Alcad AT30 SERIES Training manual

Operating and 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.: [phone]
Fax: [phone]
www.alcadusa.com

HOW TO READ THE AT30 MODEL NUMBER
Your AT30 model number is coded to describe the options that are included. Please find the model
number on the data nameplate and write it in the spaces provided below. Then follow the chart to
determine the configuration of your battery charger.
AT30 -
- - -
ABCDEFGHJKLMNP
DESCRIPTION CODE FEATURE DESCRIPTION CODE FEATURE
ASERIES AT30 AT30 CHARGER 1STANDARD
012 12 Vdc 2MEDIUM AIC
024 24 Vdc 3HIGH AIC
048 48 Vdc
F
AC CIRCUIT
BREAKER
RATING
(SEE TABLE) 0NO AC BREAKER
B
NOMINAL
DC OUTPUT
VOLTAGE
130 130 Vdc 1SUPPLIED
CODE FEATURE CODE FEATURE GAC FUSES
(200 kAIC) 0NOT SUPPLIED
0025 25 Adc 0200 200 Adc 1STANDARD
0030 30 Adc 0250 250 Adc 2MEDIUM AIC
0040 40 Adc 0300 300 Adc 3HIGH AIC
0050 50 Adc 0400 400 Adc
H
DC CIRCUIT
BREAKER
RATING
(SEE TABLE) 0NO DC BREAKER
0075 75 Adc 0500 500 Adc 1SUPPLIED
0100 100 Adc 0600 600 Adc JDC FUSES
(20 kAIC) 0NOT SUPPLIED
0125 125 Adc 0800 800 Adc 3SUPPLIED
C
NOMINAL
DC OUTPUT
CURRENT
0150 150 Adc 1000 1000 Adc KAUX ALARM
RELAY BOARD 2NOT SUPPLIED
208 208 Vac 60 Hz 1SUPPLIED
240 240 Vac 60 Hz LGROUND BUS 0NOT SUPPLIED
480 480 Vac 60 Hz 1SUPPLIED
220 220 Vac 50/60 Hz MLIGHTNING
ARRESTOR 0NOT SUPPLIED
380 380 Vac 50/60 Hz 1FUNGUS PROOFING
DAC INPUT
VOLTAGE
416 416 Vac 50/60 Hz 2STATIC PROOFING
0UNFILTERED
NTREATMENTS
0NOT INCLUDED
1FILTERED1INSTALLED
EOUPUT
FILTERING
2BATTERY ELIMINATOR PNEMA-2 TYPE
DRIP SHIELD 0NOT 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
(208-600 Vac)
OPTIONAL DC
FUSE RATING
(12/24/48/130 Vdc)
SSTANDARD 5,000 AIC 5,000 AIC
MMEDIUM AIC 25,000 AIC 10,000 AIC 200,000 AIC 20,000 AIC
HHIGH AIC 65,000 AIC 25,000 AIC
* Contact your sales representative for 500-600 Vac circuit breaker AIC ratings.
NOTE:
The model number listed on the charger data nameplate does not include any field-installed
options. Also, certain accessories are not included in the model number, even if they are shipped with the
charger. Check off below any accessories that were included, or that you install yourself.
wall/rack mounting brackets zero-center ground detection meter w/test switch
NEMA-2 type drip shield end of discharge alarm relay
NEMA-4/12/13 type enclosure battery discharge alarm relay
cabinet heater strips barrier type auxiliary alarm terminal block
pad/key lock for front panel door external temperature compensation probe
analog ac voltmeter w/sel switch DNP3 Level 2 / Modbus communications module
analog ac ammeter w/sel switch forced load sharing interconnection cable
Please find the serial number on the
data nameplate and record it here:

