Pivot ATLAS User manual

MODULAR SWITCH MODE
BATTERY CHARGER / POWER SUPPLY
USER’S MANUAL
Important Safety,
Installation,
Operation, and
Maintenance
Instructions

ATLAS 2 of 44 User’s Manual
TABLE OF CONTENTS
TABLE OF CONTENTS..............................................................................................................................2
IMPORTANT SAFETY INSTRUCTIONS....................................................................................................3
1. INTRODUCTION.................................................................................................................................5
2. THEORY OFOPERATION................................................................................................................6
3. RECEIVING AND INSTALLING THE CHARGER.............................................................................6
4. AC INPUT ...........................................................................................................................................9
5. DC OUTPUT.......................................................................................................................................9
6. BATTERY TEMPERATURE SENSOR............................................................................................10
7. USER INTERFACE MODULE (UIM)...............................................................................................11
7.1. User Interface Module (UIM)...................................................................................................11
7.2. Digital Meter...........................................................................................................................12
8. CHARGER OPERATION.................................................................................................................13
9. LED INDICATORS...........................................................................................................................14
9.1. UIM LEDs...............................................................................................................................14
9.2. iPM Bi-Color LED ...................................................................................................................15
10. ETHERNET COMMUNICATION......................................................................................................15
10.1. Direct Local Communication .................................................................................................15
10.2. Networked Remote or Local Communication ........................................................................16
10.3. Manual (Static) Mode .............................................................................................................16
10.4. Changing the Ethernet Port Settings .....................................................................................17
10.5. Automatic (DHCP) Mode ........................................................................................................18
10.6. Restoring the Factory-Default Ethernet Port Settings............................................................19
11. WEB SERVER..................................................................................................................................19
11.1. Dashboard .............................................................................................................................19
11.2. Configuration >> System Settings.........................................................................................22
11.3. Configuration >> Charge Settings .........................................................................................22
11.4. Configuration >> Alarm Settings ...........................................................................................25
11.5. Configuration >> Date and Time Settings ..............................................................................27
11.6. Configuration >> Ethernet Settings >> Ethernet Port.............................................................27
11.7. Configuration >> Ethernet Settings >> SNMP ........................................................................28
11.8. Configuration >> User Accounts ...........................................................................................28
11.9. Configuration >> Upgrades....................................................................................................30
11.10. History ...................................................................................................................................31
11.11. Logout ...................................................................................................................................34
12. MAINTENANCE................................................................................................................................34
13. TROUBLESHOOTING AND SERVICING.......................................................................................34
13.1. ATLAS Charger Troubleshooting Chart.................................................................................35
13.2. UIM Replacement Information................................................................................................38
13.3. Service Parts List...................................................................................................................39
14. CHARGER WIRE DIAGRAMS ........................................................................................................40
15. SPECIFICATIONS............................................................................................................................42

