SBS AT10.1 SERIES Training manual

Operating and Service Instructions
AT10.1SERIES
MICROPROCESSOR-CONTROLLED
FLOAT BATTERY CHARGER
SINGLE PHASE INPUT
GROUP II
(30 - 100 Adc OUTPUT)
Address: N56 W16665 Ridgewood Drive
Menomonee Falls, WI 53051
Tel: [phone]
Fax: [phone]
Online: www.SBSBattery.com

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
A B C D E F G H J K L M N P
Follow the chart below to determine the configuration of the AT10.1.
DESCRIPTION CODE FEATURE DESCRIPTION CODE FEATURE
A SERIES AT10 AT10.1 BATTERYCHARGER S STANDARD
012 12 Vdc M MEDIUMAIC
024 24 Vdc H HIGH AIC
048 48 Vdc
F
AC CIRCUIT
BREAKER
RATING
(SEE TABLE) 0 NO AC BREAKER
B NOMINAL
DC OUTPUT
VOLTAGE 130 130 Vdc F SUPPLIED
030 30 Adc G AC FUSES
(200 kAIC) X NOT SUPPLIED
040 40 Adc S STANDARD
050 50 Adc M MEDIUMAIC
075 75 Adc H HIGH AIC
C NOMINAL DC OUTPUT
CURRENT
100 100 Adc
H
DC CIRCUIT
BREAKER
RATING
(SEE TABLE) 0 NO DC BREAKER
F SUPPLIED
U UNFILTERED
J DC FUSES
(20 kAIC) X NOT SUPPLIED
F FILTERED (STANDARD) A SUPPLIED
D DC OUTPUT
FILTERING E BATT ELIMINATOR FILTER K AUX ALARM
RELAYBOARD X NOT SUPPLIED
120 120 Vac 60 Hz G SUPPLIED
208 208 Vac 60 Hz L COPPER
GROUND BUS X NOT SUPPLIED
240 240 Vac 60 Hz L SUPPLIED
480 480 Vac 60 Hz M LIGHTNING
ARRESTOR X NOT SUPPLIED
600 550-600 Vac60 Hz F APPLIED
220 220 Vac 50/60 Hz N FUNGUS
PROOFING X NOT APPLIED
380 380 Vac 50/60 Hz S APPLIED
E AC INPUT
VOLTAGE
416 416 Vac 50/60 Hz P STATIC
PROOFING X NOT APPLIED
DESCRIPTION CODE FEATURE DESCRIPTION CODE FEATURE
INPUT AND OUTPUT 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)
S STANDARD 5,000 AIC 5,000 AIC
M MEDIUM AIC 25,000 AIC 10,000 AIC 200,000 AIC 20,000 AIC
H HIGHAIC 65,000 AIC 20,000 AIC
* Contact your sales representative 500-600 Vac 60Hzcircuit breaker AIC ratings.
NOTICE .
The factory-configured model number printed on the AT10.1 data nameplate decal does not
feature certain options and accessories. Nor does it feature any field-installed options. Check off below
any options and/or accessories that are initiallyincluded, or are installed after shipment.
floor/wall/rack-mounting brackets zero-center ground detection meter w/test switch
NEMA Type 2 drip shield end of discharge alarm relay
NEMA Type 4 (12/13) cabinet battery discharge alarm relay
cabinet heater strips barrier type auxiliary alarm terminal block(s)
pad/key lock for front panel door external temperature compensation probe
analog ac voltmeter DNP3 Level 2 / Modbus communications module
analog ac ammeter forced load sharing signal interconnection cable
Please find the serial number on the
data nameplate and record it here:

MANUFACTURER'S WARRANTY
Remove this sheet as needed from bound manual.
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.
During the term of the warranty period: parts, assemblies, or components
deemed to be defective will be repaired or replaced at the manufacturer's
option, free of charge. All costs related to removal, reinstallation and
transportation will be paid by the purchaser/customer and/or operator of
the product. Evaluation, repair and/or replacement of any defective
part(s) are FOB manufacturer's factory.
This warranty does not cover products or parts that are damaged from
improper use or abuse, as determined by the manufacturer. Accessory
items or additional items carry only their respective manufacturer’s
warranty. Consumable items (such as fuses and electrolytic capacitors),
which wear out under normal use are specifically not covered by this
standard warranty. Any consequential damage due to diagnosis or repair
by any party other than the manufacturer's authorized personnel is not
covered under this warranty.

