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Alcad AT30 SERIES User Manual

Alcad AT30 SERIES
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Operating and Service Instructions
AT30 SERIES
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

Table of Contents

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Alcad AT30 SERIES Specifications

General IconGeneral
Operating temperature-20°C to +50°C
Battery voltage12V, 24V
Input voltage50/60Hz
Output Voltage12V, 24V
Protection FeaturesShort circuit, Reverse Polarity

Summary

HOW TO READ THE ALCAD AT30 MODEL NUMBER

IMPORTANT SAFETY INSTRUCTIONS

1 Receiving and Installing the AT30 Battery Charger

1.4 Moving the AT30

Guidance on safely moving the AT30 unit, including weight and enclosure type considerations.

1.5 Mounting the AT30

Details on selecting and performing the appropriate mounting method for the AT30 enclosure.

1.5.1 Floor-Mounting the AT30 (standard)

Procedure and considerations for securely mounting the AT30 unit to the floor.

2 Operating the AT30 Battery Charger

2.1 Starting the AT30

Steps and procedures for safely starting the AT30 battery charger for the first time.

2.3 Setting the AT30 parameters

Detailed guide on adjusting various operating parameters of the AT30 charger.

2.4 Performing routine maintenance

Guidelines for regular maintenance tasks to ensure the AT30 operates reliably.

1.1. STORING THE AT30

1.2. REPORTING SHIPPING DAMAGE

Procedure for documenting and reporting any damage discovered upon delivery of the AT30.

1.3. UNPACKING AND INSPECTING THE AT30

Steps for removing the AT30 from packaging and performing an initial inspection for damage.

1.4. MOVING THE AT30

1.5 Mounting the AT30

1.5.1. Floor-Mounting the AT30 (standard)

Procedure and considerations for securely mounting the AT30 unit to the floor.

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

Guidelines and procedure for wall-mounting the AT30, including kit requirements.

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

Instructions for installing the AT30 unit into a standard EIA relay rack.

1.5 Mounting the AT30

PROCEDURE (Style-5030)

Steps for floor-mounting the AT30 in the Style-5030 enclosure.

PROCEDURE (Style-163)

Steps for floor-mounting the AT30 in the Style-163 enclosure.

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

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

1.6. CHANGING THE TRANSFORMER TAPS

1.7. MAKING THE AC INPUT CONNECTIONS

1.8. MAKING THE DC OUTPUT CONNECTIONS

1.9. WIRING THE AT30 FOR REMOTE SENSING

DISABLING REMOTE SENSE

1.10. WIRING TO THE REMOTE ALARM CONTACTS

Auxiliary Alarm Relay Board (optional)

PROCEDURE

Steps for wiring annunciators to the Auxiliary Alarm Relay Board.

1.11. INSTALLING THE TEMP. COMPENSATION PROBE (OPTIONAL)

INSTALLING AT30

Using temperature compensation

Explanation of how temperature compensation affects battery charging voltage and current.

INSTALLING AT30

1.12. INSTALLING FOR REMOTE COMMUNICATION (OPTIONAL)

Reference to separate instructions for optional remote communication setup.

1.13. INSTALLING FOR FORCED LOAD SHARING (OPTIONAL)

Reference to Appendix F for instructions on optional forced load sharing.

2. OPERATING THE AT30 BATTERY CHARGER

2.1.1. Understanding the startup sequence

Explanation of the AT30's initialization process and initial operation after power-up.

2.1.2. Checking the installation

Pre-startup checks to ensure correct installation, voltage, and polarity for the AT30.

2.1.3. Starting the AT30

Step-by-step guide to powering on and initiating operation of the AT30 battery charger.

OPERATING THE AT30

FACTORY SETTINGS FOR ALL PARAMETERS

Table showing default settings for float voltage, equalize voltage, alarms, and current limit.

2.2. USING THE AT30 FRONT PANEL FEATURES

2.2.1. If the meter displays an error message

Troubleshooting guide for interpreting and resolving error codes displayed on the AT30.

2.2.2. Selecting the meter mode

Instructions on changing the digital meter's display mode to show voltage, current, or equalize time.

2.2.3. Selecting the Float or Equalize mode

2.2.4. Choosing the Equalize method

Guide to selecting manual or automatic methods for equalize charging on the AT30.

Manual Equalize Method

Auto-Equalize Timer Method

Procedure for automatic equalize charging, detailing behavior during AC power interruptions.

2.2.5. Testing the front panel indicators

2.2.6. Testing the Auxiliary Relay Board (optional)

How to test the alarm relays on the optional Auxiliary Relay Board.

2.2.7. Interpreting the alarm indicators

Explanation of the AT30's front panel alarm indicators and their meanings.

2.3. SETTING PARAMETERS IN THE AT30

2.3.1. Understanding Parameter Settings

Overview of adjustable parameters and how changes are saved internally in the AT30.