ATLAS 3 of 44 User’s Manual
IMPORTANT SAFETY INSTRUCTIONS
1. SAVE THESE INSTRUCTIONS –This manual contains important safety and operating instructions.
Keep it in a location where it is available to anyone who may operate the charger.
2. Before using battery charger, read all instructions and cautionary markings on battery charger,
battery, and product using battery.
LOOK FOR THIS SYMBOL TO POINT OUT SAFETY PRECAUTIONS.
IT MEANS: BE ALERT—YOUR SAFETY IS INVOLVED. IF YOU DO
NOT FOLLOW THESE SAFETY INSTRUCTIONS, INJURY OR
PROPERTY DAMAGE CAN OCCUR.
3. DANGER: TO REDUCE THE RISK OF FIRE OR ELECTRIC SHOCK, CAREFULLY READ AND
FOLLOW THESE IMPORTANT SAFETY AND OPERATING INSTRUCTIONS BEFORE INSTALLING
OR OPERATING THE CHARGER.
4. INSTRUCTIONS IMPORTANTES CONCERNANT LA SECURITÉ.
5. WARNING: TO REDUCE THE RISK OF FIRE, INSTALL THIS BATTERY CHARGER ON A
SURFACE OF NON-COMBUSTIBLE MATERIAL.
6. DANGER: RISK OF ELECTRIC SHOCK. DISCONNECT CHARGER FROM BATTERY AND AC
POWER BEFORE SERVICING. TURNING OFF THE CHARGER DOES NOT REDUCE THIS RISK.
7. DANGER: RISK OF ELECTRIC SHOCK. DO NOT TOUCH UNINSULATED PORTION OF AC OR
DC CONNECTORS OR UNINSULATED BATTERY TERMINAL.
8. DANGER: RISQUE DE CHOCKS ÉLECTRIQUES. NE PAS TOUCHER LES PARTIES NON
ISOLÉES DU CONNECTEUR DE SORTI OU LES BORNES NON ISOLÉES DE L’ACCUMULATEUR.
9. CAUTION: CHARGE ONLY BATTERIES OF THE SAME TYPE, VOLTAGE, CELL NUMBER, AND
AMP-HOUR CAPACITIES AS THE CHARGER IS CONFIGURED FOR. OTHER TYPES OF
BATTERIES MAY BURST CAUSING PERSONAL INJURY AND DAMAGE. BEFORE CHARGING
ANY OTHER TYPE OF RECHARGEABLE BATTERY, CHANGE THE CHARGER
CONFIGURATION/SETTINGS AS RECOMMENDED BY THAT BATTERY MANUFACTURER.
10. ATTENTION: UTILISER POUR CHARGER UNIQUEMENT LES ACCUMULATEURS AU PLOMB À
ELECTROLYTE LIQUIDE. D’AUTRES TYPES D’ACCUMULATEURS POURRAIENT ÉCLATER ET
CAUSER DES.
11. DANGER: TO PREVENT ELECTRICAL SHOCK, DO NOT TOUCH EITHER AC OR DC
UNINSULATED PARTS. MAKE SURE ALL ELECTRICAL CONNECTORS ARE IN GOOD WORKING
CONDITION. DO NOT USE CONNECTORS THAT ARE CRACKED, CORRODED OR DO NOT MAKE
ADEQUATE ELECTRICAL CONTACT. USE OF A DAMAGED OR DEFECTIVE CONNECTOR MAY
RESULT IN A RISK OF OVERHEATING OR ELECTRIC SHOCK.
12. WARNING: HAZARD OF ELECTRIC SHOCK.

ATLAS 4 of 44 User’s Manual
13. WARNING: BATTERIES GENERATE EXPLOSIVE GASES. TO PREVENT ARCING OR
BURNING NEAR BATTERIES, DO NOT DISCONNECT DC CHARGING CORD FROM BATTERIES
WHEN THE CHARGER IS OPERATING. KEEP SPARKS, FLAME, AND SMOKING MATERIALS
AWAY FROM BATTERIES.
14. WARNING: ALWAYS SHIELD EYES WHEN WORKING NEAR BATTERIES. DO NOT PUT
WRENCHES OR OTHER METAL OBJECTS ACROSS BATTERY TERMINAL OR BATTERY TOP.
ARCING OR EXPLOSION OF THE BATTERY CAN RESULT.
15. WARNING: BATTERIES PRODUCE HYDROGEN GAS, WHICH CAN EXPLODE IF IGNITED.
NEVER SMOKE, USE AN OPEN FLAME, OR CREATE SPARKS NEAR THE BATTERY. VENTILATE
THE AREA WHEN THE BATTERY IS CHARGING IN AN ENCLOSED PLACE.
16. WARNING: BATTERIES CONTAIN CAUSTIC MATERIAL, WHICH MAY CAUSE BURNS. DO
NOT GET IN EYES, ON SKIN, OR CLOTHING. IF CONTACT WITH THE EYES OCCURS, FLUSH
IMMEDIATELY WITH CLEAN WATER FOR 15 MINUTES AND OBTAIN MEDICAL ATTENTION.
17. WARNING: DE-ENERGIZE ALL AC AND DC POWER CONNECTIONS BEFORE SERVICING
THIS UNIT. IF INJURY DOES OCCUR, APPLY STANDARD TREATMENT FOR ELECTRICAL SHOCK
AND, IF NECESSARY, CONSULT WITH A PHYSICIAN.
18. WARNING: THE CHARGER IS NOT FOR OUTDOOR USE. DO NOT EXPOSE THE CHARGER
TO RAIN OR SNOW.
19. CAUTION: DO NOT OPERATE THE CHARGER IF IT HAS RECEIVED A SHARP BLOW, BEEN
DROPPED, OR OTHERWISE DAMAGED. HAVE A QUALIFIED SERVICE TECHNICIAN EXAMINE
AND REPAIR AS NEEDED.
20. WARNING: DO NOT DISASSEMBLE THE CHARGER. HAVE THE CHARGER EXAMINED BY A
NATIONAL RAILWAY SUPPLY SERVICE AGENT. INCORRECT RE-ASSEMBLY OF THE CHARGER
MAY RESULT IN AN EXPLOSION, ELECTRIC SHOCK, OR FIRE.
21. CAUTION: MAKE SURE THE BATTERY SYSTEM HAS THE PROPERLY RATED VOLTAGE,
AMP-HOURS, AND TYPE FOR THIS CHARGING SYSTEM.
SAVE THESE INSTRUCTIONS
This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to
part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful
interference when the equipment is operated in a commercial environment. This equipment generates, uses
and can radiate radio frequency energy and, if not installed and used in accordance with the instruction
manual, may cause harmful interference to radio communications. Operation of this equipment in a
residential area is likely to cause harmful interference in which case the user will be required to correct the
interference at his own expense.