MANUFACTURER'S WARRANTY
Remove this sheet as needed from bound manual.
 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. Contact your sales representative for more information &
pricing regarding the extended spare parts warranty.
 Magnetic Parts 25-Year Extended Warranty
(equal to 5% of the original purchase price)
Lifetime warranty (limited to 25 years from date of shipment) covers
battery charger major electromagnetic components (T1 transformer, L1
inductor & L2 inductor) as applicable. Coverage is for 100% replacement
of any covered magnetic component that fails during normal use. Abuse,
neglect, and damage from outside sources or improper application will
make this warranty null and void. The manufacturer reserves the right to
make final determination regarding the application of this warranty. The
manufacturer will be responsible for costs related to inbound and
outbound freight of warranted magnetic components (T1, L1 & L2).
Freight cost is based on standard UPS rates or common carrier only, as
appropriate. Costs related to removal and/or reinstallation of warranted
magnetic components will be the responsibility of the purchaser/customer
and/or operator of the product. Contact your sales representative for more
information & pricing regarding the magnetic parts extended warranty.
.NOTICE .
Requests for returns or warranty claims must be made via manufacturer's
Return Material Authorization (RMA) instructions and assignment.
Contact your sales representative for more information & pricing
regarding returns or warranty claims. Returns that do not follow this
procedure will not be honored.
Election to any of the above offered extended warranties must be done
within the terms of the initial standard warranty.

IMPORTANT SAFETY INSTRUCTIONS
i
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. This manual contains important safety and operating instructions, and should
therefore be filed for easy access.
3. Remove all jewelry, watches, rings, etc. before proceeding with installation or
service.
4. Maintain at least 6in / 152mm of free air on all vented surfaces for cooling.
Allow sufficient clearance to open the front panel for servicing.
5. Connect or disconnect the battery only when the AT10.1 is off, to prevent
arcing or burning.
6. Do not operate the AT10.1 if it has been damaged in any way. Refer to
qualified service personnel.
7. Do not disassemble the AT10.1. Only qualified service personnel should
attempt repairs. Incorrect reassembly may result in explosion, electrical
shock, or fire.
8. Do not install the AT10.1 outdoors, or in wet or damp locations, unless
specifically ordered for that environment.
9. Do not use the AT10.1 for ANY purpose not described in this manual.
!WARNING
10. Do not touch any uninsulated parts of the AT10.1, especially the input and
output connections, as there is the possibility of electrical shock.
11. During normal operation, batteries may produce explosive gas. Never smoke,
use an open flame, or create arcs in the vicinity of the AT10.1 or the battery.
12. Turn the AT10.1 off before connecting or disconnecting the battery to avoid
shock hazards and/or equipment damage.
13. De-energize and lock out all ac and dc power sources to the AT10.1 before
servicing.
14. Do not operate the AT10.1 with any power source that does not match the
specified ac and dc voltage ratings. Refer to the data nameplate decal affixed
to the outside panel for operational requirements.
15. Do not operate the AT10.1 with the Plexiglas safety shield or any other
supplied guards removed or improperly installed.