IMPORTANT SAFETY INSTRUCTIONS
i
PLEASE READ AND FOLLOW
ALL SAFETY INSTRUCTIONS
1. Before using this equipment, read all instructions and cautionary
markings on: A) this equipment, B) battery, and C) any other equipment
to be used in conjunction with this equipment.
2. This manual contains important safety and operating instructions, and
therefore should be filed for easy access.
3. Remove all jewelry, watches, rings, etc. before proceeding with
installation or service.
4. Do not touch any uninsulated parts of this equipment, especially the
input and output connections, as there is the possibility of electrical
shock.
5. During normal operation, batteries may produce explosive gas. Never
smoke, use an open flame, or create arcs in the vicinity of this 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 arcing or burning.
9. De-energize all ac and dc inputs to the battery charger before servicing.
10. Do not operate battery charger if it has been damaged in any way. Refer
to qualified service personnel.
11. Do not disassemble battery charger. Only qualified service personnel
should attempt repairs. Incorrect reassembly may result in explosion,
electrical shock, or fire.
12. Do not install the battery charger outdoors, or in wet or damp locations
unless specifically ordered for that environment.
PLEASE READ AND FOLLOW
ALL SAFETY INSTRUCTIONS

TABLE OF CONTENTS
ii
QUICK OPERATION ..................................................................................................Back Cover
HOW TO READ THE AT30 MODEL NUMBER.............................................Inside Front Cover
IMPORTANT SAFETY INSTRUCTIONS ......................................................................................i
1Receiving and Installing the AT30 Battery Charger
1.1 Storing the AT30 ....................................................................................................2
1.2 Reporting shipping damage ...................................................................................2
1.3 Unpacking and inspecting the AT30 ......................................................................2
Inspection checklist................................................................................................2
1.4 Moving the AT30 ....................................................................................................3
Enclosure type and weight table............................................................................3
1.5 Mounting the AT30.................................................................................................4
1.5.1 Floor-Mounting the AT30 (standard)................................................................4
1.5.2 Wall-Mounting the AT30 (optional)..................................................................6
1.5.3 Rack-Mounting the AT30 (optional).................................................................8
1.6 Changing the transformer taps.............................................................................10
1.7 Making the ac input connections..........................................................................12
1.8 Making the dc output connections........................................................................14
1.9 Wiring the AT30 for remote sensing.....................................................................16
1.10 Wiring to the remote alarm contacts ....................................................................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
2Operating 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
2.1.3 Starting the AT30...........................................................................................24
Using the digital meter...................................................................................24
Factory settings table.....................................................................................25
2.2 Using the AT30 front panel features
2.2.1 If the meter displays an error message .........................................................26
2.2.2 Selecting the meter mode..............................................................................26
2.2.3 Selecting the Float or Equalize mode............................................................27
2.2.4 Choosing the Equalize method......................................................................27
Manual Timer method....................................................................................27
Manual Equalize method ...............................................................................28
Auto-Equalize Timer method.........................................................................28
2.2.5 Testing the front panel indicators...................................................................29
2.2.6 Testing the Auxiliary Relay Board (optional) .................................................29
2.2.7 Interpreting the alarm indicators....................................................................29

TABLE OF CONTENTS
iii
2.3 Setting the AT30 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............................................................34
Disabling the ground detection alarm ............................................................35
2.3.5 Setting the current limit value.........................................................................35
2.3.6 Enabling the high dc voltage shutdown feature.............................................36
2.3.7 Adjusting the Voltmeter accuracy ..................................................................37
2.3.8 Using the Low Level Detector (LLD)..............................................................38
2.3.9 Using the front panel security feature............................................................39
2.4 Performing routine maintenance ..........................................................................40
Sample preventive maintenance procedure.........................................................42
3Servicing the AT30 Battery Charger
3.1 A step-by-step troubleshooting procedure ...........................................................44
3.2 Interpreting front panel error messages ...............................................................45
3.3 Using the troubleshooting chart............................................................................48
3.4 Troubleshooting chart begins on..........................................................................49
3.5 Replacing defective components..........................................................................58
3.6 Ordering replacement parts..................................................................................62
APPENDIX A: AT30 Performance Specifications...................................................................64
APPENDIX B: Field Installable Accessories...........................................................................65
APPENDIX C: Standard Drawings *
AT30 Series Battery Charger Outline: NEMA-1 Style-5018 Enclosure........................................66
AT30 Series Battery Charger Outline: NEMA-1 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 Board.........78
AT30 Series Battery Charger Schematic -Standard w/o Options ...............................................80
AT30 Series Battery Charger Schematic -with Common Options...............................................82
AT30 Series Battery Charger Connection Diagram -Power Wiring w/Common Options ............84
AT30 Series Battery Charger Connection Diagram -Control Signal Wiring ................................86
AT30 Series Battery Charger Connection Details -I/O Panels & Rectifier Assemblies...............88
APPENDIX D: Recommended Float/Equalize Voltages / Temp. Compensation...............90
APPENDIX E: DNP3 Level 2 / Modbus Communications Module.........................................91
APPENDIX F: Forced Load Sharing.........................................................................................92
MANUAL SPECIFICATIONS (document control information / online availability) .....................94
* Note: A customized record drawing 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 featured in this manual are not sufficient, please contact your Sales Representative for
drawing availability from the battery charger manufacturer.