ATLAS 5 of 44 User’s Manual
1. INTRODUCTION
The ATLAS is a modular switch mode (high frequency) battery charger / power supply platform designed for
railroad signal and communication, as well as other industrial stationary / reserve power applications.
ATLAS is convection cooled with no fans or other moving parts and designed to provide maximum reliability in
industrial environments. The modular architecture provides redundancy and maximizes uptime, and the
system controller combines the simplicity of rotary switches to adjust the float voltage with sophisticated
communication, alarming, and logging options. The universal AC input enables the charger to be used with a
wide range of AC voltages and frequencies, and the system features high energy efficiency and power factor.
As is illustrated in Figure 1-1, an ATLAS system includes a chassis. The chassis has a User Interface Module
(UIM) that serves as the system controller and user interface and an access panel for the AC input and DC
output terminals. Chassis are available with four (4) or two (2) slots for Intelligent Power Modules (iPMs).
Figure 1-1: ATLAS System Components
Both 12 Vdc, 400W, 20A and 24 Vdc, 400W, 10A iPMs are available. Figure 1-2 shows the corresponding
maximum system DC output current for a given number of iPMs. An ATLAS system can be set to charge
batteries within a voltage range of 1.00 to 20.00 volts (12 Vdc nominal system) or 10.00 to 40.00 volts (24 Vdc
nominal system) for nickel-cadmium (Ni-Cd), valve regulated lead-acid (VRLA), and flooded/vented lead-acid
batteries. The values shown throughout this manual in the instruction tables and figures are for generic use
and may be different from the actual values programmed in your unit. Customized settings are available,
contact a Lester Electrical service agent at 1-402-477-8988.

ATLAS 6 of 44 User’s Manual
Number of iPMs
Maximum System DC Output Current (A)
12 Vdc iPMs
24 Vdc iPMs
1
20
10
2
40
20
3
60
30
4
80
40
Figure 1-2: Number of iPMs and the Corresponding Maximum System DC Output Current
2. THEORY OF OPERATION
The charger has an "IE" profile which is (1) a constant-current bulk/start phase followed by (b) a constant-
voltage float phase. When the charger is first started, if the battery pack voltage is below the charger float
voltage value, it will output a constant current in the bulk phase. The constant current value is controlled by
the “Max DC Output Current” setting available via the charger web server using the Ethernet port.
When the battery pack nears the charger float voltage value, the charger will transition from the bulk phase
into the float phase. The output current will decrease in order to maintain a constant float voltage. The
charger float voltage value is controlled by either (1) the “NUMBER OF CELLS” and “VOLTS PER CELL”
rotary switches on the UIM or (2), if the “NUMBER OF CELLS” rotary switches are set to “00”, the “Number of
Cells” and “Float Voltage Per Cell” settings available via the charger web server control the float voltage value
(see Section 11.3 for valid ranges). The constant float voltage will be maintained indefinitely to keep the
battery pack fully charged.
The charger web server, which is detailed in Section 11, includes other settings, such as battery temperature
compensation, that can be adjusted per the requirements of the battery pack and overall system.
3. RECEIVING AND INSTALLING THE CHARGER
WARNING: NEVER PLACE ANYTHING ON TOP OF THE CHARGER WHILE OPERATING. DAMAGE
TO THE CHARGER OR BATTERIES COULD OCCUR.
WARNING: THE CHARGER MUST BE SET UP FOR THE PROPER USER SPECIFICATIONS BEFORE
STARTING THE INITIAL CHARGE.
WARNING: CHARGERS CAN IGNITE FLAMMABLE MATERIALS AND VAPORS. DO NOT USE NEAR
FUELS, GRAIN DUST, SOLVENTS, THINNERS, OR OTHER FLAMMABLES.
WARNING: REPLACE WORN, DAMAGED, OR CUT ELECTRICAL CORDS AND CONNECTORS
IMMEDIATELY.
Proper installation of the charger is important in order to achieve good charger performance and to prevent
damage to the charger and batteries.
When a charger is received, a check for possible in-transit damage should be made. If any damage is found,
it should be reported as a claim to the carrier.
The dimensions for the charger and mounting brackets are shown in Figure 3-1 (4-slot chassis) and Figure 3-
2 (2-slot chassis).
To permit free air flow for convention cooling, allow 2 inches (2") minimum between the charger sides and
other equipment and 4 inches (4") minimum on top of the charger. Do not mount the charger above other
heat generating equipment.
The charger can be mounted on a shelf, countertop, floor, wall, or rack. The charger case includes four (4)
cushioned feet that are designed to prevent marring of mounting surface and to absorb vibration. The
charger includes adjustable mounting brackets that provide highly flexible mounting options. See Figure 3-1
(4-slot chassis) or Figure 3-2 (2-slot chassis) for details.