2.3.2. Setting the Float and Equalize voltages

Step-by-step instructions for setting the float and equalize output voltages for the AT30.

2.3.2. Setting the Float and Equalize voltages

2.3.3. Setting the Equalize Timer

2.3.4. Setting the Alarms

Guide for configuring high and low DC voltage alarms and other fault indicators on the AT30.

Setting the High DC Voltage Alarm

Setting the low DC Voltage Alarm

Procedure for adjusting the low DC voltage alarm threshold on the AT30.

Adjusting Ground Detection Sensitivity

Using Ground Detection in Charger Standby Mode

Disabling the Ground Detection Alarm

Steps to disable the ground detection alarm circuit and isolate it from chassis ground.

2.3.5. Setting the current limit value

How to adjust the AT30's DC output current limit for overload protection.

2.3.6. Enabling the High DC Voltage shutdown feature

2.3.7. Adjusting the Voltmeter Accuracy

2.3.8. Using the Low Level Detector (LLD)

2.3.9. Using the front panel security feature

2.4. Performing routine maintenance

2.4.1. Keep it clean

Instructions for cleaning the AT30 charger to ensure proper cooling and operation.

2.4.2. Check power and signal connections

Procedure for verifying the security and condition of all electrical connections to the AT30.

2.4.3. Check remote sense wiring (optional)

Guidance for inspecting the remote sense wiring for proper function and condition.

2.4.4. Check temperature compensation probe (optional)

2.4.5. Measuring the output ripple voltage (filtered models only)

Procedure for measuring AC ripple voltage on filtered AT30 models.

2.4.6. Viewing the voltage and alarm settings

How to review current parameter settings like float voltage and alarms on the AT30.

SAMPLE PREVENTIVE MAINTENANCE PROCEDURE

Exercise front panel controls

Check voltage and alarm settings

Procedure for verifying voltage and alarm settings using the EDIT/ENTER key.

Final checks

Final steps in maintenance, including safety cover and latch checks.

3 SERVICING THE AT30

3.1. A STEP-BY-STEP TROUBLESHOOTING PROCEDURE

A systematic approach to diagnosing and resolving problems with the AT30 battery charger.

Determining the condition of the charger:

Key questions to ask and checks to perform to accurately assess the AT30's operational status.

3.2. INTERPRETING FRONT PANEL ERROR MESSAGES

E 01 Resistor R2 open or defective

Troubleshooting steps for an open or defective R2 resistor affecting AT30 parameters.

E 02 Short circuit on output

Procedure for diagnosing and resolving output short circuits or battery issues causing E 02 error.

E 03 High DC Voltage Shutdown

Steps to restart the AT30 after a high DC voltage shutdown and check alarm settings.

Error Code

E 04 Internal memory failure

Troubleshooting for AT30 internal memory failures, including potential replacement of the control board.

E 06 R4 or R14 is defective, or remote sense wiring failed

Diagnosing defective resistors or failed remote sense wiring causing E 06 error.

E 08 Defective temperature compensation probe

Diagnosing and resolving E 08 errors related to the temperature compensation probe or its wiring.

Error Code

E 09 Misadjusted current limit

Troubleshooting steps for E 09 error related to improperly adjusted current limit settings.

E 10 Open internal feedback loop

Diagnosing E 10 errors caused by an open internal feedback loop in the control circuit.

E 13 Internal over-temperature

Troubleshooting for E 13 errors indicating internal over-temperature conditions.

3.3. USING THE TROUBLESHOOTING CHART

Determining the condition of the charger:

Key questions to ask and checks to perform to accurately assess the AT30's operational status.

SYMPTOM

Front panel meter displays all segments "On" or all segments "Off." Charger may have no output.

Troubleshooting for AT30 front panel display issues and lack of output current.

AC breaker trips (or fuses clear) immediately

Troubleshooting steps for AC breaker trips or blown fuses occurring immediately after power-up.

AC breaker trips (or fuses clear) after a few minutes

Troubleshooting for AC breaker trips or blown fuses occurring after a few minutes of operation.

SYMPTOM

DC breaker trips (or fuses clear) immediately

Troubleshooting for DC breaker trips or blown fuses occurring immediately after power-up.

DC breaker trips (or fuses clear) after a few minutes

Troubleshooting for DC breaker trips or blown fuses occurring after a few minutes of operation.

SYMPTOM

No output current, and AC ON lamp is out, but ac and dc breakers are on

Troubleshooting for AT30 with no output current and AC ON lamp off.

No output current, but AC ON lamp is on, and ac and dc breakers are on

Troubleshooting for AT30 with no output current but AC ON lamp illuminated.

HIGH DC VOLTAGE indicator is on

Troubleshooting for the HIGH DC VOLTAGE indicator being illuminated on the AT30.