RECEIVING THE AT30
2
1. RECEIVING THE AT30
1.1. STORING THE AT30
If you store the AT30 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 32 to 122° F / 0 to 50° C
are acceptable. Storage should not exceed 2 years due to the limited shelf
life of the dc filter capacitors when they are not in service.
1.2. REPORTING SHIPPING DAMAGE
If, on delivery of the AT30 or related goods, you discover any damage or
shortage, make notation on all copies of delivering carrier's delivery
receipt before signing, and notify the delivery person of your findings. If
loss or damage is discovered after delivery, notify delivering carrier
immediately and request an inspection. The manufacturer does not assume
any liability for damage during transportation or handling.
Should the goods require an inspection by or return to the 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 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 materials from the AT30. Remove the
AT30 from the shipping pallet for inspection. Save all shipping materials
until you are sure that there is no shipping damage.
Once the AT30 is unpacked, inspect the unit for possible shipping
damage, using the checklist below. If shipping damage has occurred, refer
to Section 1.2 on this page for proper reporting.
INSPECTION CHECKLIST
oEnclosure exterior and interior are not marred or dented.
oThere is no visible damage to exterior or interior components.
oAll internal components are secure.
oPrinted circuit boards are firmly seated on their standoffs.
oAll hardware is tight.
oAll wire terminations are secure.
oThe User's Manual and Quick Setup Sheet are supplied.
oYou received all items on the packing list.

INSTALLING THE AT30
3
1.4. MOVING THE AT30
Once you have established that the AT30 is undamaged, identify the
enclosure style of your unit. Please refer to the table below.
Standard AT30 NEMA-1 Type Enclosures
( Style-5018 / Style-5030 / Style-163 / Style-198 )
Output Voltage
Ampere
Rating 12 Vdc 24 Vdc 48 Vdc 130 Vdc
25 Adc n/a n/a n/a Style-5018
30 Adc n/a n/a n/a Style-5018
40 Adc n/a n/a n/a Style-5018
50 Adc Style-5018 Style-5018 Style-5018 Style-5018
75 Adc Style-5018 Style-5018 Style-5018 Style-5018
100 Adc Style-5018 Style-5018 Style-5018 Style-5030
125 Adc Style-5030 Style-5030 Style-5030 Style-5030
150 Adc Style-5030 Style-5030 Style-5030 Style-5030
200 Adc Style-5030 Style-5030 Style-5030 Style-5030
250 Adc Style-5030 Style-5030 Style-5030 Style-163 *
300 Adc Style-5030 Style-5030 Style-5030 Style-163 *
400 Adc n/a Style-163 * Style-163 * Style-163 *
500 Adc n/a Style-163 * Style-163 * Style-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. Comprehensive
weight data for the AT30 product line is available in the product literature.
Enclosure Outline Drawing
Internal Layout Drawing
Style-5018 JE5085-00 JE5088-99
Style-5030 JE5086-00 JE5089-99
Style-163 JE5095-00 JE5098-99
Style-198 JE5096-00 JE5099-99
Standard AT30 NEMA-1 type enclosures do not feature lifting eyes for
moving. Instead, whenever possible move the unit with a forklift truck
using the supplied shipping pallet. To hoist the unit into a wall-mount or
rack-mount location, use a heavy-duty sling applicable to the enclosure
size and unit weight. To relocate the enclosure, use a forklift truck by
lifting the unit through the gap located between the cabinet mounting legs.