ATLAS 7 of 44 User’s Manual
Wall or Shelf Mounting
The charger can be fastened to a wall for wall or shelf mounting, by attaching the mounting brackets to the
last two side mounting screw holes near the rear of the charger. Then, 1/4" bolts or lag screws can be
installed in each of the (4) key slots or by using the top and bottom 0.281 diameter round holes in the
mounting brackets (4 bolts total).
Rack Mounting
The 4-slot chassis can be mounted to a standard Electronic Industries Association (EIA) 19” (483mm) rack
system. The 2-slot can also be mounted to a standard EIA 19” rack system using an optional mounting
bracket. An industry standard 3/8" square hole rack, 12-24 UNC cage nuts, and 12-24 UNC rack screws are
recommended. A 12-24 screw should be installed through each of the 2 highest slots and 1 of the 2 lowest,
0.218" X 0.312" slots in both of the 2 mounting brackets (a total of 6 screws minimum). The 12-24 screws
should be tightened to 40 in--lb. If other sizes and/or types of fasteners are used, the quantity, location and
tightening torque should be designed as recommended by the manufacturer to be at least as strong as the
above recommendation. By adjusting the locations of the mounting brackets along the 1/2" spacing of screw
holes along the side of the charger, many different mounting configurations are possible, from flush mounted
to forward mounted.
The patterns of the mounting bracket rack mounting holes and slots are shown in Figure 3-1 (4-slot chassis).
Figure 3-1: Dimensions for 4-Slot Chassis and Mounting Brackets

ATLAS 8 of 44 User’s Manual
Figure 3-2: Dimensions for 2-Slot Chassis and Mounting Brackets