SYMPTOM

LOW DC VOLTAGE indicator is on, but ac and dc breakers are closed; ac input voltage is normal; there is output current

Troubleshooting for LOW DC VOLTAGE indicator with normal AC input and output current.

DC OUTPUT FAILURE indicator is on, but ac input voltage is normal, and ac & dc breakers are closed

Troubleshooting for DC OUTPUT FAILURE indicator with normal AC input and breakers.

SYMPTOM

AC INPUT FAILURE indicator is on

Troubleshooting for the AC INPUT FAILURE indicator being illuminated on the AT30.

POS GND or NEG GND indicator is on

Troubleshooting for POS GND or NEG GND indicators on the AT30, related to ground faults.

Summary alarm relay is in alarm mode, but no front panel alarm indicator is on

Troubleshooting when the summary alarm relay is active but no front panel indicator is lit.

3.5. REPLACING DEFECTIVE COMPONENTS

Removing the safety shield (if present)

Instructions for removing and reinstalling the plexiglas safety shield for component access.

Replacing the control circuit board (A1) and/or gate driver board (A15)

Replacing the ac input or dc output circuit breaker (CB1/CB2)

Steps for safely removing and replacing the AC input or DC output circuit breakers on the AT30.

Replacing the ac surge suppressors (VR2, VR4 or VR5)

Replacing the dc surge suppressor (VR1)

Procedure for replacing the DC surge suppressor on the AT30.

Replacing the dc surge suppressor networks (VR6/C4, VR7/C5)

Procedure for replacing DC surge suppressor networks on the AT30.

Replacing the power (ballast) resistor (R3) - 48 and 130 Vdc units only

Replacing resistors (R3, R4, R6 & R14) on the gate driver board (A15)

Procedure for replacing resistors soldered onto the AT30 gate driver board.

3.6. ORDERING REPLACEMENT PARTS

Symbol Description

APPENDIX A SPECIFICATIONS

APPENDIX B FIELD INSTALLABLE ACCESSORIES AND OPTIONS

Remote Temperature Compensation Probe

Details and ordering information for the temperature compensation probe assembly and cables.

APPENDIX C (Standard Drawings)

APPENDIX C (Standard Drawings)

APPENDIX C (Standard Drawings)

APPENDIX C (Standard Drawings)

APPENDIX C (Standard Drawings)

APPENDIX C (Standard Drawings)

APPENDIX C (Standard Drawings)

APPENDIX C (Standard Drawings)

APPENDIX C (Standard Drawings)

APPENDIX C (Standard Drawings)

APPENDIX C (Standard Drawings)

APPENDIX C (Standard Drawings)

APPENDIX C (Standard Drawings)

APPENDIX C (Standard Drawings)

APPENDIX C (Standard Drawings)

APPENDIX C (Standard Drawings)

APPENDIX C (Standard Drawings)

APPENDIX C (Standard Drawings)

APPENDIX C (Standard Drawings)

APPENDIX C (Standard Drawings)

APPENDIX C (Standard Drawings)

APPENDIX C (Standard Drawings)

APPENDIX C (Standard Drawings)

APPENDIX C (Standard Drawings)

APPENDIX D RECOMMENDED FLOAT AND EQUALIZE VOLTAGES

TEMPERATURE COMPENSATION

Explanation of temperature compensation for battery charging and how to adjust voltages.

APPENDIX E COMMUNICATIONS MODULE

APPENDIX F FORCED LOAD SHARING

SYSTEM REQUIREMENTS

Prerequisites and system requirements for implementing forced load sharing on AT30 chargers.

INSTALLING THE INTERCONNECTION CABLE

Procedure for installing the interconnecting cable for AT30 forced load sharing.

OPERATING CHARGERS WITH LOAD SHARING

WHEN TEMPERATURE COMPENSATION IS INSTALLED

Considerations for using temperature compensation when forced load sharing is active.

TROUBLE SHOOTING

Troubleshooting common issues with the AT Series Forced Load Sharing option.

MANUAL SPECIFICATIONS

COMMUNICATIONS MODULE

FORCED LOAD SHARING

SYSTEM REQUIREMENTS

Prerequisites and system requirements for implementing forced load sharing on AT30 chargers.

INSTALLING THE INTERCONNECTION CABLE

Procedure for installing the interconnecting cable for AT30 forced load sharing.

OPERATING CHARGERS WITH LOAD SHARING

WHEN TEMPERATURE COMPENSATION IS INSTALLED

Considerations for using temperature compensation when forced load sharing is active.

TROUBLE SHOOTING

Troubleshooting common issues with the AT Series Forced Load Sharing option.

MANUAL SPECIFICATIONS

QUICK OPERATION

Startup

Essential steps for powering on the AT30 battery charger after installation.

Changing between Float and Equalize Modes

How to switch the AT30 between float and equalize charging modes using the CHRG MODE key.

Setting

Steps for adjusting key AT30 operating parameters like float voltage and alarms via the front panel.