INSTALLING THE AT30
4
1.5. MOUNTING THE AT30
Chose the mounting method for the unit enclosure from the table below.
ENCLOSURE ENCLOSURE
MANUAL
SECTION
MOUNTING METHOD
Style-5018 Style-5030/163/198
1.5.1 Floor-Mounting STANDARD STANDARD
1.5.2 Wall-Mounting OPTIONAL n/a
19in / 483mm
Rack-Mounting n/a n/a
1.5.3 23-24in / 584-610mm
Rack-Mounting OPTIONAL n/a
1.5.1. Floor-Mounting the AT30 (standard)
To floor mount the AT30, you must consider the following:
1. Overall footprint of enclosure. Refer to the standard outlines drawing listed
in Appendix C, starting on Page 66.
2. The location:
• Should be free of drips and splatter. If dripping liquids are a problem,
install a drip shield. 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 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 conduit knockouts located on the sides (and sometimes top)
of the enclosure, featured on the standard outline drawings listed in
Appendix C, starting on Page 66.
PROCEDURE (Style-5018)
1. Install four (4) 0.25in / 6.4mm bolts into the floor per mounting dimensions
featured in the outline drawing (JE5085-00).
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 hardware (0.25in / 6.4mm), onto the floor-
mounting bolts and tighten securely.

INSTALLING THE AT30
5
PROCEDURE (Style-5030)
1. Install four (4) 0.375 / 9.5mm or 0.5in/12.7mm bolts into the floor per
mounting dimensions featured in the outline drawing (JE5086-00).
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 hardware (0.375 / 9.5mm or 0.5in/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 hardware (0.5in/12.7mm), onto the floor-
mounting bolts and tighten securely.
STANDARD NEMA-1 AT30 ENCLOSURE TYPES
Style-5018
see outline
JE5085-00
Style-5030
see outline
JE5086-00
Style-163
see outline
JE5095-00

INSTALLING THE AT30
6
1.5.2. Wall-Mounting the AT30 (Style-5018 enclosure only)
AT30 battery chargers housed in the floor-mounted Style-5018 enclosure
can be wall-mounted. You do not need to modify the standard Style-5018
enclosure for wall mounting, but a special wall-mounting kit (EI5008-00)
is required. For kit availability see ordering information in Appendix B on
page 65. The kit includes two (2) mounting brackets, hardware and special
instructions for the wall mounting procedure. In planning for wall
mounting of the AT30, you should consider the following:
1. The wall must be strong enough to properly support the weight of the AT30.
The weight of your AT30 may be different from the table value, depending
on options or accessories you ordered. See the Weight Table located in
Section 1.4 on page 3.
2. Placement of conduit entrances. Note the standard pre-fab conduit knockouts
located on 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 explosive materials.
4. Maintain at least 6in / 152mm of free air on top, bottom and both sides of the
enclosure for air cooling.
5. Allow 36in / 914mm front clearance for access to the charger for operation
and maintenance.
PROCEDURE
1. Install eight (8) 0.25in / 6.4mm bolts (not
supplied), rated to support the AT30
weight plus a safety factor of at least two
(2) times, onto the wall.
2. Place the AT30 Style-5018 enclosure onto
the mounted triangular brackets.
3. Use the supplied 0.25in / 6.4mm hardware
to mount the enclosure to the wall-
mounting brackets and tighten securely.
4. See the diagram on the opposite page for
the wall-mounted Style-5018 enclosure
footprint and mounting pattern.
5. Dimensions are in/mm.