TABLE OF CONTENTS
ii
HOW TO READ THE AT10.1 MODEL NUMBER....................................... Inside Front Cover
MANUFACTURER'S WARRANTY..............................................................Removable Form
IMPORTANT SAFETY INSTRUCTIONS................................................................................i
1 Receiving and Installing the AT10.1 Battery Charger
1.1 Storing the AT10.1..........................................................................................2
1.2 Reporting shipping damage.............................................................................2
1.3 Unpacking and inspecting the AT10.1..............................................................2
Inspection checklist.........................................................................................2
1.4 Moving the AT10.1..........................................................................................3
Enclosure type and weight table ......................................................................3
1.5 Mounting the AT10.1.......................................................................................3
1.5.1 Wall-Mounting the AT10.1.........................................................................4
1.5.2 Floor-Mounting the AT10.1........................................................................6
1.5.3 Rack-Mounting the AT10.1........................................................................8
1.6 Changing transformer taps............................................................................10
1.7 Making the ac input connections....................................................................12
1.8 Making the dc output connections..................................................................14
1.9 Wiring the AT10.1 for remote sensing ............................................................16
1.10 Wiring to the remote alarm contacts...............................................................18
Auxiliary Alarm Relay PC Board (optional)......................................................19
1.11 Installing the temperature compensation probe (optional)................................20
Using temperature compensation ..................................................................22
1.12 Installing the AT10.1 for remote communications (optional) .............................23
1.13 Installing the AT10.1 for forced load sharing (optional) ....................................23
2 Operating the AT10.1 Battery Charger
2.1 Starting the AT10.1
2.1.1 Understanding the start-up sequence.......................................................24
2.1.2 Checking the installation.........................................................................24
2.1.3 Starting the AT10.1.................................................................................24
Using the digital meter ............................................................................24
Factory settings table..............................................................................25
2.2 Using the AT10.1 front panel features
2.2.1 If the meter displays anerror 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 Alarm Relay PC Board (optional) ..............................29
2.2.7 Interpreting the alarm indicators...............................................................29

TABLE OF CONTENTS
iii
2.3 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 ...................................................... 34
Disabling the ground detection alarm....................................................... 35
2.3.5 Setting the Current Limit value ................................................................35
2.3.6 Enabling the high dc voltage shutdownfeature......................................... 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
3 Servicing the AT10.1 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
Replacement parts tables (begin on)..............................................................62
APPENDIX A: AT10.1 Performance Specifications.......................................................... 70
APPENDIX B: Field Installable Accessories .................................................................... 71
APPENDIX C: Standard Drawings *
Outline: AT10.1 Group II Battery Charger NEMA-1 Style-5017 Enclosure...................................72
Outline: AT10.1 Group II Battery Charger NEMA-1 Style-5018 Enclosure...................................74
Internal Component Layout: AT10.1 Style-5017 Enclosure w/Common Options .........................76
Internal Component Layout: AT10.1 Style-5018 Enclosure w/Common Options .........................78
Instrument Panel / PC Board Detail: AT10.1 Group II Battery Charger........................................80
Schematic: AT10.1 Group II Battery Charger - Standard w/o Options .........................................82
Schematic: AT10.1 Group II Battery Charger - with Common Options.........................................84
Connection Diagram: AT10.1 Group II Battery Charger - Standard w/o Options .........................86
Connection Diagram: AT10.1 Group II Battery Charger - with Common Options.........................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
APPENDIX G: CE Grounding Compliance ....................................................................... 94
MANUAL SPECIFICATIONS............................................................................................. 96
* A customized record drawing package is availablefor your particular AT10.1, 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 AT10.1 manufacturer.

RECEIVING THE AT10.1
2
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. Storage should not exceed two (2) years due to the
limited shelf life of the dc filter capacitors when they are not in service.
1.2. REPORTING SHIPPING DAMAGE
Upon delivery of the AT10.1 (or related products) if 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 products 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 AT10.1
Carefully remove all shipping materials from the AT10.1. Remove the
AT10.1 from the shipping pallet for inspection. Save all shipping
materials until you are sure that there is no shipping damage.
Once the AT10.1 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
 Enclosure exterior and interior are not marred or dented.
 There is no visible damage to exterior or interior components.
 All internal components are secure.
 Printed circuit boards are firmly seated on their standoffs.
 All hardware is tight.
 All wire terminations are secure.
 The User's Manual is included.
 You received all items on the packing list.

