Accessories

    APPENDIX B FIELD INSTALLABLE ACCESSORIES AND OPTIONS All options and accessories listed below are available in kits for field installation. Kits contain all parts and hardware with detailed installation instructions. To order accessories/options, please provide the following information for each kit: •...

  • Page 78: Outline: At10.1 Group Ii Battery Charger Nema-1 Style-5017 Enclosure

    APPENDIX C Outline: AT10.1 Group II Battery Charger NEMA-1 Style-5017 Enclosure (JE5025-00)
  • Page 79 APPENDIX C http://www.ATSeries.net/PDFs/JE5025-00.pdf...

  • Page 80: Outline: At10.1 Group Ii Battery Charger Nema-1 Style-5018 Enclosure

    APPENDIX C Outline: AT10.1 Group II Battery Charger NEMA-1 Style-5018 Enclosure (JE5026-00)
  • Page 81 APPENDIX C http://www.ATSeries.net/PDFs/JE5026-00.pdf...

  • Page 82: Internal Component Layout: At10.1 Style-5017 Enclosure W/Common Options

    Style-5017 Enclosure w/Common Options (JE5028-99) NOTICE 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 supplied in all such units. Optional components (A5...
  • Page 83 APPENDIX C http://www.ATSeries.net/PDFs/JE5028-99.pdf...

  • Page 84: Internal Component Layout: At10.1 Style-5018 Enclosure W/Common Options

    Style-5018 Enclosure w/Common Options (JE5029-99) NOTICE 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 supplied in all such units. Optional components (A5...
  • Page 85 APPENDIX C http://www.ATSeries.net/PDFs/JE5029-99.pdf...

  • Page 86: Instrument Panel / Pc Board Detail: At10.1 Group Ii Battery Charger

    APPENDIX C Instrument Panel / PC Board Detail: AT10.1 Group II Battery Charger w/Optional Auxiliary Alarm 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 main AT alarm conditions.
  • Page 87 APPENDIX C http://www.ATSeries.net/PDFs/JE5030-29.pdf...

  • Page 88: Schematic: At10.1 Group Ii Battery Charger - Standard W/O Options

    APPENDIX C Schematic: AT10.1 Group II Battery Charger Standard w/o Options (JE5032-00)
  • Page 89 APPENDIX C http://www.ATSeries.net/PDFs/JE5032-00.pdf...

  • Page 90: Schematic: At10.1 Group Ii Battery Charger - With Common Options

    APPENDIX C Schematic: AT10.1 Group II Battery Charger w/Common Options (JE5032-99)
  • Page 91 APPENDIX C http://www.ATSeries.net/PDFs/JE5032-99.pdf...

  • Page 92: Connection Diagram: At10.1 Group Ii Battery Charger - Standard W/O Options

    APPENDIX C Connection Diagram: AT10.1 Group II Battery Charger Standard w/o Options (JE5034-00)
  • Page 93 APPENDIX C http://www.ATSeries.net/PDFs/JE5034-00.pdf...

  • Page 94: Connection Diagram: At10.1 Group Ii Battery Charger - With Common Options

    APPENDIX C Connection Diagram: AT10.1 Group II Battery Charger w/Common Options (JE5034-99)
  • Page 95 APPENDIX C http://www.ATSeries.net/PDFs/JE5034-99.pdf...

  • Page 96: Appendix D: Recommended Float/Equalize Voltages / Temp. Compensation

    APPENDIX D RECOMMENDED FLOAT AND EQUALIZE VOLTAGES This table contains suggested values for commonly used batteries. Consult your battery manufacturer's documentation for specific values and settings for your battery type. Recommended Recommended Battery Cell Type Float Voltage/cell Equalize Voltage/cell Antimony (1.215 Sp. Gr.) 2.17 2.33 Antimony (1.250 Sp.

  • Page 97: Appendix E: Dnp3 Level 2 / Modbus Communications Module

    APPENDIX E COMMUNICATIONS MODULE ONLINE SUPPLEMENTS http://www.ATSeries.net/PDFs/JA0102-04.pdf Operating Instructions http://www.ATSeries.net/PDFs/JD5008-00.pdf Field Installation OVERVIEW Your AT10.1 Microprocessor-controlled Float Battery Charger features provisions for an optional Communications Module, which allows user's to remotely monitor and control the charger over a serial connection. This option supports DNP3 Level 2 and Modbus protocols over RS-232 or RS-485 half-duplex.

  • Page 98: Appendix F: Forced Load Sharing

    SYSTEM REQUIREMENTS • The forced load sharing feature is designed only to work with two (2) AT10.1 Series battery chargers. You cannot force load sharing with three (3) or more AT10.1s. •...

  • Page 99: Trouble Shooting

    APPENDIX F OPERATING THE AT10.1 WITH FORCED LOAD SHARING Restore external power connections to both AT10.1s, and restart according to the normal procedure in the AT10.1 Operating and Service Instructions. After the AT10.1s restart, the Primary charger attempts to establish communication with the Secondary. If communication is successful, the AT10.1s behave as follows: •...

  • Page 100: Appendix G: Ce Grounding Compliance

    APPENDIX G CE COMPLIANCE - PROPER GROUNDING • It is the responsibility of the installer of the AT10.1 to supply suitable grounding and approved ground wire. • The AT10.1 chassis must be grounded in accordance with the national electrical codes of the country where installed. •...
  • Page 101 USER NOTES...

  • Page 102: Manual Specifications

    MANUAL SPECIFICATIONS DOCUMENT NUMBER The text and graphics contained within this manual are controlled by the battery charger manufacturer's internal part number (JA5018-00). The revision level and dates of this manual's text and graphics are listed below. These controls supercede all other available dates. The first two and last two pages of this manual are reserved for company-specific front and back cover artwork.
  • Page 103 MANUAL SPECIFICATIONS RELATED DOCUMENTS Doc. No. Online Hyperlink Description http://www.ATSeries.net/PDFs/JA0102-01.pdf JA0102-01 AT10.1 G1 Manual (unlabeled) http://www.ATSeries.net/PDFs/JA0102-02.pdf JA0102-02 AT10.1 G2 Manual (unlabeled) http://www.ATSeries.net/PDFs/JA0102-03.pdf JA0102-03 AT30 Manual (unlabeled) http://www.ATSeries.net/PDFs/JA0102-04.pdf JA0102-04 AT Comm. Module Manual (unlabeled) http://www.ATSeries.net/PDFs/JA0102-05.pdf JA0102-05 AT-DC Dist Panel Manual (unlabeled) http://www.ATSeries.net/PDFs/JC5020-01.pdf JC5020-01 AT Series Charger Quick Setup Sheet...
  • Page 104 QUICK SET-UP Scan this QR Code… …for a handy guide which will 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.com JA5059-02 - Rev.

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