ATLAS 9 of 44 User’s Manual
4. AC INPUT
WARNING: FAILURE TO PROPERLY CONNECT THE AC VOLTAGE CONDUCTORS COULD CAUSE
SERIOUS DAMAGE TO THE CHARGER.
WARNING: DO NOT OPERATE THE CHARGER WITHOUT PROPER GROUNDING. IMPROPER
GROUNDING CAN RESULT IN THE RISK OF AN ELECTRIC SHOCK.
CAUTION: TO REDUCE THE RISK OF ELECTRIC SHOCK OR FIRE, DISCONNECT AC POWER
FROM THE CHARGER BEFORE INSTALLING OR REMOVING UNIT.
WARNING: DO NOT TOUCH THE CHARGER'S TERMINALS OR AN ELECTRICAL SHOCK COULD
OCCUR. A VOLTAGE IS PRESENT ON THE DC TERMINALS EVEN AFTER THE AC IS DISCONNECTED
BECAUSE OF THE ENERGY STORED IN THE CAPACITORS.
The charger has an AC input rating of 100-240 volts, 50-200 hertz, single-phase. The charger has an AC
operating range of 90-264 volts, 45-205 hertz. Below 100 volts, the charger may reduce output power.
Use an appropriate size wire for the AC input. Quarter-inch (1/4") ring terminals are required for proper
connection to the AC input binding posts (A.A.R.) located on the front of the charger. Open the access door
cover on the front of the charger. Route the AC wires and/or conduit in accordance with the National
Electrical Code and all local codes and ordinances. Dress field installed Class 2 or Class 3 circuits at
least 1/4 inch (6.3 mm) away from power, light, or Class 1 circuits. Connect the AC input terminals on
the two right-most posts, as marked on the A.A.R. terminal board, inside of the access door. Connect the AC
ground to the terminal lug provided, as also marked on the inside of the access door. Close the access door
after tightening all of the binding post nuts.
5. DC OUTPUT
WARNING: DO NOT TOUCH THE CHARGER'S TERMINALS OR AN ELECTRICAL SHOCK COULD
OCCUR.
WARNING: BATTERIES GENERATE EXPLOSIVE GAS. CHARGE ONLY IN WELL VENTILATED
AREAS. TO PREVENT ARCING OR BURNING NEAR BATTERIES, DO NOT DISCONNECT THE DC
CHARGING CONNECTOR(S) FROM THE BATTERIES WHEN THE CHARGER IS OPERATING. IF THE
CHARGE CYCLE MUST BE INTERRUPTED, UNPLUG THE AC POWER CORD BEFORE
DISCONNECTING THE DC OUTPUT CONNECTOR(S) FROM THE BATTERIES. KEEP SPARKS, FLAME,
AND SMOKING MATERIALS AWAY FROM BATTERIES. TO REDUCE THE RISK OF FIRE, DO NOT USE
THE CHARGER NEAR FLAMMABLE MATERIALS OR VAPORS.
Use Table 5-1 to select the appropriate gauge and length DC output cable for your application. Maximum
wire gauge is 4 AWG to fit the openings for the DC wiring above the binding posts (A.A.R.). Dress field
installed Class 2 or Class 3 circuits at least 1/4 inch (6.3 mm) away from power, light, or Class 1
circuits.
Quarter-inch (1/4") ring terminals are required for proper connection to the DC output binding posts (A.A.R.)
located on the front of the charger. Open the access door cover on the front of the charger. Connect the DC
output terminals on the two left-most posts, with positive (+) on the left and negative (-) on the right, as
marked on the A.A.R. terminal board, inside of the access door. Check to make sure that the polarity of the
DC output wires are the same as those connected to the battery. The charger will not operate in a reversed
polarity condition. If the DC polarity is reversed, the main DC output fuse will protect the charger from internal
damage. Correct the reversed wires and replace the fuse. Close the access door after tightening all of the
binding post nuts.

ATLAS 10 of 44 User’s Manual
Maximum DC Cable Length per Wire Gauge
Wire Gauge
(AWG)
Rated Voltage / Chassis Size
Maximum Output
Current in Amps
Maximum Length
in Feet
12
24V / 2-slot
20
14
10
12V / 2-slot
40
10
24V / 2-slot
20
20
24V / 4-slot
40
10
8
12V / 2-slot
40
18
24V / 2-slot
20
36
24V / 4-slot
40
18
6
12V / 2-slot
40
29
24V / 2-slot
20
58
12V / 4-slot
80
15
24V / 4-slot
40
29
4
12V / 2-slot
40
46
24V / 2-slot
20
92
12V / 4-slot
80
23
24V / 4-slot
40
46
Table 5-1: Maximum DC Cable Length
6. BATTERY TEMPERATURE SENSOR
WARNING: IT IS IMPORTANT TO MOUNT THE TEMPERATURE SENSOR ON THE BATTERIES
FOR PROPER TEMPERATURE COMPENSATION. IF THIS CANNOT BE DONE, LOCATE THE SENSOR
AS LOW AS POSSIBLE IN THE BUNGALOW, ENCLOSURE, OR CABINET.
The external battery temperature sensor is an optional way of extending battery life by using temperature
compensation. One end of the temperature sensor cable has a three-pin plug that plugs into a receptacle
labeled “BATTERY TEMP SENSOR” on the UIM (see Figure 7-1). The other end of the cable has the
temperature sensor sealed in a terminal.
The terminal-type sensor should be attached to a negative (-) battery post near the center of the battery pack.
If the threaded stud is long enough above the battery jumper nut, attach the sensor with another nut. Torque
this nut to proper specifications. If the stud is too short, the nut holding the jumper wire will need to be
removed. Open or remove the load and charging circuits to the batteries. Remove the nut holding the jumper
and add the sensor, then torque the nut to the proper specifications. Then close or connect the load and
charging circuits back to the batteries.
Securely fasten the temperature sensor cable to protect the sensor from being torn from the battery.
Secure the sensor cable to a fixed object to ensure the sensor will not be pulled loose. Use a cable tie mount
on the battery or on the adjacent battery, if necessary.