INSTALLING THE AT10.1
3
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 30 Adc 40 Adc 50 Adc 75 Adc 100 Adc
12 Vdc Style-5017 140 lbs
63 kg
Style-5017
155 lbs
70 kg
Style-5017
170 lbs
77 kg
Style-5018
220 lbs
100 kg
Style-5018
280 lbs
127 kg
24 Vdc Style-5017 150 lbs
68 kg
Style-5017
180 lbs
82 kg
Style-5017
190 lbs
86 kg
Style-5018
250 lbs
113 kg
Style-5018
320 lbs
145 kg
48 Vdc Style-5017 170 lbs
77 kg
Style-5017
220 lbs
100 kg
Style-5017
240 lbs
109 kg
Style-5018
340 lbs
154 kg
Style-5018
440 lbs
200 kg
130 Vdc Style-5017 220 lbs
100 kg
Style-5018
300 lbs
136 kg
Style-5018
320 lbs
145 kg
Style-5018
440 lbs
200 kg n/a
Actual unit weight is approximately 20 lbs / 9kg below listed shipping weight in table.
The Style-5017 & Style-5018 enclosures do not feature top lifting eyes for
moving. Move the AT10.1 with a forklift whenever possible, using the
supplied shipping pallet.
To lift the AT10.1 into a wall-mount or rack-mount installation, use a
heavy-duty sling or a scissor lift. To place the AT10.1 into a floor-mount
installation, use a forklift, lifting the Style-5018 enclosure from the
bottom between the mounting legs.
For further AT10.1 standard cabinet information, see the outline drawings
for the Style-5017 (JE5025-00) and Style-5018 (JE5026-00) enclosures
in Appendix C on pages 72 and 74.
1.5. MOUNTING THE AT10.1
The AT10.1 must be installed in manner that allows easy access to the
front ac (CB1) and dc (CB2) circuit breakers. Chose a mounting method
for the AT10.1 enclosure from the table below. ENCLOSURE
MANUAL
SECTION MOUNTING METHOD Style-5017 Style-5018
1.5.1 Wall-Mounting STANDARD OPTIONAL
1.5.2 Floor-Mounting OPTIONAL STANDARD
19in / 483mm Rack-Mounting OPTIONAL n/a
1.5.3 23-24in / 584-610mm
Rack-Mounting OPTIONAL OPTIONAL

INSTALLING THE AT10.1
4
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.
2. The wall must be strong enough to properly support the weight of the
AT10.1, plus a safety factor. See the Weight Table featured in Section 1.4
on page 3. The weight of your AT10.1 may be different, depending on the
feature, options, and accessories ordered with the unit.
3. Be conscious of planned ac input and dc output wiring to the AT10.1,
selecting conduit entrances carefully. Note the standard pre-fab conduit
knockouts located on the sides of the enclosures.
4. The location:
• Should be free of drips and splatter. If falling particles and liquids are a
problem, install NEMA-2 type drip shield accessory (EI0191-01). For
kit availability, see ordering information in Appendix B on page 71.
• Should be between 0 and 122 °F / -18 and 50 °C, with relative humidity
between 5% and 95% non-condensing.
• Must be free of flammable or explosive materials.
5. Maintain at least 6in / 152mm of free air on all vented surfaces for cooling.
6. Allow at least 36in / 914mm front clearance for access to the AT10.1 for
operation and maintenance.
NOTICE
If you need to wall-mount the AT10.1, housed in a Style-5018 enclosure,
a wall-mounting bracket accessory (EI5008-00) is required. For kit
availability see ordering information in Appendix B on page 71. The kit
includes two (2) mounting brackets, special hardware, and Installation
Instructions (JA5063-00) for the wall-mounting procedure.